Transmision Automatica VW-AUDI 09G

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Service Department. Technical Information

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Repair Group
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00 - Technical data
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32 - Torque converter
37 - Controls, housing
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38 - Gears, control
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39 - Final drive - differential
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2011 Volkswagen AG, Wolfsburg K0258992320

CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Passat 200 ...
6-speed automatic gearbox 09G - Edition 07.2011
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Automatic gearbox control unit J217 with fuzzy logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.5 Control units in vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.6 Information on „09G gearbox“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.7 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.8 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.9 Gaskets, seals and oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.10 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.11 Electrical components . . . . . . . . . . . . . . . . . . .e.n.A.G.. V. o.lk.s.w.ag. e.n.A.G. . . . . . . . . . . . . . . . . . . . 4
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1.12 Guided fault finding, vehicle self-diagnosis oand
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2 Capacities . . . . . . . . . . . . . . . . . .o.ris.e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.nt.e. . . . . . . . . . 5
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2.1 Planetary gearbox and final drive au . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c . . . . . . .
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3 Code - engine allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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3.1 Gearbox codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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4 Golf 2004 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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5 Golf Plus 2005 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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6 Golf 2009 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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7 Touran 2003 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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8 Passat 2006 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9 Passat CC 2009 ►, CC 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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32 - Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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1 Proper handling and installation of torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.1 Identification of torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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1.2 Draining torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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1.3 Removing and installing torque converter oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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1.4 Installing torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 n in

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37 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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1 Connecting »tester« . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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1.1 Connecting vehicle diagnosis, testing and information system VAS 5051 . . . . . . . . . . . . 16
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2 Electrical and electronic components and their locations . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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3 Multifunction switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.1 Removing multifunction switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Installing multifunction switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Adjusting multifunction switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4 Emergency release of selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1 Moving pushbutton to installation position in the handle . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6 Selector mechanism up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.1 Overview of selector mechanism up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2 Removing and installing selector mechanism with selector lever . . . . . . . . . . . . . . . . . . . . 34
6.3 Removing and installing selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.4 Checking selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.5 Adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7 Selector mechanism from 03.2009 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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7.1 Overview of selector mechanism in vehicles from 03.2009 onwards . . . . . . . . . . . . . . . . . . 45

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8 Checking selector mechanism . .u.tho. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e.e o.r . . . . . . . 48
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8.1 Selector lever in „P“ position andss ignition switched on . . . . . . . . . . . . . . . . . . . . . .c. . . . . . 48
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8.2 Selector lever in „N“ position and ignition switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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8.3 Selector lever in position „Tiptronic“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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8.4 Ignition and light switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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8.5 Selector lever position display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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9 Removing and installing gearbox, Golf 2004 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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9.1 Removing gearbox, Golf 2004 with 1.6 l - 75 kW, 1.6 l - 85 kW (FSI) and 2.0 l - 110 kW (FSI)
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9.2 Installing gearbox, Golf 2004 with 1.6 l - 75 kW, 1.6 l - 85 kW (FSI) and 2.0 l - 110 kW (FSI)
engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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9.3 Removing gearbox, Golf 2004 with 2.5 l - 110 kW and 125 kW engines . . . . . . . . . . . . . . 55
9.4 Installing gearbox, Golf 2004 with 2.5 l - 110 kW and 125 engines . . . . . . . . . . . . . . . . . . 63
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9.5 Torque settings, gearbox to engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

10 Removing and installing gearbox, Golf Plus 2005 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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10.1 Removing gearbox, Golf Plus 2005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

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10.2 Installing gearbox, Golf Plus 2005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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11 Removing and installing gearbox, Touran 2003 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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11.1 Removing gearbox, Touran 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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11.2 Installing gearbox, Touran 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

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12 Removing and installing gearbox, Passat 2003 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
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12.1 Removing gearbox, Passat with 1.6 l - 85 kW and 2.0 l - 110 kW engines . . . . . . . . . . . . 88
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12.2 Installing gearbox, Passat with 1.6 l - 85 kW and 2.0 l - 110 kW engines . . . . . . . . . . . . . . 94
12.4 Removing gearbox, Passat with 1.8 l - 118 kW and 2.0 l - 147 kW engines . . . . . . . . . . . . 96
12.5 Installing gearbox, Passat with 1.8 l - 118 kW and 2.0 l - 147 kW engines . . . . . . . . . . . . 102
13 Removing and installing gearbox, Passat CC 2009 ►, CC 2010 ► . . . . . . . . . . . . . . . . . . 105
13.1 Removing gearbox, Passat CC 2009, CC 2010 with 2.0 l 147 kW TFSI engine . . . . . . . . 105
13.2 Installing gearbox, Passat CC 2009, CC 2010 with 2.0 l 147 kW TFSI engine . . . . . . . . . . 113
14 Removing and installing gearbox, Golf 2009 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
14.1 Removing gearbox, Golf 2009 with 2.5 l - 125 kW engine . . . . . . . . . . . . . . . . . . . . . . . . . . 116
14.2 Installing gearbox, Golf 2009 with 2.5 l - 125 kW engine . . . . . . . . . . . . . . . . . . . . . . . . . . 124
14.3 Torque settings, Golf 2009 with 2.5 l - 125 kW engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
15 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
16 ATF cooler for 1.6 l - 85 kW and 2.0 l - 110 kW engines . . . . . . . . . . . . . . . . . . . . . . . . . . 128
16.1 Assembly overview - ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
17 ATF lines, ATF water cooler and additional ATF cooler, Passat with 2.0 l TFSI engine . . 129
17.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
18 Checking ATF level and topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
18.1 Checking ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
18.2 Topping up ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
18.3 Draining and filling ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
38 - Gears, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

1 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2 Removing and installing ATF pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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2.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

3 Removing and installing ATF strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4 Removing and installing valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4.1 Overview - valve chest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4.2 Removing valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.3 Installing valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.4 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5 Removing and installing wiring harness for solenoid valves and senders . . . . . . . . . . . . . . 155
5.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
6 Removing and installing gearbox input speed sender G182 . . . . . . . . . . . . . . . . . . . . . . . . 156
6.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
6.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7 Removing and installing gearbox output speed sender G195 . . . . . . . . . . . . . . . . . . . . . . 157
7.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . g.e.n.A.G.. V. o. lk. s.w.a.ge. n. A. G. d. . . . . . . . . . . . . . . . . . 157
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39 - Final drive - differential . . . . . . . . . . . is.e. . . . . . . . . . . . . . . . . . . . . . . . u.ar.an.t . . . . . . . 158
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1 Renewing oil seals for flange shaftsauth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.r a. . . . . .
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1.1 Renewing oil seal for left flange shaft .......................................... 158
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1.2 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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Contents iii
AG. Volkswagen AG d
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CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤d ,byGolf
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6-speed automatic gearbox 09G - Edition
horis 07.2011 nte
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iv Contents
00 – Technical data
1 General repair notes
Edition 01.2011, version 10.0
To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Obviously, the basic rules for safety also apply dur‐
ing repair work.
A number of generally valid instructions applicable for the various
repair procedures - which were formerly repeated a number of
times at numerous places in the workshop manual - are summar‐
ised here. They apply to this workshop manual.
1.1 Gearbox
The „automatic gearbox 09G“ has six hydraulically actuated for‐
ward gears. When the torque converter lock-up clutch closes,
2nd, 3rd, 4th, 5th and 6th gears become mechanically driven
gears by eliminating torque converter slip.
1.2 Torque converter

The torque converter is equipped with a lock-up clutch. The lock-
up clutch locks up depending on load and speed. The 2nd, 3rd,
4th, 5th and 6th gears can be driven mechanically (without slip).
1.3 ATF
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Use only ATF which hasy been Volks ordered as a part from the ot ⇒
gu Elec‐
tronic parts catalogue ised„ETKA“ .
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The ATF levelss ain
ut the planetary gearbox and final drive are ra
c
checked and topped
s up together.
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1.4 Automatic gearbox control unit -J217-

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with ⇒ fuzzy logic

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The gear change point, which is dependent on the driving situa‐

h re
tion and driving resistance, is determined automatically.

ole,
spec
Advantages:
t to the co
• Gear changes will be fuel-consumption orientated.

• Maximum engine output is always available.
rrectne
• Individual adaptation of gear change points in all driving sit‐

uations.
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• Gear change points are infinitely variable.

inform
mer
1.5 Control units in vehicle

atio
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The installation locations of all vehicle control units and other

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useful information can also be found here ⇒ Current flow dia‐

t
sd
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grams, Electrical fault finding and Fitting locations.

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1.6 Information on „09G gearbox“

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Design and function of gearbox rig ht
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♦ ⇒ Multimedia training; Automatic gearbox 09G Prote
cted AG.
agen
♦ ⇒ Self-study programme No. 291 ; Automatic gearbox 09G
1. General repair notes 1

1.7 Tools
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A summary of the special tools and Vworkshop
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the workshop manual precedeseeach db
y repair procedure and can ua
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be found in „Special tools/Workshop
thoris equipment“ binder. tee
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The catalogue is also available
ss on ⇒ CD-ROM and can be ordered c
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the usual way from Bertelsmann.
un
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Uncertainty often occurs with smaller bolts having low tightening
y li
rm
ab
forces. Torque wrench 2...10 Nm -V.A.G 1783- can be used with
pe
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these bolts.
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1.8 Gearbox
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♦ If gearbox covers have been unbolted or gearbox has no fluid,
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do not run engine or tow vehicle.
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♦ First thoroughly clean connecting points and surrounding

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areas and then loosen bolts. en

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♦ When installing the gearbox, ensure that dowel sleeves be‐
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♦ Place removed parts on a clean surface. Cover parts to pre‐
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vent soiling. Use plastic sheeting and paper. Use lint-free
cloths only!
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing.
♦ If repair work cannot be performed immediately, carefully cov‐
er or seal components.
♦ With gearbox removed, secure torque converter against falling
out.
Gearboxes with and without filler pipe
Here is an »example« with a filler pipe as it is installed in »older«
gearboxes. This pipe has been discontinued.
2 Rep. gr.00 - Technical data

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➤ , Golf 2004 ➤ , Golf 2009 ➤ ,aGolf ran Plus 2005 ➤ , Passat 200 ...
tee
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6-speed automatic gearbox or
ac
09G - Edition 07.2011
ss
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This »old« filler opening with the red cap is not needed because
un
pt
ATF can be drained or filled as required through the bottom hole.
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The »height« of this tube determines the level of the ATF.
rm
ab
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The tube must be removed to drain the fluid.
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♦ After installation, check the ATF level and top up
hole
spec
⇒ page 134 .
es, in part or in w
t to the co
♦ Capacities ⇒ page 5 .
rrectness of i
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1.9 Gaskets, seals and oil
nform
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♦ Always renew O-ring, seals and gaskets.

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♦ Before installing a radial oil seal, coat sealing lips and area
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between them with sealing grease -G 052 128- .
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♦ Open side of oil seal faces oil.
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♦ After installing, check ATF level.
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Be careful when working with oil. Dispose of drained oil ac‐
cording to regulations. Remember: one drop of oil will contam‐
inate 1,000 litres of water.
1.10 Nuts and bolts

♦ Loosen and tighten bolts and securing nuts for covers and
housings diagonally.
♦ Torque settings are specified for unoiled bolts and nuts.
♦ Threads of bolts secured with locking fluid must be cleaned
with a wire brush. Then insert bolts with locking fluid AMV 185
100 A1.
♦ Use a thread chaser to clear residual locking fluid from all
threaded holes into which self-locking bolts are to be screwed.
Otherwise there is a danger of bolts shearing when subse‐
quently being removed.
♦ Always renew self-locking bolts and nuts.
1. General repair notes 3

1.11 Electrical components

You have probably at some time received an electrical shock
when touching a metal object. This is due to the electrostatic
charge of the human body. This charge can disturb the function
of electrical components of the gearbox and of the selector mech‐
anism.
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– Before beginning work on electrical components, touch an Vol
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a
not
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not touch connectors or »open« electronic components ho
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1.12 Guided fault finding, vehicle self-diag‐
nosis and test instruments
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f
Before making repairs to the gearbox, determine the cause of the
in
fault as precisely as possible with the aid of „guided fault finding“.
form
mer
atio
Guided fault finding is carried out using the vehicle diagno‐
om
n
sis, testing and information system -VAS 5051B- ⇒ page 16 .
c
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The guided functions will guide you to the ATF temperature
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in the shortest way possible ⇒ page 16 .

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2 Capacities
2.1 Planetary gearbox and final drive

Capacities „6-speed automatic gearbox 09G“
Initial filling approx. 7.0 l
Change approx. 3.0 l
Lubricant ATF is available as a part. Therefore, the part number
for it can be found in the ⇒ Electronic parts catalogue
„ETKA“.
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2. Capacities 5
6-speed automatic gearbox 09G - Edition 07.2011 gen AG
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3 Code - engine allocation ris nte
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Codes for Golf 2004 ► ⇒ page 7
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Codes for Golf 2009 ► ⇒ page 9
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Codes for Golf Plus 2005 ► ⇒ page 8
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Codes for Touran 2003 ► ⇒ page 10
h re
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Codes for Passat 2006 ► ⇒ page 11
spec
t to the co
Codes for Passat CC 2009 ►, CC 2010 ► ⇒ page 12
3.1 Gearbox codes
rrectne
Code letters -arrow-
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Code letters -arrow 1-

„Automatic gearbox 09G“ -arrow 2-
Example:
GGZ 08 05 02
I I I I
Identification Day Month Year -2002-
code of manufacture
The gearbox code also appears on the vehicle identification
plates.

4 Golf 2004 ►
If Genuine parts are required for a repair, always refer to the
gearbox code.
„Automatic gearbox 09G“
Identification GJY »GJX« »FUF« »HFU« »KBV«
code »GSY« »HFR« »GJZ« »HRM« KGL
»HFS« »HTM« »HFT« »JUJ«
»HTN« AG. Volkswa»JUG«
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Engine utho 1.6 l - 75 kW 1.6 l - 85 kW 2.0 lee- o110
ra kW 2.5 l - 110 kW 2.5 l - 125 kW
ss a (FSI) (FSI)c
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4. Golf 2004 ► 7
5 Golf Plus 2005 ►

gearbox code.
Identification code »HFS« »HLP« »HFX«
»HTN« »JTV« »HTQ«
»JTY« KGN »JTW«
»KGJ«
Engine 1.6 l - 75 kW 1.6 l - 85 kW (FSI) 2.0 l - 110 kW (FSI)
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6 Golf 2009 ►
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If Genuine parts are required for a repair, always referVoto
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„Automatic
sa
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Identification KGL, MAN
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Engine 2.5 l - 125 kW
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6. Golf 2009 ► 9
7 Touran 2003 ►
If Genuine parts are required for aArepair, always refer to the
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Identification code
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a »FUH« »GKC«
ra
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»GKB« »HFX« »HTR«
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»GXY« »HTQ« JTX
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»HLP« »JTW« KGP
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Engine 1.6 l - 85 kW 2.0 l - 110 kW 1.8 l - 110 kW
wit
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(China)
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c
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8 Passat 2006 ►
gearbox code.
Identification code »HXK« »HFT« »JYY« »HHP«
»JUB« »HVW« KGV »HRN«
KGS »HXJ« »JUD«
»JUC« JZV
KGT KGU
Engine 1.6 l - 85 kW (FSI) 2.0 l - 110 kW (FSI) n1.8
AG.l V-o118
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2.0 l - 147 kW (FSI)
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8. Passat 2006 ► 11
9 Passat CC 2009 ►, CC 2010 ►

gearbox code. AG. Volkswagen
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Identification code tho
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»JZV«
or »KGU«
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Engine ss 2.0 l - 147 kW (FSI)
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32 – Torque converter
1 Proper handling and installation of
torque converter
– Always secure torque converter.
An unsecured torque converter may slide out when the gearbox
is tipped.
AG. Volkswagen AG d
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Therefore, always work with care.

c
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1.1 Identification of torque converter

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There are various torque converters. They are identified by codes.

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Torque converter/gearbox allocation ⇒ Replacement parts cata‐
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1.2 Draining torque converter
agen
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Special tools and workshop equipment required
1. Proper handling and installation of torque converter 13

♦ -V.A.G 1358 A- Oil extraction unit
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♦ -V.A.G 1358 A/1- Oil extraction probe
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– Extract ATF from torque converter using -V.A.G 1358 A- and
, is n
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probe -V.A.G 1358 A/1- .
hole
spec
1.3 Removing and installing torque convert‐
es, in part or in w
t to the co
er oil seal
rrectness of i
♦ Thrust piece -T10175-
l purpos
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♦ extractor lever -VW 681-
14 Rep. gr.32 - Torque converter

Removing
– Pry out seal with lever -VW 681- .
Installing
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– Drive in seal flush thrust piece -T10175- .
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1.4 Installing torque converter do

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– Carefully push on torque converter hub via oil seal to first stop.
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and torque converter can be felt to slip in place. Prote
cted AG.
agen
The torque converter is properly inserted when it can easily be

turned by hand and is seated equally deep in gearbox around the
entire circumference.
Caution
If engine and gearbox are brought together with force because

the torque converter is improperly fitted, both gearbox and tor‐
que converter will be damaged.
1. Proper handling and installation of torque converter 15

37 – Controls, housing
1 Connecting »tester«
Volkswagen offers various devices such as
♦ Vehicle diagnosis, testing and information system -VAS 5051-
♦ Vehicle diagnosis, testing and information system -VAS
5051B-
♦ Tester -VAS 5051/11A-
♦ Vehicle diagnosis and service information system -VAS 5052-
♦ Diagnostic system -VAS 5053-
The operation of these »devices« is described in the respective
user's manuals.
The following description refers to the vehicle diagnosis, testing
and information system -VAS 5051- ⇒ page 16 .
1.1 Connecting vehiclewdiagnosis,

agen
AG. Volkswatesting
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does
and information
d by Vsystem -VAS 5051-
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Special tools and workshop
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♦ Vehicle diagnosis, testing and information system -VAS 5051- ce
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WARNING
m
at
om
♦ During a road test, always secure testing and measuring

on
c
equipment on the back seat.

in t
or
his
ate
♦ These devices may be operated only by a passenger dur‐

do
priv
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– Push connector of diagnosis cable -VAS 5051/1- -2- or - rig ht
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VAS 5051/3- onto diagnosis connection.
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16 Rep. gr.37 - Controls, housing

– Switch on »tester« -arrow-.

AG . Volkswagen AG
The »tester« is ready for use when it is possible kto
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agen be‐ does
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tween the buttons Guided functions and bGuidedyV
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finding on the »right« of the screen. orise nte
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Depending on equipment and versionss of the tester, other func‐
a c
tions may be »displayed« such as:
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♦ Self-diagnosis
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The »tester« is now ready for use.
es, in part or in w
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– Switch on ignition.
– Touch a button on the screen to start the desired function.
rrectness of i
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1. Connecting »tester« 17
2 Electrical and electronic components and their locations
1 - Control unit for automatic

gearbox -J217-
❑ The control unit trans‐
mits and receives data
from the ⇒ data bus.
❑ Location and removing
and installing
⇒ page 19
❑ Can be checked using
„guided fault finding“ of -
VAS 5051-
2 - Engine control unit
❑ The control unit trans‐
mits and receives data
from the data bus
❑ Location and removing
and installing ⇒ Rep.
Gr. 23 for the respective
engine code letter ⇒
Rep. Gr. 24 for the re‐
spective engine code
letter agen
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3 - Multifunction switch -F125- byV gu
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❑ Location ⇒ pageuth19 o eo
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❑ Can be checked ss using c
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„guided fault finding“ of -

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❑ Removing, installing
ab
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and adjusting
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⇒ page 23 .
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4 - Valve body
spec
❑ Location ⇒ page 20
t to the co
❑ Components can be
checked using „guided
fault finding“ of -
rrectne
VAS 5051-
❑ Allocation ⇒ Electronic parts catalogue „ETKA“
ss o
cial p
5 - Wiring harness for sender

inform
❑ With gearbox oil temperature sender -G93-

mer
atio
m
o
n
c
i
or
❑ Removing and installing ⇒ page 155

thi
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6 - Gearbox oil temperature sender -G93-

en
ng
t.
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❑ Location ⇒ page 20 ht. Cop py
rig
❑ Can be checked using „guided fault finding“ of -VAS 5051- rig ht
py by
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by lksw
7 - Wiring harness for solenoid valves
cted agen
Prote AG.
8 - Automatic gearbox hydraulic pressure sender 1 -G193-
❑ Not installed in all gearboxes

9 - Automatic gearbox hydraulic pressure sender 2 -G194-
❑ Not installed in all gearboxes
10 - Gearbox input speed sender -G182-
❑ Can be checked using „guided fault finding“ of -VAS 5051-
11 - Gearbox output speed sender -G195-
❑ Can be checked using „guided
gen AG
. Volkswafault finding“ of -VAS 5051-
gen AG
a does
lksw n
12 - Selector lever db
y Vlock solenoid -N110-
o ot g
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❑ Location:thoris selector lever lock solenoid is located in tethe
e o selector mechanism.
u ra
❑ Can s be checked using „guided fault finding“ of -VAS 5051-
s a c
ce
le
un
13 - Tiptronic switch -F189-
pt
an
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itte
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rm
ab
pe
❑ Can be checked using „guided fault finding“ of -VAS 5051-
ility
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14 - Terminal 50 voltage supply relay -J682-

h re
hole
❑ In E box in engine compartment ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
spec
es, in part or in w
t to the co
15 - Diagnostic connection
rrectness of i
16 - Selector lever position display -Y6-

l purpos
❑ Removing and installing ⇒ Electrical system; Rep. gr. 90 ; Gauges, instruments; Dash panel insert .
nform
mercia
Automatic gearbox control unit -J217- -arrow-

com
tion in
r
Location: Control unit is located in the front left wheel housing.

te o
thi
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iva
do
– Wheel housing liner must be removed for removing and in‐

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fo
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Cop py
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rig ht
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Prote AG.
Multifunction switch -F125-

Location: multifunction switch is located on top of the gearbox.
2. Electrical and electronic components and their locations 19

Valve body
Location: valve body is bolted to underside of gearbox housing
and covered by pan.
Solenoid valves -N88- and -N89- as well as pressure control
valves -N90- , -N91- , -N92- , -N93- , -N282- and -N283- are se‐
cured to valve body.
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Wiring harness for sender
itte
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erm
ab
♦ With integrated gearbox oil temperature sender -G93-
ility
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-arrow-
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Location: Wiring harness is attached to valve body in gearbox.
hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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Wiring harness for solenoid valves
rm
m
atio
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Location: Wiring harness is attached to valve body in gearbox.

o
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Cop py
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CC 2010 ➤ , Golf d2004
by
Vo ➤ , Golf 2009 ➤ , Golf Plusot2005gu
ara ➤ , Passat 200 ...
oris
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6-speed automatic gearbox 09G nte- Edition 07.2011
eo
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Hydraulic pressure sender 1 -G193- and hydraulic pressure send‐
ce
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nl
er 2 -G194-
pt
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itte
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This sender is not installed in all gearboxes.
erm
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Location:
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Automatic gearbox hydraulic pressure sender 1 -G193- -1- and
hole
spec
automatic gearbox hydraulic pressure sender 2 -G194- are bolted
es, in part or in w
into the valve body.
t to the co
rrectness of i
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at
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ate
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Gearbox input speed sender -G182- and gearbox output speed
for
en
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sender -G195-
n
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Cop py
Location: senders are installed in gearbox housing above valve
t. rig
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body.
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Tiptronic switch -F189-

Location: Tiptronic switch is integrated into selector mechanism.
In vehicles with a multifunctional steering wheel, the buttons on
the steering wheel and their cable connections must also be
checked.
2. Electrical and electronic components and their locations 21

Diagnostic connection
Location: diagnosis connector -arrow- is located on left below
driver storage compartment.
AG. Volkswagen AG d
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Selector lever position display -Y6- orised
nte
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Location: in dash panel insert ss a c
ce
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Cop py
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rig ht
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Prote AG.

3 Multifunction switch -F125-

Removing multifunction switch -F125- ⇒ page 23
Installing multifunction switch -F125- ⇒ page 24
Adjusting multifunction switch -F125- ⇒ page 25
3.1 Removing multifunction switch -F125-

– Move selector lever to position „N“.
– Switch off ignition.
– Do not open cooling system.
– In order to remove selector lever cable from gearbox, first re‐
lease cable -1- and then remove it from cable support bracket
-2-.
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Work with care to avoid bending cable. Do not use pliers, or the
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retaining tabs on the cable support bracket may break off.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
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ion
c
– Lever cable -1- off lever -3- using an open jaw spanner -2-.
in t
or
his
ate
– Pull connector off multifunction switch -F125- .

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Cop py
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3. Multifunction switch F125 23

– Unscrew nut -1-.

– Remove spring ring -2- and lever -3- from selector shaft -4-.
AG. Volkswagen AG d
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– Carefully bend back hooks of lock washer -2- using a screw‐
l purpos
driver.
– If hooks are broken off, renew lock washer.
nform
ercia
– Unscrew nut -1-.

m
at
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ion
– Unscrew bolt -5-.
c
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– Pull multifunction switch -4-, together with washers -2- and

a
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riv
-3-, off selector shaft -6-.

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Prote AG.
3.2 Installing multifunction switch -F125-

♦ Torque wrench -V.A.G 1331-
Install in reverse order of removal. During this step, observe the

following:

wage es n
– Place multifunction switch olks
y V -4- on selector shaft -6-.
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– Tighten securing thbolts
or
is -5- for multifunction switch hand-tight. tee o
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– Carefully bendssback hooks of lock washer -2-. c
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– Put washers -2- and -3- on selector shaft -6-.
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– Install washer -2- with hooks pointing up.
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– Install washer -2- with long, narrow guides in long, narrow re‐
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cesses of selector shaft -6-.
h re
hole
spec
– Tighten nut -1- to 7 Nm.
es, in part or in w
t to the co
– Secure nut -1- by bending up hooks on lock washer -2-.
– If hooks are broken off, renew lock washer.
rrectness of i
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nf
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orm
m
atio
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– Place lever -3- on selector shaft -4-.
n in
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– Use lever -3- to shift gearbox to „P“ position, i.e. press lever
t
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-3- back (opposite direction of travel) to stop.
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– Now use lever -3- to shift gearbox to „N“ position. To do this,

t.
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push lever -3- two detent positions forwards in direction of Cop py
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– Place spring ring -2- and nut -1- on selector shaft -4-.
by lksw
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Prote AG.
– Tighten nut -1- to 13 Nm.
Vehicles with 6-cylinder petrol engine
– Install coolant reservoir ⇒ 6-cylinder fuel injection engine,
mechanics; Rep. gr. 19 ; Removing and installing parts of
cooling system .
– With ignition switched off, connect battery earth strap ⇒ Elec‐
trical system; Rep. gr. 27 ; Battery; Disconnecting and con‐
necting battery .
Continuation for all vehicles
– Check selector mechanism ⇒ page 33 .
3.3 Adjusting multifunction switch -F125-

♦ Setting gauge -T10173-
– Move selector lever to position „N“.

– Do not kink selector lever cable.
3. Multifunction switch F125 25

3.3.1 Adjustment prerequisites

• Selector lever cable is disconnected from selector shaft lever.
• Selector shaft is set to „N“ position.
wage es n
• Securing bolts for multifunction switchyV
o-F125-
lks have been loos‐ ot g
ua
ened. ised b ran
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• Selector shaft lever has been
sa
ut removed. or
ac
s
– Place setting gauge on selector shaft -2- and turn multifunction
ce
le
un
pt
switch -1- until setting gauge engages in lug on multifunction
an
d
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switch connector.
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– Secure setting gauge on selector shaft -2- with bolt -3-.
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– Tighten bolts -arrows- to 6 Nm.
ole,
spec
– Remove setting gauge.
t to the co
– Continue installation in reverse order of removal ⇒ page 24 .
rrectness o
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mer
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Cop py
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Prote AG.

4 Emergency release of selector lever

Do not remove knob.
– Depress brake pedal or set handbrake.
In an emergency:
– Unclip selector cover and hold to side.
Vehicles up to 02.2009
– Press yellow plastic wedge from right to left.
Lever can now be moved from position »P«.
Vehicles from 03.2009 onwards

– Press yellow plastic wedge.
Lever can now be moved from position »P«.
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Prote AG.
4. Emergency release of selector lever 27

5 Removing and installing selector lev‐

er handle
Brief description
Depending on the model, different handles may be installed.
Handle is removed together with selector cover.
Removing:
– Shift selector lever to position „D“.
Handle with pushbutton on side:
– First pull button far enough out of knob that a small gap is
visible between knob and button. Button locks when released.
– Hold button in this position with a cable tie or wire to prevent
it from being pressed in.
Handle with front pushbutton:

Button does not need to be pulled out by hand. The pushbutton
engages in installation position -arrow- when the handle is pulled
off.
AG. Volkswagen AG d
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Further procedure for sall handles:
s c
ce
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un
pt
– Unclip cover.
an
d
itte
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– Pull connector from selector cover.

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– Push sleeve upwards to release knob.

wit
is n
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t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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Cop py
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28
cted agen
Prote AG.
Rep. gr.37 - Controls, housing
Only handle with clip:

– Cut open clip beneath boot -arrow- using side cutters.
Further procedure for all handles:
– Pull handle off selector lever without pressing button.
Note
Do not press button again after removal as it will no longer be

possible to install the handle.
Installing
– Install in reverse order of removal, observing the following:
• Selector lever is in position „D“.
Handle with pushbutton on side:

• Button in handle is pulled out and secured against being
pressed in.
AG. Volkswagen AG d
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Handle with front pushbutton: by Vol not
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• Pushbutton is in installationthposition
or -arrow-. eo
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If the pushbutton was pressed
s by mistake, the installation position
s
ce
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can be restored.
nl
pt
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itte
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– Move pushbutton to installation position ⇒ page 30 .

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rrectness of i
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at
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ion
c
in t
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ate
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Cop py
t. rig
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co lksw
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cted agen
Prote AG.
5. Removing and installing selector lever handle 29

Note
New handle is supplied with installation guard. Do not remove

guard until just before installing. To remove, pull it out.
Further procedure for all handles:

– Push handle fully onto selector lever and lock.
– Push sleeve downwards to lock.
Only handle with clip:
– Push on handle with new clip onto stop.
– Secure clip with hose clip pliers -V.A.G 1275- .
– Push pushbutton after installing it. swage
es n
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Note utho
or
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ce
le
If not installed correctly, pushbutton remains inserted in handle

un
pt
after being pressed. If this happens, remove handle again and
an
d
itte
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move pushbutton to installation position again ⇒ page 30 . The
erm
ab
handle can then be installed again.
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Continue installation in reverse order of removal.
ole,
spec
5.1 Moving pushbutton to installation posi‐
t to the co
tion in the handle
rrectne
5.1.1 Handle with pushbutton on side
ss o
cial p
f
– First pull button far enough out of knob that a small gap is
inform
visible between knob and button. Button locks when released.
mer
atio
m
– Hold button in this position with a cable tie or wire to prevent

o
n
c
it from being pressed in.

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Prote AG.
5.1.2 Handle with front pushbutton

With this kind of handle, the pushbutton cannot be pulled out.
There are 2 ways of moving the pushbutton into the installation
position, »with« and »without« installation guard. Both of them are
described here.

Place handle »with« installation guard in installation position:

When using the installation guard, make sure that it has wan ageeyelet
es n
-arrow- at the front. Other types of installation guard yV
oare
lks not suit‐ ot g
ua
able. ised b ran
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– Holding the button down, completely push in installation guard
with eyelet -arrow- until the installation guard engages, then
rrectness of i
release the button. When the installation guard is pulled out,
the pushbutton engages in the installation position.
l purpos
Place handle »without« installation guard in installation position:
nform
mercia
at
om
ion
c
in t
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ate
do
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– Carefully unclip trim of handle -A- upwards.
t. C rig
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Prote AG.
5. Removing and installing selector lever handle 31

– Using a screwdriver, press the small lever -1- for the tie rod
into the groove -2-. When this is done, the pushbutton -3- is
pressed into the installation position.
-I- Pushbutton in pressed position
-II- Pushbutton in installation position
Note
♦ Only press the lever into the groove and no further.

♦ Do not clip the trim of the handle onto the selector mechanism
until the handle has been fitted. This makes it possible to check
whether the small lever engages in the tie rod when the push‐
button is pressed.
AG. Volkswagen AG d
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rrectness of i
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mercia
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ion
c
in t
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ate
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Cop py
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32
c by lksw
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Rep. gr.37 - Controls, housing Prote AG.
6 Selector mechanism up to 02.2009
WARNING
Before working on vehicle with engine running, move selector

lever into position „P“ and apply handbrake.
Selector mechanism from 03.2009 onwards ⇒ page 45
6.1 Overview of selector mechanism up to 02.2009
1 - Selector cover with knob

❑ Do not remove knob
without reason. For
emergency release, on‐
ly the cover needs to be
unclipped ⇒ page 27 .
❑ Before removal of han‐
dle, pull button out past
its pressure point. Se‐
cure button with a cable
tie or tape. This will pre‐
vent the button kswagefrom be‐ es n
Vol
ing accidentally pressed
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d by ua
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into
ori the knob.
se
tee
th or
❑s auIf button is pressed into ac
s
removed handle
ce
le
un
pt
– Always pull out button

an
d
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past the felt pressure

rm
ab
point before installing

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ility
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knob.
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hole
2 - Selector mechanism with

spec
selector lever
es, in part or in w
t to the co
❑ Removing and installing

⇒ page 34
rrectness of i
3 - Bolt with spring

❑ 3 Nm
l purpos
4 - Pin
nform
ercia
❑ Removing ⇒ page 34
❑ Do not grease
m
a
com
tion in
5 - Securing clip
r
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❑ Always renew after re‐

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6 - Nut
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❑ 9 Nm t. C rig
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❑ Qty. 4
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7 - Selector housing
AG.
❑ With seal
8 - Selector lever cable
❑ Cable must not be greased
❑ Checking ⇒ page 42
❑ Adjusting ⇒ page 43
6. Selector mechanism up to 02.2009 33

9 - Hexagon nut with washer

❑ 8 Nm
❑ Qty. 4
6.2 Removing and installing selector mech‐

anism with selector lever
Note
Following installation, cable must be checked for ease of move‐

ment and be adjusted.
– Remove centre console ⇒ Rep. gr. 68 ; Compartments, cov‐

ers and trims .
– Remove Bowden cable from gearboxV⇒ page 34 .
olkswa AG. gen AG
agen do
– Remove exhaust system yV
below
olks
w
heat shield ⇒ Rep. egr.
s no 26 ;
t gu
Removing and installing
ised parts of exhaust system .
b ara
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ho
– Remove heat shield
au
t
beneath vehicle. or
ac
ss
– Remove 4 nuts for selector mechanism »from above«. ce
e
nl
pt
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itte
Torque setting for nuts: 8 Nm y li

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ility
– After installing, check cable ⇒ page 42 .
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6.3 Removing and installing selector lever

h re
hole
spec
cable
es, in part or in w
t to the co
Note
rrectness of i

l purpos

nf
ercia
Removing
orm
m
atio
– Move selector lever to position „S“ position.

om
n in
c

or
thi
e
t
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iva
-2-.
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rig ht
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Prote AG.

– Raise vehicle.
To remove cable and/or selector mechanism, first remove heat
shield and, if necessary, parts of exhaust system now ⇒ Rep. gr.
26 ; Removing and installing parts of exhaust system .
– Remove heat shield.
– Remove -selector housing- beneath selector lever.
AG. Volkswagen AG d
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nl
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es, in part or in w
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atio
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Prote AG.

AG. Volkswagen AG d
agen oes
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– Remove securing clip. Always renew securing clip.

nform
mercia
a
com
tion in
r
te o
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-Selector housing- is pushed forwards slightly on cable.
AG. Volkswagen AG d
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To remove cable, securing tab must be pushed forwards -1-.
wit
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– At same time, push -pin- up with a screwdriver -2-.
hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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– Please insert -screwdriver- from underneath whilst pushing
by lksw
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securing tab forwards.
AG.

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es, in part or in w
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Clarification: t. Cop py
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♦ -1- Push tab forwards pyri by
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♦ -2- Push pin up Prote AG.

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rm
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove selector lever cable.

Remove selector housing from cable.
nform
ercia
Installing
m
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com
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Do not grease cable.

on in
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te o
thi
– Route selector lever cable free of tension, insert in cable sup‐

s
iva
port bracket on gearbox but do not yet secure.

do
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cum
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– Ensure that selector lever cable is properly routed during in‐

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stallation.
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– Also clip cable into retainer. Ensure that retainer does not
rig ht
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contact gearbox oil cooler. by c lksw
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AG. Volkswagen AG d
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CC 2010 ➤ , Golf 2004 ➤uth, Golf 2009 ➤ , Golf Plus 2005 ➤ , Passat 200
o e o ...
ra
a
6-speed automatic gearbox
ss 09G - Edition 07.2011 c
ce
e
nl
pt
du
-Nuts- 8 Nm
an
itte
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erm
ab
– Put selector housing onto cable.
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
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for
en
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t.
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– Insert selector lever cable into selector mechanism.
Co
Cop py
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rig ht
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by lksw
cted agen
Prote AG.
– Insert cable into bearing and insert pin from above, down‐
wards through eye.
When you have checked freedom of movement of cable
⇒ page 42 , insert securing clip.
– Attach cable with new securing clip on cable support bracket

of selector mechanism.

AG. Volkswagen AG d
agen oes
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t to the co
– Install selector housing, heat shield and exhaust system.

– Adjust selector lever cable after installing ⇒ page 42 .
rrectness o
cial p
f inform
mer
atio
om
n
c
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Cop py
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6-speed automatic gearbox 09G - Edition 07.2011 agen AG. Volkswagen AG do
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6.4 Checking selector lever cable ho
ris
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tee
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Brief description ss
ce
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un
To check ease of movement of selector lever cable, it must be
pt
an
d
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removed from the gearbox and the free end must be placed so
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that it does not bump against anything.
ility
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Then move selector lever and reinstall the cable.
wit
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ole,
Then the selector lever cable must be adjusted ⇒ page 43 .
spec
Do not grease the connections of the cable!
t to the co
Checking
– Move selector lever to position »P« position.
rrectne
– Loosen bolt -2- of the Bowden cable -1-.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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pr
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fo
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t.
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Cop py
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rig ht
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by lksw
cted agen
Prote AG.
– Lever cable -1- from selector shaft lever -3- using an open jaw
spanner -2-.
Vehicles up to 02.2009

-2-.
Vehicles from 03.2009 onwards

– Remove securing clip.

– Move selector lever repeatedly from »P« to »S« and back to
»P«.
• Selector lever must move easily.
– Reinstall cable.
– Adjust cable ⇒ page 43 .
6.5 Adjusting selector lever cable

AG. Volkswagen AG d
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The selector lever cable must always be adjusted whenever
rm
ab
pe
ility
♦ The selector lever cable has been removed from the gearbox.
ot
wit
, is n
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♦ The engine and/or gearbox has been removed and installed.
hole
spec
♦ Parts of the assembly mounting have been removed and in‐
es, in part or in w
t to the co
stalled.
♦ The cable itself or the selector mechanism has been removed
and installed.
rrectness of i
♦ The position of the engine and gearbox is shifted, for example
l purpos
to install it free of tension.

Adjusting
nform
ercia
– Move selector lever to „P“ position.

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Cop py
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Prote AG.

Adjuster screw -2- must be »loosened«.

– Set selector shaft lever -3- to „P“ on gearbox (push lever back‐
wards).
WARNING
Be sure that the parking lock is engaged.
– To do this, turn both front wheels simultaneously »under the

car« in the same direction until the parking lock can be head
to engage.
• The parking lock is engaged when both front wheels cannot
be turned in the same direction at the same time.
– Gently push knob of selector lever forwards and backwards
AG. Volkswagen AG d
but under no circumstances must you shift
lksw
out
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In this way the inner cable of the Bowden
ris
ed
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cable finds it optimal ran
tee
position. utho
or
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– Tighten adjusting screw -arrow-
s to 13 Nm.
ce
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nl
pt
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– Tighten bolt -2- to 15 Nm.
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ility
This completes the adjustment.
ot p
wit
, is n
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spec
es, in part or in w
t to the co
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Cop py
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Prote AG.

7 Selector mechanism from

agen
AG. Volk03.2009
swagen AG
does
onwards db
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WARNING ss c
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un
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Before working on vehicle with engine running, move selector
an
d
itte
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lever into position „P“ and apply handbrake.
rm
ab
pe
ility
ot
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Selector mechanism in vehicles up to 02.2009 ⇒ page 33
hole
spec
7.1 Overview of selector mechanism in vehicles from 03.2009 onwards
es, in part or in w
t to the co
1 - Handle with selector cover
rrectness of i
❑ Do not remove knob
without reason. Only un‐
l purpos
clip cover for emergen‐

cy release ⇒ page 27 .
nform
ercia

⇒ page 28
m
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tion in
2 - Selector lever and selector
r
te o
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mechanism with selector lever
s
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cable
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❑ With selector lever lock
en
ng
t.
solenoid -N110-
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❑ Cable must not be
t. rig
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greased
p by
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Prote AG.
⇒ page 46
❑ Checking ⇒ page 42
3 - Bolt
❑ 8 Nm
4 - Hexagon flange nut
❑ 8 Nm
❑ Qty. 4
5 - Selector housing
6 - Securing clip
❑ Always renew after re‐
moving
7. Selector mechanism from 03.2009 onwards 45

6-speed automatic AG. Volksw
gengearbox
agen AG
09G - Edition
does 07.2011
swa k not
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7.2 Removing and installing selector lever
e nte
ris
tho eo
and selector mechanism with selector
au ra
ss c
ce
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lever cable from 03.2009 onwards

nl
pt
du
an
itte
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Brief description
erm
ab
ility
ot p
Selector mechanism and selector lever cable are not allowed to
wit
, is n
be separated from one another. Both are removed together. In
h re
the engine compartment, it may be necessary to provide instal‐
hole
spec
lation space. Often, it is necessary to remove air filter.
es, in part or in w
t to the co
In the interior, it may be necessary to remove centre console.
rrectness of i
Note
l purpos

nform
mercia
– Move selector lever to position „P“ position.
at
om
ion
c
in t
– Remove selector lever knob ⇒ page 28 .
or
his
ate
– Remove centre console ⇒ Rep. gr. 68 .

do
priv
cum
for
en
ng
– Remove 4 bolts.
t.
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Cop py
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Torque setting 8 Nm. opyri
gh by
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ht
c by lksw
cted agen
Prote AG.
– Remove securing clip.

– Securing clips for selector lever cable must always be re‐
newed.
– Remove cable from ball head.
– To remove cable and/or selector mechanism, heat shield must
now be removed and, if necessary, parts of exhaust system.
– Remove heat shield.

– Remove selector mechanism.

Install in reverse order of removal.
– Before reinstalling cable, set „P“ in vehicle and on gearbox.
– Before you put on ball head: check cable ⇒ page 42 .
– Install parts of ⇒ exhaust system; Rep. gr. 26 .
– Install heat shield ⇒ Rep. gr. 66 .
– Adjust selector lever cable after installing ⇒ page 43 .
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rm
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
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tion in
r
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thi
s
iva
do
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t.
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Cop py
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Prote AG.
7. Selector mechanism from 03.2009 onwards 47

8 Checking selector mechanism

It must not be possible to start the engine in the selector lever
positions „R“, „D“ or „S“.
On right-hand drive vehicles, the starter must operate only in se‐
lector lever positions „P“ and „N“ when the locking button in the
selector lever handle is not pressed.
Over 5 km/h
When the selector lever is shifted to „N“, the selector lever lock
solenoid must not lock the selector lever. Selector lever can be
shifted back into a driving range.
Under 5 km/h
When the selector lever is shifted to „N“, the selector lever lock
solenoid must lock the selector lever only after ca 1 second. Se‐
lector lever cannot be shifted out of „N“ position until brake pedal
is depressed.
8.1 Selector lever in „P“ position and ignition

switched on
• Brake pedal is not depressed:
Selector lever is locked and cannot be shifted out of „P“ position
with the lock button pressed. Solenoid for selector lever lock
blocks selector lever. Volkswa
AG. gen AG
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• Brake pedal is depressed: olksw not
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Solenoid for selector lever lock releaseshselector lever. It is pos‐ nte
t o selector lever from
sible to shift into a driving gear. Slowlyaushift
eo
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„P“ through to „S“, checking whether sselector
s
lever position in ce
le
dash panel insert corresponds to actual selector lever position.

un
pt
an
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8.2 Selector lever in „N“ position and ignition
rm
ab
pe
ility
switched on
ot
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, is n
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• Brake pedal is not depressed:

hole
spec
Selector lever is locked and cannot be shifted out of „N“ position

es, in part or in w
t to the co
with the lock button pressed. Solenoid for selector lever lock
blocks selector lever.
• Brake pedal is depressed:
rrectness of i
Solenoid for selector lever lock releases selector lever. It is pos‐

l purpos
sible to shift into a driving gear.
8.3 Selector lever in position „Tiptronic“

nform
mercia
– Shift selector lever into Tiptronic gate.

com
tion in
r
The illumination of the „D“ symbol in the selector mechanism cov‐

te o
thi
er must go out. „+“ and „-“ symbols must light up.

s
iva
do
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rp
cum
Symbols in the dash panel insert must change from „P R N D S“

fo
en
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to „6 5 4 3 2 1“.
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Cop py
8.4 Ignition and light switched on

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The respective symbol in the shift mechanism cover lights up.
cted agen
Prote AG.
8.5 Selector lever position display

Simultaneous illumination of all selector lever position display
segments indicates gearbox emergency running mode.

9 Removing and installing gearbox,

Golf 2004 ►
Removing gearbox, Golf 2004 with 1.6 l - 75 kW, 1.6 l - 85 kW
(FSI) and 2.0 l - 110 kW (FSI) engines ⇒ page 49 wage
e ks s no
Vol t gu
Installing gearbox, Golf 2004 with 1.6 l - 75 kW, 1.6 l -e85
d b kW (FSI)
y ara
and 2.0 l - 110 kW (FSI) engines ⇒ page 55 horis nte
eo
t
au ra
Removing gearbox, Golf 2004 with 2.5 l - 110 kW
ss and 125 engines c
⇒ page 55
ce
le
un
pt
an
d
itte
Installing gearbox, Golf 2004 with 2.5 l - 110 kW and 125 engines
y li
erm
ab
⇒ page 63
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Torque settings, Golf 2004 ▸ ⇒ page 64
is n
h re
ole,
9.1 Removing gearbox, Golf 2004 with 1.6 l
spec
- 75 kW, 1.6 l - 85 kW (FSI) and 2.0 l -
t to the co
110 kW (FSI) engines
rrectne
– Before beginning with removal, »if possible« print out a diag‐
nosis log. Before sending back removed gearbox in the usual
manner, secure log to gearbox.
ss o
cial p
f
Brief description
inform
mer
The gearbox is removed downwards as a unit. The engine re‐
atio
mains in the vehicle.
om
n
c
i
or
n
Battery carrier, air filter and engine cover are removed »from
thi
te
above«. Engine and gearbox must then be supported so that left
sd
iva
o
r
assembly mounting can be removed.

p
cum
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fo
en
ng
Noise insulation is removed and drive shafts are pressed off

t.
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op
»from below«. Gearbox is lowered using gearbox jack. C py
t. rig
gh ht
pyri by
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co lksw
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cted agen
Note Prote AG.
The subframe is not to be removed.
9. Removing and installing gearbox, Golf 2004 ► 49


equipment required
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Torque wrench -V.A.G
1332-
♦ Gearbox support -3282- AG. Volkswagen AG d
agen oes
ksw
♦ Adjustment plate -3282 by
/36-
Vol not
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♦ Hose clamps to t25ho mm
r eo
-3094- ss au ra
c
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♦ Socket -T10179-
nl
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itte
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erm
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ility
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es, in part or in w
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nf
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orm
m
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om
n in
or c
thi
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sd
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Cop py
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Prote AG.
♦ Insert -V/175-

♦ Support bracket -10 - 222 A-
♦ Adapter -10 - 222 A /13-

The following description shows the gearbox with the 2-litre petrol
engine (FSI). Deviations from other engine types in the Golf are
minimal. However, torque settings for bolting gearbox to engine
go into detail »as usual« (large and small engines, FSI and multi-
point injection engines).
Removing:
– Raise vehicle. All 4 supports of lifting platform must be at same
height.
. Volkswagen AG
– Remove battery and battery carrier ⇒ Rep. gr. a27
gen;ADiscon‐
G does
lksw not
necting and connecting battery; Removing by
Voand installing bat‐ gu
ara
tery . ris
ed nte
tho eo
– Remove engine cover and air cleaner
ss
au with intake hose. ra
c ce
le

un
pt
an
d
itte
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-2-.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Place hose clamps up to Ø 25 mm -3094- onto the hoses and

remove hoses from the ATF cooler.
– Disconnect electrical connections to gearbox and starter.
AG. Volkswagen AG d
agen oes
– Remove upper starter motor bolt. olksw not
byV gu
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un
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rm
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ility
ot
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, is n
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hole
– Set up support bracket -10 - 222 A- and support engine and
spec
gearbox. Do not raise.
es, in part or in w
t to the co
– Remove upper connecting bolts between engine and gearbox.
Bolts may be installed with a socket -T10179- . When tightening,
rrectness of i
however, observe the lower tightening torque ⇒ page 64 .
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
– Merely remove the six bracket bolts -A-.

r
rp
cum
fo
en
g
During installation, first bolt bracket to gearbox with 40 Nm torque.

n
t.
yi Co
Cop py
When the two bracket bolts are tightened to vehicle, a screwdriver ht. rig
rig ht
may be inserted between the two bolts to adjust to »previous
py by
co Vo
by lksw
seating«. These two larger bolts are tightened to 60 Nm. Prote
cted AG.
agen
The bracket is removed later.

– Depress brake pedal to remove bolt for left drive shaft

-arrow- (second mechanic required).
Note
After this, do not set vehicle on the ground any more ⇒ Rep. gr.
40 ; Repairing drive shafts; Removing and installing drive shafts;
Removing drive shafts with triple-roller joint AAR2600i .
– Remove noise insulation tray.

– If heat shield is installed over right drive shaft, remove it from
engine.
– Remove vacuum pump with bracket and lines. »The
olks
wpump
age is es n
ot g
located near the ATF filler pipe«. db
y V ua
ran
e
ris tee
– Now pull electrical connectors off gearbox.
ut
ho or
a ac
ss
– Remove starter ⇒ Rep. gr. 27 ; Removing and installing start‐
ce
le
un
er .
pt
an
d
itte
y li
erm
ab
– Remove ⇒ pendulum support, first -A- and then -B-.
ility
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wit
On installation, first tighten -B-, then -A-. Torque settings ⇒ Rep.
is n
h re
gr. 40 ; Assembly overview - subframe, anti-roll bar, suspension
ole,
spec
links .
t to the co
rrectness o
cial p
f inform
mer
atio
– Unbolt suspension links from suspension struts on both sides.
om
n
c
i
or
n
Torque settings ⇒ Rep. gr. 40 ; Assembly overview - subframe,
thi
te
anti-roll bar, suspension links .

sd
iva
o
pr
cum
r
– Press both drive shafts out of gearbox. For procedure, refer to

fo
en
ng
⇒ Rep. gr. 40 ; Repairing drive shafts; Removing and instal‐

t.
yi Co
op
ling drive shafts; Removing drive shafts with triple-roller joint C py
ht. rig
AAR2600i . rig ht
py by
co Vo
by lksw
– Remove left drive shaft. cted agen
Prote AG.
– Raise right shaft as far as possible and secure in this position.

AG. Volkswagen AG d
agen oes
olksw not
yV gu
CC 2010 ➤ , Golfse2004
d b ➤ , Golf 2009 ➤ , Golf Plus 2005 ara ➤ , Passat
nte
200 ...
ri
6-speed automatic
ut
ho gearbox 09G - Edition 07.2011 eo
ra
s a c
s
– Now remove assembly mounting bracket. To do this, lower
ce
le
un
pt
engine and gearbox slightly via support bracket -10 - 222 A-
an
d
itte
y li
spindles. rm
ab
pe
ility
Four turns are sufficient.
ot
wit
, is n
h re
– If exhaust system retainer is present on gearbox, remove it.
hole
spec
– Remove lower connecting bolts between engine and gearbox.
es, in part or in w
t to the co
– Leave an easily accessible bolt in for safety purposes.
– Start with the two lower bolts.
rrectness of i
l purpos
nform
ercia
Note
m
a
com
tio
On some smaller engines up to 1.6 litres, one of the lower
n in
r
-bolts- can be backed out of the gearbox but not removed from
te o
thi
the hole.
s
iva
do
r
rp
cum
fo
en
g
– If this bolt must be removed, first remove front exhaust pipe.

n
t.
yi Co
Cop py
⇒ Rep. gr. 26 ; Removing and installing parts of the exhaust ht. rig
rig ht
system py by
co Vo
by lksw
cted agen
The hole for removing the torque converter nut is covered with a Prote AG.
rubber cap on the rear of the engine.
– Remove this cap.
– Remove six -torque converter nuts- with insert -V/175- .
Note
Continue turning the engine carefully!
– Before you now remove final connecting bolt, support gearbox

with engine and gearbox jack -V.A.G 1383 A- , gearbox sup‐
port -3282- and adjustment plate -3282 /36- .
– Only now is the final bolt removed.
– Carefully push gearbox off engine.
Note
Observe torque converter. It must be removed together with gear‐

box.
– When lowering, observe clearance between left drive shaft

and subframe. If necessary, adjust gearbox support -3282-
slightly.

Volkswa
– Keep in mind that if a new agearbox
gen AG is installed,
. gen AG
doparts
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9.2 Installing gearbox, Golf 2004 with 1.6 l -
rrectness of i
75 kW, 1.6 l - 85 kW (FSI) and 2.0 l - 110
kW (FSI) engines
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During installation, first bolt bracket to gearbox with 40 Nm + 90°
AG.
torque.
When the two bracket bolts are tightened to vehicle, a screwdriver
seating«. These two larger bolts are tightened to 60 Nm + 90°.
Torque settings, gearbox to engine ⇒ page 64
The engine and gearbox should be mounted tension-free in the
assembly mounting. The correct procedure is described in ⇒ Rep.
gr. 10 ; Removing and installing engine; Notes on installation .
– Adjust selector lever cable ⇒ page 43 .
– After installing, check ATF level ⇒ page 134 .
– Carry out basic settings. To do this:
– Connect vehicle diagnosis, testing and information system -
VAS 5051- and then select „Perform basic settings“ under
Guided functions .

- 110 kW and 125 kW engines
Brief description
The gearbox is removed downwards separately. The engine re‐


»from below«. Gearbox is lowered using gearbox jack.
Note

equipment required
V.A.G 1383 A-
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♦ Gearbox support -3282- agen
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♦ Support bracket -10 - 222

A-
♦ Adapter -10 - 222 A /8-
♦ Adapter -10 - 222 A /3-
♦ Hook -10 - 222 A /10-
♦ Shackle -10 - 222 A /12-
♦ Adapter -10 - 222 A /7-
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Removing:
height.


Note
– Remove air filter with engine cover.
– Pull off hoses -arrows- and remove intake hose from throttle
valve unit.
– Remove battery and battery carrier ⇒ Rep. gr. 27 ; Discon‐
necting and connecting battery; Removing and installing bat‐
tery .

lease cable -1- and then remove it from cable support bracket . Volkswag
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♦ Multifunction switch
♦ Starter motor
♦ Earth strap to bracket
– Remove wiring retainer -1- from starter bolt -1-.

– Remove upper starter motor bolt.
To support engine and gearbox:
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ling drive shafts; Removing drive shafts with triple-roller joint
AAR2600i .
– Remove left drive shaft.

– Now pull electrical connectors -1- and -2- off gearbox.
– Pull connector beneath starter -1- out of retainer and separate.

– Unbolt retainer from lower starter bolt.
– Remove lower starter bolt and remove starter.
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Note
– Hook adapter -10 - 222 A /7- into engine block.

– Pull coolant hoses off ATF cooler.
Tighten right spindle one turn (more is not necessary).
– Support engine and gearbox with left spindle. Do not raise.
– Remove bracket -A-.

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engine and gearbox slightly via left spindle of support bracket
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rrectness of i
Six turns are sufficient.

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110 kW and 125 engines
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– Renew all bolts of left assembly mounting.
– First screw in all bolts by hand.
torque.
Guided functions .

AG. Volkswagen AG d
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9.5 Torque settings, gearbox to engine r nte
tho eo
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Golf 2004 with 1.6 l - 75 kW and 2.0 l - 110 kW (FSI) engines
ce
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⇒ page 64
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Golf 2004 with 1.6 l - 85 kW (FSI) engine ⇒ page 65
rm
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Golf 2004 with 2.5 l - 110 kW and 125 kW engines ⇒ page 66
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9.5.1 Torque settings, Golf 2004 with 1.6 l - 75 kW and 2.0 l - 110 kW (FSI) engines
hole
spec
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1 - Direction of travel
A - Bolt for 2.0 l - 110 kW (FSI)
rrectness of i
engine
B - Bolt for 1.6 l -75 kW engine l purpos
- Drive plate to torque convert‐
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❑ 60 Nm
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❑ Qty. 6; remove and in‐
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❑ 40 Nm
❑ These bolts are located
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- Two dowel sleeves in engine
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– Ensure that retainer does not contact gearbox oil cooler.

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9.5.2 Torque settings, Golf 2004 with 1.6 l - 85 kW (FSI) engine
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1 - Direction of travel cted agen
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er
❑ 60 Nm
- M12 bolts ⇒ M12
❑ 80 Nm
❑ 65 Nm if you use socket
-T10179- .
- M10 bolts ⇒ M10
❑ 40 Nm
in lower flange
-arrows-

-Nuts- 8 Nm
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9.5.3 Specified torques, Golf 2004 with 2.5 l - 110 kW and 125 kW engines
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-Nuts- 8 Nm
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Golf Plus 2005 ►
Removing gearbox, Golf Plus 2005 with 1.6 l - 75 kW, 1.6 l - 85
kW (FSI) and 2.0 l - 110 kW (FSI) engines ⇒ page 68
Installing gearbox, Golf Plus 2005 with 1.6 l - 75 kW, 1.6 l - 85 kW
(FSI) and 2.0 l - 110 kW (FSI) engines ⇒ page 74
Torque settings, Golf Plus 2005 ▸ ⇒ page 75
AG. Volkswagen AG d
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equipment required
V.A.G 1383 A-
1332-
♦ Gearbox support -3282-
♦ Adjustment plate -3282 /36-
♦ Hose clamp to Ø 25 mm
-3094-
♦ Socket -T10179- n AG. Volkswagen AG do
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10. Removing and installing gearbox, Golf Plus 2005 ► 69

♦ Adapter -10 - 222 A /8-
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♦ Wing supports -T10311- ise
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The following description shows the gearbox with the 2-litre
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The figure shows the right support.

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points in direction of travel.

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Do not set vehicle on the ground ⇒ Rep. gr. 40 ; Repairing drive
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mer
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atio
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shafts with triple-roller joint AAR2600i .

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engine.
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er .


Torque settings for suspension link bolts ⇒ Rep. gr. 40 ; Assem‐
bly overview - subframe, anti-roll bar, suspension links .
⇒ Rep. gr. 40 ; Repairing drive shafts; eRemoving
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box.
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necessary, adjust gearbox support -3282- slightly.

be transferred.
10.2 Installing gearbox, Golf Plus 2005


torque.
Torque settings, gearbox to engine ⇒ page 75 .
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Torque settings, gearbox to engine
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⇒ page 76
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Golf Plus 2005 with 2.5 l - 110 kW engine ⇒ page 78

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10.3.1 Torque settings, Golf Plus 2005 with 1.6 l - 75 kW and 2.0 l - 110 kW (FSI)
engines
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A - Bolt for 2.0 l - 110 kW (FSI) horis nte
eo
engine s aut ra
c
s
B - Bolt for 1.6 l -75 kW engine
ce
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pt
du
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erm
ab
er
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❑ 60 Nm
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stall with insert -V/175- . es, in part or in w
t to the co
- M12 bolts ⇒ M12
❑ 80 Nm
rrectness of i
-T10179- .
l purpos
- M10 bolts ⇒ M10

❑ 40 Nm
nform
ercia

m
at
in lower flange
om
ion
c
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at
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olkswagen AG
ag en AG. V
CC 2010Vo➤lks,wGolf 2004 ➤ , Golf 2009
does
n➤
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sed by
6-speed automaticua gearbox 09G - Edition 07.2011
ran
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-Nuts- 8 Nm ss
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pt
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d
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erm
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t to the co
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mer
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c
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10.3.2 Torque settings, Golf Plus 2005 with 1.6 l - 85 kW (FSI) engine
i
o
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t.
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op py
. C rig
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- Drive plate to torque convert‐ by c lksw
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er Prote AG.
❑ 60 Nm
- M12 bolts ⇒ M12
❑ 80 Nm
-T10179- .
- M10 bolts ⇒ M10
❑ 40 Nm
in lower flange
-arrows-

-Nuts- 8 Nm
AG. Volkswagen AG d
agen oes
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10.3.3 Torque settings, Golf Plus 2005 with 2.5 l - 110 kW engine
an
itte
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erm
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wit
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er
es, in part or in w
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❑ 60 Nm
rrectness of i
- M12 bolts ⇒ M12
l purpos
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nf
ercia
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-T10179- .
rm
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atio
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o
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or c
❑ 40 Nm
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in lower flange
o
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-arrows- . C rig
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rig by
copy Vo
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-Nuts- 8 Nm
AG. Volkswagen AG d
agen oes
olksw not
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or eo
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nl
pt
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AG. Volkswagen AG d
agen oes
olksw not
CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005d➤ by , Passat 200 ...
V gu
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6-speed automatic gearbox 09G - Edition 07.2011 tho ris
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Touran 2003 ►
erm
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ot p
Removing gearbox, Touran 2003 with 1.6 l - 85 kW, 2.0 l - 85 kW,
wit
is n
2.0 l - 110 kW and 1.8 l - 110 kW engines ⇒ page 80 .
h re
ole,
spec
Installing gearbox, Touran 2003 with 1.6 l - 85 kW, 2.0 l - 85 kW,
2.0 l - 110 kW and 1.8 l - 110 kW engines ⇒ page 84
t to the co
Torque settings, Touran 2003 ⇒ page 85
rrectne
11.1 Removing gearbox, Touran 2003
ss o
cial p
f i
nform
mer
atio
m
o
n
c
i
or
n
equipment required
thi
te
sd
va

i
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pr
cum
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V.A.G 1383 A-
fo
en
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t.
yi Co
♦ Torque wrench -V.A.G t. Cop py
1332-
rig
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pyri by
Vo
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by c
lksw
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Prote AG.
-3094-
♦ Socket -T10179-

♦ Insert -V/175-
lkswage es n
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ss
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nl
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es, in part or in w
t to the co
rrectness of i
l purpos
♦ Adapter -10 - 222 A /22-
nf
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o
Removing:
rm
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atio
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lease cable -1- and then remove it from cable support bracket t. C rig
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-2-. yri
p by
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11. Removing and installing gearbox, Touran 2003 ► 81

AG. Volkswagen AG d
agen oes
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– Remove engine cover and air filter.
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– Disconnect electrical connections to gearbox.
wit
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spec
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form
mer
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c
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The bracket will be removed later.
– Remove vacuum pump with bracket and lines. »The pump is
located near the ATF filler pipe«.
– Remove starter. The lower bolt has a nut which must be un‐
screwed first ⇒ Rep. gr. 27 ; Removing and installing starter .

AG. Volkswagen AG d
6-speed
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agen automatic gearbox oes 09G - Edition 07.2011
n
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– Unbolt suspension links from suspension ris struts on both sides.
e
tee
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ut or
– Press both drive shafts out of gearbox.
ss
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For procedure, refer to ac
ce
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nl
pt
du
an
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AAR2600i .
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rrectness of i
– Raise both shafts as far as possible and secure in this position.
l purpos
nf
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orm
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agen
Prote AG.
(On installation, first tighten -B-, then -A-.)

spindles.
Five turns are sufficient. The left drive shaft should be tied up.
One of the lower -bolts- cannot be removed from the bore.

– To remove this bolt, remove front exhaust pipe.
⇒ Rep. gr. 26 ; Removing and installing parts of the exhaust
system
The torque converter nut bore is concealed with a rubber cap on
the rear of the engine.

Note

– When lowering, observe the area of the left drive shaft. If nec‐
essary, adjust gearbox support -3282- slightly.
Please note the left drive shaft on installation; if necessary, press
the suspension strut out slightly.

be transferred.
AG. Volkswagen AG d
agen oes
ksw
11.2 Installing gearbox, Touran 2003
ol not
y V gu
d b ara
rise nte
– Check whether adowel
ut
ho
sleeves are pressed into engine flange. e or a
ss c
ce
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nl
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wit
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es, in part or in w
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rrectness of i
torque.
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nf
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or
Torque settings, gearbox to engine ⇒ page 85 .

m
m
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– After installing, check ATF level ⇒ page 134 . Cop py
t. rig
gh ht
yri
– Carry out basic settings. To do this: p by
co Vo
by lksw
cted agen
Prote AG.


Guided functions .
11.3 Torque settings, gearbox to engine

Touran 2003 with 1.6 l - 85 kW (FSI) engine ⇒ page 85
Touran 2003 with 2.0 l - 85 kW (FSI) and 1.8 l - 110 kW (FSI)
engines ⇒ page 86
Touran 2003 with 2.0 l - 110 kW (FSI) engine ⇒ page 87
11.3.1 Torque settings, Touran 2003 with 1.6 l - 85 kW (FSI) engine

er
❑ 60 Nm
- M12 bolts ⇒ M12
AG. Volkswagen AG d
❑ 80 Nm agen oes
olksw not
y V gu
❑ 65 Nm if you use socket ise
d b ara
nte
-T10179- . thor eo
au ra
s c
- M12 bolts ⇒ M12 s
ce
e
nl
pt
❑ 80 Nm
du
an
itte
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erm
ab
-T10179- .
ility
ot p
wit
, is n
- M10 bolts ⇒ M10
h re
hole
❑ 40 Nm
spec
es, in part or in w
t to the co
in lower flange
rrectness of i
-arrows-
l purpos
nf
ercia
orm
m
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n in
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thi
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

11.3.2 Torque settings, Touran 2003 with 2.0 l - 85 kW (FSI) and 1.8 l - 110 kW
(FSI) engines

er
❑ 60 Nm
- M12 bolts ⇒ M12
❑ 80 Nm
-T10179- .
- M12 bolts ⇒ M12
❑ 80 Nm
-T10179- .
- M10 bolts ⇒ M10
❑ 40 Nm
in lower flange
-arrows-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
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Prote AG.

11.3.3 Torque settings, Touran 2003 with 2.0 l - 110 kW (FSI) engine

er
❑ 60 Nm
- M12 bolts ⇒ M12 gen AG
. Volkswagen AG
swa does
❑ 80 Nm y Volk not
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db ara
orise nte
eo
-T10179- . au
th
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- M12 bolts ⇒ M12
ce
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nl
pt
du
an
❑ 80 Nm
itte
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erm
ab
ility
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-T10179- .
wit
, is n
h re
- M10 bolts ⇒ M10
hole
spec
❑ 40 Nm
es, in part or in w
t to the co
in lower flange
rrectness of i
-arrows-
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.


Passat 2003 ►
Removing gearbox, Passat with 1.6 l - 85 kW and 2.0 l - 110 kW
engines ⇒ page 88
Installing gearbox, Passat with 1.6 l - 85 kW and 2.0 l - 110 kW
engines ⇒ page 94
Torque settings ⇒ page 95
Removing gearbox, Passat with 1.8 l - 118 kW and 2.0 l - 147 kW
engines ⇒ page 96 .
Installing gearbox, Passat with 1.8 l - 118 kW and 2.0 l - 147 kW
engines ⇒ page 102
12.1 Removing gearbox, Passat with 1.6 l -

85 kW and 2.0 l - 110 kW engines
Brief description
Noise insulation is removed and drivewshafts
gen AGare pressed off
. Volkswagen AG
does
s a
»from below«. Gearbox is loweredy V using gearbox jack.
olk not
gu b ara
ed nte
oris e
th or
au
Note ss
ac
ce
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nl
pt
du

an
itte
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


equipment required
V.A.G 1383 A-
1332-
-3094-
♦ Socket -T10179-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
♦ Insert -V/175-
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
12. Removing and installing gearbox, Passat 2003 ► 89

♦ Socket -T10035-
AG. Volkswagen AG d
agen oes
olksw not
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ara
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♦ Adapter -10 - 222 A /13- s
ce
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nl
pt
du
– »If possible«, print out a diagnosis log for this vehicle before
an
itte
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removal. Secure diagnosis log on removed gearbox before
erm
ab
returning it in the usual way.
ility
ot p
wit
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– Raise vehicle.
h re
hole
spec
es, in part or in w
t to the co
tery .
– Remove engine cover and air cleaner with intake hose. rrectness of i
l purpos

nform
ercia
-2-.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.

n AG. V6-speed automatic
olkswagen AG
gearbox 09G - Edition 07.2011
ks wage doe s no
Vol t gu
by ara
Work with care to avoid bending ris cable. Do not use pliers, or
ed
the nte
retaining tabs on the cable support
autho bracket may break off. eo
ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Press cable out of additional retainer on gearbox. Prote
cted AG.
agen

♦ Starter motor
– When working with tools, observe connection for multifunction
switch.
Socket -T10035- simplifies the work.



AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Remove all six bracket bolts -A-.
es, in part or in w
t to the co
The bracket will be removed later after lowering gearbox.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
g

n
t.
yi Co
Cop py
t. rig
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pyri by
Note
o Vo
by c lksw
cted agen
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engine.
– Pull both electrical connectors off gearbox.
er .


links .

AAR2600i .
– Remove left drive shaft. agen
AG. Volkswagen AG d
oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e

nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
o
rm
m
spindles.
atio
om
n in
c

or
thi
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sd
a

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cu
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f
en
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t.
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op
– Leave an easily accessible bolt in for safety purposes. C py
t. rig
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– Start with the two lower bolts. cop Vo
by lksw
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AG.


Note

port -3282- and adjustment plate -3282 /36- . agen
AG. Volkswagen AG d
w oes
olks not
– Only now is the final bolt removed. byV gu
ara
ed nte
ris
– Carefully push gearbox off engine. tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
Note
y li
rm
ab
pe
ility
ot
wit
, is n
box.
h re
hole
spec
– When lowering, observe clearance between left drive shaft
es, in part or in w
t to the co
and subframe. If necessary, adjust gearbox support -3282-
slightly.
rrectness of i
l purpos
nform
ercia
be transferred.
m
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
12.2 Installing gearbox, Passat with 1.6 l - 85

kW and 2.0 l - 110 kW engines
torque.


Guided functions .

Specified torques for 1.6 l - 85 kW engine ⇒ page 95
Specified torques for 2.0 l - 110 kW engine ⇒ page 96
12.3.1 Specified torques for 1.6 l - 85 kW engine
er
❑ 60 Nm
❑ Qty. 6; remove and in‐ AG. Volkswagen AG d
agen oes
ksw
stall with insert -V/175- . by Vol not
gu
ara
d
ise nte
- M12 bolts ⇒ M12 thor eo
au ra
❑ 80 Nm ss c
ce
le

un
pt
an
d
-T10179- .
itte
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rm
ab
- M10 bolts ⇒ M10
pe
ility
ot
wit
❑ 40 Nm
, is n
h re
hole
spec
in lower flange
es, in part or in w
t to the co
-arrows-
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

12.3.2 Specified torques for 2.0 l - 110 kW engine

AG. Volkswagen AG d
agen oes
1 - Direction of travel olksw not
byV gu
ara
ed
nte
A - Bolt for 2.0 l - 110 kW (FSI) horis
eo
engine aut ra
ss c
ce
le
B - Bolt for other engines
un
pt
an
d
itte
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erm
ab
er
ility
ot p
❑ 60 Nm
wit
is n
h re
ole,
spec
t to the co
- M12 bolts ⇒ M12
❑ 80 Nm
rrectne
-T10179- .
s
- M10 bolts ⇒ M10
s o
cial p
f
❑ 40 Nm
inform
mer
atio
in lower flange
om
n
c
i
or
n
thi
e
-arrows-
t
sd
iva
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pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
12.4 Removing gearbox, Passat with 1.8 l -

Brief description
Note


equipment required
V.A.G 1383 A-
1332-
-3094-
♦ Socket -T10179-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
♦ Insert -V/175-
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Socket -T10035-
lkswage es n
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byV ua
d ran
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tho
u or
a ac
ss
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nl
pt
du
an
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erm
ab
ility
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wit
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
♦ Adapter -10 - 222 A /13-

orm
m
atio

om

n in
or c

thi
te
sd
iva
– Raise vehicle.
o
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m
f
en
ng

t.
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t. C rig
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pyri by
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– Remove battery ⇒ Rep. gr. 27 ; Disconnecting and connecting
c by lksw
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battery; Removing and installing battery . Prote AG.
– Unbolt ATF cooler from battery carrier, pull off and set to side.
– Remove battery carrier.


-2-.
– Unbolt upper line retainer from gearbox.
– Unbolt lower line retainer from gearbox.
– Unbolt ATF lines from gearbox.
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Note

box.


be transferred.
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12.5 Installing gearbox, Passat with 1.8 l - th or
au ac
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– Renew seals on ATF lines.
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– Tighten ATF lines on gearbox ⇒ page 129 .
– Tighten both line brackets ⇒ page 129 .


Guided functions .
12.6.1 Specified torques for 1.8 l 118 kW TFSI engine
er
❑ 60 Nm
- M12 bolts ⇒ M12
❑ 80 Nm
-T10179- .
- M10 bolts ⇒ M10
❑ 40 Nm
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AG. Volkswagen AG d
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12.6.2 Specified torques for 2.0 l 147 kW TFSI engine d by
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❑ 80 Nm
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❑ 40 Nm
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Passat CC 2009 ►, CC 2010 ►
Removing gearbox, Passat CC 2009, CC 2010 with 2.0 l 147 kW
TFSI engine ⇒ page 105 .
Installing gearbox, Passat CC 2009, CC 2010 with 2.0 l 147 kW
TFSI engine ⇒ page 113
13.1 Removing gearbox, Passat CC 2009,

CC 2010 with 2.0 l 147 kW TFSI engine
Brief description
Note

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13. Removing and installing gearbox, Passat CC 2009 ►, CC 2010 ► 105


equipment required
V.A.G 1383 A-
1332-
-3094-
♦ Socket -T10179-
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♦ Insert -V/175-
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♦ 2 adapters -10 - 222 A /3-

♦ Shackle -10 - 222 A /12-
♦ Tensioning strap -T10038-
♦ Wedge -T10161-
♦ Bracket -T10346-
– Turn steering to straight-ahead position.
– Pull out ignition key and engage steering wheel lock.
– Raise vehicle.
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lkswage es n
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After this, do not set vehicle on ir se
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d b ground any more ⇒ Rep. gr. ua
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o tee
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Removing drive shafts withss
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triple-roller joint AAR2600i . ac
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– Remove battery ⇒ Rep. gr. 27 ; Disconnecting and connecting

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wit
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– Remove battery carrier.

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WARNING
Hot steam may escape when expansion tank is opened. Wear

protective goggles and clothing to avoid eye injuries and scald‐
ing. Cover cap with a cloth and carefully open.
– Open coolant reservoir.

♦ Starter motor
– Unbolt ATF line from gearbox. agen

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– Remove upper starter motor bolt. d byV gu
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– Raise vehicle. ut
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– Unbolt „vehicle level sender“ from suspension link. ⇒ Rep. gr.

hole
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40 ; Removing and installing front/right vehicle level sender -

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G78/G289- .
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– Raise right drive shaft as far as possible and secure to sus‐

pension strut in this position.
– Unbolt wire retainer from lower starter bolt.
– Pull out plug.
Note
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On installation, first tighten -B-, then -A-.oTorque
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gr. 40 ; Assembly overview - subframe, d by anti-roll bar, suspension
V ua
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♦ To remove upper engine/gearbox securing bolts, it is neces‐

sary first to unbolt the ATF lines from the gearbox. ATF will run
nf
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between the engine and the intermediate plate.
orm
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♦ To prevent this, first separate the lines -arrows- under the ve‐
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hicle so that the ATF drains out »below«.

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– Remove charge air hose -1-. rig ht
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– Place drip tray under gearbox. Prote
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agen
– Separate both ATF lines.

Leave the drip tray for workshop hoist -VAS 6208- under the
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– Lower vehicle.
– Cover the area of the ATF line connections and the ATF cooler
on the gearbox with cloths.
lkswage es n
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– Pull off line -2- and raise as quickly as possible so that ATF in
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– Pull of line -1- and raise; then secure both lines in this position
using, for example, a cable tie.
Note
The lines will not be removed.
– Seal ATF lines and holes in gearbox with appropriate plugs.



AG. Volkswagen AG d
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– Connect ATF lines with new seals and tighten. Torque setting:
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⇒ page 114 . swa
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13.2 Installing gearbox, Passat CC 2009, CC

2010 with 2.0 l 147 kW TFSI engine
– Thoroughly clean up ATF which has escaped.
When installing bracket, first bolt it to gearbox.


seating«.
– Renew seals on ATF lines.
– Tighten ATF lines on gearbox.
VAS 5051- and then select „Perform basicgsettings“
AG. Volkunder
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13.3 Torque settings,
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13.3.1 Specified torques for 2.0 l 147 kW TFSI engine
an
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❑ 60 Nm
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- M12 bolts ⇒ M12
s
❑ 80 Nm
s o
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❑ 65 Nm if you use socket f inform

-T10179- .
mer
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- M10 bolts ⇒ M10

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❑ 40 Nm
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Specified torques
Component Torque setting
Gearbox bracket to gearbox (4 x M10 bolts) 40 Nm + 90°
Gearbox bracket to gearbox mounting (2 x M12 bolts) 60 Nm + 90°
. Volkswagen AG
gen AG
Bracket for ATF olklines
swa to gearbox ⇒ page 115
does
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ATF lines riseto
d ATF cooler ⇒ page 115
b ara
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o eo
ATF alines
ut
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to gearbox ra 25 Nm
c
Observe
ss
bolt lengths ⇒ page 115
ce
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nl
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Bracket for ATF lines to gearbox
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ATF line to gearbox

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Bolt -1- = M8 x 45
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Bolt -2- = M8 x 38
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ATF lines to ATF cooler


Golf 2009 ►
Removing gearbox, Golf 2009 with 2.5 l - 125 kW engine
⇒ page 116 .
Installing gearbox, Golf 2009 with 2.5 l - 125 kW engine
⇒ page 124

- 125 kW engine
manner, secure log to gearbox. wage
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Brief description ed by ara
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equipment required
V.A.G 1383 A-
1332-
♦ Insert -V/175- agen
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♦ Wedge -T10161- ed by ara
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♦ Support bracket -10 - 222

A-
♦ Adapter -10 - 222 A /8-
♦ Adapter -10 - 222 A /3-
♦ Hook -10 - 222 A /10-
♦ Shackle -10 - 222 A /12-
♦ Adapter -10 - 222 A /7-
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♦ Hose clamp pliers -V.A.G 1921-
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Removing:
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Note
Removing drive shafts with. Vtriple-roller
gen AG
olkswagen AGjoint
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-2-.

AG. Volkswagen AG d
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– Lever cable -1- off lever -3- using
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♦ Starter motor
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nf
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atio
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To support engine and gearbox:

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– Remove wiring -1- from transportation bracket -3-.

– Unbolt transportation bracket -3- from engine -2- and pull out
of eye -arrow-.
– Attach a shackle -10 - 222 A /12- in »this« eye.
– Set up support device -10 - 222 A- .

– Extend right hook -10 - 222 A /10- using adapter -10 - 222 A /
7- .
The hook faces downwards and will later be hooked into the en‐
gine block.
– Remove lower part of left wheel housing
agen liner.
AG. Volkswagen AG d
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– Now pull electrical connectors -1- and -2- off gearbox. agen
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– Pull connector beneath starter -1- out of retainer and separate.
rrectness of i
– Unbolt retainer from lower starter bolt.
l purpos
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– Drain coolant.
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– Turn cap -1- in direction of arrow and remove.
Note
Continue turning the engine carefully! n AG. Volkswagen AG do

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– Hook adapter -10 - 222 A /7- into engine block.
ot
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– Pull coolant hoses off ATF cooler.
hole
spec
Tighten right spindle one turn (more is not necessary).
es, in part or in w
t to the co
– Support engine and gearbox with left spindle. Do not raise.
rrectness of i
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mercia
a
com
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– Remove bracket -A-.

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engine and gearbox slightly via left spindle of support bracket
-10 - 222 A- .
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♦ Observe torque converter. It must be removed together with

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gearbox.
wit
is n
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♦ Keep in mind that if a new gearbox is installed, parts such as

ole,
spec
be transferred.
t to the co
rrectness

o
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f in
125 kW engine
form
mer
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torque.


– After installing, check ATF level ⇒ page 134 . n AG. Volkswagen AG do
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– Carry out basic settings. To do this: byV
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– Connect vehicle diagnosis, testing and information
tho system - tee
or
VAS 5051- and then select „Perform basic
ss
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settings“ under ac
Guided functions .
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14.3 Torque settings, Golf 2009 with 2.5 l - 125 kW engine
itte
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er
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❑ 60 Nm
rrectness of i
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- M12 bolts ⇒ M12

❑ 80 Nm
nf
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or
-T10179- .
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- M10 bolts ⇒ M10
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❑ 40 Nm
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- Two dowel sleeves in engine Cop py
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-Nuts- 8 Nm
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15 Transporting gearbox
Special tools and workshop equipment required AG. Volkswagen AG d
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♦ Shackle -10 - 222 A /12- d by Vo gu
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spec
t to the co
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Shackle 10-222 A/12 can be used to transport the gearbox and
set up gearbox support 3282.
ss
– During transportation, protect torque converter -arrow- from
o
cial p
f
falling out, e.g. with a wire -A-.
inform
mer
– Keep in mind that there is oil in the gearbox. Do not turn gear‐
atio
box with breather downwards during transport or while on
om
n
repair stand. Oil will run out.
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15. Transporting gearbox 127

16 ATF cooler for 1.6 l - 85 kW and 2.0 l

- 110 kW engines
16.1 Assembly overview - ATF cooler
1 - Gearbox housing
2 - Seal
❑ Always renew
3 - ATF cooler
❑ Installation position:
⇒ page 128 .
4 - Seal
❑ Always renew
AG. Volkswagen AG d
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❑ Position: convex side ss
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⇒ Item 7 (page 128)
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7 - Bolt
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❑ 36 Nm
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– When installing ATF cooler -1-, insert lug -arrow B- into recess
in gearbox housing.

17 ATF lines, ATF water cooler and ad‐

ditional ATF cooler, Passat with 2.0 l
TFSI engine
17.1 Overview
A - ATF lines on gearbox

⇒ page 130
B - »External« ATF heat ex‐
changer ⇒ page 131
C - ATF lines ⇒ page 132
D - Additional ATF cooler
⇒ page 133
AG. Volkswagen AG d
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17. ATF lines, ATF water cooler and additional ATF cooler, Passat with 2.0 l TFSI engine 129
17.1.1 ATF lines on gearbox
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1 - ATF line wage does
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❑ Always renew oil ed seal
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❑ 20 Nm ut
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2 - ATF line s
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❑ Always renew oil seal
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❑ 20 Nm
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3 - Nut
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❑ 9 Nm
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17.1.2 External ATF heat exchanger
1 - Bolt
❑ 8 Nm
2 - Nut
❑ 9 Nm
3 - External ATF cooler
4 - Bolt
❑ 9 Nm
5 - ATF line
❑ »Supply.«
6 - ATF line
❑ »Return« AG. Volkswagen AG d
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❑ Always renew oil seal by Vol not
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7 - Nut thor eo
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17.1.3 ATF lines
1 - ATF line
❑ »Return« from addition‐
al cooler.
❑ 25 Nm
2 - ATF line
❑ »Supply« to additional
cooler.
❑ 25 Nm
3 - Nut
❑ 9 Nm
AG. Volkswagen AG d
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17.1.4 Additional ATF cooler
1 - Additional ATF cooler

❑ To remove and install,
remove front bumper
cover ⇒ Rep. gr. 63 ;
Assembly overview -
front bumper cover
2 - Bolt
❑ 5 Nm n AG. Volkswagen AG do
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3 - Bolt d byV ua
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❑ 9 Nm utho tee
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4 - ATF line ss
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5 - ATF line
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❑ »Supply.«
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6 - Bolt
❑ 5 Nm
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7 - Bolt
❑ 9 Nm
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18 Checking ATF level and topping up

Observe these notes as well.
♦ About this workshop manual ⇒ page 1
♦ About ATF ⇒ page 1
♦ About »filler pipe« ⇒ page 2
♦ If necessary, the breather pipe of the adapter for oil filling -VAS
6262 A- has to be shortened ⇒ page 135 .
Special tools and workshop AG. Volkswagen AG d

equipment required agen oes
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♦ Torque wrench -V.A.G orise nte
1331- aut
h eo
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♦ Used oil collection and ex‐
ce
le
un
pt
traction unit -V.A.G 1782-
an
d
itte
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♦ Vehicle diagnosis, testing
rm
ab
pe
ility
and information system -
ot
VAS 5051-
wit
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hole
♦ Drip tray for workshop hoist
spec
-VAS 6208-
es, in part or in w
t to the co
♦ Adapter for filling oil -VAS
6262 A-
rrectness of i
♦ Adapter -VAS 6262/2-
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Shortening breather pipe of adapter for oil filling -VAS 6262 A- :

– In order to ensure that the breather pipe of the adapter for oil
filling -VAS 6262 A- does not bump against the bottom of the
oil bottle, the pipe must be shortened to the length -a- in the
case of some bottles that are used.
Dimension -a- = 210 mm
Note
The dimension -a- is measured from the shaft (green area in the
counting glass) of the adapter for oil filling -VAS 6262 A- .
– Mark dimension -a- on the breather pipe and shorten pipe with
pipe cutter -VAS 6056/2- .
If ATF must be added, use only ATF listed in ⇒ Electronic parts
catalogue ⇒ ETKA .
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o ot g
– If ATF level is checked, oil seal -arrow- on ATF inspection
ed
by V plug ua
ran
must always be renewed. horis tee
ut or
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ss
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un
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18. Checking ATF level and topping up 135

18.1 Checking ATF level

– Switch off engine.
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The ATF temperature should not be more than approx. 30° C at
wit
, is n
h re
the start of the test.
hole
spec
• Gearbox is not in emergency running mode and ATF temper‐
es, in part or in w
ature is not above approx. 30° C.
t to the co
• Vehicle must be standing level
rrectness of i
• Selector lever in „P“.
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– Connect »tester« and continue switching until it is ready for

operation ⇒ page 16 .
nform
ercia
– Press Guided functions »on right«.

m
at
– Then select vehicle, the gearbox and Check ATF level .
om
ion
c
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– Press → .
o
his
ate
do
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– Start engine.
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for
en
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– Raise vehicle.
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– Place drip tray under gearbox.
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– Press → .
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If a test temperature between 35 °C and 45 °C is displayed:
– Remove inspection plug for ATF level from oil pan.

The ATF present in the overflow pipe runs out.

If ATF drips out of drilling:
ATF does not need topping up.
– Fit new seal to plug and tighten to 27 Nm. This concludes the
ATF check.
If no ATF drips out of inspection hole:
– Top up ATF ⇒ page 137 .
18.2 Topping up ATF

agen
AG. Volkswagen AG d
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– With engine »running«,d b screw in adapter for filling oil -VAS
yV t gu
ara
6262/2- hand-tight.
horise nte
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au ac
– Shake oil bottles
ss before opening them.
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nl
– Before screwing adapter for oil filling -VAS 6262 A- onto oil
pt
du
an
itte
bottle, take note of the notes regarding the breather pipe
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erm
ab
⇒ page 135 .
ility
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– Add 1 l of ATF.
wit
, is n
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hole
– Pull off adapter for oil filling -VAS 6262- at quick-release con‐
spec
nection and check:
es, in part or in w
t to the co
If ATF now flows out of hole in adapter:
ATF does not need topping up.
– Drain ATF until it drips. rrectness of i
l purpos
– Fit new seal to plug and tighten to 27 Nm. This concludes the
ATF check.
nform
ercia
If no ATF drips out:

m
at
om
– Add another litre ⇒ page 137 .

on
c
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or
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ate
WARNING
do
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cum
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An ATF level which is too low or too high will impair the function
n
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of the gearbox. But if the gearbox was 2 litres low, it must be C py
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18.3 Draining and filling
olks
wageATF
nA oes
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– Switch off engine. rise nte
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ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
– Remove inspection plug for ATF level from oil pan -arrow-.
thi
s
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– Unscrew and remove ATF inspection plug -A-.

– Always renew oil seal -B-.
– Unscrew and remove overflow pipe -C-.
– Drain ATF.
– Screw in overflow pipe -C- ⇒ page 154 .

– Screw in oil filler adapter -VAS 6262/2- hand tight.

– Shake oil bottles before opening them.
– Before screwing adapter for oil filling -VAS 6262 A- onto oil
bottle, take note of the notes regarding the breather pipe
⇒ page 135 .
– Add 3 litres of ATF ⇒ Electronic parts catalogue ⇒ ETKA
through filler pipe.
AG. Volkswagen AG d
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– Screw in ATF inspection plug -A- hand-tight with new seal
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-B-.
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ility
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wit
– Start engine, shift through all selector lever positions with ve‐
, is n
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hicle stationary, leaving selector lever in each position for
hole
about 10 seconds.
spec
es, in part or in w
t to the co
– Finally, check ATF level and top up ⇒ page 134 .
rrectness of i
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nform
mercia
a
com
tion in
r
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38 – Gears, control
1 Renewing oil seal for selector shaft
– Remove multifunction switch -F125- .

– Carefully lever out selector shaft seal using a screwdriver. Do
not damage selector shaft.
– Drive in new seal to stop with thrust piece -T10174-. Do not
cant oil seal in the process. wage
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– Adjust multifunction switch -F125- . ed
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140 Rep. gr.38 - Gears, control

2 Removing and installing ATF pan

♦ Drip tray -V.A.G 1306-
AG. Volkswagen AG d
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2.1 Removing
rm
ab
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ility
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– Remove noise insulation below engine.
wit
, is n
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hole
– Place drip tray -V.A.G 1306- underneath.
spec
es, in part or in w
– Unscrew ATF inspection plug -A-.
t to the co
– Remove overflow pipe -C- and allow remaining ATF to drain.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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2. Removing and installing ATF pan 141

– Loosen oil pan bolts -arrows- diagonally.

– Remove oil pan together with gasket.
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2.2 Installing au ac
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nl
pt
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following:
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erm
ab
ility
– Clean the two magnets in recesses of oil pan. Ensure that
ot p
magnets are seated correctly in pan.
wit
, is n
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hole
– Check that seal is undamaged and all spacer sleeves (qty. 8)
spec
are present.
es, in part or in w
t to the co
Otherwise renew seal.
– Fit oil sump with seal, taking care not to pinch any wires.
rrectness of i
– Ensure that oil pan gasket is seated correctly.
l purpos
– Tighten pan bolts -arrows- diagonally in several stages; torque

specification ⇒ page 154 .
nform
mercia
at
om
ion
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ate
do
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– Screw in overflow pipe -C-; torque specification ⇒ page 154 .

– Fill with ATF; check ATF level and top up ⇒ page 134 .
AG. Volkswagen AG d
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tion in
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Prote AG.
2. Removing and installing ATF pan 143

3 Removing and installing ATF strainer
3.1 Removing
– Remove oil pan ⇒ page 141 .
– Unscrew ATF strainer bolts -arrows-.
– Pull ATF strainer -A- off valve body.
AG. Volkswagen AG d
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3.2 Installing s
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– Thinly coat seals on intake neck of ATF strainer with ATF.

itte
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– The ATF strainer must be renewed if seals are loose or de‐

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fective.
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– Fit oil strainer -A- and tighten bolts; torque settings

hole
spec
⇒ page 154 .
es, in part or in w
t to the co
– Install oil pan ⇒ page 141 .

rrectness of i
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4 Removing and installing valve body
WARNING
lkswage es n
Do not run engine or tow vehicled by Vwith pan removed or when
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there is no ATF in gearbox.orise
ran
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♦ The valve body and the wiring harnesses can also be removed
un
pt
an
d
when the gearbox is installed.

itte
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♦ Moisten seals with ATF before fitting. Other lubricants lead to
ility
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malfunction of the gearbox hydraulics.
wit
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♦ Always renew a valve body which is fouled or defective.
ole,
spec
♦ Do not use fluffy cloths.
t to the co
♦ After the pan has been installed, the ATF level must be
checked and topped up ⇒ page 134 .
rrectne
4.1 Overview - valve chest
ss o
cial p
f
1 - ATF inspection plug
inform
mer
❑ Checking ATF level and
atio
topping up ⇒ page 134
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n
c
❑ Torque setting
i
or
n thi
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⇒ page 154
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2 - Seal
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❑ Always renew
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3 - Overflow pipe
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❑ Unscrew to drain ATF
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❑ Torque setting
AG.
⇒ page 154
4 - Oil pan
⇒ page 141
5 - Bolt
❑ Tighten oil pan bolts di‐
agonally in several
stages.
❑ Torque setting
⇒ page 154
6 - Seal
❑ With spacer sleeves
(qty. 8)
❑ Examine before fitting
❑ Renew brittle, cracked
or deformed seal
7 - Magnet
❑ Qty. 2 in depressions in
pan
❑ Clean oil pan before in‐
stalling
8 - Bolt
❑ For securing valve body in gearbox
4. Removing and installing valve body 145

❑ Qty. 12, various lengths ⇒ page 151
❑ Always renew bolts
❑ Torque setting ⇒ page 154
9 - Bolt
❑ Qty. 3
❑ For securing strainer to valve body
10 - ATF strainer
AG. Volkswagen n AG do
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11 - Valve body Vol ot g
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❑ Removing ⇒ pageoris147e
tee
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❑ Installing ⇒ page
ss
a 150
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12 - Bolt
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13 - Bolt
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15 - Bolt
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nform
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17 - Gearbox housing
m
a
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❑ Shown here without gearbox oil cooler

n in
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18 - Breather cap
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19 - Multifunction switch -F125-

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❑ Removing ⇒ page 23
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❑ Installing ⇒ page 24
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20 - Gearbox oil temperature sender -G93-
❑ Integrated into wiring harness
❑ Cable routing ⇒ page 152 .
21 - Bolt
22 - Bolt
23 - Wiring harness for sender
❑ With gearbox oil temperature sender -G93-
❑ For gearbox input speed sender -G182-
❑ For gearbox output speed sender -G195-
❑ Always renew oil seal on housing

24 - Seal
❑ Always renew
25 - ATF drain plug
26 - Selector lever
27 - Washer
28 - Nut
❑ Location: centring collar faces washer ⇒ Item 27 (page 147)
29 - Spring
30 - Damper piston
31 - Wiring harness for solenoid valves
❑ Always renew oil seal on housing
32 - Bolt
4.2 Removing valve body

AG. Volkswagen AG d
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es, in part or in w
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♦ Angle wrench -V.A.G 1756-

rrectness of i
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nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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op
– Remove oil pan ⇒ page 141 . C py
t. rig
gh ht
yri by
– Remove ATF strainer ⇒ page 144 . op Vo
by c lksw
cted agen
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– Pull connectors off solenoid valves ⇒ Item 1 (page 153)
AG.
through ⇒ Item 8 (page 153) .

A flat-blade screwdriver with a shaft diameter of 2.5 mm is well

suited to release connector housing on solenoid valves.
Caution
If connector or connector housing is damaged, the wiring har‐

ness or solenoid valve must be renewed.
– Separate connectors ⇒ Item A (page 153) and

⇒ Item B (page 153) .
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– Unbolt retainer for connectors ⇒ Item 1 (page 154) and y Volks ot g
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⇒ Item 2 (page 154) . ris
ed
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tho or
– Unscrew gearbox oil temperature sender -G93-s au ac
⇒ Item 3 (page 154) and carefully pull out of valve
s body.
ce
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pt
du
an
itte
– Bend back securing tab on selector lever, if fitted.
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ility
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spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia
– Remove selector lever -1- from selector shaft.

m
at
om
io
– In the process, carefully grip selector lever -1- with pliers -2-
n
c
in t
r
so that torque is not transferred to multifunction switch -F125- .

o
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ate
do
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– Note spool valve -A- on valve body into which selector lever
engages so that this is not damaged.

The spool valve is very »sensitive«. Even the slightest damage

will lead to faults in operation.
– Therefore, always push spool valve into valve body, secure
against falling out and never interchange.
– Loosen marked bolts (Qty. 12) -arrows-.
Caution
If other bolts are loosened, the valve body will warp.
AG. Volkswagen AG d
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nl
pt
– Unbolt brackets -1- and -2-.
du
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es, in part or in w
t to the co
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nf
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orm
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– Unbolt valve body and remove.
AG. Volkswagen AG d
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nl
pt
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– When removing valve body, observer damper piston -2-.
ility
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– Remove piston with spring.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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priv
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4.3 Installing valve body
op Vo
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cted agen
Prote AG.
So that no wiring is pinched during installation:
– Route wires -1-, -3-, -4- and -5- as shown in figure and fix them
in place.
The distance -a- must be maintained to prevent wiring harness
-5- from coming into contact with planetary gearbox and thereby
becoming damaged during vehicle operation.

The valve body is secured with bolts of 3 different lengths.

– Before installing valve body, sort bolts by length.
AG. Volkswagen AG d
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un
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– Coat damper piston -2- with ATF and insert with spring.
rm
ab
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– Carefully insert valve body and start 2 bolts.
ot
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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Lengths of bolts and location on valve body ht. rig
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Bolts -arrows- M 6x21, Qty. 3
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Bolts -arrows A- M 6x16, Qty. 2
Bolts -arrows B- M 6x28, Qty. 4
– Check that no wire is pinched.

– First fit remaining bolts and retainers -1- and -2- and tighten
by hand.
– Install gearbox oil temperature sender -G93- and tighten; tor‐
que settings ⇒ page 154 .
– Push connector (Qty. 8) onto solenoid valves ⇒ page 152 .
– Tighten retainer for connectors ⇒ page 152 ; torque setting
⇒ page 154 .
– Push on connectors ⇒ Item A (page 153) and
⇒ Item B (page 153) .
– Tighten valve body diagonally from centre outwards; torque
setting ⇒ page 154 .
– Install selector lever.
lkswage es n
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byV ua
d ran
ir se tee
o
– Tighten selector lever
auth nut -1- to specified torque or
ac
⇒ page 154 . ss
ce
le
un
pt
– In the process, carefully grip selector lever -1- with pliers -2-
an
d
itte
so that torque is not transferred to multifunction switch -F125- .

y li
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pe
ility
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spec
es, in part or in w
t to the co
rrectness of i
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– Bend up securing tab on nut.

– Install ATF strainer ⇒ page 144 .
nform
ercia

m
a
com
ti
on in
r
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thi
– Connect -VAS 5051- and continue to switch until „Function/

s
iva
component selection“ is displayed.

do
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– Then press „Drive (Repair group 01; 10...26; 28...39)“.

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– Then „6-speed automatic gearbox 09G“.
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– Press „01 - Self-diagnosis“. cop Vo
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– Press „Functions“.
AG.
– Press „Basic setting“.
4.3.1 Wire routing, connectors, connections

and retainer on valve body
This chapter contains information and figures pertaining to work
on the valve body.
Wire routing, connectors and connections

1 - Solenoid valve 4 -N91-

❑ Colour of wire to valve:
green/brown
green/grey
yellow/violet
red/blue
white/black
❑ Colour of wire to valve: AG. Volkswagen AG d
agen oes
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green/blue by Vol not
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7 - Solenoid valve 1 -N88- tho r eo
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white
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A - Connection for gearbox
hole
spec
output speed sender -G195-
es, in part or in w
t to the co
❑ Colour of wire to sender:
blue/orange
B - Connection for gearbox in‐
rrectness of i
put speed sender -G182-

l purpos
❑ Colour of wire to sender:

white/red
nf
ercia
orm
m
atio
Retainer for connectors, fixing wires in place

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1 - Retainer for connection

gearbox output speed sender -
G195-
❑ Torque setting
⇒ page 154
2 - Retainer for connection
gearbox input speed sender -
G182-
❑ Torque setting
⇒ page 154
3 - Gearbox oil temperature
sender -G93-
❑ Colour of wire on send‐
er: orange/orange
4 - Selector lever AG. Volkswagen AG d
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❑ Torque setting olksw not
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⇒ page 154 ised b ara
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Pfeile - au
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❑ Wire are fixed in place
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es, in part or in w
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nform
mercia
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c
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or
4.4 Specified torques

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5 Removing and installing wiring har‐

ness for solenoid valves and senders
5.1 Removing
– Drain ATF ⇒ page
wag138
en AG. . V
olkswagen AG
does
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Vol gu
– Removeeoil
d b pan ⇒ page 141 .
y ara
nte
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– Remove
au
th ATF strainer ⇒ page 144 . ra
ss c
– Remove valve body ⇒ page 147 .
ce
e
nl
pt
du
an
– Pull connector off gearbox.
itte
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ab
-1- connector for sender in gearbox
ility
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-2- Connector for solenoid valves
h re
hole
spec
– Unbolt connector housing from gearbox.
es, in part or in w
t to the co
– Pull connector housing with wiring harness outwards out of
gearbox housing.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
5.2 Installing
at
do
priv
cum
or
– Renew seal on connector housing.

f
en
ng
t.
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– Carefully thread wiring harness into gearbox from outside.
Cop py
ht. rig
rig ht
– Moisten seal on connector housing with ATF and press con‐
py by
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nector housing into gearbox to stop.
by lksw
cted agen
Prote AG.
– Tighten connector housing; torque setting ⇒ page 154 .
– Install valve body ⇒ page 150 .
– Install ATF strainer ⇒ page 144 .
5. Removing and installing wiring harness for solenoid valves and senders 155
6 Removing and installing gearbox in‐

6.1 Removing
– Remove valve body ⇒ page 147 .
– Unscrew bolt -1- from gearbox input speed sender -G182- .
– Pull sender out of gearbox.
lkswage es n
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d ran
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a ac
ss
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es, in part or in w
t to the co
rrectness of i
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6.2 Installing
nform
ercia

m
at
following:
om
ion
c
in t
r
– Press sender into gearbox to stop.

o
his
ate
do
riv
– Tighten bolt -1- for gearbox input speed sender -G182- ; torque
p
cum
or
specifications ⇒ page 154 .

f
en
ng
t.
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– Install valve body ⇒ page 150 . t. Cop py
rig
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7 Removing and installing gearbox out‐

wage es n
7.1 Removing olks ot g
byV ua
d ran
ir se tee
– Remove valve body ⇒ page u147
th .
o
or
a ac
ss
– Unscrew bolt -2- from gearbox output speed sender -G195- .
ce
e
nl
pt
du
an
– Pull sender out of gearbox.
itte
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erm
ab
ility
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
or
7.2 Installing
f
en
ng
t.
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op
C py
t. rig
gh
following:
ht
pyri by
Vo
co lksw
by
cted
– Press sender into gearbox to stop.
agen
Prote AG.
– Tighten bolt -2- for gearbox output speed sender -G195- ; tor‐
que specifications ⇒ page 154 .
– Install valve body ⇒ page 150 .
7. Removing and installing gearbox output speed sender G195 157

39 – Final drive - differential

1 Renewing oil seals for flange shafts
Brief description
Flange shaft O-rings can be replaced with gearbox in situ.
Left drive shaft is removed completely.
gen AG
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Right drive shaft remains
db
y V in vehicle and is only detached
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uafrom
gearbox. orise ran
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– Right drive
ss shaft remains in wheel bearing; use thrust piece -c
a a
T10177- . Remove left drive shaft; use thrust piece -T10176- .
ce
e
nl
pt
du
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1.1 Renewing oil seal for left flange shaft
itte
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erm
ab
ility
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♦ Puller -T10055-
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate

do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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Removing
– Remove left drive shaft ⇒ Rep. gr. 40 ; Removing and instal‐
ling drive shafts .
158 Rep. gr.39 - Final drive - differential

– Seal drive shaft aperture on transmission with a clean cloth

-A-.
– Carefully drill a hole (size 2 to 4 mm) -B- into outer sheet metal
ring -C- of oil seal.
Note
♦ Grease drill bit -B- so that swarf adheres to it.

♦ Drill only through sheet metal ring -C- because gearbox may
otherwise be damaged.
– Screw a self-tapping screw, approx. 4 mm in diameter, into

hole drilled in oil seal -arrow-.
Note
♦ Do not screw in sheet metal screw too far to avoid damaging

bearing behind it.
♦ Pull out oil seal using puller -T10055- and adapter -T10055/2- .
♦ Remove cloth and carefully clean gearbox and drive shaft
aperture.
♦ No iron chips must enter gearbox or drive shaft aperture; vac‐
uum up chips if necessary.
♦ If only the sheet metal ring of seal could be pulled out, carefully
lever out rest of seal with a screwdriver.
Installing
Install in reverse order of removal.eDuring
n AG. Volthis
kswagstep,
en AGobserve the
following: olks
wag does
not
yV gu
db a
– Apply ATF to circumference
or
ise and sealing lips of new oil seal.
ran
te
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Installation position:
ss
a c
ce
le
Open side of oil seal faces gearbox.

un
pt
an
d
itte
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rm
ab
– Drive in new seal onto stop with thrust piece -T10176- . Do not
pe
ility
cant oil seal.

ot
wit
, is n
h re
– Install drive shaft ⇒ Rep. gr. 40 ; Removing and installing

hole
spec
drive shafts .
es, in part or in w
t to the co
– Finally, check ATF level and top up ⇒ page 134 .

– Install noise insulation.
rrectness of i
l purpos
nform
mercia
1.2 Renewing seal for right flange shaft

com
tion in
r
te o
thi

s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
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rig ht
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co Vo
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cted agen
Prote AG.
1. Renewing oil seals for flange shafts 159

♦ Puller -T10055-
Removing
– Remove noise insulation.
– Remove right drive shaft from gearbox
. Volkswag⇒
en ARep. gr. 40 ; Re‐
gen AG
moving and installinglkdrive
swa shafts .
G do
es n
Vo ot g
by u
– Raise drive shaft
ris
ed as high as possible and secure. Take
ara
ncare
tee
not to damage
utho paint on drive shaft in the process. or
sa ac
– Seal drive
s
shaft aperture on transmission with a clean cloth
ce
e
nl
-A-.
pt
du
an
itte
y li
– Carefully drill a hole (size 2 to 4 mm) -B- into outer sheet metal
erm
ab
ring -C- of oil seal.

ility
ot p
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
♦ Grease drill bit -B- so that swarf adheres to it.

♦ Drill only through sheet metal ring -C- because gearbox may
rrectness of i
otherwise be damaged.
l purpos
nf
ercia
orm
m
atio
om
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160 Rep. gr.39 - Final drive - differential

– Screw a self-tapping screw, approx. 4 mm in diameter, into

hole drilled in oil seal -arrow-.
Note
G. Volkswage
♦ Do not screw in sheet metal screwlktoo
swa far to avoid damaging
gen A n AG d
oes
bearing behind it. o n ot g
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is
♦ Pull out oil seal using puller
ut
hor
-T10055- and adapter -T10055/2- . tee
or
a ac
♦ ss
Remove cloth and carefully clean gearbox and drive shaft
ce
e
aperture.
nl
pt
du
an
itte
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♦ No iron chips must enter gearbox or drive shaft aperture; vac‐
erm
ab
uum up chips if necessary.
ility
ot p
wit
, is n
♦ If only the sheet metal ring of seal could be pulled out, carefully
h re
lever out rest of seal with a screwdriver.
hole
spec
es, in part or in w
t to the co
Installing
following:
rrectness of i
– Apply ATF to circumference and sealing lips of new oil seal.
l purpos
Installation position:
nform
ercia
Open side of oil seal faces gearbox.

m
at
om
io
– Drive in new seal onto stop with thrust piece -T10177- . Do not
n
c
in t
r
cant oil seal.

o
his
ate
do
riv
– Install drive shaft ⇒ Rep. gr. 40 ; Removing and installing

p
cum
or
drive shafts .
f
en
ng
t.
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1. Renewing oil seals for flange shafts 161

Transmision Automatica VW-AUDI 09G

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Transmision Automatica VW-AUDI 09G

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Service

Golf Plus 2005 ➤ , Passat 2006 ➤ ,

6-speed automatic gearbox 09G

Service Department. Technical Information

39 - Final drive - differential

All rights reserved.

Copyright © 2011 Volkswagen AG, Wolfsburg K0258992320

3.1 Gearbox codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5 Golf Plus 2005 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1 Proper handling and installation of torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.4 Installing torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 n in

7.1 Overview of selector mechanism in vehicles from 03.2009 onwards . . . . . . . . . . . . . . . . . . 45

9.5 Torque settings, gearbox to engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

10.1 Removing gearbox, Golf Plus 2005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

11.2 Installing gearbox, Touran 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

38 - Gears, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

2.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

1.2 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

1.2 Torque converter

1.4 Automatic gearbox control unit -J217-

with ⇒ fuzzy logic

The gear change point, which is dependent on the driving situa‐

tion and driving resistance, is determined automatically.

• Gear changes will be fuel-consumption orientated.

• Individual adaptation of gear change points in all driving sit‐

• Gear change points are infinitely variable.

1.5 Control units in vehicle

The installation locations of all vehicle control units and other

useful information can also be found here ⇒ Current flow dia‐

grams, Electrical fault finding and Fitting locations.

1.6 Information on „09G gearbox“

♦ ⇒ Self-study programme No. 291 ; Automatic gearbox 09G

1. General repair notes 1

Uncertainty often occurs with smaller bolts having low tightening

♦ First thoroughly clean connecting points and surrounding

areas and then loosen bolts. en

2 Rep. gr.00 - Technical data

1.9 Gaskets, seals and oil

♦ Always renew O-ring, seals and gaskets.

♦ Open side of oil seal faces oil.

1.10 Nuts and bolts

1. General repair notes 3

1.11 Electrical components

The guided functions will guide you to the ATF temperature

in the shortest way possible ⇒ page 16 .

4 Rep. gr.00 - Technical data

2.1 Planetary gearbox and final drive

3.1 Gearbox codes

Code letters -arrow 1-

6 Rep. gr.00 - Technical data

5 Golf Plus 2005 ►

8 Rep. gr.00 - Technical data

»GXY« »HTQ« JTX

Engine 1.6 l - 85 kW 2.0 l - 110 kW 1.8 l - 110 kW

10 Rep. gr.00 - Technical data

9 Passat CC 2009 ►, CC 2010 ►

12 Rep. gr.00 - Technical data

Therefore, always work with care.

1.1 Identification of torque converter

There are various torque converters. They are identified by codes.

Special tools and workshop equipment required

1. Proper handling and installation of torque converter 13

♦ -V.A.G 1358 A- Oil extraction unit

14 Rep. gr.32 - Torque converter