- If the sensor lever (arrow) were damaged, the entire mechatronics assembly would have to be replaced.
2. Touch the ground (body) of the vehicle with your bare hand, which will discharge the electrostatic charge.
Attention:
The manual transmission mechatronics "J743" may only be touched or removed after the electrostatic charge has been removed by touching a grounded object, such as a mass (body), with your bare hand a car.
Do not touch the contacts in the gearbox wiring harness connector with your hands, as electrostatic charge can damage the control unit and, consequently, the mechatronics.
3. Carefully insert the DSG automatic transmission mechatronics "J743" into the gearbox housing, as shown in the figure below.
4. Make sure that the centering pin (A) is correctly inserted into the fixed position in the gearbox housing (arrow 1) and the sensor lever (B) into the wire (arrow 2) located in the gearbox housing, as shown in the figure below.
Note: Be careful not to pinch the wire of the gearbox input shaft speed sensor "G182" and the oil temperature sensor in the multi-plate clutch "G509".
5. When installing the mechatronics of the DSG automatic transmission "J743", do not pinch the plug connection wire (A), shown in the figure below. If the wire were damaged, the C182 gearbox input speed sensor/G509 multi-plate clutch oil temperature sensor would have to be replaced. The long sensor on the rear of the J743 DSG automatic transmission's mechatronics system must not be damaged.
6. Hand tighten the new mounting screws (1) through (10) shown in the figure below.
7. Tighten the screws in the specified sequence with a tightening torque of 5 Nm + and tighten an additional 90° (1/4 turn).
8. Secure the wire (A) first to the upper and then to the lower brackets (arrows), as shown in the figure below.
9. After inserting the wiring harness connector, secure it.
10. Replace both O-rings (arrows) on the mechatronics input as shown in the figure below.
11. Lubricate both O-rings with DSG automatic transmission fluid.
12. Clean the sealing surfaces and remove any remaining oil.
13. Ensure that the new oil pan seal is installed correctly.
14. Install the oil pan. Be careful not to pinch any wires.
15. Screw in the new oil pan mounting screws (A), shown in the figure below (arrows), tighten them in several steps crosswise, applying the appropriate tightening torque.
16. After installing the new transmission oil pump cover (A), tighten the mounting screws (arrows) in several steps, applying the appropriate tightening torque, as shown in the figure below.
17. After installing the wire holder on the oil pan, tighten the nuts with a torque of 10 N·m.
18. The mechatronics wiring harness connector should be installed as follows:
- The arrows on the mechatronics and on the wiring harness connector, as well as the protrusion, must be in a straight line and pointing upwards, as shown in the figure below.
- The wiring harness connector should be carefully pushed in until it stops and the locking mechanism should be locked by turning it to the right in the direction of the arrow, as shown in the figure below.
19. Connect the water hose to the lower fitting of the cooling system radiator. Tighten the hose clamp. Fill the engine cooling system with coolant.
20. If present, install a connecting cable between the charge air cooler and the charge air pipe.
Note: After disconnecting and then reconnecting the wire connecting the battery terminal to the vehicle ground (body), some additional work must be performed.
21. Connect the wire connecting the battery terminal to the ground (body) of the vehicle.
Caution: Do not start the engine or tow the vehicle without DSG transmission fluid.
22. Replace the transmission oil filter (for more details, see the relevant section in this chapter).
23. Fill the gearbox with transmission oil (for more details, see the relevant section in this chapter).
24. Install the lower protective cover of the engine compartment (for more details, see the corresponding section in the chapter "Body").
25. After installing the mechatronics of the DSG "J743" automatic transmission, it is necessary to initialize the transmission using special equipment.