Engine Lubrication: Service and Repair

Lubrication system components, removing and installing

Note:
^ If when repairing an engine, metal shavings or large amounts of small metal particles are found in the engine oil, caused for example by partial seizure of crankshaft or conrod bearings. Perform the following work sequences to prevent consequential damage once repairs are complete:
^ 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 catalytic converter! Markings.

Disassembling and assembling oil filter bracket, Refer to Oil Filter Housing, Service and Repair
Disassembling and assembling oil pump with balancer shaft gear assembly, Refer to Oil Pump, Service and Repair
Removing and installing oil pump with balancer shaft gear assembly, Refer to Oil Pump, Service and Repair
Checking oil pressure and oil pressure switch, Refer to Oil Pressure, Testing and Inspection

Engine oil specifications
Use engine oils which conform with VW standard 500 00, 501 01 or 502 00. Only in exceptional cases: Multigrade and single grade oils conforming with API-SF and SG or ACEA A2/A3.

Note:
^ In the factory the engine is filled with engine oil conforming with VW standard 503 00. This engine oil is designed for long service intervals (ESI).
^ Engine oils conforming to VW standard 500 00, 501 01 or 502 00 may also be used.

Oil system capacity
Without oil filter: 3.5 L
With oil filter: 4.0 L
Top up to MAX. mark if necessary.

Cylinder Block Components:

1- 15 Nm
2- Sealing flange
^ Must be seated on dowel sleeves
3- Cylinder block
4- Dipstick
5- Guide tube
6- Dipstick guide
^ Secured to intake manifold
7- Oil spray jet
^ For piston cooling
8- Pressure relief valve, 27 Nm
9- Oil pump with balancer shaft gear assembly
^ With pressure relief valve of 12 bar
10- 15 Nm + 1/4 turn (90°) further
^ Observe different lengths of bolts, Refer to Fig. 2
11- 15 Nm
12- Oil pan
^ Clean sealing surface before installing
13- Seal
^ Replace
^ Cut open seals which have been rolled on
14- Oil drain plug, 30 Nm
15- Chain sprocket
16- 20 Nm
17- Chain guard
18- Chain

Oil Dipstick Mark Identification.:

Dipstick marks
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: Top up with max. 0.5 L of engine oil!






Bolt allocation for balancer shaft gear assembly
A - M7 x 40 hex bolt
B - M7 x 55hex bolt
C - M7 x 90 hex bolt
D - Sealing plug with O-ring