Attention: Block "Mechatronic" is under high pressure, it must not be dismantled.
1. Block location "Mechatronic" indicated in illustration 1.5 (point 5). The description of removal/installation is given for the case when the DSG is removed.
2. Remove the breather cap (4 in illustration 1.5) and plug it with a suitable plug so that the working fluid of the block does not leak out "Mechatronic".
3. Position the DSG on the mounting stand so that the unit "Mechatronic" was located on top. Drain gear oil if necessary (see Section 6).
4. Using a screwdriver, carefully remove the sensor lock "G182" rpm at the DSG input and pull this sensor out of the DSG crankcase in the direction of the arrow (see resist. illustration).
8.4 Removing the sensor "G641" No. 3 revolutions of the input shaft
5. Depress both clutch engagement levers from the block plungers "Mechatronic", otherwise the levers will jam the block on the plungers and it will not be possible to remove it. Insert lever T10407 between both levers and the DSG housing so that the slight bend in the lever is against the block cover mounting nut "Mechatronic" (see resist. illustration). Do not insert the lever all the way. The lever must be in contact with the DSG housing with its entire rear surface.
8.5 Installing the lever for depressing the clutch lever
6. Turn the lever counterclockwise (see resist. illustration), while simultaneously applying force to its end to prevent the lever from slipping. Thus, the levers are pressed from the plungers.
8.6 Depressing the levers from the plungers
7. The lever must remain installed between the lever and the DSG housing throughout the entire removal process.
8.7 Locking the levers in the depressed position
If necessary, pry the lever away from the DSG with a screwdriver (see resist. illustration). Be careful not to damage the rubber seals of the plungers.
8. Remove 7 bolts (A and B on resist. illustrations) diagonally, discharge your static charge and remove the block "Mechatronic".
8.8 Block bolts "Mechatronic"
A Bolts M8x35, 3 pcs., to be replaced, 10 Nm
B Bolts M8x90, 4 pcs., to be replaced, 10 Nm
Attention: Do not loosen the cap nuts!
Do not drain the working fluid from it, and also make sure that the fluid does not leak out through the vent hole. If the unit needs to be repaired, send it to the workshop refilled.
9. If block "Mechatronic" jammed and cannot be removed, then the activator (arrow on resist illustrations) reverse gear is wedged in the upper left side of the DSG housing. In this case, do not use excessive force to remove. It will be correct to re-install the block "Mechatronic", secure it with one bolt and bring it into the manual removal position as described in the subsection below.
8.9 Stuck activator
10. View of the selector forks with the block removed "Mechatronic" indicated on op. illustrations. Before installation, make sure (check by hand), that all four forks are in the center position, i.e. all pairs of gears are in neutral (one of the gears is engaged in extreme positions). If necessary, to facilitate the movement of the fork, you can slightly turn the gear.
8.10 View of the selector forks with the block removed "Mechatronic"
N Neutral position (in the middle)
R Reverse gear, when it is engaged, the protruding block plunger "Mechatronic" engages on the DSG crankcase
1-7 1st - 7th gears
11. New block "Mechatronic" comes filled, do not drain the working fluid from it. Clean sealed with block "Mechatronic" surface from dirt and grease/oil.
12. Screw guide pins T10406 by hand (see resist. illustration).
8.12 Guide pins
13. Make sure all activators protrude 25mm (and on the opposite illustrations).
8.13 Plunger protrusion
14. Clean the mating surfaces of the block from oil and grease "Mechatronic" and DSG. Pay attention to the block gasket - it must be correctly planted around the entire perimeter. Make sure the sensor retainer is not damaged.
15. Install the block "Mechatronic", preventing movement of the selector forks from the neutral position. Also keep an eye on the position of the plungers and clutch levers. Tighten new block mounting bolts "Mechatronic" by hand, turning the guide pins T10406 as necessary.
16. Make sure the plungers go straight into the cups of the levers (see resist. illustration), by pulling the plungers with your hands or, for example, with a curved electrode.
8.16 Smooth entry of the plunger into the lever cup
Note: Improperly seated plungers will damage the block "Mechatronic".
Tighten block bolts "Mechatronic" with a force of 10 Nm diagonally.
17. Turn lever T10407 clockwise and remove it.
18. Install the DSG sensor in the crankcase "G182". If the sensor retainer is damaged, the block must be replaced "Mechatronic".
19. Remove the plug and install the cap on the breather.
Block installation "Mechatronic" in position for removal
20. Block installation "Mechatronic" to the manual removal position may be required when it cannot be moved to this position using the scan tool. The essence of the procedure is to wring out the jammed activator by hand (arrow in illustration 8.9) reverse gear to the removal position. To do this, press the selector fork behind the lock cover in the position "R".
21. Set the selector lever on the DSG to position "R", moving it all the way towards the cable holder, as shown in illustration 6.6.
22. Remember the installation position of the lever and remove it from the selector shaft, and then remove the cover (see illustration 6.7).
Note: After this block "Mechatronic" will not be jammed and may fall out, so it must be secured with at least one bolt.
A leaking cap should be replaced.
23. Through the resulting opening, push the selector fork to the left, looking in the direction of travel (see resist. illustration). This will push back the jammed activator and the block "Mechatronic" can be removed.
8.23 Pressing on the selector fork
24. Install the cover only after filling the transmission oil.