DSG Mechatronic & Ecu Repair Training Programmes.
DSG Mechatronic & Ecu Repair Training Programmes.
At Carmelo Institute, trading as Auto ECU Repairs, we are proud to present a cutting-edge training program dedicated to the professional development of mechanics, auto-electricians, and diagnostic technicians. Our courses are designed for those ready to master modern vehicle control technologies, focusing on two of the most intricate and in-demand areas in today's workshops: DSG Mechatronic System Repair and Engine Control Unit (ECU) Diagnostics & Repair.
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.
Key Topics Covered:
Overview of DSG / S-Tronic platforms (DQ200, DQ250, DL501, etc.)
System architecture: solenoids, clutch packs, ECU integration
Common failure symptoms: jerky shifts, gear skipping, fault codes
Diagnostics using VCDS, ODIS, Launch, and other scan tools
Valve body, solenoid, and accumulator service
Removal, disassembly, and rebuild of the Mechatronic unit
Teach-in procedures, adaptation resets, clutch calibration
Best practices for fluid service, cleanliness, and reinstallation
Ideal For: Transmission techs, diagnostic specialists, workshop owners
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.
Key Topics Covered:
ECU architecture: processor, CAN interface, memory modules
Flashing, coding, and reprogramming ECUs
Using bench tools: KESS, KTAG, Autotuner, MPPS, and more
Software fault detection (DTC mapping, EEPROM dumps)
Soldering techniques: BGA, SMD, rework stations
Repairing water-damaged or shorted ECUs
Immobiliser (IMMO OFF), tuning, and cloning techniques
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:
Introduction to dual-clutch systems: dry vs wet clutch
Overview of DSG platforms: DQ200, DQ250, DQ381, DL501, etc.
Role of the Mechatronic unit in gear shifting and clutch control
Understanding clutches, gear sets, sensors, and actuators
System integration with ECU, TCU, and CAN bus
🛠 Day 2: Common Failures & Diagnostics
Objective: Learn to diagnose DSG issues using professional tools.
Topics Covered:
Common DSG symptoms: gear skipping, jerking, failure to engage, limp mode
Interpreting fault codes and freeze frame data
Live data analysis for clutch wear, oil temperature, pressure readings
Using VCDS, ODIS, Launch, and Topdon for diagnostics
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:
Safe removal of DSG mechatronic units from vehicles
Valve body structure and solenoid function
Testing solenoids for resistance and actuation
Understanding accumulators, seals, and pressure valves
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:
Cleaning, preparation, and replacement of worn components
Seal kits, filters, and o-rings: sourcing and fitting
Reassembly of solenoids, harnesses, and pressure valves
Fluid management: correct types, levels, and bleeding
Avoiding contamination and maintaining cleanroom practices
Hands-on:
Full mechatronic rebuild in workshop environment
Quality control checklist for reassembled units
🔄 Day 5: Adaptation, Calibration & Final Testing
Objective: Complete the process with programming and vehicle testing.
Topics Covered:
Adaptation and teach-in procedures using VCDS/ODIS
Clutch calibration and pressure point adjustments
Resetting basic settings and learning values
Road testing and post-repair validation
Fluid service intervals, DSG service kits, and workshop best practices
Hands-on:
Final installation and adaptation of rebuilt unit
Simulated road test and fault-free validation
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:
What is an ECU? Purpose, types, and evolution
Internal architecture: microcontroller, EEPROM, Flash, CAN transceivers
ECU locations, connections, and vehicle system interactions
Introduction to automotive communication protocols (CAN, LIN, K-Line)
Introduction to diagnostic tools and ECU pinouts
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:
Understanding fault codes (DTCs) and how to interpret them
Setting up ECUs on a bench: power supply, boot pin, and ignition simulation
Reading ECU info (ID, VIN, mileage, software version)
Using diagnostic tools: Launch, Autel, VCDS, ODIS
Introduction to bench tools: KESS, KTAG, MPPS, Autotuner
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:
Full flash vs partial read: understanding maps and structure
Flash memory and EEPROM: function and importance
Reading and writing using KESS, KTAG, Autotuner, BDM/JTAG
EEPROM editing basics: hex viewers, checksums, and WinOLS overview
IMMO OFF, ECU virginizing, and cloning strategies
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:
Identifying and testing key components: transistors, regulators, CAN chips, resistors
Diagnosing common failures: water damage, overheating, voltage spikes
SMD and BGA soldering techniques
Using hot air stations and rework tools
Replacing damaged components (capacitors, FETs, connectors)
Tracing PCB faults and jumper wire techniques
Hands-on:
Micro soldering and component replacement on dead ECUs
ECU board diagnostics with multimeter and oscilloscope
🔄 Day 5: Advanced Repairs & Final Assessments
Objective: Apply skills to real-world repair scenarios and evaluate competency.
Topics Covered:
Case studies: dead ECU repair, injector driver faults, no communication
Final recap: hardware vs software fault tracing
Creating a structured diagnostic and repair workflow
Business application: quoting, turnaround time, repair warranty
Tips for sourcing ECUs, components, and datasheets
Hands-on:
Full diagnostic and repair of live ECUs
Simulation of customer complaints and solution pathway
Certification:
On successful completion, participants receive a Certificate of Competency in DSG Mechatronic System Repair & or Competency in Ecu Diagnostics and Repairs from the Carmelo Institute.
For More Info:
📍 Location:
6 St John Lane, Houghton Estate, Johannesburg, 2198
📞 Contact: +27 60 290 9588
🟢📱 WhatsApp: +27 60 290 9588
📧 Email: training@autoecurepairs.co.za
🌐 Website: www.autoecurepairs.co.za