Engine Lubrication: Service and Repair
Lubrication System Components, Removing and Installing
Notes:
^ If large quantities 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 to prevent further damage from occurring later
^ Oil level must not be above the max. mark - danger of catalyst damage!
Oil system capacity:
WITH oil filter 3.8 ltrs. (4.0 quarts)
Engine oil specifications:
Only use engine oil conforming to VW standard: 50500.
1. Cap
2. Gasket
- Replace if damaged
3. Dipstick
^ Oil level must not be above the max. mark!
^ Area above shaded zone up to max. mark: Do not top up with engine oil!
^ Oil level in shaded zone: Engine oil can be topped up
^ Area min. mark up to shaded zone: Top-up engine oil
4. Seal
- Replace
5. Banjo bolt
^ 25 Nm (18 ft. lbs.)
6. to turbocharger
7. 25 Nm (18 ft. lbs.)
8. Oil filter bracket
9. 0.9 bar oil pressure switch F1
^ 25 Nm (18 ft. lbs.)
^ Gray
^ Checking
- If sealing ring is leaking, nip open and replace.
10. Gasket
^ Replace
11. 0-ring
- Replace
12. Oil cooler
- Coat contact area to flange, outside the seal, with AMV 188 100 02
- Ensure clearance to adjacent components
- See note
13. 25 Nm (18 ft. lbs.)
14. Oil filter
- Loosen using strap wrench
- Tighten by hand
- Observe installation instructions on oil filter
15. Gears
^ Backlash, checking refer to Fig. 1
^ Axial clearance, checking refer to Fig. 2
16. Oil pump cover with pressure relief valve
^ Opening pressure: 5.7 to 6.7 bar
17. 10 Nm (7 ft. lbs.)
18. Oil Pan
- Clean sealing surface before installing
19. Oil drain plug
^ 30 Nm (22 ft. lbs.)
20. 20 Nm (15 ft. lbs.)
- Remove and install both rear bolts (trans. end) with 3185 hinged socket
21. Gasket
- Replace
^ Before fitting gasket coat oil pan flange/cylinder block flange with "D2"
22. Suction pipe
- Clean strainer if soiled
23. 0-ring
- Replace
24. 10 Nm (7 ft. lbs.)
- Insert with AMV 188 100 02
25. oil spray jet
^ For piston cooling
26. Guide
- Pull off to draw out oil
Fig. 1 Oil pump backlash, checking
^ New: 0.05 mm
^ Wear limit: 0.20 mm
Fig. 2 Oil pump axial clearance, checking
^ Wear limit: 0.15 mm