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 mete/ particles are found, this could indicate that the crankshaft and connecting rod bearings are damaged. To prevent consequential damage perform the following repairs:
^ Thoroughly clean oil passages
^ Replace oil spray jets
^ Replace oil cooler
^ Replace oil filter
^ The oil level must not be above the max. mark-danger of damage to three way catalytic converter! Marking see Fig. 1

Checking oil pressure and oil pressure switch.
Oil system capacity:
Without oil filter 4.0 liters.
With oil filter 4.5 liters.

Engine oil specifications:
Use engine oil to VW standard 500 00, 50101 or 502 00. Only in exceptional cases: Multi-grade oils corresponding to API-SF or SG.

Part I
Part II Disassembling oil filter bracket





1-15 Nm
2-Sealing flange
^ Must be located on dowel sleeves
^ Clean sealing surface before installing
^ Insert with silicone sealant D 176 404 A2
^ Removing and installing
3-Chain tensioner with tensioning rail, 15 Nm
^ Check for wear
^ When installing, pretension spring and install
4-Chain sprocket
^ For oil pump drive
^ Check for wear
5-Cylinder block
^ Removing and installing crankshaft.
^ Disassembling and assembling pistons and connecting rods.
6-Dipstick
^ The oil level must not be above the max. mark!
^ Markings see Fig.1
7-Guide
^ For dipstick
^ Pull off to extract oil
8-Guide tube
9-Oil spray jet
^ For piston cooling
10-Pressure relief valve, 27 Nm
^ Opening pressure: 1.3 to 1.6 bar
11-15 Nm
12-Suction pipe
^ Clean strainer if soiled
13-0 ring
^ Replace
14-Baffle plate
15-15 Nm
^ Loosen and tighten with Tbar and socket, 10 mm 3185
^ Remove with hexagon key extension, 5 mm 3249
16-Oil pan
^ Clean sealing surface before installing
^ Insert with silicone sealant D 176 404 A2
^ Removing and installing.
17-Oil drain plug,30 Nm
If sealing ring is leaking nip open and replace.
18-Gasket
^ Replace
19-Oil return pipe
^ From turbocharger
20-10 Nm
21-Oil pump
^ With pressure relief valve of 12 bar
^ Before installing, check that both dowel sleeves for centering oil pump/cylinder head are installed
^ Replace running surfaces and gears are scored
22-Chain sprocket
^ For oil pump
^ Check for wear
23-25 Nm
24-Roller chain
^ Mark D.O.R. before removing
^ Check for wear
25-Dowel sleeves
^ Check for tight fit





Fig. 1 Markings on oil dipstick
1-max. mark
2-min. mark
a-Area above hatched field up to max. mark: Do not top-up with engine oil!
b-Oil level within hatched field: can be topped-up with engine oil
c-Area from min. mark up to hatched field: fill with max. 0.5 ltr. of engine oil!

Part II





1-Sealing plug, 40 Nm
2-Seal
^ If sealing ring is leaking nip open and replace.
3-Spring
^ For pressure relief valve, approx. 4 bar
4-Piston
^ For pressure relief valve, approx. 4 bar
5-Gasket
^ Replace
6-Nonreturn valve, 8 Nm
7-Seal
^ Install onto shoulder of pipe
^ Replace if damaged
8-Connecting-pipe
^ For cylinder block breather
9-Retaining clip
^ Check for tight fit
10-Sealing plug, 15 Nm
11-Seal
^ If sealing ring is leaking nip open and replace.
12-20 Nm
13-Oil supply pipe
^ To turbocharger
14-Banjo bolt, 30 Nm
15-Gasket
^ Replace
16-1.4 bar oil pressure switch (F1), 25 Nm
^ Black
^ Checking
17-Seal
^ If sealing ring is leaking nip open and replace.
18-15 Nm + 1/4 turn (90°) further
^ Replace
19-Gasket
^ Replace
^ Fit into groove on oil cooler
20-Oil filter
^ Loosen with strap wrench
^ Tighten by hand
^ Observe installation instructions on oil filter
21-25 Nm
22-Oil cooler
^ Make sure clearance to adjacent components
^ Coat contact area to flange, outside the seal, with AMV 188 100 02
23-Oil filter bracket
^ With pressure relief valve approx. 4 bar