Volkswagen Workshop Service and Repair Manuals

Removing and installing oil sump Special tools and workshop equipment required

t  Oil filter tool -3417-

t  Allen key, long reach -T10058-

t  Torque wrench -V.A.G 1331- t  Hand drill with plastic brush t  Flat scraper t  Silicone sealant D 176,501 A1 Removing –  Drain off engine oil. –  Remove oil filter with oil filter tool -3417-. Remove poly V-belt → Chapter. Only vehicles with air conditioner   Note t  The air conditioning system lines must not be opened. t  Prevent damage to condenser and refrigerant lines and hoses. t  Do NOT stretch, kink or bend lines and hoses. –  Remove air conditioner compressor: → Heating, air conditioning; Rep. gr.87. –  Secure AC compressor to lock carrier. Make sure lines are not kinked.

–  Remove securing bolt -arrows- for gearbox.

–  Unscrew all sump securing bolts -arrows-.

–  Unscrew sump securing bolts on gearbox side -arrows- using Allen key, long reach -T10058-.   Note t  The sump is sealed with liquid sealant. t  When hardened, the sealant has a high adhesive strength.

–  Carefully lever off sump from cylinder block at recess -arrow- using assembly lever. –  Remove sump. Loosen sump with light blows of a rubber headed hammer if necessary. –  Remove sealant residues from cylinder block with a flat scraper.

–  Remove sealant residues on sump with a rotating brush, e.g. an electric drill with plastic brush attachment (wear eye protection). –  Clean sealing surfaces. They must be free of oil and grease. Installing   Note t  Observe use-by-date of sealant. t  The sump must be installed within 5 minutes of applying silicone sealing compound. t  The sump can be positioned more easily and with greater security if M6 studs are inserted into the cylinder block flange at two positions as guides.

–  Cut off nozzle on tube at front marking (Ø of nozzle approx. 3 mm). –  Apply silicone sealant to clean sealing surface of sump as shown. Sealant bead must be: t  2…3 mm thick. t  Run bead along inner side of bolt holes -arrows-.   Note The sealing compound bead must not be thicker, otherwise excessive sealing compound will enter the sump and may block the oil suction pipe strainer. –  Fit sump immediately and lightly tighten all sump securing bolts. –  Tighten new sump securing bolts to 8 Nm + turn 90° further. Specified torques for gearbox bolts: → Rep. gr.34   Note Let sealing compound dry for approx. 30 minutes after installing oil sump. Only then fill with engine oil. –  Fill oil filter with engine oil and tighten it with oil filter tool -3417-. Specified torque: 20 Nm –  Fill engine oil. Engine oil capacity → Chapter. –  Install air conditioner compressor: → Heating, air conditioning; Rep. gr.87. Install poly V-belt → Chapter. Further assembly is basically the reverse of the dismantling sequence.