Volkswagen 2.0L Engine AEG: Lubrication system (eng.)

Volkswagen 2.0L Engine AEG: Lubrication system (eng.)
Volkswagen New Beetle
2.0 Liter 4-cyl General, Engine (Engine Code AEG)
17 Engine-Lubrication system (Page GR-17)
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Lubrication system components, removing and installing
Oil pan, removing and installing
Oil pressure and oil pressure switch, checking
Dynamic oil pressure warning system, function
Volkswagen New Beetle
2.0 Liter 4-cyl General, Engine (Engine Code AEG)
Lubrication system components, removing and installing (Page 17-1)
Notes:
If quantities of metal particles or other material (caused, for example, by crankshaft
seizure or connecting rod bearings) are found in the engine oil during repairs,
thoroughly clean the oil passages and replace the oil cooler to prevent future
damage from occurring later.
The oil level must not be above the Max. mark - danger of damage to catalyst!
Marks
Page 17-6 , Fig. 1
Oil pressure, checking
Page 17-10
Oil system capacity1) :
Without oil filter 3.5 liters (3.7 quarts)
With oil filter 4.0 liters (4.2 quarts)
Engine oil specifications:
Owner's Manual
Volkswagen New Beetle
2.0 Liter 4-cyl General, Engine (Engine Code AEG)
Lubrication system components, removing and installing (Page 17-2)
Part I
Oil filter flange, disassembling
Page 17-4 , Part II
1 - Oil pump
12 bar (174 psi) pressure relief
- Before installing, ensure that both oil pump/cylinder head centering sleeves are in
place
- Replace if running surfaces and/or gears are scored
2 - Chain sprocket
3 - 20 Nm (15 ft lb)
4 - Chain
5 - Sealing flange
Removing and installing:
Page 13-25
- Insert with silicone sealant D 176 404 A2
Page 13-25
Crankshaft oil seal (pulley side), replacing
Page 13-21
6 - 15 Nm (11 ft lb)
Volkswagen New Beetle
2.0 Liter 4-cyl General, Engine (Engine Code AEG)
Lubrication system components, removing and installing (Page 17-3)
7 - Chain tensioner (with tensioning rail)
15 Nm (11 ft lb)
- When installing, pretension spring and then install
8 - Dipstick
Oil level must NOT be above the Max. mark!
Marks:
Page 17-6 , Fig. 1
9 - Guide
- Remove to draw oil out
10 - Guide tube
11 - Dowel sleeves
12 - O - ring
- Replace
13 - Suction pipe
- Clean strainer
14 - Baffle plate
15 - Oil pan
- Clean sealing surface before installing
- Install with silicone sealant D 176 404 A2
16 - Seal
- Replace
17 - Oil pan drain plug
30 Nm (22 ft lb)
Page 17-7
Volkswagen New Beetle
2.0 Liter 4-cyl General, Engine (Engine Code AEG)
Lubrication system components, removing and installing (Page 17-4)
Part II
1 - Sealing plug
40 Nm (30 ft lb)
2 - Seal
3 - Spring
for pressure relief valve, approx. 4 bar (58 psi)
4 - Piston
for pressure relief valve
5 - Gasket
- Replace
6 - Check valve
8 Nm (71 in. lb)
7 - Seal
- Install onto sealing cap shoulder (item 8)
8 - Sealing cap
9 - Retaining clip
10 - Sealing plug
15 Nm (11 ft lb)
11 - Seal
- If sealing ring is leaking; nip open and replace.
Volkswagen New Beetle
2.0 Liter 4-cyl General, Engine (Engine Code AEG)
Lubrication system components, removing and installing (Page 17-5)
12 - 1.4 bar oil pressure switch F1
25 Nm (18 ft lb)
Black
Checking
Page 17-10
13 - Seal
If sealing ring is leaking; nip open and replace.
14 - Oil filter flange
15 - 15 Nm (11 ft lb) + 1 /4 turn (90
Replace
) further
16 - Gasket
Replace
- Fit into groove on oil cooler
17 - Oil cooler
Installed position: must be turned fully clockwise (viewed from below) until touching
its own bracket
- See note
Page 17-1
18 - 25 Nm (18 ft lb)
19 - Oil filter
- Loosen with strap wrench
- Hand tighten
- Observe installation instructions on oil filter
Volkswagen New Beetle
2.0 Liter 4-cyl General, Engine (Engine Code AEG)
Lubrication system components, removing and installing (Page 17-6)
Fig. 1 Engine oil dipstick, marks
1- Max. mark
2- Min. mark
a- Area above cross - hatched zone up to Max. mark: Do NOT top - up with engine oil!
b- Area within cross - hatched zone: CAN be topped - up with engine oil
c- Area from Min. mark up to cross - hatched zone: FILL with 0.5 liter of engine oil
maximum!
Volkswagen New Beetle
2.0 Liter 4-cyl General, Engine (Engine Code AEG)
Lubrication system components, removing and installing (Page 17-7)
Oil pan, removing and installing
Special tools, workshop equipment, testers, measuring instruments and auxiliary
items required
3185 Extension socket wrench
3249 Socket
Hand drill with plastic brush
D176404 A2 Silicone sealant
Oil pan, removing
- Remove center and right insulation trays:
General body repairs; Repair group 50
- Drain engine oil.
- Loosen and tighten oil pan bolts using 3185 extension socket wrench, unscrew using
3249 socket.
Volkswagen New Beetle
2.0 Liter 4-cyl General, Engine (Engine Code AEG)
Lubrication system components, removing and installing (Page 17-8)
- Remove oil pan, it may be necessary to free it up by tapping it lightly with a rubber
hammer.
- Remove sealant residue on engine block with a flat scraper.
- Remove sealant residue on the oil pan with a rotating brush, e.g. hand drill with a
plastic brush (wear protective glasses).
- Clean sealing surface, MUST be free of oil and grease.
Oil pan, installing
Notes:
Note the "use by" date on the sealant container.
Oil pan must be installed within 5 minutes of applying silicone sealing compound.
- Cut - off tube nozzle at forward mark (nozzle approx. 3 mm )
- Apply silicone sealing compound, as shown, to clean oil pan sealing surface. Sealing
compound bead must be:
2 to 3 mm thick.
must follow curve on inside of bolt holes - arrows - .
Note:
Sealing compound bead must not be thicker than specified, otherwise excess compound
will enter the oil pan and could block the oil suction pipe strainer.
Volkswagen New Beetle
2.0 Liter 4-cyl General, Engine (Engine Code AEG)
Lubrication system components, removing and installing (Page 17-9)
- Apply silicone sealing bead as shown to the clean sealing surface of the oil pan.
(illustration shows position of sealant bead on engine block).
- Install oil pan immediately and tighten all oil pan bolts lightly.
1- Tighten all bolts oil pan/engine block only lightly cross over
2- Lightly tighten three oil pan/transmission bolts
3- Lightly tighten oil pan/engine block cross over bolts
4- Tighten three oil pan/transmission bolts
45 Nm (33 ft lb)
5- Tighten all bolts oil pan/engine block cross over
15 Nm (11 ft lb)
Notes:
When installing the oil pan with the engine removed; Ensure oil pan is flush with
engine block on flywheel side.
After installing oil pan; allow sealant to dry for approx 30 minutes before filling with
engine oil.
Assembly is the reverse of the disassembly procedure.
Volkswagen New Beetle
2.0 Liter 4-cyl General, Engine (Engine Code AEG)
Lubrication system components, removing and installing (Page 17-10)
Oil pressure and oil pressure switch, checking
Special tools, workshop equipment, test and measuring appliances and auxiliary
items required
VAG 1342 Oil pressure tester
VAG 1527 B Voltage tester
VW 1594 Adaptor kit
Volkswagen New Beetle
2.0 Liter 4-cyl General, Engine (Engine Code AEG)
Dynamic oil pressure warning system, function (Page 17-11)
The oil pressure switch is normally open (engine not running) and closes when minimum
dynamic pressure is attained.
Oil pressure warning is activated approx.: 10 seconds after ignition is switched ON
(terminal 15 ON)
Oil pressure warning switch ON delay: approx. 3 seconds
Oil pressure warning switch shut OFF delay: approx. 5 seconds.
Oil pressure warning light, checking
After switching ON the ignition (engine not running), the oil pressure warning light
(instrument panel) must stay ON for approx. 3 seconds and then switch OFF.
Note:
The check will be aborted if the engine is running.
Volkswagen New Beetle
2.0 Liter 4-cyl General, Engine (Engine Code AEG)
Dynamic oil pressure warning system, function (Page 17-12)
Warning criteria
Optical oil pressure warning (oil pressure warning light flashes) and the 3 time buzzer for
acoustic warning, will switch ON under the following conditions:
Ignition switched ON (engine NOT running) = Oil pressure switch CLOSED
Engine RPM greater than 1500 rpm = Oil pressure switch OPEN
At engine speeds greater than 5000 rpm, the oil pressure warning is not erased; not
even if the oil pressure switch is closed. Oil pressure warning only erases below
5000 rpm.
If the oil pressure switch is opened at an engine speed greater than 1500 rpm for
anywhere from 0.5 to 3 seconds, it is stored in the instrument panel Control Module.
If this condition occurs 3 times during engine running; an oil pressure warning is
immediately released and since it is under 1500 rpm will not be erased. Oil pressure
warning erasure occurs when the oil pressure switch "over 1500 rpm" is closed for
longer than 5 seconds or with the ignition switched OFF.
Test conditions
Ensure engine oil level OK
Page 17-6
Oil pressure warning light K3 must light up with ignition switched ON for approx. 3
seconds
Engine oil temperature 80 C minimum (Radiator cooling fan must come on at least
once)
Volkswagen New Beetle
2.0 Liter 4-cyl General, Engine (Engine Code AEG)
Dynamic oil pressure warning system, function (Page 17-13)
Oil pressure switch, checking
-
Remove oil pressure switch F1 and screw into tester.
Screw tester into oil filter flange instead of pressure switch.
Connect brown tester wire to engine Ground.
Connect VAG 1527 B Voltage tester between battery Plus and oil pressure switch
using jumper wires from VW 1594 adaptor kit.
- Start engine and slowly increase speed.
At 1.2 to 1.6 bar, LED must light up
If LED does not light up
- Replace oil pressure switch.
Oil pressure switch, checking
- Remove oil pressure switch F1 and screw into tester.
- Screw tester into Oil filter flange instead of pressure switch
- Start engine (engine oil temperature approx. 80 C)
Oil pressure at idle: 2.0 bar minimum
Oil pressure at 2000 rpm: 3.0 to 4.5 bar
If specifications not obtained
- Check oil filter assembly (w/ pressure relief valve)
Page 17-5 (item 14) or
replace oil pump
Page 17-2 (item 1).
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