Engine Lubrication: Service and Repair

LUBRICATION SYSTEM COMPONENTS, REMOVING AND INSTALLING:

NOTES:
^ If when repairing an engine, metal shavings or a large quantity of small metal particles caused, for example, by partial seizure of crankshaft and conrod bearings, are found in the engine oil, to prevent consequential damage, apart from thoroughly cleaning oil passages, replace the oil cooler.
^ The oil level must not be above the max. mark, otherwise there is danger of catalyst damage!

Oil System Capacity:
^ Without oil filter 5.0L (5.3 quarts)
^ With oil filter 5.5L (5.8 quarts)

Engine Oil Specifications::

NOTE: Use engine oil that complies with VW standard 500 00 or 501 01. Under emergency conditions you can use Multi-grade oils corresponding to API-SF or SG standards.








Part I:
1 - Vibration damper center bolt
^ Removing, installing and tensioning toothed belt Service and Repair
^ Loosen and tighten using 3419 counterhold Service and Repair
Screw length: 65 mm
^ Coal threads and bolt head contact surface with sealing paste AMV 188 001 02
^ Tightening torque:
460 Nm (340 ft lb)
Screw length: 110 mm
^ Tightening torque:
160 Nm (118 ft lb) + 1/2 turn (2 x 90°) further
^ 90° additional turn can be carried out in several stages.
2 - Vibration damper with ribbed V-belt pulley
^ from 10.91
^ Vibration damper and crankshaft toothed belt sprocket can only be installed in one position
3 - Ribbed belt
^ from 10.91
^ Mark direction of rotation before removing
^ Check for wear
^ Remove/install with 3299 lever Service and Repair
4 - 10 Nm (7 ft lb)
5 - Mounting screw for vibration damper with ribbed belt
^ 20Nm (15 ft lb)
Ribbed belt pulley
^ 20 Nm + 1/4 turn (90° further)
6 - Front toothed belt guard - lower part
^ to remove; remove vibration damper if necessary
7 - Front toothed belt guard, upper section
8 - 15 Nm (11 ft lb)
9 - Woodruff key
^ with locking tab
10 - Tensioner
^ from 10.91
^ Removing, installing and tensioning toothed belt Service and Repair
11 - Camshaft sprocket securing bolt
^ Observe steel type marking on bolt head:
8.8 = 85 Nm (63 ft lb)
10.9 = 100 Nm (74 ft lb)
^ Loosen and tighten with 3036 counterhold
12 - Toothed belt Service and Repair
^ Removing and installing
13 - Camshaft sprocket
^ Note position when removing installing toothed belt Service and Repair
14 - Toothed belt guard - rear
^ to remove, take off vibration damper if necessary
15 - Oil pump housing
^ When installing; note coupling ring on crankshaft
^ Only replace as an assembly
16 - Oil pump drive gears
^ Identification mark "A" points in direction of end plate
17 - End plate
18 - Pressure relief valve
^ 40 Nm (30 ft lb)
^ Opening pressure: 5.3 to 6.3 bar
19 - Oil seal
^ Replacing Service and Repair
20 - Crankshaft sprocket
21 - Idler wheel
22 - V-belt
^ from 09.91
^ for generator
^ Check tension using thumb:
Max. deflection:
New V-bell approx. 2 mm
Used V-bell approx. 5 mm
^ Check V-belt tension en vehicles with toothed rack tensioner
23 - Vibration damper with V-belt pulley
^ from 09.91
^ Installing vibration damper and crankshaft toothed belt sprocket only possible in one position
24 - V-belt
^ from 09.91
^ for power steering pump
^ Check tension using thumb Deflection: approx. 5 mm (new and used V-belt)
^ Adjusting V-belt tension:



Part II:



1 - Cap
2 - Oil filler pipe
3 - To Intake hose
^ Breather hose secured with retainer to oil filler pipe item -2-
^ Ensure sufficient clearance to throttle valve housing
4 - Positive Crankcase Ventilation valve
5 - Sealing ring
^ Replace if damaged
6 - 0-ring
^ Replace if damaged
7 - Oil pressure switch F22
^ 25 Nm (18 ft lb)
^ 0.3 bar, brown
^ 0.25 bar, blue
^ Checking Testing and Inspection
^ If sealing ring leaking; nip open and replace.
8 - Oil pressure switch
^ 6 Nm (53 inch lb)
^ Remove and install with commercial type multi-point key 8
^ Coat with -D6- locking fluid when installing
9 - Adapter
^ 50 Nm (37 ft lb)
10 - 1,8 bar oil pressure switch F1
^ 25 Nm (18 ft lb)
^ White
^ Wire: Yellow
^ Checking Testing and Inspection
11 - Oil pan gasket
^ Replace
^ Do not stick-on, ensure positioned correctly
12 - Coupling ring
^ for oil pump
^ with four drive lugs
^ Split with chisel to remove
^ Heat new coupling ring to 200 °C max. before fitting
13 - Gasket
^ Replace
14 - 10 Nm (7 ft lb)
15 - Suction pipe
16 - Oil pan
17 - 2O Nm (15 ft lb)
^ M8, install bolt with hexagon head to gearbox side
18 - 10 Nm (7 ft lb)
^ Remove and install with 3249 socket
^ With flywheel installed:
Turn flywheel so that the recess aligns with bolt
19 - Mounting plate
^ Replace
20 - Sealing ring
^ Replace
21 - Oil drain plug
^ 50 Nm (37 ft lb)
22 - Oil collector
23 - Oil filter
^ Loosen with sockets 2067
^ Tighten by hand
^ Observe installation instructions on oil filter
24 - 20 Nm (15 ft lb)
25 - 25 Nm (18 ft lb)
26 - Guide tube
^ for dipstick
27 - Oil cooler
^ Coat contact area to flange, outside the seal, with AMV 188 100 02
^ Ensure clearance to adjacent components
^ See note Service and Repair
28 - Banjo bolt
^ 70 Nm (52 ft lb)
29 - Oil filter bracket
^ Installation position fixed by fitted pins
^ With oil non-return valve for hydraulic lifters
30 - Woodruff key
^ Check for tight fit
31 - from coolant pipe Service and Repair
32 - Dipstick
^ Oil level must not be above max. mark
^ Cap. difference between mm. and max. mark: 1.5 ltr. (1.6 qts)