Volkswagen Workshop Service and Repair Manuals

Removing and installing oil sump

Caution Finding metal shavings or a large quantity of small metal particles during engine repair could indicate that the crankshaft bearings or conrod bearings are damaged. To avoid any subsequent damage, the following work must be carried out following the repair: Thoroughly clean oil channels. Renew oil cooler Renew oil filter element

Special tools and workshop equipment required

t	10 mm jointed spanner -VAS 3185-

t	Allen key, long reach -T10058-

t	Torque wrench (5…50 Nm) -V.A.G 1331-

t	Used oil collection and extraction unit -V.A.G 1782-

t  Silicone sealant -D176404A2- t  Hand drill with plastic brush t  Eye protection t  Flat scraper Removing –  Remove noise insulation → General body repairs, exterior; Rep. gr.66. –  Place used oil collection and extraction unit -V.A.G 1782- under engine and drain engine oil.   Note Observe environmental regulations for disposal.

–  Loosen clamp -2-, raise retaining clip -1- and remove connecting hose on »cold side« → Item.

–  Remove securing bolts -arrows- of charge air pipe and press pipe aside.

–  Remove securing bolt -arrow- and push coolant circulation pump 2 -V178- aside.

–  Remove securing bolt -arrow- of charge air pipe on »hot side«. –  Pull connector off oil level and oil temperature sender -G266-. –  Remove connecting bolts for sump to gearbox. –  Remove oil sump securing bolts in diagonal sequence. –  Loosen sump with light blows of a rubber headed hammer if necessary. –  Remove sealant residue from cylinder block using a flat scraper.   WARNING Wear eye protection.

–  Remove sealant residue on sump with a rotating brush, e.g. a hand drill with a plastic brush. –  Clean sealing surfaces. They must be free of oil and grease. Installing   Note t  Observe expiry date of sealing compound. t  The sump must be installed within 5 minutes of applying silicone sealing compound.

–  Cut off tube nozzle at forward marking (approx. 3 mm nozzle diameter). –  Apply silicone sealing compound, as shown, to clean sealing surface on sump. Sealant bead must be: t  2…3 mm thick. t  Run bead along inner side of bolt holes -arrows-.   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 sealant bead in area of rear sealing flange -arrows-. t  Oil sump must be installed within 5 minutes after applying sealant. –  Install sump immediately and tighten connecting bolts for sump to gearbox and all sump bolts lightly. Ensure that sump is flush against intermediate plate and gearbox flange.   Note When installing sump with engine out of vehicle, ensure that sump is flush with cylinder block at flywheel end. –  Tighten sump bolts diagonally to 15 Nm. –  Tighten bolts securing sump to gearbox to 40 Nm.   Note Let sealing compound dry for approx. 30 minutes after installing oil sump. Only then fill with engine oil. Further assembly is basically the reverse of the dismantling sequence.