Volkswagen Workshop Service and Repair Manuals

Removing and installing oil sump Special tools and workshop equipment required

t  Jointed wrench 10 mm -3185-

t  Special wrench, long reach -T10058- t  Hand drill with plastic brush t  Sealant → Electronic parts catalogue t  Eye protection Removing –  Drain engine oil → Booklet.

–  Remove air hose; loosen hose clip -2- and raise retaining clip -1- for this.

–  Remove bolts -arrows-. –  Free coolant hose -3-. –  Loosen hose clip -2-. –  Disconnect electrical connector -1- on charge pressure sender -G31- and remove right air pipe.

–  Unscrew bolt -arrow- and push coolant circulation pump 2 -V178- to the side.

–  Unscrew bolt -arrow- on left air pipe.

–  Disconnect electrical connector -arrow- on oil level and oil temperature sender -G266-.

–  Remove front noise insulation -1- for sump, loosen securing parts -arrows- for this. –  In vehicles with an auxiliary heater, remove the bracket for the coolant lines from the oil sump on the right.

–  Unscrew bolts -arrows- of sump to gearbox connection. –  Slacken bolts -1 … 20- in diagonal sequence and remove. –  Release oil sump carefully from adhesive. Installing   Caution Danger of soiling lubrication system and bearings. Cover open parts of engine.   WARNING Risk of eye injury. Wear safety goggles.

–  Remove sealant residues from sump and cylinder block using rotating plastic brush or similar. –  Clean sealing surfaces; they must be oil- and grease-free.   Note

Observe use-by-date of sealant. –  Cut off nozzle on tube at front marking (Ø of nozzle approx. 2 mm).   Caution Danger of blocking lubrication system with excess sealant. Do not apply sealant bead thicker than specified. –  Apply bead of sealant onto clean sealing surface of sump as illustrated.

l  Thickness of sealant bead: 2…3 mm.   Note t  Take particular care when applying the sealant bead near the rear sealing flange -arrows-. t  The sump must be installed within 5 minutes after sealant is applied.

–  Position oil sump and tighten bolts → Fig.. l  The oil sump must be flush with the gearbox flange at the intermediate plate.   Note t  When installing sump with engine removed from the vehicle, ensure that sump is flush with cylinder block at flywheel end. t  Allow sealant to dry for approx. 30 minutes after installing sump. Only then fill with engine oil. –  Install coolant circulation pump 2 -V178-. –  Install air pipes → Chapter. –  Installing intake hoses with screw-type clips → Fig.. –  Install noise insulation → General body repairs, exterior; Rep. gr.66. –  Replenish engine oil and check oil level → Booklet.