Upper Oil Pan: Installing

WARNING: This page is about a different car, the 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

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

NOTE:

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.

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

Fig 1: Identifying Assembly Tool -T10118- And Testing Tool For Brake Wear -VW 136-

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-- Secure the spring by inserting the gauge VW 136 into the hole in the guide rail as shown.

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

WARNING: Danger of eye injury.

Wear protective eyewear.

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

Fig 2: Cleaning Remaining Sealant With Rotating Plastic Brush

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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 block are clean.

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

Fig 3: Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 1 Mm)

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-- Apply the silicone sealant onto the clean sealing surface of the upper oil pan as shown -arrows-.

Fig 4: 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 the excess sealant could enter the oil pan and clog the oil intake tube strainer.

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 5: Identifying Upper Oil Pan Bolt Tightening Sequence

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

-- Install the bolts -arrows-. Tightening specification, refer to Fig 6.

Fig 6: Identifying Lower Timing Chain Cover Bolts

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Fig 7: Identifying Bolts

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-- Remove the gauge VW 136 from the guide rail -arrow-. The spring now returns to its installed position.

Fig 8: Identifying Testing Tool For Brake Wear -VW 136- And Guide Rail

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Further installation is in the reverse order of removal.