VW 6 Speed DQ250 Dual Clutch Transmission 02E Repair Manual Edition 09.2015

Service
Repair Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jetta 2005 ➤
Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E
CBF CCT CBE CJAA CPLA CPP
Engine ID BRM BPY A A A A
Edition 09.2015
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
30 - Clutch
34 - Controls, Housing
35 - Gears, Shafts
39 - Final Drive, Differential
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2016 Volkswagen AG, Wolfsburg D3E80020F58

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
6-Speed Dual Clutch Transmission 02E - Edition 09.2015
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Brief Overview - Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 O-Rings, Gaskets and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 DSG® Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.7 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Troubleshooting . . . . . . . . . .k.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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2.1 Troubleshooting,lkGeneral gen AGInformation .d.oe. s.n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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2.2 Transmission ed b “Control Module Malfunction Behavior”
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ran Information . . . . . . . . . . . . . . . . . . . . 6
2.3 oris
Fault Finding, Special Information . . . . . . . . . . . . .te.e.o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3 Transmission
ss Identification . . . . . . . . . . . . . . . . . . . . . .c. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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3.1 Transmission Code, Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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4 Engine Codes - Engine Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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4.1 Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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5 Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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1 Overview - Dual Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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2 Dual Clutch, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1 Remove Clutch End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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2.2 Clutch End Cover, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.3 Dual Clutch, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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2.4 Dual Clutch, Installing and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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1 Electrical and Electronic Components, Component Locations in DSG® Transmission . . . . 33

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1.1 DSG Transmission Mechatronic J743 , Removing and Installing, Transmission Installed
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1.2 DSG transmission Mechatronic J743 , Removing and Installing, Transmission Removed
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1.3 Transmission Input Speed Sensor G182 and Clutch Oil Temperature Sensor G509 ,
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Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2 Transmission Fluid Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3 Oil Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4 Selector Shaft Lever Gasket, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5 Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.1 Overview - Selector Mechanism, Vehicles through 02/2009 . . . . . . . . . . . . . . . . . . . . . . . . 62
5.2 Selector Lever Cable, Removing and Installing, through 02/2009 . . . . . . . . . . . . . . . . . . . . 64
5.3 Overview - Selector Mechanism, Vehicles from 03/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.4 Selector Mechanism, Removing and Installing, Vehicles from 03/2009 . . . . . . . . . . . . . . . . 73
5.5 Selector Lever Cable, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.6 Selector Lever Cable, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.7 Selector Lever, Emergency Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.8 Selector Lever Handle, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.9 Button in Handle, Moving into Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.10 Selector Mechanism, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Contents i
6 Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and
Golf Wagon from MY 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.1 Transmission, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.2 Transmission, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.3 Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7 Transmission, Removing and Installing, Jetta from MY 2011 . . . . . . . . . . . . . . . . . . . . . . 102
7.1 Transmission, Removing, Jetta MY 2011 with 2.0L 103 kW Diesel . . . . . . . . . . . . . . . . . . 102
7.2 Transmission, Installing, Jetta MY 2011 with 2.0L 103 kW Diesel . . . . . . . . . . . . . . . . . . . . 113
7.3 Transmission, Removing, Jetta MY 11, 2.0L 147 kW Gasoline Engine . . . . . . . . . . . . . . . . 115
7.4 Transmission, Installing, Jetta MY 11, 2.0L 147 kW Gasoline Engine . . . . . . . . . . . . . . . . 127
7.5 Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
8 Transmission, Transporting and Securing to Assembly Stand . . . . . . . . . . . . . . . . . . . . . . 131
9 Transmission Fluid and Transmission Fluid Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
9.1 Transmission Fluid Filter, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
9.2 Fluid Level, Checking and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
9.3 Fluid, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
10 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

1 No Repairs to Gears and Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

1 Flange Shaft or Stub Shaft Seals, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.1 Component Location Overview - Seals . . . . . . . . . w. a.g.en. A. G. ..V.o.lk.sw. a. g.e.n .A.G.d.oe.s. . . . . . . . . . . . 145
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1.2 Left Flange Shaft Seal, Replacing . . . . . . . . b. y.V.o. . . . . . . . . . . . . . . . . . . . . . .ot.g.ua. . . . . . . . 146
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1.3 Right Flange Shaft or Stub Shaft Seal, Replacing ho
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2 Special Tools . . . . . . . . . . . . . . . . . .ss.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ac. . 151
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3 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

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1 General Repair Information
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⇒ “1.1 Tools”, page 1
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⇒ “1.2 Transmission”, page 1
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⇒ “1.3 Brief Overview - Guide”, page 2
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⇒ “1.4 O-Rings, Gaskets and Seals”, page 3
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⇒ “1.5 DSG® Transmission Fluid”, page 3
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⇒ “1.6 Bolts and Nuts”, page 5
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⇒ “1.7 Electrical Components”, page 5

This Repair Manual Was Developed for the Technician.
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It should offer support and help. Using ELSA offers the ability to
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– Click the Feedback Button at the top in the menu toolbar.

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More Information on the Dual-Clutch Transmission DSG®.
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For more information about the transmission functions. Refer to
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A complete list of special tools and workshop equipment used in
the repair manual can be found at the beginning of each repair
section and in the “Special Tools and Workshop Equipment” fold‐
er.
Uncertainties often exist on smaller screws with lower tightening
specifications. The Torque Wrench 2-10Nm - VAG1783- can be
used on these screws.
1.2 Transmission
Always make sure that no dirt or contaminants enter an »open«
transmission. Any dirt that enters can cause transmission failure,
especially if the DSG Transmission Mechatronic - J743- and/or
the oil pump are »exposed«.
♦ Do not run the engine and do not tow the vehicle if the trans‐
mission cover is removed or if there is no transmission fluid
inside the transmission.
♦ Thoroughly clean the connection points and the area around
them first, and then loosen them.
♦ When installing the transmission, make sure the alignment
sleeves are seated correctly between the engine and the
transmission.
1. General Repair Information 1

♦ Place the removed parts on a clean surface and cover them

so that they do not become contaminated. Use foil and paper.
Only use lint-free cloths.
♦ Only install clean components. Install original parts immedi‐
ately after removing them from their packaging.
♦ Carefully cover or seal opened components if repairs are not
performed immediately.
1.3 Brief Overview - Guide
1 - Filter
❑ Refer to
⇒ “9 Transmission Fluid wage
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Filter”, page 132 ir se
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2 - Check Plug.
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Filter”, page 132
❑ Near the pendulum sup‐
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3 - Drain Plug
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⇒ “1.5 DSG® Transmis‐
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sion Fluid”, page 3

❑ This bolt is no longer in‐
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The oil can be drained

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4 - Transmission Fluid Cooler
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5 - DSG Transmission Mecha‐
tronic - J743-
❑ Refer to
⇒ “1 Electrical and Elec‐
tronic Components,
Component Locations in DSG® Transmission”, page 33
6 - Transmission Input Speed Sensor - G182- and Clutch Oil Temperature Sensor - G509-
❑ Refer to
⇒ “1 Electrical and Electronic Components, Component Locations in DSG® Transmission”, page 33 .
7 - Oil Pump
❑ Refer to ⇒ “3 Oil Pump, Removing and Installing”, page 57
8 - Clutch Cover for the DSG®
9 - Dual Clutch
❑ Refer to ⇒ “1 Overview - Dual Clutch”, page 15
2 Rep. Gr.00 - General, Technical Data

1.4 O-Rings, Gaskets and Seals

♦ Replace the O-rings, seals and gaskets.
♦ Flange shaft and selector shaft seals are illustrated as shaft
seals.
♦ After removing the gaskets and seals, check the contact sur‐
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♦ Before installing the seals, lightly oil the outer circumference
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♦ Only use DSG® transmission fluid. Other lubricants cause
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♦ The open side of the gaskets point toward the fluid to be sealed
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♦ After installing, check transmission fluid level and fill. Refer to

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1.5 DSG® Transmission Fluid
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⇒ “1.5.1 Fluid Function”, page 3
⇒ “1.5.2 Transmission Fluid Filter, When To Change ”,
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Shake the bottles before opening.

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Fluid is available as an original part. Original part number. Refer
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The Quality of Transmission Fluid Is Crucial to Transmission
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Do not mix additives into the transmission fluid. Do not fill with a Prote AG.
different transmission fluid.
Determine the correct fluid and other important information. Refer
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page 4 .
The drained transmission fluid must not be used again.
Caution
Be very careful when handling transmission fluid. Dispose of

drained transmission fluid correctly.
1.5.1 Fluid Function

The fluid does not just »lubricate« the transmission.
Imagine: the filter also transports the finest differential abrasive
parts in both filters. The fluid makes sure the lubricating film does
not wear off the differential tooth flanks. At the same time, it acts
as a switch valve pressure medium to enable it to perform its
functions.
It also seals the selector lever and helps the synchronizer rings
when shifting gears. The fluid conserves and transports warmth

and minimizes noise. The fluid performs many functions. The

DSG® transmission fluid fulfills many requirements.
To maintain this degree of performance, the filter on the trans‐
mission should be replaced during the oil maintenance service.
1.5.2 Transmission Fluid Filter, »When To

Change«
The transmission fluid filter does not need to be changed in every
case.
Do Not Replace the Filter If
♦ The transmission fluid cooler or its O-rings were replaced and
no coolant has entered the transmission fluid.
♦ The selector shaft seal was replaced.
♦ The flange or stub shaft seal was replaced.
♦ Leaking Mechatronic covers, multi-plate clutch or oil pump
were replaced.
♦ The Transmission Input Speed Sensor - G182- with Clutch Oil
Temperature Sensor - G509- was replaced. agen
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♦ The 60,000 km maintenance interval was reached. auth eo
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♦ Coolant has entered the transmission fluid.
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♦ Metal shavings were found in the transmission fluid.
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♦ The clutch is burned or has a mechanical fault.
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1.5.3 Fluid and Fluid Level Troubleshooting
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For more information regarding the fluid. Refer to
⇒ “1.5.1 Fluid Function”, page 3 . But the fluid cannot disappear
»without a trace«.
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Fluid can only be missing if it has leaked from the transmission.
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– Determine where the fluid has leaked out of the transmission.
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Repair this leak first. Fill with new transmission fluid and make
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sure the level is »correct«. Refer to
om
⇒ “9 Transmission Fluid and Transmission Fluid Filter”, n in

or c
thi
page 132 .
te
sd
iva
o
r
Filling the fluid »just in case« does not correct a malfunction. It

rp
cu
o
does not help to find the malfunction and it gives a false sense of
f
en
ng
t.
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security.
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Cop py
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1.5.4 Transmission Fluid Drain and Check
ht
pyri by
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Plug -A-
cted agen
Prote AG.
Through transmission production date “09/20/2004”, transmis‐

sions were installed with two plugs.
Then the second plug was discontinued so that draining oil and
adjusting the oil level can both be done using the plug -A-.
A plastic overflow tube is located behind this plug (with 8 mm hex
socket head, tightening specification: 3 Nm). Its length deter‐
mines the fluid level in the transmission.

1.6 Bolts and Nuts

♦ Loosen or tighten bolts and nuts on covers or housing diago‐
nally.
♦ The tightening specifications given apply to unoiled bolts and
nuts.
♦ Use a wire brush to clean the threads of the bolts that were
installed with locking fluid. Install the bolts with Locking Fluid
- AMV 185 101 A1- .
♦ Clean all threaded holes containing self-locking bolts, with a
thread tap to remove any locking fluid residue. Otherwise the
bolts could shear the next time they are removed.
♦ Always replace self-locking bolts and nuts.
1.7 Electrical Components

Almost everyone has been shocked at one time or another when
coming into contact with a metal object. The reason for this is the
build-up of static electricity in the human body. This charge can
damage the electrical components in the transmission and the
selector mechanism when touching them.
– Touch a grounded object, such as, a water pipe or a vehicle
hoist, before working on electrical components. Do Vnot touch
. olkswagen AG
the connector terminals directly. swagen AG does
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ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
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tion in
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Prote AG.

2 Troubleshooting
⇒ “2.1 Troubleshooting, General Information”, page 6
⇒ “2.2 Transmission Control Module Malfunction Behavior Infor‐
mation”, page 6
⇒ “2.3 Fault Finding, Special Information”, page 7
2.1 Troubleshooting, General Information

Before beginning any repair work, the cause of damage should
be determined using “Guided Fault Finding”.
Perform Guided Fault Finding using the Vehicle Diagnostic
Tester .
2.2 Transmission “Control Module Malfunc‐

tion Behavior” Information
The control module operates with highly developed software. This
software has the ability to execute electrical functions, monitor
and control within milliseconds. Everything modern transmission
electronics »have to offer« »is contained« in thisGcontrol module.
. Volkswagen AG
This should also be kept in mind duringlktroubleshooting.
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However, no electronics can do iwhat se
d b they were not designed to ran
do. Likewise, it is not possibleuthto
or detect electronically where the tee
or
transmission housing is leaking
ss
a and oil is escaping, for example. ac
However, it is possible to detect the effects of »low oil«. A failure
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nl
in “gear monitoring” would be recognized causing the control pt

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an
itte
module to respond that both clutches are open (no traction). y li

erm
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ility
This should be known during troubleshooting and also when
ot p
working with the Volkswagen tester. It is possible that the cause

wit
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for the malfunction might not be found during Guided Fault
hol
Finding .
spec
es, in part or in w
t to the co
In addition to the highly developed software, much has been done

to protect the transmission should there be a malfunction (safety
features). And so, when necessary, malfunctions are saved and
rrectness of i
a replacement program is started.

l purpos
Control Module Behavior During A Malfunction

If a component in the transmission malfunctions, the control mod‐
nform
ercia
ule reacts with a replacement function. In order to protect the

transmission, there are four different kinds of malfunctions:
m
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om
tio
1- The malfunction is so minor that it is possible to continue

n in
r c
driving with a replacement program while maintaining driv‐

o
thi
e
ing safety. The driver is not notified of this via the Selector
t
s
a
do
riv
Lever Transmission Range Display - Y5- . The display

p
cum
or
shows the selector lever position normally. If changes in

f
en
ng
t.
driving behavior can even be detected.
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2- The individual lever positions blink in the Selector Lever
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Transmission Range Display - Y5- . This signals to the driver
op Vo
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that the gear selection is currently not possible. Example:
agen
Prote AG.
Driving in reverse, lever in “R” and vehicle drives backwards.
If “D” is engaged in this situation, the letter “D” blinks in the
Selector Lever Transmission Range Display - Y5- . In this
case, the control module prevents 1st gear from being en‐
gaged to avoid damaging the transmission. The gear is only
engaged when the vehicle is stopped. If testing this, do so
carefully!
3- The Selector Lever Transmission Range Display - Y5- is
completely lit up and blinking. The selector lever position is
indicated/highlighted. Example: the transmission fluid tem‐
perature is too high. Reasons could include: towing a trailer

AG. Volkswagen AG d
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Golf Variant 2007 ➤ , Golf
thor Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011eo ➤
u ra
6-Speed
ss a Dual Clutch Transmission 02E - Edition 09.2015 c
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nl
pt
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with too large of a load, accessories installed on the front of
an
itte
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the vehicle, »lack of cooling air«.
erm
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ility
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4- The selector lever position engaged cannot be recognized.
wit
The Selector Lever Transmission Range Display - Y5-
is n
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blinks. Differences in the driving and shifting can definitely
ol ,
e
spec
be felt. It is not possible to shift into reverse. There is a »se‐
rious malfunction«, a sub-transmission is switched off,
t to the co
transmission repair is necessary.
2.3 Fault Finding, Special Information
rrectne
⇒ “2.3.1 Transmission Range Display, No R ”, page 7
ss
⇒ “2.3.2 Touch Function Malfunction, Not Changing Gears as
o
cial p
f
Usual”, page 7
inform
mer
⇒ “2.3.3 Drive Faulty - Insufficient Oil Suspected”, page 7
atio
om
⇒ “2.3.4 No Faults are Stored”, page 7
n
c
i
or
n thi
e
⇒ “2.3.5 Faults are Stored”, page 8

t
sd
iva
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pr
cum
⇒ “2.3.6 Malfunctions Outside Transmission ”, page 8
for
en
ng
t.
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2.3.1 Transmission Range Display, No “R” Cop py
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Simultaneous lighting of all segments on the transmission range cop Vo
by lksw
display indicates the transmission is in emergency mode. The
cted agen
Prote AG.
vehicle can no longer drive in reverse.
2.3.2 Touch Function Malfunction, Not

Changing Gears as Usual
Check the lock washers on the selector lever cable mounting
bracket at the top of the transmission. The washer -B- especially
must never be used twice.
The lock washer -B- can deteriorate if it loses its »residual stress«.
The -arrow- points to the selector lever cable adjustment screw.
2.3.3 »Drive« Faulty - Insufficient Oil Suspec‐

ted
First click here once. Refer to
⇒ “1.5 DSG® Transmission Fluid”, page 3 .
Only add fluid if it has definitely been seen that oil has leaked out.
Under any other circumstances it is just an »unnecessary ex‐
pense« that does not help.
2.3.4 No Faults are Stored

In this case, it is especially up to the technician to find the solution.
Experience shows that often a »fault« that is attributed to the
transmission was caused by other components or assemblies.
It can be the case that poor shifting behavior is a result of insuf‐
ficient engine air supply. Do not make such a mistake.
If such faults are to be eliminated, work can be performed sensibly
with the VWtester.
2. Troubleshooting 7
2.3.5 Faults are Stored

Find out which faults have been stored. Volkswagen testers offer
Guided Fault Finding . Using Guided Fault Finding cor‐
rectly can determine the cause of many malfunctions.
2.3.6 Malfunctions »Outside Transmission«

AG. Volkswagen
If, for example, there is a malfunction in the transmission:
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agen “ABSAG does n
signal missing” is stored in the transmission y Vol and perhaps another ot g
ua
db
control module also says: “ABS signal o ris missing”: Then do not con‐
e ran
tee
tinue to suspect the transmission au
th control module is »faulty«. or
a
ss c
The entry simply means: the transmission (and possibly other
ce
e
nl
pt
control modules) is waiting for a signal from the BUS but is not
du
an
itte
receiving it. In this case, the ABS control module would have a
y li
erm
ab
problem. The DSG Transmission Mechatronic - J743- must never
ility
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be removed here under any circumstances. In this example, the
wit
, is n
fault points to problems with the ABS.
h re
hol
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
om
tion in
or c
thi
te
s
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cum
or
f
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t.
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Cop py
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Prote AG.

3 Transmission Identification
⇒ “3.1 Transmission Code, Reading”, page 9
Example -arrow-:
GKF - Transmission Code

10.05.2 - 05/10/2002
14 - Plant Code
14 15 - Time
001 - Serial Number
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pt
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spec
es, in part or in w
t to the co
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nform
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ti
On some transmissions, additional code letters are applied on top

on in
c
of the transmission near the selector lever cable -arrows-.

or
thi
te
s
a
The transmission code is also listed on the vehicle data label.

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If the vehicle data label is not available, a different transmission

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was accidentally installed or there is no definite way to identify the
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op py
installed transmission, read the transmission code letters directly
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from the transmission. p by
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Reading the code directly off the transmission. Refer to Prote AG.
⇒ “3.1 Transmission Code, Reading”, page 9 .
3.1 Transmission Code, Reading

The transmission code is on every transmission in at least two
different locations.
3. Transmission Identification 9
One is on top of the transmission near the selector lever cable

-two arrows-.
If these cannot be read or are »on the head«, the transmission
code can also be read under the left subframe mount transmis‐
sion bracket.
To read the transmission code letters under the transmission

bracket directly from the transmission, the engine and transmis‐
sion must be supported. The left subframe mount transmission
bracket -A- must be removed. It is important to lower the engine/
transmission just enough until it is possible to slide the olksbracket
wage es n
ot g
toward the rear. If lowered any farther, the pendulum d by support
V ua
ran
could be damaged. After being assembled, the ori selector lever ca‐
se
tee
ble must be adjusted. Refer to aut
h or
ac
⇒ “5.6 Selector Lever Cable, Adjusting”, page
ss 80 .
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e
nl
pt
Perform the Following:
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– Remove the air filter housing.
ab
ility
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♦ Vehicles with a gasoline engine. Refer to ⇒ Rep. Gr. 24 ; Air
wit
, is n
Filter; Air Filter Housing, Removing and Installing .
h re
e
hol
spec
♦ Vehicles with a diesel engine. Refer to ⇒ Rep. Gr. 23 ; Diesel
es, in part or in w
Direct Injection System; Air Filter Housing, Removing and In‐
t to the co
stalling .
rrectness of i
– Remove the battery and the battery tray -arrows-. Refer to ⇒
Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Remov‐
l purpos
ing and Installing .

Mount the Engine Support Bridge - 10-222A- and support the en‐
nform
ercia
gine with the transmission. Do not lift.

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om
tion in
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thi
te
s
a
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or
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Prote AG.

– Remove the bolts -1 and 2- from the transmission bracket

-A-.
The bolts must be replaced.
– Then slightly lower the engine/transmission using the Engine
Support Bridge - 10-222A- spindles until the transmission
bracket can be removed.
AG. Volkswagen AG d
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In most cases two turns on the spindle are enough to remove the
ce
le
un
pt
bracket in direction of -arrow-.
an
d
itte
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After reading the transmission code, re-assemble in reverse order
ility
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of removal.
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– Follow all the instructions.
hol
spec
– Replace all the bolts from the left subframe mount.
es, in part or in w
t to the co
– Install all new bolts first by hand.
rrectness of i
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– Attach the transmission bracket -A- to the transmission using
nform
ercia
the bolts -1 and 2-. Refer to

⇒ “6.3 Tightening Specifications”, page 100 .
m
at
om
ion
– After installing the transmission bracket, always adjust the se‐
c
in t
or
lector lever cable. Refer to

his
te
iva
⇒ “5.6 Selector Lever Cable, Adjusting”, page 80 .

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pr
cum
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3. Transmission Identification 11
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4 Engine Codes - Engine Allocation
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⇒ “4.1 Codes”,au page 12
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4.1 Codes
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If original parts are needed for a repair, always pay attention to
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the transmission codes.
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DSG Transmission 02E
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JBT, JPS, KDC, GPW, GYQ, HLH, HBP, HFQ, HLE, HBQ, HRW,
KNF, KPY, KVV, HQH, HQQ, HQN, HQF, HQL, HXS, HUS, HUT, HXW,
t to the co
LRC HXU, JPL, KCW, JPJ, KCU, KMW, JPP, KCZ, KNC,
KMZ, KPQ, LQS, KMX, KPS, KQC, KPV, LQZ, LTL,
MKJ, MLW LQT, LTD, LQV, MMA, MSX,
rrectne
LTE, MFL, MFM, MSY, NJL, NJM,
MSU, MSV, NJK, NLQ, NVW, PBG,
NLP, PBF, PPY PPZ, PQL
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1.4L - 103 kW TSI 1.9L - 74 kW TDI 2.0L - 100 kW TDI 2.0L - 147 kW
in
1.4L - 125 kW TSI 1.9L - 77 kW TDI 2.0L - 103 kW TDI
form
TFSI
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2.0L - 125 kW TDI
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installed in Golf Wagon from MY 2007, Golf Wagon from MY 2010, Jetta from MY 2005 and
n
c
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or
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Jetta from MY 2011
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For the following data. Refer to the Parts Catalog.
pr
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♦ The individual gear ratios

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♦ Transmission fluid
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♦ Clutch allocation
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5 Capacity
Capacities DSG Transmission 02E
Refill Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
Change Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
Change after removing and installing the Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
Mechatronic with the transmission installed
Grease Transmission fluid for DSG® transmission 02E. Refer to the
Parts Catalog .
AG. Volkswagen AG d
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d by ara
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pt
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ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
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n in
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thi
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5. Capacity 13
6 Special Tools
Special tools and workshop equipment required
♦ Torque Wrench 2-10Nm - VAG1783-
AG. Volkswagen AG d
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es, in part or in w
t to the co
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hoGolf
ris Variant 2007 ➤ , Golf Variant 2010 ➤te,e Jetta 2005 ➤ , Jetta 2011 ➤
t or
au 6-Speed Dual Clutch Transmission ac 02E - Edition 09.2015
ss
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pt
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30 – Clutch
itte
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1 Overview - Dual Clutch
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Dual Clutch General Information
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The term »clutch« is not completely accurate on closer examina‐
tion. DSG® clutches always contain at least two »clutches« which
rrectne
is why the term “dual clutch” is more appropriate. In this case, the
clutch has two clutch disc packs - that is, a wet clutch. The outer,
larger clutch plate pack is called “K 1” (clutch 1). The “K 1” shifts
ss
reverse gear and »1st«, »3rd« and »5th« gears. The inner, small‐
o
cial p
f i
er “K 2” (clutch 2) shifts the gears »2«, »4« and »6«.
nform
mer
Assembling the dual clutch requires special care, because all of
atio
m
the components were balanced to each other at the manufacturer.

o
n
c
When positioning components during installation, do not rotate
i
or
n thi
e
out of their original position, otherwise imbalances will occur, cre‐

t
sd
va
ating diminished shift comfort and life span.

i
o
pr
cum
for
en
ng
Replacement clutches are supplied with the circlip already instal‐ yi

t.
Co
led. t. Cop py
rig
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To avoid the risk of turning parts from one another in the first p by
co Vo
place, it is shown here how the clutch is assembled in the trans‐
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mission housing and installed. Follow the descriptions exactly.
AG.
Refer to ⇒ “2 Dual Clutch, Removing and Installing”, page 18 .

Replacement Part Package
1. Overview - Dual Clutch 15

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Golf Variant 2007 ➤ , Golf Variant
orise 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 n➤
tee
h
6-Speed Dual Clutch Transmission
aut 02E - Edition 09.2015 or
ac
ss
ce
le
1 - Dual Clutch with Circlip
un
pt
an
d
itte
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erm
ab
Caution
ility
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The
♦ drive plate (upper
, is n
h re
section of the dual clutch)
e
hol
spec
of a new clutch is not se‐
es, in part or in w
cured with the circlip, it
t to the co
only sits »taut« in the
clutch.
rrectness of i
The
♦ drive plate must re‐
main engaged between
l purpos
the teeth of the outer

clutch plate carrier.
nform
ercia
If♦the drive plate is loos‐

ened, the plates in the
m
at
om
dual clutch can slip out of
ion
c
place and it cannot be ad‐
in t
or
his
e
justed correctly during in‐

t
iva
do
stallation under the cir‐
pr
cum
cumstances.
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2 - Circlip
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❑ Quantity: 10, with vari‐
o Vo
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ous thicknesses for ad‐
agen
Prote AG.
justment
❑ When installing the dual
clutch, the thickness of
the circlip must be de‐
termined. Refer to
⇒ page 28
3 - Clutch End Cover
4 - Clutch End Cover Circlip
Individual Components of Disassembled Dual Clutch
Caution
16 Rep. Gr.30 - Clutch

1 - DSG® Clutch/Clutch Hous‐

ing
❑ Outer clutch plate carri‐
er gen AG
. Volkswagen AG
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2 - Seal db
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❑ Quantity:
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ris
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3 - Inner
ss Clutch Plate Carrier c
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nl
❑ Do not remove
pt
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Caution
ility
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Do not lift or remove the
h re
inner clutch plate carrier
hol
spec
under any circumstan‐
es, in part or in w
ces. The clutch plates
t to the co
could rotate themselves.
rrectness of i
4 - Outer Clutch Plate
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❑ Quantity: 4
5 - Inner Clutch Plate
nf
ercia
o
❑ Quantity: 4
rm
m
atio
m
6 - Thrust Washer
o
n in
or c
7 - Circlip
thi
te
sd
iva
❑ If the circlip was re‐

o
r
rp
cu
moved in order to rein‐

o
m
f
en
ng
sert the plates, it should

t.
yi Co
op
be replaced with a new C py
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ring of the same thick‐
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ness.
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cted agen
Prote AG.
8 - Circlip
❑ After installing a new du‐
al clutch, redetermine
the thickness. Refer to
⇒ page 28 .
9 - Drive Plate
10 - Circlip
❑ Replace after removing
❑ Do not install any wavy circlips
1. Overview - Dual Clutch 17

AG. Volkswagen AG d
agen oes
olksw not
V
Golf Variant d b 2007 ➤ , Golf Variant 2010 ➤ , Jetta
y gu
ara 2005 ➤ , Jetta 2011 ➤
ise nte
6-Speedthor Dual Clutch Transmission 02E - Edition 09.2015
eo
au ra
ss c
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nl
2 Dual Clutch, Removing and Installing
pt
du
an
itte
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erm
ab
⇒ “2.1 Remove Clutch End Cover”, page 18
ility
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wit
⇒ “2.2 Clutch End Cover, Installing”, page 20
is n
h re
ol ,
⇒ “2.3 Dual Clutch, Removing”, page 24
spec
⇒ “2.4 Dual Clutch, Installing and Adjusting”, page 25
t to the co
Before the dual clutch can be removed, remove the clutch end
cover from the dual clutch. Refer to
rrectne
⇒ “2.1 Remove Clutch End Cover”, page 18 .
2.1 Remove Clutch End Cover
ss o
cial p
f i
Brief Description
nform
mer
The clutch cover closes the transmission toward the outside. A
atio
m
circlip holds the clutch end cover in place. Remove the circlip and
o
n
c
pry out the clutch end cover. Always replace the clutch end cover
i
or
n thi
e
and the locking ring. Never use a hammer to install the clutch
t
sd
va
cover and never lubricate the center seal or touch it. If this should
i
o
pr
cum
or
occur, the clutch cover will certainly leak!

f
en
ng
t.
yi Co
The transmission must be removed in order to work on the cover. t. Cop py
rig
gh ht
yri
– Remove the transmission. Refer to p by
co Vo
⇒ “6 Transmission, Removing and Installing, Jetta from MY
by lksw
cted agen
Prote
2005 , Golf Wagon from MY 2007 and Golf Wagon from MY
AG.
2010”, page 88 or
⇒ “7 Transmission, Removing and Installing, Jetta from MY
2011”, page 102 .
– Secure the transmission on the assembly stand. Refer to
⇒ “8 Transmission, Transporting and Securing to Assembly
Stand”, page 131 .
– Place a Drip Tray under the transmission.
– Drain the fluid.

Then the second plug was discontinued so that draining oil and
adjusting the oil level can both be done using plug -A-.
A plastic overflow tube is located in this hole (with 8 mm hex
– Remove this overflow pipe and drain the remaining transmis‐
sion fluid.
Note
Approximately 5 liters (5.28 qts) of transmission fluid will flow out.

Leave the Drip Tray under the transmission.
– Install the overflow pipe and tighten it to 3 Nm.

– Install the drain plug with a new seal -arrow-.

Tightening Specification: 45 Nm
– Remove the filter if necessary.

There are Often Uncertainties as to Whether the Filter Must Be
Replaced or Not.
The information on changing the fluid filter can help when making
this decision. Refer to
⇒ “1.5.2 Transmission Fluid Filter, When To Change AG. Vo4lk.swagen AG d
g”,enpage
swa oes
olk not
yV gu
edb ara
ris nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
e
hol
spec
es, in part or in w
t to the co
– Insert the new filter with the seat facing downward and tighten
rrectness of i
the housing to 20 Nm.
l purpos
– After repairing, the filter does not have to be changed again

when the filling fluid. nf
ercia
Removing the Clutch End Cover

rm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Dual Clutch, Removing and Installing 19

– Pry out the circlip -2- for the clutch end cover with a screwdriver
-1- in direction of -arrow- and remove.
– Remove the clutch end cover -2- with a screwdriver -1- (or a agen
AG. Volkswagen AG d
pry bar) through the opening for the starter in the direction
Volkswof
oes
not
gu
-arrow- and then remove the clutch end cover. ed by ara
n ris tee
utho or
a ac
ss
Note
ce
e
nl
pt
du
an
itte
♦ The clutch end cover that was removed cannot be installed
y li
erm
ab
again.
ility
ot p
wit
♦ Only install a »new« clutch end cover. Refer to
, is n
h re
⇒ “2.2 Clutch End Cover, Installing”, page 20 .
e
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
2.2 Clutch End Cover, Installing

m
a
om
tion in
r c
⇒ “2.2.1 Clutch End Covers Delivered without Bushings, Instal‐

o
thi
e
ling”, page 21
t
s
a
do
priv
cum
r
⇒ “2.2.2 Clutch End Covers Delivered with Bushings, Installing”,

fo
en
g
page 23
n
t.
yi Co
Cop py
There Are Two Types of Clutch End Covers.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Clutch end covers that are delivered without bushings. Refer

to
⇒ “2.2.1 Clutch End Covers Delivered without Bushings, In‐
stalling”, page 21 .
♦ Clutch end covers that are delivered with a white bushing. Re‐
fer to
⇒ “2.2.2 Clutch End Covers Delivered with Bushings, Instal‐
ling”, page 23 .
2.2.1 Clutch End Covers Delivered without

Bushings, Installing
♦ Clutch Cover Plate Guide Sleeve - T10302-
Always replace the clutch end cover and the locking ring. Never
use a hammer to install the clutch cover and never lubricate the
center seal or touch it.
Caution
Do not touch the hole in the center in a new clutch end cover.
The clutch end cover must not be touched inside the hole, oiled
or come into contact with any other substances in that area.
Leaks will develop.
– Only hold the clutch end cover as illustrated.
Caution agen AG. Volkswagen AG d

oes
lksw
o n ot g
yV u
Clean theris
eassembly
db sleeve before use and do not
ara
use
nte scratch‐
ed assembly
utho sleeves. eo
r
a ac
ss
ce
e
nl
pt
du
The new clutch cover must not have any oil in the around the
an
itte
y li
center seal and it must be dry.

erm
ab
ility
ot p
– Clean end of clutch shaft if necessary.

wit
, is n
h re
Do not apply adhesive to inside of the cover.

hol
spec
– If this is done, carefully remove the adhesive!

es, in part or in w
t to the co
Only coat outer edge of seal with DSG® transmission fluid.

– Place the sleeve on a level surface
rrectness of i
The center seal on new clutch end cover must now be »pre-
l purpos
formed«:
nform
mercia
a
om
tion in
or c
thi
te
s
a
do
priv
cum
or
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
21
copy Vo
by lksw
cted agen 2. Dual Clutch, Removing and Installing
Prote AG.
olkswagen AG
6-Speed Dual Clutch Transmission 02E - Edition 09.2015 swagen AG. V does
k not
Vol gu
d by ara
– Guide the clutch end cover horizontally and evenly over othe ris
e nte
whole sleeve. This brings the sealing lip into its installation
auth eo
ra
position. ss c
ce
e
nl
pt
– Remove the sleeve upward out of the clutch end cover and
du
an
itte
place it on the end of the clutch shaft.
y li
erm
ab
ility
ot p
wit
, is n
h re
e
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
– Guide the clutch end cover horizontally over the sleeve and
thi
te
sd
a
press it evenly onto its seat.

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi
Caution
Co
Cop py
t. rig
gh ht
yri
Handle with care. Any type of impact on the clutch end cover
p by
co Vo
lksw
will cause leaks.
by
cted agen
Prote AG.
The clutch end cover can be carefully lifted in its seat using a
screwdriver -arrow- until a »new« locking clip can be installed.
– Install the new circlip.
– Remove the Clutch Cover Plate Guide Sleeve - T10302- .

2.2.2 Clutch End Covers Delivered with Bush‐

ings, Installing
Always replace the clutch end cover and the locking ring. Never
use a hammer to install the clutch cover and never lubricate the
center seal or touch it.
Caution
Do not touch the hole in the center in a new clutch end cover.
The clutch end cover must not be touched inside the hole, oiled
or come into contact with any other substances in that area.
Leaks will develop. olksw AG. V agen AG
agen does
olksw not
yV gu
db ara
rise nte
tho eo
Do Not Remove the Bushing!
s au ra
c
s
ce
e
nl
The new clutch cover must not have any oil in the around the
pt
du
an
center seal and it must be dry.
itte
y li
erm
ab
– Clean the end of the clutch shaft if necessary.
ility
ot p
wit
, is n
Do not apply any stickers to inside of the clutch end cover.
h re
e
hol
spec
– If this is done, carefully remove the adhesive!
es, in part or in w
t to the co
Only coat outer edge of seal with DSG® transmission fluid.
rrectness of i
l purpos
– Install the clutch end cover with bushing.
nform
ercia
Caution
m
a
om
tion in
Handle with care. Any type of impact on the clutch end cover
or c
will cause leaks.

thi
te
s
a
do
priv
cum
or
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
The clutch end cover can be carefully lifted in its seat using a
screwdriver -arrow- until a »new« locking clip can be installed.
– Install the new circlip.

– Only remove the bushing once the circlip is installed.
2.3 Dual Clutch, Removing

To remove and install the dual clutch, the transmission must be
secured in a vertical position on the assembly stand.
– Remove the clutch end cover. Refer to
⇒ “2.1 Remove Clutch End Cover”, page 18 .
– Pry out the drive plate circlip -2- with a screwdriver -1- in gdi‐
rection of -arrow-. lkswa e es n
Vo ot gu
by ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
e
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Remove the drive plate in direction of -arrows-.

m
at
om
ion
c
in t
or
his
te
iva
do
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove the circlip -arrow-.

This circlip must be remeasured and replaced later when instal‐
ling. Volkswa AG. gen AG
agen does
olksw not
yV gu
Cautionsed b ara
nte
ri
ho eo
ut ra
Carefully remove
ss a the dual clutch. Make sure that no other parts c
of the clutch fall out. Never turn over the clutch for this reason!
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Carefully remove the dual clutch from the transmission.
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
om
tion in
or c
thi
te
s
a
do
riv
– Remove the pump shaft -A-.

p
cum
or
f
en
g
– The pump shaft will be inserted first after the installation of the
n
t.
yi Co
op
new clutch. Set the shaft down until then. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2.4 Dual Clutch, Installing and Adjusting

♦ Clutch Retaining Bar - T10303-
Caution
♦ The drive plate of a new clutch is not secured with a circlip,

it only sits “taut” in the clutch.
♦ Thus, press the drive plate into the outer clutch plate car‐
rier with both thumbs during the following steps.
♦ The drive plate must remain engaged between the teeth
of the outer clutch plate carrier.
♦ If the drive plate is loosened, the clutch plates in the dual
clutch can slip out of place. The dual clutch may not be
correctly set during installation under certain circumstan‐
ces.

• Transmission must be turned »vertically in assembly bracket«.

This is the only position in which the clutch axial play can later
be adjusted without malfunctions.
. Volkswagen AG
a gen AG d
• Make sure the transmission is secure Vol inside the Holding Fix‐
ksw
oes
not
gu
ture - VW313- or Engine And eTransmission
db
y Holder - ara
nte
VAS6095- . Refer to thoris
eo
⇒ “8 Transmission, Transporting
s au and Securing to Assembly ra
c
Stand”, page 131 . Do not turn it.
s
ce
e
nl
pt
du
• The large lamella carrier is inserted in all clutch discs in the
an
itte
y li
clutch. The large lamella carrier must not slipped out of the
erm
ab
lowest clutch disc.
ility
ot p
wit
is n
• Oil pump shaft is removed.
h re
ol ,
spec
• Do not install any wavy circlips
t to the co
– Take the dual clutch out of the packaging by pressing the drive
plate into the outer clutch plate carrier with both thumbs.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
for
en
ng
– Next, secure the drive plate in the outer clutch plate carrier
t.
yi Co
op
with the “old” circlip -A- from the removed clutch. C py
t. rig
gh ht
yri by
• Do not use the new circlip that was delivered with the package. cop Vo
by lksw
cted agen
Prote
• The circlip must be installed so that the tab of the drive plate
AG.
-arrow- and the color-marked teeth of the outer clutch plate

carrier are positioned between both ends of the circlip.
– Check the bottom of the dual clutch to see if the four hub gas‐
kets are seated correctly and engage them in one another if
necessary.
• The ends of the rings should not stand over one another.
– Turn the rings one time. They must move freely and must not
stick.

Important! Installation Position of the Drive Plate

– Verify that the protruding tab -arrow- of the drive plate is posi‐
tioned between the color-marked teeth of the outer clutch plate
carrier.
If no marking is available:
– Mark the location of the tab to the outer clutch plate carrier
circumference with a waterproof marker as shown.
• When installing, the drive plate tab must be placed back on
this marked location.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
– Insert the Clutch Retaining Bar - T10303- in the position on the
h re
clutch end cover as shown.
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
– Set the dual clutch using rotating and lifting movements into
te
sd
a
the clutch housing, but do not let it fall in. Press the drive plate
iv
o
r
rp
cu
into the outer clutch pack carrier with both thumbs in direction
o
m
f
en
ng
of -arrows- to install.
t.
yi Co
op py
Do not install on clutch. The clutch is inserted with the cover as it
t. C rig
gh ht
yri
was in the packaging. p by
co Vo
by lksw
cted agen
Prote AG.
• A second technician should hold the Clutch Retaining Bar -

T10303- .
Note
♦ The retaining pin remains there until clutch end cover is in‐
stalled.
♦ The dual clutch must not be turned any more now, otherwise
the Clutch Retaining Bar - T10303- could be twisted in its po‐
sition.

wage es n
– Remove and dispose of the old locking ring -2- using a screw‐y Volks ot g
ua
driver -1- in direction of -arrow-. ris
ed
b ran
tee
tho or
s au ac
Caution s
ce
e
nl
pt
du
an
itte
Do not remove or lift the inner clutch plate carrier, under any
y li
erm
ab
circumstances. The clutch plates could rotate themselves.
ility
ot p
wit
, is n
h re
e
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
om
tio
– Remove the drive plate from the installed clutch in direction of
n in
r c
-arrows-, if necessary, use a screwdriver to carefully pry it out

o
thi
te
of the teeth of the outer clutch plate carrier.
s
a
do
priv
cum
r
– Move the drive plate to the side.

fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Identifying the Circlip for the Dual Clutch.

– Select the 2 mm thick ring from the circlips delivered and install
it -arrow-.
Note
For the initial measurement, temporarily insert 2 mm thick circlip.

After the measurement has been determined, replace it with the
final circlip.
First Measurement
• The Clutch Retaining Bar - T10303- remains installed.
– Install the Dial Gauge Holder - VW387- on the transmission
flange.

– Place the -dial gauge test probe- on the input shaft.

– Set the -dial gauge- to “0” with 2 mm pretension.
– Raise the dual clutch
agen
up
AG. Vas
olksfar
wagas the
en AG dostop and note the meas‐
urement result.
Volksw es n
ot g
by ua
ed ran
SecondhoMeasurement
ris tee
t or
au a
• The
ss Clutch Retaining Bar - T10303- remains installed.
c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ol ,
spec
t to the co
rrectnes
– Place the dial gauge test probe on the
s o
-inner clutch plate carrier hub-.
cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
e
Do not place the dial gauge test probe on the circlip.

t
sd
iva
o
pr
cum
for
– Set the -dial gauge- to “0” again with 2 mm pretension.

en
ng
t.
yi Co
op
– Raise the dual clutch up as far as the stop again and note this
C py
ht. rig
measurement as well
rig ht
py by
co Vo
by lksw
cted
Now the Calculation Will Be Made to Determine Which of the Re‐
agen
Prote AG.
maining Nine Circlips Will Be Finally Installed:
– Use this formula:
2nd measurment value - 1st measurment value + 1.85 mm =
circlip thickness
– Note the result.
The remaining nine circlips are staggered in 0.1 mm increments.
– Measure all the circlips and determine the one that is the clos‐
est match to the result.
Determined Measurement for New Circlip
the New Circlip
2.27 mm 2.3 mm
2.24 mm 2.2 mm
Note
If the measurement determined for the new circlip is 2 mm, the

circlip that was inserted temporarily remains installed.

– Remove the 2 mm circlip and replace it with the circlip that was
measured.
– Dispose of all other remaining circlips and the 2 millimeter thick
circlip.
Note
Circlips must only be installed one time.
lkswage es n
o ot g
yV ua
– Insert the pump shaft by lifting the pump shaft and turning it ised b ran
slightly -arrow- so that it slides all the way into the splines.uthor tee
or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ol ,
e
spec
t to the co
rrectne
– Insert the drive plate into the dual clutch.
• The protruding tab on the drive plate -arrow- must be installed
ss
between the marked teeth or the marking applied to the outer
o
cial p
f
clutch plate carrier.
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Install the »new« drive plate circlip.

• The circlip must be installed so that the tab of the drive plate
and the color-marked teeth of the outer clutch pack carrier are
positioned between both ends of the circlip.
• The circlip must be completely engaged.
– Check the exact installation position of the circlip and that the
circlip is engaged using a screwdriver.

– Now remove the Clutch Retaining Bar - T10303- between the

dual clutch and the housing.
– Install the clutch end cover. Refer to
⇒ “2.2 Clutch End Cover, Installing”, page 20 .
When the Installation Is Completed, the Clutch Is Adjusted Cor‐
rectly.
– Install the transmission. Refer to
⇒ “6.2 Transmission, Installing”, page 97 or
⇒ “7.4 Transmission, Installing, Jetta MY 11, 2.0L 147 kW
Gasoline Engine”, page 127 .
– Fill with transmission fluid. Refer to
⇒ “9.3 Fluid, Draining and Filling”, page 136 .
– After installing the transmission, perform the basic set-
ting using the Guided Functions using the Vehicle Diag‐
nostic Tester . Volkswa AG. gen AG
agen does
olksw not
yV gu
db ara
rise nte
tho eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
te
iva
do
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3 Special Tools
♦ Clutch Cover Plate Guide Sleeve - T10302-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ol ,
spec
♦ Clutch Retaining Bar - T10303-
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

34 – Controls, Housing
1 Electrical and Electronic Compo‐
nents, Component Locations in
DSG® Transmission
The electric/electronic components are located inside the trans‐
mission.
The Selector Lever Sensor System Control Module - J587- and
the Shift Lock Solenoid - N110- are located on the selector lever.
1 - DSG Transmission Mecha‐

tronic - J743-
❑ Behind the »large« met‐
al cover
❑ Removing and installing
with transmission instal‐
led. Refer to
⇒ “1.1 DSG Transmis‐
sion Mechatronic J743 ,
Removing and Instal‐
ling, Transmission In‐
stalled”, page 34 .
❑ Removing and installing
with transmission re‐
moved. Refer to
⇒ “1.2 DSG transmis‐ lkswage es n
sion Mechatronic J743 , d byV
o ot g
ua
Removing and Instal‐ o
ir se
ran
tee
ling, Transmission Re‐ au th or
ac
moved”, page 45 . ss
ce
e
nl
pt
2 - Transmission Input Speed

du
an
itte
Sensor - G182- and Clutch Oil

y li
erm
ab
Temperature Sensor - G509-

ility
ot p
❑ The DSG Transmission

wit
, is n
Mechatronic - J743-
h re
e
must be removed first

hol
spec
before the sensor can

es, in part or in w
t to the co
be removed. Refer to
⇒ “1.1 DSG Transmis‐
sion Mechatronic J743 ,
Removing and Instal‐
rrectness of i
ling, Transmission In‐

l purpos
stalled”, page 34 .
3 - Selector Lever - E313-
nform
ercia
❑ For more information on

m
the selector lever. Refer

a
om
ti
to
on in
c
⇒ “5 Selector Mecha‐
or
thi
e
nism”, page 62
t
s
a
do
priv
cum
or
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Electrical and Electronic Components, Component Locations in DSG® Transmission 33

1.1 DSG Transmission Mechatronic -

J743- , Removing and Installing, Trans‐
mission Installed
⇒ “1.1.1 Mechatronic, Removing, Transmission Installed”,
page 34
⇒ “1.1.2 Mechatronic, Installing, Transmission Installed”,
page 39
⇒ “1.2 DSG transmission Mechatronic J743 , Removing and In‐
stalling, Transmission Removed”, page 45 .
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Used Oil Collection and Extraction Unit - SMN372500- n AG. Volkswagen AG do
swage es n
♦ Oil Filler - VAS6262A- byV
olk ot g
ua
d ran
ir se
♦ Speed Sender Release Tool - T10465- th o tee
or
au ac
ss
1.1.1 Mechatronic, Removing, Transmission
ce
e
nl
pt
Installed
du
an
itte
y li
erm
ab
ility
ot p
transmission.
wit
is n
h re
Any dirt that enters can cause transmission failure, especially if
ol ,
e
spec
the DSG Transmission Mechatronic - J743- and/or the oil pump
are »exposed«.
t to the co
In regard to »contaminated oil«, also observe information on
changing the oil filter. Refer to
rrectne
⇒ “1.5.2 Transmission Fluid Filter, When To Change ”, page 4 .
The Mechatronic can get stuck on the alignment pins when the
ss
transmission is very warm. Let the transmission cool down.
o
cial p
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– Move the selector lever into “P”.
form
mer
– Disconnect the battery ground cable. Refer to ⇒ Electrical atio

m
Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and

o
n
c
i
or
Connecting .
thi
te
sd
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– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.

i
o
pr
cum
or
Gr. 50 ; Noise Insulation .

f
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If present: t. Cop py
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– Remove the connecting hose between the charge air cooler p by
co Vo
and the charge air pipe. Refer to ⇒ Rep. Gr. 21 ; Charge Air
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System .
AG.
Only on the 1.4L Engine

– Move the lock carrier into the service position. Refer to ⇒ Body
Exterior; Rep. Gr. 50 ; Lock Carrier; Service Position .
Continuation for All Vehicles
Note
It is possible that parts, which have nothing to do with the Me‐

chatronic unit, will have to be removed. It depends on the vehicle
equipment. Make sure there is enough room around the Mecha‐
tronic unit.
34 Rep. Gr.34 - Controls, Housing

♦ Depending on the vehicle, the parts could be:

♦ Fan mount -arrow-
♦ Additional lines for the A/C systems
♦ Charge or cold air pipes
Caution
There is a risk of damaging the DSG Transmission Mecha‐

tronic - J743- with static electricity.
♦ Do not touch contacts in DSG Transmission Mechatronic
- J743- connector with hands.
– To discharge any static electricity, touch the vehicle ground

with hand (without wearing a glove). Refer to
⇒ “1.7 Electrical Components”, page 5 .
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– Turn the Mechatronic connector lock -1- »counter-clockwise«
d byV
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to release and disconnect the connector. o
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The connector is located on the transmission near the starter
erm
ab
ility
-A-.
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es, in part or in w
t to the co
– Remove the wires and bracket from the front of the transmis‐
rrectness of i
sion cover -arrows- (two M6 nuts).
l purpos
Tightening Specification for the nuts: 10 Nm

– Position lines in cover area upward and tie up.
nf
ercia
orm
– Place the Used Oil Collection and Extraction Unit -
m
atio
m
SMN372500- under the transmission near the »large« cover.

o
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Caution
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Fluid will leak out of the cover when the bolts are removed. Risk
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of injury due to hot transmission fluid. Cop py
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cted agen
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– Loosen bolts on the transmission cover -arrows- diagonally
first and then remove them. Hold the cover in place at the same
time.
– Drain the gear oil and remove the cover and seal.
Approximately three liters (3.1 quarts) of transmission fluid will
drain out.
Note
Always replace the »small« oil pump cover, the seal and the bolts
on the transmission cover.

AG. Volkswagen n AG do
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– Remove the oil pump cover -A-. ed
by
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es, in part or in w
t to the co
– Remove the bolts -2 and 3- from the transmission pendulum
rrectness of i
support. Refer to ⇒ Rep. Gr. 10 .
l purpos
The transmission can now be »pressed down« slightly to remove

the Mechatronic.
nf
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Before handling the Mechatronic, touch a grounded object again. cop Vo
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Refer to ⇒ “1.7 Electrical Components”, page 5 .
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– Release the connector -1- of the Transmission Input Speed

Sensor - G182- and Clutch Oil Temperature Sensor - G509-
using the Speed Sensor Release Tool - T10465- .

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♦ If the Speed Sender Release Tool - T10465- is not available,
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the connector can be removed by carefully using two screw‐ , is n
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drivers as follows:
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♦ Press only on the release with the screwdriver -1-. Do not use
t to the co
a screwdriver as a lever.
♦ Loosen the connector with the screwdriver -2-.
rrectness of i
♦ Be very careful. The connector locking mechanisms can
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break. Replace the sensor if this happens.
nform
ercia
Do Not Pull On the Wire

m
– Disconnect the connector.
at
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– First remove line from the lower clamp -arrow I-.

t.
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– Then remove from the second clamp -arrow II- and move it to yri
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the side. Do not kink line.
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– Loosen and remove the bolts -1 through 10- in the specified

sequence.

– Carefully pull the Mechatronic out of the transmission housing

until the sensor arm -B- on rear side is no longer located in
transmission housing.
When handling the Mechatronic, be particularly aware of the
»long« sensor arm -B-.
– Carefully move the DSG Transmission Mechatronic - J743-
downward.
Store the Mechatronic Properly
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Caution
c by lksw
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Never lift the Mechatronic by the »sensor arm« and never let
it rest on the arm.

Replace the Mechatronic if the »arm« Gets Damaged.
1.1.2 Mechatronic, Installing, Transmission

Installed
Before handling the Mechatronic, touch a grounded object again.
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AG. Volkswagen AG d
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ris ➤ , Jetta 2011 ➤
ed
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♦ The DSG Transmission Mechatronic - J743- and the trans‐ Prote
cted AG.
agen
mission must be the same temperature. Otherwise the align‐
ment pins will not »clamp« during installation.
♦ Make sure the Transmission Input Speed Sensor - G182- and
the Clutch Oil Temperature Sensor - G509- are installed be‐
fore installing the Mechatronic.
♦ Do not pinch the line.
– Carefully mount the Mechatronic onto the alignment pins

-arrow-. The goal is for the »sensor arm« to be in its
-installation position-.

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– Hold the Mechatronic facing up. The sensor arm must not
n
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i
or
touch the sensor wheel. -Detail-

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– Make sure the Mechatronic unit is installed correctly.

pr
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en
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– Install the new bolts -1 through 10- hand-tight.

t.
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– Tighten the bolts to 5 Nm + 90° (1/4 turn) in the specified se‐
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– Engage the wire -A- first into the upper and then the lower tab
-arrows-.
– Connect the connector.

– Replace both -O-rings- if installing the »old« Mechatronic.

– Coat the O-rings with DSG® transmission fluid.
A »new« Mechatronic already has »new« O-rings.
– Replace the transmission cover gasket.
– Clean the sealing surface on the transmission.
– Make sure the seal fits correctly.
– Place the transmission cover -A- over the Mechatronic. Be

careful not to pinch any wires when doing this.
– Install new bolts -arrows- and tighten to 10 Nm diagonally and
in several steps.
– Attach the cable bracket to the transmission cover and tighten

the nuts -arrows- to 10 Nm.AG. Volkswagen A
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– Set the new oil pump cover -A- in place and tighten the bolts
-arrows- in a diagonal sequence to 8 Nm in stages.
rrectness of i
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nform
mercia
at
om
ion
c
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42
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Rep. Gr.34 - Controls, Housing
AG.
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Connect the connector byV
o -A- from the DSG Transmission
lk ot g
ua Mecha‐
tronic - J743- ras ise follows.
d ran
tee
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– The arrow
ss
au
-D- on the Mechatronic -B- must line up with the
ac
connector -A- as well as with the tab -C-.
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– Connect the connector -A- carefully all the way and then turn
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the lock »clockwise« in the direction of -arrow-.
erm
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ility
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– Install the hose between the charge air cooler and the charge
wit
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air pipe, if was removed earlier. Refer to ⇒ Rep. Gr. 21 ;
h re
ol ,
Charge Air System .
spec
– Attach the pendulum support to the transmission using new
t to the co
bolts. Refer to ⇒ Rep. Gr. 10 .
– Reinstall any removed vehicle parts.
rrectne
– Connect the battery and follow the steps after connecting the
battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery;
ss
Battery, Disconnecting and Connecting .
o
cial p
f inform
– Do not start the engine.
mer
atio
m
– Change the filter if the fluid is dirty.

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– Replace the DSG® fluid and filter. Refer to
te
sd
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⇒ “9 Transmission Fluid and Transmission Fluid Filter”,

iv
o
pr
c
page 132 . um
for
en
ng
t.
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Co
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SMN372500- under the transmission near the drain plug.
t. C rig
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pyri by
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cted agen
Prote AG.
– Remove the drain plug near the pendulum support -arrow-.

– Measure the length of the vent pipe, dimension -a- before in‐
stalling Oil Filler - VAS6262A- on the oil bottle and shorten the
pipe if necessary. Refer to ⇒ page 134 .
Dimension -a- = 210 mm
Note
Dimension -a- is measured starting from the shaft (the green sur‐
face) on the Oil Filler - VAS6262A- .
– Install the Oil Filler - VAS6262A- into the check hole hand-
tight.
AG. Volkswagen AG d
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– Shake the bottles before opening. d by V gu
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– Attach the Oil Filler - VAS6262A- to the oil bottle. Beut sure to
ho eo
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read the instructions. Refer to ⇒ page 133 . ss a c
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– Fill three (3.1 quarts) liters of fluid.
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– To change containers, close the shut-off valve or hold the Oil
erm
ab
Filler - VAS6262A- higher than the transmission.
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Start the engine and check the fluid level. The Oil Filler -
h re
VAS6262A- remains installed.
e
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spec
es, in part or in w
– Check the fluid level and fill if necessary. Refer to
t to the co
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.
rrectness of i
50 ; Noise Insulation .
l purpos
– Connect the Vehicle Diagnostic Tester .
– Perform a basic setting on the DSG Transmission Mechatronic

nform
ercia
- J743- .
m
at
om
ion
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or
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Golf Variant 2007 ➤ , Golf Variant A2010
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6-Speed Dual agen
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1.2 DSG transmission Mechatronic - J743- , au
tho eo
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Removing and Installing, Transmission
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⇒ “1.2.1 Mechatronic, Removing, Transmission Removed”, page
ility
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45
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⇒ “1.2.2 Mechatronic, Installing, Transmission Removed”,
e
hol
page 50
spec
es, in part or in w
t to the co
rrectness of i
♦ Used Oil Collection and Extraction Unit - SMN372500-
l purpos
♦ Speed Sender Release Tool - T10465-

nform
ercia
transmission. Any dirt that enters can cause transmission failure,

especially if the DSG Transmission Mechatronic - J743- and/or
m
a
om
t
the oil pump are »exposed«.
ion in
or c
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1.2.1 Mechatronic, Removing, Transmission
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agen
Prote AG.
SMN372500- or Drip Tray under the transmission.
– Remove the bolt -A- near the pendulum support.
– Remove the overflow pipe.
– Tighten the overflow pipe to 3 Nm.

– Remove the filter if necessary.

There Are Often Uncertainties As to Whether the Filter Must Be
Replaced or Not. . Volkswage n AG n AG d
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The information on changing the fluid yV
ofilter
lks can help when makings not
gu
this decision. Refer to ise
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⇒ “1.5.2 Transmission FluidutFilter,
ho
r
When To Change ”, page 4 . eo
ra
sa c
– Insert the new filter with
s the seat facing downward and tighten
ce
le
the housing to 20 Nm.

un
pt
an
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ility
Note
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After repairing, the filter does not have to be changed again when
hol
spec
filling the fluid.
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove the transmission cover and the transmission fluid

pump cover.
nform
mercia
at
om
Note
ion
c
in t
or
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e
Always replace the transmission fluid pump cover, the bolts for
t
iva
do
the transmission fluid pump cover as well as the gasket and the
pr
cum
r
fo
transmission cover bolts.

en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Before handling the Mechatronic, touch a grounded object again.


– Release the connector -1- of the Transmission Input Speed

Sensor - G182- and Clutch Oil Temperature Sensor - G509-
using the Speed Sensor Release Tool - T10465- .
AG. Volkswagen AG d
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Note rised ara
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♦ If the Speed Sender
ss Release Tool - T10465- is not available, c
the connector can be removed by carefully using two screw‐
ce
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pt
drivers as follows:
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♦ Press only on the release with the screwdriver -1-. Do not use
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♦ Loosen the connector with the screwdriver -2-.
hol
spec
♦ Be very careful. The connector locking mechanisms can
es, in part or in w
t to the co
break. Replace the sensor if this happens.
rrectness of i
– Disconnect the connector.
l purpos
nform
mercia
at
om
– First remove line from lower clamp -arrow I-.

on
c
in t
or
– Then remove it from the upper clip -arrow II- and move it to the
his
te
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side. Do not kink line.

do
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t.
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Cop py
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rig ht
py by
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Prote AG.
– Remove the bolts -1 through 10- is a diagonal sequence. Start

with the bolt -1-.

AG. Volkswagen AG d
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t.
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Cop py
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Prote AG.
Replace all 10 -bolts-.

– Remove the DSG Transmission Mechatronic - J743- .
When handling the Mechatronic, be particularly aware of the
»long« sensor arm.
Caution
it rest on the arm.

lkswage es n
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Store the Mechatronic Properly
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1.2.2 Mechatronic, Installing, Transmission

Removed
Caution
it rest on the arm.
– Make sure the Transmission Input Speed Sensor - G182- and

the Clutch Oil Temperature Sensor - G509- are installed.
AG. Volkswagen AG d
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pt
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e
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n
c
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en
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cted agen
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– Replace both -O-rings- for the Mechatronic connection if an

»old« Mechatronic is being re-installed.
A »new« Mechatronic already has »new« rings.
– Coat the O-rings with DSG® transmission fluid.
AG. Volkswagen AG d
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– Carefully place the Mechatronic on the alignment pin -arrow-.
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The goal is for the »sensor arm« to be in its
an
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-installation position-.
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– The sensor arm must not touch the sensor wheel. -Detail-
– Do not pinch the line.
– Make sure the Mechatronic unit is installed correctly. lkswage es n
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All of the bolts -1 through 10- must be replaced. ir se
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nform
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t.
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Cop py
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co lksw
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cted agen
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– Install the bolts -1 through 10- »by hand«.

– Tighten all the bolts -1 through 10- in a diagonal sequence to
5 Nm. Then tighten an addition 90° in the same order. Start
with the bolt -1-.

– Install the Transmission Input Speed Sensor - G182- and

Clutch Oil Temperature Sensor - G509- wire in the upper
clamp -arrow II- first. Then install them in the lower clip
-arrow I-. gen AG
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– Press the connector
db
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Always replace uthe
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ra
transmission scover.
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nl
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Replace the transmission cover -gasket-.
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atio
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– Fasten bolts -arrows- for the transmission cover -A- »in a di‐
agonal sequence« to 10 Nm.
After Installing Transmission
– Fill the fluid without replacing filter. Refer to
page 132 .
– Connect the Vehicle Diagnostic Tester .
– Perform a basic setting on the DSG Transmission Mechatronic
- J743- .
1.3 Transmission Input Speed Sensor -

G182- and Clutch Oil Temperature Sen‐
sor - G509- , Removing and Installing
Both sensors are a single component and can only be replaced
together. They are »coated with oil« in transmission near the mul‐
ti-plate clutch. Before removing, the DSG Transmission Mecha‐
tronic - J743- must be removed.

Often, the sensor wire is pulled. It will get damaged. If the wire
was pulled, the sensor must be replaced.
Removing
– Remove the DSG Transmission Mechatronic - J743- . Refer
to
⇒ “1.1 DSG Transmission Mechatronic J743 , Removing and
Installing, Transmission Installed”,
gen AG page 34 n. AG d
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– Remove the boltut and carefully pry out the
ho sensor with screw‐e or
driver and/or
ss pliers.
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Install an »old« sensor only if:
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• The sensor is working correctly.
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• The wire was not pulled out during removal.
hol
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If this is not the case, a »new« sensor should be installed.
es, in part or in w
t to the co
– Coat the sensor with DSG® transmission fluid and then install
it.
rrectness of i
– Tighten the bolt to 10 Nm.
l purpos
– Install the DSG Transmission Mechatronic - J743- . Refer to

⇒ “1.1 DSG Transmission Mechatronic J743 , Removing and
Installing, Transmission Installed”, page 34 .
nf
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orm
Do not pinch line when installing the Mechatronic!
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2 Transmission Fluid Cooler, Remov‐

ing and Installing
Removing
♦ Hose Clamps - Up To 25mm - 3094-
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♦ Engine Bung Set - VAS6122- agen oes
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– Move the selector lever into “P”.orise nte
h eo
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– Remove the battery and thesbattery
s a tray. Refer to ⇒ Electrical c
Equipment; Rep. Gr. 27 ; Battery; Battery, Removing and In‐
ce
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nl
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stalling .
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– Place a lint-free cloth on to transmission fluid cooler and trans‐
erm
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mission to absorb escaping coolant.
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Note
es, in part or in w
t to the co
♦ The cooling system is under pressure when the engine is
warm.
rrectness of i
♦ Cover the coolant reservoir cap with a cloth and open it care‐
fully before removing the coolant hoses.
l purpos
– Disconnect the coolant hoses with Hose Clamps - Up To
nf
ercia
25mm - 3094- and remove them from the transmission fluid
orm
cooler.
m
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– Seal off the transmission fluid cooler connections with suitable
n in
or c
sealing plugs taken from the Engine Bung Set - VAS6122- .

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– Remove the bolts -A- and the transmission fluid cooler -B-.
Caution
Coolant must not drip into transmission!
Installing
2. Transmission Fluid Cooler, Removing and Installing 55

– Replace the O-rings -C- from the transmission fluid cooler

-B-.
– Mount the transmission fluid cooler -B-, at the same time, pay
attention to the O-rings -C-.
– Tighten the new bolts -A- to 20 Nm + 90° (1/4 turn).
– Attach the coolant hoses to the transmission fluid cooler and

remove the Hose Clamps - Up To 25mm - 3094- .
– Install the battery and the battery tray. Refer to ⇒ Electrical
stalling .
– Check the coolant level and fill if necessary. Refer to ⇒ Rep.
Gr. 19 .
– After repairing, check the transmission fluid level and fill. Refer
to ⇒ “9.2 Fluid Level, Checking and Filling”, page 133 .
Caution
Do not start engine during coolant level test if the transmission

AG. Volkswagen AG d
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Rep. Gr.34 - Controls, Housing
3 Oil Pump, Removing and Installing

♦ Wrench - Pump/Injector Long Reach - T10054- .
Brief Description
The oil pump can be replaced without removing transmission. The
vehicle must be raised and any covers installed on bottom of front
end must be removed. The control arm to suspension strut con‐
nection does not need to be separated. The drive axle also does
not have to be removed. “Perform basic calibration” is not needed.
Only the DSG® transmission fluid and pump cover have to be
replaced.
Removing
. Volkswagen AG
a gen AG does
– Remove the lower section of the left wheel housing liner. VoRefer
lksw not
gu
to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner;
ed
by Over‐ ara
nte
view - Front Wheel Housing Liner . tho
ris eo
au ra
– Place the Used Oil Collection and Extraction
ss Unit - c
ce
e
SMN372500- under the transmission.

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– Remove the bolt -A- near the pendulum support.
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– Remove the overflow pipe.

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– Tighten the overflow pipe to 3 Nm.

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– Replace the bolt seal -arrow-.

a
do
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– The Used Oil Collection and Extraction Unit - SMN372500-

fo
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remains under the transmission.

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3. Oil Pump, Removing and Installing 57

– Remove the bolts -arrows- and the oil pump cover -A-.
There is Still Oil in Oil Pump Cover
– Remove the bolts -arrows- and the pump -1- from the align‐
ment pins and pull the input shaft from the pump.
Remove the top bolt with the Wrench - Pump/Injector Long Reach
- T10054- .
Installing
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– Install the input shaft -A- all the way into the transmission. Turn
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the input shaft while doing this.
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– Always use a new metal seal -B-.
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• The two alignment pins -C- must be inside the transmission
es, in part or in w
housing.
t to the co
– When positioning the oil pump, pay attention to driveshaft
splines and correct seating on the alignment pins.
rrectness of i
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Different Oil Pump Bolts -1-

a
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tion in
c
All four bolts -arrows- with flat heads

or
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Tightening Specification
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♦ 5 Nm + 90° (1/4 turn)

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3 bolts with flat head, top bolt -arrow- with countersunk head
Tightening Specification
♦ Countersunk bolt: tighten with the Wrench - Pump/Injector
Long Reach - T10054- 8 Nm without additional turn
♦ Flat head bolts: 8 Nm +90° (1/4 turn)
– Set the new oil pump cover -A- in place and tighten new bolts
-arrows- in diagonal sequence and in several steps to 8 Nm.
Transmission does not have oil. »New« oil must now be added
and adjust to the correct oil level. Refer to
page 132 . agen
AG. Volkswagen AG d
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olks t
– Install the left wheel housing
ed
by liner. Refer to ⇒ Body Exterior;
V gu
ara
Rep. Gr. 66 ; WheelhoHousing Liner; Overview - Front Wheel ntee
ris
Housing Liner . s aut or
ac
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nl
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es, in part or in w
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3. Oil Pump, Removing and Installing 59

4 Selector Shaft Lever Gasket, Replac‐

ing
♦ Press Piece - Shift Rod/Alternator - VW423-
♦ Puller - Crankshaft/Power Steering Seal - T20143-
– Remove the selector lever cable from the transmission. Refer
to
⇒ “5.2 Selector Lever Cable, Removing and Installing, through
02/2009”, page 64 .
– Carefully pry the lever -A- off the selector shaft.
AG. Volkswagen AG d
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– Pry out the seal in the direction of -arrow-. ed by
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t to the co
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– Fill the space between the sealing/dust lip -arrow- halfway with
Sealing Grease - G 052 128 A1- .
s
– Lightly lubricate the outer edge of the gasket.

s o
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– Install the new gasket all the way. Do not tilt the gasket when
installing it.
• The closed side of the gasket -arrow- points to the Press Piece
- Shift Rod/Alternator - VW423- .
– Install the lever and tighten the nut to 20 Nm.
The Selector Shaft Lever Fits on the Splines in One Position Only.
. Volkswagen AG
a gen AG does
– Attach the selector lever cable to the transmission and adjust.Vol
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Refer to ⇒ “5.6 Selector Lever Cable, Adjusting”, page 80ed .
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4. Selector Shaft Lever Gasket, Replacing 61

5 Selector Mechanism
⇒ “5.1 Overview - Selector Mechanism, Vehicles through
02/2009”, page 62
⇒ “5.2 Selector Lever Cable, Removing and Installing, through
02/2009”, page 64
⇒ “5.3 Overview - Selector Mechanism, Vehicles from 03/2009”,
page 72
⇒ “5.4 Selector Mechanism, Removing and Installing, Vehicles
from 03/2009”, page 73
⇒ “5.5 Selector Lever Cable, Checking”, page 80
⇒ “5.6 Selector Lever Cable, Adjusting”, page 80
AG. Volkswagen AG d
⇒ “5.7 Selector Lever, Emergency Release”, page
lksw
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⇒ “5.8 Selector Lever Handle, Removing
ris
ed
b
and Installing”, ara
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page 82 ut
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⇒ “5.9 Button in Handle, Moving
s
into Installation Position”,
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page 85
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⇒ “5.10 Selector Mechanism, Checking”, page 86
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Move the selector lever into “P” and set the parking brake be‐
es, in part or in w
fore working with the engine running.
t to the co
rrectness of i
5.1 Overview - Selector Mechanism, Vehicles through 02/2009
l purpos
nform
mercia
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tion in
or c
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1 - Shift Cover with Handle

❑ Do not remove the han‐
dle unnecessarily. Only
the cover must be un‐
clipped for the emergen‐
cy release. Refer to
⇒ “5.7 Selector Lever,
Emergency Release”,
page 82 .
❑ Pull the button past its
pressure point before
removing the handle.
Secure the button with a
cable tie or some suita‐
ble wire. This prevents
the locking button from
being pushed back into
knob accidentally.
2 - Selector Lever and Selector
Mechanism
❑ With Shift Lock Solenoid
- N110-
❑ Emergency release.
Refer to
page 82 .
❑ Short description for re‐
moval and installation:
– Remove the center con‐
sole.
– Remove the selector

lever cable from the n AG. Volkswagen AG do
transmission. Refer toolkswage es n
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⇒ “5.2 Selector Lever d by
V ua
ran
Cable, Removing ori and
se
tee
Installing, through
aut
h or
ac
02/2009”, spage
s 64 .
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nl
pt
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– If necessary, disconnect or remove sections of the exhaust system. Refer to ⇒ Rep. Gr. 26 .
an
itte
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erm
ab
– Remove the heat shield under the selector mechanism.

ility
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– Adjust the selector lever cable after installing. Refer to

h re

hol
spec
es, in part or in w
t to the co
3 - Bolt with Spring

❑ 3 Nm
rrectness of i
4 - Pin
❑ Removing. Refer to
l purpos
⇒ “5.2 Selector Lever Cable, Removing and Installing, through 02/2009”, page 64 .
❑ Do not lubricate
nf
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or
5 - Locking Plate
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❑ Always replace after removing

o
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or c
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6 - Nut
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❑ 9 Nm
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❑ Quantity: 4
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7 - Gearshift Housing
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5. Selector Mechanism 63
8 - Adjusting Bolt
❑ 13 Nm
9 - Lock Washer
10 - Lock Washer
11 - Selector Lever Cable
❑ Do not grease the selector lever cable.
❑ Removing and installing. Refer to
⇒ “5.2 Selector Lever Cable, Removing and Installing, through 02/2009”, page 64 .
❑ Checking. Refer to ⇒ “5.5 Selector Lever Cable, Checking”, page 80 .
❑ Adjusting. Refer to ⇒ “5.6 Selector Lever Cable, Adjusting”, page 80 .
12 - Hex Nut with Collar
❑ 8 Nm
❑ Quantity: 4
5.2 Selector Lever Cable, Removing and In‐

stalling, through
swa
02/2009
gen AG
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After installation, the selector lever cable must be checked for

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ease of movement and adjusted.

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Removing
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– Move the selector lever into “S”.

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ol ,
spec
t to the co
rrectness o
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f inform
mer
atio
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n
c
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or
n thi
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Loosen the adjusting screw -arrow-.
Note
Use pliers to remove the lock washer -B- from the cable bracket.. Volkswag
Do not use a sharp-edged lever. This could damage theswselector
agen
AG en AG
does
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– Remove the lock washers -A and B-. The au lock washers must
t or
ac
later be replaced ss
when adjusting the selector lever cable.
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– Raise the vehicle.
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To remove the selector level cable or the selector mechanism, the
ility
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heat shield under the selector mechanism must be removed as
wit
follows:
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Caution
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Risk of damaging the decoupling element.
rrectness of i
♦ Do not bend the decoupling element more than 10°.
l purpos
♦ Do not load the decoupling element.

♦ Do not damage the wire mesh on the decoupling element.
nform
mercia
a
om
tio
– Loosen the nuts on the clamping sleeve -1- and then slide it
n in
or c
toward the rear.
thi
te
s
a
do
riv
– Remove the front tunnel brace -arrows- from the underbody.

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– If necessary remove the exhaust system bracket from the

subframe -arrows-.
– Tie up the front exhaust pipe.
ks wage es n
– If equipped, remove nuts -1 and 2-, and remove Vol the rear tunnel ot g
by ua
brace. ris
ed ran
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tho or
– Disengage the center muffler and the au rear muffler from the re‐ ac
ss
taining loops -arrows- and tie them to the body for example
ce
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nl
with a wire. Remove the exhaust system rear section, if nec‐
pt
du
an
essary.
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ility
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– Remove the underbody trim panel nuts -arrows-.
rrectne
– Remove the lock washers -2 and 3-.
s
– Lower the underbody trim panel on the inside just enough until
s o
cial p
f
the heat shield -1- for the center tunnel can be removed.
inform
mer
atio
om
n
c
i
or
n thi
te
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– Remove the -selector housing- from under the selector lever.
– Remove the locking plate on the cable mounting bracket. Al‐

ways replace the locking plate.

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The -shift housing- is pushed forward slightly on the selector lever
es, in part or in w
cable.
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rrectness of i
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The locking strap must be pushed forward in order to remove the

selector lever cable in direction of -arrow 1-.
– Push the -pin- upward with a screwdriver at the same time in
direction of -arrow 2-. Volkswa AG. gen AG
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– Insert the -screwdriver- from underneath while pushing the
l purpos
securing tab forward.
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For Clarity
AG. Volkswagen AG d
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nform
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tion in
or c
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– Remove the selector lever cable.

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Remove the selector lever cable from the selector housing.
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Installing by c lksw
cted agen
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Do not lubricate the selector lever cable.
– Route the selector lever cable making sure it is without ten‐
sion. Install also into the cable bracket on the transmission. Do
not secure yet with the lock washers. Do not clip in the ball
head.
– When installing, make sure the selector lever cable is routed

correctly.
If the heat shield underneath is bent, there will be noises. The
selector lever cable will then »flap« on the heat shield.
– Pay attention to the heat shield. Push it upward into the tunnel
in the direction of -arrow-.
– Position the selector housing on the selector lever cable.
lkswage es n
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– Install the selector lever cable into the selector mechanism.
ility
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– Insert the selector lever cable into the bracket and then insert
h re
the bolt through the eye from the top in the direction of
hol
-arrow 2-. spec

es, in part or in w
t to the co
Install the locking plate only after having checked the selector
lever cable for ease of movement. Refer to
⇒ “5.5 Selector Lever Cable, Checking”, page 80 .
rrectness of i
l purpos
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or
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– Secure the selector lever cable with a new securing plate to
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the cable bracket on the selector mechanism. Prote
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agen

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es, in part or in w
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Cop py
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gh ht
pyri by
Vo
o
– Install the selector housing. by c lksw
cted agen
Prote AG.
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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ k,sJetta
wage 2005 ➤ , Jetta 2011
n AG n AG d
oes ➤
not
ol
6-Speed Dual Clutch Transmission 02E d by - Edition 09.2015
V gu
ar
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ris tee
ho
– Install the heat shield -1- under the selector
sa
ut
mechanism and or
ac
attach with the lock washers -2 and s3-.
ce
e
nl
pt
du
– Attach the underbody trim panel to the body -arrows-.
an
itte
y li
erm
ab
– Install the exhaust system and align it without tension. Refer
ility
ot p
to ⇒ Rep. Gr. 26 .
wit
, is n
h re
– Install the tunnel braces under the exhaust system. Refer to
e
⇒ Body Exterior; Rep. Gr. 50 ; Tunnel Brace . hol
spec
es, in part or in w
t to the co
– Adjust the selector lever cable after installing. Refer to
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
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sd
iva
5.3 Overview - Selector Mechanism, Vehicles from 03/2009
o
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op
1 - Shift Cover with Handle
C py
ht. rig
rig ht
❑ Do not remove the han‐
py by
co Vo
by lksw
dle unnecessarily. Only Prote
cted AG.
agen
the cover must be un‐
clipped for the emergen‐
cy release. Refer to
page 82 .
❑ Pull the button past its
pressure point before
removing the handle.
Secure the button with a
cable tie or some suita‐
ble wire. This prevents
the locking button from
being pushed back into
knob accidentally.
❑ Selector lever handle,
Removing and instal‐
ling. Refer to
⇒ “5.8 Selector Lever
Handle, Removing and
Installing”, page 82 .
2 - Selector Mechanism with
Selector Lever and Selector
Lever Cable
❑ With integrated Selector
Lever Sensor System
Control Module - J587-
with Selector Lever -
E313- , Tiptronic Switch
- F189- , Selector Lever
Park Position Lock
Switch - F319- and Shift
Lock Solenoid - N110- .
❑ The selector lever cable
can only be replaced to‐
gether with the selector
mechanism

❑ Do not grease the selector lever cable.
❑ Removing and installing. Refer to
⇒ “5.4 Selector Mechanism, Removing and Installing, Vehicles from 03/2009”, page 73 .
❑ Checking. Refer to ⇒ “5.5 Selector Lever Cable, Checking”, page 80 .
❑ Adjusting. Refer to ⇒ “5.6 Selector Lever Cable, Adjusting”, page 80 .
3 - Bolt
❑ 8 Nm
4 - Hex Nut with Collar
❑ 8 Nm
❑ Quantity: 4
5 - Gearshift Housing
❑ Available only together with the selector mechanism. Refer to the Parts Catalog.
6 - Adjusting Bolt
❑ 13 Nm
7 - Lock Washer
8 - Locking Plate
5.4 Selector Mechanism, Removing andgIn‐

AG. en AG Volkswa
agen does
olksw not
stalling, Vehicles ifrom 03/2009
y V gu
d b ara
se n r tee
ho
⇒ “5.4.1 Selector Mechanism with
au Selector Housing, Removing
t or
ac
and Installing”, page 73 ss
ce
e
nl
pt
du
⇒ “5.4.2 Selector Mechanism without Selector Housing, Remov‐ an

itte
ing and Installing”, page 77 y li

erm
ab
ility
ot p
5.4.1 Selector Mechanism with Selector wit

, is n
Housing, Removing and Installing

h re
e
hol
spec
es, in part or in w
Brief Description
t to the co
The selector mechanism and the selector lever cable must be

separated from each other. Both are removed with the selector
housing.
rrectness of i
Remove the center console inside the vehicle interior.

l purpos
It is necessary to remove the heat shield under the vehicle.

nform
ercia
It is possible to remove and install the selector mechanism with

m
selector lever cable alone without the selector housing. Refer to

a
om
ti
⇒ “5.4.2 Selector Mechanism without Selector Housing, Remov‐

on in
c
ing and Installing”, page 77 .

or
thi
te
s
a
do
priv
cum
or
Note
f
en
ng
t.
yi Co
op py
After installation, the selector lever cable must be checked for
t. C rig
gh ht
yri
ease of movement and adjusted. p by
co Vo
by lksw
cted agen
Prote AG.
Removing
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
– Remove the selector lever handle and disconnect the con‐
erm
ab
nector -2- from the cover while doing so. Refer to
ility
ot p
⇒ “5.8 Selector Lever Handle, Removing and Installing”, page
wit
, is n
82 .
h re
hol
spec
– Remove the center console. Refer to ⇒ Body Interior; Rep.
es, in part or in w
Gr. 68 ; Center Console .
t to the co
– Disconnect the connector -1- from the selector mechanism to
the vehicle wiring harness.
rrectness of i
– Remove the air filter housing:
l purpos
♦ Gasoline engine. Refer to ⇒ Rep. Gr. 24 ; Air Filter; Air Filter

Housing, Removing and Installing .
nform
ercia
♦ TDI engine. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection

m
a
System; Air Filter Housing, Removing and Installing .
om
tion in
or c
thi
e

t
s
a
do
priv
cum
or
f
en
ng
Note
t.
yi Co
Cop py
t. rig
gh ht
Use pliers to remove the lock washer -B- from the cable bracket. pyri by
Vo
o
by c
Do not use a sharp-edged lever. This could damage the selector
lksw
cted agen
Prote
lever cable rubber grommet.
AG.
– Remove the lock washers -A and B-. The lock washers must
later be replaced when adjusting the selector lever cable.
To remove the selector level cable or the selector mechanism, the
heat shield under the selector mechanism must be removed as
follows:
Caution


– Loosen the nuts on the clamping sleeve -1- and then slide it
toward the rear.
– Remove the front tunnel brace -arrows- from the underbody.
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
ho eo
aut ra
ss c
– If necessary remove the exhaust system bracket from the
ce
e
nl
pt
du
subframe -arrows-.
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
e
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– If equipped, remove nuts -1 and 2-, and remove the rear tunnel
nf
ercia
brace.
orm
m
atio
– Disengage the center muffler and the rear muffler from the re‐
om
n in
taining loops -arrows- and tie them to the body for example
or c
with a wire. Remove the exhaust system rear section, if nec‐
thi
te
sd
a
essary.
iv
o
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cu
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m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove the underbody trim panel nuts -arrows-.

– Remove the lock washers -2 and 3-.
– Lower the underbody trim panel on the inside just enough until
the heat shield -1- for the center tunnel can be removed.
Note
A second technician is required under the vehicle to remove the

selector mechanism.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
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eo
h
6-Speed Dual Clutch Transmission 02E - Edition
s aut
09.2015 ra
c
s
ce
e
nl
– Remove the nuts -arrows- in the vehicle interior.
pt
du
an
itte
y li
– Remove the bracket -A-, if equipped.
erm
ab
ility
ot p
– Remove the selector mechanism -B- with the selector lever
wit
is n
cable and selector housing downward.
h re
ol ,
e
spec
Installing
t to the co
Install in reverse order of removal.
rrectne
Note
s
♦ Do not bend or kink the selector lever cable.
s o
cial p
f i
♦ Do not lubricate the selector lever cable.
nform
mer
♦ Tightening specifications. Refer to
atio
m
⇒ “5.3 Overview - Selector Mechanism, Vehicles from

o
n
c
03/2009”, page 72 .
i
or
n thi
te
sd
iva
o
pr
cum
or
– Install the heat shield -1- under the selector mechanism and
f
en
ng
attach with the lock washers -2 and 3-.

t.
yi Co
Cop py
t. rig
– Attach the underbody trim panel to the body -arrows-. Refer to yri
gh by
ht
⇒ Body Exterior; Rep. Gr. 50 ; Underbody Trim Panels . cop Vo
by lksw
cted agen
Prote
– Install the exhaust system and align it without tension. Refer
AG.
to ⇒ Rep. Gr. 26 .
– Install the tunnel braces under the exhaust system. Refer to
⇒ Body Exterior; Rep. Gr. 50 ; Tunnel Brace .
– Install the center console. Refer to ⇒ Body Interior; Rep. Gr.
68 ; Center Console .
– Install the selector lever handle. Refer to
82 .
– Adjust the selector lever cable. Refer to
– Check the selector mechanism. Refer to
⇒ “5.10 Selector Mechanism, Checking”, page 86 .
– Install the air filter housing:

5.4.2 Selector Mechanism without Selector

Housing, Removing and Installing
Brief Description
The selector mechanism and the selector lever cable must be
separated from each other. Both are removed together.
Remove the center console inside the vehicle interior.
A cord is attached to the selector lever cable prior to removal. The
cord is used to remove and install the selector lever cable be‐
tween the tunnel and the heat shield.
The selector mechanism with selector lever cable can be re‐
moved and installed together with the selector housing. Refer to
⇒ “5.4.1 Selector Mechanism with Selector Housing, Removing
and Installing”, page 73 .
Removing
– Remove the selector lever handle and disconnect the con‐

nector -2- from the cover while doing so. Refer to
82 .
AG. Volkswagen A
– Remove the center console. olks
Refer
wage to ⇒ Body Interior;
n G do
es nRep.
ot g
Gr. 68 ; Center Console
db
y .
V ua
r e an
ris tee
– Disconnect the connector
tho -1- from the selector mechanism to or
the vehicle wiring
s au harness. ac
s
ce
e
nl
– Remove the air filter housing:

pt
du
an
itte
y li

erm
ab

ility
ot p
wit
is n
♦ Diesel engine. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection

h re
ol ,

spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
77
op Vo
by c lksw
Prote
cted AG.
agen 5. Selector Mechanism
Note
Use pliers to remove the lock washer -B- from the cable bracket.
Do not use a sharp-edged lever. This could damage the selector
lever cable rubber grommet.
– Remove the lock washers -A and B-. The lock washers must
later be replaced when adjusting the selector lever cable.
– Attach a longer cord to the end of the selector lever cable. The
cord is used to guide the selector lever cable between the tun‐
nel and the heat shield during installation.
– Remove the four bolts attaching the selector mechanism to the

selector housing.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
e
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Pull the selector mechanism and selector lever cable carefully

out of the center tunnel. Make sure the cord is pulled through
far enough so that it can reached from inside the engine com‐
partment.
– Remove the selector lever cable cord.
Note
The selector mechanism is available only together with the se‐

lector housing and selector lever cable. Refer to the Parts Cata‐
log.
Installing
Install in reverse order of removal. Note the following:
A second technician is needed for threading the selector lever
cable from the passenger compartment into the engine compart‐
ment.
Note n AG. Volkswagen AG do

lkswage es n
o ot g
byV ua
ed ran
♦ Do not bend or kink the or selector lever cable.
is tee
th or
u
♦ Do not lubricate the
ss selector lever cable.
a ac
ce
e
nl
♦ Tightening specifications. Refer to
pt
du
an
⇒ “5.3 Overview - Selector Mechanism, Vehicles from
itte
y li
erm
03/2009”, page 72 .
ab
ility
ot p
wit
, is n
– Secure the cord that was involved when removing the selector
mechanism from the engine compartment on the end of the h re
hol
spec
selector lever cable.
es, in part or in w
t to the co
– Guide the selector mechanism and selector lever cable

through the opening in the center tunnel.
rrectness of i
– From the engine compartment, have the second technician

pull the cord with the selector lever cable through the tunnel
l purpos
until it is possible to attach the selector lever cable to the cable

bracket.
nf
ercia
– Remove the selector lever cable cord.

orm
m
atio
om
– Attach the selector mechanism to the selector housing with

n in
or c
four bolts.
thi
te
sd
iva
– Install the center console. Refer to ⇒ Body Interior; Rep. Gr.

o
r
rp
cu
68 ; Center Console .
o
m
f
en
ng
t.
yi Co
– Install the selector lever handle. Refer to . Cop py
t rig
gh ht
yri by
82 . cop Vo
by lksw
cted agen
Prote
AG.

– Check the selector mechanism. Refer to
⇒ “5.10 Selector Mechanism, Checking”, page 86 .
– Install the air filter housing:
5.5 Selector Lever Cable, Checking

Brief Description
The selector lever cable must be removed from the transmission
in order to check it for ease of movement. Do not let the removed
end touch anything.
Then the selector lever is moved and the selector lever cable in‐
stalled again on the transmission.
After that, the selector lever cable must be adjusted. Refer to
Do not lubricate the selector lever cable connections.
AG. Volkswagen AG d
agen
Checking olksw
oes
not
byV gu
ara
d
– Move the selector lever into
oris »P«.
e nte
eo
h
ut ra
– Remove the selectors lever cable from the lever on the trans‐
s a c
mission.
ce
e
nl
pt
du
an
– Move the selector lever from »P« to »S« and back to »P« sev‐
itte
y li
erm
eral times.
ab
ility
ot p
• The selector lever must have ease of movement.
wit
, is n
h re
– Install the selector lever cable with new lock washers and the
hol
spec
»loosened« adjustment screw.
es, in part or in w
t to the co
rrectness of i
5.6 Selector Lever Cable, Adjusting
l purpos

nform
ercia
Selector Lever Cable Must Always Be Adjusted If:

m
a
om
tio
♦ The selector lever cable was removed from the transmission.

n in
or c
thi
e
♦ The engine and/or transmission were removed and installed.

t
s
a
do
priv
cum
♦ Sections of the subframe mount were removed and installed.

or
f
en
ng
t.
yi Co
♦ The selector lever cable itself or the selector mechanism was Cop py
removed and installed. ht. rig
rig ht
py by
o Vo
♦ The engine/transmission position was changed, for example,
by c lksw
cted agen
were installed without tension.
Prote AG.
Adjusting

Move the Lever on the Transmission into “P”.

The lever on the transmission must be pushed »all the way to the
rear«.
– Pull the lever forward.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hol
spec
es, in part or in w
t to the co
– Push the lever »to the rear« -arrow-.
rrectness of i
“P” is in the Second Detent.
l purpos
Note
nform
ercia
♦ Raise the vehicle to make sure the transmission is in “P” (park‐

m
a
om
t
ing lock is engaged). The front wheels must not turn together
ion in
c
in any direction.
or
thi
te
s
a
♦ The transmission is also in “P” if the vehicle does not move

do
riv
with wheels spinning freely.

p
cum
or
f
en
ng
t.
yi Co
Cop py
– Install the selector lever cable with the loosened adjusting ht. rig
rig ht
screw -arrow- and the new lock washer -A and B-.
py by
co Vo
by lksw
cted agen
– Tap the handle on the selector lever back and forth gently but
Prote AG.
do not move it out of “P” under any circumstances.

This places the selector lever cable core in its optimal position.
– Tighten the adjusting bolt -arrow- to 13 Nm.
This ends the adjustment.
5.7 Selector Lever, Emergency Release

Do Not Remove the Handle
– Unclip the shift cover and hold it to the side.
– Press the brake or set the parking brake.
Vehicles through 02/2009
– Press on the yellow plastic piece from the right to the left in
direction of -arrow-.
– Or press it onto the solenoid pins.
Vehicles from 03/2009

– Push onto the yellow plastic part -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
, is n
h re
hol
spec
5.8 Selector Lever Handle, Removing and

es, in part or in w
t to the co
Installing
Brief Description
rrectness of i
There are different handles depending on the model.

l purpos
The handle is removed together with the shift cover.

nform
ercia
Removing
m
– Move the selector lever into “D” position.

at
om
ion
c
in t
or
his
te
iva
do
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Handle with Side Button

– Pull the button out of the handle just far enough until a small
gap is visible between the handle and the button. The button
locks when released.
– Secure the button in this position with a cable tie or wire to
prevent the button from being pressed in.
Handle with Front Button

– It is not necessary to pull out the button by hand. The button
AG. Volkswagen AG d
locks in the installation position -arrow- when the
lkswhandle is re‐
agen oes
not
moved. by Vo gu
a
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
e
hol
spec
Vehicle with Sleeve
es, in part or in w
t to the co
– Unclip the cover.
Disconnect the connector from the shift cover.
rrectness of i
Push the sleeve upward in direction of -arrow- to unlock the han‐
l purpos
dle.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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Vehicle with Clamp

m
f
en
ng
t.
yi Co
– Cut the clamp under the boot -arrow- with a side cutter. Cop py
t. rig
gh ht
yri
All Handles p by
co Vo
by lksw
cted agen
– Remove the handle from the selector lever without pushing the Prote AG.
button.
Note
Do not push the button once the handle has been removed oth‐
erwise it will not be possible to install the handle again.
Installing
– Install in reverse order of removal while noting the following:
• The selector lever is in the “D” position.
Handle with Side Button

• The button inside the handle is pulled out and if necessary is
protected from getting pushed in again.
Handle with Front Button n AG. Volkswagen AG do

lkswage es n
o ot g
• The button is in the installation position -arrow-.
d byV ua
ran
ir se tee
If the button was pushed in by mistake,uththe installation position
o
or
can be set again. ss
a ac
ce
e
nl
– Move the button into the installation position. Refer to
pt
du
an
⇒ “5.9 Button in Handle, Moving into Installation Position”,
itte
y li
erm
page 85 .
ab
ility
ot p
wit
, is n
h re
Note
e
hol
spec
es, in part or in w
A new handle is delivered with an assembly fastener. Remove
t to the co
the retainer just before installing.
rrectness of i
l purpos
nf
ercia
orm
Vehicle with Sleeve
m
atio
om
n in
– Install the handle all the way onto the selector lever and lock
or c
thi
it.
te
sd
iva
o
r
– Push the sleeve downward to lock it.

rp
cu
o
m
f
en
ng
Vehicle with Clamp

t.
yi Co
Cop py
. rig
– Install the handle all the way with a new clamp.
t
gh ht
pyri by
Vo
co
– Clamp off the clamps using Hose Clamp Pliers - VAG1275- .
by lksw
cted agen
Prote AG.
– Press the button after installation.
Note
If the button stays in the handle after being pressed, this means
it was installed incorrectly. If this happens, remove the handle
again and move the button in the installation position again. Refer
to
⇒ “5.9 Button in Handle, Moving into Installation Position”,
page 85 . Then the handle can be installed again.
Further installation is performed in reverse order of the removal.

5.9 Button in Handle, Moving into Installa‐

tion Position
⇒ “5.9.1 Handle with Side Button”, page 85
⇒ “5.9.2 Handle with Front Button”, page 85
5.9.1 Handle with Side Button

– Pull the button out of the handle just far enough until there is
a small gap between the handle and the button. The button
locks when released.
– Secure the button in this position with a cable tie or wire to
prevent the button from being pressed in.
5.9.2 Handle with Front Button

The button cannot be pulled out on these handles.
There are two ways to move the button into the installation posi‐
tion, »with« or »without« the assembly fastener. Both possibilities
are described here.
Move the Handle »with« an Assembly Fastener into the Installa‐
tion Position:
When using an assembly fastener, make sure that it has an eye
-arrow- at the front. Other assembly fasteners are not suitable.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– With the button pressed and push the assembly fastener (with
wit
, is n
h re
the eye) -arrow- all the way in until it latches into the assembly
fastener. Then release the button. The button locks into the
hol
spec
installation position when the assembly fastener is pulled out.

es, in part or in w
t to the co
Moving the Handle »without« an Assembly Fastener into the In‐

stallation Position:
rrectness of i
l purpos
nform
mercia
a
om
tion in
or c
thi
te
s
a
do
priv
cum
or
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
85
op Vo
by c lksw
Prote
cted AG.
agen 5. Selector Mechanism
– Carefully unclip the handle trim -A- upward.

AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
e
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– Push the small lever -1- for the pull rod into the groove -2- with
orm
a screwdriver. This pushes the button -3- into the installation
m
atio
m
position.
o
n in
or c
-I- the button is in the pressed position
thi
te
sd
iva
o
r
-II- the button is in the installation position

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ng
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♦ Clip the handle trim back onto the selector mechanism only
after the handle is installed. This way it is possible to see if the
small lever engages into the pull rod when the button is push‐
ed.
5.10 Selector Mechanism, Checking

Do not operate the starter when the selector lever is in “R”, “D”
and “S”.
If the selector lever position “N” is selected at speeds greater than
km/h (3.1 mph), the shift lock solenoid must not engage and block
the selector lever. The selector lever can be shifted into another
gear.
When shifting into the selector lever position “N” at speeds below
km/h (3.1 mph) (almost stopped), the shift lock solenoid may en‐
gage only after approximately one second. The selector lever can
only be moved out of “N” when the brake pedal is pressed.
Selector Lever in “P” and the Ignition Turned On:
• If the brake pedal is not depressed:

The selector lever is locked and cannot be moved out of “P” when
the button is pressed. The shift lock solenoid blocks the selector
lever.
• If the brake pedal is depressed:
The shift lock solenoid releases the selector lever. It is possible
to select a gear. Move the selector lever slowly from “P” through
“S”; while doing this, check whether the selector lever position

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The selector lever is locked and cannot be moved out of “P” when
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The shift lock solenoid releases the selector lever. It is possible
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Selector Level in the “tiptronic” Position
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• Move the selector lever into the tiptronic gate:
The illuminated “D” symbol in the selector mechanism cover must
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Simultaneous lighting of all segments on the transmission range Prote AG.
display indicates the transmission is in emergency mode.
6 Transmission, Removing and Instal‐

ling, Jetta from MY 2005 , Golf Wag‐
on from MY 2007 and Golf Wagon
from MY 2010
⇒ “6.1 Transmission, Removing”, page 88 .
⇒ “6.2 Transmission, Installing”, page 97 .
6.1 Transmission, Removing

Brief Description
The transmission is removed downward separately.
Remove the battery, the air filter and the starter »from above«.
Coolant hoses are clamped off. Before removing the subframe
mount, the engine and transmission must be supported.
»From underneath«:
The -subframe-, with the -pendulum support-, with the
-steering gear- and with -both control arms- are removed togeth‐
er.
Removing the -subframe-. Refer to ⇒ Rep. Gr. 40 . If done cor‐
rectly, the subframe can be removed and installed without the
customer experiencing increased
agen
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In this way, -subframe- can be secured and removed correctly.
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The Locating
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Installing the Locating Pins - T10096- is simple. It is very useful

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♦ Engine Support Bridge - 10-222A-

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♦ Transmission Support - Mounting Plate 42A - 3282/42A-

♦ Engine Support Bridge - Engine Support Feet - 10-222A/8-
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♦ Engine Support Bridge - Engine Support 3 - 10-222A/3-

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♦ Transmission Support - 3282-

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♦ Engine Support Bridge - Gearbox Bracket - T10346-

Removing
– Move the selector lever into »P«.

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To perform work sequence, the ground cable must be discon‐
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– Disconnect the battery ground cable. Refer to ⇒ Electrical
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– Remove the battery and the battery tray. Refer to ⇒ Electrical
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– Remove the selector lever cable from the transmission

-arrows-.
Note
Use pliers to remove the lock washer from the cable bracket. Do
not use a sharp-edged lever. This could damage the selector lev‐
er cable rubber grommet.
Both lock washers must later be replaced when adjusting selector

lever cable.
Remove the selector lever cable very carefully from the transmis‐
sion cable bracket. Do not bend the selector lever cable at the
same time.
The selector lever cable can also be slid back slightly from the
cable bracket and later removed when lowering transmission.
Watch the selector lever cable when lowering the transmission.
During later installation, only clip in the »new« lock washers after
the selector lever cable has been checked and adjusted. Refer to
⇒ “5.5 Selector Lever Cable, Checking”, page 80 .
6. Transmission, Removing and Installing, Jetta from MY 2005 , Golf Wagon from MY 2007 and Golf Wagon from MY 2010 89
– Disconnect the coolant hoses with Hose Clamps - Up To

25mm - 3094- and remove them from the transmission fluid
cooler.
– Seal the transmission fluid cooler with clean plugs.
– Remove the starter -A-. Refer to ⇒ Electrical Equipment; Rep.

Gr. 27 ; Starter; Starter, Removing and Installing .
Remove the »lower« starter bolt first.
Caution


⇒ “1.7 Electrical Components”,
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– Turn the Mechatronic ed
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– Remove all the upper bolts between the engine and the trans‐
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These tools are suitable for this.

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On some transmissions a bolt is located in the starter hole

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– Remove both filler pieces from the left and right fender upper
edges.
rrectness of i
– If there are hose and cable connections located near the en‐
l purpos
gine lifting eyes for the Engine Support Bridge - 10-222A- ,

these must now be removed.
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Check in following engine types which tool is needed to support

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2.0L TDI Engine - Jetta from MY 2005 and Golf Wagon from MY
2007
♦ Engine Support - Bracket w/Spindle and Hook - 10-222A/10-
2.0L TDI Engine - Golf Wagon from MY 2010


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2.0L TFSI Engine

– Attach the Engine Support Bridge - Gearbox Bracket -
T10346- to the rear hole of the three locating holes for the
battery tray.
– Use a M6 collar bolt or one of the bolts for the battery tray.

»flat side« toward engine compartment
♦ Use the Engine Support Bridge - Spindle Spacer - 10-222A/
17- on the »front« spindle.
Continuation for All Engines
– Pretension the engine/transmission assembly with the spin‐
dles, but do not lift.
– Loosen left and right front wheel bolts.
– Lift the vehicle, all four mounts from lifting platform at the same
height.
– Remove the front wheels.
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– Remove the noise insulation. Refer to ⇒ Body Exterior;
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– Remove the lower section of the left frontho wheel housing liner.
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– Disconnect the exhaust system at the clamping
rise sleeve and nte
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remove the bracket for the exhaust system
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-arrows-. Refer to ⇒ Rep. Gr. 26 . s
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– Remove the pendulum support from the transmission.
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– Secure the subframe. Refer to ⇒ Suspension, Wheels, Steer‐
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Prote AG.
ing; Rep. Gr. 40 ; Subframe; Subframe, Securing .
Note
If the -subframe- is not secured, a vehicle alignment must be per‐

formed later.
– Remove the subframe and steering gear. Refer to ⇒ Suspen‐

sion, Wheels, Steering; Rep. Gr. 40 ; Subframe
– Remove the drive axles from the transmission. Refer to ⇒
Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Re‐
moving and Installing .
– Tie the right drive axle as high up as possible.

– Move the left drive axle to the rear and secure it. Be careful
not to damage the surface protection.
– There may be a small cover plate on the plate between the

engine and transmission above the right flange shaft. Remove
the cover plate -A-.

-A-.
– Then lower the engine/transmission slightly using the Engine
Support Bridge - 10-222A- spindles so that the transmission
– Remove the transmission bracket in direction of -arrow-.

To remove the transmission 02E, the Transmission Support -
3282- is equipped with the Transmission Support - Mounting Plate
- 3282/42A- and positioned on the Engine and Gearbox Jack -
VAS6931- .
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– Align the arms of the Transmission Support so that they match

up with the holes in the Transmission Support - Mounting Plate
42A - 3282/42A- .
– Install the mounting element as illustrated on the Transmission
Support - Mounting Plate 42A - 3282/42A- .
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♦ Deviating from the illustration of the Adjusting Plate the front
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♦ DSG® transmission 02E “AWD” is shown in the illustration.

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Note
Pay attention to all of the lines when lowering the transmission.
Transport the transmission and secure to the assembly stand.

Refer to
Install the transmission. Refer to
⇒ “6.2 Transmission, Installing”, page 97 .
6.2 Transmission, Installing

Install in reverse order of removal. Nevertheless, important steps
should be named here:
Note
♦ Always replace the needle bearing -arrow- after separating the

engine and transmission. AG. Volkswagen AG d
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– Make sure the intermediate plate fits correctly.
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– Guide the selector lever cable into the cable bracket as soon
as possible.
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Check the selector lever cable when raising the transmission. Do
not fail to place it in the cable mounting bracket »early«.
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Do not grease the selector lever cable.
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Guide the engine and transmission together by hand until the en‐
mer
gine flange and transmission flange come into contact with one
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– Insert the transmission without pinching any lines.
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– Attach the transmission to the engine. Transmission to engine
tightening specifications. Refer to

Install the left subframe mount as follows:

– Replace all bolts -1 and 2- for the left subframe mount.
– Fasten the transmission bracket -A- to the transmission using
the bolts -1-.
– The align the engine/transmission in its installation position.
Lift until the transmission bracket is touching the transmission
mount completely.
Caution
There is a risk of damaging the threads in transmission bracket

by inserting the bolts at an angle.
♦ Before installing the bolts -2-, the transmission bracket
and transmission mount support arm must be absolutely
parallel to each other. If necessary, lift the back of the
transmission using the Engine and Gearbox Jack .
Install the engine/transmission mount without tension. Refer to ⇒

Rep. Gr. 10 .
– Tighten the bolts -2- to the tightening specification.
WARNING
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– Removessthe Engine Support Bridge - 10-222A- .
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27 ; Starter; Starter, Removing and Installing .

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-B- must line up with the connector -A- as well as with the tab
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– Selector lever cable lock washers -arrows- must be replaced.

– Always adjust the selector lever cable. Refer to
Gr. 19 ; Cooling System Components .
– Attach the drive axles to the transmission. Refer to ⇒ Sus‐
pension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Re‐
– Install the heat shield above the right drive axle, if equipped.
At the same time tighten the bolts -1- to 25 Nm.
– Install the subframe and steering gear. Refer to ⇒ Suspen‐ AG. Volkswagen AG d
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– Assemble the exhaust system and install the exhaust system
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bracket to the subframe. Refer to ⇒ Rep. Gr. 26 .
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– Install the lower section of the left front wheel housing liner.
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Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner;
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– Install the battery tray and the battery. Refer to ⇒ Electrical
stalling .
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– Install the air filter housing.
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– Install the front wheels. Refer to ⇒ Suspension, Wheels,
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Steering; Rep. Gr. 44 ; Wheel Installation Tightening Specifi‐

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The -arrows- point to the alignment sleeves in the engine.

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Continuation for All Engines

– Tighten the transmission bracket -A- to the transmission to 40
Nm + 90° using the bolts -1-.
– Tighten the bolts -2- to 60 Nm + 90°.
Note
Pry the transmission bracket into the correct seat using a screw‐
driver while tightening the bolts -2-.
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7 Transmission, Removing and Instal‐
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⇒ “7.1 Transmission, Removing, Jetta MY 2011 with 2.0L 103 kW
e
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spec
Diesel”, page 102 .
es, in part or in w
t to the co
⇒ “7.2 Transmission, Installing, Jetta MY 2011 with 2.0L 103 kW
⇒ “7.3 Transmission, Removing, Jetta MY 11, 2.0L 147 kW Gas‐
rrectness of i
oline Engine”, page 115 .
l purpos
⇒ “7.4 Transmission, Installing, Jetta MY 11, 2.0L 147 kW Gaso‐

line Engine”, page 127 .
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7.1 Transmission, Removing, Jetta MY

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2011 with 2.0L 103 kW Diesel
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Brief Description
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»From above«:
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The battery, air filter and starter are removed. The steering gear cted agen
Prote AG.
wiring harness is disconnected and »freed up«. This way it can
be lowered together with the subframe and the steering gear. En‐
gine and transmission are supported before the left subframe
mount is removed.
er.

customer experiencing increased tire wear later. It is recommen‐
ded to read this information »prior« to removing the transmission.
Locating Pins - T10096- and Subframe Locking Pin (2 pc.) -
T10452- will be needed.
If the -subframe- is not secured by the pins, then later an axle
alignment will be necessary.
In this case, an axle alignment is unnecessary and expensive ad‐
for the customer!
Installing the Locating Pins - T10096- and Subframe Locking Pin
(2 pc.) - T10452- is simple. It is very useful though.



♦ Engine and Gearbox Jack - VAS6931-
♦ Engine Support Bridge - 10-222A- wage
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♦ Hose Clamps - Up To 25mm - 3094- ed
by or Hose Clamps - Up To ua
ran
40mm - 3093- thoris tee
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♦ Tensioning Strap - T10038-
ss
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♦ Engine Support - Basic Set - T40091-
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♦ Engine Support - Supplement Kit - T40093A-
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♦ Engine Bung Set - VAS6122-
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Removing
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Note
rrectness of i
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– Disconnect the battery ground cable. Refer to ⇒ Electrical
at
om
io
n
c
in t
r
Connecting .
o
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– Remove the engine cover. Refer to ⇒ Rep. Gr. 15 ; Cylinder
pr
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r
Head; Engine Cover, Removing and Installing .

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– Remove the complete air filter housing. Refer to ⇒ Rep. Gr. . Cop py
23 ; Diesel Direct Injection System; Overview - Air Filter .
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– Remove the battery and the battery tray. Refer to ⇒ Electrical Prote AG.
Connecting .
7. Transmission, Removing and Installing, Jetta from MY 2011 103


-arrows-.
Note
♦ Use pliers to remove the lock washer from the cable bracket.
Do not use a sharp-edged lever. Otherwise the selector lever
cable could get damaged.
♦ Remove the cable bracket -2- from the transmission, if nec‐
essary. Remove the bolts -1- and the lock washer -3-.
♦ Replace the bolts -1- and the lock washers.
♦ Bolt tightening specification -1- 20 Nm +90°.
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Risk of damaging the selector lever acable.
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♦ Remove the selector level cable from the cable bracket ce
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when lowering transmission. an
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– Clamp the coolant hoses with Hose Clamps - Up To 25mm -

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3094- or Hose Clamps - Up To 40mm - 3093- and remove the

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hoses from the transmission fluid cooler.

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– Seal off the transmission fluid cooler connections with sealing

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plugs taken from for example the Engine Bung Set - Cop py
VAS6122- .
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Remove the »lower« bolt first.
Caution


⇒ “1.7 Electrical Components”, page 5 .
– Turn the Mechatronic connector lock -1- »counter-clockwise«
to release and disconnect the connector.
them up.
mission. gen AG
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Cop py
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One bolt is located inside the hole for the starter -arrow-. Use Prote AG.
Socket - Xzn 14 - T10061- to remove the bolt.
– Remove the plenum chamber cover. Refer to ⇒ Body Exterior;
Rep. Gr. 50 ; Plenum Chamber Cover; Plenum Chamber
Cover, Removing and Installing .

– Remove the bolts -arrows- for the left and right lock carrier
retaining brackets.
– Remove the lower mounts on the Engine Support Bridge - En‐

gine Support 28 - 10-222A/28- and replace them with the
Engine Support Bridge - Engine Support 28-2 - 10-222A/
28-2- .
– Remove the bolts -arrows- for securing the engine support
bridge on the lock carrier from the Engine Support Bridge -
Engine Support 28-2 - 10-222A/28-2- .
• Use the bolts present in the Engine Support Bridge - Engine
Support 28-2 - 10-222A/28-2- for attaching the Engine Support
Bridge - Engine Support 28 - 10-222A/28- . Not the bolts for
the retaining bracket.
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– Install the Engine Support Bridge - Engine Support
ss a 28 - ra
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10-222A/28- and tighten the bolts to 8 Nm -arrows-.
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Caution
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A second technician is needed to mount the Engine Support
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Bridge on the vehicle to prevent the Engine Support Bridge
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from tipping.
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– If there are hose and cable connections located near the en‐ t to the co
rrectness of i

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Install the Engine Support Bridge - 10-222A- as shown.

nform
ercia
– First slide the Moveable Joints -2- onto the Square Pipe from
the Engine Support Bridge - 10-222A- .
m
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io
– Mount the Engine Support Bridge - 10-222A- on the suspen‐

n
c
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or
sion strut towers and have a second technician hold it to

his
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prevent it from tipping.

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– Push the Engine Support - Basic Set - Square Pipe -

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T40091/1- - 6- from the front left and right through the Engine
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Support Bridge - Engine Support 28 - 10-222A/28- - 7- and
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place on each side of the Engine Support - Supplement Kit -
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Movable Joint - T40093/4- - 5-. by c lksw
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– Slide the Engine Support - Basic Set - Rail with Holes -
T40091/2- - 4- with the Engine Support - Supplement Kit -

Mount - T40093/5- -9- in the Engine Support - Supplement Kit

- Moveable Joint - T40093/4- - 5-.
– Install the locking pins into the Engine Support - Basic Set -
Rail with Holes - T40091/2- -4- and secure it with the cotter
pins.
1 - Engine Support Bridge - En‐

gine Support 31 - Adapter 2 -
10-222A/31-2- agen
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2 - Engine Support - Basic Set d by V gu
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- Moveable Joint - T40091/3- rise nte
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4 - Engine Support - Basic Set
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5 - Engine Support - Supple‐
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ment Kit - Movable Joint -

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T40093/4-
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- Square Pipe - T40091/1-
rrectness of i
gine Support 28 - 10-222A/28-
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with Engine Support Bridge -

Engine Support 28-2 -
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10-222A/28-2-
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8 - Engine Support Bridge -
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Spindle - 10-222A/11-
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ment Kit - Mount 5 - T40093/5-
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10 - Engine Support - Bracket yi

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– Tighten all the threaded connections on the Engine Support

Bridge - 10-222A- hand-tight. While doing so, adjust the height
of the Engine Support Bridge - 10-222A- parallel over the En‐
gine Support Bridge - Engine Support 28 - 10-222A/28- .
– Pretension the engine/transmission assembly with the spin‐
dles, but do not lift.
height.
– Remove the left front housing liner. Refer to ⇒ Body Exterior;
Rep. Gr. 66 ; Wheel Housing Liner; Overview - Front Wheel
Housing Liner .

Caution

– Separate the exhaust system at the clamping sleeve and re‐

move the bracket from the subframe -arrows-. Refer to ⇒ Rep.
Gr. 26 .
– Remove the bolts -11- and then remove the pendulum support
from the transmission.
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– Secure the subframe before removing. Refer to ⇒ Suspen‐

e
hol
spec
sion, Wheels, Steering; Rep. Gr. 40 ; Subframe; Subframe,

es, in part or in w
Securing .
t to the co
Note
rrectness of i
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formed later.
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sion, Wheels, Steering; Rep. Gr. 40 ; Subframe .

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Cop py
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– Remove the heat shield above the right drive axle -arrows-.
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rrectness of i
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nform
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at
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ion
c
– There may be a small cover plate on the plate between the
in t
or
engine and transmission above the right flange shaft. Remove
his
te
iva
this cover plate -A-, if equipped.
do
pr
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Cop py
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-A-.
Support Bridge - 10-222A- spindles so that the transmission

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es, in part or in w
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VAS6931- .
– Align the arms of the Transmission Support - 3282- so that
they match up with the holes in the Transmission SupportA-G. Volkswagen
Mounting Plate 42A - 3282/42A- . lksw
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– Install the mounting element as illustrated onristhe
ed Transmission
b ran
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Support - Mounting Plate 42A - 3282/42A- ut .
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– Place the Engine and Gearbox Jack -sVAS6931- under the
ce
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• The arrow symbol on the Transmission Support - Mounting
erm
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the transmission.
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transmission.
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shown.
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♦ DSG® transmission 02E “AWD” is shown in the illustration.

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The mounting elements on the “FWD” are identical.
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– Support the transmission by lifting it from underneath using the Cop py
Engine and Gearbox Jack - VAS6931- . ht. rig
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Note
Pay attention to all of the lines when lowering the transmission.

Refer to
⇒ “7.2 Transmission, Installing, Jetta MY 2011 with 2.0L 103 kW

7.2 Transmission, Installing, Jetta MY 2011

with 2.0L 103 kW Diesel
Note
Refer to “Transmission, Removing”

⇒ “7.1 Transmission, Removing, Jetta MY 2011 with 2.0L 103 kW
Diesel”, page 102 for a list of the special tools needed.

Note agen
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♦ Always replace the needle bearing -arrow-oriafter
sed
separating the nte
engine and transmission. aut
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♦ If the needle bearing in the crankshaft is damaged, the gears
ce
le
un
will no longer shift correctly.
pt
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– Replace the needle bearing in the crankshaft. Refer to ⇒ Rep.
ility
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Gr. 13 ; Crankshaft; Needle Bearing in Crankshaft, Replacing .
wit
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– Transmission pins (not splines) on the driveshaft must also be
e
hol
spec
lightly lubricated.
es, in part or in w
t to the co
rrectness of i
l purpos
as possible.
nform
ercia

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Guide the engine and transmission together by hand until the en‐ his
te
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pr
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another all around.

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sion »are in alignment«. by c lksw
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the bolts -1-.
mount completely.
Caution


Rep. Gr. 10 ; Subframe Mount .
– Tighten the bolts -2- to the tightening specification. Refer to
WARNING AG. Volkswagen AG d

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Only remove the Engine Support Bridge - 10-222A- oris when all
e nte
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the left and right subframe mount bolts are tightened
aut
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to the ra
tightening specification. ss c
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nl
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– Remove the Engine Support Bridge - 10-222A- .
erm
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tronic - J743- as follows. t to the co

rrectness of i
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– Install the heat shield over the right drive axle. Refer to ⇒
t
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Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles,

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Overview and Servicing; Drive Axle Heat Shield .

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– Install the subframe and steering gear. Refer to ⇒ Suspen‐ C py
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sion, Wheels, Steering; Rep. Gr. 40 ; Subframe . gh ht
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wage e
– Attach the pendulumy Vsupport
olks to the transmission susing
not
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bolts. Refer to ⇒iseRep. Gr. 10 .
d b ara
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ac
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Gr. 19 .
orm
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– Assemble the exhaust system and then attach the exhaust
om
n in
system bracket to the subframe. Refer to ⇒ Rep. Gr. 26 .
or c
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– Install the plenum chamber cover. Refer to ⇒ Body Exterior;
sd
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Cop py
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– Install the bolts -arrows- for the left and right lock carrier re‐ p by
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taining brackets to the tightening specification. Refer to ⇒
lksw
cted agen
Prote
Body Exterior; Rep. Gr. 50 ; Lock Carrier; Lock Carrier - At‐
AG.
tachments .
– Install the battery tray and the battery. Refer to ⇒ Electrical
stalling .
– Install the air filter. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct
Injection System; Overview - Air Filter .
– Install the engine cover. Refer to ⇒ Rep. Gr. 15 ; Cylinder
– Install the left front housing liner. Refer to ⇒ Body Exterior;
Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel Housing Lin‐
er, Removing and Installing .
cations .
7.3 Transmission, Removing, Jetta MY 11,

2.0L 147 kW Gasoline Engine
Brief Description
»From above«:
The battery, air filter and starter are removed. The steering gear
wiring harness is disconnected and »freed up«. This way it can
be lowered together with the subframe and the steering gear. En‐

gine and transmission are supported before the left subframe

mount is removed.
er.

customer experiencing increased tire wear later. It is recommen‐
ded to read this information »prior« to removing the transmission.
Locating Pins - T10096- and Subframe Locking Pin (2 pc.) -
T10452- will be needed. AG. Volkswagen AG d
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If the -subframe- is not secured by the pins, then later an ed axle
b ara
nte
is
alignment will be necessary. hor eo
aut ra
c
In this case, an axle alignment is unnecessary and expensive ad‐ ss
ce
e

nl
pt
du
for the customer!
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ab
Installing the Locating Pins - T10096- and Subframe Locking Pin
ility
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(2 pc.) - T10452- is simple. It is very useful though.
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♦ Torque Wrench 1331 5-50Nm - VAG1331- ss o

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♦ Engine and Gearbox Jack - VAS6931-

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atio
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♦ Hose Clamps - Up To 25mm - 3094- or Hose Clamps - Up To

te
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40mm - 3093-
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for

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♦ Engine Support - Basic Set - T40091-
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♦ Engine Support - Supplement Kit - T40093A- co Vo
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♦ Engine Bung Set - VAS6122-

olksw
02E - Edition 09.2015
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– Move the selector lever into »P«. tho eo
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– Disconnect the battery ground cable. Refer to ⇒ Electrical es, in part or in w
t to the co
Connecting .
rrectness of i
– Remove the engine cover. Refer to ⇒ Rep. Gr. 15 ; Cylinder
l purpos
– Remove the complete air filter housing. Refer to ⇒ Rep. Gr.

24 ; Air Filter; Air Filter Housing, Removing and Installing .
nf
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– Remove the battery and the battery tray. Refer to ⇒ Electrical
atio
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-arrows-.

Note
♦ Use pliers to remove the lock washer from the cable bracket.
Do not use a sharp-edged lever. Otherwise the selector lever
cable could get damaged.
♦ Remove the cable bracket -2- from the transmission, if nec‐
essary. Remove the bolts -1- and the lock washer -3-. lkswage es n
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♦ Replace the bolts -1- and the lock washers. d b ran
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♦ Bolt tightening specification -1- 20 Nm +90°. au ac
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Risk of damaging the selector lever cable.
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♦ Remove the selector level cable from the cable bracket
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when lowering transmission.
es, in part or in w
t to the co
rrectness of i
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Note
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– Clamp the coolant hoses with Hose Clamps - Up To 25mm -
t
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hoses from the transmission fluid cooler. cted agen
Prote AG.
– Seal off the transmission fluid cooler connections with sealing

plugs taken from for example the Engine Bung Set -
VAS6122- .


Remove the »lower« bolt first.
Caution

– To discharge any static electricity, touch the vehicle

AG. Voground
lkswagen AG
with hand (without wearing a glove). Refer agen
ksw to
does
ol not
⇒ “1.7 Electrical Components”, pagee d b5.
y V gu
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– Turn the Mechatronic connectorau lock -1- »counter-clockwise«
th eo
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to release and disconnect the
s connector.
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mission.
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. Volkswagen AG
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤k,swJetta
agen 2011 ➤
AG does
not
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nform
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Cop py
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One bolt is located inside the hole for the starter -arrow-. Use
Socket - Xzn 14 - T10061- to remove the bolt.
– Remove the plenum chamber cover. Refer to ⇒ Body Exterior;

– Remove the bolts -arrows- for the left and right lock carrier
retaining brackets.
AG. Volkswagen AG d
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– Remove the lower mounts on the Engine Support Bridge - En‐
ility
ot p
gine Support 28 - 10-222A/28- and replace them with the
wit
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Engine Support Bridge - Engine Support 28-2 - 10-222A/
h re
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28-2- .
hol
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es, in part or in w
– Remove the bolts -arrows- for securing the engine support
t to the co
bridge on the lock carrier from the Engine Support Bridge -
Engine Support 28-2 - 10-222A/28-2- .
rrectness of i
• Use the bolts present in the Engine Support Bridge - Engine
Support 28-2 - 10-222A/28-2- for attaching the Engine Support
l purpos
Bridge - Engine Support 28 - 10-222A/28- . Not the bolts for

the retaining bracket.
nform
mercia
at
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c
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pr
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t.
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Cop py
– Install the Engine Support Bridge - Engine Support 28 -
t. rig
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yri
10-222A/28- and tighten the bolts to 8 Nm -arrows-.
p by
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Prote AG.
Caution
A second technician is needed to mount the Engine Support

Bridge - 10-222A- on the vehicle to prevent the Engine Support
Bridge - 10-222A- from tipping.
– If there are hose and cable connections located near the en‐
Install the Engine Support Bridge - 10-222A- as shown.

– First slide the Moveable Joints -2- onto the Square Pipe from
the Engine Support Bridge - 10-222A- .
– Mount the Engine Support Bridge - 10-222A- on the suspen‐
sion strut towers and have a second technician hold it to
prevent it from tipping.
– Push the Engine Support - Basic Set - Square Pipe -
T40091/1- - 5- from the front left and right through the Engine
Support Bridge - Engine Support 28 - 10-222A/28- - 6- and
place on each side of the Engine Support - Supplement Kit -
Movable Joint - T40093/4- - 4-.
– Push the Engine Support - Basic Set - Rail with Holes -
T40091/2- - 7- with the Engine Support - Supplement Kit -

Mount - T40093/5- - 8- in the Engine Support - Supplement Kit

- Movable Joint - T40093/4- - 4-.
– Install the locking pins into the Engine Support - Basic Set -
Rail with Holes - T40091/2- -7- and secure it with the cotter AG. Volkswagen AG d
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1 - Engine Support Bridge - En‐ auth
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gine Support 31 - Adapter 2 - ss c
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10-222A/31-2-
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- Moveable Joint - T40091/3-
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10-222A/31-1-
es, in part or in w
t to the co
ment Kit - Movable Joint -
T40093/4-
rrectness of i
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- Square Pipe - T40091/1-

nf
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gine Support 28 - 10-222A/28-
or
with Engine Support Bridge -
m
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Engine Support 28-2 -
om
10-222A/28-2-
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- Rail with Holes - T40091/2-
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ment Kit - Mount 5 - T40093/5- C py
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9 - Engine Support Bridge -
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Spindle - 10-222A/11- Prote
cted AG.
agen
❑ Engaged in the engine

lifting eye -arrow-.
– Tighten all the threaded connections on the Engine Support

Bridge hand-tight. While doing so, adjust the height of the En‐
gine Support Bridge parallel over the Engine Support Bridge -
Engine Support 28 - 10-222A/28- .
– Lightly preload the engine/transmission assembly using the
spindle, but do not lift it.
height.
– Remove the left front housing liner. Refer to ⇒ Body Exterior;
Rep. Gr. 66 ; Wheel Housing Liner; Overview - Front Wheel
Housing Liner .

lkswage es n
Golfd byVariant
Vo 2007 ➤ , Golf Variant 2010
ot g
ua ➤ , Jetta 2005 ➤ , Jetta 2011 ➤
ran
ho
ir se 6-Speed Dual Clutch Transmission
tee 02E - Edition 09.2015
ut or
a ac
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Caution
un
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es, in part or in w
t to the co
– Separate the exhaust system at the clamping sleeve and re‐
rrectness of i
move the bracket from the subframe -arrows-. Refer to ⇒ Rep.
l purpos
Gr. 26 .
nform
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at
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– Remove the bolts -11- and then remove the pendulum support cop Vo
by lksw
from the transmission.
cted agen
Prote AG.
– Secure the subframe before removing. Refer to ⇒ Suspen‐

sion, Wheels, Steering; Rep. Gr. 40 ; Subframe; Subframe,
Securing .
Note

formed later.


– Remove the heat shield above the right drive axle -arrows-.

AG. Volkswagen AG d
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– There may be a small cover plateut on the plate between the
ho eo
ra
engine and transmission above
s the right flange shaft. Remove
s a c
this cover plate -A-, if equipped.
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s
-A-.
s o
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f i

nform
Support Bridge - 10-222A- spindle so that the transmission

mer

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cial p
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VAS6931- .
– Align the arms of the Transmission Support so that they match
up with the holes in the Transmission Support - Mounting Plate
42A - 3282/42A- .
– Install the mounting element as illustrated on the Transmission
Support - Mounting Plate 42A - 3282/42A- .
– Place the Engine and Gearbox Jack - VAS6931- under the
vehicle.
• The arrow symbol on the Transmission Support - Mounting
the transmission.
transmission.
shown.
Note

-arrow-.
AG. Volkswagen AG d
♦ DSG® transmission 02E “AWD” is shown in the illustration. lksw
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The mounting elements on the “FWD” are identical.
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– Support the transmission by lifting it from underneath using
ss a the ra
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Engine and Gearbox Jack - VAS6931- .
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Note
Pay attention to all of the lines when lowering the transmission. rrectness of i
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Refer to
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atio
m

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c
⇒ “7.4 Transmission, Installing, Jetta MY 11, 2.0L 147 kW Gaso‐

or
thi
e
line Engine”, page 127 .

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7.4 Transmission, Installing, Jetta MY 11,

2.0L 147 kW Gasoline Engine
Note
♦ Refer to “Transmission, Removing”

⇒ “7.3 Transmission, Removing, Jetta MY 11, 2.0L 147 kW
Gasoline Engine”, page 115 for a list of the special tools nee‐
ded.
♦ Install the engine/transmission mount without tension. Refer
to ⇒ Rep. Gr. 10 .

Note
♦ Always replace the needle bearing -arrow- after separating the

engine and transmission.
♦ If the needle bearing in the crankshaft is damaged, the gears
will no longer shift correctly.
swage es n
– Replace the needle by V bearing in the crankshaft. Refer
olk ot g to ⇒ Rep.
ua
Gr. 13 ; Crankshaft;
ir se
d Needle Bearing in Crankshaft, Replacing
ran
tee .
tho
or
– Transmission
ss
au
pins (not splines) on the driveshaft must also ac be
lightly lubricated.
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ab
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as possible.
es, in part or in w
t to the co

rrectness of i
Guide the engine and transmission together by hand until the en‐
l purpos
another all around.
nf
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c
sion »are in alignment«.

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the bolts -1-.
mount completely.
Caution


Rep. Gr. 10 ; Subframe Mount .
– Tighten the bolts -2- to the tightening specification.
agen
AGRefer toagen AG do
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⇒ “7.5 Tightening Specifications”, page 129
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WARNING tho or
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Only remove the Engine Support Bridge - 10-222A- when all

pt
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the left and right subframe mount bolts are tightened to the
itte
tightening specification. y li
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ility
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– Remove the Engine Support Bridge - 10-222A- .
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spec

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t to the co

rrectness of i
tronic - J743- as follows.

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-C-.
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m
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ti

on in
or c
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t.
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– Install the heat shield over the right drive axle. Refer to ⇒
Co
op py
Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles,
t. C rig
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Overview and Servicing; Drive Axle Heat Shield . p by
co Vo
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cted agen
– Install the subframe and steering gear. Refer to ⇒ Suspen‐ Prote AG.

– Attach the pendulum support to the transmission using new

bolts. Refer to ⇒ Rep. Gr. 10 .

Gr. 19 .
– Assemble the exhaust system and attach the exhaust system
bracket to the subframe. Refer to ⇒ Rep. Gr. 26 .
– Install the plenum chamber cover. Refer to ⇒ Body Exterior;
– Install the bolts -arrows- for the left and right lock carrier re‐
taining brackets to the tightening specification. Refer to ⇒
Body Exterior; Rep. Gr. 50 ; Lock Carrier; Lock Carrier - At‐
tachments .
– Install the battery tray and Athe
G. Vobattery.
lkswagen Refer
AG do to ⇒ Electrical
agen
Equipment; Rep.VoGr. lksw 27 ; Battery; Battery, Removing
es n
ot g and In‐
stalling . ed by ua
rais nte
or e
– Install the
au air filter. Refer to ⇒ Rep. Gr. 24 ; Air Filter; Air rFilter
th o
ac
Housing,
ss Removing and Installing .
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ility
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– Install the engine cover. Refer to ⇒ Rep. Gr. 15 ; Cylinder

, is n
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spec

es, in part or in w
t to the co

rrectness of i
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nf
cations .
ercia
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m
atio
m
7.5 Tightening Specifications

o
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or c
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Engine: 2.0L TDI; 2.0L TFSI

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The -arrows- point to the alignment sleeves. p by
co Vo
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Prote AG.

M12 - 80 Nm
❑ When using the Insert
Tool - 18 mm - T10179- :
65 Nm.
M10 - 40 Nm
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es, in part or in w
t to the co
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– Tighten the transmission bracket -A- to the transmission to 40 t. C rig
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Nm + 90° using the bolts -1-. yri
p by
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– Tighten the bolts -2- to 60 Nm + 90°.
agen
Prote AG.
Note
Pry the transmission bracket into the correct seat using a screw‐
driver while tightening the bolts -2-.

8 Transmission, Transporting and Se‐

curing to Assembly Stand
Always secure heavy parts when transporting.
Remember there is fluid in the transmission. Do not turn the
transmission with the vents facing downward when transporting
or when it is on the assembly stand. The fluid will leak out.
Note
Remove the bleeder caps if necessary and use oil-tight plugs.
Transmission, Transporting
– Use appropriate lifting tools, for example part of Engine Sling
- 2024A- and the Engine/Gearbox Support Shackle - 10-222A/
12- (not illustrated).
The transmission can also be lifted using the Transmission Sup‐

port Jig - 3336- .
AG. Volkswagen AG d
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olksw not
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d
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es, in part or in w
Example: Secure the Transmission on the Assembly Stand.
t to the co
rrectness of i
l purpos
nform
mercia
at
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ion
c
in t
or
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8. Transmission, Transporting and Securing to Assembly Stand 131

9 Transmission Fluid and Transmis‐

sion Fluid Filter
⇒ “9.1 Transmission Fluid Filter, Replacing”, page 132
⇒ “9.2 Fluid Level, Checking and Filling”, page 133
⇒ “9.3 Fluid, Draining and Filling”, page 136
Pay attention to the general repair information. Refer to
⇒ “1 General Repair Information”, page 1 .
9.1 Transmission Fluid Filter, Replacing
Note
♦ The transmission fluid filter usually does not need to be re‐

placed.
♦ Change the transmission fluid filter “yes or no”. Refer to
page 4 .
Removing
G. Volkswage nA n AG d
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♦ Vehicles with a diesel engine. Refer to V⇒
olksRep. Gr. 23 ; Diesel not
gu
by
Direct Injection System; Air FilterisHousing,
ed Removing and In‐ ara
nte
stalling . utho
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sa c
– Remove the battery with thes battery tray. Refer to ⇒ Rep. Gr.
ce
e
27 ; Battery; Battery, Removing and Installing .

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Note
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♦ A little bit of fluid remains inside the transmission fluid filter.

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This will drain out once the transmission fluid filter is removed.
es, in part or in w
t to the co
♦ Lay some cloths down near the transmission fluid filter before
removing it.
rrectness of i
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tion in
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– Loosen the filter housing -arrow- approximately seven turns.

– Wait 10 seconds.
This allows the fluid to flow from the filter housing back into the
transmission.
– Remove the filter housing and the transmission
agen
fluid
AG. Vo lkswafilter.
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Installing ed by ua
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Install in reverse order of removal.
au
tho Note the following: or
ac
ss
– Thoroughly clean any lubricated areas on the transmission.
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t to the co
– Install the transmission fluid filter with the collar -arrow- down‐
rrectness of i
ward.
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– Install the filter housing and tighten it to 20 Nm.

Further installation is performed in reverse order of the removal.
nform
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9.2 Fluid Level, Checking and Filling
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Note the following information:
♦ Use the DSG® transmission fluid available as a replacement
part. Refer to the Parts Catalog .
♦ It is necessary to use the Oil Filler - Adapter 6 - VAS6262/6-
on some oil containers.
♦ It may be necessary to shorten the bleed pipe on the Oil Filler
- VAS6262A- . Refer to ⇒ page 134 .
9. Transmission Fluid and Transmission Fluid Filter 133

Shorten the Bleed Pipe on the Adapter For Oil Filling - VAS6262A-
as Follows:
– Shorten the bleed pipe to dimension -a-. This assures the pipe
on the Adapter For Oil Filling - VAS6262A- will not touch the
bottom on some oil containers.
Dimension -a- = 210 mm
Note
Dimension -a- is measured starting from the shaft (the green sur‐
face) on the Oil Filler - VAS6262A- .
If dimension -a- is greater than 210 mm:
– Make a mark on the bleed pipe, dimension -a-, and cut it, with
for example the Brake Line Tool Kit - Pipe Cutter -
VAS6056/2- .
– Clean the Oil Filler - VAS6262A- .

♦ Vehicle Diagnostic Tester
♦ Used Oil Collection and Extraction Unit - SMN372500- AG. Volkswagen AG d
agen oes
lksw not
♦ Oil Filler - VAS6262A- d byV
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Requirements ut
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♦ The vehicle is level and all hoist mounts are the same height. s ce
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♦ The noise insulation has been removed.

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♦ The Vehicle Diagnostic Tester is connected.
ility
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♦ To begin working, the oil temperature should not be higher

, is n
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than 45 °C (113 °F).

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hol
spec
♦ Test temperature: 35 ° to 45 °C (95 ° to 113 °F)

es, in part or in w
t to the co
Checking
– Connect the Vehicle Diagnostic Tester and identify the vehicle
rrectness of i
in Guided Functions .
l purpos
– Select DSG Transmission .

– Select Check Fluid Level .
nform
mercia
a
om
tio
Note
n in
or c
thi
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s
a
Let the transmission cool down if the oil temperature is higher than
do
priv
45 °C (113 °F).
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The engine is idling and the selector lever is in “P”. C py
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Prote AG.

– Move the Used Oil Collection and Extraction Unit -

SMN372500- or a Drip Tray under the transmission near the
transmission drain and check plug.
– Remove the oil drain plug.
Through transmission production
agen
AG. Voldate
kswag“09/20/2004”,
en AG
does transmis‐
sions were installed
Vowith
lksw two plugs. not
g by ua
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It is important risto not to interchange the bolts. Remove the
nte bolt
tho the pendulum support
-A- only, near
eo
au ra
c
ss
Transmissions Installed after 09/20/2004, that is, that are »young‐
ce
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nl
pt
du
er« have Only One Bolt -A-.
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itte
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– Always replace the gasket for the drain plug -arrow-.
rrectness of i
Note
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Even if the level of transmission fluid is too low, first a small
nf
ercia
amount of transmission fluid will flow out of the overflow tube,

orm
because it fills during operation.
m
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om
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– Let the excess fluid drain.

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– Install the drain plug with a new gasket as soon as all the fluid
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– If no transmission fluid comes out, then fill. . Cop py
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Filling
rig by
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Prote AG.
9. Transmission Fluid and Transmission Fluid Filter 135

AG. Volkswagen AG d
agen oes
Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 Vol ➤ , Jetta 2011 ➤
ksw not
gu
by
6-Speed Dual Clutch Transmission 02E - Editionris
e 09.2015
d ara
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– Install the Oil Filler - VAS6262A- into the check shole
s hand- c
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– Fill 1 liter (1.05 quarts) of transmission fluid.
spec
– Remove the Adapter for Oil Filling - VAS6262A- at the quick-
t to the co
release coupling and check it.
If Fluid Flows Out of the Adapter Hole
rrectne
The fluid must not be topped off.
s
– Let the excess fluid drain.
s o
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– As soon as the fluid has run out (it begins to drip), remove the
nform
Oil Filler - VAS6262A- and install the bolt with new gasket.
mer
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If No Fluid Flows Out of Hole

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Install the oil drain plug with new gasket and tighten.
Drain Plug Tightening Specification: 45 Nm
9.3 Fluid, Draining and Filling

Use the DSG® transmission fluid available as a replacement part.
Refer to the Parts Catalog .
Brief Description
Read the fluid temperature first. If it is higher than 50 °C (122 °F),
then let the transmission cool down.
Turn off the engine, remove the overflow pipe and drain any fluid.
Then reinstall the overflow pipe and »overfill« the transmission
with fluid.
Start the engine and drain any excess fluid until the fluid level has
reached the overflow tube.
♦ Vehicle Diagnostic Tester
♦ Oil Filler - VAS6262A-
Requirements
♦ The engine is off.
♦ The vehicle is level and all hoist mounts are the same height.
♦ Noise insulation is removed if necessary
♦ The selector lever is in “P.”
♦ The Vehicle Diagnostic Tester is connected.
♦ To begin working, the fluid temperature should not be higher
than 45 °C (113 °F).

Procedure
– Follow the rules for clean working conditions when working on
the transmission.
– Only use the DSG® transmission fluid available as a replace‐
ment part. Other oils can cause malfunctions or transmission
failure.
WARNING
Risk of injury due to hot transmission fluid.
– Connect the Vehicle Diagnostic Tester and identify the vehicle

in Guided Functions .
– Select DSG Transmission .
– Select Check Fluid Level .
Note
Let the transmission cool down if the fluid temperature is higher

than 45 °C (113 °F).
WARNING
Do not start the engine if there is no transmission fluid in the

transmission.
– Engine off - do not start!

– Remove the drain plug near the pendulum support -arrow-.
A »black overflow pipe« made out of plastic is located in thiswhole
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9. Transmission Fluid and Transmission Fluid Filter
AG.
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tight.
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– Fill 5.5 liters (5.8 qts) oil.
AG.
– To change containers, close the shut-off valve or hold the Oil

Filler - VAS6262A- higher than the transmission.
– Tighten the drain plug -A- only hand-tight.

– Start the engine.
– Press the brake pedal and select each selector lever position
for approximately three seconds, then move the selector lever
back into »P«.
– Do not turn off the engine.
– Then check the fluid level and fill if necessary. Refer to

10 Special Tools
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♦ Transmission Support - aut ra
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Mounting Plate 42A -
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♦ Torque Wrench 1331
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5-50Nm - VAG1331-
40-200Nm - VAG1332-
rrectness of i
♦ Engine and Gearbox Jack -
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VAS6931-
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10. Special Tools 139

♦ Engine Support Bridge -

10-222A-
♦ Hose Clamps - Up To
25mm - 3094- or Hose
Clamps - Up To 40mm -
3093-
♦ Engine Support - Basic Set
- T40091-
♦ Engine Support - Supple‐
ment Kit - T40093A-
♦ Engine Bung Set -
VAS6122-
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10-222A-
Mounting Plate 42A -
3282/42A-
Engine Support Feet -
10-222A/8-
Engine Support 3 -
10-222A/3-
3282-
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♦ Wrench - Pump/Injector Long Reach - T10054- .
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♦ Puller - Crankshaft/Power Steering Seal - T20143-
atio
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♦ Oil Filler - VAS6262A-

♦ Press Piece - Shift Rod/Alternator - VW423-
AG. Volkswagen AG d
♦ Vehicle Diagnostic Tester agen oes
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35 – Gears, Shafts
1 No Repairs to Gears and Shafts
AG. Volkswagen AG d
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144
AG.
Rep. Gr.35 - Gears, Shafts
39 – Final Drive, Differential

1 Flange Shaft or Stub Shaft Seals, Re‐
placing
⇒ “1.1 Component Location Overview - Seals”, page 145
⇒ “1.2 Left Flange Shaft Seal, Replacing”, page 146
⇒ “1.3 Right Flange Shaft or Stub Shaft Seal, Replacing”,
page 148
Do not remove both bolts in the right and left flange shafts or the
right stub shaft at the same time. If the differential bevel gears
rotate, it will be difficult to install the bolts.
1.1 Component Location Overview - Seals
agen Note
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Do not removerised all the bolts in the left and right flange
ara
nte shafts at the same time. If the differential bevel gears
inside uthe
th differential rotate, it will be difficult to installe othe
o
r a bolts.
a c
ss
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1 - Right Flange Shaft or Stub

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Shaft Seal
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❑ Replacing. Refer to
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⇒ “1.3 Right Flange

h re
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Shaft or Stub Shaft

spec
Seal, Replacing”,
page 148 .
t to the co
2 - Right Flange Shaft

❑ Removing and instal‐
rrectne
ling. Refer to
⇒ “1.3 Right Flange
s
Shaft or Stub Shaft

s o
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Seal, Replacing”,
f in
page 148 .
form
mer
atio
3 - Bolt
om
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❑ 30 Nm
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❑ Replace after removing opy
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6 - Selector Shaft Seal

⇒ “4 Selector Shaft Lev‐
er Gasket, Replacing”,
page 60 .
7 - Left Flange Shaft Seal
⇒ “1.2 Left Flange Shaft
Seal, Replacing”,
page 146 .
1. Flange Shaft or Stub Shaft Seals, Replacing 145

8 - Left Flange Shaft

❑ Removing and instal‐
ling. Refer to ⇒ “1.2 Left Flange Shaft Seal, Replacing”, page 146 .
9 - Bolt
❑ 30 Nm
1.2 Left Flange Shaft Seal, Replacing

♦ Slide Hammer Set - VW771-
♦ Slide Hammer Set - Hook - VW771/37-
♦ Seal Installer - Flange Shaft - 3305-
♦ Sealing Grease - G 052 128 A1-
♦ Shop Crane - Drip Tray - VAS6208-
Removing
– Press the brake and remove the bolt from the left drive axle
-arrow- (second technician).
Note
After this, the vehicle must not stand on the ground. Refer to ⇒
moving and Installing . swa
gen AG
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does
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– Remove the left front wheel. orise nte
eo
th
au ra
– Remove the noise insulation.
ss Refer to ⇒ Body Exterior; Rep. c
ce
e
nl
pt
du
an
– Remove the lower section of the left front wheel housing liner.
itte
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erm
Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner;

ab
ility

ot p
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– Remove the left drive axle. Refer to ⇒ Suspension, Wheels,

h re
ol ,
Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

spec
– Place the Shop Crane - Drip Tray - VAS6208- or Used Oil

t to the co
Collection and Extraction Unit - SMN372500- under the trans‐

mission.
rrectness o
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atio
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146 Rep. Gr.39 - Final Drive, Differential

ks wage es n
– Remove the flange shaft bolt, by installingVol two bolts into the ot g
by ua
flange and counterholding the flange
ris
e shaft using a tire iron.
d ran
tee
tho or
– Remove the flange shaft together
sa
u with the pressure spring. ac
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– Remove the flange seal using the Slide Hammer Set - VW771-
rrectness of i
and Slide Hammer Set - Hook - VW771/37- .
l purpos
Installing
– Lightly oil the new gasket on the outer edge.
nform
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– Fill the space on the new seal between the sealing and dust pyri by
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lip halfway with Sealing Grease - G 052 128- -arrow-.
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– Install the seal all the way in without
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– Install the flange shaft. horis tee
t or
au ac
– Tighten the new flange sshaft
s bolt to the tightening specifica‐
tion. Push the flange shaft against the transmission so that the
ce
le
un
pt
bolt engages in the thread.
an
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itte
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erm
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– Install the left drive axle. Refer to ⇒ Suspension, Wheels,
ility
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, is n
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spec
es, in part or in w
t to the co
– Install the left wheel. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 44 ; Wheel Installation Tightening Specifica‐
tions .
rrectness of i
l purpos

nform
ercia
m
at
om
i
Tightening Specifications
on
c
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or
♦ Refer to
his
te
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⇒ “1.1 Component Location Overview - Seals”, page 145 .
pr
cum
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1.3 Right Flange Shaft or Stub Shaft Seal,
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Replacing
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♦ Seal Installer - Axle Flange - 3158-

Removing
– Remove the right wheel.
– If equipped, remove the drive axle heat shield from the engine
-arrows-.
– Remove the right drive axle. Refer to ⇒ Suspension, Wheels,
Vehicles with an Intermediate Shaft

AG. Volkswagen A
gen 2007 ➤ , GolfGVariant
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ara
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– After removing drive axle -A-, remove the intermedi‐ the
ss
a right
u ra
c
ate shaft -B- from the mounting bracket -C- -arrows- and from
ce
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nl
the transmission stub shaft.
pt
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Continuation for All Vehicles erm
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ility
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– Place the Shop Crane - Drip Tray - VAS6208- or Used Oil
wit
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Collection and Extraction Unit - SMN372500- under the trans‐
h re
mission.
hol
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove the stub shaft bolt -arrow- or the flange shaft.

– Remove the stub shaft or flange shaft together with the pres‐
nform
ercia
sure spring.
m
a
om
t
– Pry out the gasket.
ion in
or c
Installing
thi
te
s
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do
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– Lightly oil the new gasket on the outer edge.

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– Fill the space on the new seal between the sealing and dust
lip halfway with Sealing Grease - G 052 128- -arrow-.
– Install the seal all the way in without tilting it.

– Install the stub shaft or flange shaft.
– Tighten the new flange shaft bolt to the tightening specifica‐
tion. Push the stub shaft or flange shaft against the transmis‐
sion so that the bolt engages in the thread.
Vehicles with an Intermediate Shaft
– Replace the O-ring on the stub shaft.
– Grease the splines on the stub shaft.
Note
Refer to the Parts Catalog for the grease allocation.

– Guide the intermediate shaft -B- through the mounting bracket

-C- and onto the stub shaft.
– Tighten the intermediate shaft on the mounting bracket to the
specification -arrows-. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 40 ; Drive Axles, Removing and Installing .
Continuation for All Vehicles
– Install the right drive axle. Refer to ⇒ Suspension, Wheels,
– Install the right wheel. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 44 ; Wheel Installation Tightening Specifica‐
tions .
AG. Volkswagen AG d
agen oes
– Install the noise insulation. Refer to ⇒ Body VExterior;
olks
w
Rep. Gr. not
gu
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50 ; Noise Insulation . sed b ara
nte
ri
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Tightening Specifications aut ra
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♦ Refer to
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⇒ “1.1 Component Location Overview - Seals”, page 145 .
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2 Special Tools
Special tools and workshop

equipment required
♦ Slide Hammer Set -
VW771-
♦ Slide Hammer Set - Hook -
VW771/37-
♦ Seal Installer - Flange Shaft agen
AG. Volkswagen AG d
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- 3305- olksw not
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♦ Torque Wrench 1331 horis nte
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5-50Nm - VAG1331- s aut ra
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40-200Nm - VAG1332-
an
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♦ Seal Installer - Axle Flange - s3158-
s
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3 Revision History
DRUCK NUMBER: MEX5R006621
Fac‐ Edit Job Fee Notes Quality
tory Edi‐ Type dba Checke
Edi‐ tion ck d By
tion
09.2 10/1 Fac‐ N/A Eric P.

015 2/20 tory
15 Up‐
date
05.2 6/17/ Re‐ N/A Jim H
013 2015 for‐
mat
07/2 Lo‐ 102 Eric P
2/20 cal 858
14 Feed 4
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1/13/ Lo‐ 988 Fix Metta d b Data for Trans‐
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2014 cal 140 mission
rise Removing. GWR nte
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08/2 Lo‐ 959 Fixed Metta Data to add Gary R
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3. Revision History 153

Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.
•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
. Volkswagen AG
are made applicable to earlier models. Therefore, part numbers gen AGin this manual
alisted dare
oes for reference only. Always
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check with your authorized Volkswagen retailer parts department
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•= Any time the battery has been disconnected on anau automatic transmission vehicle, it will be necessaryor
ac to
ss
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
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•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
y li
erm
ab
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
ility
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vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
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•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
hol
spec
es, in part or in w
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
t to the co
become inoperable, even if the correct code is used in a later attempt.
•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
rrectness of i
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
l purpos
starting the vehicle while you are under it.
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
nform
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others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
m
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being fully alert.
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•=
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Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
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•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
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goggles, gloves and other protective clothing whenever the job requires working with harmful substances. Co
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•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near py by
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machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe Prote
cted AG.
agen
injury could result.
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.
•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
crushed by heavy parts.
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
AG. Volkswagen AG d
replacement parts meeting
swagen Volkswagen specifications.
oes Makeshift tools, parts and procedures will not make good
olk not
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•= Catch draining
fuel, oil or brake fluid in suitable
ss
a containers.r aDo
not use empty food or beverage containers that
c
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
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nl
pt
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once, but do not store the oily rags, which can ignite and burn spontaneously.
an
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•=
ility
Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
ot p
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fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
, is n
listed. h re
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es, in part or in w
•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
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ignited, it will ignite gas trapped in the cells and cause the battery to explode.
rrectness of i
•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
l purpos
govern the disposal of wastes.

nform
ercia
•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
m
a
om
ti
trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
on in
c
automotive chemical refrigerants.

or
thi
te
s
a
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•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
p
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or
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negative terminal (ground strap) and the ABS control module connector.
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•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
Page 2 of 3
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
tire from the rim before attempting any repair.
•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
I have read and I understand these Cautions and Warnings.
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Page 3 of 3
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VW 6 Speed DQ250 Dual Clutch Transmission 02E Repair Manual Edition 09.2015

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Service

Service Department. Technical Information

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Copyright © 2016 Volkswagen AG, Wolfsburg D3E80020F58

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3.1 Transmission Code, Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4 Engine Codes - Engine Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.2 Clutch End Cover, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.4 Dual Clutch, Installing and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1 Electrical and Electronic Components, Component Locations in DSG® Transmission . . . . 33

35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

3 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

⇒ “1.4 O-Rings, Gaskets and Seals”, page 3

⇒ “1.7 Electrical Components”, page 5

submit comments and/or improvement suggestions to Volkswa‐

– Click the Feedback Button at the top in the menu toolbar.

1. General Repair Information 1

♦ Place the removed parts on a clean surface and cover them

1.3 Brief Overview - Guide

Fluid Filter, When To

sion Fluid”, page 3

The oil can be drained

through the check plug

2 Rep. Gr.00 - General, Technical Data

1.4 O-Rings, Gaskets and Seals

♦ After installing, check transmission fluid level and fill. Refer to

Shake the bottles before opening.

to the Parts Catalog.

Be very careful when handling transmission fluid. Dispose of

1.5.1 Fluid Function

1. General Repair Information 3

and minimizes noise. The fluid performs many functions. The

1.5.2 Transmission Fluid Filter, »When To

1.5.3 Fluid and Fluid Level Troubleshooting

– Determine where the fluid has leaked out of the transmission.

⇒ “9 Transmission Fluid and Transmission Fluid Filter”, n in

Filling the fluid »just in case« does not correct a malfunction. It

Through transmission production date “09/20/2004”, transmis‐

4 Rep. Gr.00 - General, Technical Data

1.6 Bolts and Nuts

1.7 Electrical Components

1. General Repair Information 5

2.1 Troubleshooting, General Information

2.2 Transmission “Control Module Malfunc‐

in “gear monitoring” would be recognized causing the control pt

module to respond that both clutches are open (no traction). y li

working with the Volkswagen tester. It is possible that the cause

In addition to the highly developed software, much has been done

a replacement program is started.

Control Module Behavior During A Malfunction

ule reacts with a replacement function. In order to protect the

1- The malfunction is so minor that it is possible to continue

driving with a replacement program while maintaining driv‐

Lever Transmission Range Display - Y5- . The display

shows the selector lever position normally. If changes in

6 Rep. Gr.00 - General, Technical Data

2.3 Fault Finding, Special Information

⇒ “2.3.4 No Faults are Stored”, page 7

⇒ “2.3.5 Faults are Stored”, page 8

2.3.2 Touch Function Malfunction, Not

2.3.3 »Drive« Faulty - Insufficient Oil Suspec‐

2.3.4 No Faults are Stored

2.3.5 Faults are Stored