6 Speed Automatic Gearbox 09g VW Golf 5 Passat b6 Eng 07 2011
6 Speed Automatic Gearbox 09g VW Golf 5 Passat b6 Eng 07 2011
6 Speed Automatic Gearbox 09g VW Golf 5 Passat b6 Eng 07 2011
Workshop Manual
CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ ,
Golf Plus 2005 ➤ , Passat 2006 ➤ ,
Passat CC 2009 ➤ , Touran 2003 ➤
6-speed automatic gearbox 09G
Edition 07.2011
Repair Group
00 - Technical data
32 - Torque converter
37 - Controls, housing
38 - Gears, control
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.
K0258992320
CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Passat 200 ...
6-speed automatic gearbox 09G - Edition 07.2011
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Automatic gearbox control unit J217 with fuzzy logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.5 Control units in vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.6 Information on „09G gearbox“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.7 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.8 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.9 Gaskets, seals and oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.10 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.11 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.12 Guided fault finding, vehicle self-diagnosis and test instruments . . . . . . . . . . . . . . . . . . . . 4
2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Planetary gearbox and final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Code - engine allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Gearbox codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Golf 2004 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Golf Plus 2005 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Golf 2009 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7 Touran 2003 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 Passat 2006 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9 Passat CC 2009 ►, CC 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
32 - Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Proper handling and installation of torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Identification of torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Draining torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Removing and installing torque converter oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 Installing torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
37 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1 Connecting »tester« . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.1 Connecting vehicle diagnosis, testing and information system VAS 5051 . . . . . . . . . . . . 16
2 Electrical and electronic components and their locations . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3 Multifunction switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 Removing multifunction switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Installing multifunction switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Adjusting multifunction switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4 Emergency release of selector lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1 Moving pushbutton to installation position in the handle . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6 Selector mechanism up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.1 Overview of selector mechanism up to 02.2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2 Removing and installing selector mechanism with selector lever . . . . . . . . . . . . . . . . . . . . 34
6.3 Removing and installing selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.4 Checking selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.5 Adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7 Selector mechanism from 03.2009 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Contents i
CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Passat 200 ...
6-speed automatic gearbox 09G - Edition 07.2011
ii Contents
CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Passat 200 ...
6-speed automatic gearbox 09G - Edition 07.2011
Contents iii
CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Passat 200 ...
6-speed automatic gearbox 09G - Edition 07.2011
iv Contents
CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Passat 200 ...
6-speed automatic gearbox 09G - Edition 07.2011
00 – Technical data
1 General repair notes
Edition 01.2011, version 10.0
To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Obviously, the basic rules for safety also apply dur‐
ing repair work.
A number of generally valid instructions applicable for the various
repair procedures - which were formerly repeated a number of
times at numerous places in the workshop manual - are summar‐
ised here. They apply to this workshop manual.
1.1 Gearbox
The „automatic gearbox 09G“ has six hydraulically actuated for‐
ward gears. When the torque converter lock-up clutch closes,
2nd, 3rd, 4th, 5th and 6th gears become mechanically driven
gears by eliminating torque converter slip.
1.3 ATF
Use only ATF which has been ordered as a part from the ⇒ Elec‐
tronic parts catalogue „ETKA“ .
The ATF levels in the planetary gearbox and final drive are
checked and topped up together.
1.7 Tools
A summary of the special tools and workshop equipment used in
the workshop manual precedes each repair procedure and can
be found in „Special tools/Workshop equipment“ binder.
The catalogue is also available on ⇒ CD-ROM and can be ordered
the usual way from Bertelsmann.
Uncertainty often occurs with smaller bolts having low tightening
forces. Torque wrench 2...10 Nm -V.A.G 1783- can be used with
these bolts.
1.8 Gearbox
♦ If gearbox covers have been unbolted or gearbox has no fluid,
do not run engine or tow vehicle.
♦ First thoroughly clean connecting points and surrounding
areas and then loosen bolts.
♦ When installing the gearbox, ensure that dowel sleeves be‐
tween the engine and gearbox are correctly located.
♦ Place removed parts on a clean surface. Cover parts to pre‐
vent soiling. Use plastic sheeting and paper. Use lint-free
cloths only!
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing.
♦ If repair work cannot be performed immediately, carefully cov‐
er or seal components.
♦ With gearbox removed, secure torque converter against falling
out.
Gearboxes with and without filler pipe
Here is an »example« with a filler pipe as it is installed in »older«
gearboxes. This pipe has been discontinued.
This »old« filler opening with the red cap is not needed because
ATF can be drained or filled as required through the bottom hole.
The »height« of this tube determines the level of the ATF.
The tube must be removed to drain the fluid.
♦ After installation, check the ATF level and top up
⇒ page 134 .
♦ Capacities ⇒ page 5 .
Caution
2 Capacities
2. Capacities 5
CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Passat 200 ...
6-speed automatic gearbox 09G - Edition 07.2011
4 Golf 2004 ►
If Genuine parts are required for a repair, always refer to the
gearbox code.
„Automatic gearbox 09G“
Identification GJY »GJX« »FUF« »HFU« »KBV«
code »GSY« »HFR« »GJZ« »HRM« KGL
»HFS« »HTM« »HFT« »JUJ«
»HTN« »JUG« »HTP«
»JTY« »KGH« »JUH«
KGJ KGK
Engine 1.6 l - 75 kW 1.6 l - 85 kW 2.0 l - 110 kW 2.5 l - 110 kW 2.5 l - 125 kW
(FSI) (FSI)
4. Golf 2004 ► 7
CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Passat 200 ...
6-speed automatic gearbox 09G - Edition 07.2011
6 Golf 2009 ►
If Genuine parts are required for a repair, always refer to the
gearbox code.
„Automatic gearbox 09G“
Identification KGL, MAN
code
Engine 2.5 l - 125 kW
6. Golf 2009 ► 9
CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Passat 200 ...
6-speed automatic gearbox 09G - Edition 07.2011
7 Touran 2003 ►
If Genuine parts are required for a repair, always refer to the
gearbox code.
„Automatic gearbox 09G“
Identification code »FUH« »GKC« »HHH«
»GKB« »HFX« »HTR«
»GXY« »HTQ« JTX
»HLP« »JTW« KGP
»JTV« KGM
Engine 1.6 l - 85 kW 2.0 l - 110 kW 1.8 l - 110 kW
(China)
8 Passat 2006 ►
If Genuine parts are required for a repair, always refer to the
gearbox code.
„Automatic gearbox 09G“
Identification code »HXK« »HFT« »JYY« »HHP«
»JUB« »HVW« KGV »HRN«
KGS »HXJ« »JUD«
»JUC« JZV
KGT KGU
Engine 1.6 l - 85 kW (FSI) 2.0 l - 110 kW (FSI) 1.8 l - 118 kW (TFSI) 2.0 l - 147 kW (FSI)
8. Passat 2006 ► 11
CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Passat 200 ...
6-speed automatic gearbox 09G - Edition 07.2011
32 – Torque converter
1 Proper handling and installation of
torque converter
– Always secure torque converter.
An unsecured torque converter may slide out when the gearbox
is tipped.
Removing
– Pry out seal with lever -VW 681- .
Installing
Caution
37 – Controls, housing
1 Connecting »tester«
Volkswagen offers various devices such as
♦ Vehicle diagnosis, testing and information system -VAS 5051-
♦ Vehicle diagnosis, testing and information system -VAS
5051B-
♦ Tester -VAS 5051/11A-
♦ Vehicle diagnosis and service information system -VAS 5052-
♦ Diagnostic system -VAS 5053-
The operation of these »devices« is described in the respective
user's manuals.
The following description refers to the vehicle diagnosis, testing
and information system -VAS 5051- ⇒ page 16 .
WARNING
1. Connecting »tester« 17
CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Passat 200 ...
6-speed automatic gearbox 09G - Edition 07.2011
Valve body
Location: valve body is bolted to underside of gearbox housing
and covered by pan.
Solenoid valves -N88- and -N89- as well as pressure control
valves -N90- , -N91- , -N92- , -N93- , -N282- and -N283- are se‐
cured to valve body.
Diagnostic connection
Location: diagnosis connector -arrow- is located on left below
driver storage compartment.
Work with care to avoid bending cable. Do not use pliers, or the
retaining tabs on the cable support bracket may break off.
– Lever cable -1- off lever -3- using an open jaw spanner -2-.
– Pull connector off multifunction switch -F125- .
Note
Installing
– Install in reverse order of removal, observing the following:
• Selector lever is in position „D“.
Note
Note
– Using a screwdriver, press the small lever -1- for the tie rod
into the groove -2-. When this is done, the pushbutton -3- is
pressed into the installation position.
-I- Pushbutton in pressed position
-II- Pushbutton in installation position
Note
WARNING
Note
Note
Removing
– Move selector lever to position „S“ position.
– In order to remove selector lever cable from gearbox, first re‐
lease cable -1- and then remove it from cable support bracket
-2-.
Work with care to avoid bending cable. Do not use pliers, or the
retaining tabs on the cable support bracket may break off.
– Lever cable -1- off lever -3- using an open jaw spanner -2-.
– Raise vehicle.
To remove cable and/or selector mechanism, first remove heat
shield and, if necessary, parts of exhaust system now ⇒ Rep. gr.
26 ; Removing and installing parts of exhaust system .
– Remove heat shield.
– Remove -selector housing- beneath selector lever.
Clarification:
♦ -1- Push tab forwards
♦ -2- Push pin up
-Nuts- 8 Nm
– Put selector housing onto cable.
– Insert cable into bearing and insert pin from above, down‐
wards through eye.
When you have checked freedom of movement of cable
⇒ page 42 , insert securing clip.
– Lever cable -1- from selector shaft lever -3- using an open jaw
spanner -2-.
Vehicles up to 02.2009
WARNING
WARNING
Note
– Remove 4 bolts.
Torque setting 8 Nm.
Note
Work with care to avoid bending cable. Do not use pliers, or the
retaining tabs on the cable support bracket may break off.
– Lever cable -1- off lever -3- using an open jaw spanner -2-.
Note
After this, do not set vehicle on the ground any more ⇒ Rep. gr.
40 ; Repairing drive shafts; Removing and installing drive shafts;
Removing drive shafts with triple-roller joint AAR2600i .
Note
Note
Note
Note
Removing:
– Before beginning with removal, »if possible« print out a diag‐
nosis log. Before sending back removed gearbox in the usual
manner, secure log to gearbox.
– Move selector lever to position »P« position.
– Raise vehicle. All 4 supports of lifting platform must be at same
height.
Note
After this, do not set vehicle on the ground any more ⇒ Rep. gr.
40 ; Repairing drive shafts; Removing and installing drive shafts;
Removing drive shafts with triple-roller joint AAR2600i .
– Pull off hoses -arrows- and remove intake hose from throttle
valve unit.
– Remove battery and battery carrier ⇒ Rep. gr. 27 ; Discon‐
necting and connecting battery; Removing and installing bat‐
tery .
Work with care to avoid bending cable. Do not use pliers, or the
retaining tabs on the cable support bracket may break off.
– Lever cable -1- off lever -3- using an open jaw spanner -2-.
– Disconnect electrical connections to gearbox and starter.
♦ Multifunction switch
♦ Starter motor
♦ Earth strap to bracket
– Unbolt transportation bracket -3- from engine -2- and pull out
of eye -arrow-.
– Attach a shackle -10 - 222 A /12- in »this« eye.
Note
Note
9.5.1 Torque settings, Golf 2004 with 1.6 l - 75 kW and 2.0 l - 110 kW (FSI) engines
1 - Direction of travel
A - Bolt for 2.0 l - 110 kW (FSI)
engine
B - Bolt for 1.6 l -75 kW engine
- Drive plate to torque convert‐
er
❑ 60 Nm
❑ Qty. 6; remove and in‐
stall with insert -V/175- .
- M12 bolts ⇒ M12
❑ 80 Nm
❑ 65 Nm if you use socket
-T10179- .
- M10 bolts ⇒ M10
❑ 40 Nm
❑ These bolts are located
in lower flange
- Two dowel sleeves in engine
-arrows-
-Nuts- 8 Nm
1 - Direction of travel
- Drive plate to torque convert‐
er
❑ 60 Nm
❑ Qty. 6; remove and in‐
stall with insert -V/175- .
- M12 bolts ⇒ M12
❑ 80 Nm
❑ 65 Nm if you use socket
-T10179- .
- M10 bolts ⇒ M10
❑ 40 Nm
❑ These bolts are located
in lower flange
- Two dowel sleeves in engine
-arrows-
-Nuts- 8 Nm
9.5.3 Specified torques, Golf 2004 with 2.5 l - 110 kW and 125 kW engines
1 - Direction of travel
- Drive plate to torque convert‐
er
❑ 60 Nm
❑ Qty. 6; remove and in‐
stall with insert -V/175- .
- M12 bolts ⇒ M12
❑ 80 Nm
❑ 65 Nm if you use socket
-T10179- .
- M10 bolts ⇒ M10
❑ 40 Nm
❑ These bolts are located
in lower flange
- Two dowel sleeves in engine
-arrows-
-Nuts- 8 Nm
Note
Work with care to avoid bending cable. Do not use pliers, or the
retaining tabs on the cable support bracket may break off.
– Lever cable -1- off lever -3- using an open jaw spanner -2-.
Note
Note
Note
Note
If the top does not contact the engine, it is not properly en‐
gaged in the engine block.
Continue installation in reverse order of removal.
– Renew all bolts of left assembly mounting.
– First screw in all bolts by hand.
During installation, first bolt bracket to gearbox with 40 Nm + 90°
torque.
When the two bracket bolts are tightened to vehicle, a screwdriver
may be inserted between the two bolts to adjust to »previous
seating«. These two larger bolts are tightened to 60 Nm + 90°.
Torque settings, gearbox to engine ⇒ page 75 .
The engine and gearbox should be mounted tension-free in the
assembly mounting. The correct procedure is described in ⇒ Rep.
gr. 10 ; Removing and installing engine; Notes on installation .
– Adjust selector lever cable ⇒ page 43 .
– After installing, check ATF level ⇒ page 134 .
– Carry out basic settings. To do this:
– Connect vehicle diagnosis, testing and information system -
VAS 5051- and then select „Perform basic settings“ under
Guided functions .
10.3.1 Torque settings, Golf Plus 2005 with 1.6 l - 75 kW and 2.0 l - 110 kW (FSI)
engines
1 - Direction of travel
A - Bolt for 2.0 l - 110 kW (FSI)
engine
B - Bolt for 1.6 l -75 kW engine
- Drive plate to torque convert‐
er
❑ 60 Nm
❑ Qty. 6; remove and in‐
stall with insert -V/175- .
- M12 bolts ⇒ M12
❑ 80 Nm
❑ 65 Nm if you use socket
-T10179- .
- M10 bolts ⇒ M10
❑ 40 Nm
❑ These bolts are located
in lower flange
- Two dowel sleeves in engine
-arrows-
-Nuts- 8 Nm
10.3.2 Torque settings, Golf Plus 2005 with 1.6 l - 85 kW (FSI) engine
1 - Direction of travel
- Drive plate to torque convert‐
er
❑ 60 Nm
❑ Qty. 6; remove and in‐
stall with insert -V/175- .
- M12 bolts ⇒ M12
❑ 80 Nm
❑ 65 Nm if you use socket
-T10179- .
- M10 bolts ⇒ M10
❑ 40 Nm
❑ These bolts are located
in lower flange
- Two dowel sleeves in engine
-arrows-
-Nuts- 8 Nm
10.3.3 Torque settings, Golf Plus 2005 with 2.5 l - 110 kW engine
1 - Direction of travel
- Drive plate to torque convert‐
er
❑ 60 Nm
❑ Qty. 6; remove and in‐
stall with insert -V/175- .
- M12 bolts ⇒ M12
❑ 80 Nm
❑ 65 Nm if you use socket
-T10179- .
- M10 bolts ⇒ M10
❑ 40 Nm
❑ These bolts are located
in lower flange
- Two dowel sleeves in engine
-arrows-
-Nuts- 8 Nm
♦ Insert -V/175-
Work with care to avoid bending cable. Do not use pliers, or the
retaining tabs on the cable support bracket may break off.
– Lever cable -1- off lever -3- using an open jaw spanner -2-.
Note
11.3.2 Torque settings, Touran 2003 with 2.0 l - 85 kW (FSI) and 1.8 l - 110 kW
(FSI) engines
11.3.3 Torque settings, Touran 2003 with 2.0 l - 110 kW (FSI) engine
Note
♦ Socket -T10035-
Work with care to avoid bending cable. Do not use pliers, or the
retaining tabs on the cable support bracket may break off.
– Lever cable -1- off lever -3- using an open jaw spanner -2-.
Note
After this, do not set vehicle on the ground any more ⇒ Rep. gr.
40 ; Repairing drive shafts; Removing and installing drive shafts;
Removing drive shafts with triple-roller joint AAR2600i .
Note
Note
1 - Direction of travel
- Drive plate to torque convert‐
er
❑ 60 Nm
❑ Qty. 6; remove and in‐
stall with insert -V/175- .
- M12 bolts ⇒ M12
❑ 80 Nm
❑ 65 Nm if you use socket
-T10179- .
- M10 bolts ⇒ M10
❑ 40 Nm
❑ These bolts are located
in lower flange
- Two dowel sleeves in engine
-arrows-
1 - Direction of travel
A - Bolt for 2.0 l - 110 kW (FSI)
engine
B - Bolt for other engines
- Drive plate to torque convert‐
er
❑ 60 Nm
❑ Qty. 6; remove and in‐
stall with insert -V/175- .
- M12 bolts ⇒ M12
❑ 80 Nm
❑ 65 Nm if you use socket
-T10179- .
- M10 bolts ⇒ M10
❑ 40 Nm
❑ These bolts are located
in lower flange
- Two dowel sleeves in engine
-arrows-
Note
♦ Socket -T10035-
Work with care to avoid bending cable. Do not use pliers, or the
retaining tabs on the cable support bracket may break off.
– Lever cable -1- off lever -3- using an open jaw spanner -2-.
– Unbolt upper line retainer from gearbox.
– Unbolt lower line retainer from gearbox.
– Unbolt ATF lines from gearbox.
– Disconnect electrical connections to gearbox and starter.
♦ Multifunction switch
♦ Starter motor
♦ Earth strap to bracket
– Remove upper starter motor bolt.
– Remove upper connecting bolts between engine and gearbox.
Bolts may be installed with a socket -T10179- . When tightening,
however, observe the lower tightening torque ⇒ page 103 .
Socket -T10035- simplifies the work.
Note
After this, do not set vehicle on the ground any more ⇒ Rep. gr.
40 ; Repairing drive shafts; Removing and installing drive shafts;
Removing drive shafts with triple-roller joint AAR2600i .
Note
Note
1 - Direction of travel
- Drive plate to torque convert‐
er
❑ 60 Nm
❑ Qty. 6; remove and in‐
stall with insert -V/175- .
- M12 bolts ⇒ M12
❑ 80 Nm
❑ 65 Nm if you use socket
-T10179- .
- M10 bolts ⇒ M10
❑ 40 Nm
❑ These bolts are located
in lower flange
- Two dowel sleeves in engine
-arrows-
1 - Direction of travel
- Drive plate to torque convert‐
er
❑ 60 Nm
❑ Qty. 6; remove and in‐
stall with insert -V/175- .
- M12 bolts ⇒ M12
❑ 80 Nm
❑ 65 Nm if you use socket
-T10179- .
- M10 bolts ⇒ M10
❑ 40 Nm
❑ These bolts are located
in lower flange
- Two dowel sleeves in engine
-arrows-
Note
Note
After this, do not set vehicle on the ground any more ⇒ Rep. gr.
40 ; Repairing drive shafts; Removing and installing drive shafts;
Removing drive shafts with triple-roller joint AAR2600i .
Work with care to avoid bending cable. Do not use pliers, or the
retaining tabs on the cable support bracket may break off.
– Lever cable -1- off lever -3- using an open jaw spanner -2-.
WARNING
Note
Note
– Raise vehicle.
Leave the drip tray for workshop hoist -VAS 6208- under the
gearbox; more ATF will run out.
– Lower vehicle.
– Cover the area of the ATF line connections and the ATF cooler
on the gearbox with cloths.
– Remove bolts -1- and -2- but do not pull off lines yet.
– Pull off line -2- and raise as quickly as possible so that ATF in
line can run out below into drip tray.
– Pull of line -1- and raise; then secure both lines in this position
using, for example, a cable tie.
Note
– Connect ATF lines with new seals and tighten. Torque setting:
⇒ page 114 .
– Before you now remove final connecting bolt, support gearbox
with engine and gearbox jack -V.A.G 1383 A- , gearbox sup‐
port -3282- and adjustment plate -3282 /36- .
– Only now is the final bolt removed.
– Carefully push gearbox off engine.
Note
1 - Direction of travel
- Drive plate to torque convert‐
er
❑ 60 Nm
❑ Qty. 6; remove and in‐
stall with insert -V/175- .
- M12 bolts ⇒ M12
❑ 80 Nm
❑ 65 Nm if you use socket
-T10179- .
- M10 bolts ⇒ M10
❑ 40 Nm
❑ These bolts are located
in lower flange
- Two dowel sleeves in engine
-arrows-
Specified torques
Component Torque setting
Gearbox bracket to gearbox (4 x M10 bolts) 40 Nm + 90°
Gearbox bracket to gearbox mounting (2 x M12 bolts) 60 Nm + 90°
Bracket for ATF lines to gearbox ⇒ page 115 9 Nm
ATF lines to ATF cooler ⇒ page 115 25 Nm
ATF lines to gearbox 25 Nm
Observe bolt lengths ⇒ page 115
Note
Removing:
– Move selector lever to position »P« position.
– Raise vehicle. All 4 supports of lifting platform must be at same
height.
Note
After this, do not set vehicle on the ground any more ⇒ Rep. gr.
40 ; Repairing drive shafts; Removing and installing drive shafts;
Removing drive shafts with triple-roller joint AAR2600i .
– Pull off hoses -arrows- and remove intake hose from throttle
valve unit.
Work with care to avoid bending cable. Do not use pliers, or the
retaining tabs on the cable support bracket may break off.
– Lever cable -1- off lever -3- using an open jaw spanner -2-.
– Disconnect electrical connections to gearbox and starter.
♦ Multifunction switch
♦ Starter motor
♦ Earth strap to bracket
– Unbolt transportation bracket -3- from engine -2- and pull out
of eye -arrow-.
– Attach a shackle -10 - 222 A /12- in »this« eye.
Note
Note
1 - Direction of travel
- Drive plate to torque convert‐
er
❑ 60 Nm
❑ Qty. 6; remove and in‐
stall with insert -V/175- .
- M12 bolts ⇒ M12
❑ 80 Nm
❑ 65 Nm if you use socket
-T10179- .
- M10 bolts ⇒ M10
❑ 40 Nm
❑ These bolts are located
in lower flange
- Two dowel sleeves in engine
-arrows-
-Nuts- 8 Nm
15 Transporting gearbox
Special tools and workshop equipment required
♦ Shackle -10 - 222 A /12-
1 - Gearbox housing
2 - Seal
❑ Always renew
3 - ATF cooler
❑ Installation position:
⇒ page 128 .
4 - Seal
❑ Always renew
5 - Washer
6 - Dished washer
17.1 Overview
17. ATF lines, ATF water cooler and additional ATF cooler, Passat with 2.0 l TFSI engine 129
CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Passat 200 ...
6-speed automatic gearbox 09G - Edition 07.2011
1 - ATF line
❑ Always renew oil seal
❑ 20 Nm
2 - ATF line
❑ Always renew oil seal
❑ 20 Nm
3 - Nut
❑ 9 Nm
1 - Bolt
❑ 8 Nm
2 - Nut
❑ 9 Nm
3 - External ATF cooler
4 - Bolt
❑ 9 Nm
5 - ATF line
❑ »Supply.«
❑ Always renew oil seal
6 - ATF line
❑ »Return«
❑ Always renew oil seal
7 - Nut
❑ 9 Nm
17. ATF lines, ATF water cooler and additional ATF cooler, Passat with 2.0 l TFSI engine 131
CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Passat 200 ...
6-speed automatic gearbox 09G - Edition 07.2011
1 - ATF line
❑ »Return« from addition‐
al cooler.
❑ 25 Nm
2 - ATF line
❑ »Supply« to additional
cooler.
❑ 25 Nm
3 - Nut
❑ 9 Nm
17. ATF lines, ATF water cooler and additional ATF cooler, Passat with 2.0 l TFSI engine 133
CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Passat 200 ...
6-speed automatic gearbox 09G - Edition 07.2011
Note
The dimension -a- is measured from the shaft (green area in the
counting glass) of the adapter for oil filling -VAS 6262 A- .
– Mark dimension -a- on the breather pipe and shorten pipe with
pipe cutter -VAS 6056/2- .
If ATF must be added, use only ATF listed in ⇒ Electronic parts
catalogue ⇒ ETKA .
WARNING
An ATF level which is too low or too high will impair the function
of the gearbox. But if the gearbox was 2 litres low, it must be
carefully inspected. There is probably a »major« leak.
– Remove inspection plug for ATF level from oil pan -arrow-.
38 – Gears, control
1 Renewing oil seal for selector shaft
Special tools and workshop equipment required
♦ Thrust piece -T10174-
2.1 Removing
– Remove noise insulation below engine.
– Place drip tray -V.A.G 1306- underneath.
– Unscrew ATF inspection plug -A-.
– Remove overflow pipe -C- and allow remaining ATF to drain.
2.2 Installing
Install in reverse order of removal. During this step, observe the
following:
– Clean the two magnets in recesses of oil pan. Ensure that
magnets are seated correctly in pan.
– Check that seal is undamaged and all spacer sleeves (qty. 8)
are present.
Otherwise renew seal.
– Fit oil sump with seal, taking care not to pinch any wires.
– Ensure that oil pan gasket is seated correctly.
– Tighten pan bolts -arrows- diagonally in several stages; torque
specification ⇒ page 154 .
3.1 Removing
– Remove oil pan ⇒ page 141 .
– Unscrew ATF strainer bolts -arrows-.
– Pull ATF strainer -A- off valve body.
3.2 Installing
– Thinly coat seals on intake neck of ATF strainer with ATF.
– The ATF strainer must be renewed if seals are loose or de‐
fective.
– Fit oil strainer -A- and tighten bolts; torque settings
⇒ page 154 .
– Install oil pan ⇒ page 141 .
– Fill with ATF; check ATF level and top up ⇒ page 134 .
WARNING
♦ The valve body and the wiring harnesses can also be removed
when the gearbox is installed.
♦ Moisten seals with ATF before fitting. Other lubricants lead to
malfunction of the gearbox hydraulics.
♦ Always renew a valve body which is fouled or defective.
♦ Do not use fluffy cloths.
♦ After the pan has been installed, the ATF level must be
checked and topped up ⇒ page 134 .
24 - Seal
❑ Always renew
25 - ATF drain plug
❑ Torque setting ⇒ page 154
26 - Selector lever
27 - Washer
28 - Nut
❑ Location: centring collar faces washer ⇒ Item 27 (page 147)
❑ Torque setting ⇒ page 154
29 - Spring
❑ Allocation ⇒ Electronic parts catalogue „ETKA“
30 - Damper piston
31 - Wiring harness for solenoid valves
❑ Always renew oil seal on housing
❑ Removing and installing ⇒ page 155
❑ Cable routing ⇒ page 152 .
32 - Bolt
❑ Torque setting ⇒ page 154
Caution
– Note spool valve -A- on valve body into which selector lever
engages so that this is not damaged.
Caution
– Coat damper piston -2- with ATF and insert with spring.
– Carefully insert valve body and start 2 bolts.
– First fit remaining bolts and retainers -1- and -2- and tighten
by hand.
– Install gearbox oil temperature sender -G93- and tighten; tor‐
que settings ⇒ page 154 .
– Push connector (Qty. 8) onto solenoid valves ⇒ page 152 .
– Tighten retainer for connectors ⇒ page 152 ; torque setting
⇒ page 154 .
– Push on connectors ⇒ Item A (page 153) and
⇒ Item B (page 153) .
– Tighten valve body diagonally from centre outwards; torque
setting ⇒ page 154 .
– Install selector lever.
5.1 Removing
– Drain ATF ⇒ page 138 .
– Remove oil pan ⇒ page 141 .
– Remove ATF strainer ⇒ page 144 .
– Remove valve body ⇒ page 147 .
– Pull connector off gearbox.
-1- connector for sender in gearbox
-2- Connector for solenoid valves
– Unbolt connector housing from gearbox.
– Pull connector housing with wiring harness outwards out of
gearbox housing.
5.2 Installing
– Renew seal on connector housing.
– Carefully thread wiring harness into gearbox from outside.
– Moisten seal on connector housing with ATF and press con‐
nector housing into gearbox to stop.
– Tighten connector housing; torque setting ⇒ page 154 .
– Install valve body ⇒ page 150 .
– Install ATF strainer ⇒ page 144 .
– Install oil pan ⇒ page 141 .
– Fill with ATF; check ATF level and top up ⇒ page 134 .
5. Removing and installing wiring harness for solenoid valves and senders 155
CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Passat 200 ...
6-speed automatic gearbox 09G - Edition 07.2011
6.1 Removing
– Remove valve body ⇒ page 147 .
– Unscrew bolt -1- from gearbox input speed sender -G182- .
– Pull sender out of gearbox.
6.2 Installing
Install in reverse order of removal. During this step, observe the
following:
– Press sender into gearbox to stop.
– Tighten bolt -1- for gearbox input speed sender -G182- ; torque
specifications ⇒ page 154 .
– Install valve body ⇒ page 150 .
7.1 Removing
– Remove valve body ⇒ page 147 .
– Unscrew bolt -2- from gearbox output speed sender -G195- .
– Pull sender out of gearbox.
7.2 Installing
Install in reverse order of removal. During this step, observe the
following:
– Press sender into gearbox to stop.
– Tighten bolt -2- for gearbox output speed sender -G195- ; tor‐
que specifications ⇒ page 154 .
– Install valve body ⇒ page 150 .
Torque settings ⇒ page 154
Removing
– Remove left drive shaft ⇒ Rep. gr. 40 ; Removing and instal‐
ling drive shafts .
Note
Note
Installing
Install in reverse order of removal. During this step, observe the
following:
– Apply ATF to circumference and sealing lips of new oil seal.
Installation position:
Open side of oil seal faces gearbox.
– Drive in new seal onto stop with thrust piece -T10176- . Do not
cant oil seal.
– Install drive shaft ⇒ Rep. gr. 40 ; Removing and installing
drive shafts .
– Finally, check ATF level and top up ⇒ page 134 .
– Install noise insulation.
♦ Puller -T10055-
Removing
– Remove noise insulation.
– Remove right drive shaft from gearbox ⇒ Rep. gr. 40 ; Re‐
moving and installing drive shafts .
– Raise drive shaft as high as possible and secure. Take care
not to damage paint on drive shaft in the process.
– Seal drive shaft aperture on transmission with a clean cloth
-A-.
– Carefully drill a hole (size 2 to 4 mm) -B- into outer sheet metal
ring -C- of oil seal.
Note
Note
Installing
Install in reverse order of removal. During this step, observe the
following:
– Apply ATF to circumference and sealing lips of new oil seal.
Installation position:
Open side of oil seal faces gearbox.
– Drive in new seal onto stop with thrust piece -T10177- . Do not
cant oil seal.
– Install drive shaft ⇒ Rep. gr. 40 ; Removing and installing
drive shafts .
– Finally, check ATF level and top up ⇒ page 134 .
– Install noise insulation.