Audi A4: General, Technical data
Repair Information
General Repair Information
Using the Repair Manual
Refer to the "7-Speed DSG
Transmission 0CK" repair manual for all special procedures with
the transmission installed, depending on the model. The
servicing repair manual either does not describe them or
describes them only partially. Both repair manuals are needed
for a successful repair.
The highest level of care and cleanliness along with tools
that function properly are required to ensure a proper and
successful transmission repair. Of course the general safety
precautions also apply when carrying out repair work.
Some general repair information that applies to several
procedures throughout this manual is summarized here. They apply
to this repair manual.
Oil, Environmental and Disposal Regulations
- Handle ATF, transmission fluid and other oils carefully.
- Dispose of drained fluid properly.
- Follow the legal, environmental, and disposal regulations.
- Follow the instructions listed on the fluid packaging.
Special Tools
Refer to Workshop Equipment and Special Tools for a complete
list of special tools used in the repair manual.
Transmission
- Follow all the guidelines for clean working conditions.
Refer to
→ Chapter "Rules for Cleanliness When Working on DSG
Transmission".
- Do not run the engine or tow the vehicle when the
transmission is open or when there is no transmission fluid.
- If installing parts that can be used again, clean and check
them and replace if necessary.
- During installation, make sure the alignment sleeves are
fitted correctly.
O-Rings, Shaft Seals, Seals
- Always replace the O-rings, shaft seals and seals.
- After removing the seals, examine the contact surface on the
housing or shaft for burrs resulting from removal or for other
signs of damage.
- Clean the housing separating surface thoroughly before
assembling.
- Before installing, lightly lubricate shaft seal outer
circumference and sealing lips with ATF or gear oil, depending
on the installation location.
- Depending on the component location, coat the O-rings
lightly with ATF or transmission fluid to insert them. This
prevents them from being crushed when being installed.
- Use only ATF in the ATF area. Other lubricants cause
malfunctions in the hydraulic transmission control.
- The open side on the shaft seals faces the fluid to be
sealed off.
- After installing check the ATF level or the transmission
fluid level with the transmission installed and correct. Refer
to "7-Speed Dual Clutch Transmission 0CK"
→ Rep. Gr.34; ATF; ATF Level, Checking or for
transmission fluid level checking and correcting, refer to
→ Rep. Gr.34; Transmission Fluid. Specification.
Refer to the Parts Catalog.
Bolts and Nuts
- Loosen the bolts opposite the tightening sequence.
- Nuts and bolts which secure covers and housings should be
tightened in steps according to the specified tightening
sequence or method.
- Bolts or nuts for securing covers and housings should be
loosened and tightened diagonally in stages if no tightening
sequence is specified.
- Always replace self-locking bolts and nuts.
- If nothing else is specified: use a wire brush to clean the
threads of bolts that were screwed in with locking compound. Use
locking fluid when installing the bolts. Refer to the Parts
Catalog.
- If self-locking bolts were installed or if regular bolts
were installed with locking fluid, then the threaded holes must
be cleaned, for example with a thread tap. Otherwise there is
the risk that the bolts could break off the next time they are
removed.
- The tightening specifications given apply to unoiled bolts
and nuts.
Circlips, Snap Rings
- Do not stretch the circlips.
- Replace damaged or stretched circlips.
- The circlips must rest at the bottom of the groove.
Bearings
- Install needle bearings with the lettered side (thicker
metal) facing the fitting tool.
- Coat and install the bearings with gear oil or with ATF,
depending on the installation location.
- Do not interchange the outer or inner races of bearings of
the same size.
- Always replace the tapered roller bearings on one shaft
together and use new bearings from a single manufacturer.
Shims
- Measure the shims at several locations with a micrometer.
Different shim thicknesses make it possible to select the
required thickness precisely; install two shims if necessary.
- Check for burrs or damage. Only install flawless shims.
Mechatronic
Caution
There is a risk of destroying the transmission
control module (Mechatronic) with electrostatic
discharge.
- Always discharge "static electricity" before working
with connectors or the Mechatronic. Do this by touching
a grounded object, for example vehicle ground, the
heater or the hoist.
- Do not touch connector terminals in the transmission
connector with hands.
Contact Corrosion
Contact corrosion can occur if inadequate fasteners (bolts,
nuts, washers, etc.) are used.
For this reason, only fasteners with a special surface
coating may be installed.
Furthermore, only rubber or plastic parts and adhesive made
of electrically non-conductive materials are used.
If there are doubts about whether parts can be used or not,
use new parts. Refer to the Parts Catalog.
Note:
- Original replacement parts are recommended because they have
been tested.
- The use of Audi accessories is recommended.
- Contact corrosion damage is not covered under warranty.
ATF Pump, Deactivating and Draining the Hydraulic Pump Reservoir
WARNING
The system is under pressure.
The ATF transmission "7-Speed Dual Clutch
Transmission 0CK" is equipped with an electronic ATF
pump and a hydraulic pressure reservoir.
The electronic ATF pump can start up at any time.
The ATF system also remains under pressure with the
ignition switched off due to the hydraulic pressure
reservoir.
- The electronic ATF pump must be deactivated every
time before opening the transmission, and the hydraulic
pressure reservoir is drained.
- When the system status is not clear, for example the
cause of a faulty transmission control module or
transmission is unknown, only loosen the mechatronic
bolts to a minimal degree, so that the oil pressure in
the pressure reservoir can decrease slowly.
- Disconnect the Transmission Control Module -J217-
connector before removing the oil pan.
- Wear protective eyewear.
ATF Pump, Deactivating and Draining the Hydraulic Pump
Reservoir
- Connect Vehicle Diagnostic Tester with the vehicle and start
the Diagnostic mode.
- Select vehicle test
- 02-Transmission electronics, functions
- 02 ATF pressure reduction/Disabling the
ATF pump or 02-ATF level ⇒
Draining ATF
Rules for Cleanliness When Working on DSG
Transmission
- Thoroughly clean the connection points and the surrounding
area before loosening.
- Clean the transmission and transmission components using
Cleaning Solution -D 009 401 04-.
- Use lint-free cloths for cleaning, for example, the "WYPALL
X70/WORKHORSE" cloth made by Kimberly-Clark Professional.
- Seal all open lines and connections immediately with clean
plugs or caps from the Engine Bung Set -VAS6122-.
- Place the removed parts on a clean surface and cover them.
Use foil or lint-free cloths.
- Carefully cover or seal opened components if the repair will
not be done immediately.
- Only install clean parts: remove the replacement parts from
their packaging just before installing them.
- Protect the disconnected connectors from dirt and moisture
and only connect when they are dry.
READ NEXT:
1 - Flywheel
Refer to the Parts Catalog because there are different versions
depending on the date of manufacture.
Removing an installing. Refer to
→ Chapter "Flywheel, Removing
Special tools and workshop equipment required
Puller - Clutch Module -T40176-
Clutch Disc Shaft Spline Lubricant -G 000 100-
Sealing Grease. Refer to the Parts Catalog.
Removing
Note
T
SEE MORE:
Timing Chain Cover
Overview - Timing Chain Cover
All procedures and components are described under:
→ Servicing - 4-Cylinder 2.0L 4V TFSI Engine; Rep. Gr.15; Timing Chain Cover.
Camshaft Adjustment Valve 1 -N205-/ Exhaust Camshaft Adjustment Valve 1
-N318-, Removing and Installing
Special tools and workshop equipment required
Trim Removal Wedge -3409-
Removing
- Unlock the rear seat backrest.
- Make sure the button -2-
(indicator) is in the "up" position.
- Push the tabs in the direction of -arrows-
on both sides of the trim using a -3409-.
- Remove t