Oil Pan, Upper Section

Oil Pan, Upper Section

Special tools, testers and auxiliary items required

• Body Repair Saw (VAS 5108)

• 300 mm Universal Grip Pliers (VAS 5433)

• Protective eye-wear

• Hand drill with plastic brush attachment

• Sealant

Removing

• Engine oil drained.

• Engine secured to Engine and Transmission Holder (VAS 6095). Refer to => [ Engine, Securing to Engine and Transmission Holder ] Engine, Securing to Engine and Transmission Holder

- Vehicles with multitronic transmission. Refer to : Remove damper unit=> [ Damper Unit ] Damper Unit and flywheel => [ Flywheel, Multitronic Transmission ] Flywheel, Multitronic Transmission.

- Vehicles with automatic transmission 09L: Remove drive plate. Refer to => [ Drive Plate, Automatic Transmission 09L ] Drive Plate, Automatic Transmission 09L.

- Remove lower section of oil pan. Refer to => [ Oil Pan Lower Section ] Oil Pan Lower Section.

- Remove oil pump. Refer to => [ Oil Pump ] Service and Repair.

- Remove bolts - arrows - and remove lower oil baffle.





- Remove the bolts - 1 through 4 - on the timing chain lower cover.





- Remove bolts - 1 to 6 - for upper section of oil pan.





- Carefully loosen the oil pan upper section from the bond and press it off the cylinder block alignment bushings.

Installing

• Replace gaskets, seals and O-rings.

- Remove any old sealant from the grooves on the oil pan upper section as well as on the timing chain lower cover - arrows - with a screwdriver.





CAUTION!
Wear safety glasses.

- Remove any remaining sealant on oil pan upper section using for example a rotating plastic brush.





- Seal off the oil return channel with adhesive tape - 1 -.





- Cover the cylinder block with a cloth - 2 -.

- Seal off any open threaded holes with adhesive tape to protect them from any shavings.

- Secure a 2.5 mm thick metal strip - 1 - exactly 65 x 100 mm big, using the 300 mm Universal Grip Pliers (VAS 5433) next to the alignment bushing.





• The metal strip serves as a stop when sawing and at the same time protects the sealing surface on the guide frame.

CAUTION!
Wear safety glasses.

- Saw the alignment bushing at same height as the metal strip in a Body Saw (VAS 5108).

- Repeat this on the second alignment bushing.

- Remove any burrs on the alignment bushings.

- Make a 1.5 mm chamfer on the oil pan lower section on both holes for the alignment bushings using a deburring tool.





- Clean the sealing surfaces on the oil pan lower section and the on the timing chain lower cover; they must be free of oil and grease.

• Note the expiration date of the sealing compound.

- Cut tube nozzle at front marking (jet dia. approximately 2 mm).





- Apply the sealant bead - arrow - to the clean sealing surface on the oil pan upper section as illustrated.





• The grooves - arrows - of sealing surfaces must be completely filled with sealant.

• The sealant bead must be 1.5 to 2.0 mm above the sealing surface.

- Apply a sealant bead - arrow - to the clean sealing surface of the lower timing chain cover as shown in the illustration.





• The groove of sealing surface must be completely filled with sealant.

• The sealant bead must stand 1.5 to 2.0 mm above the sealing surface.

• The sealant bead must run all the way into the corners.

• Sealant bead must not be thicker than specified, otherwise sealant could get into oil pan and clog the oil pump strainer.

• The oil pan (upper section) must be installed within 5 minutes after application of sealant.

- Insert the seal - 1 - and the O-ring - 2 - in the guide frame.





- Mount the oil pan lower section, paying attention to the alignment bushings, and tighten the bolts - 1 through 6 - diagonally to 5 Nm.





- Pre-tighten bolts - 1 to 4 - in diagonal sequence to 5 Nm.





- Tighten the bolts - 1 through 6 - diagonally.





- Tighten the bolts - 1 through 4 - diagonally.





Further installation is in reverse order of removal, note the following:

- Install oil pump. Refer to => [ Oil Pump ] Service and Repair.

- Install lower section of oil pan. Refer to => [ Oil Pan Lower Section ] Oil Pan Lower Section.

- Vehicles with multitronic transmission. Refer to: Install flywheel => [ Flywheel, Multitronic Transmission ] Flywheel, Multitronic Transmission and damper unit => [ Damper Unit ] Damper Unit.

- Vehicles with automatic transmission 09L. Refer to: Install drive plate => [ Drive Plate, Automatic Transmission 09L ] Drive Plate, Automatic Transmission 09L.

- After installing the engine, fill with oil and check the oil level.

Tightening Specifications