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)

• Special Wrench, Long Reach (T10054)

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) transmission fluid and pump cover have to 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 fluid. Refer to => [ When To Change the Fluid Filter : ] DSG Transmission Fluid.

- Remove the drain 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 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 fluid.

- Tighten the overflow tube to 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 fluid 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 seal - 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 - 1 -






All four bolts - arrows - with flat heads

Tightening specification:

• 5 Nm + 90° (1/4) additional turn.

3 bolts with flat heads, top bolt - arrow - is countersunk






Tightening specification:

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

• Flat head bolt: 8 Nm + 90° (1/4) additional 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 fluid. You must now add new fluid and adjust to the correct oil level. Refer to => [ Transmission Fluid Level, Checking and Filling ] Transmission Fluid Level, Checking and Filling.

- Install the left wheel housing liner.

- Install the noise insulation.