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Home >> Volkswagen >> 2005 >> New Beetle (1C1) L4-1.9L DSL Turbo (BEW) >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatically Shifted Manual Transmission/Transaxle >> Service and Repair >> Transmission Gear Oil Level, Checking and Topping Up

Transmission Gear Oil Level, Checking and Topping Up



Transmission gear oil level, checking and topping up, 02E, 6 SPD. DSG A/T

Special tools and equipment

VAS 5051 Vehicle Diagnosis, Testing and Information System:




V.A.G 1306 Drip tray:





- VAS 6262 Adapter
- Safety goggles
- Acid-resistant protective gloves
- Commercially available transparent hose (approximately 1 meter) suitable for connection to adapter VAS 6262 with appropriate funnel

Checking

Requirements
- Transmission not in emergency running mode
- Vehicle level
- Selector lever set to "P"
- Engine off
- Air conditioning system and heater switched off
- Vehicle Diagnosis, Testing and Information System VAS 5051 connected, vehicle self-diagnosis and vehicle system "02 Transmissions electronics" selected
- At start of test, gear oil temperature must not be in excess of 35°C (allow transmission to cool down if necessary)

Note:
- Gear oil temperature is read by the Vehicle Diagnosis, Testing and Information System VAS 5051.
- Gear oil level changes with gear oil temperature.
- Checking gear oil level when gear oil temperature is too low will result in overfilling.
- Checking gear oil level when gear oil temperature is too high will result in underfilling.
- Both overfilling and underfilling have an adverse effect on transmission operation.

WARNING: Only use the proper gear oil available from the Parts catalog for the Direct shift transmission 02E. Other oils can cause malfunctioning or transmission failure.

Reading gear oil temperature





Displayed on VAS 5051:
- From list -1- select diagnostic function "08 Reading measured value block".





Displayed on VAS 5051:
1 - Enter display group - maximum value = 255
- Use keypad -2- to enter "19" using key pad for "Display group number 19" and confirm entry with Q key.





Displayed on VAS 5051:
- Read transmission oil temperature in display zone -1-.

Checking and topping up oil level

CAUTION: The filling hose, funnel and charging adapter VAS 6262 must be clean and the transmission oil must not be mixed with other oils.

- Move selector lever to position "P", apply parking brake.

CAUTION:
- Do not start the engine if there is little or no oil in the transmission following repair work or severe loss of gear oil.
- In such cases, pre-filling is required with the engine cold and not running.

- Start engine and let idle.
- Press and hold brake pedal.
- With brake pedal pressed shift selector lever through all positions "P, R, N, D, S" at idle, retaining each position for minimum of 3 seconds.
- To ensure vehicle is absolutely level, drive onto a four-column hoist or over an inspection pit.
- Remove center sound insulation.

WARNING:
- To avoid possible injury, always keep clear of coolant fan when working in vicinity of radiator.
- Radiator coolant fan can switch on without warning.





Display on VAS 5051:
- Read gear oil temperature in display zone -1-.
- Switch off engine when gear oil temperature of 40°C is reached.
- Wait approximately 4 minutes.
- Place drip tray V.A.G 1306 beneath transmission.

WARNING:
- Use safety glasses.
- Wear acid-resistant protective gloves.





- Remove inspection plug (arrow).





- Gear oil present in overflow pipe (arrow -2-) is discharged first.
- If gear oil continues to leak out from inspection opening via overflow pipe:
- Allow surplus gear oil to drain.
- Gear oil needs to be topped up in this case. Oil level is then OK.

Note: Do not reuse gear oil discharged. Dispose of oil properly.





- Replace oil seal (arrow) for inspection plug.





- Install inspection plug (arrow).
- Tightening torque: 45 Nm
- This completes check of gear oil level.
- Terminate function "08 Read measured value (data) block" by touching [] key.
- Touch "06 End output".
- Switch off ignition and disconnect Data Link Connector (DLC).
- If no further gear oil emerges from inspection opening, top up gear oil
- Topping up gear oil





- Gear oil must be topped off if at 40°C no gear oil emerges at inspection opening via overflow pipe (arrow -2-).





- Thread adapter VAS 6262 into opening of inspection plug (arrow) hand tight.
- Attach hose with funnel to adapter and hold funnel as high as possible over transmission.
- Start by pouring in just a small quantity of gear oil for transmission via funnel.

Check gear oil level (several times if necessary)
- Remove hose from adapter VAS 6262 and use clean plug to seal hose.





Gear oil in overflow pipe (arrow -2-) is discharged first.
If gear oil continues to emerge from inspection opening via overflow pipe:
- Allow surplus gear oil to drain.
- Gear oil need not be topped up in this case; oil level is OK.
- If no further gear oil emerges from inspection opening, gear oil must be added and checked until level is OK.
- Unscrew adapter VAS 6262 from transmission.

Note: Gear oil discharged is not to be reused. Dispose of oil properly.





- Replace oil seal (arrow) for inspection plug.





- Screw in inspection plug (arrow).
- Tightening torque: 45 Nm
- This completes check of gear oil level.
- Terminate function "08 Read measured value block" by touching [] key.
- Touch "06 End output".
- Switch off ignition and disconnect Data Link Connector (DLC).
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