Oil Pan
Oil Pan
Special tools, testers and auxiliary items required
• Torque Wrench 5-50 Nm (V.A.G 1331)
• Drip Tray For VAS 6100 (VAS 6208)
• Protective glasses
Removing
CAUTION!
Do not run engine with the oil pan removed or without transmission oil filling and do not tow vehicle.
• Observe notes for Direct Shift Automatic Transmission 02E => [ Notes for Direct Shift Automatic Transmission 02E ] Notes For Direct Shift Automatic Transmission 02E.
• Observe general repair notes for working on the transmission => [ General Repair Notes ] General Repair Notes.
• Coat O-rings and sealing rings with transmission oil. Other lubricating substances lead to functional problems in the hydraulic transmission control.
• Additional work must be performed when disconnecting and reconnecting battery Ground (GND) cable.
- Place selector lever in position "P".
- First determine whether a coded radio is installed. In this case, determine anti-theft coding.
- With ignition switched off, disconnect Battery Ground (GND) wire.
- Remove power steering refill tank from battery console, while doing this do not kink hoses.
- Connect refill tank to lock carrier.
- Remove battery
- Disconnect intake hose - 1 - and connector - 2 - from Mass Air Flow (MAF) sensor.
- Remove bolts - 3 - and - 4 -.
- Remove air filter completely.
- Disconnect central connector - 1 -, to do so, turn lever - arrow - in direction of - arrow - and pull off connector.
- Remove center and left sections of noise insulation below engine/transmission.
- Disconnect all lines and bracket from transmission oil pan.
- Place lines upward in area of oil pan and tie securely.
- Remove protective plate - 1 - at bottom on transmission - arrows -.
- Place appropriate receptacle underneath transmission.
CAUTION!
• Wear protective glasses.
• Wear protective gloves.
- Remove bolt - A - near pendulum support.
Up to transmission production date "September 20, 2004", transmissions with two bolts were installed.
A plastic overflow tube is located in this hole (with 8 mm hex socket head, torque specification: 3 Nm). Its length determines the oil level in the transmission.
- Remove oil tube.
- Drain oil.
- Hand-tighten overflow tube to 3 Nm.
- Replace seal - arrow -.
- Install bolt - arrow - and tighten to 45 Nm.
- Grasp with hand (without gloves) on to vehicle Ground (GND) so that you are electrostatically discharged.
CAUTION!
• Only touch or remove Direct Shift Gearbox (DSG) Mechatronic (J743) after you have been electrostatically discharged on a grounded object beforehand, e.g. skin contacts vehicle Ground (GND).
• Connector terminals of transmission connector must not be touch by hand under any circumstances because control module and therefore Mechatronic may be destroyed by static discharge.
- Loosen bolts - arrows - of oil pan - A - in diagonal sequence and remove.
• Some transmission oil remains in the oil pan because not all of it can flow out.
- Remove oil pan together with oil pan gasket.
- Always replace oil pan gasket.
Installing
Installation is in reverse order of removal, note the following:
- Replace both O-rings - arrows - on connection of Mechatronic.
- Coat O-rings with direct shift transmission oil.
- Clean sealing surfaces and eliminate oil residue.
- Make sure new oil pan gasket is seated correctly.
- Place oil pan on. Do not pinch lines when doing this.
- Install new bolts - arrows - for oil pan - A - and tighten in stages to 10 Nm in diagonal sequence.
- Change transmission oil filter and transmission oil => [ Transmission Oil and Filter ] Transmission Oil and Filter.
Inspection plug seal must be replaced after checking transmission oil.
- Install center and left sections of noise insulation below engine/transmission.
- Install battery console and battery.
- Install power steering refill tank on battery console, do not kink hoses while doing this.
- Install complete air filter housing.
- Connect battery and observe safety precautions after connecting battery.