Oil pan, removing and installing

Fig 1: Identifying Special Tools - Oil Pan, Removing And Installing

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Special tools, testers and auxiliary items required

Engine support bridge 10-222 A
Multi-point socket T10058
Old oil collecting and extracting device V.A.G 1782
Shop crane VAS 6100

Insert pad for front fender T40045
Hand drill with plastic brush attachment
Protective glasses
Sealant

Removing

NOTE:

All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

Fig 2: Removing Engine Cover

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Remove engine cover - arrows -.
Remove rubber seal on fender attachment edges.

Fig 3: Placing Insert Pad For Front Fender T40045 On Both Sides Between Fender Attachment Edge And Web Plate Lying Beneath

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To prevent damage to fender edges when using engine support bridge 10-222 A , place insert pad for front fender T40045 on both sides between fender attachment edge and web plate lying beneath.

Fig 4: Positioning Engine Support Bridge 10-222 A With Adapters 10-222/3 On Fender Attachment Edge

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Position engine support bridge 10-222 A with adapters 10-222/3 on fender attachment edge.
Hook in spindles at engine lifting eyes, as shown.
Pretension engine slightly with spindles.
Remove ribbed belt → Ribbed belt, removing and installing

Fig 5: Identifying Exhaust Pipe Fasteners

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For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

Fig 6: Identifying Quick-Release Fasteners And Noise Insulation

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Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
Remove quick-release fasteners - 3 - and remove rear noise insulation, if installed.
Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.

Fig 7: Removing Bolts And Torque Supports From Oil Pan

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Remove bolts - arrows - and remove torque supports from oil pan.
Remove turbocharger oil return line - 1 - from oil pan.

Fig 8: Disconnecting Connector For Oil Level Thermal Sensor -G266-

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Disconnect electrical harness connector - arrow - at Oil Level Thermal Sensor G266.

Fig 9: Removing Bracket For Refrigerant Line On Oil Pan

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Remove bracket for refrigerant line on oil pan - arrow -.

Fig 10: Separating Connector For Wiring To Air Conditioning Compressor Clutch Solenoid

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Separate connector - 1 - for wiring to air conditioning compressor clutch solenoid.

CAUTION: The air conditioning refrigerant circuit must not be opened.

Remove air conditioning compressor from bracket - arrows -.

NOTE:

To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

Hang up A/C compressor with attached lines at bottom of vehicle.

Fig 11: Disconnecting Electrical Harness Connector At Left Front Level Control System Sensor G78

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Disconnect electrical harness connector - arrow - at Left Front Level Control System Sensor G78.

Fig 12: Removing Stabilizer Bar Mountings

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Remove stabilizer bar mountings - 1 - and - 2 -.

Fig 13: Subframe Supported Using Workshop Crane V.A.G 1202 A

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Support subframe with workshop crane VAS 6100 or V.A.G 1202 A.

Fig 14: Starter Wiring Bracket Cable Ties

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Cut through cable ties - arrows - , open starter harness retainer and take harness out.

Fig 15: Identifying Lower Nut, Bolts, Front Bolt & Engine Mount Plate

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Remove lower nut - 3 - on engine mount.
Remove bolts - 4 - and - 5 - on engine mount plate.
Remove front bolt - 1 - for subframe and remove engine mount plate - 2 -.
Repeat work procedure on opposite side of vehicle.

Fig 16: Subframe Supported Using Workshop Crane V.A.G 1202 A

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Slowly lower subframe with workshop crane VAS 6100 or V.A.G 1202 A.
Lift engine slightly upward using spindles of engine support bridge 10-222 A , paying attention to clearance of shift linkage and exhaust system.

Fig 17: Removing Bolts For Transmission/Oil Pan

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Remove bolts - arrows - for transmission/oil pan.

Fig 18: M10 Bolts Removal Sequence

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Remove M10 bolts - arrows -.
Loosen bolts - 1 to 18 - in a diagonal sequence.
Remove oil pan, and if necessary loosen by applying light strikes with a rubber hammer.

Installing

Installation is in reverse order of removal, note the following:

NOTE:

Replace seal.
Secure all hose connections using hose clamps appropriate for the model type .
During installation, all cable ties must be re-installed at the same location.

Fig 19: Removing Sealant Residue From Oil Pan With Rotating Brush

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Remove residual sealant from oil pan and at cylinder block, e.g. using a rotating plastic brush.

CAUTION: Wear safety glasses.

Clean sealing surfaces, they must be free of oil and grease.

Fig 20: Cutting Tube Nozzle At Front Marking

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Cut off nozzle on tube of sealant at front mark (dia. of nozzle approx. 2 mm).

Fig 21: Identifying Silicone Sealing Compound Application Area

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Apply sealant bead as illustrated to clean sealing surface of oil pan.

Thickness of sealant bead: 2 to 3 mm.

NOTE:

The sealant bead may not be thicker than 3 mm, otherwise excess sealant could enter the oil pan and clog the oil intake tube.
Apply a bead of sealant at the rear area of the sealing flange very carefully - arrows -.
The oil pan must be installed within 5 minutes of being applied with sealant.

Fig 22: M10 Bolts Installation Sequence

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Install oil pan immediately and tighten bolts in described sequence:
Pre-tighten bolts - 1 to 18 - in diagonal sequence to 5 Nm.
Tighten oil pan/transmission bolts to 45 Nm.
Tighten bolts M10 - arrows - to 40 Nm.

Tighten bolts - 1 to 18 - in diagonal sequence to 15 Nm.

Fig 23: Ensuring That Oil Pan Is Positioned Flush With Intermediate Plate At Flywheel End

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NOTE:

When installing the oil pan - 3 - on a removed engine, make sure that the flywheel end of the oil pan is aligned flush with the intermediate plate - 1 - , therefore the oil pan must extend beyond the cylinder block - 2 - by dimension - a - 0.8 mm.
After installing oil pan, allow sealant to dry for approx. 30 minutes. Only after then may the engine oil be replenished.

Install subframe → 40 - FRONT SUSPENSION .
Install stabilizer bar → 40 - FRONT SUSPENSION .
Install A/C compressor → 87 AIR CONDITIONING
Install ribbed belt → Ribbed belt, removing and installing .

Add engine oil and check oil level.

The rest of assembly is basically a reverse of disassembling sequence.

Torque specifications

Part I Oil pan, balance shaft assembly → Part I oil pan, balance shaft module, component overview