VOLKSWAGEN JETTA 2011 (06) PDF MANUAL

FREE ENGLISH VOLKSWAGEN JETTA 2011 (06) PDF USER GUIDE

FREE ENGLISH VOLKSWAGEN JETTA 2011 (06) PDF USER MANUAL

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FREE ENGLISH VOLKSWAGEN JETTA 2011 (06) PDF OWNER MANUAL

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FREE ENGLISH VOLKSWAGEN JETTA 2011 (06) PDF REFERENCE MANUAL

FREE ENGLISH VOLKSWAGEN JETTA 2011 (06) PDF INSTRUCTION MANUAL

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VOLKSWAGEN JETTA 2011 (06) PDF SUMMARY:

What normal basic safety precautions should be observed when working on motor vehicles?

The normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

What should you do before beginning work on electrical components?

Before beginning work on electrical components, touch an earthed object, for example a water pipe or lifting platform.

What should you be aware of regarding dirt and the gearbox?

Always make sure that no dirt can enter an »open« gearbox. In particular, dirt entering an »exposed« mechatronic unit for dual clutch gearbox -J743- and/or oil pump can lead to gearbox failure.

What should you do if gearbox covers have been unbolted or the gearbox has no fluid?

If gearbox covers have been unbolted or gearbox has no fluid, do not run engine or tow vehicle.

What should you do before loosening bolts?

First thoroughly clean connecting points and surrounding areas and then loosen bolts.

What should you ensure when installing the gearbox?

When installing the gearbox, ensure that dowel sleeves between the engine and gearbox are correctly located.

What should you do with removed parts?

Place removed parts on a clean surface. Cover parts to prevent soiling. Use plastic sheeting and paper. Use lint-free cloths only!

What kind of parts should you install?

Install only clean parts; do not remove Genuine parts from packaging until immediately before installing.

What should you do if repair work cannot be performed immediately?

If repair work cannot be performed immediately, carefully cover or seal components.

What should you do with O-rings, seals, and gaskets?

Renew O-rings, seals and gaskets.

What should you coat radial oil seals with before installing?

Before installing a radial oil seal, coat sealing lips and area between these with sealing grease -G 052 128- and outer circumference with dual clutch gearbox oil.

What kind of lubricant should you use?

Only use dual clutch gearbox oil. Other lubricants will cause problems in function.

Which side of the radial oil seal should face the oil?

Open side of radial oil seal faces oil.

What should you do after installing a radial oil seal?

After installation, change the oil and adjust the oil level at the same time.

What should you do with securing bolts and nuts for covers and housings?

Loosen and tighten securing bolts and nuts for covers and housings diagonally.

What is specified for torque settings?

Torque settings are specified for unoiled bolts and nuts.

What should you do with threads of bolts secured with locking fluid?

Threads of bolts secured with locking fluid must be cleaned with a wire brush. Then insert bolts with locking fluid -AMV 185 101 A1-.

What should you do with threaded holes into which self-locking bolts are to be screwed?

All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid using a thread chaser. Otherwise there is a danger of bolts shearing when subsequently being removed.

What should you do with self-locking bolts and nuts?

Always renew self-locking bolts and nuts.

What should you do if you have received an electrical shock when touching a metal object?

Before beginning work on electrical components, touch an earthed object, for example a water pipe or lifting platform. Please do not grip plug contacts directly.

What should you do before making repairs?

Before making repairs, determine the cause of the fault as precisely as possible with the aid of “guided fault finding”. Fault finding is performed with the vehicle diagnostic tester.

How should you plan fault finding?

Try to plan the fault search sensibly. Be aware »what sort of problem« is on hand and which means of fault finding are available. Finding a fault without a thought-out search would be -magic- and does not lead to success.

What should you check first when planning fault finding?

Therefore, first check Technical Solutions to see if a solution to the problem is listed.

Who can you contact for fault finding help?

It is also possible to contact your TSC or the importer in your country. Make use of this possibility! This will save time, work and expenses.

What should you have on hand when calling your importer or the TSC?

When calling your importer or the ⇒ TSC, have a diagnosis log on hand.

What should you check if the touch function does not work/there is no gear change?

Check securing clip on cable support bracket of selector lever cable on top of gearbox. In particular, clip -B- must never be reused. Due to the loss of its »own tension«, this clip -B- may go lost.

What should you do if there is inadequate power transfer, possibly insufficient fluid?

First click here. Top up fluid only when it has been ascertained that fluid has escaped. Anything else is »expensive fun« which will not help.

What should you do if no faults have been saved?

In this case, the solution depends on you. Experience shows that »faults« attributed to the gearbox often are caused by other components or assemblies. It has occurred in the past that poor shifting behaviour was due to insufficient air intake of the engine. Don’t make the same sort of mistakes. Only after such faults have been excluded can one work meaningfully with the VW tester.

What should you do if faults have been saved?

First consider what the saved faults indicate. The VW testers offer Guided fault finding. Properly used, Guided fault finding will locate the sources of many faults.

What should you do if there are faults “not caused by the gearbox?”

In such a case, under no circumstances should the mechatronic unit for dual clutch gearbox -J743- be removed without further consideration.

How do you read the gearbox code letters to identify the gearbox?

The code appears on every gearbox in at least two places. Once on top of the gearbox close to the selector lever cable -two arrows-. If it is not legible or is»upside down«, the gearbox code may also be found under the bracket of the left assembly mounting.

What must be done to see the code directly on the gearbox behind the bracket?

To see the code directly on the gearbox behind the bracket, the engine and gearbox must be supported. Bracket -A- for the left-hand assembly mounting must be removed. In the process, it is important to lower the engine and gearbox only enough so that the bracket can be pushed back. If it is lowered further, the ⇒ pendulum support will be damaged. Following assembly, the selector lever cable must be adjusted.

What steps should you take to see the code directly on the gearbox behind the bracket?

Perform the following steps: – Remove complete air filter housing. ♦ Vehicles with petrol engines ⇒ Rep. gr. 24 ; Removing and installing air filter. ♦ Vehicles with diesel engines ⇒ Rep. gr. 23 ; Removing and installing air filter. – Remove battery and battery tray -arrows- ⇒ Rep. gr. 27 ; Battery; Removing and installing battery. Set up support bracket -10 – 222 A- and support engine with gearbox. Do not raise. – Remove all bolts -1- and -2- for bracket -A-. Bolts must be renewed. – Then lower engine and gearbox slightly using spindles of support bracket -10 – 222 A- until bracket can be removed.

What should you observe after reading the gearbox code and reassembling?

– Nevertheless, observe all the following instructions. – Renew all bolts on left assembly mounting. – First screw in all bolts by hand. – For a description of proper installation of bracket -A- on gearbox with bolts -1- and -2-, see ⇒ page 87. – Always adjust selector lever cable after installing bracket ⇒ page 70.

What should you always refer to if Genuine parts are required for a repair?

If Genuine parts are required for a repair, always refer to the gearbox code.

What should you do before removing the clutch?

The cover over the clutch must be removed before the clutch can be removed.

What steps should you take to remove the clutch cover (end cover)?

Perform the following steps: The cover seals the gearbox. The cover is held in place by a retaining ring. After the retaining ring has been removed, the cover can be levered out of its seat. Cover and retaining ring must always be renewed. Never install a new cover with a hammer and never oil the centre seal or touch it with a hand! However, if this should happen, the cover is certain to leak! The gearbox must be removed for work on cover. – Remove gearbox ⇒ page 76. – Secure gearbox to assembly stand ⇒ page 89. – Drain oil. To gearbox manufacture date „20 September 2004“, gearboxes were constructed with 2 plugs. The second plug was then discontinued, and oil could be drained and the level checked with only one plug -A-. A plastic overflow tube (with 8 mm hexagon socket head bolt, torque setting 3 Nm) is located in this hole. Its length determines the oil level in the gearbox. – Remove this oil pipe. – Drain oil. – Screw in overflow pipe with 3 Nm torque. – Install drain plug -A- with new seal. Torque setting: 45 Nm. – Remove the filter if necessary. Often, doubts arise as to whether the filter must be renewed or not. The notes on the oil filter change ⇒ page 4 can help you in reaching this decision. – Insert new filter with shoulder downwards and tighten cover to 20 Nm. – Following repair work, it is not necessary to change filter again when filling oil. Remove cover. – Remove retaining ring from cover. Cover can be levered out with a screwdriver. Install only a »new« cover ⇒ page 18.

What should you never do when installing a new clutch cover?

Never install a new cover with a hammer and never oil the centre seal or touch it with a hand!

What should you do if you accidentally touch or oil the center seal of the clutch cover?

However, if this should happen, the cover is certain to leak!

What are the two types of clutch covers?

♦ Covers supplied without a bush ⇒ page 18. ♦ Covers supplied with a white bush ⇒ page 20.

What steps should you take to install covers supplied without bush?

Perform the following steps: Cover and retaining ring must always be renewed. Never install a new cover with a hammer and never oil the centre seal or touch it with a hand! Caution Do not grasp new cover in centre hole. The hole of the cover must not be touched, oiled or brought into contact with other materials. Leaks will result. – Only handle cover as shown in the picture! Special tools and workshop equipment required ♦ Assembly sleeve -T10302- Caution Clean assembly sleeve before using. Do not use a scratched sleeve. New cover must be free of oil and dry around centre seal! – If necessary, clean end of clutch shaft. There must be no stickers on the inside of the cover. – If any stickers are present, remove them carefully! Moisten only the outer edge of the seal with DSG oil. – Set sleeve on a flat surface. The centre seal of the new cover must now be »preformed«: – Guide cover horizontally and evenly over entire sleeve. This will bring the sealing lip into installation position. – Now remove sleeve upwards out of cover and set sleeve on end of clutch shaft – Guide cover horizontally over sleeve and press evenly onto its seat. Caution Work carefully. Any sort of blow to the cover is certain to cause leaks. It is possible to lever cover carefully into its seat with a screwdriver -arrow- until »new« retaining ring can be installed. – Install new retaining ring.

What steps should you take to install covers supplied with a bush?

What steps should you take to remove the clutch?

Perform the following steps: To remove or install clutch, gearbox must be securely attached to an assembly stand in vertical position. – Remove clutch cover (end cover) ⇒ page 16. – Remove retaining ring from clutch cover. – Remove cover from clutch. – Remove retaining ring -arrow-. Note: this retaining ring must be measured again during installation and renewed. Caution Carefully remove clutch. Ensure that end cover or other parts of clutch do not fall out. Therefore, do not turn over clutch under any circumstances! But if this should happen ⇒ page 29. – Remove clutch. – Remove pump shaft -A-. – Pump shaft is not inserted until after new clutch is installed. Set shaft aside until then.

What should you make sure of when removing clutch from packing?

– When removing clutch from packing, press on clutch cover. This is to prevent the clutch cover and the plate carriers beneath it from sliding out of the inner plates.

What should you make sure of regarding the 4-piston rings?

– Make sure that the 4 -piston rings- are correctly located. Ring gaps should not be »over each other«. – Turn rings once. They must move freely and must not bind.

How should the clutch cover be positioned?

Position of clutch cover – Look to see whether there is a marking on clutch -arrow-. – If there is no mark, make a coloured mark. Later the »lug« of the cover must be placed at the marked spot. Set down clutch so that it cannot tip over. The clutch is now ready for installation ⇒ page 24.

What steps should you take to install and adjust the clutch?

Caution Avoid removing or lifting plate carriers. Not even a little bit! The plates could turn. Perform the following steps:

Gearbox must be turned »vertical in assembly bracket«. Only this way is it possible later to adjust axial play of the clutch without error.
It is essential that the gearbox be securely clamped in support clamp -VW 313- or engine and gearbox support -VAS 6095-⇒ page 89. It must not be turned.
Inside the clutch, the large plate carrier goes through all plates. It must not slip out of the lowest plates.
The pump shaft of the oil pump is removed.
Do not install corrugated retaining rings. Special tools and workshop equipment required ♦ Retaining pin -T10303- – First set -retaining pin- on seat of cover. – Then insert -clutch- without letting it fall in. Do not mount on clutch. Clutch is inserted with cover as it was when packaged. – The -retaining pin- should be held by a second mechanic in the process. -Retaining pin- remains inserted until all further work has been »completed«. Do not remove the pin until instructed to do so. But not yet. – Carefully remove clutch cover -arrow- from clutch and lay it to side. Caution Avoid removing or lifting plate carriers. Not even a little bit! The plates could turn. – Select 2 mm retaining ring from among the rings supplied and install it temporarily -arrow-. Before this ring is removed again, 2 measurements must be made. First measurement
Retaining pin -T10303- remains in! – Screw universal dial gauge -VW 387- to gearbox flange. – Set -tip of dial gauge- on input shaft. – Set -dial gauge- to 0 with preload. – Raise clutch to stop and note result of measurement. Second measurement
Retaining pin -T10303- remains in! – Set tip of dial gauge -on hub of large plate carrier-. Tip must not sit on retaining ring. – Set -dial gauge- to 0 with preload again. – Raise clutch to stop again and also note this result. Now it can be determined which of the remaining 9 rings will ultimately be installed: – Use this formula: Second measurement minus first measurement plus 1.85 mm = thickness of ring to be installed – Please make a note of this result. The remaining 9 retaining rings are in increments of 0.1 millimetre. – Measure all rings and determine which ring is closest to your result. – Remove 2 mm thick ring and install calculated ring. – Dispose of all remaining rings and the 2 mm thick ring. Retaining rings are only allowed to be installed once. – Insert -pump shaft-. – Install clutch cover so that lug aligns with marking. – Then remove retaining pin -T10303-. – Install cover (end cover) ⇒ page 18. This concludes the installation and the clutch is correctly adjusted. After installing gearbox – Conduct basic adjustment of mechatronic unit for dual clutch gearbox -J743-.

What should be done if parts of the clutch have slipped out or plate carriers have been lifted?

The large plate carrier »and if necessary, also the small one« can be threaded into all inner plates by hand with gentle turning movements. Especially the clutch cover should always be installed in the same position as was the case in the »delivery« of the new clutch ⇒ page 24.

What is essential to do before removing the mechatronic unit (gearbox installed)?

Always make sure that no dirt can enter an »open« gearbox. In particular, dirt entering an »exposed« mechatronic unit for dual clutch gearbox -J743- and/or oil pump can lead to gearbox failure. Please also refer to the notes on the oil filter change regarding »dirty oil«.

What should you do if the mechatronic unit sticks on the dowel pins when the gearbox is very warm?

The mechatronic unit can stick on the dowel pins when the gearbox is very warm. Then let the gearbox cool off.

What steps should you take to remove the mechatronic unit (gearbox installed)?

Perform the following steps: Always make sure that no dirt can enter an »open« gearbox. In particular, dirt entering an »exposed« mechatronic unit for dual clutch gearbox -J743- and/or oil pump can lead to gearbox failure. Please also refer to the notes on the oil filter change regarding »dirty oil«. The mechatronic unit can stick on the dowel pins when the gearbox is very warm. Then let the gearbox cool off. – Move selector lever to position „P“ position. – With ignition switched off, disconnect battery earth strap ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and connecting battery. – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 ; Noise insulation; Assembly overview – noise insulation. If present: – Remove connecting hose between charge air cooler and charge air pipe ⇒ Rep. gr. 21 ; Removing and installing parts of charge air cooling. For 1.4 l engines only – Move lock carrier to service position ⇒ Rep. gr. 50 ; Lock carrier, service position. Continuation for all vehicles Note It is possible that parts having nothing to do with the mechatronic unit must be removed. This depends on the vehicle’s equipment. This will create enough space to remove the mechatronic unit. ♦ Depending on the vehicle, these parts may include, for example, ♦ Fan support -arrow-♦ Additional lines for air conditioner ♦ Charge air or air cooling pipes – Remove electrical wiring and retainers -arrows- from front of »large« gearbox cover. – Release mechatronic unit connector -1- by turning and pull off connector. Note Connector is located close to starter -A- on front of gearbox. – Raise lines near cover and tie. – Position used oil collection and extraction unit -V.A.G 1782- under gearbox. – Remove bolt -A- near pendulum support. To gearbox manufacture date „20 September 2004“, gearboxes were constructed with 2 plugs. A plastic overflow tube (with 8 mm hexagon socket head bolt, torque setting 3 Nm) is located in this hole. Its length determines the oil level in the gearbox. – Remove this oil pipe. About 5.0 litres of oil will run out. Used oil collection and extraction unit -V.A.G 1782- should remain under gearbox. – Screw overflow tube back in, 3 Nm. – Loosen bolts -arrows- of cover diagonally and remove. – Guide cover past starter bolt. – Remove cover and seal. Note ♦ Cover bolts always must be renewed. ♦ Likewise, cover seal must also be renewed. The pendulum support can be removed to make space for removing the mechatronic unit. This allows the gearbox to be »pushed back« a little. Before touching mechatronic unit, touch an earthed object ⇒ page 6. – Carefully release connector of gearbox input speed sender -G182- with oil temperature sender in multi-plate clutch -G509-using a small screwdriver -1-. – Only press onto locking mechanism with screwdriver -1-. – Do not lever it. Do not use screwdriver as a lever. – Use screwdriver -2- to loosen connector. Be very careful. The fastener of the connector can break. If this happens, the sender must be renewed. Do not pull on line! – Pull off connector. – Remove line from retaining lugs -arrows-. – Loosen securing bolts -1- through -10- in given order and remove. Note ♦ The side cover -A-, cover for oil pump, does not need to be removed in order to remove or install the mechatronic unit. ♦ For greater clarity, the side cover has been removed in the next illustration. – Carefully pull mechatronic unit out of gearbox housing so that sender arm -B- on back is no longer in gearbox housing. When handling mechatronic unit, pay special attention to the »long« sender arm -B-. – Carefully swing mechatronic unit for dual clutch gearbox -J743- downwards. Lay mechatronic unit to side properly. Caution Never lift mechatronic unit on »sender arm« or lay it on arm. If »arm« is damaged, mechatronic unit must be renewed.

What should you do before touching the mechatronic unit (gearbox installed)?

Before touching mechatronic unit, touch an earthed object.

What steps should you take to install the mechatronic unit (gearbox installed)?

Perform the following steps: Before touching mechatronic unit, touch an earthed object. If »arm« is damaged, mechatronic unit must be renewed. – Carefully set mechatronic unit for dual clutch gearbox -J743- in gearbox housing. Note ♦ The side cover should not be removed in order to remove other parts ♦ The side cover is not shown in this illustration. This is to make it clear how the »long arm« will be damaged if the mechatronic unit is canted. Mechatronic unit for dual clutch gearbox -J743- and gearbox should be at same temperature. This stops down pins from »jamming« during insertion. – Do not pinch wiring. Be very careful: do not pinch wiring! – Carefully set mechatronic unit on dowel pins -arrow-. Ensure that »sender arm« locates in its -fitting position-. – Hold mechatronic unit upwards for this purpose. Sender arm is not allowed to strike sender wheel. -Detail- – Look to see if mechatronic unit has made contact correctly. – Screw in new bolts -1- through -10- hand-tight. – Tighten bolts in given order to 5 Nm + 90° (1/4 turn). – Hook line -A- first in upper retaining lug, and then in lower -arrows-. – Push on connector and engage. – Renew both -O-rings- if you reinstall the »old« mechatronic unit. – Moisten O-rings with dual clutch gearbox oil. (Of course a »new« mechatronic unit already has »new« seals.) – Clean cover seal and sealing surfaces on gearbox. – Ensure proper seating of seal. – Set cover over mechatronic unit, being careful not to pinch any wiring. – Insert new bolts -arrows- and tighten diagonally in several stages to 10 Nm. – Attach wire retainer to cover and tighten nuts to 10 Nm. – Push on connector for mechatronic unit for dual clutch gearbox -J743- and engage lock by turning. – If removed, install connecting hose between charge air cooler and charge air pipe ⇒ Rep. gr. 21 ; Removing and installing parts of charge air cooling. – Reinstall any parts which may have been removed from the vehicle. – Connect battery earth ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and reconnecting battery. – Do not start engine! – Please renew filter if oil is contaminated. – Change oil and filter for dual clutch gearbox ⇒ page 90. – Install noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 ; Noise insulation; Assembly overview – noise insulation. – Conduct basic adjustment of mechatronic unit for dual clutch gearbox -J743-.

What is essential to do before removing the mechatronic unit (gearbox removed)?

What steps should you take to remove the mechatronic unit (gearbox removed)?

Perform the following steps: – Remove bolt -A- near pendulum support. To gearbox manufacture date „20 September 2004“, gearboxes were constructed with 2 plugs. A plastic overflow tube (with 8 mm hexagon socket head bolt, torque setting 3 Nm) is located in this hole. Its length determines the oil level in the gearbox. – Position used oil collection and extraction unit -V.A.G 1782- or a drip tray under gearbox. – Remove this oil pipe. – Drain oil. Please also refer to the notes on the oil filter change ⇒ page 4 regarding »dirty oil«. – Screw in overflow pipe with 3 Nm torque. – Remove the filter if necessary. Often, doubts arise as to whether the filter must be renewed or not. The notes on the oil filter change ⇒ page 4 can help you in reaching this decision. – Insert new filter with shoulder downwards and tighten cover to 20 Nm. – Following repair work, it is not necessary to change filter again when filling oil. – Remove both -covers-. »Small« cover of oil pump and bolts of »large« cover must always be renewed. Likewise, seal of »large« cover must be renewed. Before touching mechatronic unit, touch an earthed object ⇒ page 6. – Carefully release connector of gearbox input speed sender -G182- with oil temperature sender in multi-plate clutch -G509-using a small screwdriver -1-. – Using a screwdriver -1-, only press against locking mechanism, do not lever. Do not screwdrivers as a lever. – With a second screwdriver -2-, loosen connector. Take the utmost care. The fastener of the connector can break. If this happens, renew the sender. Do not pull on line! – Pull off connector. – First pull line out of lower clip -arrow I-. – Then remove it from upper clip -arrow II- and lay to side. Do not kink line. – Remove securing bolts -1 … 10- diagonally. Start with bolt -1-. All 10 -securing bolts- must be renewed. – Remove mechatronic unit for dual clutch gearbox -J743-. When handling mechatronic unit, pay special attention to the »long« sender arm. Caution Never lift mechatronic unit on »sender arm« or lay it on arm. If »arm« is damaged, mechatronic unit must be renewed. Lay mechatronic unit to side properly.

What should you do before installing the mechatronic unit (gearbox removed)?

Caution Never lift mechatronic unit on »sender arm« or lay it on arm. If »arm« is damaged, mechatronic unit must be renewed. – Before installation, make certain that gearbox input speed sender -G182- with oil temperature sender in multi-plate clutch -G509- is installed.

How do you renew O-rings when refitting an old mechatronic unit?

Renew both -O-rings- at the connection for the mechatronic unit if you refit an »old« mechatronic unit. Moisten O-rings with dual clutch gearbox oil.

How do you set the mechatronic unit on the dowel pin?

Carefully set the mechatronic unit on the dowel pin -arrow-. Ensure that the »sender arm« locates in its -fitting position-.

What should you do with the sender arm when installing the mechatronic unit?

The sender arm is not allowed to strike the sender wheel.

What should you do with the wiring when installing the mechatronic unit?

Do not pinch the wiring and be very careful.

What should you do with the securing bolts when installing the mechatronic unit?

All securing bolts -1 … 10- must be renewed. First start all securing bolts -1 … 10- »by hand«. Then, tighten all securing bolts -1 … 10- diagonally to 5 Nm and then turn 90° further in the same sequence. Start with bolt -1-.

How do you secure the wiring for the gearbox input speed sender?

First, press the wiring for the gearbox input speed sender -G182- with the oil temperature sender in the multi-plate clutch -G509- into the upper clip -arrow II-. Then into the lower clip -arrow I-.

What should be renewed when pressing the connection onto the mechatronic unit?

The »small« cover of the oil pump and bolts of »large« cover must always be renewed. Likewise, the -seal- of the »large« -cover- must be renewed.

How should cover bolts be tightened?

Tighten cover bolts »diagonally« to 10 Nm.

What should be done after installing the gearbox?

Fill with oil without renewing the filter. Conduct a basic adjustment of the mechatronic unit for the dual clutch gearbox -J743-.

What happens if the cable is pulled on the gearbox input speed sender?

If the cable is pulled on, the sender must be renewed.

How do you remove the gearbox input speed sender and oil temperature sender?

Remove the bolt and carefully lever out the sender with a screwdriver and/or pliers.

When should you reinstall the old sender?

Reinstall the »old« sender only if you know for certain that the sender has no defect and the cable was not pulled on when it was removed. If this is not the case, install a »new« sender.

How do you install the sender?

Moisten the sender with dual clutch gearbox oil and insert. Tighten the bolt to 10 Nm. Install the mechatronic unit for the dual clutch gearbox -J743-. Take special care: Never pinch the mechatronic unit wiring during installation.

What special tools and workshop equipment are required to remove and install the gearbox oil cooler?

Hose clamps -3094- and torque wrench -V.A.G 1331- are required.

How do you remove the gearbox oil cooler?

Move the selector lever to the “P” position.
Remove the battery and battery tray.
Lay lint-free cloths on the gearbox oil cooler and gearbox to catch escaping coolant.
Clamp off coolant hoses using hose clamps -3094- and remove from the gearbox oil cooler.
Remove bolts -A- and remove the gearbox oil cooler -B-.

Caution: No coolant must be allowed to drip into the gearbox.

How do you install the gearbox oil cooler?

Renew O-rings -C- of the gearbox oil cooler -B-.
Set the gearbox oil cooler -B- in place, observing O-rings -C-.
Screw in new bolts -A- and tighten to 20 Nm + 90° (1/4 turn).
Attach coolant hoses to the gearbox oil cooler and remove hose clamps -3094-.
Install the battery tray and battery.
Check the coolant level and top up with coolant as needed.
Following repairs, fill with oil without renewing the filter.

Caution: Do not start the engine while checking the coolant level if gearbox oil has not yet been filled.

How do you install a new filter?

Insert the new filter with the shoulder downwards and tighten the cover to 20 Nm.

What special tools and workshop equipment are required to remove the oil pump?

Torque wrench -V.A.G 1331- and used oil collection and extraction unit -V.A.G 1782- are required.

How do you remove the oil pump?

Remove the noise insulation.
Remove the lower part of the front left wheel housing liner.
Position the used oil collection and extraction unit -V.A.G 1782- under the gearbox.
Remove bolt -A- near the pendulum support.
Remove the oil pipe (gearboxes manufactured to “20 September 2004” have a plastic overflow tube with an 8 mm hexagon socket head bolt, torque setting 3 Nm).
Drain the oil.
Screw in the overflow pipe with 3 Nm torque.
Renew the seal for the plug.
Remove bolts -arrows- and remove the oil cooler cover -A-.
Remove bolts -arrows- and pull the oil pump -1- off the dowel pins and pull out the oil pump drive shaft.

How do you install the oil pump?

Push the input shaft -A- for the oil pump into the gearbox as far as it will go. Turn the input shaft slightly whilst doing this.
Always use a new metal seal -B-.
Ensure that the 2 dowel pins -C- are located in the gearbox housing.
When fitting the oil pump, observe the splines of the input shaft and the proper seating of the dowel pins.
Set the new oil pump cover -A- in place and tighten the new bolts -arrows- diagonally in several stages to 8 Nm.
Change the oil and filter for the dual clutch gearbox.
Install the left wheel housing liner.
Install the noise insulation.

What is the torque setting for the bolts with flat heads and the uppermost bolt with a countersunk head when installing the oil pump?

Countersunk head bolt: 8 Nm without additional turn (tighten with socket -T10054-)
Flathead bolts: 8 Nm + 90° (1/4 turn)
All 4 bolts with flat heads -arrows-: 5 Nm + 90° (1/4 turn)

What special tools and workshop equipment are required to renew the seal on the selector shaft lever?

Tube -VW 423-, puller hooks -T20143-, and torque wrench -V.A.G 1331- are required.

How do you renew the seal on the selector shaft lever?

Remove the selector lever cable from the gearbox.
Unbolt lever -A- and carefully pry off the selector shaft.
Pry the seal out -in the direction of the arrow-.
Fill the space between the sealing lip and dust lip -arrow- with sealing grease -G 052 128 A1-.
Lightly oil the outer circumference of the oil seal.
Drive in the new seal to stop; do not cant the oil seal in the process.
Apply the lever and tighten the nut to 20 Nm.
Install and adjust the selector lever cable on the gearbox.

What should be done before working on a vehicle with the engine running?

Before working on a vehicle with the engine running, move the selector lever into position „P“ and apply the handbrake.

How do you remove and install the selector lever cable on vehicles up to 02.2009?

Move the selector lever to the “S” position.
Loosen the adjustment screw -arrow-.
Remove securing clips -A- and -B-. Securing clips must be renewed when the Bowden cable is later adjusted.
Raise the vehicle.
Remove the heat shield under the selector mechanism and, if necessary, parts of the exhaust system.
Remove the -selector housing- beneath the selector lever.
Remove the locking plate of the cable support bracket. Always renew the locking plate.
Push the selector housing forwards slightly on the cable.
Push the securing tab forwards -1-.
At the same time, push the -pin- up with a screwdriver -2-.
Remove the selector lever cable.
Remove the selector housing from the cable.
Route the selector lever cable without tension. Also, insert it in the cable support bracket on the gearbox. Do not secure with securing clips yet. Do not clip in the ball head.
Ensure that the selector lever cable is properly routed during installation.
Put the selector housing onto the cable.
Insert the selector lever cable into the selector mechanism.
Insert the cable into the bearing and insert the pin from above, downwards through the eye. When you have checked the freedom of movement of the cable, insert the locking plate.
Attach the cable with a new locking plate on the cable support bracket of the selector mechanism.

How do you remove and install the selector mechanism with the selector lever and selector lever cable on vehicles from 03.2009 onwards?

Move the selector lever to the “P” position.
Remove the selector lever handle.
Remove the center console.
Remove 4 bolts. Torque setting: 8 Nm.
Raise the vehicle.
Remove the heat shield beneath the selector mechanism.
Loosen the adjustment screw -arrow-.
Remove securing clips -A- and -B-. Securing clips must be renewed when the Bowden cable is adjusted.
Remove the selector mechanism.
Install in reverse order of removal.

How do you check the selector lever cable?

Move the selector lever to the »P« position.
Remove the cable from the lever on the gearbox.
Move the selector lever repeatedly from »P« to »S« and back to »P«.
- The selector lever must move easily.
Install the cable using a new securing clip and »loosened« adjusting screw.
Adjust the cable.

When does the selector lever cable need to be adjusted?

The selector lever cable must always be adjusted whenever:

The selector lever cable has been removed from the gearbox.
The engine and/or gearbox has been removed and installed.
Parts of the assembly mounting have been removed and installed.
The cable itself or the selector mechanism has been removed and installed.
The position of the engine and gearbox is shifted, for example, to install it free of tension.

How do you adjust the selector lever cable?

Move the selector lever in the vehicle to the “P” position.
Shift the lever on the gearbox to the “P” position. The lever on the gearbox must be pressed »all the way back«.
Install the cable with the loosened adjusting screw -arrow- and new securing clips -A- and -B-.
Push the lever on the gearbox backwards -arrow-. This also puts the gearbox in position “P”.
Gently push the knob of the selector lever forwards and backwards, but under no circumstances must you shift out of “P”.
Tighten the adjusting screw -arrow- to 13 Nm.

How do you perform an emergency release of the selector lever on vehicles up to 02.2009?

Do not remove the knob.
Unclip the selector cover and hold it to the side.
Depress the brake pedal or set the handbrake.
Press the yellow plastic part -arrow- from right to left.

How do you perform an emergency release of the selector lever on vehicles from 03.2009 onwards?

Do not remove the knob.
Unclip the selector cover and hold it to the side.
Depress the brake pedal or set the handbrake.
Press the yellow plastic wedge -arrow-.

How do you remove and install the selector lever knob?

Before removal, pull the lock button out past its pressure point.
Secure the locking button with a cable tie or wire against being pressed in.
Unclip the cover.
Push the sleeve upwards to release the knob.
Lock the handle again after installing.

What should you check when inspecting the selector mechanism?

The starter must not operate in the selector lever positions “R”, “D,” or “S”.
On a right-hand drive vehicle, the starter must only operate in selector lever positions “P” and “N” when the lock button is not pressed.
When the selector lever is shifted to position “N” at speeds above 5 km/h, the solenoid for the selector lever lock must not engage and block the selector lever.
When traveling at speeds below 5 km/h (almost stationary) and shifting into selector lever position “N”, the solenoid for selector lever lock should only engage after about 1 second.
The selector lever cannot be shifted out of the “N” position until the brake pedal is depressed.

How do you remove the gearbox?

Move the selector lever to the “P” position.
Remove the complete air filter housing.
Remove the battery and battery tray.
Remove the selector lever cable from the gearbox.
Lay lint-free cloths on the gearbox oil cooler and gearbox to catch escaping coolant.
Clamp off coolant hoses using hose clamps -3093/3094- and remove hoses from the gearbox oil cooler.
Seal off the gearbox oil cooler with clean plugs.
Remove the starter -A-.
Release the mechatronic unit connector -1- by turning and pulling off the connector.
Unbolt the wiring retainer from the front of the »black« gearbox cover (2 M6 nuts).
Remove all upper connecting bolts between the engine and gearbox.
Remove both filler pieces from the upper edge of the left and right wings.
Remove hose and cable connections in the area of the engine support eye for the support bracket -10-222A-.
Support the engine and gearbox, but do not raise.
Take up the weight of the engine/gearbox assembly on the spindles, do not lift.
Loosen the wheel bolts on the front left and front right.
Raise the vehicle. All 4 supports of the lifting platform must be at the same height.
Remove the front wheels.
Remove the noise insulation.
Remove the lower part of the front left wheel housing liner.
If present, remove the heat shield above the right drive shaft.
Separate the exhaust system at the clamp and remove the exhaust system bracket from the subframe.
Tie up the front exhaust pipe.

Note: The flexible joint of the front exhaust pipe must not be bent more than 10° – danger of damage.
Unbolt the pendulum support from the gearbox.
Secure the subframe before removal.

Note: If the -subframe- is not located, it will be necessary to perform wheel alignment later.
Remove the subframe with the steering box.
Unbolt the drive shafts from the gearbox.
Raise the right drive shaft as high as possible and secure it.
Put the left drive shaft to the rear and secure it (do not damage the surface protection when doing this).
Remove the cover plate -A- located above the right drive shaft flange on the intermediate plate for the engine and gearbox.
Remove all bolts -1- and -2- for bracket -A-.
Lower the engine and gearbox slightly using the spindles of the support bracket -10 – 222 A- so that the bracket can be removed.
Remove the bracket -arrow-.
Set up the gearbox support -3282- with the adjustment plate -3282/42 A- and put it onto the engine and gearbox support -V.A.G 1383 A-.
Align the arms of the gearbox support according to the holes in the adjustment plate -3282/42 A-.
Screw in the support elements as illustrated on the adjustment plate -3282/42 A-.
Position the engine and gearbox jack -V.A.G 1383 A- under the vehicle.

Note: The arrow on the adjustment plate -3282/42 A- points in the direction of travel.
Align the gearbox support -3282- parallel to the gearbox.
Screw pin -3282/29- into the gearbox.
Secure both other support elements on the gearbox as shown in the illustration.

Note: Rather than as shown in the illustration on the adjustment plate, the front support element is bolted onto the gearbox as shown -arrow-.
Raise the gearbox and engine support -V.A.G 1383 A- from below to support the gearbox.
Remove the remaining engine/gearbox connecting bolts.
Press the gearbox off the engine, »observing the selector lever cable,« and lower the gearbox.

How do you install the gearbox?

Check the needle bearing -arrow- in the crankshaft. If it is damaged or tarnished blue, it must be renewed.
If it is not damaged, grease lightly with high-temperature grease -G052133A2-.
The end of the gearbox shaft (but not the splines) also must be lightly greased.
Check for proper seating of both dowel sleeves between the engine and gearbox.
Check for proper seating of the intermediate plate.
Guide the selector lever cable as soon as possible into its cable support bracket.
Readjust the gearbox support until the engine and gearbox are »aligned with each other«.
Turn the crankshaft slightly if necessary.
Renew the securing clips for the selector lever cable.
Always adjust the selector lever cable.
Check the coolant level and top up if necessary.

What are the torque settings for the engine when installing the gearbox?

1.4 l TSI
- M12 – 80 Nm
  - If an 18 mm insert -T10179- is used: 65 Nm
- M10 – 40 Nm – Arrows point towards dowel sleeves
1.9 l TDI; 2.0 TDI; 2.0 l TFSI
- M12 – 80 Nm
  - If an 18 mm insert -T10179- is used: 65 Nm.
- M10 – 40 Nm

How do you continue the installation for all engines?

Renew all bolts on the left assembly mounting.
First screw in all bolts by hand.
First bolt bracket -A- to gearbox with bolts -1- with 40 Nm + 90° further turn.
Tighten bolts -2- to 60 Nm + 90°.
Install the subframe with the steering box.

What should you consider when transporting the gearbox?

Always secure heavy parts for transport.
Keep in mind that there is oil in the gearbox.
Do not turn the gearbox with the breather downwards during transport or while on the repair stand.

How do you change the oil and filter and adjust the oil level?

Read the oil temperature. If it is above 50 °C, let the gearbox cool off.
With the engine stopped, unscrew the overflow pipe and drain the oil.
Re-install the overflow pipe and »overfill« the gearbox.
Start the engine and drain excess oil until the oil level attains the level of the overflow pipe.
Remove the air filter housing.
Connect the vehicle diagnostic tester and identify the vehicle in Guided functions.
Check fluid level.
Position used oil collection and extraction unit -V.A.G 1782- or drip tray -VAS 6208- under the gearbox.
Loosen the filter housing through 7 turns.
Wait for 10 seconds. This way, the oil will flow from the filter housing back into the gearbox.
Now remove the filter housing.
After inserting the new filter element with the -shoulder- downwards, tighten the housing to 20 Nm.
Raise vehicle.
Position used oil collection and extraction unit -V.A.G 1782- or drip tray -VAS 6208- under the gearbox.
Remove the inspection plug near the pendulum support -arrow-.
Remove the oil pipe.
Screw the overflow tube back in, 3 Nm.
Screw the adapter -A- from -VAS 6262- or -VAS 6262 A- hand-tight into the inspection hole.
Add 5.5 l of dual clutch gearbox oil.
Continue to switch the vehicle diagnostic tester until the ⇒ DSG® oil temperature is displayed.
Now start the engine.
Depress the brake pedal and select each selector lever position for about 3 seconds.
Move the selector lever to position »P« position.
When the oil temperature has reached 35 °C to 45 °C: Disconnect the quick-release coupling of the adapter for filling oil -VAS 6262 A- with the engine running.
Let surplus oil drain out.
Remove the adapter for filling oil -VAS 6262- or -VAS 6262 A- and install the plug with the new seal.
Switch off the engine.
Install noise insulation.

How do you renew the oil seal for the left flange shaft?

Remove the left wheel.
Remove the noise insulation.
Remove the lower part of the front left wheel housing liner.
Remove the left drive shaft.
Place a drip tray for the workshop hoist -VAS 6208- under the gearbox.
Remove the flange shaft securing bolt by screwing 2 bolts into the flange and counterholding the flange shaft with a lever.
Pull out the flange shaft together with the compression spring.
Pull out the flange shaft oil seal using the multi-purpose tool -VW 771- and puller hooks -VW 771/37-.
Lightly oil the outer circumference of the new oil seal.
Half-fill the space between the sealing lip and dust lip of the new seal with sealing grease -G 052 128- -arrow-.
Drive in the new seal to stop, being careful not to cant the seal.
Insert the flange shaft.
Tighten the new countersunk bolt to 30 Nm. When doing this, press the flange shaft against the gearbox so that the bolt engages in the thread.
Install the left drive shaft.
Install the left wheel housing liner.
Install the left wheel.
Change the oil for the dual clutch gearbox.
Install the noise insulation.

How do you renew the seals for the right flange shaft or stub shaft?

Remove the right wheel.
Remove the noise insulation.
Remove the drive shaft heat shield from the engine -arrows-, if fitted.
Remove the right drive shaft.
After removing the right drive shaft -A-, unbolt the intermediate shaft -B- from the bearing bracket -C- -arrows- and pull out the stub shaft of the gearbox.
Place a drip tray for the workshop hoist -VAS 6208- under the gearbox.
Remove the securing bolts -arrow- for the stub shaft or flange shaft.
Pull out the stub shaft or flange shaft together with the compression spring.
Pry the seal out using the assembly lever.
Lightly oil the outer circumference of the new oil seal.
Half-fill the space between the sealing lip and dust lip of the new seal with sealing grease -G 052 128- -arrow-.
Drive in the new seal to stop, being careful not to cant the seal.
Insert the stub shaft or flange shaft.
Tighten the new countersunk bolt to 30 Nm. When doing this, press the stub shaft or flange shaft against the gearbox so that the bolt engages in the thread.
Renew the O-ring of the stub shaft.
Grease the splines of the stub shaft with grease for the clutch plate splines -G 000 100-.
Guide the intermediate shaft -B- through the bearing bracket -C- onto the stub shaft of the gearbox.
Bolt the intermediate shaft to the bearing bracket to the specified torque -arrows-.
Install the right drive shaft.
Install the right wheel.
Change the oil for the dual clutch gearbox.
Install the noise insulation.

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