Elements of the lubrication system of four- and five-cylinder engines, except for the 1.6-I engine with the AHL index
- 1 - sealing ring. If damaged, use a new O-ring;
- 2 - cover;
- 3 - dipstick for measuring the level of engine oil;
- 4 - probe lock. When pumping out oil from the oil pan must be removed;
- 5 - sealing ring. At installation it is necessary to use a new sealing ring;
- 6 - oil supply pipeline, 20 Nm. Oil supply to turbocharger only on AEB engines;
- 7 - adapter. If there is damage, a new adapter must be used;
- 8 - sealing ring. If damaged, a new O-ring must be used;
- 9 - bolt, 25 Nm;
- 10 - oil filter holder;
- 11 - oil pressure sensor, 25 Nm. If the oil pressure sensor installation is leaking, a new sealing ring must be used;
- 12 - sealing ring. If damaged, a new O-ring must be used;
- 13 - oil heat exchanger. When installing the oil heat exchanger, the surface mating with the flange must be lubricated with a thin layer of sealant, AMV-18810002;
- 14 - nut, 25 Nm;
- 15 - oil filter;
- 16 - cover;
- 17 - oil pump drive gear;
- 18 - oil pump rotors;
- 19 - oil pump cover with oil pressure relief valve. The oil pressure relief valve opens at 5.7-6.7 bar;
- 20 - bolt, 10 Nm;
- 21 - bolt, 25 Nm;
- 22 - oil deflector;
- 23 - bolt. An articulated wrench must be used to loosen the oil pan bolts;
- 24 - oil drain plug;
- 25 - sealing ring;
- 26 - oil pan. When installing the oil pan, it is necessary to clean the mating surface of the oil pan from traces of the gasket;
- 27 - oil pan gasket. A new oil pan gasket must be used when installing. Before installing the gasket, apply a coat of sealant D2 to the junction of the sealing flange and the cylinder block. On 1.6-I engines with code AHL and on five-cylinder engines, there is no oil pan gasket, and liquid silicone sealant VW-D176404A2 is used instead;
- 28 - gasket. If there is damage, a new gasket must be used.
- 29 - oil return pipeline. Turbo oil return on AEB engines only;
- 30 - bolt, 10 Nm;
- 31 - oil intake tube. Before installing the oil intake tube, it is necessary to clean the strainer;
- 32 - bolt, 10 Nm;
- 33 - sealing ring;
- 34 - bypass valve, 27 Nm. Valve opening pressure 2.5–3.2 bar;
- 35 - nozzles for spraying oil on the lower part of the engine;
- 36 - shut-off valve of the oil return pipeline, 50 Nm.
Four- and five-cylinder engines
To remove the oil pan, it is necessary to loosen the fastening of the power unit and, using a lifting mechanism, raise the power unit.
Removing
1. Remove the lower engine mudguard.
2. Drain the engine oil by loosening the oil drain plug about half a turn. Place an oil drain container under the drain plug and unscrew the plug completely. If necessary, press down on the plug when unscrewing to prevent the oil from leaking prematurely. When the oil is completely drained, screw the oil drain plug back into place (see table "Oil drain plug tightening torques").
3. Remove poly V-belt.
4. On vehicles with an air conditioning system, unscrew the tensioner pulley and remove the A/C compressor drive belt.
5. Drain coolant (remove lower radiator hose).
6. Using a steel rod (2) with a diameter of 5 mm, secure the radiator fan pulley against rotation and unscrew the radiator fan mounting bolt from the reverse side. Remove the radiator fan.
7. Unscrew the engine bracket. Bracket shown on removed engine.
8. Disconnect the wire connection, release the clamps and remove the starter wire.
9. Loosen screws if available (2 and 5) and remove the bracket located between the oil pan and intake manifold. Do not unscrew bolts 1, 3 and 4 securing the second bracket.
10. Unscrew the upper part of the left support of the power unit.
11. Using a marker, mark the location of threaded connections 1, fixing bushings 2 on the supports of the power unit.
12. Unscrew the lower fastening of both supports of the power unit.
13. Hook the slings of the lifting mechanism on the power unit and lift it so that the lower part of it only touches the front wall of the body.
14. Remove the left support of the power unit.
15. Support the power unit support bracket with a jack through a wooden block so that it remains in place after unscrewing the bolts.
16. Unscrew the nuts 1 fastening the supports of the power unit in the lower left and right parts. First of all, unscrew bolts 2 and 3 on the left and right sides from the bracket, then bolts 4 on the left and right sides.
17. Loosen the lower bolt securing the right gearbox support 2 a few turns, then unscrew the front bolt 1.
18. Loosen the nut until it is level with the end of the bolt.
19. Being careful, jack down the power unit bracket. In order not to displace the axle, lower and release the bracket from the front.
20. Remove the jack and turn the stabilizer down.
21. Unscrew bolts and remove the oil pallet from the block of cylinders.
Installation
1.6-I engines with code AHL and five-cylinder engines
1. Using a plastic or wooden scraper, scrape the old gasket off the surface of the cylinder block that mates with the oil pan.
2. Using a rotating metal brush mounted on an electric drill, clean the sealant.
3. Apply a coat of sealant VW-D176404A2 with a diameter of 3 mm to the mating surface of the oil pan.
Warning: After applying a layer of sealant to the oil pan, install the oil pan within 5 minutes. The drying time of the sealant is 30 minutes, and only after that can engine oil be poured into the engine.
Warning: The sealant layer should only be 3 mm in diameter, as in the case of a thick sealant layer, excess sealant will enter the oil and may block the strainer.
Four-cylinder engines other than 1.6-I engine code AHL
1. Using a wooden or plastic scraper, clean the mating surfaces of the oil pan and cylinder block from the sealant.
2. Before installing the gasket, apply a thin layer of D2 sealant at the junction of the seal cap and the engine block.
3. Install a new gasket without using sealant.
All engines
Location of bolts of fastening of a support of the power unit
1. Tighten the oil pan bolts evenly and gradually. Do not overtighten the bolts, otherwise the oil pan gasket will be deformed.
2. Lower the engine and remove the hoist straps.
3. Using a jack through a wooden block, lift the engine bracket and screw in the bolts on the left and right sides and tighten them to the required torque.
Warning: New bolts must be used to attach the engine bracket.
4. Screw on the motor torque mount. Tighten all bolts to 25 Nm.
5. Tighten the M10 bolts securing the gearbox support to a torque of 40 Nm and the gearbox support bracket (M8 bolts) torque 25 Nm.
6. Tighten the bracket bolts located between the oil pan and the intake manifold to 25 Nm.
7. Route the starter wire through the bracket on the oil pan, close the wire holder and secure it with new ties.
8. Install the drive belt and radiator fan.
Vehicles with air conditioning
1. Install the A/C compressor drive belt tensioner.
2. Install the A/C compressor drive belt.
3. Install the lock bracket.
4. Lower the car.
5. Fill the engine with engine oil. Take a test drive and check the tightness of the oil pan installation. Tighten the oil pan bolts slightly if necessary.
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