Fluid Pump: Service and Repair

Oil Pump

Important Information

Volkswagen experience shows that the instruction to remove the pump will not be given.

However, the wish for a description of the removal and installation will be fulfilled here.

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

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

Removing

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. You do not need to "perform basic calibration". Only the Direct Shift Gearbox (DSG) oil and pump cover must be replaced.

- Remove the noise insulation.

- Remove the lower part of left front wheel housing liner.

- Place the (V.A.G 1782) under transmission.

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

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





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

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

- Remove this oil overflow tube.

- Drain the oil.

- Install the overflow tube and tighten it to 3 Nm.

- Replace the plug seal - arrow -.





- The (V.A.G 1782) remains under the transmission.

- Remove the small oil pump cover bolts - arrows - and remove the oil pump cover - A -.





There is still oil in the oil pump cover.

- Remove the oil pump bolts - arrows - and remove the oil pump - 1 - from the alignment pin and oil pump driveshaft.





It may be necessary to remove the upper bolt using (T10054 ).

Installing

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





- A new metal seal - B - must always be used.

• The 2 alignment pins - C - must be located in transmission housing.

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

Various Oil Pump Bolts - 1 -

All 4 bolts with flat heads





Tightening specification:

• 5 Nm + 90° (1/4) additional turn

3 bolts with a flat head, upper bolt is countersunk





Tightening specification

• Countersunk bolt: 8 Nm without tightening angle (tighten using (T10054))

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

- Set new oil pump cover - A - in place and tighten new bolts - arrows - in diagonal sequence and in multiple stages to 8 Nm.





Transmission does not have oil. You must now add new oil and adjust to the correct oil level.

- Replace the oil and filter. Refer to => [ Oil Filter and Oil Level, Changing and Adjusting ] Testing and Inspection.

- Install left front wheel housing liner.

- Install noise insulation.