Mechatronic, With Transmission Installed
Mechatronic, with Transmission Installed
For removing and installing with the transmission removed, refer to => [ Mechatronic, with Transmission Removed ]
Special tools, testers and auxiliary items required
• Torque wrench (VAG 1331)
• Used oil collection and extraction device (VAG 1782 )
Removing
Always make sure that no dirt enters an open transmission.
Dirt entering can cause a transmission malfunction especially with an open direct shift gear (DSG) mechatronic and/or oil pump.
In regard to contaminated oil, also observe information on changing the oil filter.
- Place selector lever in the "P" position.
- Disconnect battery ground cable with ignition system switched off.
- Remove noise insulation.
- If present, remove connecting hose between charge air cooler and charge air tube.
- Remove cable bracket from large front transmission cover (2 M6 nuts).
- Release mechatronic connector retainer by rotating and remove connector.
- Position lines in cover area upward and tie up.
- Place the used oil collection and extraction device (VAG 1782) under the transmission.
- Remove plug- A - near pendulum support.
Up to transmission production date September 20, 2004, transmissions with two plugs were installed.
A plastic overflow tube is located in this hole (removed with 8 mm socket, tightening specification: 3 Nm). Its length determines the oil level in the transmission.
- Remove this oil tube.
Approximately 5 liters of oil will flow out. Used oil collection and extraction device (VAG 1782) should remain below transmission from now on.
In regard to contaminated oil , also observe information on changing the oil filter.
- Install overflow tube, tighten to 3 Nm.
- Loosen cover bolts - arrows - diagonally and remove.
- Remove cover and seal.
Small oil pump cover and large cover bolts must always be replaced.
Large cover seal must also be replaced.
- Remove 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.
Before handling mechatronic, touch a grounded object again.
- Carefully release the connector of the transmission input speed sensor with clutch oil temperature sensor using a small screwdriver - 1 - and at the same time carefully pry out the connector using a second screwdriver - 2 -.
CAUTION!
Be very careful. The connector locking mechanisms can break. If this happens, replace the sensor. Do not pull on wire!
- Remove connector.
- Remove wire from retaining tabs - arrows -.
- Loosen bolts - 1 through 10 - in the specified order and remove.
- Pull the mechatronic out of transmission housing far enough until sensor arm - B - on rear side is no longer located in transmission housing.
• When handling the mechatronic, be particularly aware of the long sensor arm.
- Carefully swivel the DSG mechatronic (J743) downward.
- Store mechatronic properly.
Storing Mechatronic
CAUTION!
Never lift the mechatronic by, or allow it to rest on, the sensor arm. If sensor arm is damaged, mechatronic must be replaced!
Installing
Before handling mechatronic, touch a grounded object again.
- Carefully insert the DSG mechatronic (J743) into the 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.
CAUTION!
Do not pinch line!
- Install new bolts - 1 through 10 - hand tight.
- Tighten bolts in sequence shown to 5 Nm + 90° (1/ 4 additional rotation).
- Engage wire - A - first into top, then into bottom retaining tab - arrows -.
- Connect and engage connector.
- Replace both O-rings - arrows -, if the old mechatronic unit is being reinstalled.
- Coat the O-rings with DSG transmission oil.
(A new mechatronic already has new rings.)
- Clean the cover seal and transmission sealing surfaces.
- Ensure correct seal seating.
- Place cover over mechatronic without pinching any lines.
- Install new bolts - arrows - and tighten diagonally in multiple stages to 10 Nm.
- Set new oil pump cover - A - in place and tighten bolts - arrows - in diagonal sequence and in multiple stages to 8 Nm.
- Install cable bracket on large cover and tighten nuts to 10 Nm.
- Connect the connector of the DSG mechatronic and engage the retainer by turning.
- If present, install connecting hose between charge air cooler and charge air tube.
- Install any other parts removed.
- Connect battery ground cable.
CAUTION!
Do not start engine!
- Replace the DSG oil and filter.
- Install noise insulation.
- Perform basic measurement on the DSG mechatronic.