Page 1 Service Workshop Manual Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ , Octavia II 2010 ➤ , Rapid 2011 ➤ , Rapid India 2011 ➤ , Rapid NH 2013 ➤ , Rapid NH 2014 ➤...
Page 2 Service List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups R e p a i r G r o u p 00 - Technical data 30 - Clutch 34 - Controls, housing 35 - Gears, shafts 39 - Final drive - differential...
Page 3: Table Of Contents
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Contents 00 - Technical data ........... .
Page 4 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Removing and installing selector lever control cable, vehicles up to 05.2009 (Octavia II, Superb II, Yeti) ............123 2.10...
Page 5: Technical Data
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 00 – Technical data Identification (SRL000769; Edition 01.2015) ⇒ “1.1 Identification of the gearbox”, page 1...
Page 6: Safety Instructions
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Safety instructions ⇒ “2.1 Safety precautions when working on vehicles with a start/ stop system”, page 2 ⇒...
Page 7 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Caution 2. Safety instructions...
Page 8: Repair Instructions
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Repair instructions ⇒ “3.1 General points”, page 4 ⇒ “3.2 Explanation of the terms used in this workshop manual”, page 7 ⇒...
Page 9 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Gearbox with different output shafts ♦ -A- - Rigid shafts up to 11.2008 ♦ -B- - Flange shafts as of 11.2008 Summary of components of gearbox for vehicles Fabia II, Room‐...
Page 10 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 The gearbox has an opening in the housing -arrow-. Vehicles Octavia II, Superb II and Yeti Note When installing pay attention that nothing falls into this open‐...
Page 11: Explanation Of The Terms Used In This Workshop Manual
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 The “7-speed double clutch gearbox DSG - 0AM” has two sepa‐ rate, different oil fillings. One for the area with gearbox oil -arrow A- and the other one for the area with hydraulic oil -arrow B-.
Page 12 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 CAN databus Data transfer. Before transmission, electrical signals are put into certain forms (BUS). Further information on this can be found in ⇒...
Page 13: Contact Corrosion
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 sition) to the gearbox. The selector lever positions or shifting are transmitted via a separate control unit in the shift mechanism via the CAN databus to the mechatronics.
Page 14: Working With Testing Devices
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 ♦ Specified torques given are for unlubricated nuts, bolts and screws. ♦ Clean the thread of the screws that are inserted with a locking agent with a wire brush.
Page 15: Notes On Tow Starting And Towing
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Notes on tow starting and towing Caution When towing the vehicle, the selector lever must be in position N and it must not be towed further than 50 km and faster than 50 km/h, otherwise the gearbox will be destroyed.
Page 16: Technical Data
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Technical data ⇒ “4.1 Filling capacity”, page 12 ⇒ “4.2 Allocation gearbox - engine”, page 13 ⇒...
Page 17: Allocation Gearbox - Engine
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Caution Only spare part gear oils should be used for the 7-speed double clutch gearbox DSG - 0AM.
Page 18 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Automatic gearbox DSG 0AM - front-wheel drive Gearbox Identification charac‐ ters Manufactured from 11.2012 throug 04.2013...
Page 19 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Automatic gearbox DSG 0AM - front-wheel drive Gearbox Identification charac‐ ters Assignment Engine 1.2 ltr./77 kW TSI...
Page 20 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Automatic gearbox DSG 0AM - front-wheel drive Gearbox Identification charac‐ ters Manufactured from 05.2009 06.2009 11.2009...
Page 21 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Automatic gearbox DSG 0AM - front-wheel drive Gearbox Identification characters Manufac‐ 05.2014 11.2014 05.2014 11.2014 tured 11.2014...
Page 22 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Automatic gearbox DSG 0AM - front-wheel drive Gearbox Identification characters Assignment Engine 1.2 ltr./77 kW TFSI 1.4 ltr./90 kW TSI...
Page 23 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Automatic gearbox DSG 0AM - front-wheel drive Gearbox Identification charac‐ ters Manufactured from 05.2010 11.2010 06.2011...
Page 24 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Automatic gearbox DSG 0AM - front-wheel drive Gearbox Identification charac‐ ters Manufactured from 11.2012 06.2013 11.2013...
Page 25: Calculation Of Gear Ratios
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Automatic gearbox DSG 0AM - front-wheel drive Gearbox Identification charac‐ ters Assignment Engine 1.5 l/77 kW TDI CR...
Page 26: Overview Of Transmission System
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Overview of Transmission System The 7-speed double clutch gearbox DSG - 0AM has 2 drive shafts and 3 output shafts.
Page 27: Electrical Components
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Electrical components ⇒ “6.1 Electric/electronic components and fitting locations of the automatic gearbox DSG - 0AM”, page 23 Electric/electronic components and fit‐...
Page 28 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 ❑ Removing and installing ⇒ “2.5 Removing and Installing the cover for the shift mechanism”, page 109 4 - Gearbox input r.p.m.
Page 29 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Gearbox input r.p.m. sender - G182- Fitting location: The gearbox input speed sender - G182- is clip‐...
Page 30 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Brake light switch - F- and brake pedal switch - F47- Fitting location: The brake light switch - F- and brake pedal switch - F47- -3- is located on the master brake cylinder -4-.
Page 31 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 1 - Diagnostic connection ❑ Fitting location: Dash panel in the area of the driver's footwell 2 - Selector lever position indi‐...
Page 32 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 ❑ Tiptronic switch - F189- , selector lever sensor control unit - J587- and selector lever switch locked in P - F319- are integrated into the shift mechanism.
Page 33 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Kick-down switch - F8- An initialised value of the accelerator pedal position sender - G79- / accelerator pedal position sender 2 - G185- (integrated in the accelerator pedal module) is stored as a kick-down signal in the engine control unit.
Page 34 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 4 - Gearbox input r.p.m. sender - G182- ❑ Fitting location ⇒ page 31 ❑ is checked by self-diagnosis ❑...
Page 35 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Gearbox input r.p.m. sender - G182- Fitting location: The gearbox input speed sender - G182- is clip‐...
Page 36: Clutch
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 30 – Clutch Clutch operation ⇒ “1.1 Assembly overview - clutch release mechanism”, page 32 ⇒...
Page 37 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 gearbox up to 05.2011”, page 41 6 - Screw ❑ Replace after disassembly ❑ 8 Nm + 90°...
Page 38: Removing And Installing Clutch Release Mechanism
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 8 - Ball pin ❑ for small engaging lever Pos. 7 ❑ replace when replacing the double clutch 9 - Screw ❑...
Page 39 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Removing – Remove the small engaging bearing with the adjusting wash‐ – Remove the large engaging lever.
Page 40 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Insert the plastic support of the engaging levers and check for correct fit. Note Only some older gearboxes have no clamp.
Page 41 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 • The small engaging bearing fits in only one position due to the 4 grooves.
Page 42 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Note If all the mentioned parts are only removed and reinstalled, ♦ there is nothing to adjust.
Page 43 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Insert ball pin -2-. Installation instructions for the new engaging lever K2 The new engaging lever K2 is delivered with guide bushing upper and lower part in the transport position.
Page 44 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 In the installation position, the openings of the guide bushing bot‐ tom part lie vertically to the engaging lever and the sleeve can be moved freely at the same time.
Page 45: Adjust Clutch Release Mechanism
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Adjust clutch release mechanism ⇒ “1.3.1 Adjust clutch release mechanism, gearbox up to 05.2011”, page 41 ⇒...
Page 46 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 ces on the gearbox side and the tolerances in the clutch deter‐ mine the thickness of the adjusting washer.
Page 47 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Place the straightedge - T40100- upright on the flange of the clutch housing. Caution The straightedge - T40100- must remain in this position during the following measurements.
Page 48 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Determine dimension -A1- of the large engaging bearing for clutch • Do not insert an adjusting washer! –...
Page 49 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Position the digital depth gauge twice at opposite-facing points for a precise measurement. In this way, an even more precise value is determined as the in‐...
Page 50 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Please read off the value of the clutch tolerance from the new clutch. ♦ The clutch tolerance value you have read off for clutch K1 is 0.0 mm...
Page 51 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Determine dimension -A2- of the small engaging bearing for clutch K2. – Only insert the small bearing.
Page 52 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Position the gauge block - T10374- with the large opening up‐ wards on the small bearing.
Page 53 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Position the digital depth gauge twice at opposite-facing points for a precise measurement. In this way, an even more precise value is determined as the in‐...
Page 54 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Please read off the value of the clutch tolerance from the new clutch. ♦ The clutch tolerance value you have read off for clutch K2 is 0.4 mm...
Page 55 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Measure all the adjusting washers and prepare the corre‐ sponding adjusting washer for installation.
Page 56 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 and the tolerances in the clutch determine the thickness of the adjusting washer. Conditions •...
Page 57 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Install the old circlip of the outer drive shaft -arrow-. Determine dimension -B-. – Place the straightedge - T40100- upright on the flange of the clutch housing.
Page 58 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Measure the distance to the circlip. – Note the result and name it B 1 .
Page 59 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Insert the large engaging lever. • Do not insert an adjusting washer! – Position the gauge block - T10466- on the large engaging bearing.
Page 60 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Perform a second measurement at the opposite point of the gauge block - T10466- in the same way.
Page 61 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Please read off the value of the clutch Tolerance -arrow- from the new clutch.
Page 62 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Remove the gauge block - T10466- and remove the large en‐ gaging lever. Determine dimension -A2- of the small engaging bearing for clutch K2.
Page 63 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Only guide bushing upper part by hand. – Turn the guide bushing bottom part with your other hand in the -direction of arrow- at the same time so that the sleeve can be moved freely.
Page 64 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Insert the small engaging bearing. The small engaging bearing fits in only one position due to the 8 grooves.
Page 65 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Position the rod of the digital depth gauge on the gauge block - T10466- , as shown in the figure, and measure the distance from the shaft end.
Page 66 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Please read off and note the value of the clutch tolerance from the new clutch -arrow-.
Page 67: Clutch
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Clutch ⇒ “2.1 Summary of components - double clutch”, page 63 ⇒ “2.2 Remove double clutch”, page 66 ⇒...
Page 68 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 8 - Clamp ❑ for small engaging lever ❑ not present on older versions ❑ replace when replacing the double clutch gearbox 9 - Sealing ring ❑...
Page 69 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 2.1.2 Summary of components - double clutch as of 06.2011 1 - Hinge bearing ❑ for large engaging lever for K1 clutch ❑...
Page 70: Remove Double Clutch
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 12 - Small engaging lever for K2 clutch ❑ is removed and installed together with the top and bottom part of the guide bushing Pos. 11 and 14 ❑...
Page 71 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Detach the clutch upwards when the gearbox is removed. The mechatronics remains on the gearbox.
Page 72 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Turn gearbox so that the clutch is facing up. – Remove the circlip of the hub -arrow-.
Page 73: Install Double Clutch
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Position the supporting bridge - T10323- parallel to the flange of the clutch housing.
Page 74 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 ♦ Extractor - T10373- ♦ Supporting bridge - T10323- ♦ Thrust piece - T10368- ♦ Thrust piece - T10376- ♦...
Page 75 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Position the extractor onto the clutch. – Insert the clutch with extractor - T10373- into the gearbox and then remove the extractor.
Page 76 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Turn the clutch against the extractor - T10373- by hand so that the clutch finds its fitting position.
Page 77 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Turn the clutch by hand and, while turning it, pay attention to the small engaging lever.
Page 78: Replacing The Sealing Ring For The Outer Drive Shaft
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Replacing the sealing ring for the outer drive shaft Special tools and workshop equipment required ♦...
Page 79: Replace Gasket Ring For Inner Drive Shaft
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Drive in new shaft seal so that it is flush with the clutch housing.
Page 80 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Screw in gasket ring extractor for shaft seals - T10420- without spindle into the small inner shaft sealing ring.
Page 81: Controls, Housing
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 34 – Controls, housing Mechatronics for double clutch gear‐ box - J743- ⇒ “1.1 Summary of components - mechatronics for double clutch gearbox J743 ”, page 77...
Page 82 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 On some transmissions, a cover is present above the engaging lever. The cover protects against contamination.
Page 83: Remove Mechatronics For Double Clutch Gearbox J743 ; Gearbox Installed
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Remove mechatronics for double clutch gearbox - J743- ; gearbox installed. Special tools and workshop equipment required ♦...
Page 84 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Disconnect the battery-earth strap with the ignition off ⇒ Elec‐ trical System; Rep. gr. 27 .
Page 85 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Disconnect plug -2- at the coolant temperature sender at ra‐ diator outlet - G83- .
Page 86 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Unclip the fan shroud e.g. using a screwdriver and remove ⇒ Engine; Rep. gr. 19 .
Page 87 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Where present, remove the cover above the engaging lever. – Remove the electrical lines from the bottom holder at the front of the mechatronics and tie up.
Page 88 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Now both levers of the clutch control must be pressed off the me‐ chatronics with the assembly lever - T10407- . Otherwise the levers for mechatronics strike the tappets and the mechatronics cannot be removed.
Page 89 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Turn the assembly lever - T10407- to the left in -direction of arrow- and thus press the engaging lever away from the tappets.
Page 90 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Unscrew short screws -A- (3 screws, M8 x 35) crosswise in stages. Caution Do not remove more than 7 screws! There are 4 long and 3 short screws.
Page 91: Bringing The Mechatronics For Double Clutch Gearbox J743 To The Removal Position By Hand
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Make sure that no oil flows out of the ventilation -arrow- (close the ventilation opening with a suitable screw plug).
Page 92 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Remove the lock washer -arrow- of the selector lever control cable, the selector lever control cable must be left in the fitting position.
Page 93: Install Mechatronics For Double Clutch Gearbox J743 ; Gearbox Installed
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Install the cover and the gearshift lever again. Fill gearbox with gear oil ⇒ “5 Change gearbox oil”, page 174...
Page 94 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 • Before installing the mechatronics, make sure that no oil is in the gearbox. •...
Page 95 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 N - Neutral R - Reverse gear 1 - first gear 2 - second gear...
Page 96 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Set the 4 gear switches on the rear side of the mechatronics for double clutch gearbox - J743- into the specified position.
Page 97 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 • The seal for mechatronics for double clutch gearbox - J743- must be attached all around.
Page 98 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Incorrectly mounted tappets will damage the mechatronics. The tappets can be put into their correct positions by means of a hook made from welding wire.
Page 99 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Install the cover against contamination above the engaging lever. Caution ♦ Under no circumstances must the plug contacts in the plug...
Page 100 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Attach the bottom coolant hose at the radiator -arrow- and fill up with coolant ⇒ Engine; Rep. gr. 19 .
Page 101: Shift Mechanism
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Shift mechanism ⇒ “2.1 Summary of components - Gearshift mechanism”, page 97 ⇒ “2.2 Inspecting the gearshift mechanism”, page 104 ⇒...
Page 102 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 1 - Cover with handle ❑ removing ⇒ “2.5 Removing and In‐ stalling the cover for the shift mechanism”,...
Page 103 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 ❑ Removing and installing ⇒ “2.9 Removing and installing selector lever control cable, vehicles up to 05.2009 (Octavia II, Superb II, Yeti)”, page 123...
Page 104 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 ❑ Removing and installing handle as of 11.2012 (CW 45) ⇒ “2.6 Removing and installing handle for shift mechanism”, page 112 ❑...
Page 105 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Remove the shift mechanism together with the selector lever con‐ trol cable from the shift housing...
Page 106 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 ❑ tighten using hose binding claw - V.A.G 1275- 4 - Centre console ❑ remove it for the removal and installation procedure of the gearshift mechanism 5 - Noise insulation ❑...
Page 107: Summary Of Components - Gearshift Mechanism
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 2.1.4 Summary of components - Gearshift mechanism (Rapid India) 1 - Cover with handle ❑ Depending upon vehicle equipment ❑...
Page 108: Inspecting The Gearshift Mechanism
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 10 - Screw ❑ for cable support to gearbox ❑ 2 pieces ❑ 23 Nm 11 - Selector lever control cable ❑...
Page 109: Inspecting And Adjusting The Selector Lever Control Cable
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Selector lever in position N, button on selector lever pressed and ignition switched on •...
Page 110 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 • The selector lever must automatically jump back again to po‐ sition P. If this is not the case, then the gearshift mechanism must be set ⇒...
Page 111 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Check if the lock washer -arrow- is correctly fitted and secured towards the bottom.
Page 112: Check The Function Of The Ignition Key Removal Lock
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 The figure shows the gearbox from the rear. -P- position is in the direction towards the cable support -arrow-.
Page 113: Removing And Installing The Cover For The Shift Mechanism
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Note Up to 10.2011, this condition is not valid for the vehicles Fabia ll and Roomster, where there is no ignition key anti-removal lock and the key can be withdrawn in any selector lever position.
Page 114 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Remove cover using the release tool - T30098- . Pull up rear left and right cover -arrows-.
Page 115 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Carefully press the release tool - T30098- in -direction of arrow- and subsequently clip the cover out of the centre console.
Page 116: Removing And Installing Handle For Shift Mechanism
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Insert the plug connection -C- for lamp for selector lever scale illumination - L101- .
Page 117 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Vehicles Superb II Vehicles Fabia II, Roomster and Rapid Continued for all vehicles – Pull the cover upwards over the handle.
Page 118 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Open the warm-type clamp below the handle -arrow- and pull off handle with cover.
Page 119 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Open the warm-type clamp below the handle -arrow-. – Detach the selector lever handle -1- together with the selector lever collar from the selector lever towards the top -arrow A- so that the lock button -2- is not pressed in.
Page 120: Installing The Lock Button At The Selector Lever Handle
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Tighten warm-type clamp -arrow- using the hose binding claw . Note The selector lever handle is correctly locked only if the warm- ♦...
Page 121 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Carefully guide the release tool - T40203- in -direction of arrow- into the selector lever handle up to the stop -1-.
Page 122: Removing And Installing Shift Mechanism With Selector Lever Control Cable
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Removing and installing shift mecha‐ nism with selector lever control cable Special tools and workshop equipment required ♦...
Page 123 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Disconnect the plug connection -A- from the gearshift mech‐ anism. – Unscrew the screws -arrows- from the shift housing.
Page 124 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Remove the rear tunnel bridge -1- and the front tunnel bridge -2- from the body (if present).
Page 125 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Release the nuts -1- and -2-. Note A second mechanic is needed under the vehicle to remove the shift mechanism.
Page 126 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Insert the shift mechanism and tighten the rear nuts -1- by hand. – Mount the strut for centre console -3- onto the shift mechanism as illustrated in the fig.
Page 127: Removing And Installing Selector Lever Control Cable, Vehicles Up To 05.2009
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Carefully press the selector lever control cable -2- onto the gearshift lever and secure in the cable support with a new lock washer -1-.
Page 128 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Expose the selector lever control cable -A- from the gearbox shift lever with the removal tool for the inner lining of the door panel -MP8-602/1- .
Page 129 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Loosen the clips -arrows- and remove the heat shield to the rear. – Unscrew the nuts -1- and push the shift housing -2- as far as possible onto the selector lever control cable towards the front.
Page 130 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Caution – Pull the locking tab -3-, which secures the bolt -4-, carefully in the -direction of arrow A-.
Page 131: Emergency Release Of Gearshift Mechanism Out Of Position P
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Screw the gear shift housing onto the shift mechanism -arrows-. – Carefully press the selector lever control cable -2- onto the gearshift lever and secure in the cable support with a new lock washer -1-.
Page 132 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 If the selector lever cannot be moved out of position P despite the checks, emergency release of the solenoids must be performed.
Page 133 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Vehicles up to production date 05.2009 – Press from right to left -arrow- on the yellow plastic wedge.
Page 134: Removing And Installing The Tiptronic Switch F189
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Depress the brake pedal or pull on the handbrake. – Press the yellow plastic wedge -A- in -direction of arrow 1-.
Page 135: Checking The Plug Connections At The Shift Mechanism (Octavia Ii, Superb Ii, Yeti)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 2.15 Checking the plug connections at the shift mechanism (Octavia II, Superb II, Yeti) Before repairing or checking the plug connections, try to deter‐...
Page 136: Removing And Installing The Gearbox
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Removing and installing the gearbox ⇒ “3.1 Removing the gearbox”, page 132 ⇒ “3.2 Installing the gearbox”, page 165 ⇒...
Page 137 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Gearbox with different output shafts. A - Rigid shafts up to 11.2008 B - flange shafts as of 11.2008 –...
Page 138 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 On some engines, one of the screws is located in the assembly opening for the starter -arrow-.
Page 139 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Fit supporting device -T30099- . Note Use only one spindle of the supporting device on 1.2/77 kW en‐...
Page 140 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Unhook the plug connections -1 … 3- from the bottom bracket at the front of the gearbox and disconnect.
Page 141 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Remove the screw -arrow- and release the coupling rod from the anti-roll bar on the left side.
Page 142 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Remove the right flange shaft with the pressure spring from the gearbox with the socket insert - T10107 A- .
Page 143 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Then lower the engine and gearbox via the spindles of the supporting device - MP9-200 (10-222 A)- as far as necessary so that there is a gap of dimension -a- between the gearbox console and the gearbox mount.
Page 144 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Unscrew the last connecting screw -arrow- at engine and gearbox. – Separate the gearbox from the engine and carefully lower it.
Page 145 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 ♦ ⇒ “3 Repair instructions”, page 4 All cable straps which are detached or cut open when removing, should be fitted on again in the same place when installing.
Page 146 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 On some engines, one of the screws is located in the assembly opening for the starter -arrow-.
Page 147 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Screw on the bracket - T10346- into the rear opening for fas‐ tening the battery tray.
Page 148 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Remove pendulum support from gearbox, to do so, release the bolts -arrows B and C-.
Page 149 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Remove the screw -arrow- and release the coupling rod from the anti-roll bar on the left side.
Page 150 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Remove the right flange shaft with the pressure spring from the gearbox with the socket insert - T10107 A- .
Page 151 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Then lower the engine and gearbox via the spindles of the supporting device - MP9-200 (10-222 A)- as far as necessary so that there is a gap of dimension -a- between the gearbox console and the gearbox mount.
Page 152 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Unscrew the last connecting screw -arrow- at engine and gearbox. – Separate the gearbox from the engine and carefully lower it.
Page 153 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 ♦ ⇒ “2 Safety instructions”, page 2 ♦ ⇒ “3 Repair instructions”, page 4 All cable straps which are detached or cut open when removing, should be fitted on again in the same place when installing.
Page 154 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Remove the lock washer -arrow- of the selector lever control cable, the selector lever control cable must be left in the fitting position.
Page 155 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Position the supporting device - MP9-200 (10-222A)- as shown. Position the supporting device - MP9-200 (10-222A)- so that the supports -A- are located next to screw -arrow 1- and the support for the front flap -arrow 2-.
Page 156 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Disconnect the wiring loom of the generator, of the lambda probe after catalytic converter - G130- and of the lambda probe - G39- from the supports -arrows-.
Page 157 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Unscrew the nuts -arrows- from the steering joint on the track control arm on both sides.
Page 158 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Tie up the drive shafts as far as possible. Avoid damaging the paintwork of the drive shafts during this operation.
Page 159 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Do not undo screw -arrow- yet on the engine side in the vicinity of the right rigid shaft or right flange shaft.
Page 160 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Unscrew the fixing screws -arrows- for the console on the gearbox. – Remove the gearbox console.
Page 161 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 In some cases, they are installed at the front holder on the gear‐ box. Note If a new gearbox is installed, the holders must be modified to the new gearbox.
Page 162 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Gearbox with different output shafts: A - Rigid shafts up to 11.2008 B - flange shafts as of 11.2008 –...
Page 163 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 On some engines, one of the screws is located in the assembly opening for the starter -arrow-.
Page 164 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Unclip the rubber grommet and hook the shackle - 10-222 A/ 12- into the rear engine lifting eye.
Page 165 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Unhook the plug connections -1-, -2- and -3- from the bottom bracket at the front of the gearbox and disconnect.
Page 166 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Unscrew nut -1- from both sides of coupling rod -3-. – On both sides, remove the coupling rod -3- from the anti-roll bar -2- and press to the rear.
Page 167 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – To remove, insert 2 screws in the right flange and counterhold the flange shaft using an assembly lever.
Page 168 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Unscrew the nuts -3- from the left frame side rail and tie up the radiator fan control unit - J293- -4-.
Page 169: Installing The Gearbox
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Align arms of the gearbox mount - 3282- to match the holes in the adjusting plate - 3282/59- .
Page 170 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 ♦ Replace the self-locking nuts and screws when undertaking assembly work. ♦ Replace screws which have been tightened to a torquing angle as well as gasket rings and seals.
Page 171 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Insert the gearbox console -1- between the gearbox and the supporting arm of the gearbox mount.
Page 172 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Screw the steering joints to the track control arms -arrows- ⇒ Chassis; Rep. gr. 40 .
Page 173: Tightening Torques
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Tightening torques Fastening of gearbox to engines 1.6 l/77 kW TDI CR+; 1.8 l/118 kW TFSI on Octavia II vehicles 1.6 l/77 kW TDI CR+;...
Page 174 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 1.2 l/77 kW TSI on Octavia II, Fabia II, Roomster and Yeti vehicles Pos. Screw...
Page 175 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 ♦ Screw -arrow 2- (3 pieces) tightening torque 40 Nm + 90° ♦ Screws -arrow 1- (2 pieces) tightening torque 40 Nm + 90°...
Page 176: Transport The Gearbox And Secure To The Assembly Support
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Transport the gearbox and secure to the assembly support Special tools and workshop equipment required ♦...
Page 177 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Raise the gearbox on the assembly stand - MP9-101- Attach gearbox to assembly stand - MP9-101- –...
Page 178: Change Gearbox Oil
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 Change gearbox oil Special tools and workshop equipment required ♦ Adapter -VAS 6262A- ♦ Adapter -VAS 6262/4- ♦...
Page 179 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 The new oil is filled via the air release hole. Note If the gearbox is installed, the air filter or the battery with the bat‐...
Page 180 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Screw the oil bottle onto the adapter - VAS 6262 A- . Note If the oil dispenser thread does not match the adapter - VAS 6262 A- thread, the adapter must also -VAS 6262/6- be used.
Page 181: Gears, Shafts
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 35 – Gears, shafts Pinions and shafts At present no repairs are carried out on the pinions and shafts.
Page 182: Final Drive - Differential
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 39 – Final drive - differential Replace gasket rings for rigid shafts and flange shafts ⇒...
Page 183: Replacing Gasket Ring For Left Rigid Shaft (Octavia Ii, Superb Ii, Yeti)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 5 - Conical screw ❑ Replace after disassembly ❑ 30 Nm 6 - Sealing ring ❑...
Page 184 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 ♦ Thrust piece - T30028 (3305)- ♦ Sealing grease - G 052 128 A1- ♦ Catch pan Removing •...
Page 185 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – If present, remove front left vehicle level sensor - G78- . – Unhook the steering joint from the track control arm.
Page 186: Replacing Gasket Ring For Right Rigid Shaft (Octavia Ii, Superb Ii, Yeti)
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Fill half the space between the sealing lip and dust lip with sealing grease - G 052 128- .
Page 187 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 ♦ Socket insert - T10107A- or socket insert 6 mm, commercially available ♦ Thrust piece - T30028 (3305)- ♦...
Page 188 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Tie up the drive shaft as far as possible. Avoid damaging the paintwork on the drive shaft during this operation.
Page 189: Replacing The Left Flange Shaft Gasket Ring
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Replace the O-ring -1- at the rigid shaft. – Replace the circlip -2- at the rigid shaft.
Page 190 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 ♦ Sealing grease - G 052 128 A1- ♦ Catch pan Removing • Observe the general repair instructions ⇒...
Page 191 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Tie up the drive shaft as far as possible. Avoid damaging the paintwork on the drive shaft during this operation.
Page 192: Replacing The Right Flange Shaft Seal Ring
Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Drive in the new gasket ring with thrust piece - T30028 (3305)- up to the stop, do not twist the new gasket ring.
Page 193 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Remove the protective cap for right drive shaft from the engine -arrows-. – Remove right drive shaft from flange shaft ⇒ Chassis; Rep.
Page 194 Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fabia II 2011 ➤ , Octavia II 2004 ➤ ... Gearbox 0AM-DSG - Edition 01.2015 – Carefully drive the new gasket ring into the gearbox up to the stop, during this procedure do not twist the gasket ring.

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Skoda Fabia II 2007 Workshop Manual

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