Upper Oil Pan

Special tools and workshop equipment required 

• Torque Wrench (5-50 Nm) V.A.G 1331
• Locking Pin T10115
• Adapter Plates 2036/1
• 3 M8 x 20 Bolts and 3 Washers
• Hand Drill with Plastic Brush Attachment
• Protective Eyewear
• Silicone Sealant D 174 003 A2

Removing 

-- Loosen the adjuster and sprocket on the camshafts, refer to VALVE TIMING, ADJUSTING .

-- Remove the control housing cover. Refer to CONTROL HOUSING COVER .

-- Tension the chain tensioner -1- and secure it using the locking pin T10115.

Fig 1: Identifying Glide Track Installed To Relieve Tension On Chain Tensioner And To Remove Locking Pin T10115

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the guide rail -2-.

-- Remove the sealing flange. Refer to SEALING FLANGE, BELT PULLEY SIDE .

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

-- Remove the oil intake pipe bolts -2 and 4- and intake pipe.

Fig 2: Identifying Bolts And Intake Line

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolts -1-.

-- Pry off the upper oil pan from the cylinder block at the designated points using a suitable screwdriver -A-.

Fig 3: Identifying Screwdriver To Pry Off Upper Section Of Oil Pan From Cylinder Block At Designated Points

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

B - Crankshaft bearing cap 6

C - Crankshaft bearing cap 1

Installing 

-- Remove the remainder of sealant from the upper oil pan and cylinder block, for example, using a rotating plastic brush.

-- Clean the sealing surfaces so they are completely free of any oil or grease.

-- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 1 mm).

Fig 4: Identifying Scissors To Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 1 mm)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Note the shelf life date.

-- Apply the sealant beads -1, 2 and 3- as shown onto the clean sealing surface of the upper oil pan.

Fig 5: Identifying Application Pattern For Sealant Bead On Clean Surface Of Oil Pan, Upper Section

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• The sealant bead must be 1.5 to 2.0 mm thick.

-- Place the upper oil pan onto the cylinder block and align it on the transmission side.

-- Install 2 bolts each at the front and rear hand tight.

-- Wipe off any excess sealant in the area of the -arrows-.

Fig 6: Identifying Surfaces To Wipe Clean Of Excess Sealant Area

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the bolts again slightly.

-- Install the adapter plates 2036/1 from the adjustable rod 2036 to the cylinder block as shown.

-- Press the upper oil pan firmly against the adapter plates 2036/1 and tighten the bolts again hand tight.

-- Install the remaining bolts and tighten them hand tight.

Make sure that the upper oil pan makes contact with the adapter plates 2036/1.

-- Tighten all the bolts in a diagonal sequence working from the inside towards the outside.

-- Install a new seal -5- onto the oil pump -6-.

Fig 7: Identifying New Seal For Oil Pump

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the oil intake pipe -1-, the bracket -4- and the bolts -2 and 3-.

-- Install the guide rail -2-, relieve the tension on the chain tensioner -1- and remove the locking pin T10115.

Fig 8: Identifying Glide Track Installed To Relieve Tension On Chain Tensioner And To Remove Locking Pin T10115

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Adjust the valve timing. Refer to VALVE TIMING, ADJUSTING .

The rest of the installation follows the reverse of the removal procedures. When doing this note the following:

• After installing the oil pan, allow the sealant to dry for approximately 30 minutes. Only after then may the engine oil be added.
• Remove the locking pin T40069 from the rear of the cylinder block and install the locking bolt.

-- Fill the coolant. Refer to one of the following:

• Jetta from MY 05 through 10, Jetta Sport Wagon (US)/Jetta Wagon (Canada) for MY 09 and Jetta Sport Wagon (US)/Golf Wagon (Canada) from MY 10, refer to DRAINING AND FILLING .

Tightening Specifications