Upper Oil Pan

WARNING: This page is about a different variant/trim than selected.

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

WARNING:

To prevent injuries from shavings, wear protective goggles and protective clothing.

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

CAUTION:

Make sure that no sealant residue enters the engine.

-- 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.

NOTE:

The upper oil pan must be installed within 5 minutes after application of sealant.

-- 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

Component		Nm
Upper oil pan to cylinder block		25
Oil intake pipe to oil pump		10
Oil intake pipe to upper oil pan		10