Mechatronic, with Transmission Installed
Mechatronic, with Transmission Installed
Removal and installation with transmission removed --> [ Mechatronic, with Transmission Removed ] Mechatronic, with Transmission Removed
Special tools, testers and auxiliary items required
• Torque wrench (V.A.G 1331)
• Old oil collecting and extracting device (V.A.G 1782)
Mechatronic, removing (transmission installed)
Always make sure that no dirt enters an open transmission. Dirt entering can cause a transmission malfunction with open Direct Shift Gearbox (DSG) Mechatronic (J743) and/or oil pump.
- Place selector lever in position "P".
- Disconnect battery Ground (GND) strap with ignition switched off.
- Remove noise insulation
- If present, remove connecting hose between charge air cooler and charge air tube21 Removal and Installation.
- If equipped and if required, remove additional interfering parts in front of cover.
- Remove cable bracket from front transmission cover (2 nuts M6).
- Release Mechatronic connector retainer by rotating and remove connector.
- Position lines in cover area upward and tie up.
- Place used oil collection and extraction device (V.A.G 1782) under transmission.
- Remove drain plug- 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 transmission.
- Remove this oil tube.
Approx. 5.0 liters of oil will flow out. Used oil collection and extraction device (V.A.G 1782) should remain below transmission.
- Reinstall overflow tube, 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 bolts - arrows - and remove cover - A -.
Before handling Mechatronic, touch a Grounded object again.
- Carefully release connector of the Transmission Input Speed (RPM) Sensor (G182) with Clutch Oil Temperature Sensor (G509) using a small screwdriver - 1 - and at the same time carefully pry out connector using a second screwdriver - 2 -.
• Do not pull on wire!
- Remove connector.
- Remove wire from retaining tabs - arrows -.
- Loosen bolts - 1 - through - 10 - in specified order and remove.
- Pull Mechatronic out of transmission housing far enough until sensor arm - B - on rear side is longer, located in transmission housing.
When handling the Mechatronic, be particularly aware of the long sensor arm.
- Carefully swivel Direct Shift Gearbox (DSG) Mechatronic (J743) downward.
Store Mechatronic properly
CAUTION!
Never lift the Mechatronic by, or allow it to rest on, the sensor arm.
If arm is damaged, Mechatronic must be replaced.
Mechatronic, installing (transmission installed)
Before handling Mechatronic, touch a Grounded object again.
If arm is damaged, 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 line.
- 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 - on connection of Mechatronic unit.
- Coat O-rings with direct shift transmission oil.
(A new Mechatronic already has new rings)
- Clean cover seal and seal surfaces on transmission.
- 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 cover and tighten nuts to 10 Nm.
- Connect connector of Direct Shift Gearbox (DSG) Mechatronic (J743) and engage retainer by turning.
- If present: Install connecting hose between charge air cooler and charge air tube21 Removal and Installation.
- Reinstall any vehicle parts removed.
- Connect battery Ground (GND) strap
- Do not start engine!
- Change DSG oil and filter --> [ Transmission, Changing Oil, Filter and Adjusting Oil Level ] Transmission, Changing Oil, Filter and Adjusting Oil Level.
- Install noise insulation
- Perform basic measurement on Direct Shift Gearbox (DSG) Mechatronic (J743).