MECHATRONIC, Removing And Installing: Removing
- The transmission is installed.
Danger of causing damage to the transmission.
- Do not let the engine run when the DSG Transmission Mechatronic -J743- is removed or when there is no transmission fluid in the engine. Do not tow the vehicle either.
Pay attention to MECHATRONIC SAFETY PRECAUTIONS .
Pay attention to REPAIR INFORMATION .
The dual clutch is self-adjusting. Vibrations can affect the adjusting tool. In addition, when the Mechatronic is removed, the "abrupt pulling away" of the Assembly Lever - Mechatronic :T10407 among the engaging levers will have a negative effect on the adjusting tool.
After unpacking or installing, do not dispose of the packaging and the ventilation pipe cap of a new Mechatronic. They are required for returning the removed Mechatronic.
The fluid in a new Mechatronic is already filled correctly. Do not drain out any fluid.
Beware of the danger of electrocution.
An electrical shock can result in death.
Follow the High Voltage System General Warnings. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .
- A high voltage technician must de-energize the high voltage system before work can be performed on the high voltage system or before any servicing work can be performed on the body.
- Only hybrid electrically instructed persons may perform all work on a vehicle with a high voltage system. All work must be performed by a high voltage technician.
High voltage at the high voltage system of the hybrid vehicle. Danger of electrocution! The following procedure requires work on the high voltage system. To de-energize the high voltage system. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .
Secure the rear lid so that it cannot close because the battery is going to be disconnected.
Access to the luggage compartment when the power is off possible but with difficulty.
- To de-energizing the high voltage system. Refer to HIGH VOLTAGE SYSTEM, DE-ENERGIZING .
-- Move the selector lever into >>P<<.
-- Connect the Vehicle Diagnostic Tester and turn on the ignition.
-- Select Guided Functions .
-- Select Move Gear Selector Into -Neutral- under "7-speed DSG® transmission".
-- Turn off the ignition.
-- Lift the vehicle.
-- Remove the noise insulation below engine/transmission. Refer to NOISE INSULATION .
-- Remove the fan shroud. Refer to FAN SHROUD, REMOVING AND INSTALLING [For engine(s) CZTA] or RADIATOR/COOLANT FAN [For engine(s) CBPA] or RADIATOR/RADIATOR FAN [For engine(s) CNLA] or RADIATOR/RADIATOR FAN [For engine(s) CVCA] or RADIATOR/RADIATOR FAN [For engine(s) CPPA, CPRA, CPKA, CPLA] .
Risk of burning due to hot steam and hot coolant.
- When engine is warm, the cooling system is under pressure.
- Reduce pressure by cover coolant expansion tank cap with cloths and carefully opening.
-- Remove the cap -arrow- from the coolant reservoir.
-- Place the Shop Crane - Drip Tray:VAS6208 underneath.
-- Disconnect the connector -2- on the Engine Coolant Temperature Sensor on Radiator Outlet -G83-.
-- Open the clamp -1-. Remove the left coolant hose at the bottom of the radiator and drain the coolant.
-- Bring the lock carrier into the service position. Refer to LOCK CARRIER .
-- Unclip and remove the damper cover -1- upward from the retainers -arrows-.
Vehicles with Secondary Air Injection (AIR) System
-- Squeeze the locking ring -arrows- on both sides and remove the air lines -1 and 2- from the damper -3-.
-- Remove the damper -1- upward from the rubber bushings -arrows-.
For All Vehicles
-- Disconnect the 12V battery. Refer to BATTERY .
-- Remove the Electric Drive Power and Control Electronics -JX1-. Refer to ELECTRIC DRIVE POWER AND CONTROL ELECTRONICS .
-- Remove the high voltage cables bracket from the transmission housing. Shown in illustration below, not called out.
-- Remove the bracket -1- for the Electric Drive Power And Control Electronics -JX1- -arrows-. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .
-- Disconnect the connector -1- from the valve -2- on the Mechatronic and pull the wiring harness from the front bracket on the transmission.
Danger of dirt.
Always clean the connection locations and the area around them before loosening.
The Mechatronic hydraulic system is not open. Dirt can cause the system to malfunction.
If Hydraulic Line Doesn't Need to Be Removed
-- Remove the clamps -2- from the valve block/Mechatronic.
-- Seal the hydraulic line connection -2- with new sealing plug -3-.
If Hydraulic Line Needs To Be Removed
-- Remove the bolt -1- for the hydraulic line -3- on the engine.
-- Remove the clamps -2- from the valve block/Mechatronic.
-- Remove the hydraulic line -3- on the engine and valve block/Mechatronic at the same time.
- Seal the hydraulic line connections -1 and 2- immediately with new sealing plugs -3 and 4- from the Repair Kit :5C0 998 152
. Preferably the hydraulic fluid should remain in the line if possible, otherwise it should not become dirty.
- Seal the connections on the engine -A- and the valve block/Mechatronic -C- with new sealing plugs -B and D- from the Repair Kit :5C0 998 152
.
- Always use new plugs from the Repair Kit : 5C0 998 152 . Refer to the Parts information. The sealing plugs cannot be used again.
The engine/transmission is not shown in the illustration.
-- Remove the cap -1- from the Mechatronic. The bleeder -2- remains on the ventilation -3- while doing this.
- The bleeder -2- must be removed so that no hydraulic fluid can leak out of the Mechatronic.
- The bleeder will get damaged and must be replaced during installation.
- Seal the breather -1- with a plug or the Protective Cap : 0AM 325 120 A
so that no fluid can leak out -arrow-. Refer to the Parts information.
-- If equipped remove the cover over the engaging levers.
The cover prevents dirt from getting in.
Risk of damaging transmission components.
- Never touch the contacts in the transmission connector. The electrostatic discharge will damage the control module and Mechatronic.
-- To electrostatically discharge, touch the Ground (GND) (without glove).
-- Disconnect the connector -1- for the DSG Transmission Mechatronic -J743- by pulling the locking mechanism upward in direction of -arrow-.
-- Remove the nuts -2 and 3- from the double bolts.
-- Remove the bracket for the electric wires from the transmission.
-- Place the Used Oil Collection and Extraction Unit :SMN372500 underneath.
-- Remove the drain plug from the transmission.
-- Drain the fluid and then install the drain plug and tighten it.
-- Unclip Transmission Input Speed Sensor 3 -G641- carefully from the housing in direction of -arrow- with a screwdriver.
In the following work step, both engaging levers on the dual clutch are lifted by the Mechatronic valve lifters. Otherwise the engaging levers will jam the Mechatronic by the lifters and then it is not possible to remove the Mechatronic.
-- Insert the Assembly Lever - Mechatronic :T10407 under the lifter -2- between the transmission housing and both engaging levers -1- in direction of -arrow-, as illustrated.
-- Insert the Assembly Lever - Mechatronic :T10407 just far enough until the groove on it lines up with the rib on the housing -arrows-, as illustrated. Do not insert it all the way.
The back of the Assembly Lever must touch the transmission housing.
-- Turn the Assembly Lever - Mechatronic :T10407 counter-clockwise 90° -arrow A-, in order to lift the engaging lever off the lifters -1- in direction of -arrow B-.
-- Hold the Assembly Lever - Mechatronic :T10407 against the transmission housing with a screwdriver to prevent it from slipping while turning it.
The Assembly Lever - Mechatronic :T10407 remains inserted between the engaging levers and transmission housing while removing and installing the Mechatronic.
Press the Assembly Lever - Mechatronic :T10407 against the transmission housing, if necessary.
Risk of damaging transmission components.
- Touch or remove the DSG Transmission Mechatronic -J743- only after having electrostatically discharged yourself by touching a grounded metal object (for example, bare handed with a ground).
- Never touch the contacts in the transmission connector. The control module as well as the Mechatronic can become damaged by the static discharge.
-- To electrostatically discharge, touch the ground (without glove). Do not touch connector or >>open<< electronic components directly.
Risk of damaging the DSG Transmission Mechatronic -J743-.
- Do not loosen the bolts on the cover for the DSG Transmission Mechatronic -J743-.
- Place the removed DSG Transmission Mechatronic -J743- so that no fluid can leak out.
- Do not remove the valve block from the Mechatronic.
-- Remove the bolts -arrows 2- diagonally.
-- Remove the bolts -arrows 1-.
-- Remove the Mechatronic -B- and valve block -A- from the transmission.
Risk of damaging the DSG Transmission Mechatronic -J743-.
- It may not be possible to remove the Mechatronic.
- In this case, the gear selector is caught on the top of the Mechatronic on the left side.
- Do not use increased force to remove the Mechatronic.
- In this case, it will be necessary to manually move the Mechatronic into its removal position. Refer to MECHATRONIC, MOVING INTO REMOVAL POSITION BY HAND .
Before installing the Mechatronic the rest of the oil must be extracted from the transmission.
-- Extract the remaining oil from the transmission using the Suction Pump:VAS5226 .