Removing and installing parts of the lubrication system Removing and installing parts of the lubrication system

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Julianna Little
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1 Side 1 av 15 Removing and parts of the lubrication system Removing and parts of the lubrication system 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 => Page Oil system capacity1): Without oil filter 5.0 ltrs. With oil filter 5.5 ltrs. 1) Up-to-date figures: => "Emission and idling test" binder Engine oil specification: Vehicles without long-life service Naturally aspirated Diesel (engine codes AAB, AJA): Only use engine oil conforming to VW standard , , , or or multi-grade oil to ACEA B3/B4. Turbo Diesel (engine codes ACV, AJT, AHY, AUF): Only use engine oil conforming to VW standard or Engine oil specification: Vehicles05.99 with long-life service Only use engine oil conforming to VW standard or Note: Engine oils conforming to VW standard or can be used furthermore. The oil must then be changed every 12 months or every 15,000 km and the service interval display must be programmed correspondingly. Procedure: => Maintenance manual I =>Page 17-4 II =>Page 17-10

2 Side 2 av 15 Part I Nm + 1/2 turn (180 ) further Renew Threads and shoulder must be free of oil and grease Counterhold with T10025 to loosen and tighten Removing,

3 Side 3 av 15 and tensioning camshaft toothed belt=> Page Nm + 1/4 turn (90 ) further Ribbed belt Mark direction of rotation before removing Check for wear Remove and install with lever 3299 => Page Vibration damper with ribbed V-belt pulley When note fixing arrangement 5. Toothed belt guard - upper part 6. Camshaft toothed belt Mark D.O.R. before removing Check for wear Do not kink

4 Side 4 av 15 Removing, and tensioning: Vehicles => Page Camshaft sprocket securing bolt Observe steel type markings on bolt head: 8.8 = 85 Nm 10.9 = 100 Nm To loosen and tighten use counterhold Camshaft sprocket Note position when toothed belt: Vehicles => Page 13-45, Removing, and tensioning camshaft toothed belt Nm

5 Side 5 av Rear toothed belt guard =>Page 13-12, item Nm 12. Oil pump When note coupling ring on crankshaft => Page 17-15, item 38 Only renew complete Must be located on dowel sleeves 13. End plate 14. Oil pump Identification mark " " points in direction of end plate 15. Pressure relief valve, 40 Nm Opening pressure: bar 16. Seal Renewing => Page Crankshaft toothed belt sprocket

6 Side 6 av Tensioner Idler wheel Remove with puller 3034 and bolt 3034/1 20. Toothed belt guard - lower part 21. Vibration damper with V-belt pulley When note fixing arrangement Nm Coat threads and bolt head contact surfaces with sealing paste AMV Counter-

7 Side 7 av 15 hold with T10025 to loosen and tighten Removing, and tensioning camshaft toothed belt=> Page V-belt For alternator Check tension by thumb pressure max. deflection: new V-belt approx. 2 mm used V-belt approx. 5 mm Checking V-belt tension on vehicles with toothed rack tensioner =>Page V-belt For P.A.S vane pump Check tension by thumb pressure deflection: approx. 5 mm (new and used V- belt) Adjusting V-belt tension: => Running gear; Repair

8 Side 8 av 15 group 48; Assembly overview: vane pump, reservoir, hydraulic pipes 25. Washer Renew diamond coated Part II 1. Oil filter Loosen with strap wrench Tighten by hand Note instructions on filter when Nm 3. Oil collector 4. Oil cooler Coat contact

9 Side 9 av 15 area to flange, outside the seal, with AMV Ensure clearance to adjacent components See note => Page O-ring Renew if damaged 6. Oil filter bracket Installation position determined by dowel pin 7. Sealing ring Renew 8. Sealing plug, 40 Nm 9. Sealing plug, 20 Nm 10. Banjo bolt, 30 Nm 11. Oil supply pipe Engine codes ACV, AHY, AJT, AUF, AXG, AXL, AYC To exhaust turbocharger 12. Banjo bolt, 70 Nm 13. Cap 14. Gasket Renew if

10 Side 10 av 15 damaged 15. Dipstick The oil level must not be above the max. mark! 16. Oil filler tube Engine code: AAB, AJA Engine codes ACV, AHY, AJT, AUF, AXG, AXL, AYC with crankcase breather valve Nm bar oil pressure switch (F1), 25 Nm Only on vehicles

11 Side 11 av 15 with two oil pressure switches If sealing ring is leaking nip open and replace. Checking => Page Oil pressure retention valve 20. Adapter, 50 Nm If sealing ring is leaking nip open and replace bar oil pressure switch (F22), 25 Nm Only on vehicles with two oil pressure switches On vehicles with one oil pressure switch: 0.7 bar (F1) If sealing ring is leaking nip open and replace. Checking

12 Side 12 av 15 => Page Oil spray jet For piston cooling Nm Install with AMV Sump gasket Series production: Silicone sealant Case of repair: Gasket Renew 25. Suction pipe Clean strainer if soiled 26. Sump Clean sealing surface before Nm M8, install bolt with hexagon head to gearbox side 28. Oil seal Renew if damaged 29. Oil level/temperature sender (G266)

13 Side 13 av 15 Check => Current flow diagrams, Electrical fault finding and Fitting locations binder 30. Retaining clip Nm Nm Remove and install with socket 3249 With flywheel installed: Turn flywheel so that cutouts align with bolts 33. Spreader clip 34. Sump cover 35. Oil drain plug, 50 Nm 36. Securing plate Engine code: AAB, AJA Renew 37. Gasket Renew 38. Coupling ring For oil pump With four drive lugs Heat new coupling

14 Side 14 av 15 ring to max. 200 C before fitting 39. Guide tube For dipstick Engine codes ACV, AJT, AHY, AUF, AXG, AXL, AYC with connection for oil return pipe Nm Nm 42. Oil return pipe Engine codes ACV, AHY, AJT, AUF, AXG, AXL, AYC To exhaust turbocharger

15 Side 15 av 15

Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical 17 Engine-Lubrication system (Page GR-17)

Volkswagen New Beetle 1.8 Liter 4-Cyl. 5V Turbo OBD II Engine Mechanical 17 Engine-Lubrication system (Page GR-17) 17 Engine-Lubrication system (Page GR-17) Lubrication system components, removing and installing Oil pressure and oil pressure switch, checking Sump, removing and installing Valve gear, servicing (Page