Engine Lubrication: 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 connecting rod bearings) are found in the engine oil when performing repairs, clean the oil passages thoroughly and replace the oil cooler in order to prevent further damage from occurring later.
^ The oil level must not be above the max. mark, or there is danger of damage to the catalyst! Marking, Refer to Fig 1.
- - Thoroughly clean oil passages
- - Replace oil spray jets, oil cooler, and oil filter
Checking oil pressure and oil pressure switch, Refer to Oil Pressure, Testing and Inspection
Oil system capacity:
^ Without oil filter: 4.0 liters
^ With oil filter: 4.5 liters (4.8 qt )
Oil Capacities up to MY 2000
^ Additional Information, Maintenance Schedule for appropriate model year
Checking oil pressure, Refer to Oil Pressure, Testing and Inspection
Engine oil specifications:
The following terms must appear on the oil container singly or in combination with other designations:
^ VW502 00 or VW500 00 or VW501 01
^ ACEA A2 or ACEA AS
^ API-SJ or API-SL
^ 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. 15 Nm
2. Sealing flange
^ Must be located on dowel sleeves
^ Clean sealing surface before installing
^ Insert with silicone sealant D 176 404 A2, Refer to Timing Cover, Service and Repair, Front Sealing Flange, Removing and Installing
^ Replacing crankshaft oil seal (pulley end), Refer to Seals and gaskets, engine, Front Crankshaft Seal, Service and Repair
^ Removing and installing, Refer to Timing Cover, Service and Repair, Front Sealing Flange, 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, Refer to Crankshaft, Engine, Service and Repair
^ Disassembling and assembling pistons and connecting rods, Refer to Piston, engine, Service and Repair
6. Dipstick
^ Oil level must not be above max mark!
^ Markings, Refer to Fig. 1.
7. Guide
^ For dipstick
^ Pull off to extract oil
8. Guide tube
9. Oil spray jet
^ For piston cooling
10. Pressure relieve valve, 27 Nm
^ Opening pressure: 1.3 to 1.6 bar
11. 15 Nm
12. Suction pipe
^ Clean strainer if soiled
13. O-ring
^ Replace
14. Baffle plate
15. 15 Nm
^ Loosen and tighten with T-bar and socket, 10 mm 3185
^ Remove with hexagon key extension, 5 mm 3249
16. Oil pan
^ Clean sealing surface before installing
^ Install with silicone sealant D 176 404 A2, Refer to Oil Pan, Service and Repair
^ Removing and installing, Refer to Oil Pan, Service and Repair
17. Oil drain plug, 30 Nm
^ 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.
^ If sealing ring is leaking nip open and replace.
18. Seal
^ Replace
19. Oil return pipe
^ From turbocharger
20. 10 Nm
21. Oil pump
^ With with positive pressure relief valve 12 bar
^ Before installing, check that both dowel sleeves for centering oil pump/cylinder head are installed
^ Replace if running surfaces and gears are scored
22. Chain sprocket
^ For oil pump
^ Check for wear
23. 25 Nm
24. Roller chain
^ Mark direction of rotation 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 liter. 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, approximately 4 bar
4. Piston
^ For pressure relief valve, approximately 4 bar
5. Gasket
^ Replace
6. Non-return valve, 8 Nm
7. O-ring
^ Replace
^ Fit onto shoulder of connecting pipe - 8 -
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,Refer to Oil Pressure, Testing and Inspection
17. Seal
^ If sealing ring is leaking nip open and replace
18. 15 Nm +1/4 turn (90°) further
^ Replace
19. Gasket
^ Replace
^ Install 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
^ Ensure clearance to adjacent components
^ Coat contact area to flange, outside seal, with AMV 188 100 02
23. Oil filter bracket
^ With pressure relief valve approximately 4 bar