Volkswagen Touareg 2004-06

Oil Pan

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Removal & Installation



3.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove the engine from the vehicle.
  6.  
  7. Separate the engine from the transmission.
  8.  
  9. Attach a hoist to lift the engine, then secure the engine on a suitable engine assembly stand.
  10.  
  11. If equipped, unplug the 3-pin connector from the Oil Level Thermal Sensor.
  12.  
  13. Remove the bolts, then remove the oil pan.
    NOTE
    Loosen the oil pan with light blows of a rubber mallet if necessary.

  14.  
  15. Remove the sealant residue from cylinder block and oil pan. Sealing surfaces must be free of oil and grease.
  16.  

To install:

  1. Apply silicone sealant D 176 404 A2 or equivalent as shown. Sealing compound bead must be 2 to 3 mm thick and run on the inside of bolt holes.
    NOTE
    The sealing compound bead must not be thicker otherwise excess sealant will enter the oil pan and may block the oil suction pipe strainer.



    Click image to see an enlarged view

    Fig. Apply the sealant as shown-3.2L engines

  2.  
  3. Install oil pan immediately and tighten all oil pan bolts lightly. Tighten the oil pan bolts to 9 ft. lbs. (12 Nm).
    NOTE
    After installing the oil pan, the sealant must be allowed to dry for 30 minutes. Only after then may the engine oil be replenished.

  4.  
  5. The remaining installation is the reverse of removal.
  6.  

4.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove the engine from the vehicle.
  6.  
  7. Separate the engine from the transmission.
  8.  
  9. Attach a hoist to lift the engine, then secure the engine on a suitable engine assembly stand.
  10.  
  11. Remove the right engine mount.
  12.  
  13. Unscrew the oil filter housing.
  14.  
  15. At the left cylinder head, unfasten the bracket from the oil dipstick guide tube and pull the guide tube out.
  16.  
  17. Unfasten the bracket of the coolant drain pipe at the upper oil pan. If necessary, loosen the banjo bolt slightly.
  18.  
  19. Remove the bolts, then remove the lower and upper part of oil pan.
    NOTE
    Loosen the oil pan with light blows of a rubber mallet if necessary.

  20.  
  21. Remove the sealant residue from cylinder block and oil pan. Sealing surfaces must be free of oil and grease.
  22.  

To install:

  1. Apply silicone sealant D 176 404 A2 or equivalent as shown to the upper oil pan. Sealant bead must be about 1.5 mm thick and run on the inside of bolt holes.
    NOTE
    The sealing compound bead must not be thicker otherwise excess sealant will enter the oil pan and may block the oil suction pipe strainer.

  2.  
  3. Install the upper oil pan immediately.
    1. First tighten all oil pan bolts lightly in a diagonal sequence.
    2.  
    3. Tighten oil pan bolts (1) to 11 ft. lbs. (15 Nm) and bolts (2) to 16 ft. lbs. (22 Nm) in a diagonal sequence.

      Click image to see an enlarged view

      Fig. Apply sealant to the upper oil pan as shown-4.2L engines



      Click image to see an enlarged view

      Fig. Upper oil pan bolt identification-4.2L engines

    4.  

  4.  
  5. Apply silicone sealant D 176 404 A2 or equivalent as shown to the lower oil pan. Sealant bead must be about 1.5 mm thick and run on the inside of bolt holes.
  6.  
  7. Install the lower oil pan immediately.
  8.  
  9. First tighten all oil pan bolts lightly in a diagonal sequence. Then tighten again in a diagonal sequence to 7 ft. lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Apply sealant to the lower oil pan as shown-4.2L engines

  10.  
  11. Set the oil dipstick guide tube in place. Fasten the coolant drain pipe to upper part of oil pan to 7 ft. lbs. (10 Nm) and to the cylinder block to 22 ft. lbs. (30 Nm).
    NOTE
    After installing the oil pan, the sealant must be allowed to dry for 30 minutes. Only after then may the engine oil be replenished.

  12.  
  13. The remaining installation is the reverse of removal.
  14.  

 
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