2.5l - Lubrication - Engine Code(s): Bpr & Bps (hatchback) Volkswagen New Beetle A4 рестайлинг

GENERAL REPAIR INFORMATION

Note. The oil level must not exceed the Max. mark - danger of catalytic converter damage! If large quantities of metal particles or abraded material are detected during engine repairs, it may be an indication of a damaged crankshaft or rod bearings. To prevent further damage, perform the following steps after the repair

Carefully clean the oil passages.

Replace the oil injection jets.

Replace the oil cooler.

Replace the oil filter.

ENGINE OIL

Oil Capacities and Specifications

For engine oil capacities and specifications refer to the Owner's Manual and/or Service Net.

Scheme 1

1 - Max. mark

2 - Min. mark

a - Area above hatched area up to the Max. mark: Do not add engine oil.

b - Oil level at hatched area: Can be replenished with engine oil

c - Range from the Min. mark to the hatched area: fill with a Max. 0.5 liters of engine oil.

OIL FILTER HOUSING, DRAINING

Note. When installing the oil drain adapter T40057, a valve in the oil filter housing is opened. If the T40057 is removed, the valve is closed again.

Special tools and workshop equipment required

1. Oil drain adapter T40057

Remove the dust cap -1 - from the oil filter housing -2-.

Scheme 2

Hold the hose for the T40057 in a container and install the T40057 to the oil filter housing -2- until seated.

Let the engine oil drain.

Scheme 3

1. Cylinder Block
2. Oil Pump Drive Chain Beginning with Model Year (MY) 2008 the roller chain has been changed to a tooth chain.
3. Bolt, 20 Nm + 90° (1/4) additional turn Replace
4. Bolt, 25 Nm
5. Oil Filter Bracket Assembly overview, refer to «OIL FILTER BRACKET ASSEMBLY OVERVIEW»(/volkswagen/new-beetle/a4-2005-2011/remont/lubrication-system/#25l-lubrication-engine-codes-bpr-bps-hatchback) .
6. Oil Pump Sprocket Removal and Installation, refer to one of the following: «OIL PUMP, THROUGH MY 2007»(/volkswagen/new-beetle/a4-2005-2011/remont/lubrication-system/#25l-lubrication-engine-codes-bpr-bps-hatchback__oil-pump-through-my-2007) . «OIL PUMP, FROM MY 2008»(/volkswagen/new-beetle/a4-2005-2011/remont/lubrication-system/#25l-lubrication-engine-codes-bpr-bps-hatchback__oil-pump-from-my-2008) . Lettering points outward With anti-twist mechanism
7. Oil Pump Removal and Installation, refer to one of the following: «OIL PUMP, THROUGH MY 2007»(/volkswagen/new-beetle/a4-2005-2011/remont/lubrication-system/#25l-lubrication-engine-codes-bpr-bps-hatchback__oil-pump-through-my-2007) . «OIL PUMP, FROM MY 2008»(/volkswagen/new-beetle/a4-2005-2011/remont/lubrication-system/#25l-lubrication-engine-codes-bpr-bps-hatchback__oil-pump-from-my-2008) .
8. Bolt, 25 Nm
9. Oil Dipstick Oil level must not be above the Max. mark!
10. Retaining Ring Clipped in to the intake manifold.
11. Guide Tube
12. Stud Bolt, 25 Nm
13. O-ring Replace
14. Seal Replace
15. Bracket
16. Bolt, 10 Nm
17. Lower Oil Pan Removal and installation, refer to «LOWER OIL PAN»(/volkswagen/new-beetle/a4-2005-2011/remont/lubrication-system/#25l-lubrication-engine-codes-bpr-bps-hatchback__lower-oil-pan) .
18. Bolt, 10 Nm
19. Oil Drain Plug, 30 Nm Replace
20. Decoupling Element Bolt, 10 Nm.
21. Oil Intake Pipe
22. 25 Nm
23. Upper Oil Pan Removal and installation, refer to «UPPER OIL PAN»(/volkswagen/new-beetle/a4-2005-2011/remont/lubrication-system/#25l-lubrication-engine-codes-bpr-bps-hatchback__upper-oil-pan) .
24. O-ring Replace

Scheme 4

1. Bolt, 25 Nm
2. Oil Filter Bracket Removing: -- Drain the coolant. Refer to «DRAINING AND FILLING»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback__draining-and-filling) . -- Remove the intake manifold. Refer to «INTAKE MANIFOLD»(/volkswagen/new-beetle/a4-2005-2011/remont/fuel-system/#25l-multiport-fuel-injection-engine-codes-bpr-bps-hatchback__intake-manifold) . -- Remove the connection for the thermostat. -- Disconnect the coolant hose from the thermostat housing. -- Drain the oil filter housing and remove, refer to «OIL FILTER HOUSING, DRAINING»(/volkswagen/new-beetle/a4-2005-2011/remont/lubrication-system/#25l-lubrication-engine-codes-bpr-bps-hatchback__oil-filter-housing-draining) . -- Remove the oil filter bracket, the vent hose -item 6- remains connected.
3. Gasket Replace
4. Oil Pressure Switch -F1-, 20 Nm 1.4 bar, black Checking, refer to «OIL PRESSURE AND SWITCH, CHECKING»(/volkswagen/new-beetle/a4-2005-2011/remont/lubrication-system/#25l-lubrication-engine-codes-bpr-bps-hatchback__oil-pressure-and-switch-checking) .
5. from Intake Hose See -item 1- (Intake Tube) in «AIR FILTER ASSEMBLY OVERVIEW»(/volkswagen/new-beetle/a4-2005-2011/remont/fuel-system/#25l-multiport-fuel-injection-engine-codes-bpr-bps-hatchback) .
6. Vent Hose Due to 4 point lock, only disconnect when the oil filter bracket is to be removed.
7. Dust Cap
8. Oil Filter Housing, 25 Nm Remove and install using oil filter wrench 3417. Draining, refer to «OIL FILTER HOUSING, DRAINING»(/volkswagen/new-beetle/a4-2005-2011/remont/lubrication-system/#25l-lubrication-engine-codes-bpr-bps-hatchback__oil-filter-housing-draining) .
9. Seal Replace Insert when oiled. Note the installed position: Service flag must be at the top.
10. Oil Filter Element Drain the oil filter housing before removing, refer to «OIL FILTER HOUSING, DRAINING»(/volkswagen/new-beetle/a4-2005-2011/remont/lubrication-system/#25l-lubrication-engine-codes-bpr-bps-hatchback__oil-filter-housing-draining) . Replace, refer to the Maintenance ; Booklet 14.1.
11. Gasket Replace
12. Oil Cooler See note in «GENERAL REPAIR INFORMATION»(/volkswagen/new-beetle/a4-2005-2011/remont/lubrication-system/#25l-lubrication-engine-codes-bpr-bps-hatchback__general-repair-information) . Ensure sufficient clearance to surrounding components. Coolant hose connection diagram, refer to «COOLANT HOSE CONNECTION DIAGRAM»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback) .
13. Bolt, 25 Nm
14. to Thermostat Housing
15. Gasket Replace

FASTENER TIGHTENING SPECIFICATIONS

OIL PRESSURE AND SWITCH, CHECKING

Special tools and workshop equipment required

1. Oil pressure gauge VAG 1342
2. Voltage tester VAG 1527B
3. Connector test set VAG 1594C
4. Vehicle diagnostic tester

1. Engine oil level OK.
2. Engine oil temperature at least 80 °C (176 °F) (radiator fan must start up once)

Note. For the functional check and servicing of the optical and acoustic oil pressure warning, refer to SYSTEM WIRING DIAGRAM.

Bring the lock carrier into service position. Refer to Description and Operation .

Support the lock carrier using a sleeve -B-, 80 millimeters (mm) in length, for example, from VW 540/1A and a M8 x 100 bolt -A-.

Scheme 5

Remove the oil pressure switch -F1- and install it into the VAG 1342.

Scheme 6

Install the VAG 1342 into the oil filter bracket in place of the oil pressure switch.

Connect the brown wire of the VAG 1342 to ground (GND).

Connect the VAG 1527B using adapter cables from VAG 1594C to B+ and the oil pressure switch.

1. Light Emitting Diode (LED) must not light up.

If LED lights up, replace the oil pressure switch (1.4 bar).

If the LED does not light up

Start the engine and increase the engine speed.

1. The LED must illuminate at 1.2 to 1.6 bar. Replace the oil pressure switch if it does not.

Increase engine speed further.

1. At higher engine speeds the oil pressure must not exceed 7.0 bar
2. At 2000 RPM and an oil temperature of 80 °C (176 °F), the oil pressure must be 2.7 to 4.5 bar.

If the specification is not obtained

Check the screen in the oil intake pipe for contamination.

Note. Also, mechanical damage, for example, bearing damage can also be the cause of too low oil pressure.

If no malfunction can be found

Replace the oil pump. Refer to one of the following

1. «OIL PUMP, THROUGH MY 2007»(/volkswagen/new-beetle/a4-2005-2011/remont/lubrication-system/#25l-lubrication-engine-codes-bpr-bps-hatchback__oil-pump-through-my-2007) .
2. «OIL PUMP, FROM MY 2008»(/volkswagen/new-beetle/a4-2005-2011/remont/lubrication-system/#25l-lubrication-engine-codes-bpr-bps-hatchback__oil-pump-from-my-2008) .

If the specification is exceeded

Check the oil passages.

Replace the oil filter bracket if necessary.

LOWER OIL PAN

Special tools and workshop equipment required

1. Torque wrench (5-50 Nm) VAG 1331
2. Hand drill with plastic brush attachment
3. Protective eyewear
4. Silicone sealant D 174 003 A2

Removing

Remove the noise insulation. Refer to Description and Operation .

Drain the engine oil.

Note. Observe disposal regulations!

Remove the lower oil pan bolts.

Pry off the lower oil pan at the lift out pockets provided -arrows- on the upper oil pan. Be careful not to damage the sealing surfaces in the process.

Scheme 7

Replace the damaged lower oil pan.

Installing

Remove the remainder of sealant from the upper and lower oil pans using a rotating plastic brush.

Clean the sealing surfaces so they are completely free of any oil or grease.

Cut the tube nozzle at the front mark (nozzle diameter approximately 1 millimeter (mm)).

Scheme 8

Note the shelf life date.

Note. The lower oil pan must be installed within 5 minutes after application of sealant.

With the engine removed, apply the sealant bead -A- as shown onto a clean sealing surface of the upper oil pan.

Scheme 9

1. The sealant bead must be 1.5 to 2.0 mm thick.

Note. With the engine installed, apply the sealant in the same manner onto the lower oil pan. Sealant bead must be routed on inside of the holes for bolts.

Install all bolts and tighten them in diagonal sequence.

The rest of the installation follows the reverse of the removal procedures. When doing this note the following

1. After installing the lower oil pan, allow the sealant to dry for approximately 30 minutes. Only after then may the engine oil be added.

Tightening Specifications

UPPER OIL PAN

Special tools and workshop equipment required

1. Torque wrench (5-50 Nm) VAG 1331
2. Locking pin T10115
3. Adapter plates 2036/1
4. 3 M8 x 20 bolts and washers
5. Hand drill with plastic brush attachment
6. Protective eyewear
7. Silicone sealant D 174 003 A2

Removing

Loosen the camshaft gears. Refer to VALVE TIMING, ADJUSTING .

Remove the control housing cover. Refer to CONTROL HOUSING COVER .

Tension the chain tensioner -1- and secure it using T10115.

Scheme 10

Remove the guide rail -2-.

Remove the belt pulley side sealing flange. Refer to SEALING FLANGE, BELT PULLEY SIDE .

Remove the lower oil pan. Refer to LOWER OIL PAN .

Remove the bolts -2 and 4- and the oil intake pipe.

Scheme 11

Remove the bolts -1-.

Pry off the upper oil pan from the cylinder block at the designated points using a suitable screwdriver -A-.

Scheme 12

B - Bearing cap 6 for the crankshaft

C - Bearing cap 1 for the crankshaft

Installing

Remove the remainder of sealant from the upper oil pan and cylinder block using a rotating plastic brush.

Clean the sealing surfaces so they are completely free of any oil or grease.

Cut the tube nozzle at the front mark (nozzle diameter approximately 1 millimeter (mm)).

Note the shelf life date.

Note. The upper oil pan must be installed within 5 minutes after application of sealant.

Apply the sealant bead -1, 2 and 3- as shown onto a clean sealing surface of the upper oil pan.

Scheme 13

1. The sealant bead must be 1.5 to 2.0 mm thick.

Place the upper oil pan onto the cylinder block and align it on the transmission side.

Install 2 bolts each at the front and rear hand tight.

Wipe off excess sealant in area of the -arrows-.

Scheme 14

Loosen the bolts again slightly.

Secure the 2036/1 from the 2036 onto the cylinder block as shown.

Press the upper oil pan firmly onto the 2036/1 and tighten the bolts again hand tight.

Install the remaining bolts and tighten by hand.

Make sure that upper oil pan makes contact on the 2036/1.

Tighten all bolts in a diagonal sequence from the inside working toward the outside.

Install new seal -5- into the oil pump -6-.

Scheme 15

Secure the oil intake pipe -1- and the bracket -4- with the bolts -2 and 3-.

Install the guide rail -2-, relieve the tension on the chain tensioner -1- and pull out the T10115.

Adjust the valve timing. Refer to VALVE TIMING, ADJUSTING .

The rest of the installation follows the reverse of the removal procedures. When doing this note the following

1. After installing the oil pan, allow the sealant to dry for approximately 30 minutes. Only after then may the engine oil be added.
2. Remove the T40069 from the cylinder block and install the locking bolt.
3. Fill with coolant. Refer to «DRAINING AND FILLING»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback__draining-and-filling) .

Tightening Specifications

OIL PUMP, THROUGH MY 2007

Note. This description applies to engines that have a roller chain as the timing mechanism drive chain. In Model Year (MY) 2008, the timing mechanism drive chain was changed from a roller chain to a toothed chain.

Special tools and workshop equipment required

1. Torque wrench (5-50 Nm) VAG 1331
2. Counter hold tool T10172
3. Oil pump align plate T03005

Removing

Remove the upper oil pan. Refer to UPPER OIL PAN .

Tension the chain tensioner -1-, secure it using the T10115 and remove it.

Remove the bolt -1-.

Scheme 16

Hold the sprocket -2- in place using the T10172.

Remove the oil pump sprocket from the oil pump and remove the oil pump.

Installing

1. Crankshaft is secured

Replace the O-ring -item 24- in LUBRICATION SYSTEM COMPONENTS OVERVIEW and hand tighten the bolts with the oil pump to the cylinder block.

Place the sprocket with the lettering facing outward onto the oil pump shaft and install it with a new bolt -1- (drive chain not yet installed).

Tightening specification: 20 Nm + 90° (1/4) additional turn

Loosen the bolts -2 through 4-.

Scheme 17

1. Oil pump must be able to be slid easily.

Check the T03005. If there are still protective shields on the magnets, remove them.

Check that there are no shavings located on the magnets of the T03005.

1. The contact surfaces on the crankshaft, the tool and the chain sprocket must be clean.

Place the T03005 on to the crankshaft and secure it with 2 bolts -1- for the vibration damper/crankshaft pulley.

Scheme 18

Tightening specification: 30 Nm

Oil pump is activated by magnets.

Remove the T40069.

Scheme 19

Press the crankshaft in the axial bearing play toward the belt drive -arrow 1- and secure it with a shim as shown in the illustration.

Scheme 20

Press the oil pump lightly toward the chain drive -arrow 2-.

Note. This step is important in order to guarantee the correct position of the sprockets to each other.

In this condition, first tighten the bolts -2 and 3- and then bolt -4- to 25 Nm.

Install the T40069 again. Crankshaft must only be rotated slightly around the Top Dead Center (TDC) point for this. Otherwise there is a risk the valves rest on the pistons.

Remove the T03005.

If a new oil pump is installed, fill the oil pump with some engine oil via the intake passage and rotate the oil pump several times through.

Place the drive chain onto the oil pump sprocket.

Install the upper oil pan. Refer to UPPER OIL PAN .

Install the guide rail -2-, relieve the tension on the chain tensioner -1- and pull out the T10115.

Note. Make sure that the drive chain lies correct in the guide rail -4- and in the tensioning rail -3-.

Adjust the valve timing. Refer to VALVE TIMING, ADJUSTING .

The rest of the installation follows the reverse of the removal procedures. When doing this note the following

1. Remove the T40069 from the cylinder block and install the locking bolt (30 Nm).
2. Fill with coolant. Refer to «DRAINING AND FILLING»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback__draining-and-filling) .

OIL PUMP, FROM MY 2008

Note. In Model Year (MY) 2008, the timing mechanism drive chain was changed from a roller chain to a toothed chain. The gears are now wider and tool T03005/1 must also be used when securing the oil pump.

Special tools and workshop equipment required

1. Torque wrench (5-50 Nm) VAG 1331
2. Counter hold tool T10172
3. Oil pump align plate T03005
4. Oil pump shim T03005/1

Removing

Remove the upper oil pan. Refer to UPPER OIL PAN .

Tension the chain tensioner -1-, secure it using the T10115 and remove it.

Remove the bolt -1-.

Hold the sprocket -2- in place using the T10172.

Remove the sprocket from the oil pump and remove the oil pump.

Installing

1. Crankshaft is secured

Replace the O-ring -item 24- in LUBRICATION SYSTEM COMPONENTS OVERVIEW and hand tighten the oil pump bolts.

Place the sprocket with the lettering facing outward onto the oil pump shaft and secure it with a new bolt -1- (drive chain not yet installed).

Tightening specification: 20 Nm + 90° (1/4) additional turn

Loosen the bolts -2 through 4-.

1. Oil pump must be able to be slid easily.

Check the T03005. If there are still protective shields on the magnets, remove them.

Check that there are no shavings located on the magnets of the T03005.

1. The contact surfaces on the crankshaft, the tool and the chain sprocket must be clean.

Place the T03005/1 and the T03005 on the crankshaft and secure both with the two bolts -1- from the vibration damper/crankshaft pulley.

Scheme 21

Tightening specification: 30 Nm

Oil pump is activated by magnets.

Remove the T40069.

Press the crankshaft in the axial bearing play toward the belt drive -arrow 1- and secure it with a shim as shown in the illustration.

Press the oil pump lightly toward the chain drive -arrow 2-.

Note. This step is important in order to guarantee the correct position of the sprockets to each other.

In this condition, first tighten bolts -2 and 3- and then bolt -4- to 25 Nm.

Install the T40069 again. Crankshaft must only be rotated slightly around the Top Dead Center (TDC) point for this. Otherwise there is a risk the valves rest on the pistons.

Remove the T03005 and the T03005/1.

If a new oil pump is installed, fill the oil pump with some engine oil via the intake passage and rotate the oil pump several times through.

Place the drive chain onto the oil pump sprocket.

Install the upper oil pan. Refer to UPPER OIL PAN .

Install the guide rail -2-, relieve the tension on the chain tensioner -1- and pull out the T10115.

Note. Make sure that the drive chain lies correct in guide rail -4- and in the tensioning rail -3-.

Adjust the valve timing. Refer to VALVE TIMING, ADJUSTING .

The rest of the installation follows the reverse of the removal procedures. When doing this note the following

1. Remove the T40069 from the cylinder block and install the locking bolt (30 Nm).
2. Fill with coolant. Refer to «DRAINING AND FILLING»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback__draining-and-filling) .

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 22

Scheme 23

1. Adapter plates 2036/1
2. Oil pump shim T03005/1
3. Oil drain adapter T40057
4. Locking pin T10115

Scheme 24

Special tools and workshop equipment required

1. Oil pressure gauge VAG 1342
2. Voltage tester VAG 1527B
3. Connector test set VAG 1594C
4. Vehicle diagnostic tester

Scheme 25

Special tools and workshop equipment required

1. Torque wrench (5-50 Nm) VAG 1331
2. Counterhold tool T10172
3. Oil pump align plate T03005

See also:
• DRAINING AND FILLING
• INTAKE MANIFOLD
• AIR FILTER ASSEMBLY OVERVIEW
• COOLANT HOSE CONNECTION DIAGRAM
• Description and Operation
• VALVE TIMING, ADJUSTING
• CONTROL HOUSING COVER
• SEALING FLANGE, BELT PULLEY SIDE
• OIL FILTER BRACKET ASSEMBLY OVERVIEW
• OIL PUMP, THROUGH MY 2007
• OIL PUMP, FROM MY 2008
• LOWER OIL PAN
• UPPER OIL PAN
• OIL FILTER HOUSING, DRAINING
• OIL PRESSURE AND SWITCH, CHECKING
• GENERAL REPAIR INFORMATION