Oil Pump: Service and Repair

Lubrication System Components, Removing And Installing

Note:
^ If large of metal particles or other deposits (caused, for example, by partial seizure of the crankshaft or conrod bearings) are found in the engine oil when performing repairs, clean the oil passages thoroughly and replace the oil cooler (mandatory) to prevent future damage.
^ The oil level must NOT be above the MAX mark - there is the possible danger of damaging the catalyst!

Oil pressure, checking, Refer to Engine Oil Pressure, Testing and Inspection

Oil capacity up to MY 2000
^ With oil filter 4.5 liters (4.75 quarts)

Oil capacity from MY 2001, refer to Oil, Specifications, Capacities

Engine oil specifications:
The following terms must appear on the oil container singly or in combination with other designations:
^ VW 505 00
^ ACEA B3 or ACEA B4
^ API Service CF4 or API Service CG4
^ Engine oils are graded according to their viscosity. The proper grade to be used in your engine depends on existing climatic or seasonal conditions.
^ The engine oil which was first put into your engine has a viscosity grade of SAE 5W-40. You can use this oil over all temperature ranges for normal driving. If engine oil viscosity grade SAE 5W-40 is not available, you can also use SAE 5W-30.





Part I
1. Oil pump
^ 12 bar pressure relief
^ Make sure both centering dowels are installed
^ Replace if any running surfaces or gears are scored
2. Chain sprocket
3. 25 Nm (18 ft. lbs.)
4. Chain
5. Sealing flange
6. 15 Nm (11 ft. lbs.)
7. Chain tensioner (with tensioning rail)
^ 15 Nm (11 ft. lbs.)
^ To installs first pretension spring
8. Dipstick
^ Oil level must NOT be above the MAX. mark!
9. Guide
^ Remove to draw out oil
10. Guide tube
11. Centering dowels
12. O-ring
^ Always replace
13. Suction pipe
^ Clean strainer if soiled
14. Baffle plate
15. Oil pan
^ Clean sealing surfaces before installing
^ Install with silicone sealant D 176 404 A2
16. Seal
^ Integral with oil drain plug
17. Oil drain plug
^ 30 Nm (22 ft. lbs.)
^ Replace if leaking. See Parts Supplier for correct application. In some cases seal and drain plug are combined; do not interchange with separate seal and drain plug.





Part II
1. Sealing plug
^ 25 Nm (18 ft. lbs.)
2. Gasket
^ Always replace
3. Oil cooler
4. Gasket
^ Always replace
^ Install into oil cooler groove
5. Seal
^ If seal leaks nip open and replace.
6. Plug
^ 10 Nm (7 ft. lbs.)
7. Sealing plug
^ Do NOT open
8. Spring
^ For pressure relief valve approximately 5 bar
9. Piston
^ For pressure relief valve approximately 5 bar
10. 0.9 bar oil pressure switch -F1-
^ 25 Nm (18 ft. lbs.)
11. Gasket
^ Always replace
12. 15 Nm (11 ft. lbs.) plus additional1/4 turn (90°)
^ Always replace
^ Place bolts first top left and right then tighten all four bolts over cross
13. Oil filter bracket
14. Seal
^ Always replace
15. Oil supply pipe
^ To the turbocharger
16. Banjo bolt
^ 20 Nm (15 ft. lbs.)
17. Sealing cap
^ 25 Nm (18 ft. lbs.)
^ Loosen and tighten using 3417 oil filter wrench
18. O-ring
^ Always replace
19. Oil filter element





Fig. 1 Dipstick, markings
1. MAX. mark
2. MIN. mark
a. Area above cross-hatched zone up to the MAX. mark:
Do not top-up with engine oil!
b. Oil level within cross-hatched zone:
Can be topped-up with engine oils as necessary
c. Area from MIN. mark up to cross-hatched zone:
Fill with 0.5 ltr. (0.47 quarts) of engine oil maximum!