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 (mandatory) to prevent future damage.
^ The oil level must not be above the max. mark or there is the possibility of damage to the catalytic converter.

Checking oil pressure; Refer to Oil Testing and inspection

Oil system capacity
^ with oil filter: 4.5 liters

Engine oil specifications
Only use engine oil conforming to VW standard 505 01.





1. 15 Nm
2. Sealing flange
3. Chain tensioner with tensioning rail, 15 Nm
^ When installing, pretension spring and install
4. Dipstick
^ Oil level must not exceed max mark!
5. Guide
^ Pull off to extract oil
^ With rubber grommet for engine cover
6. Guide tube
7. Oil spray jet
^ For piston cooling
8. 25 Nm
^ Insert without sealant
9. Dowel sleeves
10. 15 Nm
11. Suction line
^ Clean strainer if soiled
12. O-ring
^ Always replace
13. Baffle plate
14. 15 Nm
15. 15 Nm
16. Oil pan
17. Seal
^ Always replace
18. Oil drain plug, 30 Nm
^ Replace plug with attached seal
19. Oil pump
^ With pressure relief valve of 12 bar
^ Before installing, check that both dowel sleeves for centering oil pump/cylinder block are installed
^ Replace if contact surfaces and gears are scored
20. Chain gear for oil pump
21. 25 Nm
^ Use counter-bracket T10051 to loosen and tighten
22. Chain
^ Mark direction of rotation before removing

Fig. 1 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: Engine oil level can be topped up.
c. Area from min. mark up to hatched field: Add a max. of 0.5 liter of engine oil!

Part 2: Disassembling oil filter bracket





1. Oil pressure switch -F1-, 20 Nm
^ 0.7 bar connector, brown
2. Seal
^ Always replace
3. 15 Nm plus an additional 1/4 turn (90°)
^ Always replace
^ First install upper left and lower right bolt, then tighten four bolts diagonally
4. Oil filter bracket
5. Seal
^ Always replace
6. Oil supply line
7. Banjo bolt, 20 Nm
8. Sealing cap, 25 Nm
^ Loosen and tighten with oil filter wrench 3417
9. O-ring
^ Always replace
10. Oil filter element
^ Note installed position: top
11. Sealing plug, 25 Nm
12. Seal
^ Always replace
13. Oil cooler
14. Seal
15. Sealing plug, 10 Nm
^ If sealing ring is leaking, cut open and replace
16. Sealing plug
^ For pressure relieve valve
^ Do not loosen

Part 3: Removing and installing oil return line to turbocharger

Assembly overview





1. Oil supply line
^ To exhaust turbocharger
2. Union nut, 22 Nm
^ When tightening and loosening counter hold line union
3. Seal
^ Always replace
4. Banjo bolt, 25 Nm
5. Clamp
6. 10 Nm
7. Bracket
8. 25 Nm
^ Always replace
9. 10 Nm
10. 10 Nm

Work sequence
Removing





^ Remove sound insulation.
^ Position drip tray VAG1306 underneath.
^ Remove air filter housing.
^ Unscrew union nut -2- or banjo bolt -4- at oil filter bracket.
^ Remove bolt -6-.
^ Unfasten union nut -2- at turbocharger.
^ Remove bolt -9- from bracket -7-.
^ Remove nut -8- and remove bracket -7-.
^ Remove oil return line -1-.

Installing





Installation is performed in reverse sequence of removal. In the process, note the following:

CAUTION: Adhere strictly to the installation procedure for the oil return line.

^ Install bracket -7- with nut -8- loosely to exhaust manifold.
^ Install union nut -2- or banjo bolt -4- at oil filter bracket hand-tight.
^ Install union nut -2- hand-tight at turbocharger.
^ Install union nut -2- or banjo bolt -4- at oil filter bracket with correct tightening torque.





^ Install union nut -2- to turbocharger with correct tightening torque.
^ Position clamps -5- on oil return line.
^ Install bolts -6- and -9- with correct tightening torque.
^ Tighten nut -8- with correct tightening torque.