Oil Pan: Service and Repair

Oil pan, removing and installing
Special tools and equipment





^ 3185 Jointed wrench
^ T10058 Socket insert
^ V A G 1331 Torque wrench (5.50 Nm)
^ Hand drill with plastic brush attachment
^ Silicone sealing compound D 176 404 A2

Removing

Note: On BHP engines the oil pan consists of two sections (upper and lower parts). The oil pan is removed completely from block or remove lower part as applicable, observe assembly instructions
- Remove center and right side sound insulation:





Engines with oil pan guard

- Remove bolts -2- and take sleeves -3- off front and rear parts of oil pan cover.
- Press spreader pin out upward and remove spreader rivet -4-.
- Remove oil pan cover -1-.

Continue for all engines
- Drain engine oil.

Note: Observe waste disposal regulations!

Engines: APK, AQY
- Pull 3-pin connector off oil level/oil level thermal sensor -G266

Continue for all engines
- Unbolt oil pan.

Note: Loosen bolts on flywheel end of oil pan with jointed wrench 3185 and remove with socket T10058.

- Remove oil pan.

Note: It may be necessary to release the pan with light blows from a rubber headed hammer.





- Remove sealant residue from cylinder block with a flat scraper.
- Remove sealant residue from oil pan with a rotating brush, e.g. a hand drill with a plastic brush attachment (wear protective goggles).
- Clean sealing surfaces. They must be free of oil and grease.

Installing

Note:
^ Observe the use by date of the sealant.
^ The oil pan must be installed within 5 minutes of applying silicone sealing compound.





- Cut off tube nozzle at front marking (nozzle approximately 3 mm diameter).
- Apply silicone sealing compound, as shown, to clean oil pan sealing surface. Sealing compound bead must be:
2 to 3 mm thick
For BHP engine 1 to 2 mm and run on inside of bolt holes (arrows)

Note: The sealing compound bead must not be thicker, otherwise excess sealing compound will enter the oil pan and may block the oil suction pipe strainer.





- Apply sealing compound bead carefully to areas marked by (arrows).
- Install oil pan immediately and tighten bolts as follows:

Note:
^ When installing the oil pan on an engine which is removed from the vehicle, ensure that the oil pan is Rush with the cylinder block on the flywheel end.
^ The sealant must be allowed to cure for approximately 30 minutes after installing the pan. After this time the engine may be filled with engine oil.

1. Tighten all oil pan/cylinder block bolts lightly using a diagonal sequence.
2. Tighten three oil pan/transmission bolts lightly.
3. Tighten all oil pan/cylinder block bolts lightly using a diagonal sequence again.
4. Tighten oil pan/transmission bolts to 45 Nm.
5. Tighten all oil pan/cylinder block bolts to 15 Nm using a diagonal sequence.

Oil pan, lower part

Note:
^ Observe the use by date of the sealant.
^ The lower part of the oil pan must be installed within 5 minutes of applying silicone sealing compound.





Apply silicone sealing compound AMV 176 501 as shown, to clean sealing surface of lower part of oil pan.
- Sealing compound bead must be: A = 2 3 mm thick
- Run sealing compound bead along inner side of bolt holes (arrows)

Note: The sealing compound bead must not be thicker, otherwise excess sealing compound will enter the oil pan and may block the oil suction pipe strainer.

Engines with oil sump guard

Note:
^ Check condition of rubber bushings in cylinder block (for mounting spreader rivets) before installing oil pan cover.
^ Before bolts are reinstalled, clean threads and apply sealant D 000 600 A2.





- Insert spreader pin flush with spreader rivet -4- and install in oil pan cover -1 -
- Tighten bolts -2- in front and rear ends of oil sump to 37 Nm.

Continuation for all engines
The rest of the assembly is basically in reverse order to the removal sequence.