Worksheet 1 – DSG general (solution)

1. Worksheet 1 – DSG general (solution) • DSG – repair Which cleanliness rules must you observe at all times when working on the dual-clutch gearbox? • See ELSA: • Power transmission • dual-clutch gearbox • General repair instructions • Gearbox • Do not let the engine run and do not tow the vehicle with the gearbox covers removed or if the gearbox is without oil. • Thoroughly clean all connection points and their surrounding areas before opening them. • When installing the gearbox, make sure that the fitting bushings between engine and gearbox are seated correctly. • Place disassembled parts onto a clean surface and cover them to keep them free from dirt. Use foils and paper. Use only lint-free rags! • Only install clean parts: Replacement parts should not be removed from their packaging until they are ready to be installed. • Carefully cover or seal opened components if the repairs are not immediately carried out.

2. Worksheet 2 – 6-speed DSG 02E (solution) • DSG – repair 1. Replace the clutch module and carry out the prescribed adjustment work. 1.1 What special tools are required? • T10303 retaining bolt • T10054 mounting sleeve • Dial gauge and dial gauge holder 1.2 What do you have to keep in mind and how do you proceed? • See ELSA: • Power transmission • dual-clutch gearbox • 30 Clutch, actuation • Removing and installing clutches • Installing and adjusting clutches • Important: Observe “Notes about the clutch” in the workshop manual! • Gearbox must been removed beforehand. • Inside seal of the end cover must not be touched. • Discs must be correctly positioned when assembling. • Note the pretension on the dial gauge. • Dispose of all other adjusting rings. 1.3 What adaption functions must be carried out after installation using tester VAS 5051B? A basic measurement with the VAS 5051 must be performed.

3. Worksheet 3 – 6-speed DSG 02E (solution) • DSG – repair 2. Replace the mechatronics using the technical literature. 2.1 What should be noted for removal and installation? • See ELSA: • Power transmission • Dual-clutch gearbox • 34 Gearbox, mech. operat., assy • Electrical/electronic components and installation locations • Removing and fitting mechatronics for dual-clutch gearbox • Before you touch the mechatronics, touch an earthed object! 2.2 Which components must be replaced when changing the mechatronics? • The smaller cover of the oil pump and the screw of the larger cover must always be replaced. • The gasket of the larger cover must also be replaced.

4. Worksheet 4 – 6-speed DSG 02E (solution) • DSG – repair 3. Replace the oil pump using the technical literature. 3.1 What should be noted for removal and installation? • See ELSA: • Power transmission • Dual-clutch gearbox • 34 Gearbox, mech. oper., ASSY • Remove and install oil pump • Slide oil pump drive shaft into the gearbox all the way up to the stop, rotating the drive shaft a little while doing so. Always use a new metal gasket.  The two locating pins must be engaged in the gearbox housing.  When fitting the oil pump, observe the gear teeth of the drive shaft and that the locating pins are correctly seated. 3.2 What special tools do you need? • T10054 Socket • V.A.G 1782 Waste oil container and extractor unit

5. Worksheet 5 – 6-speed DSG 02E (solution) • DSG – repair 4. In the group clarify the power transmission for the seven different gears and label the graphics with the corresponding gears. 3rd 1st _______gear _______gear R 5th _______gear _______gear 2nd 4th _______gear _______gear 6th _______gear

6. Worksheet 6 – 7-speed DSG 0AM (solution) • DSG – repair 1. Replace the clutch module and carry out the prescribed adjustment work. 1.1 What special tools are required? 3438 hook, T10323 support bridge, T10368 thrust pad, T10373 puller, T10374 callipers, T40100 ruler, T10376 thrust pad 1.2 Make a note of your approach. • See ELSA: • Power transmission • 30 Clutch, actuation • Removing and installing dual clutches • Important: Do not oil or grease anything! 1.3 What adaption functions must be carried out after installation using tester VAS 5051B? A basic measurement with the VAS 5051 must be performed.

7. Worksheet 7 – 7-speed DSG 0AM (solution) • DSG – repair 2. Replace the mechatronics using the technical literature. 2.1 What should be noted for removal and installation? • See ELSA: • Power transmission • 34 Gearbox, mech. oper. • Mechatronics for dual-clutch gearboxes ... • Important: Do not work on the pressure accumulator. The accumulator is pressurised and must not be opened. • Note: New mechatronic units are filled with oil. Do not drain any oil. A removed mechatronics unit is returned with oil. 2.2 Which special-purpose tools are needed? • T10407 Assembly lever • T10406 Guide pin

8. Worksheet 8 – 7-speed DSG 0AM (solution) • DSG – repair 3. In the group clarify the power transmission for the eight different gears and label the graphics with the corresponding gears. 4th 7th _______gear _______gear 3rd 2nd _______gear _______gear 5th R _______gear _______gear 1st 6th _______gear _______gear

9. Worksheet 9 – DSG general (solution) • DSG – repair • Carry out a basic measurement using guided functions or guided fault finding. • 1. Make a note of your approach. • VAS 5051B: • Guided fault finding • Functions • Performing a basic measurement of the dual-clutch gearbox 2. After which repairs or fault entries is a basic measurement necessary? • After replacing the following components: • Mechatronics • Gearbox • Multi-disk clutches • New engine and ABS control units must be “familiarised” with the mechatronics for dual-clutch gearbox J743. (adapting installation info)