Name: 6-speed dual clutch gearbox 02E
Brand: Volkswagen
SKU: CDG28e17367a0ab
Price: 26.49 EUR
Availability: InStock

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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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