Direct Shift Gearbox (DSG) Transmission MECHATRONIC -J743-
Special tools and workshop equipment required
- Release Tool T10465
- Assembly Pin T40199
Removing
Risk of transmission damage.
- Do not run engine or tow the vehicle with the oil pan removed or without transmission fluid.
General repair instructions, refer to REPAIR INFORMATION .
Observe cleanliness rules when working on transmissions, refer to CLEAN WORKING CONDITIONS .
-- Remove the ATF pan. Refer to OIL PAN .
-- Remove the fan shroud. Refer to [For engine(s) CETA, CCTA] Removal and Installation or to [For engine(s) CDMA] Removal and Installation or to [For engine(s) CBRA] Removal and Installation or to [For engine(s) BPY] Removal and Installation .
On Vehicles with a Lower Coolant Hose on the Left Side:
Risk of burning due to hot steam and hot coolant.
- When the engine is warm, the cooling system is under pressure.
- Reduce pressure by covering coolant expansion tank cap with cloths and carefully opening.
-- Drain the coolant. Refer to [For engine(s) CETA, CCTA] General Information or to [For engine(s) CDMA] General Information or to [For engine(s) CBRA] General Information or to [For engine(s) BPY] General Information .
-- Remove the lower coolant hose -1-. Refer to [For engine(s) CETA, CCTA] Removal and Installation or to [For engine(s) CDMA] Removal and Installation or to [For engine(s) CBRA] Removal and Installation or to [For engine(s) BPY] Removal and Installation .
All Vehicles:
Risk of destroying Mechatronic with electrostatic discharge.
- Do not touch contacts in connector with hands.
-- To discharge electrostatic, touch vehicle ground with hand (without glove).
Risk of damaging electrical wire.
- Do not pull on electrical wire.
-- Disconnect the connector -1- from the transmission input speed sensor -G182- and clutch oil temperature sensor -G509- using T10465 -arrow-.
If electrical wire is damaged, input speed sensor and clutch oil temperature sensor must be replaced.
-- First remove the line from lower clamp -arrow I-.
-- Remove the electric wire from the clip -arrow II- and move it to the side. Be careful not to bend it.
-- Remove the bolts in the following sequence: -1 to 10-.
Risk of damaging the Mechatronic.
- After removing the bolts from the mechatronic, do not remove it.
-- Remove the bolts in the following sequence: -1 to 10-.
Risk of damaging the Mechatronic.
- Without the T40199, the long sensor arm of the mechatronic will be damaged during removal.
-- Attach 3 threaded holes for the bolts of the mechatronic for each T40199, as shown in the image.
The illustration shows the installation position with the cover removed for the oil pump.
The cover for the oil pump must not be removed for this work.
The long sensor arm -B- of the Direct Shift Gearbox (DSG) Transmission Mechatronic -J743- may not be damaged.
-- Carefully remove DSG transmission Mechatronic from the T40199.
Risk of damaging the Mechatronic.
- The tabs -arrow 2- on the sensor arm -B- can break off.
- Do not lift the Mechatronic by sensor arm or lay it on arm.
If sensor arm is damaged, the Mechatronic must be replaced.
-- Store Mechatronic properly.
Installing
Install in reverse order, paying attention to the following:
Tightening specifications, refer to:
-- Remove all the caps on the new Mechatronic if replacing the DSG transmission Mechatronic.
Replace the bolts for the DSG transmission Mechatronic.
Replace O-rings -arrows- on DSG transmission Mechatronic connector.
If DSG transmission Mechatronic is replaced, O-rings are contained in replacement part delivery package.
-- Carefully insert DSG transmission Mechatronic in transmission housing through the T40199.
The illustration shows the installation position with the cover removed for the oil pump.
The cover for the oil pump must not be removed for this work.
The long sensor arm -B- of the DSG transmission Mechatronic may not be damaged.
-- Make sure the alignment pin -A- in the transmission housing -arrow 1- and the sensor arm -B- in the guide -arrow 2- fit correctly on the transmission housing.
-- Carefully position the Mechatronic on the alignment pins and make sure the sensor arm moves into its installed position.
- Electrical wire to input speed sensor and clutch oil temperature sensor must not be pinched.
-- Remove the assembly pin T40199.
-- Tighten the DSG transmission Mechatronic bolts. Refer to Figure.
-- First engage electrical wire in upper retaining tab -arrow II- and then in lower tab -arrow* I-.
-- Connect connector to input speed sensor and clutch oil temperature sensor and check connector engagement.
-- Install the oil pan. Refer to OIL PAN .
-- Install DSG transmission Mechatronic electrical connector and lock retainer by turning.
-- Install the particulate fan shroud. Refer to [For engine(s) CETA, CCTA] Removal and Installation or to [For engine(s) CDMA] Removal and Installation or to [For engine(s) CBRA] Removal and Installation or to [For engine(s) BPY] Removal and Installation .
Risk of damage to the engine through overheating.
- If the coolant was drained, only fill up the transmission fluid and do not start the engine yet.
- First start the motor when the coolant is filled for the engine cooling.
-- Fill the transmission with fluid. Refer to TRANSMISSION FLUID, REPLACING OR FILLING AFTER REPAIR .
On Vehicles with a Lower Coolant Hose on the Left Side:
-- Install coolant hose under -1-. Refer to [For engine(s) CETA, CCTA] Removal and Installation or to [For engine(s) CDMA] Removal and Installation or to [For engine(s) CBRA] Removal and Installation or to [For engine(s) BPY] Removal and Installation .
-- Fill coolant system. Refer to [For engine(s) CETA, CCTA] General Information or to [For engine(s) CDMA] General Information or to [For engine(s) CBRA] General Information or to [For engine(s) BPY] General Information .
All vehicles:
-- Start the engine and run at idle.
-- Press brake and shift through all selector lever positions "P, R, N, D, S" at idle, retaining each position for at least 3 seconds.
-- Move the selector lever into "P".
-- Transmission fluid level, checking and filling, refer to TRANSMISSION FLUID, CHECKING AND FILLING .
-- Perform a basic setting using the vehicle diagnostic tester.