Upper and Lower Sections of Oil Pan, Removing and Installing
Upper and Lower Sections of Oil Pan, Removing and Installing
Special tools and equipment
^ Engine support bracket 10-222A with adapter 10-222A/3
^ Drip tray V.A.G 1306
^ Electric drill with plastic brush attachment
^ Silicone sealant D 176 404 A2
^ Torque wrench 10 Nm/ 45 Nm
- Obtain radio code on vehicles with coded radio.
- With ignition switched off, disconnect battery Ground strap.
- Pull out dipstick.
- Unbolt dipstick guide tube at front of cylinder head (right side), and pull out of oil pan from the top.
- Remove noise insulation panel -arrows-.
- Remove bumper.
- Move lock carrier to service position.
WARNING: Hot steam can escape from the expansion tank when the filler cap is opened. Cover the filler cap with a cloth and unscrew it carefully.
- Unscrew cap on coolant expansion tank.
- Place drip tray V.A.G 1306 below engine.
- Turn drain screw -arrow- on radiator anticlockwise, if necessary fit drain hose to connection.
- Also open coolant drain screw-arrow at rear right of sump Refer to Draining coolant.
- Drain engine oil.
Use a separate container to collect the engine oil.
- Set up support bracket 10-222A with adapter 10-222A/3 on bolted flanges for wing panels.
- Attach support bracket to front and rear lifting eyes on engine.
- Raise engine as far as possible with spindles of support bracket.
- Cut open cable ties -arrows-, open retainer for starter cable and take out cable.
- Unbolt torque reaction support at front of oil pan.
- Unbolt coolant pipe from oil pan.
- Unplug connector from oil pressure switch on left of oil pan.
- Remove torque reaction support-1-.
- Release hose clamps -arrows-.
- Remove water pipe -2-.
- Remove oil filter.
- Release hose clamps -arrows-.
- Remove oil cooler-1-.
- Unscrew lower nuts on engine mountings -1(left and right sides).
- Mark positions of securing points -1- and locating sleeves -2- under engine mountings on left and right sides.
- Remove front subframe bolts -2- and -3- (left and right).
- Unscrew bolts -4-.
- Move stabilizer bar downward.
- Remove charge air cooler -2- on right side (release hose connection at top, and 3 rubber mountings).
- Remove air duct from connector elbow on alternator-3-.
- Disconnect cable from terminal 30/B+ -1-. Tightening torque: 16 Nm
- Disconnect cable from terminal D+ -2-. Tightening torque: 4 Nm
- Remove hex socket head bolt -1- and securing nut-2-. Tightening torque: 45 Nm
- Loosen bolt -3-. Tightening torque 22 Nm
- Remove alternator -4- from below.
1. Remove air pipe -1-.
2. Mounting for oil pipe and air conditioner pipes
3. Mounting on cylinder block
4. Release hose clamp
- Disconnect cable from terminal 30/B+ -1-. Tightening torque: 16 Nm
- Unplug connector for terminal 50 -2-.
- Remove right wheel.
- Unscrew top bolt -1- from right wheel housing. Tightening torque: 65 Nm
- Unscrew lower bolt (accessible from engine side). Tightening torque: 65 Nm
- Remove starter from front of vehicle.
To avoid having to check and adjust wheel alignment, only loosen the front subframe mountings and lower the subframe at the front.
- Remove lower section of sump.
- Disconnect return pipes for turbocharger from upper section of oil pan.
- Unbolt cover plate -2- for oil pump sprocket.
Note:
^ When loosening bolt -2- securing cover plate, counter-hold at welded nut.
^ When installing, make sure that the plate engages in position -arrows-.
- Unbolt two oil supply pipes, and pull longer of two pipes downward to disconnect from upper section of oil pan.
- Unbolt oil pump from engine so that shorter oil supply pipe can be disconnected (do not remove oil pump),
- Unscrew bolts securing upper section of sump to gearbox.
- Unbolt upper section of oil pan from engine.
Note: Two M6 bolts and two M8 bolts are located vertically at rear of oil pan upper section (in front of joint between engine and gearbox).
Installing:
Install in the opposite order to removing. When installing, note the points:
- Clean sealing surfaces; ensure that they are free of oil and grease.
WARNING: Wear protective goggles.
- Remove any residues of sealant on oil pan and engine block using plastic brush attachment, or similar.
Note: The oil pan must be installed within 5 minutes after applying silicone sealant D 454 300 A2.
- Cut off nozzle of tube at front marking (diameter of nozzle approximately 3 mm).
^ Thickness of sealant bead: 2 ... 3 mm
Note: The bead of sealant must not be thicker than 3 mm, as otherwise excess sealant may enter the oil pan and block the strainer in the oil intake pipe.
- Make sure sealing surface is clean and then apply silicone sealant on sealing surface of sump, as shown in illustration. (Illustration shows position of sealant on cylinder block.)
Note: Be particularly careful when applying the sealant around the rear sealing flange -arrows in illustration-.
- Locate oil pan in position immediately, and tighten all bolts securing pan to cylinder block to 5 Nm initially.
- Tighten bolts securing oil pan to gearbox to 45 Nm.
- Tighten bolts securing oil pan to cylinder block in diagonal sequence in 2 stages; tighten to 10 Nm when tightening second time.
- Tighten M10 bolts securing oil pan to cylinder block to 45 Nm.
- Clean both sealing surfaces for lower section of oil pan; ensure that they are free of oil and grease.
Note: Do not use any adhesive or sealant.
- Fit new gasket on lower section of oil pan and install on upper section of pan with two diagonally opposite bolts.
- Tighten all securing bolts hand-tight.
- Tighten bolts to 10 Nm with torque wrench, working from center outward.
- Fit new seal on oil drain plug and tighten to 30 Nm.
Note:
^ When installing the upper section of the oil pan with the engine removed from the vehicle, ensure that the pan is positioned flush with the cylinder block at the flywheel end.
^ The sealant must be left to dry for about 30 minutes after installing the oil pan before the engine can be filed with oil.
- Fill with coolant.
- Fill engine with oil.
- Install subframe.
- Install lock carrier in normal position.
- Install bumper.
- Install noise insulation.
Tightening torques
Other tightening torques
^ Combi bolt-4- must be replaced after removing.