Oil Pan

WARNING: This page is about a different car, the 2008 Volkswagen Jetta, 2008 Volkswagen GLI, 2007 Volkswagen Jetta, and 2006 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

T bar and socket 10 mm 3185
Hex ball socket 3249 or hex ball socket T10058
Torque wrench (5-50 Nm) VAG 1331
Drip tray for AS 6100 VAS 6208
Hand drill with plastic brush attachment
Protective eyewear
Flat scraper
Silicone sealant D 176 404 A2

Removing

-- Remove the noise insulation. Refer to Description and Operation .

-- Drain the engine oil.

NOTE:

Observe disposal regulations!

-- Remove the charge air pipe bolts -arrows- and remove the air guide pipe.

Fig 1: Identifying Charge Air Pipe Bolts

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-- Remove the coolant pump bracket bolts -1-.

Fig 2: Identifying Charge Air Pipe Bolts

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-- Remove the charge air pipe bolt -2-.

-- Remove the oil return line bolts -arrows-.

Fig 3: Identifying Oil Return Line

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-- Disconnect the electrical connector -1- for the oil level thermal sensor if the vehicle has a service interval display.

-- Remove the transmission/oil pan -arrows- bolts.

Fig 4: Identifying Removal/Installation Of Mounting Bolts To Transmission/Oil Pan

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the oil pan bolts on the flywheel side using the 3185 and remove the using T10058.

-- Remove the remaining bolts and remove the oil pan. Loosen the oil pan with light blows of a rubber headed hammer if necessary.

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

-- Remove any remaining sealant from the oil pan using a rotating brush, for example, a drill with plastic brush attachment (wear protective glasses).

Fig 5: Identifying Removal Of Residual Sealant On Oil Pan E.G. With Rotating Plastic Brush

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

Installing

NOTE:

Note the expiration date of the sealing compound.

The oil pan must be installed and tightened immediately after application of silicon sealant.

-- Cut the tube nozzle at the front marking (nozzle diameter approximately 3 mm).

Fig 6: Identifying Application Of Sealant To Clean Sealing Surface

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-- Apply silicone sealant to he clean sealing surfaces of the oil pan as shown. The sealing compound bead must be:

2 to 3 mm thick
And run on the inside of the bolt holes -arrows-

NOTE:

Sealant bead must not be thicker than specified. Otherwise, excess sealant could get into the oil pan and clog the strainer in the intake line of the oil pump.

With the transmission removed, the oil pan must seal flush with cylinder block.

With the transmission installed, the oil pan must make contact on transmission.

After installing the oil pan, allow the sealant to dry for approximately 30 minutes. Only after then may the engine oil be added.

-- Install the oil pan immediately and tighten the bolts -1 to 20- as follows:

Fig 7: Identifying Removal/Installation Of Mounting Bolts To Transmission/Oil Pan

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1 - Tighten all bolts of the oil pan to cylinder block bolts -1 through 20- very lightly in a diagonal sequence.

2 - Tighten the oil pan to transmission bolts -arrows- lightly.

3 - Tighten the oil pan to cylinder block bolts -1 through 20 - again, lightly in diagonal sequence.

4 - Tighten the oil pan to transmission bolts -arrows- to 40 Nm.

5 - Tighten the oil pan to cylinder block bolts -1 through 20- in a diagonal sequence to 15 Nm.

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