1998-2005 Volkswagen Lupo 2 Door Descriptions of work -> Automated manual gearbox (DSG): Checking oil level, filling hydraulic oil as required User Manual
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Descriptions of work -> Automated manual gearbox (DSG): Checking oil level, filling hydraulic oil as required for Your Volkswagen Lupo 2 Door First Generation (1998-2005)

Lupo 1999 ➤ , Lupo 3L 1999 ➤  
Maintenance - Edition 03.2018  
♦ Socket - 3357-  
♦ Torque wrench - V.A.G 1331- (5-50 Nm)  
Carry out following procedure:  
– Remove noise insulation tray below engine and gearbox, if fit‐  
ted.  
– To check gear oil, unscrew oil plug -arrow-.  
The oil level is correct, when the gearbox is filled to lower edge  
of filler hole.  
Use gearbox oil specification “G50 SAE 75W90”.  
– Screw in plug -arrow-, and tighten to 25 Nm.  
4.34  
Automated manual gearbox (DSG):  
Checking oil level, filling hydraulic oil as  
required  
Special tools and workshop equipment required  
♦ Torque wrench - V.A.G 1331- (5-50 Nm)  
86  
4. Descriptions of work:  
Lupo 1999 ➤ , Lupo 3L 1999 ➤  
Maintenance - Edition 03.2018  
♦ Torque wrench - V.A.G 1783-  
4.34.1  
Checking oil level  
Carry out following procedure:  
Requirement  
•
Vehicle standing on level ground  
– Disconnect battery terminal clamp on battery negative termi‐  
nal.  
Note  
♦ It is absolutely necessary to disconnect the battery, because  
the hydraulic pump even starts running with ignition switched  
off and hydraulic oil flows out of system.  
♦ The battery is located in luggage compartment. On some ve‐  
hicles however the battery is installed in engine compartment.  
– Loosen pressure accumulator 1/2 turn using AF 24 open jaw  
spanner (the hydraulic oil level in reservoir rises).  
– Checking oil level: The oil level must be within the area of the  
grid -arrow-; if necessary correct oil level ⇒ page 88 .  
– If oil level is OK, tighten pressure accumulator to torque set‐  
ting. Specified torque: 40 Nm  
Note  
When the battery is reconnected, check the vehicle equipment  
(radio, clock, electric windows) as per workshop manual and/or  
operating instructions.  
– Tighten battery clamp on battery negative terminal to 5 Nm.  
– Switch on ignition (hydraulic oil level in expansion tank drops).  
– Carry out visual check of hydraulic system for leaks.  
4. Descriptions of work:  
87  
Lupo 1999 ➤ , Lupo 3L 1999 ➤  
Maintenance - Edition 03.2018  
4.34.2  
Correcting oil level  
Carry out following procedure:  
Requirement  
•
Vehicle standing on level ground  
– Disconnect battery terminal clamp on battery negative termi‐  
nal.  
Note  
♦ It is absolutely necessary to disconnect the battery, because  
the hydraulic pump even starts running with ignition switched  
off and hydraulic oil flows out of system.  
♦ The battery is located in luggage compartment. On some ve‐  
hicles however the battery is installed in engine compartment.  
– Loosen pressure accumulator 1/2 turn using AF 24 open jaw  
spanner (the hydraulic oil level in reservoir rises).  
– Open reservoir filler cap.  
– Replenish or extract oil: The oil level must be within the area  
of the grid -arrow-.  
Note  
♦ If fluid level is above specified range, fluid must be extracted.  
♦ If fluid level is below above-mentioned area, hydraulic system  
must be checked for leaks (repair measure). It is not sufficient  
just to fill fluid. If the hydraulic system is not leaking, replenish  
central hydraulic oil - G004 000 M2- .  
– Tighten pressure accumulator to torque. Specified torque: 40  
Nm  
– Tighten reservoir filler cap. Specified torque: 2 Nm  
– Connect battery terminal clamp on battery negative terminal.  
– Switch on ignition (hydraulic oil level in fluid reservoir drops).  
– Now select a few gears.  
The complete hydraulic system is now bled.  
– Disconnect battery terminal clamp on battery negative termi‐  
nal again.  
88  
4. Descriptions of work:  
Lupo 1999 ➤ , Lupo 3L 1999 ➤  
Maintenance - Edition 03.2018  
– Loosen pressure accumulator 1/2 turn using AF 24 open jaw  
spanner (the hydraulic oil level in reservoir rises).  
– Checking oil level: The oil level must be within the area of the  
grid -arrow-; if necessary correct oil level again.  
Specified torques  
Pressure accumulator to hydraulic unit 40 Nm  
Reservoir cap 2 Nm  
Note  
When the battery is reconnected, check the vehicle equipment  
(radio, clock, electric windows) as per workshop manual and/or  
operating instructions.  
– Tighten battery terminal clamp on battery negative terminal to  
5 Nm.  
– Switch on ignition (hydraulic oil level in expansion tank drops).  
– Carry out visual check of hydraulic system for leaks.  
4.35  
Brake system: inspect for leaks and  
damage.  
Check following components for leaks and damage:  
♦ Brake master cylinder  
♦ Brake servo (for anti-lock brake system: hydraulic unit)  
♦ Brake pressure regulator and  
♦ Brake caliper  
– Ensure that brake hoses are not twisted.  
– Additionally ensure that brake hoses do not touch any vehicle  
components when steering is at full lock.  
– Check brake hoses are not porous or brittle.  
– Check brake hoses and lines for chafing.  
– Check brake connections and fastenings for correct seating,  
leaks and corrosion.  
WARNING  
Faults found must always be rectified (repair measure).  
4. Descriptions of work:  
89  

Related Topics

Descriptions of work
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