VWSSP 850183
Service Bulletin Details
Public Details for: VWSSP 850183
Vwssp 890183 - self study program / the 2019 jetta introduction
Models from 2019
2019 VOLKSWAGEN GOLF R |
Models from 2018
2018 VOLKSWAGEN GOLF R |
Self Study Program 850183 The 7-speed Dual Clutch Transmission 0GC Design and Function - Tablet Format, Version 1.1 Volkswagen Group of America, LLC Volkswagen Academy Printed in U.S.A. Printed 5/2018 Course Number SSP 850183, Version 1.1 ©2018 Volkswagen Group of America, LLC. All rights reserved. All information contained in this manual is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen Group of America, LLC., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, nor may these materials be modified or reposted to other sites without the prior expressed written permission of the publisher. All requests for permission to copy and redistribute information should be referred to Volkswagen Group of America, LLC. Always check Technical Bulletins and the latest electronic repair information for information that may supersede any information included in this booklet. Trademarks: All brand names and product names used in this manual are trade names, service marks, trademarks, or registered trademarks; and are the property of their respective owners. Table of Contents Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Transmission Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Oil Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Mechatronic Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Knowledge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Introduction The development story behind the new 7-speed dual clutch transmission 0GC: • The dual clutch transmission 0BT made its debut at Volkswagen Commercial Vehicles with the T5 model year 2010 • The 0BT was used in the 2011 Tiguan with the designation 0BH (not for the North American Region) • A new transmission production site was set up in China. The 0BH transmission was slightly altered for that factory and was given the designation 0DE • Further developments have allowed fuel consumption and CO2 reduction, increasing efficiency. The result is the dual clutch transmission 0GC s556_077 1 Introduction The Development Goal for the 7-speed Dual-clutch Transmission 0GC The main priority during the development of the 7-speed dual clutch transmission 0GC was CO2 emission reduction. The following technical modifications have cut CO2 emissions by 6g/km compared with the dual clutch transmission 0DE: • Low-friction shaft bearings and differential bearings • Low-friction seals on the shafts • A new oil pump concept • A low-leakage hydraulic system • Low-friction transmission oil A further 1g/km of CO2 is saved with the start/stop system. Compared with the dual clutch transmission 02E/0D9, an additional CO2 reduction of 3g/ km is achieved due to the 7th forward gear in the OGC. s556_016 2 Introduction Technical Data Type of Transmission Hydraulic dual clutch transmission Number of Gears 7 forward gears and 1 reverse gear Number of Drive Shafts 2 concentric drive shafts Number of Output Shafts 2 output shafts Number of Clutches 2 wet clutches Maximum Torque 420Nm (309 lb/ft) Weight 85kg (+ 2kg auxiliary hydraulic pump) Number of Hydraulic Pumps 2 hydraulic pumps Oil Volume 7 liters s556_015 3 Transmission Design Transmission Bearings Floating Bearings Fixed and floating bearings are used for the output shafts in the dual clutch transmission 0GC. The shafts are installed in way that ensures low friction and no preload. Advantages of using fixed and floating bearings: • Heat expansion of the shaft is not critical • Changing axial loading is not critical All gears use single synchromesh and are carbon-coated. s556_008 The floating bearings are cylindrical roller bearings and are located in the clutch housing. The cylindrical roller bearings can absorb radial forces. Fixed Bearings Double Groove Ball Bearings s556_010 The fixed bearings are deep groove ball bearings and are located in the transmission housing. The deep groove ball bearings can absorb radial and axial forces. 4 s556_037 s556_036 The double groove ball bearings in the differential can absorb radial and axial forces. The small contact surfaces between the balls and the bearing races reduce the rolling resistance. Transmission Design Seals The seals on these components are low-friction: Output Shaft 1 Seals for Deep Groove Ball Bearings • Gasket on clutch cover • Seals on pressure transfer to dual clutch • Seals for deep groove ball bearings Gasket on Clutch Cover Seals on Pressure Transfer to Dual Clutch s556_070 Input Shafts 1 and 2 5 Seals for Deep Groove Ball Bearings Output Shaft 2 Oil Circuit Oil Management Oil Levels A low-friction gear oil is shared between the gears, the dual clutch and the J743 Dual-Clutch Transmission Mechatronic. The mechatronic unit has its own oil chamber. The oil cools the valve coils and reduces the operating noise. The oil level in the gear case is reduced to a minimum to avoid unnecessary churning/drag losses. G487 and G489 Gear Position Distance Sensor 1 and 3 s556_071 Oil Level in Mechatronic Unit 6 Oil Level in Gear Case Oil Circuit Oil Distribution in the Gear Case D The oil is distributed in the gear casing by the following components: • Baffle plate (A) • Oil guide with oil pick-ups (B) • Oil channel (C) E The baffle plate and the oil channel ensure a consistently low oil level in the gear casing. An oil guide ensures lubrication of the bearings on the output shafts. A B C s556_073 Baffle Plate Oil Reservoir Baffle Plate The baffle plate is located in the transmission on the clutch housing. s556_072 Design The baffle plate is a plastic cover plate with an inlet opening and a drain hole. It is bolted onto the clutch housing creating an oil reservoir. Task The baffle plate ensures a low oil level when the vehicle is moving and at higher transmission temperatures. This reduces oil churning by the gear wheels and increases the efficiency. The oil level is increased by the baffle plate being empty when the transmission is cold and the vehicle moves off. This helps the intake of oil by the pumps. 7 Function The oil for the clutches is supplied to the baffle plate via an oil channel. The oil temperature influences the filling quantity in the oil reservoir. If the oil is warm, more oil flows in than can drain out of the drain hole. The oil level in the baffle plate increases, compensating for the expansion of the oil in the gear casing. Result Unnecessary oil churning losses are avoided. Oil Circuit Oil Pumps The 7-speed dual clutch transmission has one mechanically driven hydraulic pump and one electrically driven hydraulic pump. The electrically driven hydraulic pump is the V475 Transmission Fluid Auxiliary Hydraulic Pump 1. It is driven by a brushless direct current motor. There is a changeover valve between the pumps. The Automatic Transmission Pressure Regulating Valve 4 N218 regulates the position of the piston in the changeover valve via a control line. Combustion Chamber Electric Motor for V475 V475 s556_068 N218 Changeover Valve Control Line 8 Suction Filter ATF Drain Plug for Mechatronic Unit Oil Chamber Mechanically Driven Main Oil Pump Overflow Pipe with ATF Drain Plug and Seal Oil Circuit Mechanically Driven Main Oil Pump The mechanically driven Main Oil Pump (MOP) is a vane pump. It is driven by gear teeth on the clutch pack. Task Cam Ring Supply of low-friction gear oil for: • Oil supply to the mechatronic unit Rotor Gap • Cooling and actuation of the dual clutches Housing • Cooling and lubrication of shafts and gears Cam Ring Design There are movable vanes on the rotor. The vanes create 12 chambers inside a magnetic cam ring. There is a non-return valve in the pump housing. Rotor System Pressure Pressure Side Rotor Function Vane During pumping operation, the vanes are pressed against the cam ring by the system pressure. The centrifugal forces on the vanes help seal the individual chambers. The chamber sealing is controlled according to the pump load and this optimizes the efficiency of the main oil pump. There is no system pressure when the engine is started. The slightly magnetic cam ring pulls the vanes outwards and improves the pump start-up and pressure build-up. The delivery rate per revolution is 8 cubic centimeters. Non-Return Valve 9 Vane s556_060 s556_079 Oil Circuit Changeover Valve The changeover valve is located between the main oil pump and V475 Transmission Fluid Auxiliary Hydraulic Pump 1. Task Design Function The changeover valve distributes the oil flow from the auxiliary hydraulic pump. There is a spring-loaded piston in the changeover valve. When the piston is in the rest position, the oil flow is used to supply the mechatronic unit. Changeover Valve Oil Flow from the Auxiliary Hydraulic Pump s556_041 Spring-loaded Piston Oil Flow for Cooling s556_056 Oil Flow to the Mechatronic Unit Piston in Rest Position s556_057 Control Line Piston Releases Oil Flow for Cooling If oil is forced against the piston via the control line, the oil flow is directed to cool the clutches. The non-return valve in the main oil pump prevents oil flowing to the pressure supply. 10 Oil Circuit Transmission Fluid Auxiliary Hydraulic Pump 1 V475 The Transmission Fluid Auxiliary Hydraulic Pump 1 V475 is an annular gear pump (duocentric pump). It is activated on-demand and driven by an electric motor. Task The auxiliary hydraulic pump supports the mechanically driven main oil pump with the pressure supply and with cooling, during the following conditions: • When there is a high load requirement in the low rev range • In stop-and-go traffic • In start/stop mode Housing • During idling drag Outer Ring s556_043 Design The outer ring has one more tooth than the inner gear. The inner gear and outer ring have different centering points. Line to Changeover Valve Function The outer ring and the inner gear rotate in one direction. The cavity varies during rotation due to the offset centering of the inner gear to the outer ring. When the cavity becomes larger past the suction opening, the oil is drawn in. The cavity is reduced as the pump turns towards the outlet. The oil is pushed out of the pump at the outlet and is delivered to the changeover valve. Technical data Delivery rate: approx. 3 cubic centimeters per revolution 11 Inner Gear Supply from Suction Filter Oil Circuit Transmission Fluid Auxiliary Hydraulic Pump 1 V475 This electric motor is bolted to the outside of the clutch housing. It can be replaced without opening the Transmission. Task The motor drives the auxiliary hydraulic pump. Design The motor is a brushless direct-current motor with control electronics and a position sensor on the rotor. There are cooling oil bores in the motor housing. This component is connected to the Powertrain CAN-Bus. Electric Motor Function The speed demand signal is sent from the Powertrain CAN-Bus to the Mechatronic unit, then on to the motor. The motor control module activates the motor and measures speed using the rotor position sensor. Among other things, this allows for motor seizure detection. Low-friction gear oil flows through the bores in the motor housing to the inside and cools the motor. Cooling Oil Bores s556_044 Control Unit with Connector Technical data Max. speed: Control range: Start-up time: 12 4,000rpm from 100 to 4,000rpm 50 ms Auxiliary Hydraulic Pump Oil Circuit Interaction of Hydraulic Pumps While driving, the mechatronic unit recognizes the oil demand for different driving situations. It regulates the interaction of the pumps so that sufficient oil is always available. The four operating states are: • Oil supplied by the mechanically driven main oil pump • Support of the oil supply by the auxiliary hydraulic pump • The cooling function of the auxiliary hydraulic pump • Activation of the auxiliary hydraulic pump in start/stop mode The mechatronic unit controls the changeover valve with the Automatic Transmission Pressure Regulating Valve 4 N218. The position of the piston in the changeover valve is varied using the control line. Temperature OK Q (oil flow) OK Changeover Valve Control Line N218 Mechatronic Unit s556_045 Return Valve (RV) N218 RV Changeover Valve Aux Pump MOP Oil Supply from the Mechanically Driven Main Oil Pump The mechanically driven Main Oil Pump (MOP) delivers the oil flow (Q) for the mechatronic unit. 13 V475 s556_058 The following applies to all regulating modes: The oil supply to the clutches and gear actuators always takes priority over the cooling of the clutches and the gears. Oil Circuit Support of the Oil Supply by the Auxiliary Hydraulic Pump The auxiliary hydraulic pump is activated when the mechanically driven main oil pump (MOP) is not delivering enough oil. This can occur in the following driving situations: • When there is a high load requirement in the low rev range • In stop-and-go traffic • In start/stop mode The additionally delivered oil flow passes through the changeover valve (CV) to the non-return valve (RV). The non-return valve is lifted and the oil flow from both pumps is used to supply oil. Temperature OK Q (oil flow) not OK Q (oil flow) OK N218 RV Changeover Valve Aux Pump MOP V475 s556_059 The mechatronic unit detects when the oil flow rate through the mechanically driven main oil pump is too low. 14 Return Valve (RV) Mechatronic Unit Mechatronic Unit Return Valve (RV) N218 RV Changeover Valve Aux Pump MOP V475 s556_060 The motor drives the auxiliary hydraulic pump. The oil supply is safeguarded together with the mechanical main oil pump. Oil Circuit Cooling Function of the Auxiliary Hydraulic Pump If, at low engine speeds, the mechatronic unit calculates a high temperature at the clutches, it will activate the Auxiliary Hydraulic Pump (AP) and Automatic Transmission Pressure Regulating Valve 4 N218. The Changeover Valve is operated by the control line. The oil delivered by the auxiliary hydraulic pump now cools the clutches. Temperature not OK Q (oil flow) OK Q (oil flow) OK N218 RV Changeover Valve Aux Pump V475 s556_0561 The mechatronic unit calculates a temperature that is too high at the clutches (T not OK). Return Valve (RV) Mechatronic Unit Mechatronic Unit Return Valve (RV) MOP 15 Temperature OK N218 RV Control Line Changeover Valve Aux Pump MOP V475 s556_062 Activating the auxiliary hydraulic pump (AP) and the N218 ensures additional cooling of the clutches (T OK). Oil Circuit Activation of the Auxiliary Hydraulic Pump in Start/Stop Mode If, at low engine speeds, the mechatronic unit calculates a high temperature at the clutches, it will activate the auxiliary hydraulic pump and the Automatic Transmission Pressure Regulating Valve 4 N218. The changeover valve is operated by the control line. The oil delivered by the auxiliary hydraulic pump now cools the clutches. Temperature OK Temperature OK Q (oil flow) OK Mechatronic Unit Return Valve (RV) Brake Applied N218 RV Changeover Valve Aux Pump MOP V475 s556_063 No oil is pumped when the combustion engine is switched off. 16 Return Valve (RV) Mechatronic Unit Q (oil flow) OK Brake Not Applied N218 RV Changeover Valve Aux Pump MOP V475 s556_064 When the driver releases the brake, the auxiliary hydraulic pump (AP) is activated during the starting procedure. Mechatronic Unit Overview of Mechatronic Unit The following illustrations show the design of the mechatronic unit with the sensors and actuators. G612 Sensors G487 G632 G489 Key G487 Gear Position Distance Sensor 1 G488 Gear Position Distance Sensor 2 G489 Gear Position Distance Sensor 3 G490 Gear Position Distance Sensor 4 G612 Transmission Input Speed Sensor 2 (drive shaft 2) G632 Transmission Input Speed Sensor 1 (drive shaft 1) The following two senders have been integrated into the mechatronic unit and are not visible from the outside: G545 Hydraulic Pressure Sensor 1 (measures the actuation pressure on clutch K1) G546 Hydraulic Pressure Sensor 2 (measures the actuation pressure on clutch K2) s556_047 G490 17 G488 Mechatronic Unit Actuators The Sub-transmission Valves N436, N440 and N472 are pilot valves. They regulate the position of a downstream modulating piston. The Pressure Regulating Valve N218 influences the direction of the oil flow from the auxiliary hydraulic pump in the changeover valve. Electrical Connection N435 Key N439 N218 Automatic Transmission Pressure Regulating Valve 4 (actuates the changeover valve) N433 Sub-transmission 1 Valve 1 (operates the gear actuator for gears 1 and 5) N440 N434 Sub-transmission 1 Valve 2 (operates the gear actuator for gears 3 and 7) N435 Sub-transmission 1 Valve 3 (actuates clutch K1) N436 Sub-transmission 1 Valve 4 (safety valve 1) N437 Sub-transmission 2 Valve 1 (operates the gear actuator for gears 2 and 6) N438 Sub-transmission 2 Valve 2 (operates the gear actuator for gears 4 and R) N439 Sub-transmission 2 Valve 3 (actuates clutch K2) N440 Sub-transmission 2 Valve 4 (safety valve 2) N471 Cooling Oil Valve (regulates the flow rate for cooling oil requirements) N433 N471 N436 N434 N472 N438 N472 Main Pressure Valve (regulates the working pressure) DBV Pressure Relief Valve DBV s556_046 N218 N437 18 Mechatronic Unit Low-leakage Valve Control The low-leakage valve control is a combination of a 3/3-way proportional valve (pilot valve) with a downstream modulating piston. When no current is supplied to the pilot valve, the modulating piston opens the return for sub-Transmission 1 (SG1). This configuration allows for the working pressure to be regulated by low pressure. Pilot Valve Advantages: • The solenoid in the 3/3-way proportional valve is small, requiring only a low control pressure to operate the modulating piston. This saves space and weight No Current Return • The solenoid has a low power consumption Inflow Further Explanation: The term oil pressure (control pressure) is used in a closed hydraulic system. If a valve (gear actuator valve) opens the hydraulic system, the term oil flow rate is used. The delivered oil flow rate maintains the oil pressure in the opened system. Modulating Piston Spring Control Line Supply and Return SG1 19 s556_081 Mechatronic Unit Pilot Valve (Sub-transmission 1 Valve 4 N436) Solenoid Task Armature The pilot valve regulates the position of the modulating piston. Design The pilot valve contains a solenoid, an armature and a piston. s556_049 Control Edge Function Control Edge A magnetic field is created when the solenoid is energized. This moves the armature with the piston up and down inside a cylinder. The position of the piston is set by means of an equilibrium of forces between the strength of the magnetic field and the pressure applied to the modulating piston. The control edges on the cylinder modulate the control pressure acting on the modulating piston. Modulating Piston (SV1) Piston Cylinder Control Line from Pilot Valve Control Chamber Spring Task The modulating piston supplies the gear and clutch actuators in subtransmission 1 with low-friction gear oil. Control Chamber Design Valve Body Modulating Piston 20 s556_075 The spring-loaded modulating piston is located in the valve body of the mechatronic unit. The modulating piston is located between two control chambers. Control Line Regulated Oil Volume Mechatronic Unit Pilot Valve Function Full Current When a stronger current is supplied to the solenoid, the armature moves downward with the piston. The supply is opened by the restrictor and the control pressure passes from the pilot valve to the left-hand control chamber of the modulating piston. Return Inflow Unequal Forces Modulating Piston s556_074 The modulating piston is pushed against the spring because a lack of equilibrium between the left-hand control chamber and the right-hand control chamber. Right-hand Control Chamber Left-hand Control Chamber High Oil Flow Rate to SG1 s556_083 Left-hand Control Chamber Equal Forces Spring Modulating Piston Right-hand Control Chamber The regulated oil flow reaches sub-Transmission 1 (SG1) through the open modulating piston. At the same time, part of the oil flows through the control line to the right-hand control chamber. Together with the spring, the oil pushes the modulating piston against the control pressure from the pilot valve. It establishes an equilibrium of forces. Left-hand Control Chamber 21 s556_084 High Oil Flow Rate to SG1 Control Line Mechatronic Unit Pilot Valve Varying Current If the current to the solenoid is reduced, the control pressure from the pilot valve to the regulating valve is also reduced. Return Inflow Unequal Forces Modulating Piston s556_082 The modulating piston will be moved to the left by the spring, reducing the oil flow to sub-transmission 1. At the same time, less oil flows to the right-hand control chamber. Right-hand Control Chamber Low Control Pressure on Modulating Piston s556_086 Left-hand Control Chamber Spring Equal Forces Modulating Piston Right-hand Control Chamber An equilibrium of forces between the left-hand and right-hand control chamber is established again. The oil flow rate to sub-transmission 1 (working pressure) is regulated by applying a low control pressure to the modulating piston (low pressure) because of this. 22 Left-hand Control Chamber s556_085 Low Oil Flow Rate to SG1 Control Line Mechatronic Unit Hydraulics Diagram DBV N472 N218 MP CV MOP V475 VOL BP SG1 SG2 N471 RD N436 SV1 N440 SV2 VS N433 N434 G487 N435 K1 G488 G545 23 N439 K2 N437 G490 G546 N438 G489 R See next page for Legend Mechatronic Unit Hydraulics Diagram Legend G487 Gear Position Distance Sensor 1 N440 Sub-transmission 2 Valve 4 (safety valve 2) G488 Gear Position Distance Sensor 2 N471 Cooling Oil Valve (regulates the flow rate for cooling oil requirements) G489 Gear Position Distance Sensor 3 N472 Main Pressure Valve (regulates the working pressure) G490 Gear Position Distance Sensor 4 V475 Transmission Fluid Auxiliary Hydraulic Pump 1 G545 Hydraulic Pressure Sensor 1 (measures the actuation pressure on clutch K1) BP Bypass Valve G546 Hydraulic Pressure Sensor 2 (measures the actuation pressure on clutch K2) DBV Pressure Relief Valve N218 Automatic Transmission Pressure Regulating Valve 4 (actuates the changeover valve) K2 Clutch 2 N433 Sub-transmission 1 Valve 1 (operates the gear actuator for gears 1 and 5) MP Main Pressure Valve N434 Sub-transmission 1 Valve 2 (operates the gear actuator for gears 3 and 7) N435 Sub-transmission 1 Valve 3 (actuates clutch K1) N436 Sub-transmission 1 Valve 4 (safety valve 1) N437 Sub-transmission 2 Valve 1 (operates the gear actuator for gears 2 and 6) N438 Sub-transmission 2 Valve 2 (operates the gear actuator for gears 4 and R) CV Changeover Valve K1 Clutch 1 MOP Main Oil Pump RD Residual Pressure Valve (regulates the cooling oil pressure to 3 bar) SG1 Sub-transmission 1 SG2 Sub-transmission 2 SV1 Safety Valve 1 SV2 Safety Valve 2 VOL Volume Regulating Valve VS Valve, Spray Pipe N439 Sub-transmission 2 Valve 3 (actuates clutch K2) Working Pressure Circuit Cooling Circuit Return Return 24 Service Maintenance Information about Towing The DSG oil must be changed at the maintenance intervals specified in ELSAPro. The drain plug is located at the rear of the gear case. There is no need to change the oil filter. The filter has been designed for lifetime use. If a vehicle with the 0GC transmission has to be towed, the usual restrictions for automatic transmissiones need to be observed: • Turn ON ignition The following general steps should be performed when changing the oil: • Oil temperature of 35°C–45°C • Turn OFF the engine • Set the selector lever to the “P” position • Wait 4–5 minutes before draining • Activate the manual release mechanism for the parking lock • Move the selector lever to the “N” position • The maximum towing speed is 50km/h • The maximum towing distance is 50km • If you tow the vehicle with a raised axle, then only raise the front axle. Reason The reason for the waiting time is: The oil in the baffle plate needs time to drain into the gear case. You will find exact details on the oil change in the repair manual. * Always verify the correct procedure in ElsaPro! ElsaPro has the latest information in case procedures change. 25 If the engine is not running, the oil pump will not be driven and certain parts in the transmission will not be lubricated. If you do not observe the towing requirements, serious transmission damage may result. Please observe the further descriptions and information on the topic of towing in the owner's manual. Knowledge Assessment An on-line Knowledge Assessment (exam) is available for this Self-Study Program. The Knowledge Assessment may or may not be required for Certification. You can find this Knowledge Assessment at: www.vwwebsource.com For Assistance, please call: Volkswagen Academy, Certification Program Headquarters 1-877-791-4838 (8:00 a.m. to 8:00 p.m. EST) Or, E-mail: [email protected] 26 Volkswagen Group of America 2200 Ferdinand Porsche Drive Herndon, VA 20171 May 2018