Upper part of oil pan, removing and installing

Special tools, testers and auxiliary items required 

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• Old oil collecting and extracting device V.A.G 1782
• Protective glasses
• Hand drill with plastic brush attachment
• Sealant

Removing 

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• Remove sound insulation by loosening fasteners - 1, 2, 4  -.

• Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
• Remove engine → Engine, removing .
• Separate engine and transmission → Engine and transmission, separating .
• Secure engine to assembly stand → Engine, securing to assembly stand .

• Remove drive plate → Drive plate, removing and installing .
• Remove left and right timing chain covers → Left and right timing chain covers, removing and installing .
• Remove intake manifold → 24 - MULTIPORT FUEL INJECTION (MFI) .
• Remove oil filter housing → Oil filter housing, removing and installing .

• Remove lower timing chain cover → Timing chain lower cover, removing and installing .
• Remove ribbed belt tensioner → Ribbed belt, removing and installing .
• Remove front coolant pipe → Front coolant line, removing and installing .
• Remove generator → 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

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• Remove bolts - arrows  - and remove air generator bracket.

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• Disconnect electrical connector - 1  - at Oil Level Thermal Sensor G266.
• Place old oil collecting and extracting device V.A.G 1782 under engine.

• Remove oil pan (lower part) - 2  - and pry out carefully.
• Remove oil pump → Oil pump, removing and installing .

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• Remove bolts - 1 to 7  - for upper section of oil pan.
• Press upper part of oil pan from alignment pins of cylinder block.

Installing 

• Tightening torques → Ribbed belt drive, assembly overview , Upper part of oil pan, tightening sequence 

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• Using rotating plastic brush, remove any remaining sealant from oil pan (upper part) and at cylinder block.
• Clean sealing surfaces so they are completely free of any oil or grease.

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• Cut off nozzle on tube of sealant at front mark (dia. of nozzle approx. 1 mm).

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• Insert new seals - 1 to 4  - into grooves on cylinder block.

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• Apply sealant beads - 1 and 2  - on clean sealing surfaces of upper part of oil pan, as shown in illustration.

• Thickness of sealant beads: 2.5 mm.

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• Position lower part of oil pan and tighten bolts → Upper part of oil pan, tightening sequence 

The rest of installation is in reverse order of removal, note the following:

• Install oil pump → Oil pump, removing and installing .
• Install coolant pump → Coolant pump, removing and installing .
• Install lower section of oil pan → Installing .
• Install front coolant pipe → Front coolant line, removing and installing .

• Install ribbed belt tensioner → Ribbed belt, removing and installing .
• Install generator → 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .
• Install lower timing chain cover → Timing chain lower cover, removing and installing .
• Install crankshaft seal, transmission side → Transmission-side crankshaft sealing ring, replacing .

• Install oil filter housing → Oil filter housing, removing and installing .
• Install intake manifold → 24 - MULTIPORT FUEL INJECTION (MFI) .
• Install left and right timing chain covers → Left and right timing chain covers, removing and installing .
• Install drive plate → Drive plate, removing and installing .

• Install engine → Engine, installing .
• Add engine oil and check oil level → Oil level, checking .