Gear Oil Level, Checking and Filling
Gear Oil Level, Checking and Filling
Special tools, testers and auxiliary items required
• Vehicle Diagnosis, Testing and Information System (VAS 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. Refer to the electronic parts catalog ETKA
Work procedure
Proceed as follows:
• Observe general repair notes. Refer to => [ Repair Instructions ] Repair Instructions.
• Observe cleanliness rules when working on transmissions. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
• Follow notes in regard to Direct Shift (DSG) transmission 02E oil disposal regulations. Refer to => [ Transmission ] 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 System (VAS 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 ] 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,.
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 System (VAS 5051B) while filling oil. If 45°C is exceeded, cancel procedure and let transmission cool.
- If gear oil level is OK,.
Final measures
• Tightening specifications, refer to => [ DSG Transmission Gear Oil Overview ] DSG Transmission Gear Oil Overview.
• Replace inspection plug gasket - arrow -.
- Remove Adapter For Oil Filling (VAS 6262) from transmission.
- Tighten inspection plug - B -.
• Ignore - A -.
- End function 011 - Measured values by pressing left arrow button.
- Press 06 - End output.
- Switch ignition off and disconnect diagnostic connector.