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 connecting rod 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 or there is a danger of damage to the catalytic converter!
- Markings; Refer to Fig 1
Checking oil pressure and oil pressure switch, Refer to Oil Pressure Testing and Inspection
Oil system capacity
with oil filter: 4.0 liters
Engine oil specifications:
Use engine oils according to VW standard 500 00, 501 01 or 502 00. Multigrade and single grade oils conforming with API-SF and SO or ACEA A2/A3 may also be used if oil to VW standard is not available.
Note:
^ In the factory the engine is filled with engine oil conforming to VW standard 503 00. This engine oil is designed for long service intervals.
^ Engine oils according to VW standard 500 00, 501 01 or 502 00 can be used.
Engine oil specifications: Models from 05.99 with long-life service
Use engine oil conforming to VW standard 503 00
Note:
^ In the factory the engine is filled with engine oil conforming to VW standard 503 00. This engine oil is designed for long service intervals.
^ Engine oils according to VW standard 500 00, 501 01 or 502 00 can be used. The oil must be changed every 12 months or every 15,000 km and the service interval display must be programmed correspondingly.
Engines: AEG, APK, AQY, AVH, AZG, BEV, assembly overview
1. 15 Nm
2. Bracket
^ For engines: APK, AQY
^ For oil level/oil temperature sensor wiring harness
3. 25 Nm
4. Pressure relief valve, 27 Nm
5. Oil spray jet
^ For piston cooling
6. Dipstick
^ Oil level must not exceed Max mark!
7. Dipstick guide
^ Fastened to intake manifold
^ Pull off to extract oil
8. Guide tube
9. Adjustment bushings
10. O-ring
^ Always replace
11. 15 Nm
12. Suction line
^ Refer to Parts Supplier
^ Clean strainer if soiled
13. Baffle plate
14. 15 Nm
15. 15 Nm
16. Oil pan
^ Clean sealing surface before installing
^ Insert with silicone sealant D 176 404 A2
17. Seal
^ Always replace
18. Oil drain plug, 30 Nm
19. 10 Nm
20. Oil level thermal sensor -G266
^ For engines: APK, AQY
21. Seal
22. 25 Nm
23. Sealing flange
^ Must be located on dowel sleeves
^ Insert with silicone sealant D 176 404 A2
24. Chain tensioner with tensioning rail, 15 Nm
^ When installing, pretension spring first
25. Chain
26. 20 Nm
^ Use counter support T10051 to loosen and tighten
27. Chain sprocket for oil pump
^ Observe installation position
28. Oil pump
^ With pressure relief valve of 12 bar
^ Before installing, check that both dowel sleeves for centralizing oil pump/cylinder block are installed
^ Replace if running surfaces and gears are scored
Engines: BBW, BEJ, BER, assembly overview
1. 15 Nm
2. Sealing flange
^ Must be located on dowel sleeves
^ Insert with silicone sealant D 176 404 A2
3. Chain tensioner with tensioning rail, 15 Nm
^ When installing, pretension spring first
4. Dipstick
^ Oil level must not exceed Max mark!
5. Dipstick guide
^ Fastened to intake manifold
^ Pull off to extract oil
6. Guide tube
7. Oil spray jet
^ For piston cooling
8. Pressure relief valve, 27 Nm
9. 15 Nm
10. Suction line
^ Refer to Parts supplier
^ Clean strainer if dirty
11. O-ring
^ Always replace
12. Baffle plate
13. Rubber bushing
^ On cylinder block
^ Replace if damaged
14. Sleeves
15. Oil pan guard
16. 37 Nm
17. Rivert spreader
^ With spreader pin
18. Seal
^ Always replace
19. Oil drain plug, 30 Nm
20. Oil pan
^ Clean sealing surface before installing
^ Insert with silicone sealant D 176 404 A2
21. 20 Nm
^ Use counter support T10051 to loosen and tighten
22. Chain sprocket for oil pump
^ Observe installation position
23. Oil pump
^ With pressure relief valve of 12 bar
^ Before installing, check that both dowel sleeves for centralizing oil pump/cylinder block are installed
^ Replace if contact surfaces and gears are scored
24. Chain
25. Adjustment bushings
Engine: BHP, assembly overview
1. 15 Nm
2. Sealing flange
^ Must be located on dowel sleeves
^ Insert with silicone sealant D 176 404 A2
3. Pressure relief valve, 27 Nm
4. Oil spray jet
5. Dipstick
^ Oil level must not exceed Max mark!
6. Dipstick guide
^ Fastened to intake manifold
^ Pull off to extract oil
7. Guide tube
8. Adjustment bushings
9. O-ring
^ Always replace
10. 15 Nm
11. Suction line
^ Refer to Parts supplier
^ Clean strainer if dirty
12. Baffle plate
13. Oil pan, upper part
^ Clean sealing surface before installing
^ Insert with silicone sealant D 176 404 A2
14. 15 Nm
15. 22 Nm
16. Oil pan, lower part
^ Clean sealing surface before installing
^ Insert with silicone sealant D 176 404 A2
17. Seal
^ Always replace
18. Oil drain plug, 30 Nm
19. 10 Nm
20. Oil pump
^ With pressure relief valve of 12 bar
^ Before installing, check that both dowel sleeves for centralizing oil pump/cylinder block are installed
^ Replace if contact surfaces and gears are scored
21. Chain sprocket for oil pump
^ Observe installation position
22. Chain
23. 20 Nm
^ Use counter support T10051 to loosen and tighten
24. Chain tensioner with tensioning rail, 15 Nm
^ When installing, pretension spring first
Fig. 1 Dipstick marks
1. Max. mark
2. Min. mark
a - Area above hatched field up to max. mark: Do not add engine oil
b - Oil level within hatched field: May add engine oil
c - Area from min. mark up to hatched field: Add max. 0.5 liters of engine oil