Volkswagen Workshop Service and Repair Manuals

Notes:

• ◆ If when repairing an engine, metal shavings or a large quantity of small metal particles caused, for example, by partial seizure of crankshaft and conrod bearings, are found in the engine oil, to prevent consequential damage, apart from thoroughly cleaning oil passages, it is necessary to renew the oil cooler.
• ◆ The oil level must not be above the max. mark - danger of damage to catalyst!

Checking oil pressure

Oil system capacity1):

     without oil filter 3.5 ltrs.
     with oil filter 4.0 ltrs.

     1)     Up-to-date figures:

=> "Emission test"

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.

• Cap
• Gasket
• ◆ Renew if damaged
• 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 engine oil
• Guide
• ◆ Pull off to draw out oil
• Non-return valve, 5 Nm

• Plugs
• Oil pressure switch (F22), 25 Nm
• ◆ Checking => Page 17-8
• ◆ If sealing ring is leaking nip open and replace.
• Vehicles ä 07.95
• ◆ 0.3 bar, brown
• Vehicles08.95 ▸
• ◆ 0.25 bar, blue
• 1,8 bar oil pressure switch (F1), 25 Nm
• ◆ White
• ◆ Wiring: yellow
• ◆ Checking => Page 17-8
• ◆ If sealing ring is leaking nip open and replace.
• 20 Nm

• Oil filter bracket
• O-Ring
• ◆ Renew if damaged
• Oil cooler
• ◆ Coat contact area to flange, outside the seal, with AMV 188 100 02
• ◆ Ensure clearance to adjacent components
• ◆ Observe note
  => Page 17-1
• 25 Nm
• Oil filter
• ◆ Loosen with strap wrench
• ◆ Tighten by hand
• ◆ Observe installation instructions on oil filter

• Gears
• ◆ Checking backlash
  => Fig. 1
• ◆ Checking axial clearance
  => Fig. 2
• Oil pump cover with pressure relief valve
• ◆ Opening pressure: 5.7...6.7 bar
• 10 Nm
• 20 Nm
• ◆ Only loosen and tighten the bolts flywheel end with jointed wrench 3185
• Oil drain plug, 30 Nm
• Seal
• ◆ Renew
• Sump
• ◆ Clean sealing surface before installing

• Gasket
• ◆ Renew
• ◆ Before fitting coat sump/cylinder block flanges with "D2"
• Suction pipe
• ◆ Clean strainer if soiled
• Gasket
• ◆ Only gasket, no wash plate
• ◆ Renew if damaged
• ◆ To remove unbolt oil pump cover
• Pressure relieve valve, 27 Nm
• ◆ Opening pressure: 2.5...3.2 bar
• ◆ Vehicles ä 07.95 only
• Oil spray jet
• ◆ For piston cooling
• ◆ Vehicles ä 07.95 only
• Gasket
• ◆ Renew

→ 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