Dis-Assembly Instruction DSG6

Dis-/assembly instruction VAG DSG6 02E Mechatronic

Brand VAG

Model DQ250

Product Mechatronic

Version 1.0

Document code P0051.03.01

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Content

1. Required Tools .................................................................................................................3

2. Disassembly ....................................................................................................................4

3. Assembly instruction .......................................................................................................8

4. Basic settings with VCDS ...............................................................................................11

5. Test drive.......................................................................................................................15

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1. Required Tools

Required Tools Measurement

Ratchet -

Cap 10mm

Cap 24mm

Flat screwdriver -

Hex key 8mm

Hex key 14mm

Torx head 30

Oil drip tray Min. 10L

Torque wrench with a range of at least 5 to 35Nm.

Special VW tool to fill the gearbox with oil (VAS 6262).

Tip:

To create more room during dis-/assembly it is possible to remove

the engine mount under the engine block. When this is gone it will

be possible to pull the engine block to the rear and thus create more

room in front.

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2. Disassembly

Step Action

2.1 Turn the ignition off

2.2 See if there is a radio with radio

code, and check the radio code.

2.3 When the ignition is off,

disconnect the ground cable

from the battery.

2.4 Turn the bayonet fitting of the

Mechatronic connector counter

clockwise and pull the plug.

2.5 Tighten the bolts -2- of holder -1-

on the oil sump and remove the

holder from the oil sump.

2.6 Place an oil drip tray under the

transmission.

Step Action

2.7 Unscrew the oil plug -B- (hex

14mm) and then remove the

overflow pipe (hex 8mm) behind

the drain plug. Drain the oil.

2.8 When the gearbox is empty,

mount the overflow pipe (6Nm)

and then the oil plug -B- again,

specified torque 35Nm.

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Step Action

2.9 Loosen the bolts (torx

30) of the cover on

the side of the

gearbox. Remove the

cover cap.

Step Action

2.10 Loosen the bolts of

the oil sump in

diagonal sequence

(torx 30).

2.11 Remove the oil sump

and rubber packing.

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Step Action

2.12 Disconnect the 4-pin

connector (sensor G182 and

G502).

Step Action

2.13 Remove the bolts from the

Mechatronic in specified

order.

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Step Action

2.14 Carefully pull the

Mechatronic away

from the gearbox

housing. While doing

so, pay close attention

to the long sensor arm

below the oil pump.

This is very vulnerable.

Step Action

2.15 Check the

Mechatronic for

visible damage. If

damaged, please

report this when filling

out the

Remanufacture Order

Form which is sent

along with the

Mechatronic to

ACtronics.

2.16 Place the Mechatronic

in ACtronics’ transport

box. Again, be careful

with the long sensor

arm.

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3. Assembly instruction

Step Action

3.1 Carefully place the Mechatronic

in the gearbox housing. Pay

attention to the long sensor

arm, which must be placed into

the housing as pictured.

Step Action

3.2 Mount the bolts of the

Mechatronic in the order

specified, specified torque 5Nm

+ 90⁰ (¼ turn).

3.3 Mount the 4-pin connector

(G182 and G502).

3.4 Place the oil sump and mount

the bolts in diagonal sequence,

specified torque 10 Nm.

3.5 Place the cover cap of the oil

pump and mount the bolts in

diagonal sequence, specified

torque 8Nm.

3.6 Mount the holder on the oil

sump.

3.7 Connect the ground cable. Do

not start the engine!

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Change oil filter

Step Action

3.8 Selector lever in position P

3.9 Remove air filter

3.10 Remove battery and battery

support

Recommendation:

- A residual amount of oil will remain in

the oil filter. This will leak when

removing the oil filer.

- Before removing the oil filter, cover the

surrounding area with absorbent cloths.

3.11 Loosen filter case -arrow- about

7 rev. to begin with.

3.12 Wait approx. 10 seconds so that

the oil from the filter case can

flow back into the gearbox.

3.13 Now the filter case and oil filter

can be removed.

Step Action

Recommendation:

Clean the oil-polluted areas on the

gearbox thoroughly.

3.14 Place the new oil filter with

collar -arrow- downwards.

3.15 Insert and tighten the filter

case (with 20Nm).

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Fill gearbox with oil

Stap Actie

3.16 Only use the specified oil to fill the gearbox (set VAS6262).

3.17 Unscrew the drain plug, and check if the overflow pipe is present.

3.18 Mount the adapter -A- steadily in the drain hole.

3.19 Fill the gearbox with the specified amount of oil.

3.20 Remove the adapter and fit the drain plug.

3.21 Start the engine, keep the brake pedal pressed in and select every gear with

the selector lever fora bout 3 seconds. Put the gear selector lever back into

position P. Do not turn the engine off.

3.22 Disassemble the drain plug again, at a gearbox temperature of 35⁰C to

45⁰C. For gearbox temperature, see measuring block, group 019 (VCDS).

The gearbox will run empty, until the overflow pipe, and wait until it drips.

The oil level is now up to par.

3.23 Fit the drain plug, specified torque 35Nm.

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4. Basic settings with VCDS

NOTE: Make sure that the following

steps are taken in specified order,

followed by the test drive.

Conditions:

Oil temperature 30 to 100 degrees, see Measuring Blocks, group 019 .

Put the gear selector lever in position P.

Turn the ignition on.

Start the engine and let it idle for at least 1 minute.

Press the brake pedal (applies to the whole procedure).

Do not use the gas pedal.

Step Action (Transmission tolerances calibration)

4.1 Start VCDS

4.2 Select [02 - Transmission]

4.3 Select [Basic Settings - 04]

4.4 Go to group 061 and press [Go!]

Wait until the numbers have stopped moving, and then the

gearbox will also stop making sounds. At the top of the screen

it will say “ON” instead of “OFF”. Now the basic settings for

group 061 are done (this can take up to a minute).

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Step Action (Transmission tolerances (synchronization point))


Wait until the numbers have stopped moving, and then the

gearbox will also stop making sounds. At the top of the screen

it will say “ON” instead of “OFF”. Now the basic settings for

group 060 are done (this can take up to a minute).

Step Action (Gear adaption)

4.6 Control Module Software version < 0800 (circled in the

picture below)


Activate basic settings [ON/OFF/Next]

4.8 Control Module Software Version> = 0800 : (circled in the

picture below)


Activate basic settings [ON/OFF/Next]

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Step Action (Value reset (gear safety function))


4.11 Activate basic settings [ON/OFF/Next]

4.12 Wait until the numbers have stopped moving, and then the gearbox

will also stop making sounds. At the top of the screen it will say “ON”

instead of “OFF”. Now the basic settings for group 068 are done.

Step Action (Value reset (pressure adaptation))






Step Action (Value reset (ESP and cruise control installation)






Step Action (Value reset (steering wheel installation tiptronic))






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Step Action (basic settings)

4.22 [Done , Go Back] Ignition off , wait 10 seconds and turn it

back on.

4.23 [Error Codes - 02] Check and delete error codes after

successful test.

4.24 [Close Controller , Go Back - 06] Finally, do the test drive.

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5. Test drive

Conditions:

Oil temperature 30 to 100 degrees, see Measuring Blocks, group 019 .

Don’t use the Cruise Control.

Step Action (Test drive)

5.1 Drive in Tiptronic mode from standstill until 6th

gear. Make sure

to drive for at least 5 minutes in 4th

or 6th gear, and an

additional 5 minutes in 3rd or 5th gear. Also switch gears

between 1200 and 3500 rpm (this is necessary for the clutch

calibration).

Put the gear selector in “D” and hit the brakes fast, followed by a

(full throttle) acceleration (this is necessary for the oil return line

check) . Make sure that the gearbox switches gears while driving

slow, and check for leakage from the gearbox.

NOTE 1:

If the test drive cannot be performed immediately, or exactly as

described, the remaining adjustments will take place

automatically during “normal” driving.

NOTE 2:

For some modules [ON/OFF/Next] does not work. If an error

occurs when pressing the button, or if the status of the basic

settings do not turn on, just let the selected group finish the

procedure on its own.

It is normal that the gearbox makes noise while performing the

basic settings/adaptation. Therefore, do not terminate the basic

settings prematurely.

Documents

Dis-Assembly Instruction DSG6