VW 6 Speed Automatic Transmission 09g Repair Manual Edition 072015 D3e8001eaac PDF

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Service

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6-Speed Automatic Transmission 09G AG.

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Edition 07.2015

Service Department. Technical Information

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Repair Group

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List of Workshop Manual Repair Groups

00 - General, Technical Data 32 - Torque Converter 37 - Controls, Housing

38 - Gears, Hydraulic Controls

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39 - Final Drive, Differential

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 © 2015 Volkswagen AG, Wolfsburg

D3E8001EAAC

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

Contents General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Control Module J217 with Fuzzy Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Information on the “Transmission 09G” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seals, Gaskets and Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Guided Fault Finding, OBD and Test Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification on Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Planetary Gear and Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Codes - Engine Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 2 2 2 2 3 4 4 4 4 5 5 6 6 7 8

32 - Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

1 1.1 1.2 1.3 1.4 2

. Volkswage Overview - Torque Converter . . . . . . . . . . . . . . . . k.s.w.ag. e.n.A.G. . . . . . . . n. A. G. d. o.e.s .n . . . . . . . . . . l o o Torque Converter, Removing and Installing .d.by. V. . . . . . . . . . . . . . . . . . . . . . . . t.g.ua.r . . . . . . an e s i Torque Converter, Checking . . . . . . . . . th.o.r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .tee. o. . . u r Torque Converter, Discharging . . . . .ss.a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.c .

Torque Converter Seal, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 2 2.1 3 3.1 4 5

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»Tester«, Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical and Electronic Components and Component Locations . . . . . . . . . . . . . . . . . . . . Multifunction Transmission Range Switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multifunction Transmission Range Switch F125 , Removing . . . . . . . . . . . . . . . . . . . . . . . . Multifunction Transmission Range Switch F125 , Installing . . . . . . . . . . . . . . . . . . . . . . . . Multifunction Transmission Range Switch F125 , Adjusting . . . . . . . . . . . . . . . . . . . . . . . . Selector Mechanism through 02/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview - Selector Mechanism through 02/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shift Mechanism with Selector Lever, Removing and Installing, through 02/2009 . . . . . . . . Selector Lever Cable, Removing and Installing, through 02/2009 . . . . . . . . . . . . . . . . . . . . Selector Lever Cable, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selector Lever Cable, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selector Lever, Emergency Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selector Lever Handle, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Button in Handle, Moving into Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selector Mechanism, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selector Mechanism from 03/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview - Selector Mechanism from 03/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selector Mechanism, Removing and Installing, Vehicles from 03/2009 . . . . . . . . . . . . . . . . Transmission, Removing and Installing, Jetta from 2005, Golf Wagon from 2007, Jetta Wagon from 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 14 20 20 21 22 24 24 26 28 37 38 39 40 42 44 46 46 47

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1 2 3 3.1 3.2 3.3 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 5 5.1 5.2 6

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37 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents

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6.1 6.2 6.3 6.4 6.5 7 7.1 7.2 7.3 7.4 7.5 8 9 10 10.1 10.2 11 11.1 11.2 11.3 12

Transmission, Removing, Vehicles with 2.0L - 85kW and 2.0L - 110kW Engines . . . . . . . . Transmission, Installing, Vehicles with 2.0L - 85kW and 2.0L - 110kW Engines . . . . . . . . Transmission, Removing, Vehicles with 2.5L - 110 kW and 2.5L -125 kW Engines . . . . . . Transmission, Installing, Vehicles with 2.5L - 110 kW and 2.5L - 125 kW Engines . . . . . . Tightening Specifications, Transmission to Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission, Removing and Installing, Jetta from MY 2011 . . . . . . . . . . . . . . . . . . . . . . Transmission, Removing, Jetta MY 2011 1.6L 77 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission, Removing, Jetta MY 2011, 2.0L 85 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission, Removing, Jetta MY 2011, 2.5L 125 kW . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission, Installing, Jetta MY 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightening Specifications, Transmission to Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission, Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission, Securing in Engine/Transmission Holder . . . . . . . . . . . . . . . . . . . . . . . . . . ATF Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview - ATF Cooler Round Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview - ATF Cooler Rectangular Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATF Level, Checking and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATF Level, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATF, Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATF, Draining and Filling . . . . . .g.en. A. G . ..V.o.lk.sw. a. g.e.n A .G . .d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a oes ksw l o Special Tools . . . . . . . . .by. V. . . . . . . . . . . . . . . . . . . . . . . n.o.t g.u.a . . . . . . . . . . . . . . . . . . . . . . .

38 - Gears, Hydraulic

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Selector Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Fluid Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Fluid Pan, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATF Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATF Screen, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview - Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Body, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Valve Wiring Harness (14-Pin Connector), Removing and Installing . . . . . . . . . . Sensor Wiring Harness (8-Pin Connector), Removing and Installing . . . . . . . . . . . . . . . . . . Transmission Input Speed Sensor G182 , Removing and Installing . . . . . . . . . . . . . . . . . . Transmission Output Speed Sensor G195 , Removing and Installing . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rrectness of i t to the co nform spec a t i h re o n in wit thi s

1 2 2.1 3 3.1 4 4.1 4.2 4.3 4.4 4.5 4.6 5

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124 125 125 127 127 128 128 135 148 149 150 151 153

39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 r te o iva r rp fo g n

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Flange Shaft Seals, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Location Overview - Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Flange Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Flange Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . do c um en

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

155 155 156 157 159 160

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

00 –

General, Technical Data

1

General Repair Information

(Edition 07.2015) ⇒ “1.1 Torque Converter”, page 1 ⇒ “1.2 ATF”, page 1 ⇒ “1.3 Transmission Control Module J217 with Fuzzy Logic”, page 1 ⇒ “1.4 Vehicle Control Modules”, page 2 ⇒ “1.5 Information on the Transmission 09G ”, page 2 ⇒ “1.6 Tools”, page 2 ⇒ “1.7 Transmission”, page 2 ⇒ “1.8 Seals, Gaskets and Oil”, page 3 ⇒ “1.9 Bolts and Nuts”, page 4 ⇒ “1.11 page 4

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AG. Volkswagen AG d agen oes ksw not l o gu Guided Fault Finding, OBD y V and Test Instruments”, b ara d e nte is r o eo h ut ra a c Safety Precautions”, page 4 s s urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

General information that applies to various different repair proce‐ dures is listed here instead of repeating it multiple times through‐ out the manual. They apply to this repair manual.

1.1

Torque Converter

The torque converter is equipped with a lock-up clutch. The lockup clutch closes depending on load and speed. The 2nd, 3rd, 4th, 5th and 6th gears can be mechanically driven (without slip).

1.2

ATF

ATF is a permanent filling. The ATF does not need to be replaced during maintenance.

The ATF levels inside the planetary gear and inside the final drive are checked and filled at the same time. Prote cted by c o py rig ht . C op yi

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Use only the ATF listed as a replacement part in the Parts Cata‐ log. Other oils can cause malfunctions or transmission failure.

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The highest level of care and cleanliness along with tools that function properly are required to ensure a proper and successful transmission repair. The usual basic safety precautions also ap‐ ply when carrying out vehicle repairs.

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⇒ “1.10 Electrical Components”, page 4

Determining the driving situation and driving resistance depend‐ ent shift point occurs automatically. Advantages: •

It is shifted depending on fuel consumption

•

Maximum engine output is always available

•

Individual adaptation of shift points in all driving situations

•

Gear shift points are infinitely variable 1. General Repair Information

1

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

1.4

Vehicle Control Modules

The component locations of all vehicle control modules and other useful information can also be found in ⇒ Wiring diagrams, Trou‐ bleshooting & Component locations. . Volkswagen AG gen AG d

1.5

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Tools

A complete list of special tools and workshop equipment required for repair procedures in a manual can be found at the beginning of each Repair Group section and in the Workshop Equipment and Special Tools catalog.

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Transmission

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1.7

The “6-speed automatic transmission 09G” has six hydraulically controlled forward gears. By passing the torque converter slip, 2nd, 3rd, 4th, 5th and 6th gears become mechanically driven gears if lock-up clutch is closed. AG.

♦ Do not run the engine and do not tow the vehicle if the trans‐ mission cover is removed or if there is no transmission fluid inside the transmission. ♦ Thoroughly clean the connection points and the area around them first, and then loosen them. ♦ When installing the transmission, make sure the alignment sleeves are seated correctly between the engine and the transmission. ♦ Place the removed parts on a clean surface and cover them so that they do not become contaminated. Use foil and paper. Only use lint-free cloths. ♦ Only install clean parts: Remove the replacement parts from their packaging just before installing them. ♦ Carefully cover or seal opened components if repairs are not performed immediately. ♦ With the transmission removed, secure the torque converter so that it cannot fall out.

2

Rep. Gr.00 - General, Technical Data

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Uncertainties often exist on smaller bolts with lower tightening specifications. For these bolts the Torque Wrench 1783 - 2-10Nm - VAG1783- can be used.

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♦ Refer to Self Study Program Automatic Transmission 09G.

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ss ♦ Refer to Multimedia Training; Automatic Transmission 09G.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 Transmission with and without Filler Tube Illustrated here, for »example,« is filler tube as it was installed in »older« transmissions. This tube has been omitted.

The »old« filler hole with the red cap is not needed because the ATF is drained and filled at the lower hole when necessary. The »height« of this rising tube corresponds to the height of the ATF level. To drain, the overflow pipe is removed. ♦ After installing, check the ATF level and fill. Refer to ⇒ “11 ATF Level, Checking and Filling”, page 112 .

1.8

Seals, Gaskets and Oil

♦ Always replace the O-rings, gaskets and seals. AG. Volkswagen AG d oes not gu ara nte ise r o eo After removing the gaskets and seals,uthcheck the contact sur‐ ra a resulting from removal c s faces on the housing or shaft for burrs s

n ♦ Flange shaft, torque converter and selector shaft are wage ksgaskets Vol y illustrated as shaft seals. db

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♦ Coat the O-rings with ATF before inserting to prevent crushing rings during assembly.

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♦ Only use ATF. Other lubricants cause malfunctions in the hy‐ draulic transmission control. ♦ Before installing the seals, lightly oil the outer circumference and fill the space between the sealing lips -arrow- halfway with Grease - G 052 128 A1- . ♦ The open side of the gaskets point toward the fluid to be sealed in. ♦ Check the ATF level after installing. Refer to ⇒ “11 ATF Level, Checking and Filling”, page 112 . Caution

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Be cautious when handling ATF. Dispose of drained fluid prop‐ erly. ht rig py Co t.

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♦ Capacities. Refer to ⇒ “3 Capacities”, page 6 .

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Bolts and Nuts

♦ The tightening specifications given apply to unoiled bolts and nuts. ♦ Use a wire brush to clean the threads of the bolts that were installed with locking fluid. Install the bolts with Locking Fluid - AMV 185 101 A1- . ♦ Clean the threaded holes for the self-locking bolts or for the bolts coated with locking fluid (for example with a thread tap). Otherwise there is the risk that the bolts could break off the next time they are removed. ♦ Always replace self-locking bolts and nuts.

Electrical Components

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– Touch a grounded object, such as a water line or a hoist, be‐ fore working on electrical components. Do not touch the con‐ nector terminals or »open« electronic components directly. Prote cted by

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Almost everyone has been shocked at one time or another when coming into contact with a metal object. The reason for this is the build-up of static electricity in the human body. This charge can damage the electrical components in the transmission and the selector mechanism when touching them.

Guided Fault Finding, OBD and Test In‐ struments

Before beginning any repair work on the automatic transmission, determine the cause of the damage using “Guided Fault Finding”. Perform Guided Fault Finding using, for example a Vehicle Diagnostic Tester . Refer to ⇒ “1 Tester, Connecting”, page 13 . The Guided Functions finds the ATF temperature quickly. Re‐ fer to ⇒ “1 Tester, Connecting”, page 13 .

1.12

Safety Precautions

Pay Attention to the Following to Avoid Personal Injury and Ve‐ hicle Damage: WARNING

Risk of injury and accident by accidentally engaging a gear with the engine running. ♦ Move the selector lever into “P” and set the parking brake before working with the engine running.

4

Rep. Gr.00 - General, Technical Data

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♦ Loosen or tighten the bolts and nuts on the covers or housings diagonally.

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1.9

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

2

Transmission Identification

⇒ “2.1 Identification on Transmission”, page 5 The “6-speed automatic transmission 09G” in installed in the Jetta from MY 2005, the Bore from MY 2006, the Golf Wagon from MY 2007, the Jetta Wagon from MY 2008 and the Jetta MY 2011. Transmission allocation to the engine. Refer to ⇒ “4 Engine Codes - Engine Allocation”, page 7 .

Identification on Transmission

“Automatic transmission 09G - 6-speed” -arrow 2-

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Code letters -arrow-

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The transmission code is also listed on the vehicle data label.

2. Transmission Identification

5

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

3

Capacities

⇒ “3.1 Planetary Gear and Final Drive”, page 6

3.1

Planetary Gear and Final Drive Capacities

Original filling by the manufacturer Filling after draining in service Change

“6-Speed Automatic Transmission 09G” Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03 Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03 the replacement capacity may differ depending on the engine ♦ No change ♦ Permanent fill; only change after repairs for exam‐ ple when removing the ATF pan

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ATF is available as a replacement part. Therefore the part numbers are also located in the Parts Catalog.

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Grease

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

4

Engine Codes - Engine Allocation

If original parts are needed for a repair, always pay attention to the transmission codes. “Automatic Transmission 09G”

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»KBV«, »KGL«, »MAN«, »PDW« 2.5L - 125 kW

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4. Engine Codes - Engine Allocation

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

5

Special Tools

Special tools and workshop equipment required ♦ Torque Wrench 1783 - 2-10Nm - VAG1783-

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1

Torque Converter AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h Removing and Installing”, page 10 t u ra a c s s

Overview - Torque Converter

⇒ “1.1 Torque Converter,

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⇒ “1.2 Torque Converter, Checking”, page 10

⇒ “1.3 Torque Converter, Discharging”, page 11

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1 - Torque Converter ❑ Secure the torque con‐ verter from falling when the transmission is re‐ moved or during trans‐ port. Refer to ⇒ Fig. ““Secure the Tor‐ que Converter from Fall‐ ing Out.”“ , page 10 ❑ There are different tor‐ que converters. ❑ Use the code letters to identify them. Refer to the Parts Catalog. ❑ Removing and instal‐ ling. Refer to ⇒ “1.1 Torque Convert‐ er, Removing and In‐ stalling”, page 10 . ❑ Checking. Refer to ⇒ “1.2 Torque Convert‐ er, Checking”, page 10 . ❑ Draining. Refer to ⇒ “1.3 Torque Convert‐ er, Discharging”, page 11 .

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⇒ “1.4 Torque Converter Seal, Removing and Installing”, page 11

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2 - Seal ❑ For the torque converter ❑ Replacing. Refer to ⇒ “1.4 Torque Converter Seal, Removing and In‐ stalling”, page 11 .

1. Overview - Torque Converter

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– Carefully remove the torque converter from the transmission. Installing

– Press torque converter hub carefully through the seal until the first stop. – Lightly press the torque converter toward the transmission and turn it until the opening on torque converter hub -arrow- en‐ gage in the driver on ATF pump gear and torque converter slides inward noticeably. The converter is installed correctly if it is easy to turn is by hand and if it fits evenly deep in the transmission. Caution

If the engine and transmission are connected with force when the torque converter is installed incorrectly, damage to the transmission and torque converter results.

1.2

Torque Converter, Checking

– Check the torque converter hub -arrow- for wear grooves. Note

The torque converter is welded together and must be replaced as a complete unit if it is damaged or faulty.

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Rep. Gr.32 - Torque Converter

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Torque Converter, Removing and Instal‐ ling

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Unsecured torque converters can slide out if the transmission is tipped.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

1.3

Torque Converter, Discharging

Special tools and workshop equipment required ♦ Used Oil Collection and Extraction Unit - SMN372500Drain the torque converter as follows if the ATF is contaminated: – Extract the ATF from the torque converter using the Used Oil Collection and Extraction Unit - SMN372500- and the oil ex‐ traction sensor.

Torque Converter Seal, Removing and Installing

AG. Volkswagen AG d agen oes ksw not l o V gu Special tools and workshop equipment required by ara d e nte is r o eo ♦ Seal Installer - Torque Converter Seal - T10175h ut ra a c s s ♦ Puller - Seal Lever - VW681es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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– Pry out the seal with the Puller - Seal Lever - VW681- .

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– Coat the outer circumference and the sealing lips on the new seal with ATF. Installation position: open side of the seal toward the trans‐ mission.

– Install the seal using the Seal Installer - Torque Converter Seal - T10175- until it is flush.

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1.4

1. Overview - Torque Converter

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

2

Special Tools

Special tools and workshop equipment required ♦ Used Oil Collection and Extraction Unit - SMN372500-

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♦ Seal Installer - Torque Converter Seal - T10175-

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

37 –

Controls, Housing

1

»Tester«, Connecting

♦ Vehicle Diagnostic Tester The operation of these »devices« is described in the respective owner's manuals. Connecting the Vehicle Diagnostic Tester to the Data Link Con‐ nector. WARNING

♦ During a road test, always secure testing and measuring equipment on the rear seat. ♦ Only a passenger may use the equipment during the road test.

The Vehicle Diagnostic Tester is ready for use when it is possible to select between the fields/buttons Guided Functions and Guided Functions on the »right« side of the screen. Depending on equipment and tester version, additional functions may be »displayed«, for example: ♦ ElsaWin ♦ Measuring Equipment ♦ On Board Diagnostics (OBD) The »Tester« is Now Ready to be Used.

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte field/button on othe ris screen to start desired function. eo h ut ra a c s s

– Switch the ignition on.

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– Touch a

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– Turn on the Vehicle Diagnostic Tester .

1. »Tester«, Connecting

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

2

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Electrical and Electronic Components and Component Locations un le

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1 - Transmission Control Mod‐ ule - J217❑ The control module sends and receives data from the Data bus. ❑ Component location on the Jetta from MY 2005, Bora from 2006, Golf Wagon from 2007, Jetta Wagon from 2008. Re‐ fer to ⇒ Fig. ““ Transmission Control Module J217- -arrow- on the Jet‐ ta from MY 2005, the Bora from MY 2006, the Golf Wagon from MY 2007 and the Jetta Wag‐ on from MY 2008”“ , page 16 ❑ Component location on the Jetta, from MY 2011, with a 1.8L or 2.0L En‐ gine. Refer to ⇒ Fig. ““ Transmission Control Module J217- -A- on the Jetta from MY 2011 with 2.0L - 85 kW and 1.8L - 125 kW Engine”“ , page 16 . ❑ Component location on the Jetta, from MY 2011, with a 2.5L - 125 kW en‐ gine. Refer to ⇒ Fig. ““ Transmission Control Module J217- -A- on the Jetta from MY 2011, with a 2.5L 125 kW Engine”“ , page 16 . ❑ Can be checked in “Guided Fault Finding” using the Vehicle Diagnostic Tester . 2 - Engine Control Module ❑ The control module sends and receives data from the Data bus ❑ Component location, Removing and installing. Refer to ⇒ Rep. Gr. 23 and ⇒ Rep. Gr. 24 . 3 - Multifunction Transmission Range Switch - F125❑ Component location. Refer to ⇒ Fig. ““ Multifunction Transmission Range Switch -F125- ”“ , page 16 ❑ Can be checked in “Guided Fault Finding” using the Vehicle Diagnostic Tester . ❑ Removing, installing and adjusting. Refer to ⇒ “3 Multifunction Transmission Range Switch F125 ”, page 20 . 4 - Valve Body ❑ Component location. Refer to ⇒ Fig. ““Valve Body”“ , page 17 ❑ The components can be checked in “Guided Fault Finding” using the Vehicle Diagnostic Tester . ❑ Allocation. Refer to the Parts Catalog. 5 - Sensor Wiring Harness ❑ 8-pin wiring harness

14

Rep. Gr.37 - Controls, Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 ❑ With Transmission Fluid Temperature Sensor - G93❑ Component location. Refer to ⇒ Fig. ““Sensor Wiring Harness”“ , page 17 ❑ Removing and installing. Refer to ⇒ “4.4 Sensor Wiring Harness (8-Pin Connector), Removing and Installing”, page 149 . ❑ Allocation. Refer to the Parts Catalog. 6 - Transmission Fluid Temperature Sensor - G93❑ Component location. Refer to ⇒ Fig. ““Sensor Wiring Harness”“ , page 17 ❑ Can be checked in “Guided Fault Finding” using the Vehicle Diagnostic Tester . 7 - Solenoid Valve Wiring Harness ❑ Wiring harness, 14-pin ❑ Component location. Refer to ⇒ Fig. ““Solenoid Valve Wiring Harness”“ , page 17 AG. Volkswagen AG d agen oes w s k not ❑ Removing and installing. Refer to Vol gu y b ara 148 . ⇒ “4.3 Solenoid Valve Wiring Harness (14-Pin Connector), Removing and Installing”, page d nte ise r o eo h ❑ Allocation. Refer to the Parts Catalog. ut r ac

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9 - Automatic Transmission Hydraulic Pressure Sensor 2 - G194❑ Not installed in all transmissions ❑ Allocation. Refer to the Parts Catalog. ❑ Component location. Refer to ⇒ Fig. ““ Automatic Transmission Hydraulic Pressure Sensor 1 -G193- and Automatic Transmission Hy‐ draulic Pressure Sensor 2 -G194- ”“ , page 18 10 - Transmission Input Speed Sensor - G182❑ Component location. Refer to ⇒ Fig. ““ Transmission Input Speed Sensor -G182- and Transmission Output Speed Sensor -G195- ”“ , page 18 ❑ Removing and installing. Refer to ⇒ “4.5 Transmission Input Speed Sensor G182 , Removing and Installing”, page 150 . ❑ Can be checked in “Guided Fault Finding” using the Vehicle Diagnostic Tester . do c um en

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11 - Transmission Output Speed Sensor - G195❑ Component location. Refer to ⇒ Fig. ““ Transmission Input Speed Sensor -G182- and Transmission Output Speed Sensor -G195- ”“ , page 18 ❑ Removing and installing. Refer to ⇒ “4.6 Transmission Output Speed Sensor G195 , Removing and Installing”, page 151 . ❑ Can be checked in “Guided Fault Finding” using the Vehicle Diagnostic Tester . agen lksw Vo by

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8 - Automatic Transmission Hydraulic Pressure Sensor 1 - G193❑ Not installed in all transmissions ❑ Allocation. Refer to the Parts Catalog. ❑ Component location. Refer to ⇒ Fig. ““ Automatic Transmission Hydraulic Pressure Sensor 1 -G193- and Automatic Transmission Hy‐ draulic Pressure Sensor 2 -G194- ”“ , page 18

12 - Shift Lock Solenoid - N110❑ Component location: the shift lock solenoid is located in the selector mechanism. ❑ Can be checked in “Guided Fault Finding” using the Vehicle Diagnostic Tester . 13 - Tiptronic Switch - F189❑ Component location. Refer to ⇒ Fig. ““ Tiptronic Switch -F189- ”“ , page 18 ❑ Can be checked in “Guided Fault Finding” using the Vehicle Diagnostic Tester . 14 - Terminal 50 Power Supply Relay - J682❑ Inside the engine compartment E-box. Refer to ⇒ Wiring diagrams, Troubleshooting & Component lo‐ cations. 15 - Data Link Connector ❑ Component location. Refer to ⇒ Fig. ““Data Link Connector”“ , page 19

2. Electrical and Electronic Components and Component Locations

15

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 16 - Transmission Range Display - Y6❑ Component location. Refer to ⇒ Fig. ““ Transmission Range Display -Y6- ”“ , page 19 ❑ Removing and installing. Refer to ⇒ Electrical Equipment; Rep. Gr. 90 ; Instrument Cluster . Transmission Control Module - J217- -arrow- on the Jetta from MY 2005, the Bora from MY 2006, the Golf Wagon from MY 2007 and the Jetta Wagon from MY 2008 Component location: The control module is located in left front wheel housing. – The wheel housing liner must be removed for the removal and installation.

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Transmission Control Module - J217- -A- on the Jetta 2011 with 2.0L - 85 kW and 1.8L - 125 kW Engine

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– For removing and installing the plenum chamber cover must be removed. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Plenum Chamber Cover; Plenum Chamber Cover, Removing and In‐ stalling .

Transmission Control Module - J217- -A- on the Jetta from MY 2011, with a 2.5L 125 kW Engine

Rep. Gr.37 - Controls, Housing

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Component location: The multifunction transmission range switch is located on upper side of the transmission.

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Multifunction Transmission Range Switch - F125-

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Component location: The control module is located inside the en‐ gine compartment in the front and on left side next to the battery.

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Component location: The control module is located in the right plenum chamber.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 Valve Body Component location: the valve body is bolted to underside of transmission housing and is covered by the transmission fluid pan.

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Sensor Wiring Harness ♦ With integrated Transmission Fluid Temperature Sensor G93- -arrow-.

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Component location: the wiring harness is secured to valve body in the transmission.

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Component location: the wiring harness is secured to valve body in the transmission. agen lksw Vo by

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♦ 8-pin wiring harness

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The Solenoid Valve 1 - N88- , Solenoid Valve 2 - N89- , Solenoid Valve 3 - N90- , Solenoid Valve 4 - N91- , Solenoid Valve 5 - N92- , Solenoid Valve 6 - N93- , Solenoid Valve 9 - N282- and Solenoid Valve 10 - N283- are secured on the valve body.

2. Electrical and Electronic Components and Component Locations

17

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 Automatic Transmission Hydraulic Pressure Sensor 1 - G193and Automatic Transmission Hydraulic Pressure Sensor 2 G194These sensor are not installed in all transmissions. Component location: Automatic Transmission Hydraulic Pressure Sensor 1 - G193-1- and Automatic Transmission Hydraulic Pressure Sensor 2 G194- -2- are inside the valve body.

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Component location: the sensors are installed above the valve body in the transmission housing. 1 - Transmission Input Speed Sensor - G182-

2 - Transmission Output Speed Sensor - G195-

Rep. Gr.37 - Controls, Housing

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If the vehicle has a multifunction steering wheel, check the but‐ tons on the steering wheel and the corresponding wire connec‐ tions.

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Component location: the tiptronic switch is integrated in selector mechanism.

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Tiptronic Switch - F189-

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Transmission Input Speed Sensor - G182- and Transmission Output Speed Sensor - G195-

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 Data Link Connector Component location: the data link connector -arrow- is located on the left under the driver side storage compartment

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Transmission Range Display - Y6-

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Component location: inside the instrument cluster

2. Electrical and Electronic Components and Component Locations

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

3

Multifunction Transmission Range Switch - F125-

⇒ “3.1 Multifunction Transmission Range Switch F125 , Remov‐ ing”, page 20 . ⇒ “3.2 Multifunction Transmission Range Switch F125 , Instal‐ ling”, page 21 . ⇒ “3.3 Multifunction Transmission Range Switch F125 , Adjust‐ ing”, page 22 .

3.1

Multifunction Transmission Range n AG. Volkswagen AG do Switch - F125- , Removing es n wage o olks

– Move the selector lever into “N”.rised tho au s s

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– If necessary remove the air filter housing:

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♦ Gasoline engine. Refer to ⇒ Rep. Gr. 24 ; Air Filter; Air Filter Housing, Removing and Installing .

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– Turn off the ignition.

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– To remove the selector lever cable from the transmission, re‐ lease the selector lever cable -arrows 1- and then remove it from the cable bracket -arrow 2-. Note

♦ Do not use pliers because the mounting tabs on the cable

bracket could break off.

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– Disconnect the connector from the Multifunction Transmission Range Switch - F125- . AG.

Rep. Gr.37 - Controls, Housing

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♦ Do not bend or kink the selector lever cable.

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ProCarManuals.com

♦ TDI engine. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Overview - Air Filter .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Remove the nut -1-. – Remove the spring washer -2- and the lever -3- from the se‐ lector shaft -4-.

–

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– Remove the nut -1-.

– Remove the bolts -5-.

– Remove the multifunction transmission range switch -4- and the washers -2 and 3- from the selector shaft -6-.

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Multifunction Transmission Range Switch - F125- , Installing

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♦ Torque Wrench 1331 5-50Nm - VAG1331-

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3.2

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Install in reverse order of removal while. Note the following: agen lksw Vo by

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3. Multifunction Transmission Range Switch F125

21

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

–

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switch hand-tight.

– Bend back the hooks on the lock washer -2-. – Install the washers -2 and 3- on the selector shaft -6-. – Install the washer -2- with the long narrow guide into the long narrow recesses in the selector shaft -6-. – Tighten the nut -1- to 7 Nm. – Secure the nut -1- it by bending the hook on the lock washer -2- upward. – Replace the lock washer if a hook breaks off.

– Attach the lever -3- to the selector shaft -4-.

– Move the transmission into the “N” position with the lever -3-. Push the lever -3- two position forward in the direction of travel.

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– Adjust the Multifunction Transmission Range Switch - F125- . Refer to ⇒ “3.3 Multifunction Transmission Range Switch F125 , Ad‐ justing”, page 22 . AG.

ProCarManuals.com

– Move the selector lever -3- into “P”. This means, push the se‐ lector lever -3- opposite the drive direction until it stops.

– Mount the spring washer -2- and the nut -1- on the selector shaft -4-. – Tighten the nut -1- to 13 Nm. – Check the selector mechanism. Refer to ⇒ “4.9 Selector Mechanism, Checking”, page 44 . – If removed, install the air filer housing. ♦ Gasoline engine. Refer to ⇒ Rep. Gr. 24 ; Air Filter; Air Filter Housing, Removing and Installing . ♦ TDI engine. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Overview - Air Filter .

3.3

Multifunction Transmission Range Switch - F125- , Adjusting

Special tools and workshop equipment required ♦ Gauge - Multi Function Switch - T10173– Move the selector lever into “N”. – Do not bend the selector lever cable. Adjustment Requirements •

Selector lever cable is removed from the lever/selector shaft

•

The selector shaft is in “N”.

•

The bolts on the Multifunction Transmission Range Switch F125- have been loosened.

•

The lever/selector shaft is removed.

22

Rep. Gr.37 - Controls, Housing

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– Install the washer -2- with the hooks facing upward.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 Adjusting – Place the Gauge - Multi Function Switch - T10173- on the se‐ lector shaft -2- and turn the Multifunction Transmission Range Switch - F125- -1- until the Adjustment Gauge engages in the tab on the Multifunction Transmission Range Switch - F125connector. Note

If the tab on the connector does not lock into the groove in the Gauge - Multi Function Switch - T10173- , then the transmission is no longer in “N”. In this case, shift the transmission into “N” using the Gauge - Multi Function Switch - T10173- . – Secure the Gauge - Multi Function Switch - T10173- to the selector shaft -2- with the bolt -3-. – Tighten the bolts -arrows- to 6 Nm. – Remove the Gauge - Multi Function Switch - T10173- .

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– Further installation is performed in reverse order of removal. Refer to ⇒ “3.2 Multifunction Transmission Range Switch F125 , In‐ stalling”, page 21 .

3. Multifunction Transmission Range Switch F125

23

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⇒ “4.1 Overview - Selector Mechanism through 02/2009”, page 24 ⇒ “4.2 Shift Mechanism with Selector Lever, Removing and In‐ stalling, through 02/2009”, page 26 ⇒ “4.3 Selector Lever Cable, Removing and Installing, through 02/2009”, page 28 ⇒ “4.4 Selector Lever Cable, Checking”, page 37 ⇒ “4.5 Selector Lever Cable, Adjusting”, page 38 ⇒ “4.6 Selector Lever, Emergency Release”, page 39 ⇒ “4.7 Selector Lever Handle, Removing and Installing”, page 40

Move the selector lever into “P” and set the parking brake be‐ fore working with the engine running.

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WARNING

AG.

Selector mechanism from 03/2009. Refer to ⇒ “5 Selector Mechanism from 03/2009”, page 46 .

4.1

24

Overview - Selector Mechanism through 02/2009

Rep. Gr.37 - Controls, Housing

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⇒ “4.9 Selector Mechanism, Checking”, page 44

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⇒ “4.8 Button in Handle, Moving into Installation Position”, page 42

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 1 - Shift Cover with Handle ❑ Do not remove the han‐ dle unnecessarily. Only the cover must be un‐ clipped for the emergen‐ cy release. Refer to ⇒ “4.6 Selector Lever, Emergency Release”, page 39 . ❑ Pull the button past its pressure point before removing the handle. Secure the button with a cable tie or some suita‐ ble wire. This prevents the button from being pushed back into knob accidentally. ❑ If the button is pushed in with the handle re‐ moved: Installing, pull out button beyond the noticeable press point.

2 - Selector Mechanism with Selector Lever ❑ Removing and instal‐ ling. Refer to ⇒ “4.2 Shift Mechanism with Selector Lever, Re‐ moving and Installing, through 02/2009”, page 26 . 3 - Bolt with Spring ❑ 3 Nm 4

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28 .

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❑ Do not lubricate

5 - Locking Plate ❑ Always replace after removing

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6 - Nut ❑ 9 Nm ❑ Quantity: 4

7 - Gearshift Housing ❑ With seal

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9 - Hex Nut and Washer ❑ 8 Nm ❑ Quantity: 4

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8 - Selector Lever Cable ❑ Do not grease the cable. ❑ Removing and installing. Refer to ⇒ “4.3 Selector Lever Cable, Removing and Installing, through 02/2009”, page 28 . ❑ Checking. Refer to ⇒ “4.4 Selector Lever Cable, Checking”, page 37 . ❑ Adjusting. Refer to ⇒ “4.5 Selector Lever Cable, Adjusting”, page 38 .

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–

4. Selector Mechanism through 02/2009

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

4.2

Shift Mechanism with Selector Lever, Removing and Installing, through 02/2009 Note

After installation, the selector lever cable must be checked for ease of movement and adjusted. Removing – Remove the selector lever handle. Refer to ⇒ “4.7 Selector Lever Handle, Removing and Installing”, page 40 . – Remove the center console. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Console . – If necessary remove the air filter housing: ♦ Gasoline engine. Refer to ⇒ Rep. Gr. Housing, Removing and Installing .

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– Remove the selector lever cable from the transmission. Refer to ⇒ “4.3 Selector Lever Cable, Removing and Installing, through 02/2009”, page 28 . – Raise the vehicle.

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To remove the selector level cable or the selector mechanism, the heat shield under the selector mechanism must be removed as follows: Caution

Risk of damaging the decoupling element.

♦ Do not bend the decoupling element more than 10°. ♦ Do not load the decoupling element.

– Loosen the nuts on the clamping sleeve -1- and then slide it toward the rear. Prote cted by

Rep. Gr.37 - Controls, Housing

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26

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– Remove the front tunnel brace -arrows- from the underbody.

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♦ Do not damage the wire mesh on the decoupling element. ht rig py Co t.

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♦ TDI engine. Refer to ⇒ Rep. Gr. 23 ; System; Overview - Air Filter .

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– Tie up the front exhaust pipe.

– If equipped, remove nuts -1 and 2-, and remove the rear tunnel brace.

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– Lower the underbody trim panel on the inside just enough until the heat shield -1- for the center tunnel can be removed.

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– Remove the lock washers -2 and 3-.

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– Remove the underbody trim panel nuts -arrows-.

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ProCarManuals.com

– Disengage the center muffler and the rear muffler from the re‐ taining loops -arrows- and tie them to the body for example with a wire. Remove the exhaust system rear section, if nec‐ essary.

– Remove the four nuts on the selector mechanism »from above«. – Remove the selector mechanism from below, while doing so, do not bend or kink the selector level cable. Installing Install in reverse order of removal while. Note the following: Tightening specifications for the nuts. Refer to ⇒ “4.1 Overview - Selector Mechanism through 02/2009”, page 24 . – Insert the selector lever cable into the cable bracket/transmis‐ sion and carefully push it onto the selector shaft lever. Do not bend the selector shaft lever when doing this, otherwise shift‐ ing can no longer be adjusted precisely. – Do not bend or kink the selector lever cable. – Engage the selector level cable -1- in the clip -arrow- on the transmission. When routing the selector lever cable to the ATF cooler, maintain a minimum 5 mm space.

4. Selector Mechanism through 02/2009

27

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Install the heat shield -1- under the selector mechanism and attach with the lock washers -2 and 3-. – Attach the underbody trim panel to the body -arrows-. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Underbody Trim Panels . – Install the exhaust system and align it without tension. Refer to ⇒ Rep. Gr. 26 ; Exhaust System; Exhaust System, Instal‐ ling without Tension or ⇒ Rep. Gr. 26 ; Exhaust Pipes/ Mufflers; Exhaust System, Installing without Tension . – Install the tunnel braces under the exhaust system. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Tunnel Brace . – Install the center console. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Console . – Install the selector lever handle. Refer to ⇒ “4.7 Selector Lever Handle, Removing and Installing”, page 40 . – Adjust the selector lever cable. Refer to ⇒ “4.5 Selector Lever Cable, Adjusting”, page 38 . – Check the selector mechanism. Refer to ⇒ “4.9 Selector Mechanism, Checking”, page 44 . ♦ Gasoline engine. Refer to ⇒ Rep. Gr. 24 ; Air Filter; Air Filter Housing, Removing and Installing . ♦ TDI engine. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Overview - Air Filter . . Volkswagen AG gen AG wa olks yV b ed ris ho t au

Selector Lever Cable, Removing and In‐ stalling, through 02/2009 ss Note

After installation, the selector lever cable must be checked for ease of movement and adjusted. Removing

– Move the selector lever into “S”.

– If necessary remove the air filter housing: ♦ Gasoline engine. Refer to ⇒ Rep. Gr. 24 ; Air Filter; Air Filter Housing, Removing and Installing .

AG.

Rep. Gr.37 - Controls, Housing

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28

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♦ TDI engine. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Overview - Air Filter .

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ProCarManuals.com

– If removed, install the air filer housing.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – To remove the selector lever cable from the transmission, re‐ lease the selector lever cable -arrows 1- and then remove it from the cable bracket -arrow 2-. Note ♦ Do not use pliers because the mounting tabs on the cable

bracket could break off.

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♦ Do not bend or kink the selector lever

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– Raise the vehicle.

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– Pry the selector lever cable -1- off the lever -3- using an open end wrench -2-. To remove the selector level cable or the selector mechanism, the heat shield under the selector mechanism must be removed as follows:

Risk of damaging the decoupling element. ♦ Do not bend the decoupling element more than 10°. ♦ Do not load the decoupling element.

– Loosen the nuts on the clamping sleeve -1- and then slide it toward the rear.

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– Remove the front tunnel brace -arrows- from the underbody.

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♦ Do not damage the wire mesh on the decoupling element.

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ProCarManuals.com

Caution

– If necessary remove the exhaust system bracket from the subframe -arrows-. – Tie up the front exhaust pipe.

4. Selector Mechanism through 02/2009

29

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– Remove the underbody trim panel nuts -arrows-. – Remove the lock washers -2 and 3-.

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ProCarManuals.com

– Lower the underbody trim panel on the inside just enough until the heat shield -1- for the center tunnel can be removed.

– Remove the -selector housing- from under the selector lever.

30

Rep. Gr.37 - Controls, Housing

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ris center muffler and the rear muffler fromntthe ee re‐ – Disengagehthe t o or u taining loops -arrowsand tie them to the body for example ac a s s with a wire. Remove the exhaust system rear section, if nec‐ essary.

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– Remove selector lever cable locking plate. Always replace the locking plate.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

4. Selector Mechanism through 02/2009

31

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 The -selector housing- is push slightly onto the selector lever ca‐ ble in the direction of -arrow-.

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The locking strap must be pushed forward in order to remove the cable in direction of -arrow 1-.

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Rep. Gr.37 - Controls, Housing

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32

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– Insert the -screwdriver- from underneath while pushing the securing tab forward.

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– Push the -pin- upward in direction of -arrow 2-at the same time with a screwdriver .

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Golf Variant

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For Clarity

4. Selector Mechanism through 02/2009

33

ProCarManuals.com

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

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– Remove the selector lever cable.

Remove the selector housing from the selector lever cable. Installing

Do not lubricate the selector lever cable.

– Route the selector lever cable without tension and place it in the cable bracket on the transmission. Do not secure it there. – When installing, make sure the selector lever cable is routed correctly.

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Rep. Gr.37 - Controls, Housing

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Clip the selector lever cable into the bracket. Make sure the bracket does not touch the ATF cooler. Tighten the -nuts- to 8 Nm.

– Position the selector housing on the selector lever cable.

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– Secure the selector lever cable with a new securing plate to the cable bracket on the selector mechanism.

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t uplate Install the locking only after having checked the selector sa s lever cable for ease of movement. Refer to ⇒ “4.4 Selector Lever Cable, Checking”, page 37 .

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– Install the selector lever cable into the selector mechanism.

4. Selector Mechanism through 02/2009

35

ProCarManuals.com

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

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Rep. Gr.37 - Controls, Housing

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36

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– Install the selector housing.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Install the heat shield -1- under the selector mechanism and attach with the lock washers -2 and 3-. – Attach the underbody trim panel to the body -arrows-. lkswaalign gen AGit without tension. Refer – Install the exhaustagsystem n AG. Voand does w e ks26 not System, Instal‐ l to ⇒ Rep. Gr. ; Exhaust System; Exhaust o V gu y b Tension or ⇒ Rep. Gr. 26 ; Exhaust ara Pipes/ d ling without nte ise r o Mufflers; Exhaust System, Installing without Tension eo . h t au

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– If removed, install the air filer housing.

♦ Gasoline engine. Refer to ⇒ Rep. Gr. 24 ; Air Filter; Air Filter Housing, Removing and Installing . ♦ TDI engine. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Overview - Air Filter .

4.4

Selector Lever Cable, Checking

Brief Description

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To check the selector lever cable for ease of movement, remove it from the transmission and position the removed end so it does not make contact anywhere. Then selector lever is moved and the selector lever cable installed again on the transmission. After that, the selector lever cable must be adjusted. Refer to ⇒ “4.5 Selector Lever Cable, Adjusting”, page 38 . ht rig py Co t.

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– Adjust the selector lever cable after installing. Refer to ⇒ “4.5 Selector Lever Cable, Adjusting”, page 38 .

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ss – Install the tunnel braces under the exhaust system. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Tunnel Brace .

– Move the selector lever into »P«. – Loosen the bolt -2- on the selector lever cable -1-.

4. Selector Mechanism through 02/2009

37

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 olksw

–

– Move the selector lever from »P« to »S« and back to »P« sev‐ eral times. •

The selector lever must have ease of movement.

– Reinstall the selector level cable with the »loosened« adjust‐ ing screw. – Adjust the selector lever cable. Refer to ⇒ “4.5 Selector Lever Cable, Adjusting”, page 38 .

4.5

Selector Lever Cable, Adjusting

Special tools and workshop equipment required ♦ Torque Wrench 1331 5-50Nm - VAG1331-

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Selector Lever Cable Must Always Be Adjusted If: Prote cted by c o p yri gh t. C op yi

♦ The selector lever cable was removed from the transmission. ♦ The engine and/or transmission were removed and installed. agen lksw Vo by

♦ Sections of the subframe mount were removed and installed. AG.

ProCarManuals.com

•

Selector mechanism and selector lever cable move easily when shifting.

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•

♦ The selector lever cable itself or the selector mechanism was removed and installed. ♦ The engine/transmission position was changed, for example, were installed without tension. Adjusting – Move the selector lever into “P” position. •

The adjusting screw -2- must be »loosened«.

– Move the lever/selector shaft -3- into “P” (push the lever to the rear). WARNING

Make sure the parking lock is latched. – From »underneath the vehicle«, rotate both front wheels in the same direction and at the same time until the parking lock au‐ dibly engages. •

The parking lock is engaged when it is not possible to rotate both front wheels in the same direction at the same time.

– Tap the handle on the selector lever back and forth gently but do not move it out of “P” under any circumstances. This places the selector lever cable core in its optimal position.

38

Rep. Gr.37 - Controls, Housing

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from the cable bracket -arrows-.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Tighten the bolt -2- to 13 Nm.

4.6

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s thes Handle

Selector Lever, Emergency Release

– Unclip the shift cover and hold it to the side. – Press the brake or set the parking brake.

rrectness of i t to the co nform spec at i h re o n wit in t his

Vehicles through 02/2009

The lever can now be moved out of »P«.

Vehicles from 03/2009 – Push on the yellow plastic part. The lever can now be moved out of »P«.

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– Press on the yellow plastic piece from the right to the left -arrow-.

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Do Not Remove

4. Selector Mechanism through 02/2009

39

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

4.7

Selector Lever Handle, Removing and Installing Note

♦ There are different handles depending on the model. ♦ The handle is removed together with the shift cover. ♦ It is possible that the button could be pressed into the handle.

Never install the handle when the button is pressed in.

Removing – Move the selector lever into “D” position. Handle with the Button on the Side – Pull the button out of the handle just far enough until there is a small gap between the handle and the button. The button locks when released.

Handle with Front Button

rrectness of i t to the co nf o r m spec atio h re n in wit

It is not necessary to pull out the button by hand. The button locks in the installation position -arrow- when the handle is removed.

Handle with Sleeve

– Unclip the cover.

– Disconnect the connector from the shift cover.

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Rep. Gr.37 - Controls, Housing

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– Push the sleeve upward in the direction of -arrow- to unlock the handle.

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– Secure the button in this position with a cable tie or wire to prevent the button from being pressed in.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 Handle with Clamp – Cut the clamp under the boot -arrow- with a side cutter. Continuation for All Handles – Remove the handle from the selector lever without pushing the button. Note

Do not push the button after removal or it will not be possible to install the handle again. Installing – Install in reverse order of removal while. Note the following: •

The selector lever is in the “D” position.

Handle with the Button on the Side The button inside the handle is pulled out and if necessary is protected from getting pushed in again.

The button is in the installation position -arrow-.

If the button was pushed in by mistake, the installed position can be set again.

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– Move the button into the installation position. Refer to ⇒ “4.8 Button in Handle, Moving into Installation Position”, page 42 .

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Handle with Front Button

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•

4. Selector Mechanism through 02/2009

41

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 Note

A new handle is delivered with an assembly fastener. Remove the retainer just before installing. Handle with Sleeve – Install the handle all the way onto the selector lever and lock it. – Push the sleeve downward to lock it. Only Handles with Clamps – Install the handle all the way with a new clamp. – Clamp off the clamps using Hose Clamp Pliers - VAG1275- . – Press the button after installation.

If the button stays in the handle after being pressed, this means it was installed incorrectly. If this happens, remove the handle again and move the button in the installation position again. Refer to ⇒ “4.8 Button in Handle, Moving into Installation Position”, page 42 . Then install the handle again. Further installation is performed in the reverse order of the re‐ moval.

4.8

Button in Handle, Moving into Installa‐ tion Position

⇒ “4.8.1 Handle with Side Button”, page 42 ⇒ “4.8.2 Handle with Front Button”, page 42

4.8.1

Handle with Side Button

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– Pull the button out of the handle just far enough a small gap between the handle and the button. The button locks when released.

4.8.2

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– Secure the button in this position with a cable tie or wire to prevent the button from being pressed in.

Handle with Front Button

The button cannot be pulled out on these handles.

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Rep. Gr.37 - Controls, Housing

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42

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There are two ways to move the button into the installation posi‐ tion, »with« or »without« the assembly fastener. Both possibilities are described here. ht rig py Co t.

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Note

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 Move the Handle »with« an Assembly Fastener into the Installa‐ tion Position: When using an assembly fastener, make sure that it has an eye -arrow- at the front. Other assembly fasteners are not suitable.

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– With the button pressed and push the assembly fastener (with the eye) -arrow- all the way in until it latches into the assembly fastener. Then release the button. The button locks into the installation position when the assembly fastener is pulled out.

– Carefully unclip the handle trim -A- upward.

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Moving the Handle »without« an Assembly Fastener into the In‐ stallation Position:

4. Selector Mechanism through 02/2009

43

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Push the small lever -1- for the pull rod into the groove -2- with a screwdriver. This pushes the button -3- into the installation position. -I- the button is in the pressed position -II- the button is in the installation position Note

♦ ♦

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Selector Mechanism, Checking

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4.9

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small lever engages into the pull rod when the button is push‐ ed.

⇒ “4.9.1 Selector Lever in P and Ignition Switched On”, page 44

⇒ “4.9.3 Selector Level in Tiptronic Position”, page 45 ⇒ “4.9.4 Ignition and Lights Switched On”, page 45 ⇒ “4.9.5 Transmission Range Display”, page 45

Starter must not be able to be operated in selector lever positions “R”, “D”, “S” and in tiptronic position. The shift lock solenoid must not block the selector lever when the lever is in “N” position. The selector lever can be moved back into a another driving mode.

4.9.1 •

Selector Lever in “P” and Ignition Switched On

If the brake pedal is not depressed:

The selector lever is locked and cannot be moved out of “P” when the button is pressed. The shift lock solenoid blocks the selector lever. •

If the brake pedal is depressed:

The shift lock solenoid releases the selector lever. It is possible to select a gear. Move the selector lever slowly from “P” through “S”; while doing this, check whether the selector lever position displayed in instrument cluster matches actual selector lever po‐ sition.

4.9.2 •

Selector Lever in “N” and Ignition Switched On

If the brake pedal is not depressed:

44

Rep. Gr.37 - Controls, Housing

AG.

In the selector lever is moved into the “N” position the shift lock solenoid can block the selector lever after approximately one sec‐ ond. The selector lever can only be moved out of “N” when the brake pedal is pressed.

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Below 5 km/h (3.1 mph)

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⇒ “4.9.2 Selector Lever in N and Ignition Switched On”, page 44

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 The selector lever is locked and cannot be moved out of “N” when the button is pressed. The shift lock solenoid blocks the selector lever. •

If the brake pedal is depressed:

The shift lock solenoid releases the selector lever. It is possible to select a gear.

4.9.3 •

Selector Level in “Tiptronic” Position

Move the selector lever into the tiptronic gate:

The “D” symbol illumination must go out in the selector mecha‐ nism cover and the “+” and “-” symbols must turn on. The selector lever position display in the instrument cluster must change from “P R N D S” to “6 5 4 3 2 1” when the selector lever is moved into the tiptronic gate.

4.9.4

Ignition and Lights Switched On

The respective symbol is being lit up in the selector mechanism n AG. Volkswagen AG do es n wage cover. o olks au

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ss Simultaneous lighting of all segments on the transmission range display indicates the transmission is in emergency mode.

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4.9.5

4. Selector Mechanism through 02/2009

45

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Selector Mechanism from 03/2009

⇒ “5.1 Overview - Selector Mechanism from 03/2009”, page 46 ⇒ “5.2 Selector Mechanism, Removing and Installing, Vehicles from 03/2009”, page 47 WARNING

Move the selector lever into “P” and set the parking brake be‐ fore working with the engine running. Gearshift mechanism, vehicles through 02/2009. Refer to ⇒ “4 Selector Mechanism through 02/2009”, page 24 .

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1 - Shift Cover with Handle ❑ Do not remove the han‐ dle unnecessarily. Un‐ clip only the cover for the emergency release. Refer to ⇒ “4.6 Selector Lever, Emergency Release”, page 39 . ❑ Removing and instal‐ ling. Refer to ⇒ “4.7 Selector Lever Handle, Removing and Installing”, page 40 .

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Overview - Selector Mechanism from 03/2009 ht rig py Co t.

5.1

2 - Selector Lever and Selector Mechanism with Selector Lev‐ er Cable ❑ With integrated Selector Lever Sensor System Control Module - J587with Selector Lever E313- , Tiptronic Switch - F189- , Selector Lever Park Position Lock Switch - F319- and Shift Lock Solenoid - N110- . ❑ The selector lever cable can only be replaced to‐ gether with the selector mechanism. Refer to ⇒ “5.2 Selector Mecha‐ nism, Removing and In‐ stalling, Vehicles from 03/2009”, page 47 . ❑ Do not grease the selec‐ tor lever cable. ❑ Removing and instal‐ ling. Refer to ⇒ “5.2 Selector Mechanism, Removing and Installing, Vehicles from 03/2009”, page 47 . ❑ Checking. Refer to ⇒ “4.4 Selector Lever Cable, Checking”, page 37 . ❑ Adjusting. Refer to ⇒ “4.5 Selector Lever Cable, Adjusting”, page 38 .

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Rep. Gr.37 - Controls, Housing

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5

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AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d Golf Variant 2007 ➤ , Golf Variant 2010 ➤ nte ise, Jetta 2005 ➤ , Jetta 2011 ➤ r o eo h 6-Speed Automatic Transmission 09Gau-t Edition 07.2015 ra c s s

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 3 - Bolt ❑ 8 Nm 4 - Hex Nut with Collar ❑ 8 Nm ❑ Quantity: 4 5 - Gearshift Housing 6 - Selector Lever Cable ❑ Must not be removed from the selector mechanism and is replaced together as a single component. 7 - Transmission

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Selector Mechanism, Removing and In‐ stalling, Vehicles from 03/2009

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⇒ “5.2.1 Selector Mechanism with Selector Housing, Removing and Installing”, page 47

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5.2

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Note

♦ Do not bend or kink the selector lever cable. ♦ Do not lubricate the selector lever cable.

Brief Description

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Selector Mechanism with Selector Housing, Removing and Installing

The selector mechanism and the selector lever cable must be separated from each other. Both are removed with the selector housing. Prote cted by c o py rig ht . C op yi

Remove the center console inside the vehicle interior. agen lksw Vo by

It is necessary to remove the heat shield under the vehicle.

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5.2.1

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⇒ “5.2.2 Selector Mechanism without Selector Housing, Remov‐ ing and Installing”, page 51

It is possible to remove and install the selector mechanism with selector lever cable alone without the selector housing. Refer to ⇒ “5.2.2 Selector Mechanism without Selector Housing, Remov‐ ing and Installing”, page 51 . Note

After installation, the selector lever cable must be checked for ease of movement and adjusted. Removing

5. Selector Mechanism from 03/2009

47

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Move the selector lever into “P”.

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– Remove the selector lever handle and disconnect the con‐ nector -2- from the cover while doing so. Refer to ⇒ “4.7 Selector Lever Handle, Removing and Installing”, page 40 .

rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Remove the center console. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Console .

– Remove the center console. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Console . – Remove the air filter housing:

♦ Gasoline engine. Refer to ⇒ Rep. Gr. 24 ; Air Filter; Air Filter Housing, Removing and Installing .

– To remove the selector lever cable from the transmission, re‐ lease the selector lever cable -arrows 1- and then remove it from the cable bracket -arrow 2-.

bracket could break off.

♦ Do not bend or kink the selector lever cable.

– Pry the selector lever cable -1- off the selector shaft lever -3using for example an open end wrench -2-.

48

Rep. Gr.37 - Controls, Housing

AG.

♦ Do not use pliers because the mounting tabs on the cable

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Note

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♦ TDI engine. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Overview - Air Filter .

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– Disconnect the connector -1- from the selector mechanism to the vehicle wiring harness.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Disconnect the selector lever cable -1- from the bracket -arrow- on the transmission. – Raise the vehicle. To remove the selector mechanism, the heat shield under the se‐ lector mechanism must be removed as follows: Caution

Risk of damaging the decoupling element. ♦ Do not bend the decoupling element more than 10°. ♦ Do not load the decoupling element. ♦ Do not damage the wire mesh on the decoupling element. – Loosen the nuts on the clamping sleeve -1- and then slide it toward the rear.

– If necessary remove the exhaust system bracket from the AG. Volkswagen AG d subframe -arrows-. agen o

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– Tie up the front exhaust pipe.

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– If equipped, remove nuts -1 and 2-, and remove the rear tunnel brace. – Disengage the center muffler and the rear muffler from the re‐ taining loops -arrows- and tie them to the body for example with a wire. Remove the exhaust system rear section, if nec‐ essary.

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– Remove the front tunnel brace -arrows- from the underbody.

5. Selector Mechanism from 03/2009

49

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Remove the underbody trim panel nuts -arrows-. – Remove the lock washers -2 and 3-. – Lower the underbody trim panel on the inside just enough until the heat shield -1- for the center tunnel can be removed. Note

A second technician is required under the vehicle to remove the selector mechanism.

– Remove the nuts -arrows- in the vehicle interior. – Remove the selector mechanism -B- with the selector lever cable and selector housing downward. Installing Install in reverse order of removal. Note ♦ Do not bend or kink the selector lever cable. ♦ Do not lubricate the selector lever cable.n AG. Volkswagen AG age ksw

Vol ♦ Tightening specifications. Refer by to

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Rep. Gr.37 - Controls, Housing

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50

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– Carefully press the selector lever cable onto the selector shaft lever and into the cable bracket.

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– Remove the bracket -A-, if equipped.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Install the heat shield -1- under the selector mechanism and attach with the lock washers -2 and 3-. – Attach the underbody trim panel to the body -arrows-. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Underbody Trim Panels . – Install the exhaust system and align it without tension. Refer to ⇒ Rep. Gr. 26 ; Exhaust System; Exhaust System, Instal‐ ling without Tension or ⇒ Rep. Gr. 26 ; Exhaust Pipes/ Mufflers; Exhaust System, Installing without Tension . – Install the tunnel braces under the exhaust system. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Tunnel Brace . – Install the center console. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Console . – Install the selector lever handle. Refer to ⇒ “4.7 Selector Lever Handle, Removing and Installing”, page 40 . – Adjust the selector lever cable. Refer to ⇒ “4.5 Selector Lever Cable, Adjusting”, page 38 . – Check the selector mechanism. Refer to ⇒ “4.9 Selector Mechanism, Checking”, page 44 . ♦ Gasoline engine. Refer to ⇒ Rep. Gr. 24 ; Air Filter; Air Filter Housing, Removing and Installing . ♦ TDI engine. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Overview - Air Filter . n AG. Volkswagen AG do e wage

Brief Description

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Selector Mechanism without Selector Housing, Removing and Installing

The selector mechanism and the selector lever cable must be separated from each other. Both are removed together. Remove the center console inside the vehicle interior. A cord is attached to the selector lever cable prior to removal. The cord is used to remove and install the selector lever cable be‐ tween the tunnel and the heat shield. The selector mechanism with selector lever cable can be re‐ moved and installed together with the selector housing. Refer to ⇒ “5.2.1 Selector Mechanism with Selector Housing, Removing and Installing”, page 47 . Removing

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– Move the selector lever into “P”.

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5.2.2

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– Install the air filter housing:

5. Selector Mechanism from 03/2009

51

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Remove the selector lever handle and disconnect the con‐ nector -2- from the cover while doing so. Refer to ⇒ “4.7 Selector Lever Handle, Removing and Installing”, page 40 . – Remove the center console. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Console . – Disconnect the connector -1- from the selector mechanism to the vehicle wiring harness. – Remove the center console. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Console . – Remove the air filter housing: ♦ Gasoline engine. Refer to ⇒ Rep. Gr. 24 ; Air Filter; Air Filter Housing, Removing and Installing . ♦ TDI engine. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Overview - Air Filter . – To remove the selector lever cable from the transmission, re‐ . Volkswaitgen AG lease the selector lever cable -arrows 1- andwathen remove gen AG does s k not l o from the cable bracket -arrow 2-. gu yV

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♦ Do not use pliers because the mounting tabs on the cable

bracket could break off.

♦ Do not bend or kink the selector lever cable.

– Attach a longer cord to the end of the selector lever cable. The cord is used to guide the selector lever cable between the tun‐ nel and the heat shield during installation.

Rep. Gr.37 - Controls, Housing

AG.

52

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– Disconnect the selector lever cable -1- from the bracket -arrow- on the transmission.

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– Pry the selector lever cable -1- off the selector shaft lever -3using for example an open end wrench -2-.

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Note

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Remove the four bolts attaching the selector mechanism to the selector housing.

– Pull the selector mechanism and selector lever cable out of the center tunnel. Make sure the cord is pull through far enough so that it can reached from inside the engine com‐ AG. Volkswagen AG d agen oes ksw not l partment. o V g – Remove the selector lever cable cord. es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

The selector mechanism is available only together with the se‐ lector housing and selector lever cable. Refer to the Parts Cata‐ log. Installing

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Install in reverse order of removal. Note the following: A second technician will be needed for inserting the selector lever cable from the passenger compartment into the engine compart‐ ment. Note

♦ Do not bend or kink the selector lever cable. ♦ Tightening specifications. Refer to

⇒ “5.1 Overview - Selector Mechanism from 03/2009”, page 46 .

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– Secure the cord that was involved when removing the selector mechanism from the engine compartment on the end of the selector lever cable.

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♦ Do not lubricate the selector lever cable.

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Note

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– Guide the selector mechanism and selector lever cable through the opening in the center tunnel. – From the engine compartment, the second technician pulls the cord with the selector lever cable through the tunnel until it is possible to attach the selector lever cable to the cable bracket. – Remove the selector lever cable cord.

5. Selector Mechanism from 03/2009

53

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Attach the selector mechanism to the selector housing with four bolts. – Install the center console. Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Console . AG. Volkswagen AG d agen oes ksw not l o V gu – Install the selector lever handle.byRefer to ara d nte ⇒ “4.7 Selector Lever Handle, iseRemoving and Installing”, page r o eo h t 40 . u ra a

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– Check the selector mechanism. Refer to ⇒ “4.9 Selector Mechanism, Checking”, page 44 . – Install the air filter housing: ♦ Gasoline engine. Refer to ⇒ Rep. Gr. 24 ; Air Filter; Air Filter Housing, Removing and Installing .

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♦ TDI engine. Refer to ⇒ Rep. Gr. 23 ; Diesel Direct Injection System; Overview - Air Filter .

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– Adjust the selector lever cable. Refer to ⇒ “4.5 Selector Lever Cable, Adjusting”, page 38 .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

6

Transmission, Removing and Instal‐ ling, Jetta from 2005, Golf Wagon from 2007, Jetta Wagon from 2008

⇒ “6.1 Transmission, Removing, Vehicles with 2.0L - 85kW and 2.0L - 110kW Engines”, page 55 . ⇒ “6.2 Transmission, Installing, Vehicles with 2.0L - 85kW and 2.0L - 110kW Engines”, page 60 . ⇒ “6.3 Transmission, Removing, Vehicles with 2.5L - 110 kW and 2.5L -125 kW Engines”, page 63 . ⇒ “6.4 Transmission, Installing, Vehicles with 2.5L - 110 kW and 2.5L - 125 kW Engines”, page 69 . ⇒ “6.5 Tightening Specifications, Transmission to Engine”, page 71 .

6.1

n AG. Volkswagen AG do es n wage s k l ot g Vo y ua b Before removing, print out the diagnostic protocol for this ran ed ve‐ s i tee r before hicle »if possible«. Affix the protocol on to transmission o h t or u way. ac a sending back the removed transmission in the usual ss es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

Brief Description

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The transmission is remove downward separately. The engine remains in the vehicle.

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Remove the battery, the battery tray, the air filter and the engine cover »from above«. Both the engine and the transmission are supported and it is possible to remove the left subframe mount. Remove the noise insulation and the drive axles »from under‐ neath«. The transmission is lowered with the transmission jack. Note

The subframe is not removed.

Special tools and workshop equipment required

♦ Torque Wrench 1332 40-200Nm - VAG1332-

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♦ Transmission Support - 3282-

♦ Transmission Support - Mounting Plate 36 - 3282/36-

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♦ Insert Tool - 18mm - T10179-

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♦ Hose Clamps - Up To 25mm - 3094-

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♦ Engine and Gearbox Jack - VAS6931-

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–

Transmission, Removing, Vehicles with 2.0L - 85kW and 2.0L - 110kW Engines

♦ Socket - Sw15 - V/175♦ Engine Support Bridge - 10-222A♦ Engine Support Bridge - Gearbox Adapter - 10-222A/13♦ Tensioning Strap - T10038The following describes the “automatic transmission 09G” with a 2.0L FSI gasoline engine. There are only slight differences for the other engine versions. Tightening specifications: transmission to engine »as usual«, detailed for each engine (large and small ma‐ chine; FSI/MPI engine).

6. Transmission, Removing and Installing, Jetta from 2005, Golf Wagon from 2007, Jetta Wagon from 2008

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Before removing, print out the diagnostic protocol for this ve‐ hicle »if possible«. Affix the protocol on to transmission before sending back the removed transmission in the usual way. Removing – Move the selector lever into »P«. – See if a coded radio is installed. If so, obtain the anti-theft code. – Disconnect the battery ground cable with the ignition switched off. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and Connecting . – Remove the battery and the battery tray. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Removing and In‐ stalling . – Remove the engine cover and the air filter with the intake hose. – To remove the selector lever cable from the transmission, re‐ lease the selector lever cable -arrows 1- and then remove it from the cable bracket -arrow 2-. Note

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bracket could break off.

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♦ Do not bend or kink the selector lever cable.

– Pry the selector lever cable -1- off the selector shaft lever -3using for example an open end wrench -2-.

– Disconnect the connectors from the transmission and starter. Prote cted by

Rep. Gr.37 - Controls, Housing

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– Remove the upper starter bolt.

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– Mount the Hose Clamps - Up To 25mm - 3094- on the hoses and remove the hoses form the ATF cooler.

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♦ Do not use pliers because

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Mount the Engine Support Bridge - 10-222A- and support the engine with the transmission. Do not lift. – Remove the upper engine/transmission connecting bolts.

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– Remove the bolts -2- that attach the transmission mount to the transmission bracket -A- and the bolts -1- that attach the trans‐ mission bracket to the transmission. ht rig py Co t.

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– Remove the ground cable from the transmission bracket -A-, if equipped.

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Remove the bolts using the Insert Tool 18 mm - T10179- . Use olkswagto the lower tightening specification when tightening. en AG. VRefer agen to Engine”, AG does ⇒ “6.5 Tightening Specifications, Transmission ksw not l o V gu by ara page 71 . d e

The left driveshaft must be removed later in the procedure. – With the vehicle still standing on its wheels, loosen the left front collar bolt -arrow- a maximum 90°, otherwise the wheel bear‐ ing will get damaged. Refer to ⇒ Suspension, Wheels, Steer‐ ing; Rep. Gr. 40 ; Drive Axles, Removing and Installing . – Raise the vehicle and remove the front wheels. – Remove the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Noise Insulation . – Remove the vacuum pump with its bracket and lines. »The pump is located near the ATF filler tube.« – Disconnect the connectors from the transmission, if this has not already been done. – Remove the starter. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Starter; Starter, Removing and Installing .

6. Transmission, Removing and Installing, Jetta from 2005, Golf Wagon from 2007, Jetta Wagon from 2008

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Remove the pendulum support: First bolt -A- then bolts -B-. Note

When installing tighten that bolt -B- first, and then bolt -A-. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 for the tightening specifications.

– Remove the control arms from the wheel bearing housing on both sides.

– If equipped, remove the heat shield above the right drive axle -arrows-.

– Remove the left drive axle. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

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Rep. Gr.37 - Controls, Housing

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– Remove both drive axles from the transmission. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Re‐ moving and Installing .

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Tightening specifications. Refer to ⇒ Suspension, Wheels, Steer‐ ing; Rep. Gr. 40 .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Lift the right drive axle as far as possible and then tie it up.

– Remove the subframe mount transmission bracket. To do this slightly lower the engine with the transmission using the En‐ gine Support Bridge - 10-222A- spindles. Four turns are sufficient. – Remove the exhaust system bracket from the transmission, if equipped. – Remove the lower engine/transmission connecting bolts. – Start with the two lower bolts.

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– If it is necessary to remove this bolt, exhaust pipe must be removed. Refer to ⇒ Rep. Gr. 26 .

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– Remove this plug.

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The hole for removing the converter nuts on the back of the engine is covered with a rubber plug.

– Remove the six converter nuts -arrow- with the Socket - Sw15 - V/175- . Note

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– For safety, leave one bolt installed that is easily accessible.

6. Transmission, Removing and Installing, Jetta from 2005, Golf Wagon from 2007, Jetta Wagon from 2008

59

– Before removing the last connecting bolt, support the trans‐ mission with the Engine and Gearbox Jack - VAS6931- , the Transmission Support - 3282- and the Transmission Support - Mounting Plate 36 - 3282/36- . – Use the bolt -1- to secure the transmission to the Transmission Support - 3282- . – Remove the last bolt.

– Press the transmission off of the engine, at the same time press the torque converter off of the engine drive plate.

ProCarManuals.com when removing and installing the transmission. Replace the wiring harness in the transmission if the connector gets dam‐ aged. Refer to ⇒ “4.1 Overview - Valve Body”, page 128 .

♦ Pay attention to the torque converter. It must be removed to‐

gether with the transmission. Secure the torque converter with, for example a wire -A- to prevent it from falling out.

♦ Bear in mind that when installing a new transmission, the cable

bracket and the selector lever cable bracket for example must be replaced.

6.2

Transmission, Installing, Vehicles with 2.0L - 85kW and 2.0L - 110kW Engines

– Check that the alignment sleeves are pressed into the engine flange.

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Rep. Gr.37 - Controls, Housing

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♦ The connector on the transmission must not be damaged

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– Make sure there is enough clearance around the subframe while lowering. Adjust the Transmission Support - 3282- slight‐ ly, if necessary.

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– Make sure the intermediate plate fits correctly between the engine and the transmission. The plate must contact the en‐ gine along entire perimeter when pressing lightly against en‐ gine using both hands. If it is above the engine, then it is not hooked into the cylinder block correctly.

– Make sure the torque converter is installed correctly. Refer to ⇒ “1.1 Torque Converter, Removing and Installing”, page 10 . Further installation is performed in the reverse order of the re‐ moval. The engine and the transmission must be mounted in the sub‐ frame mount without tension. Refer to ⇒ Rep. Gr. 10 ; Engine, Removing and Installing for the procedure. – Replace all the bolts from the left subframe mount.

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– Install all new bolts first by hand.

6. Transmission, Removing and Installing, Jetta from 2005, Golf Wagon from 2007, Jetta Wagon from 2008

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 First tighten the bolts -1- to 40 Nm +90° when installing the trans‐ mission bracket -A- on the transmission. – Align the engine/transmission in its installed position. Lift until the transmission bracket is touching the transmission mount completely. Caution

There is a risk of damaging the threads in transmission bracket by inserting bolts at an angle. ♦ Before installing the bolts -2-, the transmission bracket and transmission mount support arm must be absolutely parallel to each other. If necessary, lift the back of the transmission using the Engine and Gearbox Jack VAS6931- . Adjust the »old fit« between both bolts using a screwdriver when tightening the transmission bracket to the transmission mount bolts -2-. Tighten the two larger bolts to 60 Nm +90°.

– Install the pendulum support. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Overview - Subframe . – Attach the drive axles to the transmission. Refer to ⇒ Sus‐ pension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Re‐ moving and Installing . G. Volkswagen

AG nA – Align the exhaust system free of tension.lksRefer wage to ⇒ Rep. Gr. does n ot g VoInstalling without Ten‐ 26 ; Exhaust System; Exhaust System, y ua db ran e sion or ⇒ Rep. Gr. 26 ; Exhaust tee risPipes/Mufflers; Exhaust o h t or System, Installing without Tension . a au

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– Install the starter. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Starter; Starter, Removing and Installing .

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– Connect the coolant hoses to the ATF cooler and check the coolant level. Refer to ⇒ Rep. Gr. 19 . – Attach the selector lever cable to the transmission and adjust it. Refer to ⇒ “4.5 Selector Lever Cable, Adjusting”, page 38 . – Install the battery tray and the battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Removing and In‐ stalling . – Check the ATF level after installing. Refer to ⇒ “11 ATF Level, Checking and Filling”, page 112 . – Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Noise Insulation . – Install the wheels. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 44 ; Wheel Installation Tightening Specifications . – Perform a basic setting. Connect the Vehicle Diagnostic Test‐ er and then select “Perform basic setting” under Guided Functions . Prote cted by c o p yri gh t. C op yi

Transmission to engine tightening specifications. Refer to ⇒ “6.5.1 Tightening Specifications, Vehicles with 2.0L - 85kW and 2.0L - 110kW Engines”, page 71 . AG.

Rep. Gr.37 - Controls, Housing

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Tightening Specifications

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Transmission to engine tightening specifications. Refer to ⇒ “6.5 Tightening Specifications, Transmission to Engine”, page 71 .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 Component

Nm

Drive plate to torque converter Selector cable bracket to transmission Cable bracket to transmission

60 8 20

6.3

Transmission, Removing, Vehicles with 2.5L - 110 kW and 2.5L -125 kW En‐ gines

– Before removing, print out the diagnostic protocol for this ve‐ hicle »if possible«. Affix the protocol on to transmission before sending back the removed transmission in the usual way. Brief Description The transmission is removed downward separately. The engine remains in the vehicle.

Remove the noise insulation and the drive axles »from under‐ neath«. The transmission is lowered with the transmission jack. Note

The subframe is not removed. Special tools and workshop equipment required

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♦ Engine and Gearbox Jack - VAS6931-

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♦ Transmission Support -

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♦ Socket - Sw15 - V/175-

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♦ Drive Axle Wedge Tool - T10161♦ Torque Wrench 1332 40-200Nm - VAG1332-

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♦ Transmission Support - Mounting Plate 36 - 3282/36♦ Engine Support Bridge - 10-222A♦ Engine Support Bridge - Engine Support Feet - 10-222A/8♦ Engine Support - Automatic Transmission Hook - 10-222A/7♦ Engine Support - Bracket w/Spindle and Hook - 10-222A/10♦ Engine Support Bridge - Engine Support 3 - 10-222A/3♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12♦ Tensioning Strap - T10038Removing

– See if a coded radio is installed. If so, obtain the anti-theft code.

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– Disconnect the battery ground cable. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and Connecting .

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– Move the selector lever into »P«.

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Remove the battery, the battery tray, the air filter and the engine cover »from above«. Both the engine and the transmission are supported and it is possible to remove the left subframe mount.

6. Transmission, Removing and Installing, Jetta from 2005, Golf Wagon from 2007, Jetta Wagon from 2008

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 The left drive axle must be removed later in the procedure. – With the vehicle still standing on its wheels, loosen the left front collar bolt -arrow- a maximum 90°, otherwise the wheel bear‐ ing will get damaged. Refer to ⇒ Suspension, Wheels, Steer‐ ing; Rep. Gr. 40 ; Drive Axles, Removing and Installing . – Remove the engine cover and the air filter.

– Disconnect the hoses -arrows- and remove the intake hose from the throttle valve.

– To remove the selector lever cable from the transmission, re‐ olkswagen AG en AG. V does lease the selector lever cable -arrows 1- and then remove it olkswag not V gu y b from the cable bracket -arrow 2-. ara d e es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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♦ Do not use pliers because the mounting tabs on the cable

bracket could break off.

♦ Do not bend or kink the selector lever cable.

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– Pry the selector lever cable -1- off the selector shaft lever -3using for example an open end wrench -2-. – Disconnect the connections from the transmission and starter. ♦ Multifunction transmission range switch ♦ Starter

♦ Ground cable on the transmission bracket.

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– Remove the battery and the battery tray. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Removing and In‐ stalling .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Remove the wiring bracket -1- from the starter bolt -arrow-. – Remove the upper starter bolt. olkswagen AG en AG. V – Remove the upper bolts. doeconnecting wagengine/transmission s

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– Remove the wires -1- from the transport strap -3-.

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– Remove the transport strap -3- from the engine -2- and pull it out of the eye -arrow-.

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– Install the Engine Support Bridge - 10-222A- .

– Extend the right Engine Support - Bracket w/Spindle and Hook - 10-222A/10- with the Engine Support - Automatic Transmis‐ sion Hook - 10-222A/7- . ht rig py Co t.

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The hook points downward and will be engaged on cylinder block later. AG.

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– Insert a Engine/Gearbox Support Shackle (2 pc.) - 10-222A/ 12- in »this« eye.

– Raise the vehicle and remove the front wheels. – Remove the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Noise Insulation . – Remove the lower section of the left wheel housing liner. Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel Housing Liner, Removing and Installing . – If equipped, remove the heat shield above the right drive axle -arrows-.

6. Transmission, Removing and Installing, Jetta from 2005, Golf Wagon from 2007, Jetta Wagon from 2008

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Remove the control arms from the wheel bearing housing on both sides -arrows-.

– Remove both drive axles from the transmission. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Re‐ moving and Installing .

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– Lift the right drive axle as far as possible and then tie it up.

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– Disconnect the connectors -1 and 2- from the transmission.

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– Remove the left drive axle. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Remove the connector from the bracket under the starter -1and then disconnect it. – Remove bracket from lower starter bolt. – Remove the lower starter bolt and then remove the starter.

– Remove the pendulum support: First bolt -A- then bolts -B-.

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– Turn the cap -1- in the direction of -arrow- and remove it.

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Carefully rotate the engine further!

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– Remove the six converter nuts -arrow- with the Socket - Sw15 - V/175- .

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– Drain the coolant. Refer to ⇒ Rep. Gr. 19 ; Coolant System/ Coolant; Coolant, Draining and Filling or ⇒ Rep. Gr. 19 ; Cooling System Components; Coolant, Draining and Filling . gen AG. Volkswagen AG d

6. Transmission, Removing and Installing, Jetta from 2005, Golf Wagon from 2007, Jetta Wagon from 2008

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Engage the Engine Support - Automatic Transmission Hook 10-222A/7- on the cylinder block. – Remove the coolant hoses from the ATF cooler. Tension the right spindle one turn (more turns are not necessary). – Support the engine and transmission with the left spindle. Do not lift.

– Remove the transmission mount bolts -2- to the transmission bracket -A- and remove the transmission bracket bolts -1- to AG. Volkswagen AG d the transmission. agen oe w olks

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y V -A-. To do so, slightly lower – Remove the transmission bracket db ise r the engine with the transmission using the spindles of the En‐ tho gine Support Bridge - s10-222A. au

– Remove the lower engine/transmission connecting bolts.

– Before removing the last connecting bolt, support the trans‐ mission with the Engine and Gearbox Jack - VAS6931- , the Transmission Support - 3282- and the Transmission Support - Mounting Plate 36 - 3282/36- . – Use the bolt -1- to secure the transmission to the Transmission Support - 3282- . – Remove the last bolt.

– Press the transmission off of the engine, at the same time press the torque converter off of the engine drive plate. – Make sure there is enough clearance around the subframe while lowering. Adjust the Transmission Support - 3282- slight‐ ly, if necessary.

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Rep. Gr.37 - Controls, Housing

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– For safety, leave one bolt installed that is easily accessible.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

♦ The connector on the transmission must not be damaged

when removing and installing the transmission. Replace the wiring harness in the transmission if the connector gets dam‐ aged. Refer to ⇒ “4.1 Overview - Valve Body”, page 128 .

♦ Pay attention to the torque converter. It must be removed to‐

gether with the transmission. Secure the torque converter with, for example a wire -A- to prevent it from falling out.

♦ Bear in mind that when installing a new transmission, the cable

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– Check that the alignment sleeves are pressed into the engine flange. – Make sure the intermediate plate fits correctly between the engine and the transmission. The plate must contact the en‐ gine along entire perimeter when pressing lightly against en‐ gine using both hands. If it is above the engine, then it is not hooked into the cylinder block correctly. – Make sure the torque converter is installed correctly. Refer to ⇒ “1.1 Torque Converter, Removing and Installing”, page 10 . Further installation is performed in the reverse order of the re‐ moval. The engine and the transmission must be mounted in the sub‐ frame mount without tension. Refer to ⇒ Rep. Gr. 10 ; Engine, Removing and Installing for the procedure description. – Replace all the bolts from the left subframe mount. r fo ng

– Install all new bolts first by hand.

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6. Transmission, Removing and Installing, Jetta from 2005, Golf Wagon from 2007, Jetta Wagon from 2008

69

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 First tighten the bolts -1- to 40 Nm +90° when installing the trans‐ mission bracket -A- on the transmission. – Align the engine/transmission in its installed position. Lift until the transmission bracket is touching the transmission mount completely. Caution

There is a risk of damaging the threads in transmission bracket by inserting bolts at an angle. ♦ Before installing the bolts -2-, the transmission bracket and transmission mount support arm must be absolutely parallel to each other. If necessary, lift the back of the transmission using the Engine and Gearbox Jack . Adjust the »old fit« between both bolts using a screwdriver when tightening the transmission bracket to the transmission mount bolts -2-. Tighten the two larger bolts to 60 Nm +90°.

– Install the pendulum support. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Overview - Subframe . – Attach the drive axles to the transmission. Refer to ⇒ Sus‐ pension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Re‐ moving and Installing . – Align the exhaust system free of tension. Refer to ⇒ Rep. Gr. 26 ; Exhaust System; Exhaust System, Installing without Ten‐ sion or ⇒ Rep. Gr. 26 ; Exhaust Pipes/Mufflers; Exhaust olkswagen AG en AG. V does wagTension System, Installing without . s k n l o o t gu a

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d ran Gr. – Install the starter. ise Refer to ⇒ Electrical Equipment; Rep. tee or hStarter, t or 27 ; Starter; Removing and Installing . a au

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– Install the battery tray and the battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Removing and In‐ stalling . – Check the ATF level after installing. Refer to ⇒ “11 ATF Level, Checking and Filling”, page 112 . – Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Noise Insulation . – Install the wheels. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 44 ; Wheel Installation Tightening Specifications . – Perform a basic setting. Connect the Vehicle Diagnostic Test‐ er and then select “Perform basic setting” under Guided Functions . Tightening Specifications Transmission to engine tightening specifications. Refer to ⇒ “6.5.2 Tightening Specifications, Vehicles with 2.5L - 110 kW and 2.5L -125 kW Engines”, page 73 . Prote cted by

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– Attach the selector lever cable to the transmission and adjust it. Refer to ⇒ “4.5 Selector Lever Cable, Adjusting”, page 38 .

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– Connect the coolant hoses to the ATF cooler and check the coolant level. Refer to ⇒ Rep. Gr. 19 .

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Transmission to engine tightening specifications. Refer to ⇒ “6.5 Tightening Specifications, Transmission to Engine”, page 71 .

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 Component

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Selector cable bracket to transmission Cable bracket to transmission

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6.5

Tightening Specifications, Transmission to Engine

⇒ “6.5.1 Tightening Specifications, Vehicles with 2.0L - 85kW and 2.0L - 110kW Engines”, page 71 . ⇒ “6.5.2 Tightening Specifications, Vehicles with 2.5L - 110 kW and 2.5L -125 kW Engines”, page 73 .

6.5.1

Tightening Specifications, Vehicles with 2.0L - 85kW and 2.0L - 110kW En‐ gines

Note ♦ The -arrows- point to the alignment sleeves in the engine. ♦ If necessary the bolt length may differ from the illustration.

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♦ When removing and installing pay attention to the different bolt lengths.

6. Transmission, Removing and Installing, Jetta from 2005, Golf Wagon from 2007, Jetta Wagon from 2008

71

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 1 - Direction of Travel A - Bolt for 2.0L 110 kW FSI Engine B - Bolt for 1.6L 75 kW Engine M12 - 80 Nm ❑ When using the Insert Tool - 18 mm - T10179- : 65 Nm.

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M10 - 40 Nm ❑ These bolts are located inside the lower flange

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6.5.2

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♦ The -arrows- point to the alignment sleeves in the engine. ♦ When removing and installing pay attention to the different bolt lengths. ♦ If necessary the bolt length may differ from the illustration.

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6. Transmission, Removing and Installing, Jetta from 2005, Golf Wagon from 2007, Jetta Wagon from 2008

73

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

7

Transmission, Removing and Instal‐ ling, Jetta from MY 2011

⇒ “7.2 Transmission, Removing, Jetta MY 2011, 2.0L 85 kW”, page 82 . ⇒ “7.3 Transmission, Removing, Jetta MY 2011, 2.5L 125 kW”, page 91 . ⇒ “7.4 Transmission, Installing, Jetta MY 2011”, page 100 . ⇒ “7.5 Tightening Specifications, Transmission to Engine”, page 102 .

7.1

Transmission, Removing, Jetta MY 2011 1.6L 77 kW

– Before removing, print out the diagnostic protocol for this ve‐ hicle »if possible«. Affix the protocol on to transmission before sending back the removed transmission in the usual way.

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♦ Transmission Support Mounting Plate 36 3282/36-

74

Rep. Gr.37 - Controls, Housing

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♦ Torque Wrench 1332 40-200Nm - VAG1332-

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♦ Drive Axle Wedge Tool T10161-

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♦ Transmission Support 3282-

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♦ Socket - Sw15 - V/175-

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♦ Engine and Gearbox Jack VAS6931-

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 ♦ Engine Support Bridge - 10-222A-

♦ Tensioning Strap - T10038-

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♦ Engine Support - Basic Set - T40091-

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Removing

– See if a coded radio is installed. If so, obtain the anti-theft code. c o p yri gh t. C op yi

– Disconnect the battery ground cable. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and Connecting .

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♦ Hose Clamps - Up To 25mm - 3094-

7. Transmission, Removing and Installing, Jetta from MY 2011

75

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–

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Filter Housing, Removing and Installing .

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– Remove the battery and the battery tray. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Removing and In‐ stalling .

– To remove the selector lever cable from the transmission, re‐ lease the selector lever cable -arrows 1- and then remove it from the cable bracket -arrow 2-.

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– Pry the selector lever cable -1- off the selector shaft lever -3using for example an open end wrench -2-.

– Mount the Hose Clamps - Up To 25mm - 3094- on the hoses and remove the hoses form the ATF cooler. – Disconnect the connections from the transmission and starter. ♦ Multifunction Transmission Range Switch ♦ Starter

76

Rep. Gr.37 - Controls, Housing

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♦ Do not bend or kink the selector lever cable.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Remove the upper bolts -1 through 3- between the engine and the transmission. – Remove the plenum chamber cover. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Plenum Chamber Cover; Plenum Chamber Cover, Removing and Installing .

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Use the bolts in the Engine Support Bridge - Engine Support 28-2 - 10-222A/28-2- for attaching the Engine Support Bridge - Engine Support 28 - 10-222A/28- . Not the bolts for the re‐ taining bracket.

– Install the Engine Support Bridge - Engine Support 28 10-222A/28- and tighten the bolts to 8 Nm -arrows-. agen lksw Vo by

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– Remove the bolts -arrows- for securing the engine support bridge on the lock carrier from the Engine Support Bridge Engine Support 28-2 - 10-222A/28-2- .

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– Remove the lower mounts on the Engine Support Bridge - En‐ gine Support 28 - 10-222A/28- and replace with the Engine Support Bridge - Engine Support 28-2 - 10-222A/28-2- .

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A second technician is needed to mount the Engine Support Bridge - 10-222A- on the vehicle to prevent the Engine Support Bridge - 10-222A- from tipping. AG.

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– Remove the bolts -arrows- for the left and right lock carrier retaining brackets.

– If there are hose and cable connections located near the en‐ gine lifting eyes for the Engine Support Bridge - 10-222A- , these must now be removed. – Install the Engine Support Bridge - 10-222A- as shown.

7. Transmission, Removing and Installing, Jetta from MY 2011

77

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – First slide the Moveable Joints -item 2- onto the Square Pipe from the Engine Support Bridge - 10-222A- . – Mount the Engine Support Bridge - 10-222A- on the suspen‐ sion strut towers and have a second technician hold it to prevent it from tipping. – Push the Engine Support - Basic Set - Square Pipe T40091/1- -item 5- from the front left and right through the Engine Support Bridge - Engine Support 28 - 10-222A/28-item 6- and place on each side of the Engine Support Supplement Kit - Movable Joint - T40093/4- -item 4-. – Push the Engine Support - Basic Set - Rail with Holes T40091/2- -item 7- with the Engine Support - Supplement Kit - Mount - T40093/5- -item 8- in the Engine Support - Supple‐ ment Kit - Movable Joint - T40093/4- -item 4-. – Install the locking pins into the Engine Support - Basic Set Rail with Holes - T40091/2- -item 7- and secure it with the cotter pins.

9 - Engine Support Bridge Spindle - 10-222A/11❑ Engaged in the engine lifting eye -arrow-.

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8 - Engine Support - Supple‐ ment Kit - Mount 5 - T40093/5-

– Tighten all the threaded connections on the Engine Support Bridge - 10-222A- hand-tight. While doing so, adjust the height of the Engine Support Bridge - 10-222A- parallel over the En‐ gine Support Bridge - Engine Support 28 - 10-222A/28- .

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Rep. Gr.37 - Controls, Housing

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s no olks – Lightly tension the engine/transmission assembly via the En‐ t gu yV b ara d gine Support Bridge - 10-222Aspindle, do not lift. n ise

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– Raise the vehicle and remove the front wheels. – Remove the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Noise Insulation . – Remove the left front housing liner. Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel Housing Lin‐ er, Removing and Installing . Caution

Risk of damaging the decoupling element. ♦ Do not bend the decoupling element more than 10°. ♦ Do not load the decoupling element. Prote cted by c o p yri gh t. C op yi

– Remove the front exhaust pipe from the engine and lay on the subframe. Refer to ⇒ Rep. Gr. 26 .

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♦ Do not damage the wire mesh on the decoupling element.

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– With the vehicle still standing on its wheels, loosen the left front collar bolt -arrow- a maximum 90°, otherwise the wheel bear‐ ing will get damaged. Refer to ⇒ Suspension, Wheels, Steer‐ ing; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

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– Remove the bolts -arrows- for the cover plate -1- from the transmission housing, and remove the cover plate.

7. Transmission, Removing and Installing, Jetta from MY 2011

79

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Remove the six converter nuts -arrow- for example with the Socket - Sw15 - V/175- . Note

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When installing, first tighten bolts -B-, and then the bolts -A-. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Overview - Subframe for the tightening specifications.

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– Remove the pendulum support: First bolt -A- then bolts -B-.

– Remove the control arms from the wheel bearing housing on both sides -arrows-. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Front Suspension and Control Arm; Overview - Front Suspension and Control Arm for the tightening specifications.

80

Rep. Gr.37 - Controls, Housing

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– Remove the starter. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Starter; Starter, Removing and Installing .

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– Disconnect the connectors -1- and -2- from the transmission.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Remove both drive axles from the transmission. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Re‐ moving and Installing . en AG – Remove the left drive axle. Refer to ⇒ gSuspension, n AG. VolkswagWheels, does wa e ksRemoving Steering; Rep. Gr. 40 ; Drive Axles, and Installing . not g l o V

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– Remove the transmission mount bolts -2- to the transmission bracket -A- and remove the transmission bracket bolts -1- to the transmission. Prote cted by c o py rig ht . C op yi

– Remove the transmission bracket -A-. To do this slightly lower the engine with the transmission using the Engine Support Bridge - 10-222A- spindle.

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– Lift the right driveshaft as far as possible and then tie it up.

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– Remove the connecting bolt -8- from between the engine and the transmission. – Leave the connecting bolt -5- for safety.

7. Transmission, Removing and Installing, Jetta from MY 2011

81

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Before removing the last connecting bolt, support the trans‐ mission with the Engine and Gearbox Jack - VAS6931- , the Transmission Support - 3282- and the Transmission Support - Mounting Plate 36 - 3282/36- . – Secure the transmission to the Transmission Support - 3282using the nut -1- on the double bolt. – Remove the last connecting bolt. – Press the transmission off of the engine, at the same time press the torque converter off of the engine drive plate. – Guide the transmission past the power steering line, if instal‐ AG. Volkswagen AGit. led, and past the subframe the Trans‐ doAdjust agen when lowering es w s olk mission Supportby-V3282slightly, if necessary. not gua

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Note ♦ The connector on the transmission must not be damaged

when removing and installing the transmission. Replace the wiring harness in the transmission if the connector gets dam‐ aged. Refer to ⇒ “4.1 Overview - Valve Body”, page 128 .

♦ Pay attention to the torque converter. It must be removed to‐

gether with the transmission. Secure the torque converter with, for example a wire -A- to prevent it from falling out.

♦ Bear in mind that when installing a new transmission, the cable

bracket and the selector lever cable bracket for example must be replaced.

7.2

Transmission, Removing, Jetta MY 2011, 2.0L 85 kW

– Before removing, print out the diagnostic protocol for this ve‐ hicle »if possible«. Affix the protocol on to transmission before sending back the removed transmission in the usual way.

82

Rep. Gr.37 - Controls, Housing

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 Special tools and workshop equipment required ♦ Engine and Gearbox Jack - VAS6931♦ Socket - Sw15 - V/175♦ Transmission Support - 3282♦ Drive Axle Wedge Tool - T10161♦ Torque Wrench 1332 40-200Nm - VAG1332♦ Transmission Support - Mounting Plate 36 - 3282/36♦ Engine Support Bridge - 10-222A♦ Hose Clamps - Up To 25mm - 3094♦ Tensioning Strap - T10038♦ Engine Support - Basic Set - T40091Removing – Move the selector lever into »P«. – Disconnect the battery ground cable. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and Connecting . . Volkswagen AG gen AG does n

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– To remove the selector lever cable from the transmission, re‐ lease the selector lever cable -arrows 1- and then remove it from the cable bracket -arrow 2-. Note

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– See if a coded radio is installed. If so, obtain the anti-theft code.

7. Transmission, Removing and Installing, Jetta from MY 2011

83

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Pry the selector lever cable -1- off the selector shaft lever -3using for example an open end wrench -2-.

– Mount the Hose Clamps - Up To 25mm - 3094- on the hoses and remove the hoses form the ATF cooler. – Disconnect the connections from the transmission and starter. ♦ Multifunction transmission range switch ♦ Starter – Remove the upper starter bolt.

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– Remove the bolts -arrows- for the left and right lock carrier retaining brackets.

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– Remove the lower mounts on the Engine Support Bridge - En‐ gine Support 28 - 10-222A/28- and replace with the Engine Support Bridge - Engine Support 28-2 - 10-222A/28-2- . r te o iva r rp fo g n

Use the bolts in the Engine Support Bridge - Engine Support 28-2 - 10-222A/28-2- for attaching the Engine Support Bridge - Engine Support 28 - 10-222A/28- . Not the bolts for the re‐ taining bracket. AG.

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Rep. Gr.37 - Controls, Housing

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– Remove the bolts -arrows- for securing the engine support bridge on the lock carrier from the Engine Support 28-2 10-222A/28-2- . ht rig py Co t.

ProCarManuals.com

– Remove the upper bolts between the engine and the trans‐ mission.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Install the Engine Support Bridge - Engine Support 28 10-222A/28- and tighten the bolts to 8 Nm -arrows-. AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h A second technician ut is needed to mount the Engine Support ra a c s Bridge - 10-222As on the vehicle to prevent the Engine Support

Caution

– First slide the Moveable Joints -2- onto the Square Pipe from the Engine Support Bridge - 10-222A- .

– Push the Engine Support - Basic Set - Square Pipe T40091/1- -5- from the front left and right through the Engine Support Bridge - Engine Support 28 - 10-222A/28- -6- and place on each side of the Engine Support - Supplement Kit Movable Joint - T40093/4- -4-. – Slide the Engine Support - Basic Set - Rail with Holes T40091/2- -8- with the Engine Support - Supplement Kit Mount - T40093/5- -9- in the Engine Support - Supplement Kit Moveable Joint - T40093/4- -4-.

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– Install the locking pins into the Engine Support - Basic Set Rail with Holes - T40091/2- -8- and secure it with the cotter pins. AG.

ProCarManuals.com

– Mount the Engine Support Bridge - 10-222A- on the suspen‐ sion strut towers and have a second technician hold it to prevent it from tipping.

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– Install the Engine Support Bridge - 10-222A- as shown.

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– If there are hose and cable connections located near the en‐ gine lifting eyes for the Engine Support Bridge - 10-222A- , these must now be removed.

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Bridge - 10-222A- from tipping.

7. Transmission, Removing and Installing, Jetta from MY 2011

85

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 1 - Engine Support Bridge - En‐ gine Support 31 - Adapter 2 10-222A/31-2-

10 - Engine Support Bridge Spindle - 10-222A/11❑ Engaged in the Engine/ Gearbox Support Shackle (2 pc.) 10-222A/12- .

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9 - Engine Support - Supple‐ ment Kit - Mount 5 - T40093/5-

– Tighten all the threaded connections on the Engine Support Bridge - 10-222A- hand-tight. While doing so, adjust the height of the Engine Support Bridge - 10-222A- parallel over the En‐ gine Support Bridge - Engine Support 28 - 10-222A/28- . – Lightly tension the engine/transmission assembly via the En‐ gine Support Bridge - 10-222A- spindle, do not lift. – Remove the upper engine/transmission connecting bolts.

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Rep. Gr.37 - Controls, Housing

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8 - Engine Support - Basic Set - Rail with Holes - T40091/2-

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7 - Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12❑ Engaged in the engine lifting eye.

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6 - Engine Support Bridge - En‐ gine Support 28 - 10-222A/28with Engine Support Bridge Engine Support 28-2 10-222A/28-2-

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5 - Engine Support - Basic Set - Square Pipe - T40091/1-

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4 - Engine Support - Supple‐ ment Kit - Movable Joint T40093/4-

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3 - Engine Support Bridge - En‐ gine Support 31 - Adapter 1 10-222A/31-1-

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2 - Engine Support - Basic Set - Moveable Joint - T40091/3-

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 The left drive axle must be removed later in the procedure. – With the vehicle still standing on its wheels, loosen the left front collar bolt -arrow- a maximum 90°, otherwise the wheel bear‐ ing will get damaged. Refer to ⇒ Suspension, Wheels, Steer‐ ing; Rep. Gr. 40 ; Drive Axles, Removing and Installing . – Raise the vehicle and remove the front wheels. – Remove the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Noise Insulation . – Remove the left front housing liner. Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel Housing Lin‐ er, Removing and Installing . Vehicles with Power Steering – Remove the brackets and the power steering lines from the transmission. Continuation for All Vehicles – Disconnect the connectors -1 and 2- from the transmission.

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♦ Do not bend the decoupling element more than 10°.

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♦ Do not load the decoupling element. ♦ Do not damage the wire mesh on the decoupling element. – Separate the exhaust system at the double clamp and remove the exhaust pipe bracket from the subframe. Refer to ⇒ Rep. Gr. 26 .

Note

When installing, first tighten bolts -B-, and then the bolts -A-. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Overview - Subframe for the tightening specifications.

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– Remove the pendulum support: First bolt -A- then bolts -B-.

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a – Remove the starter. Refer to ⇒ Electrical Equipment; Rep. ksw Gr. Vol 27 ; Starter; Starter, Removing and Installing . ed by

7. Transmission, Removing and Installing, Jetta from MY 2011

87

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Remove the control arms from the wheel bearing housing on both sides. AG. Volkswagen AG d oes not gu ara nte eo ra c

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– Remove both drive axles from the transmission. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Re‐ moving and Installing .

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Rep. Gr.37 - Controls, Housing

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– Lift the right drive axle as far as possible and then tie it up.

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– Remove the left drive axle. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

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– If equipped, remove the heat shield above the right drive axle -arrows-.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Remove the ground cable from the transmission bracket -A-, if equipped.

– Remove the transmission mount bolts -2- to the transmission bracket -A- and remove the transmission bracket bolts -1- to the transmission.

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– For safety, leave one bolt installed that is easily accessible.

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The hole for the converter bolts on the back of the engine is cov‐ ered with a rubber plug. – Remove this plug.

– Remove the six converter nuts -arrow- with the Socket - Sw15 - V/175- . Note

Carefully rotate the engine further!

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– Remove the lower connecting bolts between the engine and the transmission.

7. Transmission, Removing and Installing, Jetta from MY 2011

89

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– Secure the transmission to the Transmission Support - 3282using the nut -1- on the double bolt. – Remove the last bolt. – Press the transmission off of the engine, at the same time press the torque converter off of the engine drive plate.

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– Guide the transmission past the power steering line, if instal‐ led, and past the subframe when lowering it. Adjust the Trans‐ mission Support - 3282- slightly, if necessary.

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– Before removing the last connecting bolt, support the trans‐ mission with the Engine and Gearbox Jack - VAS6931- , the Transmission Support - 3282- and the Transmission Support - Mounting Plate 36 - 3282/36- .

, Jetta 2011 ➤

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6-Speed Automatic Transmission 09G - Edition 07.2015

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 Note ♦ The connector on the transmission must not be damaged

when removing and installing the transmission. Replace the wiring harness in the transmission if the connector gets dam‐ aged. Refer to ⇒ “4.1 Overview - Valve Body”, page 128 .

♦ Pay attention to the torque converter. It must be removed to‐

gether with the transmission. Secure the torque converter with, for example a wire -A- to prevent it from falling out.

♦ Bear in mind that when installing a new transmission, the cable

bracket and the selector lever cable bracket for example must be replaced. Note

♦ If the needle bearing in the crankshaft is damaged, the gears

will no longer shift correctly.

♦ If it is not damaged, coat it lightly with High Temperature

Grease . Refer to the Parts Catalog. ly.

7.3

Transmission, Removing, Jetta MY 2011, 2.5L 125 kW

– Before removing, print out the diagnostic protocol for this ve‐ olkswagbefore en AG hicle »if possible«. Affix the protocol on toagtransmission en AG. V does ksw in the usual way. not l sending back the removed transmission o V g y db

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♦ Transmission Support - 3282♦ Drive Axle Wedge Tool - T10161♦ Torque Wrench 1332 40-200Nm - VAG1332♦ Transmission Support - Mounting Plate 36 - 3282/36♦ Engine Support Bridge - 10-222A♦ Hose Clamps - Up To 25mm - 3094♦ Tensioning Strap - T10038♦ Engine Support - Basic Set - T40091Removing

– Move the selector lever into »P«. – See if a coded radio is installed. If so, obtain the anti-theft code. r fo ng

– Disconnect the battery ground cable. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and Connecting . Prote cted by c o p yri gh t. C op yi

– Remove the engine cover with the air filter. Refer to ⇒ Rep. Gr. 24 ; Air Filter; Air Filter Housing, Removing and Installing .

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♦ Socket - Sw15 - V/175-

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ProCarManuals.com

♦ Grease the transmission driveshaft pins (not the splines) light‐

7. Transmission, Removing and Installing, Jetta from MY 2011

91

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Disconnect the hoses -arrows- and remove the intake hose from the throttle valve.

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– To remove the selector lever cable from the transmission, re‐ lease the selector lever cable -arrows 1- and then remove it from the cable bracket -arrow 2-.

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♦ Do not bend or kink the selector lever cable.

– Pry the selector lever cable -1- off the selector shaft lever -3using for example an open end wrench -2-.

92

Rep. Gr.37 - Controls, Housing

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bracket could break off.

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♦ Do not use pliers because the mounting tabs on the cable

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– Remove the battery and the battery tray. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Removing and In‐ stalling .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Mount the Hose Clamps - Up To 25mm - 3094- on the hoses and remove the hoses form the ATF cooler. – Disconnect the connections from the transmission and starter. ♦ Multifunction transmission range switch ♦ Starter

– Remove the wiring bracket -1- from the starter bolt -arrow-. – Remove the upper starter bolt. – Remove the upper engine/transmission connecting bolts. – Remove the plenum chamber cover. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Plenum Chamber Cover; Plenum Chamber Cover, Removing and Installing .

– Remove the wires -1- from the transport strap -3-. – Remove the transport strap -3- from the engine -2- and pull it out of the eye -arrow-. – Insert a Engine/Gearbox Support Shackle (2 pc.) - 10-222A/ 12- in »this« eye.

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– Remove the bolts -arrows- for the left and right lock carrier retaining brackets.

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So that engine and transmission can be supported:

7. Transmission, Removing and Installing, Jetta from MY 2011

93

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Remove the lower mounts on the Engine Support Bridge - En‐ gine Support 28 - 10-222A/28- and replace with the Engine Support Bridge - Engine Support 28-2 - 10-222A/28-2- . – Remove the bolts -arrows- for securing the engine support bridge on the lock carrier from the Engine Support Bridge Engine Support 28-2 - 10-222A/28-2- . •

Use the bolts in the Engine Support Bridge - Engine Support 28-2 - 10-222A/28-2- for attaching the Engine Support Bridge - Engine Support 28 - 10-222A/28- . Not the bolts for the re‐ taining bracket.

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a – Install the Engine Support Bridge - Engine ksw Support 28 Vol y b 8 Nm -arrows-. 10-222A/28- and tighten the boltsedto

– Install the Engine Support Bridge - 10-222A- as shown. – First slide the Engine Support - Basic Set - Movable Joints T40091/3- -2- onto the Square Pipe from the Engine Support Bridge - 10-222A- . – Mount the Engine Support Bridge - 10-222A- on the suspen‐ sion strut towers and have a second technician hold it to prevent it from tipping.

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– Additionally attach the Engine Support - Bracket w/Spindle and Hook - 10-222A/10- -7- on the right Engine Support - Basic Set - Square Pipe - T40091/1- .

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– Push the Engine Support - Basic Set - Rail with Holes T40091/2- -9- with the Engine Support - Supplement Kit Mount - T40093/5- -10- in the Engine Support - Supplement Kit - Movable Joint - T40093/4- -4-. – Install the locking pins into the Engine Support - Basic Set Rail with Holes - T40091/2- -9- and secure it with the cotter pins.

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Rep. Gr.37 - Controls, Housing

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– Push the Engine Support - Basic Set - Square Pipe T40091/1- -5- from the front left and right through the Engine Support Bridge - Engine Support 28 - 10-222A/28- -6- and place on each side of the Engine Support - Supplement Kit Movable Joint - T40093/4- -4-.

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A second technician is needed to mount the Engine Support Bridge - 10-222A- on the vehicle to prevent the Engine Support Bridge - 10-222A- from tipping.

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Caution

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 1 - Engine Support Bridge - En‐ gine Support 31 - Adapter 2 10-222A/31-22 - Engine Support - Basic Set - Moveable Joint - T40091/33 - Engine Support Bridge - En‐ gine Support 31 - Adapter 1 10-222A/31-14 - Engine Support - Supple‐ ment Kit - Movable Joint T40093/45 - Engine Support - Basic Set - Square Pipe - T40091/16 - Engine Support Bridge - En‐ gine Support 28 - 10-222A/28with Engine Support Bridge Engine Support 28-2 10-222A/28-2-

8 - Engine Support - Automatic Transmission Hook - 10-222A/ 79 - Engine Support - Basic Set - Rail with Holes - T40091/210 - Engine Support - Supple‐ ment Kit - Mount 5 - T40093/511 - Engine Support Bridge Spindle - 10-222A/11-

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12 - Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12❑ Engaged in the engine lifting eye -arrow-.

– Extend the right Engine Support - Bracket w/Spindle and Hook - 10-222A/10- -7- with the Engine Support - Automatic Trans‐ mission Hook - 10-222A/7- -8-.

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The hook on the Engine Support - Automatic Transmission Hook - 10-222A/7- points downward and will be engaged on cylinder block later. – Engage the left Engine Support Bridge - Spindle - 10-222A/ 11- -11- in the Engine/Gearbox Support Shackle (2 pc.) 10-222A/12- -12-.

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7. Transmission, Removing and Installing, Jetta from MY 2011

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ProCarManuals.com

7 - Engine Support - Bracket w/ Spindle and Hook - 10-222A/ 10-

95

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 The left driveshaft must be removed later in the procedure. – With the vehicle still standing on its wheels, loosen the left front collar bolt -arrow- a maximum 90°, otherwise the wheel bear‐ ing will get damaged. Refer to ⇒ Suspension, Wheels, Steer‐ ing; Rep. Gr. 40 ; Drive Axles, Removing and Installing . – Raise the vehicle and remove the front wheels. – Remove the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Noise Insulation . – Remove the left front housing liner. Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Front Wheel Housing Lin‐ er, Removing and Installing . Vehicles with Power Steering – Remove the brackets and the power steering lines from the transmission -arrows-. Continuation for All Vehicles Caution

♦ Do not bend the decoupling element more than 10°. ♦ Do not load the decoupling element. ♦ Do not damage the wire mesh on the decoupling element. – Separate the exhaust system at the double clamp and remove the front exhaust pipe bracket from the subframe. Refer to ⇒ Rep. Gr. 26 . Volkswagen AG – Remove the control arms from the gen AG bearing housing does on wawheel s k not l o both sides. V gu y

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– If equipped, remove the heat shield above the right drive axle -arrows-.

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Rep. Gr.37 - Controls, Housing

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Risk of damaging the decoupling element.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Remove both drive axles from the transmission. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Re‐ moving and Installing . – Remove the left drive axle. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing .

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– Remove bracket from lower starter bolt. – Remove the lower starter bolt and the starter. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Starter; Starter, Removing and Installing .

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– Remove the connector from the bracket under the starter -1and then disconnect it.

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– Lift the right drive axle as far as possible and then tie it up.

7. Transmission, Removing and Installing, Jetta from MY 2011

97

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Remove the pendulum support: First bolt -A- then bolts -B-.

– Turn the cap -1- in the direction of -arrow- and remove it.

Note

Carefully rotate the engine further!

– Engage the Engine Support - Automatic Transmission Hook 10-222A/7- on the cylinder block.

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– Support the engine and transmission with the left spindle. Do not lift.

Rep. Gr.37 - Controls, Housing

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– Remove the six converter nuts -arrow- with the Socket - Sw15 - V/175- .

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Remove the ground cable from the transmission bracket -A-, if equipped.

– Remove the transmission mount bolts -2- to the transmission bracket -A- and remove the transmission bracket bolts -1- to the transmission.

– For safety, leave one bolt installed that is easily accessible.

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– Before removing the last connecting bolt, support the trans‐ mission with the Engine and Gearbox Jack - VAS6931- , the Transmission Support - 3282- and the Transmission Support - Mounting Plate 36 - 3282/36- . – Secure the transmission to the Transmission Support - 3282using the nut -1- on the double bolt. – Remove the last bolt.

– Press the transmission off of the engine, at the same time press the torque converter off of the engine drive plate. ht rig py Co t.

– Guide the transmission past the power steering line and past the subframe when lowering it. Adjust the Transmission Sup‐ port - 3282- slightly, if necessary.

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– Remove the subframe mount transmission bracket -A-. To do this slightly lower the engine with the transmission using the Engine Support Bridge - 10-222A- spindles.

7. Transmission, Removing and Installing, Jetta from MY 2011

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transmission during removal and installation, for example, by coming in contact with the power steering line. Replace the wiring harness in the transmission if the connector gets dam‐ aged. Refer to ⇒ “4.1 Overview - Valve Body”, page 128 .

♦ Pay attention to the torque converter. It must be removed to‐

gether with the transmission. Secure the torque converter with, for example a wire -A- to prevent it from falling out.

♦ Bear in mind that when installing a new transmission, the cable

bracket and the selector lever cable bracket for example must be replaced.

7.4

Transmission, Installing, Jetta MY 2011

– Check that the alignment sleeves are pressed into the engine flange.

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– Replace all the bolts from the left subframe mount. – Install all new bolts first by hand.

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The engine and the transmission must be mounted in the sub‐ frame mount without tension. Refer to ⇒ Rep. Gr. 10 ; Engine, Removing and Installing for the procedure description.

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Further installation is performed in the reverse order of the re‐ moval.

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– Make sure the torque converter is installed correctly. Refer to ⇒ “1.1 Torque Converter, Removing and Installing”, page 10 .

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– Make sure the intermediate plate fits correctly between the engine and the transmission. The plate must contact the en‐ gine along entire perimeter when pressing lightly against en‐ gine using both hands. If it is above the engine, then it is not hooked into the cylinder block correctly.

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Note

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 First tighten the bolts -1- to 40 Nm +90° when installing the trans‐ mission bracket -A- on the transmission. – Align the engine/transmission in its installed position. Lift until the transmission bracket is touching the transmission mount completely. Caution

There is a risk of damaging the threads in transmission bracket by inserting bolts at an angle. ♦ Before installing the bolts -2-, the transmission bracket and transmission mount support arm must be absolutely parallel to each other. If necessary, lift the back of the transmission using the Engine and Gearbox Jack . Adjust the »old fit« between both bolts using a screwdriver when tightening the transmission bracket to the transmission mount bolts -2-. Tighten the two larger bolts to 60 Nm +90°.

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– Attach the drive axles to the transmission. Refer to ⇒ Sus‐ pension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Re‐ moving and Installing . – Install the heat shield over the right drive axle, if removed. Re‐ fer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Overview and Servicing; Drive Axle Heat Shield . – Assemble the exhaust system and install the exhaust system bracket to the subframe. Refer to ⇒ Rep. Gr. 26 . – Install the starter. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Starter; Starter, Removing and Installing . – Attach the clamps for the power steering line to the transmis‐ sion. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 48 ; Hydraulic Power Steering; Overview - Hydraulic Power Steer‐ ing . Prote cted by c o p yri gh t. C op yi

– Attach the selector lever cable to the transmission and adjust it. Refer to ⇒ “4.5 Selector Lever Cable, Adjusting”, page 38 .

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– Install the plenum chamber cover. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Plenum Chamber Cover; Plenum Chamber Cover, Removing and Installing .

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– Connect the coolant hoses to the ATF cooler and check the coolant level. Refer to ⇒ Rep. Gr. 19 ; Cooling System Com‐ ponents .

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– Install the pendulum support with new bolts first on the trans‐ mission -B arrows- and then on the subframe -arrow A-. Tight‐ ening specification. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Overview - Subframe .

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WARNING

7. Transmission, Removing and Installing, Jetta from MY 2011

101

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Install the bolts -arrows- for the left and right lock carrier re‐ taining brackets to the tightening specification. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Lock Carrier; Lock Carrier - At‐ tachments . – Install the battery tray and the battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Removing and In‐ stalling . – Connect the battery and follow the steps after connecting the battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and Connecting . – Check the ATF level after installing. Refer to ⇒ “11 ATF Level, Checking and Filling”, page 112 . – Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Noise Insulation . – Install the wheels. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 44 ; Wheel Installation Tightening Specifications .Volkswa AG. agen

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Refer to ⇒ “7.5 Tightening Specifications, Transmission to Engine”, page 102 . Component

Nm

Drive plate to torque converter Selector cable bracket to transmission Cable bracket to transmission

7.5

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Tightening Specifications, Transmission to Engine

⇒ “7.5.3 Tightening Specifications, Jetta MY 2011, 2.5L 125 kW Engine”, page 105 . c o p yri gh t. C op yi

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7.5.1

♦ The -arrows- point to the alignment sleeves in the engine. ♦ When removing and installing pay attention to the different bolt lengths. ♦ If necessary the bolt length may differ from the illustration.

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⇒ “7.5.2 Tightening Specifications, Jetta MY 2011, 2.0L 85 kW Engine”, page 104 .

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 1 - Direction of Travel M12 - 80 Nm ❑ When using the Insert Tool - 18mm - T10179- : 65 Nm.

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M10 - 40 Nm ❑ These bolts are located inside the lower flange ❑ In conjunction with the cover plate the bolt length is 35 mm

7. Transmission, Removing and Installing, Jetta from MY 2011

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7.5.2

Tightening Specifications, Jetta MY 2011, 2.0L 85 kW Engine

Note ♦ The -arrows- point to the alignment sleeves in the engine. ♦ When removing and installing pay attention to the different bolt lengths. ♦ If necessary the bolt length may differ from the illustration. 1 - Direction of Travel M12 - 80 Nm ❑ When using the Insert Tool - 18mm - T10179- : 65 Nm. M10 - 40 Nm Volkswagen AG does ❑ These bolts are located swagen AG. k not l o V inside the lower flange gu y b a

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7.5.3

Tightening Specifications, Jetta MY 2011, 2.5L 125 kW Engine

Note ♦ The -arrows- point to the alignment sleeves in the engine. ♦ When removing and installing pay attention to the different bolt lengths. ♦ If necessary the bolt length may differ from the illustration. 1 - Direction of Travel M12 - 80 Nm ❑ When using the Insert Tool - 18mm - T10179- : 65 Nm.

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M10 - 40 Nm ❑ These bolts are located inside the lower flange

7. Transmission, Removing and Installing, Jetta from MY 2011

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8

Transmission, Transporting

Special tools and workshop equipment required ♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12♦ Shop Crane - VAS6100The Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12- can be used when transporting the automatic transmission and for setting up the Transmission Support - 3282- . – Secure the torque converter for example with a wire -A- to prevent it from falling when being transported. – Secure the Engine/Gearbox Support Shackle (2 pc.) 10-222A/12- at the top of the transmission housing. – Engage the hook of the Shop Crane - VAS6100- into the shackles a shown in the illustration.

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Rep. Gr.37 - Controls, Housing

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106

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– Lift the transmission with the Shop Crane - VAS6100- and En‐ gine/Gearbox Support Shackle (2 pc.) - 10-222A/12- .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

9

Transmission, Securing in Engine/ Transmission Holder

Special tools and workshop equipment required ♦ Holding Fixture - VW313♦ Holding Fixture - VW540♦ Engine And Transmission Holder - VAS6095AProcedure •

Drain the ATF. Refer to ⇒ “11.3 ATF, Draining and Filling”, page 115 .

– Secure the transmission on the Holding Fixture - VW540-arrows-. – Insert the transmission into the Holding Fixture - VW313- or the Engine And Transmission Holder - VAS6095A- using the Shop Crane - VAS6100- .

The center of gravity of the transmission is outside the center of rotation at the holding fixture. To prevent back swing, a sec‐ ond technician must hold transmission housing when rotating the transmission on the Holding Fixture - VW313- .

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WARNING

9. Transmission, Securing in Engine/Transmission Holder

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10

ATF Cooler

⇒ “10.1 Overview - ATF Cooler Round Version”, page 108 . ⇒ “10.2 Overview - ATF Cooler Rectangular Version”, page 109 .

Overview - ATF Cooler Round Version

7 - Bolt ❑ 36 Nm

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❑ Installed position: The convex side faces to‐ ward the bolt -item 7⇒ Item 7 (page 108)

ATF Cooler Installation Position – Insert the tab -arrow B- into the transmission housing opening when installing the ATF cooler -1-.

108

Rep. Gr.37 - Controls, Housing

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6 - Plate Spring

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5 - Washer

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3 - ATF Cooler ❑ Installation position. Re‐ fer to ⇒ Fig. ““ATF Cooler In‐ stallation Position”“ , page 108

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2 - O-Ring ❑ Replace after removing

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10.1

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

10.2

Overview - ATF Cooler Rectangular Version

⇒ “10.2.1 ATF Cooler, Removing and Installing, Rectangular Ver‐ sion ”, page 109 1 - Transmission 2 - O-Rings ❑ Always replace.

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4 - Bolt ❑ 20 Nm ❑ Quantity: 4 M8 x 25

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10.2.1

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Removing and Instal‐ ling, Rectangular Ver‐ sion ”, page 109 .

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3

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ATF Cooler, Removing and Installing, Rectangular Version

Special Tools and Equipment Special tools and workshop equipment required ♦ Hose Clamps - Up To 25mm - 3094♦ Hose Clamps - Up To 40mm - 3093♦ Spring clip pliers Removing – Move the selector lever into »P«.

10. ATF Cooler

109

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– Disconnect the selector lever cable on the clips -arrow-.

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Note

♦ Mark the ATF cooler coolant hoses to prevent confusing them AG.

when installing them later.

♦ The cooling system is under pressure when the engine is

warm.

♦ Cover the coolant reservoir cap with a cloth and open it care‐

fully before removing the coolant hoses.

– Clamp the coolant hoses with Hose Clamps - Up To 25mm 3094- and remove them from the ATF cooler. – Seal the coolant hoses and connections with plugs taken from the Engine Bung Set - VAS6122- .

110

Rep. Gr.37 - Controls, Housing

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– Remove the battery and battery tray. Refer to ⇒ Rep. Gr. 27 .

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– Remove the engine cover with the air filter. Refer to ⇒ Rep. Gr. 24 .

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– Remove the bolts -arrows- and remove the ATF cooler. pe rm itte d

Installing

Tightening Specification -item 4- ⇒ Item 4 (page 109) .

Install in reverse order of removal while. Note the following: Note

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Always replace the O-rings.

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•

10. ATF Cooler

111

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⇒ “11.2 ATF, Filling”, page 114 ⇒ “11.3 ATF, Draining and Filling”, page 115 Note the following information: ♦ Refer to this repair manual. Refer to ⇒ “1 General Repair Information”, page 1 . ♦ ATF. Refer to ⇒ “1.2 ATF”, page 1 . ♦ For the »filler tube« ⇒ page 3 . ♦ It is necessary to use the Oil Filler - Adapter 6 - VAS6262/6on some oil containers.

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– Shorten the pipe to dimension -a-. This assures the bleed pipe on the Oil Filler - VAS6262A- will not touch the bottom on some oil containers. •

Dimension -a- = 210 mm Note

Dimension -a- is measured starting from the shaft (the green sur‐ face) on the Oil Filler - VAS6262A- . – Make a mark on the bleed pipe, dimension -a-, and cut it, with for example the Brake Line Tool Kit - Pipe Cutter VAS6056/2- .

Special tools and workshop equipment required ♦ Torque Wrench 1331 5-50Nm - VAG1331♦ Used Oil Collection and Extraction Unit - SMN372500♦ Vehicle Diagnostic Tester

112

Rep. Gr.37 - Controls, Housing

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Shorten the Bleed Pipe on the Oil Filler - VAS6262A- as Follows:

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♦ It may be necessary to shorten the bleed pipe on the Oil Filler - VAS6262A- . Refer to ⇒ page 112 .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 ♦ Shop Crane - Drip Tray - VAS6208♦ Oil Filler - VAS6262A♦ Oil Filler - Adapter 2 - VAS6262/2♦ Also for some oil containers Oil Filler - Adapter 6 - VAS6262/6If ATF is Filled, Only Use the ATF Available As A Replacement Part. Refer to the Parts Catalog. – Always replace the seal -arrow- for the ATF check plug when checking the ATF level.

ATF Level, Checking

Procedure

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11.1

11. ATF Level, Checking and Filling

113

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 The ATF temperature must not be more than approximately 30 ° C (86 °F) at the start of the test. •

Transmission is not in emergency running mode, and ATF temperature is not higher than 30 °C (86 °F).

•

Vehicle is level

•

The selector lever is in “P.”

– Connect the Vehicle Diagnostic Tester and move through se‐ lections until it is ready to be used. Refer to ⇒ “1 Tester, Connecting”, page 13 . – Press »right« Guided Functions . – Select the vehicle, the transmission and check ATF level . – Press the → button. – Start the engine. – Raise the vehicle. – Remove the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Noise Insulation .

– Press the → button.

–

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ATF flows out of the overflow pipe. If ATF Continues to Leak Out of Hole ATF does not need to be topped off. – Tighten the ATF check plug with a new gasket to 27 Nm. The ATF level test is now completed. If No Oil Drips Out of the Hole

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11.2 Procedure •

Place the Drip Tray or Used Oil Collection and Extraction Unit - SMN372500- under the transmission.

114

Rep. Gr.37 - Controls, Housing

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– Fill with ATF. Refer to ⇒ “11.2 ATF, Filling”, page 114 .

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If

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– Place the Drip Tray or Used Oil Collection and Extraction Unit - SMN372500- under the transmission.

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– Shake the fluid containers before opening.

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Caution

The ATF filler tool must be clean and the ATF must not be mixed with any other ATF. Refer to the Parts Catalog for the allocation. – Attach the Oil Filler - VAS6262A- to the oil bottle. Be sure to read the instructions. Refer to ⇒ page 112 . – Fill one liter (1.05 quarts) of ATF.

– Remove the Oil Filler - VAS6262A- at the quick-release cou‐ pling and check it. If ATF Flows Out of Adapter Hole

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– Fill another liter. Refer to ⇒ “11.2 ATF, Filling”, page 114 .

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– Tighten the ATF check plug with a new gasket to 27 Nm. The ATF level test is now completed.

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– Allow ATF to drain until it drips.

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WARNING

Too little or too much ATF will impair transmission function. If two liters (2.1 quarts) are missing, the transmission should be checked more closely. There is probably a »larger« leak.

11.3

ATF, Draining and Filling

Procedure – Turn off the engine. •

Place the Drip Tray or Used Oil Collection and Extraction Unit - SMN372500- under the transmission.

11. ATF Level, Checking and Filling

115

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– Remove the ATF check plug from the ATF pan -arrow-.

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– Remove the overflow pipe -1- through the check hole. – Let the ATF drain.

Note

For some »older« transmissions with filling tube -arrow- the ATF can be filled through the filling tube. – Remove the Oil Filler - Adapter 2 - VAS6262/2- from the oil pan and tighten the ATF check plug with the old seal. – Move the selector lever into “P” position. – Start the engine, shift through all the selector lever positions. Leave the selector lever in each position for approximately 10 seconds. – Check the ATF level and add if necessary. Refer to ⇒ “11 ATF Level, Checking and Filling”, page 112 .

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– Fill with three liters (3.1 quarts) of ATF. Refer to the Parts Cat‐ alog.

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– Install the Oil Filler - Adapter 2 - VAS6262/2- hand-tight in the ATF-check hole.

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– Attach the Oil Filler - VAS6262A- to the oil bottle. At the same time pay attention to the instructions. Refer to ⇒ page 112 .

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– Install the overflow pipe.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

12

Special Tools

Special tools and workshop equipment required ♦ Engine and Gearbox Jack VAS6931♦ Torque Wrench 1332 40-200Nm - VAG1332♦ Transmission Support 3282♦ Transmission Support Mounting Plate 36 3282/36♦ Hose Clamps - Up To 25mm - 3094-

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♦ Insert Tool - 18mm T10179-

12. Special Tools

117

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 Special tools and workshop equipment required ♦ Engine and Gearbox Jack VAS6931♦ Socket - Sw15 - V/175♦ Transmission Support 3282♦ Drive Axle Wedge Tool T10161♦ Torque Wrench 1332 40-200Nm - VAG1332-

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♦ Transmission Support Mounting Plate 36 3282/36-

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 ♦ Engine Support Bridge 10-222A♦ Engine Support Bridge Engine Support Feet 10-222A/8♦ Engine Support - Automatic Transmission Hook 10-222A/7♦ Engine Support - Bracket w/Spindle and Hook 10-222A/10♦ Engine Support Bridge Engine Support 3 10-222A/3-

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♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/ 12-

12. Special Tools

119

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 ♦ Torque Wrench 1331 5-50Nm - VAG1331♦ Used Oil Collection and Ex‐ traction Unit - SMN372500♦ Vehicle Diagnostic Tester ♦ Shop Crane - Drip Tray VAS6208-

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♦ Tensioning Strap - T10038-

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♦ Also for some oil containers Oil Filler - Adapter 6 VAS6262/6-

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 ♦ Gauge - Multi Function Switch - T10173-

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♦ Torque Wrench 1331 5-50Nm - VAG1331-

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♦ Engine Support - Basic Set - T40091-

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121

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 ♦ Engine And Transmission Holder - VAS6095A-

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♦ Holding Fixture - VW540-

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♦ Shop Crane -

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 ♦ Engine Support Bridge - 10-222A-

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♦ Tensioning Strap - T10038-

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♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12-

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38 –

Gears, Hydraulic Controls

1

Selector Shaft Seal, Replacing

Special tools and workshop equipment required ♦ Seal Installer - Selector Shaft Oil Seal - T10174Removing – Remove the Multifunction Transmission Range Switch F125- . Refer to ⇒ “3.1 Multifunction Transmission Range Switch F125 , Re‐ moving”, page 20 . – Remove the selector shaft seal carefully using a screwdriver or the Puller - Crankshaft/Power Steering Seal - T20143- . Do not to damage the selector shaft when doing this. n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d with ran Coat the outer edge of the oil seal and the sealingiselips tee r o ATF. h t or u ac a s s Installed position: open side of the seal faces the transmission

Installing

– Install the new seal all the way using the Seal Installer - Se‐ lector Shaft Oil Seal - T10174- . Do not tilt the seal when installing it.

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– Install the Multifunction Transmission Range Switch - F125- . Refer to ⇒ “3.2 Multifunction Transmission Range Switch F125 , In‐ stalling”, page 21 . – Adjust the Multifunction Transmission Range Switch - F125- . Refer to ⇒ “3.3 Multifunction Transmission Range Switch F125 , Ad‐ justing”, page 22 .

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

2

Transmission Fluid Pan

⇒ “2.1 Transmission Fluid Pan, Removing and Installing”, page 125

2.1

Transmission Fluid Pan, Removing and Installing

Special tools and workshop equipment required ♦ Shop Crane - Drip Tray - VAS6208♦ Torque Wrench 1783 - 2-10Nm - VAG1783Removing – Remove the noise insulation. Refer to ⇒ Body VolkswagenRep. AG do n AG.Exterior; es n wage Gr. 50 ; Noise Insulation . o olks V by

ed – Place the Drip Tray or Used Oil ris Collection and Extraction Unit o h t - SMN372500- under the transmission. au

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– Loosen the bolts on the ATF pan -arrows- diagonally.

Some residual ATF will remain in the oil pan. – Remove the ATF pan and gasket.

Install in reverse order of removal while. Note the following:

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Installing

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– Remove the overflow pipe -C- and drain any remaining ATF.

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– Remove the ATF check plug -A-.

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– Check the seal for damage and make sure all of the spacers (quantity: 8) are present. Otherwise, replace the seal. – Insert the oil pan with the seal, when doing this be sure not to pinch any lines. – Make sure the oil pan seal is seated correctly.

2. Transmission Fluid Pan

125

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Tighten the ATF pan bolts -arrows- diagonally and in several steps to the tightening specification. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 .

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– Only install the ATF check plugs -A- with a new gasket -B- handtight. – Fill with ATF and check the level. Refer to ⇒ “11 ATF Level, Checking and Filling”, page 112 .

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Rep. Gr.38 - Gears, Hydraulic Controls

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– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Noise Insulation .

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r – Replace the gasket -B- for the ATF ho check plug -A-. ut

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

3

ATF Screen

⇒ “3.1 ATF Screen, Removing and Installing”, page 127

3.1

ATF Screen, Removing and Installing

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte Remove the transmission fluid pan. Referorto is eo h ⇒ “2 Transmission Fluid Pan”, page 125 ut . ra a c s s

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– Remove the bolts -arrows- from the ATF screen.

– Remove the ATF screen -A- from the valve body.

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Installing

– Lightly coat the seals on the ATF screen suction collar with ATF.

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– Install the transmission fluid pan. Refer to ⇒ “2 Transmission Fluid Pan”, page 125 .

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– Mount the ATF screen -A- on the valve body and tighten the bolts -arrows- to the tightening specification. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 .

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– Replace the ATF screen if the seals are loose or faulty.

– Fill with ATF and check the level. Refer to ⇒ “11 ATF Level, Checking and Filling”, page 112 .

3. ATF Screen

127

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

4

Valve Body

⇒ “4.1 Overview - Valve Body”, page 128 ⇒ “4.2 Valve Body, Removing and Installing”, page 135 ⇒ “4.3 Solenoid Valve Wiring Harness (14-Pin Connector), Re‐ moving and Installing”, page 148 ⇒ “4.4 Sensor Wiring Harness (8-Pin Connector), Removing and Installing”, page 149 ⇒ “4.5 Transmission Input Speed Sensor G182 , Removing and Installing”, page 150 ⇒ “4.6 Transmission Output Speed Sensor G195 , Removing and Installing”, page 151 WARNING

Do not run the engine or tow the vehicle when the ATF pan is removed or when there is no ATF in the transmission.

♦ Install the O-rings with ATF. Other types of lubrication lead to faults in the transmission control module hydraulics. ♦ Always replace a contaminated or faulty valve body. un le

♦ Only use lint-free cloths

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♦ Check the ATF level after installing the ATF pan. Refer to ⇒ “11 ATF Level, Checking and Filling”, page 112 .

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⇒ “4.1.2 Wire Routing, Connector, Connectors and Bracket on Valve Body”, page 132

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⇒ “4.1.1 Tightening Specifications”, page 132 .

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♦ The valve bodies and the wiring harnesses can also be re‐ moved with the transmission installed.

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1 - ATF Check Plug ❑ ATF level, checking and filling. Refer to ⇒ “11 ATF Level, Checking and Filling”, page 112 . ❑ Tightening specifica‐ tion. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 .

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

2 - Seal ❑ Replace after removing

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5 - Bolt ❑ Tighten the ATF pan bolts diagonally and in several steps. ❑ Tightening specifica‐ tion. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 .

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4 - Transmission Fluid Pan ❑ Removing and instal‐ ling. Refer to ⇒ “2 Transmission Fluid Pan”, page 125 .

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3 - Overflow Pipe ❑ Remove in order to drain the ATF ❑ Tightening specifica‐ tion. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 .

6 - Seal ❑ With spacers (quantity: 8) ❑ Check before installing ❑ Replace brittle, cracked or deformed seals 7 - Magnet ❑ Quantity: 2; in depressions in the ATF pan ❑ Clean before installing the ATF pan. 8 - Bolt ❑ For fastening the valve body to the transmission ❑ Quantity 12; with different lengths ⇒ Fig. ““Bolt Lengths and Component Locations on the Valve Body”“ , page 144 ❑ Replace after removing ❑ Tightening specification. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 . 9 - Bolt ❑ Quantity: 3 ❑ For attaching the ATF screen to the valve body ❑ Tightening specification. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 . 10 - ATF Screen ❑ Removing and installing. Refer to ⇒ “3 ATF Screen”, page 127 .

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 11 - Valve Body ❑ Removing and installing. Refer to ⇒ “4.2 Valve Body, Removing and Installing”, page 135 . ❑ Solenoid valve identification. Refer to ⇒ “4.1.2 Wire Routing, Connector, Connectors and Bracket on Valve Body”, page 132 . ❑ Allocation. Refer to the Parts Catalog. 12 - Bolt ❑ Tightening specification. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 . 13 - Bolt ❑ Tightening specification. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 . 14 - Transmission Input Speed Sensor - G182❑ Removing and installing. Refer to ⇒ “4.5 Transmission Input Speed Sensor G182 , Removing and Installing”, page 150 . 15 - Bolt ❑ Tightening specification. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 . 16 - Transmission Output Speed Sensor - G195❑ Removing and installing. Refer to ⇒ “4.6 Transmission Output Speed Sensor G195 , Removing and Installing”, page 151 .

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F125 ”, page 20 . ❑ Adjusting. Refer to ⇒ “3.3 Multifunction Transmission Range Switch F125 , Adjusting”, page 22 . pe rm itte d

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20 - Transmission Fluid Temperature Sensor - G93❑ Integrated inside the sensor wiring harness -item 23- ⇒ Item 23 (page 130) . ❑ Removing and installing. Refer to ⇒ “4.3 Solenoid Valve Wiring Harness (14-Pin Connector), Removing and Installing”, page 148 . ❑ Wire routing. Refer to ⇒ “4.1.2 Wire Routing, Connector, Connectors and Bracket on Valve Body”, page 132 rrectness of i t to the co nform spec a t i h re o n in wit thi s

21 - Bolt ❑ Tightening specification. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 . 22 - Bolt ❑ Tightening specification. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 .

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23 - Sensor Wiring Harness ❑ With connector ❑ With an O-ring on the connector; always replace the O-ring ❑ With Transmission Fluid Temperature Sensor - G93❑ For the Transmission Input Speed Sensor - G182❑ For the Transmission Output Speed Sensor - G195❑ Removing and installing. Refer to ⇒ “4.4 Sensor Wiring Harness (8-Pin Connector), Removing and Installing”, page 149 . ❑ Wire routing. Refer to ⇒ “4.1.2 Wire Routing, Connector, Connectors and Bracket on Valve Body”, page 132 ❑ Allocation. Refer to the Parts Catalog. ht rig py Co t.

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17 - Transmission Housing ❑ Illustrated here without the ATF cooler

24 - Seal ❑ if present, replace after removing 25 - ATF Drain Plug ❑ Not installed on all transmissions ❑ Tightening specification. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 .

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 26 - Gearshift Lever ❑ For the selector shaft ❑ inside, on the valve body ❑ Removing and installing. Refer to ⇒ “4.2 Valve Body, Removing and Installing”, page 135 . 27 - Washer 28 - Nut ❑ Installed position: the centering bushing faces the washer -item 27- ⇒ Item 27 (page 131) ❑ Tightening specification. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 . 29 - Spring ❑ If equipped ❑ Allocation. Refer to the Parts Catalog. 30 - Damper Piston AG. Volkswagen AG d ❑ If equipped agen oes ksw not l o gu y V to the Parts Catalog. ❑ Allocation. Refer b ar d

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32 - Bolt ❑ Tightening specification. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 .

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o eo 31 - SolenoiduthValve Wiring Harness ra a c s ❑ Withs 14-pin connector ❑ With an O-ring on the connector; always replace the O-ring ❑ Component locations of the solenoid valves and wiring harness routing. Refer to ⇒ “4.1.2 Wire Routing, Connector, Connectors and Bracket on Valve Body”, page 132 . ❑ Removing and installing. Refer to ⇒ “4.3 Solenoid Valve Wiring Harness (14-Pin Connector), Removing and Installing”, page 148 .

4. Valve Body

131

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4.1.1

Wire Routing, Connector, Connectors and Bracket on Valve Body

In this chapter, the information regarding assembly work on the valve body is shown in illustrations. Vehicles with a generation 2 transmission (such as transmission codes “MAN” or “PDW”) Vehicles with generation 3 transmission (such as transmission code “NTJ”) Wire Routing, Connector and Connectors - Vehicles with Gener‐ ation 2 Transmission. Refer to ⇒ page 132 . Note ♦ In this chapter, the information regarding assembly work on the valve body is shown in illustrations. ♦ Mark the solenoid valve and/or sensor and its connector before disconnecting them.

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Rep. Gr.38 - Gears, Hydraulic Controls

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 1 - Solenoid Valve 4 - N912 - Solenoid Valve 6 - N933 - Solenoid Valve 5 - N924 - Solenoid Valve 9 - N2825 - Solenoid Valve 10 - N2836 - Solenoid Valve 3 - N907 - Solenoid Valve 1 - N888 - Solenoid Valve 2 - N89A - Transmission Output Speed Sensor - G195- Con‐ nector B - Transmission Input Speed Sensor - G182- Connector

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Bracket for Connectors, Securing the Wires Note

The -arrows- in the illustration point to the wire brackets or the secured wires.

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133

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 1 - Bracket for the Transmis‐ sion Output Speed Sensor G195- Connector ❑ Tightening specifica‐ tion. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 .

3 - Transmission Fluid Tem‐ perature Sensor - G93un le

Wire Routing, Connector and Connectors - Vehicles with Gener‐ ation 3 Transmission. Refer to ⇒ page 132 .

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Note

♦ In this chapter, the information regarding assembly work on the valve body is shown in illustrations. ♦ Mark the solenoid valve and/or sensor and its connector before disconnecting them.

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4.2

Valve Body, Removing and Installing

Special tools and workshop equipment required ♦ Torque Wrench 1331 5-50Nm - VAG1331♦ Digital Torque Wrench - VAG1756Ac o p yri gh t . C op yi

Vehicles with a generation 2 transmission (such as transmission codes “MAN” or “PDW”)

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8 - Automatic Transmission Pressure Regulating Valve 2 N216-

Removing on Vehicles with Generation 2 Transmission. Refer to ⇒ page 135 . – See if a coded radio is installed. If so, obtain the anti-theft code. – Disconnect the battery ground cable. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and Connecting . – Remove the transmission fluid pan. Refer to ⇒ “2 Transmission Fluid Pan”, page 125 .

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Remove the ATF screen. Refer to ⇒ “3 ATF Screen”, page 127 . – Make a sketch, similar to the illustration, of all the sensors and solenoid valves and their connectors. – Mark the solenoid valve and/or sensor and its connector be‐ fore disconnecting them. WARNING

It is absolutely required to draw or take pictures and to make identifying marks so that connectors at solenoid valves cannot be interchanged unintentionally when reinstalling the sensors and valve body. In some circumstances, confusing the connectors could cause damage to the transmission.

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– Carefully pry out the connector retaining tabs on the solenoid valves -1 through 8- using a small screwdriver and then dis‐ connect the connectors.

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The wiring harness or the valve body with the solenoid valves must be replaced if the one of the connectors gets damaged.

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– Disconnect the connectors -A and B-.

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If equipped, remove the connectors from the Automatic Transmission Hydraulic Pressure Sensor 1 - G193and the Automatic Transmission Hydraulic Pressure Sensor 2 - G194- . Refer to ⇒ Fig. ““ Automatic Transmission Hydraulic Pressure Sensor 1 -G193- and Automatic Transmission Hydraulic Pressure Sensor 2 -G194- ”“ , page 18 .

– Remove the bracket for the connectors -1 and 2-. – Remove the Transmission Fluid Temperature Sensor - G93-3- carefully from the valve body. – Disengage the wiring harnesses from the brackets -arrows-.

4. Valve Body

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – If equipped, bend the locking plate on the selector lever back -arrows-.

pliers -2- so that the torque is not transferred onto the Multi‐ function Transmission Range Switch - F125- .

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– Always slide the valve into the body, secure it against falling out and never interchange it.

Caution

When loosening the other bolts, the function of the valve body can be impaired or the valve body will distort. – Remove the bracket -1 and 2-. – Loosen the valve body bolts -arrows-, -arrows A- and -arrows B- diagonally and then remove the valve body. -3- valve body description, for example, A2

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Only the indicated bolts -arrows- may be loosened.

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The valve body bolts on the transmission housing have different lengths and must be replaced.

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– Make sure the slider -3- on the valve body in which the shift lever engages is not damaged.

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – When removing the valve body, it may be necessary to protect the damper piston -2- against falling out or remove it with the spring. Removing on Vehicles with Generation 3 Transmission. Refer to ⇒ page 135 . – See if a coded radio is installed. If so, obtain the anti-theft code. – Disconnect the battery ground cable. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and Connecting . – Remove the transmission fluid pan. Refer to ⇒ “2 Transmission Fluid Pan”, page 125 . – Remove the ATF screen. Refer to ⇒ “3 ATF Screen”, page 127 . – Make a sketch, similar to the illustration, of all the sensors and solenoid valves and their connectors. – Mark the solenoid valve and/or sensor and its connector be‐ fore disconnecting them.

It is absolutely required to draw sketches or take pictures and to make identifying marks so that connectors at solenoid valves cannot be interchanged unintentionally when reinstalling the sensors and valve body. In some circumstances, confusing the connectors could cause damage to the transmission.

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WARNING

4. Valve Body

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

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The wiring harness or the valve body with the solenoid valves must be replaced if the one of the connectors gets damaged. – Disconnect the connector -B-. Note

If equipped, remove the connectors from the Automatic Transmission Hydraulic Pressure Sensor 1 - G193and the Automatic Transmission Hydraulic Pressure Sensor 2 - G194- . Refer to ⇒ Fig. ““ Automatic Transmission Hydraulic Pressure Sensor 1 -G193- and Automatic Transmission Hydraulic Pressure Sensor 2 -G194- ”“ , page 18 . – Remove the Transmission Fluid Temperature Sensor - G93-A- carefully from the valve body.

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– Remove the selector lever -1- from the selector shaft. – While doing so, carefully hold the selector lever -1- firmly with pliers -2- so that the torque is not transferred onto the Multi‐ function Transmission Range Switch - F125- .

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The actuator valve is very »sensitive«. Even minor damage leads to malfunction.

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– Always slide the valve into the body, secure it against falling out and never interchange it.

4. Valve Body

141

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 The valve body bolts on the transmission housing have different lengths and must be replaced. Only the indicated bolts -arrows- may be loosened. Caution

When loosening the other bolts, the function of the valve body can be impaired or the valve body will distort. – Loosen the valve body bolts -arrows-, -arrows A- and -arrows B- diagonally and then remove the valve body. Installing Vehicles with a generation 2 transmission (such as transmission codes “MAN” or “PDW”) Vehicles with generation 3 transmission (such as transmission code “NTJ”) Procedure on Vehicles with Generation 2 Transmission. Refer to ⇒ page 142 .

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– Route the wiring harness -5- into the ted.

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– Attach the wiring harnesses to the transmission with tape. – Coat the damper piston -2- with ATF and then insert it with the spring into the transmission housing, as illustrated. – Mount the valve body and install the two bolts hand-tight.

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4. Valve Body

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♦ If the wires are too short to be connected to the sensors or

attached to the designated location on the valve body, then they were routed incorrectly or are pinched by the valve body. The valve body must be removed again and wires must be routed correctly.

– Tighten the valve body starting from the inside and working out diagonally to the tightening specification. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 . – Install the Transmission Fluid Temperature Sensor - G93- to the tightening specification. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 .

The wiring harness or the valve body with the solenoid valves must be replaced if the one of the connectors gets damaged. – Tighten the bracket for the connectors. Refer to ⇒ page 133 and ⇒ “4.1.1 Tightening Specifications”, page 132 for the tight‐ ening specification. – Connect the connectors -item A- ⇒ Item A (page 133) and -item B- ⇒ Item B (page 133) . – If equipped, connect the connectors vertically to Automatic Transmission Hydraulic Pressure Sensor 1 - G193- and Au‐ tomatic Transmission Hydraulic Pressure Sensor 2 - G194-4-, if equipped. Refer to ⇒ Fig. ““ Automatic Transmission Hydraulic Pressure Sensor 1 -G193- and Automatic Transmission Hydraulic Pressure Sensor 2 -G194- ”“ , page 18 .

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In some circumstances, confusing the connectors could cause damage to the transmission.

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– Connect the connectors (quantity: 8) to the solenoid valves according to the markings made earlier. Refer to ⇒ “4.1.2 Wire Routing, Connector, Connectors and Bracket on Valve Body”, page 132 .

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♦ Replace all the valve body bolts.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Engage the wiring harness -3- in the bracket -7- -arrow B-. – Attach the selector lever -2- to the selector shaft -6-. Volkswa

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– Tighten the nut on the selector lever -1- to the tightening spec‐ ification. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 . – While doing so, carefully hold the selector lever -1- firmly with pliers -2- so that the torque is not transferred onto the Multi‐ function Transmission Range Switch - F125- .

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– Make sure the slider -3- on the valve body in which the shift lever engages is not damaged.

– Connect the battery ground cable. Refer to ⇒ Electrical Equip‐ ment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and Connecting . – Fill with ATF and check the level. Refer to ⇒ “11 ATF Level, Checking and Filling”, page 112 . – Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Noise Insulation . – Connect the Vehicle Diagnostic Tester and select “function/ component selection”. – Then press “Powertrain (Repair Group 01; 10 to 26; 28 to 39)”. – Then the “6-speed automatic transmission 09G”. – Press “01 - OBD”. – Press “Functions”. – Press “basic setting”. Procedure on Vehicles with Generation 3 Transmission. Refer to ⇒ page 142 . – Observe the exact wire routing so that they do not become pinched when installing the valve body.

4. Valve Body

145

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Route the wiring harness -5- into the transmission as shown. The distance -a- must be maintained so that the wiring harness -5- does not touch the planetary gear and get damaged when the vehicle is being driven. – Place the wiring harnesses -1 to 5- over the edge of the trans‐ mission according to the illustration. – Attach the wiring harnesses to the transmission with tape. – Mount the valve body and install the two bolts hand-tight. The wiring harnesses -1 to 5- must not get pinched by the valve body.

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– Install the remaining new bolts and the bracket and tighten hand-tight. Note ♦ If the wires are too short to be connected to the sensors or

attached to the designated location on the valve body, then they were routed incorrectly or are pinched by the valve body. The valve body must be removed again and wires must be routed correctly.

– Tighten the valve body starting from the inside and working out diagonally to the tightening specification. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 . – Install the Transmission Fluid Temperature Sensor - G93- to the tightening specification. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 . – Connect the connectors (quantity: 8) to the solenoid valves according to the markings made earlier. Refer to ⇒ “4.1.2 Wire Routing, Connector, Connectors and Bracket on Valve Body”, page 132 . olkswagen AG en AG. V does ag ksw not Vol gu y b ara d nte Caution ise r o eo h t u ra a c s s circumstances, confusing the connectors could cause In some

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– Tighten the bracket for the connectors. Refer to ⇒ page 133 and ⇒ “4.1.1 Tightening Specifications”, page 132 for the tight‐ ening specification. – Push the connectors together ⇒ Item B (page 135) .

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– If equipped, connect the connectors vertically to Automatic Transmission Hydraulic Pressure Sensor 1 - G193- and Au‐ tomatic Transmission Hydraulic Pressure Sensor 2 - G194-4-, if equipped. Refer to ⇒ Fig. ““ Automatic Transmission Hydraulic Pressure Sensor 1 -G193- and Automatic Transmission Hydraulic Pressure Sensor 2 -G194- ”“ , page 18 .

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♦ Replace all the valve body bolts.

4. Valve Body

147

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Engage the wiring harness -3- in the bracket -7- -arrow B-. – Attach the selector lever -2- to the selector shaft -6-. Make sure the pin on the selector lever -2- engages into the slider -1- -arrow A-. Position the slider if necessary. – Install the washer -5- and nut -4- on the selector shaft -6-. The centering collar on the nut must face the washer and fit into the washer when the nut is tightened. The wiring harness must be routed underneath the selector shaft lever. n AG. Volkswagen A –

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– While doing so, carefully hold the selector lever -1- firmly with pliers -2- so that the torque is not transferred onto the Multi‐ function Transmission Range Switch - F125- .

– Bend up the locking plate at the nuts -arrows-, if equipped. – Install the transmission fluid screen. Refer to ⇒ “3 ATF Screen”, page 127 . – Install the transmission fluid pan. Refer to ⇒ “2 Transmission Fluid Pan”, page 125 . – Connect the battery ground cable. Refer to ⇒ Electrical Equip‐ ment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and Connecting .

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– Then press “Powertrain (Repair Group 01; 10 to 26; 28 to 39)”. – Then the “6-speed automatic transmission 09G”. – Press “01 - OBD”. – Press “Functions”. – Press “basic setting”.

4.3

Solenoid Valve Wiring Harness (14-Pin Connector), Removing and Installing

Removing – Drain the ATF. Refer to ⇒ “11.3 ATF, Draining and Filling”, page 115 . – Remove the transmission fluid pan. Refer to ⇒ “2 Transmission Fluid Pan”, page 125 .

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– Connect the Vehicle Diagnostic Tester ⇒ Vehicle diagnostic tester and select “function/component selection”.

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– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Noise Insulation; Overview - Noise Insulation .

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– Fill the ATF and check the level. Refer to ⇒ “11 ATF Level, Checking and Filling”, page 112 .

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– Make sure the slider -3- on the valve body in which the shift lever engages is not damaged.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Remove the ATF screen. Refer to ⇒ “3 ATF Screen”, page 127 . – Remove the valve body. Refer to ⇒ “4.2 Valve Body, Removing and Installing”, page 135 . – Disconnect the connector -2- for the solenoid valves from the transmission connector. – Remove the 14-pin transmission connector bolt. – Remove the transmission connector with the wiring harness outward from the transmission housing. Installing Install in reverse order of removal while. Note the following: – Replace the O-ring on the transmission connector. – Coat the O-ring with ATF. – Push the transmission connector all the way into the trans‐ mission. . Volkswagen AG AGRefer – Tighten the bolt for the 14-pin transmission connector. does agen ksw not l to ⇒ “4.1.1 Tightening Specifications”, page 132 for the correct o V gu y b ara d tightening specification. n se

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– Install the transmission fluid pan. Refer to ⇒ “2 Transmission Fluid Pan”, page 125 . – Fill with ATF and check the level. Refer to ⇒ “11 ATF Level, Checking and Filling”, page 112 .

4.4 Removing

Sensor Wiring Harness (8-Pin Connec‐ tor), Removing and Installing

– Drain the ATF. Refer to ⇒ “11.3 ATF, Draining and Filling”, page 115 . – Remove the transmission fluid pan. Refer to ⇒ “2 Transmission Fluid Pan”, page 125 .

– Remove the valve body. Refer to ⇒ “4.2 Valve Body, Removing and Installing”, page 135 .

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– Remove the ATF screen. Refer to ⇒ “3 ATF Screen”, page 127 .

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t – Install the valve body. Refer to ⇒ page 142 . au

4. Valve Body

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Disconnect the sensor connector -1- from the transmission connector. – Remove the bolt from the 8-pin transmission connector. – Remove the transmission connector with the wiring harness outward from the transmission housing. Installing Install in reverse order of removal while.

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– Coat the O-ring with ATF.

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– Push the transmission connector all the way into the trans‐ mission.

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– Tighten the bolt for the 8-pin transmission connector to the tightening specification. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 . – Install the valve body. Refer to ⇒ page 142 . – Install the ATF screen. Refer to ⇒ “3 ATF Screen”, page 127 .

– Fill with ATF and check the level. Refer to ⇒ “11 ATF Level, Checking and Filling”, page 112 .

Transmission Input Speed Sensor G182- , Removing and Installing

Removing

– Remove the valve body. Refer to ⇒ “4.2 Valve Body, Removing and Installing”, page 135 . Prote cted by

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– Remove the Transmission Input Speed Sensor - G182- from the transmission housing.

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– Remove the bolt -1- from the Transmission Input Speed Sen‐ sor - G182- .

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– Install the transmission fluid pan. Refer to ⇒ “2 Transmission Fluid Pan”, page 125 .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 Vehicles with a Generation 3 Transmission. Installing Install in reverse order of removal while. Note the following: . Volkswagen AG gen AG d

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Transmission Output Speed Sensor G195- , Removing and Installing

Removing

– Remove the valve body. Refer to ⇒ “4.2 Valve Body, Removing and Installing”, page 135 . r fo ng

– Remove the bolt -2- from the Transmission Output Speed Sensor - G195- . ht rig py Co t.

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– Remove the Transmission Output Speed Sensor - G195- from the transmission housing. agen lksw Vo by

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4. Valve Body

151

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 Vehicles with a Generation 3 Transmission. Installing Install in reverse order of removal while. Note the following: – Press the Transmission Output Speed Sensor - G195- all the way into the transmission housing. – Tighten the bolt -2- for the Transmission Output Speed Sensor - G195- to the tightening specification. Refer to ⇒ “4.1.1 Tightening Specifications”, page 132 . – Install the valve body. Refer to ⇒ page 142 .

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5

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Special Tools un le

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♦ Seal Installer - Selector Shaft Oil Seal - T10174-

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Special tools

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♦ Torque Wrench 1331 5-50Nm - VAG1331-

♦ Digital Torque Wrench - VAG1756A-

♦ Torque Wrench 1783 - 2-10Nm - VAG1783-

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 ♦ Shop Crane - Drip Tray - VAS6208-

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39 –

Final Drive, Differential

1

Flange Shaft Seals, Replacing

⇒ “1.1 Component Location Overview - Seals”, page 155 ⇒ “1.2 Left Flange Shaft Seal, Replacing”, page 156 ⇒ “1.3 Right Flange Shaft Seal, Replacing”, page 157 Brief Description The seals for the flange shafts can be replaced with the trans‐ mission installed. – On the left side, the driveshaft must be removed. Install the seal using the Seal Installer - Flange Shaft Oil Seal LH T10176- . – The drive axle remains in the wheel bearing on the right side. Install the seal using the Seal Installer - Flange Shaft Oil Seal RH - T10177- .

Component Location Overview - Seals

1 - Torque Converter Seal ❑ Replacing. Refer to ⇒ “1.4 Torque Converter Seal, Removing and In‐ stalling”, page 11 .

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4 - Left Seal ❑ For the left flange shaft ❑ Replacing. Refer to ⇒ “1.2 Left Flange Shaft Seal, Replacing”, page 156 .

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3 - Gearshift Shaft Seal ❑ Replacing. Refer to ⇒ “1 Selector Shaft Seal, Replacing”, page 124 .

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2 - Right Seal ❑ For the right flange shaft ❑ Replacing. Refer to ⇒ “1.3 Right Flange Shaft Seal, Replacing”, page 157 .

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1. Flange Shaft Seals, Replacing

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

1.2

Left Flange Shaft Seal, Replacing

Special tools and workshop equipment required ♦ Shop Crane - Drip Tray - VAS6208♦ Puller - Unit Injector - T10055♦ Seal Installer - Flange Shaft Oil Seal LH - T10176Removing – Remove the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Noise Insulation . – Remove the left drive axle. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Removing and Installing . – Place the Drip Tray for example -VAS6208- under the trans‐ mission. – Seal the opening in the transmission for the driveshaft with a clean cloth -A-. – Carefully drill a 2 to 4 mm hole -B- into the outer metal ring -C- in the seal.

♦ Grease the drill bit -B- so that the shavings will stick. ♦ Drill only through the metal ring -C- otherwise the transmission

could get damaged.

♦ Be careful not to install the screw too deep so that the bearing

underneath does not become damaged.

♦ Remove the seal with the Puller - Unit Injector - T10055- and

the Puller - Unit Injector - Adapter 2 - T10055/2- .

♦ Remove the cloths and carefully clean the transmission and

the opening for the drive axle.

♦ Iron shavings must not get into the transmission or into the

opening for the drive axle. Vacuum up any shavings if neces‐ sary.

♦ If only the metal ring of the seal could be removed, carefully

pry out the rest of the seal using screwdriver.

Installing

Install in reverse order of removal while. Note the following:

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Installation position:

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156

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The open side of the seal faces the transmission.

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– Coat the outer circumference and the sealing lips on the new seal with ATF.

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Note

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Install the new seal using the Seal Installer - Selector Shaft Oil Seal - T10176- . Do not tilt the seal. – Install the drive axle. Refer to ⇒ Suspension, Wheels, Steer‐ ing; Rep. Gr. 40 ; Drive Axles, Removing and Installing . – Check the ATF level and add if necessary. Refer to ⇒ “11 ATF Level, Checking and Filling”, page 112 . – Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Noise Insulation .

1.3

Right Flange Shaft Seal, Replacing

Special tools and workshop equipment required ♦ Shop Crane - Drip Tray - VAS6208♦ Puller - Unit Injector - T10055♦ Seal Installer - Flange Shaft Oil Seal RH - T10177– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Noise Insulation . lkswagaxle en AG – If equipped, remove the heat shield above the right AG. Vodrive does agen ksw not -arrows-. l o V

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– Place the Drip Tray for example Shop Crane - Drip Tray VAS6208- under the transmission.

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– Seal the opening in the transmission for the drive axle with a clean cloth -A-. – Carefully drill a 2 to 4 mm hole -B- into the outer metal ring -C- in the seal. Note

♦ Drill only through the metal ring -C- otherwise the transmission

could get damaged.

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Removing

1. Flange Shaft Seals, Replacing

157

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015 – Install a 4 mm screw into the drilled hole in the gasket -arrow-. Note ♦ Be careful not to install the screw too deep so that the bearing

underneath does not become damaged.

♦ Remove the seal with the Puller - Unit Injector - T10055- and

the Puller - Unit Injector - Adapter 2 - T10055/2- .

♦ Remove the cloths and carefully clean the transmission and

the opening for the driveshaft.

♦ Iron shavings must not get into the transmission or into the

opening for the driveshaft. Vacuum up any shavings if neces‐ sary.

♦ If only the metal ring of the seal could be removed, carefully

pry out the rest of the seal using screwdriver.

Installing Install in reverse order of removal while. following: olkswNote agen Athe G en AG. V does n

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The open side of the seal faces the transmission.

– Install the new seal using the Seal Installer - Flange Shaft Oil Seal RH - T10177- . Do not tilt the seal. – Mount the right drive axle to the transmission. Refer to ⇒ Sus‐ pension, Wheels, Steering; Rep. Gr. 40 ; Drive Axles, Re‐ moving and Installing . – Check the ATF level and add if necessary. Refer to ⇒ “11 ATF Level, Checking and Filling”, page 112 .

AG.

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158

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– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Noise Insulation .

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Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-Speed Automatic Transmission 09G - Edition 07.2015

2

Special Tools

Special tools and workshop equipment required

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♦ Seal Installer - Flange Shaft Oil Seal LH - T10176-

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♦ Puller - Unit Injector - T10055-

♦ Shop Crane - Drip Tray - VAS6208-

2. Special Tools

159

DRUCK NUMBER: MEX5R005321 Job Fee Notes Type dba ck

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Rep. Gr.39 - Final Drive, Differential

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108 451 4& 108 537 4 04.2 10/1 Lo‐ 104 015 4/20 cal 795 14 Feed 7 back

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04.2 6/17/ Re‐ 015 2015 for‐ mat 04.2 04/0 Lo‐ 015 3/20 cal 15 Feed back

109 Updated the HRV and Eric P. 298 quantity and size of bolts for 2 & gen 3 - Valve Body R&I 109 896 7 N/A Jim H

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07.2 07/2 Fac‐ 015 0/20 tory 15 Up‐ date

Quality Checke d By

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Revision History

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Cautions & Warnings

•=

If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered wholly or in part by any of the extensive warranties issued by Volkswagen.

•=

Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.

•=

Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications, are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always check with your authorized Volkswagen retailer parts department for the latest information.

•=

Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).

•=

Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.

•=

For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and n AG. Volkswagen AG do es n wage become inoperable, even if the correct code is used in a later ksattempt. l ot o V

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starting the vehicle while you are under it.

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•=

gu y ara db nte ise r o e o wheels If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the h t u ra a c from s keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others s

to

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•=

Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.

•=

Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear goggles, gloves and other protective clothing whenever the job requires working with harmful substances.

•=

Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe injury could result.

•=

Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with new parts where indicated, and any other time it is deemed necessary by inspection.

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Page 1 of 3

© 2002 Volkswagen of America, Inc.

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Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from being fully alert. rrectness of i t to the co nform spec a t i h re o n in wit thi s

•=

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Please read these WARNINGS and CAUTIONS before proceeding with maintenance and repair work. You must answer that you have read and you understand these WARNINGS and CAUTIONS before you will be allowed to view this information.

All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Version 1.0

•=

Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

•=

Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust. Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.

•=

Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be crushed by heavy parts.

•=

Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good repairs.

•=

Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at once, but do not store the oily rags, which can ignite and burn spontaneously.

•=

Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque olkswagen AG listed. en AG. V

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•=

the battery. If explode.

does not gu ara escaping hydrogen nte eo r

gas is ac

Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that govern the disposal of wastes. rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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ag ksw Vol y b Keep sparks, lighted matches, and open flame away from ed the top of ris o h ignited, it will ignite gas trapped in the cells and cause the battery to t au s s

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The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment, trained in related safety precautions, and familiar with regulations governing the discharging and disposal of automotive chemical refrigerants.

•=

Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery negative terminal (ground strap) and the ABS control module connector.

•=

Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase system pressure and may cause the system to burst.

•=

When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these components is not separately fused, disconnect the control module connector(s).

•=

Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device. Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians should test, disassemble or service the airbag system. r fo ng

•=

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Cautions & Warnings

Page 2 of 3 © 2002 Volkswagen of America, Inc. All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Version 1.0

Cautions & Warnings •=

Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.

•=

Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit must never be electrically tested while it is not installed in the vehicle.

•=

Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the tire from the rim before attempting any repair.

•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.

Page 3 of 3

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© 2002 Volkswagen of America, Inc.

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I have read and I understand these Cautions and Warnings.

c o p yri gh t. C op yi

All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

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