Oil pan (upper part), removing and installing

Special tools, testers and auxiliary items required 

Fig 1: Identifying Old Oil Collecting And Extracting Device V.A.G 1782

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

Removing 

• Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
• Remove engine: Vehicles with manual transmission → Engine (vehicles with manual transmission)  , vehicles with automatic transmission → Engine (vehicles with automatic transmission), removing .
• Disconnect engine and transmission: Vehicles with manual transmission → Engine (vehicles with manual transmission), separating  , vehicles with automatic transmission → Engine and transmission (vehicles with automatic transmission), separating .
• Secure engine on engine and transmission holder: Vehicles with manual transmission → Engine (vehicles with manual transmission), securing to engine and transmission holder  , vehicles with automatic transmission → Engine (vehicles with automatic transmission), securing to assembly stand .

• Remove covers for timing chains → Timing chain covers (All), removing and installing .

Fig 2: Locating Tensioning Bolt And Ribbed Belt

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• Loosen tensioning bolt - arrow  - and remove ribbed belt.

Fig 3: Removing Tensioning Roller

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• Remove tensioning roller - arrows  -.

Fig 4: Removing Hose Clamps And Disconnecting Coolant Hose

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• Remove hose clamps - 1  - and disconnect coolant hose.

Fig 5: Disconnecting Coolant Hose On Generator, Electrical Connector & Removing Electrical Wire On Generator

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• Disconnect coolant hose - 3  - on generator.
• Disconnect electrical connector - 1  -.
• Remove electrical wire - 2  - on generator.

Fig 6: Removing Generator Bolts

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• Remove bolts - arrows  -.

• Remove generator.

Fig 7: Removing Bolts & Bracket For Generator

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• Remove bolts - arrows  -.
• Remove bracket for generator.

Fig 8: Removing Bolts And Torque Support From Engine

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• Remove bolts - arrows  - and remove torque support from engine.

Fig 9: Removing Front Coolant Pipe On Engine

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• Remove front coolant pipe on engine - arrows  -.

Fig 10: Disconnecting Coolant Hose & Removing Coolant Pump

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• Disconnect coolant hose - 1  -.
• Remove coolant pump - arrows  -.

Fig 11: Removing/Installing Drive Shaft For Coolant Pump From Oil Pump

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• Remove drive shaft - arrow  - for coolant pump from oil pump.

Fig 12: Removing Bolt From Oil Dipstick Guide Tube At Cylinder Head

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• Remove guide pipe for oil dipstick at cylinder head - arrow  - , pull up and remove.

Fig 13: Disconnecting Electrical Harness Connector On Oil Level Thermal Sensor G266 And Free Up Electrical Wire

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• Disconnect electrical connector on Oil Level Thermal Sensor G266 - arrow  - and free up electrical wire.

Fig 14: Removing Oil Pan (Lower Part)

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• Remove oil pan (lower part) - 1  - and pry out carefully.

Fig 15: Removing Bolts And Oil Pipes

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• Remove bolts and remove oil pipes - 1  - and - 2  -.

Fig 16: Removing Bolts For Upper Section Of Oil Pan

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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 

Fig 17: Using Rotating Plastic Brush To Remove Remaining Sealant From Oil Pan (Upper Part) And At Cylinder Block

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

Fig 18: Cutting Tube Nozzle At Front Marking

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

Fig 19: Inserting New Seals Into Grooves On Cylinder Block

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• Insert new seals - 1 to 4  - into grooves on cylinder block.
• Apply sealant beads - arrows  - to clean sealing surface of cylinder block as depicted in illustration.

• Thickness of sealant bead: 1.5 to 2.0 mm.

Fig 20: Removing Bolts For Upper Section Of Oil Pan

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• With a second technician, position upper section of oil pan and pre-tighten screws - 1 to 7  - to 5 Nm in diagonal sequence.
• Tighten bolts - 1 to 7  - diagonally to 15 Nm.

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

• Install coolant pump → Coolant pump, removing and installing .
• Install lower section of oil pan Installing .
• Replace O-ring at guide tube for oil dipstick and insert guide tube into hole in oil pan (upper part).
• When installing generator bracket, note two alignment bushings.

• Install covers for timing chains Installing .
• Install ribbed belt Installing .
• Install engine: Vehicles with manual transmission → Engine (vehicles with manual transmission), installing  , vehicles with automatic transmission → Engine (vehicles with automatic transmission), installing .
• Add engine oil and check oil level → Oil level, checking .

Torque specifications