MECHATRONIC, Removing And Installing: Installing

• Seal the Mechatronic vent with a plug or the Protective Cap :0AM 325 120 A  so that no fluid can leak out. Refer to the Parts information.
• The connection on the valve block/Mechatronic is sealed with a sealing plug -arrow- from the Repair Kit :5C0 998 152  .

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-- Check each of the 4 shift forks by hand first.

Each shift fork has three positions:

• Gear engaged
• Neutral -N-
• Gear engaged

-- Move all four shift forks one time into each position -arrows- one after the other.

-- After doing this, move the shift forks back into the center position -N-.

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1. N - Neutral
2. R - Reverse Gear
3. 1 - First Gear
4. 2 - Second Gear
5. 3 - Third Gear
6. 4 - Fourth Gear
7. 5 - Fifth Gear
8. 6 - Sixth Gear
9. 7 - Seventh Gear

-- Clean the sealing surface, which the Mechatronic will be touching later.

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-- Install the Guide Bolt - Mechatronic :T10406  hand tight.

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Adjust the gear selector:

-- Move the four gear selectors on the back of the DSG Transmission Mechatronic -J743- into the correct positions.

• Correct position: -a- = 25 mm

-- Clean the sealing surface on the Mechatronic.

• The seal on the DSG Transmission Mechatronic -J743- must fit completely into the groove.
• The Assembly Lever :T10407  is inserted between the engaging lever and the transmission housing.

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• The two alignment sleeves -1 and 2- for centering the Mechatronic on the transmission housing must be installed.

-- Mount the Mechatronic -B- together with the valve block -A-. Make sure that the Mechatronic gear positions are not pressed out of their position.

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-- Hand-tighten bolts -arrows 1 and 2- and remove the Guide Bolt - Mechatronic :T10406  .

-- Tighten the Mechatronic bolts. Refer to Figure.

• Both clutch positioners must fit correctly into the mounts on the clutch engaging levers.
• The rubber grommets on the clutch positioners must not be damaged.
• The rubber grommets must seal the Mechatronic tight.

-- Turn the Assembly Lever - Mechatronic :T10407  slowly and carefully clockwise and remove it.

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• The lifters must move slowly into the mounts.

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-- Pull the lifters far enough until they fit correctly in the mounts.

-- Install the Transmission Input Speed Sensor 3 -G641-.

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-- Be careful of the sensor. The clip must not be damaged.

• The sensor must fit completely in its retainer and must be touching the transmission housing. Replace the Mechatronic if the sensor is loose or if the clip is broken.

-- To electrostatically discharge, touch the ground (without glove). Do not touch connector or >>open<< electronic components directly.

-- Connect and lock the Mechatronic connector.

-- Attach the front bracket -A- to the transmission -arrows-.

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-- If a protective cap is located in the switch valve connector -2-, it must be removed before attaching the connector -1-.

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-- Connect the connector -1- to the valve -2- on the Mechatronic and attach the wiring harness to the front bracket on the transmission.

-- Install the hydraulic line -3- on the engine and valve block/Mechatronic.

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-- Push the clamps -2- onto the valve block/Mechatronic.

-- Pull on the hydraulic pipe -3- to check it.

-- Tighten the bolt -1- on the engine for the hydraulic line to the tightening specification.

-- Remove the Protective Cap -arrow- from the vent -1- on the DSG Transmission Mechatronic -J743-.

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• If more than 20 ml of hydraulic fluid leaked out, then at least 30 ml (may need more depending on how much leaked out) of hydraulic fluid must be added via the vent -1- using the disposable syringe -2-.

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• For the disposable syringe from the Repair Kit :5C0 998 152  and the correct hydraulic fluid. Refer to the Parts information.
• Fill the new disposable syringe with at least 30 ml hydraulic fluid from the new Power Steering Fluid :G 004 000 M2  container.

-- Push the new cap -1- on the ventilation -3-. It is replacement part with a vent -2-.

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Assemble the rest in reverse order. Note the following:

-- Fill the transmission fluid. Refer to TRANSMISSION FLUID, DRAINING AND FILLING .

-- Check the adjustment of the selector lever cable; re-adjust if necessary SELECTOR LEVER CABLE, CHECKING AND ADJUSTING .

-- Install the bracket -1- for the Electric Drive Power And Control Electronics -JX1- -arrows-. Refer to High Voltage System General Warnings .

-- Install the high voltage cables bracket on the transmission housing. Shown in illustration below, not called out.

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Install the Electric Drive Power and Control Electronics -JX1-. Refer to ELECTRIC DRIVE POWER AND CONTROL ELECTRONICS .

Vehicles with Secondary Air Injection (AIR) System 

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-- Install the damper -1-.

-- Attach the air line -1 and 2- to the damper -3-.

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For All Vehicles 

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-- Install the damper cover -1-.

-- Connect the 12V battery. Refer to BATTERY .

-- Reset the service position. Refer to LOCK CARRIER .

-- Install the fan shroud. Refer to FAN SHROUD, REMOVING AND INSTALLING [For engine(s) CZTA] or RADIATOR/COOLANT FAN [For engine(s) CBPA] or RADIATOR/RADIATOR FAN [For engine(s) CNLA] or RADIATOR/RADIATOR FAN [For engine(s) CVCA] or RADIATOR/RADIATOR FAN [For engine(s) CPPA, CPRA, CPKA, CPLA] .

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-- Fill the engine coolant. Refer to COOLANT SYSTEM/COOLANT [For engine(s) CZTA] or COOLANT SYSTEM/COOLANT [For engine(s) CBPA] or COOLANT SYSTEM/COOLANT [For engine(s) CNLA] or COOLING SYSTEM/COOLANT [For engine(s) CVCA] or COOLANT SYSTEM/COOLANT [For engine(s) CPPA, CPRA, CPKA, CPLA] .

-- Install the noise insulation. Refer to NOISE INSULATION .

-- Energize the high voltage system and complete the required documentation. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .

• Bleed the hydraulic clutch mechanism for the decoupler using the Vehicle Diagnostic Tester in Guided Functions  after energizing the high voltage system.

-- Perform basic measurement  . Refer to WORKING WITH TESTER .