Project 1 - 2001 VW Beetle TDI Oil Change Using Oil Extractor

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The TDI Guy is changing oil on a 2001 VW Beetle with the ALH engine. This is the same engine that comes stock from the VW factory in the MK4 Golf and Jetta TDI's. This is a repair that TDI owners and DIY's can do with just a few tools. The steps and tools needed to change the oil fast in your TDI are listed below:

• Run the engine to warm the oil to a normal operating temperature.

• A lifting device or ramps is not needed for this repair.

• Properly park the Beetle TDI on level ground and turn the engine "OFF".

• Raise the hood with the hood release lever inside cabin.

• Using a 10mm nut driver remove three (3) nuts that secures the top engine cover.

• Remove the oil dip stick.

• Remove the hose from bracket on back of engine cover.

• Remove the engine cover.

Oil Extraction

The TDI Guy used a tool that creates a vacuum to remove the engine oil from the top of the engine. A Mityvac oil extractor was used for this procedure. It uses a pumping action to create a vacuum in the chamber of the extractor. A suction tube is inserted in the vehicle oil dip stick tube. Vacuum created in the cylinder of the extractor lifts the old oil from the engine crankcase. Oil enters the  extractor reservoir where it is stored for disposal. Remove old oil from the ALH engine using the steps below:

• Connect the main suction tube of the Mityvac oil extractor into the engine oil dip stick tube.

• Extract the oil by pumping the extractor several times to create a vacuum. Figure 1-1 shows The TDI Guy using the Mityvac oil extractor setup for changing oil on the 2001 Beetle.

Figure 1-1 Mityvac Oil Extractor Setup on Beetle

• Continue the pumping action until all of the old oil has been drained. The suction tube should be clear and no bubbles should appear in the suction tube to the extractor.

• Remove the suction tube from the dip stick.

Removing Oil Filter

The oil filter is easily removed by following the below steps:

• Using a 3/8-inch square drive ratchet, 3/8-inch square drive six (6) inch extension and filter wrench, remove the oil filter cover by turning counter-clockwise. Figure 1-2 shows the oil filter cover being removed.

Figure 1-2 Removing The Oil Filter Cover on The ALH Engine

• Place paper towels or an old rag around the filter housing to catch dripping oil from oil filter.

• Carefully remove (its fill of oil) the oil filter from the filter housing and discard.

• Use a scratch awl or hook pick and remove the two (2) 0-rings from the stem of the oil filter cover (Figure 1-3).

Figure 1-3 Removing O-Rings From Oil Filter Cover

• Install two (2) new 0-rings with the fingers (no picks) that came with the new oil filter.

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Removing Oil in Filter Housing

• Place the extractor suction tube into the oil filter housing (See Figure 1-4).

• Apply several pumps of the extractor until all of the old oil has been removed from all crevices and the sump of the oil filter housing.

Note

This step will remove old engine oil from all crevices in the oil filter housing. When changing oil from, the bottom the old oil cannot be removed from the filter housing using this method.

Figure 1-4 Removing Oil From Filter Housing With Oil Extractor

• Remove the suction tube of the oil extractor from the oil filter housing.

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Filling Engine Crankcase

• Using a funnel, fill the Beetle oil filter housing with one (1) gallon of synthetic 5W-40 engine oil (Figure 1-5) The TDI Guy has had good results with Shell Rotella T synthetic motor oil. It is available at most Walmart stores and super centers for less than twenty (20) dollars.

• Figure 1-6 shows an ALH engine with 100,000 miles on the odometer. Shell Rotella T synthetic 5W-40 has been used in this engine since it was new. As noticed, there are no  noticeable varnish stains or sludge on the camshaft and lifters. The camshaft assembly is very clean for this mileage.

Figure 1-6 100,000 Mile ALH Engine Using Shell Rotella T 5W-40 Engine Oil

Figure 1-5 Filling Oil Filter Housing With Engine Oil

• Remove funnel and clean up any oil that was spilled on engine.

Replace Oil Filter

• Place a new replacement oil filter in the Bettle oil filter housing cavity (See Figure 1-7). A replacement filter can be obtained from a VW dealer parts center. It can also be ordered on the Internet at TDI Parts.

Figure 1-7 Placing New Oil Filter in Filter Housing

• Screw the oil filter cover onto the threads of the oil filter housing.

• Using a 3/8-inch square drive ft-lb torque wrench and oil filter wrench, tighten to specification shown in Table 1-1.

Table 1-1 Oil Filter Cover Torque Specification

Finishing Up

• Remove all tools from the work area.

• Start the Beetle and run the engine for two (2) minutes.

• Shut the engine "OFF" and check for oil leaks.

• Install top engine cover and hose that was previously removed.

• Insert dip stick in dip stick tube.

• Close the hood.

• Test drive vehicle.

Tools, Parts and Equipment Needed

• 10mm nut driver

• Mityvac P/N 07400 oil extractor, or equivalent

• 3/8-inch square drive ratchet

• 3/8-inch square drive six (6) inch extension

• 3/8-inch square drive oil filter wrench

• Scratch awl or pick

• One (1) gallon Shell Rotella T Synthetic 5W-40 engine oil

• Oil funnel

• Mann's oil filter P/N 5218

• 3/8-inch square drive 80 ft-lb torque wrench

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Summary

The cost for this repair can evaporate a $100.00 bill when done by a dealer or independent service center. Here are the numbers that the oil change cost for this repair, including tools:

• Mityvac P/N 07400 oil extractor - $ 69.95. Ordered tool from Napa Auto Parts.

• Oil filter wrench for import cars - $4.99. Ordered tool from Harbor Freight

• Oil filter - Mann's P/N 5218, $8.00. Ordered part from TDI Parts.

• One (1) gallon Shell Rotella T 5W-40 synthetic engine oil - $15.99. Purchased from local Dallas area Walmart.

Total parts and tools - $98.93. The oil extractor and filter wrench you can add to your tool collection. Your next oil change can be done for $24.00. Compare that to a dealer price of $100.00 and no down time or customer waiting