Direct Shift Gearbox Mechatronic, Transmission Installed
Direct Shift Gearbox Mechatronic, Transmission Installed
Special tools, testers and auxiliary items required
• Torque wrench (5-50 Nm) (VAG 1331)
• Used oil collecting and extracting device (VAG 1782 )
Removing
Always make sure no dirt enters an open transmission.
Dirt entering can cause a transmission malfunction especially with the Direct Shift Gearbox (DSG) mechatronic and/or oil pump open.
- Place the selector lever in the Park "P" position.
- Disconnect the battery ground cable.
- Remove the noise insulation, as necessary.
- Remove the cable bracket from the large front transmission cover (2 M6 nuts).
- Release the mechatronic connector retainer by rotating and removing the connector.
- Position the lines in the cover area upward and tie up.
- Place the (VAG 1782) under the transmission.
- Remove the plug - A - near the pendulum support.
Up to transmission production date "September 20, 2004", transmissions with two plugs were installed.
Following that, the second plug was discontinued and the oil is drained and the oil level is checked only with the plug - A -.
The oil level in the transmission is determined with the length of the plastic overflow tube with 8 mm hex head (tightening specification: 3 Nm).
- Remove the overflow tube.
Leave the (VAG 1782) under the transmission because approximately 5 liters of oil will drain out.
- Reinstall the overflow tube; tightening specification: 3 Nm.
- Loosen and remove the cover bolts - arrows - in a diagonal pattern.
- Remove the cover and seal.
- Always replace the small oil pump cover and the bolts for the large cover.
- Replace the large cover seal.
The seal on the large cover must also be replaced.
- Remove the oil pump cover - A -.
In order to have enough free space to remove the mechatronic, the pendulum support can be removed.
Then the transmission can be pressed down and back slightly.
• Touch a grounded object before touching the mechatronic. Refer to => [ Electrical Components ] General Repair Information.
- Carefully disconnect the transmission input speed (RPM) sensor and the clutch oil temperature sensor electrical connector using a small screwdriver - 1 - and at the same time carefully pry out the connector using a second screwdriver - 2 -.
- If the connector retainer breaks, replace the sensor.
Do not pull on the wire!
- Remove the connector.
- Remove the wire from the retaining tabs - arrows -.
- Loosen and remove the mechatronic bolts - 1 through 10 - in the specified sequence.
- Remove the mechatronic from the transmission housing far enough until the sensor arm - B - on the rear side is no longer located in the transmission housing.
• When working with the mechatronic, be especially careful of the long sensor arm.
- Carefully tip the mechatronic unit down.
- Store the mechatronic unit properly.
CAUTION!
Never lift the mechatronic by, or allow it to rest on, the sensor arm.
If the arm is damaged, the mechatronic must be replaced.
Installing
• Touch a grounded object before touching the mechatronic. Refer to => [ Electrical Components ] General Repair Information.
• Replace the mechatronic if the sensor arm is damaged.
- Carefully install the mechatronic into the transmission housing:
- Ensure the alignment pin - A - in the transmission housing - arrow 1 - and the sensor arm - B - in the guide - arrow 2 - are seated correctly on the transmission housing.
- Do not pinch the wire.
- Install new bolts - 1 through 10 - and tighten by hand.
- Tighten the bolts in the specified sequence to 5 Nm + an additional 90° (1/4 ) turn.
- Hook the wire - A - first into the upper, and then into the lower retaining tabs - arrows -.
- Connect the electrical connector.
- Replace both seals if the old mechatronic is being reinstalled.
- Coat the O-ring with DSG oil (G 052 182).
A new mechatronic already has new seals.
- Clean the cover seal and sealing surfaces on the transmission.
- Ensure the correct seal seating.
- Place the cover over the mechatronic without pinching any lines.
- Install the new bolts - arrows - and tighten in a diagonal sequence in multiple stages to 10 Nm.
- Set the new oil pump cover - A - in place and tighten the bolts - arrows - in diagonal sequence and in multiple stages to 8 Nm.
- Install the cable bracket on the large cover and tighten the nuts to 10 Nm.
- Connect the electrical connector for the mechatronic and engage the retainer by turning.
- Install any parts that were removed.
- Connect the battery ground cable.
CAUTION!
Do not start engine!
- Replace the DSG oil and filter. Refer to => [ Oil Filter, Changing and Oil Level, Adjusting ] 02E Transmission (Direct Shift Gearbox).
- Install the noise insulation, as necessary.
- Perform the basic measurement on the mechatronic.