Upper Oil Pan

WARNING: This page is about a different car, the 2009 Volkswagen GTI and 2008 Volkswagen GTI. 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-

Removing

-- Remove the transmission, refer to one of the following:

Automatic Transmission: [For transmission(s) 09G] [For engine(s) CCTA] Removal and Installation .
Manual Transmission: [For transmission(s) 02Q] Removing .
Direct Shift Gearbox Transmission: [For transmission(s) 02E] Removal and Installation .

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

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

-- Remove the right front wheel housing liner. Refer to FRONT WHEEL HOUSING LINER .

-- Remove the bolts -arrows-.

Fig 1: Identifying Air Guide Pipe And Bolts

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

-- Remove the bolts -arrows-.

Fig 3: Identifying Bolts

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CAUTION:

Risk of injury. When removing the upper oil pan, the chain tensioner spring for the oil pump 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.

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

Fig 4: Identifying Upper Part Of Oil Pan Tightening Sequence

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CAUTION:

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

Installing

Tightening specifications, refer to OIL PAN AND OIL PUMP OVERVIEW .

NOTE:

Note the expiration date of the silicone sealant.

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

-- Using the assembly tool -T10118-, pull the spring in the oil pump drive chain tensioner 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 any sealant residue from the cylinder block with a flat scraper.

WARNING:

Risk of eye injury.

Wear protective eyewear.

-- Remove the remaining sealant on the upper oil pan and 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 oil pan. If deformation is found and the cover cannot be aligned, replace the cover after installing the upper oil pan.

-- Clean the sealing surfaces, they 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 3 mm).

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

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-- Apply the silicone sealant -D 174 003 A2- to the clean sealing surface of the upper oil pan as shown -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 application of the silicone sealant.

The sealant bead may not be thicker than specified, otherwise the 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 -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 Outer Oil Pan 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

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The rest of the installation is basically a reverse of the removal sequence.