Volkswagen Workshop Service and Repair Manuals

Notes:

• ◆ If large quantities of metal particles or other deposits (caused, for example, by partial seizure of the crankshaft or conrod bearings) are found in the engine oil when performing repairs, clean the oil passages thoroughly and renew the oil cooler in order to prevent further damage from occurring later.
• ◆ The oil level must not be above the max. mark - danger of damage to catalyst!
  Marking , Fig.3

Checking oil pressure => Page 17-10

Oil system capacity1):

     without oil filter 3.3 ltrs.
     with oil filter 3.8 ltrs.

     1)     Up-to-date figures:

=> "Emission and idling test" binder

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
• ◆ Marking => Fig. 3
• Guide
• ◆ Pull off to extract oil
• Non-return valve, 5 Nm

• Oil temperature sender (G8), 10 Nm
• Oil pressure switch (F22), 25 Nm
• ◆ 0.3 bar, brown
• ◆ 0.25 bar, blue
• ◆ Checking => Page 17-10
• ◆ If sealing ring is leaking nip open and replace.
• 1,8 bar oil pressure switch (F1), 25 Nm
• ◆ White
• ◆ Wiring: yellow
• ◆ Checking => Page 17-10
• ◆ If sealing ring is leaking nip open and replace.
• Oil filter bracket
• ◆ Engine code: AAM, ABS, ADZ
• 25 Nm

• Oil filter bracket
• ◆ Engine codes: 2E, ADY, AGG
• 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
• ◆ See 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:
       Socket head bolts: 3249
       Hexagon head bolts: 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
• Baffle plate
• ◆ Only fit with oil pump removed
• Pressure relief valve, 27 Nm
• ◆ Engine codes: 2E, ADY, AGG
• ◆ Opening pressure: 2.5...3.2 bar

• Oil spray jet
• ◆ Engine codes: 2E, ADY, AGG
• ◆ For piston cooling
• 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

→ Fig. 3     Marking on oil dipstick

•      1 -     max. mark
•      2 -     min. mark
•      a -     Area above hatched field up to max. mark: Do not replenish with engine oil!
•      b -     Oil level within hatched field: can be replenished with engine oil
•      c -     Area from min. mark up to hatched field: replenish with max. 0.5 ltr. of engine oil!