Upper Oil Pan

Special tools and workshop equipment required

Assembly Tool T10118
Brake Pad Wear Indicator Testing Tool VW 136
Torque Wrench 5-50 Nm V.A.G 1331
Hand drill with plastic brush attachment
Protective goggles
Silicone sealant.

Removing

-- Remove the transmission. Refer to Removal and Installation .

-- Remove the lower oil pan. Refer to LOWER OIL PAN .

-- Remove the oil pump. Refer to OIL PUMP .

-- Remove the transmission-side sealing flange. Refer to TRANSMISSION-SIDE SEALING FLANGE .

-- Remove the right front wheel housing liner. Refer to Wheel Housing Liners .

-- Remove the bolts -arrows-.

Fig 1: Air Guide Pipe And Bolts

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-- Lift the clamps -1 and 2- and remove the air guide pipe.

-- Remove the bolt -1-

Fig 2: Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

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-- Disconnect the wiring bracket mount next to the after-run coolant pump -V51- from the upper oil pan.

-- Disconnect the connector -1-.

Fig 3: Oil Pressure Regulation Switch N428, Bolt And Electrical Connector

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-- Remove the bolts -arrows-.

Fig 4: Identifying Bolts

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WARNING:

Risk of injury. When removing the upper oil pan the chain tensioner spring for the oil pump motor will jump from the upper oil pan to the lower timing chain cover. When removing the upper oil pan, do not reach between the section and the lower timing chain cover.

-- Remove the bolts -1 through 14- and pry out the upper oil pan.

Fig 5: Identifying Upper Part Of Oil Pan Tightening Sequence

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NOTE:

There may be 13 bolts installed, depending on the version.

CAUTION:

First pry the upper oil pan out on the transmission side. When prying out, be careful not to bend the timing chain cover.

Installing

For the correct tightening specifications, refer to OIL PAN AND OIL PUMP OVERVIEW

Silicone sealant.

NOTE:

Note the expiration date of the silicone sealant.

The oil pan (upper section) must be installed within 5 minutes after application of silicone sealant.

-- Mount the T10118 and pull the spring in the oil pump drive chain tensioner in the direction of the -arrow-.

Fig 6: Identifying Assembly Tool -T10118- And Testing Tool For Brake Wear -VW 136-

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-- Secure the spring by inserting the VW 136 into the hole in the guide rail as illustrated.

-- Remove any sealant residue on the cylinder block using a flat blade scraper.

WARNING:

Danger of eye injury.

Wear protective goggles.

-- Remove the sealant residue on the upper oil pan, for example using a rotating plastic brush.

Fig 7: Identifying Rotating Plastic Brush To Remove Sealant Residue From Sealing Flange, Cylinder Block And Upper Part Of Oil Pan

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

-- Cut the tube nozzle at the front marking (nozzle diameter: approximately 3 mm).

Fig 8: Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 Mm)

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-- Apply silicone sealant to clean sealing surface upper oil pan as shown in the illustration -arrows-.

Fig 9: Upper Oil Pan Section Sealing Surface

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CAUTION:

The lubrication system could be plugged with excess sealant.

Do not apply sealant bead thicker than indicated.

Thickness of sealant bead: 2 to 3 mm

NOTE:

The oil pan (upper section) must be installed within 5 minutes after application of silicone sealant.

The sealant bead may not be thicker than specified, otherwise excess sealant could enter the oil pan and clog the oil intake tube.

-- Position the upper oil pan immediately and tighten the bolts, tightening sequence, refer to Figure.

-- Install the bolts -arrows-. Tightening specification, refer to TIMING CHAIN GUARD AND Camshaft Adjustment Valve 1 -N205- OVERVIEW .

Fig 10: Identifying Bolts

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-- Remove the VW 136 from the guide rail -arrow-. The spring now returns to the installation position.

Fig 11: Identifying Testing Tool For Brake Wear -VW 136- And Guide Rail

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-- Install the sealing flange on the transmission side. Refer to TRANSMISSION-SIDE SEALING FLANGE .

-- Install the oil pump. Refer to OIL PUMP .

-- Replace the baffle plate.

-- Install the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER .

Assemble in reverse order of disassembly.