Fluid Pan: Service and Repair
Oil Pan
Special tools, testers and auxiliary items required
• Oil Collecting and Extracting Device (V.A.G 1782)
• Drip Tray (VAS 6208)
Removing
Risk of transmission damage.
• Do not run engine or tow vehicle with oil pan removed or without transmission fluid.
• => [ Repair Information ] Repair Information
• => [ Clean Working Conditions ] Clean Working Conditions.
• Refer to the information on the DSG transmission 02E => [ Transmission ] Transmission.
• Coat O-rings and seals with transmission fluid. Other lubricants can cause malfunctions or transmission failure.
- Drain the transmission fluid. Refer to => [ Transmission Oil, Draining, Changing and Filling ] Transmission Oil, Draining, Changing and Filling.
Risk of injury through fan turning on automatically.
• Separate electrical connections before working on the fan shroud.
- Separate electrical connections - 1 - for fans below the fan shroud.
- Pull out bolts - arrows - and pull the fan shroud downwards with fans.
- Remove air guide hose to charge air cooler by loosening hose clamps - 1 and 2 -.
Vehicles with a left lower coolant hose in front of the transmission fluid pan:
Risk of burning due to hot steam and hot coolant.
• When engine is warm, the cooling system is under pressure.
• Reduce pressure by covering coolant expansion tank cap with cloths and carefully opening.
- Open coolant expansion tank cap.
- Separate electrical connection - 2 - on the Engine coolant temperature sensor on radiator (G83).
- Place (VAS 6208) under the engine.
- Remove coolant hose below - 1 - from cooler, to do this lift the clamp, drain coolant.
All Vehicles:
- Remove the nuts - arrows - and the bracket on the front side of the transmission fluid pan.
• The threaded bolts are welded to the front of the oil pan.
- Remove the lower shield - A - (if equipped) from the transmission - arrow -.
There is a risk of destroying the control module (Mechatronic) with static discharge.
• Do not touch contacts in transmission connector with hands.
- To discharge static, touch vehicle ground with hand (without glove).
- Disconnect the connector - 1 - on the transmission by turning screw connection counterclockwise.
• Ignore - A -.
- Place the (V.A.G 1782) under the transmission.
- Loosen the bolts - arrows - diagonally.
- Remove the oil pan - A - with oil pan gasket and let gear oil remaining in oil pan drain into the used (V.A.G 1782).
Installation
Install in reverse order, paying attention to the following:
• Tightening specifications => [ Oil Pan - Tightening Specification
and Sequence ] Oil Pan, Mechatronic and Transmission Fluid Pump Overview.
• Replace oil pan seal and bolts.
• Replace O-rings - arrows - on direct shift gearbox (DSG) mechatronic (J743) connector.
- Clean sealing surfaces; they must be free from oil or grease.
- Coat O-rings on direct shift gearbox (DSG) mechatronic connector with gear oil.
• Make sure the new oil pan seal is correctly seated.
• Do not jam lines when installing the oil pan.
- Install the oil pan - A - and gasket and tighten => [ Oil Pan - Tightening Specification
and Sequence ] Oil Pan, Mechatronic and Transmission Fluid Pump Overview.
- Install the air guide and coupling.
- Connect the connector of the DSG mechatronic and engage the retainer by turning.
- Install the fan shroud.
Risk of damage to the engine through overheating.
• If the coolant was drained, only fill up the transmission fluid and do not yet start the engine.
• First start the motor when the coolant is filled for the engine cooling.
- Fill the transmission fluid. Refer to => [ Transmission Oil, Draining, Changing and Filling ] Transmission Oil, Draining, Changing and Filling.
Vehicles with a left lower coolant hose in front of the transmission fluid pan:
- Install coolant hose under - 1 -.
- Be sure to follow the procedure for connecting the battery and afterwards.
- Fill up coolant.
All Vehicles:
- => [ Transmission Fluid, Checking and Filling ] Transmission Fluid, Checking and Filling.