Volkswagen Workshop Service and Repair Manuals

Removing and installing upper part of sump Special tools and workshop equipment required

t  Assembly tool -T10118-

t  Locking tool -T40265- t  Silicone sealant -D 174 003 A2- Removing –  Remove gearbox → Rep. gr.34. –  Remove oil pump → Chapter. –  Remove sealing flange on gearbox side → Chapter. –  Remove front part of right wheel housing liner → General body repairs, exterior; Rep. gr.66.

–  Remove bolts -arrows-. –  Remove air pipe by lifting clips -1 and 2-.

–  Unscrew bolt -1-. –  Unscrew cable retainer next to continued coolant circulation pump -V51- from upper part of sump.

–  Unscrew bolts -arrows-.   DANGER! Risk of injury! When removing upper part of sump, spring of chain tensioner for oil pump drive jumps from upper part of sump to lower timing chain cover. When removing upper part of sump, do not grip between upper part of sump and lower timing chain cover.

–  Remove bolts -1 to 14- and lever off upper part of sump.   Caution Lever off upper part of sump on gearbox side first. When levering off, exercise caution to ensure the timing chain cover is not bent in the process. Installing l  Specified torque → Chapter.   Note t  Note expiry date of silicone sealant. t  The sump (top section) must be installed within 5 minutes after applying the silicone sealant. –  Remove sealant residue from cylinder block with a flat scraper.   WARNING Risk of eye injury. Wear safety goggles.

–  Remove remaining sealant on upper part of sump and lower timing chain cover e.g. using rotating plastic brush.   Note Check timing chain cover for deformation. To do this, fit sump upper part first without sealant and check gap between cover and sump upper part. If deformation is evident and cover cannot be aligned, renew cover after upper part of sump has been installed. –  Clean sealing surfaces. They must be oil and grease free. –  Check oil galleries in upper part of sump and crankcase for soiling.

–  Cut off nozzle on tube at front marking (Ø of nozzle approx. 3 mm).

–  Apply silicone sealant -D 174 003 A2- onto clean sealing surface of upper part of sump, as illustrated -arrow-. l  Thickness of sealant bead: 2…3 mm   Note t  After applying the silicone sealant, the top part of the sump must be fitted within 5 minutes. t  The bead of sealant must not be thicker than specified, otherwise excess sealant can enter the sump and obstruct the strainer in the oil intake pipe. l  On gearbox side, upper part of sump and crankcase must be flush.

–  Fit upper part of sump straightaway and tighten bolts -1 to 14- in 3 stages as follows: 1 -  Tighten bolts hand tight. 2 -  Tighten bolts to 15 Nm. 3 -  Turn bolts 90° further. –  Install bolts -arrows-. Specified torque for cover with 15 bolts → Fig..

Specified torque for cover with 8 bolts → Fig.. Further assembly is basically the reverse of the dismantling sequence.