00-4, Code Letters, Assembly Allocation, Ratios, Equipment: Transmission Identification

Volkswagen Jetta 2005->
(A5)
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Transmission identification
The "6 Spd. Direct Shift Automatic Transmission 02E Front
Wheel Drive" is installed in the Jetta 2005 . Allocation
00-4, Code letters, assembly allocation, ratios, equipment .
Location on transmission
Transmission code letters are located at top on

transmission, in the area of oil cooler.
Example for one transmission:
HLH = Transmission code letters
13.08.04 = Production date 13th August 2004
14 = Plant code
06:32 = Time
0011 = Serial number
The transmission code letters are also listed on the vehicle

data plates.
Note:
If the data plate is not available, a different

transmission was accidentally installed or there is no
definite way to identify the installed transmission,
read the transmission code letters directly from the
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transmission 00-1, Transmission code, reading .
Transmission code, reading
Short description
On some transmissions, additional transmission code

letters are located on the top of the transmission in the area
of the selector lever cable - arrows - .
To read the transmission code letters, under the console,

directly from the transmission, the engine and transmission
must be supported. The console - A - of left assembly
mounting must be removed.
When doing this, it is important to lower the

engine/transmission only far enough until the console can
be slid toward rear. If lowered farther, the pendulum
support will be damaged.
After reassembly, selector lever cable must be adjusted

34-9, Selector lever cable, checking and adjusting .
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- Disconnect electrical harness connector - 2 - from Mass

Air Flow (MAF) Sensor G70 .
- Disconnect vent hose - 1 - and air guide hose - 5 - .
- Open spring clamp - 3 - using hose clamp pliers VAS

5024 A and disconnect air guide hose from tube.
- Unscrew bolt - 4 - and remove air filter housing.
- Check whether a coded radio is installed. In this case,

obtain the anti-theft coding.
Note:
Additional procedures must be performed when

disconnecting and reconnecting battery Ground
(GND) strap
Repair Manual, Electrical Equipment, Repair Group 27,

Battery, disconnecting and reconnecting battery
- Remove battery
Repair Manual, Electrical Equipment,, Repair Group 27,

Battery; removing and installing battery
- Remove battery carrier.

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- Place engine support bridge 10-222 A with adapters 10-

222 A/8 and adapter 10-222 A/3 in front of gas-filled strut
for hood.
- If hose and cable connections are found in the area of

engine lifting eyes for engine support bridge 10-222 A ,
they must be removed now.
- Engage spindles 10-222 A/10 of engine support bridge on

left and right engine lifting eyelets and support engine with
transmission. Do not lift up.
- Remove all bolts - 1 - and - 2 - of console - A - .
Bolts must be replaced.
Carefully lower engine with transmission via both spindles

by 2 rotations, alternating sides.
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A maximum of 4 rotations is sufficient in order to remove

the console - A - toward rear.
After that, transmission code letters can now be read off,

reassembly is performed in the reverse order.
Note:
Follow all the following instructions nevertheless.
Replace all bolts of left subframe mount.
First, screw in all new bolts by hand.
- Bolt on console - A - on transmission with bolts - 1 - and -

2 - 34-10, Tightening torques .
- Adjust selector lever cable 34-9, Selector lever cable,

checking and adjusting .
Notes for 6 Spd. Direct Shift Automatic Transmission 02E Front Wheel Drive
00 - 2
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Notes for "6 Spd. Direct Shift Automatic

Transmission 02E Front Wheel Drive"
For detailed information regarding functions of "6 Spd.
Direct Shift Automatic Transmission 02E Front Wheel
Drive" , refer to
Self-study program no. 308 Direct Shift Transmission
02E .
Information can also be obtained via CD-ROM

Multimedia Training; Direct Shift Transmission .
Transmission
The "6 Spd. Direct Shift Automatic Transmission 02E Front

Wheel Drive" is also called a double-clutch transmission.
Engine torque is transferred to transmission via the dual-
mass flywheel. Transmission is constructed as a 6-speed
manual transmission. Alternating hydraulic actuation of the
two wet multi-plate clutches permits operation similar to
that of an automatic transmission, i.e. the gears are
engaged automatically or manually via the Tiptronic mode.
A clutch pedal is not installed.
Safety functions of Mechatronic unit
If individual or several components or sensors fail, Direct

Shift Gearbox (DSG) Mechatronic unit J743 activates the
corresponding substitute functions or emergency running
program. This ensures non-destructive operation of the
transmission with respective implications on shift function
and quality.
Shift mechanism
The selector lever position is no longer transferred

mechanically via selector lever cable and Multi-Function
Transmission Range (TR) Switch -F125- as with the
automatic transmission. Selector lever positions or gear
shifts are transferred via a separate control module in shift
mechanism via CAN-Bus to the transmission control
module . Gear shift occurs without a cable as well. Only in
selector lever position "P" is the parking lock selected
mechanically via the selector lever cable.
Shift point change when driving up- or downhill ranges
At uphill or downhill ranges, the shifts are automatically

selected dependent on the accelerator pedal position and
vehicle speed via additional shift characteristics maps.
Shift characteristics map for extreme uphill driving is

adapted to the engine performance
Notes for 6 Spd. Direct Shift Automatic Transmission 02E Front Wheel Drive
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Shift characteristics map for extreme downhill driving

is adapted to the braking effect of the engine
Direct gear selection by way of the Tiptronic function

permits utilization of engine braking action with a
specific gear engaged, e.g. on a downhill gradient
with a trailer.
Guided Fault Finding, Vehicle On Board Diagnostic (OBD)

and Test Instruments
Before performing service work on the automatic

transmission, cause of damage must be exactly determined
via "Guided Fault Finding" .
"Guided Fault Finding" is performed using Vehicle

Diagnosis, Testing and Information System VAS 5051 .
Capacities
00 - 3
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Capacities
Capacities 6 Spd. Direct Shift Automatic Transmission 02E Front Wheel

Drive
New filling 7.2 L
Replacement in service approx. 5.2 L
department
Change interval Repair Manual, Maintenance
Lubricant Transmission oil for Direct Shift Transmission 02E
Electronic Replacement Parts Catalog "ETKA"
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru
огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi
Code letters, assembly allocation, ratios, equipment

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Direct shift transmission 02E - 6-speed

Transmission Code letters GAY GKF GPU
Manufactured from 05.05 05.05 05.05
to 05.05 05.05 05.05
Allocation Model Jetta 2005 Jetta 2005 Jetta 2005
Engine 1.9 L -74 kW 2.0 L - 100 kW 2.0 L - 100 kW
Turbo-Diesel Turbo-Diesel, Turbo-Diesel,
1.9 L -77 kW 2.0 L - 103 kW 2.0 L - 103 kW
Turbo-Diesel Turbo-Diesel Turbo-Diesel
Ratio: Z 2 : Z Final drive 1 70 : 16 = 4,375 69 : 17 = 4,059 69 : 17 = 4,059
for 1st to 4th gear
1
Final drive 2 70 : 21 = 3,333 69 : 22 = 3,136 69 : 22 = 3,136
for 5th/6th and
reverse gear
1. Gear 45 : 13 = 3,462 45 : 13 = 3,462 45 : 13 = 3,462
2. Gear 41 : 20 = 2,050 41 : 20 = 2,050 41 : 20 = 2,050
3. Gear 39 : 30 = 1,300 39 : 30 = 1,300 39 : 30 = 1,300
4. Gear 37 : 41 = 0,902 37 : 42 = 0,881 37 : 42 = 0,881
5. Gear 32 : 35 = 0,914 32 : 35 = 0,914 32 : 35 = 0,914
6. Gear 31 : 41 = 0,756 31 : 42 = 0,738 31 : 42 = 0,738
Reverse Gear 33 : 13 x 22 : 14 = 33 : 13 x 22 : 14 = 33 : 13 x 22 : 14 =
3,989 3,989 3,989
Transmission Code letters GPV GPW GYM
to 05.05 05.05 05.05
Engine 1.9 L -74 kW 1.9 L -74 kW 2.0 L - 100 kW
Turbo-Diesel Turbo-Diesel Turbo-Diesel,
1.9 L -77 kW 1.9 L -77 kW 2.0 L - 103 kW
for 1st to 4th gear
1
Final drive 2 70 : 21 = 3,333 70 : 21 = 3,333 69 : 22 = 3,136
for 5th/6th and
reverse gear
1. Gear 45 : 13 = 3,462 45 : 13 = 3,462 45 : 13 = 3,462
2. Gear 41 : 20 = 2,050 41 : 20 = 2,050 41 : 20 = 2,050
3. Gear 39 : 30 = 1,300 39 : 30 = 1,300 39 : 30 = 1,300
4. Gear 37 : 41 = 0,902 37 : 41 = 0,902 37 : 42 = 0,881

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5. Gear 32 : 35 = 0,914 32 : 35 = 0,914 32 : 35 = 0,914

6. Gear 31 : 41 = 0,756 31 : 41 = 0,756 31 : 42 = 0,738
Reverse Gear 33 : 13 x 22 : 14 = 33 : 13 x 22 : 14 = 33 : 13 x 22 : 14 =
3,989 3,989 3,989
Transmission Code letters GYN GYQ GYR
to 05.05 02.05
Engine 2.0 L - 100 kW 1.9 L -77 kW 1.9 L -74 kW
Turbo-Diesel, Turbo-Diesel Turbo-Diesel
2.0 L - 103 kW 1.9 L -77 kW
Turbo-Diesel Turbo-Diesel
for 1st to 4th gear
1
Final drive 2 69 : 22 = 3,136 70 : 21 = 3,333 70 : 21 = 3,333
for 5th/6th and
reverse gear
1. Gear 45 : 13 = 3,462 45 : 13 = 3,462 45 : 13 = 3,462
2. Gear 41 : 20 = 2,050 41 : 20 = 2,050 41 : 20 = 2,050
3. Gear 39 : 30 = 1,300 39 : 30 = 1,300 39 : 30 = 1,300
4. Gear 37 : 42 = 0,881 37 : 41 = 0,902 37 : 41 = 0,902
5. Gear 32 : 35 = 0,914 32 : 35 = 0,914 32 : 35 = 0,914
6. Gear 31 : 42 = 0,738 31 : 41 = 0,756 31 : 41 = 0,756
Reverse Gear 33 : 13 x 22 : 14 = 33 : 13 x 22 : 14 = 33 : 13 x 22 : 14 =
3,989 3,989 3,989
Transmission Code letters HBP HBQ HFQ
to 05.05 05.05 07.05
Engine 2.0 L -100 kW 1.9 L -74 kW 2.0 L - 100 kW
Turbo-Diesel Turbo-Diesel Turbo-Diesel,
1.9 L -77 kW 2.0 L - 103 kW
for 1st to 4th gear
1
Final drive 2 70 : 23 = 3,043 69 : 22 = 3,136 70 : 23 = 3,043
for 5th/6th and
reverse gear
1. Gear 45 : 13 = 3,462 45 : 13 = 3,462 45 : 13 = 3,462
2. Gear 41 : 20 = 2,050 43 : 20 = 2,150 41 : 20 = 2,050
3. Gear 39 : 30 = 1,300 41 : 28 = 1,464 39 : 30 = 1,300

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4. Gear 37 : 41 = 0,902 41 : 38 = 1,079 37 : 41 = 0,902

5. Gear 32 : 35 = 0,914 35 : 32 = 1,094 32 : 35 = 0,914
6. Gear 31 : 41 = 0,756 35 : 38 = 0,921 31 : 41 = 0,756
Reverse Gear 33 : 13 x 22 : 14 = 33 : 13 x 22 : 14 = 33 : 13 x 22 : 14 =
3,989 3,989 3,989
Transmission Code letters HJQ HLE HLF
to 05.05 05.05
Engine 2.0 L - 100 kW 2.0 L -100 kW 2.0 L - 100 kW
Turbo-Diesel, Turbo-Diesel Turbo-Diesel,
2.0 L - 103 kW 2.0 L - 103 kW
for 1st to 4th gear
1
Final drive 2 69 : 22 = 3,136 70 : 23 = 3,043 69 : 22 = 3,136
for 5th/6th and
reverse gear
1. Gear 45 : 13 = 3,462 45 : 13 = 3,462 45 : 13 = 3,462
2. Gear 41 : 20 = 2,050 41 : 20 = 2,050 41 : 20 = 2,050
3. Gear 39 : 30 = 1,300 39 : 30 = 1,300 39 : 30 = 1,300
4. Gear 37 : 42 = 0,881 37 : 41 = 0,902 37 : 42 = 0,881
5. Gear 32 : 35 = 0,914 32 : 35 = 0,914 32 : 35 = 0,914
6. Gear 31 : 42 = 0,738 31 : 41 = 0,756 31 : 42 = 0,738
Reverse Gear 33 : 13 x 22 : 14 = 33 : 13 x 22 : 14 = 33 : 13 x 22 : 14 =
3,989 3,989 3,989
Transmission Code letters HLH HQF HQH
to 07.05 07.05
Engine 1.9 L -74 kW 2.0 L - 100 kW 1.9 L -74 kW
Turbo-Diesel Turbo-Diesel, Turbo-Diesel
1.9 L -77 kW 2.0 L - 103 kW
for 1st to 4th gear
1
Final drive 2 70 : 21 = 3,333 70 : 23 = 3,043 70 : 21 = 3,333
for 5th/6th and
reverse gear
1. Gear 45 : 13 = 3,462 45 : 13 = 3,462 45 : 13 = 3,462
2. Gear 41 : 20 = 2,050 41 : 20 = 2,050 41 : 20 = 2,050

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3. Gear 39 : 30 = 1,300 39 : 30 = 1,300 39 : 30 = 1,300

4. Gear 37 : 41 = 0,902 37 : 41 = 0,902 37 : 41 = 0,902
5. Gear 32 : 35 = 0,914 32 : 35 = 0,914 32 : 35 = 0,914
6. Gear 31 : 41 = 0,756 31 : 41 = 0,756 31 : 41 = 0,756
Reverse Gear 33 : 13 x 22 : 14 = 33 : 13 x 22 : 14 = 33 : 13 x 22 : 14 =
3,989 3,989 3,989
Transmission Code letters HQK HQL HQN
to 05.05
Engine 1.9 L -74 kW 2.0 L - 100 kW 1.9 L -74 kW
Turbo-Diesel Turbo-Diesel, Turbo-Diesel
1.9 L -77 kW 2.0 L - 103 kW 1.9 L -77 kW
for 1st to 4th gear
1
Final drive 2 69 : 22 = 3,136 70 : 23 = 3,043 70 : 21 = 3,333
for 5th/6th and
reverse gear
1. Gear 45 : 13 = 3,462 45 : 13 = 3,462 45 : 13 = 3,462
2. Gear 43 : 20 = 2,150 41 : 20 = 2,050 41 : 20 = 2,050
3. Gear 41 : 28 = 1,464 39 : 30 = 1,300 39 : 30 = 1,300
4. Gear 41 : 38 = 1,079 37 : 41 = 0,902 37 : 41 = 0,902
5. Gear 35 : 32 = 1,094 32 : 35 = 0,914 32 : 35 = 0,914
6. Gear 35 : 38 = 0,921 31 : 41 = 0,756 31 : 41 = 0,756
Reverse Gear 33 : 13 x 22 : 14 = 33 : 13 x 22 : 14 = 33 : 13 x 22 : 14 =
3,989 3,989 3,989
Transmission Code letters HQQ HRW HTB
to 07.05 07.05
Engine 1.9 L -74 kW 2.0 L - 147 kW 2.0 L - 100 kW
Turbo-Diesel Turbo-FSI Turbo-Diesel,
1.9 L -77 kW 2.0 L - 103 kW
for 1st to 4th gear
1
Final drive 2 69 : 22 = 3,136 69 : 22 = 3,136 70 : 23 = 3,043
for 5th/6th and
reverse gear
1. Gear 45 : 13 = 3,462 45 : 13 = 3,462 45 : 13 = 3,462

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2. Gear 43 : 20 = 2,150 43 : 20 = 2,150 41 : 20 = 2,050

3. Gear 41 : 28 = 1,464 41 : 28 = 1,464 39 : 30 = 1,300
4. Gear 41 : 38 = 1,079 41 : 38 = 1,079 37 : 41 = 0,902
5. Gear 35 : 32 = 1,094 35 : 32 = 1,094 32 : 35 = 0,914
6. Gear 35 : 38 = 0,921 35 : 38 = 0,921 31 : 41 = 0,756
Reverse Gear 33 : 13 x 22 : 14 = 33 : 13 x 22 : 14 = 33 : 13 x 22 : 14 =
3,989 3,989 3,989
Transmission Code letters HUS HUT HVV
to 05.05 12.05
Engine 2.0 L - 147 kW 2.0 L - 147 kW 1.4 L - 103 kW
Turbo-FSI Turbo-FSI Turbo-FSI
1.4 L - 125 kW
Turbo-FSI
for 1st to 4th gear
1
Final drive 2 69 : 22 = 3,136 69 : 22 = 3,136 72 : 20= 3,600
for 5th/6th and
reverse gear
1. Gear 45 : 13 = 3,462 45 : 13 = 3,462 45 : 13 = 3,462
2. Gear 43 : 20 = 2,150 43 : 20 = 2,150 43 : 20 = 2,150
3. Gear 41 : 28 = 1,464 41 : 28 = 1,464 41 : 28 = 1,464
4. Gear 41 : 38 = 1,079 41 : 38 = 1,079 41 : 38 = 1,079
5. Gear 35 : 32 = 1,094 35 : 32 = 1,094 35 : 32 = 1,094
6. Gear 35 : 38 = 0,921 35 : 38 = 0,921 35 : 38 = 0,921
Reverse Gear 33 : 13 x 22 : 14 = 33 : 13 x 22 : 14 = 33 : 13 x 22 : 14 =
3,989 3,989 3,989
Transmission Code letters HXS HXU HXW
to
Engine 2.0 L - 100 kW 1.9 L -74 kW 2.0 L - 147 kW
Turbo-Diesel, Turbo-Diesel Turbo-FSI
2.0 L - 103 kW 1.9 L -77 kW
for 1st to 4th gear
1
Final drive 2 70 : 23 = 3,043 70 : 21 = 3,333 69 : 22 = 3,136
for 5th/6th and
reverse gear
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1. Gear 45 : 13 = 3,462 45 : 13 = 3,462 45 : 13 = 3,462

2. Gear 41 : 20 = 2,050 41 : 20 = 2,050 43 : 20 = 2,150
3. Gear 39 : 30 = 1,300 39 : 30 = 1,300 41 : 28 = 1,464
4. Gear 37 : 41 = 0,902 37 : 41 = 0,902 41 : 38 = 1,079
5. Gear 32 : 35 = 0,914 32 : 35 = 0,914 35 : 32 = 1,094
6. Gear 31 : 41 = 0,756 31 : 41 = 0,756 35 : 38 = 0,921
Reverse Gear 33 : 13 x 22 : 14 = 33 : 13 x 22 : 14 = 33 : 13 x 22 : 14 =
3,989 3,989 3,989
Transmission Code letters HYC
Manufactured from 07.06
to
Engine 2.0 L - 100 kW

Turbo-Diesel,
2.0 L - 103 kW
Turbo-Diesel
Ratio: Z 2 : Z 1 Final drive 1 70 : 17 = 4,118
for 1st to 4th gear
Final drive 2 70 : 23 = 3,043
for 5th/6th and reverse gear
1. Gear 45 : 13 = 3,462
2. Gear 41 : 20 = 2,050
3. Gear 39 : 30 = 1,300
4. Gear 37 : 41 = 0,902
5. Gear 32 : 35 = 0,914
6. Gear 31 : 41 = 0,756
Reverse Gear 33 : 13 x 22 : 14 = 3,989
00 - 5
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Calculation of transmission ratios "i"
Example:
6. Gear Final drive

Drive gear ZG 1 = 41 ZA 1 = 21
Driven gear ZG 2 = 31 ZA 2 = 70
i=Z2:Z1)
i G = gear ratio = ZG 2 : ZG 1 = 31 : 41 = 0,756
i A = axle ratio = ZA 2 : ZA 1 = 70 : 21 = 3,333
i total = overall ratio
= i G x i A = 0.756 x 3.333 = 2,52
)Z = no. of teeth drive gear, Z 2 = no. of teeth driven gear

1
General Repair Notes
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The maximum possible care, cleanliness and proper tools
are essential to ensure satisfactory and successful
transmission repairs. The usual basic safety precautions
also apply when carrying out vehicle repairs.
A number of generally applicable instructions for individual

repair procedures, which are otherwise mentioned at
various points in the Repair Manual, are summarized here.
They apply to this Repair Manual.
Special tools and equipment
A complete list of special tools and equipment used in this

repair manual is listed before each repair description and
in: "Special tools catalog" .
Notes for tow starting and towing
Caution!
When towing the vehicle, selector lever must be in

position "N" and the vehicle must not be towed for
more than 50 km and no faster than 50 km/h, since the
transmission will otherwise be destroyed.
Note:
Tow-starting the engine, e.g. when the battery is too

weak or the starter is defective, is not possible.
Transmission components, overview

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Filter
Transmission Input Speed (RPM)

Sensor G182 and Clutch Oil
Temperature Sensor G509
Transmission oil pump
cover for transmission oil pump
Drain plug
Check plug
Direct Shift Gearbox (DSG)

Mechatronic unit J743
Oil pan
cover (sealing cover) for clutch
Clutch
Transmission oil cooler
Rules for cleanliness

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Thoroughly clean all connections and the surrounding

area before disconnecting.
Only install clean components: Only unpack

replacement parts immediately prior to installation.
Always replace paper seals. Remove old seal

completely and thoroughly clean sealing surfaces.
Place removed parts on clean surface and cover

them so they do not become soiled. Use foils and
paper. Use lint-free cloths only!
Carefully cover over opened components or seal, if

repairs are not carried out immediately.
Transmission
If covers are unscrewed from transmission or

transmission has no oil, do not run engine and do not
tow vehicle.
When installing transmission, make sure centering

sleeves are correctly seated between engine and
transmission.
Only install clean components: Only unpack

replacement parts immediately prior to installation.
If transmission was replaced, oil level must be

checked.
Mechatronic unit unit
Mechatronic unit is to be allocated to transmission

code letters Electronic Replacement Parts Catalog
"ETKA" .
Electrical components
When touching a metal object, it may cause an electrostatic

discharge. The reason for this is the electrostatic charge of
the human body. This charge can lead to functional
problems by touching the electrical components of the
transmission and selector lever mechanism.
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- Touch a grounded object, e.g. a water tube or a lifting

platform, before working on the electrical components!
- Do not make direct contact on connector terminals.
Transmission oil and filter
Caution!
Handle the oil very carefully. Dispose of drained oil in

an appropriate manner.
Shake oil bottle before opening.
Do not mix additives into the oil, do not add a

different oil as well.
For every oil change, filter must be replaced as well.
Drained oil must not be reused.
Always use only transmission oil for direct shift

transmission Electronic Replacement Parts
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Catalog "ETKA" .
Oil level in transmission and in final drive are checked

and filled together.
Gaskets and sealing rings
Always replace O-rings, gaskets and seals.
After removing gaskets and seals, always inspect the

contact surfaces at housing or shaft for burrs and
damage and repair them.
Before installing a radial shaft seal, coat sealing lips

and space in between - arrow - with sealing grease
G 052 128 A1 and outer circumference with
transmission oil for direct shift transmission.
The open side of the seals face toward the oil.
Lubricate O-rings with transmission oil for direct shift

transmission before installing, this prevents the rings
from being damaged when installing.
For oiling purposes, always use only transmission oil

for direct shift transmission. Other lubricating
substances cause functional problems in the
hydraulic transmission control.
After installing, check oil level 34-11, Changing

transmission oil and checking oil level .
- Filling quantities and specification 00-3, Capacities .
Bolts and nuts

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Loosen and tighten bolts or nuts for securing covers

and housings in diagonal sequence.
Do not distort especially delicate parts, e.g.

Mechatronic unit unit, and loosen and tighten in
stages in a diagonal sequence
The tightening torques stated apply to non-oiled nuts

and bolts.
Using a wire brush, clean threads of bolts which are

secured with locking compound. Then install bolts
with locking fluid AMV 185 100 A1 .
All threaded bores in which self-locking bolts are

threaded must be cleaned of remaining locking fluid
using a tap. Otherwise there is danger that the bolts
may shear when removed again.
Always replace self-locking nuts and bolts.
Locking elements
Do not over-stretch circlip, replace if necessary.
Securing rings must be fully seated in groove.
Guided Fault Finding, Vehicle On Board Diagnostic (OBD)

and Test Instruments
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Before performing service work on the transmission,

cause of damage must be determined as exactly as
possible via "Guided Fault Finding" .
"Guided Fault Finding" is performed using Vehicle

Diagnosis, Testing and Information System VAS
5051 .
Clutch components
30 - 1
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Clutch components
Notes
Clutches of Direct Shift Gearbox always contain at least

two clutch packs, which is why it is described as a "double
clutch" .
The outer, larger disc pack is named "K1" (Clutch 1).

Reverse gear and gears "1" , "3" and "5" are shifted via
"K1" .
Gears "2" , "4" and "6" are shifted via the inner, smaller disc
pack "K2" .
Assembling the clutch requires special care because all

components were calibrated to each other by the
manufacturer. When assembling, if position of parts in
relation to each other are turnd, imbalance occurs to
burden shifting comfort.
To avoid the risk of turning parts from one another in the

first place, it is shown here how the clutch is assembled in
the transmission housing and installed.
Overview
Note :
Observe notes for direct shift transmission 02E 00-

2, Notes for 6 Spd. Direct Shift Automatic
Transmission 02E Front Wheel Drive .
Observe general repair notes and rules of cleanliness

for working on the transmission 00-6, General
Repair Notes .
In case components of the clutch slip out or the clutch

pack carrier is lifted up, then use light rotating
motions to reposition the large, and if necessary the
small, clutch pack carrier in all of the inner clutches.
The clutch cover, especially, must always be installed

in the same position, as it was when the new clutch
was "delivered" 30-2, Installing .
Clutch components
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Circlip
Large clutch pack carrier
Do not remove
Caution!
Avoid removing or lifting up the clutch

pack carrier. Not even slightly! The
clutch discs could turn themselves.
Double clutch housing
With assembled clutch "K2"
Seal
4x
Outer clutch disc
4x
Clutch components
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Inner clutch disc
4x
Thrust washer
Circlip
In case the circlip has been

removed to install new clutch
discs, use a new circlip of
same thickness
Clutch cover
Circlip
Always replace
Re-determine thickness
30-2, Clutch, installing and
adjusting
Clutch, removing and installing
30 - 2
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Before clutch can be removed, the cover (end cover) for
clutch must be removed 30-2, Clutch cover (end cover),
removing and installing .
Clutch cover (end cover), removing and installing
Removing
Note:
Observe notes for Direct-Shift Transmission 02E

00-2, Notes for 6 Spd. Direct Shift Automatic

Repair Notes .
The cover is held in its seated position by a circlip.

After the circlip is removed, the cover can be pried
out of its seated position.
Cover and circlip must always be replaced
Never install a new cover with a hammer and never

lubricate the middle gasket or touch it by hand! This
would result in leaks.
To perform work on the cover, the transmission must be

removed.
- Remove transmission 34-10, Transmission, removing

and installing .
- Attach transmission to assembly stand 34-10,

Attaching transmission to assembly stand .
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Warning!
Wear protective glasses.
Wear protective gloves.
- Unscrew drain plug - arrow - .
Approx. 5.0 liters of oil will drain out. Container still remains
standing under transmission.
- Replace sealing ring for drain plug - arrow - .
- Install drain plug - arrow - and tighten to 45 Nm.
- Remove filter housing - 1 - from transmission.
- Before removing the filter housing from the transmission,

tip it slightly in its place.
This allows oil to flow back into transmission from filter

housing.
Note:
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Always replace O-ring - 2 - .
- Remove filter - 3 - .
- Coat new O-ring - 2 - with transmission oil.
- Coat O-ring in intake collar - arrow - of new filter with

transmission oil.
- install new filter with intake collar - arrow - downward and

tighten filter housing to 20 Nm.
- After performing repairs, the filter does not need to be

changed again when filling with oil.
- Remove circlip from cover.
cover can be pried out using a screwdriver.
Install new cover only 30-2, Installing .
Installing
Note:
Cover and circlip must always be replaced.
Never install a new cover with a hammer and never

lubricate the middle gasket or touch it by hand!
Caution!
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Do not touch the new cover in the middle hole. The

cover must not be touched, oiled or come into contact
with any other substances in that area. This would
result in leaks.
- Grasp cover - A - in the hand only as shown in the

illustration!
Special tools, testers and auxiliary items required
Assembly sleeve T10302
- Clean assembly sleeve T10302 before use, do not use

scratched assembly sleeves.
New cover in area of center seal must be free of oil and

dry!
- If required, clean shaft end of clutch cover for

transmission.
Only outer edge of seal may be coated with transmission

oil for Direct Shift Transmission 02E.
- Place assembly sleeve T10302 on a level surface.

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Center seal - B - of new cover - A - must now be "pre-

formed" :
- Guide it horizontally and evenly over the entire assembly

sleeve T10302 . This sets the sealing lips in installation
position.
- Now remove assembly sleeve T10302 upward from cover

and place assembly sleeve on shaft end of clutch cover for
transmission.
- Guide cover - A - horizontally over assembly sleeve

T10302 and press into place uniformly.
Caution!
Use caution when handling. Any type of impact - even

very lightly - on the cover will surely result in leaks.
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It is possible to pry the cover into its place - arrow -

carefully using a screwdriver - 1 - , until the new securing
ring can be installed.
- Install new securing ring.
Clutch, removing
In order to remove and install the clutch, transmission must

be secured firmly in vertical position on assembly stand.
- Remove clutch cover 30-2, Clutch cover (end cover),

removing and installing
- Remove securing ring - arrow - for clutch cover - 1 - .
- Remove clutch cover from clutch.
- Remove securing ring - arrow - .

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Note:
When installing, this circlip must later be replaced

and be measured.
Carefully remove the clutch. Make sure that the

clutch pack carrier or other parts of the clutch do not
fall out; for this reason, do not turn over the clutch!
If this has happened however, components can be

assembled according to overview of clutch pack
carrier 30-1, Overview .
- Completely remove clutch - A - in - direction of arrow - .
- Pull out input shaft - A - for transmission oil pump.
Note:
The transmission oil pump drive shaft is installed only

after the installation of the new clutch. Lay the shaft
aside until that point.
Preparing for clutch installation

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Clutch as replacement part
Clutch
Clutch cover of a new clutch

is not secure by a securing
ring Item - 5 - . It sits
slightly "taut" in clutch. Parts
of clutch should be prevented
from falling out during
transport. It can be removed
with some caution.
Ten securing rings
Rings have varying thickness.

They are stepped in 0.1-mm
increments.
For this, please observe

instructions in 30-2, Clutch,
installing and adjusting .
Cover (end cover) for clutch

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Make sure that inner sealing

lip is not damaged 30-2,
Installing
Securing ring
For cover (sealing cover)
Securing ring
For clutch cover
- When removing the clutch from the packaging, pressure

must already be applied to the clutch cover.
This should prevent the clutch cover and the underlying

clutch pack carrier from slipping out of the inner clutch
discs.
- Check the four piston rings - A - for proper seating.
Note:
Ends of the rings must not stand "above one

another" .
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Important! Position of the clutch cover on the clutch
- Before removing clutch cover, check whether a marking -

arrow A - is applied on the clutch.
- If there is no marking present, make a color marking

yourself. Later, the "tab" of the clutch cover - arrow B -
must be installed again on this marked location - arrow A -
.
- In the case of a new clutch installed, remove securing ring

-1-.
- Carefully remove clutch cover from clutch - arrows - and

set it aside.
Caution!
Avoid removing or lifting up the clutch pack carrier.

Not even slightly! The clutch discs could turn
themselves.
Set down clutch so that it cannot fall over.
The clutch is now prepared for installation 30-2, Clutch,

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installing and adjusting .
Clutch, installing and adjusting
Caution!
Avoid removing or lifting up the clutch pack carrier.

Not even slightly! The clutch discs could turn
themselves..
Note:
The transmission must be positioned vertically in the

assembly stand and the opening for the clutch must
be facing upward. This is the only position in which
the clutch axial play can later be adjusted without
complications. .
TThe transmission must be very tightly secured in the

assembly stand assembly stand 34-10, Attaching
transmission to assembly stand . It must not be turnd.
In the clutch, the large clutch pack carrier is installed

into all clutch discs, and must not be slip out of the
bottom clutch disc.
Input shaft of transmission oil pump has been

removed.
Retaining bolts T10303

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Dial gauge holder VW 387
Dial gauge
- First, place retaining bolt T10303 on to seat - arrow - of

cover (end cover).
- Then, carefully install clutch - direction of arrow - , do

not let it drop in.
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Retaining bolt T10303 must be held in place by a second

technician when doing this.
Retaining bolt T10303 remains there until the clutch cover

is installed.
- Determine the ring with 2 mm thickness - arrow - from all

supplied securing rings and install it temporarily.
Before this ring is removed again, two measurements must

be performed first.
First measurement:
Retaining bolt T10303 remains installed!
- Screw universal dial gauge holder VW 387 on to

transmission flange.
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- Place plunger of dial gauge on to transmission input shaft.
- Set dial gauge to "0" with pre-load.
- Lift clutch upward until it stops and note the measurement

result.
Second measurement:
Retaining bolt T10303 remains installed!
- Place gauge plunger onto tab of large clutch pack carrier.
Note:
The plunger must not sit on the circlip.
- Reset dial gauge to "0" with pre-load.

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- Lift clutch upward again to stop and note this result as

well.
The calculation will be made to determine which of the

remaining nine circlips will be finally installed:
- For this, use this formula:
Second measurement minus first measurement plus 1.85

mm = thickness of ring to be installed.
- Note this result.
The nine remaining securing rings are stepped in 0.1 mm

increments.
- Measure all rings and then determine the ring which

matches your result.
- Remove the 2 millimeter thick ring and replace with the

determined ring.
- install input shaft for transmission oil pump, turn slightly in

- direction of arrow - when doing this.
- install clutch cover so that tab - arrow B - coincides with

marking - arrow A - .
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- Place new securing ring - 1 - into clutch.
- Remove retaining bolt T10303 .
- Install cover (sealing cover) for clutch 30-2, Installing .
This concludes the installation, the clutch is correctly

adjusted.
After installing transmission:
- Perform basic calibration of Direct Shift Gearbox (DSG)

Mechatronic unit J743 using Vehicle Diagnosis, Testing
and Information System VAS 5051 .
Electrical/electronic components and component locations
34 - 1
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Electrical/electronic components and component

locations
Data Link Connector (DLC)
Component location: Cover in

drivers side footwell
Transmission Range (TR) Display

Y6
Component location:
Integrated in instrument
cluster 34-1, Transmission
Range (TR) Display
Unlit selected gear display

indicates emergency mode
with inactive Transmission
Control Module (TCM).
Completely lit selected gear

display indicates emergency
mode with active

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Transmission Control Module

(TCM).
Can only be replaced together

with instrument cluster
Repair Manual, Electrical Equipment,

Repair Group 90, Instrument cluster;
removing and installing instrument cluster
Cover of shift mechanism with

Selector Lever Scale Illumination
L101
Selector Lever Scale

Illumination L101 is integrated
in frame of cover; component
location 34-1, Slector Lever
Scale Illumination
Selector Lever Scale

Illumination L101 is checked
via On Board Diagnostic
(OBD).
Removing and installing

34-9, Selector mechanism
handle and cover, removing
and installing
Check harness connector

34-9, Checking harness
connectors on selector
mechanism .

Component location 34-1,

Mechatronic unit
Checked electrically via On

Board Diagnostic (OBD)

34-4, Direct Shift Gearbox
(DSG) Mechatronic unit
J743 , removing and
installing .

Sensor G182 and Clutch Oil
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Component location 34-1, /

Before sensor can be

removed, Direct Shift
Gearbox (DSG) Mechatronic
unit J743 must be removed
J743 , removing and installing

34-5, Sensor, removing and
installing .
Shift Lock Solenoid N110

Shift Lock Solenoid


mechanism .
The Shift Lock Solenoid N110

is integrated in selector
mechanism. Removal and
installation is only possible in
conjunction with selector
mechanism 34-9, Selector
mechanism, removing and
installing .
Selector Lever E313 with

Tiptronic Switch F189 , Selector
Lever Sensor System Control
Module J587 and Selector Lever
Park Position Lock Switch F319

with

Tiptronic Switch F189 ,

Selector Lever Sensor
System Control Module J587
and Selector Lever Park
Position Lock Switch F319
are integrated in selector
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mechanism.
Components cannot be
replaced separately. Removal
and installation is only
possible in conjunction with
selector mechanism 34-9,
Selector mechanism,

mechanism .
Brake light switch F

Brake light switch
Signal transfer from engine

control module to
transmission control module
via CAN-Bus

Repair Manual, Brake System, Repair

Group 46, Brake pedal assembly
overview; removing and installing brake
light switch
Kick Down Switch F8

Kick Down Switch
Signal transfer from engine

control module to
transmission control module
via CAN-Bus

Repair Manual, Corresponding engine,

Repair Group 20, Electronic Power
Control (EPC)
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Transmission Range (TR) Display Y6
Component location: Transmission Range (TR) Display Y6

- arrow - is located in the instrument cluster.
Slector Lever Scale Illumination L101
Component location: Slector Lever Scale Illumination L101

- 1 - is integrated on underside of frame for cover - 2 - .
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Direct Shift Gearbox (DSG) Mechatronic unit J743
Component location: Direct Shift Gearbox (DSG)

Mechatronic unit J743 is bolted on to transmission housing
at front and covered by transmission oil pan.
Control module is integrated permanently on the Direct

Shift Gearbox (DSG) Mechatronic unit J743 .
Checked electrically via On Board Diagnostic (OBD)
The solenoid valves N88 , N89 , N90 , N91 , N92 and the
pressure control valves 1 N215 , 2 N216 , 3 N217 4 N218 ,
5 N233 and 6 N371 are secured in Mechatronic unit.
The following sensors are located in the control module:
Automatic Transmission Hydraulic Pressure Sensor 1

-G193- and Automatic Transmission Hydraulic
Pressure Sensor 2 -G194-
Transmission Fluid Temperature Sensor -G93- and

Temperature Sensor (in Control Module) -G510-
Transmission Output Speed (RPM) Sensor G195 and

Transmission Output Speed (RPM) Sensor 2 G196
Driveshaft 1 Speed Sensor -G501- and Driveshaft 2

Speed Sensor -G502-
Gear Position Distance Sensors 1 G487 , 2 G488 , 3

G489 and 4 G490
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Removing and installing Direct Shift Gearbox (DSG)

Mechatronic unit J743 34-4, Direct Shift Gearbox (DSG)
Mechatronic unit J743 , removing and installing .
Transmission Input Speed (RPM) Sensor G182 / Clutch Oil

Component location: Transmission Input Speed (RPM)

Sensor -G182- / Clutch Oil Temperature Sensor -G509- - A
- is bolted on under the Direct Shift Gearbox (DSG)
Mechatronic unit J743 on transmission housing.
Removing and installing Transmission Input Speed (RPM)

Sensor G182 / Clutch Oil Temperature Sensor G509 34-
5, Sensor, removing and installing .
Shift Lock Solenoid N110
Component location: Shift Lock Solenoid -N110- - arrow -

is located in the shift mechanism.
Shift Lock Solenoid N110 is installed permanently into shift

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mechanism and cannot be replaced individually. Removal

and installation is only possible in conjunction with selector
mechanism 34-9, Selector mechanism, removing and
installing .
Selector Lever E313 with Tiptronic Switch F189 , Selector

Lever Sensor System Control Module J587 and Selector
Lever Park Position Lock Switch F319
Component location: The Selector Lever E313 is integrated

in selector mechanism.
Tiptronic Switch F189 , Selector Lever Sensor System

Control Module -J587- and Selector Lever Park Position
Lock Switch -F319- are integrated in circuit board - arrow -
of selector mechanism.
Components cannot be replaced separately. Removal and

installation is only possible in conjunction with selector
mechanism 34-9, Selector mechanism, removing and
installing .
Brake light switch F
Component location: Brake Light Switch F - arrow - is

located in foot pedal assembly.
Note:
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In order to assure sufficiently secure fitting, switch

must not be installed more than once.
Kick Down Switch F8
An learned value of Throttle Position (TP) Sensor G79 /

Accelerator Pedal Position Sensor 2 G185 (integrated in
accelerator pedal module) is stored in Engine Control
Module (ECM) as kick-down signal.
Oil pan, Mechatronic unit, transmission oil pump

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Component overview
Oil pan

34-3, Oil pan, removing and
installing
Bolt, 10 Nm
Replace
5x
For mounting oil pan with oil

pan gasket to transmission
housing.
Gasket
Replace
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Bolt, 5 Nm + 90 (1/4)
additional turn.
10x
Replace
For mounting Direct Shift

Gearbox (DSG) Mechatronic
unit J743 on transmission
housing
Follow order for loosening

and tightening 34-4, Direct
Shift Gearbox (DSG)
Mechatronic unit J743 ,

Mechatronic unit
With O-rings on connector
O-rings, replacing

J743 , removing and installing
Direct shift transmission

34-10, Transmission,
Ventilation tube
Pressed into transmission
Always replace after

disconnecting
Ventilation cover
installed on ventilation tube
Nut, 20 Nm
Always replace
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Lever/selector shaft
install so that discontinuous

groove matches up to shift
rod
Sealing ring for selector shaft
Installation position: Lettering

must point outward to
lever/selector shaft
Replace 34-8, Seal,

Bolt, 20 Nm + 90 (1/4)
additional turn
For mounting transmission oil

cooler on transmission
housing
Replace
Transmission fluid cooler

34-6, Transmission oil cooler,
O-rings
Replace
Mounting bracket
for selector lever cable
Bolt, 20 Nm + 90 (1/4)
additional turn.
Replace
2x
For mounting support bracket

on transmission housing
Filter housing
Tightening torque, filter

housing to transmission: 20
Nm
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O-ring
Replace
Transmission oil filter
Always replace with every oil

change.
Note installed position

34-11, Transmission oil and
filter, changing

Sensor G182 with Clutch Oil

34-5, Sensor, removing and
installing
Bolt, 10 Nm
Replace
Alignment pin
2x
For oil pump on transmission

housing
Gasket
Replace
Transmission oil pump

34-7, Transmission oil pump,
cover for transmission oil pump
With vulcanized gasket
Replace

34-7, Transmission oil pump,

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Bolt, 8 Nm
Replace
4x
For mounting cover to

transmission housing
Bolt, 5 Nm + 90 (1/4)
additional turn.
Replace
4x
For mounting transmission oil

pump on transmission
housing
loosen and tighten in diagonal

sequence
Seal
Replace
Drain plug, 45 Nm
Overflow tube, 3 Nm
Made of plastic
Seal
Replace
Check plug, 45 Nm
Shield
Installed on some
transmissions
Bolt, 32 Nm
4x
For mounting shield to

transmission housing
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Oil pan, removing and installing
34 - 3
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Torque wrench V.A.G 1331
Drip tray for workshop crane VAS 6208
Protective glasses
Removing
Caution!
Never run engine and do not tow vehicle with oil pan
removed or without the transmission fluid filled up.
Note:


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Repair Notes .
Coat O-rings and sealing rings with transmission oil.

Other lubricating substances lead to functional
problems in the hydraulic transmission control.
Additional work must be performed when

(GND) strap

Engine switched off.
- First determine whether a coded radio is installed. In this

case, determine the anti-theft coding.
- With ignition switched off, disconnect Battery Ground

(GND) wire

disconnecting and connecting batteries
- Remove noise insulation
Repair Manual, Body Exterior, Repair Group 50, Body

front, Noise Insulation - assembly overview
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- Unscrew nuts - 2 - from bracket - 1 - on oil pan and

remove bracket from threaded pin on oil pan.
Note:
Threaded pins are welded on at front on transmission

at oil pan.
- If installed, remove shield - A - at bottom on transmission

- arrows - .
- Place appropriate receptacle underneath transmission.
Warning!

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- Unscrew drain plug - A - .
Approx. 5.0 liters of oil will drain out. Container remains

- Replace sealing ring for drain plug - A - .
- Screw in drain plug - A - and tighten to 45 Nm.
- turn bayonet connection - 1 - of connector

counterclockwise and disconnect connector from
transmission.
- Grasp with hand (without gloves) on to vehicle Ground

(GND) so that you are electrostatically discharged.
Caution!
Only touch or remove Direct Shift Gearbox (DSG)

Mechatronic unit J743 after you have been
electrostatically discharged on a grounded object
beforehand, e.g. skin contacts vehicle Ground
(GND).
Connector terminals of transmission connector

must not be touch by hand under any
circumstances because control module and
therefore Mechatronic unit may be destroyed by
static discharge.
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- Loosen bolts - arrows - of oil pan - A - in diagonal

sequence and remove.
Note:
Some transmission oil remains in the oil pan because

not all of it can drain out.
- Remove oil pan together with oil pan gasket.
- Always replace oil pan gasket.
Installing
Installation is performed in the reverse order of removal.

Note the following:
- Replace both O-rings - arrows - on connection of

Mechatronic unit.
- Coat O-rings with transmission oil for direct shift

transmission.
- Clean sealing surfaces and eliminate oil residue.
- Make sure new oil pan gasket is seated correctly.

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- Place oil pan on. Do not pinch lines when doing this.
- Screw in new bolts for oil pan and tighten in stages to 10

Nm in diagonal sequence.
- Change gear oil 34-11, Transmission oil and filter for

Direct Shift Transmission (DSG), changing and checking oil
level .
Check plug seal must be replaced after checking

transmission oil.
- Install noise insulation

- Connect battery

disconnecting and connecting battery
Direct Shift Gearbox (DSG) Mechatronic unit J743 , removing and installing
34 - 4
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Direct Shift Gearbox (DSG) Mechatronic unit J743 ,

Direct Shift Gearbox (DSG) Mechatronic unit J743 ,
Removing
Caution!
Note:


Repair Notes .
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(GND) strap

If Mechatronic unit is to be replaced with transmission

removed, transmission must be secured to assembly stand
34-10, Attaching transmission to assembly stand .
- Move selector lever to position "P" .
- First determine whether a coded radio is installed. In this

case, determine the anti-theft coding.

(GND) wire


counterclockwise and disconnect connector from
transmission.

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- arrows - .
- If present, remove connecting hose between charge air

cooler and charge air tube
Repair Manual, Engine, Repair Group 21,

Note:

at oil pan.
- Place lines upward in area of oil pan and tie securely.

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- Unscrew bolts - arrows - and remove cover for

transmission oil pump - A - .
Caution!
Only touch or remove Direct Shift Gearbox (DSG)

Mechatronic unit J743 after you have been
electrostatically discharged on a grounded object
beforehand, e.g. skin contacts vehicle Ground
(GND).
Connector terminals of transmission connector

must not be touch by hand under any
circumstances because control module and
therefore Mechatronic unit may be destroyed by
static discharge.
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- Loosen bolts - arrows - of oil pan - A - in diagonal

sequence and remove.
Note:
Some transmission oil remains in the oil pan because

not all of it can drain out.
- Remove oil pan together with oil pan gasket.
- Always replace oil pan gasket.
cover for transmission oil pump and oil pan bolts must
always be replaced.
Caution!
If cover for transmission oil pump is not removed, the

long Transmission Output Speed (RPM) Sensor G195 /
Transmission Output Speed (RPM) Sensor 2 G196 on
the rear side will be damaged when removing Direct
Shift Gearbox (DSG) Mechatronic unit J743 .
- Carefully release connector of Transmission Input Speed

(RPM) Sensor G182 with Clutch Oil Temperature Sensor
G509 using a small screwdriver - 1 - and simultaneously
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pry out carefully using a second screwdriver - 2 - .
Note:
Do not pull on wire of connector! If wire is damaged,

the Transmission Input Speed (RPM) Sensor G182 /
Clutch Oil Temperature Sensor G509 must be
replaced.
- Disconnect connector without pulling on the wire.
- Remove wire from retaining tabs - arrows - .
- Loosen and unscrew mounting bolts - 1 - to - 10 - in the

specified sequence.
- Pull Mechatronic unit unit out of transmission housing far

enough until sensor arm - B - on rear side is longer located
in transmission housing.
- Carefully swivel Direct Shift Gearbox (DSG) Mechatronic

unit J743 downward.
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- Remove Direct Shift Gearbox (DSG) Mechatronic unit

J743 .
Caution!
Never lift up Mechatronic unit unit on sensor arm or set

it down on it.
- Transport and store Mechatronic unit as depicted in the

illustration.
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When handling Mechatronic unit, pay special attention to

the long sensor arm - arrow - .
Installing
- Before installation, ensure that Transmission Input Speed

(RPM) Sensor G182 and Clutch Oil Temperature Sensor
G509 are installed.
If sensor arm - arrow - is damaged, the Mechatronic

unit must be replaced.
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- Carefully place Direct Shift Gearbox (DSG) Mechatronic

unit J743 into transmission housing.
- Make sure alignment pin - A - in transmission housing -

arrow 1 - and sensor arm - B - in guide - arrow 2 - are
seated correctly on transmission housing.
Note:
Do not pinch wire of Transmission Input Speed

(RPM) Sensor G182 and of Clutch Oil Temperature
Sensor G509 .
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Wire of connector - A - must not be pinched when

installing Direct Shift Gearbox (DSG) Mechatronic
unit J743 . If wire is damaged, the Transmission Input
Speed (RPM) Sensor G182 / Clutch Oil Temperature
Sensor G509 must be replaced.
Long sensor on rear side of Direct Shift Gearbox

(DSG) Mechatronic unit J743 must not be damaged.
- Screw in new bolts - 1 - to - 10 - hand-tight.
- Tighten bolts in specified sequence to 5 Nm + 90 (1/4

additional rotation).
- Engage wire - A - first into top, then into bottom retaining

tab - arrows - .
- Connect and engage connector.

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- Replace both O-rings - arrows - on connection of

Mechatronic unit.
- Coat O-rings with direct shift transmission oil.
- Clean sealing surfaces and eliminate oil residue.
- Make sure new oil pan gasket is seated correctly.
- Place oil pan on. Do not pinch lines when doing this.
- Screw in new bolts - arrows - for oil pan - A - and tighten

in stages to 10 Nm in diagonal sequence.
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- Install new cover for transmission oil pump - A - and

tighten bolts - arrows - in several stages to 8 Nm in
diagonal sequence.
- Screw bracket - 1 - on oil pan with nuts - 2 - to 10 Nm.
- Connect connector of Direct Shift Gearbox (DSG)

Mechatronic unit J743 and engage lock by rotating.
- If present: Install connecting hose between charge air

cooler and charge air tube
Repair Manual, Corresponding engine, Repair Group 21,
- Connect battery Ground (GND) strap

- Do NOT start engine!
- Change transmission oil filter and transmission oil 34-

11, Transmission oil and filter for Direct Shift Transmission
(DSG), changing and checking oil level .

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- Perform basic calibration of Direct Shift Gearbox (DSG)

Mechatronic unit J743 using Vehicle Diagnosis, Testing
and Information System VAS 5051 .
Transmission Input Speed (RPM) Sensor G182 and Clutch Oil Temperature Sensor G509 , removing a...
34 - 5
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Transmission Input Speed (RPM) Sensor G182 and

Clutch Oil Temperature Sensor G509 , removing and
installing
Sensor, removing and installing
Removing
Note:
Both sensors are combined into one component and

can only be replaced together. They are located in
transmission in vicinity of clutch. Before removing,
Direct Shift Gearbox (DSG) Mechatronic unit J743
must be removed.
Caution!
Do not pull on wire of connector! If wire is damaged,

the Transmission Input Speed (RPM) Sensor G182 /
Clutch Oil Temperature Sensor G509 must be replaced.
- Remove Direct Shift Gearbox (DSG) Mechatronic unit

J743 34-4, Direct Shift Gearbox (DSG) Mechatronic unit
J743 , removing and installing .
Do not pull on wire!
- Unscrew bolt - B - and carefully pry out sensor - A - using

a screwdriver and/or pliers.
- Carefully disconnect connector - C - .
Installing
Only install old sensor, if it is for certain that:

Transmission Input Speed (RPM) Sensor G182 and Clutch Oil Temperature Sensor G509 , removing a...
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Sensor functions properly.
Its wire was not pulled during removal.
- Coat sensor with transmission oil for Direct Shift Gearbox

and install.
- Tighten bolt - B - to 10 Nm.
- Install Direct Shift Gearbox (DSG) Mechatronic unit J743

34-4, Direct Shift Gearbox (DSG) Mechatronic unit
J743 , removing and installing .
Transmission oil cooler, removing and installing
34 - 6
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Special tools, testers and auxiliary items

required
Hose clamps up to Ø 25 mm 3094
Pliers for spring-type clamps VAS

5024 A
Removing
Note:

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Repair Notes .

disconnecting and reconnecting battery

- Place selector lever in position "P" .
- Check whether a coded radio is installed. If this is the

case obtain anti-theft coding..
- Remove engine cover

removing and installing engine; removing engine


- Remove battery
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Warning!
When opening the coolant expansion tank, hot steam

could es covere. Wear eye protection and protective
clothing to prevent eye injuries and scalding. Cover
cover with a rag and open carefully.
- When engine is warm, the cooling system is under

pressure. Before disconnecting coolant hoses, slowly
unscrew cover of expansion tank and release pressure.
- Place lint-free rags on oil cooler and transmission, to

catch es covering coolant.
- Clamp off coolant hoses of transmission oil cooler using

hose clamps 3094 .
- Open spring clips and disconnect coolant hoses from

transmission oil cooler.
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- Unscrew bolts - A - and remove transmission oil cooler -

B-.
Caution!
Coolant must not drip into transmission!
Installing
- Replace O-rings - C - of oil cooler - B - .
- Install oil cooler - B - , pay attention to O-rings - C - when

doing this.
- Screw in new bolts - A - and tighten to 20 Nm + 90 (1/

4 additional rotation).
- Connect coolant hoses of transmission oil cooler and

remove hose clamps 3094 .
- Replace transmission oil filter and change transmission oil

34-11, Transmission oil and filter for Direct Shift
Transmission (DSG), changing and checking oil level .
- Install battery carrier.

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- Install battery

battery; removing and installing battery
- Install air filter housing and connect harness connector - 2

- to Mass Air Flow (MAF) Sensor G70 .
- Connect vent hose - 1 - and air guide hose - 5 - .
- Connect air guide hose and secure spring clip - 3 - using

spring clip pliers VAS 5024 A .
- Checking coolant level and adding coolant if necessary
Caution!
Do not start engine during coolant level test if there is

still no transmission oil filling.
Transmission oil pump, removing and installing
34 - 7
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Removing
Caution!
Note:


Repair Notes .
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- Remove left front wheel.

- arrows - .
- Unscrew bolts - 1 - to - 3 - and remove cover for left wheel

housing liner.
Warning!

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- Unscrew bolts - arrows - and remove cover for

transmission oil pump - A - .
Oil is still located in cover for transmission oil pump.
- Unscrew bolts - arrows - and remove transmission oil

pump - 1 - from alignment pins and input shaft for
transmission oil pump.
Installing
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- Slide input shaft - A - for transmission oil pump into

transmission until it stops. turn input shaft slightly while
doing this.
- Replace gasket for transmission oil pump - B - on

transmission.
The 2 alignment pins - C - must be located in

transmission housing.
Note:
Observe installation dimension - a - of shaft - A - =

approx. 23 mm.
- If necessary, carefully remove metal shavings on sensor

wheel - B - , however the sensor wheel must not be
demagnetized.
- Remove paper seal between transmission oil pump and

transmission.
- Remove paper seal remnants and clean the transmission.
- Clean sealing surfaces for transmission oil pump and

transmission.
- install new paper seal between transmission oil pump and

transmission, secure with transmission oil if necessary.
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- Slide transmission oil pump - 1 - on to input shaft, pay

attention to splines of oil pump/input shaft when doing this.
- Also make sure that transmission oil pump - 1 - is seated

correctly on alignment pins of transmission housing.
- Screw in new bolts - arrows - hand-tight and then tighten

to 5 Nm + 90 ( 1 / 4 additional rotation) in diagonal
sequence.
- Put on new cover for transmission oil pump - A - and

tighten new bolts - arrows - in several stages to 8 Nm in
diagonal sequence.
- Change transmission oil filter and transmission oil 34-

11, Transmission oil and filter for Direct Shift Transmission
(DSG), changing and checking oil level .
- Install cover for left wheel housing liner.

- Install wheel
Repair Manual, Suspension, Wheels, Steering, Repair

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Group 44,
.
Selector shaft lever seal, replacing
34 - 8
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required
Tube VW 423
Pulling hook T20143/2
Seal, removing and installing
Removing
- Remove selector lever cable from transmission 34-9,

Selector mechanism, removing and installing .
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- Unscrew nut - arrow - from selector shaft.
- Carefully pry lever - A - from selector shaft.
- Pry out seal using pulling hook T20143/2 .
Installing
- Lightly oil new seal on outer circumference.
- Fill area between sealing lip and dust lip halfway with
sealing grease G 052 128 .
- Drive in new seal to stop. Do not distort oil seal when

doing this.
Note:
Lettering - arrow - on sealing ring must point outward

(toward press tool).
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Lever of selector shaft fits on to splines only in one

position.
- Install lever and tighten to 20 Nm.
- Install selector lever cable on transmission 34-9,

Selector mechanism, removing and installing and adjust
34-9, Adjusting .
Selector mechanism
34 - 9
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Selector mechanism
Warning!
Shift selector lever into position "P" and engage

parking brake before working with the engine running.
Selector mechanism, checking
In selector lever positions "S" , "D" , "R" and in

Tiptronic position, the starter motor will not operate.
For speeds exceeding 5 km/h and shifting into

selector lever position "N" , the shift lock solenoid
must not engage to lock the selector lever. Selector
lever can be shifted into a driving mode.
For speeds below 5 km/h (almost standstill) and

shifting into selector lever position "N" , the shift lock
solenoid must only engage after approx. 1 second.
Selector lever can only be shifted out of position "N"
with the brake pedal operated.
Selector lever in position "P" , button pressed on

selector lever and ignition switched on
Brake pedal is not being operated
Selector lever is locked and cannot be switched out of

position "P" with button pressed. Shift lock solenoid is
locking the selector lever.
Brake pedal is being operated
Shift lock solenoid enables the selector lever. Selecting a

driving mode is possible. Switch selector lever slowly
through from "P" to "R, N, D, S" ; while doing this check
whether selector lever position in instrument panel install
matches the selector lever position.
Selector lever in position "N" , button pressed on

selector lever and ignition switched on
Brake pedal is not being operated
Selector lever is locked and cannot be switched out of

position "N" with button pressed. Shift lock solenoid is
locking the selector lever.
Brake pedal is being operated

Selector mechanism
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Shift lock solenoid enables the selector lever. Selecting a

driving mode is possible.
Note:
Shifting from position "N" to "D" with brake pedal

operated is also possible without pressing button on
selector lever. However, from position "N" to "R" the
button on selector lever must also be pressed.
Selector lever in position "D" , ignition switched on
Selector lever is locked and cannot be shifted from position

"D" to position "S" .
Press the button on selector lever
Selector lever is released and can be shifted from position

"D" to position "S" .
Move selector lever into Tiptronic gate .
The illumination of the "D" symbol must go out in selector

lever display and the "+" and "-" symbols must light up.
The selector lever display in instrument panel install must

change from "P R N D S" to "6 5 4 3 2 1" when selector
lever is moved in Tiptronic gate.
Shift selector lever in Tiptronic gate to "+" and "" .
The display "6 5 4 3 2 1" in instrument cluster must indicate

(change) accordingly a gear higher or lower when shifting
selector lever to "+" or "" .
- Check and adjust selector lever cable 34-9, Selector

lever cable, checking and adjusting .
- Check ignition key removal lock 34-9, Ignition key

removal lock, checking function .
Transmission Range (TR) Selector Lever Display
Simultaneous lighting of all segments of Transmission

Range (TR) selector lever display indicates transmission in
emergency running mode.
Selector lever cable, checking and adjusting

Selector mechanism
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Pliers for spring-type clamps VAS 5024 A
Checking
- Switch ignition off.

.
Selector mechanism
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- Release retaining disc - A - and remove upward.
- remove retaining disc - B - upward.
- Press off selector lever cable from lever/selector shaft and

set it on top.
- Set down the selector lever cable so that the end can
move freely.
Note:
Do not bend or kink selector lever cable.
- Shift selector lever from "P" to "S" .
- Check protective sleeve on selector lever cable for

damage on selector mechanism at front, replace cable if
necessary.
Selector mechanism and selector lever cable must

have freedom of movement during shifting, if
necessary, replace selector lever cable 34-9,
Selector lever cable, removing and installing or
service selector mechanism 34-9, Selector
mechanism, assembly overview .
Do not grease ball socket of selector lever cable and

lever/selector shaft.
- Carefully press selector lever cable onto lever/selector

shaft.
- install new retaining discs up to stop and engage.

Selector mechanism
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Adjusting
- Press lever on transmission in - direction of arrow - into

position "P" .
Retaining discs - A - and - B - are installed.
- Loosen bolt - arrow - .
- Turn both front wheels in one direction, e.g. by pushing

the vehicle forward until detent lever in transmission
engages into parking lock gear and wheels are locked
Selector mechanism
WWW.ALL-TRANS.BY
(cannot be turned together in one direction).
Note:
The selector lever must remain in position "P" with

bolt - arrow - loosened, otherwise the setting is not
correct.
- Carefully move selector lever lightly toward front and rear

without shifting into another selector lever position.
- Tighten bolt - arrow - gently to 13 Nm.
Note:
When tightening bolt - arrow - , make sure that

selector lever cable is not slid even once.
Checking adjustment of selector lever cable
- Pull selector lever out of position "P" with button pressed

approx. 5 mm toward rear and hold, do not shift into "R" .
- Release selector lever.
Selector lever must spring back into position "P"

automatically.
- Adjust selector lever if necessary Topic 34-9 .
- Place selector lever in position "N" .
- Pull selector lever out of position "N" with button pressed

approx. 5 mm toward rear and hold, do not shift into "D" .
Selector lever must spring back into position "N"

automatically.
- Press selector lever out of position "N" with button

pressed approx. 5 mm toward front and hold, do not shift
into "R" .
Selector lever must spring back into position "N"

automatically.
- Check shift mechanism 34-9, Selector mechanism,

checking .
Selector mechanism
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- Install engine cover

removing and installing engine
Ignition key removal lock, checking function
Start
↓
↓
- Remove ignition key.

↓
↓
↓
Can selector lever Testing Shift Lock Solenoid N110 in
be switched out of function "Guided Fault Finding" using
Yes
"P" with lock button Vehicle Diagnosis, Testing and
pressed? Information System VAS 5051 .
↓
No
↓
Selector mechanism
Function
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OK.
↓
- install ignition key.
- Depress foot brake.
- Switch on ignition.
↓
Testing Shift Lock
Solenoid N110 in
function "Guided Fault
Can selector lever be switched out
No Finding" using Vehicle
of "P" with lock button pressed?
Diagnosis, Testing and
Information System VAS
5051 .
↓
Yes
↓
Place selector lever in position "S" . Selector
lever remains in this position.
↓
- Release foot brake.

↓
A B
A B
Testing Ignition Switch Key Lock Solenoid

Can ignition
N376 in function "Guided Fault Finding" using
key be pulled Yes
Vehicle Diagnosis, Testing and Information
out?
System VAS 5051 .
↓
↓ Yes
↓
- Replace
Testing Selector Lever Park Position Selector
↓ No
Lock Switch F319 . Is it OK? Lever Park
Position Lock
Switch F319 .
↓
↓ No
Selector mechanism
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- Depress foot brake.

- Ignition, switching on and off
No
- Place selector lever in
Can ignition key be pulled out?
position "P" .
↓
Yes
↓
Ignition key removal lock OK.
Selector mechanism, assembly overview
Cover with handle
For the emergency release,

only the cover must be
unclipped 34-9, Manually
releasing the selector
mechanism out of position P .
Symbol install and circuit

Selector mechanism
WWW.ALL-TRANS.BY
board with Slector Lever
Scale Illumination L101 are
integrated in the cover.
Removing 34-9, Selector

mechanism handle and cover,

mechanism .
Clamp
Replace
Tension using hose clamp

pliers V.A.G 1275
Selector lever and selector

mechanism
With Shift Lock Solenoid

N110
Emergency release 34-9,

Manually releasing the
selector mechanism out of
position P .

mechanism .
Short description for removal

and installation:
- Remove center console.
- Remove cable from

transmission 34-9,
Selector lever cable,
- Remove catalytic
converter and disengage
center muffler from bracket.
- Remove heat shield

beneath vehicle.
- Adjust selector lever cable

after installing 34-9,
Selector lever cable,
Selector mechanism
WWW.ALL-TRANS.BY
Bolt with spring, 3 Nm
Pin
Removing 34-9, Selector

lever cable, removing and
installing
Do not lubricate
Locking washer
Always replace after removing
Nut, 9 Nm
4x
Selector housing
with seal
Locking washer
Make sure it engages when

installing
Locking washer
Mounting bracket
for selector lever cable
Bolt, 20 Nm + 90 (1/4)
additional turn.
Replace
2x
For mounting support bracket

on transmission housing
Selector lever cable
Selector lever cable is not

greased.
Selector mechanism
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34-9, Selector lever cable,
Checking and adjusting 34-

9, Selector lever cable,
checking and adjusting
Nut, 9 Nm
4x
Selector mechanism handle and cover, removing and

installing
Removing
- Pry cover - 1 - out of center console - arrows - .
- Pull out button - 2 - over its press point in - direction of

arrow - and secure it using a cable tie or a suitable wire.
This prevents the button from being pressed into the

handle unintentionally.
Selector mechanism
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- Disconnect harness connector - 1 - from circuit board of

cover.
- When doing this, counter hold at circuit board - arrow - .
- Fold boot upward.
- Press retainers - 1 - on the sides inward - arrows - and

slide it then upward in - direction of arrow - .
- Now remove selector lever handle.
Installing

Note the following:
If button should be pressed in with the handle removed,

then pull out button past its press point and secure it using
a cable tie or a suitable wire.
Before installing handle, make sure that lock stands at

upper stop.
- Install handle with cover on to selector lever and press on

to selector lever until it stops.
Note:
A second engaging must be noticeable when

pressing down the handle.
Selector mechanism
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- Press lock - 1 - downward far enough until it engages -

arrows - .
Note:
Check immediately whether the handle is secured

correctly. Lock - 1 - must stand only a few millimeters
over the selector lever.
- Connect connector to circuit board, remove cable tie/wire

from button on handle and slide it past the press point into
handle.
- Install cover in center console. To do so, press cover first

at front at ashtray/storage compartment and then at rear
into retainers in center console.
Selector mechanism, removing and installing

Selector mechanism
WWW.ALL-TRANS.BY
Removing
Note:

(GND) strap

- First check whether a coded radio is installed. If this is the

case obtain anti-theft coding.

(GND) wire

disconnecting and connecting batteries
- Remove handle and cover for selector mechanism 34-

9, Selector mechanism handle and cover, removing and
installing .
- Remove center console and air guide
Repair Manual, Body Interior, Repair Group 68, storage

Selector mechanism
WWW.ALL-TRANS.BY
compartments, covers and panels; removing and installing

center console
- Pull out connector housing - 1 - of electrical harness

connector out of mount - 2 - toward front.




Selector mechanism
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- Release retaining disc - 1 - and remove upward.
- Remove retaining disc - 3 - upward.
- Press off selector lever cable - 2 - from lever/selector

shaft in - direction of arrow - and set it on top.
Note:
- Raise vehicle.

- Unscrew nuts and remove trim for vehicle floor on left and
right sides - arrows - .
- Remove catalytic converter.

Selector mechanism
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- Unscrew nuts - 1 - and - 2 - and remove rear cross

member.
Note:
A second technician is required to remove the rear

part of exhaust system.
- Disengage exhaust system at retaining loops - arrows - .
- Detach rear muffler on retaining loops and remove rear

- Loosen nuts - arrows - and lower the heat shield.
- Disengage selector lever cable from heat shield at left

front.
- Pull heat shield toward rear as far as possible and guide

past subframe. Then remove heat shield toward front.
- Lower vehicle
Note:
A second technician is required when detaching shift

Selector mechanism
WWW.ALL-TRANS.BY
mechanism below vehicle.
- Remove nuts - 1 - and - 2 - .
- Remove selector mechanism downward together with

selector lever cable.
Note:
Selector mechanism can also be replaced without selector

lever cable, disconnect selector lever cable from selector
mechanism to do so. Remove selector lever cable 34-9,
Selector lever cable, removing and installing .
Installing

Note the following:
Tightening torques of bolts and nuts as well as

specifications whether bolts and nuts are to be replaced
34-9, Selector mechanism, assembly overview .
Note:
- install selector mechanism and tighten rear nuts - 1 -

Selector mechanism
WWW.ALL-TRANS.BY
hand-tight.
- Connect brace for center console - 3 - on to selector

mechanism as depicted in the illustration.
- Tighten nuts - 1 - and - 2 - .
Harness connector - 1 - must not be connected when

connector housing - 2 - is engaged in selector mechanism.
By connecting (high resistance by spring), the locking
mechanism breaks off from connector housing.
- Connect connector - 1 - and connector housing - 2 - and

then engage into selector mechanism.
- Install air guide and center console
Repair Manual, Body Interior, Repair Group 68, storage

compartments, covers and panels; removing and installing
center console
- Install handle and cover for selector mechanism 34-9,

Selector mechanism handle and cover, removing and
installing .
- Connect battery Ground (GND) strap

- Ignition key removal lock, checking function 34-9,

Ignition key removal lock, checking function .

Selector mechanism
WWW.ALL-TRANS.BY



checking .
- Install heat shield and trim for vehicle floor
Repair Manual, Body Exterior, Repair Group 66, Exterior

equipment
- Install exhaust system and align it free of tension

Selector lever cable, removing and installing

Selector mechanism
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Removing
- Remove cover for selector mechanism 34-9, Selector

mechanism handle and cover, removing and installing .

.
Selector mechanism
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- Release retaining disc - 1 - and remove upward.
- Remove retaining disc - 3 - upward.
- Press off selector lever cable - 2 - from lever/selector

shaft in - direction of arrow - and set it on top.
Note:
- Raise vehicle.

Selector mechanism
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- Unscrew nuts and remove trim for vehicle floor on left and
right sides - arrows - .
- Remove catalytic converter
- Unscrew nuts - 1 - and - 2 - and remove rear cross

member.
Note:
A second technician is required to remove the rear

- Disengage exhaust system at retaining loops - arrows - .
- Detach rear muffler on retaining loops and remove rear

Selector mechanism
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- Loosen nuts - arrows - and lower the heat shield.
- Disengage selector lever cable from heat shield at left

front.
- Pull heat shield toward rear as far as possible and guide

past subframe. Then remove heat shield toward front.
Selector mechanism
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- Remove nuts - 1 - and slide shift

mechanism housing - 2 - as far as
possible forward on selector lever cable.
Caution!
Always make sure that securing tab

moves only a maximum of 5 mm in -
direction of arrow A - . If this value is
exceeded, there is the risk that the
securing tab will break off. Then the
complete selector mechanism must be
replaced.
- Pull securing tab - 3 - gently in -

direction of arrow A - (max. 5 mm).
- Using a screwdriver, press out bolt - 4 -

in - direction of arrow B - .
Note :
Bolt may slip out of its guide when pressing out. It

must then be installed again in the same place for the
installation.
- Remove locking washer - 5 - .
- Remove selector lever cable.
Installing

Note the following:
Note:
Check protective sleeve of selector lever cable for

damage, protective sleeve can only be replaced
together with selector lever cable.
Check protective sleeve for correct seating and do

not install protective sleeve twisted.
Tightening torques of bolts and nuts as well as

specifications whether bolts and nuts are to be replaced
34-9, Selector mechanism, assembly overview .
Do not grease ball socket of selector lever cable and ball

head/selector lever.
- Guide selector lever cable with protective sleeve into

cover. Do not damage protective sleeve when doing this.
Selector mechanism
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- Slide shift mechanism housing - 2 -

forward as far as possible on selector
lever.
Do not grease bolt - 4 - .
- install bolt - 4 - only in upper section of

mount.
- Slide selector lever cable into mount.
Caution!
Always make sure that securing tab

moves only a maximum of 5 mm in -
direction of arrow A - . If this value is
exceeded, there is the risk that the
securing tab will break off. Then the
complete selector mechanism must be
replaced.
- Pull securing tab - 3 - gently in -

direction of arrow A - (max. 5 mm).
- Move selector lever cable slightly

toward front and rear in alternation. When
doing this, press bolt - 4 - downward by
Selector mechanism
WWW.ALL-TRANS.BY
hand simultaneously.
- Install new locking washer - 5 - .
- Tighten nuts - 1 - .
Caution!
Do not touch circuit board of selector mechanism

with the fingers under any circumstances, since
the electrical components on the circuit board
may be destroyed by static discharge.
Circuit board can only be replaced together with

selector mechanism!
- Carefully press selector lever cable - 2 - on to

lever/selector shaft on transmission in opposite - direction
of arrow - .
- install retaining disc - 1 - up to stop and engage.
- Install a new retaining disc - 3 - .
- Shift selector lever from "P" to "S" .
Shift mechanism and selector lever cable must have

freedom of movement during this, if necessary,
replace selector lever cable or service shift
mechanism.
- Install heat shield and trim for vehicle floor
Repair Manual, Body Exterior, Repair Group 66, Exterior

equipment

Selector mechanism
WWW.ALL-TRANS.BY





checking .
Manually releasing the selector mechanism out of

position "P"
Shift Lock Solenoid N110 locks the selector lever in

position "P" . Selector lever can then only be shifted out of
"P" only with ignition on or engine start, brake pedal
pressed and button on selector lever handle pressed.
With interference in voltage supply to shift lock solenoid

(battery discharged or faulty fuse) or malfunctioning
solenoid, selector lever cannot be shifted out of position
"P" , meaning that the vehicle cannot be driven since the
parking lock has been engaged.
If this is the case:
- Check fuses Electrical Wiring Diagrams,

Troubleshooting and Component Locations binder .
Selector mechanism
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- Check battery voltage

Checking battery
If selector lever cannot be shifted out of position "P" despite

testing, emergency release of the solenoid can be
performed. If selector lever is shifted back into position "P"
afterward, it is however locked again in position "P" .
Performing manual release
Do not remove handle.
- Unclip shift cover and hold to the side.
- Operate brake or activate parking brake.
- Press on yellow plastic piece in - direction of arrow - .
- Now press button on selector lever handle and shift

selector lever out of position "P" .
Note:
If selector lever is shifted back into position "P"

afterward, it is locked mechanically by shift lock
solenoid again in position "P" .
Tiptronic Switch F189 , removing and installing
Tiptronic Switch F189 is integrated permanently in selector

mechanism and cannot be replaced separately. If Tiptronic
Switch F189 is malfunctioning, selector mechanism must
be replaced 34-9, Selector mechanism, removing and
installing .
Shift Lock Solenoid N110 removing and installing
Shift Lock Solenoid N110 is integrated permanently in

Selector mechanism
WWW.ALL-TRANS.BY
selector mechanism and cannot be replaced separately. If

Shift Lock Solenoid N110 is malfunctioning, selector
mechanism must be replaced 34-9, Selector
mechanism, removing and installing .
Selector Lever Park Position Lock Switch F319 ,

Selector Lever Park Position Lock Switch F319 is

integrated permanently in selector mechanism and cannot
be replaced separately. If Selector Lever Park Position
Lock Switch F319 is malfunctioning, selector mechanism
must be replaced 34-9, Selector mechanism, removing
and installing .
Selector Lever Sensor System Control Module J587 ,

Selector Lever Sensor System Control Module J587 is

integrated permanently in selector mechanism and cannot
be replaced separately. If Selector Lever Sensor System
Control Module J587 is malfunctioning, selector
mechanism must be replaced 34-9, Selector
mechanism, removing and installing .
Checking harness connectors on selector mechanism
Before servicing or checking harness connectors, the

cause of damage must be determined first via "Guided
Fault Finding" using Vehicle Diagnosis, Testing and
Information System VAS 5051 .
Before checking harness connectors, all control modules in

vehicle must be checked for DTC entries using Vehicle
Diagnosis, Testing and Information System VAS 5051 ,
repair if necessary.
- Checking harness connectors Electrical Wiring

Diagrams, Troubleshooting and Component Locations
binder .
A - 10-pin connector for connecting wires from selector

mechanism to transmission (with CAN wires)
B - 4-pin connector to Shift Lock Solenoid N110 1 ,
Selector mechanism
Selector Lever Sensor System Control Module J587 and

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Selector Lever Park Position Lock Switch F319

C - 10-pin connector to Slector Lever Scale Illumination
L101 in selector mechanism cover
Transmission, removing and installing
34 - 10
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required
Engine support bridge 10-222 A
Adapter 10-222 A/8
Hose clamps up to Ø 25 mm 3094
Transmission support 3282
Pin 3282/29
Mount 3282/52
Security mount 3282/59

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required
Adjustment plate 3282/42
Engine-/gearbox jack V.A.G 1383 A
Pliers for spring-type clamps VAS

5024 A

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Socket T10035
High temperature grease G 052 133 A2
Grease G 000 100
Transmission, removing
Note:


Repair Notes .
All cable ties opened or cut during transmission

removal must be reinstalled at the same locations.

disconnecting and reconnecting battery

- Check whether a coded radio is installed. If this is the

case obtain anti-theft coding.

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Note:
All cable ties opened or cut during transmission

removal must be reinstalled at the same locations.


- Remove battery

Do not loosen bolt - B - .

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- Press retaining disc - A - upward and remove it.
- remove retaining disc - C - upward.
- Unscrew bolts - 1 - and remove support bracket - D - .
- Press off selector lever cable from lever/selector shaft in -

direction of arrow - and set it on top.
Note:
- Fold back boot and unscrew cable - 1 - on magnetic

switch.
- Disconnect electrical harness connector - 2 - on magnetic

switch.
- Unscrew Ground (GND) wire - 3 - .
Caution!
Never touch the contacts in the transmission

connector, under any circumstances, because
electrostatic discharge could destroy the control
module along with the Mechatronic units unit.
- Grasp with hand (without gloves) on to vehicle Ground

(GND) so that you are electrostatically discharged.

counterclockwise and disconnect from transmission.
- Unscrew bolts from starter and remove it.

WWW.ALL-TRANS.BY
- Remove all engine/transmission connecting bolts - 1 - to -

4 - accessible from above. To do so, use socket install
T10035 .
Warning!
When opening the coolant expansion tank, hot steam

could es covere. Wear eye protection and protective
clothing to prevent eye injuries and scalding. Cover
cover with a rag and open carefully.
- The cooling system is under pressure when engine is

warm. Before clamping off coolant hoses, slowly unscrew
sealing cover from expansion tank and dissipate pressure.
- Place lint-free cloth on to transmission oil cooler and

transmission to absorb exiting coolant.
- Clamp off coolant hoses of transmission oil cooler using

hose clamps 3094 .
- Open spring clips and disconnect coolant hoses from

transmission oil cooler.
- Plug transmission oil cooler with clean plug.

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Note:

at oil pan.
Unscrew the lower nut from below after noise

insulation has been removed from engine.
- Unscrew bolt - 1 - from rear intake hose - 3 - and

disengage line - 2 - from Secondary Air Injection (AIR)
system and disconnect in - direction of arrow - .
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- Remove bracket for coolant lines and fuel on valve cover.

Loosen bolts - 1 - to do so.
- Remove fuel hose - 2 - on tandem pump. Absorb exiting

fuel with a rag.
- Seal fuel hose - 2 - and tandem pump with clean plugs.
- Unscrew bolts - 3 - and - 5 - and remove bracket - 4 - .
- Place engine support bridge 10-222 A with adapters 10-

222 A/8 and adapter 10-222 A/3 in front of gas-filled strut
for hood.
- If hose- and cable connections are found in the area of

engine lifting eyes for engine support bridge 10-222 A ,
they must be removed now.
- Engage spindles 10-222 A/10 of engine support bridge on

left and right engine lifting eyelets and support engine with
transmission.
- Clamp engine using spindles, do not raise.

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- Release connector coupling by pulling locking clip - arrow

-.
- Disconnect hose/tube without tools.
- Remove air guide hose - 2 - . To do so, lift retaining clips -

1 - slightly and disconnect air guide hose from tubes.
- Remove right air guide hose. To do so, lift retaining clips -

arrows - slightly and disconnect air guide hose from tubes.
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- arrows - .
- Unscrew bolt - 1 - and remove small cover plate - 2 - for

flywheel.
- Unbolt brace for front exhaust tube - arrows - .
- Remove catalytic converter
.
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- Disconnect electrical harness connector - 1 - on Oil Level

Thermal Sensor G266 .
- Unclip wiring harness from bracket - 2 - .
- Remove bolts - arrows - .
Note:
Pendulum support is removed with the subframe.
- Remove left front wheel.
- Unscrew bolts - 1 - to - 3 - and remove cover for left wheel

housing liner.
- Remove left drive axle

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Group 40, Servicing drive axles; removing and installing
drive axles
- If present, disconnect electrical harness connector - 2 - at

Left Front Level Control System Sensor G78 .
- Remove bolt - 1 - .
- Remove subframe with left control arm and left console

Group 40, Assembly overview: Subframe, anti roll bar,
control arm; removing and installing subframe
Caution!
Locating pins T10096 must be used to remove console

for transverse link, since then an axle alignment must
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be performed otherwise.
- Remove bolts - 1 - and - 2 - .
- Lower engine/transmission assembly on spindle of engine

support bridge 10-222 A approximately 2 rotations each on
alternating sides.
- Lower engine/transmission assembly approx. 4 rotations.
- Remove console - A - .
- Lower engine/transmission assembly on spindle of engine

support bridge 10-222 A evenly on alternating sides until
dimension - a - is reached between transmission housing
and transmission bearing.
Dimension - a - = 100 110 mm
To remove direct shift transmission 02E, transmission

support 3282 is aligned using adjustment plate 3282/42
and attached to engine/transmission jack V.A.G 1383 A .
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- Align transmission support arms to correspond with the

holes in Adjustment Plate 3282/42 .
- Screw in attachments as depicted on adjustment plate

3282/42 .
- Place engine/transmission jack V.A.G 1383 A under

vehicle. Arrow symbol on adjustment plate 3282/42 points
in the direction of travel.
- Align transmission support 3282 parallel to transmission.
- Secure support to transmission with bolt - 1 - .
- Screw bolt 3282/29 into transmission.
- install security mount - 2 - into transmission and secure by

tightening nut.
- Support transmission from below by lifting

engine/transmission jack V.A.G 1383 A .
- Remove the remaining connecting bolts for

engine/transmission - 5 - and - 6 - .
- Press off transmission from alignment bushings - A - .

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- Pull transmission slightly off engine.
- Pull anti roll bar and steering gear toward rear and guide
the right flanged shaft of transmission past on flywheel.
- Carefully lower transmission slightly using

engine/transmission jack V.A.G 1383 A .
- Change position of transmission by lowering via the

spindles of transmission support 3282 .
Transport transmission 34-10, Transporting the

transmission .
Attach transmission to assembly stand 34-10, Attaching

transmission to assembly stand .
Transporting the transmission
A part of the engine sling 3282 can be used to transport the

direct shift transmission as well as to align the transmission
support 2024 A .
- Engage workshop crane VAS 6100 in conjunction with a

shackle 10-222A/12 into engine sling 2024 A .
Transmission can also be transported using transmission

support jig 3336 .
Attaching transmission to assembly stand

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required
Holding plate VW 309
Holding fixture VW 313
Transmission support VW 353
- Secure transmission support VW 353 to transmission and

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to holding plate VW 309 .
- Secure transmission using transmission support and

holding plate in holding fixture VW 313 .
Warning!
The center of gravity of the transmission is located

outside the turning center at holding fixture. To turn
the transmission, a second technician must hold the
transmission housing to prevent back-swing.
Note:
Venting for the transmission housing must be closed

before turning a filled transmission on the assembly
stand so that the clutch faces upward.
Transmission, installing

Note the following:
Note:
Replace self-locking nuts and bolts during assembly

work.
Always replace bolts that are secured with tightening

torque as well as securing elements, O-rings and
gaskets.
Secure all hose connections using hose clamps

appropriate for the model type Electronic Parts
Catalog "ETKA" .
All cable ties opened or cut during engine removal

must be reinstalled at the same locations during
installation.
Lightly grease input shaft end with high temperature

grease G 052 133 A2 .
Clean input shaft splines and hub splines, remove

corrosion and apply only a very thin coating of
lubricating grease G 000 100 on splines. Always
remove excessively applied grease.
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- Make sure centering sleeves - A - for centering engine to

transmission are installed in cylinder block. Install centering
sleeves if necessary.
Vehicles with intermediate shaft
- Replace O-ring - 1 - for right stub shaft if it is not a new

transmission being installed.
Continuation for all vehicles
- Make sure that intermediate plate is engaged on engine

sealing flange and has been slid on to centering sleeves.
- Carefully raise transmission using engine/transmission

jack V.A.G 1383 A and bring into installation position using
transmission support 3282 .
- Pull anti roll bar and steering gear toward rear and guide
the right flanged shaft of transmission past on flywheel.
- Change position of transmission by raising via the

spindles of transmission support 3282 .
- Intermediate shaft of right drive axle must be installed

correctly on to splines of stub shaft at transmission

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drive axles
- Bolt transmission to engine 34-10, Tightening torques .
- Install small cover plate - 2 - for flywheel and tighten bolt -

1-.
- Install subframe mount as follows:
- install transmission support - A - between transmission

and support jig of transmission mount.
- Lift transmission uniformly up to transmission mount

support jig via engine support bridge spindle.
- Tightly bolt transmission support - A - to transmission with

new bolts - 1 - 34-10, Tightening torques .
- Next, screw in bolts - 2 - hand-tight only.
- Remove Transmission Support 3282 from transmission.
- Install subframe with left control arm and left console

Group 40, Assembly overview: Subframe, anti roll bar,
control arm; removing and installing subframe
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- If present, firmly screw bolt - 1 - for Left Front Level

Control System Sensor G78

Tightening torques: Exterior lights, lamps, switches;
tightening torques: vehicle level sensor
- Connect harness connector - 2 - to Left Front Level

Control System Sensor G78 .
- Install left drive axle

drive axles
- Install wheel

Group 44,
.
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- Bolt on pendulum support to transmission using new bolts

- arrows B - 34-10, Tightening torques .
- Screw bracket - 1 - on oil pan with nuts - 2 - to 10 Nm.
.
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- Bolt on brace for front exhaust tube - arrows - .
- Connect harness connector - 1 - to Oil Level Thermal

Sensor G266 .
- Clip wiring harness into bracket - 2 - .
- If present, install shield - A - at bottom on transmission -

arrows - .
Note:
Use lubricant (water with no additives) for the

assembly as necessary. Do not use oil-based
lubricants.
Hose connections of charge air system are secured

by connector couplings. For connector couplings,
always note the following point:
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When assembling, make sure retaining tabs - A - are

engaged securely.
- Install air guide hose - 2 - at left and engage it with

retaining clips - 1 - .
- Install air guide hose at right and engage it with retaining

clips - arrows - .
- Install noise insulation and cover for left wheel housing

liner

.
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- Check adjustment of subframe mount
- Tighten bolts for transmission support 34-10,

Tightening torques .
- Install starter

Starter; removing and installing starter
- Install electrical harness connector - 2 - and Ground

(GND) wire - 3 - .
Note:
- Attach support bracket - D - and tighten with bolts - 1 -

34-2, Component overview .
- Connect selector lever cable to lever/selector shaft in

opposite - direction of arrow - .
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- Secure selector lever cable with new retaining discs - A -

and - C - .
- Check adjustment of selector lever cable and adjust if

necessary 34-9, Selector lever cable, checking and
adjusting .
- install bracket - 4 - and bolt tightly with bolts - 3 - and - 5 -

.
- Install fuel hose - 2 - on tandem pump.
- Install bracket for coolant and fuel lines on valve cover

and tighten bolts - 1 - .
- Install battery carrier.
- Install rear intake hose - 3 - and connect in opposite -

direction of arrow - to line - 2 - and engage.
- Tighten bolt - 1 - .
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- Connect coolant hoses of transmission oil cooler and

remove hose clamps 3094 .
- Install battery



- Check transmission oil level, top off if necessary 34-11,

Changing transmission oil and checking oil level .
Tightening torques
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Engine/transmission mount
Item no. Bolt Nm

1, 2, 3 M12x55 80
4, 6 M12x70 80
5 M10x50 40
A Dowel sleeves
Transmission subframe mount
A - 40 Nm + 90 ( 1 / 4 additional rotation) - replace
B - 60 Nm + 90 ( 1 / 4 additional rotation) - replace
Pendulum supports
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A - 40 Nm + 90 ( 1 / 4 additional rotation) - replace
B -100 Nm + 90 ( 1 / 4 additional rotation) - replace
Sequence for removing and installing
Removing: Unscrew bolt - B - first, then bolts - A - .
Installing: Tighten bolts - A - first, then bolt - B - .

Transmission oil and filter for Direct Shift Transmission (DSG), changing and checking oil level
34 - 11
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Transmission oil and filter for Direct Shift

Transmission (DSG), changing and checking oil
level

required
Vehicle Diagnosis, Testing and

Information System VAS 5051
Drip tray for workshop crane VAS

6208
Adapter for oil filling VAS 6262
Protective glasses
Protective gloves
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Caution!
Engine is not to be started if there is little or no

oil in the transmission following repair work or
severe loss of transmission fluid.
Only transmission oil for direct shift transmission

available as replacement part must be used in the
Direct Shift Transmission 02E. Other oils lead to
malfunctions or to failure of the transmission,
replacement part number Electronic Parts
Catalog "ETKA" .
Note:
Observe notes for direct shift transmission 02E 00-

2, Notes for 6 Spd. Direct Shift Automatic

Repair Notes .
Transmission oil temperature is read off on the

Vehicle Diagnosis, Testing and Information System
VAS 5051 .
Transmission oil level changes with transmission oil

temperature.
Performing transmission oil level check when

transmission oil temperature is too low causes
overfilling.
Performing transmission oil level check when

transmission oil temperature is too high causes
insufficient filling.
Excess filling and insufficient filling both affect the

function of the transmission.
Always replace sealing ring for drain/check plug.
Requirements
Engine off.
Vehicle in horizontal position, all lifting platform take-

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up points uniformly at same height so that it stands

horizontally.
Selector lever in "P" .
VAS 5051 is connected
To begin work, oil temperature must not be higher

than 35 C.
It is important not to interchange drain plug - A - and

check plug - B - . Check plug - B - is located in
vicinity of pendulum support.
Transmission oil and filter, changing
Note:
Follow the sequence of each of the following

instructions until the oil change is completed.
Filter, removing and installing

.
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- Raise vehicle.

- Lower the vehicle.
- Unbolt filter housing - 1 - from transmission.
- Before removing filter housing from transmission, tip it

slightly in its seating.

This allows oil to flow back into transmission from filter

housing.
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Note:
Always replace O-ring - 2 - .
- Remove filter - 3 - .
- Coat new O-ring - 2 - with transmission oil.
- Coat O-ring in suction collar - arrow - of new filter with

transmission oil.
- install new filter with suction collar - arrow - downward

and tighten filter housing to 20 Nm.


Changing transmission oil and checking oil level
- Raise vehicle.
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- arrows - .
Drip tray is positioned under transmission.
Warning!
Approx. 5.0 liters of oil will drain out.
- Unscrew check plug - B - .
Note:
Overflow tube is screwed in at opening of check plug

-B-.
Check whether overflow tube is screwed in

transmission to 3 Nm, tighten if necessary.
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Overflow tube has an 8 mm interior hex head.
The length of the overflow tube determines the oil

level in the transmission. When replacing, allocate via
replacement part number in Electronic Parts
Catalog "ETKA" .
- Shake oil containers before opening.
Caution!
Filler hose and adapter VAS 6262 must be clean

and transmission oil must not be mixed with
other oils!
- Screw in adapter - A - of VAS 6262 into opening for check

plug hand-tight.
To change bottles, shut-off valve can be closed or oil filler

adapter VAS 6262 can be held higher than the
transmission.
- Pour in 5.5 liters transmission oil for direct shift

transmission via the adapter VAS 6262 .
- Read off transmission oil temperature indicated in display

field of VAS 5051 .
- Start engine.
- Depress brakes and select each selector lever position for

approx. 3 seconds. Move selector lever back into "P" .
Do not turn off engine!
Warning!
When working in vicinity of cooler, always ensure

clearance to fan - danger of injury!
Fan can only switch on by itself.

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At a transmission oil temperature of 35 C to 45 C:
- With engine running, disconnect quick-acting coupling of

adapter for oil filling VAS 6262 .
- Let excess oil drain.
Note:
Every 30 seconds, a small wave of fluid exits the

overflow tube, independent of the height of the
transmission oil level (Reason: Cool oil impulse to
clutch). This wave is not criteria indicating an
excessive transmission oil level and must therefore
not be considered when determining the transmission
oil level.
Transmission oil draining out must not be refilled or

reused. Dispose of oil in an appropriate manner
00-6, Transmission oil and filter .
- As soon as oil flows out (it begins to drip), unscrew

adapter for oil filling VAS 6262 and install check plug - B -
with new seal.
Tightening torque: 45 Nm
- Turn engine off.
This concludes the transmission oil and filter change.
Oil level in transmission is correctly adjusted.

Wheels and shafts
35 - 1
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Wheels and shafts

No repairs are performed on the wheels and shafts at this
time.
Sealing rings for flange shaft or stub shaft, replacing
39 - 1
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Sealing rings for flange shaft or stub shaft,

replacing
Sealing rings, assembly overview
Right seal
for right drive flange
Replace 39-1, Sealing

rings for flange shaft or stub
shaft on right side, replacing
Right drive flange
Conical head bolt, 30 Nm
Replace
Right stub shaft
seal
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For left flanged shaft
Replace 39-1, Replace

sealing ring for left drive
flange
Left drive flange
Conical head bolt, 30 Nm
Replace
Replace sealing ring for left drive flange

required
Slide hammer VW 771
Pulling hook VW 771/37

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Thrust piece 3305
Sealing grease G 052 128 A1
Removing
- Remove left wheel.

- Remove left front wheelhousing liner
Repair Manual, Body Exterior, Repair Group 66,

Wheelhousing liner; removing and installing front
wheelhousing liner
- Remove left drive axle

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drive axles
- Unscrew mounting bolt for flange shaft. To do so, screw

two bolts into flange and counterhold flange shaft using pry
bar.
- Pull out flange shaft together with compression spring.
- Pull out seal for flange shaft using slide hammer VW 771
and pull hook VW 771/37 .
Installing
- Lightly oil new sealing ring on outer circumference.
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- Drive in new sealing ring to stop using thrust piece 3305 .

Do not distort sealing ring when doing this.
- install drive flange.
- Secure flange shaft with new conical head bolt and

tighten to 30 Nm.
- Install left drive axle

drive axles
- Install left front wheelhousing liner

Wheelhousing liner, removing and installing; front
wheelhousing liner
- Install left wheel

Group 44,


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Sealing rings for flange shaft or stub shaft on right side,

replacing

required
Seal driver-frt wheel bearing 3158
Drip tray for workshop crane VAS

6208
Pulling hook T20143/2
Sealing grease G 052 128 A1

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Grease for clutch disc splines G

000 100
Removing
- Remove right wheel.

- Remove right drive axle

drive axles
- After removing right drive axle - A - , unscrew

intermediate shaft - B - from mounting bracket - C - -
arrows - and remove from transmission stub shaft.
Vehicles with flange shaft

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- Unscrew mounting bolt for flange shaft. To do so, screw

two bolts into flange and counterhold flange shaft using pry
bar.
- Unscrew mounting bolt - arrow - for stub shaft or flange

shaft.
- Pull out stub shaft or flange shaft together with

compression spring.
- Pull out flange shaft seal using pull hook T20143/2 .
Installing
- Lightly oil new sealing ring on outer circumference.
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- Drive in new sealing ring to stop using drift sleeve 3158 .

Do not distort sealing ring when doing this.
- install stub shaft or flange shaft.
- Screw in new conical head bolt for securing stub shaft or

flange shaft and tighten to 30 Nm.
- Replace O-ring - 1 - for stub shaft.
- Grease splines on stub shaft using grease for clutch disc

splines G 000 100 .
- Guide intermediate shaft - B - through mounting bracket -

C - on to transmission stub shaft.
- Tightly bolt intermediate shaft to mounting bracket to

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tightening torque - arrows -
Repair Manual, Suspension, Repair Group 40,
- Install right drive axle

drive axles
- Install right wheel

Group 44,


Wheelhousing liner, removing and installing; front
wheelhousing liner

00-4, Code Letters, Assembly Allocation, Ratios, Equipment: Transmission Identification

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00-4, Code Letters, Assembly Allocation, Ratios, Equipment: Transmission Identification

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Volkswagen Jetta 2005->

Transmission code letters are located at top on

Example for one transmission:

 HLH = Transmission code letters

 13.08.04 = Production date 13th August 2004

 0011 = Serial number

The transmission code letters are also listed on the vehicle

 If the data plate is not available, a different

transmission 00-1, Transmission code, reading .

Transmission code, reading

On some transmissions, additional transmission code

To read the transmission code letters, under the console,

When doing this, it is important to lower the

After reassembly, selector lever cable must be adjusted

- Disconnect electrical harness connector - 2 - from Mass

- Disconnect vent hose - 1 - and air guide hose - 5 - .

- Open spring clamp - 3 - using hose clamp pliers VAS

- Unscrew bolt - 4 - and remove air filter housing.

- Check whether a coded radio is installed. In this case,

 Additional procedures must be performed when

Repair Manual, Electrical Equipment, Repair Group 27,

Repair Manual, Electrical Equipment,, Repair Group 27,

- Remove battery carrier.

- Place engine support bridge 10-222 A with adapters 10-

- If hose and cable connections are found in the area of

- Engage spindles 10-222 A/10 of engine support bridge on

- Remove all bolts - 1 - and - 2 - of console - A - .

Bolts must be replaced.

Carefully lower engine with transmission via both spindles

A maximum of 4 rotations is sufficient in order to remove

After that, transmission code letters can now be read off,

 Follow all the following instructions nevertheless.

 Replace all bolts of left subframe mount.

 First, screw in all new bolts by hand.

- Bolt on console - A - on transmission with bolts - 1 - and -

- Adjust selector lever cable 34-9, Selector lever cable,

Notes for "6 Spd. Direct Shift Automatic

Information can also be obtained via CD-ROM

The "6 Spd. Direct Shift Automatic Transmission 02E Front

Safety functions of Mechatronic unit

If individual or several components or sensors fail, Direct

The selector lever position is no longer transferred

Shift point change when driving up- or downhill ranges

At uphill or downhill ranges, the shifts are automatically

 Shift characteristics map for extreme uphill driving is

 Shift characteristics map for extreme downhill driving

 Direct gear selection by way of the Tiptronic function

Guided Fault Finding, Vehicle On Board Diagnostic (OBD)

Before performing service work on the automatic

"Guided Fault Finding" is performed using Vehicle

Capacities 6 Spd. Direct Shift Automatic Transmission 02E Front Wheel

Code letters, assembly allocation, ratios, equipment

Direct shift transmission 02E - 6-speed

4. Gear 37 : 41 = 0,902 37 : 41 = 0,902 37 : 42 = 0,881

5. Gear 32 : 35 = 0,914 32 : 35 = 0,914 32 : 35 = 0,914

3. Gear 39 : 30 = 1,300 41 : 28 = 1,464 39 : 30 = 1,300

4. Gear 37 : 41 = 0,902 41 : 38 = 1,079 37 : 41 = 0,902

2. Gear 41 : 20 = 2,050 41 : 20 = 2,050 41 : 20 = 2,050

3. Gear 39 : 30 = 1,300 39 : 30 = 1,300 39 : 30 = 1,300

HLH = Transmission code letters

13.08.04 = Production date 13th August 2004

0011 = Serial number

If the data plate is not available, a different

Additional procedures must be performed when

Follow all the following instructions nevertheless.

Replace all bolts of left subframe mount.

First, screw in all new bolts by hand.

Shift characteristics map for extreme uphill driving is

Shift characteristics map for extreme downhill driving

Direct gear selection by way of the Tiptronic function

Tow-starting the engine, e.g. when the battery is too

Transmission Input Speed (RPM)

Transmission oil pump

cover for transmission oil pump

Direct Shift Gearbox (DSG)

cover (sealing cover) for clutch

Transmission oil cooler

Thoroughly clean all connections and the surrounding

Only install clean components: Only unpack

Always replace paper seals. Remove old seal

Place removed parts on clean surface and cover

Carefully cover over opened components or seal, if

If covers are unscrewed from transmission or

When installing transmission, make sure centering

Only install clean components: Only unpack

If transmission was replaced, oil level must be

Mechatronic unit is to be allocated to transmission

Shake oil bottle before opening.

Do not mix additives into the oil, do not add a

For every oil change, filter must be replaced as well.

Drained oil must not be reused.

Always use only transmission oil for direct shift

Oil level in transmission and in final drive are checked

Always replace O-rings, gaskets and seals.

After removing gaskets and seals, always inspect the

Before installing a radial shaft seal, coat sealing lips

The open side of the seals face toward the oil.

Lubricate O-rings with transmission oil for direct shift

For oiling purposes, always use only transmission oil

Loosen and tighten bolts or nuts for securing covers

Do not distort especially delicate parts, e.g.

The tightening torques stated apply to non-oiled nuts

Using a wire brush, clean threads of bolts which are

All threaded bores in which self-locking bolts are

Always replace self-locking nuts and bolts.

Do not over-stretch circlip, replace if necessary.

Securing rings must be fully seated in groove.

Before performing service work on the transmission,

"Guided Fault Finding" is performed using Vehicle