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VOLKSWAGEN JETTA 2005 (05) PDF MANUAL
VOLKSWAGEN JETTA 2005 (05) ngfor private or commercial purposes, in part or in whole, is not permittedunle
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Service
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Workshop Manual
Golf Variant 2007 Golf Variant 2010 Jetta 2005 Jetta 2011
6-speed automatic gearbox 09G
Edition 04.2010
Service Department. Technical Information
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
Service List of Workshop Manual RepassiaruthGoriserdobyuVoplksswaLgeisnAtGo.VoflkWswagoenrAkGsdohesonopt guMaranateenorauc al
Repair GroupsList of Workshop Manual Repair Groups
Repair Group 00 - Technical data 32 - Torque converter 37 - Controls, housing 38 - Gears, control 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 © 2010 Volkswagen AG, Wolfsburg
MEX5R005320
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1
Suggestions and criticism, general repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Suggestions and criticism of this workshop manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.6 Automatic gearbox control unit J217 with fuzzy logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.7 Control units in vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.8 Information on "09G gearbox" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.9 1.10 1.11 1.12
Tools . . Gearbox Gaskets, Nuts and
. . . . . . . . . . . . . . . . . . . . seals and oil bolts . . . . .
. .
.
. . . .
. . . . . . . ...ss...a.u..th...o..r.is...e.d..
.b...y....V....o.l...k.s...w....a....g.e...n....A....G.........V...o..l...k.s...w....a....g..e....n...A....G.....d...o...e..s....n...o...t..g....u..a..r...a.n....te....e...o.r....ac....
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2 3 4 4
1.13 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.14 Guided fault finding, vehicle self-diagnosis and testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2
Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Gearbox codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Planetary gearbox and final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4
Codes, gearbox allocation, ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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32 - Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1
Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Identification of torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Draining torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Removing and installing torque converter oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Installing torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
37 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1
Connecting "tester" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Connecting vehicle diagnosis, testing and information system VAS 5051 . . . . . . . . . . . . 11
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2
Electrical and electronic components and their locations . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3
Multifunction switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1 Removing multifunction switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2 Installing multifunction switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3 Adjusting multifunction switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4
Selector mechanism up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.1 Overview of selector mechanism up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2 Removing and installing selector mechanism with selector lever up to 02.2009 . . . . . . . . 23
4.3 Removing and installing selector lever cable up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . 23
4.4 Checking selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.5 Adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.6 Emergency release of selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.7 Removing and installing knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.8 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5
Selector mechanism from 03.2009 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.1 Overview of selector mechanism in vehicles from 03.2009 onwards . . . . . . . . . . . . . . . . . . 35
5.2 Removing and installing selector lever and selector mechanism with selector lever cable from 03.2009 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.3 Emergency release of selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
i Contents
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6
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, . .
Jetta . . . .
.
.
.
38
6.1 Removing gearbox, vehicles with 1.6 l - 75 kW and 2.0 l - 110 kW (FSI) engines . . . . . . . . 38
6.2 Installing gearbox, vehicles with 1.6 l - 75 kW and 2.0 l - 110 kW (FSI) engines . . . . . . . . 45
6.3 Removing gearbox, vehicles with 2.5 l, 110 kW engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.4 Installing gearbox, vehicles with 2.5 l, 110 kW engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.5 Torque settings, gearbox to engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7
Removing and installing gearbox, Jetta 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.1 Removing gearbox, Jetta 2011 with 2.0 l - 85 kW engine . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.2 Installing gearbox, Jetta 2011 with 2.0 l - 85 kW engine . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.3 Removing gearbox, Jetta 2011 with 2.5 l - 125 kW engine . . . . . . . . . . . . . . . . . . . . . . . . 63
7.4 Installing gearbox, Jetta 2011 with 2.5 l - 125 kW engine . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.5 Torque settings, gearbox to engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8
Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9
ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
9.1 Assembly overview - ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10 Checking ATF level and topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 10.1 Checking ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 10.2 Topping up ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 10.3 Draining and filling ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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38 - Gears, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1
Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2
ATF pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.1 Removing and installing ATF pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3
ATF strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.1 Removing and installing ATF strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4
Valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.2 Removing and installing valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.3 Removing and installing wiring harness with 14-pin connector (for solenoid valves) . . . . . . 103
4.4 Removing and installing wiring harness with 8-pin connector (for sender) . . . . . . . . . . . . 105
4.5 Removing and installing gearbox input speed sender G182 . . . . . . . . . . . . . . . . . . . . . . . . 106
4.6 Removing and installing gearbox output speed sender G195 . . . . . . . . . . . . . . . . . . . . . . 107
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1
Renewing oil seals for flange shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.1 Renewing oil seal for flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
ii Contents
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
00 Technical data
1
Suggestions and criticism, general
repair notes
1.1
This
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or
ac
and be an aid to you. If you use ELSA, you can send us sug-
gestions, "praise and criticism" from anywhere in the world.
You can do this by clicking the Feedback button at the top in the menu bar.
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You will not always receive a reply from Volkswagen but your message will always be read. We make great effort to implement your suggestions for the workshop manuals.
1 1. Suggestions and criticism, general repair notes
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
ceptany liability with respect to the correctness of information in this documen
1.2
General repair notes
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.
1.3
Gearbox
The "6-speed automatic gearbox 09G" has six hydraulically ac- tuated forward 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.
1.4
Torque converter
The torque converter is equipped with a lock-up clutch. The lockup clutch locks up depending on load and speed. The 2nd, 3rd, 4th, 5th and 6th gears can be driven mechanically (without slip).
1.5
ATF
The ATF is filled for life. The ATF need not be changed during a service. UtTcrhohseneecicAokneTpldFayraAtlesnTvdcFeatlwsotsapshilanopiuctgehthhoudreihesueapd"psEblaytTbonVeKgoeeleAktanst"hwroy.aergrgde.eneaAreGrbd.oVaxoslkasanwpdaagferinnt afArlGodmdroievtsheneoatrgeuaEralnetece-orac
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1.6
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.
Advantages:
· Gear changes will be fuel-consumption orientated.
· Maximum engine output is always available.
· Individual adaptation of gear change points in all driving sit- uations.
· Gear change points are infinitely variable.
1.7
Control units in vehicle
The installation locations of all vehicle control units and other useful information can also be found in Current flow diagrams, Electrical fault finding and Fitting locations.
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1.8
Information on "09G gearbox"
Design and function of gearbox
Multimedia training; Automatic gearbox 09G
Self-study programme No. 291 ; Automatic gearbox 09G
1.9
Tools
A summary of the special tools and workshop equipment used in the workshop manual precedes each repair procedure and can be found in "Special tools/Workshop equipment" binder.
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2 Rep. Gr.00 - Technical data
The catalogue the usual way
fisroamlsoBearvtaeillsambGlaeonlsofsnanV.utahorrCiiaseDndt-bRy2V0Oo0lMk7swaangde,ncG6AaoG-nsl.fpVbVeoeleakosdrrwiadaanegutreteon2dAm0G1a0dtoicesgn,eoJtagerubtatoraaxn2te00e9o0rG5ac
, Jetta - Edition
2011 04.2010
Uncertainty often occurs with smaller bolts having low tightening forces. Torque wrench 2...10 Nm -V.A.G 1783- can be used with these bolts.
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1.10 Gearbox
If gearbox covers have been unbolted or gearbox has no fluid, do not run engine or tow vehicle.
First thoroughly clean connecting points and surrounding areas and then loosen bolts.
When installing the gearbox, ensure that dowel sleeves be- tween the engine and gearbox are correctly located.
Place removed parts on a clean surface. Cover parts to pre- 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.
This "old" filler opening with the red cap is not needed because ATF can be drained or filled as required through the bottom hole. The "height" of this tube determines the level of the ATF. The tube must be removed to drain the fluid. After installation, check the ATF level and top up
page 77 . Capacities page 7 .
3 1. Suggestions and criticism, general repair notes
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
1.11 Gaskets, seals and oil
Always renew O-rings, seals and gaskets. Before installing a radial oil seal, coat sealing lips and area
between them with sealing grease -G 052 128- . Open side of oil seal faces oil. After installing, check ATF level.
Bcoerdcianrgetfsous alCruewthagohuruiestleianodtnbiwyoVnoosrlkk.siRwnagegmewneiAtmhGb.oVeiolr.l:kDsownisaegpedonrsoAeGp odooffedos rnilaowtingiuleladcraonotneieltaoarmacc -- inate 1,000 litres of water.
1.12 Nuts and bolts
Loosen and tighten securing bolts and securing nut 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.
1.13 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. Before beginning work on electrical components, touch an
earthed object, for example a water pipe or lifting platform. Do not touch connectors or "open" electronic components directly.
4 Rep. Gr.00 - Technical data
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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
1.14 Guided fault finding, vehicle self-diag- nosis and testing
Before making repairs to the automatic gearbox, determine the cause of the fault as precisely as possible with the aid of "guided fault finding". Guided fault finding is carried out using the vehicle diagno- sis, testing and information system -VAS 5051B- page 11 . The guided functions will guide you to the ATF temperature in the shortest way possible page 11 .
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
5 1. Suggestions and criticism, general repair notes
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
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ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
2
Gearbox identification
"6-speed automatic gearbox 09G" is fitted in Jetta 2005 , Bora 2006 , Golf Variant 2007 , Jetta Wagon 2008 and Jetta 2011.
The allocation of the gearbox to the vehicles can be found here:
Codes, gearbox allocation, ratios page 8 .
2.1
Gearbox codes
Code letters -arrow-
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Code letters -arrow 1"6-speed automatic gearbox 09G" -arrow 2Example:
GGZ
08
05
I
I
I
Identification Day Month code
02 I Year -2002of manufacture
The gearbox code also appears on the vehicle identification plates.
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6 Rep. Gr.00 - Technical data
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
3
Capacities
3.1
Planetary gearbox and final drive
Initial filling Change
Lubricant
Capacities
"6-speed automatic gearbox 09G" approx. 7.0 l Filled for life no change
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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7 3. Capacities
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
4
Codes, gearbox allocation, ratios
If Genuine parts are required for a repair, always refer to the gearbox code.
Identification code Engine
"HFS", "HTN", "JTY"
1.6 l - 75 kW
"Automatic gearbox 09G"
"MAM"
"HFT", "HTP", "HDN", "HFU",
"JUH"
"HRM", "JUJ"
"KGL"
2.s0saulth-o8ris5edkbWy Volksw2a.g0enlA(-FG1S.1VI)0olkksWwagen2A.G5dloe-s1n1ot0gukaWrantee
2.5
or ac
l
-
125
kW
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8 Rep. Gr.00 - Technical data
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
32 Torque converter
1
Torque converter
1.1
Identification of torque converter
There are various torque converters. They are identified by codes.
Torque converter/gearbox allocation Replacement parts cata- logue ETKA
1.2
Draining torque converter
Special tools and workshop equipment required
-V.A.G 1358 A- Oil extraction unit
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
-V.A.G 1358 A/1- Oil extraction probe
Extract ATF from torque converter using -V.A.G 1358 A- and probe -V.A.G 1358 A/1- .
1.3
Removing and installing torque convert-
er oil seal
Special tools and workshop equipment required
Thrust piece -T10175-
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9 1. Torque converter
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ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010 Oil seal extractor lever -VW 681-
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
Removing Pry out seal with lever -VW 681- .
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Installing Drive in seal flush thrust piece -T10175- .
1.4
Installing torque converter
Carefully push on torque converter hub via oil seal to first stop.
Turn torque converter towards gearbox using light pressure until notch in hub -arrow- engages in follower of pump gear and torque converter can be felt to slip in place.
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.
10 Rep. Gr.32 - Torque converter
37
1
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011
Controls, housing ssauthorisedby
Volkswagen AG.
Vo6lk-sswpaegeedn
automatic gearbox
AG does not guarantee orac
09G
-
Edition
04.2010
Connecting "tester"
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
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 11 .
1.1
Connecting vehicle diagnosis, testing
and information system -VAS 5051-
Special tools and workshop equipment required
Vehicle diagnosis, testing and information system -VAS 5051-
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WARNING During a road test, always secure testing and measuring
equipment on the back seat. These devices may be operated only by a passenger dur-
ing a test drive.
Push connector of diagnosis cable -VAS 5051/1- -2- or VAS 5051/3- onto diagnosis connection.
11 1. Connecting "tester"
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010 Switch on "tester" -arrow-. The "tester" is ready for use when it is possible to choose between the buttons Guided functions and Guided fault finding on the "right" of the screen. Depending on equipment and version of the tester, other func- tions may be "displayed" such as: ElsaWin Testing Self-diagnosis The "tester" is now ready for use. Switch on ignition. Touch a button on the screen to start the desired function.
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
12 Rep. Gr.37 - Controls, housing
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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
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.
Installation location in Jetta 2005 , Bora 2006 , Golf Variant 2007 , Jetta Wagon 2008 page 14
Installation location in Jetta 2011 with 2.0 l 85 kW engine page 15 .
Installation location in Jetta 2011 with 2.5 l 125 kW engine page 15 .
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. spective letter
e2n4gfionretshcseoaudtrheeor-ised
by
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AG
does
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or
ac
3 - Multifunction switch -F125-
Location page 15
Can be checked using "guided fault finding" of VAS 5051-
Removing, installing and adjusting page 18 .
ngfor private or commercial purposes, in part or in whole, is not permittedunle
4 - Valve body Location page 15 Components can be checked using "guided fault finding" of -VAS 5051 Allocation Electronic parts catalogue "ETKA"
5 - Wiring harness, 8-pin For senders With gearbox oil temperature sender -G93 Location page 16 Removing and installing page 105 Allocation Electronic parts catalogue "ETKA"
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6 - Gearbox oil temperature sender -G93 Location page 16 Can be checked using "guided fault finding" of -VAS 5051-
7 - Wiring harness, 14-pin For solenoid valves
ceptany liability with respect to the correctness of information in this documen
13 2. Electrical and electronic components and their locations
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Location page 16 Removing and installing page 103 Allocation Electronic parts catalogue "ETKA"
8 - Hydraulic pressure sender 1 for automatic gearbox -G193 Not installed in all gearboxes Allocation Electronic parts catalogue "ETKA" Location page 16
9 - Hydraulic pressure sender 2 for automatic gearbox -G194 Not installed in all gearboxes Allocation Electronic parts catalogue "ETKA" Location page 16
10 - Gearbox input speed sender -G182 Location page 17 Removing and installing page 106 Can be checked using "guided fault finding" of -VAS 5051-
11 - Gearbox output speed sender -G195 Location page 17 Removing and installing page 107 Can be checked using "guided fault finding" of -VAS 5051-
12 - Selector lever lock solenoid -N110-
Location: selector lever lock solenoid is located in the selector mechanism.
Can be checked using "guided fault finding" of -VAS 5051-
13 - Tiptronic switch -F189 Location page 17 Can be checked using
"guided
fauslstafuitnhodriisnegd b"yoVfol-kVswAaSge5n0AG51. V-olkswagen AG
does
not
guarantee or ac
14 - Terminal 50 voltage supply relay -J682-
In E box in engine compartment Current flow diagrams, Electrical fault finding and Fitting locations.
15 - Diagnostic connection Location page 17
16 - Selector lever position display -Y6 Location page 17 Removing and installing Electrical system; Rep. Gr. 90 ; Gauges, instruments; Dash panel insert .
Automatic gearbox control unit -J217- -arrow- in Jetta 2005 , Bora 2006 , Golf Variant 2007 , Jetta Wagon 2008 Location: control unit is located in front left wheel housing. Wheel housing liner must be removed for removing and in-
stalling.
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
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14 Rep. Gr.37 - Controls, housing
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
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Golf Variant 2007 ssau,thGo6rios-esldfpbVeyeaVdorilkaasnwutato2gem0n1aA0tGic. Vgo,elkJasewrbtatogaexn20A09G0G5do-esEn,doJtitgeiuotatnraan02te40e.o12r1a0c10 Automatic gearbox control unit -J217- -A- in Jetta 2011 with 2.0 l - 85 kW engine Location: control unit is located in plenum chamber on right. Plenum chamber cover must be removed for removal and in-
stallation Rep. Gr. 50 ; Plenum chamber cover; Removing and installing plenum chamber cover .
Automatic gearbox control unit -J217- -A- in Jetta 2011 with 2.5 l - 125 kW engine Location: control unit is located in front left of engine compartment next to battery.
Multifunction switch -F125Location: multifunction switch is located on top of the gearbox.
Valve body Location: valve body is bolted to underside of gearbox housing and covered by pan. Solenoid valves -N88- , -N89- , -N90- , -N91- , -N92- , -N93- , N282- and -N283- are attached to valve body.
15 2. Electrical and electronic components and their locations
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010 Wiring harness, 8-pin Wiring harness for senders With integrated gearbox oil temperature sender -G93-arrowLocation: wiring harness is attached to valve body in gearbox.
Wiring harness, 14-pin Wiring harness for solenoid valves. Location: wiring harness is attached to valve body in gearbox.
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
Hydraulic pressure sender 1 for automatic gearbox -G193- and hydraulic pressure sender 2 for automatic gearbox -G194This sender is not installed in all gearboxes. Location: Automatic gearbox hydraulic pressure sender 1 -G193- -1- and automatic gearbox hydraulic pressure sender 2 -G194- -2- are bolted into valve body.
16 Rep. Gr.37 - Controls, housing
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ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 GsLeoencadaretbioronx-G:ins1ep9nu5dt-esprseeadresiennstdsaselalrueth-doGriis1ne8dg2bey-VaaornlbksdowxgagheeoanurAbsGoin.xVg6oola-ukssbtpwpoeuavgeteedsnvpAaaeGulevtdedoomesanotitcgugaeraantrebeoorxac 09G - Edition 04.2010 body. 1 - Gearbox input speed sender -G1822 - Gearbox output speed sender -G195-
Tiptronic switch -F189Location: Tiptronic switch is integrated into selector mechanism. In vehicles with a multifunction steering wheel, the buttons on the steering wheel and their cable connections must also be checked.
Diagnostic connection Location: diagnosis connector -arrow- is located on left below driver storage compartment.
Selector lever position display -Y6Location: in dash panel insert
17 2. Electrical and electronic components and their locations
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
3
Multifunction switch -F125-
Removing multifunction switch -F125- page 18
Installing multifunction switch -F125- page 19
Adjusting multifunction switch -F125- page 20
3.1
Removing multifunction switch -F125-
Carry out procedure as follows:
Move selector lever to position "N".
Switch off ignition. In order to remove selector lease cable -arrows 1- and bracket -arrow 2-.
tlheevnerrecmabolevefriot mfrogmeacrabbsoslxaeu,thsfoiurrisspetpdrobeyr-tVolkswagen
AG.
Volkswagen
AG
does
not
guarantee
or
ac
Note
Do not use any pliers, otherwise securing tabs on cable sup- port bracket could break off.
Do not bend or kink selector lever cable.
Lever cable -1- off lever -3- using an open jaw spanner -2-. Pull connector off multifunction switch -F125- .
ngfor private or commercial purposes, in part or in whole, is not permittedunle
Unscrew nut -1-. Remove spring ring -2- and lever -3- from selector shaft -4-.
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18 Rep. Gr.37 - Controls, housing
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Carefully bend back hooks of lock washer -2- using a screw- driver.
Renew securing clip if hooks have broken off. Unscrew nut -1-. Remove bolts -5-. Pull multifunction switch -4-, together with washers -2- and
-3-, off selector shaft -6-.
ceptany liability with respect to the correctness of information in this documen
3.2
Installing multifunction switch -F125-
Special tools and workshop equipment required
Torque wrench -V.A.G 1331-
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
ngfor private or commercial purposes, in part or in whole, is not permittedunle
Carry out procedure as follows: Install in the reverse order of removal, observing the following: Place multifunction switch -4- on selector shaft -6-. Tighten securing bolts -5- for multifunction switch hand-tight. Bend hooks of lock washer -2- back. Put washers -2- and -3- on selector shaft -6-. Install washer -2- with hooks pointing up. Install washer -2- with long, narrow guides in long, narrow re-
cesses of selector shaft -6-. Tighten nut -1- to 7 Nm. Secure nut -1- by bending up hooks on lock washer -2-. Renew securing clip if hooks have broken off.
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19 3. Multifunction switch F125
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Push lever -3- onto selector shaft -4-. Use lever -3- to shift gearbox to "P" position, i.e. press lever
-3- back (opposite direction of travel) to stop. Now use lever -3- to shift gearbox to "N" position. To do this,
push lever -3- two detent positions forwards in direction of travel. Place spring ring -2- and nut -1- on selector shaft -4-. Tighten nut -1- to 13 Nm. Check selector mechanism page 33 .
3.3
Adjusting multifunction switch -F125-
Special tools and workshop equipment required
Setting gauge -T10173-
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
Move selector lever to position "N". Do not kink selector lever cable.
3.3.1 Adjustment prerequisites
· Selector lever cable is disconnected from selector shaft lever. · Selector shaft is set to "N" position. · Securing bolts for multifunction switch -F125- have been loos-
ened. · Selector shaft lever has been removed.
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20 Rep. Gr.37 - Controls, housing
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Carry out procedure as follows:
Place setting gauge on selector shaft -2- and turn multifunction switch -1- until setting gauge engages in lug on multifunction switch connector.
STRCieeogcmnhuttoiernevnuesebssesoiaetnulttttishsntotingar-isaglelgardrgatboiauyowVugnosgelik-ensot.wonraeg6sveeenNlreAmsGce.t.oVororldskeshwraafotgfe-nr2eA-mGwoditovheasblnootltgpu-a3arg-a.nete1e o9r ac.
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ceptany liability with respect to the correctness of information in this documen
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21 3. Multifunction switch F125
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
G6-oslpf eVeadriaanutto2m00a7ticge,aGrboolfxV0a9riGassn-atuEt2hod0rii1stei0odnby0Vo4,lk.J2sew0tat1ag0e2n0A0G5. Volks,wJaegtetan A2G0d1o1esnot guaranteeorac
4
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 35 .
4.1
Overview of selector mechanism up to 02.2009
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1 - Selector cover with knob Do not remove knob without reason. For emergency release, on- ly the cover needs to be unclipped page 31 . Before removing knob, pull button out past its pressure point. Secure button with cable tie or appropriate wire against being pressed in. This will prevent the button from being accidentally pressed into the knob. If button is pressed into removed handle
Always pull out button past the felt pressure point before installing knob.
2 - Selector mechanism with selector lever
Removing and installing page 23
3 - Bolt with spring 3 Nm
4 - Pin Removing page 23 Do not grease
5 - Locking plate Always renew after re- moving
6 - Nut 9 Nm Qty. 4
7 - Selector housing With seal
8 - Selector lever cable Cable must not be greased Removing and installing page 23 Checking page 30
22 Rep. Gr.37 - Controls, housing
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Adjusting page 30
9 - Hexagon nut with washer 8 Nm Qty. 4
ceptany liability with respect to the correctness of information in this documen
4.2
Removing and installing selector mech-
anism with selector lever up to 02.2009
Carry
out procedure Note
sas asuthfoorlisloedwbsy :Volkswagen
AG. Volkswagen
AG does not
guarantee or ac
Following installation, selector lever cable must be checked for ease of movement and be adjusted.
ngfor private or commercial purposes, in part or in whole, is not permittedunle
Remove selector lever cable from gearbox page 23 .
Remove centre console Rep. Gr. 68 ; Compartments, cov- ers and trims .
Remove selector lever cable from gearbox page 23 .
Remove exhaust system below heat shield Rep. Gr. 26 ; Removing and installing parts of exhaust system .
Remove heat shield beneath selector mechanism.
Remove 4 nuts for selector mechanism "from above".
Torque setting for nuts: 8 Nm
Take selector mechanism out downwards.
Check selector lever cable after installing page 30 .
4.3
Removing and installing selector lever
cable up to 02.2009
Carry out procedure as follows:
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Note Following installation, selector lever cable must be checked for ease of movement and be adjusted.
Removing Move selector lever to position "S" position. In order to remove selector lever cable from gearbox, first re-
lease cable -arrows 1- and then remove it from cable support bracket -arrow 2-.
Note
Do not use any pliers, otherwise securing tabs on cable sup- port bracket could break off.
Do not bend or kink selector lever cable.
t. Copyright by Volkswagen AG.
23 4. Selector mechanism up to 02.2009
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010 Lever cable -1- off lever -3- using an open jaw spanner -2-. Raise vehicle. To remove cable and/or selector mechanism, heat shield and, if necessary, parts of exhaust system must be removed Rep. Gr. 26 ; Removing and installing parts of exhaust system . Remove heat shield beneath selector mechanism. Remove -selector housing- beneath selector lever.
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
24 Rep. Gr.37 - Controls, housing
t. Copyright by Volkswagen AG.
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ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Remove locking plate for selector lever cable. Always renew locking plate.
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
-Selector housing- is pushed forwards slightly on cable --.
To remove selector lever cable, securing tab must be pushed for- wards in -direction of arrow 1-. At same time, -pin- is pushed up with a screwdriver
-arrow 2-.
Please insert -screwdriver- from underneath whilst pushing securing tab forwards.
25 4. Selector mechanism up to 02.2009
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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
ceptany liability with respect to the correctness of information in this documen
ngfor private or commercial purposes, in part or in whole, is not permittedunle
Clarification: -1- Push tab forwards -2- Push pin up
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
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26 Rep. Gr.37 - Controls, housing
t. Copyright by Volkswagen AG.
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
Remove selector lever cable. Remove selector housing from selector lever cable. Installing Do not grease cable. Route selector lever cable free of tension and insert in cable
support bracket on gearbox. However, do not secure it there yet. Ensure that selector lever cable is properly routed during in- stallation.
27 4. Selector mechanism up to 02.2009
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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010 Also clip selector lever cable into bracket. Make sure that bracket does not make contact with ATF cooler. Tighten -nuts- to 8 Nm.
Put selector housing onto selector lever cable. Insert selector lever cable into selector mechanism.
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
Insert selector lever cable into bearing and insert pin from above, downwards through eye -direction of arrow 2-.
When you have checked freedom of movement of cable page 30 , insert locking plate.
Attach selector lever cable with new locking plate on cable support bracket of selector mechanism.
28 Rep. Gr.37 - Controls, housing
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
Install selector housing, heat shield and exhaust system. Adjust selector lever cable after installing page 30 .
29 4. Selector mechanism up to 02.2009
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
4.4
Checking selector lever cable
Brief description
To check ease of movement of selector lever cable, it must be removed from the gearbox and the free end must be placed so that it does not bump against anything.
Then move selector lever and reinstall the selector lever cable.
Then the selector lever cable must be adjusted page 30 .
Do not grease connection of selector lever cable.
Carry out procedure as follows:
Move selector lever to position "P" position.
Loosen bolt -2- of selector lever cable -1-.
Lever cable -1- from selector shaft lever -3- using an open jaw spanner -2-.
·
CcMSaeaotlbcvelheceetsoisserltreloeecgvmteeootrrhvlmeeervdue-safrtrrormremopowsevscsaeaau-tt.bheeoladerissleysidluyfbrp.yoVpmoolkr"stPwb"argtaoecn"kASeG"t.abVnoydlkpsbrweaascgskeinntAogG"Pdo"e.s not guaranteeorac
Install selector lever cable again.
Adjust selector lever cable!
4.5
Adjusting selector lever cable
Special tools and workshop equipment required
Torque wrench -V.A.G 1331-
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
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The selector lever cable must always be adjusted whenever The selector lever cable has been removed from the gearbox. The engine and/or gearbox has been removed and installed.
30 Rep. Gr.37 - Controls, housing
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Parts of the assembly mounting have been removed and in- stalled.
The cable itself or the selector mechanism has been removed and installed.
The position of the engine and gearbox is shifted, for example to install it free of tension.
Carry out procedure as follows: Move selector lever to "P" position. · 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.
Note
Raise vehicle, to be sure that the gearbox is in "P" (parking lock engaged). It should not be possible to turn both front wheels to- gether in the same direction.
Gently push knob of selector lever forwards and backwards but under no circumstances must you shift out of "P".
In this way the inner cable of the Bowden cable finds it optimal
position. Tighten bolt -2- to 13 Nm.
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
4.6
Emergency release of selector lever
Do not remove knob.
Unclip selector cover and hold to side.
Depress brake pedal or set handbrake.
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
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31 4. Selector mechanism up to 02.2009
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Press yellow plastic part -arrow- from right to left. Lever can now be moved from position "P".
4.7
Removing and installing knob
It is possible with all knobs that the button is pressed into the knob. Never install a knob with the button pressed in.
Before removal, pull button out past its pressure point.
Secure button with a cable tie or wire against being pressed in.
Unclip cover.
Release knob.
Lock knob again after installing.
Press plastic partssuanutdhoerisrekdnbyoVbolbksawcakgednoAwGn. V.olkswagen AG does not guaranteeorac
Remove transport guard of a "new" knob after releasing knob. Pull connector from cover. Pull off knob upwards.
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
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32 Rep. Gr.37 - Controls, housing
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
In vehicles with button -arrow- at front on knob Button -arrow- is not allowed to be pressed in when knob is being fitted and removed.
ngfor private or commercial purposes, in part or in whole, is not permittedunle
However, should this happen, unclip knob trim upwards. Press small lever for pull rod -arrow- back into groove before
installing knob.
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
ceptany liability with respect to the correctness of information in this documen
4.8
Checking selector mechanism
The starter must not operate in the selector lever positions "R", "D" or "S".
On right-hand drive vehicles, the starter must operate in selector lever positions "P" and "N" only when the button in the gear knob is not pressed.
When selector lever is shifted to position "N" at speeds above 5 km/h, solenoid for selector lever lock must not engage and block selector lever. Selector lever can be shifted into a driving range.
t. Copyright by Volkswagen AG.
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When the vehicle is moving at speeds below 5 km/h (almost sta- tionary) and the selector lever is shifted to position "N", the sole- noid for selector lever lock should only engage after about 1 second. Selector lever cannot be shifted out of "N" position until brake pedal is depressed.
4.8.1
Selector lever in "P" position and ignition switched on
· Brake pedal not depressed:
33 4. Selector mechanism up to 02.2009
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
ceptany liability with respect to the correctness of information in this documen
Selector lever is locked and cannot be shifted out of "P" position when the button is pressed. Solenoid for selector lever lock blocks selector lever.
·Ss"dPiaob"sllBeethhnrtarpoookaiudsenghefphoilfetritndiosnsaet"elolSesrdst"caae,cutpotcdohrohrrreririelvsseeeicsnvsdkebegpiyndrogVg:nlooedlwkcasskrhw.tearoSegthellsoeneewaArlesGlsyec.eVtssloeohsrlckieflstteolwesvraceegltelreoevnprceAotleorGsvrpidteoloieoers.vnsietnI.itoortinsfgruopianmroanst-ee or ac
4.8.2
Selector lever in "N" position and ignition switched on
ngfor private or commercial purposes, in part or in whole, is not permittedunle
· Brake pedal not depressed:
Selector lever is locked and cannot be shifted out of "N" position with the push button pressed. Solenoid for selector lever lock blocks selector lever.
· Brake pedal depressed:
Solenoid for selector lever lock releases selector lever. It is pos- sible to shift into a driving gear.
4.8.3 Selector lever in position "Tiptronic"
· Shift selector lever into Tiptronic gate.
The illuminated "D" symbol in the selector mechanism cover must go out and the "+" and "-" symbols must light up.
When the selector lever is shifted into the Tiptronic gate, the se- lector lever position display in the dash panel insert must change from "P R N D S" to "6 5 4 3 2 1".
Protected by copyright. Copyi
4.8.4 Ignition and light switched on
The respective symbol in the shift mechanism cover lights up.
4.8.5 Selector lever position display
Simultaneous illumination of all selector lever position display segments indicates gearbox emergency running mode.
t. Copyright by Volkswagen AG.
34 Rep. Gr.37 - Controls, housing
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
5
Selector
mGeoclfhVasasrnaiuatihnsortmis2ed0b0fyr7Voolmksw, aG06geo-3snlfp.A2VeGea0. Vdr0oialak9nsutwto2agm0e1an0tAicGdgo,eeJasernbotttoagxu2a0r0a90ntG5ee
, Jetta - Edition
or ac
2011 04.2010
onwards
WARNING Before working on vehicle with engine running, move selector lever into position "P" and apply handbrake.
Selector mechanism in vehicles up to 02.2009 page 22 .
5.1
Overview of selector mechanism in vehicles from 03.2009 onwards
t. Copyright by Volkswagen AG.
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1 - Selector cover with knob Do not remove knob without reason. For emergency release, on- ly the cover needs to be unclipped page 37 . Before removing knob, pull button out past its pressure point. Secure button with cable tie or appropriate wire against being pressed in. This will prevent the button from being accidentally pressed into the knob. If button is pressed into removed handle
Always pull out button past the felt pressure point before installing knob.
2 - Selector lever and selector mechanism with selector lever cable
With selector lever lock solenoid -N110-
Selector lever cable is not greased
Removing and installing page 36
Checking page 30 Adjusting page 30
3 - Bolt 8 Nm
4 - Hexagon flange nut 8 Nm Qty. 4
5 - Selector lever housing
6 - Selector lever cable Is not allowed to be removed from selector mechanism and is renewed jointly as one component
7 - Gearbox
35 5. Selector mechanism from 03.2009 onwards
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
5.2
Removing and installing selector lever
and selector mechanism with selector
lever cable from 03.2009 onwards
Note
Selector mechanism and selector lever cable are not allowed to be separated from one another. Both are removed together.
Following installation, selector lever cable must be checked for ease of movement and be adjusted.
Carry out procedure as follows:
Move selector lever to position "P" position.
Remove selector lever handle page 32 .
Remove centre console Rep. Gr. 68 ; Compartments, cov- ers and trims .
Pull connector off selector mechanism.
Remove 4 bolts. Torque setting 8 Nm.
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
In order to remove selector lever cable from gearbox, first re- lease cable -arrows 1- and then remove it from cable support bracket -arrow 2-. Note
Do not use any pliers, otherwise securing tabs on cable sup- port bracket could break off.
Do not bend or kink selector lever cable.
Lever cable -1- off lever -3- using an open jaw spanner -2-. Raise vehicle. Remove exhaust system below heat shield Rep. Gr. 26 ;
Removing and installing parts of exhaust system . Remove heat shield beneath selector mechanism.
36 Rep. Gr.37 - Controls, housing
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Remove selector mechanism.
Install in reverse order of removal.
Install heat shield beneath selector mechanism.
Install parts of exhaust system Rep. Gr. 26 ; Removing and installing parts of exhaust system .
Adjust selector lever cable after installing page 30 .
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
5.3
Emergency release of selector lever
Press yellow plastic wedge. Lever can now be moved from position "P".
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
37 5. Selector mechanism from 03.2009 onwards
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
6
Removing and installing gearbox,
Jetta 2005 , Bora 2006 , Golf Var-
iant 2007 , Jetta Wagon 2008
Removing gearbox, vehicles with 1.6 l - 75 kW and 2.0 l - 110 kW (FSI) engines page 38
Installing gearbox, vehicles with 1.6 l - 75 kW and 2.0 l - 110 kW (FSI) engines page 45
Removing gearbox, vehicles with 2.5 l - 110 kW engine page 45
Installing gearbox, vehicles with 2.5 l - 110 kW engine page 53
Torque settings page 54
6.1
Removing gearbox, vehicles with 1.6 l -
75 kW and 2.0 l - 110 kW (FSI) engines
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. Brief description
ss authorised
by
Volkswagen
AG.
Volkswagen
AG
does
not
guarantee
or
ac
The gearbox is removed downwards as a unit. The engine re-
mains in the vehicle.
Battery, battery carrier, air filter and engine cover are removed "from above". Engine and gearbox must then be supported so that left assembly mounting can be removed.
Noise insulation is removed and drive shafts are pressed off "from below". Gearbox is lowered using gearbox jack.
Note The subframe is not to be removed.
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
38 Rep. Gr.37 - Controls, housing
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Special tools and workshop equipment required Engine and gearbox jack -
V.A.G 1383 A Torque wrench -V.A.G
1332 Gearbox support -3282 Adjustment plate -3282 /36 Hose clamps to 25 mm Ø
-3094 Socket -T10179-
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
Insert -V/175-
39 6. Removing and installing gearbox, Jetta 2005 , Bora 2006 , Golf Variant 2007 , Jetta Wagon 2008
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010 Support bracket -10 - 222 A-
Adapter -10 - 222 A /13-
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
Tensioning strap -T10038-
Following descriptions show "automatic gearbox 09G" with 2-litre petrol engine (FSI). Deviations to other engine types are minimal. However, torque settings for bolting gearbox to engine go into detail "as usual" (large and small engines, FSI and multi-point in- jection engines). 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. Carry out procedure as follows: Move selector lever to position "P" position. Remove battery and battery tray Rep. Gr. 27 ; Disconnect- ing and connecting battery; Removing and installing battery . Remove engine cover and air filter with intake hose.
40 Rep. Gr.37 - Controls, housing
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
ngfor private or commercial purposes, in part or in whole, is not permittedunle
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
In order to remove selector lever cable from gearbox, first re- lease cable -arrows 1- and then remove it from cable support bracket -arrow 2-.
Note
Do not use any pliers, otherwise securing tabs on cable sup- port bracket could break off.
Do not bend or kink selector lever cable.
Lever
csas abutlheor-is1e-d
by Volkswagen AG. Volkswagen AG
off lever -3- using an open
does
jaw
nsopt agunanraentree-o2r-a.c
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
Tighten hose clamps up to Ø 25 mm -3094- on hoses and remove hoses from ATF cooler.
Disconnect electrical connections to gearbox and starter. Remove upper starter motor bolt.
Set up support bracket -10 - 222 A- and support engine with gearbox. Do not raise.
Remove upper engine/gearbox connecting bolts. Bolts may be installed with a socket -T10179- . However, note lower torque setting when tightening page 54 .
41 6. Removing and installing gearbox, Jetta 2005 , Bora 2006 , Golf Variant 2007 , Jetta Wagon 2008
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
If present, remove earth strap from bracket -A-. Remove 2 securing bolts for gearbox mounting on bracket
-A- and 4 bolts for bracket on gearbox. 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 .
Raise vehicle.
Remove noise insulation tray.
Remove vacuum pump with bracket and lines. "The pump is located near the ATF filler tube."
If not already done, now gearbox. Remove starter Rep. starter .
remove Gr. 27 ;
eRleecmtroicvainl gcoassnnanudtehoicnritssoetdrasblylifVnrooglmkswagen
AG.
Volkswagen
AG
does
not
guarantee
or
ac
Remove pendulum support, first bolt -A- and then bolts -B-.
Note When installing, first tighten bolts -B-, then bolt -A-, torque set- tings Rep. Gr. 40 ; Assembly overview - subframe, anti-roll bar, suspension links .
Unbolt suspension link from wheel bearing housing on both sides.
Torque settings Rep. Gr. 40 ; Assembly overview - subframe, anti-roll bar, suspension links .
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
42 Rep. Gr.37 - Controls, housing
ceptany liability with respect to the correctness of information in this documen
If
present,
remove
heat
Golf Variant 2007 shield abosvsaeuthroigrishetd
bdyrViv,oelGk6sso-wshlafpagVeeftneaAdriGaa.nVutoto2lkm0sw1aa0tgicengA,eGJaderobtetoasxn2o0t0g90uGa5ra-ntEee,doJriateicottna
2011 04.2010
-arrows-.
ngfor private or commercial purposes, in part or in whole, is not permittedunle
Press both drive shafts out of gearbox. This procedure is de- scribed in Rep. Gr. 40 ; Repairing drive shafts; Removing and installing drive shafts .
Remove left drive shaft Rep. Gr. 40 ; Repairing drive shafts; Removing and installing drive shafts .
Raise right shaft as far as possible and secure in this position.
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
Now remove assembly mounting bracket. To do this, lower engine and gearbox slightly via support bracket -10 - 222 Aspindles.
4 turns are sufficient. If exhaust system retainer is present on gearbox, remove it. Remove lower engine/gearbox connecting bolts. Leave an easily accessible bolt installed for safety. Start with two lower bolts.
43 6. Removing and installing gearbox, Jetta 2005 , Bora 2006 , Golf Variant 2007 , Jetta Wagon 2008
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Note
On some smaller engines up to 1.6 litres, one of the lower -bolts- can be backed out of the gearbox but not removed from the hole.
If this bolt has to be removed then remove front exhaust pipe Rep. Gr. 26 ; Removing and installing parts of exhaust system .
The hole for removing rubber cap on the rear Remove this cap.
the torque converter of the engine.
nut
is
covsesraeutdhorwiseitdhbyaVolkswagen
AG. Volkswagen
AG does not
guarantee or ac
Remove six -torque converter nuts- with insert -V/175- .
Note Continue turning the engine carefully!
ngfor private or commercial purposes, in part or in whole, is not permittedunle
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- .
Secure gearbox to gearbox support -3282- using bolt -1-. Only now is the final bolt removed. Press gearbox off engine while simultaneously pressing tor-
que converter out of drive plate of engine. Note clearance from subframe when lowering. If necessary,
readjust gearbox support -3282- slightly.
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
44 Rep. Gr.37 - Controls, housing
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Note Pay attention to torque converter. It must be removed together
with gearbox. Secure torque converter to prevent it from falling out. Keep in mind that if a new gearbox is installed, parts such as cable support bracket and retainer for gate selector cable must be transferred.
ceptany liability with respect to the correctness of information in this documen
6.2
Installing gearbox, vehicles with 1.6 l -
75 kW and 2.0 l - 110 kW (FSI) engines
Check whether dowel sleeves are pressed into engine flange.
Check seat of intermediate plate between engine and gear- box. The plate must make contact with the engine along its entire perimeter when it is pressed gently with both hands against the engine. If the top does not contact the engine, it is not properly engaged in the engine block.
Continue installation in reverse order of removal.
The engine and gearbox should be mounted tension-free in the assembly mounting. The correct procedure is described in Rep. GWrh.RFe1iner0snitne;sswRctaeraelmlliwlnobgivon,ilnftaisgrlslotabnsnocdlletrseifntwbsaytssbasshrlalaeuaintchmnogkdrbiese.letynd-bgmAyi-nVooeoulk;nnsNtwtoinaogggteee.nsaAroGbn.oVxionluskstsawinlalaggetisnoeAn-G.does not guaranteeorac curing bolts -1-, tighten to 40 Nm and 90° further.
Two bolts -2- for securing bracket to gearbox mounting can be tightened by inserting a screwdriver between the two bolts to ad- just to "previous seating". These two larger bolts are tightened to 60 Nm + 90°.
Torque settings, gearbox to engine page 54 .
Adjust selector lever cable page 30 .
After installing, check ATF level page 77 .
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 .
ngfor private or commercial purposes, in part or in whole, is not permittedunle
6.3
Removing gearbox, vehicles with 2.5 l,
110 kW engine
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.
Protected by copyright. Copyi
Brief description
The gearbox is removed downwards separately. The engine re- mains in the vehicle.
Battery, battery carrier, air filter and engine cover are removed "from above". Engine and gearbox must then be supported so that left assembly mounting can be removed.
t. Copyright by Volkswagen AG.
45 6. Removing and installing gearbox, Jetta 2005 , Bora 2006 , Golf Variant 2007 , Jetta Wagon 2008
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 Nbeolioswe "i.nGs6ue-lsaass aptruiboethonoerxdisiseisadrbuelyotmVowomolekvsarewetdiadcgaeugnnsedAianGdrgb.rViogvoxeelkas0srw9hbaGaogfxet-snjEAaaGcdrekidt.oipoersnens0ost4ge.u2da0rao1nft0fee"forroacm
Note The subframe is not to be removed. Special tools and workshop equipment required Engine and gearbox jack -
V.A.G 1383 A Insert -V/175 Gearbox support -3282 Wedge -T10161 Torque wrench -V.A.G
1332 Adjustment plate -3282 /36-
46 Rep. Gr.37 - Controls, housing
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Support bracket -10 - 222 A-
Adapter -10 - 222 A /8 Adapter -10 - 222 A /7 Hook -10 - 222 A /10 Adapter -10 - 222 A /3 Shackle -10 - 222 A /12-
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
Tensioning strap -T10038-
Carry out procedure as follows: 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. Move selector lever to position "P" position. Raise vehicle.
47 6. Removing and installing gearbox, Jetta 2005 , Bora 2006 , Golf Variant 2007 , Jetta Wagon 2008
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Depress brake pedal to remove bolt for left drive shaft -arrow- (second mechanic required).
Note After this, do not set vehicle on the ground 40 ; Repairing drive shafts; Removing and
iansnssaytuathmlloirnoisgreeddbyriVvoRelkesswpha.agGfetnsr.A.G.
Volkswagen
AG
does
not
guarantee
or
ac
Remove engine cover and air filter.
Pull off hoses -arrows- and remove intake hose from throttle valve unit.
Remove battery and battery tray Rep. Gr. 27 ; Disconnect- ing and connecting battery; Removing and installing battery .
ngfor private or commercial purposes, in part or in whole, is not permittedunle
Protected by copyright. Copyi
In order to remove selector lever cable from gearbox, first re- lease cable -arrows 1- and then remove it from cable support bracket -arrow 2-.
Note Do not use any pliers, otherwise securing tabs on cable sup-
port bracket could break off. Do not bend or kink selector lever cable.
Lever cable -1- off lever -3- using an open jaw spanner -2-. Disconnect electrical connections to gearbox and starter. Multifunction switch Starter motor Earth strap to bracket
t. Copyright by Volkswagen AG.
48 Rep. Gr.37 - Controls, housing
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Remove cable retainer -1- from starter bolt -arrow-. Remove upper starter motor bolt. Remove upper engine/gearbox connecting bolts. To support engine and gearbox:
Remove cables -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.
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
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 noise insulation tray. Remove lower part of left wheel housing liner.
If present, remove heat shield above right drive shaft -arrows-.
49 6. Removing and installing gearbox, Jetta 2005 , Bora 2006 , Golf Variant 2007 , Jetta Wagon 2008
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010 Unbolt suspension link from wheel bearing housing on both sides.
Press both drive shafts out of gearbox. This procedure is de- scribed in Rep. Gr. 40 ; Repairing drive shafts; Removing and installing drive shafts .
Remove left drive shaft Rep. Gr. 40 ; Repairing drive shafts; Removing and installing drive shafts .
Raise right shaft as far as possible and secure in this position.
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
Now pull electrical connectors -1- and -2- off gearbox.
50 Rep. Gr.37 - Controls, housing
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
ceptany liability with respect to the correctness of information in this documen
ngfor private or commercial purposes, in part or in whole, is not permittedunle
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Pull connector beneath starter -1- out of retainer and separate.
Unbolt retainer Remove lower
from lower starter bolt
starter bolt. and remove
starter.
ss authorised
by
Volkswagen
AG. Volkswagen
AG does not
guarantee or ac
Remove pendulum support, first bolt -A- and then bolts -B-.
Drain coolant.
Turn cap -1- in -direction of arrow- and remove.
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
Remove six -torque converter nuts- with insert -V/175- .
Note Continue turning the engine carefully!
51 6. Removing and installing gearbox, Jetta 2005 , Bora 2006 , Golf Variant 2007 , Jetta Wagon 2008
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010 T ighHPStuuoelponl pkcrooiagrodthlaaet pnnsttgpehiinrnoed-s1leea0sno-don2feg2fe2AtuaTArrnbF/o7(cxm-owioonrliteteohr.ieslennfgtoisntpeninebdcloleecs.ksssD.aauortyhon)r.oisetdrbayiVsoelk.swagen AG. Volkswagen AG does not guaranteeorac
Remove 2 securing bolts for gearbox mounting on bracket -A- and 4 bolts for bracket on gearbox.
Now remove assembly mounting bracket. To do this, lower engine and gearbox slightly via left spindle of support bracket -10 - 222 A- .
4 turns are sufficient. Remove lower engine/gearbox connecting bolts. Leave an easily accessible bolt installed for safety.
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- .
Secure gearbox to gearbox support -3282- using bolt -1-. Only now is the final bolt removed. Press gearbox off engine while simultaneously pressing tor-
que converter out of drive plate of engine. Note clearance from subframe when lowering. If necessary,
readjust gearbox support -3282- slightly.
52 Rep. Gr.37 - Controls, housing
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
Note Pay attention to torque converter. It must be removed together
with gearbox. Secure torque converter to prevent it from falling out. Keep in mind that if a new gearbox is installed, parts such as cable support bracket and retainer for gate selector cable must be transferred.
t. Copyright by Volkswagen AG.
6.4
Installing gearbox, vehicles with 2.5 l,
110 kW engine
Check whether dowel sleeves are pressed into engine flange.
Protected by copyright. Copyi
Check seat of intermediate plate between engine and gear- box. The plate must make contact with the engine along its entire perimeter when it is pressed gently with both hands against the engine. If the top does not contact the engine, it is not properly engaged in the engine block.
Continue installation in reverse order of removal.
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 .
Renew all bolts on left assembly mounting.
First screw in all bolts by hand.
When installing, first screw bracket -A- onto gearbox using se- curing bolts -1-, tighten to 40 Nm and 90° further.
Two bolts -2- for securing bracket to gearbox mounting can be tightened by inserting a screwdriver between the two bolts to ad- just to "previous seating". These two larger bolts are tightened to 60 Nm + 90°.
Torque settings, gearbox to engine page 54 .
Adjust selector lever cable page 30 .
After installing, check ATF level page 77 .
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 .
53 6. Removing and installing gearbox, Jetta 2005 , Bora 2006 , Golf Variant 2007 , Jetta Wagon 2008
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
6VVee.p5hhaiiccglleeess54wwiitthhT12o..65rqll --u71e510skWekWttainnedngg2ssins.,0aeugtlhoe-ri1sape1adr0gbbyeokVWo5xlk5s(twFoaSgeeI)nneAgnGgi.nVinoeelksswagen AGdoesnot guaranteeorac 6.5.1 Torque settings, vehicles with 1.6 l - 75 kW and 2.0 l - 110 kW (FSI) engines
1 - Direction of travel A - Bolt for 2.0 l - 110 kW (FSI) engine B - Bolt for 1.6 l -75 kW engine - Drive plate to torque convert- er
60 Nm Qty. 6; remove and in-
stall with insert -V/175- . - M12 bolts M12
80 Nm 65 Nm if you use socket
-T10179- M10 bolts M10
40 Nm These bolts are located
in lower flange - 2 dowel sleeves in engine -arrows-
54 Rep. Gr.37 - Controls, housing
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Make sure that bracket does not make contact with ATF cool- er.
-Nuts- 8 Nm
6.5.2
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
Torque settings, vehicles with 2.5 l - 110 kW engine
ngfor private or commercial purposes, in part or in whole, is not permittedunle
1 - Direction of travel
- Drive plate to torque convert- er
60 Nm Qty. 6; remove and in-
stall with insert -V/175- .
- M12 bolts M12 80 Nm 65 Nm if you use socket -T10179-
- M10 bolts M10 40 Nm These bolts are located in lower flange
- 2 dowel sleeves in engine -arrows-
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
55 6. Removing and installing gearbox, Jetta 2005 , Bora 2006 , Golf Variant 2007 , Jetta Wagon 2008
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010 Make sure that bracket does not make contact with ATF cool- er. -Nuts- 8 Nm
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
56 Rep. Gr.37 - Controls, housing
t. Copyright by Volkswagen AG.
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ceptany liability with respect to the correctness of information in this documen
ngfor private or commercial purposes, in part or in whole, is not permittedunle
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011
6-speed automatic gearbox 09G - Edition 04.2010
7
Removing and Jetta 2011
installing
gearbox, ssauthorised by Volkswagen AG. Volkswagen AG does not guaranteeorac
Removing gearbox, Jetta 2011 with 2.0 l - 85 kW engine
page 57
Installing gearbox, Jetta 2011 with 2.0 l - 85 kW engine page 63
Removing gearbox, Jetta 2011 with 2.5 l - 125 kW engine page 63
Installing gearbox, Jetta 2011 with 2.5 l - 125 kW engine page 72
Torque settings page 72
7.1
Removing gearbox, Jetta 2011 with 2.0
l - 85 kW engine
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.
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Special tools and workshop equipment required Engine and gearbox jack -
V.A.G 1383 A Insert -V/175 Gearbox support -3282 Wedge -T10161 Torque wrench -V.A.G
1332 Adjustment plate -3282 /36-
t. Copyright by Volkswagen AG.
57 7. Removing and installing gearbox, Jetta 2011
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010 Support bracket -10 - 222 A-
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
Hose clamps to 25 mm -3094-
Tensioning strap -T10038-
Engine support basic set -T40091-
Carry out procedure as follows: Move selector lever to position "P" position. Remove air filter. Remove battery and battery tray Rep. Gr. 27 ; Disconnect-
ing and connecting battery; Removing and installing battery .
58 Rep. Gr.37 - Controls, housing
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
In order to remove selector lever cable from gearbox, first re- lease cable -arrows 1- and then remove it from cable support bracket -arrow 2-.
Note
Do not use any pliers, otherwise securing tabs on cable sup- port bracket could break off.
Do not bend or kink selector lever cable.
Levessraucthaobrisleed-b1y -Voolkfsf wleavgeenrA-G3.-Vuoslkisnwgagaenn
AG does not
open jaw
gsuparaannteneeorrac-2-.
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
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Tighten hose clamps up to Ø 25 mm -3094- on hoses and remove hoses from ATF cooler.
Disconnect electrical connections to gearbox and starter. Multifunction switch Starter motor Remove upper starter motor bolt. Remove plenum chamber cover Rep. Gr. 50 ; Plenum
chamber cover; Removing and installing plenum chamber cover .
Set up support bracket -10 - 222 A- and support engine and gearbox. Do not raise.
1 - -T40091/32 - -10-222 A /31-13 - -10-222 A /124 - -10-222 A /35 - -10-222 A /31-46 - -10-222 A /31-37 - -T40091/18 - -10-222 A /189 - -10-222 A /31-2 Remove upper engine/gearbox connecting bolts.
59 7. Removing and installing gearbox, Jetta 2011
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
If present, remove earth strap from bracket -A-.
Remove 2 securing bolts for gearbox mounting on bracket
-A- and 4 bolts for bracket on gearbox. The bracket is removed later.
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
ngfor private or commercial purposes, in part or in whole, is not permittedunle
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 .
Raise vehicle and remove front wheels. Remove noise insulation tray. Remove front left wheel housing liner Rep. Gr. 66 ; Wheel
housing liner; front wheel housing liner . For vehicles with power steering Remove brackets with power assisted steering line from gear-
box. Continuation for all vehicles
Now pull electrical connectors -1- and -2- off gearbox. Remove starter Rep. Gr. 27 ; Removing and installing
starter . Separate exhaust system at double clamp and remove ex-
haust pipe bracket from subframe Rep. Gr. 26 ; Removing and installing parts of exhaust system .
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Remove pendulum support, first bolt -A- and then bolts -B-.
Note When installing, first tighten bolts -B-, then bolt -A-, torque set- tings Rep. Gr. 40 ; Assembly overview - subframe, anti-roll bar, suspension links .
t. Copyright by Volkswagen AG.
60 Rep. Gr.37 - Controls, housing
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Unbolt suspension link from wheel bearing housing on both sides.
Torque settings Rep. Gr. 40 ; Assembly overview - subframe, anti-roll bar, suspension links .
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
If present, remove heat shield above right drive shaft -arrows-.
Press both drive shafts out of gearbox. This procedure is de- scribed in Rep. Gr. 40 ; Repairing drive shafts; Removing and installing drive shafts .
Remove left drive shaft Rep. Gr. 40 ; Repairing drive shafts; Removing and installing drive shafts .
Raise right shaft as far as possible and secure in this position.
61 7. Removing and installing gearbox, Jetta 2011
t. Copyright by Volkswagen AG.
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ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Now remove assembly mounting bracket. To do this, lower engine and gearbox slightly via support bracket -10 - 222 Aspindles.
4 turns are sufficient.
Remove lower connecting bolts between engine and gearbox.
Leave an easily accessible bolt installed for safety.
The torque converter nut bore is concealed with a rubber cap on
the rear of the engine.
Remove Remove
this cap. six -torque
converstseaurthnoruistesd-bywViothlksiwnasgeerntA-GV./V1o7lk5s-w.agen AG
does
not
guarantee or ac
Note Continue turning the engine carefully!
ngfor private or commercial purposes, in part or in whole, is not permittedunle
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- .
Secure gearbox to gearbox support -3282- using nut -1- at double bolt.
Only now is the final bolt removed. Press gearbox off engine while simultaneously pressing tor-
que converter out of drive plate of engine. When lowering gearbox, guide it past power assisted steering
line and past subframe. If necessary, readjust gearbox support -3282- slightly.
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62 Rep. Gr.37 - Controls, housing
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Note Pay attention to torque converter. It must be removed together
with gearbox. Secure torque converter to prevent it from falling out. Keep in mind that if a new gearbox is installed, parts such as cable support bracket and retainer for gate selector cable must be transferred.
ceptany liability with respect to the correctness of information in this documen
ngfor private or commercial purposes, in part or in whole, is not permittedunle
7.2
Installing gearbox, Jetta 2011 with 2.0 l
- 85 kW engine
Check whether dowel sleeves are pressed into engine flange.
Check seat of intermediate plate between engine and gear- box. The plate must make contact with the engine along its entire perimeter when it is pressed gently with both hands against the engine. If the top does not contact the engine, it is not properly engaged in the engine block.
CTaGshors.enet1eimn0nubg;eliynRimenesmoatuanonldvlatiignstnsiegogaaun.athrTonbinhrdoiseerxidencsbvosyhetrVaorroeslullkecilsndtwogpabrrgedeoenecnmgreAioodGnfuue. Vrnr;eeotNelmkisodsowtdetvaeeasgnsel.oscnnirAoibGnine-dsfdorteeaisnelnlaoitntigRoutnhaereap.n.teeorac Renew all bolts on left assembly mounting.
First screw in all bolts by hand.
When installing, first screw bracket -A- onto gearbox using se- curing bolts -1-, tighten to 40 Nm and 90° further.
Two bolts -2- for securing bracket to gearbox mounting can be tightened by inserting a screwdriver between the two bolts to ad- just to "previous seating". These two larger bolts are tightened to 60 Nm + 90°.
Torque settings, gearbox to engine page 73 .
Adjust selector lever cable page 30 .
After installing, check ATF level page 77 .
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 .
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7.3
Removing gearbox, Jetta 2011 with 2.5
l - 125 kW engine
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.
Brief description
The gearbox is removed downwards separately. The engine re- mains in the vehicle.
Battery, battery carrier, air filter and engine cover are removed "from above". Engine and gearbox must then be supported so that left assembly mounting can be removed.
t. Copyright by Volkswagen AG.
63 7. Removing and installing gearbox, Jetta 2011
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010 Noise insulation is removed and drive shafts are pressed off "from below". Gearbox is lowered using gearbox jack.
Note The subframe is not to be removed.
Special tools and workshop equipment required Engine and gearbox jack -
V.A.G 1383 A Insert -V/175 Gearbox support -3282 Wedge -T10161 Torque wrench -V.A.G
1332 Adjustment plate -3282 /36-
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
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Support bracket -10 - 222 A-
64 Rep. Gr.37 - Controls, housing
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Hose clamps to 25 mm -3094-
Tensioning strap -T10038-
Engine support basic set -T40091-
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
Carry out procedure as follows: Move selector lever to position "P" position. Remove engine cover and air filter. Pull off hoses -arrows- and remove intake hose from throttle
valve unit.
65 7. Removing and installing gearbox, Jetta 2011
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
ceptany liability with respect to the correctness of information in this documen
RinegmaonG6vd-eosclpbof eanVetnatdeerricaaytnuianttnog2dm0bb0aaa7ttitctetersgysreay;,uaRtGthrroebaorimsoylefxdoVb0vyai9RVnriGogaelknpsa-tw.nEG2adgd0reii.1tnni0oA2snGt7a.0l;Vli4,Donl.Jkgi2ses0cwbtt1oaaa0gntet2nen0erA0ycG5t.-does,nJotegtutaara2nt0ee1o1rac
ngfor private or commercial purposes, in part or in whole, is not permittedunle
In order to remove selector lever cable from gearbox, first re- lease cable -arrows 1- and then remove it from cable support bracket -arrow 2-. Note
Do not use any pliers, otherwise securing tabs on cable sup- port bracket could break off.
Do not bend or kink selector lever cable.
Lever cable -1- off lever -3- using an open jaw spanner -2-.
t. Copyright by Volkswagen AG.
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Tighten hose clamps up to Ø 25 mm -3094- on hoses and remove hoses from ATF cooler.
Disconnect electrical connections to gearbox and starter. Multifunction switch Starter motor
66 Rep. Gr.37 - Controls, housing
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Remove cable retainer -1- from starter bolt -arrow-. Remove upper starter motor bolt. Remove upper engine/gearbox connecting bolts. Remove plenum chamber cover Rep. Gr. 50 ; Plenum
chamber cover; Removing and installing plenum chamber cover . To support engine and gearbox:
Remove cables -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 bracket -10 - 222 A- and support engine and gearbox. Do not raise.
1 - -T40091 /3-
2 - -T40091 /1-
3 - -10-222 A /31-14 - -10-222 A /125 - -10-222 A /31-46 - -10-222 A /31-37 - -10-222 A /3-
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
8 - -10-222 A /7-
9 - -10-222 A /31-2-
10 - -10-222 A /10-
Extend right hook -10 - 222 A /10- -no. 10- with adapter -10 222 A /7- -no. 8-.
The hook faces downwards and will later be hooked into the en- gine block.
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
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67 7. Removing and installing gearbox, Jetta 2011
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Depress brake pedal to remove bolt for left drive shaft
-arrow- (second mechanic required). Note
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
After this, do not set vehicle on the ground any more Rep. Gr.
40 ; Repairing drive shafts; Removing and installing drive shafts .
ngfor private or commercial purposes, in part or in whole, is not permittedunle
Raise vehicle and remove front wheels. Remove noise insulation tray. Remove front left wheel housing liner Rep. Gr. 66 ; Wheel
housing liner; front wheel housing liner . For vehicles with power steering Remove brackets with power assisted steering line from gear-
box. Continuation for all vehicles Separate exhaust system at double clamp and remove ex-
haust pipe bracket from subframe Rep. Gr. 26 ; Removing and installing parts of exhaust system .
Unbolt suspension link from wheel bearing housing on both sides.
Torque settings Rep. Gr. 40 ; Assembly overview - subframe, anti-roll bar, suspension links .
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If present, remove heat shield above right drive shaft -arrows-.
t. Copyright by Volkswagen AG.
68 Rep. Gr.37 - Controls, housing
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Press both drive shafts out of gearbox. This procedure is de- scribed in Rep. Gr. 40 ; Repairing drive shafts; Removing and installing drive shafts .
Remove left drive shaft Rep. Gr. 40 ; Repairing drive shafts; Removing and installing drive shafts .
Raise right shaft as far as possible and secure in this position.
Now pull electrical connectors -1- and -2- off gearbox.
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
Pull connector beneath starter -1- out of retainer and separate. Unbolt retainer from lower starter bolt. Remove lower starter bolt and remove starter Rep. Gr. 27 ;
Removing and installing starter .
69 7. Removing and installing gearbox, Jetta 2011
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Remove pendulum support, first bolt -A- and then bolts -B-.
Turn cap -1- in direction of arrow ansdsaurtehomrisoedvbey.Volkswagen AG. Volkswagen AG does not guaranteeorac
ngfor private or commercial purposes, in part or in whole, is not permittedunle
Remove six -torque converter nuts- with insert -V/175- . Note
Continue turning the engine carefully!
Hook adapter -10 - 222 A /7- into engine block. Tighten right spindle one turn (more is not necessary). Support engine and gearbox with left spindle. Do not raise.
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t. Copyright by Volkswagen AG.
70 Rep. Gr.37 - Controls, housing
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
If present, remove earth strap from bracket -A-. Remove 2 securing bolts for gearbox mounting on bracket
-A- and 4 bolts for bracket on gearbox.
Now remove assembly mounting bracket. To do this, lower engine and gearbox slightly via support bracket -10 - 222 Aspindles.
4 turns are sufficient. Remove lower connecting bolts between engine and gearbox. Leave an easily accessible bolt installed for safety.
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- .
Secure gearbox to gearbox support -3282- using nut -1- at
OPdqourneuelysbcslneogonbewvoaelirtrsb.teothrxeoouffitfnoeafnl dbgroinivlteerwepmhlaiolteevsessoadifumt.heuonrlistgeaidnnbeey.oVoulksslwyapgreensAsGin. Vgoltkosrw-agen AG does not guaranteeorac
When lowering gearbox, guide it past power assisted steering line and past subframe. If necessary, readjust gearbox support -3282- slightly.
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
71 7. Removing and installing gearbox, Jetta 2011
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010 PayNaottteentsisoaunthtooristeodrbqyuVoelkcsownagveenrAteGr..VIot lmksuwsagt ebneArGedmoeosvneotdgtuoarganetetheoerarc with gearbox. Secure torque converter to prevent it from falling out.
Keep in mind that if a new gearbox is installed, parts such as cable support bracket and retainer for gate selector cable must be transferred.
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
7.4
Installing gearbox, Jetta 2011 with 2.5 l
- 125 kW engine
Check whether dowel sleeves are pressed into engine flange.
Check seat of plate between engine and gearbox. The plate must make contact with the engine along its entire perimeter when it is pressed gently with both hands against the engine. If the top does not contact the engine, it is not properly en- gaged in the engine block.
Continue installation in reverse order of removal.
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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 .
Renew all bolts on left assembly mounting.
First screw in all bolts by hand.
When installing, first screw bracket -A- onto gearbox using se- curing bolts -1-, tighten to 40 Nm and 90° further.
Two bolts -2- for securing bracket to gearbox mounting can be tightened by inserting a screwdriver between the two bolts to ad- just to "previous seating". These two larger bolts are tightened to 60 Nm + 90°.
Torque settings, gearbox to engine page 72 .
Adjust selector lever cable page 30 .
After installing, check ATF level page 77 .
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 .
7.5
Torque settings, gearbox to engine
Jetta 2011 with 2.0 l - 85 kW engine page 73 .
Jetta 2011 with 2.5 l - 125 kW engine page 74 .
72 Rep. Gr.37 - Controls, housing
7.5.1
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Torque settings, Jetta 2011 with 2.0 l - 85 kW engine
- Drive plate to torque convert- er
60 Nm Qty. 6; remove and in-
stall with insert -V/175- .
- M12 bolts M12 80 Nm 65 Nm if you use socket -T10179-
- M10 bolts M10 40 Nm These bolts are located in lower flange
- Two dowel sleeves in engine -arrows-
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
Make sure that bracket does not make contact with ATF cool- er.
-Nuts- 8 Nm
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
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73 7. Removing and installing gearbox, Jetta 2011
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
7.5.2 Torque settings, Jetta 2011 with 2.5 l - 125 kW engine
1 - Direction of travel - Drive plate to torque convert- er
60 Nm Qty. 6; remove and in-
stall with insert -V/175- . - M12 bolts M12
80 Nm 65 Nm if you use socket
-T10179- M10 bolts M10
40 Nm These bolts are located
in lower flange - Two dowel sleeves in engine -arrows-
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
Make sure that bracket does not make contact with ATF cool- er.
-Nuts- 8 Nm
74 Rep. Gr.37 - Controls, housing
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
8
Transporting gearbox
Special tools and workshop equipment required
Shackle -10 - 222 A /12-
Shackle 10-222 A/12 can be used to transport the automatic gearbox and set up gearbox support 3282. During transportation, protect torque converter -arrow- from
falling out, e.g. with a wire -A-.
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
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75 8. Transporting gearbox
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
9
ATF cooler
9.1
Assembly overview - ATF cooler
1 - Gearbox housing 2 - O-ring
Always renew 3 - ATF cooler
Installation position: page 76
4 - O-ring Always renew
5 - Washer 6 - Dished washer
7
Position: convex side
-
faces bolt
Bolt
Item
7
(pasgs aeuth7o6ris)ed
by
Volkswagen AG.
Volkswagen AG
does
not
guarantee or ac
36 Nm
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
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Position: ATF cooler When installing ATF cooler -1-, insert lug -arrow B- into recess
in gearbox housing.
76 Rep. Gr.37 - Controls, housing
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
10
Checking ATF level and topping up
Please follow instructions:
About this workshop manual page 1
About ATF page 2
About "filler pipe" page 3
Special tools and workshop equipment required Torque wrench -V.A.G
1331 Used oil collection and ex-
traction unit -V.A.G 1782 Vehicle diagnosis, testing
and information system VAS 5051 Drip tray for workshop hoist -VAS 6208 Adapter for filling oil -VAS 6262 Adapter -VAS 6262/2-
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
77 10. Checking ATF level and topping up
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
If ATF must be added, use only ATF listed in Electronic parts
catalogue ETKA . If ATF level is checked, oil
must always be renewed.
sesaslau-tahorrrisoewd b-yoVnolkAswTaFgeinnsApGe. Vctoiloksnwpalguegn
AG
does
not
guarantee
or
ac
10.1 Checking ATF level
Carry out procedure as follows: Switch off engine.
t. Copyright by Volkswagen AG.
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The ATF temperature should not be more than approx. 30 °C at the start of the test. · Gearbox is not in emergency running mode and ATF temper-
ature is not above approx. 30 °C. · Vehicle must be standing level · Selector lever in "P". Connect "tester" and continue switching until it is ready for op-
eration page 11 . Press Guided functions "on right". Then select vehicle, the gearbox and Check ATF level . Press . Start engine. Raise vehicle. Place drip tray under gearbox. Press . If a test temperature between 35 °C and 45 °C is displayed:
78 Rep. Gr.37 - Controls, housing
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Remove inspection plug for ATF level from oil pan.
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
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 79 .
10.2 Topping up ATF
Carry out procedure as follows: With engine "running", screw in adapter for filling oil -VAS
6262/2- hand-tight. Add 1 l of ATF. Pull off adapter for oil filling -VAS 6262- at quick-release con-
nection and check: If ATF now flows out of hole in adapter: ATF does not need topping up. Drain ATF until it drips. Fit new seal to plug and tighten to 27 Nm. This concludes the
ATF check. If no ATF drips out: Add another litre page 79 .
WARNING An ATF level which is too low or too high will impair the function of the gearbox. But if the gearbox was 2 litres low, it must be carefully inspected. There is probably a "major" leak.
79 10. Checking ATF level and topping up
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
10.3 Draining and filling ATF
Carry out procedure as follows: Switch off engine.
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
Remove inspection plug for ATF level from oil pan -arrow-.
Remove overflow pipe -1- through inspection hole. Drain ATF. Install overflow pipe. Install plug hand-tight. Add 3 litres of ATF Electronic parts catalogue ETKA
through filler pipe. Start engine, shift through all selector lever positions with ve-
hicle stationary, leaving selector lever in each position for about 10 seconds. Finally, check ATF level and top up page 77 .
80 Rep. Gr.37 - Controls, housing
t. Copyright by Volkswagen AG.
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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
38 Gears, control
1
Renewing oil seal for selector shaft
Special tools and workshop equipment required
Thrust piece -T10174-
Carry out procedure as follows: Remove multifunction switch -F125- page 18 . 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. Adjust multifunction switch -F125- page 20 .
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
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81 1. Renewing oil seal for selector shaft
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011
2
ATF pan 6-speed
automatic
gearbox
09G
-
Edition
04.2010
ss authorised
by
Volkswagen
AG. Volkswagen
AG does not
guarantee or ac
2.1
Removing and installing ATF pan
Special tools and workshop equipment required
Drip tray for workshop hoist -VAS 6208-
ngfor private or commercial purposes, in part or in whole, is not permittedunle
Torque wrench -V.A.G 1783-
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2.1.1 Removing
Remove noise insulation below engine. Place drip tray underneath. Unscrew and remove ATF inspection plug -A-. Remove overflow pipe -C- and allow remaining ATF to drain.
t. Copyright by Volkswagen AG.
82 Rep. Gr.38 - Gears, control
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ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Loosen oil pan bolts -arrows- diagonally. Remove oil pan together with gasket.
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
2.1.2 Installing
Install in the reverse order of removal, observing the following: Clean two magnets in recesses of oil pan. Make sure that
magnets make full contact with oil pan. Check that seal is undamaged and all spacer sleeves (qty. 8)
are present. Otherwise renew seal. Fit oil sump with seal, taking care not to pinch any wires. Ensure proper seating of oil pan gasket. Tighten pan bolts -arrows- diagonally in several stages; torque
specification page 89 .
83 2. ATF pan
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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010 Screw in overflow pipe -C-; torque specification page 89 . Insert seal -B- for ATF inspection plug -A-. Screw in ATF inspection plug -A- hand-tight with new seal -B-. Fill with ATF; check ATF level and top up page 77 .
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
84 Rep. Gr.38 - Gears, control
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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
3
ATF strainer
3.1
Removing and installing ATF strainer
3.1.1 Removing
Remove oil pan page 82 . Unscrew ATF strainer bolts -arrows-. Pull ATF strainer -A- off valve body.
3.1.2 Installing
TTPfehhlcaietncivleAyeTA.cFoTaFsttrssaterinaaeilnsreomrn-uAisn-ttoabnkeetorenvneaeclwvkeeodbf oAifdTsyFeaasssnltasrduatahtionrirgeiesherldtoewboynisVthebolokAosltwTrsaFdge.e-n AG. Volkswagen AG does not guaranteeorac
-arrows-; torque specification page 89 .
Install oil pan page 82 .
Fill with ATF; check ATF level and top up page 77 .
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85 3. ATF strainer
ceptany liability with respect to the correctness of information in this documen
ngfor private or commercial purposes, in part or in whole, is not permittedunle
Golf Variant 2007 , Golf Variant 6-speed automatic gearbox 09G -
E2d0i1ti0ossnau0th4,or.Ji2see0dtt1bay0V2o0lk0sw5agen,AJGe.tVtaolk2s0w1a1gen AG
does
not
guarantee
or
ac
4
Valve body
Removing and installing valve body page 91 Solenoid valve identification page 90 Sender identification page 91 . Torque settings page 89
WARNING Do not run engine or tow vehicle with pan removed or when there is no ATF in gearbox.
The valve body and the wiring harnesses can also be removed when the gearbox is installed.
Insert O-rings with ATF. Other lubricants lead to malfunction of the gearbox hydraulics.
Always renew a valve body which is fouled or defective. Do not use fluffy cloths. After the pan has been installed, the ATF level must be
checked and topped up page 77 .
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86 Rep. Gr.38 - Gears, control
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
4.1
Assembly overview
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
1 - ATF inspection plug
Checking ATF level and
2
topping Torque
page
- Seal Always
up page 77
setting r8e9sns aeuwthorised
by
Volkswagen
AG. Volkswagen
AG does not
guarantee or ac
ngfor private or commercial purposes, in part or in whole, is not permittedunle
3 - Overflow pipe Unscrew to drain ATF Torque setting page 89
4 - Oil pan Removing and installing page 82
5 - Bolt Tighten oil pan bolts di- agonally in several stages. Torque setting page 89
6 - Seal With spacer sleeves (qty. 8) Examine before fitting Renew brittle, cracked or deformed seal
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7 - Magnet Qty. 2 in depressions in pan Clean oil pan before in- stalling
8 - Bolt For securing valve body in gearbox Qty. 12, various lengths page 95 Always renew bolts Torque setting page 89
9 - Bolt Qty. 3 For securing strainer to valve body Torque setting page 89
10 - ATF strainer Removing and installing page 85
11 - Valve body Removing and installing page 91 Solenoid valve identification page 90 Allocation Electronic parts catalogue "ETKA"
12 - Bolt Torque setting page 89
87 4. Valve body
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
13 - Bolt Torque setting page 89
14 - Gearbox input speed sender -G182 Removing and installing page 106
15 - Bolt Torque setting page 89
16 - Gearbox output speed sender -G195 Removing and installing page 107
17 - Gearbox housing Shown here without ATF cooler
18 - Breather cap
19 - Multifunction switch -F125 Removing and installing page 18 Adjusting page 20
20 - Gearbox oil temperature sender -G93 Integrated into wiring harness Item 23 (page 88)
21 - Bolt Torque setting page 89
22 - Bolt Torque setting page 89
23 - Wiring harness with 8-pin connector
With O-ring on plug, always renew O-ring
WFFSooeitrrnhggdgeeeeaar arrlobbrbcooaoxxtxiioonsousnpaitlsuuptthtueostrmisppsepepdaeebegyrdeeaVdots9uleks1rsneewdnasegdeerenn-rAdG-GeG1r.81V-2o9Gl-5k9s-w3-agen AG does not guaranteeorac
Removing and installing page 105
Allocation Electronic parts catalogue "ETKA"
ngfor private or commercial purposes, in part or in whole, is not permittedunle
24 - Seal Always renew
25 - ATF drain plug Torque setting page 89
26 - Selector lever For selector shaft Removing and installing page 91
27 - Washer
28 - Nut Location: centring collar faces washer Item 27 (page 88) Torque setting page 89
29 - Spring Allocation Electronic parts catalogue "ETKA"
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30 - Damper piston
31 - Wiring harness with 14-pin connector For solenoid valves With O-ring on plug, always renew O-ring Solenoid valve locations and wiring harness routing page 90
t. Copyright by Volkswagen AG.
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88 Rep. Gr.38 - Gears, control
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Removing and installing page 103 32 - Bolt
Torque setting page 89
4.1.1 Torque settings
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
89 4. Valve body
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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
4.1.2 Solenoid valve identification
1 - Wiring harness for solenoid valves with 14-pin connector -arrow-
Removing and installing page 103
2 - Solenoid valve 1 -N883 - Solenoid valve 2 -N894 - Solenoid valve 4 -N915 - Solenoid valve 6 -N936 - Solenoid valve 5 -N927 - Solenoid valve 9 -N2828 - Solenoid valve 10 -N2839 - Solenoid valve 3 -N90-
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90 Rep. Gr.38 - Gears, control
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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011
4.1.3 Sender
1 - Hydraulic pressure
sidenednetrificatsisoaunthorised by
Volksw6a-gsepneAeGd. VaoulktsowmagaetnicAGgedoaersbnooxt g0ua9raGnte-e
Edition
or ac
04.2010
1 for automatic gearbox -
G193-
Not installed in all gear- boxes
Allocation Electronic parts catalogue "ETKA"
2 - Connector to gearbox input speed sender -G182-
3 - Wire on gearbox input speed sender -G182-
4 - Hydraulic pressure sender 2 for automatic gearbox G194-
Not installed in all gear- boxes
Allocation Electronic parts catalogue "ETKA"
t. Copyright by Volkswagen AG.
5 - Wire on gearbox output speed sender -G195-
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6 - Connector to gearbox out- put speed sender -G195-
7 - Bracket of gearbox oil tem- perature sender -G93-
8 - Gearbox oil temperature sender -G93-
9 - Wiring harness for sender with 8-pin connector -arrow-
Removing and installing page 105
4.2
Removing and installing valve body
Special tools and workshop equipment required
Torque wrench -V.A.G 1331-
91 4. Valve body
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Angle wrench -V.A.G 1756-
4.2.1 Removing
Carry out procedure as follows:
With ignition switched off, disconnect battery earth strap Electrical system; Rep. Gr. 27 ; Battery; Disconnecting and connecting battery .
Remove oil pan page 82 .
Remove ATF strainer page 85 .
Draw a sketch of all senders and solenoid valves with their respective connectors analogous to figure.
Before separating connectors at senders and solenoid valves,
solenoid valve or sender identified.
WARNING
and
respective
connescstaoutrhomriseudsbtybVeolkswagen AG.
Volkswagen AG
does
not
guarantee or ac
This sketch and identification are absolutely vital to prevent in-
advertently interchanging sender and solenoid valve when
reinstalling valve body.
Under certain circumstances, interchanging connectors may lead to destruction of the gearbox.
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
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92 Rep. Gr.38 - Gears, control
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ceptany liability with respect to the correctness of information in this documen
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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
Use a small screwdriver to pry out securing bolts of connectors on solenoid valves -2- to -9- carefully and pull off connectors.
If a connector is damaged, the wiring harness or the valve body together with the solenoid valves must be renewed.
If present, carefully pull off connectors for automatic gearbox hydraulic pressure sender 1 -G193- -1- and automatic gearbox hydraulic pressure sender 2 -G194- -4-.
93 4. Valve body
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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
Separate connectors -2- and -5-. Unscrew bracket bolts -3-. If a connector is damaged, the wiring harness or the gearbox
input speed sender -G182- or the gearbox output speed send- er -G195- must be renewed. Unscrew bolt -6-. For reinstallation, make sure bracket is attached to gearbox oil temperature sender -G93- -7-. Carefully pull gearbox oil temperature sender -G93- -7- out of valve body together with bracket. Unhook wiring harness from bracket -8-.
94 Rep. Gr.38 - Gears, control
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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Remove selector lever -1- from selector shaft.
In the process, carefully grip selector lever -1- with pliers -2so that torque is not transferred to multifunction switch -F125- .
Note spool valve -3- on valve body into which selector lever
engages
so
that
this
is
not
damaged.
ss authorised by Volkswagen
AG. Volkswagen
AG does not
guarantee or ac
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. The bolts are of different lengths and must be replaced.
ngfor private or commercial purposes, in part or in whole, is not permittedunle
Only the marked securing bolts -arrows- may be loosened. If other bolts are loosened, the function of the valve body is im- peded or the valve body falls to pieces. Loosen securing bolts -arrows-, -arrows A- and -arrows B- for
valve body diagonally and carefully remove valve body. Remove brackets -1- and -2-. -3- valve body designation, e.g. A2 in this case.
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95 4. Valve body
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010 When removing valve body, secure damper piston -2- to pre- vent it from falling out or remove together with spring if nec- essary.
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
4.2.2 Installing
Carry out procedure as follows: Routing of wires must be noted precisely to prevent them from
being trapped when valve body is positioned. Route wiring harness -5- in specified recess in gearbox ac-
cording to figure. 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. Route wiring harnesses -1-, -3-, -4- and -5- over edge of the
gearbox according to figure. Secure wiring harnesses on gearbox with adhesive tape. Damper piston -2- must be installed in gearbox in illustrated
position. If damper piston -2- has been removed, it must be cleaned
together with spring and installed in accordance with Item 29 (page 88) and Item 30 (page 88) . Coat damper piston -2- and mounting in gearbox with ATF. Insert spring in damper piston. Insert damper piston with spring into mounting in gearbox. To prevent damper piston from falling out, press it into gearbox until valve body is positioned. Carefully put on valve body, without pressing on forcefully.
96 Rep. Gr.38 - Gears, control
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Wiring harnesses -1-, -3-, -4- and -5- are not allowed to be trapped by valve body.
All bolts -arrows- for securing valve body must be inserted. Note different bolt lengths:
Bolts -arrowsBolts -arrows ABolts -arrows B-
M6×21 M6×16 M6×28
Tighten brackets -1- and -2- for wiring harness hand-tight with new bolts.
Tighten remaining, new bolts for valve body -arrows-, -arrows A- and -arrows B- hand-tight.
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
If lines -3-, -5- and -9- are too short to be connected to senders or bolted to intended points on valve body, they have been incorrectly routed or trapped by valve body. Remove valve body again and route cables correctly.
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
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97 4. Valve body
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
G6-oslpf eVeadriaanutto2m00a7ticge,aGsrsboaoulftxhVor0ias9erdiGabny-VtEo2lkd0si1wti0aognen0A4,G.J2.eV0tot1alk0s2w0a0ge5nAG,dJoeestntaot 2gu0a1ra1nteeorac
Cables -3-, -5- and -9- are not allowed to be trapped. Tighten new bolts -arrows-, -arrows A- and -arrows B- from
inside to outside to specified torque page 89 .
98 Rep. Gr.38 - Gears, control
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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
EnsHPuuoresohkthswaeitrleisncegtloehrcatleornvreelesrvs-e2-r-3p-oininntto-o2s-reeesltesnaacgiunttahoeogrrriess-es7hd-bainy-fVttaoo-rl6rksos-pw.woagoBel-nv.AaGlv. eVo-lk1s-wagen AG does not guaranteeorac -arrow A-. If necessary, position spool valve accordingly. Set washer -5- and nut -4- on selector shaft -6-. Centring collar of nut must face washer and run into washer on tightening. Wiring harness must be routed beneath selector lever. Tighten selector lever nut -1- to specified torque page 89 . In the process, carefully grip selector lever -1- with pliers -2-
so that torque is not transferred to multifunction switch -F125- . Note spool valve -3- on valve body into which selector lever
engages so that this is not damaged.
Connect the connectors to solenoid valves -2- to -9- according to the identifications which you have noted.
99 4. Valve body
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ceptany liability with respect to the correctness of information in this documen
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G6-oslpf eVeadriaanuttos2sma0u0atho7tircisegdeb,yaGVrobolkolsfxwVa0ag9eriGnaAn-GtE.2Vd0oi1ltki0sownag0e4,n.JA2eG0tt1dao0e2s0n0ot5guara,ntJeeeotrtaac 2011
WARNING Under certain circumstances, interchanging connectors may lead to destruction of the gearbox. If a connector is damaged, the wiring harness or the valve body together with the solenoid valves must be renewed. Route wiring harness -1- as shown in figure. Join connectors -2- and -5-.
100 Rep. Gr.38 - Gears, control
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ceptany liability with respect to the correctness of information in this documen
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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
The mating part of the connectors must bear the same identifica- tion as the respective connector itself. Place the bracket onto the gearbox oil temperature sender -
G93- -7-. Insert gearbox oil temperature sender -G93- in valve body to-
gether with bracket. Tighten bolt -6-, torque setting page 89 . If present, carefully push connectors onto automatic gearbox
hydraulic pressure sender 1 -G193- -1- and automatic gearbox hydraulic pressure sender 2 -G194- -4- at right angles. Tighten bolts -3- for connector retainers -2- and -5-; torque specifications page 89 .
101 4. Valve body
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
If cables are too short to be bolted on, they have been incor- rectly routed or trapped by the valve body. Remove valve body again and route cables correctly.
Attach wiring harness to retainer -8- and route it as shown in figure.
Install ATF strainer page 85 . Install oil pan page 82 . With ignition switched off, connect battery earth strap Elec-
trical system; Rep. Gr. 27 ; Battery; Disconnecting and con- necting battery . Fill with ATF; check ATF level and top up page 77 . Connect -VAS 5051- and continue to advance until "Function/ component selection" is displayed. Then press "Drive (Repair group 01; 10 ... 26; 28 ... 39)". Then "6-speed automatic gearbox 09G". Press "01 - Self-diagnosis". Press "Functions". Press "Basic setting".
102 Rep. Gr.38 - Gears, control
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ceptany liability with respect to the correctness of information in this documen
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ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
4.3
Removing and installing wiring harness
with 14-pin connector (for solenoid
valves)
4.3.1
Remove
Removing
oil pan page
82ss.authorised by Volkswagen
AG. Volkswagen
AG does not
guarantee or ac
Remove ATF strainer page 85 .
Draw a sketch of all senders and solenoid valves with their respective connectors analogous to figure.
Before separating connectors at solenoid valves, solenoid valve and respective connector must be identified.
WARNING
This sketch and identification are absolutely vital to prevent in- advertently interchanging sender and solenoid valve connector when reinstalling the wiring harness. Under certain circumstances, interchanging connectors may lead to destruction of the gearbox.
t. Copyright by Volkswagen AG.
Protected by copyright. Copyi
103 4. Valve body
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
Use a small screwdriver to pry out securing bolts of connectors on solenoid valves -2- to -9- carefully and pull off connectors.
If a connector is damaged, the wiring harness or the valve body together with the solenoid valves must be renewed.
Pull connector -2- off gearbox connector. Unscrew bolt for 14-pin gearbox connector. Pull connector and wiring harness outwards out of gearbox
housing.
4.3.2 Installing
Install in the reverse order of removal, observing the following: Renew O-ring on connector. Push connector with new O-ring into gearbox to stop.
104 Rep. Gr.38 - Gears, control
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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Tighten bolt for 14-pin gearbox connector; torque specification page 89 .
Tighten securing bolts for gearbox speed sender connector retainers; torque specifications page 89 .
Tighten bolt on bracket of gearbox oil temperature sender G93- , torque setting page 89 .
Install ATF strainer page 85 .
Install oil pan page 82 .
4.4
Removing and installing wiring harness
with 8-pin connector (for sender)
4.4.1 Removing
Remove oil pan page 82 . Remove ATF strainer page 85 . If present, carefully pull off connectors for automatic gearbox
hydraulic pressure sender 1 -G193- -1- and automatic gearbox hydraulic pressure sender 2 -G194- -4-. Senders -1- and -4- are notsisnausthtaorlisleeddbyinVoalklsl wgaegaenrbAoGx.eVsol.kswagen AG does not guaranteeorac
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
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105 4. Valve body
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Separate connectors -2- and -5-.
If a connector is damaged, the wiring harness or the gearbox input speed sender -G182- or the gearbox output speed send- er -G195- must be renewed.
Unscrew bolt -6-.
For reinstallation, make sure bracket is attached to gearbox oil temperature sender -G93- -7-.
Carefully pull gearbox oil temperature sender -G93- -7- out of valve body together with bracket.
Unhook wiring harness from bracket -8-.
Pull connector -1- off gearbox connector.
UPhounulslsccirnoegnw.nebcotlot rfoarn8d-pwinirignegashsrabautorhnoxreiscseodsnboynVueotcwlktsoawrra.dgsenoAuGt.oVfolgksewaargbeonxAG does not guaranteeorac
ngfor private or commercial purposes, in part or in whole, is not permittedunle
4.4.2 Installing
Install in the reverse order of removal, observing the following:
Renew O-ring on connector.
Push connector with new O-ring into gearbox to stop.
Tighten bolt for 8-pin gearbox connector; torque specification page 89 .
Tighten bolt on bracket of gearbox oil temperature sender G93- , torque setting page 89 .
Install ATF strainer page 85 .
Install oil pan page 82 .
4.5
Removing and installing gearbox input
speed sender -G182-
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4.5.1 Removing
Remove valve body page 91 .
t. Copyright by Volkswagen AG.
106 Rep. Gr.38 - Gears, control
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011
Unscrew bolt -1- from gearbox Pull sender out of gearbox.
insps auutthsorpiseedebdy
Volks6w-asgpeneAeGd. VaoultkoswmaagteincAgGedaorebsonoxt sender -G182- .
09G - Edition
guarantee or ac
04.2010
ngfor private or commercial purposes, in part or in whole, is not permittedunle
t. Copyright by Volkswagen AG.
4.5.2 Installing
Install in the reverse order of removal, observing the following:
Protected by copyright. Copyi
Press sender into gearbox to stop.
Tighten bolt -1- for gearbox input speed sender -G182- ; torque specifications page 89 .
Install valve body page 96 .
4.6
Removing and installing gearbox output
speed sender -G195-
4.6.1 Removing
Remove valve body page 91 . Unscrew bolt -2- from gearbox output speed sender -G195- . Pull sender out of gearbox.
4.6.2 Installing
Install in the reverse order of removal, observing the following: Press sender into gearbox to stop.
107 4. Valve body
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010 Tighten bolt -2- for gearbox output speed sender -G195- ; tor- que specifications page 89 . Install valve body page 96 .
ssauthorised by Volkswagen AG. Volkswagen AG does not guarantee orac
108 Rep. Gr.38 - Gears, control
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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
39 Final drive - differential
1
Renewing oil seals for flange shafts
(Gearbox installed)
Only the left-hand side is described here. Renewing oil seal on right-hand side is nearly identical.
On right, drive shaft remains installed in wheel bearing. Drive in seal with thrust piece -T10177- .
Left drive shaft must be removed. Drive in seal with thrust piece -T10176- .
1.1
Special
Renewing oil seal for flange
tools and workshop equipment required
shaft ssauthorised by Volkswagen AG. Volkswagen AG does not guaranteeorac
Drip tray for workshop hoist -VAS 6208-
Puller -T10055-
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
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109 1. Renewing oil seals for flange shafts
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Jetta
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ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
Thrust piece -T10177-
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1.1.1 Removing flange shaft oil seal
Carry out procedure as follows: Remove noise insulation tray. Place drip tray underneath. Mark position of -nuts- that are used for bolting suspension link
onto wheel bearing housing. Relocate this position during assembly if at all possible. Unscrew suspension link from wheel bearing housing.
Press drive shaft out of gearbox. This procedure is described in Rep. Gr. 40 ; Repairing drive shafts; Removing and in- stalling drive shafts .
110 Rep. Gr.39 - Final drive - differential
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010
Right: If present, remove heat shield above right drive shaft
-arrows-.
Raise right shaft as far as possiblessaaunthdorisseedcbyuVreolkisnwtahgiesnpAoGs. Vitoiolkns.wagen AG does not guaranteeorac
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
t. Copyright by Volkswagen AG.
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Left: 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 . Remove left drive shaft Rep. Gr. 40 ; Repairing drive shafts;
Removing and installing drive shafts . Seal drive shaft aperture on transmission with a clean cloth
-A-. Carefully drill a hole -B- (size 2 to 4 mm) into outer sheet metal
ring -C- of oil seal. Note
Grease drill bit -B- so that metal chips adhere. Drill only through sheet metal ring -C- because gearbox may
otherwise be damaged.
111 1. Renewing oil seals for flange shafts
ngfor private or commercial purposes, in part or in whole, is not permittedunle
ceptany liability with respect to the correctness of information in this documen
Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010 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; vacuum 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.
1.1.2 Installing flange shaft oil seal
Install in the reverse order of removal, observing the following: IOnpsteAPanprlleapsstliyidsoeAnoioTlpfFsooestiaoiltlisociennira:cslutfrmaacifgeehsretgnaecsaessfraabaurtonhaoxdrs.issepedobayslVisnoiglbksllewipabsgyeonhfAaoGni.ldVs.oelkaslw. agen AG does not guaranteeorac Left-hand side Drive seal -A- to stop with thrust piece -T10176- . Do not cant
oil seal in the process.
Right side Drive seal -A- to stop with thrust piece -T10177- . Do not cant
oil seal in the process. Install drive shaft Rep. Gr. 40 ; Repairing drive shafts; Re-
moving and installing drive shafts . Finally, check ATF level and top up page 77 . Install noise insulation.
112 Rep. Gr.39 - Final drive - differential
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