17 - Lubrication: 1 Removing and Installing Parts of Lu Brication System

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Eos 2006 ➤ , Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran ...

4-cylinder injection engine (1.4 and 1.6 l direct injection) - Edition 04.2014

17 – Lubrication
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1 Removing and installing parts of lu‐ ol not
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♦ Finding metal shavings or a large quantity of small metal par‐

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ticles during engine repair could indicate that the conrod bear‐

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ings are damaged. To prevent this from causing further

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damage, perform the following repairs:

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♦ Thoroughly clean oil channels.

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♦ Renew oil filter.

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♦ The oil level must not be above the max. mark - danger of
damage to catalytic converter! Markings ⇒ page 135 .
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Engine oil (oil capacities, engine oil specification) ⇒ page 132

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Assembly overview ⇒ page 132 .


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Removing and installing sump ⇒ page 135 .

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Removing and installing oil pump ⇒ page 136 .

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Checking oil pressure and oil pressure switch ⇒ page 138 .
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1.1 Engine oil
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Oil capacities p by
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With oil filter 3.6 l Prote AG.

Engine oil specifications


Golf, Golf Plus ⇒ Maintenance ; Booklet 38 “Engine oils”
Touran ⇒ Maintenance ; Booklet 18.1 “Engine oils”
Passat ⇒ Maintenance ; Booklet 21.1 .“Engine oils”
Eos ⇒ Maintenance ; Booklet 23.1 “Engine oils”

1.2 Assembly overview

132 Rep. gr.17 - Lubrication


Eos 2006 ➤ , Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran ...
4-cylinder injection engine (1.4 and 1.6 l direct injection) - Edition 04.2014

1 - Oil dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 135 .
2 - Gasket
❑ Renew. n AG. Volkswagen AG do
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❑ Only engine codes yV
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BAG, BLP, BLF ir se
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3 - Oil cooler au ac
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❑ Only engine codes

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BAG, BLP, BLF

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4 - Coolant pipe

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❑ For oil cooler.

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❑ Only engine codes
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BAG, BLP, BLF

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5 - 8 Nm

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6 - O-ring

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❑ Renew.

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7 - Chain sprocket

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❑ For oil pump drive.

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❑ Removing and installing

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(engine codes BAG,

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BLP, BLF) ⇒ page 100
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❑ Removing and installing

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(engine code BKG,


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BLN) ⇒ page 107 .


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8 - Valve timing housing

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❑ Removing and installing C py
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⇒ page 45 .
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❑ Removing and installing
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(Touran) ⇒ page 49 .
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❑ Install with sealant D 176 501 A1.


❑ When installing, install two -M6x80- studs in camshaft housing and cylinder block as guides.
❑ To guide valve timing housing, secure oil sump in position with two bolts.
9 - Seal
❑ Renew if damaged.
10 - Cap
❑ Renew seal if damaged.
11 - Oil filter cover, 25 Nm
❑ With bypass valve opening pressure: 2.50 bar.
❑ With non-return valve.
12 - Valve
13 - 10 Nm
14 - 10 Nm
15 - Securing bolt
❑ Observe tightening procedure ⇒ page 59 .
❑ Renew.
❑ Contact surface for securing bolt must be free of oil and grease.
❑ Oil threads before inserting.
❑ Secure pulley against turning with counterhold 3415.

1. Removing and installing parts of lubrication system 133


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4-cylinder injection
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❑ The turning s au angle
further can be measured with a commercial protractor.
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16 - Belt pulley
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❑ Contact surfaces of pulley must be free of oil and grease.

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❑ Removing and installing poly V-belt ⇒ page 44 .

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❑ Secure pulley against turning with counterhold -3415- .
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17 - Seal

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urposes, in part or in wh

❑ Renew.

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18 - Bearing bush
❑ Contact surfaces of bearing bush must be free of oil and grease.

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19 - Pressure regulating valve

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❑ With breather hose.

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20 - 10 Nm

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21 - 20 Nm + turn 90° further

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❑ Renew.

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22 - Chain sprocket
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❑ For oil pump.

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❑ Lock with counterhold -T10172- .


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23 - Drive chain
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❑ For oil pump.
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❑ Before removing, mark direction of rotation (installation position).
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❑ Removing and installing (engine codes BAG, BLP, BLF) ⇒ page 100
❑ Removing and installing (engine code BKG, BLN) ⇒ page 107 .
24 - 25 Nm
25 - Oil pump
❑ Renew complete only.
26 - 10 Nm
27 - Oil level and oil temperature sender - G266-
❑ Renew if damaged.
❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
28 - Oil sump
❑ Removing and installing ⇒ page 135 .
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant D 176 600 A1.
29 - Oil drain plug, 30 Nm
❑ With attached seal.
❑ Renew.
30 - 13 Nm
❑ Loosen and tighten flywheel end bolts only with socket insert -T10058- .
31 - 45 Nm

134 Rep. gr.17 - Lubrication


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4-cylinder injection engine gu(1.4 and 1.6 l direct
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Markings onaut oil dipstick
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1 - Max. mark

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2 - Min. mark
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a - Area above hatched field up to max. mark: Do not top up with

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engine oil!

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b - Oil level within hatched zone: can be topped up with engine
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c - Area from min. mark up to hatched field: Must be topped up,
max. 0.5 l of engine oil!

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1.3 Removing and installing oil sump


Special tools and workshop equipment required

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♦ Special wrench, long reach - T10058-


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♦ Torque wrench (5…50 Nm) - V.A.G 1331-

♦ Hand drill with plastic brush


♦ Flat scraper
♦ Eye protection
♦ Silicone sealant D 176 600 A1
Removing
– Remove engine splash protection.
– Disconnect front exhaust pipe from exhaust manifold
⇒ page 288 .

1. Removing and installing parts of lubrication system 135


Eos 2006 ➤ , Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran ...
4-cylinder injection engine (1.4 and 1.6 l direct injection) - Edition 04.2014

– Pull 3-pin connector off oil level and oil temperature sender -
G266- -1-.
– Drain engine oil.
– Unbolt sump sealed with liquid gasket.
– Remove sump, it may be necessary to release sump by tap‐
ping lightly with a rubber head hammer.
– Remove sealant residue 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 pro‐
tection).
– Clean sealing surfaces. They must be free of oil and grease.
Installing

Note

cardiagn.com
♦ Observe expiry date of sealing compound.
♦ The oil sump must be installed within 5 minutes of applying
silicone sealing compound.
♦ Sump can be positioned more easily and with greater security
if M6 studs are inserted as guides into the cylinder block flange
at two positions.

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– Cut off tube nozzle at oforward
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– Apply silicone thosealing compound, as shown, to clean sealing
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surface ons sump. Sealing compound bead must be:
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♦ 2…3 mm thick.
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♦ Run bead along inner side of bolt holes -arrows-.


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Note
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The sealing compound bead must not be thicker, otherwise ex‐


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cessive sealing compound will enter the sump and may block the
oil suction pipe strainer.
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– Install sump immediately and tighten all sump bolts lightly.


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– Tighten oil sump bolts to 13 Nm.


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Note
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Let sealing compound dry for approx. 30 minutes after installing


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sump. Only then fill with engine oil.


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1.4 Removing and installing oil pump
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Special tools and workshop equipment required py by
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Prote AG.

136 Rep. gr.17 - Lubrication


Eos 2006 ➤ , Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran ...
4-cylinder injection engine (1.4 and 1.6 l direct injection) - Edition 04.2014

♦ Counterhold tool - T10172/1-

Removing
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– Remove sump ⇒ pageks135
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– Hold oil pump isprocketby with counterhold - T10172/1-ua. ran
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– Loosen chain au sprocket securing bolt.
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Do not remove bolt completely.

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– Press chain tensioner in direction of arrow with a screwdriver.


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– Remove chain sprocket securing bolt.


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– Take chain sprocket off oil pump and out of chain.


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– Loosen oil pump securing bolts -arrows- and remove them.


– Remove oil pump from cylinder block.
Installing
• The oil pump must be filled with oil before it is installed.

1. Removing and installing parts of lubrication system 137


Eos 2006 ➤ , Golf 2004 ➤ , Golf Plus 2005 ➤ n, APassat 2006
G. Volkswagen A➤
G d,oTouran ...
wage es n
4-cylinder injection engine (1.4 and 1.6
y Vol direct injection) - Edition 04.2014
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– Press chain tensioner in direction of uarrow
tho with a screwdriver. or
a ac
ss
– Seat chain sprocket in chain and fit chain sprocket onto oil

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pump shaft.

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– Observe installation position of chain sprocket on oil pump


shaft -arrow-.

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– Fit new chain sprocket securing bolt.


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– Hold sprocket with counterhold - T10172/1- .

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– Fit torque wrench (5…50 Nm) - V.A.G. 1331- as shown.


– Tighten securing bolt to 20 Nm + turn 90° further.
– Install sump ⇒ page 135 .

1.5 Checking oil pressure and oil pressure switch

138 Rep. gr.17 - Lubrication


Eos 2006 ➤ , Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran ...
4-cylinder injection engine (1.4 and 1.6 l direct injection) - Edition 04.2014

Special tools and workshop


equipment required
♦ Oil pressure tester - V.A.G
1342-
♦ Voltage tester - V.A.G
1527B-
♦ Auxiliary measuring set -
V.A.G 1594C- n AG. Volkswagen AG do
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Note

Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations

1. Removing and installing parts of lubrication system 139


Eos 2006 ➤ , Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran ...
4-cylinder injection engine (1.4 and 1.6 l direct injection) - Edition 04.2014

Test procedure
– Remove oil pressure switch - F1- and screw it into oil pressure
tester - V.A.G 1342- .
– Screw tester into cylinder head in place of oil pressure switch.
– Connect brown wire of tester to earth (-).
– Connect voltage tester - V.A.G 1527B- to battery positive (+)
and oil pressure switch using cables from auxiliary
agen
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– If LED lights up, renew oil pressure
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If LED does not light up: ss

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– Start engine and increase speed slowly. At 0.3…0.7 bar the

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LED must light up; otherwise renew oil pressure switch.

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– Increase engine speed further. At 2000 rpm and an oil tem‐

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perature of 80 °C the oil pressure should be at least 2.0 bar.

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At higher engine speeds, the oil pressure must not exceed 7.0

spec
bar.
es, in part or in w

t to the co

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140 Rep. gr.17 - Lubrication

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