DSG Mechatronic System Repair

Whether you're an experienced professional or a technician looking to grow, our courses combine deep technical theory with real-world, practical workshop training. Delivered by experts and backed by global technical standards, our programs are essential for anyone servicing VAG (Volkswagen, Audi) platforms and beyond.

ECU Diagnostics & Component-Level Repair

Our ECU training focuses on understanding, diagnosing, and repairing faults at both software and hardware levels. This course is invaluable for workshops looking to stop outsourcing ECU repairs and retain business in-house.

 DSG Mechatronic System Repair (DSG/S-Tronic: 

5 Day Course 

⚙ Day 1:System Overview & Platform Familiarization

Objective: Understand DSG/S-Tronic architecture, variants, and operational theory.

Topics Covered:

1. Introduction to dual-clutch systems: dry vs wet clutch

2. Overview of DSG platforms: DQ200, DQ250, DQ381, DL501, etc.

3. Role of the Mechatronic unit in gear shifting and clutch control

4. Understanding clutches, gear sets, sensors, and actuators

5. System integration with ECU, TCU, and CAN bus

🛠 Day 2: Common Failures & Diagnostics

Objective: Learn to diagnose DSG issues using professional tools.

Topics Covered:

1. Common DSG symptoms: gear skipping, jerking, failure to engage, limp mode

2. Interpreting fault codes and freeze frame data

3. Live data analysis for clutch wear, oil temperature, pressure readings

4. Using VCDS, ODIS, Launch, and Topdon for diagnostics

5. Troubleshooting wiring, sensors, and communication faults

Hands-on:

Connecting scan tools to live DSG systems

Diagnosing real-world fault cases

🔧 Day 3: Mechatronic Unit Disassembly & Component Testing

Objective: Disassemble the mechatronic unit and test internal components.

Topics Covered:

1. Safe removal of DSG mechatronic units from vehicles

2. Valve body structure and solenoid function

3. Testing solenoids for resistance and actuation

4. Understanding accumulators, seals, and pressure valves

5. Recognizing wear patterns and internal damage

Hands-on:

Disassembly and inspection of mechatronic units

Solenoid and valve body bench testing

🧰 Day 4: Rebuilding & Reassembly

Objective: Rebuild the mechatronic unit and reassemble to OEM standards.

Topics Covered:

1. Cleaning, preparation, and replacement of worn components

2. Seal kits, filters, and o-rings: sourcing and fitting

3. Reassembly of solenoids, harnesses, and pressure valves

4. Fluid management: correct types, levels, and bleeding

5. Avoiding contamination and maintaining cleanroom practices

6. Hands-on:

Full mechatronic rebuild in workshop environment

Quality control checklist for reassembled units

 ECU Diagnostics & Component-Level Repair

Duration: 5 Days

🔧 Day 1: ECU Fundamentals & Architecture

Objective: Build foundational understanding of ECU design, internal components, and system integration.

Topics Covered:

1. What is an ECU? Purpose, types, and evolution

2. Internal architecture: microcontroller, EEPROM, Flash, CAN transceivers

3. ECU locations, connections, and vehicle system interactions

4. Introduction to automotive communication protocols (CAN, LIN, K-Line)

5. Introduction to diagnostic tools and ECU pinouts

6. Identifying different ECU brands (Bosch, Siemens, Delphi, Magneti Marelli, etc.)

🛠 Day 2: Diagnostics & Bench Setup

Objective: Learn to diagnose ECU faults and simulate communication on the bench.

Topics Covered:

1. Understanding fault codes (DTCs) and how to interpret them

2. Setting up ECUs on a bench: power supply, boot pin, and ignition simulation

3. Reading ECU info (ID, VIN, mileage, software version)

4. Using diagnostic tools: Launch, Autel, VCDS, ODIS

5. 
   

6. Introduction to bench tools: KESS, KTAG, MPPS, Autotuner

7. Detecting corrupted software or bricked ECUs

Hands-on:

Reading ECU via OBD and bench

Preparing bench harnesses and test jigs

🧠 Day 3: Software Reading, Flashing & Cloning

Objective: Master software-level repair techniques: reading, writing, cloning, and immobiliser control.

Topics Covered:

1. Full flash vs partial read: understanding maps and structure

2. Flash memory and EEPROM: function and importance

3. Reading and writing using KESS, KTAG, Autotuner, BDM/JTAG

4. EEPROM editing basics: hex viewers, checksums, and WinOLS overview

5. IMMO OFF, ECU virginizing, and cloning strategies

6. Backing up and restoring ECU data safely

Hands-on:

Cloning ECUs

Performing IMMO OFF on sample files

🧰 Day 4: Hardware Repair Techniques

Objective: Repair ECUs at component level using precision tools and techniques.

Topics Covered:

1. Identifying and testing key components: transistors, regulators, CAN chips, resistors

2. Diagnosing common failures: water damage, overheating, voltage spikes

3. SMD and BGA soldering techniques

Using hot air stations and rework tools

4. Replacing damaged components (capacitors, FETs, connectors)

5. Tracing PCB faults and jumper wire techniques

Hands-on:

Micro soldering and component replacement on dead ECUs

ECU board diagnostics with multimeter and oscilloscope