Volkswagen Workshop Service and Repair Manuals

Notes:

• ◆ All the components shown in the illustration can be removed and installed with the engine installed.
• ◆ Always renew gaskets and oil seals.
• ◆ If large quantities of metal particles or filings -such as those associated with damage to crankshaft or conrod bearings - are discovered in the engine oil, the oil passages must be throughly cleaned and the oil cooler renewed to avoid further engine damage.

Lubrication system capacity (in litres):

• ◆ The capacity depends upon oil sump form.

• ◆ Engine oil requirements => fig.4

• Dipstick
• ◆ Diference min....max.:
  Round dipstick = 1 litre
  Flat dipstick = 0.75 litre.
• Dipstick tube
• Oil temperature sender

• Seal
• ◆ Renew
• 0.3 Oil pressure switch, 25 Nm
• ◆ Checking:
  Engine Codes DX, JH, JJ, KT, 2H =>page 17-15
• 1.8 bar Oil pressure switch, 25 Nm
• ◆ Checking =>page 17-13
• Oil filter bracket
• ◆ 8/84 ▸Engine Codes: DX, JH, KT, 2H
• ◆ ▸7/84 =>page 17-8

• O-Ring
• ◆ Renew if damaged
• Oil cooler
• ◆ 8/84▸Engine Codes: DX, JH, KT, 2H
• ◆ ▸7/84 =>page 17-15
• 25 Nm
• Oil filter
• ◆ Loosen with strap wrench
• ◆ Tighten by hand
• ◆ Follow installation instructions on filter

• Gears
• ◆ Checking backlash => fig.1
• ◆ Checking axial clearance => fig.2
• ◆ Gear width:
  Engines with hydraulic tappets: 30 mm.
  Engines without hydraulic tappets: 26 or 30 mm
• Oil pump cover with pressure relief valve
• ◆ Engine Codes DX, JH, JJ, KT, 2H
• ◆ Opening pressure: 5.7...6.7
• 10 Nm
• 20 Nm
• Drain plug, 30 Nm

• Sump
• Sump gasket
• ◆ Renew
• ◆ Do not use gasket sealer, position correctly
• Suction pipe
• ◆ Engine Codes DX, JH, JJ, KT, 2H
• Baffle plate
• ◆ Engine Codes DX, JH, JJ, KT, 2H
• Baffle
• ◆ Engine Code: EG
• ◆ If very, remove the baffle and strainer for cleaning by bending flanges open

• Strainer
• ◆ Engine Code: EG
• ◆ Clean
• Oil pump cover with pressure relief valve
• ◆ Engine Code: EG
• Seal
• ◆ Renew
• 25 Nm
• Gasket
• ◆ Renew if damaged
• Oil filler cap