Removal 4-cylinder petrol engine
Place the vehicle over a pit or on a lift.
Remove the lower engine mudguard.
Drain the engine oil by loosening the oil drain plug about half a turn. Place an oil drain container under the drain plug and unscrew the plug completely. If necessary, press down on the plug when unscrewing to prevent the oil from leaking prematurely.
When the oil has completely drained, screw the oil drain plug back into place.
Remove poly V-belt.
Cars with air conditioning.Unscrew the tension roller of the V-ribbed belt of the air conditioning compressor drive and remove the belt.
Engine 1.8-I / 150 hp With a steel rod with a diameter of 5 mm, fix the radiator fan pulley from turning and unscrew and remove the radiator fan from the back of the pulley (see fig. 2.87).
Remove the bolts securing the torque compensator support to the motor and bracket and leave the support in place (see fig. 2.93).
Unscrew the torque compensator support bracket from the engine (see fig. 2.94).
Engine 1.8-I / 150 hpDisconnect the electrical wires from the oil pan to the starter. Loosen the clamp and remove the air pipe from the turbocharger.
Engine 1.8-I / 150 hp Unscrew the top nut securing the left engine mount.
Loosen the nuts on both engine mounts (see fig. 2.95).
Hook the power unit with the slings of the lifting mechanism and lift it so that the lower part of it only touches the front wall of the body (see fig. 2.96).
Engine 1.8-I/150 HP. Remove the left engine mount. Also, unscrew the oil return line from the turbocharger to the oil pan.
Remove the oil pan mounting bolts. For access to the rear oil pan mounting bolts on a 1.8-I / 150 hp engine. turn the crankshaft of the engine so that the notch on the flywheel is located under the bolt (see fig. 2.97).
Remove the oil pan. If the pan does not come off, tap it lightly with a rubber mallet.
Engine 1.8-I / 150 hp Rotate the oil pan forward and to the left while depressing the lower radiator hose and remove it.
Installation
Using a plastic or wooden scraper, clean the mating surfaces of the cylinder block and oil pan from the old gasket.
Install a new oil pan gasket.
Tighten the oil pan bolts evenly and gradually. Do not overtighten the bolts, otherwise the oil pan gasket will be deformed.
Engine 1.8-I / 150 hpTighten the bolts securing the oil pan to the gearbox to 45 Nm.
Tighten the oil pan bolts to 10 Nm and the M10 bolts to 45 Nm.
Engine 1.8-I / 150 hpScrew the oil return pipe from the turbocharger into the oil pan with a new gasket and tighten the bolts to 10 Nm.
Lower the engine and remove the hoist straps. The engine has 150 hp. when lowering, install the left support.
Tighten the support nuts to 25 Nm.
Screw on the torque compensator support holder and on a 125 hp engine. tighten the bolts to a torque of 40 Nm, and on the engine 150 hp. torque 25 Nm.
Attach the wires leading to the starter to the oil pan.
Engine 1.8-I / 150 hpInstall the radiator fan and V-belt.
Install poly V-belt.
Cars with air conditioning.Screw the tension roller of the V-ribbed belt of the air conditioning compressor drive and install the belt.
Fill the engine with engine oil. Take a test drive and check the tightness of the oil pan installation. Tighten the oil pan bolts slightly if necessary.
Engine 1.9-I-TDI
All operations and instructions for removing and installing the oil pan are similar to the operations for removing and installing the oil pan of a 4-cylinder gasoline engine. This section describes operations that are unique to the 1.9-I-TDl engine.
When removing the oil pan, it is not necessary to remove the engine mounts and torque compensator mounts.
The HAZET 2528-10 wrench must be used to loosen the rear oil pan bolts.
Before installing the oil pan, AUDI-D2 or Loctite Ultra Black sealant must be applied to the transitions from the engine block to the cover.
Install the oil pan with a new gasket and, crosswise, tighten the bolts to 20 Nm.
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