Cutie DSG 1 Service Manual

Service
Workshop Manual
CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ ,
Golf Plus 2005 ➤ , Passat 2006 ➤ ,
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
32 - Torque converter
37 - Controls, housing
38 - Gears, control
39 - Final drive - differential
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Technical information should always be available to the foremen and mechanics, because their
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All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg K0258992320

CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Passat 200 ...
6-speed automatic gearbox 09G - Edition 07.2012
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V. o.lk.s.w.a. . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1.9 Gaskets, seals and oil . . . . . . . . . . . . . .lk.sw. a. g.e.n . . . . . . . . . . . G . .do. e.s.no. . . . . . . . . . . . . . . . . 3
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1.10 Nuts and bolts . . . . . . . . . . . . . . . e.d.by. . . . . . . . . . . . . . . . . . . . . . . . . .gu. a.ra. . . . . . . . . . . . . 3
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1.11 Electrical components . . . . . . .tho. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t.ee. o. . . . . . . . . .
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1.12 Guided fault finding, vehicle self-diagnosis
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2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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2.1 Planetary gearbox and final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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3 Code - engine allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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3.1 Gearbox codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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4 Golf 2004 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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5 Golf Plus 2005 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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6 Golf 2009 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7 Touran 2003 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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8 Passat 2006 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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9 Passat CC 2009 ►, CC 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
32 - Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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1 Proper handling and installation of torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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1.1 Identification of torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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1.2 Draining torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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1.3 Removing and installing torque converter oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . do

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1.4 Installing torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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37 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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1 Connecting »tester« . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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1.1 Connecting vehicle diagnosis, testing and information system VAS 5051 . . . . . . . . . . . . 16
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2 Electrical and electronic components and their locations . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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
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7.1 Overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.2 Removing and installing selector mechanism with selector housing . . . . . . . . . . . . . . . . . . 46
7.3 Removing and installing selector mechanism without selector housing . . . . . . . . . . . . . . . . 48
8 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.1 Selector lever in “P” position and ignition switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.2 Selector lever in “N” position and ignition switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.3 Selector lever in position “Tiptronic” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.4 Ignition and light switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.5 Selector lever position display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9 Removing and installing gearbox, Golf 2004 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.1 Removing gearbox, Golf 2004 with 1.6 l - 75 kW, 1.6 l - 85 kW (FSI) and 2.0 l - 110 kW (FSI)
engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.2 Installing gearbox, Golf 2004 with 1.6 l - 75 kW, 1.6 l - 85 kW (FSI) and 2.0 l - 110 kW (FSI)
engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.3 Removing gearbox, Golf 2004 with 2.5 l - 110 kW and 125 kW engines . . . . . . . . . . . . . . 57
9.4 Installing gearbox, Golf 2004 with 2.5 l - 110 kW and 125 engines . . . . . . . . . . . . . . . . . . 65
9.5 Torque settings, gearbox to engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
10 Removing and installing gearbox, Golf Plus 2005 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
10.1 Removing gearbox, Golf Plus 2005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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10.2 Installing gearbox, Golf Plus 2005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
11 Removing and installing gearbox, Touran 2003 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
11.1 Removing gearbox, Touran 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
11.2 Installing gearbox, Touran 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
12 Removing and installing gearbox, Passat 2003 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
12.1 Removing gearbox, Passat with 1.6 l - 85 kW and 2.0 l - 110 kW engines . . . . . . . . . . . . 89
12.2 Installing gearbox, Passat with 1.6 l - 85 kW and 2.0 l - 110 kW engines . . . . . . . . . . . . . . 95
12.4 Removing gearbox, Passat with 1.8 l - 118 kW and 2.0 l - 147 kW engines . . . . . . . . . . . .
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12.6 Torque settings,
ed by gearbox to engine . . . . . . .gu. a.ra. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
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ss gearbox, Passat CC 2009, CC 2010 with 2.0c l 147 kW TFSI engine . . . . . . . . 106
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13.2 Installing gearbox, Passat CC 2009, CC 2010 with 2.0 l 147 kW TFSI engine . . . . . . . . . . 114
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14 Removing and installing gearbox, Golf 2009 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

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14.1 Removing gearbox, Golf 2009 with 2.5 l - 125 kW engine . . . . . . . . . . . . . . . . . . . . . . . . . . 117
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14.2 Installing gearbox, Golf 2009 with 2.5 l - 125 kW engine . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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14.3 Torque settings, Golf 2009 with 2.5 l - 125 kW engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
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15 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

16 ATF cooler for 1.6 l - 85 kW and 2.0 l - 110 kW engines . . . . . . . . . . . . . . . . . . . . . . . . . . 129
16.1 Assembly overview - ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
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17 ATF lines, ATF water cooler and additional ATF cooler, Passat with 2.0 l TFSI engine . . 130
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17.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

18 Checking ATF level and topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
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18.1 Checking ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

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18.2 Topping up ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

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18.3 Draining and filling ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

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38 - Gears, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

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1 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

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2 Removing and installing ATF pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
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2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
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2.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

3 Removing and installing ATF strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4 Removing and installing valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.1 Overview - valve chest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.2 Removing valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.3 Installing valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
4.4 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5 Removing and installing wiring harness for solenoid valves and senders . . . . . . . . . . . . . . 156
5.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
6 Removing and installing gearbox input speed sender G182 . . . . . . . . . . . . . . . . . . . . . . . . 157
6.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
6.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7 Removing and installing gearbox output speed sender G195 . . . . . . . . . . . . . . . . . . . . . . 158
7.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
7.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1 Renewing oil seals for flange shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.2 Renewing seal for right flange shaft . . . . .V.ol.ks.w.a.g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
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Contents iii
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iv Contents
00 – Technical data
1 General repair notes
(VRL004969; Edition 07.2012)
Edition 07.2012 version 12.0
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. AG. Volkswagen AG d
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A number of generally valid instructions applicable for the various
by Vol not
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repair procedures - which were formerly repeated a numberrise
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times at numerous places in the workshop manual - uaretho summar‐ eo
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ised here. They apply to this workshop manual. ss a c
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1.1 Gearbox
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The “automatic gearbox 09G” has six hydraulically actuated for‐
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ward gears. When the torque converter lock-up clutch closes,
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2nd, 3rd, 4th, 5th and 6th gears become mechanically driven
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gears by eliminating torque converter slip.
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1.2 Torque converter
t to the co
The torque converter is equipped with a lock-up clutch. The lock-
up clutch locks up depending on load and speed. The 2nd, 3rd,
rrectness of i
4th, 5th and 6th gears can be driven mechanically (without slip).
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1.3 ATF
Use only ATF which has been ordered as a part from the ⇒ Elec‐
nf
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o
tronic parts catalogue “ETKA” .
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The ATF levels in the planetary gearbox and final drive are
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checked and topped up together.

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1.4 Automatic gearbox control unit -J217-
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with ⇒ fuzzy logic
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Advantages: Prote AG.
• Gear changes will be fuel-consumption orientated.

• Maximum engine output is always available.
• Individual adaptation of gear change points in all driving sit‐
uations.
• Gear change points are infinitely variable.
1.5 Control units in vehicle

The installation locations of all vehicle control units and other
useful information can also be found here ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations.
1.6 Information on “09G gearbox”

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

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.
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1.8 Gearbox
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♦ If gearbox covers have been unbolted or gearbox has no fluid,
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do not run engine or tow vehicle.
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♦ First thoroughly clean connecting points and surrounding
h re
hole
areas and then loosen bolts.
spec
es, in part or in w
♦ When installing the gearbox, ensure that dowel sleeves be‐
t to the co
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 rrectness of i
cloths only!
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♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing.
nf
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♦ If repair work cannot be performed immediately, carefully cov‐

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er or seal components.
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♦ With gearbox removed, secure torque converter against falling

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Gearboxes with and without filler pipe

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2 Rep. gr.00 - Technical data

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CC 2010 d by V➤ , Golf 2004 ➤ , Golf 2009 ➤
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ran
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tee 09G - Edition 07.2012
ut or
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This »old« filler opening with the red cap is not needed because
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ATF can be drained or filled as required through the bottom hole.
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The »height« of this tube determines the level of the ATF.
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The tube must be removed to drain the fluid.
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♦ After installation, check the ATF level and top up
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⇒ page 135 .
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♦ Capacities ⇒ page 5 .
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1.9 Gaskets, seals and oil
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♦ Always renew O-ring, seals and gaskets.
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♦ Before installing a radial oil seal, coat sealing lips and area
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between them with sealing grease -G 052 128- .

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♦ Open side of oil seal faces oil.

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♦ After installing, check ATF level.
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Be careful when working with oil. Dispose of drained oil ac‐
AG.
cording to regulations. Remember: one drop of oil will contam‐

inate 1,000 litres of water.
1.10 Nuts and bolts

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

1.11 Electrical components

You have probably at some time received an electrical shock
when touching a metal object. This is due to the electrostatic
charge of the human body. This charge can disturb the function
of electrical components of the gearbox and of the selector mech‐
anism.
– Before beginning work on electrical components, touch an
earthed object, for example a water pipe or lifting platform. Do
not touch connectors or »open« electronic components direct‐
ly.
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1.12 Guided fault finding, vehicle self-diag‐ ss aut ra
c
nosis and test instruments
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Before making repairs to the gearbox, determine the cause of the
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fault as precisely as possible with the aid of “guided fault finding”.
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Guided fault finding is carried out using the vehicle diagno‐
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sis, testing and information system -VAS 5051B- ⇒ page 16 .
hole
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The guided functions will guide you to the ATF temperature
es, in part or in w
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in the shortest way possible ⇒ page 16 .
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2 Capacities
2.1 Planetary gearbox and final drive

Capacities “6-speed automatic gearbox 09G”
Initial filling approx. 7.0 l
Change approx. 3.0 l
Lubricant ATF is available as a part. Therefore, the part number
for it can be found in the ⇒ Electronic parts catalogue
“ETKA”.
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2. Capacities 5
3 Code - engine allocation

Codes for Golf 2004 ► ⇒ page 7
Codes for Golf 2009 ► ⇒ page 9
Codes for Golf Plus 2005 ► ⇒ page 8
Codes for Touran 2003 ► ⇒ page 10
Codes for Passat 2006 ► ⇒ page 11
Codes for Passat CC 2009 ►, CC 2010 ► ⇒ page 12
3.1 Gearbox codes

Code letters -arrow-
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Code letters -arrow 1-
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“Automatic gearbox 09G” -arrow 2-

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Example:
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GGZ 08 05 02
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Identification Day Month Year -2002-

code of manufacture
rrectne
The gearbox code also appears on the vehicle identification

plates.
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If Genuine parts are required for a repair, alwaysss refer to the
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gearbox code.
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“Automatic gearbox 09G”
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Identification GJY »GJX« »FUF« »HFU« »KBV«
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code »GSY« »HFR« »GJZ« »HRM« KGL
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»HFS« »HTM« »HFT« »JUJ«
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»JTY« »KGH« »JUH«
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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)
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4. Golf 2004 ► 7
5 Golf Plus 2005 ►

If Genuine parts are required for a repair, always refer to the
gearbox code.
Identification code »HFS« »HLP« »HFX«
»HTN« »JTV« »HTQ«
»JTY« KGN »JTW«
»KGJ«
Engine 1.6 l - 75 kW 1.6 l - 85 kW (FSI) 2.0 l - 110 kW (FSI)
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6 Golf 2009 ►
gearbox code.
Identification KGL, MAN
code
Engine 2.5 l - 125 kW
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6. Golf 2009 ► 9
7 Touran 2003 ►
gearbox code.
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)
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8 Passat 2006 ►
gearbox code.
Identification code »HXK« »HFT« »JYY« »HHP«
»JUB« »HVW« KGV »HRN«
KGS »HXJ« »JUD«
»JUC« JZV
KGT KGU
Engine 1.6 l - 85 kW (FSI) 2.0 l - 110 kW (FSI) 1.8 l - 118 kW (TFSI) 2.0 l - 147 kW (FSI)
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8. Passat 2006 ► 11
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CC 2010 ➤ , Golf olk2004
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sed b gearbox 09G - Edition 07.2012 ua
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9 Passat CC 2009 ►, CC 2010 ►
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gearbox code.
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Identification code »JZV« »KGU«
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Engine 2.0 l - 147 kW (FSI)
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32 – Torque converter
1 Proper handling and installation of
torque converter
– Always secure torque converter.
An unsecured torque converter may slide out when the gearbox
is tipped.
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Therefore, always work with care.

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1.1 Identification of torque converter

There are various torque converters. They are identified by codes.
nform
ercia
Torque converter/gearbox allocation ⇒ Replacement parts cata‐

m
at
logue ⇒ ETKA
om
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1.2 Draining torque converter

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Special tools and workshop equipment required

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agen
Prote AG.
♦ -V.A.G 1358 A- Oil extraction unit
♦ -V.A.G 1358 A/1- Oil extraction probe

– Extract ATF from torque converter using -V.A.G 1358 A- and
probe -V.A.G 1358 A/1- . AG. Volkswagen AG d
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1.3 Removing and installing torqueedconvert‐
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♦ Thrust piece -T10175-

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♦ extractor lever -VW 681-

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14 Rep. gr.32 - Torque converter

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

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– Carefully push on torque converter hub via oil seal to first stop.
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– Turn torque converter towards gearbox using light pressure

es, in part or in w
t to the co
until notch in hub -arrow- engages in follower of pump gear

and torque converter can be felt to slip in place.
The torque converter is properly inserted when it can easily be
rrectness of i
turned by hand and is seated equally deep in gearbox around the

entire circumference.
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Caution
nf
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orm
m
atio
If engine and gearbox are brought together with force because

om
n in
the torque converter is improperly fitted, both gearbox and tor‐

or c
que converter will be damaged.

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1. Proper handling and installation of torque converter 15

A n AG d G. Volkswage
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CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf PlusVo2005
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37 – Controls, housing
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1 Connecting »tester«
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Volkswagen offers various devices such as
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♦ Vehicle diagnosis, testing and information system -VAS 5051-
es, in part or in w
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♦ Vehicle diagnosis, testing and information system -VAS
5051B-
rrectness of i
♦ Tester -VAS 5051/11A- l purpos
♦ Vehicle diagnosis and service information system -VAS 5052-

♦ Diagnostic system -VAS 5053-
nform
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The operation of these »devices« is described in the respective

m
user's manuals.
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The following description refers to the vehicle diagnosis, testing
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and information system -VAS 5051- ⇒ page 16 .
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1.1 Connecting vehicle diagnosis, testing
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♦ Vehicle diagnosis, testing and information system -VAS 5051- Prote AG.
WARNING
♦ During a road test, always secure testing and measuring

equipment on the back seat.
♦ These devices may be operated only by a passenger dur‐
ing a road test.
– Push connector of diagnosis cable -VAS 5051/1- -2- or -

VAS 5051/3- onto diagnosis connection.
16 Rep. gr.37 - Controls, housing

– Switch on »tester« -arrow-.

The »tester« is ready for use when it is possible to choose be‐
tween the buttons Guided functions and Guided fault
finding on the »right« of the screen.
Depending on equipment and version of the tester, other func‐

tions may be »displayed« such as:
♦ ElsaWin
♦ Testing
♦ Self-diagnosis
The »tester« is now ready for use.
– Switch on ignition.
G. Volkswagen
– Touch a buttonlkson
wagthe
en Ascreen to start the
AG do
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1. Connecting »tester« 17
2 Electrical and electronic components and their locations
1 - Control unit for automatic

gearbox -J217-
❑ The control unit trans‐
mits and receives data
from the ⇒ data bus.
❑ Location and removing
and installing
⇒ page 19
❑ Can be checked using
“guided fault finding” of -
VAS 5051-
AG. Volkswagen AG d
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❑ The control unit trans‐ ise
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❑ Location and removing
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Gr. 23 for the respective
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3 - Multifunction switch -F125-
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❑ Location ⇒ page 19
❑ Can be checked using
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“guided fault finding” of -
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❑ Removing, installing
and adjusting
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⇒ page 23 .
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5 - Wiring harness for sender
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❑ With gearbox oil temperature sender -G93-
❑ Removing and installing ⇒ page 156
6 - Gearbox oil temperature sender -G93-
❑ Can be checked using “guided fault finding” of -VAS 5051-
7 - Wiring harness for solenoid valves
8 - Automatic gearbox hydraulic pressure sender 1 -G193-
❑ Not installed in all gearboxes

9 - Automatic gearbox hydraulic pressure sender 2 -G194-
❑ Not installed in all gearboxes
❑ Location ⇒ page 21 lkswage es n
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by ara
10 - Gearbox input speed sender -G182- rised nte
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❑ Removing and installing ⇒ page au157 ra
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11 - Gearbox output speed sender -G195-
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12 - Selector lever lock solenoid -N110-
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❑ Location: selector lever lock solenoid is located in the selector mechanism.
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13 - Tiptronic switch -F189-
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14 - Terminal 50 voltage supply relay -J682-
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❑ In E box in engine compartment ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
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15 - Diagnostic connection
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16 - Selector lever position display -Y6-
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❑ Removing and installing ⇒ Electrical system; Rep. gr. 90 ; Gauges, instruments; Dash panel insert .
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Automatic gearbox control unit -J217- -arrow-
AG.
Location: Control unit is located in the front left wheel housing.

– Wheel housing liner must be removed for removing and in‐
stalling.
Multifunction switch -F125-

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

Valve body
Location: valve body is bolted to underside of gearbox housing
and covered by pan.
Solenoid valves -N88- and -N89- as well as pressure control
valves -N90- , -N91- , -N92- , -N93- , -N282- and -N283- are se‐
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Wiring harness for sender
rrectne
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♦ With integrated gearbox oil temperature sender -G93-
s
-arrow-
s o
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Location: Wiring harness is attached to valve body in gearbox.
nform
mer
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Wiring harness for solenoid valves
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Location: Wiring harness is attached to valve body in gearbox.

Hydraulic pressure sender 1 -G193- and hydraulic pressure send‐

er 2 -G194-
This sender is not installed in all gearboxes.
Location:
Automatic gearbox hydraulic pressure sender 1 -G193- -1- and
automatic gearbox hydraulic pressure sender 2 -G194- are bolted
into the valve body.
Gearbox input speed sender -G182- and gearbox output speed
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sender -G195-
Location: senders are installed in gearbox housing above valveolkswage es n
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body. db
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Tiptronic switch -F189-
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Location: Tiptronic switch is integrated into selector mechanism.
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In vehicles with a multifunctional steering wheel, the buttons on

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or c
the steering wheel and their cable connections must also be

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checked.
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2. Electrical and electronic components and their locations 21

Diagnostic connection
Location: diagnosis connector -arrow- is located on left below
driver storage compartment.
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Selector lever position display -Y6-
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3 Multifunction switch -F125-

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

– Move selector lever to position “N”.
– Switch off ignition.
– Do not open cooling system.
– In order to remove selector lever cable from gearbox, first re‐
lease cable -1- and then remove it from cable support bracket
-2-.
AG. Volkswagen AG d
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Work with care to avoid bending cable. Do not use pliers, or the
wit
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retaining tabs on the cable support bracket may break off.
h re
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spec
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t to the co
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– Lever cable -1- off lever -3- using an open jaw spanner -2-. n in
or c
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sd
– Pull connector off multifunction switch -F125- .

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3. Multifunction switch F125 23

– Unscrew nut -1-.

– Remove spring ring -2- and lever -3- from selector shaft -4-.
– Carefully bend back hooks of lock washer -2- using a screw‐
cardiagn.com
driver.
– If hooks are broken off, renew lock washer.
– Unscrew nut -1-.
– Unscrew bolt -5-.
– Pull multifunction switch -4-, together with washers -2- and
-3-, off selector shaft -6-.
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3.2 Installing multifunction switch -F125-

ole,
spec

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♦ Torque wrench -V.A.G 1331-

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Install in reverse order of removal. During this step, observe the
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following: py by
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– Place multifunction switch -4- on selector shaft -6-.

– Tighten securing bolts -5- for multifunction switch hand-tight.
– Carefully bend back hooks of lock washer -2-.
– Put washers -2- and -3- on selector shaft -6-.
– Install washer -2- with hooks pointing up.
– Install washer -2- with long, narrow guides in long, narrow re‐
cesses of selector shaft -6-.
– Tighten nut -1- to 7 Nm.
– Secure nut -1- by bending up hooks on lock washer -2-.
– If hooks are broken off, renew lock washer.
– Place lever -3- on selector shaft -4-.
cardiagn.com
– Use lever -3- to shift gearbox to “P” position, i.e. press lever
-3- back (opposite direction of travel) to stop.
– Now use lever -3- to shift gearbox to “N” position. To do this,
push lever -3- two detent positions forwards in direction of
travel.
– Place spring ring -2- and nut -1- on selector shaft -4-.
– Tighten nut -1- to 13 Nm.
Vehicles with 6-cylinder petrol engine
– Install coolant reservoir ⇒ 6-cylinder fuel injection engine,
mechanics; Rep. gr. 19 ; Removing and installing parts of
cooling system . n AG. Volkswagen AG age does
ksw
– With ignition switched off, connect battery
by
Vol earth strap ⇒ Elec‐
not
gu
ara
trical system; Rep. gr. 27 ; Battery;
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ed
nte
necting battery . ut
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Continuation for all vehicles
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– Check selector mechanism ⇒ page 33 .

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3.3 Adjusting multifunction switch -F125-

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♦ Setting gauge -T10173-

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– Move selector lever to position “N”.

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– Do not kink selector lever cable.
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Prote AG.
3. Multifunction switch F125
3.3.1 Adjustment prerequisites

• Selector lever cable is disconnected from selector shaft lever.
• Selector shaft is set to “N” position.
• Securing bolts for multifunction switch -F125- have been loos‐
ened.
• Selector shaft lever has been removed.
– Place setting gauge on selector shaft -2- and turn multifunction
switch -1- until setting gauge engages in lug on multifunction
switch connector.
– Secure setting gauge on selector shaft -2- with bolt -3-.
– Tighten bolts -arrows- to 6 Nm.
– Remove setting gauge.
– Continue installation in reverse order of removal ⇒ page 24 .
cardiagn.com
AG. Volkswagen AG d
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4 Emergency release of selector lever

Do not remove knob.
– Depress brake pedal or set handbrake.
In an emergency:
– Unclip selector cover and hold to side.
Vehicles up to 02.2009
– Press yellow plastic wedge from right to left.
Lever can now be moved from position »P«.
cardiagn.com
Vehicles from 03.2009 onwards
– Press yellow plastic wedge.
Lever can now be moved from position »P«.
AG. Volkswagen AG d
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4. Emergency release of selector lever
5 Removing and installing selector lev‐

er handle
Brief description
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Depending on the model, different handles may be
yV
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Handle is removed together with selector cover.
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Removing: ss
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– Shift selector lever to position “D”. du
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Handle with pushbutton on side:
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– First pull button far enough out of knob that a small gap is
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visible between knob and button. Button locks when released.
h re
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spec
– Hold button in this position with a cable tie or wire to prevent
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it from being pressed in.
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nform
mercia
Handle with front pushbutton:
at
om
ion
c
Button does not need to be pulled out by hand. The pushbutton
in t
or
his
e
engages in installation position -arrow- when the handle is pulled

at
do
riv
off.
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Further procedure for all handles:

– Unclip cover.
– Pull connector from selector cover.
– Push sleeve upwards to release knob.

Only handle with clip:

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

possible to install the handle.
Installing
– Install in reverse order of removal, observing the following:
• Selector lever is in position “D”.
Handle with pushbutton on side:
cardiagn.com
• Button in handle is pulled out and secured against being
pressed in.
Handle with front pushbutton:

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• Pushbutton is in installation position
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agen -arrow-.
AG does
not
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If the pushbutton was pressed
ised by mistake, the installation position
b ara
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can be restored. hor eo
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– Move pushbuttons to installation position ⇒ page 30 .
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5. Removing and installing selector lever handle
Note
New handle is supplied with installation guard. Do not remove

guard until just before installing. To remove, pull it out.

– Push handle fully onto selector lever and lock.
– Push sleeve downwards to lock.
Only handle with clip:
– Push on handle with new clip onto stop.
– Secure clip with hose clip pliers -V.A.G 1275- .
– Push pushbutton after installing it.
AG. Volkswagen AG d
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Note rised ara
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If not installed correctly, pushbutton remainss inserted in handle
s c
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after being pressed. If this happens, remove handle again and
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pt
du
move pushbutton to installation position again ⇒ page 30 . The
an
itte
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handle can then be installed again.
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Continue installation in reverse order of removal.
, is n
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hole
spec
5.1 Moving pushbutton to installation posi‐
es, in part or in w
t to the co
tion in the handle
rrectness of i
5.1.1 Handle with pushbutton on side
l purpos
– First pull button far enough out of knob that a small gap is
visible between knob and button. Button locks when released.
nform
ercia
– Hold button in this position with a cable tie or wire to prevent

m
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it from being pressed in. ion

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Prote AG.
5.1.2 Handle with front pushbutton

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

Place handle »with« installation guard in installation position:

When using the installation guard, make sure that it has an eyelet
-arrow- at the front. Other types of installation guard are not suit‐
able.
– Holding the button down, completely push in installation guard

with eyelet -arrow- until the installation guard engages, then
release the button. When the installation guard is pulled out,
the pushbutton engages in the installation position.
Place handle »without« installation guard in installation position:
cardiagn.com
– Carefully unclip trim of handle -A- upwards.
AG. Volkswagen AG d
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5. Removing and installing selector lever handle
AG. Volkswagen AG d
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CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , hGolf
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6-speed automatic gearbox 09G - Edition
s au 07.2012 ra
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– Using a screwdriver, press the small lever -1- for the tie rod
du
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into the groove -2-. When this is done, the pushbutton -3- is
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pressed into the installation position.
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-I- Pushbutton in pressed position
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-II- Pushbutton in installation position
spec
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t to the co
Note
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♦ Only press the lever into the groove and no further.
l purpos
♦ Do not clip the trim of the handle onto the selector mechanism
until the handle has been fitted. This makes it possible to check
whether the small lever engages in the tie rod when the push‐
nform
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button is pressed.
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6 Selector mechanism up to 02.2009

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WARNING d byV ua
ran
ir se tee
tho
or
Before working on vehicle with engine running,
au move selector ac
ss
lever into position “P” and apply handbrake.
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Selector mechanism from 03.2009 onwards ⇒ page 45
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6.1 Overview of selector mechanism up to 02.2009 , is n
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hole
spec
es, in part or in w
1 - Selector cover with knob
t to the co
❑ Do not remove knob
without reason. For
rrectness of i
emergency release, on‐
ly the cover needs to be
l purpos
unclipped ⇒ page 27 .
❑ Before removal of han‐
nform
ercia
dle, pull button out past
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its pressure point. Se‐
m
at
cure button with a cable
om
io
tie or tape. This will pre‐
n
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or
vent the button from be‐
his
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– Always pull out button
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agen
point before installing
knob.
2 - Selector mechanism with

selector lever
❑ Removing and installing
⇒ page 34
3 - Bolt with spring
❑ 3 Nm
4 - Pin
❑ Removing ⇒ page 34
❑ Do not grease
5 - Securing clip
❑ Always renew after re‐
moving
6 - Nut
❑ 9 Nm
❑ Qty. 4
7 - Selector housing
❑ With seal
8 - Selector lever cable
❑ Cable must not be greased
❑ Checking ⇒ page 42
❑ Adjusting ⇒ page 43
6. Selector mechanism up to 02.2009 33

6-speed automatic gearbox 09G - Edition
gen AG
.07.2012
Volkswagen AG
d wa oes
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9 - Hexagon nut with washer ed
b ara
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❑ 8 Nm tho eo
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❑ Qty. 4
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6.2 Removing and installing selector mech‐
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es, in part or in w
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Note
Following installation, cable must be checked for ease of move‐
rrectness of i
ment and be adjusted.
l purpos
– Remove centre console ⇒ Rep. gr. 68 ; Compartments, cov‐

ers and trims .
nform
ercia
– Remove Bowden cable from gearbox ⇒ page 34 .

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com
ti
– Remove exhaust system below heat shield ⇒ Rep. gr. 26 ;
on in
Removing and installing parts of exhaust system .
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– Remove heat shield beneath vehicle.
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– Remove 4 nuts for selector mechanism »from above«.
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Torque setting for nuts: 8 Nm
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– After installing, check cable ⇒ page 42 .
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6.3 Removing and installing selector lever
cable
Note

Removing
– Move selector lever to position “S” position.
-2-.

– 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.
cardiagn.com
– Remove -selector housing- beneath selector lever.
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– Remove securing clip. Always renew securing clip.

-Selector housing- is pushed forwards slightly on cable.
To remove cable, securing tab must be pushed forwards -1-.

– At same time, push -pin- up with a screwdriver -2-.
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– Please insert -screwdriver- from underneath whilst pushing

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securing tab forwards.

rrectness of i
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mercia
a
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ti
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on in
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co lksw
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– Remove selector lever cable.

Remove selector housing from cable.
Installing
Do not grease cable.
– Route selector lever cable free of tension, insert in cable sup‐
port bracket on gearbox but do not yet secure.
– Ensure that selector lever cable is properly routed during in‐
stallation.
– Also clip cable into retainer. Ensure that retainer does not
contact gearbox oil cooler.

-Nuts- 8 Nm
– Put selector housing onto cable.
AG. Volkswagen AG d
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– Insert selector lever cable into selector mechanism. Volksw
oes
not
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– Insert cable into bearing and insert pin from above, down‐
rrectne
wards through eye.
When you have checked freedom of movement of cable
ss
⇒ page 42 , insert securing clip.
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– Attach cable with new securing clip on cable support bracket

of selector mechanism.

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– Install selector housing, heat shield and exhaust system.

o
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– Adjust selector lever cable after installing ⇒ page 42 .

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6.4 Checking selector lever cable

Brief description
To check ease of movement of selector lever cable, it must be
removed from the gearbox and the free end must be placed so
that it does not bump against anything.
Then move selector lever and reinstall the cable.
Then the selector lever cable must be adjusted ⇒ page 43 .
Do not grease the connections of the cable!
Checking
. Volkswagen AG
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– Move selector lever to position
Vol »P« position.
ksw not
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– Loosen bolt -2- of theorBowden
ise cable -1-. nte
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– Lever cable -1- from selector shaft lever -3- using an open jaw
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spanner -2-.
Vehicles up to 02.2009
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– In order to remove selector lever cable from gearbox, first re‐ cted agen
Prote AG.
-2-.
Vehicles from 03.2009 onwards

– Remove securing clip.

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

cardiagn.com
The selector lever cable must always be adjusted whenever
♦ The selector lever cable has been removed
gen AG
. Volfrom
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♦ The engine and/or gearbox
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♦ Parts of the assembly thomounting have been removed and in‐ or
stalled. s au ac
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♦ The cable itself or the selector mechanism has been removed

un
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and installed.
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– Move selector lever to “P” position.

t to the co
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Adjuster screw -2- must be »loosened«.

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

car« in the same direction until the parking lock can be head
to engage.
• The parking lock is engaged when both front wheels cannot
be turned in the same direction at the same time.
– Gently push knob of selector lever forwards and backwards
but under no circumstances must you shift out of “P”.
In this way the inner cable of the Bowden cable finds it optimal
position.
– Tighten adjusting screw -arrow- to 13 Nm.
cardiagn.com
– Tighten bolt -2- to 15 Nm.
This completes the adjustment.
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7 Selector mechanism from 03.2009

onwards
WARNING
Before working onswvehicle

agen
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Volkswagen AG
does move selector
lever into position
by Volk
“P” and apply handbrake. not
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Selector
ss mechanism in vehicles up to 02.2009 ⇒ page 33c
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7.1 Overview - selector mechanism
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1 - Handle with selector cover
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❑ Do not remove knob
hole
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without reason. Only un‐
es, in part or in w
clip cover for emergen‐
t to the co
cy release ⇒ page 27 .
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⇒ page 28
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2 - Centre console cover
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cases. nf
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3 - Selector lever and selector

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❑ Checking ⇒ page 42 Prote AG.
4 - Bolt
❑ 8 Nm
5 - Hexagon flange nut
❑ 8 Nm
❑ Qty. 4
6 - Selector housing
❑ Available only together
with selector mecha‐
nism ⇒ Electronic parts
catalogue (ETKA)
7 - Bracket
❑ For selector lever cable
8 - Selector lever cable
❑ can only be replaced together with selector mechanism ⇒ page 34
9 - Gearbox
10 - Tunnel/bodywork
7. Selector mechanism from 03.2009 onwards 45

7.2 Removing and installing selector mech‐

anism with selector housing
Brief description
Selector mechanism and selector lever cable are not allowed to
be separated from one another. Both are removed together withAG. Volkswagen
the selector housing. lksw
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In the interior, the centre console must be removed.
ris
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The selector mechanism with selector lever cable can be re‐
nl
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moved and installed separately without removing and installing
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Following installation of selector mechanism, selector lever cable
t to the co
must be checked for ease of movement and be adjusted.
Removing
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– Remove selector lever handle ⇒ page 28 .
l purpos
– Remove centre console ⇒ Rep. gr. 68 ; Compartments, cov‐

ers and trims .
nform
ercia
– Separate electrical connector from selector mechanism to ve‐

m
at
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hicle wiring harness.
ion
c
in t
or
– Remove air filter housing ⇒ Rep. gr. 24 ; Removing and in‐
his
ate
stalling air filter .
do
priv
cum
for
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– Lever selector lever cable -1- off selector shaft lever -3- using
t.
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an open-end spanner -2-. C py
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Caution cted agen
Prote AG.
The catches of the selector lever cable break off very easily. If
a locking lug is broken off, the complete selector mechanism
together with selector lever cable must be replaced.
– Carefully push together catches of selector lever cable togeth‐

er -arrows- and remove selector lever cable upwards out of
cable support bracket.
– Do not bend or kink cable.
– Unhook selector lever cable -1- from bracket -arrow-, if

present, on gearbox.
– Raise vehicle.
– To remove cable and/or selector mechanism, parts of exhaust
system must now be removed ⇒ Exhaust system; Rep. gr.
26 .
– Remove heat shield ⇒ Rep. gr. 66 .

Note
To remove selector mechanism, a 2nd mechanic is required un‐

der the vehicle.
AG. Volkswagen AG d
– Remove nuts -arrows- inside vehicle. lksw
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Specified torques ⇒ Item 5 (page 45) rised ara
nte
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– Remove selector mechanism together
s au with selector lever ca‐ ra
c
ble and selector housing downwards.
s
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Installing
an
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Install in reverse order of removal.
ility
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Note
hole
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es, in part or in w
t to the co
♦ Do not bend or kink selector lever cable.
♦ Do not grease selector lever cable.
rrectness of i
cardiagn.com
– Carefully press selector lever cable onto gearbox selector lev‐
l purpos
er and insert in cable support bracket.

– Install parts of ⇒ exhaust system; Rep. gr. 26 .
nform
ercia
– Install heat shield ⇒ Rep. gr. 66 .

m
at
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io
– Install centre console ⇒ Rep. gr. 68 ; Compartments, covers
n
c
in t
r
and trims .
o
his
ate
do
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– Install selector lever handle ⇒ page 28 .

p
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for
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– Adjust selector lever cable ⇒ page 43 .

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– Install air filter housing ⇒ Rep. gr. 24 ; Removing and installing
co lksw
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air filter . Prote AG.

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age, nPassat 200 ...AG does
AG n
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6-speed automatic gearbox 09G - Edition 07.2012d by V gu
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7.3 Removing and installing selector
ss mech‐ au ac
anism without selector housing
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Brief description
erm
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Selector mechanism and selector lever cable are not allowed to
wit
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be separated from one another. Both are removed together.
h re
hole
In the interior, the centre console must be removed.
spec
es, in part or in w
t to the co
A cord must be attached to the Bowden cable before it is removed.
The cord is needed to guide the Bowden cable between the tunnel
and the heat shield.
rrectness of i
The selector mechanism with selector lever cable can also be
removed and installed with the selector housing ⇒ page 46 .
l purpos
nf
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Note
orm
m
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or
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– Remove selector lever knob ⇒ page 28 .
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o
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f
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t.
– Remove centre console ⇒ Rep. gr. 68 .
yi Co
Cop py
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– Separate electrical connector from selector mechanism to ve‐ rig ht
py by
hicle wiring harness.
co Vo
by lksw
cted agen
Prote AG.
– Remove air filter housing ⇒ Rep. gr. 24 ; Removing and in‐
stalling air filter .
– Remove securing clip.

– Securing clips for selector lever cable must always be re‐
newed.
– Remove cable from ball head.
– Then a long cord must be attached to the end of the Bowden
cable. The cord in needed to guide the Bowden cable between
the tunnel and heat shield during installation.
– Remove 4 bolts.

– Carefully pull selector mechanism with Bowden cable out of

the centre tunnel. Ensure that the cord remains accessible
from the engine compartment after being pulled by the Bow‐
den cable.
– Remove cord from Bowden cable.
Installing
Install in reverse order of removal, observing the following:
A second mechanic is needed to guide Bowden cable from pas‐
senger compartment into engine compartment.
Note
♦ Do not bend or kink selector lever cable.

♦ Do not grease selector lever cable.
– Attach Bowden cable to cord which was drawn into the pas‐
senger compartment during removal.
. Volkswagen AG
gen AG does
– Carefully guide selector mechanism with Bowden cable olks
wa
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not
through opening in centre tunnel. byV gu
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– Have the second mechanic pull cord with Bowden
aut
h cable ra
through tunnel from engine compartment until
s Bowden cable
s c
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can be attached to support bracket.
e
nl
pt
du
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– Remove cord from Bowden cable.
y li
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ility
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– Secure selector mechanism to selector housing using 4 bolts.
wit
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Specified torque: 8 Nm
hole
spec
es, in part or in w
– Before you put on ball head: check cable ⇒ page 42 .
t to the co
– Install centre console ⇒ Rep. gr. 68 ; Compartments, covers
and trims .
rrectness of i
– Install selector lever handle ⇒ page 28 .
l purpos
– Adjust selector lever cable after installing ⇒ page 43 .

nform
ercia
– Install air filter housing ⇒ Rep. gr. 24 ; Removing and installing

m
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air filter .
ion
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olkswagen AG
wag en AG. V
CC 2010 ➤ , Golf 2004 ➤ , Golf 2009olks➤ , Golf Plus 2005 ➤ , Passat
does
not 200 ...
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6-speed automatic gearbox 09G
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b ara
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8 Checking selector mechanism
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pt
du
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It must not be possible to start the engine in the selector lever
y li
erm
ab
positions “R”, “D” or “S”.
ility
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wit
On right-hand drive vehicles, the starter must operate only in se‐ , is n
h re
lector lever positions “P” and “N” when the locking button in the
hole
selector lever handle is not pressed.
spec
es, in part or in w
t to the co
Over 5 km/h
When the selector lever is shifted to “N”, the selector lever lock
solenoid must not lock the selector lever. Selector lever can be
rrectness of i
shifted back into a driving range.
l purpos
Under 5 km/h
When the selector lever is shifted to “N”, the selector lever lock
nf
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o
solenoid must lock the selector lever only after ca 1 second. Se‐
rm
m
lector lever cannot be shifted out of “N” position until brake pedal
atio
m
is depressed.
o
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or c
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8.1 Selector lever in “P” position and ignition
te
sd
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switched on
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• Brake pedal is not depressed:
Co
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rig ht
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with the lock button pressed. Solenoid for selector lever lock by c lksw
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blocks selector lever. Prote AG.
• Brake pedal is depressed:

Solenoid for selector lever lock releases selector lever. It is pos‐
sible to shift into a driving gear. Slowly shift selector lever from
“P” through to “S”, checking whether selector lever position in
dash panel insert corresponds to actual selector lever position.
8.2 Selector lever in “N” position and ignition

switched on
• Brake pedal is not depressed:
Selector lever is locked and cannot be shifted out of “N” position
with the lock button pressed. Solenoid for selector lever lock
blocks selector lever.
• Brake pedal is depressed:
Solenoid for selector lever lock releases selector lever. It is pos‐
sible to shift into a driving gear.
8.3 Selector lever in position “Tiptronic”

– Shift selector lever into Tiptronic gate.
The illumination of the “D” symbol in the selector mechanism cov‐
er must go out. “+” and “-” symbols must light up.
Symbols in the dash panel insert must change from “P R N D S”
to “6 5 4 3 2 1”.
8.4 Ignition and light switched on

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

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

9 Removing and installing gearbox,

Golf 2004 ►
Removing gearbox, Golf 2004 with 1.6 l - 75 kW, 1.6 l - 85 kW
(FSI) and 2.0 l - 110 kW (FSI) engines ⇒ page 51
Installing gearbox, Golf 2004 with 1.6 l - 75 kW, 1.6 l - 85 kW (FSI)
and 2.0 l - 110 kW (FSI) engines ⇒ page 57
Removing gearbox, Golf 2004 with 2.5 l - 110 kW and 125 engines
⇒ page 57
Installing gearbox, Golf 2004 with 2.5 l - 110 kW and 125 engines
⇒ page 65
Torque settings, Golf 2004 ▸ ⇒ page 66
9.1 Removing gearbox, Golf 2004 with 1.6 l n AG. Volkswagen A

G do
- 75 kW, 1.6 l - 85 kW (FSI) and 2.0 y Voll -
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110 kW (FSI) engines d b ran
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– Before beginning with removal, »if possible« sprint
sa out a diag‐ ac
nosis log. Before sending back removed gearbox in the usual
ce
cardiagn.com
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nl
pt
manner, secure log to gearbox.
du
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itte
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Brief description
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The gearbox is removed downwards as a unit. The engine re‐
wit
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mains in the vehicle.
h re
hole
spec
Battery carrier, air filter and engine cover are removed »from
es, in part or in w
above«. Engine and gearbox must then be supported so that left
t to the co
assembly mounting can be removed.
Noise insulation is removed and drive shafts are pressed off
rrectness of i
»from below«. Gearbox is lowered using gearbox jack.
l purpos
Note
nf
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orm
The subframe is not to be removed.
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Prote AG.
9. Removing and installing gearbox, Golf 2004 ► 51

Special tools and workshop

equipment required
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Torque wrench -V.A.G
1332-
♦ Gearbox support -3282-
♦ Adjustment plate -3282 /36-
♦ Hose clamps to 25 mm
-3094-
AG. Volkswagen AG d
agen oes
♦ Socket -T10179- Volksw not
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♦ Support bracket -10 - 222 A-
♦ Adapter -10 - 222 A /13-

The following description shows the gearbox with the 2-litre petrol
engine (FSI). Deviations from other engine types in the Golf are
minimal. However, torque settings for bolting gearbox to engine
go into detail »as usual« (large and small engines, FSI and multi-
point injection engines). gen AG
. Volkswagen AG
d wa oes
olks not
– Before beginning with removal, »if possible« dprint
by out a diag‐
V gu
ara
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nosis log. Before sending back removed gearbox
rise in the usual nte
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Removing:
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– Raise vehicle. All 4 supports of lifting platform must be at same
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– Move selector lever to position »P« position.
wit
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– Remove battery and battery carrier ⇒ Rep. gr. 27 ; Discon‐
hole
spec
necting and connecting battery; Removing and installing bat‐
es, in part or in w
tery .
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– Remove engine cover and air cleaner with intake hose.
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retaining tabs on the cable support bracket may break off. Prote AG.

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

remove hoses from the ATF cooler.
– Disconnect electrical connections to gearbox and starter.
– Remove upper starter motor bolt.
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– Set up support bracket -10 - 222 A- and support engine and

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gearbox. Do not raise.

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– Remove upper connecting bolts between engine and gearbox.

es, in part or in w
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Bolts may be installed with a socket -T10179- . When tightening,

however, observe the lower tightening torque ⇒ page 66 .
rrectness of i
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r
– Merely remove the six bracket bolts -A-.

te o
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During installation, first bolt bracket to gearbox with 40 Nm torque.

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When the two bracket bolts are tightened to vehicle, a screwdriver

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– Depress brake pedal to remove bolt for left drive shaft

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

– If heat shield is installed over right drive shaft, remove it from
engine.
– Remove vacuum pump with bracket and lines. »The pump is
located near the ATF filler pipe«.
– Now pull electrical connectors off gearbox.
– Remove starter ⇒ Rep. gr. 27 ; Removing and installing start‐
er .
– Remove ⇒ pendulum support, first -A- and then -B-.
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On installation, first tighten -B-, then -A-. Torque settings ⇒ Rep.
gr. 40 ; Assembly overview - subframe, anti-roll bar, suspensionen AG. Volkswagen AG
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– Unbolt suspension links from suspension struts on both sides.
spec
es, in part or in w
t to the co
Torque settings ⇒ Rep. gr. 40 ; Assembly overview - subframe,
anti-roll bar, suspension links .
– Press both drive shafts out of gearbox. For procedure, refer to
rrectness of i
⇒ Rep. gr. 40 ; Repairing drive shafts; Removing and instal‐
ling drive shafts; Removing drive shafts with triple-roller joint
l purpos
AAR2600i .
– Remove left drive shaft.
nform
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– Raise right shaft as far as possible and secure in this position.

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– Now remove assembly mounting bracket. To do this, lower
un
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engine and gearbox slightly via support bracket -10 - 222 A-
itte
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spindles.
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Four turns are sufficient.
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– If exhaust system retainer is present on gearbox, remove it.
hole
spec
es, in part or in w
– Remove lower connecting bolts between engine and gearbox.
t to the co
– Leave an easily accessible bolt in for safety purposes.
– Start with the two lower bolts.
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Note
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On some smaller engines up to 1.6 litres, one of the lower
r
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– If this bolt must be removed, first remove front exhaust pipe.
Co
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Cop py
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⇒ Rep. gr. 26 ; Removing and installing parts of the exhaust
gh ht
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The hole for removing the torque converter nut is covered with a
rubber cap on the rear of the engine.
– Remove this cap.
– Remove six -torque converter nuts- with insert -V/175- .
Note
Continue turning the engine carefully!
– Before you now remove final connecting bolt, support gearbox

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

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

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

– Keep in mind that if a new gearbox is installed, parts such as

cable support bracket and retainer for gate selector cable must
be transferred.
9.2 Installing gearbox, Golf 2004 with 1.6 l -

75 kW, 1.6 l - 85 kW (FSI) and 2.0 l - 110
kW (FSI) engines
– Check whether dowel sleeves are pressed into engine flange.
– Check seating of plate between engine and gearbox. The plate
must make contact with the engine along its entire perimeter
cardiagn.com
when it is pressed gently with both hands against the engine.
If the top does not contact the engine, it is not properly en‐
gaged in the engine block.
– 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°
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Torque settings, gearbox to engine ⇒ page 66
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The engine and gearbox should be mounted tension-free in the

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erm
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gr. 10 ; Removing and installing engine; Notes on installation .

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– After installing, check ATF level ⇒ page 135 .

t to the co
– Carry out basic settings. To do this:

– Connect vehicle diagnosis, testing and information system -
VAS 5051- and then select “Perform basic settings” under
rrectne
Guided functions .
s
9.3 Removing gearbox, Golf 2004 with 2.5 l

s o
cial p
f i
- 110 kW and 125 kW engines

nform
mer
atio
– Before beginning with removal, »if possible« print out a diag‐

om

n
c
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or

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Brief description
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The gearbox is removed downwards separately. The engine re‐

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♦ Insert -V/175-
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♦ Wedge -T10161-
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♦ Support bracket -10 - 222

A-
♦ Adapter -10 - 222 A /8-
♦ Adapter -10 - 222 A /3-
♦ Hook -10 - 222 A /10-
♦ Shackle -10 - 222 A /12-
♦ Adapter -10 - 222 A /7-
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♦ Hose clamp pliers -V.A.G 1921-

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Removing:
height.


Note
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40 ; Repairing drive shafts; Removing and installing drive
yV
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lks ot g
Removing drive shafts with triple-roller joint AAR2600i
ise
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– Remove air filter with engine cover. ss
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– Pull off hoses -arrows- and remove intake hose from throttle
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valve unit.
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♦ Multifunction switch
♦ Starter motor
♦ Earth strap to bracket
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– Remove wiring retainer -1- from starter bolt -1-.
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To support engine and gearbox:
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– Remove wiring -1- from transportation bracket -3-.

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

– Set up support device -10 - 222 A- .

– Extend right hook -10 - 222 A /10- using adapter -10 - 222 A /
7- .
The hook faces downwards and will later be hooked into the en‐
gine block.
– Remove lower part of left wheel housing liner.
– Remove heat shield above right drive shaft.
AG. Volkswagen AG d
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AAR2600i .
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– Raise right shaft as far as possible and secure in this position. i

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

– Unbolt retainer from lower starter bolt.
– Remove lower starter bolt and remove starter.
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AG. Volkswagen AG d
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– Drain coolant. Volksw
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– Turn cap -1- in direction of arrow and remove.

rrectness of i
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nform
mercia
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tion in
r
te o
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Cop py
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by
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Prote AG.

Note
– Hook adapter -10 - 222 A /7- into engine block.

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

-10 - 222 A- .
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Six turns are sufficient.

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Note

box.

be transferred.
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110 kW and 125 engines
– Check whether dowel
agen
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– Check seating db
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nform
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Guided functions .
cop Vo
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9.5 Torque settings, gearbox to engine

Golf 2004 with 1.6 l - 75 kW and 2.0 l - 110 kW (FSI) engines
⇒ page 66
Golf 2004 with 1.6 l - 85 kW (FSI) engine ⇒ page 67
Golf 2004 with 2.5 l - 110 kW and 125 kW engines ⇒ page 68
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- .
cardiagn.com
- M12 bolts ⇒ M12
❑ 80 Nm
❑ 65 Nm if you use socket
-T10179- .
- M10 bolts ⇒ M10 n AG. Volkswagen AG do
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- Two dowel sleeves in engine
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-arrows-
an
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itte
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es, in part or in w
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mercia
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tion in
– Ensure that retainer does not contact gearbox oil cooler.

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-Nuts- 8 Nm
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9.5.2 Torque settings, Golf 2004 with 1.6 l - 85 kW (FSI) engine
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rrectne
ss
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er
inform
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❑ 60 Nm
atio
m

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- M12 bolts ⇒ M12

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- M10 bolts ⇒ M10
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❑ 40 Nm
AG.
❑ These bolts are located

in lower flange
-arrows-

-Nuts- 8 Nm
9.5.3 Specified torques, Golf 2004 with 2.5 l - 110 kW and 125 kW engines
cardiagn.com
AG. Volkswagen AG d
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-Nuts- 8 Nm
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Golf Plus 2005 ►
Removing gearbox, Golf Plus 2005 with 1.6 l - 75 kW, 1.6 l - 85
kW (FSI) and 2.0 l - 110 kW (FSI) engines ⇒ page 70
Installing gearbox, Golf Plus 2005 with 1.6 l - 75 kW, 1.6 l - 85 kW
(FSI) and 2.0 l - 110 kW (FSI) engines ⇒ page 76
Torque settings, Golf Plus 2005n A▸G⇒
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10.1 Removing
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-3094-
♦ Socket -T10179-
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♦ Insert -V/175-
10. Removing and installing gearbox, Golf Plus 2005 ► 71

♦ Adapter -10 - 222 A /8-
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The following description shows the gearbox with the 2-litre petrol
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engine (FSI). Deviations from other engine types in the Golf are
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spec
es, in part or in w
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Removing:
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height.
nform
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m
– Remove battery and battery carrier ⇒ Rep. gr. 27 ; Discon‐ at

om
io
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Do not set vehicle on the ground ⇒ Rep. gr. 40 ; Repairing drive

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B - Bolt for 1.6 l -75 kW engine
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10.3.2 Torque settings, Golf Plus 2005 with 1.6 l - 85 kW (FSI) engine
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-Nuts- 8 Nm


Touran 2003 ►
Removing gearbox, Touran 2003 with 1.6 l - 85 kW, 2.0 l - 85 kW,
2.0 l - 110 kW and 1.8 l - 110 kW engines ⇒ page 81 .
Installing gearbox, Touran 2003 with 1.6 l - 85 kW, 2.0 l - 85 kW,
2.0 l - 110 kW and 1.8 l - 110 kW engines ⇒ page 85
Torque settings, Touran 2003 ⇒ page 86
11.1 Removing gearbox,

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11. Removing and installing gearbox, Touran 2003 ► 81

♦ Insert -V/175-
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(On installation, first tighten -B-, then -A-.)
spindles.
Five turns are sufficient. The left drive shaft should be tied up.
One of the lower -bolts- cannot be removed from the bore.

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

Note

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

be transferred.
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Guided functions .

Touran 2003 with 1.6 l - 85 kW (FSI) engine ⇒ page 86
Touran 2003 with 2.0 l - 85 kW (FSI) and 1.8 l - 110 kW (FSI)
engines ⇒ page 87
Touran 2003 with 2.0 l - 110 kW (FSI) engine ⇒ page 88
AG. Volkswagen AG d
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11.3.2 Torque settings, Touran 2003 with 2.0 l - 85 kW (FSI) and 1.8 l - 110 kW
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11.3.3 Torque settings, Touran 2003 with 2.0 l - 110 kW (FSI) engine

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cardiagn.com
in lower flange
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Passat 2003 ►
Removing gearbox, Passat with 1.6 l - 85 kW and 2.0 l - 110 kW
engines ⇒ page 89
Installing gearbox, Passat with 1.6 l - 85 kW and 2.0 l - 110 kW
engines ⇒ page 95
Torque settings ⇒ page 96
Removing gearbox, Passat with 1.8 l - 118 kW and 2.0 l - 147 kW
engines ⇒ page 97 .
Installing gearbox, Passat with 1.8 l - 118 kW and 2.0 l - 147 kW
engines ⇒ page 103
12.1 Removing gearbox, Passat with 1.6 l -

85 kW and 2.0 l - 110 kW engines
AG. Volkswagen AG d
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12. Removing and installing gearbox, Passat 2003 ► 89


equipment required
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12.2 Installing gearbox, Passat with 1.6 l - 85

kW and 2.0 l - 110 kW engines
torque.


Guided functions .

Specified torques for 1.6 l - 85 kW engine ⇒ page 96
Specified torques for 2.0 l - 110 kW engine ⇒ page 97
12.3.1 Specified torques for 1.6 l - 85 kW engine

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12.4 Removing gearbox, Passat with 1.8 l -

Brief description
Note


equipment required
V.A.G 1383 A-
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♦ Socket -T10179-
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– Raise vehicle.
– Remove battery ⇒ Rep. gr. 27 ; Disconnecting and connecting
battery; Removing and installing battery .
– Unbolt ATF cooler from battery carrier, pull off and set to side.
– Remove battery carrier.


-2-.
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12.5 Installing gearbox, Passat with 1.8 l -
com
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Torque settings ⇒ page 104 .
torque.
– Renew seals on ATF lines.
– Tighten ATF lines on gearbox ⇒ page 130 .
– Tighten both line brackets ⇒ page 130 .


Guided functions .
12.6.1 Specified torques for 1.8 l 118 kW TFSI engine
er
❑ 60 Nm
- M12 bolts ⇒ M12
❑ 80 Nm
-T10179- .
cardiagn.com
- M10 bolts ⇒ M10
❑ 40 Nm
in lower flange
-arrows-
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Passat CC 2009 ►, CC 2010 ►
Removing gearbox, Passat CC 2009, CC 2010 with 2.0 l 147 kW
TFSI engine ⇒ page 106 .
Installing gearbox, Passat CC 2009, CC 2010 with 2.0 l 147 kW
TFSI engine ⇒ page 114
13.1 Removing gearbox, Passat CC 2009,

CC 2010 with 2.0 l 147 kW TFSI engine
Brief description
cardiagn.com
assembly mounting can be removed. gen AG
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♦ Insert -V/175-
13. Removing and installing gearbox, Passat CC 2009 ►, CC 2010 ► 107

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– Turn steering to straight-ahead position.
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s
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– Remove battery ⇒ Rep. gr. 27 ; Disconnecting and connecting
battery; Removing and installing battery .
– Remove battery carrier.

-2-.

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

protective goggles and clothing to avoid eye injuries and scald‐
ing. Cover cap with a cloth and carefully open.
cardiagn.com
– Open coolant reservoir.
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engine.
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40 ; Removing and installing front/right vehicle level sender -
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AAR2600i .
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cardiagn.com
es, in part or in w
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– Raise vehicle.
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– Place drip tray under gearbox.
nform
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– Separate both ATF lines.

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gearbox; more ATF will run out.
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– 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.
cardiagn.com
AG. Volkswagen AG d
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AG. Volkswagen AG d
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– Connect ATF lines with new seals and tighten. Torque setting:
⇒ page 115 .
Note

box.
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necessary, adjust gearbox support -3282- slightly.
cardiagn.com
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13.2 Installing gearbox, Passat CC 2009, CC

t to the co
2010 with 2.0 l 147 kW TFSI engine

rrectness of i
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❑ 40 Nm
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Specified torques
Component Torque setting
Gearbox bracket to gearbox (4 x M10 bolts) 40 Nm + 90°
Gearbox bracket to gearbox mounting (2 x M12 bolts) 60 Nm + 90°
Bracket for ATF lines to gearbox ⇒ page 116 9 Nm
ATF lines to ATF cooler ⇒ page 116 25 Nm
ATF lines to gearbox 25 Nm
Observe bolt lengths ⇒ page 116
Bracket for ATF lines to gearbox
AG. Volkswagen AG d
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ATF lines to ATF cooler

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Prote AG.


Golf 2009 ►
Removing gearbox, Golf 2009 with 2.5 l - 125 kW engine
⇒ page 117 .
Installing gearbox, Golf 2009 with 2.5 l - 125 kW engine
⇒ page 125
14.1 Removing gearbox, Golf 2009 with 2.5 l

- 125 kW engine
Brief description
The gearbox is removed downwards separately. The engine re‐
cardiagn.com
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equipment required
V.A.G 1383 A-
1332-
♦ Insert -V/175-
♦ Wedge -T10161-
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♦ Support bracket -10 - 222

A-
♦ Adapter -10 - 222 A /8-
♦ Adapter -10 - 222 A /3-
♦ Hook -10 - 222 A /10-
♦ Shackle -10 - 222 A /12-
♦ Adapter -10 - 222 A /7-
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Special tools and workshop equipmenthor required eo
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♦ Hose clamp pliers -V.A.G 1921-
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Removing:
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Prote
cted 14. Removing and installing gearbox, Golf 2009 ►
AG.
agen

Note
– Remove air filter with engine cover.
– Pull off hoses -arrows- and remove intake hose from throttle
valve unit.
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Rep. gr.37 - Controls, housing Prote
cted AG.
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Work with care to avoid bending cable. the or
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– Remove wiring retainer -1- from starter bolt -1-.
To support engine and gearbox:
– Remove wiring -1- from transportation bracket -3-.

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

– Extend right hook -10 - 222 A /10- using adapter -10 - 222 A /
7- .
The hook faces downwards and will later be hooked into the en‐
gine block.
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– Remove heat shield above right drive shaft.

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– Now pull electrical connectors -1- and -2- off gearbox. ss c
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– Pull connector beneath starter -1- out of retainer and separate.
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– Unbolt retainer from lower starter bolt.

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– Remove lower starter bolt and remove starter.
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– Drain coolant.

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

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Continue turning
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– Hook adapter -10 - 222 A /7- into engine block.

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– Pull coolant hoses off ATF cooler.

Tighten right spindle one turn (more is not necessary).
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– Support engine and gearbox with left spindle. Do not raise.

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– Remove bracket -A-.

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

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

125 kW engine
torque.


Guided functions .
14.3 Torque settings, Golf 2009 with 2.5 l - 125 kW engine
er
❑ 60 Nm
cardiagn.com
- M12 bolts ⇒ M12
❑ 80 Nm
-T10179- .
- M10 bolts ⇒ M10 agen
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-Nuts- 8 Nm
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15 Transporting gearbox
♦ Shackle -10 - 222 A /12-
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Shackle 10-222 A/12 can be used to transport the gearbox and
t to the co
set up gearbox support 3282.
– During transportation, protect torque converter -arrow- from
cardiagn.com
falling out, e.g. with a wire -A-.
rrectne
– Keep in mind that there is oil in the gearbox. Do not turn gear‐
s
box with breather downwards during transport or while on
s o
repair stand. Oil will run out.
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16 ATF cooler for 1.6 l - 85 kW and 2.0 l

- 110 kW engines
16.1 Assembly overview - ATF cooler
1 - Gearbox housing
2 - Seal
❑ Always renew
3 - ATF cooler
❑ Installation position:
⇒ page 129 .
4 - Seal
❑ Always renew
5 - Washer
6 - Dished washer
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❑ Position: convex side
faces bolt
⇒ Item 7 (page 129)
7 - Bolt
❑ 36 Nm AG. Volkswagen AG d
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Position: ATF cooler

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– When installing ATF cooler -1-, insert lug -arrow B- into recess
on
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16. ATF cooler for 1.6 l - 85 kW and 2.0 l - 110 kW engines 129
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17 ATF lines, ATF water cooler and ad‐
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ditional ATF cooler, Passat with 2.0 l
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17.1 Overview
rrectne
A - ATF lines on gearbox
s
⇒ page 131
s o
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B - »External« ATF heat ex‐
nform
changer ⇒ page 132
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C - ATF lines ⇒ page 133

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D - Additional ATF cooler
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⇒ page 134
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1 - ATF line ss c
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17. ATF lines, ATF water cooler and additional ATF cooler, Passat with 2.0 l TFSI engine 131
17.1.2 External ATF heat exchanger
1 - Bolt
❑ 8 Nm
2 - Nut
❑ 9 Nm
3 - External ATF cooler
4 - Bolt
❑ 9 Nm
5 - ATF line
❑ »Supply.«
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17.1.3 ATF lines
1 - ATF line
❑ »Return« from addition‐
al cooler.
❑ 25 Nm
2 - ATF line
❑ »Supply« to additional
cooler.
❑ 25 Nm
3 - Nut
❑ 9 Nm
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17. ATF lines, ATF water cooler and additional ATF cooler, Passat with 2.0 l TFSI engine 133
AG. Volkswagen AG d
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17.1.4 du
Additional ATF cooler
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❑ To remove and install,
hole
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remove front bumper
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cover ⇒ Rep. gr. 63 ;
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Assembly overview -
front bumper cover
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2 - Bolt
❑ 5 Nm
l purpos
3 - Bolt
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❑ 9 Nm
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4 - ATF line
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❑ 5 Nm
7 - Bolt
❑ 9 Nm

18 Checking ATF level and topping up

Observe these notes as well.
♦ About this workshop manual ⇒ page 1
♦ About ATF ⇒ page 1
♦ About »filler pipe« ⇒ page 2
♦ If necessary, the breather pipe of the adapter for oil filling -VAS
6262 A- has to be shortened ⇒ page 136 .

equipment required
1331-
cardiagn.com
♦ Used oil collection and ex‐
traction unit -V.A.G 1782-
♦ Vehicle diagnosis, testing
and information system -
VAS 5051-
olkswagen AG
♦ Drip tray for workshop
agen hoist
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♦ Adapter
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6262
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♦ Adapter -VAS 6262/2-

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18. Checking ATF level and topping up 135

Shortening breather pipe of adapter for oil filling -VAS 6262 A- :

– In order to ensure that the breather pipe of the adapter for oil
filling -VAS 6262 A- does not bump against the bottom of the
oil bottle, the pipe must be shortened to the length -a- in the
case of some bottles that are used.
Dimension -a- = 210 mm
Note
The dimension -a- is measured from the shaft (green area in the
counting glass) of the adapter for oil filling -VAS 6262 A- .
– Mark dimension -a- on the breather pipe and shorten pipe with
pipe cutter -VAS 6056/2- .
If ATF must be added, use only ATF listed in ⇒ Electronic parts
catalogue ⇒ ETKA .
AG. Volkswagen AG d
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– If ATF level is checked, oil seal -arrow- on ATF inspection plug
is n
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must always be renewed.
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18.1 Checking ATF level

– Switch off engine.
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The ATF temperature should not be more than approx. 30° C at
ss
the start of the test.
o
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• Gearbox is not in emergency running mode and ATF temper‐
form
mer
ature is not above approx. 30° C.
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• Vehicle must be standing level
n
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• Selector lever in “P”.

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

The ATF present in the overflow pipe runs out.

If ATF drips out of drilling:
ATF does not need topping up.
– Fit new seal to plug and tighten to 27 Nm. This concludes the
ATF check.
If no ATF drips out of inspection hole:
– Top up ATF ⇒ page 138 .
18.2 Topping up ATF

– With engine »running«, screw in adapter for filling oil -VAS
6262/2- hand-tight.
– Shake oil bottles before opening them.
– Before screwing adapter for oil filling -VAS 6262 A- onto oil
bottle, take note of the notes regarding the breather pipe
⇒ page 136 .
cardiagn.com
– Add 1 l of ATF.
– Pull off adapter for oil filling -VAS 6262- at quick-release con‐
nection and check:
If ATF now flows out of hole in adapter:
ATF does not need topping up.
– Drain ATF until it drips.
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– Fit new seal to plug and tighten to 27 Nm. This concludes othe
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If no ATF drips out: utho eo
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– Add another litre ⇒ page 138 .
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An ATF level which is too low or too high will impair the function
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18.3 Draining and filling ATF

– Switch off engine.
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– Unscrew and remove ATF inspection plug -A-.

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– Unscrew and remove overflow pipe -C-.

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

– Shake oil bottles before opening them.
– Before screwing adapter for oil filling -VAS 6262 A- onto oil
bottle, take note of the notes regarding the breather pipe
⇒ page 136 .
– Add 3 litres of ATF ⇒ Electronic parts catalogue ⇒ ETKA
through filler pipe.
– Screw in ATF inspection plug -A- hand-tight with new seal

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38 – Gears, control
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– Remove multifunction switch -F125- .
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– Carefully lever out selector shaft seal using a screwdriver. Do
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– Adjust multifunction switch -F125- .

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1. Renewing oil seal for selector shaft 141

2 Removing and installing ATF pan

♦ Drip tray -V.A.G 1306-
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– Remove noise insulation below engine.
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– Place drip tray -V.A.G 1306- underneath.
– Unscrew ATF inspection plug -A-.
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– Remove overflow pipe -C- and allow remaining ATF to drain.
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142 Rep. gr.38 - Gears, control

– Loosen oil pan bolts -arrows- diagonally.

– Remove oil pan together with gasket.
2.2 Installing
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– Clean the two magnets in recesses of oil pan. Ensure that
magnets are seatedencorrectly
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2. Removing and installing ATF pan 143

– Screw in overflow pipe -C-; torque specification ⇒ page 155 .

– Fill with ATF; check ATF level and top up ⇒ page 135 .
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3 Removing and installing ATF strainer
3.1 Removing
– Remove oil pan ⇒ page 142 .
– Unscrew ATF strainer bolts -arrows-.
– Pull ATF strainer -A- off valve body.
cardiagn.com
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 155 . AG. Volkswagen
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– Install oil pan ⇒ page 142 . y Vol ot g
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4 Removing and installing valve

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♦ Always renew a valve body which is fouled or defective.
♦ Do not use fluffy cloths.
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♦ After the pan has been installed, the ATF level must be
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4.1 Overview - valve chest
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1 - ATF inspection plug

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❑ Checking ATF level and

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❑ Always renew cted agen
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3 - Overflow pipe
❑ Unscrew to drain ATF
❑ Torque setting
⇒ page 155
4 - Oil pan
⇒ page 142
5 - Bolt
❑ Tighten oil pan bolts di‐
agonally in several
stages.
❑ Torque setting
⇒ page 155
6 - Seal
❑ With spacer sleeves
(qty. 8)
❑ Examine before fitting
❑ Renew brittle, cracked
or deformed seal
7 - Magnet
❑ Qty. 2 in depressions in
pan
❑ Clean oil pan before in‐
stalling
8 - Bolt
❑ For securing valve body in gearbox

❑ Qty. 12, various lengths ⇒ page 152
❑ Always renew bolts
❑ Torque setting ⇒ page 155
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❑ Installing ⇒ page 151
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12 - Bolt
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13 - Bolt
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14 - Gearbox input speed sender -G182-

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❑ Shown here without gearbox oil cooler
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18 - Breather cap
19 - Multifunction switch -F125-
❑ Installing ⇒ page 24
20 - Gearbox oil temperature sender -G93-
❑ Integrated into wiring harness
❑ Cable routing ⇒ page 153 .
21 - Bolt
22 - Bolt
23 - Wiring harness for sender
❑ With gearbox oil temperature sender -G93-
❑ For gearbox input speed sender -G182-
❑ For gearbox output speed sender -G195-
❑ Always renew oil seal on housing
4. Removing and installing valve body 147

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24 - Seal ir se nte
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❑ Always renew ss
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25 - ATF drain plug
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❑ Torque setting ⇒ page 155 erm
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26 - Selector lever
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27 - Washer
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28 - Nut
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❑ Location: centring collar faces washer ⇒ Item 27 (page 148)
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29 - Spring
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30 - Damper piston
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31 - Wiring harness for solenoid valves

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❑ Always renew oil seal on housing
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32 - Bolt
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4.2 Removing valve body
Prote AG.

♦ Angle wrench -V.A.G 1756-

– Remove ATF strainer ⇒ page 145 .
– Pull connectors off solenoid valves ⇒ Item 1 (page 154)
through ⇒ Item 8 (page 154) .

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

suited to release connector housing on solenoid valves.
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– Separate connectors ⇒ Item A (page 154) and
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⇒ Item B (page 154) .
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– Unbolt retainer for connectors ⇒ Item 1 (page 155) and
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⇒ Item 2 (page 155) .
spec
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– Unscrew gearbox oil temperature sender -G93-
t to the co
⇒ Item 3 (page 155) and carefully pull out of valve body.
– Bend back securing tab on selector lever, if fitted.
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– Remove selector lever -1- from selector shaft. cop Vo
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– In the process, carefully grip selector lever -1- with pliers -2-
so that torque is not transferred to multifunction switch -F125- .
– Note spool valve -A- on valve body into which selector lever
engages so that this is not damaged.

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

will lead to faults in operation.
– Therefore, always push spool valve into valve body, secure
against falling out and never interchange.
– Loosen marked bolts (Qty. 12) -arrows-.

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– Unbolt brackets -1- and -2-.
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– Unbolt valve body and remove.
– When removing valve body, observer damper piston -2-.

– Remove piston with spring.
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4.3 Installing valve body ss aut ra
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So that no wiring is pinched during installation:

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– Route wires -1-, -3-, -4- and -5- as shown in figure and fix them
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-5- from coming into contact with planetary gearbox and thereby
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The valve body is secured with bolts of 3 different lengths.

– Before installing valve body, sort bolts by length.
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– Coat damper piston -2-autwith ATF and insert with spring.
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– Carefully insert valve body and start 2 bolts.
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Lengths of bolts and location on valve body

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– Check that no wire is pinched. Prote AG.

– 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 155 .
– Push connector (Qty. 8) onto solenoid valves ⇒ page 153 .
– Tighten retainer for connectors ⇒ page 153 ; torque setting
⇒ page 155 .
– Push on connectors ⇒ Item A (page 154) and
⇒ Item B (page 154) .
– Tighten valve body diagonally from centre outwards; torque
setting ⇒ page 155 .
– Install selector lever.
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– Tighten
s selector lever nut -1- to specified torque
s c
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⇒ page 155 .
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– Bend up securing tab on nut.

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– Install ATF strainer ⇒ page 145 .

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– Install oil pan ⇒ page 142 .

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– Connect -VAS 5051- and continue to switch until “Function/

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– Then “6-speed automatic gearbox 09G”.
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– Press “01 - Self-diagnosis”. cted agen
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– Press “Functions”.
– Press “Basic setting”.
4.3.1 Wire routing, connectors, connections

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

1 - Solenoid valve 4 -N91-

❑ Colour of wire to valve:
green/brown
green/grey
yellow/violet
red/blue
white/black
green/blue
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white
black
A - Connection for gearbox gen AG. Volkswagen AG
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❑ Colour of wire
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B - Connection
s
for gearbox in‐
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put speed sender -G182-

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❑ Colour of wire to sender:

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white/red
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Retainer for connectors, fixing wires in place

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Retainer for connection
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gearbox output speed sender -
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❑ Torque setting
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⇒ page 155
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2 - Retainer for connection
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gearbox input speed sender -
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G182-
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t to the co
❑ Torque setting
⇒ page 155
3 - Gearbox oil temperature
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sender -G93-
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❑ Colour of wire on send‐

er: orange/orange
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4 - Selector lever
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❑ Torque setting
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⇒ page 155
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4.4 Specified torques

5 Removing and installing wiring har‐

ness for solenoid valves and senders
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5.1 Removing d ara
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– Drain ATF ⇒ page 139 . ss a c
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– Remove ATF strainer ⇒ page 145 .
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– Remove valve body ⇒ page 148 .
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– Pull connector off gearbox.
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-1- connector for sender in gearbox
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-2- Connector for solenoid valves
– Unbolt connector housing from gearbox.
rrectness of i
– Pull connector housing with wiring harness outwards out of
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gearbox housing.
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– Renew seal on connector housing.
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– 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 155 .
– Install valve body ⇒ page 151 .
– Install ATF strainer ⇒ page 145 .
– Install oil pan ⇒ page 142 .

6 Removing and installing gearbox in‐

6.1 Removing
olkswagen AG
en AG. V
– Remove valve body
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– Unscrew bolt ris -1- from gearbox input speed sender -G182-
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6. Removing and installing gearbox input speed sender G182 157

7 Removing and installing gearbox out‐

7.1 Removing
– Remove valve body ⇒ page 148 .
– Unscrew bolt -2- from gearbox output speed sender -G195- .
– Pull sender out of gearbox.
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39 – Final drive - differential

1 Renewing oil seals for flange shafts
Brief description
Flange shaft O-rings can be replaced with gearbox in situ.
Left drive shaft is removed completely.
Right drive shaft remains in vehicle and is only detached from
gearbox.
– Right drive shaft remains in wheel bearing; use thrust piece -
T10177- . Remove left drive shaft; use thrust piece -T10176- .
1.1 Renewing oil seal for left flange shaft

♦ Puller -T10055-
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1. Renewing oil seals for flange shafts 159

– 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.
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– Drive in new seal onto stop with thrust piece -T10176- . Do not
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– Install drive shaft ⇒ Rep. gr. 40 ; Removing and installing
drive shafts .
– Install noise insulation.
1.2 Renewing seal for right flange shaft

160 Rep. gr.39 - Final drive - differential

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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
♦ Grease drill bit -B- so that swarf adheres to it.

♦ Drill only through sheet metal ring -C- because gearbox may
otherwise be damaged.
1. Renewing oil seals for flange shafts 161

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

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

bearing behind it.
♦ Pull out oil seal using puller -T10055- and adapter -T10055/2- .
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– Install drive shaft ⇒ Rep. gr. 40 ; Removing and installing
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– Install noise insulation.

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162 Rep. gr.39 - Final drive - differential

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2015 Volkswagen AG, Wolfsburg K0258992320

2.1 Planetary gearbox and final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

9 Passat CC 2009 ►, CC 2010 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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

1.2 Draining torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.3 Removing and installing torque converter oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . do

1.4 Installing torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2 Electrical and electronic components and their locations . . . . . . . . . . . . . . . . . . . . . . . . . . 18

7.1 Overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

13.3 Torque settings, gearbox to engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

14 Removing and installing gearbox, Golf 2009 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

15 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

17.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

18.1 Checking ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

18.2 Topping up ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

18.3 Draining and filling ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

38 - Gears, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

1 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

2.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

ward gears. When the torque converter lock-up clutch closes,

1.2 Torque converter

checked and topped up together.

1.4 Automatic gearbox control unit -J217-

• Gear changes will be fuel-consumption orientated.

1.5 Control units in vehicle

1.6 Information on “09G gearbox”

1. General repair notes 1

♦ First thoroughly clean connecting points and surrounding

areas and then loosen bolts.

♦ When installing the gearbox, ensure that dowel sleeves be‐

♦ If repair work cannot be performed immediately, carefully cov‐

♦ With gearbox removed, secure torque converter against falling

Gearboxes with and without filler pipe

2 Rep. gr.00 - Technical data

1.9 Gaskets, seals and oil

between them with sealing grease -G 052 128- .

♦ Open side of oil seal faces oil.

♦ After installing, check ATF level.

cording to regulations. Remember: one drop of oil will contam‐

1.10 Nuts and bolts

1. General repair notes 3

1.11 Electrical components

Before making repairs to the gearbox, determine the cause of the

4 Rep. gr.00 - Technical data

2.1 Planetary gearbox and final drive

3 Code - engine allocation

3.1 Gearbox codes

“Automatic gearbox 09G” -arrow 2-

Identification Day Month Year -2002-

The gearbox code also appears on the vehicle identification

6 Rep. gr.00 - Technical data

5 Golf Plus 2005 ►

8 Rep. gr.00 - Technical data

10 Rep. gr.00 - Technical data

If Genuine parts are required for a repair, always refer to the

“Automatic gearbox 09G”

Identification code »JZV« »KGU«

Engine 2.0 l - 147 kW (FSI)

12 Rep. gr.00 - Technical data