Upper Oil Pan

WARNING: This page is about a different car, the 2010 Volkswagen Jetta, 2009 Volkswagen Jetta, 2009 Volkswagen GLI, 2008 Volkswagen Jetta, and 2008 Volkswagen GLI. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Testing Tool for Brake Wear VW 136
Assembly Tool T10118
Torque Wrench (5-50 Nm) V.A.G 1331
Silicone Sealant D 174 003 A2
Flat Scraper
Hand Drill with Plastic Brush Attachment
Protective Eyewear

Removing

-- Remove the transmission. Refer to one of the following:

Manual Transmission: [For transmission(s) 02Q] Removal and Installation .
Direct Shift Gearbox: [For transmission(s) 02E] Removal and Installation .

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

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

-- Remove the right front wheel housing liner. Refer to Removal and Installation .

-- Remove the bolts -arrows-.

Fig 1: Identifying Air Guide Pipe And Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Remove the bolt -1-

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

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

CAUTION:

To prevent leaks in the future, do not bend the lower timing chain cover and do not reach between the mounting points.

-- Remove the bolts -arrows-.

Fig 3: 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.

CAUTION:

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

-- Remove the bolts in sequence -14 through 1- and pry off the upper oil pan.

Fig 4: Identifying Upper Part Of Oil Pan Tightening Sequence

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Installing

Tightening specifications, refer to OIL PAN AND PUMP OVERVIEW .

NOTE:

The sealing surfaces must be completely free of oil and grease.

Note the expiration date of the silicone sealant.

The upper oil pan must be installed within 5 minutes after applying the silicone sealant.

-- Install the assembly tool T10118 and pull the spring in the chain tensioner for the oil pump drive in the -direction of the arrow-.

Fig 5: Identifying Assembly Tool -T10118- And Testing Tool For Brake Wear -VW 136-

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-- Secure the spring by inserting the testing tool for brake wear VW 136 into the hole in the guide rail, as illustrated.

-- Remove the sealant residue from the cylinder block with a flat scraper.

WARNING:

Risk of eye injury.

Wear protective eyewear.

-- Remove the remaining sealant from the upper oil pan and the lower timing chain cover, for example, with a rotating plastic brush.

Fig 6: Identifying Rotating Plastic Brush To Remove Sealant Residue From Sealing Flange, Cylinder Block And Upper Part Of Oil Pan

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NOTE:

See if the timing chain cover is deformed. Then mount the upper oil pan without any sealant and check the gap between the cover and the upper pan. If deformation is found and the cover cannot be aligned, replace the cover after installing the upper oil pan.

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

-- Make sure the oil passages in the upper oil pan and in the cylinder crankcase are clean.

-- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 0.12 in).

Fig 7: Identifying Scissors To Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 Mm)

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-- Apply the silicone sealant to the clean sealing surface of the upper oil pan -arrows-.

Fig 8: Identifying Silicone Sealant -D 174 003 A2- And Sealing Surface Of Upper Oil Pan

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Thickness of sealant bead: 2 to 3 mm.

NOTE:

The upper oil pan must be installed within 5 minutes after applying the silicone sealant.

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

On the transmission side, the upper oil pan and the crankcase must align.

-- Immediately install the upper oil pan and tighten the bolts in sequence -1 through 14- in three passes as follows:

Fig 9: Identifying Upper Part Of Oil Pan Tightening Sequence

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Tighten the bolts by hand
Tighten the bolts to 15 Nm
Tighten the bolts an additional 90° (1/4) turn

-- Install the bolts -arrows-. Tightening specification, refer to Fig 10.

Fig 10: Identifying Lower Timing Chain Cover Bolts

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Fig 11: Identifying Bolts

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-- Remove the testing tool for brake wear VW 136 from the guide rail -arrow-. The spring now returns to the installed position.

Fig 12: Identifying Testing Tool For Brake Wear -VW 136- And Guide Rail

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Further installation is in the reverse order of removal.