Volkswagen Golf Variant, Jetta. Manual - part 2

– Cover the hole with a cloth before installation work.
Make sure that no dirt can enter an “open” gearbox.
♦ If gearbox covers have been unbolted or gearbox has no fluid,

do not run engine. Do not tow vehicle.

♦ First thoroughly clean connecting points and surrounding

areas and then loosen bolts.

♦ During installation, ensure that the dowel sleeves between 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, cover opened

parts carefully.

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

4. General repair notes    

5

 

Oil

The “0AM” gearbox has two oil circuits. One oil fill is for gears,

shafts and differential. A 2nd oil fill is for mechatronic unit for dual

clutch gearbox -J743- .
Both oils are Genuine parts 

⇒ page 3

 .

Do not mix “additives” in oil.
Oil which has been drained out cannot be added again.

Caution

Use caution when handling oil. Dispose of used oil properly.

One drop of oil will contaminate 600 litres of water.

4.4

Working with vehicle diagnostic testers

• Only work with vehicle diagnostic testers from Volkswagen.
♦ Vehicle diagnosis and service information system -VAS 5052

A-

♦ Vehicle diagnosis, testing and information system -VAS

5051B-

♦ Vehicle diagnostic tester -VAS 5053-
Various functions are available in the operating modes 

guided

functions

 and 

guided fault finding

. The 3 most important

functions are:
♦ Adapting installation information
♦ Reading measured values for mandatory reporting
♦ Initiating basic adjustment

4.4.1

Adapting installation information

The mechatronic unit detects other control units in the vehicle by

means of signals on the data bus. Pressing the 

Adapt instal-

lation information

 lock button instructs the mechatronic unit

to forget all communication partners.

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

6

 

ways perform the 

Adapt installation information

 function

after the following activities:
♦ After a selector lever has been installed.
♦ After another control unit has been installed, e.g. engine, ABS

or gateway.

♦ After work on the steering wheel paddle.

4.4.2

Reading measured values for mandato‐

ry reporting

You must read these measured values before contacting your

Technical Service Center or your importer.
Save the measured values in the diagnosis log so that all neces‐

sary gearbox data will be available for fault analysis.

4.4.3

Initiating basic adjustment

This teaches important settings into the mechatronic unit. Even

important adjustments are taught in again, or reset to program‐

med points. These include, for example, the synchronisation

points and “reference points” for the engaging lever and gear ac‐

tuator.
– Press the button 

DSG Mechatronic -J743- performing

basic measurement

 only:

♦ if you are prompted to do so in “guided fault finding”
♦ after you have processed a fault entry
♦ after you have installed another gearbox
♦ after you have installed a clutch
♦ or after you have installed a mechatronic unit

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

4. General repair notes    

7

 

Removing and installing the dual

clutch

Brief description
The clutch is installed “upwards” with the gearbox removed. The

mechatronic unit remains on the gearbox.
If one new clutch is installed, the positions of the engagement

bearings for “K 1” and “K 2” must be found and set. Then the clutch

is pressed onto the input shaft.
When installing a clutch, “most” mechanics push the clutch onto

the input shaft up to the stop. This is not the optimum position for

the clutch!
For this reason, pull the clutch slightly “upwards” against the re‐

taining ring after it has been installed.
After the gearbox has been installed, you must 

initiate a ba-

sic adjustment

 using the ⇒ Vehicle diagnosis, testing and

information system VAS 5051 

⇒ page 7

 .

Note

The clutch is self-adjusting. Shocks can have an effect on this

adjusting device. Therefore, please do not drop the clutch. Do not

left the clutch drop into the gearbox either when installing the

clutch. Even if the mechatronic unit has been removed, “pulling

out” the assembly lever -T10407- under the engaging levers can

have a negative effect on the adjusting device.

Transporting gearbox and securing to assembly stand

⇒ page 111

 .

Remove dual clutch 

⇒ page 8

 .

Adjust the position of the engagement bearings “K 1 and K 2”

⇒ page 12

 .

Install dual clutch 

⇒ page 22

 .

1.1

Removing dual clutch

Special tools and workshop equipment required
♦ Hook -3438-

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

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