Gear Oil Level, Checking And Filling: Notes
Special tools and workshop equipment required
- Vehicle Diagnosis, Testing and Information SystemVAS 5051B
- Old Oil Collecting and Extracting device V.A.G 1782
- Adapter for Oil Filling VAS 6262
- Safety glasses
- Acid-resistant protective gloves
- Gear oil for direct shift automatic transmission 02E.
Work procedure
Proceed as follows:
- Observe general repair notes. Refer to REPAIR INSTRUCTIONS .
- Observe cleanliness rules when working on transmissions. Refer to CLEAN WORKING CONDITIONS .
- Follow notes in regard to Direct Shift (DSG) transmission 02E oil disposal regulations. Refer to TRANSMISSION .
- Only gear oil for Direct Shift (DSG) transmission 02E that is available as a replacement part may be used. Other oils can cause malfunctions or transmission failure.
Risk of injury due to hot gear oil.
- Wear eye protection.
- Wear acid-resistant protective gloves.
There is an accident risk if a gear is accidentally engaged while the engine is running!
- Shift selector lever into P position and engage parking brake before working with the engine running.
Risk of transmission damage.
- If there is only a little gear oil or none at all left in the transmission after a repair or after heavy oil leakage, engine must not be started.
- Pre-fill transmission with gear oil after a repair or after heavy oil leakage.
- Transmission not in emergency operation mode.
- Move vehicle onto a 4-column lifting platform or over a work pit so that it stands absolutely horizontal.
- Place selector lever in position P, engage parking brake.
- Engine idling.
- Air conditioning and heater switched off.
Read transmission fluid temperature
- The gear oil level changes with the gear oil temperature. Gear oil temperature that is too low leads to overfilling, too high a temperature leads to under filling.
- An incorrect gear oil level affects transmission function.
-- Connect Vehicle Diagnosis, Testing, and Information SystemVAS 5051B.
Display on VAS 5051B:
-- In selection -1-, press On Board Diagnostic (OBD) system and activate by pressing → .
Display on VAS 5051B:
-- In selection -1-, activated 02 - Transmission electronics vehicle system by pressing → button.
Display on VAS 5051B:
-- In selection -1-, press function 011 - Measured values and activate by pressing → button.
Display on VAS 5051B:
1 - Enter display group
-- In button field -1-, press buttons 1 9 for Display group 019 and confirm entry by pressing Q button.
Display on VAS 5051B:
-- Read gear oil temperature in display field -1-.
- Specified value at beginning of test: Not higher than 30°C, otherwise let transmission cool.
Gear oil level, checking
- Tightening specifications, refer to DSG TRANSMISSION GEAR OIL OVERVIEW .
-- Remove noise insulation in center by loosening fasteners -1 through 4-.
-- Press and hold brake pedal.
-- With brake pressed, shift through all selector lever positions P, R, N, D, S at idle, retaining each position for at least 3 seconds.
-- Place used oil collection and extraction device V.A.G 1782 under transmission.
Display on VAS 5051B:
-- Read gear oil temperature in display field -1-.
- Specified value 35°C.
-- When specified value is reached, remove inspection plug -B-.
Ignore -A-.
- The collected gear oil runs out of overflow tube -arrow 2-.
Some gear oil always leaks out when opening the inspection plug -arrow 1-, regardless of the gear oil level.
-- Check whether overflow tube is securely installed in inspection plug hole.
Gear oil level cannot be checked exactly if overflow tube is loose.
- If some gear oil still leaks out at a temperature between 35°C and 45°C (due to additional warming), gear oil level is OK.
- Regardless of the gear oil level, a small wave of fluid comes out of the overflow tube every 30 seconds due to the multi-plate clutch cooling oil pulse. This procedure is irrelevant for checking gear oil level.
- Leaked gear oil must not be reused.
-- If gear oil level is OK, FINAL MEASURES .
Gear oil, filling
-- If no gear oil leaks out at the overflow tube between 35 °C and 45 °C, top off gear oil as follows.
Risk of mixing gear oil.
- Check whether Adapter For Oil Filling VAS 6262 is clean. DSG transmission gear oil must not be mixed with other oils.
-- Install DSG transmission gear oil container on Adapter For Oil Filling VAS 6262.
-- Install Adapter For Oil Filling VAS 6262 -A- in inspection plug opening and tighten by hand.
-- Hold container with Adapter For Oil Filling VAS 6262 as high as possible over DSG transmission and let gear oil run into transmission.
-- To check whether DSG transmission is filled sufficiently, disconnect quick release coupling on Adapter For Oil Filling VAS 6262 at regular intervals and seal with finger or clean plug.
- The collected gear oil runs out of overflow tube -arrow 2-.
Some oil always runs out regardless of gear oil level.
- If some gear oil still leaks out at a temperature between 35°C and 45°C (due to additional warming), gear oil level is OK.
- Regardless of the gear oil level, a small wave of fluid comes out of the overflow tube every 30 seconds due to the multi-plate clutch cooling oil pulse. This procedure is irrelevant for checking gear oil level.
- Leaked gear oil must not be reused.
- Check gear oil temperature on Vehicle Diagnosis, Testing and Information SystemVAS 5051B while filling oil. If 45°C is exceeded, cancel procedure and let transmission cool.
-- If gear oil level is OK, FINAL MEASURES .