Dis-/assembly instruction

VAG DSG6 02E Mechatronic

Brand VAG

Model DQ250

Product Mechatronic

Version 1.1

Document code P0051.03.01

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Content

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

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

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

4. Basic setting ...........................................................................Fout! Bladwijzer niet gedefinieerd.

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

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1. Required Tools

Required Tools Measurement

Ratchet -

Cap 10

Cap 24

Flat screwdriver -

Hex key 8

Hex key 14

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 14) and then remove the overflow pipe (hex 8) 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))

4.5 Go to group 060 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 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)

4.7 Go to group 062 and press [Go!] Activate basic settings [ON/OFF/Next]

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

4.9 Go to group 067 and press [Go!] Activate basic settings [ON/OFF/Next]

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Step Action (Value reset (gear safety function))

4.10 Go to group 068 and press [Go!]

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))

4.13 Go to group 065 and press [Go!]

4.14 Activate basic settings [ON/OFF/Next]

4.15 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 065 are done.

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

4.19 Go to group 069 and press [Go!]

4.20 Activate basic settings [ON/OFF/Next]

4.21 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 069 are done.

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

4.16 Go to group 063 and press [Go!]

4.17 Activate basic settings [ON/OFF/Next]

4.18 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 063 are done.

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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.