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  • Examplepage for repair manual 6-speed dual clutch gearbox 02E
  • Examplepage for repair manual 2 6-speed dual clutch gearbox 02E
  • Examplepage for repair manual 3 6-speed dual clutch gearbox 02E

6-speed dual clutch gearbox 02E

For Golf / Touran / Passat / Passat Variant / Golf Plus / EOS / Passat CC / Scirocco / Sharan

Original Volkswagen repair manual


26,49 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

10.817 KB

342 Sites

Detailed technical data

Immediately readable

This repair manual contains: Clutch, Electrical and electronic components and their locations DSG®, Removing and installing gear oil cooler, Renewing selector shaft lever oil seal with gearbox removed, Emergency release of selector lever, Selector mechanism up to 02.2009, Transporting gearbox and securing to assembly stand, Currently, no repairs can be made to gears and shafts and Overview - seals. Show more
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Repair manual 6-speed dual clutch gearbox 02E PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 General repair instructions
    1
  • 1.1 Tools
    1
  • 1.2 Gearbox
    1
  • 1.3 Overview
    1
  • 1.4 Seals
    2
  • 1.5 DSG® oil
    3
  • 1.6 Oil filter change - »Yes or no?«
    3
  • 1.7 Oil drain and inspection plug A
    3
  • 1.8 Nuts and bolts
    4
  • 1.9 Electrical components
    4
  • 2 Fault finding
    5
  • 2.1 General notes on fault finding
    5
  • 2.2 Useful information about the “behaviour of the control unit in the event of a gearbox fault”
    5
  • 2.3 Special notes on fault finding
    6
  • 3 Identification of gearbox
    8
  • 3.1 Reading gearbox code letters
    8
  • 4 Code - engine allocation
    10
  • 4.1 Golf Plus 2009 ►
    10
  • 4.2 Golf Plus 2005 ►
    10
  • 4.3 Golf 2009 ►
    11
  • 4.4 Scirocco 2009 ►
    11
  • 4.5 Golf 2004 ►
    11
  • 4.6 Touran 2003 ►
    12
  • 4.7 Passat 2006 ►
    13
  • 4.8 Eos 2006 ►
    13
  • 4.9 Passat CC 2009 ►; CC 2010 ►
    14
  • 4.10 Sharan 2011 ►
    14
  • 5 Capacity
    15
  • Clutch
    16
  • 1 Clutch
    16
  • 1.1 Assembly overview - dual clutch
    16
  • 1.2 Removing and installing clutch end cover
    18
  • 1.3 Removing dual clutch
    24
  • 1.4 Installing dual clutch
    25
  • Controls, housing
    31
  • 1 Electrical and electronic components and their locations DSG®
    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
  • 2 Removing and installing gear oil cooler
    48
  • 3 Removing and installing oil pump
    51
  • 4 Renewing selector shaft lever oil seal with gearbox removed
    55
  • 5 Emergency release of selector lever
    57
  • 6 Removing and installing selector lever handle
    58
  • 6.1 Moving push-button in the handle to installation position
    60
  • 7 Selector mechanism up to 02.2009
    62
  • 7.1 Overview of selector mechanism up to 02.2009
    62
  • 7.2 Removing and installing selector lever cable up to 02.2009
    63
  • 7.3 Checking selector lever cable
    70
  • 7.4 Adjusting selector lever cable
    70
  • 8 Checking selector mechanism
    72
  • 8.1 Selector lever in “P” position and ignition switched on
    72
  • 8.2 Selector lever in “N” position and ignition switched on
    72
  • 8.3 Selector lever in position “Tiptronic”
    72
  • 8.4 Ignition and light switched on
    72
  • 8.5 Selector lever position indicator
    72
  • 9 Selector mechanism from 03.2009 onwards
    73
  • 9.1 Overview of selector mechanism in vehicles from 03.2009 onwards
    73
  • 9.2 Removing and installing selector mechanism, from 03.2009
    74
  • 10 Removing and installing gearbox
    78
  • 10.1 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with 2.0 l petrol engine
    78
  • 10.2 Removing gearbox, Golf 2009 ►, Golf Plus 2009 ► with 2.0 l petrol engine
    85
  • 10.3 Removing gearbox, Golf Plus 2005 ► with 1.4 l petrol engine
    94
  • 10.4 Removing gearbox, Passat CC 2009 ►, CC 2010 ► diesel engine
    101
  • 10.6 Removing gearbox, Golf Plus 2009 ► with 2.0 l diesel engine
    120
  • 10.7 Removing gearbox, Golf 2009 ► 2.0 l diesel engine
    128
  • 10.8 Removing gearbox, Passat CC 2009 ►, CC 2010 ► with 3.6 l - V6 engine (all-wheel drive)
    135
  • 10.9 Removing gearbox, Golf 2004 ▸ with 1.9 l and 2.0 l diesel engine
    142
  • 10.10 Removing gearbox, Golf 2004 ► with 125 kW - 2.0 l diesel engine
    149
  • 10.11 Removing gearbox, Eos 2006 ►, with 3.2 and 3.6 l - V6 engine
    155
  • 10.12 Removing gearbox, Golf 2004 ► with 1.4 l petrol engine
    162
  • 10.13 Removing gearbox, Golf 2004 ► with 2.0 l petrol engine
    169
  • 10.14 Removing gearbox, Golf 2004 ►, with 3.2 l - V6 engine (R32 all-wheel drive)
    174
  • 10.15 Removing gearbox, Golf Plus 2005 ► with 1.9 l and 2.0 l diesel engine, with 2.0 l petrol engine
    183
  • 10.16 Removing gearbox, Eos 2006 ► with 2.0 l petrol engine
    190
  • 10.17 Removing gearbox, Eos 2005 ► with 2.0 l diesel engine
    197
  • 10.18 Removing gearbox, Touran 2003 ►
    204
  • 10.19 Removing gearbox, Passat 2006 ► with 2.0 l diesel engine
    212
  • 10.20 Removing gearbox, Passat 2006 ► with 2.0 l petrol engine
    220
  • 10.21 Removing gearbox, Passat 2006 ► with 3.6 l - V6 engine (all-wheel drive)
    225
  • 10.22 Removing gearbox, Scirocco 2009 ► with 2.0 l diesel engine
    231
  • 10.23 Removing gearbox, Scirocco 2009 ► with 2.0 l petrol engine
    240
  • 10.24 Removing gearbox, Sharan 2011 ► with 2.0 l diesel engine
    249
  • 10.25 Removing gearbox, Sharan 2011 ► with 1.8 l and 2.0 l petrol engine
    257
  • 10.26 Removing gearbox, Sharan 2011 ► with 1.4 l petrol engine
    266
  • 10.27 Install gearbox
    273
  • 11 Torque settings »gearbox to engine«
    275
  • 11.1 Torque settings (ELSA)
    275
  • 12 Transporting gearbox and securing to assembly stand
    283
  • 13 Removing and installing bevel box, Golf 2004 ► and Passat 2006 ►
    284
  • 14.1 Specified torques
    295
  • 16 Oil and oil filter
    301
  • 16.1 Oil filter: renewing
    301
  • 16.2 Checking oil level and topping up
    302
  • 16.3 Draining and filling oil
    305
  • Gears, shafts
    309
  • 1 Currently, no repairs can be made to gears and shafts
    309
  • Final drive - differential
    310
  • 1 Overview - seals
    310
  • 1.1 Renewing seals for right flange shaft or stub shaft - front-wheel drive
    311
  • 2 Renewing oil seal for left flange shaft - front and all-wheel drive
    313
  • 2.1 Renewing oil seal for right flange shaft - all-wheel drive
    314
  • 2.2 Dismantling and assembling flange shaft
    316
  • 3 Renewing oil seal for propshaft drive flange at bevel box
    318
  • 4 Assembly overview - Flange shafts and seals on bevel box
    324
  • 4.1 Renewing seal on gearbox between bevel box and gearbox
    325
  • 4.2 Removing and installing right flange shaft
    326
  • 4.3 Renewing seal for right flange shaft on outside of bevel box
    328
  • 4.4 Renewing needle bearing (polygon bearing) for right output shaft drive flange
    329
  • 4.5 Renewing seal on bevel box between gearbox and bevel box
    331
  • 5 Checking and topping up gear oil in bevel box
    333
  • 5.1 Checking gear oil in bevel box
    333
  • 5.2 Topping up gear oil in bevel box
    334
Manufacturer's designation 6-speed dual clutch gearbox 02E
Manufacturer Volkswagen
Suitable for Golf (2004 - 2007) / Touran (2003 - 2011) / Passat / Passat Variant (2005 - 2008) / Golf Plus (2005 - 2007) / EOS (2006) / Passat CC (2009) / Scirocco (2008) / Golf (2009) / Golf Plus (2009) / Sharan (2011)
Suitable car types 1K1, 3C, 5M, 1F, 357, 137, 5K1, 521, 7N1
Transmission designations 02E
Transmission types GPT, GYN, HJQ, HLE, HLF, HQL, HRW, HTB, HUT, HXS, HXW, HYC, GKF, GPU, GPQ, GYD, HFQ, HBQ, HBP, HAG, GYP, GYM, HQN, HQM, HQK, HQG, HQF, HLH, HLG, HJP, GQA, HYE, JPH, JPJ, JPK, JPL, JPN, JPR, JPS, JPY, JQA, KBG, KCT, JPZ, JPP, JPQ, KCU, KCW, KCZ, KDA, GUF, HZJ, JCA, JVG, JVY, JYW, KCV, KDC, KCY, KDB, KDF, KFV, KFW, KJL, KMW, KMX, KMY, KMZ, KNB, KNC, KNF, KNH, KNJ, KNK, KNM, KPS, GKE, HKA, HPZ, HQB, HQQ, HQR, HYD, JBT, KPQ, 02E, KLN, KND, KNE, KPU, KPW, KQX, KSA, KSB, LHR, LHT, LQS, KPV, KQC, LBK, LOZ, LPY, LQT, LQV, LRC, LRD, LTD, LTE, LQZ, LHQ, LHS, LTF, KPT, KPY, LTL, LRG, LQW, LRA, LRT, LTG, LTM, LTV, MFY, MFM, MKJ, MLW, MLX, MMA, MME, MSV, MSW, MSY, MTU, MFL, MMC, MSU, MTB, MTD, MTE, KAN, KPX, LPW, LPX, LQY, LRB, LRE, LRH, LRJ, LTK, LTP, LTQ, LTT, LTW, LTX, LXZ, MDJ, MHL, MKM, MLZ, MMB, MMD, MMH, MMJ, MRL, MST, MSX, MSZ, MTA, MTC, MTV, MTW, GSS, HBR, HDD, HUS, HVV, HXT, HXU, HXV, HXX, HZH, HTG, HXY, GYU, HAH, HUV, HXZ, JQZ, JUQ, JYX, KDE, KNL, KQA, LME, LRF, LTU, LTY, MMF, MMG, MTX, MTZ, GAY, GHG, GPV, GPW, GPX, GST, GYQ, GYR, GYS, HLJ, HQH, HQP, KFN, LSZ, LTA, LTB, MLY, MSR, MSS, LPS
Category Reparaturanleitung

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