Volkswagen Workshop Service and Repair Manuals

Note:

The oil level must not be above the max. mark - danger of damaging catalyst!

Checking oil pressure

Oil system capacity1):

• ◆ Without oil filter: 3.0 ltr.
• ◆ With oil filter 056 115 561G (approx. 120 mm long): 3.5 ltr.
• ◆ With oil filter 030 115 561E (approx. 80 mm long): 3.4 ltr.

     1)     Up-to-date figures:

=> Exhaust emissions test binder

Engine oil specifications:

Use engine oil to VW standard 500 00 or 501 01. Only in exceptional cases: Multi-grade oils corresponding to API-SF or SG.

Vehicles with oil pump driven by chain
Vehicles with Duo-centric oil pump => Page 17-11

• Cap
• ◆ Renew seal if damaged
• 0.3 or 0.25 bar oil pressure switch (F22), 25 Nm
• ◆ 0.3 bar switch: brown
• ◆ 0.25 bar switch: blue
• ◆ Wiring: blue/black
• ◆ Checking => Page 17-24
• ◆ If sealing ring is leaking nip open and replace.
• 10 Nm
• Guide tube
• Guide
• ◆ Pull off to extract oil

• Dipstick
• ◆ The 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 with max. 0.5 ltr. of engine oil!
• 1.4 or 0.9 bar oil pressure switch (F1), 25 Nm
• ◆ 1.4 bar switch: black
• ◆ 0.9 bar switch: grey
• ◆ Wiring: yellow
• ◆ Checking => Page 17-24
• ◆ If sealing ring is leaking nip open and replace.
• Camshaft sprocket

• Oil filter
• ◆ Loosen with strap wrench
• ◆ Tighten by hand
• ◆ Observe installation instructions on oil filter
• Chain sprocket
• Tensioner
• ◆ Engine code AEA, AEE, AEX, APQ only
• ◆ Tensioning toothed belts
  => Page 13-20
• 20 Nm
• Toothed belt
• ◆ Mark D.O.R. before removing
• ◆ Check for wear
• ◆ Do not kink
• ◆ Removing, installing and tensioning
  => Page 13-20
• Toothed belt guard - upper part

• Toothed belt guard - lower part
• 20 Nm
• Hexagon bolt: 90 Nm + 1/3 turn
  (120 °) further
  Multi-point screw: 90 Nm + 1/4 turn (90 °) further
• ◆ Renew
• ◆ Oil threads
• ◆ The turning further can be done in several stages
• ◆ The turning further angle can be measured with a commercial protractor e.g. Hazet 6690
• Belt pulley
• ◆ When installing note fixing arrangement
• Crankshaft toothed belt sprocket
• Oil seal
• ◆ Renewing => Page 13-31
• Sealing flange

• Gasket
• ◆ Renew
• Sealing bush
• ◆ Renew if damaged
• ◆ Insert in sealing flange first
• ◆ Coat with oil when installing
• Chain
• ◆ Tensioning => Fig. 3
• Engine code ABU 02.93...09.93:
• ◆ Removing and installing chain guide rail => Fig. 4
• Oil pump
• ◆ Checking backlash
  => Fig. 1
• ◆ Checking axial clearance
  => Fig. 2
• Oil pump cover with pressure relief valve
• ◆ Opening pressure: 4.0...5.0 bar
• ◆ Clean strainer if soiled

• Seal
• ◆ Renew
• Oil drain plug
• ◆ Metal sump: 30 Nm
• ◆ Aluminium sump: 20 Nm
• Sump
• ◆ Engine code ABD, ABU: Steel sump
• ◆ Engine code AEA, AEE, AEX, APQ: Aluminium sump
• ◆ Clean sealing surface before installing
• ◆ Removing and installing engines with liquid gasket
  => Page 17-16
• 15 Nm
• ◆ Loosen and tighten the bolts flywheel end only with:
       Socket head bolts:
       3249
       Hexagon head bolts: 3185

• Gasket
• ◆ Not on engines with liquid gasket
• ◆ Renew
• ◆ Before fitting coat sump/cylinder block flanges with "D2"
• Engine code AEA:
• ◆ Metal gasket
• Bracket
• O-ring
• ◆ Renew
• Oil separator
• To cylinder head cover
• To air cleaner or air intake elbow

→ Fig. 1     Checking oil pump backlash

     New: 0.05 mm

     Wear limit: 0.20 mm

→ Fig. 2     Checking oil pump axial clearance

     Wear limit: 0.15 mm

→ Fig. 3     Tensioning drive chain

Note:

On engines with guide rail, this must be removed when checking or adjusting chain tension.

Tension chain by moving oil pump. Check tension with light thumb pressure.

Engine codes ABD ▸ 12.93, ABU ▸ 01.93 (without guide rail):

• Deflection a = 2.0...3.0 mm

Engine codes ABD 01.94 ▸, ABU 02.93 ▸ (with and without guide rail), AEA, AEE, AEX, APQ:

• Deflection
       Test figure: a = 4.0...5.0 mm
       Setting figure: a = 3.5...4.5 mm

→ Fig. 4     Removing and installing guide rail

•      1 -     Camshaft chain sprocket
•      2 -     Oil pump
•      3 -     20 Nm
•      4 -     Guide rail
•      5 -     10 Nm
•      6 -     Drive chain

Vehicles with Duo-centric oil pump

• Cap
• ◆ Renew seal if damaged
• 1.4 bar oil pressure switch (F1), 25 Nm
• ◆ Black
• ◆ Checking => Page 17-24
• 10 Nm
• Guide tube
• Guide
• ◆ Pull off to extract oil
• Dipstick
• ◆ The 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 with max. 0.5 ltr. of engine oil!

• Camshaft sprocket
• ◆ Note position when installing toothed belt
  => Page 13-20
• Oil filter
• ◆ Loosen with strap wrench
• ◆ Tighten by hand
• ◆ Observe installation instructions on oil filter
• Gasket
• ◆ Renew
• ◆ Must be located on dowel sleeves
• Tensioner
• ◆ Tensioning toothed belts
  => Page 13-20
• 20 Nm
• Toothed belt
• ◆ Mark D.O.R. before removing
• ◆ Check for wear
• ◆ Do not kink
• ◆ Removing, installing and tensioning
  => Page 13-20
• Toothed belt guard - upper part
• Toothed belt guard - lower part

• 20 Nm
• 90 Nm + 1/4 turn (90 °) further
• ◆ Renew
• ◆ Oil threads
• ◆ The turning further can be done in several stages
• ◆ The turning further angle can be measured with a commercial protractor e.g. Hazet 6690
• Belt pulley
• ◆ When installing note fixing arrangement
• Crankshaft toothed belt sprocket
• ◆ Note position when installing toothed belt
  => Page 13-20
• 8 Nm

• Oil seal
• ◆ Renewing => Page 13-31
• Oil pump
• ◆ Only renew complete
• ◆ When installing note follower on crankshaft
  => Page 17-19 , item 24
• ◆ Must be located on dowel sleeves
• ◆ Removing and installing
  => Page 17-19
• Gasket
• Suction pipe
• ◆ Clean strainer if soiled
• Follower
• ◆ Coat with oil before installing oil pump
• Seal
• ◆ Renew

• Oil drain plug
• ◆ Metal sump: 30 Nm
• ◆ Aluminium sump: 20 Nm
• Sump
• ◆ Removing and installing engines with liquid gasket
  => Page 17-16
• ◆ Clean sealing surface before installing
• ◆ Install with silicone sealant
  D 176 404 A2
  => Page 17-16
• Socket head combi-bolt
• ◆ Metal sump: 15 Nm
• ◆ Aluminium sump to aluminium block: 13 Nm
• ◆ On aluminium block: Renew bolts (coated with sealant)
• O-ring
• ◆ Renew
• Oil separator
• To cylinder head cover
• To air cleaner or air intake elbow