Fluid Pump: Service and Repair

Oil Pump

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Used Oil Collecting and Extracting Device (V.A.G 1782)

Short Description

The oil pump can be replaced without removing the transmission. The vehicle must be raised and any covers installed on the bottom of the front end must be removed. The control arm to strut connection does not need to be separated. The drive axle also does not have to be removed. It is also not necessary to perform a basic measurement. Only the Direct Shift Gearbox (DSG(R)) oil and pump cover must be replaced.

Removing

- Remove the noise insulation.

- Remove the lower section of the left wheel housing liner..

- Place the used oil collecting and extracting device (V.A.G 1782) under the transmission.

In regard to "contaminated oil", also observe the information on when to change the filter. Refer to => [ When To Change the Oil Filter ] General Repair Information.

Up to transmission production date "September 20, 2004", transmissions with two plugs were installed.

- Remove the plug - A - near the pendulum support.






A plastic overflow tube is located in this hole (with a 8 mm hex socket head, tightening specification: 3 Nm). Its length determines the oil level in the transmission.

- Remove the overflow tube.

- Drain the oil.

- Reinstall the overflow tube; tightening specification: 3 Nm.

- Replace the seal - arrow - on the plug.






- The used oil collecting and extracting device (V.A.G 1782) remains under the transmission.

- Remove the bolts - arrows - and remove the cover - A -.






There is still oil in the oil pump cover.

- Remove the bolts - arrows - and the pump - 1 - from the alignment pins and pull the input shaft from the pump.






Remove the top bolt using the special wrench, long reach (T10054).

Installing

- Insert the oil pump input shaft - A - all the way into the transmission. Turn the input shaft while doing this.






- Always use a new metal gasket - B -.

• The 2 alignment pins - C - must be inside the transmission housing.

- When positioning the oil pump, pay attention to the input shaft splines and correct seating on the alignment pins.

Various Oil Pump Bolts

All 4 bolts - arrows - with flat heads






Tightening specification:

• 5 Nm + an additional 90° (1/4) turn.

3 bolts have a flat head and the upper bolt is countersunk






Tightening specification:

• Countersunk bolt: 8 Nm (tighten using the special wrench, long reach (T10054) )

• Flat head bolts: 8 Nm + an additional 90° (1/4) turn.

- Set the new oil pump cover - A - in place and tighten the new bolts - arrows - in a diagonal sequence and in several steps to 8 Nm.






The transmission does not have oil. You must now add new oil and adjust to the correct oil level. Refer to => [ DSG(R) Oil, Draining and Filling ] DSG(R) Oil, Draining and Filling.

- Replace the DSG(R) oil and filter. Refer to => [ Oil Filter ] Service and Repair.

- Install the left wheel housing liner..

- Install the noise insulation.