Volkswagen Golf Variant 2010 User Manual

Service

Workshop Manual

Golf Variant 2007

Golf Variant 2010

Jetta 2005

Jetta 2011

6-speed dual clutch gearbox 02E

Edition 07.2010

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Service Department. Technical Information

Service

List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups

Repair Group

00 - Technical data

30 - Clutch

34 - Controls, housing

35 - Gears, shafts

39 - Final drive - differential

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Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R006620

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																	u	r																																		t		, Jetta 2005 , Jetta 2011
																							Golf Variant 2007 , Golf Variant 2010 r
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																	s																				6-speed dual clutch gearbox 02E - Edition 07.2010
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									m		t	e																								Contents																			n				b
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00 - Technical,																data																																														w
																					.	.		.		.	.	.		.	.		. .	.	. . .	.	.	.	.	.	.		.	.		.			.	.	.		. . .	.	.		.		.			.		.	e. .	. . . . . . . . . . . . . .
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o									General repair notes
1 h																													.	.	.	.	.	.	. . . .	.	. .	.	.	.	.		.	.	.		.		.	.	.	.	. . .	. .		.		.			.	.			. .c. .	. . . . . . . . . . . . . . . .
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1.1r									Tools																																																								e
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1.2									Gearbox									.		.	.	.		.	.	.	.	.		.	.	.	. .	.	. . .	. .	. .	.	.	.		.	.	.	.		.		.	.	.	.	. .	. .	.	.		.			.	.			. . . .	. . . . . . . . . . . . . . . .
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1.3																			.		.	.	.	.	.	.	.	.		. .		. .	.	.	. . .	. .	. .		. .		.	.	.		.	.			. .	.		.	. . .	. .	.		.		.			.		.	. .o. .	. . . . . . . . . . . . . . .
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p									Electrical components
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2 m									Fault finding																																																								m
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2.1		c							General notes on fault finding																																																							n	i
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2.2				r																																																														of a gearbox fault“
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2.3 Special notes on fault finding																																																								u
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									Gearbox identification																					.	.	.	.	.	. . . .	. .	. . .			.	.	.	.		.	.			. .	.		.	. . .	t. .	.	.			.			.	.		. . . . .	. . . . . . . . . . . . . . .
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5									Capacity
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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		15
1	Notes on clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	15
2	Removing and installing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	16
2.1	Removing clutch cover (end cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	16
2.2	Installing clutch cover (end cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	18
2.3	Removing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	21
2.4	Preparing installation of multi-clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
2.5	Installing and adjusting clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	24
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		31
1	Electrical and electronic components for the dual clutch gearbox and their locations . . . .	31
1.1	Removing. . . . . . . . .and. . .installing. . . . . . . mechatronic. . . . . . . . . . .unit. . .for. . .dual. . . .clutch. . . . .gearbox. . . . . . .J743. . . .(gearbox. . . . . . . .installed). . . . . . . .	31
1.2	Removing. . . . . . . . .and. . .installing. . . . . . . mechatronic. . . . . . . . . . .unit. . .for. . .dual. . . .clutch. . . . .gearbox. . . . . . .J743. . . .(gearbox. . . . . . . .removed). . . . . . . .	40
1.3	Removing and installing gearbox input speed sender G182 and oil temperature sender in
	multi-plate clutch G509 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	49
2	Removing and installing gearbox oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	51
2.1	Removing gearbox oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	51
2.2	Installing gearbox oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	52
3	Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	54
3.1	Removing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	54
3.2	Installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	56
4	Renew seal on selector shaft lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	58
5	Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	60
5.1	Overview - selector mechanism in vehicles up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . .	60
5.2	Removing and installing selector lever cable - vehicles up to 02.2009 . . . . . . . . . . . . . . . .	61
5.3	Overview of selector mechanism - vehicles from 03.2009 onwards . . . . . . . . . . . . . . . . . .	68
5.4	Removing and installing selector mechanism with selector lever and selector lever cable -
	vehicles from 03.2009 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	69
5.5	Checking selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	70
5.6	Adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	70

Contents i

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

5.7 Emergency release of selector lever														. . .	.			.	.	.		.	.	.		.	.	. .	. .	. .	. . . . .	.	.	.	.	.	.		.	.	.		. .	.		.	. . . .	. .						72
5.8 Removing and installing selector lever knob																				.	.	.		.		w..a..g.e.			. . .	.	o . . . . .	.	.	A..G..d..o.					.	.	.		. .	.		.	. . . .	. .						73
5.9	Checking selector mechanism								.		.		. .	. . . .			.	.	.		.	.		.					. . .	.		.	.					.		.	.		. .	.		.	. . . .	. .						74
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6	Removing and installing gearbox																	d.b				o																					u.a											76
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6.1	Removing gearbox													th	s																														a		e.e							76
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6.2	Installing gearbox													u																																								86
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		. . . . .	.	.		.				.		.	.	.s. . .	.		.	.		.	.	.		.	.		.	. .	. . .	.	. . . . .	.	.	.	. .		.	.		.	.	.	.	.		.	. . .c. . .
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6.3	Torque settings											u	le																																			e	a					87
		. . . . .		. .			.			.			n .	. . . .	.		.		.	.	.	.		.	.		.	. .	. . .	.	. . . . .	.	.	.	. .		.	.		.	.	.	.	.		.	. . . .
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7	Transporting gearbox and securing to assembly stand																												. . .	.	. . . . .	.	.	.	. .		.		.	.	.	.	.	.		.	. . . .	. .						89
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8														oil level																																									i
	Changing oil and filter and adjustingp																			.	.	.		.		.		. . .	. . .	.	. . . .	. .	.	.	. .		.		.	.	.	.	.		.	.	. . . .	. .						90
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8.1	Changing oil and filter	. . . .n	o																																																						y
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			.	.		.				.		.	. .	. . .	.	.	.		.		.	.	.		.		.	. .	. . . .	.	. . . .	. .	.	.	. .			.	.	.	.	.	.		.	.	. . . .	. .						92h
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35 - Gears, shafts		e																																																			95								s
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ii Contents

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

00 – Technical data

1General repair notes

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Thisc workshop manual was written for you. r

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It shouldp support you and be an aid to you. If you use ELSA,

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you can send Volkswagen suggestions and comments from any

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where in they world.

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– You can do this by clicking the Feedback button at the top

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in the menu bar.yp

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More information on the dual clutchP

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You can learn more about how the gearbox works in Self-study programme No. 308 ; The Dual Clutch Gearbox 02E .

You can gain further information from the CD ROM Multimedia training; Dual clutch gearbox .

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1. General repair notes 1

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

1.1

Tools

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A summary of the special tools and workshop equipment used indb

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the workshop manual precedes each repair procedure and can

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be found in „Special tools/Workshop equipment“ binder.

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Thecatalogueisalsoavailableon CD-ROMandcanbeun

ordered

the usual way from Bertelsmann.

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tightening

Uncertainty often occurs with smaller bolts having lowe

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thesebolts.

forces.Torquewrench-V.A.G1783-canbeusedwitho

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1.2

Gearbox

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Always make sure that no dirt can enter an »open«agearbox. In

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particular, dirt entering an »exposed« mechatronic unitp for dual

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clutchgearbox-J743-and/oroilpumpcanleadtogearboxfailure.

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♦ If gearbox covers have been unbolted or gearbox has noofluid,

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do not run engine or tow vehicle.

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♦ First thoroughly clean connecting points and surrounding

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areas and then loosen bolts.

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♦ When installing the gearbox, ensure that dowel sleeves be tween the engine and gearbox are correctly located.

♦ Place removed parts on a clean surface. Cover parts to pre vent soiling. Use plastic sheeting and paper. Use lint-free cloths only!

♦ Install only clean parts; do not remove Genuine parts from packaging until immediately before installing.

♦ If repair work cannot be performed immediately, carefully cov er or seal components.

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2Rep. gr.00 - Technical data

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

1.3Overview

1 - Filter page 90

page 4

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Notes on filter change

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2 - Inspection plug

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90

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Nearpendulumsupport.

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3 - Drain plug

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page 4

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Plug was discontinued

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as of September 2004.

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The oil can be drained

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via the inspection plug

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4 - Gearbox oil cooler

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page 51

,

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5 - Mechatronic unit for dual

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clutch gearbox -J743-

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page 31

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6 - Gearbox input speed send

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er -G182- and oil temperature

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sender in multi-plate clutch -

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G509- page 31

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8 -nCover (end cover) for multi-
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1.4O-rings, seals and gaskets

♦Renew O-rings, seals and gaskets.

♦Before installing a radial oil seal, coat sealing lips and area between these with sealing grease -G 052 128and outer cir cumference with dual clutch gearbox oil.

♦Only use dual clutch gearbox oil. Other lubricants will cause problems in function.

♦Open side of radial oil seal faces oil.

♦After installation, change the oil and adjust the oil level at the same time page 90 .

1. General repair notes 3

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

1.5Dual clutch gearbox oil

Shake before opening.

TheoilisavailableasaGenuinepart.ThereforetheGenuinepart

number for it can be found in the

Electronic parts catalogue

„ETKA“ .

The oil quality is of decisive importance for the function of the

gearbox.

Do not mix additives in oil. Do not fill any other oil.

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Please also refer to page 4 for important information aboutlks

assessing the oil.

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Oil which has been drained out cannot be filled again.u

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Caution

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of used oil properly.

Use caution when handling oil. Disposep

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of water.

One drop of oil will contaminate 600 litresno

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1.5.1

Tasks of the oil

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the gearbox.

The oil does more than just »lubricate«p

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Consider that the oil just transportedeminiscule particles of metal

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from the differential to both filters. Thiso oil ensured that the film of

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lubricant on the flanks of the teeth does not tear. In the next mo

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ment, it provides the pressure necessary for the gear actuators

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to do their job.

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In addition, it seals the spool valves

andmaids the synchro-rings

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during gear changes. Oil stores and transports heat and reduces

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noise.Theoilperformsmanytasks.Dualclutcht

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very exacting requirements.

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To maintain this ability, the filter on the gearbox should be re

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newed together with the oil in the maintenance service.p

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1.5.2

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Oil filter change - »Yes or no?«

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The oil filter does not have to be changed as a matter of course.

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Do not change the filter if:

♦The gearbox oil cooler or its O-rings have been renewed and no coolant has got into the oil.

♦The oil seal for the selector shaft has been renewed.

♦The oil seal for the flange or stub shaft has been renewed.

♦Leaking covers in the mechatronic unit, the multi-clutch or oil pump have been renewed.

♦The gearbox input speed sender -G182- with oil temperature sender in multi-plate clutch -G509- has been renewed.

The filter must be changed if:

♦The 60,000 kilometre service interval has been reached.

♦Coolant has got into the oil.

♦Metal particles have been found in the oil.

♦The clutch is burnt out or has a mechanical defect.

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4Rep. gr.00 - Technical data

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

1.5.3Oil and fault finding via oil level check

Oil and fault finding via oil level check

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You can read about all the thingso

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There is one thing it cannot do: »disappear without a trace«.

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Oil can only go missing if it has run out of the gearbox.

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Gearbox oily

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– First, checkit

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where the oil has escaped from the gearbox. Re

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first. Only then add fresh oil to achieve the

pair this leake r

»correct«t

oil level page 90 .

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uptheoildoesn'trepairanydefects.Itdoesn'thelp

»Just«topping,

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fault, but it gives one an unjustified feeling of security.

to find theo

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1.5.4

oOil drain and inspection plug -A-

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To gearbox manufacture date „20 September 2004“, gearboxes

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were constructed with 2 plugs.

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The second plug was then discontinued, and oil could be drained

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and the level checkedCwith only one plug -A-.

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A plastic overflow tube (withpo 8 mm hexagon socket head bolt,Vy

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mines the oil level in the gearbox.

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1.6Nuts and bolts

♦Loosen and tighten securing bolts and nuts for covers and housings diagonally.

♦Torque settings are specified for unoiled bolts and nuts.

♦Threads of bolts secured with locking fluid must be cleaned withawirebrush.Theninsertboltswithlockingfluid-AMV185

101 A1- .

♦All threaded holes into which self-locking bolts are to be screwed must be cleaned of residual locking fluid using a thread chaser. Otherwise there is a danger of bolts shearing when subsequently being removed.

♦Always renew self-locking bolts and nuts.

ita

1. General repair notes 5

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

1.7Electrical components

You have probably at some time received an electrical shock

when touching a metal object. This is due to the electrostatic

charge of the human body. This charge can disturbo

the function

ofelectricalcomponentsofthegearboxs

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– Before beginning workthon electrical components, touch an

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a water pipe or lifting platform.

earthed object, for examples

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Please do not gripl plug contacts directly.

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6Rep. gr.00 - Technical data

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

2Fault finding

Before making repairs, determine the cause of the fault as pre cisely as possible with the aid of „guided fault finding“.

Fault finding is performed with the vehicle diagnostic tester .

2.1General notes on fault finding

Planning fault finding

Try to plan the fault search sensibly.

–Beaware»whatsortofproblem«isonhandandwhichmeans of fault finding are available. Finding a fault without a thoughtout search would be -magic- and does not lead to success.

♦ It must also be clear that it is not necessary to look for faults

which have already been found and are known to others.

Therefore,firstcheck TechnicalSolutionstoseeifasolution

to the problem is listed.

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♦ Itisalsopossibletocontactyour TSCortheimporteryinyour

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country. Make use of this possibility! This will saveistime, work

and expenses.

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♦ Itcanalsobehelpfultoknowthefaultsenteredle

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units. Always interrogate all control units.d When searching for

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example, in this case

a fault, keep the bus system in mind. Forit

page 9 .

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♦ Whencallingyourimporterorthe TSC,n

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Useful informationlabout the „behaviour

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of the control unit inr the event of a gear

box fault“

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The control unit works with highly developed software. This soft

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ware is able to execute, monitor and control electronic functions

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in milliseconds. This control unit »has everything« that a modern

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gearbox electronics »has to offer«. This mustfalso be considered

when looking for faults.

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6-speed dual clutch gearbox 02E -isEdition 07.2010

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example, where oil is leaking from thesgearbox housing. But it is

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oil«. First a fault in

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„gear monitoring“ will be detectedtande

finally the control unit will

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power transfer).

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react by opening both clutches (nor m

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You should be aware of this wheno

looking for faults and working

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withVolkswagentesters.Itmightis

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is not discovered with

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Guided fault finding

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software, a great deal has been

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As well as the more advancedi

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done to protect the gearboxo in case of a malfunction (safety func

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tions). Consequently, when a fault occurs, if it is necessary, the

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fault is saved and a substitute program is started.

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Behaviour of the control unit in the event of a fault

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n

s

o

e

p

malfunctions, the control unit re

s

If a component in the gearboxp

f

r

s

u

o

sponds with a substitute function. Because the gearbox must be

f

l

i

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n

a

r

protected as far as possible,ethere are 4 fault responses:

r

o

c

m

m

a

1 - The fault is so minor thatotravel may be continued with a

o

m

t

n

i

c

n

substituteprogramanddrivingsafetywillbepreserved.The

i

r

i

t

driver will not be warned via the selector lever position dis

o

s

h

a

e

t

o

play -Y5- . The display indicates the selector lever position

v

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p

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m

as usual. It may be possible tofnotice changes in driving

u

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behaviour.

o

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n

n

p

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t

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o

in the selector lever

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2 - Individual selector lever positions blinkt

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position display -Y5- . The driver is beingy

warned that it is

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not possible to select this gear at the moment.bdFor example,

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driving in reverse: the lever is in „R“ and the vehicleorPis trav

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et

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n

elling backwards. If „D“ is selected in this situation, the letter

„D“ in selector lever position display -Y5- will begin blinking.

Inthissituation,thecontrolunitprevents1stgearfrombeing

engaged to prevent damage to the gearbox. The gear will

not be engaged until the vehicle has stopped moving. If you

should want to try this out, be careful.

3 - The selector lever position display -Y5- is completely illumi nated and is blinking. The selected selector lever position is recognisable or is highlighted. For example: the gearbox oil temperature is too high. Some possible causes may be the towing of a trailer with too great a load or retrofitted compo nents at the front of the vehicle leading to »insufficient air cooling«.

4 - Theselectedselectorleverpositionisnotrecognisable.The selected range display -Y5- flashes. Changes in driving and gearshiftbehaviourareclearlyapparent.Reversingnotpos sible. A »major fault« has occurred. Part of the gearbox has been switched off and the gearbox must be repaired.

2.3Special notes on fault finding

2.3.1Selector lever position display - no „R“

Simultaneous illumination of all selector lever position display segments indicates gearbox emergency running mode. The ve hicle cannot reverse.

8Rep. gr.00 - Technical data

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

2.3.2Touch function does not work - no gear change

Check securing clip on cable support bracket of selector lever cable on top of gearbox. In particular, clip -B- must never be reused.

Due to the loss of its »own tension«, this clip -B- may go lost. The -arrow- points to the Bowden cable adjusting screw.

2.3.3»Power transfer« inadequate - possibly insufficient fluid

First click here page 4 .

Top up fluid only when it has been ascertained that fluid has es caped. Anything else is »expensive fun« which will not help.

2.3.4No faults have been saved

In this case, the solution depends on you. Experience shows that
»faults« attributed to the gearbox often are caused by other com
ponents or assemblies.						.
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It has occurred in the past that poor shifting behaviour wasydueV		w
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to insufficient air intake of the engine. Don't make the samei

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of mistakes.

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work mean

Only after such faults have been excluded can onele

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ingfully with the VW tester.

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2.3.5

Faults have been savede

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TheVWtestersoffer

Firstconsiderwhatthesavedfaultsindicate.s

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Guided fault finding

. Properly used,l

Guided fault find-

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ing

will locate the sources of many faults.w

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2.3.6

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caused by the

If there are faults »nott

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gearbox«

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,

For example, if the fault „ABS signal missing“ is saved in the

s

e

gearbox memory and additionally another control unit reports

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o

p

„ABS signal missing“, then the gearboxpcontrol unit is not likely to

r

be »faulty«.

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c

Theentrymeansonlythatthegearbox(andm possiblyothercontrol

r

e

units) are expecting a signal via the bus, but does not receive it.

m

In this case, it is more likely that the ABSocontrol unit has a

o

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r

problem. In such a case, under no circumstances should the me

e

t

chatronic unit for dual clutch gearbox -J743- bepremoved without

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furtherconsideration.Thefaultinthisexampleindicatesproblems

r

in the ABS.

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2. Fault finding 9

guarant ee

or a c c e p t

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011

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6-speed dual clutch gearbox 02E - Editions

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Gearbox identificationa

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Example -arrow-:

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t

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e

GKF - Gearbox code lettersp

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10.05.2 - 10 May 2002is

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e

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14 - Factory code

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14 15 - Time

n

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001 - Serial numberp

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On some gearboxes, gearbox code is also located on the top of the gearbox near the selector lever cable -arrows-.

The gearbox code is also included on the vehicle data stickers.

If there is no vehicle data sticker, if the installed gearbox does not match the one indicated on the sticker or if the installed gearbox cannot be definitively identified: read gearbox code off gearbox.

Reading code directly on gearbox page 10 .

a n y

l i a

b

3.1Reading gearbox code letters

The code appears on every gearbox in at least two places.

10 Rep. gr.00 - Technical data

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

Once on top of the gearbox close to the selector lever cable -two arrows-.

If it is not legible or is»upside down«, the gearbox code may also be found under the bracket of the left assembly mounting.

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To see the code directly one d the gearbox behind the bracket, the

engine and gearbox must

t

t

be supported. Bracket -A- for the left-

m

i

must be removed. In the process, it is

hand assembly mountinge

r

p

and gearbox only enough so that

important to lower the engineo

n

t

back. If it is lowered further, the

the bracket can be pushed,i

s

be damaged. Following assembly, the se

pendulum support willo

e

l

be adjusted page 70 .

lector lever cable mustw

h

n

i

steps:

Perform the followingo

r

t

–

r

air filter housing.

Remove completen

a

p

♦

i

Vehicles with petrol engines Rep. gr. 24 ; Removing and

,

s

installing air filter

s

o

p

r

♦

Vehicles with

diesel engines Rep. gr. 23 ; Removing and

a

u

p

installing air filterr

l

i

c

e

m

–

Remove battery and battery tray -arrows- Rep. gr.

27 ;

m

o

Battery; Removing and installing battery .

c

r

o

e

t

Setupsupportbracket-10p-222A-andsupportenginewithgear

a

v

i

box. Do not raise.

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–Remove all bolts -1- and -2- for bracket -A-. Bolts must be renewed.

–Then lower engine and gearbox slightly using spindles of sup port bracket -10 - 222 A- until bracket can be removed.

3. Gearbox identification 11

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

In most cases, 2 turns of the spindle will be sufficient to remove the bracket -arrow-.

After gearbox code has been read, assembly can be performed in the reverse order.

–Nevertheless, observe all the following instructions.

–Renew all bolts on left assembly mounting.

–First screw in all bolts by hand.

–For a description of proper installation of bracket -A- on gear box with bolts -1- and -2-, see page 87 .

–Always adjust selector lever cable after installing bracketpage 70 .

12

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Rep. gr.00 - Technical data

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

4Code - engine allocation

4.1Identification code

If Genuine parts are required for a repair, always refer to the gearbox code.

Dual clutch gearbox ( DSG®) 02E »front-wheel drive«

	HVV	GAY, GPV,	GKF,	HBQ,
		GPW, GYQ,	GPU,	HRW,
		GYR, HBQ,	GYM,	HUS,
		HLH, HQN,	GYN,	HUT,
		HQH, HQQ,	HBP,	HXW,
		HXU, KPQ	HJQ,	MSX
			HLE, HLF,
			HFQ,
			HXS,
			HQF,
			HQL,
			HTB,
			KPS,
			LQV, LTE,
			MSV
	1.4 l - 103	1.9 l - 77 kW	2.0 l - 100,	2.0 l - 147
	and	TDI	103, 125	kW TFSI
	125 kW		kW TDI
	TSI
Installed in	Golf Variant 2007 ►, Golf Variant 2010 ►, Jetta
		2005 ►, Jetta 2011 ►

.

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4. Code - engine allocation 13

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

5Capacity

Capacity

Dual clutch gearbox 02E

Initial filling in factory

6.9 … 7.2 l

depending on vehicle and date of

gearbox construction

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Change quantity in custom

about 5.2 l

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Lubricant

th

oil

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Dual clutch gearboxs

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le

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number for it can

The oil is available as a part. Therefore the partd

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„ETKA“ .

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14 Rep. gr.00 - Technical data

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

30 – Clutch

1Notes on clutch

When carefully considered, the term »clutch« is notAG.exactlyagcoren

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rect. Clutches of DSG®s always containlksat least 2 »clutches«,

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In this case, the

n

so the term „multi-clutch“ is more appropriate.db

V

y

clutch has 2 sets of plates - making it a wet clutch. The outer,

e

is

r

o

larger set of plates is called „Ca1“ (clutch 1). The „C 1“ selects

th

u

reverse gear and gears »1«,les»3« and »5«. The smaller inner „C

s

»4« and »6«.

2“ (clutch 2) selects gears »2«,u

n

t

t

e

d

-clutch requires special care because

The assembly of the multim

r

i

balanced together during manufac

all components have beenp

t

relative to each other during assembly,

ture. If parts are rotatedn

o

imbalances develop,which are detrimental to ease of shifting and

s

i

service life.

e

o

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w

Therefore, genuinei clutches are supplied with a built-in retaining

ring.

n

t

r

o

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a

To avoid the risk of parts rotating relative to each other, the meth

p

n

od of assembling and installing the clutch in the gearbox housing

i

,

s

you should carefully refer to this de

is shown here. Therefore,s

e

scription page 16 .

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1. Notes on clutch 15

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

2Removing and installing clutch

It is currently possible to see a film demonstrating how the clutch is removed. At the time of publication, the video was available onlyinGerman.Thepathtothefilmis VolkswagenServiceNet; VW/Audi TV; Volkswagen iTV; iTV API Online; Motor/Getriebe; Alle Modelle - Hinweise zum Direkt-Schalt-Getriebe DSG . If and when it appears in English, the last two levels will be approxi mately "Engine and Gearbox" and "All models - notes on dual clutch gearbox DSG".

The cover over the clutch must be removed before the clutch can be removed page 16 .

2.1Removing clutch cover (end cover)

Perform the following steps:

The cover seals the gearbox. The cover is held in place by a re

taining ring. After the retaining ring has been removed, the cover

can be levered out of its seat. Cover and retaining ring must al

ways be renewed. Never install a new cover with a hammer and

.V

olks

if this

wag

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e

never oil the centre seal or touch it with a hand! However,n

en

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to leak!

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should happen, the cover is certaino

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r

is

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The gearbox must be removed for work on cover.

t

o

e

th

e

o

u

r

a

a

– Remove gearboxs page 76 .

s

le

n

to assembly stand page 89 .

– Secure gearboxd u

m

i

t

t

e

r

p

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t

o

n

s

–

i

,

Draineoil.

l

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manufacture date „20 September 2004“, gearboxes

To gearboxw

n

with 2 plugs.

i

were constructedr

o

t

plug was then discontinued, and oil could be drained

r

a

The secondp

n

i

and the level checked with only one plug -A-.

,

s

e

s

A plastico overflow tube (with 8 mm hexagon socket head bolt,

p

torquersetting 3 Nm) is located in this hole. Its length determines

u

p

l

the oil level in the gearbox.

a

i

c

r

e

– Remove this oil pipe.

–

m

m

Drain oil.o

c

r

o

e

– Screw intoverflow pipe with 3 Nm torque.

a

v

i

r

p

r

o

f

– Install drain plug -A- with new seal.

g

n

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y

C

p

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Torque setting: 45 Nm

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		d	s	i	h
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16 Rep. gr.30 - Clutch

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

– Remove the filter if necessary.

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Often, doubts arise as to whether the filter must belkrenewed or

g

a

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not.

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is

The notes on the oil filter change page 4thcan help you in reach

r

o

ing this decision.

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p

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– Insert new filter with shoulder downwards and tighten cover to

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20 Nm.

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–Followingrepairwork,itisnotnecessarytochangefilteragain when filling oil.

Remove cover.

– Remove retaining ring from cover. Cover can be levered out with a screwdriver. Install only a »new« cover page 18 .

2. Removing and installing clutch 17

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

2.2Installing clutch cover (end cover)

There are 2 types of cover.

♦Covers supplied without a bush page 18 .

♦Covers supplied with a white bush page 20 .

		V
	y
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2.2.1Installing covers supplied withoutm itte d ubushr n

Perform the following steps:				t	p	e
			o
		n
	s
				Never install
	i
Cover and retaining ring must always be renewed.,
	e				seal or touch
	l
a new cover with a hammer and never oil the centreo
it with a hand!	h
	w
	n
	i
	r
	o
	t
Caution	r
	a
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	n
	i
	,
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	s
Do not grasp new cover in centre hole. The hole of the cover
	o					with other
	p
must not be touched, oiled or brought into contactr
materials.Leaks will result.	u
	p
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	a
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	m
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– Only handle cover as shown in the picture!				o
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Special tools and workshop equipment required

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.

C

18 Rep. gr.30 - Clutch

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

♦ Assembly sleeve -T10302-

Caution

Clean assembly sleeve before using. Do not use a scratched sleeve.

New cover must be free of oil and dry around centre seal!

– If necessary, clean end of clutch shaft.

There must be no stickers on the inside of the cover.

–If any stickers are present, remove them carefully! Moisten only the outer edge of the seal with DSG oil.

–Set sleeve on a flat surface.

The centre seal of the new cover must now be »preformed«:

g

a

w

s

lk

o

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d

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is

t

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o

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th

e

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This

a

s

– Guide cover horizontally and evenly over entire sleeve.s

le

will bring the sealing lip into installation position.n

e

d

u

t

t

set sleeve on

l

i

– Now remove sleeve upwards out of cover andi

a

end of clutch shaft

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m

b

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2. Removing and installing clutch 19

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

–Guidecoverhorizontallyoversleeveandpressevenlyontoits seat.

Caution

Workcarefully.Anysortofblowtothecoveriscertaintocause leaks.

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en

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th

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a

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c

s

le

e

n

t

Itispossibletolevercoverd

carefullyintoitsseatwithascrewdriver

p

e

u

-arrow- until »new« retaining ring can be installed.

m

i

t

t

r

e

ring.

– Install new retainingt

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2.2.2

l

Installing covers supplied with bush

a

i

c

r

e

m

steps:

Perform the followingc

m

o

Cover and retaining ring must always be renewed. Never install

r

o

e

a new cover with a hammer and never oil the centre seal or touch

t

a

v

it with a hand!

i

o

r

p

r

f

g

n

i

y

Caution

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.t

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b

y

p

o

c

y

The hole of the coveraws

V

o

Do not grasp new cover in centre hole.bde

y

kl

must not be touched, oiled or brought intoPcontact with.G other

c

e

et

or

A

n

g

materials.Leaks will result.

Do not remove bush!

n

i

n

f i n f o r

oitam

20 Rep. gr.30 - Clutch

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

New cover must be free of oil and dry around centre seal!

– If necessary, clean end of clutch shaft.

There must be no stickers on the inside of the cover.

–If any stickers are present, remove them carefully! Moisten only the outer edge of the seal with DSG oil.

–Insert cover with bush.

Caution

Workcarefully.Anysortofblowtothecoveriscertaintocause leaks.

Itispossibletolevercovercarefullyintoitsseatwithascrewdriver -arrow- until »new« retaining ring can be installed.

– Install new retaining ring.

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p

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–

d

a

t

e

n

y

l

m

i

tDo not remove bush until retaining ring is installed.

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f

Removing clutch

o

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m

m2.3

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a

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i

o

i

n

o

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r

Perform the following steps:

t

n

o

e

s

i

h

t

a

Tovremove or install clutch, gearbox must be securely attached

o

d

i

r

c

p

to an assembly stand in vertical position.

u

r

m

o

–

f

clutch cover (end cover) page 16 .

e

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n

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t

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p

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n

.G

2. Removing and installing clutch 21

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

–Remove retaining ring from clutch cover.

–Remove cover from clutch.

– Remove retaining ring -arrow-.

Note: this retaining ring must be measured again during installa tion and renewed.

Caution

Carefully remove clutch. Ensure that end cover or other parts ofclutchdonotfallout.Therefore,donotturnoverclutchunder any circumstances!

But if this should happen page 29 .

– Remove clutch.

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en

A

A

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d

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p

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,

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l

o

– Remove pumphshaft -A-.

w

n

– Pump shaft isonot inserted until after new clutch is installed.

i

r

Set shaft asidea until then.

t

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p

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,

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o

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t

a

v

2.4

i

of multi-clutch

e

Preparingfinstallationg

r

p

r

o

n

n

i

t

Multi-clutch as replacement partC

.

p

p

C

y

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m

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d

r e s

22 Rep. gr.30 - Clutch

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

1 - Multi-clutch

The cover of a new clutch is secured with a retaining ring.

2 - Retaining rings

Qty. 10

Rings have different »thicknesses«. They are sized in 0.1 mm in crements.

Refer to instructions inpage 24 .

3 - Cover (end cover)

Ensure that inner seal

ing lip is not damaged

page 18 . Manufactur

er inserts a bush to proagen

tect sealing lip. Please

w

s

lk

o

V

leave this bush in cover.

y

b

d

e

is

r

o

4 - Retaining ring

th

u

a

s

s

For cover.n

le

e

d

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t

m

i

p

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t

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a

p

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,

s

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s

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p

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u

p

l

a

i

c

r

e

m

– mWhen removing clutch from packing, press on clutch cover.

o

c

r

This isato prevent the clutch cover and the plate carriers beneath

o

e

t

o

it from sliding out of the inner plates.

v

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A

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.G

f o r tam

2. Removing and installing clutch 23

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

– Make sure that the 4 -piston ringsare correctly located.

o

Ring gaps should not be »overs

G.

V lksw

ag

e

each other«.

en

A

en

A

G

d

g

o

a

lk

w

s

n

ot

o

V

g

– Turn rings once.s

y

They must move freely and must not bind.a

b

u

d

a

i

e

r

n

r

t

o

e

th

e

o

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r

a

a

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s

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d

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i

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y

m

i

r

a

p

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t

o

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s

i

,

e

l

o

h

e

w

t

n

c

Position of clutch cover

Important!o

i

r

t

Look to see whether there is a marking on clutch -arrow-.

–p

r

a

n

If there is no mark, make a coloured mark. Later the »lug« of

e–

i

,

s

the cover must be placed at the marked spot.

o

s

p

Set down clutch so that it cannot tip over.

r

u

p

l

a

The clutch is now ready for installation page 24 .

i

c

r

e

m

m

o

c

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d

a

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i

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p

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b

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et

g

or

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P

A

n

.G

2.5Installing and adjusting clutch

Caution

Avoidremovingorliftingplatecarriers.Notevenalittlebit!The plates could turn.

Perform the following steps:

•Gearbox must be turned »vertical in assembly bracket«. Only this way is it possible later to adjust axial play of the clutch without error.

•It is essential that the gearbox be securely clamped in support clamp -VW 313or engine and gearbox support -VAS 6095-page 89 . It must not be turned.

•Insidetheclutch,thelargeplatecarriergoesthroughallplates. It must not slip out of the lowest plates.

•The pump shaft of the oil pump is removed.

•Do not install corrugated retaining rings.

Special tools and workshop equipment required

24 Rep. gr.30 - Clutch

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

♦ Retaining pin -T10303-

– First set -retaining pinon seat of cover.

.V

enAG

g

a

w

s

lk

o

V

y

b

d

e

is

r

o

e

th

u

o

r

– Then insert -clutch- without letting it fall in.le

a

a

s

s

Do not mount on clutch. Clutch is insertedte

u

n

d

with cover as it was

when packaged.

m

i

t

r

p

e

t

o

n

s

i

,

e

l

o

h

w

n

i

r

o

t

r

a

p

n

i

,

s

e

s

o

p

r

– The -retaining pinshould be held by a second mechanic in

u

the process.

p

r

l

a

i

c

e

-Retaining pinremains inserted untilmall further work has been

»completed«.

m

c

o

r

Do not remove the pin until instructed toado so. But not yet.

o

e

t

v

i

r

p

r

o

f

g

n

i

y

p

o

C

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p

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c

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b

d

et

c

et

or

P

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c o r r e c t n e s s o

2. Removing and installing clutch 25

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed dual clutch gearbox 02E - Edition 07.2010

–Carefully remove clutch cover -arrow- from clutch and lay it to side.

Caution

Avoidremovingorliftingplatecarriers.Notevenalittlebit!The plates could turn.

o

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V lksw

ag

enA

en

g

a

w

s

lk

o

V

y

b

d

e

is

r

o

th

u

a

s

s

le

u

n

– Select 2 mm retaining ring frome d among the rings supplied and

install it temporarily -arrow-.

t

m

i

t

p

e

r

2 measurements must be

Before this ring is removed again,ot

made.

is

n

,

e

First measurement

l

ho

w

n

i

• Retaining pin -T10303-rremains in!

o

t

r

– Screw universal dial gauge -VW 387to gearbox flange.

p

n

i

,

s

e

s

o

p

r

u

p

l

a

i

c

r

– Set -tip of dial gaugeoneinput shaft.

m

m

– Set -dial gaugeto 0 with preload.

o

c r

– Raise clutch to stop and note result of measurement. e

o

t a

Second measurement	v
	i
	r
	p
	r
	o
	f
	g

i
• Retaining pin -T10303- remains in!y
p
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C
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p
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c
y
b
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et
c
et
or	.G
P

c e p t

i n f

26 Rep. gr.30 - Clutch