Volkswagen Corrado 1990 - 1994 General Engine

Engine - Lubrication System (Page GR-17)

Engine Code-PG
Dynamic oil pressure system troubleshooting Lubrication system assembly Oil capacity, specifications pan pump pump, checking pump, gears switches, checking

Engine Code-AAA
Lubrication system assembly Oil capacity, specifications pump, assembly pump, checking relief valve, checking spray jet, removing/installing warning system

Volkswagen Corrado 1990 - 1994 General Engine

Engine - Lubrication System (Page 17-2)

Notes Components shown can be removed or installed with engine in vehicle. Always replace seals and gaskets.

CAUTION!
If, as a result of engine damage, large quantities of metal shavings are found in the engine oil, oil passages should be cleaned and the oil cooler replaced. Notes Ensure that no coolant hoses or lines touch the knock sensor. This could dampen the sensor and diminish the signal.

Volkswagen Corrado 1990 - 1994 General Engine

Engine - Lubrication System (Page 17-3)

Notes Components shown can be removed or installed with engine in vehicle. Always replace seals and gaskets.

CAUTION!
If, as a result of engine damage, large quantities of metal shavings are found in the engine oil, oil passages should be cleaned and the oil cooler replaced.

Volkswagen Corrado 1990 - 1994 General Engine

Engine - Lubrication System (Page 17-4)

Fig. 1 Oil pump, checking backlash New: 0.05 mm (0.002 in.) Wear limit: 0.20 mm (0.008 in.)

Fig. 2 Oil pump, checking axial play Wear limit: 0.15 mm (0.006 in.)

Oil capacity, specifications

Fig. 3 Oil specification Use only oil marked SF or SG. B = Multi-grade oil C = Single-grade oil Engine oil capacity With oil filter 4.0L (4.3 qts) Without oil filter 3.5L (3.7 qts)

Volkswagen Corrado 1990 - 1994 General Engine

Engine - Lubrication System (Page 17-5)

Oil pressure warning system, checking

Notes Oil temperature must not exceed 85 C (205 F) remove 1.4 bar (20 psi) oil pressure switch (black insulation) insert into test unit VW 1342 as shown connect test unit to oil filter bracket in place of switch, as shown connect brown wire of test unit VW 1342 to ground connect LED test lamp V.A.G1527 a (US 1115) with lead from VW 1594 to 0.3 bar (4.4 psi) oil pressure switch A test lamp must light start engine and slowly increase RPM test lamp must go out at 0.15-0.45 bar (2.2-6.5 psi) If NO , replace switch connect LED test lamp to 1.4 bar (20 psi) oil pressure switch B (black insulation), as shown test lamp must light at 1.2-1.6 bar (17-23 psi) If NO , replace switch increase and hold engine speed at a steady 2000 RPM oil pressure must be minimum of 2.0 bar (29 psi) at 80 C (176 F)

Volkswagen Corrado 1990 - 1994 General Engine

Engine - Lubrication System (Page 17-6)

Dynamic oil pressure system, troubleshooting

Notes Always refer to appropriate wiring diagram. Test conditions engine oil level OK tachometer OK oil pressure switches OK Tools required Multimeter US 1119 test box V.A.G. 1598 with adapter 1598/8 System operation Ignition ON, engine OFF LED light flashes IF oil pressure switches OK Ignition ON, engine at idle LED flashes when oil pressure drops below 0.3 bar (4.4 psi) Ignition ON, engine speed over 2100 RPM LED flashes at oil pressure below 1.4 bar (20.0 psi) audio warning sounds after approximately 3.0 second delay audio/visual warning continues until oil pressure increases to 1.4 bar (20.0 psi) or ignition is turned off RPM tolerance 100

Volkswagen Corrado 1990 - 1994 General Engine

Engine - Lubrication System (Page 17-7)

Volkswagen Corrado 1990 - 1994 General Engine

Engine - Lubrication System (Page 17-8)

Volkswagen Corrado 1990 - 1994 General Engine

Engine - Lubrication System (Page 17-9)

Volkswagen Corrado 1990 - 1994 General Engine

Engine - Lubrication System (Page 17-10)

Volkswagen Corrado 1990 - 1994 General Engine

Engine - Lubrication System (Page 17-11)

WARNING! DO NOT re-use any fasteners that are worn or deformed in normal use. Many fasteners are designed to be used only once and become unreliable and may fail when used a second time. This includes, but is not limited to, nuts, bolts, washers, self-locking nuts or bolts, circlips, cotter pins. Always follow recommendations given in this publication. For replacements always use new parts.

CAUTION!
Always replace gaskets and seals.

CAUTION!
Part numbers are for reference only. Always check with your Parts Department for latest information.

CAUTION!

If metal shavings are found in the engine oil as a result of engine damage, clean oil passages thoroughly, then replace all oil spray jets, oil pressure relief valve, oil cooler and oil filter.

Volkswagen Corrado 1990 - 1994 General Engine

Engine - Lubrication System (Page 17-12)

Notes All components shown, with exception of oil spray jets and the oil pressure relief valve, can be replaced with engine installed. Notes Engine oil capacity with oil filter 6.0L (6.3 qts.) without oil filter 5.0L (5.3 qts.) 1 - Cylinder block 2 - 10 Nm (7 ft lb) 3 - Oil pump drive cover installing, coat seal with engine oil 4 - O-ring replace installing, coat O-ring with engine oil 5 - Oil pump drive 6 - Intermediate shaft 7 - Thrust washer 8 - Drive shaft for oil pump drive 9 - 25 Nm (18 ft lb) 10 - Oil pump see page 17-13 assembly checking, page 17-15 11 - Oil pan gasket seal flange area cylinder block/seal flange front and rear, coat both sides with AMV 188 001 02 always replace 12 - Oil drain plug - 50 Nm (37 ft lb) 13 - Gasket replace 14 - Oil pan 15 - Oil filter housing drain plug - 20 Nm (15 ft lb) 16 - Oil cooler coat seal surface with AMV 188 001 02 do not allow sealant to get onto oil cooler gasket ensure adequate side clearance 17 - Oil cooler cover - 25 Nm (18 ft lb) 18 - Oil filter note change intervals 19 - Oil filter housing, lower - 30 Nm (22 ft lb)

drain before removing 20 - Oil filter housing, upper - with by-pass valve 21 - Oil temperature sender 22 - Oil pressure switches - 25 Nm (18 ft lb) 1.4 bar (20 psi) switch, yellow wire 0.3 bar (4.4 psi), blue/black wire checking, see page 17-19 23 - O-ring replace note installation position 24 - Dipstick 25 - Oil pressure relief valve - 5 Nm (44 in. lb) note installation position replace if badly contaminated 26 - Oil spray jet removing and installing, page 17-16

Volkswagen Corrado 1990 - 1994 General Engine

Engine - Lubrication System (Page 17-13)

CAUTION!
If metal shaving are found in the engine oil as a result of engine damage, clean oil passages thoroughly, then replace all oil spray jets, oil pressure relief valve, oil cooler and oil filter.

CAUTION!
Always replace gaskets and seals.

CAUTION!
Part numbers are for reference only. Always check with your Parts Department for latest information. Notes All components shown may be replaced with engine installed.

1 - Oil pump drive shaft 2 - Oil pump housing 3 - 25 Nm (18 ft lb)

Volkswagen Corrado 1990 - 1994 General Engine

Engine - Lubrication System (Page 17-14)

4 - Oil pump gears checking backlash, page 17-15 checking axial play, page 17-15 5 - Oil pump cover with pressure relief valve opening pressure: 5.5 0.2 bar (80 3.0 psi) 6 - Piston note installation position 7 - Spring 8 - 40 Nm (30 ft lb) 9 - 10 Nm (7 ft lb) replace 10 - Oil pressure pipe secure to cylinder block with AMV 188 001 02 11 - Gasket replace 12 - 10 Nm (7 ft lb) 13 - O-ring replace coat O-ring with engine oil when installing

Volkswagen Corrado 1990 - 1994 General Engine

Engine - Lubrication System (Page 17-15)

Oil pump, checking

Backlash, checking Wear limit: 0.20 mm (0.008 in.)

Axial play, checking Wear limit: 0.10 mm (0.004 in.)

Volkswagen Corrado 1990 - 1994 General Engine

Engine - Lubrication System (Page 17-16)

Oil spray jet, removing/installing

Removing

opening pressure 2.0 bar (29 psi) remove with 4.0 mm drift Installing install by hand with 6.0 mm mandrel (arrow)

Volkswagen Corrado 1990 - 1994 General Engine

Engine - Lubrication System (Page 17-17)

Oil pressure relief valve, checking

opening pressure 2.5 bar (37 psi) clean if oil filter is excessively contaminated

Volkswagen Corrado 1990 - 1994 General Engine

Engine - Lubrication System (Page 17-18)

Oil capacity, specifications

Use only oil marked API Service SF or SG A = Multi-grade oil B = Single-grade oil Engine oil capacity with oil filter 6.0 L (6.3 qts.) without oil filter 5.0 L (5.3 qts.)

Volkswagen Corrado 1990 - 1994 General Engine

Engine - Lubrication System (Page 17-19)

Oil pressure warning system

remove 1.4 bar (20 psi) oil pressure switch B (F1-black insulation) , and screw into test unit VW 1342 screw test unit VW 1342 into oil filter bracket in place of switch connect brown wire of test unit to ground (-)

connect LED test lamp VAG 1527a (US 1115) with lead from Connector Test Kit VW 1594 to 0.3 bar (4.4 psi) oil pressure switch A (F22-brown insulation) test lamp must light start engine and slowly increase RPM test lamp must go out at 0.15 - 0.45 bar (2.2 - 6.5 psi) If NO, replace switch connect LED test lamp to 1.4 bar oil pressure switch B (F1-black insulation) test lamp must light at 1.6 - 2.0 bar (23 - 29 psi) If NO, replace switch increase and hold engine speed at a steady 2000 RPM oil pressure must be minimum of 2.0 bar (29 psi)