Oil Pan Upper Section, Removing And Installing: Installing

• Replace the seals and O-rings after removal.

-- Clean the sealant residue on the oil pan upper section -1- using the corresponding brush from the cleaning set for the sealing surfaces :VAS 294 019  .

Fig 1: Cleaning Sealing Surfaces

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• Brush :VAS 294 019/1  for gray cast-iron surfaces
• Brush :VAS 294 019/2  for aluminum surfaces
• Brush :VAS 294 019/3  for painted surfaces

-- Remove the sealant residue on the cylinder block and the oil pan upper section with a commercially available chemical sealant remover.

• Be sure to check the expiration date of the sealant.
  Fig 2: Cut Tube Nozzle At Front Marking

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• Cut the tube nozzle at the front marking (nozzle diameter: approximately 1.5 mm).

-- Apply the sealant beads -1 to 8- to the clean sealing surface on the oil pan upper section as shown.

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-- Apply the sealant bead -3- sparingly so that the groove is filled.

• Sealant bead thickness: 2.0 to 2.5 mm
• Install the oil pan upper section within five minutes of applying the sealant.

-- Position the oil pan upper section and install the bolts in the sequence shown -1 to 21- and install all the way by hand.

Fig 3: Oil Pan Upper Section - Tightening Sequence

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-- Wipe away any excess sealant at the areas marked with -arrows-.

Fig 4: Identifying Surfaces To Wipe Clean Of Excess Sealant Area

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-- Loosen the bolts slightly.

-- Tighten the Seal Installer - Valve Stem Seal Tool Adapter Plates Seal Installer - Valve Stem Seal Tool Adapter Plates :2036/1  to 20 Nm on the cylinder block.

-- Press the oil pan upper section -A- firmly onto the plates.

-- Tighten the oil pan upper section bolts.

• The oil pan upper section must continue to touch the plates.

Install in reverse order of removal. Note the following:

-- Install the oil pan lower section. Refer to OIL PAN LOWER SECTION, REMOVING AND INSTALLING .

-- Insert the lower guide rail -1-.

Fig 5: Identifying Timing Mechanism Drive Chain

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-- Push back the guide rail of the chain tensioner for the drive chain with a screwdriver -arrow- and remove the Locking Pins :T03006  .

Fig 6: Pushing Drive Chain Tensioner Guide Rail

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-- Install the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER, REMOVING AND INSTALLING .

-- Install the belt pulley side sealing flange. Refer to SEALING FLANGE, REMOVING AND INSTALLING, BELT PULLEY SIDE .

-- Remove the Crankshaft Locking Pin :T40069  .