Oil Pan
Oil Pan
Special tools, testers and auxiliary items required
• Engine support bridge (10-222 A)
• Multi-point socket (T10058)
• Old oil collecting and extracting device (V.A.G 1782 )
• Shop crane (VAS 6100)
• Insert pad for front fender (T40045)
• Hand drill with plastic brush attachment
• Protective glasses
• Sealant
Removing
• All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
- Remove engine cover - arrows -.
- Remove rubber seal on fender attachment edges.
- To prevent damage to fender edges when using engine support bridge (10-222 A), place insert pad for front fender (T40045) on both sides between fender attachment edge and web plate lying beneath.
- Position engine support bridge (10-222 A) with adapters (10-222/3) on fender attachment edge.
- Hook in spindles at engine lifting eyes, as shown.
- Pretension engine slightly with spindles.
- Remove ribbed belt => [ Ribbed Belt ] Ribbed Belt
- For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.
- Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
- Remove quick-release fasteners - 3 - and remove rear noise insulation, if installed.
- Place old oil collecting and extracting device ( V.A.G 1782) under engine and drain engine oil.
- Remove bolts - arrows - and remove torque supports from oil pan.
- Remove turbocharger oil return line - 1 - from oil pan.
- Disconnect electrical harness connector - arrow - at Oil Level Thermal Sensor (G266).
- Remove bracket for refrigerant line on oil pan - arrow -.
- Separate connector - 1 - for wiring to air conditioning compressor clutch solenoid.
CAUTION!
The air conditioning refrigerant circuit must not be opened.
- Remove air conditioning compressor from bracket - arrows -.
• To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
- Hang up A/C compressor with attached lines at bottom of vehicle.
- Disconnect electrical harness connector - arrow - at Left Front Level Control System Sensor (G78).
- Remove stabilizer bar mountings - 1 - and - 2 -.
- Support subframe with workshop crane (VAS 6100 ) or (V.A.G 1202 A).
- Cut through cable ties - arrows -, open starter harness retainer and take harness out.
- Remove lower nut - 3 - on engine mount.
- Remove bolts - 4 - and - 5 - on engine mount plate.
- Remove front bolt - 1 - for subframe and remove engine mount plate - 2 -.
- Repeat work procedure on opposite side of vehicle.
- Slowly lower subframe with workshop crane (VAS 6100 ) or (V.A.G 1202 A).
- Lift engine slightly upward using spindles of engine support bridge (10-222 A), paying attention to clearance of shift linkage and exhaust system.
- Remove bolts - arrows - for transmission/oil pan.
- Remove M10 bolts - arrows -.
- Loosen bolts - 1 to 18 - in a diagonal sequence.
- Remove oil pan, and if necessary loosen by applying light strikes with a rubber hammer.
Installing
Installation is in reverse order of removal, note the following:
• Replace seal.
• Secure all hose connections using hose clamps appropriate for the model type.
• During installation, all cable ties must be re-installed at the same location.
- Remove residual sealant from oil pan and at cylinder block, e.g. using a rotating plastic brush.
CAUTION!
Wear safety glasses.
- Clean sealing surfaces, they must be free of oil and grease.
- Cut off nozzle on tube of sealant at front mark (dia. of nozzle approx. 2 mm).
- Apply sealant bead as illustrated to clean sealing surface of oil pan.
• Thickness of sealant bead: 2 to 3 mm.
• The sealant bead may not be thicker than 3 mm, otherwise excess sealant could enter the oil pan and clog the oil intake tube.
• Apply a bead of sealant at the rear area of the sealing flange very carefully - arrows -.
• The oil pan must be installed within 5 minutes of being applied with sealant.
- Install oil pan immediately and tighten bolts in described sequence:
- Pre-tighten bolts - 1 to 18 - in diagonal sequence to 5 Nm.
- Tighten oil pan/transmission bolts to 45 Nm.
- Tighten bolts M10 - arrows - to 40 Nm.
- Tighten bolts - 1 to 18 - in diagonal sequence to 15 Nm.
• When installing the oil pan - 3 - on a removed engine, make sure that the flywheel end of the oil pan is aligned flush with the intermediate plate - 1 -, therefore the oil pan must extend beyond the cylinder block - 2 - by dimension - a - 0.8 mm.
• After installing oil pan, allow sealant to dry for approx. 30 minutes. Only after then may the engine oil be replenished.
- Install subframe.
- Install stabilizer bar.
- Install A/C compressor.
- Install ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Add engine oil and check oil level.
The rest of assembly is basically a reverse of disassembling sequence.
Tightening Specifications
Part I Oil pan, balance shaft assembly. Refer to => [ Sealing Flange and Oil Pan Component Overview ] Sealing Flange and Oil Pan Component Overview