VW 6 Speed DQ250 Dual Clutch Transmission 02E Repair Manual Edition 09.2015
VW 6 Speed DQ250 Dual Clutch Transmission 02E Repair Manual Edition 09.2015
VW 6 Speed DQ250 Dual Clutch Transmission 02E Repair Manual Edition 09.2015
Repair Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jetta 2005 ➤
Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E
CBF CCT CBE CJAA CPLA CPP
Engine ID BRM BPY A A A A
Edition 09.2015
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Repair Group
00 - General, Technical Data
30 - Clutch
34 - Controls, Housing
35 - Gears, Shafts
39 - Final Drive, Differential
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Contents
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4.1 Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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5 Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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1 Overview - Dual Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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2 Dual Clutch, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1 Remove Clutch End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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1.1 DSG Transmission Mechatronic J743 , Removing and Installing, Transmission Installed
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1.2 DSG transmission Mechatronic J743 , Removing and Installing, Transmission Removed
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1.3 Transmission Input Speed Sensor G182 and Clutch Oil Temperature Sensor G509 ,
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Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2 Transmission Fluid Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3 Oil Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4 Selector Shaft Lever Gasket, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5 Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.1 Overview - Selector Mechanism, Vehicles through 02/2009 . . . . . . . . . . . . . . . . . . . . . . . . 62
5.2 Selector Lever Cable, Removing and Installing, through 02/2009 . . . . . . . . . . . . . . . . . . . . 64
5.3 Overview - Selector Mechanism, Vehicles from 03/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.4 Selector Mechanism, Removing and Installing, Vehicles from 03/2009 . . . . . . . . . . . . . . . . 73
5.5 Selector Lever Cable, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.6 Selector Lever Cable, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.7 Selector Lever, Emergency Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.8 Selector Lever Handle, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.9 Button in Handle, Moving into Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.10 Selector Mechanism, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Contents i
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
6 Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and
Golf Wagon from MY 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.1 Transmission, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.2 Transmission, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.3 Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7 Transmission, Removing and Installing, Jetta from MY 2011 . . . . . . . . . . . . . . . . . . . . . . 102
7.1 Transmission, Removing, Jetta MY 2011 with 2.0L 103 kW Diesel . . . . . . . . . . . . . . . . . . 102
7.2 Transmission, Installing, Jetta MY 2011 with 2.0L 103 kW Diesel . . . . . . . . . . . . . . . . . . . . 113
7.3 Transmission, Removing, Jetta MY 11, 2.0L 147 kW Gasoline Engine . . . . . . . . . . . . . . . . 115
7.4 Transmission, Installing, Jetta MY 11, 2.0L 147 kW Gasoline Engine . . . . . . . . . . . . . . . . 127
7.5 Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
8 Transmission, Transporting and Securing to Assembly Stand . . . . . . . . . . . . . . . . . . . . . . 131
9 Transmission Fluid and Transmission Fluid Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
9.1 Transmission Fluid Filter, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
9.2 Fluid Level, Checking and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
9.3 Fluid, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
10 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
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ii Contents
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6-Speed Dual Clutch Transmission 02E - Edition 09.2015
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00 – General, Technical Data lks es n
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1 General Repair Information
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⇒ “1.1 Tools”, page 1
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⇒ “1.2 Transmission”, page 1
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⇒ “1.3 Brief Overview - Guide”, page 2
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⇒ “1.5 DSG® Transmission Fluid”, page 3
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⇒ “1.6 Bolts and Nuts”, page 5
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It should offer support and help. Using ELSA offers the ability to
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More Information on the Dual-Clutch Transmission DSG®.
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For more information about the transmission functions. Refer to
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1.1 Tools
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A complete list of special tools and workshop equipment used in
the repair manual can be found at the beginning of each repair
section and in the “Special Tools and Workshop Equipment” fold‐
er.
Uncertainties often exist on smaller screws with lower tightening
specifications. The Torque Wrench 2-10Nm - VAG1783- can be
used on these screws.
1.2 Transmission
Always make sure that no dirt or contaminants enter an »open«
transmission. Any dirt that enters can cause transmission failure,
especially if the DSG Transmission Mechatronic - J743- and/or
the oil pump are »exposed«.
♦ Do not run the engine and do not tow the vehicle if the trans‐
mission cover is removed or if there is no transmission fluid
inside the transmission.
♦ Thoroughly clean the connection points and the area around
them first, and then loosen them.
♦ When installing the transmission, make sure the alignment
sleeves are seated correctly between the engine and the
transmission.
1 - Filter
❑ Refer to
⇒ “9 Transmission Fluid wage
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❑ Information on changing auth or
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Change ”, page 4 .
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2 - Check Plug.
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Filter”, page 132
❑ Near the pendulum sup‐
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3 - Drain Plug
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⇒ “1.5 DSG® Transmis‐
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4 - Transmission Fluid Cooler
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Installing”, page 55
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5 - DSG Transmission Mecha‐
tronic - J743-
❑ Refer to
⇒ “1 Electrical and Elec‐
tronic Components,
Component Locations in DSG® Transmission”, page 33
6 - Transmission Input Speed Sensor - G182- and Clutch Oil Temperature Sensor - G509-
❑ Refer to
⇒ “1 Electrical and Electronic Components, Component Locations in DSG® Transmission”, page 33 .
7 - Oil Pump
❑ Refer to ⇒ “3 Oil Pump, Removing and Installing”, page 57
8 - Clutch Cover for the DSG®
9 - Dual Clutch
❑ Refer to ⇒ “1 Overview - Dual Clutch”, page 15
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♦ The open side of the gaskets point toward the fluid to be sealed
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⇒ “9.2 Fluid Level, Checking and Filling”, page 133 .
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1.5 DSG® Transmission Fluid
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⇒ “1.5.2 Transmission Fluid Filter, When To Change ”,
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⇒ “1.5.3 Fluid and Fluid Level Troubleshooting”, page 4
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⇒ “1.5.4 Transmission Fluid Drain and Check Plug A ”,
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Fluid is available as an original part. Original part number. Refer
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♦ Metal shavings were found in the transmission fluid.
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♦ The clutch is burned or has a mechanical fault.
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Fluid and Fluid Level Troubleshooting
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For more information regarding the fluid. Refer to
⇒ “1.5.1 Fluid Function”, page 3 . But the fluid cannot disappear
»without a trace«.
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Fluid can only be missing if it has leaked from the transmission.
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Repair this leak first. Fill with new transmission fluid and make
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sure the level is »correct«. Refer to
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page 132 .
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1.5.4 Transmission Fluid Drain and Check
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2 Troubleshooting
⇒ “2.1 Troubleshooting, General Information”, page 6
⇒ “2.2 Transmission Control Module Malfunction Behavior Infor‐
mation”, page 6
⇒ “2.3 Fault Finding, Special Information”, page 7
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for the malfunction might not be found during Guided Fault
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driving behavior can even be detected.
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2- The individual lever positions blink in the Selector Lever
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Transmission Range Display - Y5- . This signals to the driver
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that the gear selection is currently not possible. Example:
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Driving in reverse, lever in “R” and vehicle drives backwards.
If “D” is engaged in this situation, the letter “D” blinks in the
Selector Lever Transmission Range Display - Y5- . In this
case, the control module prevents 1st gear from being en‐
gaged to avoid damaging the transmission. The gear is only
engaged when the vehicle is stopped. If testing this, do so
carefully!
3- The Selector Lever Transmission Range Display - Y5- is
completely lit up and blinking. The selector lever position is
indicated/highlighted. Example: the transmission fluid tem‐
perature is too high. Reasons could include: towing a trailer
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with too large of a load, accessories installed on the front of
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the vehicle, »lack of cooling air«.
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4- The selector lever position engaged cannot be recognized.
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blinks. Differences in the driving and shifting can definitely
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be felt. It is not possible to shift into reverse. There is a »se‐
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transmission repair is necessary.
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⇒ “2.3.1 Transmission Range Display, No R ”, page 7
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⇒ “2.3.2 Touch Function Malfunction, Not Changing Gears as
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⇒ “2.3.3 Drive Faulty - Insufficient Oil Suspected”, page 7
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display indicates the transmission is in emergency mode. The
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vehicle can no longer drive in reverse.
2. Troubleshooting 7
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
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control modules) is waiting for a signal from the BUS but is not
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receiving it. In this case, the ABS control module would have a
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problem. The DSG Transmission Mechatronic - J743- must never
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3 Transmission Identification
⇒ “3.1 Transmission Code, Reading”, page 9
Example -arrow-:
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was accidentally installed or there is no definite way to identify the
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Reading the code directly off the transmission. Refer to Prote AG.
⇒ “3.1 Transmission Code, Reading”, page 9 .
3. Transmission Identification 9
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
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Perform the Following:
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♦ Vehicles with a diesel engine. Refer to ⇒ Rep. Gr. 23 ; Diesel
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stalling .
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– Remove the battery and the battery tray -arrows-. Refer to ⇒
Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Remov‐
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In most cases two turns on the spindle are enough to remove the
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bracket in direction of -arrow-.
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After reading the transmission code, re-assemble in reverse order
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– Follow all the instructions.
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– Replace all the bolts from the left subframe mount.
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– Install all new bolts first by hand.
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– After installing the transmission bracket, always adjust the se‐
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3. Transmission Identification 11
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
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4 Engine Codes - Engine Allocation
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⇒ “4.1 Codes”,au page 12
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4.1 Codes
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If original parts are needed for a repair, always pay attention to
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the transmission codes.
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JBT, JPS, KDC, GPW, GYQ, HLH, HBP, HFQ, HLE, HBQ, HRW,
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KNF, KPY, KVV, HQH, HQQ, HQN, HQF, HQL, HXS, HUS, HUT, HXW,
t to the co
LRC HXU, JPL, KCW, JPJ, KCU, KMW, JPP, KCZ, KNC,
KMZ, KPQ, LQS, KMX, KPS, KQC, KPV, LQZ, LTL,
MKJ, MLW LQT, LTD, LQV, MMA, MSX,
rrectne
LTE, MFL, MFM, MSY, NJL, NJM,
MSU, MSV, NJK, NLQ, NVW, PBG,
NLP, PBF, PPY PPZ, PQL
ss o
cial p
f
1.4L - 103 kW TSI 1.9L - 74 kW TDI 2.0L - 100 kW TDI 2.0L - 147 kW
in
1.4L - 125 kW TSI 1.9L - 77 kW TDI 2.0L - 103 kW TDI
form
TFSI
mer
atio
om
installed in Golf Wagon from MY 2007, Golf Wagon from MY 2010, Jetta from MY 2005 and
n
c
i
or
n
Jetta from MY 2011
thi
te
sd
iva
o
For the following data. Refer to the Parts Catalog.
pr
cum
for
en
ng
5 Capacity
Capacities DSG Transmission 02E
Refill Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
Change Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
Change after removing and installing the Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
Mechatronic with the transmission installed
Grease Transmission fluid for DSG® transmission 02E. Refer to the
Parts Catalog .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
e
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
5. Capacity 13
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
6 Special Tools
Special tools and workshop equipment required
♦ Torque Wrench 2-10Nm - VAG1783-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
30 – Clutch
itte
y li
erm
ab
ility
ot p
wit
is n
1 Overview - Dual Clutch
h re
ol ,
spec
urposes, in part or in wh
t to the co
The term »clutch« is not completely accurate on closer examina‐
tion. DSG® clutches always contain at least two »clutches« which
rrectne
is why the term “dual clutch” is more appropriate. In this case, the
clutch has two clutch disc packs - that is, a wet clutch. The outer,
larger clutch plate pack is called “K 1” (clutch 1). The “K 1” shifts
ss
reverse gear and »1st«, »3rd« and »5th« gears. The inner, small‐
o
cial p
f i
er “K 2” (clutch 2) shifts the gears »2«, »4« and »6«.
nform
mer
atio
m
n
c
i
or
n thi
e
sd
va
o
pr
cum
for
en
ng
ce
le
1 - Dual Clutch with Circlip
un
pt
an
d
itte
y li
erm
ab
Caution
ility
ot p
wit
The
♦ drive plate (upper
, is n
h re
section of the dual clutch)
e
hol
spec
of a new clutch is not se‐
es, in part or in w
t to the co
only sits »taut« in the
clutch.
rrectness of i
The
♦ drive plate must re‐
main engaged between
l purpos
nform
ercia
at
om
ion
c
in t
or
his
e
do
stallation under the cir‐
pr
cum
cumstances.
r
fo
en
ng
t.
yi Co
Cop py
2 - Circlip
t. rig
gh ht
pyri by
❑ Quantity: 10, with vari‐
o Vo
by c lksw
cted
ous thicknesses for ad‐
agen
Prote AG.
justment
❑ When installing the dual
clutch, the thickness of
the circlip must be de‐
termined. Refer to
⇒ page 28
3 - Clutch End Cover
4 - Clutch End Cover Circlip
Caution
ce
e
nl
❑ Do not remove
pt
du
an
itte
y li
erm
ab
Caution
ility
ot p
wit
, is n
h re
inner clutch plate carrier
hol
spec
under any circumstan‐
es, in part or in w
t to the co
could rotate themselves.
rrectness of i
4 - Outer Clutch Plate
l purpos
❑ Quantity: 4
5 - Inner Clutch Plate
nf
ercia
o
❑ Quantity: 4
rm
m
atio
m
6 - Thrust Washer
o
n in
or c
7 - Circlip
thi
te
sd
iva
cu
m
f
en
ng
ce
e
nl
pt
du
an
itte
y li
erm
ab
⇒ “2.1 Remove Clutch End Cover”, page 18
ility
ot p
wit
⇒ “2.2 Clutch End Cover, Installing”, page 20
is n
h re
ol ,
spec
urposes, in part or in wh
t to the co
Before the dual clutch can be removed, remove the clutch end
cover from the dual clutch. Refer to
rrectne
⇒ “2.1 Remove Clutch End Cover”, page 18 .
ss o
cial p
f i
Brief Description
nform
mer
atio
m
circlip holds the clutch end cover in place. Remove the circlip and
o
n
c
pry out the clutch end cover. Always replace the clutch end cover
i
or
n thi
e
and the locking ring. Never use a hammer to install the clutch
t
sd
va
cover and never lubricate the center seal or touch it. If this should
i
o
pr
cum
or
en
ng
t.
yi Co
The transmission must be removed in order to work on the cover. t. Cop py
rig
gh ht
yri
– Remove the transmission. Refer to p by
co Vo
⇒ “6 Transmission, Removing and Installing, Jetta from MY
by lksw
cted agen
Prote
2005 , Golf Wagon from MY 2007 and Golf Wagon from MY
AG.
2010”, page 88 or
⇒ “7 Transmission, Removing and Installing, Jetta from MY
2011”, page 102 .
– Secure the transmission on the assembly stand. Refer to
⇒ “8 Transmission, Transporting and Securing to Assembly
Stand”, page 131 .
– Place a Drip Tray under the transmission.
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
e
hol
spec
es, in part or in w
t to the co
– Insert the new filter with the seat facing downward and tighten
rrectness of i
the housing to 20 Nm.
l purpos
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Pry out the circlip -2- for the clutch end cover with a screwdriver
-1- in direction of -arrow- and remove.
– Remove the clutch end cover -2- with a screwdriver -1- (or a agen
AG. Volkswagen AG d
pry bar) through the opening for the starter in the direction
Volkswof
oes
not
gu
-arrow- and then remove the clutch end cover. ed by ara
n ris tee
utho or
a ac
ss
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
again.
ility
ot p
wit
♦ Only install a »new« clutch end cover. Refer to
, is n
h re
⇒ “2.2 Clutch End Cover, Installing”, page 20 .
e
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
a
om
tion in
r c
thi
e
ling”, page 21
t
s
a
do
priv
cum
r
en
g
page 23
n
t.
yi Co
Cop py
There Are Two Types of Clutch End Covers.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution
Do not touch the hole in the center in a new clutch end cover.
The clutch end cover must not be touched inside the hole, oiled
or come into contact with any other substances in that area.
Leaks will develop.
pt
du
The new clutch cover must not have any oil in the around the
an
itte
y li
ab
ility
ot p
h re
spec
t to the co
The center seal on new clutch end cover must now be »pre-
l purpos
formed«:
nform
mercia
a
om
tion in
or c
thi
te
s
a
do
priv
cum
or
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
21
copy Vo
by lksw
cted agen 2. Dual Clutch, Removing and Installing
Prote AG.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
olkswagen AG
6-Speed Dual Clutch Transmission 02E - Edition 09.2015 swagen AG. V does
k not
Vol gu
d by ara
– Guide the clutch end cover horizontally and evenly over othe ris
e nte
whole sleeve. This brings the sealing lip into its installation
auth eo
ra
position. ss c
ce
e
nl
pt
– Remove the sleeve upward out of the clutch end cover and
du
an
itte
place it on the end of the clutch shaft.
y li
erm
ab
ility
ot p
wit
, is n
h re
e
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
– Guide the clutch end cover horizontally over the sleeve and
thi
te
sd
a
o
r
rp
cu
o
m
f
en
ng
t.
yi
Caution
Co
Cop py
t. rig
gh ht
yri
Handle with care. Any type of impact on the clutch end cover
p by
co Vo
lksw
will cause leaks.
by
cted agen
Prote AG.
The clutch end cover can be carefully lifted in its seat using a
screwdriver -arrow- until a »new« locking clip can be installed.
– Install the new circlip.
– Remove the Clutch Cover Plate Guide Sleeve - T10302- .
Caution
Do not touch the hole in the center in a new clutch end cover.
The clutch end cover must not be touched inside the hole, oiled
or come into contact with any other substances in that area.
Leaks will develop. olksw AG. V agen AG
agen does
olksw not
yV gu
db ara
rise nte
tho eo
Do Not Remove the Bushing!
s au ra
c
s
ce
e
nl
The new clutch cover must not have any oil in the around the
pt
du
an
center seal and it must be dry.
itte
y li
erm
ab
– Clean the end of the clutch shaft if necessary.
ility
ot p
wit
, is n
h re
e
hol
spec
– If this is done, carefully remove the adhesive!
es, in part or in w
t to the co
Only coat outer edge of seal with DSG® transmission fluid.
rrectness of i
l purpos
nform
ercia
Caution
m
a
om
tion in
Handle with care. Any type of impact on the clutch end cover
or c
s
a
do
priv
cum
or
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
The clutch end cover can be carefully lifted in its seat using a
screwdriver -arrow- until a »new« locking clip can be installed.
– Install the new circlip.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
e
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
at
om
ion
c
in t
or
his
te
iva
do
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Carefully remove the dual clutch from the transmission.
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
om
tion in
or c
thi
te
s
a
do
riv
cum
or
f
en
g
– The pump shaft will be inserted first after the installation of the
n
t.
yi Co
op
new clutch. Set the shaft down until then. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Caution
ce
e
nl
pt
du
an
itte
y li
clutch. The large lamella carrier must not slipped out of the
erm
ab
lowest clutch disc.
ility
ot p
wit
is n
h re
ol ,
spec
• Do not install any wavy circlips
urposes, in part or in wh
t to the co
– Take the dual clutch out of the packaging by pressing the drive
plate into the outer clutch plate carrier with both thumbs.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
for
en
ng
– Next, secure the drive plate in the outer clutch plate carrier
t.
yi Co
op
with the “old” circlip -A- from the removed clutch. C py
t. rig
gh ht
yri by
• Do not use the new circlip that was delivered with the package. cop Vo
by lksw
cted agen
Prote
• The circlip must be installed so that the tab of the drive plate
AG.
– Check the bottom of the dual clutch to see if the four hub gas‐
kets are seated correctly and engage them in one another if
necessary.
• The ends of the rings should not stand over one another.
– Turn the rings one time. They must move freely and must not
stick.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
clutch end cover as shown.
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
– Set the dual clutch using rotating and lifting movements into
te
sd
a
the clutch housing, but do not let it fall in. Press the drive plate
iv
o
r
rp
cu
into the outer clutch pack carrier with both thumbs in direction
o
m
f
en
ng
of -arrows- to install.
t.
yi Co
op py
Do not install on clutch. The clutch is inserted with the cover as it
t. C rig
gh ht
yri
was in the packaging. p by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ The retaining pin remains there until clutch end cover is in‐
stalled.
♦ The dual clutch must not be turned any more now, otherwise
the Clutch Retaining Bar - T10303- could be twisted in its po‐
sition.
ce
e
nl
pt
du
an
itte
Do not remove or lift the inner clutch plate carrier, under any
y li
erm
ab
circumstances. The clutch plates could rotate themselves.
ility
ot p
wit
, is n
h re
e
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
om
tio
– Remove the drive plate from the installed clutch in direction of
n in
r c
thi
te
s
a
do
priv
cum
r
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
First Measurement
• The Clutch Retaining Bar - T10303- remains installed.
– Install the Dial Gauge Holder - VW387- on the transmission
flange.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ol ,
spec
urposes, in part or in wh
t to the co
rrectnes
– Place the dial gauge test probe on the
s o
-inner clutch plate carrier hub-.
cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
e
sd
iva
o
pr
cum
for
t.
yi Co
op
– Raise the dual clutch up as far as the stop again and note this
C py
ht. rig
measurement as well
rig ht
py by
co Vo
by lksw
cted
Now the Calculation Will Be Made to Determine Which of the Re‐
agen
Prote AG.
maining Nine Circlips Will Be Finally Installed:
– Use this formula:
2nd measurment value - 1st measurment value + 1.85 mm =
circlip thickness
– Note the result.
The remaining nine circlips are staggered in 0.1 mm increments.
– Measure all the circlips and determine the one that is the clos‐
est match to the result.
Determined Measurement for New Circlip
the New Circlip
2.27 mm 2.3 mm
2.24 mm 2.2 mm
Note
– Remove the 2 mm circlip and replace it with the circlip that was
measured.
– Dispose of all other remaining circlips and the 2 millimeter thick
circlip.
Note
n AG. Volkswagen AG do
lkswage es n
o ot g
yV ua
– Insert the pump shaft by lifting the pump shaft and turning it ised b ran
slightly -arrow- so that it slides all the way into the splines.uthor tee
or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ol ,
e
spec
urposes, in part or in wh
t to the co
rrectne
– Insert the drive plate into the dual clutch.
• The protruding tab on the drive plate -arrow- must be installed
ss
between the marked teeth or the marking applied to the outer
o
cial p
f
clutch plate carrier.
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
te
iva
do
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3 Special Tools
Special tools and workshop equipment required
♦ Clutch Cover Plate Guide Sleeve - T10302-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ol ,
spec
♦ Clutch Retaining Bar - T10303-
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
34 – Controls, Housing
1 Electrical and Electronic Compo‐
nents, Component Locations in
DSG® Transmission
The electric/electronic components are located inside the trans‐
mission.
The Selector Lever Sensor System Control Module - J587- and
the Shift Lock Solenoid - N110- are located on the selector lever.
pt
an
itte
ab
Mechatronic - J743-
h re
e
spec
t to the co
be removed. Refer to
⇒ “1.1 DSG Transmis‐
sion Mechatronic J743 ,
Removing and Instal‐
rrectness of i
stalled”, page 34 .
3 - Selector Lever - E313-
nform
ercia
ti
to
on in
c
⇒ “5 Selector Mecha‐
or
thi
e
nism”, page 62
t
s
a
do
priv
cum
or
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
Installed
du
an
itte
y li
erm
ab
Always make sure that no dirt or contaminants enter an »open«
ility
ot p
transmission.
wit
is n
h re
Any dirt that enters can cause transmission failure, especially if
ol ,
e
spec
the DSG Transmission Mechatronic - J743- and/or the oil pump
urposes, in part or in wh
are »exposed«.
t to the co
In regard to »contaminated oil«, also observe information on
changing the oil filter. Refer to
rrectne
⇒ “1.5.2 Transmission Fluid Filter, When To Change ”, page 4 .
The Mechatronic can get stuck on the alignment pins when the
ss
transmission is very warm. Let the transmission cool down.
o
cial p
f in
– Move the selector lever into “P”.
form
mer
n
c
i
or
Connecting .
thi
te
sd
va
o
pr
cum
or
en
ng
t.
yi Co
If present: t. Cop py
rig
gh ht
yri
– Remove the connecting hose between the charge air cooler p by
co Vo
and the charge air pipe. Refer to ⇒ Rep. Gr. 21 ; Charge Air
by lksw
cted agen
Prote
System .
AG.
Note
Caution
ce
e
Note
nl
pt
du
an
itte
y li
The connector is located on the transmission near the starter
erm
ab
ility
-A-.
ot p
wit
, is n
h re
e
hol
spec
es, in part or in w
t to the co
– Remove the wires and bracket from the front of the transmis‐
rrectness of i
sion cover -arrows- (two M6 nuts).
l purpos
nf
ercia
orm
– Place the Used Oil Collection and Extraction Unit -
m
atio
m
n in
or c
thi
te
sd
a
Caution
iv
o
r
rp
cu
o
m
f
en
ng
Fluid will leak out of the cover when the bolts are removed. Risk
t.
yi Co
of injury due to hot transmission fluid. Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Loosen bolts on the transmission cover -arrows- diagonally
first and then remove them. Hold the cover in place at the same
time.
– Drain the gear oil and remove the cover and seal.
Approximately three liters (3.1 quarts) of transmission fluid will
drain out.
Note
Always replace the »small« oil pump cover, the seal and the bolts
on the transmission cover.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
e
hol
spec
es, in part or in w
t to the co
– Remove the bolts -2 and 3- from the transmission pendulum
rrectness of i
support. Refer to ⇒ Rep. Gr. 10 .
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
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Before handling the Mechatronic, touch a grounded object again. cop Vo
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Refer to ⇒ “1.7 Electrical Components”, page 5 .
cted agen
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♦ If the Speed Sender Release Tool - T10465- is not available,
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drivers as follows:
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spec
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♦ Press only on the release with the screwdriver -1-. Do not use
t to the co
a screwdriver as a lever.
♦ Loosen the connector with the screwdriver -2-.
rrectness of i
♦ Be very careful. The connector locking mechanisms can
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Caution
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Never lift the Mechatronic by the »sensor arm« and never let
it rest on the arm.
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spec
urposes, in part or in wh
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Replace the Mechatronic if the »arm« Gets Damaged.
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♦ The DSG Transmission Mechatronic - J743- and the trans‐ Prote
cted AG.
agen
mission must be the same temperature. Otherwise the align‐
ment pins will not »clamp« during installation.
♦ Make sure the Transmission Input Speed Sensor - G182- and
the Clutch Oil Temperature Sensor - G509- are installed be‐
fore installing the Mechatronic.
♦ Do not pinch the line.
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urposes, in part or in wh
t to the co
rrectness o
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mer
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– Hold the Mechatronic facing up. The sensor arm must not
n
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– Set the new oil pump cover -A- in place and tighten the bolts
-arrows- in a diagonal sequence to 8 Nm in stages.
rrectness of i
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Rep. Gr.34 - Controls, Housing
AG.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
n AG. Volkswagen AG do
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Connect the connector byV
o -A- from the DSG Transmission
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ua Mecha‐
tronic - J743- ras ise follows.
d ran
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– The arrow
ss
au
-D- on the Mechatronic -B- must line up with the
ac
connector -A- as well as with the tab -C-.
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pt
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– Connect the connector -A- carefully all the way and then turn
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the lock »clockwise« in the direction of -arrow-.
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– Install the hose between the charge air cooler and the charge
wit
is n
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ol ,
spec
urposes, in part or in wh
t to the co
bolts. Refer to ⇒ Rep. Gr. 10 .
– Reinstall any removed vehicle parts.
rrectne
– Connect the battery and follow the steps after connecting the
battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery;
ss
Battery, Disconnecting and Connecting .
o
cial p
f inform
– Do not start the engine.
mer
atio
m
n
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– Replace the DSG® fluid and filter. Refer to
te
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pr
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page 132 . um
for
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t.
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– Place the Used Oil Collection and Extraction Unit -
Co
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SMN372500- under the transmission near the drain plug.
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co lksw
by
cted agen
Prote AG.
– Measure the length of the vent pipe, dimension -a- before in‐
stalling Oil Filler - VAS6262A- on the oil bottle and shorten the
pipe if necessary. Refer to ⇒ page 134 .
Dimension -a- = 210 mm
Note
Dimension -a- is measured starting from the shaft (the green sur‐
face) on the Oil Filler - VAS6262A- .
– Install the Oil Filler - VAS6262A- into the check hole hand-
tight.
AG. Volkswagen AG d
agen oes
olksw not
– Shake the bottles before opening. d by V gu
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– Attach the Oil Filler - VAS6262A- to the oil bottle. Beut sure to
ho eo
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read the instructions. Refer to ⇒ page 133 . ss a c
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– To change containers, close the shut-off valve or hold the Oil
erm
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Filler - VAS6262A- higher than the transmission.
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Start the engine and check the fluid level. The Oil Filler -
h re
VAS6262A- remains installed.
e
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spec
es, in part or in w
t to the co
⇒ “9.2 Fluid Level, Checking and Filling”, page 133 .
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.
rrectness of i
50 ; Noise Insulation .
l purpos
- J743- .
m
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c
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Removed
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⇒ “1.2.1 Mechatronic, Removing, Transmission Removed”, page
ility
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45
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⇒ “1.2.2 Mechatronic, Installing, Transmission Removed”,
e
hol
page 50
spec
es, in part or in w
t to the co
Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-
rrectness of i
♦ Used Oil Collection and Extraction Unit - SMN372500-
l purpos
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om
t
the oil pump are »exposed«.
ion in
or c
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do
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⇒ “1.5.2 Transmission Fluid Filter, When To Change ”, page 4 .
um
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1.2.1 Mechatronic, Removing, Transmission
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– Place the Used Oil Collection and Extraction Unit -
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Prote AG.
SMN372500- or Drip Tray under the transmission.
– Remove the bolt -A- near the pendulum support.
Through transmission production date “09/20/2004”, transmis‐
sions were installed with two plugs.
A plastic overflow tube is located in this hole (with 8 mm hex
socket head, tightening specification: 3 Nm). Its length deter‐
mines the fluid level in the transmission.
– Remove the overflow pipe.
– Drain the fluid.
In regard to »contaminated oil«, also observe information on
changing the oil filter. Refer to
⇒ “1.5.2 Transmission Fluid Filter, When To Change ”, page 4 .
– Tighten the overflow pipe to 3 Nm.
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Note
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After repairing, the filter does not have to be changed again when
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spec
filling the fluid.
es, in part or in w
t to the co
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mercia
at
om
Note
ion
c
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Always replace the transmission fluid pump cover, the bolts for
t
iva
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the transmission fluid pump cover as well as the gasket and the
pr
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AG. Volkswagen AG d
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Note rised ara
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♦ If the Speed Sender
ss Release Tool - T10465- is not available, c
the connector can be removed by carefully using two screw‐
ce
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un
pt
drivers as follows:
an
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itte
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♦ Press only on the release with the screwdriver -1-. Do not use
ility
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a screwdriver as a lever.
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♦ Loosen the connector with the screwdriver -2-.
hol
spec
♦ Be very careful. The connector locking mechanisms can
es, in part or in w
t to the co
break. Replace the sensor if this happens.
rrectness of i
– Disconnect the connector.
l purpos
nform
mercia
at
om
in t
or
– Then remove it from the upper clip -arrow II- and move it to the
his
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AG. Volkswagen AG d
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or eo
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un
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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om
ion
c
in t
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ng
t.
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Cop py
t. rig
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by c lksw
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Prote AG.
Caution
Never lift the Mechatronic by the »sensor arm« and never let
it rest on the arm.
n AG. Volkswagen AG do
lkswage es n
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byV ua
d ran
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nl
pt
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ility
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es, in part or in w
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co lksw
by
cted agen
Prote AG.
Caution
Never lift the Mechatronic by the »sensor arm« and never let
it rest on the arm.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
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nl
pt
du
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ility
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wit
is n
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ol ,
e
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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pr
cum
for
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t.
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AG. Volkswagen AG d
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– Carefully place the Mechatronic on the alignment pin -arrow-.
ce
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un
pt
The goal is for the »sensor arm« to be in its
an
d
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-installation position-.
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ility
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spec
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t to the co
rrectness of i
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nform
mercia
at
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c
in t
or
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pr
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t.
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Cop py
t. rig
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by c lksw
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Prote AG.
– The sensor arm must not touch the sensor wheel. -Detail-
– Do not pinch the line.
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– Make sure the Mechatronic unit is installed correctly. lkswage es n
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All of the bolts -1 through 10- must be replaced. ir se
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c
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nl
pt
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ab
ility
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is n
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ol ,
spec
urposes, in part or in wh
t to the co
rrectness
Replace the transmission cover -gasket-.
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
for
en
ng
t.
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t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.
– Fasten bolts -arrows- for the transmission cover -A- »in a di‐
agonal sequence« to 10 Nm.
After Installing Transmission
– Fill the fluid without replacing filter. Refer to
⇒ “9 Transmission Fluid and Transmission Fluid Filter”,
page 132 .
– Connect the Vehicle Diagnostic Tester .
– Perform a basic setting on the DSG Transmission Mechatronic
- J743- .
Often, the sensor wire is pulled. It will get damaged. If the wire
was pulled, the sensor must be replaced.
Removing
– Remove the DSG Transmission Mechatronic - J743- . Refer
to
⇒ “1.1 DSG Transmission Mechatronic J743 , Removing and
Installing, Transmission Installed”,
gen AG page 34 n. AG d
. Volkswage
wa oes
olks not
Do Not Pull On the Wire
db
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ris
– Remove the boltut and carefully pry out the
ho sensor with screw‐e or
driver and/or
ss pliers.
a ac
ce
e
nl
Installing
pt
du
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Install an »old« sensor only if:
erm
ab
ility
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, is n
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• The wire was not pulled out during removal.
hol
spec
If this is not the case, a »new« sensor should be installed.
es, in part or in w
t to the co
– Coat the sensor with DSG® transmission fluid and then install
it.
rrectness of i
– Tighten the bolt to 10 Nm.
l purpos
orm
Do not pinch line when installing the Mechatronic!
m
atio
om
n in
or c
thi
te
sd
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nl
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stalling .
du
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– Place a lint-free cloth on to transmission fluid cooler and trans‐
erm
ab
ility
mission to absorb escaping coolant.
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hol
spec
Note
es, in part or in w
t to the co
♦ The cooling system is under pressure when the engine is
warm.
rrectness of i
♦ Cover the coolant reservoir cap with a cloth and open it care‐
fully before removing the coolant hoses.
l purpos
nf
ercia
orm
cooler.
m
atio
om
n in
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sd
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t.
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rig ht
py by
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by lksw
cted agen
Prote AG.
– Remove the bolts -A- and the transmission fluid cooler -B-.
Caution
Installing
Caution
pt
du
an
itte
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erm
ab
ility
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wit
is n
h re
ol ,
e
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
for
en
ng
t.
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Cop py
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rig ht
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by lksw
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56
Prote AG.
Rep. Gr.34 - Controls, Housing
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
ce
e
pt
du
an
itte
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erm
ab
changing the oil filter. Refer to
ility
ot p
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, is n
h re
– Remove the bolt -A- near the pendulum support.
e
hol
spec
Through transmission production date “09/20/2004”, transmis‐
es, in part or in w
t to the co
sions were installed with two plugs.
A plastic overflow tube is located in this hole (with 8 mm hex
socket head, tightening specification: 3 Nm). Its length deter‐
rrectness of i
mines the fluid level in the transmission.
l purpos
nform
ercia
a
om
tion in
or c
thi
te
do
priv
cum
r
en
ng
– Remove the bolts -arrows- and the oil pump cover -A-.
There is Still Oil in Oil Pump Cover
– Remove the bolts -arrows- and the pump -1- from the align‐
ment pins and pull the input shaft from the pump.
Remove the top bolt with the Wrench - Pump/Injector Long Reach
- T10054- .
Installing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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nl
pt
du
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– Install the input shaft -A- all the way into the transmission. Turn
erm
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ility
the input shaft while doing this.
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, is n
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hol
spec
• The two alignment pins -C- must be inside the transmission
es, in part or in w
housing.
t to the co
– When positioning the oil pump, pay attention to driveshaft
splines and correct seating on the alignment pins.
rrectness of i
l purpos
nform
mercia
tion in
c
thi
te
s
a
Tightening Specification
do
priv
cum
or
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t.
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Prote AG.
3 bolts with flat head, top bolt -arrow- with countersunk head
Tightening Specification
♦ Countersunk bolt: tighten with the Wrench - Pump/Injector
Long Reach - T10054- 8 Nm without additional turn
♦ Flat head bolts: 8 Nm +90° (1/4 turn)
– Set the new oil pump cover -A- in place and tighten new bolts
-arrows- in diagonal sequence and in several steps to 8 Nm.
Transmission does not have oil. »New« oil must now be added
and adjust to the correct oil level. Refer to
⇒ “9 Transmission Fluid and Transmission Fluid Filter”,
page 132 . agen
AG. Volkswagen AG d
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olks t
– Install the left wheel housing
ed
by liner. Refer to ⇒ Body Exterior;
V gu
ara
Rep. Gr. 66 ; WheelhoHousing Liner; Overview - Front Wheel ntee
ris
Housing Liner . s aut or
ac
s
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.
ce
e
nl
pt
du
50 ; Noise Insulation .
an
itte
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erm
ab
ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
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n in
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t.
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rig ht
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by lksw
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Prote AG.
AG. Volkswagen AG d
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– Pry out the seal in the direction of -arrow-. ed by
V gu
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aut ra
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nl
pt
du
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erm
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ility
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is n
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ol ,
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spec
urposes, in part or in wh
t to the co
rrectne
– Fill the space between the sealing/dust lip -arrow- halfway with
Sealing Grease - G 052 128 A1- .
s
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
for
en
ng
t.
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t. rig
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pyri by
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by c lksw
cted agen
Prote AG.
– Install the new gasket all the way. Do not tilt the gasket when
installing it.
• The closed side of the gasket -arrow- points to the Press Piece
- Shift Rod/Alternator - VW423- .
– Install the lever and tighten the nut to 20 Nm.
The Selector Shaft Lever Fits on the Splines in One Position Only.
. Volkswagen AG
a gen AG does
– Attach the selector lever cable to the transmission and adjust.Vol
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Refer to ⇒ “5.6 Selector Lever Cable, Adjusting”, page 80ed .
b y ara
nte
ris
utho eo
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nl
pt
du
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erm
ab
ility
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is n
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ol ,
e
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
for
en
ng
t.
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Cop py
t. rig
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co lksw
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Prote AG.
5 Selector Mechanism
⇒ “5.1 Overview - Selector Mechanism, Vehicles through
02/2009”, page 62
⇒ “5.2 Selector Lever Cable, Removing and Installing, through
02/2009”, page 64
⇒ “5.3 Overview - Selector Mechanism, Vehicles from 03/2009”,
page 72
⇒ “5.4 Selector Mechanism, Removing and Installing, Vehicles
from 03/2009”, page 73
⇒ “5.5 Selector Lever Cable, Checking”, page 80
⇒ “5.6 Selector Lever Cable, Adjusting”, page 80
AG. Volkswagen AG d
⇒ “5.7 Selector Lever, Emergency Release”, page
lksw
agen 82 oes
not
o
yV gu
⇒ “5.8 Selector Lever Handle, Removing
ris
ed
b
and Installing”, ara
nte
page 82 ut
ho eo
ra
sa c
⇒ “5.9 Button in Handle, Moving
s
into Installation Position”,
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nl
page 85
pt
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itte
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⇒ “5.10 Selector Mechanism, Checking”, page 86
erm
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ility
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WARNING
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spec
Move the selector lever into “P” and set the parking brake be‐
es, in part or in w
t to the co
rrectness of i
5.1 Overview - Selector Mechanism, Vehicles through 02/2009
l purpos
nform
mercia
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tion in
or c
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– If necessary, disconnect or remove sections of the exhaust system. Refer to ⇒ Rep. Gr. 26 .
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es, in part or in w
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4 - Pin
❑ Removing. Refer to
l purpos
⇒ “5.2 Selector Lever Cable, Removing and Installing, through 02/2009”, page 64 .
❑ Do not lubricate
nf
ercia
or
5 - Locking Plate
m
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6 - Nut
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❑ 9 Nm
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7 - Gearshift Housing
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5. Selector Mechanism 63
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
8 - Adjusting Bolt
❑ 13 Nm
9 - Lock Washer
❑ Always replace after removing
10 - Lock Washer
❑ Always replace after removing
11 - Selector Lever Cable
❑ Do not grease the selector lever cable.
❑ Removing and installing. Refer to
⇒ “5.2 Selector Lever Cable, Removing and Installing, through 02/2009”, page 64 .
❑ Checking. Refer to ⇒ “5.5 Selector Lever Cable, Checking”, page 80 .
❑ Adjusting. Refer to ⇒ “5.6 Selector Lever Cable, Adjusting”, page 80 .
12 - Hex Nut with Collar
❑ 8 Nm
❑ Quantity: 4
pt
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Removing
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urposes, in part or in wh
t to the co
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Note
Use pliers to remove the lock washer -B- from the cable bracket.. Volkswag
Do not use a sharp-edged lever. This could damage theswselector
agen
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does
lever cable rubber grommet. by Volk not
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– Remove the lock washers -A and B-. The au lock washers must
t or
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later be replaced ss
when adjusting the selector lever cable.
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pt
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– Raise the vehicle.
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To remove the selector level cable or the selector mechanism, the
ility
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follows:
, is n
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Caution
es, in part or in w
t to the co
Risk of damaging the decoupling element.
rrectness of i
♦ Do not bend the decoupling element more than 10°.
l purpos
nform
mercia
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tio
– Loosen the nuts on the clamping sleeve -1- and then slide it
n in
or c
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5. Selector Mechanism 65
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
n AG. Volkswagen AG do
ks wage es n
– If equipped, remove nuts -1 and 2-, and remove Vol the rear tunnel ot g
by ua
brace. ris
ed ran
tee
tho or
– Disengage the center muffler and the au rear muffler from the re‐ ac
ss
taining loops -arrows- and tie them to the body for example
ce
e
nl
with a wire. Remove the exhaust system rear section, if nec‐
pt
du
an
essary.
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urposes, in part or in wh
t to the co
– Remove the underbody trim panel nuts -arrows-.
rrectne
– Remove the lock washers -2 and 3-.
s
– Lower the underbody trim panel on the inside just enough until
s o
cial p
f
the heat shield -1- for the center tunnel can be removed.
inform
mer
atio
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n
c
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t.
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The -shift housing- is pushed forward slightly on the selector lever
es, in part or in w
cable.
t to the co
rrectness of i
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5. Selector Mechanism 67
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
ce
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pt
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ab
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es, in part or in w
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– Insert the -screwdriver- from underneath while pushing the
l purpos
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For Clarity
AG. Volkswagen AG d
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es, in part or in w
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Remove the selector lever cable from the selector housing.
t. C rig
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pyri by
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Installing by c lksw
cted agen
Prote AG.
Do not lubricate the selector lever cable.
– Route the selector lever cable making sure it is without ten‐
sion. Install also into the cable bracket on the transmission. Do
not secure yet with the lock washers. Do not clip in the ball
head.
5. Selector Mechanism 69
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
n AG. Volkswagen AG do
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un
pt
an
d
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ab
– Install the selector lever cable into the selector mechanism.
ility
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– Insert the selector lever cable into the bracket and then insert
h re
the bolt through the eye from the top in the direction of
hol
t to the co
Install the locking plate only after having checked the selector
lever cable for ease of movement. Refer to
⇒ “5.5 Selector Lever Cable, Checking”, page 80 .
rrectness of i
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nform
mercia
at
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c
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or
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– Secure the selector lever cable with a new securing plate to
p by
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the cable bracket on the selector mechanism. Prote
cted AG.
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AG. Volkswagen AG d
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ab
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es, in part or in w
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– Install the selector housing. by c lksw
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5. Selector Mechanism 71
. Volkswage
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ k,sJetta
wage 2005 ➤ , Jetta 2011
n AG n AG d
oes ➤
not
ol
6-Speed Dual Clutch Transmission 02E d by - Edition 09.2015
V gu
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ris tee
ho
– Install the heat shield -1- under the selector
sa
ut
mechanism and or
ac
attach with the lock washers -2 and s3-.
ce
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nl
pt
du
– Attach the underbody trim panel to the body -arrows-.
an
itte
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erm
ab
– Install the exhaust system and align it without tension. Refer
ility
ot p
to ⇒ Rep. Gr. 26 .
wit
, is n
h re
– Install the tunnel braces under the exhaust system. Refer to
e
spec
es, in part or in w
t to the co
– Adjust the selector lever cable after installing. Refer to
⇒ “5.6 Selector Lever Cable, Adjusting”, page 80 .
rrectness of i
l purpos
nf
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orm
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n in
or c
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1 - Shift Cover with Handle
C py
ht. rig
rig ht
❑ Do not remove the han‐
py by
co Vo
by lksw
dle unnecessarily. Only Prote
cted AG.
agen
the cover must be un‐
clipped for the emergen‐
cy release. Refer to
⇒ “5.7 Selector Lever,
Emergency Release”,
page 82 .
❑ Pull the button past its
pressure point before
removing the handle.
Secure the button with a
cable tie or some suita‐
ble wire. This prevents
the locking button from
being pushed back into
knob accidentally.
❑ Selector lever handle,
Removing and instal‐
ling. Refer to
⇒ “5.8 Selector Lever
Handle, Removing and
Installing”, page 82 .
2 - Selector Mechanism with
Selector Lever and Selector
Lever Cable
❑ With integrated Selector
Lever Sensor System
Control Module - J587-
with Selector Lever -
E313- , Tiptronic Switch
- F189- , Selector Lever
Park Position Lock
Switch - F319- and Shift
Lock Solenoid - N110- .
❑ The selector lever cable
can only be replaced to‐
gether with the selector
mechanism
pt
du
ab
ility
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spec
es, in part or in w
Brief Description
t to the co
ti
thi
te
s
a
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priv
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or
Note
f
en
ng
t.
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op py
After installation, the selector lever cable must be checked for
t. C rig
gh ht
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ease of movement and adjusted. p by
co Vo
by lksw
cted agen
Prote AG.
Removing
5. Selector Mechanism 73
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
h
aut ra
ss c
ce
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nl
pt
du
an
itte
y li
– Remove the selector lever handle and disconnect the con‐
erm
ab
nector -2- from the cover while doing so. Refer to
ility
ot p
wit
, is n
82 .
h re
hol
spec
– Remove the center console. Refer to ⇒ Body Interior; Rep.
es, in part or in w
t to the co
– Disconnect the connector -1- from the selector mechanism to
the vehicle wiring harness.
rrectness of i
– Remove the air filter housing:
l purpos
nform
ercia
a
System; Air Filter Housing, Removing and Installing .
om
tion in
or c
thi
e
s
a
do
priv
cum
or
f
en
ng
Note
t.
yi Co
Cop py
t. rig
gh ht
Use pliers to remove the lock washer -B- from the cable bracket. pyri by
Vo
o
by c
Do not use a sharp-edged lever. This could damage the selector
lksw
cted agen
Prote
lever cable rubber grommet.
AG.
– Remove the lock washers -A and B-. The lock washers must
later be replaced when adjusting the selector lever cable.
– Raise the vehicle.
To remove the selector level cable or the selector mechanism, the
heat shield under the selector mechanism must be removed as
follows:
Caution
– Loosen the nuts on the clamping sleeve -1- and then slide it
toward the rear.
– Remove the front tunnel brace -arrows- from the underbody.
AG. Volkswagen AG d
agen oes
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– If necessary remove the exhaust system bracket from the
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nl
pt
du
subframe -arrows-.
an
itte
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erm
ab
– Tie up the front exhaust pipe.
ility
ot p
wit
, is n
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e
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– If equipped, remove nuts -1 and 2-, and remove the rear tunnel
nf
ercia
brace.
orm
m
atio
– Disengage the center muffler and the rear muffler from the re‐
om
n in
taining loops -arrows- and tie them to the body for example
or c
thi
te
sd
a
essary.
iv
o
r
rp
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o
m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.
Note
5. Selector Mechanism 75
AG. Volkswagen AG d
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jettaorise2005 ➤ , Jetta 2011 ➤ nte
eo
h
6-Speed Dual Clutch Transmission 02E - Edition
s aut
09.2015 ra
c
s
ce
e
nl
– Remove the nuts -arrows- in the vehicle interior.
pt
du
an
itte
y li
– Remove the bracket -A-, if equipped.
erm
ab
ility
ot p
– Remove the selector mechanism -B- with the selector lever
wit
is n
cable and selector housing downward.
h re
ol ,
e
spec
Installing
urposes, in part or in wh
t to the co
Install in reverse order of removal.
rrectne
Note
s
♦ Do not bend or kink the selector lever cable.
s o
cial p
f i
♦ Do not lubricate the selector lever cable.
nform
mer
atio
m
n
c
03/2009”, page 72 .
i
or
n thi
te
sd
iva
o
pr
cum
or
– Install the heat shield -1- under the selector mechanism and
f
en
ng
to ⇒ Rep. Gr. 26 .
– Install the tunnel braces under the exhaust system. Refer to
⇒ Body Exterior; Rep. Gr. 50 ; Tunnel Brace .
– Install the center console. Refer to ⇒ Body Interior; Rep. Gr.
68 ; Center Console .
– Install the selector lever handle. Refer to
⇒ “5.8 Selector Lever Handle, Removing and Installing”, page
82 .
– Adjust the selector lever cable. Refer to
⇒ “5.6 Selector Lever Cable, Adjusting”, page 80 .
– Check the selector mechanism. Refer to
⇒ “5.10 Selector Mechanism, Checking”, page 86 .
– Install the air filter housing:
♦ Gasoline engine. Refer to ⇒ Rep. Gr. 24 ; Air Filter; Air Filter
Housing, Removing and Installing .
♦ TDI engine. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection
System; Air Filter Housing, Removing and Installing .
an
itte
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ab
wit
is n
t to the co
rrectness o
cial p
f inform
mer
atio
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c
i
or
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pr
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for
en
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t.
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77
op Vo
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Prote
cted AG.
agen 5. Selector Mechanism
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
Note
Use pliers to remove the lock washer -B- from the cable bracket.
Do not use a sharp-edged lever. This could damage the selector
lever cable rubber grommet.
– Remove the lock washers -A and B-. The lock washers must
later be replaced when adjusting the selector lever cable.
– Raise the vehicle.
– Attach a longer cord to the end of the selector lever cable. The
cord is used to guide the selector lever cable between the tun‐
nel and the heat shield during installation.
n AG. Volkswagen AG do
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o ot g
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Cop py
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co lksw
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Prote AG.
Note
Installing
Install in reverse order of removal. Note the following:
A second technician is needed for threading the selector lever
cable from the passenger compartment into the engine compart‐
ment.
ce
e
nl
pt
du
an
⇒ “5.3 Overview - Selector Mechanism, Vehicles from
itte
y li
erm
03/2009”, page 72 .
ab
ility
ot p
wit
, is n
– Secure the cord that was involved when removing the selector
mechanism from the engine compartment on the end of the h re
hol
spec
selector lever cable.
es, in part or in w
t to the co
atio
om
four bolts.
thi
te
sd
iva
cu
68 ; Center Console .
o
m
f
en
ng
t.
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– Install the selector lever handle. Refer to . Cop py
⇒ “5.8 Selector Lever Handle, Removing and Installing”, page
t rig
gh ht
yri by
82 . cop Vo
by lksw
cted agen
Prote
– Adjust the selector lever cable. Refer to
AG.
5. Selector Mechanism 79
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
ce
e
nl
pt
du
an
– Move the selector lever from »P« to »S« and back to »P« sev‐
itte
y li
erm
eral times.
ab
ility
ot p
wit
, is n
h re
– Install the selector lever cable with new lock washers and the
hol
spec
»loosened« adjustment screw.
es, in part or in w
t to the co
– Adjust the selector lever cable. Refer to
⇒ “5.6 Selector Lever Cable, Adjusting”, page 80 .
rrectness of i
5.6 Selector Lever Cable, Adjusting
l purpos
a
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tio
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do
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t.
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♦ The selector lever cable itself or the selector mechanism was Cop py
removed and installed. ht. rig
rig ht
py by
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♦ The engine/transmission position was changed, for example,
by c lksw
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were installed without tension.
Prote AG.
Adjusting
– Move the selector lever into “P”.
AG. Volkswagen AG d
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nl
pt
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es, in part or in w
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– Push the lever »to the rear« -arrow-.
rrectness of i
“P” is in the Second Detent.
l purpos
Note
nform
ercia
a
om
t
ing lock is engaged). The front wheels must not turn together
ion in
c
in any direction.
or
thi
te
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or
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t.
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Cop py
– Install the selector lever cable with the loosened adjusting ht. rig
rig ht
screw -arrow- and the new lock washer -A and B-.
py by
co Vo
by lksw
cted agen
– Tap the handle on the selector lever back and forth gently but
Prote AG.
5. Selector Mechanism 81
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
AG. Volkswagen AG d
agen oes
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V gu
d by ara
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or eo
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aut ra
ss c
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un
pt
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erm
ab
ility
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t to the co
Installing
Brief Description
rrectness of i
Removing
m
ion
c
in t
or
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te
iva
do
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.
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nl
pt
du
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erm
ab
ility
ot p
wit
, is n
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hol
spec
Vehicle with Sleeve
es, in part or in w
t to the co
– Unclip the cover.
Disconnect the connector from the shift cover.
rrectness of i
Push the sleeve upward in direction of -arrow- to unlock the han‐
l purpos
dle.
nf
ercia
orm
m
atio
om
n in
or c
thi
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– Cut the clamp under the boot -arrow- with a side cutter. Cop py
t. rig
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All Handles p by
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– Remove the handle from the selector lever without pushing the Prote AG.
button.
Note
Do not push the button once the handle has been removed oth‐
erwise it will not be possible to install the handle again.
Installing
– Install in reverse order of removal while noting the following:
• The selector lever is in the “D” position.
5. Selector Mechanism 83
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
ce
e
nl
pt
du
an
⇒ “5.9 Button in Handle, Moving into Installation Position”,
itte
y li
erm
page 85 .
ab
ility
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Note
e
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spec
es, in part or in w
t to the co
the retainer just before installing.
rrectness of i
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Vehicle with Sleeve
m
atio
om
n in
– Install the handle all the way onto the selector lever and lock
or c
thi
it.
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Note
If the button stays in the handle after being pressed, this means
it was installed incorrectly. If this happens, remove the handle
again and move the button in the installation position again. Refer
to
⇒ “5.9 Button in Handle, Moving into Installation Position”,
page 85 . Then the handle can be installed again.
AG. Volkswagen AG d
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ab
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– With the button pressed and push the assembly fastener (with
wit
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the eye) -arrow- all the way in until it latches into the assembly
fastener. Then release the button. The button locks into the
hol
spec
t to the co
nform
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tion in
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priv
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85
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Prote
cted AG.
agen 5. Selector Mechanism
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
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spec
es, in part or in w
t to the co
rrectness of i
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nf
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– Push the small lever -1- for the pull rod into the groove -2- with
orm
a screwdriver. This pushes the button -3- into the installation
m
atio
m
position.
o
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♦ Push the lever into the groove and no farther. cted agen
Prote AG.
♦ Clip the handle trim back onto the selector mechanism only
after the handle is installed. This way it is possible to see if the
small lever engages into the pull rod when the button is push‐
ed.
ce
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nl
pt
du
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• If the brake pedal is not depressed:
y li
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The selector lever is locked and cannot be moved out of “P” when
ility
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the button is pressed. The shift lock solenoid blocks the selector
wit
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lever.
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hol
spec
• If the brake pedal is depressed:
es, in part or in w
t to the co
The shift lock solenoid releases the selector lever. It is possible
to select a gear.
rrectness of i
Selector Level in the “tiptronic” Position
l purpos
• Move the selector lever into the tiptronic gate:
The illuminated “D” symbol in the selector mechanism cover must
nform
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a
The transmission range display in the instrument cluster must
om
tio
change from “P R N D S” to “6 5 4 3 2 1” when the selector lever
n in
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Transmission Range Display p by
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Simultaneous lighting of all segments on the transmission range Prote AG.
display indicates the transmission is in emergency mode.
5. Selector Mechanism 87
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
pt
y li
erm
ab
h re
spec
though.
es, in part or in w
t to the co
at
om
in t
or
do
pr
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ng
t.
♦ or Hose Clamps - Up To 25 mm - 3094- (Quantity 2)
yi Co
Cop py
t. rig
♦ Transmission Support - Pins 29 - 3282/29-
gh ht
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by
♦ Engine and Gearbox Jack - VAS6931- Prote
cted AG.
agen
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pt
du
Note
an
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ab
To perform work sequence, the ground cable must be discon‐
ility
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nected from battery. Check if a coded radio is installed. If neces‐
wit
, is n
sary, obtain the anti-theft coding beforehand.
h re
e
hol
spec
es, in part or in w
– Disconnect the battery ground cable. Refer to ⇒ Electrical
t to the co
Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and
Connecting .
rrectness of i
– Remove the air filter housing.
l purpos
nform
ercia
a
om
tio
– Remove the battery and the battery tray. Refer to ⇒ Electrical
n in
or c
thi
te
s
stalling .
a
do
priv
cum
or
f
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ng
t.
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Cop py
t. rig
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Vo
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by c lksw
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Prote AG.
Note
Use pliers to remove the lock washer from the cable bracket. Do
not use a sharp-edged lever. This could damage the selector lev‐
er cable rubber grommet.
6. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010 89
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
Caution
pt
an
itte
y li
– Route the wires near the transmission cover upward and tie
erm
ab
ility
them up.
ot p
wit
, is n
– Remove all the upper bolts between the engine and the trans‐
h re
mission.
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
a
om
tion in
or c
thi
te
s
a
do
priv
cum
or
f
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
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rise nte
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pt
du
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ab
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Note
wit
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hol
spec
-arrow-.
t to the co
– Remove both filler pieces from the left and right fender upper
edges.
rrectness of i
– If there are hose and cable connections located near the en‐
l purpos
the engine.
a
om
tion in
or c
thi
te
s
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do
priv
cum
or
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
6. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010 91
AG. Volkswagen AG d
agen oes
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V gu
d by ar
Golf Variant
oris 2007 ➤ , Golf Variant 2010 ➤ , Jettaan2005
e
tee ➤ , Jetta 2011 ➤
h
6-Speed
aut Dual Clutch Transmission 02E - Edition 09.2015 or
ac
ss
ce
e
1.9L TDI Engine nl
pt
du
an
itte
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– Support the engine and transmission. Do not raise them.
erm
ab
ility
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♦ Engine Support Bridge - Engine Support 3 - 10-222A/3-
ol ,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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pr
cum
for
en
ng
2.0L TDI Engine - Jetta from MY 2005 and Golf Wagon from MY
2007
– Support the engine and transmission. Do not raise them.
♦ Engine Support Bridge - 10-222A-
♦ Engine Support Bridge - Engine Support 3 - 10-222A/3-
♦ Engine Support Bridge - Engine Support Feet - 10-222A/8-
♦ Engine Support - Bracket w/Spindle and Hook - 10-222A/10-
AG. Volkswagen AG d
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ab
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ol ,
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spec
urposes, in part or in wh
t to the co
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mer
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n
c
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♦ Engine Support Bridge - 10-222A-
Co
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♦ Engine Support Bridge - Engine Support Feet - 10-222A/8-
rig by
copy Vo
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Prote AG.
6. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010 93
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
pt
du
an
itte
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– Remove the heat shield above the right drive axle -arrows-, if
erm
ab
equipped.
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ot p
wit
, is n
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Caution
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spec
es, in part or in w
orm
m
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Prote AG.
ce
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un
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– Tie up the front exhaust pipe.
an
d
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ility
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spec
es, in part or in w
t to the co
rrectness of i
– Remove the pendulum support from the transmission.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
te
iva
do
pr
cum
r
fo
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ng
t.
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Cop py
t. rig
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by
cted
– Secure the subframe. Refer to ⇒ Suspension, Wheels, Steer‐
agen
Prote AG.
ing; Rep. Gr. 40 ; Subframe; Subframe, Securing .
Note
6. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010 95
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
pt
an
d
itte
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erm
ab
ility
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wit
, is n
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hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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te
iva
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pr
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t.
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Cop py
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rig ht
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by lksw
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Prote AG.
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pt
du
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the transmission.
erm
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transmission.
h re
ol ,
spec
– Secure both the other support elements to the transmission as
urposes, in part or in wh
shown.
t to the co
Note
rrectne
♦ Deviating from the illustration of the Adjusting Plate the front
s
transmission support is illustrated mounted to the transmission
s o
cial p
-arrow-.
f inform
mer
n
c
i
or
n thi
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sd
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pr
cum
for
t.
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op py
– Remove the remaining engine/transmission connecting bolts.
t. C rig
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pyri by
– Remove transmission from engine »while being careful of se‐
co Vo
by lksw
cted
lector lever cable« and lower the transmission.
agen
Prote AG.
Note
6. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010 97
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
Note
ce
e
pt
du
an
itte
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– Transmission pins (not splines) on the driveshaft must also be
erm
ab
lightly lubricated.
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wit
is n
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the transmission are correctly seated.
ol ,
e
spec
urposes, in part or in wh
t to the co
– Guide the selector lever cable into the cable bracket as soon
as possible.
rrectne
Check the selector lever cable when raising the transmission. Do
not fail to place it in the cable mounting bracket »early«.
ss o
Do not grease the selector lever cable.
cial p
f inform
Guide the engine and transmission together by hand until the en‐
mer
gine flange and transmission flange come into contact with one
atio
m
n
c
i
or
n thi
If they do not, »something is incorrect«!
te
sd
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pr
c
– Adjust the transmission mount until the engine and transmis‐
um
for
t.
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op
– Turn the crankshaft slightly if necessary.
C py
ht. rig
rig ht
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– Insert the transmission without pinching any lines.
co Vo
by lksw
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Prote AG.
– Attach the transmission to the engine. Transmission to engine
tightening specifications. Refer to
⇒ “6.3 Tightening Specifications”, page 100 .
Caution
WARNING
pt
an
itte
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spec
-B- must line up with the connector -A- as well as with the tab
t to the co
-C-.
– Connect the connector -A- carefully all the way and then turn
rrectne
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010 99
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
– Install the heat shield above the right drive axle, if equipped.
At the same time tighten the bolts -1- to 25 Nm.
– Install the subframe and steering gear. Refer to ⇒ Suspen‐ AG. Volkswagen AG d
sion, Wheels, Steering; Rep. Gr. 40 ; Subframe agen oes
olksw not
y V gu
b ara
– Attach the pendulum support to the transmission using new rise d
nte
bolts. Refer to ⇒ Rep. Gr. 10 . utho eo
ra
s a c
s
– Assemble the exhaust system and install the exhaust system
ce
e
nl
pt
du
an
itte
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– Install the lower section of the left front wheel housing liner.
erm
ab
Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner;
ility
ot p
wit
, is n
h re
e
spec
50 ; Noise Insulation .
es, in part or in w
t to the co
– Install the battery tray and the battery. Refer to ⇒ Electrical
Equipment; Rep. Gr. 27 ; Battery; Battery, Removing and In‐
stalling .
rrectness of i
– Install the air filter housing.
l purpos
nf
ercia
or
♦ Vehicles with a diesel engine. Refer to ⇒ Rep. Gr. 23 ; Diesel
m
m
atio
Direct Injection System; Air Filter Housing, Removing and In‐
om
n in
stalling .
or c
thi
te
sd
– Install the front wheels. Refer to ⇒ Suspension, Wheels,
iva
o
r
cu
o
m
cations .
f
en
ng
t.
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Cop py
t. rig
6.3 Tightening Specifications
gh ht
pyri by
Vo
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by
cted
Engines: 1.9L TDI; 2.0L TDI; 2.0L TFSI
agen
Prote AG.
Note
M12 - 80 Nm
AG. Volkswagen AG d
❑ When using the Insert ksw
agen oes
not
l
Tool - 18mm - T10179- : byV
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65 Nm. rised
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M10 - 40 Nm ss a ra
c
ce
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un
pt
an
d
itte
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erm
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ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
te
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pr
cum
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fo
en
ng
t.
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Cop py
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rig ht
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by lksw
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Prote AG.
Note
Pry the transmission bracket into the correct seat using a screw‐
driver while tightening the bolts -2-.
6. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010 101
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise n
Golf Variant 2007 ➤ , GolfthoVariant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011te➤
r eo
u ra
6-Speed Dual Clutch Transmission
ss a 02E - Edition 09.2015 c
ce
e
nl
pt
du
an
itte
7 Transmission, Removing and Instal‐
y li
erm
ab
ling, Jetta from MY 2011
ility
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wit
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⇒ “7.1 Transmission, Removing, Jetta MY 2011 with 2.0L 103 kW
e
hol
spec
Diesel”, page 102 .
es, in part or in w
t to the co
⇒ “7.2 Transmission, Installing, Jetta MY 2011 with 2.0L 103 kW
Diesel”, page 113 .
⇒ “7.3 Transmission, Removing, Jetta MY 11, 2.0L 147 kW Gas‐
rrectness of i
oline Engine”, page 115 .
l purpos
nf
ercia
o
⇒ “7.5 Tightening Specifications”, page 129 .
rm
m
atio
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Brief Description
o
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f
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t.
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The transmission is removed downward separately.
Co
Cop py
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»From above«:
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Vo
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by
The battery, air filter and starter are removed. The steering gear cted agen
Prote AG.
wiring harness is disconnected and »freed up«. This way it can
be lowered together with the subframe and the steering gear. En‐
gine and transmission are supported before the left subframe
mount is removed.
»From underneath«:
The -subframe-, with the -pendulum support-, with the
-steering gear- and with -both control arms- are removed togeth‐
er.
ce
le
un
pt
♦ Engine Support - Basic Set - T40091-
an
d
itte
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erm
ab
ility
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wit
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Removing
e
hol
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
nform
mercia
at
om
io
Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and
n
c
in t
r
Connecting .
o
his
te
iva
do
– Remove the engine cover. Refer to ⇒ Rep. Gr. 15 ; Cylinder
pr
cum
r
en
ng
t.
yi Co
– Remove the complete air filter housing. Refer to ⇒ Rep. Gr. . Cop py
23 ; Diesel Direct Injection System; Overview - Air Filter .
t rig
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Vo
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cted agen
– Remove the battery and the battery tray. Refer to ⇒ Electrical Prote AG.
Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and
Connecting .
Note
♦ Use pliers to remove the lock washer from the cable bracket.
Do not use a sharp-edged lever. Otherwise the selector lever
cable could get damaged.
♦ Remove the cable bracket -2- from the transmission, if nec‐
essary. Remove the bolts -1- and the lock washer -3-.
♦ Replace the bolts -1- and the lock washers.
♦ Bolt tightening specification -1- 20 Nm +90°.
AG. Volkswagen AG d
agen oes
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Caution by Vol not
gu
ara
d
rise nte
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Risk of damaging the selector lever acable.
ut
h
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♦ Remove the selector level cable from the cable bracket ce
le
un
pt
when lowering transmission. an
d
itte
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erm
wit
, is n
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hol
spec
t to the co
Note
rrectness of i
warm.
♦ Cover the coolant reservoir cap with a cloth and open it care‐
nform
ercia
at
om
ion
c
his
do
cum
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fo
t.
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plugs taken from for example the Engine Bung Set - Cop py
VAS6122- .
t. rig
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pyri by
Vo
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Prote AG.
Caution
– Remove the wires and bracket from the front of the transmis‐
sion cover -arrows- (two M6 nuts).
– Route the wires near the transmission cover upward and tie
them up.
– Remove all the upper bolts between the engine and the trans‐
mission. gen AG
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
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ion
c
in t
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do
pr
cum
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fo
en
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t.
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Cop py
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rig ht
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by lksw
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Prote AG.
AG. Volkswagen AG d
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d by ara
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aut ra
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un
pt
an
d
itte
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erm
ab
ility
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hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
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ion
c
in t
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do
pr
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t.
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Cop py
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One bolt is located inside the hole for the starter -arrow-. Use Prote AG.
Socket - Xzn 14 - T10061- to remove the bolt.
– Remove the plenum chamber cover. Refer to ⇒ Body Exterior;
Rep. Gr. 50 ; Plenum Chamber Cover; Plenum Chamber
Cover, Removing and Installing .
– Remove the bolts -arrows- for the left and right lock carrier
retaining brackets.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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h
ut
– Install the Engine Support Bridge - Engine Support
ss a 28 - ra
c
10-222A/28- and tighten the bolts to 8 Nm -arrows-.
ce
le
un
pt
an
d
itte
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Caution
erm
ab
ility
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A second technician is needed to mount the Engine Support
, is n
h re
Bridge on the vehicle to prevent the Engine Support Bridge
e
hol
spec
from tipping.
es, in part or in w
– If there are hose and cable connections located near the en‐ t to the co
gine lifting eyes for the Engine Support Bridge - 10-222A- ,
rrectness of i
– First slide the Moveable Joints -2- onto the Square Pipe from
the Engine Support Bridge - 10-222A- .
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T40091/1- - 6- from the front left and right through the Engine
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Support Bridge - Engine Support 28 - 10-222A/28- - 7- and
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place on each side of the Engine Support - Supplement Kit -
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Movable Joint - T40093/4- - 5-. by c lksw
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Prote AG.
– Slide the Engine Support - Basic Set - Rail with Holes -
T40091/2- - 4- with the Engine Support - Supplement Kit -
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10-222A/31-1-
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4 - Engine Support - Basic Set
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5 - Engine Support - Supple‐
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6 - Engine Support - Basic Set
- Square Pipe - T40091/1-
rrectness of i
7 - Engine Support Bridge - En‐
gine Support 28 - 10-222A/28-
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10-222A/28-2-
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Spindle - 10-222A/11-
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Caution
– Remove the bolts -11- and then remove the pendulum support
from the transmission.
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Cop py
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rig ht
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by lksw
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Prote AG.
– Remove the heat shield above the right drive axle -arrows-.
– Remove the drive axles from the transmission. Refer to ⇒
Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Re‐
moving and Installing .
AG. Volkswagen AG d
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– Move the left drive axle to the rear and secure it. Be careful
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not to damage the surface protection.
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Plate 42A - 3282/42A- points in the direction of travel.
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the transmission.
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transmission.
– Secure both the other support elements to the transmission as
rrectness of i
shown.
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Note
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♦ Deviating from the illustration of the Adjusting Plate the front
rm
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transmission support is illustrated mounted to the transmission
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-arrow-.
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The mounting elements on the “FWD” are identical.
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– Support the transmission by lifting it from underneath using the Cop py
Engine and Gearbox Jack - VAS6931- . ht. rig
rig ht
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The transmission is disconnected from the engine in this position.
by lksw
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– Remove the remaining engine/transmission connecting bolts.
– Remove transmission from engine »while being careful of se‐
lector lever cable« and lower the transmission.
Note
Note
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♦ Always replace the needle bearing -arrow-oriafter
sed
separating the nte
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♦ If the needle bearing in the crankshaft is damaged, the gears
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– Replace the needle bearing in the crankshaft. Refer to ⇒ Rep.
ility
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– Transmission pins (not splines) on the driveshaft must also be
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lightly lubricated.
es, in part or in w
t to the co
– Make sure both alignment sleeves between the engine and
the transmission are correctly seated.
– Make sure the intermediate plate fits correctly.
rrectness of i
– Guide the selector lever cable into the cable bracket as soon
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as possible.
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Check the selector lever cable when raising the transmission. Do
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Do not grease the selector lever cable.
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Guide the engine and transmission together by hand until the en‐ his
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gine flange and transmission flange come into contact with one
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If they do not, »something is incorrect«!
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– Adjust the transmission mount until the engine and transmis‐
rig ht
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sion »are in alignment«. by c lksw
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– Turn the crankshaft slightly if necessary.
– Insert the transmission without pinching any lines.
– Attach the transmission to the engine. Transmission to engine
tightening specifications. Refer to
⇒ “7.5 Tightening Specifications”, page 129 .
Caution
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– Remove the Engine Support Bridge - 10-222A- .
erm
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ility
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-B- must line up with the connector -A- as well as with the tab
-C-.
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– Connect the connector -A- carefully all the way and then turn
the lock »clockwise« in the direction of -arrow-.
nf
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– Install the heat shield over the right drive axle. Refer to ⇒
t
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t.
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– Install the subframe and steering gear. Refer to ⇒ Suspen‐ C py
t. rig
sion, Wheels, Steering; Rep. Gr. 40 ; Subframe . gh ht
pyri by
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es, in part or in w
t to the co
– Selector lever cable lock washers -arrows- must be replaced.
rrectness of i
– Always adjust the selector lever cable. Refer to
l purpos
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Gr. 19 .
orm
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– Assemble the exhaust system and then attach the exhaust
om
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system bracket to the subframe. Refer to ⇒ Rep. Gr. 26 .
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Cover, Removing and Installing .
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Cop py
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– Install the bolts -arrows- for the left and right lock carrier re‐ p by
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taining brackets to the tightening specification. Refer to ⇒
lksw
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Prote
Body Exterior; Rep. Gr. 50 ; Lock Carrier; Lock Carrier - At‐
AG.
tachments .
– Install the battery tray and the battery. Refer to ⇒ Electrical
Equipment; Rep. Gr. 27 ; Battery; Battery, Removing and In‐
stalling .
– Install the air filter. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct
Injection System; Overview - Air Filter .
– Connect the battery and follow the steps after connecting the
battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery;
Battery, Disconnecting and Connecting .
– Install the engine cover. Refer to ⇒ Rep. Gr. 15 ; Cylinder
Head; Engine Cover, Removing and Installing .
– Install the left front housing liner. Refer to ⇒ Body Exterior;
Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel Housing Lin‐
er, Removing and Installing .
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.
50 ; Noise Insulation .
– Install the front wheels. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 44 ; Wheel Installation Tightening Specifi‐
cations .
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Installing the Locating Pins - T10096- and Subframe Locking Pin
ility
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urposes, in part or in wh
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♦ Transmission Support - Mounting Plate 42A - 3282/42A-
rrectne
♦ Transmission Support - Pins 29 - 3282/29-
♦ Torque Wrench 1331 5-50Nm - VAG1331- ss o
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♦ Engine Support - Basic Set - T40091-
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♦ Engine Support - Supplement Kit - T40093A- co Vo
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♦ Engine Bung Set - VAS6122-
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To perform work sequence, the ground cable must be discon‐
ility
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nected from battery. Check if a coded radio is installed. If neces‐
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sary, obtain the anti-theft coding beforehand.
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– Disconnect the battery ground cable. Refer to ⇒ Electrical es, in part or in w
t to the co
Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and
Connecting .
rrectness of i
– Remove the engine cover. Refer to ⇒ Rep. Gr. 15 ; Cylinder
Head; Engine Cover, Removing and Installing .
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Cop py
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by c lksw
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Prote AG.
Note
♦ Use pliers to remove the lock washer from the cable bracket.
Do not use a sharp-edged lever. Otherwise the selector lever
cable could get damaged.
♦ Remove the cable bracket -2- from the transmission, if nec‐
n AG. Volkswagen AG do
essary. Remove the bolts -1- and the lock washer -3-. lkswage es n
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♦ Replace the bolts -1- and the lock washers. d b ran
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♦ Bolt tightening specification -1- 20 Nm +90°. au ac
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♦ Remove the selector level cable from the cable bracket
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when lowering transmission.
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t to the co
♦ Do not bend or kink the selector lever cable.
rrectness of i
– Place a lint-free cloth on to transmission fluid cooler and trans‐
mission to absorb escaping coolant.
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Note
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♦ Cover the coolant reservoir cap with a cloth and open it care‐
do
pr
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fully before removing the coolant hoses.
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t.
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Cop py
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– Clamp the coolant hoses with Hose Clamps - Up To 25mm -
t
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3094- or Hose Clamps - Up To 40mm - 3093- and remove the cop Vo
by lksw
hoses from the transmission fluid cooler. cted agen
Prote AG.
Caution
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– Remove the wires and bracket from the front of the transmis‐
itte
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sion cover -arrows- (two M6 nuts).
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ility
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– Route the wires near the transmission cover upward and tie
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them up.
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spec
– Remove all the upper bolts between the engine and the trans‐
es, in part or in w
mission.
t to the co
rrectness of i
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nform
ercia
at
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ion
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in t
or
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pr
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t.
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Cop py
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ility
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t to the co
rrectness of i
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at
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Cop py
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rig ht
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by lksw
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Prote AG.
One bolt is located inside the hole for the starter -arrow-. Use
Socket - Xzn 14 - T10061- to remove the bolt.
– Remove the plenum chamber cover. Refer to ⇒ Body Exterior;
Rep. Gr. 50 ; Plenum Chamber Cover; Plenum Chamber
Cover, Removing and Installing .
– Remove the bolts -arrows- for the left and right lock carrier
retaining brackets.
AG. Volkswagen AG d
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– Remove the lower mounts on the Engine Support Bridge - En‐
ility
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28-2- .
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es, in part or in w
t to the co
bridge on the lock carrier from the Engine Support Bridge -
Engine Support 28-2 - 10-222A/28-2- .
rrectness of i
• Use the bolts present in the Engine Support Bridge - Engine
Support 28-2 - 10-222A/28-2- for attaching the Engine Support
l purpos
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ion
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Cop py
– Install the Engine Support Bridge - Engine Support 28 -
t. rig
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10-222A/28- and tighten the bolts to 8 Nm -arrows-.
p by
co Vo
by lksw
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Prote AG.
Caution
– If there are hose and cable connections located near the en‐
gine lifting eyes for the Engine Support Bridge - 10-222A- ,
these must now be removed.
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10-222A/31-2-
nl
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2 - Engine Support - Basic Set
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- Moveable Joint - T40091/3-
ility
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3 - Engine Support Bridge - En‐
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gine Support 31 - Adapter 1 -
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hol
spec
10-222A/31-1-
es, in part or in w
t to the co
4 - Engine Support - Supple‐
ment Kit - Movable Joint -
T40093/4-
rrectness of i
5 - Engine Support - Basic Set
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with Engine Support Bridge -
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Engine Support 28-2 -
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10-222A/28-2-
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- Rail with Holes - T40091/2-
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Risk of damaging the decoupling element.
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♦ Do not bend the decoupling element more than 10°.
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♦ Do not load the decoupling element.
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spec
es, in part or in w
t to the co
– Separate the exhaust system at the clamping sleeve and re‐
rrectness of i
move the bracket from the subframe -arrows-. Refer to ⇒ Rep.
l purpos
Gr. 26 .
– Tie up the front exhaust pipe.
nform
mercia
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or
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do
pr
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fo
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t.
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Cop py
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– Remove the bolts -11- and then remove the pendulum support cop Vo
by lksw
from the transmission.
cted agen
Prote AG.
Note
– Remove the heat shield above the right drive axle -arrows-.
– Remove the drive axles from the transmission. Refer to ⇒
Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Re‐
moving and Installing .
AG. Volkswagen AG d
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– There may be a small cover plateut on the plate between the
ho eo
ra
engine and transmission above
s the right flange shaft. Remove
s a c
this cover plate -A-, if equipped.
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pt
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urposes, in part or in wh
t to the co
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en
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Cop py
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rig ht
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AG. Volkswagen AG d
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Cop py
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The transmission is disconnected from the engine in this position.
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– Remove the remaining engine/transmission connecting bolts.
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– Remove transmission from engine »while being careful of se‐
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Note
Pay attention to all of the lines when lowering the transmission. rrectness of i
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Note
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– Guide the selector lever cable into the cable bracket as soon
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spec
as possible.
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t to the co
Guide the engine and transmission together by hand until the en‐
l purpos
gine flange and transmission flange come into contact with one
another all around.
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n in
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– Attach the transmission to the engine. Transmission to engine
C py
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tightening specifications. Refer to
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pyri by
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⇒ “7.5 Tightening Specifications”, page 129 .
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Caution
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the left and right subframe mount bolts are tightened to the
itte
tightening specification. y li
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ility
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– Remove the Engine Support Bridge - 10-222A- .
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t to the co
– Connect the connector -A- carefully all the way and then turn
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ti
thi
s
a
en
ng
t.
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– Install the heat shield over the right drive axle. Refer to ⇒
Co
op py
Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles,
t. C rig
gh ht
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Overview and Servicing; Drive Axle Heat Shield . p by
co Vo
by lksw
cted agen
– Install the subframe and steering gear. Refer to ⇒ Suspen‐ Prote AG.
sion, Wheels, Steering; Rep. Gr. 40 ; Subframe .
– Install the bolts -arrows- for the left and right lock carrier re‐
taining brackets to the tightening specification. Refer to ⇒
Body Exterior; Rep. Gr. 50 ; Lock Carrier; Lock Carrier - At‐
tachments .
– Install the battery tray and Athe
G. Vobattery.
lkswagen Refer
AG do to ⇒ Electrical
agen
Equipment; Rep.VoGr. lksw 27 ; Battery; Battery, Removing
es n
ot g and In‐
stalling . ed by ua
rais nte
or e
– Install the
au air filter. Refer to ⇒ Rep. Gr. 24 ; Air Filter; Air rFilter
th o
ac
Housing,
ss Removing and Installing .
ce
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nl
pt
– Connect the battery and follow the steps after connecting the
du
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itte
ab
wit
h re
spec
t to the co
50 ; Noise Insulation .
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cations .
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orm
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atio
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n in
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f
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ng
t.
Note
yi Co
Cop py
t. rig
gh ht
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The -arrows- point to the alignment sleeves. p by
co Vo
by lksw
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Prote AG.
M12 - 80 Nm
❑ When using the Insert
Tool - 18 mm - T10179- :
65 Nm.
M10 - 40 Nm
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pt
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ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
m
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n in
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f
t.
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op py
– Tighten the transmission bracket -A- to the transmission to 40 t. C rig
gh ht
Nm + 90° using the bolts -1-. yri
p by
co Vo
by lksw
cted
– Tighten the bolts -2- to 60 Nm + 90°.
agen
Prote AG.
Note
Pry the transmission bracket into the correct seat using a screw‐
driver while tightening the bolts -2-.
Note
Transmission, Transporting
– Use appropriate lifting tools, for example part of Engine Sling
- 2024A- and the Engine/Gearbox Support Shackle - 10-222A/
12- (not illustrated).
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un
pt
an
d
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erm
ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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c
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pr
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Note
Removing
– Move the selector lever into »P«.
– Remove the air filter housing.
♦ Vehicles with a gasoline engine. Refer to ⇒ Rep. Gr. 24 ; Air
Filter; Air Filter Housing, Removing and Installing .
G. Volkswage nA n AG d
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♦ Vehicles with a diesel engine. Refer to V⇒
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⇒ “9.2 Fluid Level, Checking and Filling”, page 133 .
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9.2 Fluid Level, Checking and Filling
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Note the following information:
♦ Use the DSG® transmission fluid available as a replacement
part. Refer to the Parts Catalog .
♦ It is necessary to use the Oil Filler - Adapter 6 - VAS6262/6-
on some oil containers.
♦ It may be necessary to shorten the bleed pipe on the Oil Filler
- VAS6262A- . Refer to ⇒ page 134 .
Shorten the Bleed Pipe on the Adapter For Oil Filling - VAS6262A-
as Follows:
– Shorten the bleed pipe to dimension -a-. This assures the pipe
on the Adapter For Oil Filling - VAS6262A- will not touch the
bottom on some oil containers.
Dimension -a- = 210 mm
Note
Dimension -a- is measured starting from the shaft (the green sur‐
face) on the Oil Filler - VAS6262A- .
– Make a mark on the bleed pipe, dimension -a-, and cut it, with
for example the Brake Line Tool Kit - Pipe Cutter -
VAS6056/2- .
– Clean the Oil Filler - VAS6262A- .
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Checking
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Let the transmission cool down if the oil temperature is higher than
do
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The engine is idling and the selector lever is in “P”. C py
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Install the oil drain plug with new gasket and tighten.
Drain Plug Tightening Specification: 45 Nm
Procedure
– Follow the rules for clean working conditions when working on
the transmission.
– Only use the DSG® transmission fluid available as a replace‐
ment part. Other oils can cause malfunctions or transmission
failure.
WARNING
Note
WARNING
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9. Transmission Fluid and Transmission Fluid Filter
AG.
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
– Remove the overflow pipe -arrow- and let the fluid drain.
About 5 liters (5.28 qts) of oil will drain. wagen AG. Volkswagen AG doe
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♦ Transmission Support - aut ra
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♦ Torque Wrench 1331
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5-50Nm - VAG1331-
♦ Torque Wrench 1332
40-200Nm - VAG1332-
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♦ Engine and Gearbox Jack -
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35 – Gears, Shafts
1 No Repairs to Gears and Shafts
AG. Volkswagen AG d
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144
AG.
Rep. Gr.35 - Gears, Shafts
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
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AG. Volkswagen AG d
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Do not removerised all the bolts in the left and right flange
ara
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inside uthe
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page 148 .
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⇒ “1.3 Right Flange
s
Seal, Replacing”,
f in
page 148 .
form
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❑ 20 Nm
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Note
After this, the vehicle must not stand on the ground. Refer to ⇒
Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Re‐
moving and Installing . swa
gen AG
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does
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– Remove the left front wheel. orise nte
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th
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– Remove the noise insulation.
ss Refer to ⇒ Body Exterior; Rep. c
Gr. 50 ; Noise Insulation .
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– Remove the lower section of the left front wheel housing liner.
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– Remove the flange seal using the Slide Hammer Set - VW771-
rrectness of i
and Slide Hammer Set - Hook - VW771/37- .
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Installing
– Lightly oil the new gasket on the outer edge.
nform
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lip halfway with Sealing Grease - G 052 128- -arrow-.
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– Install the left drive axle. Refer to ⇒ Suspension, Wheels,
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– Install the left front housing liner. Refer to ⇒ Body Exterior;
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– Install the left wheel. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 44 ; Wheel Installation Tightening Specifica‐
tions .
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– Check the fluid level and fill if necessary. Refer to
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50 ; Noise Insulation .
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Tightening Specifications
on
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♦ Refer to
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⇒ “1.1 Component Location Overview - Seals”, page 145 .
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1.3 Right Flange Shaft or Stub Shaft Seal,
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Continuation for All Vehicles erm
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– Fill the space on the new seal between the sealing and dust
lip halfway with Sealing Grease - G 052 128- -arrow-.
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2 Special Tools
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40-200Nm - VAG1332-
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3 Revision History
DRUCK NUMBER: MEX5R006621
Fac‐ Edit Job Fee Notes Quality
tory Edi‐ Type dba Checke
Edi‐ tion ck d By
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08/2 Lo‐ 959 Fixed Metta Data to add Gary R
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Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.
•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
. Volkswagen AG
are made applicable to earlier models. Therefore, part numbers gen AGin this manual
alisted dare
oes for reference only. Always
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check with your authorized Volkswagen retailer parts department
by V for the latest information. gu
a
ed ran
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tho
•= Any time the battery has been disconnected on anau automatic transmission vehicle, it will be necessaryor
ac to
ss
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
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•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
y li
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a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
ility
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vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
wit
, is n
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•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
hol
spec
es, in part or in w
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
t to the co
become inoperable, even if the correct code is used in a later attempt.
•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
rrectness of i
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
l purpos
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
nform
ercia
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
m
at
being fully alert.
om
ion
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•=
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Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
t
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•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
en
ng
i t.
goggles, gloves and other protective clothing whenever the job requires working with harmful substances. Co
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•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near py by
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machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe Prote
cted AG.
agen
injury could result.
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.
•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
crushed by heavy parts.
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
AG. Volkswagen AG d
replacement parts meeting
swagen Volkswagen specifications.
oes Makeshift tools, parts and procedures will not make good
olk not
repairs. byV gu
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•= Catch draining
fuel, oil or brake fluid in suitable
ss
a containers.r aDo
not use empty food or beverage containers that
c
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
ce
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nl
pt
du
once, but do not store the oily rags, which can ignite and burn spontaneously.
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itte
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•=
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Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
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fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
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•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
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ignited, it will ignite gas trapped in the cells and cause the battery to explode.
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•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
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•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
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trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
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•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
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•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
Page 2 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
tire from the rim before attempting any repair.
•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
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Page 3 of 3
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All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
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Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
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retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
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