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!

Checking oil pressure

Oil system capacity1):

     with oil filter 4.7 ltrs.

     1)     Up-to-date figures:

=> Exhaust emissions test binder

Engine oil specifications:

Only use engine oil conforming to VW standard 50000, 50101 or 50500 or multi-grade oil corresponding to API-CD.

• Cap
• Gasket
• ◆ Renew if damaged
• Dipstick
• ◆ The oil level must not be above the max. mark!
• ◆ Markings, Fig. 3
• Guide tube
• ◆ For dipstick
• M6 = 10 Nm
  M8 = 20 Nm
• 0.25 bar oil pressure switch (F22), 25Nm
• ◆ ▸08.97
• ◆ Blue
• ◆ If sealing ring is leaking nip open and replace.
• ◆ Checking => Page 17-9

• 0.9 bar oil pressure switch (F1), 25 Nm
• ◆ Grey or brown
• ◆ If sealing ring is leaking nip open and replace.
• ◆ Checking => Page 17-9
• Oil temperature sender (G8)
• ◆ Engine code AEF
• ◆ For oil temperature gauge
• ◆ White
• Oil filter bracket
• 25 Nm
• O-ring
• ◆ Renew

• Oil cooler
• ◆ Engine codes AEF, AGD and ASX
• ◆ Coat surface contacting oil filter bracket 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
• 45 Nm
• Gears
• ◆ Checking backlash
  => Fig. 1
• ◆ Checking axial clearance
  => Fig. 2

• Oil pump cover with pressure relief valve
• ◆ Opening pressure: 5.7...6.7 bar
• Sump
• ◆ Clean sealing surface before installing
• Seal
• ◆ Renew
• Oil drain plug, 30 Nm
• 20 Nm
• ◆ Remove and install both rear bolts gearbox end with jointed spanner 3185
• Baffle plate
• Suction pipe
• ◆ Clean strainer if soiled

• Baffle plate
• ◆ With gasket
• ◆ Renew gasket if damaged
• ◆ Before fitting gasket coat sump flange/cylinder block flange with "D2"
• ◆ Engine codes AGD, AHG, AKU, ASX only renew gasket
• 10 Nm
• ◆ Install with locking fluid AMV 188 100 02
• Oil spray jet
• ◆ For piston cooling

→ Fig. 1     Checking oil pump backlash

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ Feeler gauge

     New: 0.05 mm

     Wear limit: 0.20 mm

→ Fig. 2     Checking oil pump axial clearance

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ Straight edge
• ◆ Feeler gauge

     Wear limit: 0.15 mm

→ Fig.3     Dipstick markings

•      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!