45.1. Oil filter and oil cooler installation details 1. Threaded plug, 15 Nm; 2, 4. Gasket, subject to replacement; 3. Oil cooler; 5. Sealing ring, subject to replacement; 6/7. Threaded plug, 10 // 40 Nm; 8. Not used; 9. Spring of the pressure reducing valve 5 bar; 10. Piston of the pressure reducing valve 5 bar; 11. Engine oil pressure sensor 0.7 bar, 20 Nm; 12. Sealing ring, subject to replacement; 13. Gasket, subject to replacement; 14. Bracket mounting bolt 15, 14 Nm, then tighten to an angle of 90°, subject to replacement; 15. Oil filter bracket; 16, 18. Sealing ring, subject to replacement; 17. Turbocharger oil supply line; 19. Hollow bolt, 25 Nm; 20. Cover, 25 Nm; 21, 22. Sealing ring, subject to replacement; 23. Filter element
2. The installation details of the oil pan and oil pump are shown in the illustrations.
45.2a. Oil pan and oil pump installation details (1.9 l models) 1. Bolt for fixing stop 2; 2. Front engine mount stop; 3. Oil pan; 4. Oil pump with 12 bar pressure reducing valve; 5. Oil pump sprocket; 6. Sprocket mounting bolt 5, 20 Nm, then tighten to an angle of 90°, subject to replacement; 7. Oil pump chain; 8. Housing mounting bolt 9; 9. Oil pump housing; 10. Chain tensioner 7, 16 Nm; 11. Crankshaft sprocket; 12. Centering bushings; 13. Sealing ring, subject to replacement; 14. Oil intake mounting bolt; 15. Oil intake; 16. Oil separator; 17. Oil separator mounting bolt, 16 Nm; 18/19. Oil pan mounting bolt, 15 // 40 Nm; 20. Gasket, subject to replacement; 21. Threaded drain plug, 30 Nm
45.2b. Oil pan and oil pump installation details (2.0L chain driven models) 1. Oil pan; 2. Support mounting bolt 3, 23 Nm; 3. Front engine mount; 4. Pump mounting bolt 8, 10 Nm; 5. Suction pipe; 6. Pipe mounting bolt, 10 Nm; 7. Sealing ring, subject to replacement; 8. Oil pump; 9. Oil pump drive shaft; 10. Retaining ring; 11. Balance shaft module sprocket; 12. Sprocket mounting bolt 11, 10 Nm, then tighten to an angle of 90°, subject to replacement; 13. Sprocket cover; 14. Cover fastening bolt 13.5 Nm, installed on threaded varnish; 15/16. Tensioner mounting bolt 17, 9 //20 Nm; 17. Chain tensioner 18; 18. Module 20 drive chain; 19. Crankshaft sprocket; 20. Balance shaft module; 21. Bolt M7 // M8 for fastening module 20, 13 // 20 Nm, then tighten to an angle of 90°, subject to replacement; 22. Oil intake; 23. Oil intake mounting bolt, 10 Nm; 24. Pan mounting bolt 1, 40 Nm; 25. Pan mounting bolt 1, 25 Nm; 26. Pan mounting bolt 1, 15 Nm; 27. Sealing ring, subject to replacement; 28. Drain plug, 30 Nm
45.2c. Oil pan and oil pump installation details (2.0L direct drive models) 1. Oil pan; 2. Support mounting bolt 3, 23 Nm; 3. Powertrain support; 4. Pump mounting bolt 8, 10 Nm; 5. Suction pipe; 6. Pipe mounting bolt, 10 Nm; 7. Sealing ring, subject to replacement; 8. Oil pump; 9. Oil pump drive shaft; 10. Retaining ring; 11. Balance shaft cylindrical gear; 12. Pinion mounting bolt 11, 20 Nm, then tighten to an angle of 90°, subject to replacement; 13. Hub; 14. Hub mounting bolt 13, 90 Nm, then tighten to an angle of 90°, subject to replacement; 15, 17. Thrust bearing washer; 16. Intermediate gear, subject to replacement; 18. Cylindrical gear; 19. Balance shaft module; 20. Bolt M7 // M8 for fastening module 20, 13 // 20 Nm, then tighten to an angle of 90°, subject to replacement; 21. Oil intake; 22. Oil intake mounting bolt, 10 Nm; 23. Pan mounting bolt 1, 40 Nm; 24. Pan mounting bolt 1, 45 Nm; 25. Pan mounting bolt 1, 15 Nm; 26. Sealing ring, subject to replacement; 27. Drain plug, 30 Nm
Note: The 2.0L TDI-PD (DOHC) engines are in many ways (engine assembly removal, alternator belt installation parts, crankshaft and flywheel seals) are similar to the 1.9 and 2.0 L TDI-PD (SOHC) engines. Only the features of the 2.0 L TDI-PD (DOHC) engines are described below.
