Direct Shift Gearbox Mechatronic

Direct Shift Gearbox Mechatronic

Special tools, testers and auxiliary items required

• Torque Wrench 5-50 Nm (V.A.G 1331)

• Drip Tray For VAS 6100 (VAS 6208)

Removing

CAUTION!
Do not run engine with the oil pan removed or without transmission oil filling and do not tow vehicle.

• Observe notes for Direct Shift Automatic Transmission 02E => [ Notes for Direct Shift Automatic Transmission 02E ] Notes For Direct Shift Automatic Transmission 02E.

• Observe general repair notes for working on the transmission => [ General Repair Notes ] General Repair Notes.

• Additional work must be performed when disconnecting and reconnecting battery Ground (GND) cable.

If Mechatronic is to be replaced with transmission removed, transmission must be secured to assembly stand => [ Transmission, Attaching to Assembly Stand ] Transmission, Attaching to Assembly Stand.

- Place selector lever in position "P".

- First determine whether a coded radio is installed. In this case, determine anti-theft coding.

- With ignition switched off, disconnect Battery Ground (GND) wire.

- Remove power steering refill tank from battery console, do not kink hoses while doing this.

- Connect refill tank to lock carrier.

- Remove battery

- Disconnect intake hose - 1 - and connector - 2 - from Mass Air Flow (MAF) sensor.





- Remove bolts - 3 - and - 4 -.

- Remove air filter completely.

- Bring lock carrier into service position. Radiator Support

- Disconnect central connector - 1 -, to do so, turn lever - arrow - in direction of - arrow - and pull off connector.





- Remove center and left sections of noise insulation below engine/transmission.

- Disconnect all lines and bracket from transmission oil pan.

- Place lines upward in area of oil pan and tie securely.

- Remove protective plate - 1 - at bottom on transmission - arrows -.





- Place appropriate receptacle underneath transmission.

CAUTION!
• Wear protective glasses.

• Wear protective gloves.

- Remove bolt - A - near pendulum support.





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

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

- Remove oil tube.

- Drain oil.

- Hand-tighten overflow tube to 3 Nm.

- Replace seal - arrow -.





- Install bolt - arrow - and tighten to 45 Nm.

- Remove bolts - arrows - and remove cap for transmission oil pump - A -.





• Oil is still located in cap for transmission oil pump.

- Grasp with hand (without gloves) on to vehicle Ground (GND) so that you are electrostatically discharged.

CAUTION!
• Only touch or remove Direct Shift Gearbox (DSG) Mechatronic (J743) after you have been electrostatically discharged on a grounded object beforehand, e.g. skin contacts vehicle Ground (GND).

• Connector terminals of transmission connector must not be touch by hand under any circumstances because control module and therefore Mechatronic may be destroyed by static discharge.

- Loosen bolts - arrows - of oil pan - A - in diagonal sequence and remove.





• Some transmission oil remains in the oil pan because not all of it can flow out.

- Remove oil pan together with oil pan gasket.

- Always replace oil pan gasket.

Cap for transmission oil pump and oil pan bolts must always be replaced.

CAUTION!
If cap for transmission oil pump is not removed, the long Transmission Output Speed (RPM) Sensor (G195) with Transmission Output Speed (RPM) Sensor 2 ( G196) on the rear side will be damaged when pulling off Direct Shift Gearbox (DSG) Mechatronic (J743).

- Carefully release connector of Transmission Input Speed (RPM) Sensor (G182) with Clutch Oil Temperature Sensor (G509) using a small screwdriver - 1 - and simultaneously pry out carefully using a second screwdriver - 2 -.





• Do not pull on wire of connector! If wire is damaged, the Transmission Input Speed (RPM) Sensor ( G182) with Clutch Oil Temperature Sensor (G509) must be replaced.

- Disconnect connector without pulling on wire.

- Remove wire from retaining tabs - arrows -.

- Loosen and remove mounting bolts - 1 - to - 10 - in specified sequence.





• Do not loosen any other bolts of Direct Shift Gearbox (DSG) Mechatronic (J743), otherwise function will be impaired.

- Pull Mechatronic out of transmission housing far enough until sensor arm - B - on rear side is longer located in transmission housing.





- Carefully swivel Direct Shift Gearbox (DSG) Mechatronic ( J743) downward.

CAUTION!
Never lift up Mechatronic on sensor arm or set it down on it.

- Transport and store Mechatronic as depicted in the illustration.





When handling Mechatronic, pay special attention to the long sensor arm - arrow -.





Installing

- Before installation, ensure that Transmission Input Speed (RPM) Sensor (G182) with Clutch Oil Temperature Sensor (G509) are installed.





If sensor arm - arrow - is damaged, the Mechatronic must be replaced.





- Carefully place Direct Shift Gearbox (DSG) Mechatronic (J743 ) into transmission housing.





- Make sure alignment pin - A - in transmission housing - arrow 1 - and sensor arm - B - in guide - arrow 2 - are seated correctly on transmission housing.





• Do not pinch wire of Transmission Input Speed (RPM) Sensor (G182) with Clutch Oil Temperature Sensor (G509).

• Wire of connector - A - must not be pinched when installing Direct Shift Gearbox (DSG) Mechatronic (J743). If wire is damaged, the Transmission Input Speed (RPM) Sensor (G182) with Clutch Oil Temperature Sensor ( G509) must be replaced.





• Long sensor on rear side of Direct Shift Gearbox (DSG) Mechatronic (J743) must not be damaged.

- Install new bolts - 1 - to - 10 - hand-tight.

- Tighten bolts in specified sequence to 5 Nm plus an additional 90° (1/4 turn).

- Engage wire - A - first into top, then into bottom retaining tab - arrows -.

- Connect and engage connector.

- Replace both O-rings - arrows - on connection of Mechatronic.





- Coat O-rings with direct shift transmission oil.

- Clean sealing surfaces and eliminate oil residue.

- Make sure new oil pan gasket is seated correctly.

- Place oil pan on. Do not pinch lines when doing this.

- Install new bolts - arrows - for oil pan - A - and tighten in stages to 10 Nm in diagonal sequence.





- Put on new cap for transmission oil pump - A - and tighten new bolts - arrows - in several stages to 8 Nm in diagonal sequence.





- Connect all lines and bracket on to transmission oil pan.

- Connect central connector of Direct Shift Gearbox (DSG) Mechatronic (J743) and engage lock by rotating.

- Re-install lock carrier

- Install battery console and battery.

- Install power steering refill tank on battery console, do not kink hoses while doing this.

- Install complete air filter housing.

- Connect battery and observe safety precautions after connecting battery.

- Do NOT start engine!

- Change transmission oil filter and transmission oil => [ Transmission Oil and Filter ] Transmission Oil and Filter.

- Install protective plate - 1 - at bottom on transmission, tighten bolts - arrows - to 32 Nm.





- Install center and left sections of noise insulation below engine/transmission.

- Basic calibration of Direct Shift Gearbox (DSG) Mechatronic (J743) is performed using Vehicle Diagnosis, Testing and Information System (VAS 5051) or Vehicle Diagnosis & Service Syst. (VAS 5052) in " Guided Fault Finding".