Removing the double-clutch transmission (DCT)

CAUTION: Materials harmful to health.
Contact with fluids harmful to health!

Note and follow safety instructions on containers.
Conduct all work in appropriate personal protective equipment only.

NOTE: RISK OF DAMAGE
Damage to the engine block.
Serious damage to the engine block and transmission due to damaged and corroded screws.

It is imperative that protruding threads of the transmission bolts are checked for corrosion and damage prior to removal.
It is imperative that all rust is removed from corroded threads and that they are cleaned prior to removal.
Replace rusted and damaged bolts.

NOTE: RISK OF DAMAGE
Damage to the transmission.
Damage to the transmission due to unapproved transmission oil.

Use only the approved transmission oil.
Check the transmission oil level after completing the repair.

NOTE: RISK OF DAMAGE
Damage to the flywheel and the double-clutch transmission (DCT).
Damage to the flywheel or the double-clutch transmission (DCT) through improper development and installation of the double-clutch transmission.

Orient the double-clutch transmission absolutely levelly during development and installation.

NOTE: TECHNICAL INFORMATION
Extreme cleanliness must be observed.
Contaminated parts must be cleaned before removing the double-clutch transmission (DKG).

Remove E-box

Precondition

Battery ground lead is disconnected.

NOTE: RISK OF DAMAGE
Electrostatic discharge.
Damage to or destruction of electrical components.

Leave the electrical components in their original packaging until they are being installed. Only use the original packaging for returning the product. Always package removed components straight away.
Read and comply with user information on using the associated special tool 12 7 060.
Only tap the housings of electrical components. Do not tap pins or multi-pin connectors directly.
Wear electrically conductive clothing and antistatic shoes (with ESD symbol).
For additional information see: 61 35... NOTES ON ESD (ELECTROSTATIC DISCHARGE) PROTECTION

NOTE: RISK OF DAMAGE
Damage to wires when disconnecting connectors and plug connections.
Sheared wires can cause a short circuit.

Do not pull on wires when disconnecting connectors and plug connections.

Detach positive battery terminal (1) .
Guide out the battery positive terminal (1) and place to the side.
Guide the positive battery cable (2) out of the holder (3) and lay to one side.

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Loosen screw (1) .
Unlock the cover (2) and feed out of the guides (3) in the direction of the arrow and remove.

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Guide out and remove plug connection (1) from E-Box (2) in the arrow direction.
Unlock plug connection (1) and disconnect.

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Unlock and release plug connections (1) in the arrow direction.
Feed out connector (1) and place to one side.

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Unlock plug connections (1) and disconnect.

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Thread out positive battery cable (1) and set it aside.
Unlock lock (2) .
Guide out wiring harness section (3) for the injectors and the ignition coils in the arrow direction and set aside.

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Unlock the locks (1) .
Feed out the wiring harness section (2) for the Valvetronic servomotor in the direction of the arrow and set aside.

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Unlock the locks (1) .
Feed out the wiring harness section (2) for the engine in arrow direction and set aside.

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Unlock and loosen holder (1) .
Thread the holder (1) in direction of arrow out of the E-box (2) and set aside.

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Loosen screw (1) .

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Thread E-box (1) in direction of arrow out of the guide (2) and remove.

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Remove battery carrier
Detach cable clip (1) from battery carrier (5) .
Detach coolant line (2) from battery carrier (5) .
Loosen screws (3) .
Loosen screw (4) .
Feed out battery carrier (5) and remove.

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Loosen screws (1) .

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Release screw (1) and place the grounding cable (2) to one side.

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Fold red lever (1) in arrow direction and detach plug connection (2) from control unit.

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Unlock and release coolant line (1) .

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Support the double-clutch transmission (DKG) with special tools 0 490 133 (00 2 030)and 0 495 827 (23 4 150) .
Secure double-clutch transmission (DCT) with luggage strap (3) .

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Correct: Keep double-clutch transmission (DCT) level while pulling it from flywheel.

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Incorrect: Pull double-clutch transmission out of flywheel without tilting.

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Remove screws (arrows).
Keep double-clutch transmission (DCT) completely level while pulling it from flywheel.

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