D3E8001FBC8-6-Speed Automatic Transmission 09G

Service
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Repair Manual es, in part or in w
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CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ ,
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6-Speed Automatic Transmission 09G

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Edition 07.2012
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
32 - Torque Converter
37 - Controls, Housing
38 - Gears, Hydraulic Controls
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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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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Copyright © 2016 Volkswagen AG, Wolfsburg cted
D3E8001FBC8
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CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Passat 200 ...
6-Speed Automatic Transmission 09G - Edition 07.2012
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Automatic Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Transmission Control Module J217 with Fuzzy Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.5 Vehicle Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.6 Information on the “09G Automatic Transmission” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.7 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.8 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.9 Seals, Gaskets and O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.10 Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.11 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.12 Guided Fault Finding, Vehicle Diagnosis and Test Instruments . . . . . . . . . . . . . . . . . . . . . . 4
2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Transmission and Final DriveAGCapacities . Volkswagen A.G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3 Engine Codes - Engine y Vol Allocation . . . . . . . . . . . o.t .gu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Transmission rIdentification . . . . . . . . . . . . . . . .
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3.2 Golf from MYau 2004, Engine Codes and Allocation . . . . . . r.ac. . . . . . . . . . . . . . . . . . . . . . . . .
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3.3 Golf froms MY 2009, Engine Codes and Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3.4 Golf Plus from MY 2005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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3.5 Touran from MY 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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3.6 Passat from MY 2006, Engine Codes and Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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3.7 Passat CC from MY 2009 and CC from MY 2010, Engine Codes and Allocation . . . . . . . . 7
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32 - Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
spec
urposes, in part or in wh
1 Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
t to the co
1.1 Torque Converter General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.2 Torque Converter Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
rrectne
1.3 Torque Converter, Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.4 Torque Converter Seal, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1.5 Torque Converter, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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37 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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1 Vehicle Diagnostic Tester , Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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1.1 Vehicle Diagnostic Tester , General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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1.2 Vehicle Diagnostic Tester , Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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2 Electrical and Electronic Components and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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3 Multifunction Transmission Range Switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.1 Multifunction Transmission Range Switch F125, Removing and Installing . . . . . . . . . . . . 19
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3.2 Multifunction Transmission Range Switch, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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4 Selector Lever, Emergency Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5 Selector Lever Handle, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1 Selector Lever Handle, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2 Button in Handle, Moving to Installed Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6 Selector Mechanism through 02/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1 Overview - Selector Mechanism, through 02.09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2 Shift Mechanism with Selector Lever, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 28
6.3 Selector Lever Cable, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.4 Selector Lever Cable, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.5 Selector Lever Cable, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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7 Selector Mechanism from 03/2009 agen . . . . . . . . . .A.G. d.o.es. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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7.1 Overview - Selector Mechanism,db
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from 03.09 . . . . . . . . .t .gu.a.r . . . . . . . . . . . . . . . . . . . . . . . . 39
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7.2 Selector Mechanism ho with Selector Housing, Removing and Installing
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7.3 Selector Mechanismss au
without Selector Housing, Removing and Installing
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8 Gearshift Mechanism, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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8.1 Gearshift Mechanism, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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9 Transmission, Removing and Installing, Golf from MY 2004 . . . . . . . . . . . . . . . . . . . . . . . . 46
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9.1 Transmission, Removing, Golf MY 2004 with 1.6L - 75 kW, 1.6L - 85 kW (FSI) and 2.0L - 110
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kW (FSI) Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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9.2 Transmission, Installing, Golf MY 2004 with 1.6L - 75 kW, 1.6L - 85 kW (FSI) and 2.0L - 110
spec
kW (FSI) Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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9.3 Transmission, Removing, Golf MY 2004 with 2.5L - 110kW/125 kW Engine . . . . . . . . . . . . 52
9.4 Transmission, Installing, Golf MY 2004 with 2.5L - 110kW/125 kW Engine . . . . . . . . . . . . 58
9.5 Tightening Specifications, Transmission to Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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10 Transmission, Removing and Installing, Golf Plus from MY 2005 . . . . . . . . . . . . . . . . . . . . 63
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10.1 Transmission, Removing, Golf Plus MY 2005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

10.2 Transmission, Installing, Golf Plus MY 2005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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11 Transmission, Removing and Installing, Touran from MY 2003 . . . . . . . . . . . . . . . . . . . . . . 75
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11.1 Transmission, Removing, Touran MY 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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11.2 Transmission, Installing, Touran MY 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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12 Transmission, Removing and Installing, Passat from MY 2006 . . . . . . . . . . . . . . . . . . . . . . 83

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12.1 Transmission, Removing, Passat with 1.6L - 85 kW and 2.0L - 110 kW Engine . . . . . . . . 83
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12.2 Transmission, Installing, Passat with 1.6L - 85 kW and 2.0L - 110 kW Engine . . . . . . . . . . 89
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12.3 Tightening Specifications, Transmission to Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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12.4 Transmission, Removing, Passat with 1.8L - 118 kW and 2.0L 147 kW Engine . . . . . . . . 91
12.5 Transmission, Installing, Passat with 1.8L - 118 kW and 2.0L 147 kW Engine . . . . . . . . . . 95
13 Transmission, Removing and Installing, Passat CC from MY 2009 and CC from MY 2010
........................................................................ 99
13.1 Transmission, Removing, Passat CC MY 2009, CC MY 2010, 2.0L 147 kW TFSI Engine
........................................................................ 99
13.2 Transmission, Installing, Passat CC MY 2009, CC MY 2010, 2.0L 147 kW TFSI Engine . . 105
14 Transmission, Removing and Installing, Golf from MY 2009 . . . . . . . . . . . . . . . . . . . . . . . . 108
14.1 Transmission, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
14.2 Transmission, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
14.3 Tightening Specifications, Golf MY 2009, 2.5L 125 kW Engine . . . . . . . . . . . . . . . . . . . . . . 114
15 Transmission, Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
16 ATF Cooler, 1.6L 85 kW and 2.0L 110 kW Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
16.1 Overview - ATF Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
17 ATF Lines, ATF Cooler and Auxiliary ATF Cooler, Passat, 2.0L TFSI Engine . . . . . . . . . . 118
17.1 Overview - Transmission Fluid Lines, Cooler and Auxiliary Cooler . . . . . . . . . . . . . . . . . . 118
18 ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
18.1 Transmission Fluid Level, Checking and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
18.2 ATF Level, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
18.3 ATF, Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
18.4 ATF, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
19 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
20 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
21 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
22 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
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38 - Gears, Hydraulic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

1 Selector Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2 Transmission Fluid Pan, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3 Transmission Fluid Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
3.1 Transmission Fluid Filter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4 Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.1 Overview - Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.2 Valve Body, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4.3 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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5 Solenoid Valve and Sensor Wiring Harness . . . . .o.lk.sw. a.g.e. . . . . . . . . . . . .G.do. e.s.no. . . . . . . . . 159
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5.1 Solenoid Valve and Sensor Wiring Harness, Removing db and Installing . . . . . . . . .g.ua.ra. . . . . 159
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6 Transmission Input Speed Sensor G182 ut.ho. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e o.r . 160
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6.1 Transmission Input Speed Sensor G182ss, Removing and Installing . . . . . . . . . . . . . . . . . .c 160
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7 Transmission Output Speed Sensor G195 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
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7.1 Transmission Output Speed Sensor G195 , Removing and Installing . . . . . . . . . . . . . . . . 161
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7.2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
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8 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
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39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
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1 Flange Shaft Seals, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.1 Left Flange Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.2 Right Flange Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
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2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
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3 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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Contents iii
AG. Volkswagen AG d
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iv Contents
00 – General, Technical Data lkswage

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(Edition 07.2012)
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⇒ “1.1 Transmission”, page 1
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⇒ “1.2 Torque Converter”, page 1
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⇒ “1.3 Automatic Transmission Fluid”, page 1
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⇒ “1.4 Transmission Control Module J217 with Fuzzy Logic”, page
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⇒ “1.5 Vehicle Control Modules”, page 2
⇒ “1.6 Information on the 09G Automatic Transmission ”,
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⇒ “1.7 Tools”, page 2

⇒ “1.8 Transmission”, page 2
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⇒ “1.9 Seals, Gaskets and O-rings”, page 3

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⇒ “1.10 Bolts and Nuts”, page 3
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⇒ “1.11 Electrical Components”, page 3
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⇒ “1.12 Guided Fault Finding, Vehicle Diagnosis and Test Instru‐
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Carefulness, cleanliness and the correct tools are required for
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transmission repairs to be successful. The usual basic safety pre‐ p by
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A number of generally applicable instructions for individual repair
operations, which are otherwise mentioned at various points in
this repair manual are summarized here.
1.1 Transmission
The “automatic transmission 09G” has 6 hydraulically control for‐
ward gears. By passing the torque converter slip, 2nd, 3rd, 4th,
5th and 6th gears become mechanically driven gears if the lockup
clutch is closed.
1.2 Torque Converter

The torque converter is equipped with a slip controlled torque
converter lock up clutch. The lockup clutch closes depending on
load and speed. The 2nd, 3rd, 4th, 5th and 6th gears can be me‐
chanically driven (without slip).
1.3 Automatic Transmission Fluid

Use only the automatic transmission fluid listed as a replacement
part in the Parts Catalog.
The fluid levels inside the transmission and the final drive are
checked and filled at the same time.
1.4 Transmission Control Module J217 with

Fuzzy Logic
Determining the driving situation and driving resistance depend‐
ent shift point occurs automatically.
Advantages:
• It is shifted depending on consumption
1. General Repair Information 1

• Maximum engine output is always available

• Individual adaptation of shift points in all driving situations
• Gear shift points are infinitely variable
1.5 Vehicle Control Modules

The installed locations of all vehicle control modules and other
useful information can also be found in ⇒ Wiring diagrams, Trou‐
bleshooting & Component locations.
1.6 Information on the “09G Automatic

Transmission”
For information in the 09G transmission. Refer to the Self Study
Program, Course Number 851503, 6-Speed Automatic Trans‐
mission 09G/09M, Design and Function.
1.7 Tools
A complete list of special tools and workshop equipment used in
the repair manual can be found at the beginning of each proce‐
dure and at the end of each repair group.
With small fasteners with a minimal tightening specification, un‐
certainties often exist. For these fasteners, the torque wrench -
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♦ Do not run the engine and do not tow the vehicle ifauthe trans‐
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mission pan is removed or if there is no transmission
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inside the transmission.
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♦ Always clean the connection points and the areas around
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♦ When installing the transmission, make sure the alignment
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sleeves are correctly seated between the engine and trans‐
hole
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♦ Place removed parts on a clean surface and cover them so
that they do not get dirty. Use foil, paper or lint free cloths.
♦ Only install clean components: Remove the replacement parts
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from their packaging just prior to installing them.
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♦ Carefully cover or seal unpacked components if repairs cannot

be performed immediately.
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♦ With the transmission removed, secure the torque converter

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Transmissions With and Without a Filling Tube

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transmissions. This tube has been omitted.

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2 Rep. Gr.00 - General, Technical Data

You also do not need the old filler hole with the red cap because
the transmission fluid is drained and filled at the lower hole as
necessary. The “height” of this tube corresponds to the height of
the transmission fluid level.
To drain the fluid, the tube is removed.
♦ After installing, check the transmission fluid level and fill as
required. Refer to ⇒ “18 ATF”, page 123 .
♦ Capacities. Refer to
⇒ “2.1 Transmission and Final Drive Capacities”, page 5 .
1.9 Seals, Gaskets and O-rings

♦ O-rings, gaskets and seals must be replaced.
♦ Before installing the radial shaft seal, coat the sealing lips and
the space between them with sealing grease for seal - G 052
128- .
♦ The open side of the seal faces the fluid.
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Be cautious when dealing with transmission fluid. Dispose of

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drained fluid properly. Bear in mind that: One drop of trans‐
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mission fluid can contaminate 1000 liters of drinking water.
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1.10 Bolts and Nuts
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♦ Loosen or tighten bolts and nuts for the covers or housings
diagonally.
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♦ The tightening specifications stated apply to non-lubricated
nuts and bolts.
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♦ Use a wire brush to clean the threads of the bolts that were
installed using locking fluid. Install the bolts with liquid locking
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fluid - AMV 185 100 A1- . orm

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♦ Use a thread tap to clean all threaded holes containing self

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locking bolts to remove any locking fluid residue. Otherwise

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♦ Always replace self-locking nuts and bolts.

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1.11 Electrical Components

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You have probably received a electrical shock at one time, when
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charge to the human body. This charge can damage the electrical Prote AG.
components on the transmission and the selector mechanism.
– Touch a grounded object, such as, a water pipe or a vehicle
hoist, before working on electrical components. Do not touch
the connector or »open« electronic components directly.
1. General Repair Information 3

1.12 Guided Fault Finding, Vehicle Diagnosis

and Test Instruments
Before beginning any service work on the transmission, deter‐
mine the cause of the damage using “Guided Fault Finding”.
The Guided Fault-finding is performed using the vehicle di‐
agnostic tester. Refer to
⇒ “1 Vehicle Diagnostic Tester , Connecting”, page 12 .
Guided Functions finds the transmission fluid temperature
quickly. Refer to
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2 Capacities
⇒ “2.1 Transmission and Final Drive Capacities”, page 5 n AG. Volkswagen AG do
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“6-Speed Automatic Transmission ac 09G”
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Initial filling Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
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Change Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
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Lubricant Automatic transmission fluid is available as a replace‐
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2. Capacities 5
3 Engine Codes - Engine Allocation

⇒ “3.1 Transmission Identification”,
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⇒ “3.4 Golf Plus from MY 2005”, page 7 .
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⇒ “3.6 Passat from MY 2006, Engine Codes and Allocation”, page
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⇒ “3.7 Passat CC from MY 2009 and CC from MY 2010, Engine
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Codes and Allocation”, page 7 .
3.1 Transmission Identification
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Code letters -arrow-
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Code letter -arrow 1-

“Automatic transmission 09G” -arrow 2-
Example
GGZ 08 05 02
I I I I
Identification co‐ Day Month Production year
des -2002-
The transmission code is also listed on the vehicle data label.
3.2 Golf from MY 2004, Engine Codes and

Allocation
If original equipment replacement parts are needed for a repair,
always pay attention to the transmission codes.
“Automatic Transmission 09G”
Identification codes HFU, HRM and JUJ KMV, KGL and MAN
Engine 2.5 L -110 kW 2.5 L -125 kW

3.3 Golf from MY 2009, Engine Codes and

Allocation
If original parts are needed for a repair, always pay attention to
the transmission codes.
Codes KGL, MAN
Engine 2.5L -125 kW
3.4 Golf Plus from MY 2005

Codes »HFS« »HLP« »HFX«
»HTN« »JTV« »HTQ«
»JTY« KGN »JTW«
»KGJ«
Engine 1.6L - 75 kW 1.6L - 85 kW (FSI) 2.0L - 110 kW (FSI)
3.5 Touran from MY 2003

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»GKB«
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»HLP« »JTW« KGP
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Engine 1.6L - 85 kW 2.0L - 110 kW 1.8 l - 110 kW

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Identification codes HRN, JUD, JZV and KGV
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Engine 2.0 L - 147 kW (FSI)

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3. Engine Codes - Engine Allocation 7


Identification codes JZV and KGU
Engine 2.0 L - 147 kW (FSI)
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32 – Torque Converter
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1 Torque Converter
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⇒ “1.1 Torque Converter General Information”, page 9
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⇒ “1.2 Torque Converter Identification”, page 9
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⇒ “1.3 Torque Converter, Draining”, page 9
⇒ “1.4 Torque Converter Seal, Removing and Installing”,
page 9
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⇒ “1.5 Torque Converter, Installing”, page 10 l purpos
1.1 Torque Converter General Information
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– Always secure the converter.

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Unsecured converters could slide out if the transmission is tipped.
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1.3 Torque Converter, Draining

Special tools and workshop equipment required
♦ Oil Extracting Device - VAG1358A-
♦ Oil Extracting Sensor - VAG1358A/1-
– Extract the transmission fluid from the torque converter using
the Oil Extracting Device - VAG1358A- and the Oil Extracting
Sensor - VAG1358A/1- .
1.4 Torque Converter Seal, Removing and

Installing
♦ Thrust Piece - T10175-
♦ Extractor Lever - VW681-
Removing
– Pry the seal out using the extractor lever - VW681- .
Installing
1. Torque Converter 9
– Install the seal until it is flush using the Thrust Piece - T10175- .
1.5 Torque Converter, Installing

– Press the torque converter hub through the seal as far as the
first stop.
– Lightly press the torque converter toward the transmission and
rotate it until the slots on the torque converter hub -arrow- en‐
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10 Rep. Gr.32 - Torque Converter

6-Speed Automatic
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Transmission 09G - Edition 07.2012
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2 Special Tools
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♦ Oil Extracting Sensor - VAG1358A/1-
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♦ Oil Extracting Device - VAG1358A-
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♦ Extractor Lever - VW681-
2. Special Tools 11
37 – Controls, Housing
1 Vehicle Diagnostic Tester , Connect‐
ing
⇒ “1.1 Vehicle Diagnostic Tester , General Information”,
page 12
⇒ “1.2 Vehicle Diagnostic Tester , Connecting”, page 12
1.1 Vehicle Diagnostic Tester , General In‐

formation
Volkswagen offers various testers, for example:
♦ Vehicle Diagnosis, Testing and Information System -
VAS5051-
VAS5051B-
♦ Tester - VAS5051/11A-
♦ Vehicle Diagnosis and Service System
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VAS5052-
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The following description is based on the Vehicle Diagnosis, Test‐

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12 Rep. Gr.37 - Controls, Housing

– Switch the tester on -arrow-.

The tester is ready for use when it is possible to select between
the fields/buttons Guided Functions and Guided Fault Find-
ing on the right side of the screen.
Depending on equipment and tester nversion,

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1. Vehicle Diagnostic Tester , Connecting 13

2 Electrical and Electronic Components and Locations
1 - Transmission Control Mod‐

ule - J217-
❑ The control module
sends and receives data
from the Data bus.
❑ Installed location, re‐
moving and installing.
Refer to
⇒ Fig. ““Transmission agen
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3 - Multifunction Transmission
Range Switch - F125-
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Switch F125 ”, page 19 .
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❑ Adjusting. Refer to ⇒ “3.2 Multifunction Transmission Range Switch, Adjusting”, page 21

4 - Valve Body
❑ Installed location. Refer to ⇒ Fig. ““Valve Body”“ , page 16 .
❑ The components can be checked in “Guided Fault Finding” using the vehicle diagnostic tester.
❑ For the correct allocation. Refer to the Parts Catalog.
5 - Sensor Wiring Harness
❑ With the transmission fluid temperature sensor.
❑ Installed location. Refer to ⇒ Fig. ““Sensor Wiring Harness”“ , page 16 .
❑ Removing and installing. Refer to ⇒ “5 Solenoid Valve and Sensor Wiring Harness”, page 159 .
6 - Transmission Fluid Temperature Sensor - G93-
❑ Installed location. Refer to ⇒ Fig. ““Sensor Wiring Harness”“ , page 16 .
❑ Can be checked in “Guided Fault Finding” using the vehicle diagnostic tester.
7 - Solenoid Valve Wiring Harness
❑ Installed location. Refer to ⇒ Fig. ““Solenoid Valve Wiring Harness”“ , page 16 .

8 - Automatic Transmission Hydraulic Pressure Sensor 1 - G193-
❑ Not installed in all transmissions.
❑ Installed location. Refer to
⇒ Fig. ““Automatic Transmission Hydraulic Pressure Sensor 1 and Automatic Transmission Hydraulic
Pressure Sensor 2”“ , page 17 .
9 - Automatic Transmission Hydraulic Pressure Sensor 2 - G194-
❑ Not installed in all transmissions.
❑ Installed location. Refer to
⇒ Fig. ““Automatic Transmission Hydraulic Pressure Sensor 1 and Automatic Transmission Hydraulic
Pressure Sensor 2”“ , page 17 .
10 - Transmission Input Speed Sensor - G182-
❑ Removing and installing. Refer to ⇒ “6 Transmission Input Speed Sensor G182 ”, page 160 .
11 - Transmission Output Speed Sensor - G195-
❑ Removing and installing. Refer to ⇒ “7 Transmission Output Speed Sensor G195 ”, page 161 .
12 - Shift Lock Solenoid - N110-
❑ Installed location: The shift lock solenoid is located in the selector mechanism.
13 - Tiptronic Switch - F189-
❑ Installed location. Refer to ⇒ Fig. ““Tiptronic Switch”“ , page 17 .
14 - Terminal 50 Power Supply Relay - J682-
❑ Inside the engine compartment E-box. Refer to ⇒ Wiring
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16 - Transmission Range Display - Y6-
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❑ Installed location. Refer to ⇒ Fig. ““Transmission Range Display”“ , page 18 .

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❑ Removing and installing. Refer to ⇒ Electrical Equipment; Rep. Gr. 90 ; Instrument Cluster .
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Transmission Control Module

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Installed location: The control module -arrow- is located in the left

front wheel housing.
– The wheel housing liner must be removed for the removal and
rrectness of i
installation.
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2. Electrical and Electronic Components and Locations
6-Speed Automatic Transmission 09Gw-aEdition
gen AG 07.2012n AG doe
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Installed location: The switch is located
ss
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transmission.
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Valve Body
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Installed location: The valve body is bolted to the underside of the

transmission housing and is covered by the transmission fluid
pan.
nf
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The Solenoid Valve 1 - N88- , Solenoid Valve 2 - N89- , Solenoid
m
atio
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Valve 3 - N90- , Solenoid Valve 4 - N91- , Solenoid Valve 5 - N92- ,

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Solenoid Valve 6 - N93- , Solenoid Valve 9 - N282- and Solenoid

or
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Valve 10 - N283- are secured to the valve body.

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Sensor Wiring Harness

♦ With integrated transmission fluid temperature sensor
-arrow-
Installed location: The wiring harness is secured to the valve body
in the transmission.
Solenoid Valve Wiring Harness

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

Automatic Transmission Hydraulic Pressure Sensor 1 and Auto‐ wagen AG. Volkswagen AG does
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These sensors are not installed in all transmissions. thoris e or
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Installed location: ss
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The automatic transmission hydraulic pressure sensor 1 -1- and
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the automatic transmission hydraulic pressure sensor 2 are in‐
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Transmission Input Speed Sensor and Transmission Output
at
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Speed Sensor
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Installed location: inside the transmission housing above the

at
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valve body.
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2 - Transmission output speed sensor
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Tiptronic Switch
Installed location: The Tiptronic switch is integrated in the shift
mechanism.
If the vehicle has a multifunction steering wheel, check the but‐
tons on the steering wheel and the corresponding wire connec‐
tions.
2. Electrical and Electronic Components and Locations 17

Diagnostic Connection
Installed location: The data link connector -arrow- is located under
the driver side storage compartment on the left side.
Transmission Range Display

Installed location: Inside the instrument cluster
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3 Multifunction Transmission Range

Switch - F125-
⇒ “3.1 Multifunction Transmission Range Switch F125, Removing
and Installing”, page 19 .
⇒ “3.2 Multifunction Transmission Range Switch, Adjusting”,
page 21 .
3.1 Multifunction Transmission Range

Switch F125, Removing and Installing
♦ Torque Wrench (5-50 Nm) - VAG1331-
Removing
– Move the selector lever into the “N” position.
– Turn off the ignition.
6 Cylinder Gas Vehicles
– Remove the coolant expansion tank. Refer to ⇒ Rep. Gr. 19 ;
Cooling System Components .
– Connect the battery ground cable. Refer to ⇒ Electrical Equip‐
ment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and
Connecting .
Continuation for All
– Disconnect the selector lever cable -1-
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-2- and remove it. agen oes
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tabs on the cable bracket
au
th may break off. eo
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– Pry the cable -1- off the selector shaft lever -3- using a open
end wrench -2-.
rrectness of i
– Disconnect the connector from the multifunction transmission

range switch.
l purpos
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mercia
at
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ate
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3. Multifunction Transmission Range Switch F125 19

– Remove the nut -1-. AG. Volkswagen AG d

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– Remove the spring washer ed b -2- and the selector shaft lever ara
nte
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-3- from the selector thshaft
or -4-. eo
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atio
– Bend back the hooks on the lock washer -2- using a screw‐
om
driver.
n
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– Replace the lock washer, if the hooks are broken.

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– Remove the nut -1-.
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– Remove the bolts -5-.
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– Remove the multifunction switch -4- and washers -2 and 3-
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Installing
Install in the reverse order of removal. Pay attention to the fol‐
lowing:
– Install the multifunction switch -4- to the selector shaft -6-.

– Install the multifunction switch bolts -5- hand tight.
– Install the washers -2 and 3- onto the selector shaft -6-.
– Install the washer -2- with the hooks facing up.
– Install the washer -2- with the long narrow guide into the long
narrow depression in the selector shaft -6-.
– Install and tighten the nut -1- to 7 Nm.
– Secure the nut -1- by bending the hooks on the lock washer
downward -2-.
– Replace the lock washer, if the hooks are broken.

– Install the selector lever -3- onto the selector shaft -4-.
– Move the selector lever -3- into the “P” position. This means,
push the selector lever -3- opposite the direction of travel until
it stops.
– Move the selector lever -3- into the “N” position. Push the lever
-3- two positions forward in the direction of travel.
– Install the spring washer -2- and the nut -1- onto the selector
shaft -4-.
– Tighten the nut -1- to 13 Nm.
6 Cylinder Gas Vehicles
– Install the coolant expansion tank. Refer to ⇒ Rep. Gr. 19 ;
Cooling System Components .
– Connect the battery ground cable. Refer to ⇒ Electrical Equip‐
ment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and
Connecting .
Continuation for All
– Check the selector mechanism. Refer to
⇒ “8 Gearshift Mechanism, Checking”, page
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3.2 Multifunction Transmission Range
b ara
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oris eo
Switch, Adjusting
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♦ Setting Gauge - T10173-
erm
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– Move the selector lever into the “N” position.

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– Do not bend the selector lever cable.
hole
spec
Adjustment Prerequisites
es, in part or in w
t to the co
• The selector lever cable is disconnected from the selector

shaft lever
rrectness of i
• The selector shaft is in the “N” position.

l purpos
• The bolts for the multifunction transmission range switch have

been loosened.
nform
ercia
• The selector shaft lever is removed.

m
at
– Install the Setting Gauge - T10173- onto the selector shaft

om
io
-2- and turn the multifunction switch -1- just until the setting
n
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in t
or
gauge locks onto the tab on the multifunction switch connec‐

his
ate
tor.
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– Use the bolt -3- to secure the setting gauge to the selector
f
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shaft -2-.
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– Tighten the multifunction switch bolts -arrows- to 6 Nm.
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– Remove the setting gauge. Prote
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– Further installation is performed in the reverse order.
3. Multifunction Transmission Range Switch F125 21

4 Selector Lever, Emergency Release

Do Not Remove the Handle.
– Press the brake or set the parking brake.
In Case of an Emergency.
– Unclip the shift cover and move it to the side.
Vehicles through 02.09
– Press the yellow plastic piece in, from the right to the left.
The lever can now be moved out of the “P” position.
Vehicles from 03.09

– Push down on the yellow plastic piece.
The lever can now be moved out of the “P” position.
AG. Volkswagen AG d
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Rep. Gr.37 - Controls, Housing Prote
cted AG.
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5 Selector Lever Handle, Removing

and Installing
⇒ “5.1 Selector Lever Handle, Removing and Installing”,
page 23
⇒ “5.2 Button in Handle, Moving to Installed Position”,
page 25
5.1 Selector Lever Handle, Removing and

Installing
Short Description
There are different handles depending on the model.
The handle is removed together with the shift cover.
Removing
– Move the selector lever into the “D” position.
Handle with the Button on the Side
– Pull the button out of the handle just far enough until there is
a small gap between the handle and the button. The button
locks when released.
– Prevent the button from being pressed in with a cable tie or
wire.
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Handle with the Button in the Front

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It is not necessary to pull out the button manually. The button

wit
locks in the installed position in direction of -arrow-. when the

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handle is removed.
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orm
Continuation for all Handles

m
atio
om
– Remove the cover.

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– Disconnect the connector from the selector cover.

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– Push the sleeve upward and unlock the handle.

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5. Selector Lever Handle, Removing and Installing 23

AG. Volkswagen AG d
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CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ris,eGolf Plus 2005 ➤ , Passat 200 ...
d b ara
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6-Speed Automatic Transmission 09G aut - Edition 07.2012
h o eo
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Only Handles with Clamps
un
pt
an
d
itte
– Cut the clamp under the boot -arrow- with side cutters.
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ility
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– Remove the handle from the selector lever without pushing the
h re
ole,
button.
spec
t to the co
Note
rrectne
Do not push the button once the handle has been removed oth‐
erwise it will not be possible to install the handle again.
ss o
cial p
f
Installing
inform
mer
– Install in reverse order of removal. Note the following:
atio
m
• The selector lever is in the “D” position.

o
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or
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Handle with the Button on the Side yi

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• The button inside the handle is pulled out and is protected from
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getting pushed in again. p by
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• The button is in the installed position -arrow-.
If the button was pushed in by mistake, the installed position can
be set again.
– Move the button to the installed position. Refer to
page 25 .

olkswagen AG
wag en AG. V
CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 V➤ olk,s Golf Plus 2005 ➤ , Passat
does
not200 ...
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6-Speed Automatic
sed by
Transmission 09G - Edition 07.2012
ara
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Note
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A new handle is delivered with an assembly aid. Pull out the as‐
erm
ab
ility
sembly aid just prior to installation.
ot p
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spec
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– Install the handle all the way onto the selector lever and lock
t to the co
it.
– Push the sleeve down to lock it.
rrectness of i
Only Handles with Clamps
l purpos
– Install the handle with a new clamp.
– Tighten the clamp using the hose clamp pliers - VAG1275- .
nform
ercia
– Press the button after installing it.
m
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Note
at
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If the button stays in the handle after being pressed, this means
f
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t.
it was installed incorrectly. If this happens, remove the handle
yi Co
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again and move the button to the installed position again. Refer
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page 25 . Then install the handle again.
Prote AG.
Further installation is performed in the reverse sequence.
5.2 Button in Handle, Moving to Installed

Position
Handle with the Button on the Side
– Pull the button out of the handle just far enough until there is
a small gap between the handle and the button. The button
locks when released.
– Prevent the button from being pressed in with a cable tie or
wire.
The button cannot be pulled out on these handles.
There are two way to move the button into the installed position,
»with« or »without« an assembly aid. The following describes
both ways.
Moving the Handle “with” an Assembly Aid into the Installed Po‐
sition
5. Selector Lever Handle, Removing and Installing 25

Make sure the assembly aid has an eye -arrow- at the front. Other
assembly aids cannot be used.
– Press the button and push the assembly aid (with the eye)
-arrow- all the way in until it latches into place. Then release
the button. The button locks in the installed position when the
assembly aid is pulled out.
Moving the handle “with” an assembly aid into the installed posi‐
tion agen
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– Remove the trim -A- from the handle.
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
r
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– Push the small lever -1- into the groove -2- with a screwdriver. Prote
cted AG.
agen
This pushes the button -3- into the installed position.
-I- the button is in the pressed position
-II- the button is in the installed position
Note
♦ Push the lever into the groove and no further.

♦ Install the trim back onto the selector handle only after the
handle is installed. This way it is possible to see if the small
lever fits into the pull rod when the button is pushed.

CC 2010 ➤ , Golf 2004
AG. Vo➤
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6 Selectorss Mechanism through au ra
c
02/2009
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⇒ “6.1 Overview - Selector Mechanism, through 02.09”,
erm
ab
page 27
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⇒ “6.2 Shift Mechanism with Selector Lever, Removing and In‐
h re
ole,
stalling”, page 28
spec
⇒ “6.3 Selector Lever Cable, Removing and Installing”,
t to the co
page 29
⇒ “6.4 Selector Lever Cable, Checking”, page 36
rrectne
⇒ “6.5 Selector Lever Cable, Adjusting”, page 37
s
6.1 Overview - Selector Mechanism,
s o
cial p
f
through 02.09
inform
mer
atio
m
WARNING
o
n
c
i
or
n thi
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sd
Move the selector lever into the “P” position and set the parking
iva
o
r
brake before working with the engine running.

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1 - Selector Handle with Cover co Vo
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❑ Do not remove the han‐
Prote AG.
dle unnecessarily. For

emergency release, on‐
ly the cover needs the
be removed. Refer to
⇒ “4 Selector Lever,
Emergency Release”,
page 22 .
❑ Pull the button past its
pressure point before
removing the handle.
Secure the button with a
tie strap or tape. This
prevents the button from
being pushed back into
the handle accidentally.
❑ If the button is pushed
in:
– Just before installing,
pull the button out be‐
yond the press point
(sense this by touch).
2 - Selector Mechanism with

Selector Lever
ling. Refer to
⇒ “6.2 Shift Mechanism
with Selector Lever, Re‐
moving and Installing”,
page 28 .
3 - Bolt with Spring
❑ 3 Nm
4 - Pin
❑ Removing. Refer to
6. Selector Mechanism through 02/2009 27

⇒ “6.3 Selector Lever

Cable, Removing and Installing”, page 29 .
❑ Do not lubricate.
5 - Retainer
❑ Always replace after removing.
6 - Nut
❑ 9 Nm
❑ Quantity: 4
7 - Selector Housing agen
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8 - Selector Lever
ut
ho Cable
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or
a ac
❑ Do not ss grease the cable.
ce
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nl
❑ Removing and installing. Refer to ⇒ “6.3 Selector Lever Cable, Removing and Installing”, page 29 .
pt
du
an
itte
❑ Checking. Refer to ⇒ “6.4 Selector Lever Cable, Checking”, page 36 .
y li
erm
ab
❑ Adjusting. Refer to ⇒ “6.5 Selector Lever Cable, Adjusting”, page 37 .
ility
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9 - Retainer
h re
hole
spec
10 - Nut
es, in part or in w
❑ 8 Nm
t to the co
❑ Quantity: 4
rrectness of i
l purpos
6.2 Shift Mechanism with Selector Lever,

Removing and Installing
nform
mercia
at
om
Note
on
c
in t
or
his
te
Check the cable for ease of movement after installing it.

a
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cum
for
en
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Removing
n
t.
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– Remove the center console. Refer to “Storage Compartments,
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Covers and Trim” in ⇒ Body Interior; Rep. Gr. 68 ; Center p by
o Vo
by c
Console; Center Console, Removing and Installing .
lksw
cted agen
Prote AG.
– Remove the cable from the transmission. Refer to
⇒ “6.3 Selector Lever Cable, Removing and Installing”,
page 29 .
– Remove the exhaust system components underneath the heat
shield. Refer to ⇒ Rep. Gr. 26 .
– Remove the heat shield under the vehicle.
– Remove the 4 nuts for the selector mechanism from above.
Tightening specification for the nuts: 8 Nm
Installing
Installation is performed in the reverse sequence.
– Check the cable after installing it. Refer to
⇒ “6.4 Selector Lever Cable, Checking”, page 36 .

6.3 Selector Lever Cable, Removing and In‐

stalling
Note
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gen AG does
Check the cable for ease of movement
Vol after installing it.
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Removing tho eo
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ss
– Move the selector lever into the “S” position .
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pt
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– Disconnect the selector lever cable -1- from the cable bracket
itte
y li
-2- and remove it.
erm
ab
ility
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Be careful not to bend the cable. Do not use pliers, otherwise the
wit
, is n
tabs on the cable bracket may break off.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– Pry the cable -1- off the selector shaft lever -3- using a open
orm
end wrench -2-.
m
atio
om
n in
– Lift the vehicle.
or c
thi
te
sd
To remove the cable and/or the selector mechanism, remove the
iva
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r
heat shield and, if necessary, any exhaust system components.

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Refer to ⇒ Rep. Gr. 26 .
f
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– Remove the heat shield.
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– Remove the selector housing from under the selector mech‐
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es, in part or in w
t to the co
rrectness of i
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– Remove the retainer. Always replace the retainer.

nf
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The selector housing is pushed forward on the cable.
The retainer must be pushed forward in order to remove the cable

-1-.
– Push the pin upward at the same time with a screwdriver -2-.
AG. Volkswagen AG d
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– Insert the screwdriver from underneath while pushing the re‐

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tainer forward.
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es, in part or in w
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ate
For Clarity
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pt
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ab
ility
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, is n
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hole
spec
es, in part or in w
– Remove the selector lever cable.
t to the co
Remove the selector housing from the cable
rrectness of i
Installing
l purpos
Do not grease the cable.

– Route the selector lever cable so that it is free of tension and
nform
ercia
install it into cable bracket on the transmission but do not se‐

cure it yet.
m
at
om
io
– When installing, make sure the selector lever cable is routed

n
c
in t
r
correctly.
o
his
ate
do
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– Clip the selector lever cable into the bracket. Make sure that
p
cum
or
the bracket does not touch the transmission fluid cooler.

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6-Speed Automatic Transmission 09G - Edition 07.2012 olksw AG. V agen AG
agen does
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Nuts: 8 Nm db
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– Mount the selector housing on the cable. tho eo
au ra
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nl
pt
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ab
ility
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nform
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– Install the selector lever cable into the selector mechanism.
n
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or
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ate
do
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– Insert the cable into the bracket and then insert the pin through
the eye from the top
Install the retainer only after having checked the cable for ease
of movement. Refer to
– Secure the cable with a new retainer to the cable bracket on

the selector mechanism.

AG. Volkswagen AG d
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pt
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ility
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, is n
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hole
spec
es, in part or in w
t to the co
– Install the selector housing, the heat shield and the exhaust
system.
rrectness of i
– Adjust the selector lever cable after installing. Refer to

l purpos

nform
mercia
at
om
ion
c
in t
or
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ate
do
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6.4 Selector Lever Cable, Checking . Volkswagen AG

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Short Description yV
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To check the selector lever cable for ease of movement,
thoris
discon‐ eo
nect it from the transmission and position the removed
s au end so it ra
c
does not make contact anywhere. s
ce
le
un
pt
The selector lever moves and the cable will be attached again.
an
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After that, the selector lever cable must be adjusted. Refer to
ility
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⇒ “6.5 Selector Lever Cable, Adjusting”, page 37 .
wit
is n
h re
Do not grease the cable connection! ole,
spec
Checking
t to the co
– Move the selector lever into the “P” position.
– Loosen the adjustment bolt -2- on the cable -1-.
rrectness o
cial p
f inform
mer
atio
om
n
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or
n thi
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– Pry the cable -1- off the selector shaft lever -3- using a open py by
co Vo
end wrench -2-.
by lksw
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Vehicles through 02.09
-2- and remove it.
Vehicles from 03.09

– Remove the retainer in the direction of -arrow-.

– Move the selector lever from “P” to “S” and back to “P” several
times.
• The selector lever must move easily.
– Connect the cable to the transmission.
– Adjust the cable. Refer to
AG. Volkswagen AG d
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6.5 d by Volksw
Selector Lever Cable, Adjusting
not
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Special tools and workshop
utho equipment required eo
ra
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♦ Torque Wrench s (5-50 Nm) - VAG1331-
ce
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un
pt
The Selector Lever Cable Must Always Be Adjusted If:
an
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itte
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rm
ab
♦ The selector lever cable was removed from the transmission.
pe
ility
ot
wit
♦ The engine and/or transmission were removed and installed.
, is n
h re
hole
♦ Parts of engine/transmission mounts were removed and in‐
spec
stalled.
es, in part or in w
t to the co
♦ The cable itself or the selector mechanism was removed and
installed.
rrectness of i
♦ The engine/transmission positions change, for example, were
installed free of tension.
l purpos
Adjusting
nform
ercia

m
Loosen the adjustment bolt -2-.

com
tion in
r
– Move the selector shaft lever -3- into the “P” position (push the
te o
thi
lever to the rear).

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WARNING
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Make sure the parking lock is latched.
ht
pyri by
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Prote AG.
– From underneath the vehicle, rotate both front wheels in the

same direction and at the same time until the parking lock au‐
dibly engages.
• The parking lock is engaged when it is not possible to rotate
both front wheels in the same direction at the same time.
– Lightly tap button in the handle forward and backward and
make sure to keep the handle in the “P” position.
This locates the cable core in its optimal position.

– Tighten the adjustment bolt -2- to 15 Nm.

This ends the adjustment.
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spec
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mer
atio
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te
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AG. Volkswagen G d ➤ , Golf 2009 ➤ , Golf Plus 2005 ➤ , Passat 200 ...
oes
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6-Speed guAutomatic Transmission 09G - Edition 07.2012
ara
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7 Selector Mechanism from 03/2009
s a c
s
ce
e
nl
pt
du
⇒ “7.1 Overview - Selector Mechanism, from 03.09”, page 39
an
itte
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erm
ab
⇒ “7.2 Selector Mechanism with Selector Housing, Removing and
ility
ot p
Installing”, page 40
wit
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⇒ “7.3 Selector Mechanism without Selector Housing, Removing
hole
spec
and Installing”, page 43
es, in part or in w
t to the co
7.1 Overview - Selector Mechanism, from
03.09
rrectness of i
WARNING
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Move the selector lever into the “P” position and set the parking
nform
ercia
brake before working with the engine running.

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ion
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or
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ate
1 - Selector Handle with Cover
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❑ Do not remove the han‐
for
en
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dle unnecessarily. Un‐

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clip only the cover for C py
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the emergency release. gh ht
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Refer to cop Vo
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⇒ “4 Selector Lever,
agen
Prote AG.
Emergency Release”,
page 22 .
ling. Refer to
⇒ “5 Selector Lever
Handle, Removing and
Installing”, page 23 .
2 - Center Console Cover
❑ Is installed only occa‐
sionally.
3 - Selector Lever and Selector
Mechanism with Selector Lev‐
er Cable
❑ With the shift lock sole‐
noid.
❑ Do not grease the cable.
ling. Refer to
⇒ “7.3 Selector Mecha‐
nism without Selector
Housing, Removing and
Installing”, page 43 .
❑ Checking. Refer to
Cable, Checking”,
page 36 .
❑ Adjusting. Refer to
Cable, Adjusting”,
page 37 .
4 - Bolt
❑ 8 Nm
7. Selector Mechanism from 03/2009 39

CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ .,VGolf
olkswaPlus 2005 ➤ , Passat 200 ...
gen AG
6-Speed Automatic Transmission w gen A-GEdition 07.2012
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5 - Nut rise nte
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❑ 8 Nm s au ra
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❑ Quantity: 4
nl
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6 - Selector Housing
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ility
7 - Retainer
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❑ Always replace after removing.
h re
hole
spec
8 - Selector Lever Cable
es, in part or in w
❑ Can only be replaced together with the selector mechanism. Refer to
t to the co
⇒ “6.2 Shift Mechanism with Selector Lever, Removing and Installing”, page 28 .
9 - Transmission
rrectness of i
10 - Tunnel/Body
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7.2 Selector Mechanism with Selector
orm
m
atio
Housing, Removing and Installing
om
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or c
Short Description
thi
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The selector mechanism and the selector lever cable cannot be

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separated from each other. Both are removed with the selector
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housing.
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Remove the center console inside the passenger compartment.
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It is necessary to remove the heat shield under the vehicle. cted agen
Prote AG.
It is possible to remove and install the selector mechanism with

the selector lever cable alone without the selector housing. Refer
to
⇒ “7.3 Selector Mechanism without Selector Housing, Removing
and Installing”, page 43 .
Note
After installation, the selector lever cable movement must be

checked and adjusted.
Removing
– Remove the selector lever handle. Refer to
⇒ “5 Selector Lever Handle, Removing and Installing”,
page 23 .
Covers and Trim” in ⇒ Body Interior; Rep. Gr. 68 ; Center
– Disconnect the connector from the selector mechanism to the
vehicle wiring harness.
– Remove the air filter housing. Refer to ⇒ Rep. Gr. 24 ; Injec‐
tion System; Overview - Air Filter .

wage es n
CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 yV
o ➤ , Golf Plus 2005 ➤ , Passat
lks ot g 200 ...
b ua
6-Speed Automatic
ir se
d Transmission 09G - Edition 07.2012 ran
tee
tho
u or
a ac
– Pry the cable -1- off the selector shaft lever -3- susing
s a wrench
-2-.
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le
un
pt
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itte
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ab
Caution
pe
ility
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wit
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The retainers on the selector lever cable break very easily. The
h re
complete selector mechanism with selector lever cable must
hole
spec
be replaced if one of the tabs breaks off.
es, in part or in w
t to the co
– Squeeze the retainers on the selector lever cable -arrows- and
rrectness of i
remove the selector lever cable from the cable bracket.
– Do not bend the cable.
l purpos
– Disconnect the selector lever cable -1- from the bracket
nform
ercia
-arrow- on the transmission.
m
a
com
t
ion in
r
te o
– Part of the exhaust system must now be removed in order to
thi
s
iva
remove the cable and/or the selector mechanism.
do
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fo
– Remove the heat shield.
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CC 2010 ➤ , Golfo2004
ksw ➤ , Golf 2009 ➤ , Golf
ag does Plus 2005 ➤ , Passat 200 ...
not
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6-Speed Automatic
ed by Transmission 09G - Edition 07.2012
gu
ara
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utho eo
ra
a c
ss
ce
Note nl
e
pt
du
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itte
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A second technician is required under the vehicle to remove the
erm
ab
selector mechanism.
ility
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– Remove the nuts -arrows- in the vehicle interior.
hole
spec
es, in part or in w
Tightening specification, see -item 5- in the
t to the co
⇒ “7.1 Overview - Selector Mechanism, from 03.09”, page 39 .
– Remove the selector mechanism with the selector lever cable
and selector housing downward.
rrectness of i
Installing
l purpos
Install in the reverse order of removal.
nform
mercia
at
Note
om
ion
c
in t
or
♦ Do not bend or kink the selector lever cable.
his
ate
do
riv
♦ Do not lubricate the selector lever cable.

p
cum
for
en
ng
t.
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op
– Push the selector lever cable carefully onto the selector lever C py
t. rig
and insert it into the cable bracket.
gh ht
pyri by
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by
– Install the exhaust system. Refer to ⇒ Rep. Gr. 26 . Prote
cted AG.
agen
– Install the heat shield

– Install the center console. Refer to “Storage Compartments,
– Install the selector lever handle. Refer to
page 23 .
– Adjust the selector lever cable. Refer to
⇒ “8 Gearshift Mechanism, Checking”, page 45 .
– Install the air filter housing. Refer to ⇒ Rep. Gr. 24 ; Injection
System; Overview - Air Filter .

7.3 Selector Mechanism without Selector

Housing, Removing and Installing
Short Description
The selector mechanism and the selector lever cable cannot be
separated from each other. Both are removed at the same time.
Remove the center console inside the passenger compartment.
Tie a cord/wire to the cable before removal. Use the cord/wire to
help move the cable in and out between the tunnel and the heat
shield. wage
es ks not
Vol gu
The selector mechanism witheselector
db
y lever cable can be re‐ ara
nte
moved and installed togetherthoris
with the selector housing. Refer to eo
⇒ “7.2 Selector Mechanism
s au with Selector Housing, Removing and ra
c
Installing”, page 40 . s
ce
e
nl
pt
du
an
itte
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erm
Note
ab
ility
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wit
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Check the cable for ease of movement after installing it.
h re
hole
spec
– Remove the selector lever handle. Refer to
es, in part or in w
t to the co
page 23 .
rrectness of i
l purpos

– Disconnect the connector from the selector mechanism to the
nf
ercia
vehicle wiring harness.
orm
m
– Remove the air filter housing. Refer to ⇒ Rep. Gr. 24 ; Injec‐ atio
m
tion System; Overview - Air Filter .

o
n in
or c
thi
te
sd
a
– Remove the lock washer.

iv
o
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cu
o
– Always replace the lock washer on the selector lever cable.

f
en
ng
t.
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op
– Remove the cable from the ball head. C py
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yri by
– A long cord/wire is then attached to the end of the cable. This cop Vo
by lksw
cord/wire is used to pull the cable between the tunnel and the cted agen
Prote AG.
heat shield during installation.
– Remove the 4 bolts.

– Pull the selector mechanism and cable out of the center tunnel.
Make sure the cord/wire is pulled through far enough so that
it is still reachable from the engine compartment.
– Remove the cord/wire from the cable.
Installing
Install in the reverse order of removal. Note the following:
A second technician will be needed in order to feed the cable from
the passenger compartment into the engine compartment.
Note
♦ Do not bend or kink the selector lever cable.

♦ Do not lubricate the selector lever cable.
– Attach the cord/wire to the end of the cable that was pulled
from the engine compartment into the passenger compart‐
ment while removing the selector mechanism.
– Guide the selector mechanism and cable through the opening
in the center tunnel.
– From the engine compartment, the second technician pulls the
cord/wire with the cable through the tunnel until it is possible
to attach the cable to the bracket.
– Remove the cord/wire from the cable.
– Attach the selector mechanism with 4 bolts
ksw to the selector
age es n
housing. y Vol ot g
ua
db e ran
ris tee
Tightening Specification: 8 Nm utho or
a ac
ss
– Before positioning the ball head: Check the cable. Refer to
ce
e
nl

pt
du
an
itte
y li
– Install the center console. Refer to “Storage Compartments,

erm
ab

ility
ot p

wit
, is n
h re
– Install the selector lever handle. Refer to

hole
spec

es, in part or in w
page 23 .
t to the co
– Adjust selector lever cable after installing. Refer to

rrectness of i

l purpos
⇒ “8 Gearshift Mechanism, Checking”, page 45 .

– Install the air filter housing. Refer to ⇒ Rep. Gr. 24 ; Injection
nform
ercia
System; Overview - Air Filter .

m
at
om
ion
c
in t
or
his
ate
do
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for
en
ng
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Cop py
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Prote AG.

8 Gearshift Mechanism, Checking

⇒ “8.1 Gearshift Mechanism, Checking”, page 45
8.1 Gearshift Mechanism, Checking

The engine cannot be started when the selector lever is in the “R”,
“D” and “S” positions.
Over 5 km/h (3 mph)
The shift lock solenoid must not block the selector lever when the
lever is in the “N” position. The selector lever can be moved back
into a another gear.
Below 5 km/h (3 mph)
The shift lock solenoid will block the selector lever approximately
1 second after the lever is moved into the “N” position. The se‐
lector lever can be moved out of “N” only when the brake pedal
is pressed.
Selector Lever in the “P” Position and the Ignition is Turned On
• The brake pedal is not pressed:
The selector lever is locked and cannot be shifted out of the “P”
position with the lock button pressed. The shift lock solenoid
blocks the selector lever.
• The brake pedal is pressed:
The shift lock solenoid releases the selector lever. It is now pos‐
sible to shift into a gear. Shift the selector lever slowly through
from “P” to “S”; while doing this, check whether the display for the
selector lever position in the instrument panel insert matches the
actual selector lever position. wage
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Vol t gu
Selector Lever in the “N” Position and the Ignition
ed
by is Turned On ara
ris nte
• The brake pedal is not pressed: ho eo
aut ra
ss c
The selector lever is locked and cannot be shifted out of “N” with
ce
e
nl
pt
the lock button pressed. The shift lock solenoid blocks the selec‐
du
an
itte
tor lever.
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erm
ab
ility
• The brake pedal is pressed:

ot p
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The shift lock solenoid releases the selector lever. It is now pos‐
h re
hole
sible to shift into a gear.

spec
es, in part or in w
Selector Level in the “Tiptronic” Position

t to the co
– Shift the selector lever into the Tiptronic gate.

rrectness of i
The illuminated “D” in the cover must go out. The “+” and “-” must
turn on.
l purpos
The symbols inside the instrument cluster must change from “P

R N D S” to “6 5 4 3 2 1”.
nform
ercia
Ignition and Lights Turned On

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at
om
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The appropriate symbol is being lit up in selector mechanism cov‐

n
c
in t
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er.
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ate
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Transmission Range Display

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Simultaneous lighting of all segments of the transmission range

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selector lever display indicates the transmission is in emergency Cop py
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Prote AG.
8. Gearshift Mechanism, Checking 45

9 Transmission, Removing and Instal‐

ling, Golf from MY 2004
⇒ “9.1 Transmission, Removing, Golf MY 2004 with 1.6L - 75 kW,
1.6L - 85 kW (FSI) and 2.0L - 110 kW (FSI) Engine”, page 46 .
⇒ “9.2 Transmission, Installing, Golf MY 2004 with 1.6L - 75 kW,
1.6L - 85 kW (FSI) and 2.0L - 110 kW (FSI) Engine”, page 52 .
⇒ “9.3 Transmission, Removing, Golf MY 2004 with 2.5L - 110kW/
125 kW Engine”, page 52 .
⇒ “9.4 Transmission, Installing, Golf MY 2004 with 2.5L - 110kW/
⇒ “9.5 Tightening Specifications, Transmission to Engine”,
page 59 .
9.1 Transmission, Removing, Golf MY 2004

with 1.6L - 75 kW, 1.6L - 85 kW (FSI) and
2.0L - 110 kW (FSI) Engine
– Before removing, print out the diagnostic protocol for this ve‐
hicle »if possible«. Affix the protocol on to transmission before
sending back the removed transmission in the usual way.
AG. Volkswagen AG d
Brief Description ksw
agen oes
not
ol
yV gu
The transmission is remove downward separately. The engine ised b ara
nte
remains in the vehicle. ut
hor eo
a ra
s c
The battery housing, the air filter and the engine cover are re‐ s
ce
le
moved »from above«. Engine and transmission are then suppor‐

un
pt
an
d
ted so that the left subframe mount can be removed.

itte
y li
erm
ab
Remove the noise insulation and the drive axles »from under‐
ility
ot p
neath«. The transmission is lowered with the transmission jack.
wit
is n
h re
ole,
spec
Note
t to the co
The subframe is not removed.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.


equipment required
♦ Engine and Gearbox Jack -
VAS6931-
♦ Torque Wrench 1332
40-200Nm - VAG1332-
♦ Transmission Support -
3282-
Mounting Plate 36 -
3282/36-
♦ Hose Clamps - Up To 25
mm - 3094- n AG. Volkswagen AG do
lkswage es n
o ot g
♦ Insert Tool - 18mm - d byV ua
ran
T10179- ir se tee
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a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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♦ Socket - Sw15 - V/175- m

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t.
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Cop py
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cted agen
Prote AG.
9. Transmission, Removing and Installing, Golf from MY 2004 47

♦ Engine Support Bridge - 10-222A-
♦ Engine Support Bridge - Gearbox Adapter - 10-222A /13-

The following descriptions show the 09G transmission with 2.0L
FSI gasoline engine. There are only slight differences for the other
engine versions in the Golf. Tightening specifications: transmis‐
olkswagen AG
sion to engine »as usual«, detailed for each
swa gengine
en AG. V (large and does
small machine; FSI/MPI engine). by Volk not
gu
d ara
se nte
– Before removing, print out the tho diagnostic protocol for this ve‐
ri e or
hicle »if possible«. Affix theau protocol on to transmission before ac
ss
ce
e
nl
pt
du
Removing:
an
itte
y li
erm
ab
– Lift the vehicle, all four mounts from lifting platform at the same
ility
ot p
height.
wit
, is n
h re
– Move the selector lever to »P«.
hole
spec
– Remove the battery and battery housing. Refer to ⇒ Electrical
es, in part or in w
t to the co
Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and
Connecting .
– Remove the engine cover and the air filter with the intake hose.
rrectness of i
– Disconnect the selector lever cable -1- from the cable mount‐
l purpos
ing bracket -2- and remove it.

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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o
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f
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote
AG.
straps on the cable mounting bracket may break off.

– Pry the cable -1- off the lever -3- using an open end wrench
-2-.
– Mount the Hose Clamps - Up To 25mm - 3094- on the hoses

and remove the hoses form the ATF cooler.
– Disconnect the connectors from the transmission and starter.
– Remove the upper starter bolt.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
– Mount the Engine Support Bridge - 10-222A- and support the
s
ce
le
engine and transmission. Do not lift.

un
pt
an
d
itte
y li
– Remove the upper engine/transmission bolts.

rm
ab
pe
ility
Install the bolts using the Insert Tool 18 mm - T10179- . Use the
ot
wit
, is n
lower tightening specification when tightening. Refer to

h re

hole
spec
page 59 .
es, in part or in w
t to the co
rrectness of i
l purpos
– Only remove all six bracket bolts -A-.

nform
ercia
When installing, bolt bracket to transmission first to 40 Nm.

m
a
com
Adjust the old fit between both bolts using a screwdriver when
tion in
tightening the bracket bolts to the vehicle. Tighten the two larger
r
te o
thi
bolts to 60 Nm.
s
iva
do
r
The bracket will be removed later.

rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Press the brake and remove the left drive axle bolt -arrow-. A
second technician will be needed.
Note
AG. Volkswagen AG d
agen oes
lksw no
Do not let the vehicle stand on the floor. Refer to ⇒ Rear Finalt guar
Vo
by
d
Drive; Rep. Gr. 39 ; Driveshaft;
ris
e
Driveshaft, Removing and Instal‐ antee
ling . utho or
a ac
ss
ce
le
un
– Remove the noise insulation.
pt
an
d
itte
y li
– If equipped, remove the heat shield from the engine above the
erm
ab
right drive axle.
ility
ot p
wit
is n
– Remove the vacuum pump and bracket and lines. »The pump
h re
ole,
is located near the ATF filler tube.«.
spec
– Disconnect the connectors from the transmission.
t to the co
– Remove the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.
27 ; Starter; Starter, Removing and Installing .
rrectne
– Remove the pendulum support , first -A-, and then -B-.
ss
First tighten -B- and then tighten -A-. Tightening specifications.
o
cial p
f i
Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Sub‐
nform
frame; Overview - Subframe .
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
– Remove the transverse link from the suspension strut on both
AG.
sides.
Tightening specifications. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 40 ; Subframe; Overview - Subframe .
– Remove both drive axles from the transmission. Refer to ⇒
Suspension, Wheels, Steering; Rep. Gr. 40 ; Drive Axle; Drive
Axle, Removing and Installing .
– Remove the left drive axle .
– Move the right drive axle as far upward as possible and secure
it in this position.

– Remove the subframe mount bracket. To do this slightly lower

the engine with the transmission using the Engine Support
Bridge - 10-222A- spindles.
Four turns is sufficient.
– Remove the exhaust system bracket from the transmission, if
equipped.
– Remove the lower connecting bolts between the engine and
the transmission.
– Leave one easily accessible bolt for safety.
– Start with both lower bolts.
Note
On some of the smaller engines, up to 1.6L, one of the lower

-bolts- can be loosened from the transmission but cannot be re‐
moved out of its hole.
– If these bolts must

agebe
n Aremoved, remove
G. Volkswagen AG d the front exhaust pipe.
o
w es n
olks ot g
Refer to ⇒edRep.
by
V
Gr. 26 . ua
ran
oris tee
The hole
auth for removing the converter nuts on the back of orthe engine
ac
is covered
ss with a rubber plug.
ce
e
nl
pt
– Remove these caps.

du
an
itte
y li
erm
ab
– Remove the six -converter nuts- with the Socket - Sw15 - V/

ility
ot p
175- .
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
Carefully rotate the engine an additional turn!

rrectness of i
– Before removing the last connecting bolt, support the trans‐

mission with the Engine and Gearbox Jack - VAS6931- , the
l purpos
Transmission Support - 3282- and the Transmission Support

- Mounting Plate 36 - 3282/36- .
nf
ercia
– Remove the last bolt.

rm
m
atio
m
– Separate the transmission from the engine.

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
Note
o
m
f
en
ng
t.
yi Co
op
Pay attention to the converter. It must be removed together with
C py
ht. rig
the transmission.
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Make sure there is enough clearance when lowering the left
drive axle to the subframe. If necessary, adjust the Transmis‐
sion Support - 3282- slightly afterwards.

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

bracket and the selector lever cable bracket for example must
be replaced.
9.2 Transmission, Installing, Golf MY 2004

with 1.6L - 75 kW, 1.6L - 85 kW (FSI) and
2.0L - 110 kW (FSI) Engine
– Make sure the alignment bushings are pressed into the engine
flange.
– See how the plate fits between the engine and transmission.
The plate must contact the engine along entire perimeter when
pressing lightly against engine using both hands. If it is above
the engine, then it is not hooked into the cylinder block cor‐
rectly.
AG. Volkswagen AG d
agen oes
Further installation is performed in reverse order of the removal.
Vol
ksw not
gu
y
db ara
– Replace all left assembly mounting screws. rise nte
tho eo
au ra
– First install all new bolts by hand. ss c
ce
e
nl
When installing, bolt bracket to transmission first to 40 Nm + 90°.
pt
du
an
itte
y li
erm
ab
ility
ot p
bolts to 60 Nm + 90°.
wit
, is n
h re
hole
Transmission to engine tightening specifications. Refer to
spec
es, in part or in w
page 59 .
t to the co
The engine and the transmission must be mounted in the sub‐
frame mount without tension. Refer to ⇒ Rep. Gr. 10 for the
rrectness of i
procedure.
l purpos

nform
ercia
– Check the ATF level after installing. Refer to

⇒ “18 ATF”, page 123 .
m
at
om
ion
– Perform the basic setting. To do this

c
in t
or
his
te
– Connect the Vehicle Diagnostic Tester and then select “per‐

a
do
riv
form basic setting” under Guided Functions .

p
cum
for
en
ng
t.
9.3 Transmission, Removing, Golf MY 2004
yi Co
Cop py
t. rig
with 2.5L - 110kW/125 kW Engine
gh ht
pyri by
Vo
co lksw
by
cted
– If possible, before removing print out a diagnostic protocol for
agen
Prote AG.
the vehicle. Affix the protocol to the transmission before send‐
ing back the removed transmission.
Short Description
The transmission is remove downward by itself. The engine re‐
mains in the vehicle.

Remove the battery housing, the air filter and the engine cover.
The engine with transmission are then supported so that the
transmission mount can be removed.
Remove the noise insulation and the drive axles from underneath.
Lower the transmission with the transmission jack.
Note

. Volkswagen AG
gen AG does
Special tools and workshop equipment requiredVolkswa not
y gu
db ara
♦ Engine/GearboxJjack - VAG1383A- rise nte
tho eo
♦ Socket SW15 - V/175- au ra
c
ss
ce
e
nl
♦ Transmission Support - 3282-
pt
du
an
itte
y li
♦ Wedge Tool - T10161-
erm
ab
ility
ot p
wit
, is n
h re
♦ Adjusting Plate - 3282/36-
hole
spec
es, in part or in w
t to the co
♦ Engine Support Feet - 10-222A/8-
♦ Adapter - 10-222A/7-
rrectness of i
♦ Bracket with Spindle and Hook - 10-222A/10-
l purpos
♦ Engine Support Adapter - 10-222A/3-
nf
ercia
♦ Shackle - 10-222A/12-
orm
m
♦ Hose Clip Pliers - VAG1921-
atio
om
n in
c
Procedure
or
thi
te
sd
a
– Before removing, if possible, print out the diagnostic protocol

iv
o
r
rp
cu
for the vehicle. Affix the protocol to transmission before send‐
o
m
f
en
ng
ing back the removed transmission in the usual way.

t.
yi Co
op py
t. C rig
gh ht
pyri by
Vo
– Lift the vehicle, all 4 lift points of the hoist are at the same
o
by c lksw
cted agen
height. Prote AG.
– Push the brake in order to remove the left drive axle bolt
-arrow- (second technician required).
Note
Do not set the vehicle on the floor. Refer to ⇒ Suspension,

Wheels, Steering; Rep. Gr. 40 ; Drive Axle; Drive Axle, Removing
and Installing .
– Remove the engine cover/upper air filter section.

– Disconnect the hoses -arrows- and remove the intake tube

from the throttle valve.
Equipment; Rep. Gr. 27 ; Battery; Battery, Disconnecting and
Connecting .
-2- and remove it.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
– Pry the cable -1- off thehoris
lever -3- using a open-end wrench nte
eo
-2-. aut ra
ss c
ce

le
un
pt
an
d
itte
♦ Multifunction transmission range switch

y li
erm
ab
ility
♦ Starter
ot p
wit
is n
♦ Ground cable from the transmission mount bracket

h re
ole,
spec
t to the co
rrectne
– Remove the wire bracket -1- from the starter stud bolt
-arrow-.
ss o
cial p
– Remove the upper bolt from the starter.

f inform
mer
– Remove the upper engine transmission bolts.

atio
m
So that engine and transmission can be supported:

o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Remove the lines -1- from the transport strap -3-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
– Remove the transport strap -3- from the engine -2- and pull it
nl
pt
du
out of the lifting eye -arrow-.
an
itte
y li
erm
ab
– Attach one Shackle - 10-222A/12- to this lifting eye.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Install the Engine Support Bridge - 10-222A- .
nform
ercia
– Extend the right Bracket with Spindle and Hook - 10-222A/10-

m
at
om
with the Adapter - 10-222A/7- .
ion
c
in t
or
The hook points downward and will be engaged on the cylinder

his
ate
block later. do
priv
cum
or

f
en
ng
t.
yi Co
– Remove the lower section of the left wheel housing liner. Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Remove the right drive axle heat shield bolts -arrows- and
shield.

– Remove the ball joint to lower control arm nuts -arrows- both
sides.
– Remove both drive axles from the transmission. Refer to: ⇒
– Remove the left drive axle.
– Lift the right drive axle as far as possible and then tie it up.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
– Disconnect the connectors -1 and 2- from the transmission.
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
– Remove the connector -1- from the bracket under the starter
thi
te
sd
and then disconnect it.

iva
o
pr
cum
r
fo
– Remove the bracket from the starter lower bolt.

en
ng
t.
yi Co
– Remove the lower bolt from the starter and then remove the Cop py
t. rig
starter. opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.

– Remove the pendulum support, first remove bolt -A-, and then
bolts -B-.
– Drain the coolant.
– Turn the cap -1- in the direction of -arrow- and remove it.
– Remove the six torque converter nuts -arrow- using the socket
SW15 - V/175- .
AG. Volkswagen AG d
agen oes
lksw not
Note d by Vo gu
ara
rise nte
ho eo
Carefully rotate the engine further! s aut ra
c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
– Engage the adapter - 10-222A/7- to the cylinder block. spec

es, in part or in w
t to the co
– Remove the coolant hoses from the transmission fluid cooler.
Tension the right spindle one turn (more turns are not necessary).
rrectness of i
– Support the engine and transmission with the left spindle. Do

not lift it.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove the transmission mount bracket -A-.

– Turn the left spindle on the Engine Support Bridge - 10-222A-
and slightly lower the engine and transmission.
Six turns is sufficient.
– Remove the lower bolts between the engine and the trans‐
mission.
– Support the transmission with the Engine/Gearbox Jack -
VAG1383A- , the Transmission Support - 3282- and the Ad‐
justing Plate - 3282/36- before removing the last bolt.
Note
Pay attention to the torque converter. It must be removed together

with the transmission.
. Volkswagen AG
gen AG does
swa
– The cable bracket and the selector
byV
olk lever cable bracket mustnot gu
be replaced when installingris
eda new transmission.
ara
nte
ho eo
aut ra
ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
9.4 Transmission, Installing, Golf MY 2004

rrectness of i
with 2.5L - 110kW/125 kW Engine

l purpos
– Make sure the alignment sleeves are pressed into the engine
flange.
nf
ercia
orm
m
atio
m
o
n in
c

or
thi
e
t
sd
iva
rectly.
o
r
rp
cu
o
m
f
en

ng
t.
yi Co
op py
The engine and the transmission must be secured free of tension.
. C rig
ht ht
rig by
py Vo
– Replace all transmission mount bolts.
co lksw
by
cted agen
Prote AG.
– First install all new bolts by hand.
When installing, install the transmission mount bracket to the
transmission first. Tighten the bolts to 40 Nm + 90° (1/4) additional
turn.
bolts to 60 Nm + 90° (1/4) additional turn.
Tightening specification, transmission to engine. Refer to
⇒ “9.5.3 Tightening Specifications, Golf MY 2004 with 2.5L 110
kW/125 kW Engine”, page 61 .


– Check the transmission fluid level. Refer to
⇒ “18 ATF”, page 123 .
– Perform a basic setting. To do this:
– Connect the Vehicle Diagnostic, Testing and Information Sys‐
tem - VAS5051- and then select “perform basic setting” using
the guided function .
9.5 Tightening Specifications, Transmission

to Engine
⇒ “9.5.1 Tightening Specifications, Golf MY 2004 with 1.6L 75 kW
and 2.0L 110 kW FSI Engine”, page 59
⇒ “9.5.2 Tightening Specifications, Golf MY 2004 with 1.6L 85 kW
FSI Engine”, page 60
⇒ “9.5.3 Tightening Specifications, Golf MY 2004 with 2.5L 110
kW/125 kW Engine”, page 61
9.5.1 Tightening Specifications, Golf MY 2004 with 1.6L 75 kW and 2.0L 110 kW
FSI Engine
1 - Direction of Travel
A - Bolt for 2.0L 110 kW FSI
B - Bolt for 1.6L 75 kW Engine AG. Volkswagen AG d
agen oes
lksw not
- Drive plate to converter d by Vo gu
ara
ise nte
❑ 60 Nm thor eo
u ra
❑ Quantity: 6, with Socket ss a c
- Sw15 - V/175- , Re‐
ce
e
nl
pt
moving and Installing
du
an
itte
y li
erm
- M12 Bolts ab
ility
ot p
❑ 80 Nm wit
, is n
h re
❑ 65 Nm, if using Insert
hole
Tool - 18mm - T10179-

spec
es, in part or in w
- M10 Bolts
t to the co
❑ 40 Nm
❑ These bolts are located
rrectness of i
inside the lower flange

l purpos
- Two centering sleeves inside

the engine -arrows-
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Make sure that bracket does not touch the transmission fluid
cooler.
-Nuts- 8 Nm
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut
9.5.2 Tightening Specifications, Golf MY 2004 with 1.6L 85 kW FSI Engine
ss a ra
c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
- Drive plate to converter

ot
wit
, is n
❑ 60 Nm
h re
hole
❑ Quantity: 6, with Socket

spec
- Sw15 - V/175- , Re‐

es, in part or in w
t to the co

- M12 Bolts
rrectness of i
❑ 80 Nm
l purpos
Tool - 18mm - T10179-

- M10 Bolts
nform
ercia
❑ 40 Nm
m
a
com
tio

n in
r

te o
thi
s
iva
do

r
rp
cum
the engine -arrows-

fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

cooler.
-Nuts- 8 Nm
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
9.5.3 Tightening Specifications, Golf MY 2004 with 2.5L 110 kW/125 kW Engine
wit
, is n
h re
hole
spec
1 - Driving Direction
es, in part or in w
t to the co
- Drive Plate to Torque Con‐
verter
❑ 60 Nm.
rrectness of i
❑ Quantity: 6, remove and
l purpos
install using the socket

SW15 - V/175- .
nf
ercia
o
- M12 Bolts
rm
m
atio
❑ 80 Nm.
om
n in
c
❑ 65 Nm, if using the insert

or
thi
tool 18 mm - T10179- .
te
sd
iva
o
r
rp
cu
- M10 Bolts
o
m
f
en
ng
❑ 40 Nm.
t.
yi Co
op py
❑ The bolts are located in t. C rig
gh ht
the lower flange. pyri by
Vo
o
by c lksw
cted agen
Arrows - For the Alignment Prote AG.
Sleeves inside the Engine

– Make sure that the bracket does not touch the transmission
fluid cooler.
Nuts: 8 Nm
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


ling, Golf Plus from MY 2005
⇒ “10.1 Transmission, Removing, Golf Plus MY 2005”,
page 63 .
⇒ “10.2 Transmission, Installing, Golf Plus MY 2005”,
page 70 .
⇒ “10.3 Tightening Specifications, Transmission to Engine”, page
70 .
10.1 Transmission, Removing, Golf Plus MY

2005
Brief Description
The transmission is remove downward separately. The engine
remains in the vehicle.
The battery housing, the air filter and the engine cover are re‐
moved »from above«. Engine and transmission are then suppor‐
Remove the noise insulation and the drive axles »from under‐
neath«. The transmission is lowered with the transmission jack.
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
10. Transmission, Removing and Installing, Golf Plus from MY 2005 63


equipment required
VAS6931-
40-200Nm - VAG1332-
3282-
Mounting Plate 36 -
3282/36-
♦ Hose Clamps - Up To
25mm - 3094-
♦ Insert Tool - 18mm -
T10179-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co

rrectne
♦ Socket - Sw15 - V/175-

ss o
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♦ Mud Wing Compensation Plate - T10311-

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The following descriptions show the 09G transmission with 2.0L t. C rig
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engine versions in the Golf. Tightening specifications: transmis‐
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small machine; FSI/MPI engine).

Removing:
– Lift the vehicle, all four mounts from lifting platform at the same
height.
Equipment; Rep. Gr. 27 ; Battery; Battery, Removing and In‐
stalling .

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– Now slide on the Mud Wing Compensation Plate - T10311-

onto both sides between the fender and body.
The illustration shows the right surface.
The left surface is marked with an “L”, and the right side with an
“R”. The arrow is pointing in the direction of travel.


70 .
– Only remove all six bracket bolts -A-.

Note
Do not let the vehicle stand on the floor. Refer to ⇒ Suspension,

and Installing .
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– Remove the pendulum support, first -A-, and then -B-.

sides.
Tightening specifications for control arm bolts. Refer to ⇒ Sus‐
pension, Wheels, Steering; Rep. Gr. 40 ; Subframe .
– Move the right drive axle as far upward as possible and secure
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– Remove the subframe mount bracket. To do this slightly lower

the engine with the transmission using the Engine Support
Bridge - 10-222A- spindles.
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atio
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Note
On some of the smaller engines, up to 1.6L, one of the lower

-bolts- can be loosened from the transmission but cannot be re‐
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mission with the Engine and Gearbox Jack - VAS6931- , the inform
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the transmission.
– Pay attention to the subframe clearance when lowering the

transmission. If necessary, adjust the Transmission Support -
3282- slightly afterwards.

be replaced.

10.2 Transmission, Installing, Golf Plus MY

2005
flange.
rectly.
– Replace all left assembly mounting screws. agen
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⇒ “18 ATF”, page 123 .
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Golf Plus MY 2005, 1.6L - 75 kW and 2.0L - 110 kW FSI Engine.
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⇒ “10.3.1 Tightening Specifications, Golf Plus MY 2005 with 1.6L by c lksw
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75 kW and 2.0L 110 kW FSI Engine”, page 70 . Prote AG.
Golf Plus MY 2005, 1.6L 85 kW FSI Engine. Refer to

⇒ “10.3.2 Tightening Specifications, Golf Plus MY 2005 with 1.6L
85 kW FSI Engine”, page 72 .
Golf Plus MY 2005, 2.5L 110 kW Engine. Refer to
⇒ “10.3.3 Tightening Specifications, Golf Plus MY 2005 with 2.5L
10.3.1 Tightening Specifications, Golf Plus MY 2005 with 1.6L 75 kW and 2.0L 110
kW FSI Engine

AG. Volkswagen AG d
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B - Bolt for 1.6L 75 kW Engine
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❑ 60 Nm
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- Sw15 - V/175- , Re‐
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- M12 Bolts
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❑ 80 Nm
Tool - 18mm - T10179-
nform
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❑ 40 Nm
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the engine -arrows- t. Cop py
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cooler.
-Nuts- 8 Nm

10.3.2 Tightening Specifications, Golf Plus MY 2005 with 1.6L 85 kW FSI Engine
❑ 60 Nm
- Sw15 - V/175- , Re‐
- M12 Bolts
❑ 80 Nm
Tool - 18mm - T10179-
- M10 Bolts
❑ 40 Nm
the engine -arrows-
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-Nuts- 8 Nm
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10.3.3 Tightening Specifications, Golf Plus MY 2005 with 2.5L 110 kW Engine
l purpos
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❑ 60 Nm
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❑ Quantity: 6, with Socket thi

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Tool - 18mm - T10179-
- M10 Bolts
❑ 40 Nm
the engine -arrows-

cooler.
-Nuts- 8 Nm
AG. Volkswagen AG d
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⇒ “11.1 Transmission, Removing, Touran MY 2003”, page 75
hole
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⇒ “11.2 Transmission, Installing, Touran MY 2003”, page 79 .
es, in part or in w
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80 .
rrectness of i
11.1 Transmission, Removing, Touran MY
l purpos
2003
nf
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t
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40-200Nm - VAG1332-
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3282-
Mounting Plate 36 -
3282/36-
25mm - 3094-
T10179-
11. Transmission, Removing and Installing, Touran from MY 2003 75

♦ Socket - Sw15 - V/175-
AG. Volkswagen AG d
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♦ Engine Support Bridge - Sub-Frame Adapter - 10-222A /22-
y li
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Removing:
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Be careful not to bend the cable. Do not use pliers, otherwise the yri
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-2-.
– Mount the Hose Clamps - Up To G25mm

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– Only remove the six bracket bolts -A-. C py
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Prote AG.
– Remove the starter. Remove the nut from the lower bolt and
then the lower bolt. Refer to ⇒ Electrical Equipment; Rep. Gr.


sides.
– Move both shafts as far upward as possible and secure in this

position.
– Remove the pendulum support, first -A-, and then -B-.

(When installing again, first tighten -B-, and then -A-) . Volkswagen AG
gen AG does
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– Remove the subframe mount bracket. To do thisy Vslightly lower
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Support ara
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Five turns is sufficient. Tie up the left drive
s axle.
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Leave one of the lower -bolts- in the hole.

t to the co
– Remove front exhaust pipe to remove this bolt.

rrectne
Refer to ⇒ Rep. Gr. 26 ; Exhaust Pipes/Mufflers; Overview -

Muffler .
s
The hole for the converter bolts on the back of the engine is cov‐
s o
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ered with a rubber plug.

inform
mer

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175- .
Note

mission with the Engine and Gearbox Jack - VAS6931- , the
– Watch the surrounding area closely when lowering the left
drive shaft. If necessary, adjust the Transmission Support -
3282- slightly afterwards.
AG. Volkswagen
Pay attention to the left drive shaft
lksw
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AG do
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push the suspension strut
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pt
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11.2 Transmission, Installing, Touran MY

2003
nform
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a
com
ti
flange.
on in
r
te o
thi
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Further installation is performed in reverse order of the removal. pyri by
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– Replace all left assembly mounting screws. Prote AG.

80 .
procedure.


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– Check the ATF level after installing. Refer to olksw not
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⇒ “18 ATF”, page 123 . ise
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spec
Touran MY 2003 with 1.6L - 85 kW FSI Engine. Refer to
⇒ “11.3.1 Tightening Specifications, Touran MY 2003 with 1.6L
t to the co
Touran MY 2003 with 2.0L - 85 kW (FSI), 1.8L - 110 kW (FSI)
rrectne
Engine. Refer to
85 kW FSI and 1.8L 110 kW FSI Engine”, page 81 .
ss o
cial p
Touran MY 2003 with 2.0L 110 kW FSI Engine. Refer to
f in
form
mer
atio
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n
11.3.1 Tightening Specifications, Touran MY 2003 with 1.6L 85 kW FSI Engine
c
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or
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fo
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t.
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❑ 60 Nm
Co
Cop py
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rig
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- Sw15 - V/175- , Re‐ cop Vo
by lksw
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Prote AG.
- M12 Bolts
❑ 80 Nm
Tool - 18mm - T10179-
- M12 Bolts
❑ 80 Nm
Tool - 18mm - T10179-
- M10 Bolts
❑ 40 Nm
the engine -arrows-

11.3.2 Tightening Specifications, Touran MY 2003 with 2.0L 85 kW FSI and 1.8L
110 kW FSI Engine
AG. Volkswagen AG d
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- Drive plate to dconverter
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❑ 60 Nm hor eo
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❑ Quantity:
ss 6, with Socket c
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❑ 80 Nm
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- M12 Bolts
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s
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❑ 40 Nm
inform
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c
- Two centering sleeves inside i

or
n thi
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the engine -arrows-

t
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Prote AG.

11.3.3 Tightening Specifications, Touran MY 2003 with 2.0L 110 kW FSI Engine

❑ 60 Nm
- Sw15 - V/175- , Re‐
- M12 Bolts
❑ 80 Nm
Tool - 18mm - T10179-
- M12 Bolts
❑ 80 Nm
Tool - 18mm - T10179-
- M10 Bolts
❑ 40 Nm
the engine -arrows-
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ling, Passat from MY 2006
⇒ “12.1 Transmission, Removing, Passat with 1.6L - 85 kW and
2.0L - 110 kW Engine”, page 83 .
⇒ “12.2 Transmission, Installing, Passat with 1.6L - 85 kW and
2.0L - 110 kW Engine”, page 89 .
90 .
⇒ “12.4 Transmission, Removing, Passat with 1.8L - 118 kW and
2.0L 147 kW Engine”, page 91 .
⇒ “12.5 Transmission, Installing, Passat with 1.8L - 118 kW and
2.0L 147 kW Engine”, page 95 .
96 .
12.1 Transmission, Removing, Passat with

1.6L - 85 kW and 2.0L - 110 kW Engine
Brief Description
The transmission is remove downward separately. The engine
remains in the vehicle.
The battery housing, the air filter and the engine cover are re‐
moved »from above«. Engine and transmission are thenAG. Volkswagen AG d
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Remove the noise insulation and the drive
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Prote AG.
12. Transmission, Removing and Installing, Passat from MY 2006 83


equipment required
VAS6931-
40-200Nm - VAG1332-
3282-
Mounting Plate 36 -
3282/36-
25mm - 3094-
T10179-
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tion in
r
te o
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♦ Multipoint Socket - T10035-
♦ Engine Support Bridge - Gearbox Adapter - 10-222A /13-

AG. Volkswagen AG d
– If possible perform a diagnostic protocol for this wvehicle
agen before oes
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removal. Affix protocol to removed transmission
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– Raise the vehicle. au ra
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pt
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ility
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t to the co

rrectness of i
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nform
mercia
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tion in
r
te o
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-2-.
– Remove the cable from the bracket on the transmission.

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– Disconnect the connections from the transmission and
lksw
astarter.
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♦ Multifunction Transmission Range Switch ised b ara
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♦ Starter aut ra
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♦ Ground cable to the bracket
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– Be cautious when working with the tool for the multifunction
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switch connector.
is n
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spec
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90 .
rrectne
The Multipoint Socket - T10035- will make the assembly easier.

ss o
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form
mer

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– Remove all six bracket bolts -A-.

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After the transmission hasdb
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rrectness of i
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Note
nform
ercia
Do not let the vehicle stand on the floor. Refer to ⇒ Suspension,

m
a
com
and Installing .
tion in
r
te o
thi

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iva
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t.
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op py
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ht ht
rig
right drive axle. py by
co Vo
by lksw
cted agen
– Disconnect both connectors from the transmission. Prote AG.
– Remove the lower section of the left wheel housing liner.


– Remove the pendulum support, first -A-, and theno-B-.
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First tighten -B- and then tighten -A-. Tightening ris specifications.
ed ran
tee
Refer to ⇒ Suspension, Wheels, Steering; Rep. utho Gr. 40 ; Sub‐ or
frame; Overview - Subframe . ss
a ac
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
sides.
rrectness of i
Tightening specifications for control arm bolts. Refer to ⇒ Sus‐
l purpos
pension, Wheels, Steering; Rep. Gr. 40 ; Subframe; Overview -

Subframe .
nform
ercia

m
a
com
tio
n in
r
te o
thi
s
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t.
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Cop py
ht. rig
– Move the right drive axle as far upward as possible and secure py
rig by
ht
it in this position. co Vo
by lksw
cted agen
Prote AG.
– Remove the subframe mount bracket. To do so, slightly lower

the engine with the transmission using the spindle of the En‐
gine Support Bridge - 10-222A- .
equipped.
the transmission.
The hole for removing the converter nuts on the back of the engine
is covered with a rubber plug.


175- .
Note

swa
gen AG
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does
mission with the Engine and Gearbox Jack - VAS6931-
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Transmission Support - 3282- and the Transmission
rised Support ara
nte
- Mounting Plate 36 - 3282/36- . ut
ho eo
r a ac
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itte
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ab
ility
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Note
h re
hole
spec
es, in part or in w
t to the co
the transmission.
– Make sure there is enough clearance when lowering the left
rrectness of i
drive axle to the subframe. If necessary, adjust the Transmis‐
l purpos
nform
mercia
at
om
io
n
c
in t
r
o
his
te
be replaced.
a
do
priv
cum
for
en
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
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Prote AG.
12.2 Transmission, Installing, Passat with

1.6L - 85 kW and 2.0L - 110 kW Engine
flange.
rectly.
procedure.
– Replace all left assembly mounting screws.

⇒ “18 ATF”, page 123 .
12.3 Tightening Specifications,

agen
AG.Transmission
Volkswagen AG
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Tightening Specifications afor
ut 1.6L, 85 kW Engine. Refer to
h
ra
⇒ “12.3.1 Tightening Specifications
ss for 1.6L, 85 kW Engine”, page c
ce
90 .
le
un
pt
an
d
itte
Tightening Specifications for 2.0L, 110 kW Engine. Refer to
y li
rm
ab
⇒ “12.3.2 Tightening Specifications for 2.0L, 110 kW Engine”,
pe
ility
page 91 .
ot
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12.3.1 Tightening Specifications for 1.6L, 85 kW Engine
hole
spec
es, in part or in w
t to the co
rrectness of i
❑ 60 Nm
l purpos

- Sw15 - V/175- , Re‐
nform
ercia
- M12 Bolts
m
a
com
tio
❑ 80 Nm
n in
r
te o
thi

s
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Tool - 18mm - T10179-

do
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- M10 Bolts
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❑ 40 Nm Cop py
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inside the lower flange by c lksw
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the engine -arrows-

12.3.2 Tightening Specifications for 2.0L, 110 kW Engine
B - Bolt for other engines
❑ 60 Nm
- Sw15 - V/175- , Re‐
- M12 Bolts
❑ 80 Nm
Tool - 18mm - T10179-
- M10 Bolts
❑ 40 Nm
the engine -arrows-
AG. Volkswagen AG d
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aut ra
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12.4 Transmission, Removing, Passat with

spec
es, in part or in w
1.8L - 118 kW and 2.0L 147 kW Engine

t to the co

rrectness of i
♦ Engine-/Gearbox Jack - VAG1383A-

l purpos

nform
ercia

m
at
om
♦ Hose Clamps up to 25 mm Dia. - 3094-

on
c
in t
or
♦ Insert Tool 18 mm - T10179-

his
ate
do
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♦ Socket SW15 - V/175-

p
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for
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t.
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Cop py
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♦ Engine Support Bridge - 10-222A- gh ht
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♦ Adapter - 10-222A/13- Prote
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CC 2010 ➤ , Golf 2004
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6-Speed Automatic
ss a Transmission 09G - Edition 07.2012 c
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nl
pt
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itte
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Note
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ab
ility
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the vehicle. Affix the protocol to transmission before sending
t to the co
back the removed transmission.
Short Description
rrectness of i
l purpos

nf
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orm
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c
or
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Procedure
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– Before removing, if possible print out the diagnostic protocol

t.
yi Co
op
C py
t. rig
gh
ing back the removed transmission in the usual way.
ht
pyri by
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co lksw
by
cted agen
Prote AG.

– Remove the engine cover and the air filter with the intake duct.
– Remove the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Battery, Removing and Installing .
– Remove the transmission fluid cooler from the battery housing
and move it to the side.
– Remove the battery housing.
-2- and remove it.

– Pry the cable -1- off the lever -3- using a open end wrench
-2-.
– Remove the upper wire holder from the transmission.
– Remove the lower wire holder from the transmission.
– Remove the transmission fluid pipes from the transmission.
Always replace the seals on the transmission fluid pipes.
♦ Starter agen
AG. Volkswagen AG d
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♦ Groundedcable
by from the transmission mountgubracket
ara
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– Remove
auth the bolt from the top of the starter. eo
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ss c
ce
le
un
pt
an
d
On installation, install the bolts using the 18 mm insert tool -

itte
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T10179- . Use the lower tightening specification when tightening.
erm
ab
ility
Refer to
ot p
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⇒ “13.3.1 Engine to Transmission Tightening Specifications”,
is n
h re
page 106 .
ole,
spec
The multipoint socket - T10035- will make the assembly easier.

t to the co
– Install the engine support bridge - 10-222A- and support the
engine and transmission. Do not lift it.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
– Remove the 2 transmission mount to bracket bolts and the 4
t. rig
gh ht
yri
transmission mount bracket -A- to transmission bolts.
p by
co Vo
by lksw
cted agen
After the transmission has been lowered, the bracket -A- will be
Prote AG.
removed.

– Push the brake in order to remove the left drive axle bolts
Note

and Installing .
– If equipped, remove the right drive axle heat shield bolts

-arrows- and shield. agen
AG. Volkswagen AG d
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olks ot g
– Disconnect the both connectors
db
y V from the transmission. ua
ran
e
ris tee
– Remove the lower section
ut
ho of the left wheel housing liner. or
ac
a
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove the pendulum support, first bolt -A-, and then bolts
-B-.
When installing, First tighten bolts -B- and then tighten bolt -A-. rrectness of i
Tightening specification. Refer to ⇒ Suspension, Wheels, Steer‐
l purpos
ing; Rep. Gr. 40 ; Subframe; Overview - Subframe .

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
– Remove the ball joint to lower control arm nuts -arrows- on
yi Co
op
both sides.
C py
t. rig
gh ht
yri by
Ball joint to control arm nut tightening specifications. Refer to ⇒ cop Vo
by lksw
cted
Suspension, Wheels, Steering; Rep. Gr. 40 ; Lower Control Arm
agen
Prote AG.
and Ball Joint .
– Remove both drive axles from the transmission. Refer to: ⇒

– Lift the right drive axle as far as possible and then tie it up.
– Remove the transmission mount bracket. Using the spindle on
the Engine Support Bridge - 10-222A- , lower the engine and
transmission slightly.
equipped.
mission.
– Start with both lower bolts. agen
AG. Volkswagen AG d
oes
olksw not
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The hole for removing the converter bolts onedthe
b back of the en‐
y ara
nte
gine is covered with a rubber plug. thoris
eo
au ra
– Remove this plug. ss c
ce
e
nl
pt
du
an
– Remove the six torque converter nuts -arrows- using the Sock‐
itte
y li
erm
et SW15 - V/175- .
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
Carefully rotate the engine further!
t to the co
– Support the transmission with the Engine/Gearbox Jack -
rrectness of i
l purpos
nf
ercia
orm
m
atio
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n in
c
Note
or
thi
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sd
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t.
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op py
– Make sure there is sufficient clearance to the subframe when
t. C rig
gh ht
yri
lowering the transmission. If necessary, adjust the Transmis‐ p by
co Vo
by lksw
cted agen
Prote AG.
– The cable bracket and the selector lever cable bracket must
be replaced when installing a new transmission.
12.5 Transmission, Installing, Passat with

1.8L - 118 kW and 2.0L 147 kW Engine
flange.

rectly.
The engine and the transmissionagemust
n AG. Vbe
olksmounted
wagen AG in the sub‐
does
frame mount free of tension.
olksw not
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ed
For the correct tightening
ho
ris specifications. Refer to nte
e
⇒ “12.6.2 Tightening
s aut Specifications, 2.0L 147 kW TFSI Engine”, or a
c
page 98 . s
ce
e
nl
pt
du
an
itte
y li
erm
ab
– First in all new bolts by hand.
ility
ot p
wit
When installing, secure the bracket to the transmission first.
, is n
h re
Tightening specification: 40 Nm + 90° (1/4) additional turn.
hole
spec
es, in part or in w
t to the co
bolts to 60 Nm + 90° (1/4) additional turn.
– Replace the seals for the transmission fluid pipes.
rrectness of i
– Tighten the transmission fluid pipes on the transmission. Refer
l purpos
to
⇒ “12.6.2 Tightening Specifications, 2.0L 147 kW TFSI En‐
gine”, page 98 .
nf
ercia
orm
m
– Tighten both wire holders. Refer to

atio
m
⇒ “12.6.2 Tightening Specifications, 2.0L 147 kW TFSI En‐

o
n in
c
gine”, page 98 .
or
thi
te
sd
iva

o
r
rp
cu

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m
f
en
ng
t.
yi
Co
Cop py
⇒ “18 ATF”, page 123 .
t. rig
gh ht
pyri by
Vo
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– Perform a basic setting. To do this: by c lksw
cted agen
Prote AG.
– Connect the vehicle diagnostic tester and then select “perform
basic setting” using the guided function .

to Engine
⇒ “12.6.1 Tightening Specifications, 1.8L 118 kW TFSI Engine”,
page 96
⇒ “12.6.2 Tightening Specifications, 2.0L 147 kW TFSI Engine”,
page 98
12.6.1 Tightening Specifications, 1.8L 118 kW TFSI Engine

❑ 60 Nm
- Sw15 - V/175- , Re‐
- M12 Bolts
❑ 80 Nm
Tool - 18mm - T10179-
- M10 Bolts
❑ 40 Nm
the engine -arrows-
AG. Volkswagen AG d
agen oes
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ara
ed
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pt
an
d
itte
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pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

6-Speed Automatic Transmission 09G - Edition 07.2012 AG. Volkswagen
n AG do
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12.6.2 Tightening Specifications, 2.0L 147 kW TFSI Engine
V
by ua
ed ran
oris tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
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verter
rm
ab
pe
ility
❑ 60 Nm.
ot
wit
, is n
h re
hole
spec
SW15 - V/175- es, in part or in w
t to the co
- M12 Bolts
❑ 80 Nm.
rrectness of i
tool 18 mm - T10179- .
l purpos
- M10 Bolts
nform
ercia
❑ 40 Nm.
❑ The bolts are located in
m
a
com
ti
the lower flange.
on in
r
te o
thi
Arrows - For the Alignment
s
iva
Sleeves Inside the Engine
do
r
rp
cum
fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.


ling, Passat CC from MY 2009 and
CC from MY 2010
⇒ “13.1 Transmission, Removing, Passat CC MY 2009, CC MY
2010, 2.0L 147 kW TFSI Engine”, page 99 .
⇒ “13.2 Transmission, Installing, Passat CC MY 2009, CC MY
2010, 2.0L 147 kW TFSI Engine”, page 105 .
106 .
wage
13.1 Transmission, Removing, Passat CC
byV
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ua
MY 2009, CC MY 2010, 2.0L 147 kW
d ran
ir se tee
tho
or
ss
au
TFSI Engine ac
ce
e
nl
pt
du
an
the vehicle. Affix the protocol to transmission before sending
itte
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erm
back the removed transmission.
ab
ility
ot p
Short Description:
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nf
ercia
Note
rm
m
atio
om
n in

or c
thi
te
sd
iva

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f
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t.
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op py
♦ Torque Wrench - VAG1332-
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Hose Clamps up to 25 mm Dia. - 3094-
♦ Insert Tool 18 mm - T10179-
♦ Adapter - 10-222A/3- (Qty: 2)
♦ Shackle - 10-222A/12-
♦ Tensioning Strap - T10038-
♦ Bracket - T10346-
Procedure
– Turn the steering wheel to the center position.
13. Transmission, Removing and Installing, Passat CC from MY 2009 and CC from MY 2010 99
– Remove the ignition key and engage the steering wheel lock.
– Push the brake in order to remove the left drive axle bolt
Note

and Installing .
– Remove the engine cover and the air filter with the intake duct.
– Remove the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Battery, Removing and Installing .
– Remove the battery housing.n AG. Volkswagen A
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y
– Disconnect the selector
se d b lever cable -1- from the cable bracket
ua
ran
-2- and remove oriit. tee
th or
au ac
s
s
ce
le

un
pt
an
d
itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
rrectne
-2-.
ss o
cial p
WARNING
inform
mer
Steam may escape when opening the expansion tank cap.

atio
m
Wear protective eyewear and clothing protection to prevent

o
n
c
i
or
eye injury and scalding. Cover the cap on the expansion tank
thi
e
with a cloth and open it carefully.

t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi
– Open the coolant expansion tank cap.
Co
Cop py
ht. rig
– Install the Hose Clamps up to 25 mm - 3094- to the hoses and
rig ht
py by
o Vo
remove the hoses from the transmission fluid cooler. by c lksw
cted agen
Prote AG.
Always replace the seals for the transmission fluid cooler/lines.
♦ Starter

– Remove the transmission fluid pipe -arrow- from the transmis‐

sion.
– Remove the bolt from the top of the starter.
right drive axle.
– Remove the vehicle level control system sensor from both
control arms. Refer to ⇒ Suspension, Wheels, Steering; Rep.
Gr. 43 ; Level Control System Sensor; Front Level Control
System Sensor, Removing and Installing .
Volkswa
– Remove the ball joint sto alower
gen AGcontrol arm
.
nuts
gen AG
does-arrows- on
k w
both sides. b y Vol not
gu
a d ran
se
Ball joint to control
ho
ri arm nut tightening specifications. Refer teto
e o⇒
ut
Suspension, ss Wheels,
a Steering; Rep. Gr. 40 ; Lower Control Arm
ra
c
and Ball Joint .
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
– Remove the left drive axle.

h re
hole
spec
es, in part or in w
t to the co
– Secure the right drive axle in this position as high as possible

to the strut.
rrectness of i
– Disconnect both connectors from the transmission.

l purpos
– Remove the cable bracket from lower starter bolt.

nform
ercia
– Remove the lower bolt from the starter and then remove the
starter.
m
at
om
io
n
c
in t
or
mission.
his
ate
do
riv

p
cum
for
en
g

n
t.
yi Co
Cop py
t. rig
gh ht
– Remove the plug -arrow-. yri
p by
o Vo
by c lksw
cted agen
Prote AG.
– Remove the six torque converter nuts -arrow- using the Socket
SW15 - V/175- .
Note
-B-.
When installing, first tighten bolts -B- and then tighten bolt -A-.
Tightening specification. Refer to ⇒ Suspension,wagen AGWheels, Steer‐
ing; Rep. Gr. 40 ; Subframe; AG. Vol-ksSubframe
Overview do.es
swagen
k ol not
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edb ara
ris nte
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
Note
spec
t to the co
♦ It is necessary to remove the transmission fluid pipes from the

transmission in order to remove the upper bolts that connect
the engine to the transmission. Transmission fluid will drip be‐
rrectne
tween the engine and the intermediate plate.

♦ To prevent that from happening, first disconnect the pipes
ss
-arrows- under the vehicle so that the fluid can run out at the
o
cial p
f i
bottom.
nform
mer
atio
m

o
n
c
i
or
n thi
e
– Remove the charge air hose -1-.

t
sd
iva
o
pr
cum
– Place a drip tray under the transmission.

r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Disconnect both transmission fluid pipes.

Keep the Drip Tray for Workshop Crane - VAS6208- under the
transmission to catch any fluid dripping out.
– Lower the vehicle.
– Cover the transmission fluid pipe connections and the trans‐
mission fluid cooler on the transmission with a cloth.
– Remove the bolts -1 and 2- but do not remove the pipes.

– Remove the pipe -2- and if possible, hold it up so that any fluid
still in the pipe can drain out into the drip tray.
– Remove the pipe -1- and hold it up, then secure both pipes in
this position using a cable tie. AG. Volkswagen A
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Note oris tee
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The pipes will not
s
be removed.
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pt
an
d
itte
– Seal the transmission fluid pipes and bores on the transmis‐

y li
erm
ab
sion with suitable plugs.

ility
ot p
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is n
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ole,
spec

t to the co
On installation, Install the bolts using the 18 mm Insert Tool -

T10179- . Use the lower tightening specification when tightening.
rrectne
Refer to
s
page 106 .
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
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Cop py
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– Install the Engine Support Bridge - 10-222A- and support the

engine and transmission. Do not lift it.
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es, in part or in w
t to the co
– Remove the 2 transmission mount to bracket bolts and the 4
transmission mount bracket -A- to transmission bolts.
rrectness of i
After the transmission has been lowered, the bracket will be re‐
l purpos
moved.
– Remove the transmission mount bracket. Using the spindle on
nform
ercia
the Engine Support Bridge - 10-222A- , lower the engine and

m
transmission slightly.
at
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ate

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– Disconnect the transmission fluid pipes -arrows-.
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– Support the transmission with the Engine/Gearbox Jack - Prote
cted AG.
agen
Note

– Make sure there is sufficient clearance to the subframe when

lowering the transmission. If necessary, adjust the Transmis‐

– The cable bracket and the selector lever cable bracket must
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13.2 Transmission, Installing, Passat CC MY ot p
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2009, CC MY 2010, 2.0L 147 kW TFSI
h re
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spec
Engine
es, in part or in w
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– Always remove any transmission fluid which has dripped out.
rrectness of i
flange.
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rectly.
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The engine and the transmission must be installed to the sub‐
iva
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frame free of tension.

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For the correct tightening specifications. Refer to

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⇒ “13.3.1 Engine to Transmission Tightening Specifications”, C py
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page 106 .
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– Replace the transmission mount/bracket bolts. cted agen
Prote AG.
– First, install all new bolts by hand.

When installing, first, install the bracket to the transmission.
tightening the bracket bolts to the vehicle.
– Replace the seals for the transmission fluid pipes.
– Tighten the transmission fluid pipes to the transmission. Tight‐
ening specifications. Refer to
page 106 .
⇒ “18 ATF”, page 123 .

to Engine
page 106
13.3.1 Engine to Transmission Tightening Specifications
1 - Driving Direction n AG. Volkswagen AG do

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- Drive Plate to Torque Con‐ d b ua
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SW!5 - V/175- .
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❑ 80 Nm.
hole
spec
es, in part or in w
tool 18 mm - T10179- .
t to the co
- M10 Bolts
❑ 40 Nm.
rrectness of i
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the lower flange.

nform
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Sleeves Inside the Engine

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Additional Tightening Specifications

Component Tightening Specifications
Transmission bracket to the transmission (four M10 40 Nm + 90°
bolts)
Transmission bracket to the transmission mount (two 60 Nm + 90°
M12 bolts)
Transmission fluid pipe brackets to the transmission, 9 Nm
see
⇒ Fig. ““Transmission Fluid Pipe Brackets to the Trans‐
mission”“ , page 107 .
Transmission fluid pipes to the cooler, see 25 Nm
⇒ Fig. ““Transmission Fluid Pipes to the Cooler”“ , page
107 .

Component Tightening Specifications

Transmission fluid pipes to the transmission 25 Nm
pay attention to the length of the bolts, see
⇒ Fig. ““Transmission Fluid Pipes to the Transmis‐
sion”“ , page 107 .
Transmission Fluid Pipe Brackets to the Transmission
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Transmission Fluid Pipes to the Transmission
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Bolt -1- = M8 x 45
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Bolt -2- = M8 x 38
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Transmission Fluid Pipes to the Cooler

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ling, Golf from MY 2009
⇒ “14.1 Transmission, Removing”, page 108 .
⇒ “14.2 Transmission, Installing”, page 113 .
⇒ “14.3 Tightening Specifications, Golf MY 2009, 2.5L 125 kW
Engine”, page 114 .
14.1 Transmission, Removing

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♦ Torque Wrench (40-200 gen AG
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♦ Adjusting Plate ise
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♦ Engine Support Feet - 10-222A/8-
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♦ Adapter - 10-222A/7-
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♦ Bracket with Spindle and Hook - 10-222A/10-

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♦ Engine Support Adapter - 10-222A/3-

h re
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♦ Shackle - 10-222A/12-
es, in part or in w
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– If possible, before removing print out the diagnostic protocol
rrectness of i

ing back the removed transmission.
l purpos
Short Description
nform
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Procedure
– Lift the vehicle, all 4 lift points of the hoist are at the same
height.

– Push the brake pedal in order to remove the left drive axle bolt
Note
Do not set the vehicle on the floor. agen

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– Remove the engine cover/air filter. rised
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– Disconnect the hoses -arrows- and remove the intake tube
ility
from the throttle valve. ot p
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or
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-2- and remove it.

-2-.
♦ Starter
– Remove the cable bracket -1- from the starter stud bolt
-arrow-.
– Remove the bolt from the top of the starter.
So that engine and transmission can be supported:
– Remove the lines -1- from the transport strap -3-.

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

– Attach one Shackle - 10-222A/12- to this lifting eye.
rrectness of i
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nf
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– Install the Engine Support Bridge - 10-222A- .

– Extend the right Bracket with Spindle and Hook - 10-222A/10-
with the Adapter - 10-222A/7- .
The hook points downward and will be engaged on the cylinder
block later.
– Remove the right drive axle heat shield bolts -arrows- and heat
shield.
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– Remove the ball joint to lower control arm nuts -arrows- on
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both sides.
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– Remove the left drive axle from the vehicle. t to the co

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mer
– Lift the right drive axle as far as possible and then secure it
atio
m
using, for example a tensioning strap.

o
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– Disconnect the connectors -1 and 2- from the transmission.
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– Remove the connector from the bracket under the starter -1-
wit
and then disconnect it. is n
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spec
– Remove the bracket from the lower bolt for starter.
t to the co
– Remove the lower bolt from the starter and then remove the
starter.
rrectness o
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mer
atio
om
n
c
i
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-B-.
t
sd
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– Drain the coolant.
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– Turn the cap -1- in the direction of -arrow- and remove it.

– Remove the six torque converter nuts -arrows- using the Sock‐
et SW15 - V/175- .
Note
– Engage the Adapter - 10-222A/7- to the cylinder block.

– Remove the coolant hoses from the transmission fluid cooler.
Tension the right spindle one turn (more turns are not necessary).
– Support the engine and transmission with the left spindle. Do
not lift it.
– Remove the transmission mount bracket -A-.

– Turn the left spindle on the Engine Support Bridge - 10-222A-
and slightly lower the engine and transmission.
– Remove the lower boltsenbetween
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– Leave oneoriseasily
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– Support
ss the transmission with the
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Note
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♦ Pay attention to the torque converter. It must be removed to‐

gether with the transmission.
rrectness of i
♦ The cable bracket and the selector lever cable bracket must
l purpos

nform
mercia
at
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14.2 Transmission, Installing

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– See how the plate fits between the engine and transmission. by c lksw
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rectly.
The engine and the transmission must be installed to the sub‐
frame free of tension.
– First, install all the new bolts by hand.
When installing, secure the transmission mount bracket to the
transmission first. Tightening specification: 40 Nm + 90° (1/4) ad‐
ditional turn.
AG. Volkswagen AG
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tightening the bracket bolts to the vehicle. Tighten
Volkswthe two larger not
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Tightening specifications, transmission
au to engine. Refer to
th or
ac
⇒ “14.3 Tightening Specifications, Golf
ss MY 2009, 2.5L 125 kW
ce
le
Engine”, page 114 .

un
pt
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⇒ “18 ATF”, page 123 .
ole,
spec
t to the co
rrectne
14.3 Tightening Specifications, Golf MY 2009, 2.5L 125 kW Engine
ss o
cial p
f inform
mer
atio
om
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c
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verter
❑ 60 Nm.
SW15 - V/175- .
- M12 Bolts
❑ 80 Nm.
tool 18 mm - T10179- .
- M10 Bolts
❑ 40 Nm.
the lower flange.
Sleeves Inside the Engine agen
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– Make sure that the bracket does not touch the transmission
fluid cooler.
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tion in
Nuts: 8 Nm
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15 Transmission, Transporting
agen
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♦ Shackle - 10-222A/12-
ut
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The Shackle - 10-222A/12- can be used when transporting the
ce
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un
transmission and for setting up the Transmission Support - 3282- .
pt
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– Secure the torque converter -arrow- with wire, for example
erm
ab
-A-, to prevent it from falling during transport.
ility
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– Remember there is still fluid in the transmission. Do not turn
h re
ole,
the transmission with the vents facing downward when trans‐
spec
porting or when it is on the assembly stand. The fluid will leak
out.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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te
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isCC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ n,teGolf Plus 2005 ➤ , Passat 200 ...
ed
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6-Speed Automatic Transmission ra 09G - Edition 07.2012
ss c
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16 ATF Cooler, 1.6L 85 kW and 2.0L 110
an
itte
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kW Engine
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16.1 Overview - ATF Cooler
es, in part or in w
t to the co
1 - Transmission Housing
rrectness of i
2 - Seal
l purpos
❑ Always replace.
3 - ATF Cooler
nform
ercia
❑ Installation position. Re‐

fer to
m
at
om
i
⇒ Fig. ““ATF Cooler, In‐
on
c
stallation Position”“ ,
in t
or
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e
page 117
at
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4 - Seal
um
for
en
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❑ Always replace.
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5 - Washer
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6 - Plate Spring
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❑ Installation position:
The convex side faces
toward the bolt
⇒ Item 7 (page 117)
7 - Bolt
❑ 36 Nm
ATF Cooler, Installation Position

– Insert the tab -arrow B- into the transmission housing cut-out
when installing the ATF cooler -1-.
16. ATF Cooler, 1.6L 85 kW and 2.0L 110 kW Engine 117

17 ATF Lines, ATF Cooler and Auxiliary

ATF Cooler, Passat, 2.0L TFSI En‐
gine
⇒ “17.1 Overview - Transmission Fluid Lines, Cooler and Auxiliary
Cooler”, page 118
17.1 Overview - Transmission Fluid Lines, Cooler and Auxiliary Cooler
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⇒ “17.1.1 TransmissionVFluid wage es n
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Lines to Transmission”,
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page 119 ho
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⇒ “17.1.2 External Transmis‐
ce
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sion Fluid Cooler”, page 120
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⇒ “17.1.3 Transmission Fluid
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Lines”, page 121
h re
hole
D-
spec
es, in part or in w
⇒ “17.1.4 Auxiliary Transmis‐
t to the co
sion Fluid Cooler”, page 122
rrectness of i
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17.1.1 Transmission Fluid Lines to Transmission
1 - Transmission Fluid Line

❑ 20 Nm
❑ Always replace the seal.
❑ 20 Nm
3 - Nut
❑ 9 Nm
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es, in part or in w
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r
te o
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s
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17. ATF Lines, ATF Cooler and Auxiliary ATF Cooler, Passat, 2.0L TFSI Engine 119
17.1.2 External Transmission Fluid Cooler
1 - Bolt
❑ 8 Nm
2 - Nut
❑ 9 Nm
3 - External Transmission Fluid
Cooler
4 - Bolt
❑ 9 Nm
❑ Supply line.
❑ Return line.
7 - Nut
❑ 9 Nm
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AG. Volkswagen A 6-Speed Automatic Transmission 09G - Edition 07.2012
n G do
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17.1.3 Transmission Fluid Lines
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ed
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❑ 25 Nm.
an
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❑ Return line from the
ab
ility
auxiliary cooler.
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spec
❑ 25 Nm.
❑ Supply line for the auxil‐
t to the co
iary cooler.
3 - Nut
rrectne
❑ 9 Nm
ss o
cial p
f inform
mer
atio
om
n
c
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17. ATF Lines, ATF Cooler and Auxiliary ATF Cooler, Passat, 2.0L TFSI Engine 121
17.1.4 Auxiliary Transmission Fluid Cooler
1 - Transmission Fluid Auxili‐

ary Cooler
❑ Remove when installing
and removing the front
bumper cover. Refer to
⇒ Body Exterior; Rep.
Gr. 63 ; Front Bumper;
Overview - Front Bump‐
er .
2 - Bolt
❑ 5 Nm
3 - Bolt
❑ 9 Nm
❑ Return line.
❑ Supply line.
6 - Bolt
❑ 5 Nm
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❑ 9 Nm ed by ara
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es, in part or in w
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c
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ate
do
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AG. Volkswagen AG d
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CC
oris 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , aGolf
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c
09G - Edition 07.2012
ss
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nl
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18 ATF
an
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ility
⇒ “18.1 Transmission Fluid Level, Checking and Filling”,
ot p
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page 123 , is n
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⇒ “18.2 ATF Level, Checking”, page 126
spec
es, in part or in w
⇒ “18.3 ATF, Filling”, page 127
t to the co
⇒ “18.4 ATF, Draining and Filling”, page 128
rrectness of i
18.1 Transmission Fluid Level, Checking and
Filling
l purpos
Please observe the following notes:
nform
ercia
♦ Regarding the repair manual. Refer to

m
at
⇒ “1 General Repair Information”, page 1 .
om
ion
c
in t
r
♦ Regarding the transmission fluid. Refer to

o
his
e
⇒ “1.3 Automatic Transmission Fluid”, page 1 .

at
do
priv
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♦ Regarding the filler tube. Refer to ⇒ page 2 .
for
en
ng
t.
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♦ It may be necessary to shorten the pipe on the Adapter for Oil Cop py
Filling - VAS6262A- ⇒ page 123 .
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♦ Used Oil Collecting and Extracting Device - VAG1782-
VAS5051-
♦ Drip Tray for VAS6100 - VAS6208-
♦ Adapter for Oil Filling - VAS6262A-
♦ Adapter for Filling ATF Oil - VAS6262/2-
♦ Pipe Cutter - VAS6056/2-
Shortening the Pipe on the Adapter for Oil Filling - VAS6262A- :
– Shorten the pipe to 210 mm -a-. This assures the pipe on the
Adapter for Oil Filling - VAS6262A- will not touch the bottom
of some fluid containers.
Note
Dimension -a- is measured starting from the green surface on the

adapter for Oil Filling - VAS6262A- .
18. ATF 123

– Make a mark on the pipe at dimension -a-, and cut it using the
Pipe Cutter - VAS6056/2- .
Use the Transmission Fluid Available as a Replacement Part.
Refer to the Parts Catalog.
– When checking the transmission fluid level, always replace the

seal -arrow- on the plug.
Checking
– Turn off the engine.
The transmission fluid temperature must not be more than ap‐
proximately 30 °C (86 °F) at the
agen
start
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n in
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The fluid flows out of the overflow tube.

If Fluid Continues to Drip out of Hole
The fluid does not need to be topped off.
– Install and tighten the plug with a new seal to 27 Nm. The level
check is now completed. AG. Volkswagen AG d
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hole
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es, in part or in w
t to the co
Adapter for Oil Filling - VAS6262A- to the fluid container. Refer
to ⇒ page 123 .
– Fill with 1 liter fluid.
rrectness of i
– Connect the Oil Filler Adapter - VAS6262- to the quick release
l purpos
coupling and check:

If Fluid Lows out of the Hole
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The fluid does not need to be topped off.

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WARNING
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mission. If 2 liters are missing, you should check the transmis‐
sion more closely. There is probably a larger leak.
18. ATF 125

18.2 ATF Level, Checking agen

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– Press »right« Guided Functions .
– Select the vehicle, the transmission and check ATF level .
– Start the engine.
– Raise the vehicle.
– Place the drip tray under the transmission.
If the Test Temperature 35 °C to 45 °C (95 to 113 °F) is Displayed:
– Remove the drain plug in the oil pan for checking the ATF level.

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spec
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18.3 ATF, Filling
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– Install the Oil Filler - Adapter 2 - VAS6262/2- hand-tight with

the engine »running«.
nform
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m
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t
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ion in
ing the Adapter For Oil Filling - VAS6262A- to the fluid con‐
r
te o
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s
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ATF does not need to be topped off.
– Allow the ATF to drain until it drips.
– Tighten the plug with a new seal to 27 Nm. The ATF level test
is now completed.
If No ATF Is Dripping:
– Fill another liter. Refer to ⇒ “18.3 ATF, Filling”, page 127 .
WARNING
Too little or too much ATF will impair transmission function. If

two liters are missing, the transmission should be checked
more closely. There is probably a »larger« leak.
18. ATF 127

18.4 ATF, Draining and Filling

– Turn off the engine.
– Remove the drain plug in the oil pan -arrow- for checking the
ATF level.
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ot
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hole
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es, in part or in w
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rrectness of i
⇒ “4.3 Fastener Tightening Specifications”, page 158 .

l purpos
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– Install the Oil Filler - Adapter 2 - VAS6262/2- hand-tight.

– Read the information regarding the bleed pipe before attach‐
ing the Adapter For Oil Filling - VAS6262A- to the fluid con‐
tainer. Refer to ⇒ page 123 .
– Fill 3 liters of ATF through the filler tube. Refer to the Parts
Catalog.
– Tighten the ATF check plug -A- and new gasket -B- hand-tight.
– Start the engine, shift through all the selector lever positions.
Leave the selector lever in each position for approximately 10
seconds.
– Check the ATF level and add if necessary. Refer to
⇒ “18 ATF”, page 123 .
AG. Volkswagen AG d
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18. ATF 129

19 Special Tools
♦ Hose Clamp Pliers - VAG1275-

AG. Volkswagen AG d
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♦ Torque Wrench (5-50 Nm) -

VAG1331-
♦ Used Oil Collecting and Ex‐
tracting Device - VAG1782-
♦ Vehicle Diagnosis, Testing
and Information System -
VAS5051-
♦ Drip Tray for VAS6100 -
VAS6208-
♦ Adapter for Oil Filling -
VAS6262A-
♦ Adapter for Filling ATF Oil - AG. Volkswagen AG d
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19. Special Tools 131

olkswagen AG
en AG. V
CC 2010 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Golf Plus 2005 o➤ , aPassat
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♦ Torque Wrench (40-200
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♦ Engine Support Bridge -

10-222A-
♦ Engine Support Feet -
10-222A/8-
♦ Adapter - 10-222A/7-
♦ Bracket with Spindle and
Hook - 10-222A/10-
♦ Engine Support Adapter -
10-222A/3-
♦ Shackle - 10-222A/12-
AG. Volkswagen AG d
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20 Special Tools
AG. Volkswagen AG d
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♦ Setting Gauge - T10173- utho eo
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♦ Adapter - 10-222A/13-
nf
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VAS5051-
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♦ Shackle - 10-222A/12-

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l purpos
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mercia
at
om
ion
c
in t
or
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ate
do
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VAG1331-
AG. Volkswagen AG d
agen
♦ Vehicle Diagnosis, Testing Volksw
oes
not
gu
and Information System - d by ara
VAS5051- rise nte
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♦ Drip Tray for VAS6100 - ss c
ce
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d
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VAS6262A-
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♦ Adapter for Filling ATF Oil -
, is n
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VAS6262/2-
hole
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l purpos
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♦ Engine-/Gearbox Jackise-d b ara
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VAG1383A- ut
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nl
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3282-
ility
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♦ Hose Clamps up to 25 mm
spec
es, in part or in w
Dia. - 3094-
t to the co
♦ Insert Tool 18 mm -
T10179-
rrectness of i
l purpos
nform
mercia
at
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ion
c
in t
or
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do
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21 Special Tools
♦ Adapter - 10-222A/3-
♦ Shackle - 10-222A/12-
♦ Tensioning Strap - T10038-
♦ Bracket - T10346-
VAS5051-

AG. Volkswagen AG d
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♦ Shackle - 10-222A/12-
rrectness of i
l purpos
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mercia
at
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ion
c
in t
or
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lkswage es n
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CC 2010 ir se ➤ , Golf 2004 ➤ , Golf 2009 ➤ , GolfanPlus
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VAG1331-
VAS5051-
VAS6208-
VAS6262A-
VAS6262/2-
AG. Volkswagen AG d
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♦ Engine-/Gearbox Jack -
VAG1383A-
♦ Torque Wrench -
VAG1332-
3282-
♦ Hose Clamps up to 25 mm
Dia. - 3094-
♦ Insert Tool 18 mm -
T10179-
AG. Volkswagen AG d
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22 Special Tools
VAS5051-
AG. Volkswagen AG d
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VAG1331-
VAS5051-
VAS6208-
VAS6262A-
VAS6262/2-
AG. Volkswagen AG d
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♦ Engine-/Gearbox Jack -
VAG1383A-
3282-
Nm) - VAG1332-
AG. Volkswagen AG d
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♦ Engine Support Bridge -

10-222A-
♦ Engine Support Feet -
10-222A/8-
♦ Adapter - 10-222A/7- agen
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♦ Bracket with Spindle and ed by
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Hook - 10-222A/10- horis nte
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38 – Gears, Hydraulic Controls

1 Selector Shaft Seal, Replacing
Removing
– Remove the multifunction transmission range switch.
– Carefully pry out the selector shaft seal with a screwdriver. Be
gen AG
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does
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careful not to damage the selector shaft when doing
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tilt the seal.

nl
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– Adjust the multifunction transmission range switch. Refer to
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⇒ “3.2 Multifunction Transmission Range Switch, Adjusting”,
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page 21 .
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146 Rep. Gr.38 - Gears, Hydraulic Controls

2 Transmission Fluid Pan, Removing

and Installing
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– Loosen the transmission fluid pan bolts -arrows- diagonally.

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– Clean the two magnets inside the recesses in the pan. Make
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sure that the magnets are in full contact with the pan.
– Check the gasket for damage and make sure all of the spacers
(quantity: 8) are present.
Otherwise, replace the gasket.
– Install the pan and gasket; when doing this be sure not to pinch
any wires.
– Make sure the pan gasket fits correctly.
2. Transmission Fluid Pan, Removing and Installing 147

– Tighten the pan bolts -arrows- diagonally and in several steps.

Tightening specifications. Refer to
– Install the overflow tube -C-. For the correct tightening speci‐
fication. Refer to
– Fill with transmission fluid and check the level. Refer to
⇒ “18 ATF”, page 123 .
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3 Transmission Fluid Filter

⇒ “3.1 Transmission Fluid Filter, Removing and Installing”,
page 149
3.1 Transmission Fluid Filter, Removing

and Installing
Removing
– Remove the transmission fluid pan. Refer to
⇒ “2 Transmission Fluid Pan, Removing and Installing”, page
147 .
– Remove the transmission fluid filter bolts -arrows-.
– Remove the filter -A- from the valve body. AG. Volkswagen AG d
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– Lightly coat the seals on the filter suction collar
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– Install the transmission fluid pan. Refer to
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⇒ “2 Transmission Fluid Pan, Removing and Installing”, page
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– Fill with fluid and check the level. Refer to

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3. Transmission Fluid Filter 149

4 Valve Body
⇒ “4.1 Overview - Valve Body”, page 150
⇒ “4.2 Valve Body, Removing and Installing”, page 152
⇒ “4.3 Fastener Tightening Specifications”, page 158
4.1 Overview - Valve Body
1 - Inspection Plug
❑ Transmission fluid level,
checking and filling. Re‐
fer to
⇒ “18 ATF”, page 123 .
❑ Tightening specifica‐
tion. Refer to agen
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3 - Overflow Tube
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❑ Remove in order to
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⇒ “4.3 Fastener Tight‐
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page 158 .
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4 - Transmission Fluid Pan

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5 - Bolt
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❑ Tighten the transmis‐

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6 - Gasket
❑ With spacers (quantity: 8).
❑ Check before installing.
❑ Replace a brittle, cracked or deformed gasket.
7 - Magnet
❑ Quantity: 2; in the depressions in the pan.
❑ Clean before installing the pan.
8 - Bolt
❑ Always replace the bolts.
❑ Tightening specification. Refer to ⇒ “4.3 Fastener Tightening Specifications”, page 158 .
❑ For securing the valve body to the transmission.

❑ Quantity 12; with different lengths. Refer to
⇒ Fig. ““Bolt Lengths and Locations on the Valve Body”“ , page 155 .
9 - Bolt
❑ Quantity: 3
❑ For securing the transmission fluid filter to the valve body.
10 - Transmission Fluid Filter
❑ Removing and installing. Refer to ⇒ “3 Transmission Fluid Filter”, page 149 .
11 - Valve Body
❑ Removing and installing. Refer to ⇒ “4 Valve Body”, page 150 .
12 - Bolt
13 - Bolt
14 - Transmission Input Speed Sensor - G182-
❑ Removing and installing. Refer to ⇒ “6 Transmission Input Speed Sensor G182 ”, page 160 .
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16 - Transmission Output Speed Sensor - G195-
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❑ Removing and Installing. Refer to ⇒ “7 Transmission Output Speed Sensor G195 ”, page 161 .
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17 - Transmission Housing
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18 - Vent Cap
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19 - Multifunction Transmission Range Switch - F125-
es, in part or in w
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❑ Removing and installing. Refer to ⇒ “3 Multifunction Transmission Range Switch F125 ”, page 19 .
❑ Adjusting. Refer to ⇒ “3.2 Multifunction Transmission Range Switch, Adjusting”, page 21 .
rrectness of i
20 - Transmission Fluid Temperature Sensor - G93-
❑ Integrated into the wiring harness.
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❑ Removing and installing. Refer to ⇒ “5 Solenoid Valve and Sensor Wiring Harness”, page 159 . nform
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❑ Wire routing. Refer to ⇒ “4.2.1 Wire Routing, Connectors and Bracket on Valve Body”, page 156 .
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❑ With the transmission fluid temperature sensor.
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❑ For the transmission input speed sensor and the transmission output speed sensor.
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❑ Always replace the seal on the connector housing.

❑ Wire routing. Refer to ⇒ “4.2.1 Wire Routing, Connectors and Bracket on Valve Body”, page 156 .
24 - Seal
❑ Always replace.
25 - Drain Plug
4. Valve Body 151

26 - Selector Shaft Lever

27 - Washer
28 - Nut
❑ Installed position: The centering collar faces the washer ⇒ Item 27 (page 152) .
29 - Spring
30 - Piston
31 - Solenoid Valve Wiring Harness
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❑ Always replace the s agen on the connector
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❑ Wire routing.
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Refer to ⇒ “4.2.1 Wire Routing, Connectors eo
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32 - Bolt
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⇒ “4.2.1 Wire Routing, Connectors and Bracket on Valve Body”,
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page 156
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♦ Digital Torque Wrench - VAG1756-

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WARNING
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Do not run the engine or tow the vehicle when the pan is re‐
om
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moved or when there is no transmission fluid in the transmis‐

or c
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♦ Install seals using transmission fluid. Other types of lubricants cop Vo
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♦ Always replace a dirty or faulty valve body.

♦ Only use lint free cloths
♦ Check the fluid level after installing the pan. Refer to
⇒ “18 ATF”, page 123 .
Removing
– Remove the transmission fluid filter. Refer to
⇒ “3 Transmission Fluid Filter”, page 149 .
– Disconnect the connector from the solenoid valves -item 1-
⇒ Item 1 (page 157) through -item 8- ⇒ Item 8 (page 157) .
To unlock the connector housing on the solenoid valves, use a
flat head screwdriver with a 2.5 mm diameter shaft.

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– Disconnect the connectors, see -items A and B- in the
es, in part or in w
t to the co
⇒ “4.2.1 Wire Routing, Connectors and Bracket on Valve
Body”, page 156 .
– Remove the brackets (-items 1 and 2- under “Bracket for Con‐
rrectness of i
nectors, Securing the Wires” in the
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Body”, page 156 ) for the connectors.
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– Disconnect the transmission fluid temperature sensor, see
or
-item 3- under “Bracket for Connectors, Securing the Wires” in
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– Bend the securing plate -arrows- on the selector lever back.

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– Remove the selector lever -1- from the selector shaft.

– Hold the selector lever -1- steady with pliers -2- to prevent
transferring the torque onto the multifunction transmission
range switch.
– Make sure the valve -A- on the valve body is not damaged.
The valve is very “sensitive”. Even minor damage can lead to a
malfunction.
– Always slide the valve into the body, secure it against falling
out and never exchange it.
4. Valve Body 153

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– Loosen thessbolts -arrows- (quantity 12). c
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– Remove the brackets -1 and 2-.
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– Disconnect the valve body and remove it.
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– When removing the valve body, pay attention to the piston

-2-.
– Remove the piston with the spring.
Installing
To make sure that the wires do not get pinched during installation:

– Route and secure the wires -1, 3, 4 and 5- as illustrated.

The distance -a- must be maintained so that the wiring harness
-5- does not touch the planetary gear and get damaged when the
vehicle is being driven.
The valve body is secured with bolts with three different lengths.
– Sort the bolts according to length before installing the valve
body.
– Coat the piston -2- with transmission fluid and install the
spring.
– Install the valve body carefully and secure it using 2 bolts.
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Bolt Lengths and Locations on the Valve Body

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Bolts -arrows- Quantity 6, M6 x

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Bolts -arrows A- Quantity 2, M6 x

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Bolts -arrows B- Quantity 4, M6 x

28
rrectness of i
– Make sure the wires are not pinched.

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155
AG.
4. Valve Body
– Install the remaining bolts and the brackets -1 and 2- and

tighten by hand.
– Install the transmission fluid temperature sensor and tighten
to specification. Refer to
– Connect the connectors (quantity 8) to the solenoid valves.
Refer to
⇒ “4.2.1 Wire Routing, Connectors and Bracket
n AG. Von
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wagen AG
Body”, page 156 . lkswage does
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– Connect the bracket for the connectors
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ss specifications. Refer to c
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– Connect the connectors see -items A and B- in the
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Body”, page 156 .
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– Tighten the valve body bolts working from the inside toward
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the outside diagonally. Tightening specification. Refer to
spec
es, in part or in w
t to the co
– Install the selector lever.
rrectness of i
– Tighten the nut on the selector lever -1-. For the correct tight‐
ening specification refer to
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– Hold the selector lever -1- steady with pliers -2- to prevent
nform
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transferring the torque onto the multifunction transmission

range switch.
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– Bend the securing plate -arrows- on the nut up.
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– Install the transmission fluid filter. Refer to
⇒ “3 Transmission Fluid Filter”, page 149 .
– Fill the transmission fluid and check the level. Refer to
⇒ “18 ATF”, page 123 .
– Connect the vehicle diagnostic tester and move through the
selections until “Functions/component selection” is displayed.
– Press “Drive (Repair Groups 01;10 through .26; 28 through .
39)”.
– After that “6-speed automatic transmission 09G”.
– Press “01 - OBD”.
– Press “Functions”.
– Press “basic setting”.
4.2.1 Wire Routing, Connectors and Bracket

on Valve Body
Information regarding assembly work on the valve body is shown
in illustrations in this chapter.
Wiring Routing and Connectors

1 - Solenoid Valve 4 - N91-

❑ Wiring colors to nthe
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2 - Solenoid
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❑ Wiring colors to the
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valve: yellow/purple
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valve: white/black
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valve: green/blue
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❑ Wire color to the valve: tion in

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❑ Wire color to the valve:

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A - Connector for Transmis‐
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❑ Wire color to the sensor:

blue/orange
B - Connector for Transmis‐
sion Input Speed Sensor -
G182-
❑ Wire colors to the sensor: white/red
Connector Bracket, Securing Wiring
4. Valve Body 157

1 - Connector Bracket for AG. Volkswagen AG d

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2 - Connector Bracket for
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❑ Tightening Specification
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page 158 .
3 - Transmission Fluid Tem‐
rrectness of i
perature Sensor - G93-
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❑ Wire colors on the sen‐

sor: orange/orange
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4 - Selector Lever
❑ Tightening Specification
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4.3 Fastener Tightening Specifications

5 Solenoid Valve and Sensor Wiring

Harness
⇒ “5.1 Solenoid Valve and Sensor Wiring Harness, Removing and
5.1 Solenoid Valve and Sensor Wiring Har‐

ness, Removing and Installing
Removing
– Drain the transmission fluid. Refer to ⇒ “18 ATF”, page 123 .
– Remove the valve body. Refer to
⇒ “4 Valve Body”, page 150 .
– Disconnect the connectors from the transmission:
-1- transmission sensor terminal
-2- connector for solenoid valves
– Disconnect the connector housings from the transmission.
– Disconnect the connector housing together with the wiring
harness outward from the transmissionVohousing.
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– Replace the seals hon risethe connector housings. nte
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– Carefully guidessthe wiring harness from the outside into the c
transmission.
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– Coat the connector housing seals with transmission fluid and

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then press the connector housing all the way into the trans‐
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– Connect the connector housing, tightening specification. Refer

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to ⇒ “4.3 Fastener Tightening Specifications”, page 158 .

spec
es, in part or in w
– Install the valve body. Refer to ⇒ “4 Valve Body”, page 150 .

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5. Solenoid Valve and Sensor Wiring Harness 159

6 Transmission Input Speed Sensor -

G182-
⇒ “6.1 Transmission Input Speed Sensor G182 , Removing and
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⇒ “4 Valve Body”, page 150 .
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– Remove the transmission input speed sensor bolt -1-.
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– Remove the transmission input speed sensor from the trans‐
spec
mission.
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Installing
Install in reverse order of removal. Pay attention to the following:
rrectness of i
– Press the sensor all the way into the transmission.
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– Install the transmission input speed sensor bolt -1-. Tightening

specification. Refer to
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7 Transmission Output Speed Sensor -

G195-
⇒ “7.1 Transmission Output Speed Sensor G195 , Removing and
7.1 Transmission Output Speed Sensor -

G195- , Removing and Installing lksw
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– Remove the transmission output speed sensor bolt -2-.
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– Remove the transmission output speed sensor from the trans‐
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Install in reverse order of removal. Pay attention to the following:
es, in part or in w
t to the co
– Press the sensor all the way into the transmission.
– Install the transmission output speed sensor bolt -2-. Tighten‐
rrectness of i
ing specification. Refer to
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7. Transmission Output Speed Sensor G195 161

♦ Drip Tray - VAG1306-
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Rep. Gr.38 - Gears, Hydraulic Controls
8 Special Tools
♦ Drip Tray - VAG1306-
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164
AG.
Rep. Gr.38 - Gears, Hydraulic Controls
39 – Final Drive, Differential

1 Flange Shaft Seals, Replacing
⇒ “1.1 Left Flange Shaft Seal, Replacing”, page 165
⇒ “1.2 Right Flange Shaft Seal”, page 166
1.1 Left Flange Shaft Seal, Replacing

♦ Puller - T10055-
Short Description
The seal for the flange shaft can be changed with the transmission
installed.
The drive axle is completely removed.
Removing
– Remove the left drive axle. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 40 ; Drive Axle; Drive Axle, Removing and
Installing .
– Seal off the drive axle opening in the transmission with a clean
cloth -A-.
– Carefully drill a hole, 2 to 4 mm in diameter -B- into the outer
metal ring -C- in the seal.
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1. Flange Shaft Seals, Replacing 165

– Install a 4 mm screw into the drilled hole in the seal -arrow-.
Note
♦ Be careful not to install the screw too deep otherwise the bear‐
ing underneath will get damaged.
♦ Remove the seal using the Puller - T10055- and Adapter -
T10055/2-
♦ Remove the cloth and carefully clean the transmission and the
opening for the drive axle.
♦ Metal shavings must not get into the transmission or into the
opening for the drive axle; vacuum up any shavings if neces‐
sary.
♦ If only the metal ring of the seal could be removed, carefully
pry out the remaining parts of the seal using screwdriver.
Installing
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– Check the transmission fluid level and add if necessary. Refer spec
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to ⇒ “18 ATF”, page 123 .
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the transmission.
– The drive axle remains in the wheel bearing.
Removing
– Remove the right drive axle from the transmission. Refer to ⇒
166 Rep. Gr.39 - Final Drive, Differential

– Tie the drive axle as high up as possible. Be careful not to

damage the paint on the drive axle.
– Seal off the drive axle opening in the transmission with a clean
cloth -A-.
– Carefully drill a hole, 2 to 4 mm in diameter -B- into the outer
metal ring -C- in the seal.
Note
♦ Grease the drill bit -B- so that the shavings stick to the drill bit.
♦ Drill only through the metal ring -C- otherwise the transmission
will get damaged.
– Install a 4 mm screw into the drilled hole in the seal -arrow-.
Note
♦ Be careful not to install

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opening for the drive axle.

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♦ If only the metal ring of the seal could be removed, carefully

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– Install the drive axle. Refer to ⇒ Suspension, Wheels, Steer‐ Cop py
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– Check the transmission fluid level and add if necessary. Refer
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to ⇒ “18 ATF”, page 123 .

– Install the noise insulation.
1. Flange Shaft Seals, Replacing 167

2 Special Tools
♦ Puller - T10055-
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168 Rep. Gr.39 - Final Drive, Differential

3 Revision History
DRUCK NUMBER: K0258992321
Fac‐ Edit Job Fee Notes Quality
tory Edi‐ Type dba Checke
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07.2 05/1 Link N/A Eric P.

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07.2 05/0 Re‐ N/A Eric P.
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3. Revision History
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Cautions & Warnings
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Please read these WARNINGS and CAUTIONS before proceeding with maintenance
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and repair work. You must answer that you have read and you understand these
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WARNINGS and CAUTIONS before you will be allowed to view this information.
wit
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spec
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
es, in part or in w
t to the co
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.
rrectness of i
•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
l purpos
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
nform
ercia
•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
m
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
a
com
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check with your authorized Volkswagen retailer parts department for the latest information.
n in
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•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
do
r
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c
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
um
fo
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•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
Co py
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a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
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vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
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•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
become inoperable, even if the correct code is used in a later attempt.
•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
starting the vehicle while you are under it.
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
being fully alert.
•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
injury could result.
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
lkswage es n
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Cautions & Warnings
d ran
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•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
ce
le
un
pt
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
an
d
itte
fuel or oil.
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ab
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ility
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•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
wit
, is n
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
h re
hole
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
spec
es, in part or in w
t to the co
•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
crushed by heavy parts.
rrectness of i
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
l purpos
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
repairs.
nform
mercia
a
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
com
tion in
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
r
te o
thi
once, but do not store the oily rags, which can ignite and burn spontaneously.
s
iva
do
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rp
cum
fo
•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
en
ng
t.
yi
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque op
Co
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•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is Prote
cted AG.
agen
ignited, it will ignite gas trapped in the cells and cause the battery to explode.
•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
govern the disposal of wastes.
•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
automotive chemical refrigerants.
•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
negative terminal (ground strap) and the ABS control module connector.
•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
system pressure and may cause the system to burst.
•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
Page 2 of 3
Version 1.0
Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
tire from the rim before attempting any repair.
•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between you and the airbag can
ks
increase the risk of injury in an accident.
AG. Vol wagen AG d
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hor
I understand these Cautions and e o Warnings.
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Page 3 of 3
Version 1.0

D3E8001FBC8-6-Speed Automatic Transmission 09G

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Service

Passat CC 2009 ➤ , Touran 2003 ➤

6-Speed Automatic Transmission 09G

Service Department. Technical Information

matter of course, be observed.

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3.4 Golf Plus from MY 2005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.5 Touran from MY 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1 Torque Converter General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.3 Torque Converter, Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.5 Torque Converter, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 Vehicle Diagnostic Tester , Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.1 Vehicle Diagnostic Tester , General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.2 Vehicle Diagnostic Tester , Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4 Selector Lever, Emergency Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

10.1 Transmission, Removing, Golf Plus MY 2005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

11.1 Transmission, Removing, Touran MY 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

11.2 Transmission, Installing, Touran MY 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

11.3 Tightening Specifications, Transmission to Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

12 Transmission, Removing and Installing, Passat from MY 2006 . . . . . . . . . . . . . . . . . . . . . . 83

38 - Gears, Hydraulic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

3 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

00 – General, Technical Data lkswage

⇒ “1.7 Tools”, page 2

⇒ “1.9 Seals, Gaskets and O-rings”, page 3

1.2 Torque Converter

1.3 Automatic Transmission Fluid

1.4 Transmission Control Module J217 with

1. General Repair Information 1

• Maximum engine output is always available

1.5 Vehicle Control Modules

1.6 Information on the “09G Automatic

♦ Always clean the connection points and the areas around

♦ Carefully cover or seal unpacked components if repairs cannot

♦ With the transmission removed, secure the torque converter

so that it cannot fall out.

Transmissions With and Without a Filling Tube

Here, for example, is a filler tube -arrow- as it was installed in older

transmissions. This tube has been omitted.

2 Rep. Gr.00 - General, Technical Data

1.9 Seals, Gaskets and O-rings

Be cautious when dealing with transmission fluid. Dispose of

1.10 Bolts and Nuts

fluid - AMV 185 100 A1- . orm

♦ Use a thread tap to clean all threaded holes containing self

locking bolts to remove any locking fluid residue. Otherwise

♦ Always replace self-locking nuts and bolts.

1.11 Electrical Components

1. General Repair Information 3

1.12 Guided Fault Finding, Vehicle Diagnosis

4 Rep. Gr.00 - General, Technical Data

3 Engine Codes - Engine Allocation

⇒ “3.4 Golf Plus from MY 2005”, page 7 .

⇒ “3.6 Passat from MY 2006, Engine Codes and Allocation”, page

⇒ “3.7 Passat CC from MY 2009 and CC from MY 2010, Engine

3.1 Transmission Identification

Code letter -arrow 1-

3.2 Golf from MY 2004, Engine Codes and

6 Rep. Gr.00 - General, Technical Data

3.3 Golf from MY 2009, Engine Codes and

3.4 Golf Plus from MY 2005

3.5 Touran from MY 2003

Engine 1.6L - 85 kW 2.0L - 110 kW 1.8 l - 110 kW

3.6 Passat from MY 2006, Engine Codes