DSG Transmission Mechatronic (J743), Transmission Installed
DSG Transmission Mechatronic (J743), Transmission Installed
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)
• Adapter for Oil Filling (VAS 6262 A)
• Release Tool (T10465)
Removing
Always make sure that no dirt enters an open transmission.
Dirt entering an open transmission can cause a malfunction especially with a open Mechatronic unit and/or oil pump.
In regard to contaminated oil, also observe the information on changing the oil filter. Refer to => [ When To Change the Transmission Oil Filter ] When To Change the Transmission Oil Filter.
The Mechatronic unit can get stuck on the alignment pins when the transmission is very warm. Let the transmission cold down.
- Lift the vehicle, all 4 lift points for the hoist must be at the same height.
- Move the selector lever into the "P" position.
- Remove the noise insulation.
If present:
- Remove the charge air hose from between the charge air cooler and the charge air pipe.
• It is possible that parts, which have nothing to do with the Mechatronic unit, will have to be removed. It depends on the vehicle equipment. Make sure there is enough room around the Mechatronic unit.
• Depending on the vehicle, the parts could be:
• Fan shroud
• Additional lines for the Air Conditioning (A/C) system
• Charge air pipes
- Disconnect the connector - 1 - from the Mechatronic unit.
• Ignore item - A -.
- Remove the two M6 nuts - arrows - and the wire bracket from the large transmission cover.
Tightening specification: 10 Nm
- Position the wires in the area of the cover upward and secure.
- Place the used oil collecting and extracting device (V.A.G 1782) under the transmission near the large cover.
Oil will leak out of the cover when the bolts are removed. Risk of injury due to hot oil.
- Loosen the cover bolts - arrows - diagonally and remove them. Hold the cover in place while doing this.
- Drain the oil and remove the cover and seal.
About 3 liters of oil will drain out.
• Always replace the small oil pump cover, the seal and the bolts for the large cover.
- Remove the oil pump cover bolts - arrows - and cover - A -.
- Remove the pendulum support to transmission bolts - 2 and 3 -.
The transmission can now be pressed down slightly to remove the Mechatronic unit.
Before handling the Mechatronic unit, touch a grounded object. Refer to => [ Electrical Components ] Electrical Components.
- Disconnect the connector - 1 - from the transmission input speed sensor (G182) and clutch oil temperature sensor (G509) using the release tool (T10465).
- First, remove the wire from lower clip - arrow I -.
- Then remove the wire from the upper clip - arrow II - and lay it aside. Do not kink the wire.
- Loosen and remove the bolts - 1 through 10 - in the specified sequence.
- Carefully pull the Mechatronic unit out of transmission housing far enough until the sensor arm - B - on the rear side is no longer located in the transmission housing.
When handling the Mechatronic unit, be particularly aware of the long sensor arm.
- Carefully move the Mechatronic unit downward.
Store the Mechatronic unit properly.
Never lift the Mechatronic unit by the sensor arm and never let it rest on the arm.
Replace the Mechatronic unit if the sensor arm gets damaged.
Installing
Before handling the Mechatronic unit, touch a grounded object again. Refer to => [ Electrical Components ] Electrical Components.
- Carefully install the Mechatronic unit into the transmission.
- Do not pinch the wire.
- Carefully mount the Mechatronic unit onto the alignment pins - arrow -. The goal is for the sensor arm to be in its installed position.
- Make sure the Mechatronic unit is installed correctly.
- Install the new bolts - 1 through 10 - hand tight.
- Tighten the bolts to 5 Nm + 90° (1/4) additional turn, in the specified sequence.
- Hook the wire - A - first under the upper, and then under the lower clips - arrows -.
- Connect the connector.
- Replace both O-rings if reinstalling the old Mechatronic unit.
A new Mechatronic unit already has new O-rings.
- Coat the O-rings with DSG(R) transmission oil.
- Clean the cover seal and transmission sealing surfaces.
- Make sure the seal fits correctly.
- Place the cover over the Mechatronic unit without pinching any wires.
- Install new bolts - arrows - and tighten them to 10 Nm diagonally and in several steps.
- Set the new oil pump cover - A - in place and tighten the bolts - arrows - in a diagonal sequence to 8 Nm in stages.
- Install the wire bracket to the cover and then tighten the nuts to 10 Nm.
- Connect the connector to the Mechatronic unit and engage the retainer by turning.
- If present: Install the charge air hose between the charge air cooler and charge air pipe.
- Reinstall any vehicle parts which were removed.
- Do not start the engine.
- Change the filter if the oil was dirty. Refer to => [ Oil Filter ] Service and Repair.
- Connect the vehicle diagnostic tester.
- Place the used oil collecting and extracting device (V.A.G 1782) under the transmission near the plug.
- Remove the plug - arrow - near the pendulum support.
- Measure the length of the pipe, dimension - a - before installing the adapter for oil filling (VAS 6262 A) to the oil bottle and shorten the pipe, if necessary. Refer to => [ Shortening the Pipe on the : ] Modifying the Adapter for Oil Filling (VAS 6262 A).
- a - = 210 mm
• Dimension - a - is measured starting from the shaft (green surface) on the adapter for oil filling (VAS 6262 A).
- Install the adapter for oil filling (VAS 6262 A) into the plug hole hand tight.
- Shake the bottles before opening.
- Fill with 3 liters of transmission oil.
- To change containers, close the shut-off lever or hold the adapter for oil filling (VAS 6262 A) higher than the transmission.
Start the engine and check the fluid level. The adapter for oil filling (VAS 6262 A) remains installed.
- Check the fluid level and fill if necessary. Refer to => [ Transmission Oil Level, Checking and Filling ] Transmission Oil Level, Checking and Filling.
- Install the noise insulation.
- Perform a basic setting.