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Service
Workshop Manual
Golf Variant 2007 ➤
Golf Variant 2010 ➤
Jetta 2005 ➤
Jetta 2011 ➤
6-speed automatic gearbox 09G
Edition 04.2010
Service Department. Technical Information

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   Summary of Contents for Volkswagen Golf Variant 2007

  • Page 1

    Service Workshop Manual Golf Variant 2007 ➤ Golf Variant 2010 ➤ Jetta 2005 ➤ Jetta 2011 ➤ 6-speed automatic gearbox 09G Edition 04.2010 Service Department. Technical Information...

  • Page 2

    In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R005320...

  • Page 3: Table Of Contents

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Contents 00 - Technical data ........... .

  • Page 4

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Removing and installing gearbox, Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Jetta Wagon 2008 ▸ ............

  • Page 5: Technical Data

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 00 – Technical data Suggestions and criticism, general repair notes Suggestions and criticism of this work‐...

  • Page 6: General Repair Notes

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 General repair notes To ensure flawless and successful gearbox repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential.

  • Page 7: Gearbox

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 The catalogue is also available on ⇒ CD-ROM and can be ordered the usual way from Bertelsmann.

  • Page 8: Gaskets, Seals And Oil

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 1.11 Gaskets, seals and oil ♦ Always renew O-rings, seals and gaskets. ♦ Before installing a radial oil seal, coat sealing lips and area between them with sealing grease -G 052 128- .

  • Page 9: Guided Fault Finding, Vehicle Self-diagnosis And Testing

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 1.14 Guided fault finding, vehicle self-diag‐ nosis and testing Before making repairs to the automatic gearbox, determine the cause of the fault as precisely as possible with the aid of “guided...

  • Page 10: Gearbox Identification

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Gearbox identification “6-speed automatic gearbox 09G” is fitted in Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Jetta Wagon 2008 ▸ and Jetta 2011.

  • Page 11: Capacities

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Capacities Planetary gearbox and final drive Capacities “6-speed automatic gearbox 09G” Initial filling approx. 7.0 l...

  • Page 12: Codes, Gearbox Allocation, Ratios

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Codes, gearbox allocation, ratios ▸ If Genuine parts are required for a repair, always refer to the gearbox code.

  • Page 13: Torque Converter

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 32 – Torque converter Torque converter Identification of torque converter There are various torque converters. They are identified by codes.

  • Page 14: Installing Torque Converter

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 ♦ Oil seal extractor lever -VW 681- Removing – Pry out seal with lever -VW 681- .

  • Page 15: Controls, Housing

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 37 – Controls, housing Connecting “tester” Volkswagen offers various devices such as ♦ Vehicle diagnosis, testing and information system -VAS 5051- ♦...

  • Page 16

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Switch on “tester” -arrow-. The “tester” is ready for use when it is possible to choose between...

  • Page 17: Electrical And Electronic Components And Their Locations

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Electrical and electronic components and their locations 1 - Control unit for automatic gearbox -J217- ❑ The control unit trans‐...

  • Page 18

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 ❑ Location ⇒ page 16 ❑ Removing and installing ⇒ page 103 ❑ Allocation ⇒ Electronic parts catalogue “ETKA”...

  • Page 19

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Automatic gearbox control unit -J217- -A- in Jetta 2011 ▸ with 2.0 l - 85 kW engine Location: control unit is located in plenum chamber on right.

  • Page 20

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Wiring harness, 8-pin ♦ Wiring harness for senders ♦ With integrated gearbox oil temperature sender -G93- -arrow- Location: wiring harness is attached to valve body in gearbox.

  • Page 21

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Gearbox input speed sender -G182- and gearbox output speed sender -G195- Location: senders are installed in gearbox housing above valve body.

  • Page 22: Multifunction Switch F125

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Multifunction switch -F125- Removing multifunction switch -F125- ⇒ page 18 Installing multifunction switch -F125- ⇒ page 19 Adjusting multifunction switch -F125- ⇒...

  • Page 23: Installing Multifunction Switch F125

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Carefully bend back hooks of lock washer -2- using a screw‐ driver. – Renew securing clip if hooks have broken off.

  • Page 24: Adjusting Multifunction Switch F125

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Push lever -3- onto selector shaft -4-. – Use lever -3- to shift gearbox to “P” position, i.e. press lever -3- back (opposite direction of travel) to stop.

  • Page 25

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Carry out procedure as follows: – Place setting gauge on selector shaft -2- and turn multifunction switch -1- until setting gauge engages in lug on multifunction switch connector.

  • Page 26: Selector Mechanism Up To 02.2009

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Selector mechanism up to 02.2009 WARNING Before working on vehicle with engine running, move selector lever into position “P” and apply handbrake.

  • Page 27: Removing And Installing Selector Mechanism With Selector Lever Up To 02.2009

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 ❑ Adjusting ⇒ page 30 9 - Hexagon nut with washer ❑ 8 Nm ❑ Qty. 4 Removing and installing selector mech‐...

  • Page 28

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Lever cable -1- off lever -3- using an open jaw spanner -2-. – Raise vehicle.

  • Page 29

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Remove locking plate for selector lever cable. Always renew locking plate. -Selector housing- is pushed forwards slightly on cable --.

  • Page 30

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Clarification: ♦ -1- Push tab forwards ♦ -2- Push pin up Rep. Gr.37 - Controls, housing...

  • Page 31

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Remove selector lever cable. Remove selector housing from selector lever cable. Installing Do not grease cable.

  • Page 32

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Also clip selector lever cable into bracket. Make sure that bracket does not make contact with ATF cooler.

  • Page 33

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Install selector housing, heat shield and exhaust system. – Adjust selector lever cable after installing ⇒...

  • Page 34: Checking Selector Lever Cable

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Checking selector lever cable Brief description To check ease of movement of selector lever cable, it must be removed from the gearbox and the free end must be placed so that it does not bump against anything.

  • Page 35: Emergency Release Of Selector Lever

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 ♦ Parts of the assembly mounting have been removed and in‐ stalled. ♦ The cable itself or the selector mechanism has been removed and installed.

  • Page 36: Removing And Installing Knob

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Press yellow plastic part -arrow- from right to left. Lever can now be moved from position “P”.

  • Page 37: Checking Selector Mechanism

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 In vehicles with button -arrow- at front on knob Button -arrow- is not allowed to be pressed in when knob is being fitted and removed.

  • Page 38

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Selector lever is locked and cannot be shifted out of “P” position when the button is pressed. Solenoid for selector lever lock blocks selector lever.

  • Page 39: Selector Mechanism From 03.2009 Onwards

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Selector mechanism from 03.2009 onwards WARNING Before working on vehicle with engine running, move selector lever into position “P” and apply handbrake.

  • Page 40

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Removing and installing selector lever and selector mechanism with selector lever cable from 03.2009 onwards Note Selector mechanism and selector lever cable are not allowed ♦...

  • Page 41: Emergency Release Of Selector Lever

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Remove selector mechanism. Install in reverse order of removal. – Install heat shield beneath selector mechanism.

  • Page 42: Removing And Installing Gearbox, Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Jetta Wagon 2008

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Removing and installing gearbox, Jetta 2005 ▸, Bora 2006 ▸, Golf Var‐ iant 2007 ▸, Jetta Wagon 2008 ▸...

  • Page 43

    ♦ Gearbox support -3282- ♦ Adjustment plate -3282 /36- ♦ Hose clamps to 25 mm Ø -3094- ♦ Socket -T10179- ♦ Insert -V/175- 6. Removing and installing gearbox, Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Jetta Wagon 2008 ▸...

  • Page 44

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 ♦ Support bracket -10 - 222 A- ♦ Adapter -10 - 222 A /13- ♦ Tensioning strap -T10038- Following descriptions show “automatic gearbox 09G”...

  • Page 45

    – Remove upper engine/gearbox connecting bolts. Bolts may be installed with a socket -T10179- . However, note lower torque setting when tightening ⇒ page 54 6. Removing and installing gearbox, Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Jetta Wagon 2008 ▸...

  • Page 46

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – If present, remove earth strap from bracket -A-. – Remove 2 securing bolts for gearbox mounting on bracket -A- and 4 bolts for bracket on gearbox.

  • Page 47

    – Remove lower engine/gearbox connecting bolts. – Leave an easily accessible bolt installed for safety. – Start with two lower bolts. 6. Removing and installing gearbox, Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Jetta Wagon 2008 ▸...

  • Page 48

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Note On some smaller engines up to 1.6 litres, one of the lower -bolts- can be backed out of the gearbox but not removed from the hole.

  • Page 49: Installing Gearbox, Vehicles With 1.6 L - 75 Kw And 2.0 L - 110 Kw (fsi) Engines

    Battery, battery carrier, air filter and engine cover are removed “from above”. Engine and gearbox must then be supported so that left assembly mounting can be removed. 6. Removing and installing gearbox, Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Jetta Wagon 2008 ▸...

  • Page 50

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Noise insulation is removed and drive shafts are pressed off “from below”. Gearbox is lowered using gearbox jack.

  • Page 51

    Before sending back removed gearbox in the usual manner, secure log to gearbox. – Move selector lever to position “P” position. – Raise vehicle. 6. Removing and installing gearbox, Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Jetta Wagon 2008 ▸...

  • Page 52

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Depress brake pedal to remove bolt for left drive shaft -arrow- (second mechanic required). Note After this, do not set vehicle on the ground any more ⇒...

  • Page 53

    – Remove noise insulation tray. – Remove lower part of left wheel housing liner. – If present, remove heat shield above right drive shaft -arrows-. 6. Removing and installing gearbox, Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Jetta Wagon 2008 ▸...

  • Page 54

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Unbolt suspension link from wheel bearing housing on both sides. – Press both drive shafts out of gearbox. This procedure is de‐...

  • Page 55

    – Turn cap -1- in -direction of arrow- and remove. – Remove six -torque converter nuts- with insert -V/175- . Note Continue turning the engine carefully! 6. Removing and installing gearbox, Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Jetta Wagon 2008 ▸...

  • Page 56

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Hook adapter -10 - 222 A /7- into engine block. – Pull coolant hoses off ATF cooler.

  • Page 57: Installing Gearbox, Vehicles With 2.5 L, 110 Kw Engine

    – Carry out basic settings. To do this – Connect vehicle diagnosis, testing and information system - VAS 5051- and then select “Perform basic settings” under Guided functions 6. Removing and installing gearbox, Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Jetta Wagon 2008 ▸...

  • Page 58: Torque Settings, Gearbox To Engine

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Torque settings, gearbox to engine Vehicles with 1.6 l - 75 kW and 2.0 l - 110 kW (FSI) engines ⇒...

  • Page 59

    - M10 bolts ⇒ M10 ❑ 40 Nm ❑ These bolts are located in lower flange - 2 dowel sleeves in engine -arrows- 6. Removing and installing gearbox, Jetta 2005 ▸, Bora 2006 ▸, Golf Variant 2007 ▸, Jetta Wagon 2008 ▸...

  • Page 60

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Make sure that bracket does not make contact with ATF cool‐ -Nuts- 8 Nm Rep. Gr.37 - Controls, housing...

  • Page 61: Removing And Installing Gearbox, Jetta 2011

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Removing and installing gearbox, Jetta 2011 ▸ Removing gearbox, Jetta 2011 with 2.0 l - 85 kW engine ⇒...

  • Page 62

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 ♦ Support bracket -10 - 222 A- ♦ Hose clamps to 25 mm -3094- ♦ Tensioning strap -T10038- ♦...

  • Page 63

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – In order to remove selector lever cable from gearbox, first re‐ lease cable -arrows 1- and then remove it from cable support bracket -arrow 2-.

  • Page 64

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – If present, remove earth strap from bracket -A-. – Remove 2 securing bolts for gearbox mounting on bracket -A- and 4 bolts for bracket on gearbox.

  • Page 65

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Unbolt suspension link from wheel bearing housing on both sides. Torque settings ⇒ Rep. Gr. 40 ; Assembly overview - subframe, anti-roll bar, suspension links .

  • Page 66

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Now remove assembly mounting bracket. To do this, lower engine and gearbox slightly via support bracket -10 - 222 A- spindles.

  • Page 67: Installing Gearbox, Jetta 2011 With 2.0 L - 85 Kw Engine

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Note Pay attention to torque converter. It must be removed together ♦ with gearbox. Secure torque converter to prevent it from falling out.

  • Page 68

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Noise insulation is removed and drive shafts are pressed off “from below”. Gearbox is lowered using gearbox jack.

  • Page 69

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 ♦ Hose clamps to 25 mm -3094- ♦ Tensioning strap -T10038- ♦ Engine support basic set -T40091- Carry out procedure as follows: –...

  • Page 70

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Remove battery and battery tray ⇒ Rep. Gr. 27 ; Disconnect‐ ing and connecting battery; Removing and installing battery .

  • Page 71

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Remove cable retainer -1- from starter bolt -arrow-. – Remove upper starter motor bolt. – Remove upper engine/gearbox connecting bolts.

  • Page 72

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Depress brake pedal to remove bolt for left drive shaft -arrow- (second mechanic required). Note After this, do not set vehicle on the ground any more ⇒...

  • Page 73

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Press both drive shafts out of gearbox. This procedure is de‐ scribed in ⇒ Rep. Gr. 40 ; Repairing drive shafts; Removing and installing drive shafts .

  • Page 74

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Remove ⇒ pendulum support, first bolt -A- and then bolts -B-. – Turn cap -1- in direction of arrow and remove.

  • Page 75

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – If present, remove earth strap from bracket -A-. – Remove 2 securing bolts for gearbox mounting on bracket -A- and 4 bolts for bracket on gearbox.

  • Page 76: Installing Gearbox, Jetta 2011 With 2.5 L - 125 Kw Engine

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Note Pay attention to torque converter. It must be removed together ♦ with gearbox. Secure torque converter to prevent it from falling out.

  • Page 77

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 7.5.1 Torque settings, Jetta 2011 with 2.0 l - 85 kW engine - Drive plate to torque convert‐...

  • Page 78

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 7.5.2 Torque settings, Jetta 2011 with 2.5 l - 125 kW engine 1 - Direction of travel - Drive plate to torque convert‐...

  • Page 79: Transporting Gearbox

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Transporting gearbox Special tools and workshop equipment required ♦ Shackle -10 - 222 A /12- Shackle 10-222 A/12 can be used to transport the automatic gearbox and set up gearbox support 3282.

  • Page 80: Atf Cooler

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 ATF cooler Assembly overview - ATF cooler 1 - Gearbox housing 2 - O-ring ❑ Always renew 3 - ATF cooler ❑...

  • Page 81: Checking Atf Level And Topping Up

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Checking ATF level and topping up Please follow instructions: ♦ About this workshop manual ⇒ page 1 ♦...

  • Page 82: Checking Atf Level

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 If ATF must be added, use only ATF listed in ⇒ Electronic parts catalogue ⇒ ETKA .

  • Page 83: Topping Up Atf

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Remove inspection plug for ATF level from oil pan. The ATF present in the overflow pipe runs out.

  • Page 84: Draining And Filling Atf

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 10.3 Draining and filling ATF Carry out procedure as follows: – Switch off engine. – Remove inspection plug for ATF level from oil pan -arrow-.

  • Page 85: Gears, Control

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 38 – Gears, control Renewing oil seal for selector shaft Special tools and workshop equipment required ♦...

  • Page 86: Atf Pan

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 ATF pan Removing and installing ATF pan Special tools and workshop equipment required ♦ Drip tray for workshop hoist -VAS 6208- ♦...

  • Page 87

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Loosen oil pan bolts -arrows- diagonally. – Remove oil pan together with gasket. 2.1.2 Installing Install in the reverse order of removal, observing the following: –...

  • Page 88

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Screw in overflow pipe -C-; torque specification ⇒ page 89 – Insert seal -B- for ATF inspection plug -A-.

  • Page 89: Atf Strainer

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 ATF strainer Removing and installing ATF strainer 3.1.1 Removing – Remove oil pan ⇒ page 82 –...

  • Page 90: Valve Body

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Valve body Removing and installing valve body ⇒ page 91 Solenoid valve identification ⇒ page 90 Sender identification ⇒...

  • Page 91: Assembly Overview

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Assembly overview 1 - ATF inspection plug ❑ Checking ATF level and topping up ⇒ page 77 ❑...

  • Page 92

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 13 - Bolt ❑ Torque setting ⇒ page 89 14 - Gearbox input speed sender -G182- ❑...

  • Page 93

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 ❑ Removing and installing ⇒ page 103 32 - Bolt ❑ Torque setting ⇒ page 89 4.1.1...

  • Page 94

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 4.1.2 Solenoid valve identification 1 - Wiring harness for solenoid valves with 14-pin connector -arrow- ❑ Removing and installing ⇒...

  • Page 95: Removing And Installing Valve Body

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 4.1.3 Sender identification 1 - Hydraulic pressure sender 1 for automatic gearbox - G193- ❑ Not installed in all gear‐...

  • Page 96

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 ♦ Angle wrench -V.A.G 1756- 4.2.1 Removing Carry out procedure as follows: – With ignition switched off, disconnect battery earth strap ⇒...

  • Page 97

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Use a small screwdriver to pry out securing bolts of connectors on solenoid valves -2- to -9- carefully and pull off connectors.

  • Page 98

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Separate connectors -2- and -5-. – Unscrew bracket bolts -3-. – If a connector is damaged, the wiring harness or the gearbox input speed sender -G182- or the gearbox output speed send‐...

  • Page 99

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Remove selector lever -1- from selector shaft. – In the process, carefully grip selector lever -1- with pliers -2- so that torque is not transferred to multifunction switch -F125- .

  • Page 100

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – When removing valve body, secure damper piston -2- to pre‐ vent it from falling out or remove together with spring if nec‐...

  • Page 101

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Wiring harnesses -1-, -3-, -4- and -5- are not allowed to be trapped by valve body.

  • Page 102

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Cables -3-, -5- and -9- are not allowed to be trapped. – Tighten new bolts -arrows-, -arrows A- and -arrows B- from inside to outside to specified torque ⇒...

  • Page 103

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Hook wiring harness -3- into retainer -7- -arrow B-. – Push selector lever -2- onto selector shaft -6-.

  • Page 104

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 WARNING Under certain circumstances, interchanging connectors may lead to destruction of the gearbox. If a connector is damaged, the wiring harness or the valve body together with the solenoid valves must be renewed.

  • Page 105

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 The mating part of the connectors must bear the same identifica‐ tion as the respective connector itself.

  • Page 106

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – If cables are too short to be bolted on, they have been incor‐ rectly routed or trapped by the valve body. Remove valve body again and route cables correctly.

  • Page 107: Removing And Installing Wiring Harness With 14-pin Connector (for Solenoid Valves)

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Removing and installing wiring harness with 14-pin connector (for solenoid valves) 4.3.1 Removing – Remove oil pan ⇒...

  • Page 108

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Use a small screwdriver to pry out securing bolts of connectors on solenoid valves -2- to -9- carefully and pull off connectors.

  • Page 109: Removing And Installing Wiring Harness With 8-pin Connector (for Sender)

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Tighten bolt for 14-pin gearbox connector; torque specification ⇒ page 89 – Tighten securing bolts for gearbox speed sender connector retainers;...

  • Page 110: Removing And Installing Gearbox Input Speed Sender G182

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Separate connectors -2- and -5-. – If a connector is damaged, the wiring harness or the gearbox input speed sender -G182- or the gearbox output speed send‐...

  • Page 111: Removing And Installing Gearbox Output Speed Sender G195

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Unscrew bolt -1- from gearbox input speed sender -G182- . – Pull sender out of gearbox.

  • Page 112

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Tighten bolt -2- for gearbox output speed sender -G195- ; tor‐ que specifications ⇒ page 89 –...

  • Page 113: Final Drive - Differential

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 39 – Final drive - differential Renewing oil seals for flange shafts (Gearbox installed) Only the left-hand side is described here. Renewing oil seal on right-hand side is nearly identical.

  • Page 114

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 ♦ Thrust piece -T10176- ♦ Thrust piece -T10177- 1.1.1 Removing flange shaft oil seal Carry out procedure as follows: –...

  • Page 115

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 Right: – If present, remove heat shield above right drive shaft -arrows-. – Raise right shaft as far as possible and secure in this position.

  • Page 116

    Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤ 6-speed automatic gearbox 09G - Edition 04.2010 – Screw a self-tapping screw, approx. 4 mm in diameter, into hole drilled in oil seal -arrow-.

This manual also for:

Golf variant 2010, Jetta 2005, Jetta 2011

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