00 GENERAL, TECHNICAL DATA service man/Audi_A6-C6_2004... · 2016. 12. 20. · A - Transmission Output Speed (RPM) Sensor G195 and Transmission Output Speed (RPM) Sensor 2 G196 B

TRANSMISSION

Continuously Variable Transmission (CVT) 01J

00 GENERAL, TECHNICAL DATA

TRANSMISSION IDENTIFICATION

The Continuously Variable Transmission (CVT) "multitronic 01J front wheel drive" is installed in conjunction with various engines in the Audi A6 2005 >. Allocation --> Code letters, transmission applications, ratios, equipment.

Location of code letters on transmission

Fig. 1: Identifying Code Letters And Serial Number Of Transmission Stamped On Underside Of Transmission Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.

Code letters and serial number of transmission are stamped on the underside of the transmission housing - arrow -.

CONTINUOUSLY VARIABLE TRANSMISSION (CVT) MULTITRONIC 01J FRONT WHEEL DRIVE , GENERAL INFORMATION

Continuously Variable Transmission (CVT) "multitronic 01J front wheel drive" , general information

Additional information about the function of this transmission 951103Continuously Variable Transmission

Example: FRC 03 07 01 I I I I Code letters Day Month Year (2001) of manufacture

NOTE:� The code letters of the transmission are also listed on the vehicle data

stickers.

2008 Audi A6 Quattro

TRANSMISSION Continuously Variable Transmission (CVT) 01J



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(CVT) multitronic 01J.

Guided Fault Finding

Always perform "Guided Fault Finding" using Diagnostic Operation System VAS 5051 before starting disassembly and assembly work.

CODE LETTERS, TRANSMISSION APPLICATIONS, RATIOS, EQUIPMENT

Code letters, transmission applications, ratios, equipment

CAPACITIES

Capacities

Planetary gearbox

* ATF change interval for planetary gear 4F.

ATF for CVT transmission can be obtained as replacement part, container size:

� 1.0 L - Part No. G 052 180 A2

NOTE:� The continuously variable automatic transmission multitronic 01J is also

called "Continuously Variable Transmission" , "CVT" for short.

Multitronic 01J.MTransmission Code letters HHZ Manufactured from to 09.2005Application Model Audi A6 2005 > Engine 3.2L FSI 4V -188 kWInput gearing ratio 49 : 48 1.021Front final drive ratio 43 : 9 4.778Ring gear dia. mm 203Flange shafts Center dia. mm 88 Hole circle dia. mm 104

Capacities Planetary gearbox MultitronicInitial filling approx. 7.5 L 01JChanging 4.5 to 5.0 L * See note Lubricant ATF for CVT transmission

CAUTION: The Continuously Variable Automatic Transmission Multitronic 01J requires a different ATF than shift automatics. Only ATF for CVT



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ATF, checking or changing --> ATF level, checking and topping off.

Front final drive

*Permanent fill: only fill after repair, up to 1.3 liters.

Multitronic gear oil is available as a replacement part and comes in the following container size:

� 0.5 L - Part no.G 052 190 A2

Oil level in front final drive, checking --> Front final drive, checking gear oil level.

TOWING INSTRUCTIONS

Towing instructions

REPAIR INSTRUCTIONS

Repair instructions

transmission which can be obtained as replacement pa rt must be used in the planet gearbox.

Capacities Front final drive MultitronicInitial filling approx. 1.3 L 01JChanging No change * See note Lubricant multitronic gear oil

CAUTION: The Continuously Variable Automatic Transmission Multitronic 01J requires a different axle oil than shift automatics. Only axle oil for Multitronic which can be obtained as a replacement part must be used in front final drive.

CAUTION: When towing, selector lever must be in position "N" and vehicle must not to be towed for more than 50 km or at a speed in excess of 50 km/h as otherwise transmission would be destroyed.

NOTE:� Tow-starting the engine, e.g. when the battery is too weak or the starter is

faulty, is not possible.

CAUTION: Before work is done with engine running, place selector lever in "P" position and press parking brake button to engage electromagnetic parking brake.



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The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions also, naturally apply when carrying out vehicle repairs.

A number of generally applicable instructions for individual repair procedures, which are otherwise mentioned at various points in the article, are summarized here. They apply to this article.

Special tools and equipment

For a complete list of special tools used in the article. See Special Tools.

Transmission

� Observe rules of cleanliness for working on the transmission --> Rules for cleanliness when working on transmission.

� Do not run engine with the end cover removed or without ATF filling and do not tow vehicle.

� Only install clean parts: Remove packing from replacement parts immediately prior to installation and not before.

� After installing, the following fluid levels must be checked and topped off if necessary: ATF in planetary gear --> ATF level, checking and topping off and axle oil in front final drive --> Front final drive, checking gear oil level. Capacities and specifications --> Capacities.

O-rings, seals, gaskets

� Always replace O-rings, gaskets and seals.

� After removing gaskets, examine contact surface on housing/shaft for burrs resulting from removal or for other signs of damage.

� Thoroughly clean housing joint surfaces before assembling.

� To install, thinly coat gaskets along outer circumference and on sealing lip with ATF.

� Lightly lubricate O-rings with ATF when installing to prevent the rings from being pinched when components are assembled.

� Only use ATF for automatic transmission components. Other types of lubrication cause malfunctions to occur in the transmission hydraulics.

� Open sides of oil seals face fluid side.

� When pressing in new gaskets, make sure the sealing lip does not run on the same point as the sealing lip of the old seal (use insertion depth tolerances).

� After installing, the following fluid levels must be checked and topped off if necessary: ATF in planetary gear --> ATF level, checking and topping off or axle oil in front final drive --> Front final drive, checking gear oil level. Capacities and specifications --> Capacities.

Bolts and nuts

� Loosen bolts in reverse of tightening sequence.



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� Nuts and bolts which secure covers and housings should be tightened in stages according to specified sequence and tightening method.

� Loosen and tighten bolts and nuts for securing covers and housings in a diagonal sequence and in stages, when no tightening sequence is specified.

� The tightening torques stated apply to unoiled bolts and nuts.

� Replace self-locking bolts and nuts.

� Clean threads of bolts that were applied with locking fluid using a wire brush. Then insert bolts and apply AMV 185 101 A1.

� Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (e.g. tap). Otherwise there is a risk that the bolts will shear the next time they are removed.

Locking elements

� Do not over-stretch circlips.

� Always replace circlips which have been damaged or over-stretched.

� Circlips must be properly seated in the base of the groove.

Bearings

� Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards the drift.

� Insert bearing with axle oil or ATF, depending on installation location.

� Do not interchange the outer or inner races of bearings of the same size.

� Always replace the taper roller bearings on one shaft together and use new bearings from a single manufacturer.

Shims

� Use a micrometer to measure the shims at several points. Varying tolerances make it possible to measure the required shim thickness exactly.

� Inspect for burrs and signs of damage. Install only shims that are in perfect condition.

Guided Fault Finding

Always perform Guided Fault Finding using the Diagnostic Operation System VAS 5051 before starting disassembly and assembly work.

RULES FOR CLEANLINESS WHEN WORKING ON TRANSMISSION

Rules for cleanliness when working on transmission

� Carefully clean all joints and adjacent areas before disconnecting.

� Place removed parts on a clean surface and cover them. Use sheeting or paper. Do not use fluffy cloths!



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� Carefully cover or plug unpacked components if repairs cannot be performed immediately.

� Only install clean parts: Remove packing from replacement parts immediately prior to installation and not before.

37 AUTOMATIC TRANSMISSION - CONTROLS, HOUSING

ELECTRICAL/ELECTRONIC COMPONENTS AND INSTALLED LOCATIONS

Fig. 2: Connecting Data Link Connector (DLC) Courtesy of VOLKSWAGEN UNITED STATES, INC.

Data Link Connector (DLC)

� Location: Diagnostic connector is located below lower instrument panel cover on drivers side.

Fig. 3: Identifying Sensors Of Soiling And Metal Shavings



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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Transmission Control Module (TCM) J217

� Location: Transmission Control Module (TCM) J217 is on the back end of transmission, secured directly to hydraulic control module.

The following components are integrated in Transmission Control Module (TCM) J217 :

A - Transmission Output Speed (RPM) Sensor G195 and Transmission Output Speed (RPM) Sensor 2 G196

B - Transmission Fluid Temperature Sensor G93

C - Multi-Function Transmission Range (TR) Switch F125

D - Transmission Input Speed (RPM) Sensor G182

E - Automatic Transmission Hydraulic Pressure Sensor 1 G193

F - Automatic Transmission Hydraulic Pressure Sensor 2 G194

Removing and installing Transmission Control Module (TCM) J217 --> Transmission Control Module (TCM) J217 , removing and installing.

Fig. 4: Identifying Hydraulic Control Module Components Courtesy of VOLKSWAGEN UNITED STATES, INC.

Hydraulic control module

� Location: Hydraulic control module is bolted to back end of transmission. Transmission Control Module (TCM) J217 is fastened directly to hydraulic control module.

NOTE:� Transmission Control Module (TCM) J217 is monitored with On Board

Diagnostics (OBD).



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A - Automatic Transmission Pressure Regulating Valve 1 N215 electrical connector

B - Automatic Transmission Pressure Regulating Valve 2 N216 electrical connector

C - Solenoid Valve 1 N88 electrical connector

Removing and installing hydraulic control module --> Hydraulic control module, removing and installing.

The following valves are integrated into hydraulic control module (not depicted here).

� Automatic Transmission Pressure Regulating Valve 1 N215 (clutch solenoid valve)

� Automatic Transmission Pressure Regulating Valve 2 N216 (solenoid valve gear)

� Solenoid Valve 1 N88 (clutch cooling/safety shut-off)

� Clutch cooling valve

� Minimum pressure valve

� Pressure relief valve

� Clutch control valve

� Pressure control valve

Fig. 5: Selector Lever Sensor System Control Module J587 And Tiptronic Switch F189 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Selector Lever Sensor System Control Module J587 and Tiptronic Switch F189

� Location: Selector Lever Sensor System Control Module J587 and Tiptronic Switch F189 are housed in the same component - arrow -.

Selector Lever Sensor system Control Module J587 and Tiptronic Switch F189 , removing and installing --> Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189 , removing and installing.

NOTE:� Valves are monitored via On Board Diagnostic (OBD).



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Fig. 6: Identifying Shift Lock Solenoid N110 Electrical Connector And Releasing Retainer And Pulling Out Shift Lock Solenoid N110 From The Front Courtesy of VOLKSWAGEN UNITED STATES, INC.

Shift lock solenoid N110

� Location: Shift Lock Solenoid N110 - 1 - is clipped onto shift mechanism.

Shift Lock Solenoid N110 , removing and installing --> Shift lock solenoid N110 , removing and installing.

Fig. 7: Removing/Installing Microswitch Off Courtesy of VOLKSWAGEN UNITED STATES, INC.

Transmission Park Selector Switch F305

� Location: Transmission Park Selector Switch F305 consisting of 2 micro switches is installed in shift mechanism.



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Assembly: --> Transmission Park Selector Switch F305 , removing and installing.

Fig. 8: Kick Down Switch F8 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Kick Down Switch F8

Location:

A specific value from Throttle Position (TP) Sensor G79 and Accelerator Pedal Position Sensor 2 G185 is saved in engine control module.

Accelerator pedal position sensors are integrated in accelerator module - arrow -.

NOTE:� If accelerator pedal position sensor is faulty, accelerator module must be

replaced --> 20 - FUEL SUPPLY SYSTEM .



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Fig. 9: Cruise Control Switch -E45- Courtesy of VOLKSWAGEN UNITED STATES, INC.

Cruise control switch E45

� Location: Cruise control switch is located on steering column switch.

Steering column switch, removing and installing --> 94 - LIGHTS, SWITCHES - EXTERIOR .

Fig. 10: Transmission Range (TR) Selector Lever Display -Y6- Courtesy of VOLKSWAGEN UNITED STATES, INC.

Transmission Range (TR) Display Y6

� Location: Transmission Range (TR) Display Y6 is integrated in instrument cluster.

NOTE:� A completely lit display warns of a simple malfunction. � A blinking display warns of a critical malfunction. � No display indicates a wiring fault or a faulty Transmission Range (TR)

Display Y6. � If Transmission Range (TR) Display Y6 is faulty, instrument cluster must

be replaced --> 90 - INSTRUMENTS .



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Fig. 11: Releasing Retaining Spring And Removing Selector Lever Transmission Range (TR) Position Display Y26 Upward Courtesy of VOLKSWAGEN UNITED STATES, INC.

Selector Lever Transmission Range (TR) Position Display Y26

� Selector Lever Transmission Range (TR) Position Display Y26 - 1 - is clipped into center console.

Selector Lever Transmission Range (TR) Position Display Y26 , removing and installing --> Selector Lever Transmission Range (TR) Position Display Y26 , removing and installing.

SELECTOR MECHANISM, SERVICING

Selector mechanism, servicing

Ignition key lock, checking

� To reach position "ignition on" , briefly turn ignition key lightly toward right.

� Press brake pedal and hold.

� It must be possible to shift selector lever out of position "P" without "catching" while locking button on selector lever handle is pressed.

� Switch ignition off.

� It should not be possible to remove the ignition key when selector lever is in any other position than "P".

� Place selector lever in position "P".

� Remove ignition key.

CAUTION: Before work is done with engine running, place selector lever in "P" position and press parking brake button to engage electromagnetic parking brake.



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� It must be possible to remove ignition key only in position "P".

� Selector lever cannot be shifted out of position "P" with the locking button pressed and foot brake operated.

If ignition key removal lock does not function as described, check Access/Start Authorization Switch E415 using Vehicle Diagnostic, Testing and Information System VAS 5051 in "Guided Fault Finding" function.

Selector mechanism, checking

� In selector lever positions "S" , "D" , "R" and "Tiptronic gate" the starter motor will not operate.

� If selector lever position "N" is selected at speeds greater than 5 km/h, the selector lever lock solenoid must not engage and block the selector lever. Selector lever can be shifted into driving gear.

� For speeds below 2 km/h (almost standstill) and shifting into selector lever position "N" , the shift lock solenoid must only engage after approx. 1 second. Selector lever can only be shifted out of position "N" with the brake pedal operated.

Selector lever in "P" position and ignition switched on:

� Do not operate brake pedal.

� Selector lever is locked and cannot be shifted out of "P" position. Shift Lock Solenoid N110 blocks selector lever.

� Press brake pedal and hold.

� Shift Lock Solenoid N110 releases selector lever. It is possible to shift into a driving gear. Shift selector lever slowly from "P" position through "R, N, D, S" and check whether the Transmission Range (TR) Display Y6 in the instrument cluster shows the correct selector lever position.

Selector lever in "N" position and ignition switched on:

� Do not operate brake pedal.

� After a brief pause: Selector lever is locked and cannot be shifted out of position "N" without pressing the button on selector lever handle. Shift Lock Solenoid N110 blocks selector lever.

� Operate brake pedal.

� Shift Lock Solenoid N110 releases selector lever. Selection of position "D" is possible.

Selector lever in position "D" , ignition switched on:

� Shift selector lever into "Tiptronic gate".

� Lit "D" symbol in Selector Lever Transmission Range (TR) Position Display Y26 must go out and "+" and "" symbols must light up.



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� The Transmission Range (TR) Display Y6 in the instrument cluster should switch from "PRNDS" to "654321" when the selector lever is shifted into "Tiptronic gate".

If specified values are not obtained:

� Adjust selector lever cable --> Selector lever cable, adjusting. � Check ignition key removal lock --> Ignition key lock, checking.

Selector mechanism, component overview

Fig. 12: Selector Mechanism Components, Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Lock washer

2 - Noise insulation



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3 - Retaining clip

� Secures selector lever cable to shift mechanism casing

4 - Selector lever cable

� Do not bend or kink

� Removing and installing --> Selector lever cable, removing and installing � In case of damaged rubber boot, selector lever cable must be replaced

� Lightly lubricate ball socket with polycarbamide grease G 052 142 A2 before installing.

� When installing, make sure rubber sleeve on transmission side is not twisted

� Adjusting --> Selector lever cable, adjusting

5 - Locking screw, 13 Nm

6 - Selector lever cable screws

� To remove selector lever cable, move plastic retaining spring at selector mechanism forward slightly and put screws upward, only as far as necessary.

7 - Shift lock solenoid N110

� Removing and installing --> Shift lock solenoid N110 , removing and installing

8 - Selector Lever Transmission Range (TR) Position Display Y26

� Removing and installing --> Selector Lever Transmission Range (TR) Position Display Y26 , removing and installing

9 - Clamp

� For securing selector lever handle to selector lever

� Removing and installing --> Selector lever handle, removing and installing

10 - Selector lever boot

� Separate from selector lever handle --> Separating selector lever boot from selector lever handle

11 - Selector lever handle


12 - Trim ring



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� Removing and installing --> Separating selector lever boot from selector lever handle

13 - 1.2 Nm

14 - Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189

� Removing and installing --> Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189 , removing and installing

15 - Transmission Park Selector Switch F305

� Removing and installing --> Transmission Park Selector Switch F305 , removing and installing

16 - 10 Nm

17 - Selector lever housing

� Can only be replaced as complete unit

� Removing and installing --> Selector mechanism, removing and installing

18 - Shift mechanism bottom cover

19 - 10 Nm

Selector lever handle, Selector Lever Transmission Range (TR) Position Display Y26 , component overview



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Fig. 13: Selector Lever Handle Components, Selector Lever Transmission Range Position Display Y26 , Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Clamp

� For securing selector lever handle to selector lever


2 - Trim ring

� Removing and installing --> Separating selector lever boot from selector lever handle

3 - Selector lever handle




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4 - Selector lever boot

� Separate from selector lever handle --> Separating selector lever boot from selector lever handle

5 - Selector Lever Transmission Range (TR) Position Display Y26

� Removing and installing --> Selector Lever Transmission Range (TR) Position Display Y26 , removing and installing

Shift mechanism, operating manual release

� Remove front ashtray insert.

Fig. 14: Prying Off Cover Cap In Ashtray Housing Using Screwdriver Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Pry cover cap in ashtray housing out using screwdriver - arrow -.

NOTE:� When the battery is disconnected or has been discharged, the selector

lever cannot be shifted out of the "P" position. � By operating the manual release the Shift Lock Solenoid N110 will release

the selector lever when there is no power supply.



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Fig. 15: Pressing On Manual Release Lever Using A Screwdriver And Simultaneously Shift The Selector Lever Out Of Position Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Press on manual release lever - arrow - , e.g. with a screwdriver, and at the same time, remove selector lever from "P" position.

Selector lever handle, removing and installing

Special tools, testers and auxiliary items required

Fig. 16: Identifying Hose Clamp Pliers V.A.G 1275 Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Hose clamp pliers V.A.G 1275

Fig. 17: Unclipping Mounting Frame For Selector Lever Boot From Center Console Courtesy of VOLKSWAGEN UNITED STATES, INC.



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Removing

� Place selector lever in position "N".

� Unclip mounting frame for selector lever boot - 1 - from center console and lift it upward and off - arrows -.

Fig. 18: Securing The Interlock Button In Pulled-Out Position Using A Cable Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Secure lock button in pulled-out position using a cable tie - arrow - as shown in illustration.

Fig. 19: Selector Lever Boot, Selector Lever Handle And Clamp Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:� The selector lever handle is removed together with the selector lever boot.



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� Flip selector lever boot - 1 - upward and over the selector lever handle - 2 -. � Open clamp - arrow - and pull off selector lever handle together with selector lever boot, without

touching the lock button.

Fig. 20: Securing The Interlock Button In Pulled-Out Position Using A Cable Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installing

� Place selector lever handle completely onto selector lever - lock button faces toward driver.

� When doing this, handle must engage into ring groove of selector lever.

� Remove cable tie or assembly aid, thereby the lock button mechanism engages in the vertical groove of the selector lever. If necessary, press the lock button into the selector lever handle.

NOTE:� To install selector lever handle, lock button must be pulled out as far as

stop and secured with a cable tie - arrow - or using the assembly aid included with new handle.

� If the lock button was not secured, it must not be pulled out from the handle using mechanical aids. Apply compressed air gun to bottom of handle and press lock button out with compressed air.



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Fig. 21: Selector Lever Boot, Selector Lever Handle And Clamp Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Clamp selector lever handle - 2 - to the selector lever, using clamp - arrow -. To do this, use the hose clamp pliers V.A.G 1275.

� Clip retaining frame for selector lever boot - 1 - onto center console.

Separating selector lever boot from selector lever handle

Fig. 22: Removing Selector Lever Boot From Selector Lever Handle Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing

� Remove selector lever handle --> Selector lever handle, removing and installing. � Bind the spring tabs - 1 - of selector lever handle together with a cable tie - 3 - , as shown in the

illustration.



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� Push sleeve - 2 - of selector lever boot over retaining tabs on spring tabs - arrow -. � Remove cable tie and remove sleeve with selector lever boot from selector lever.

Installing

Install in reverse order, paying attention to the following:

Installation position of selector lever boot:

� The longer side of the frame for selector lever boot faces toward driver side.

� Install selector lever handle --> Selector lever handle, removing and installing.

Selector Lever Transmission Range (TR) Position Display Y26 , removing and installing


Removing

� Place selector lever in position "N".


� Flip selector lever boot upward.



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Fig. 24: Releasing Retaining Spring And Removing Selector Lever Transmission Range (TR) Position Display Y26 Upward Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Release retaining spring - 2 - and remove Selector Lever Transmission Range (TR) Position Display Y26 - 1 - - arrow -.

� Disconnect electrical connector.

Installing

Installation is in the reverse order of removal.

Selector mechanism, component overview

NOTE:� Lubricate bearing areas and slide surfaces with polycarbamide grease G

052 142 A2 .



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Fig. 25: Selector Mechanism Components, Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Selector lever cable rubber boot

� Check whether selector lever cable rubber boot on lower shift mechanism cover is engaged correctly and properly sealed








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4 - Shift lock solenoid N110

� Removing and installing --> Shift lock solenoid N110 , removing and installing

5 - Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189

� Removing and installing --> Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189 , removing and installing

6 - 1.2 Nm

7 - 10 Nm

8 - Selector lever housing

� Can only be replaced as complete unit

� Removing and installing --> Selector mechanism, removing and installing

9 - Retaining clip


10 - Shift mechanism bottom cover

11 - 10 Nm

Shift lock solenoid N110 , removing and installing

Removing

� Place selector lever in position "S".



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Fig. 26: Pulling Climatronic Control Module J255 (Control Head) Out Of Mounting Frame Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Grasp at bottom of recesses on Climatronic Control Module J255 (operation and display unit).

� Remove Climatronic Control Module J255 (operation and display unit) from installation frame - arrows -.

� Lay Climatronic Control Module J255 (operation and control unit) on a cloth on center console to avoid damaging surface.

Fig. 27: Disconnecting Electrical Harness Connectors In Sequence By Releasing Catches Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Disconnect electrical connectors in sequence - A to D - by releasing tab - F -. � Disconnect electrical connector - E -.



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Fig. 28: Removing Gap Cover Above Ashtray Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove gap cover over ashtray - arrow -.

Fig. 29: Housing For Front Ashtray And Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Open front ashtray.

� Remove front ashtray insert.

� Remove bolts - 1 - and - 2 -. � Remove front ashtray housing - 3 - - arrow -.

� If equipped, disconnect electrical connector.



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Fig. 30: Identifying Shift Lock Solenoid N110 Electrical Connector And Releasing Retainer And Pulling Out Shift Lock Solenoid N110 From The Front Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Disconnect electrical connector - 1 - at Shift Lock Solenoid N110. � Release catches - arrow A - and remove Shift Lock Solenoid N110 forward - arrow B -.

Installing

� Selector lever in "S" position.

Fig. 31: Manual Release Lever Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Pull manual release lever - arrow - upward.

NOTE:� Shown with selector mechanism removed to provide a better illustration.



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Fig. 32: Placing Shift Lock Solenoid N110 Into Guide At An Angle From Above Courtesy of VOLKSWAGEN UNITED STATES, INC.

� At the same time, position Shift Lock Solenoid N110 at an angle in guide from above.

� Press Shift Lock Solenoid N110 into guide until it engages.

� Shift Lock Solenoid N110 ball head - 2 - must engage in operating lever on selector mechanism.

Installation is in reverse order of removal.

Torque specification

Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189 , removing and installing

Removing

� Remove selector lever handle --> Selector lever handle, removing and installing. � Remove front and rear center consoles --> 68 - INTERIOR EQUIPMENT .

NOTE:� When manual release lever is raised, Shift Lock Solenoid N110 operating

lever - 1 - swings into installation position.

Component NmFront ashtray housing to center console frame 3

NOTE:� Selector Lever Sensor System Control Module J587 with Tiptronic Switch

F189 are combined in one component. � Tiptronic Switch F189 magnets are secured to cover.



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Fig. 33: Selector Lever Sensor System Control Module J587 With Tiptronic Switch F189 And Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Disconnect electrical connector - 1 -. � Remove screws - arrows - and remove Selector Lever Sensor System Control Module J587 with

Tiptronic Switch F189.

Installing

Installation is in reverse order of removal. Note the following:

� Install rear and front center consoles --> 68 - INTERIOR EQUIPMENT . � Install selector lever handle --> Selector lever handle, removing and installing.


Selector mechanism, removing and installing

Removing

Component NmSelector Lever Sensor System Control Module J587 with Tiptronic Switch F189 to selector lever housing

1.2



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Fig. 34: Removing Rear Cross Member Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove rear crossmember - arrows -.

Fig. 35: Removing Front Transverse Beam Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove front crossmember - arrows -.

Fig. 36: Vehicle Floor Cover Left And Right Courtesy of VOLKSWAGEN UNITED STATES, INC.



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� Remove left and right vehicle floor cover - 1 -.

Fig. 37: Loosening Clamping Sleeves Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Loosen clamping sleeves - 1 - and - 2 -.

Fig. 38: Removing/Installing Mounting Bolts For Front Exhaust Pipes Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolts - 1 - and - 2 - at front exhaust pipe rear bracket.

NOTE:� Flex joint in front exhaust pipe must not be bent more than 10 ° , otherwise

it may be damaged.

NOTE:� Disregard - 3 - .



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Fig. 39: Left And Right Exhaust System Pipes Tied Up To Body Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Tie left and right exhaust system pipes up to body - arrows -.

Fig. 40: Heat Shield Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove heat shield - arrow -.



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Fig. 41: Identifying Quick-Release Fasteners & Noise Insulation Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Loosen quick-release connectors - 2 - and remove rear noise insulation.

Fig. 42: Removing Support Bracket For Selector Lever Cable Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Mark installation position of support bracket for selector lever cable.



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� Remove bolt - 1 - support bracket for selector lever cable. � Press selector lever cable ball joint - 2 - off from selector shaft lever.

Fig. 43: Disconnecting Selector Mechanism Electrical Connectors And Removing Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove front and rear center consoles --> 68 - INTERIOR EQUIPMENT . � Disconnect electrical connectors - 2 - and - 4 -. � Remove screws - 1 - , - 3 - , - 5 - and - 6 -.

� Press retaining clamps - arrows - inward and lower selector mechanism downward.

Installing


� Install selector lever bracket according to marking on console.

� Adjust selector lever cable --> Selector lever cable, adjusting. � Install exhaust system and align free of tension --> 26 - EXHAUST SYSTEM, EMISSION

CONTROLS . � Install rear crossmember --> 40 - FRONT SUSPENSION .

NOTE:� Do not bend or kink the selector lever cable.

NOTE:� A second technician is required when detaching shift mechanism below

vehicle.

NOTE:� Lightly grease ball socket of selector lever cable with polycarbamide

grease G 052 142 A2 before installing. � Do not bend or kink the selector lever cable.



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� Install front crossmember --> 50 - BODY - FRONT . � Install front and rear center consoles --> 68 - INTERIOR EQUIPMENT . � Check shift mechanism --> Selector mechanism, checking.


Transmission Park Selector Switch F305 , removing and installing

Transmission Park Selector Switch F305 consists of two micro switches. The two micro switches create the signal that the electronic ignition key removal lock needs to release the key only in selector lever position P.

The first switch is closed when the Shift Lock Solenoid N110 is not active in selector lever position "P" (with brake pedal not depressed) and also selector lever manual release below ashtray is not actuated.

The second switch is closed when the button on selector lever handle is not actuated in selector lever position "P".

Following points must be observed before replacing Transmission Park Selector Switch F305 :

1. Both switches are switched electrically in sequence, that is, both switches must be closed for ignition key to be removed. Switches can be checked using Vehicle Diagnosing, Testing and Information System VAS 5051 in Guided Fault Finding. After performing tests on vehicle system, you must select test program F305 - Gear selector position P switch via function/component selection (drive/multitronic 01J front wheel drive/01-On Board Diagnostic (OBD) capable systems/02 - Transmission Electronics/Electrical components).

2. And electrical test on the switch is also possible. If a continuity test is performed with a multimeter, note that in this case, there is a resistance value of approx. 470 Ohm when both switches are closed.

Removing

� Remove selector mechanism --> Selector mechanism, removing and installing

Component NmShift mechanism to body 10



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Fig. 44: Selector Lever Sensor System Control Module J587 With Tiptronic Switch F189 And Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove screws - arrows - and remove Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189.


� Disconnect connector - D - and remove from Shift Lock Solenoid N110. � Disconnect connector - E - and remove upward. � Press tab - C - in direction - arrow 1 -. � Remove micro switch - B - in direction - arrow 2 -.

� Disengage electrical line at selector mechanism - arrow A -.



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Fig. 46: Removing/Installing Selector Rod And Shift Selector Lever Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Unclip covers - A - on both sides of selector mechanism. � Press parking lock button - C - down and hold. � Remove selector rod - B - upward and shift selector lever in direction of - arrow - until it engages in

selector lever position "S".

Fig. 47: Removing/Installing Transmission Park Selector Switch F305 Courtesy of VOLKSWAGEN UNITED STATES, INC.



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� Press retaining screws - A - with a screwdriver through rear clip opening forward in direction - arrow -.

� Remove micro switch - B - forward. � Disengage electrical wiring from tab - arrow C - and remove micro switch from shift mechanism.

Fig. 48: Removing/Installing Transmission Park Selector Switch F305 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installing


� Guide micro switch on longer electrical line into opening under parking lock button in selector mechanism.

� Insert micro switch - B - in shift gate.

� Engage electrical line in tab - arrow C -. � Press retaining screws - A - with a screwdriver opposite direction of - arrow - to stop.

NOTE:� Retaining screws - A - must not be removed. They must only be pressed

forward far enough so micro switch - B - can be removed.

NOTE:� Micro switch must lie flush on all sides.

NOTE:� Retaining screws - A - secure micro switch - B - in shift gate. � Ignition key removal lock does not function correctly if micro switch is not



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� Secure electrical line - arrow A - at selector mechanism according to illustration. � Install micro switch - B -.

� Position connector - D - on Shift Lock Solenoid N110. � Engage connector - E - from above.

inserted correctly or properly secured.

NOTE:� Ignition key removal lock does not function correctly if micro switch is not

inserted correctly or properly secured.



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Fig. 50: Removing/Installing Selector Rod And Shift Selector Lever Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Clip in covers - A - on both sides of selector mechanism. � Install Selector Lever Sensor System Control Module J587 with Tiptronic Switch F189 --> Selector

Lever Sensor System Control Module J587 with Tiptronic Switch F189 , removing and installing � Install selector mechanism --> Selector mechanism, removing and installing

Selector lever cable, assembly overview



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Fig. 51: Selector Lever Cable, Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - 9 Nm

2 - Selector shaft lever

� With mass damper

3 - 23 Nm

4 - Lock nut, 13 Nm





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6 - Selector lever cable locking screw, 13 Nm



8 - Retaining clip


9 - Selector lever cable rubber boot

� Check whether selector lever cable rubber boot on lower shift mechanism cover is engaged correctly and properly sealed

10 - 23 Nm

11 - Selector lever cable console

12 - Bracket for selector lever cable

Selector lever cable, removing and installing

Removing




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Fig. 52: Removing Rear Cross Member Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove rear crossmember - arrows -.



Fig. 54: Vehicle Floor Cover Left And Right Courtesy of VOLKSWAGEN UNITED STATES, INC.



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� Remove left and right vehicle floor cover - 1 -.




� Remove screws - 1 - and - 2 - at front exhaust pipe rear bracket.


it may be damaged.




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Fig. 57: Left And Right Exhaust System Pipes Tied Up To Body Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Tie left and right exhaust system pipes up to body - arrows -.

Fig. 58: Heat Shield Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove heat shield - arrow -.



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Fig. 61: Identifying Lock Washers, Noise Insulation, Rubber Sleeve, Bottom Cover For Selector Mechanism And Nuts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Pry out lock washers - 1 -. � Slide noise insulation - 2 - forward. � Remove rubber boots - 3 - from lower selector mechanism cover - 4 -. � Remove nuts - 5 -.

� Swing lower selector mechanism cover and noise insulation forward.




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Fig. 62: Identifying Plastic Securing Spring, Pin, Screwdriver And Selector Lever Cable Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove selector lever cable retaining clamp - 1 - on shift mechanism downward. � Pull plastic securing spring - 2 - slightly to front and push pins - 3 - upward with a screwdriver only as far

as necessary.

� Remove selector lever cable - 4 - from shift mechanism.

Installing


Fig. 63: Inserting End Of Selector Lever Cable Into Joint Of Selector Lever Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:� Make sure that pin is not pushed fully out.

NOTE:� Do not bend or kink the selector lever cable. � Lightly grease ball socket of selector lever cable with polycarbamide

grease G 052 142 A2 before installing.



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� Slide selector lever cable into selector mechanism and secure with retaining clamp - 1 -.

� Installation position: Angled end of retaining clamp points toward rear.

� Insert end of selector lever cable - 4 - into selector lever joint. � Press pin - 3 - downward - arrow -. � Check whether plastic securing spring - 2 - has locked the pin. � Install selector lever cable bracket on new selector lever cable.


� Adjust selector lever cable --> Selector lever cable, adjusting. � Install exhaust system and align free of tension --> 26 - EXHAUST SYSTEM, EMISSION

CONTROLS . � Install rear crossmember --> 40 - FRONT SUSPENSION .

� Install front crossmember --> 50 - BODY - FRONT . � Check shift mechanism --> Selector mechanism, checking.

Torque specifications

Selector lever cable, adjusting


Fig. 64: Socket And Key T40031 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Component NmBracket to console 23Lower selector mechanism cover to selector mechanism 10Selector lever cable lock nut 13



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� Socket and key T40031

Work procedure



Fig. 66: Shifting Selector Lever To Position "S" Courtesy of VOLKSWAGEN UNITED STATES, INC.


NOTE:� Clamping screw is only accessible in selector lever position "S".



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� Loosen selector lever cable locking screw approximately 1 turn with a long hex socket head 5 mm.


� Press selector shaft lever forward on transmission with end of selector lever cable - 2 - to stop (position "S" on transmission).

� Carefully move selector lever lightly toward front and rear without shifting into another selector lever position, this releases the tension on selector lever cable.

� Check exact setting of selector lever in position "S".

Fig. 68: Shifting Selector Lever To Position "S" Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Tighten selector lever cable locking screw - arrow - in this position.


� Loosen locking screw approx. 1 turn - do not remove completely

NOTE:� When tightening locking screw, selector lever must not be moved forward

or back or adjustment will be incorrect.



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TRANSMISSION, REMOVING AND INSTALLING

Transmission, removing and installing

Fig. 69: Identifying Special Tools - Transmission, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC.


� Hose clamps up to 25 mm dia. 3094

� Transmission support 3282

Component NmSelector lever cable locking screw 13



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� Adjustment plate 3282/30

� Engine/transmission jack V.A.G 1383 A

� Wooden block

Transmission, removing

� Lock carrier and torque support installed.

� Switch ignition off.

Fig. 70: Disconnecting Ground (GND) Strap At Battery Ground (GND) Terminal Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove luggage compartment floor trim.

� Disconnect Ground (GND) lead - arrow - at the battery.

NOTE:� Reinstall cable ties that were loosened or cut off during removal at same

locations during installation.

CAUTION: Observe procedures for disconnecting battery --> 27 - STARTER, GENERATOR, CRUISE CONTROL .

NOTE:� So that the front wheels can still be turned with the battery disconnected,

the battery may only be connected when ignition key is inserted.



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Fig. 71: Removing Rear Engine Cover Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove rear engine cover - arrows -.

Fig. 72: Removing Vacuum Hoses From T-Piece On Bulkhead Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove vacuum hoses - 1 - and - 2 - from T-connector on bulkhead.

Fig. 73: Identifying Holding Plate, Intake Air Hose, Hose & Air Duct Courtesy of VOLKSWAGEN UNITED STATES, INC.



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� Remove air intake hose - 1 - at Mass Air Flow (MAF) Sensor G70. � Remove bolts for holding plate - 3 - for solenoid valves - arrows -. � Disconnect hose - 4 - from air duct - 2 -.

Fig. 74: Removing Bolt And Disconnect Air Duct At Throttle Valve Control Module Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove screw - arrow - and air duct - 2 - from Throttle Valve Control Module J338. � If installed, disconnect hose - 1 - from air duct.

Fig. 75: Removing Coolant Hoses Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Clamp off coolant hose - 2 - with a Hose Clamps Up to 25 mm dia. 3094. � Remove coolant hose at coolant reservoir and seal opening.

� Remove coolant reservoir - arrow - disconnect electrical connector at Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant reservoir.

� Lay aside coolant expansion tank with connected coolant hoses - 1 - and - 3 -.

NOTE:� For sake of illustration, air guide is shown from the rear with engine

removed.



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Fig. 76: Locating Electrical Connectors At Left Of Bulkhead Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove electrical connectors - 1 - and - 3 - at left of bulkhead from bracket and disconnect. � Guide electrical wiring to oxygen sensors downward.

Fig. 77: Removing Nut For Left Exhaust Pipe/Exhaust Manifold Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove nut - 2 - which is accessible from top for left exhaust pipe/exhaust manifold.


NOTE:� Shown from rear with engine removed to provide a better illustration.



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Fig. 78: Locating Electrical Connectors At Right Of Bulkhead Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove electrical connectors - 1 - and - 3 - at right of bulkhead from bracket and disconnect. � Guide electrical wiring to oxygen sensors downward.

Fig. 79: Removing Nut For Right Exhaust Pipe/Exhaust Manifold Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove nut - 2 - which is accessible from top for right exhaust pipe/exhaust manifold.


NOTE:� Shown from rear with engine removed to provide a better illustration.



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Fig. 80: Identifying Engine/Transmission Tightening Sequence Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove screws - 5 - and - 6 - accessible from top at engine/transmission flange.


� Remove both front wheels.



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� Loosen quick-release connectors - 1 - and - 2 - and remove noise insulation.

Fig. 82: Removing Left/Right Heat Shields For Drive Axles Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove left and right drive axle heat shield - 1 -. � Remove left and right drive axles from transmission flange shaft.

Fig. 83: Removing Subframe Transverse Beam Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove crossmember from subframe - arrows -.

NOTE:� Secure brake discs with wheel bolts.



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NOTE:� To stabilize exhaust system, clamping sleeves remain in installation

location and front exhaust pipes remain inserted in clamping sleeves.



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� Remove bolts - 1 - and - 2 - at front exhaust pipe rear bracket.

Fig. 87: Removing Bolt At Left Bracket For Front Exhaust Pipe Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolts - 1 - and - 2 -. � Remove front exhaust pipe left bracket.


it may be damaged.




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Fig. 88: Removing Nut For Left Exhaust Pipe/Exhaust Manifold Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Free up oxygen sensor wiring.

� Remove nuts - 1 - and - 3 - which are accessible from bottom for front exhaust pipe/left exhaust manifold.

� Remove front exhaust pipe with catalytic converter.

Fig. 89: Removing Bolt At Right Bracket For Front Exhaust Pipe Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolts - 1 - and - 2 - � Remove front exhaust pipe right bracket.

NOTE:� For the sake of illustration, shown with engine removed.



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Fig. 90: Removing Nut For Right Exhaust Pipe/Exhaust Manifold Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Free up oxygen sensor wiring.

� Remove nuts - 1 - and - 3 - which are accessible from bottom for front exhaust pipe/right exhaust manifold.

� Remove front exhaust pipe with catalytic converter.

Fig. 91: Disconnecting Electrical Connector On Engine Speed (RPM) Sensor G28 Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Disconnect Engine Speed (RPM) Sensor G28 electrical connector - arrow -.

NOTE:� For the sake of illustration, shown with engine removed.



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Fig. 92: Disengaging Electrical Harness Connector And Disconnecting From Transmission Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Disengage electrical harness connector - 1 - and disconnect from transmission. � Move wiring harness clear - arrows -.

Fig. 93: Removing ATF Line Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove right ATF line bracket at lower part of oil pan - arrow -.

NOTE:� Observe the rules of cleanliness for working on automatic transmissions --

> Rules for cleanliness when working on transmission .



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Fig. 94: Removing Bolt And ATF Lines From Transmission Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolt - arrow - and ATF lines from transmission. � Tie ATF lines clear up to side.

Fig. 95: Placing Plunger Of Engine/Transmission Jack V.A.G 1383 A With Block Of Wood Inserted In Between Transmission At Bottom Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Place plunger of engine/transmission jack V.A.G 1383 A with a block of wood inserted in between - 1 - on transmission at bottom.

� Raise transmission slightly using engine/transmission jack V.A.G 1383 A.

CAUTION: To continue procedure, torque support and lock carrier must be installed.



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Fig. 96: Left Transmission Support, Bolts And Transmission Mounting -- Vehicles With 8-Cyl. Engine Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolts - arrows - and remove tunnel crossmember. � Lower transmission carefully.

Fig. 97: Identifying Transmission Support And Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolts - 2 - and remove transmission support - 1 - from transmission.



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Fig. 98: Transmission Support 3282 Mounted On Engine/Transmission Jack V.A.G 1383 A Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Mount transmission support 3282 on engine/transmission jack V.A.G 1383 A.

� Place adjustment plate 3282/30 on the transmission support 3282 , as shown in the illustration.

� Align arms of transmission support to correspond with holes in the adjustment plate.

� Attach support elements on adjustment plate, as illustrated.

Fig. 99: Moving Engine/Transmission Jack V.A.G 1383 A With Transmission Mount 3282 Under Transmission And Support Transmission Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Guide engine and transmission jack V.A.G 1383 A with transmission support 3282 under transmission.

� Align adjusting plate parallel to transmission and secure support to transmission with bolt M10x20 - arrow -.


NOTE:� Adjusting plate only fits in one position.

NOTE:� The arrow symbol on the adjusting plate points in the direction of travel.



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Fig. 100: Placing Torque Support On Rubber Buffer For Torque Support And Tightening Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Loosen bolts - arrow - on torque support stop. � Press torque support stop upward and retighten bolts to 23 Nm.


� Remove bolts - 1 to 4 - and - 7 to 11 -. � Press transmission off bushings - A - and carefully lower it far enough until selector lever cable is

accessible.

NOTE:� Adjusting torque support stop prevents engine from sinking down after

removing the front transmission.



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� Slowly lower transmission.

� Pay attention to clearance of drive axles when lowering transmission.

Transmission, installing


� Check if alignment sleeves for centering engine/transmission are in the cylinder block, and install if necessary.

� Before installing transmission, tie electrical wiring to one side so that it cannot be trapped between engine


NOTE:� Before installing an exchanged transmission, clean ATF lines and ATF

cooler --> ATF lines and ATF cooler, cleaning and replace ATF auxiliary filter --> ATF additional filter, removing and installing .

� When performing repairs, replace self-locking nuts and bolts. � Always replace bolts that are secured with tightening torque as well as

sealing rings, gaskets and O-rings. � Clean input shaft splines of transmission and damper unit splines on

flywheel, remove corrosion and apply only a very thin coating of lubricant G 000 100 on splines. Excess grease must be removed.

� Secure all hose connections with hose clamps of the same type as those equipped by the factory.

� When installing, bring all cable ties back to original positions.



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and transmission.

� Raise engine far enough until selector lever cable can be installed.


Fig. 103: Moving Engine/Transmission Jack V.A.G 1383 A With Transmission Mount 3282 Under Transmission And Support Transmission Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Carefully raise transmission and bring into installation position using transmission support 3282.

� Attach transmission to engine with new bolts.

� Before inserting the lower set of bolts connecting transmission with engine, lift transmission up slightly at rear.

NOTE:� Do not bend or kink the selector lever cable. � Lightly grease ball socket of selector lever cable with polycarbamide

grease G 052 142 A2 before installing.

NOTE:� The torque specifications apply only to lightly greased, oiled, phosphated,

or black-finished nuts and bolts. � Additional lubricant such as engine or transmission oil may be used, but

do not use graphite lubricant. � Do not use degreased parts. � Tolerance for torque specification ± 15%.



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Torque specification, securing engine/transmission (transmission flange pattern)

*Replace engine/transmission securing bolt.

*Bolt strength rating 10.9

� Install transmission support --> Transmission mounting and transmission support, removing and installing.

Item Screw * See note Nm1, 10, 11 M10x45 45

2 * See note M10x80 653 M12x100 65

4, 8 M12x67 655, 6 M12x75 657 M10x90 459 M10x60 45A Alignment sleeves for centering



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Fig. 105: Left Transmission Support, Bolts And Transmission Mounting -- Vehicles With 8-Cyl. Engine Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Install tunnel crossmember - arrows -. � Install ATF lines with new O-rings --> ATF lines, ATF cooler and auxiliary ATF filter, component

overview, vehicles with 6-cyl. gasoline engine. � Install front exhaust pipe and align exhaust system free of tension --> 26 - EXHAUST SYSTEM,

EMISSION CONTROLS . � Install front crossmember --> 50 - BODY - FRONT .

� Install subframe crossmember --> 40 - FRONT SUSPENSION . � Fasten drive axles to flange shafts --> 40 - FRONT SUSPENSION .

Fig. 106: Placing Torque Support On Rubber Buffer For Torque Support And Tightening Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Loosen torque support bolts - arrows -. � Allow stop for torque support to seat on torque support rubber buffer through its own weight and

retighten bolts.

� Electrical connections and routing.

� Observe procedures for connecting battery --> 27 - STARTER, GENERATOR, CRUISE CONTROL .

� Check adjustment of selector lever cable --> Selector lever cable, adjusting. � Check oil level in front final drive --> Front final drive, checking gear oil level. � Check ATF level and top off --> ATF in planetary gear .


Component NmBolts/nuts M6 9 M8 20 M1040



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Automatic transmission, transporting


Fig. 107: Transmission Lift Hook T40013 Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Attachment and holding rig T40013

Work procedure

Fig. 108: Identifying Transmission Lift Hook T40013 Used To Transporting The Transmission Courtesy of VOLKSWAGEN UNITED STATES, INC.

The transmission lift hook T40013 can be used when transporting the transmission and for aligning transmission support 3282.

M1265Except for the following: Tunnel crossmember to chassis 40Heat shield for drive axle to transmission 23Torque support stop to lock carrier 23



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� Mount and secure transmission lift hook T40013 on upper rib of transmission housing as shown in the illustration.

Transmission, attaching to assembly stand

Fig. 109: Identifying Special Tools -- Transmission, Attaching To Assembly Stand Courtesy of VOLKSWAGEN UNITED STATES, INC.


� Holding plate VW 309

� Holding fixture VW 313

� Transmission support VW 353

� Engine and Transmission Holder VW 540



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� Workshop crane VAS 6100

� Attachment and holding rig T40013

Securing transmission in vertical position

Fig. 110: Securing Transmission To Assembly Stand With Bolts & Installing Transmission Support VW 353 Onto Holding Plate VW 309 Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Secure transmission to assembly stand with bolts - 1 - and - 2 -. � Screw transmission support VW 353 onto holding plate VW 309.

Fig. 111: Using Workshop Crane VAS 6100 To Insert Transmission Into Holding Fixture VW 313 Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Using workshop crane VAS 6100 , insert transmission into holding fixture VW 313.

CAUTION: Center of gravity of transmission is outside center of rotation at holding fixture. To turn the transmission, a second technician must hold the transmission housing to prevent back-swing.



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Fig. 112: Securing Transmission In Horizontal Position Courtesy of VOLKSWAGEN UNITED STATES, INC.

Securing transmission in horizontal position

� Bolt transmission onto engine/transmission holder VW 540 - arrows -. � Using workshop crane VAS 6100 , insert transmission into holding fixture VW 313.

Transmission mounting and transmission support, removing and installing


Fig. 113: Identifying Engine/Transmission Jack V.A.G. 1383 A Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Engine/transmission jack V.A.G 1383 A

� Wooden block

Removing

CAUTION: Center of gravity of transmission is outside center of rotation at holding fixture. To turn the transmission, a second technician must hold the transmission housing to prevent back-swing.



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� Remove front exhaust pipe rear bracket by removing bolts - 1 to 3 -.



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Fig. 116: Placing Plunger Of Engine/Transmission Jack V.A.G 1383 A With Block Of Wood Inserted In Between Transmission At Bottom Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Place plunger of engine/transmission jack V.A.G 1383 A with a block of wood inserted in between - 1 - on transmission at bottom.


Fig. 117: Removing Bolts On Tunnel Cross Member Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove tunnel crossmember bolts - arrows -.



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Fig. 118: Tunnel Cross-Member And Nuts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolts - 1 - and - 2 - and slide tunnel crossmember back slightly. � Remove transmission mounting between transmission and tunnel crossmember.

Fig. 119: Identifying Transmission Support And Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove bolts - 2 - and remove transmission support - 1 - from transmission.

Installing



Component NmTransmission support to transmission 23Transmission mount to transmission support 23Transmission mount to tunnel crossmember 23Tunnel crossmember to chassis 40



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ATF IN PLANETARY GEAR

ATF level, checking and topping off


Fig. 120: VAS 5051 Vehicle Diagnosis, Testing and Information System Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Vehicle Diagnosis, Testing and Information System VAS 5051 with Diagnostic cable VAS 5051/5A

Fig. 121: ATF Filler System F/CVT Transmission VAS 5162 Courtesy of VOLKSWAGEN UNITED STATES, INC.

� ATF Filler System F/CVT Gearbox VAS 5162

� Old oil collecting and extracting device V.A.G 1782

� Safety glasses

Front exhaust pipe bracket to transmission 23Front exhaust pipe to bracket 23

CAUTION: The Continuously Variable Automatic Transmission Multitronic 01J



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Fig. 122: Identifying Illustration On Reservoir For ATF Filler System F/CVT Transmission VAS5162 Courtesy of VOLKSWAGEN UNITED STATES, INC.

Test conditions

� Transmission not in emergency operating mode.

� Move vehicle onto a lifting platform or over a work pit so that it stands absolutely horizontal.

� Engine idling.

� Air conditioner and heating must be switched off.

requires a different ATF than shift automatics. Only ATF for CVT transmission which can be obtained as replacement part must be used in the planetary gear. ATF specifications --> Capacities .

NOTE:� The illustration on the reservoir for ATF Filler System F/Cvt Gearbox VAS

5162 in upper left graphic refers to the use of special ATF for CVT transmissions.

� The illustration also shows pictures of the steps required to fill the transmission. These steps will be explained in the following.

CAUTION:� Engine must not be started if only a small amount or no ATF is in the

transmission after repair work or after significant ATF loss. � In this case, a preliminary filling with 4.5 to 5 liters ATF must be

performed.



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Fig. 123: Connecting Data Link Connector (DLC) Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Vehicle Diagnostic, Testing and Information System VAS 5051 connected, Vehicle Self-Diagnosis and vehicle system "02 - Transmission electronics" selected.

� ATF temperature must not be higher than 30 ° C at start of test, allow transmission to cool down if necessary.

Checking ATF temperature

Display on VAS 5051 :

NOTE:� The ATF level will vary according to the temperature of the ATF. � Checking ATF level at too low ATF temperature leads to overfilling. � If the ATF level is checked when the ATF temperature is too high, this will

result in underfilling. � Over and underfilling lead to impaired functioning of transmission. � ATF temperature is read off on the Vehicle Diagnosis, Testing and

Information System VAS 5051.



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Fig. 124: Diagnostic System VAS 5051: Display Courtesy of VOLKSWAGEN UNITED STATES, INC.

� In selection - 1 - , click on the diagnostic function "08 - Read measuring value block".

Fig. 125: Diagnostic System VAS 5051: Display Courtesy of VOLKSWAGEN UNITED STATES, INC.


1 - Enter display group, max. input value = 255

� In button field - 2 - , enter "10" for "Display group 10" and confirm input by pressing Q button.




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Fig. 126: Diagnostic System VAS 5051: Display - Display Fields Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Read off ATF temperature indicated in display field - 3 -.

Checking ATF level and topping off

� Fill ATF Filler System F/Cvt Gearbox VAS 5162 with ATF for CVT transmissions.

� ATF specification --> Capacities.

NOTE:� Engine keeps running at idle speed. � The ATF level is checked at the ATF inspection plug. � ATF level is correct if a little bit of fluid still escapes at the ATF check plug

between 35 ° and 45 ° C (50 ° C for hot countries) ATF temperature (dependent on the fluid level when warming up).

CAUTION: The ATF filler tool must be clean and the ATF must not be mixed with any other ATF oils!



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Fig. 127: Securing Filled Reservoir Of ATF Filler System F/CVT Transmission VAS 5162 As High As Possible On Vehicle Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Secure filled reservoir of ATF Filler System F/Cvt Gearbox VAS 5162 as high as possible on the vehicle.

� While brake pedal is depressed, shift through all selector lever positions ( "P" , "R" , "N" , "D" , "S" ) let each position remain shifted at idle for approx. 2 seconds.

NOTE:� The shut-off valve on the ATF Filler System F/Cvt Gearbox VAS 5162 must

be closed.



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� Loosen quick-release connectors - 2 - and remove rear noise insulation. � Place old oil collecting and extracting device V.A.G 1782 beneath transmission.

CAUTION: Wear eye protection.



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Fig. 129: Identifying ATF Check Plug Courtesy of VOLKSWAGEN UNITED STATES, INC.

� If an ATF temperature of 35 ° C is reached, remove ATF check plug - B -.

If ATF continues to flow out of the ATF filler plug hole over the overflow tube before the ATF reaches 40 ° C, the ATF level is OK.

� Replace and tighten ATF check plug.

� Tightening torque: 20 Nm.

The ATF check is now completed.

� Press

Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Thread connection on shut-off valve of ATF Filler System F/Cvt Gearbox VAS 5162 into opening of ATF check plug - B -.

Fig. 131: Securing Filled Reservoir Of ATF Filler System F/CVT Gearbox VAS 5162 As High As Possible On Vehicle Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Rotate shut-off valve in direction of filler hose - lower arrow -. ATF flows into transmission. � Hold a suitable container beneath outlet of ATF Filler System F/Cvt Gearbox VAS 5162.



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Fig. 132: Checking ATF Level By Rotating Shut-Off Valve In Direction Of Outlet Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Check ATF level by rotating shut-off valve in direction of outlet - lower arrow -.

ATF level is correct when ATF drips out only lightly from outlet before 45 ° C is reached.

� If no additional ATF flows out, rotate shut-off valve back in direction of filler hose and fill with more ATF; repeat check of ATF level.

� After reaching correct ATF level, remove shut-off valve again.

� Replace and tighten ATF check plug.

� Tightening torque: 20 Nm.

NOTE:� Approx. 5 cl of ATF will initially drain from the internal oil level tube. This

is normal.

NOTE:� After removing shut- off valve, ATF drip

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