Upper part of oil pan, 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 

Fig 2: Locating Fasteners Exhaust Pipe

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

Fig 3: Identifying Quick-Release Fasteners And Noise Insulation

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• Loosen quick-release fasteners - 1 through 3  - and remove front and rear noise insulation.
• Place old oil collecting and extracting device V.A.G 1782 under engine.
• Drain engine oil.
• Remove engine: Vehicles with manual transmission → Engine, removing  , vehicles with automatic transmission → Engine, removing .

• Separate engine/transmission assembly: Vehicles with manual transmission → Engine and manual transmission, separating  , vehicles with automatic transmission → Engine and automatic transmission 09L, separating .
• Secure engine to assembly stand: Vehicles with manual transmission → Engine, securing to assembly stand  , vehicles with automatic transmission → Engine, securing to assembly stand .
• Vehicles with manual transmission: Remove clutch pressure plate →
  • 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
  • 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
  • 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
  • 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE
  • 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE
  • 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE
  and dual mass flywheel → Dual mass flywheel (vehicles with manual transmission), removing and installing .
• Vehicles with automatic transmission: Remove drive plate → Drive plate (vehicles with automatic transmission), removing and installing .

• Remove left and right timing chain covers → Left and right timing chain covers, removing and installing .
• Remove lower timing chain cover → Lower timing chain cover, removing and installing .
• Remove front sealing flange → Front sealing flange with crankshaft seal, removing and installing .
• Remove lower section of oil pan → Lower part of oil pan, removing and installing .

• Remove oil pump → Oil pump, removing and installing .

Fig 4: Removing Bolts And Lower Oil Baffle

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• Remove bolts - arrows  - and remove lower oil baffle.

Fig 5: Removing Bolts For Upper Section Of Oil Pan

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• Remove bolts - 1 to 6  - for upper section of oil pan.
• Press upper part of oil pan from alignment pins of cylinder block.

Installing 

• Remove sealant from grooves of upper part of oil pan and from sealing surfaces.

Fig 6: Using Rotating Plastic Brush To Remove Any Remaining Sealant From Upper Part Of Oil Pan And Cylinder Block

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

Fig 7: Cutting Tube Nozzle At Front Marking

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• Cut tube nozzle at front marking (jet approx. 2 mm).

Fig 8: Applying Sealant Bead On Clean Sealing Surface Of Upper Section Of Oil Pan

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• Apply sealant bead - arrow  - on clean sealing surface of upper section of oil pan as shown in illustration.

• The groove of sealing surfaces must be completely filled with sealant.
• Sealant bead must stand 1.5 to 2.0 mm above sealing surface.

Fig 9: Removing Bolts For Upper Section Of Oil Pan

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• Position upper part of oil pan in place and tighten bolts - 1 through 6  - to 5 Nm in diagonal sequence.
• Tighten bolts - 1 to 6  - in a diagonal sequence.

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

• Install oil pump → Oil pump, removing and installing .
• Install lower section of oil pan → Lower part of oil pan, removing and installing .
• Install front sealing flange → Front sealing flange with crankshaft seal, removing and installing .
• Install lower timing chain cover → Lower timing chain cover, removing and installing .

• Install oil filter housing → Oil filter housing, removing and installing .
• Install left and right timing chain covers Installing .
• Install crankshaft seal, timing chain side → Crankshaft seal, timing chain side, replacing .
• Vehicles with manual transmission: Install dual mass flywheel → Dual mass flywheel (vehicles with manual transmission), removing and installing  and clutch pressure plate →
  • 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
  • 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
  • 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
  • 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE
  • 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE
  • 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE
  .

• Vehicles with automatic transmission: Install drive plate → Drive plate (vehicles with automatic transmission), removing and installing .
• Attach transmission to engine and install engine/transmission assembly: Vehicles with manual transmission → Engine, installing  , vehicles with automatic transmission → Engine, installing .
• Add engine oil and check oil level → Oil level, checking .

Torque specifications