DSG Remap , DSG Tuning

I can offer both DSG Tuning and Engine Tuning upon request.

After a while some people tend to get bored with their car and will want to start improving the performance and make some modifications to their cars. Some people will want tuning , other will want styling. Those that want tuning will always try to push their car to the limits in order to achieve better performance, a better driving experience, a bit more adrenaline.

As we know there are quite a few modifications that can be done to an engine in order to achieve better performance, and once you have started tuning your engine on a car with DSG gearbox, sometimes you will also want more from your gearbox. There is not much you can change on a manual gearbox without splitting it apart, but on the DSG field there are new possibilities.

Many modifications can be made to the software inside the DSG Gearbox (actually in the software of the Mechatronic unit) in order to have a better car. Some of the most common DSG Tuning that can be done:

- Custom D and S program
- Increased Torque limiter
- Torque capacity upgrade to 450-500Nm
- Quiker Shifting time
- Max. shifting RPM
- Less unwanted use of 1st gear
- Raised downshift rpm
- Deactivation of automatic up-shift in M
- Modified gear ratio control for longer gears
- Paddle activation
- Modified launch control rpm
- Disable Kick Down in M-Mode

- Indivdual calibration of the shifting maps in D- or S- Mode

And many more individual settings.

In order to achieve the best out of your DSG Remap software I would need to know if your car is remapped and if possible to provide the remap for me. If this is not possible you might experience clutch slipping because of overboost or because the boos is built up to fast for the DSG to clamp.

If you need any DSG tuning file please contact me by mail at jaxelos @ gmail.com and will see what can be done for you.

DSG 02E Advanced ID, DSG6 DQ250 VCDS Advanced ID

Most people send me questions regarding what mechatronic units will fit into their cars and in order to be able to answer to this questions I need to know the ID of the current unit installed in the car.

Here you can see how to get a proper Advanced ID of the DSG6 Mechatronic unit using VCDS from Ross Tech.

This information is necessary to determine the proper software that needs to be flashed on a mechatronic unit in case you want to change mechatronic units.
I will later post same procedure with VAS and VCP.

Flashing / Programming DSG7 DQ200 Mechatronic unit 0AM927769D using VAS

Short video on how to flash the DSG7 0AM927769D DQ200 mechatronic units with wet clutch using VAS 5054. This units can be found on many DSG7 cars and are mostly sold blank so you will need to flash them with the correct software before installing them in the car.
This video is added by request from many users. If you want me to add other videos , let me know what would you like to see and I will do my best to add it.



I ALWAYS recommend VAS head for flashing and VAS , Odis or VCP for slashing SGO files. 

.....
VAS Is no longer such a good idea for flashing as it is very old and only compatible with Windows XP and Windows 7 , so I recommend using ODIS.

Changing DSG Solenoids

Here is how to change the DSG Solenoids on a Mechatronic unit from the DSG 6 02E DQ250

Cleaning DSG 6 Mechatronic unit

Here below is one of my old videos while I dismantled and put back together the DQ250 Mechatronic unit.
Some more videos will come soon. This was a defective unit and I have made the video just for documentation.
It was a long long time time ago :)

 

DSG 02E Gearbox Recommendations

DSG it is pretty strong in terms of mechanics , If you want to keep your DSG gearbox in good condition I would recommend the following :

- Changing oil before the 60.000km indicated in the book (I recommend 40-45.000km as the gearbox is very sensitive about oil quality and you can never drain it all)
- Do not overheat the car and do not push it to its limits when HOT.
- Keep the engine in good working condition (smallest problems can influence how the gearbox changes and reacts).
- Once in a while check the rear wheel bearings on the rear wheels (they have the ABS rings built in) and if you feel they are noisy change them.
- Do not drive with the car in water that can go above your DSG connector on the gearbox.
- Keep the engine room clean and once in a while (every 2-3 years) clean all the earth connections in the engine bay.
- Check your fuel filter for oil residues and change it regularly. (On some engines the vacuum pump tends to leak oil)
- Check the condition of the DMF and if it's noisy or it has play, change it before it damages the clutches, drive shafts.
- Check Cooling fluid level regularly and if it drops below level and you can not see where the water goes, check gearbox oil for contamination. DSG oil coolers tend to break and oil contamination will occur.

- Check your Engine Mounts and Gearbox Mount , worn mounts can cause discomfort when changing gears, cause "clank" noises and so long.

Need Help ? Tech Support

If you need parts or you have any problems with your DSG Gearbox of the Mechatronic unit please drop me an e-mail at jaxelos @ gmail.com and I would be more than happy to help if I can.

I can fix /repair Mechatronic units including the circuit boards if necessary.

BEFORE YOU SEND ME ANY QUESTIONS regarding problems with your DSG gearbox make sure you have checked the following: 

• ALL YOUR ABS Sensors are working in perfect condition. You can log the signal of all 4 sensors with the VCDS Tester. or VCP. The most important one here is the REAR wheel sensors.
• Make sure your diesel filter is changed and not filled up with oil.
• You changed the DSG oil and filter and you performed the DSG Adaptation correctly.
• You have no other errors on the engine control management.
• Your EGR Valve is in good working condition and engine runs as it should.
• CHECK your VACUUM Pump and be sure there are NO OIL LEAKS that will reduce the Vacuum necessary for the perfect working condition of the engine.

In order to get a better overview of your problem please try to DESCRIBE the problem as good as possible but do no write me a whole novella.
Remember to say "HI" and present yourself so I know who I am writing with and please
tell me from where you are!

I will NOT answer e-mails like this :

"I have a problem with my DSG, please help me"
or
"Do you have a file for DSG6 6?"
or similar e-mail. I will try to help the people who really need the help but please do not waste my time.
If you have a LOG file with the errors of the car please SEND the log file along with the e-mail.
Send me some details about the car also : Make, model, year, engine code, gearbox code,VIN number and please try to get the error codes... as many details about the problem as possible.

I RECEIVE INSANE HUGE AMOUNTS OF E-MAIL RELATED TO DSG PROBLEMS LATELY AND I SIMPLY
DO NOT HAVE TIME TO ANSWER EVERYBODY ANYMORE , SORRY !!

WITH MANY PEOPLE I USE DAYS TO TRY AND DIAGNOSE A PROBLEM AND AT THE END I DO NOT EVEN RECEIVE A "THANKS".

IF YOU THINK MY TIME IS WORTH SOMETHING AND YOU REALLY NEED MY HELP PLEASE MAKE A SMALL DONATION TROUGH PAYPAL.

DSG 02E Common Problems DQ250

Some of the most common symptoms of a Mechatronic Failure are :

• Flashing PRNDS in the Dash and the gearbox will switch to neutral.
• Hard engaging of the 1st gear (slams into the first gear) from a stand still point.  This can sometimes also be caused by a decallibration of the clutches so you might be able to "save the day"  by performing a recalibration with a VCDS cable. Procedure can be found on Ross Tech website. *
• Hard downshifting from 3 to 2 and 2 to 1st gear followed by some loud "clunk" noises. *
• Shaking / juddering feeling while in 2nd gear and the car pulls up. *
• Jerking between gears *
  * This problems can be caused by worn valves. Changing the affected valve might solve your problem.
• Loss of power between 1300-2000 RPM. Car feels like dead

If you have any other experiences please let me know, I will add them.

For whoever needs I can supply electronic parts for the DQ250 DSG Mechatronic / Mechatronik units.

18222 P1814 Pressure Control Valve 1 (N215), Open / Short to Ground **
18223 P1815 Pressure Control Solenoid 1 (N215), Short to B+ **
18226 P1818 Pressure Control Solenoid 2 (N216), electrical malfunction **
18227 P1819 Pressure Control Solenoid 2 (N216), Open / Short to Ground **
18228 P1820 Pressure Control Solenoid 2 (N216), Short to B+ **

** This errors can be caused by insufficient oil in the gearbox. Please check the level and the quality of oil first.

18231 P1823 Pressure Control Solenoid 3 (N217), electrical malfunction
18232 P1824 Pressure Control Solenoid 3 (N217), Open / Short to Ground
18233 P1825 Pressure Control Solenoid 3 (N217), Short to B+
18236 P1828 Pressure Control Solenoid 4 (N218), electrical malfunction
18237 P1829 Pressure Control Solenoid 4 (N218), Open / Short to Ground
18238 P1830 Pressure Control Valve 4 (N218), Short to Plus
18241 P1833 Pressure Control Solenoid 5 (N233), electrical malfunction
18242 P1834 Pressure Control Solenoid 5 (N233) Open / Short to Ground
18243 P1835 Pressure Control Solenoid 5 (N233) Short to B+
18246 P1838 Pressure Control Solenoid 6 (N371), electrical malfunction
18247 P1839 Pressure Control Solenoid 6 (N371) Open / Short to Ground
18248 P1840 Pressure Control Solenoid 6 (N371) Short to B+

  The following error is most likely caused by a mechanical problem but can also be an error on the Mechatronic unit:

19143 - Unexpected / Implausible Mechanical Gear Disengagement
P2711 - 004 - - Intermittent

 

VAG DSG Problems..

Currently, the world of transmission is dominated in Europe by manual gearboxes and in the USA and
Japan by automatic gearboxes. Both types of gearboxes have specific advantages and disadvantages.
The advantages of a manual gearbox are, for example,
• high degree of efficiency
• robust and sporty characteristic.
The advantages of an automatic gearbox are, for example,
• a high level of comfort, above all in gear changes, as there is no interruption in tractive power.
This formed the framework for Volkswagen to combine both transmission concepts into one completely
new gearbox generation: the direct shift gearbox.

Thanks to the double multi-plate clutch design and different automatic gear selection programmes, it is
well capable of meeting the high demands in comfort from drivers who favour automatic gearboxes.
Furthermore, with direct selection and lightning fast, jolt-free gear changes, it also offers a high level of
driving enjoyment to drivers who favour manual gearboxes.
In both cases, fuel consumption is at a par with economical vehicles fitted with manual gearboxes.

Well, like all gearboxes, the DSG Gearbox has it's problems also.
Although it is a strong gearbox some components are still pron to fail , in this case the mechatronic units , the heart of the gearbox, it is was not built as strong as VW thought it was.
It seems that most affected cars are the VW Passat , VW Touran and the VW Golf produced between 2003 and 2007. I have only seen a few Skoda and a few Seat.

But there is a problem with this DSG Gearboxes, it's the Mechatronic unit. This unit sits inside the gearbox and it gets pretty hot and sometimes the electric valves will get defective. Also a common problem with the DQ250 Mechatronic unit is a faulty TCM electronic module. This is mostly seen when the gearbox oil temperature goes above 40 degrees Celsius and we will start seeing error codes as "18222 P1814 Pressure Control Valve 1 (N215), Open / Short to Ground" or some other Short to Ground errors on the other valves.

Most of the valves can be refurbished but until now I have never seen anyone being able to refurbish the Pressure Control N215 or Pressure Control N216.

DSG Manuals

Before you start take a few moments to study this manuals I have here for you :

• Self-study programme is designed to help you understand the Direct Shift Gearbox
• The DSG Dual-Clutch Gearbox Environmental Commendation – Background Report
• 6-Speed Automatic Transmission 09G/09M Design and Function
• DSG 02E Repair Manual
• Double clutch gearbox 02E (DSG) Electric Connections VW Golf
• Dual clutch gearbox 02E Electrical Connections - Passat

Read them , they might be useful to you some day :) I know they have been for me.

About DSG Gearboxes

"A direct-shift gearbox (German: Direkt-Schalt-Getriebe[1]), commonly abbreviated to DSG, is an electronically controlled dual-clutch multiple-shaft manual gearbox, in a transaxle design – without a conventional clutch pedal, and with full automatic,or semi-manual control. The first actual dual-clutch transmissions derived from Porsche in-house development for 962 racing cars in the 1980s.

In simple terms, a DSG is two separate manual gearboxes (and clutches), contained within one housing, and working as one unit. It was designed by BorgWarner, and was initially licensed to the Volkswagen Group, with support by IAV GmbH.By using two independent clutches,a DSG can achieve faster shift times,and eliminates the torque converter of a conventional epicyclic automatic transmission." - From Wikipedia

    I have decided to dedicated the whole site to the VAG DSG Gearboxes and Mechatronic units. Information will be added graduate or upon request. You will also be able to find here DSG DQ250 Gearbox manuals, DSG Repair Manuals, DSG Pressure Control Valves information and many other things related to the DSG Mechatronic units and gearboxes.

    If you need DSG Mechatronic Solenoid / Valve take a look in the VAG DSG Gearbox section.
    Standard and custom software for the 02E DQ250 DSG 6 gearbox and DQ200 DSG 7 gearboxes also available upon request.