Removal and installation of DSG (Skoda Yeti 5L)

Note: The DSG is removed downwards, separately from the engine.

Removal

1. Set the selector lever to position "P".

2. Remove the top engine cover, air cleaner (see Chapter 4) and the battery with its holder (see Chapter 5).

3. Remove the windshield fairing (see Chapter 11).

4. Using the MP8-602/1 tool, separate the selector cable from the DSG (And in the illustration).



5. Remove the lock washer from the selector cable in the direction of the arrow (see illustration), - the cable must remain in the installation position.

Note: Reuse of the lock washer is not permitted. Do not bend the selector cable or squeeze it out of the support in the rear direction - the cable is removed from the holder when removing the selector mechanism.

6. Remove the ground wire (1 in the illustration) using the DSG console bolt, disconnect the electrical wiring from the starter (2) (wire and connector, see Chapter 5) and remove the starter bolt (A). Remove the second starter mounting bolt, which is not visible in the illustration. Unscrew the bolts (B) of the DSG fastening, separate the wire connection (3) from the holder together with the wiring (4) and put them aside. Remove the holder (4) from the DSG.



7. On some engines one of the bolts is located in the opening for installing the starter - unscrew this bolt (see illustration).



8. Remove any static electricity from yourself and remove the cap from the unit connector "Mechatronic" in the direction of the arrow (see illustration) and disconnect the connector.





9. Install the T30099 tool and relieve the powertrain mounts by slightly tightening the tool spindles (see illustration 5.10 Chapter 6).

Note: 1.2L models only use one spindle.

10. On models with splined differential shafts (until 11.2008) have an assistant depress the brake pedal and loosen the left front wheel hub bolt and the front wheel mounting bolts. Raise the vehicle.

Caution: After removing the hub bolt, do not lower the vehicle so that it rests on the wheels.

11. Remove the front wheels, sound insulation under the engine compartment and the front wheel arch liners (see Chapter 11).

12. Remove the boost air hose from the intercooler (bottom left), as well as a boost air tube.

13. Remove two bolts (see illustration) and remove the right drive shaft protective cover from the engine.





14. Remove the bolts (A-C in Illustration 5.16 Chapter 6) and remove the rocker support.

15. Separate the exhaust system on the double clamp and remove its bracket from the subframe. Tie up the exhaust pipe.

16. Disconnect the engine oil temperature and level sensor connector on the bottom of the engine oil pan (see Chapter 2). Release the wiring of this sensor from the holder.

17. Disconnect the stabilizer bar from its strut, secure the subframe and remove it together with the console without the steering gear, left arm and stabilizer bar (see Chapter 10).

18. If available, remove the left front suspension height sensor "G78" (see illustration).



19. On models with splined differential shafts (until 11.2008) give me three nuts (see illustration) and separate the ball joint from the right suspension arm (see Chapter 10). Disconnect both drive shafts from the differential splines and remove the left drive shaft (see Chapter 8). Tie up the right drive shaft as far as possible (see illustration 4.20), without damaging its protective coating.





20. On modules with flanged differential shafts (since 11.2008) disconnect the drive shafts from them (see Chapter 8) and tie them as far as possible (see illustration), without damaging the protective coating.



21. Remove the lower bolts securing the DSG to the engine (see illustrations).







22. Loosen the bolts (1 in the illustration) consoles approximately one turn and unscrew the bolts (2).



23. Lower the power unit on the spindles of the T30099 device so that the distance (and in the illustration) was 60-70 mm. Then unscrew the bolts (1 in illustration 4.22) console mounts and remove it.



24. Install transmission support #3282 with adjusting plate #3282/59 (see illustration) on a transmission jack and install it under the DSG. Align the support parallel to the DSG and screw bolt No. 3282/29 into the DSG. Secure the DSG to the support with belt T10038.





25. Remove the remaining DSG mounting bolt (arrow on the illustration), press the DSG away from the engine on the mounting bushings and lower it slightly, removing the selector cable from the support on the DSG. Remove the DSG from the engine compartment downwards, being careful not to damage the electrical wiring and hoses.



26. If you plan to install a new DSG, move the brackets to it (see illustration), removed from the front side of the removed DSG.



27. Replace the needle bearing in the crankshaft (see Chapter 2).

Installation

28. Installation is carried out in reverse order. Please note the following features.

29. If an old DSG is installed, replace the sealing rings (1 in the illustration) and retaining rings (2) on the splined shafts of the differential.





30. Check for the presence of two centering bushings (And in the illustration) between the engine and transmission. Check that the intermediate plate is positioned correctly. The size of the bolts is also shown in the illustration. Tighten M12 bolts with a force of 80 Nm, and M10 bolts with a force of 40 Nm.



31. It should be possible to alternate the engine and transmission by hand to fully align their flanges. If the engine/transmission does not move by hand, something is wrong. Adjust the position of the transmission support so that the DSG and engine are aligned with each other, if necessary, turn the crankshaft slightly.

32. The tightening forces for the transmission support fasteners are specified in Section "Removal and installation the engine".

33. Use a new selector cable lock washer (see illustration 4.5). Make sure the cable is routed correctly.

34. Finally, adjust the selector cable and use the diagnostic tool to apply the basic settings for the DSG.