大众7速双离合器DQ200_SSP_390_DSG_0AM.pdf

Service Training Self-study Programme 390 Design and Function The 7-speed Double-clutch Gearbox 0AM 2 The self-study programme shows the design and function of new developments. The contents will not be updated. For current testing, adjustment and repair instructions, refer to the relevant service literature. NEWAttention Note S390_002 S390_090 The new 7-speed double-clutch gearbox from Volkswagen The 7-speed double-clutch gearbox 0AM is a further development of the very successful direct-shift gearbox 02E from Volkswagen. In terms of comfort and shifting without interrupting drive, it offers the same as the direct-shift gearbox 02E. It has been designed for engines with a torque of up to 250 Nm in the Polo, Golf, Passat and Touran. Whilst the direct-shift gearbox is on a par with vehicles with manual gearbox in terms of fuel consumption, the double-clutch gearbox has succeeded in reducing fuel consumption below that of manual gearboxes by means of certain technical innovations in the gearbox. This reduction in fuel consumption makes a significant contribution towards lowering emissions and safeguarding the environment. In this self-study programme, you can find out how the new double-clutch gearbox functions and which technical highlights have helped to reduce fuel consumption. We hope you enjoy reading it. Make use of the available range of training courses for training… 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Design of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Mechatronic module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Electrohydraulic control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Oil circuit – hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Gearbox management system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Test yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Contents 4 Introduction With the new double-clutch gearbox 0AM, Volkswagen is presenting two world premieres: ●The first 7-speed gearbox for mounting transversely at the front and ●The first double-clutch gearbox with dry double clutch S390_060 Mechatronic unit Double clutch As a design feature, the dry double clutch has an extensive impact on the entire gearbox concept. In comparison with the direct-shift gearbox 02E, efficiency has once again been considerably improved thanks to the new gearbox concept. This improved efficiency makes a significant contribution towards lowering consumption and emissions. The 7-speed double-clutch gearbox 0AM is a further milestone in the Volkswagen Group's gearbox strategy, and therefore extends Volkswagen's technological advantage still further. 5 Designation 0AM WeightApprox. 70 kg including clutch Torque 250 Nm Gears7 forwards gears, 1 reverse gear Spread8.1 Operating modeAutomatic and Tiptronic modes Gearbox oil volume1.7l - G 052 171 Mechatronic unit oil volume1.0l central hydraulic/power steering box oil G 004 000 Technical data S390_003 Double clutch Mechatronic unit Design features ●Modular design of the gearbox: The clutch, mechatronic unit and gearbox each form one unit ●Dry double clutch ●Separate oil circuit, mechatronic unit and mechanical gearbox, with lifetime fillings ●7 gears on 4 shafts ●Oil pump driven subject to requirements ●No oil/water heat exchanger 6 Selector lever Actuation The selector lever is actuated as in vehicles with automatic gearboxes. The double-clutch gearbox also offers the option of shifting using Tiptronic. Precisely as in vehicles with automatic gearboxes, the selector lever is equipped with a selector lever lock and an ignition key withdrawal lock. The lock functions as before. The design is new. The selector lever positions are: P - Park To move the selector lever from this position, the ignition must be “on“ and the foot brake must be depressed. The release button on the selector lever must also be pressed. R - Reverse gear The release button must be pressed to engage this gear. N - Neutral position In this position, the gearbox is in neutral. If the selector lever is set to this position for a long time, the foot brake must be depressed again to move it from this position. D - Drive position (Normal programme) In this drive position, the forwards gears are shifted automatically. S - Sport Automatic gear selection is carried out according to a “sporty“ characteristic curve, which is 。