Oil Pan: Service and Repair

Oil pan, removing and installing

Special tools and equipment
- 10-222A engine support bridge with 10222A/1 bracket for engine
- 2024A engine sling
- 3249 puller
- VAG1202A engine hoist
- AMV 174 004 01 sealant

Note: Always replace gaskets.

Removing




- Remove noise insulation panel (arrows).
- Drain engine oil.

CAUTION! Before removing ribbed belt, note direction of rotation with chalk or felt-tip marker. Reversing the direction of rotation of a used belt can destroy the belt




- Remove bolts for ribbed belt tensioner for A/C compressor (arrows).
- Release tension on ribbed belt and remove.
- Remove belt pulley.




- Remove torque support stop (arrows).
- Remove side brace from left side of torque support bracket.




- Remove torque support bracket from engine (arrows).

Note: Illustration is shown with engine removed.




- Cut tie wraps (arrows), open bracket for starter wiring and remove wiring.




- Remove hose from turbocharger at air guide tube in lock carrier (arrow).




- Remove both nuts -1- from lower engine mount.
- Remove engine covers.




- Set 10-222A engine support bridge on fender mounting edges.




- Remove mounting eye from 2024A engine sling.
- Insert bolt -1- in center bore of 2024A engine sling and secure using cotter pin.
- Attach 2024A engine sling bolt to 10-222A engine support bridge spindle.
- Attach 2024A engine sling to mounting eyes at front and rear of engine.

WARNING! Mounting hooks and pins on the engine sling must be secured with the positioning lock (arrows).

- Using 10-222A engine support bridge spindle, lift up engine as far as possible.

Note: Lift engine only as far as possible without over-stretching or damaging any pipes or coolant hoses. Check for clearance of viscous fan; if necessary remove.

- Release tension on ribbed belt.




- Secure belt pulley for viscous fan using M5 x 60 mm bolt and unbolt using 8mm hex socket wrench.
- Remove viscous fan and place forward in fan frame.




- Use VAG 1202A engine hoist to support subframe.




- First remove front bolts -2- and -3- from subframe, then remove bolt -1-.

Note: Only loosen or lower subframe at front to avoid changing wheel alignment.




- Using VAG 1202A engine hoist slowly lower subframe.
- Pullout VAG 1202A engine hoist and swing stabilizer down.




Vehicles with manual transmission
- Loosen left transmission mount nut (arrow) until it is aligned with lower edge of bolt (approximately 4 turns).




Vehicles with automatic transmission
- Loosen rear bolt -2- for left transmission mount several turns. Remove front bolt - 1 for left transmission mount.




All models
- Loosen rear bolt -2- for right transmission mount several turns. Remove front bolt -1 for right transmission mount.
- Remove oil return line for turbocharger at oil pan.
- Unbolt oil pan.




Note:
- For vehicles with manual transmission: both rear bolts on oil pan can be reached through opening on flywheel (arrow). Turn flywheel as needed.
- Use 3249 hex ball socket to remove rear oil pan bolts.

- Remove oil pan (if necessary tap lightly using rubber hammer to remove).

Installing
Installation is the reverse of removal, noting the following:

Note:
- Replace gaskets and O-rings.
- When installing oil pan on removed engine, note that oil pan is aligned with metal plate on flywheel side (i.e. oil pan projects out over engine block 0.8 mm, or 0.0315 inch).

- Clean sealing surfaces before installing oil pan.
- Lightly spread AMV 174 004 01 sealant on front and rear contact surfaces of oil seal carrier.
- Tighten bolts between oil pan and engine block in 2 stages and diagonal sequence.
- Install oil pan and tighten all bolts between oil pan and engine block to 5 Nm (44 inch lbs.) (stage 1).
- Tighten bolts between oil pan and transmission.
Tightening torque: 45 Nm (33 ft. lbs.)
- Tighten M10 bolts between oil pan and engine block.
Tightening torque: 45 Nm (33 ft. lbs.)
- Tighten all M6 bolts between oil pan and engine block to 10 Nm (7 ft. lbs.) (stage 2).
- Place torque support on rubber buffer for torque support and tighten bolts to 25 Nm (18 ft. lbs.).
- Install ribbed belt.

Note: When installing ribbed belt, check for correct seating on belt pulley.

- Add engine oil and check oil level.

CAUTION! Do not overfill with oil past the MAX mark on the oil dipstick. Damage to the Three Way Catalytic Converter (TWC) could result.




Tightening torques