Lubrication system components

Transcription

1 Стр. 1 из Lubrication system components Note: If large quantities of metal particles or abraded material are detected during engine repairs, it may be an indication for a damaged crankshaft or rod bearings. To prevent further damage, perform the following steps after the repair: Carefully clean oil passages Replace oil injection jets Replace oil cooler Oil filter, replacing Oil level must not exceed max. marking - danger of catalytic converter damage! Engine oil 17-1, Engine oil. Lubrication system components, assembly overview 17-1, Lubrication system components, assembly overview Draining oil filter housing draining 17-1, Oil filter housing, Oil pan, removing and installing and installing 17-1, Oil pan, removing Oil pump with balance shaft drive, removing and installing 17-1, Oil pump with balance shaft drive, removing and installing Oil pressure, checking 17-1, Oil pressure and oil pressure switch, checking Engine oil. Oil fill quantity: With oil filter 4.6 L Without oil filter 4.1 L Engine oil specifications

2 Стр. 2 из 26 Use engine oils according to VW norm Note: Engine is filled with engine oil matching long service interval at factory. Engine oils conforming to VW specifications can continue to be used. These oils must be change every 12 months or every 15,000 km. The Service Reminder Indicator (SRI) must be programmed accordingly. Markings on oil dipstick 1 - Max. marking 2 - Min. marking a - Oil level near MAX-marking: Do not add engine oil! b - Oil level in center area: Oil may be topped off c - Oil level near MIN-marking: Add approx. 0.5 L engine oil! Lubrication system components, assembly overview

3 Стр. 3 из 26 Part I 17-1, Part 1 Part II 17-1, Part 2 Part III 17-1, Part 3 oil filter bracket Part 1

4 Стр. 4 из Nm Oil dipstick Oil level must not exceed max. marking! Insertion funnel Guide tube Intermediate plate Oil pump with balance shaft drive With positive pressure valve 12 bar Removing and installing 17-1, Oil pump with balance shaft drive, removing and

5 Стр. 5 из 26 installing 15 Nm plus an additional 1 / 4 turn (90 ) Replace Note different length of bolts 17-1, Bolt allocation of differential shaft gear. 15 Nm Oil pan Clean sealing surface before installing Removing and installing 17-1, Oil pan, removing and installing 15 Nm Seal Rolled on to Item Oil drain plug, 30 Nm With permanent sealing ring Replace Chain sprocket 10 Nm Only engine code AXX Protective cap Only engine code AXX Oil Level Thermal Sensor G266 Only engine code AXX Seal

6 Стр. 6 из 26 Only engine code AXX 20 Nm plus an additional 1 / 4 turn (90 ) Replace Chain guard Chain Sealing flange Must be located on dowel sleeves Removing and installing 13-2, Sealing flange on belt pulley side, removing and installing To remove and install, remove oil pan 17-1, Oil pan, removing and installing Seal for crankshaft - ribbed belt side, replacing 13-2, Seal for crankshaft - ribbed belt side, replacing Part 2

7 Стр. 7 из 26 Chain guard Chain Mark direction of travel (installation position) using color marking before removing Dowel sleeves Intermediate plate Oil pump with balance shaft drive Before installing, check whether both dowel sleeves for centering are present 9 Nm

8 Стр. 8 из 26 Cover Prevents engine oil from foaming up 40 Nm 8 Nm Oil intake pipe Clean strainer if dirty O-ring Replace 15 Nm plus an additional 1 / 4 turn (90 ) Replace Note different length of bolts 17-1, Bolt allocation of differential shaft gear Outer rotor Check contact surfaces for groove build-up Marking must be visible Inner rotor Check contact surfaces for groove build-up Oil pump cover Chain sprocket 20 Nm plus an additional 1 / 4 turn (90 ) Replace Chain adjuster with tensioning

9 Стр. 9 из 26 track Pre-load 17-1, Preloading chain tensioner to install 15 Nm Part 3 oil filter bracket Tube For crankcase ventilation Oil pressure switch F1 1.4 bar, black Checking 17-1, Oil pressure and oil pressure switch, checking

10 Стр. 10 из 26 Tightening torque 20 Nm 15 Nm With Ground (GND) wire for oil pressure switch Bracket 25 Nm Oil cooler See note 17-1, Lubrication system components Ensure sufficient clearance to surrounding components Gasket Replace 15 Nm Seal Replace Dust cap Oil filter housing, 25 Nm Remove and install using oil filter wrench Draining 17-1, Oil filter housing, draining Oil filter insert Drain oil filter housing before removing 17-1, Oil filter housing, draining Baffle Gasket

11 Стр. 11 из 26 Replace Oil filter bracket With positive pressure valve, approx. 4 bar Removing and installing 17-1, Oil filter bracket, removing and installing Spring clip Oil filter housing, draining Note: While bolting in oil drain adapter T40057, a valve in the oil filter housing is opened. If the oil drain adapter T40057 is removed, the valve closes again. Special tools, testers and auxiliary items required Oil drain adapter T40057

12 Стр. 12 из 26 - Remove dust cap from oil filter housing - arrow-. - Hold hose from oil drain adapter T40057 into container and turn oil drain adapter T40057 into oil filter housing. - Drain engine oil Oil pan, removing and installing

13 Стр. 13 из 26 Special tools, testers and auxiliary items required SW 10 hex ball socket 3185 Socket T10058 Torque wrench V.A.G 1331 Scraping tool Silicon sealant D A2 Remove oil pan - Remove noise insulation

14 Стр. 14 из 26 Repair Manual, Body Exterior, Repair Group 50, front body; noise insulation. - Drain engine oil. Note: Observe waste disposal regulations! - Remove bolts - arrows -. - Remove oil return line - arrows -. - On vehicles with Oil Level Thermal Sensor G266, disconnect connector

15 Стр. 15 из 26 - Remove mounting bolts of transmission/oil pan - arrows -. - Loosen oil pan bolts on flywheel side using socket 3185 and remove using hex ball socket T Remove remaining bolts and oil pan. It may be necessary to loosen oil pan by hitting it lightly with a rubber mallet. - Remove any remaining sealant from cylinder block using a scraping tool. - Using e.g. rotating plastic brush, remove any remaining sealant from oil pan. Install oil pan Note: Note expiration date for sealant. The oil pan must be installed and tightened immediately after application of silicon sealant.

16 Стр. 16 из 26 - Cut tube nozzle at front marking (nozzle dia. approx. 3 mm). - Apply silicon sealant to clean sealing surfaces of oil pan as shown. Sealant bead must: Be 2 to 3 mm thick Continue to inner side in area of screw holes - arrows - Note: Sealant bead must not be thicker than specified. Otherwise, excess sealant could get into oil pan and clog strainer in intake line of oil pump. With transmission removed, oil pan must seal flush with cylinder block. With transmission installed, oil pan must make contact on transmission. After installing oil pan, allow sealant to dry for approx. 30 minutes. Allow sealant to dry before adding engine oil. - Position oil pan immediately and tighten bolts as follows: 1 - Tighten all bolts of oil pan/cylinder block only very lightly in diagonal sequence. 2 - Lightly tighten bolts of oil pan/transmission. 3 - Tighten further all bolts of oil pan/cylinder block lightly in diagonal sequence. 4 - Tighten bolts of oil pan/transmission to 40 Nm.

17 Стр. 17 из Tighten all bolts of oil pan/cylinder block to 15 Nm diagonal sequence. Installation is in reverse order of removal. Oil pump with balance shaft drive, removing and installing Special tools, testers and auxiliary items required Locking pin T10027 Silicon sealant D A2 Oil pump with balance shaft drive, removing pump with balance shaft drive, removing 17-1, Oil Oil pump with balance shaft drive, installing and adjusting 17-1, Oil pump with balance shaft drive, installing and adjusting Pre-load chain tensioner tensioner 17-1, Pre-loading chain Oil pump with balance shaft drive, removing - Remove oil pan 17-1, Oil pan, removing and installing.

18 Стр. 18 из 26 - Remove chain guard. Disengage locking lugs through openings - arrows - if necessary, using a small screwdriver. - Loosen bolt from oil pump chain sprocket. Counter-hold at central bolt of harmonic balancer. Caution! Chain sprocket driving differential shafts must not be loosened! - Release tension on chain rail using a screwdriver - arrow - and secure it using an Allen wrench - 1 -, across flats 3 mm. - Remove chain sprocket of oil pump and disengage chain

19 Стр. 19 из 26 on differential shaft drive. - Loosen bolts of differential shaft gear working from outside toward inside and remove it. Oil pump with differential shaft gear, assembly overview 17-1, Part 2. Oil pump with balance shaft drive, installing and adjusting Chain tensioner pre-tensioned 17-1, Pre-loading chain tensioner - Place intermediate plate as shown on to alignment bushings of differential shaft gear - arrows -. - Install oil pump with differential shaft gear and

20 Стр. 20 из 26 intermediate plate. Tighten mounting bolts from inside working toward outside to 15 Nm plus an additional 1 / 4 turn (90 ). Note: Note different length of bolts 17-1, Bolt allocation of differential shaft gear - Set crankshaft to TDC Cylinder 1. - Set marking on chain sprocket of differential shaft - arrow - opposite alignment bore. Secure chain sprocket in this position using connecting pin T Place chain on to differential shaft chain sprocket. - Install oil pump chain sprocket and tighten bolt by hand. Note: Oil pump chain sprocket fits only in one position. To install, only the oil pump must be turned.

21 Стр. 21 из 26 - Remove connecting pin T10027 and Allen wrench Secure chain sprocket of oil pump. Tightening torque: 20 Nm plus an additional 1 / 4 turn (90 ). Counter-hold at central bolt of harmonic balancer. - Install oil pan 17-1, Oil pan, removing and installing. Installation is in reverse order of removal. Bolt allocation of differential shaft gear A - Hex collar bolt M7 40 B - Hex collar bolt M7 70 C - Hex collar bolt M7 90 D - Hex collar bolt M7 55 E - Sealing plug with O-ring Pre-loading chain tensioner

22 Стр. 22 из 26 - Pretension piston by hand - arrow -. - Press chain rail in direction of - arrow - and secure using 3 mm socket wrench Oil filter bracket, removing and installing Removing - Remove intake manifold 24-1, Intake manifold, removing and installing. - Disconnect coolant lines 19-1, Coolant lines, removing and installing. - Remove oil cooler, to do so, remove bolts - A - and - B-

23 Стр. 23 из Disconnect connector - A - from oil pressure switch and remove bolt - B - for Ground (GND) wire. - Remove mounting bolts - arrows - and remove oil filter bracket. Installing - Replace gaskets Item and Item Insert baffle plate Item Install oil filter bracket and tighten bolts uniformly to 15 Nm. - Install oil cooler with bracket for coolant lines. Installation is in reverse order of removal. Oil pressure and oil pressure switch, checking

24 Стр. 24 из 26 Special tools, testers and auxiliary items required Oil pressure gauge V.A.G 1342 Voltage tester V.A.G 1527 B Connector test set V.A.G 1594C Engine oil level OK. Engine oil temperature at least 80 C (radiator fan must start up once) Note: For the functional check and servicing of the optical

25 Стр. 25 из 26 and acoustic oil pressure warning: Wiring diagrams, Vehicle Diagnosis, Testing and Information System VAS 5051 "Function/component selection". - Remove Oil Pressure Switch F1 and install it in tester. - Thread tester into oil pan in place of oil pressure switch. - Connect brown wire of tester to Ground (GND). - Connect voltage tester V.A.G 1527 B using adapter cables from connector test kit V.A.G 1594C to B+ and oil pressure switch. LED must not light up. - If LED lights up, replace 1.4 bar Oil Pressure Switch F1. If LED does not light up: - Start engine and increase engine speed: LED must light up at 1.2 to 1.6 bar positive pressure, otherwise replace oil pressure switch. - Increase engine speed (RPM) further. At 2000 RPM and an oil temperature of 80 C, oil pressure must be between 2.7 and 4.5 bar. Oil pressure must not exceed 7.0 bar at higher engine speeds. If specified value is not reached: - Check screen in oil intake pipe for dirt Item Note: Also, mechanical damage e.g. bearing damage can also be the cause of too low oil pressure. If no malfunction can be found:

26 Стр. 26 из 26 - Replace oil pump 17-1, Oil pump with balance shaft drive, removing and installing. If specified value is exceeded: - Check oil channels. - If necessary, replace oil filter bracket with pressure valve