02E Transmission
Mechatronic
Removing
Risk of transmission damage.
• Do not run engine or tow vehicle with oil pan removed or without transmission fluid.
• Observe general repair notes. Refer to => [ Repair Instructions ] Repair Instructions.
• Observe cleanliness rules when working on transmissions. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Remove oil pan. Refer to => [ Oil Pan ] 02E Automatic Transmission.
- Remove the fan shroud.
On vehicles with the coolant hose at the bottom left:
Risk of burning due to hot steam and hot coolant.
• When engine is warm, the cooling system is under pressure.
• Cover the cap on the coolant expansion tank with a cloth and open it carefully to release the pressure.
- Drain the coolant.
- Remove the lower coolant hose - 1 -.
All vehicles:
- Remove the left noise insulation - arrows -.
- Remove bolts - arrows - and remove transmission oil pump cover - A -.
Danger of destroying the mechatronic unit.
If the transmission fluid pump cover is not removed, the long sensor arm will be damaged when removing the Mechatronic.
Risk of destroying mechatronic with static discharge.
• Do not touch contacts in connector with hands.
- To discharge static, touch vehicle ground with hand (without glove).
Risk of damaging electrical wire.
• Do not pull on electrical wire.
- Carefully release electrical connector for transmission input speed (RPM) sensor (G182) and clutch oil temperature sensor (G509) with a small screwdriver - arrow - and remove.
• If electrical wire is damaged, transmission input speed (RPM) sensor and clutch oil temperature sensor must be replaced.
- Loosen electrical wire to transmission input speed (RPM) sensor and clutch oil temperature sensor from retaining tabs on mechatronic - arrow I and arrow II -.
- Remove the bolts in the sequence - 1 through 10 -.
- Carefully pull the Mechatronic out of the transmission housing until the long sensor arm is no longer located within the transmission housing.
- Carefully pivot the Mechatronic downward and out.
Risk of damaging mechatronic.
• Ensure tabs on sensor arm do not break off.
- Store Mechatronic properly.
Risk of damaging mechatronic.
• Do not lift mechatronic by sensor arm or lay it on arm.
• If sensor arm is damaged, mechatronic must be replaced.
Installing
• Tightening specifications, refer to => [ Oil Pan, Mechatronic, and Transmission Oil Pump Assembly Overview ] Description and Operation.
Install in reverse sequence; note the following points:
• Replace direct shift gearbox (DSG) mechatronic (J743) bolts and transmission oil pump cover bolts.
• Replace transmission oil pump cover.
• Replace the o-rings - arrows - on the direct shift gearbox (DSG) mechatronic connector when installing.
• The replacement O-rings are included with the direct shift gearbox (DSG) mechatronic.
- Carefully insert direct shift gearbox (DSG) mechatronic in transmission housing:
• Mechatronic must be placed on alignment pins - arrow -.
• Sensor arm must rest in guide on transmission housing, as shown in the magnified area of the illustration.
• Electrical wire to transmission input speed (RPM) sensor and clutch oil temperature sensor must not be pinched.
- Tighten the direct shift gearbox (DSG) mechatronic bolts => [ Tightening Sequence ] Description and Operation.
- First engage electrical wire in upper retaining tab - arrow II - and then in lower tab - arrow I -.
- Connect connector to transmission input speed (RPM) sensor and (G509) and check connector engagement.
- Install oil pan. Refer to => [ Oil Pan ] 02E Automatic Transmission.
- Install transmission oil pump cover. Refer to => [ Transmission Oil Pump ] 02E Automatic Transmission.
- Complete the required steps after connecting the battery.
- Install the fan shroud.
The engine could overheat and become damaged.
• If the coolant was drained from the vehicle, fill the transmission fluid but do not start the engine yet.
• Only start the engine after filling the engine coolant.
- Fill gear oil. Refer to => [ Transmission Fluid, Changing and Filling ] Transmission Fluid, Changing and Filling.
On vehicles with the coolant hose at the bottom left:
- Install the lower coolant hose - 1 -.
- Fill the coolant.
All vehicles:
- Start engine and run at idle.
- Press brake and shift through all selector lever positions P, R, N, D, S at idle, retaining each position for at least 3 seconds.
- Place selector lever in position P.
- Gear oil level, checking and topping off. Refer to => [ Gear Oil Level, Checking and Filling ] Gear Oil Level, Checking and Filling.
- Perform a basic setting with vehicle diagnosis, testing and information system (VAS 5051B).