Volkswagen Touareg 2003 Workshop Manual
  1. Manuals
  2. Brands
  3. Volkswagen Manuals
  4. Automobile
  5. Touareg 2003
  6. Workshop manual
Volkswagen Touareg 2003 Workshop Manual

Volkswagen Touareg 2003 Workshop Manual

Automatic gearbox 09d
Hide thumbs Also See for Touareg 2003:
Table of Contents

Advertisement

Quick Links

See also: Service Manual
Service
Workshop Manual
Touareg 2003 ➤
Automatic gearbox 09D Volkswagen R GmbH
Engine ID
Edition 06.2010
Service Department. Technical Information
CBW
A

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Touareg 2003 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Volkswagen Touareg 2003

Summary of Contents for Volkswagen Touareg 2003

  • Page 1 Service Workshop Manual Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH Engine ID Edition 06.2010 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 © 2012 Volkswagen AG, Wolfsburg K0058963020...

  • Page 3: Table Of Contents

    Gearbox identification ............Identification codes, engine allocation, Touareg 2003 ► ......
  • Page 4 Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Bleeding ATF system ............

  • Page 5: Technical Data

    – One can do this by clicking the ⇒ Feedback button -at the top in the menu bar-. You will not always receive a reply from Volkswagen but your message will always be read. We make great effort to implement your suggestions for the workshop manuals.

  • Page 6: Information About 6-Speed Automatic Gearbox 09D, General Repair Notes

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Automatic gearbox 001; Rep. gr. 39 ; Final drive, differential; Ad‐ justing final drive; Definitions for the Polo 2002. – Go ahead and »Click« click the link! Have a look.

  • Page 7: Tools

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 nal drive Tools A summary of the special tools and workshop equipment used in the workshop manual precedes each repair procedure and can be found in „Special tools/Workshop equipment“ binder.

  • Page 8: Seals And Sealing Rings

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Seals and sealing rings ♦ Always renew O-rings, seals and gaskets. ♦ When seals have been removed, check contact surface on housings or shafts for burrs and damage and rectify as nec‐...

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

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Note Before beginning work on electrical components, touch an earth‐ ed object, for example a water pipe or lifting platform. Please do not touch connectors directly. 1.10 Guided fault finding, vehicle self-diag‐...

  • Page 10: Gearbox Identification

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Gearbox identification The 6-speed automatic gearbox 09D is installed in the Touareg. Allocation ⇒ page 7 The gearbox code appears on the type plate to the left on the bottom of the gearbox.

  • Page 11: Identification Codes, Engine Allocation, Touareg 2003

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Identification codes, engine alloca‐ tion, Touareg 2003 ► If parts are required for repair work, it is essential that reference is made to the gearbox code of the automatic gearbox.

  • Page 12: Capacity

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Capacity General information on Volkswagen oils can be found in ⇒ Elsa‐ Win; Internet (globe); Language; Technical information; Gearbox oils . Capacities Automatic gearbox 09D Initial filling of gearbox by...

  • Page 13: Torque Converter

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 32 – Torque converter Proper handling and installation of torque converter – Always secure torque converter. An unsecured torque converter may slide out when the gearbox is tipped.

  • Page 14: Draining Torque Converter

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 1.2.1 Removing – Apply oil seal extractor lever -VW 681- directly behind sealing lip of oil seal to avoid damaging stop ring. 1.2.2 Installing – Apply ATF to circumference and sealing lips of oil seal.

  • Page 15: Installing Torque Converter

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Installing torque converter – Lubricate torque converter hub and lips of torque converter seal each with one drop of ATF (and not more). – Push torque converter into gearbox to stop.
  • Page 16 Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Installation dimension • The torque converter is correctly installed when the distance -a- between the contact surfaces at the threaded holes of the torque converter and the torque converter housing is at least 19 mm.

  • Page 17: Controls, Housing

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 37 – Controls, housing Connecting »tester« Volkswagen offers various devices such as ♦ Vehicle diagnosis, testing and information system -VAS 5051- ♦ Vehicle diagnosis, testing and information system -VAS 5051B- ♦...

  • Page 18: Touareg

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Switch on tester -arrow-. The »tester« is ready for use when it is possible to choose be‐ tween the buttons Guided functions Guided fault on the »right« of the screen.

  • Page 19: Repairing Selector Mechanism

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Repairing selector mechanism WARNING Before working on vehicle with engine running, move selector lever to position „P“ and apply parking brake. Checking selector mechanism The starter must not operate in the selector lever positions „R“, „D“...

  • Page 20: Dismantling And Assembling Selector Mechanism

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 2.1.4 Ignition and light switched on The respective symbol in the shift mechanism cover lights up. 2.1.5 Selector lever position display Simultaneous illumination of all selector lever position display segments indicates that the gearbox is in gearbox emergency running mode.

  • Page 21: Removing And Installing Selector Lever Handle

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 ❑ Can be removed upwards. 16 - Bolt ❑ Adjusting ⇒ page 20 17 - Shift unit/cover ❑ Can be removed downwards only. 18 - Securing clip ❑ Always renew 19 - Selector lever cable ❑...
  • Page 22 Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Lever out insert. – Pull clip out of handle. – Pull button past pressure point until it is locked in position. – Now pull handle off selector lever.
  • Page 23 Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Insert clip -2-. – I - Push insert into handle to stop, and then slide upwards -arrow-. – II - Fit sleeve onto handle. Continuation for all handles –...

  • Page 24: Checking And Adjusting Selector Lever Cable

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Checking and adjusting selector lever cable Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Socket -T40031- 2.4.1 Checking – Move selector lever to „P“ position.

  • Page 25: Removing And Installing Selector Lever Cable

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 ♦ Socket -T40031- • Selector lever cable is disconnected from selector shaft lever. – Move selector lever to position „S“. – Move selector shaft lever on gearbox to position „D“.
  • Page 26 Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 2.5.1 Removing – Remove selector mechanism ⇒ page 30 – Press gaiter -arrow- forwards out of mounting bracket. To remove selector lever cable, it is sufficient to lower transfer box.

  • Page 27: Removing And Installing Cover

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Bring entire surface of cuff -arrow- in contact with mounting bracket. – Install selector mechanism ⇒ page 30 Removing and installing cover 2.6.1 Removing – Remove selector lever handle ⇒...

  • Page 28: Signal Magnet For Tiptronic Switch F189

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Signal magnet for Tiptronic switch - F189- Two signal magnets -A- and -B- are installed in cover strip -1-. These magnets send signals about the selector lever position to the printed circuit board above them.

  • Page 29: Removing And Installing Cover

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Now mark side -A- of magnet pointing »upwards«, for example with a felt pen. – Insert magnet into cover strip -arrow- with marked side »up‐ wards«. – After inserting, make sure that retaining lips -arrows- are in contact with magnet.

  • Page 30: Releasing Selector Lever Without Electrical Current (Emergency Release)

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Releasing selector lever without electri‐ cal current (emergency release) Note The selector lever handle and the cover with selector indicator -2- do not need to be removed for this.

  • Page 31: Removing And Installing Selector Lever Position P Solenoid N380

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Use a »long, thin« screwdriver to press solenoid core in -direction of arrow- from above. – Press selector lever button and move selector lever to position „N“.

  • Page 32: Removing And Installing Selector Lever Lock Solenoid N110

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Push solenoid into selector mechanism to stop until it engages in its retainer -arrow-. – Check that solenoid is located completely in retainer -arrow- to stop and lever engages-2- in locking lever -1-.

  • Page 33: Removing And Installing Selector Lever Locked In Position P Switch F319

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Push solenoid into selector mechanism to stop until it engages in its retainer -arrow-. – Check that solenoid is located completely in retainer -arrow- to stop and lever engages in locking lever.

  • Page 34: Removing And Installing Selector Mechanism

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Release connector -1- and pull off. – Remove bolt -2- and remove retainer. – Pull connector -3- out of retainer. – Pull connectors of solenoids. – Push securing lever to right and pull switch forwards and up‐...
  • Page 35 Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 ♦ Torque wrench -V.A.G 1331- ♦ Socket -T40031- 2.13.1 Removing – Remove selector lever handle ⇒ page 17 – Lift pull rod and move selector lever to position „S“.
  • Page 36 Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Pull off connector -1-. – Carefully pull catches -2- on left and right off frame. – Pull out catches -arrows- on left and right and pull cover off upwards.
  • Page 37 Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Remove securing clip -2- from selector lever cable -1- and pull selector mechanism off selector lever cable. 2.13.2 Installing Install in reverse order of removal. During this step, observe the following: –...

  • Page 38: Renewing Needle Bearing For Starter

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Renewing needle bearing for starter Needle bearing is installed in cars with V10 TDI engine. Allocation ⇒ Electronic parts catalogue „ETKA“ • Engine and gearbox removed ⇒ 10-cylinder diesel engine;...

  • Page 39: Renewing Needle Bearing For Starter

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Renewing needle bearing for starter Pulling out needle roller bearing A - Adapter from multipurpose tool -VW 771- B - Adapter -VW771/44- Driving in needle bearing – Carefully drive needle bearing in to stop.

  • Page 40: Removing And Installing Gearbox

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Removing and installing gearbox Removing and installing gearbox, vehicles with V10 TDI engine ⇒ page 36 Removing and installing gearbox, vehi‐ cles with V10 TDI engine Brief description The automatic gearbox -09D- is removed together with engine, front final drive and transfer box.
  • Page 41 Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 1 - Transfer box ❑ Notes and torque set‐ tings for installing trans‐ fer box and propshaft ⇒ Transfer box and final drive; Rep. gr. 34 ; Re‐...
  • Page 42 Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 The torque converter securing bolts and the lower engine/gear‐ box connecting bolts should be installed with engine and gearbox fitted. Ensure that at least two assembly platform plates -VAS 6131/1- are also under oil pan to support the automatic gearbox.
  • Page 43 Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Before installing gearbox, ensure that torque converter seats correctly in gearbox ⇒ page 11 – Check installation dimension -a- ⇒ page 12 Caution If engine and gearbox are brought together with force because the torque converter is improperly fitted, both gearbox and tor‐...
  • Page 44 Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Dowel sleeves -arrows- Bolt Installation position accord‐ ing to „clock“ M 12 x 140 12 o'clock M 12 x 180 1 o'clock M 12 x 155 2 o'clock 3.30 o'clock...

  • Page 45: Transporting Gearbox

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Transporting gearbox Special tools and workshop equipment required ♦ Lifting tackle -2024 A- ♦ Shackle -T10059- ♦ Workshop hoist - VAS 6100- – Secure lifting tackle -2024 A- with shackle -T10059- on work‐...

  • Page 46: Checking Atf Level And Topping Up

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Checking ATF level and topping up If the ATF circuit was opened, it must first be bleed ⇒ page 50 Only then can the ATF level be checked and toped up as neces‐...

  • Page 47: Checking Atf Level And Topping Up

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 When test temperature is reached, unscrew ATF inspection plug from oil pan. Caution An improper ATF level hinders the function of the gearbox. Checking ATF level and topping up Test conditions •...
  • Page 48 Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Surplus ATF runs out if ATF level is too high. – Drain ATF until it drips. – Install ATF inspection plug with new seal and tighten to 70 Nm.
  • Page 49 Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Drain ATF until it drips. – Install ATF inspection plug with new seal and tighten to 70 Nm. – This concludes the ATF check. – Switch off engine.

  • Page 50: Atf Lines And Atf Cooler

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 ATF lines and ATF cooler ♦ Assembly overview - vehicles with V10 TDI engine ⇒ page 46 Assembly overview - ATF lines, vehicles with V10 TDI engine 1 - Hexagon bolt, 25 Nm ❑...

  • Page 51: Removing And Installing Atf Lines And Atf Cooler

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Removing and installing ATF lines and ATF cooler 6.2.1 Removing Overview - coolers 1 - Radiator for engine coolant 2 - Retaining clips 3 - Condenser 4 - ATF cooler...
  • Page 52 Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Remove bolt for ATF line retainer from gearbox. – Remove ATF lines from gearbox. – Seal ATF lines and gearbox with clean plugs. 6.2.2 Installing Install in reverse order of removal. During this step, observe the following: –...

  • Page 53: Cleaning Atf Lines And Atf Cooler

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Install condenser -1- and ATF cooler -2-. – Insert securing clips -arrow-. – Remove plugs, push ATF lines completely into thermostat -2- and tighten bolt -1- ⇒ Item 4 (page 46) –...

  • Page 54: Bleeding Atf System

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Remove ATF lines from gearbox. – Push a hose onto one end of the ATF line between gearbox and thermostat and secure with a hose clip. Hang other end of hose in a suitable container.

  • Page 55: Control Unit For Automatic Gearbox J217

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Control unit for automatic gearbox - J217- Removing and installing automatic gear‐ box control unit -J217- Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Vehicle diagnosis, testing and information system -VAS 5051- 7.1.1...
  • Page 56 Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Release locking lugs „A“ -arrows A- by pressing down and pushing back at the same time. In this position, raise trim in vicinity of locking lugs „A“ -arrows A-.
  • Page 57 Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Follow procedure after connecting battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and connecting battery . 7. Control unit for automatic gearbox J217...

  • Page 58: Renew Seals

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Renew seals Renewing output shaft seal Special tools and workshop equipment required ♦ Puller -T10055- ♦ Adapter -T10055/2- ♦ Sleeve -T10180- ♦ Thrust piece -T10186- 8.1.1 Removing – Remove transfer box ⇒...

  • Page 59: Renewing Oil Seals For Selector Shaft

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 8.1.2 Installing – Coat sealing lips of new ring with ATF. – First put sleeve -T10180- on output shaft to prevent damage to seal. – Then drive new oil seal in to stop using thrust piece -T10180- .
  • Page 60 Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Drive in new seals using thrust piece -T10174- , taking care not to cant seals. – Install and adjust multifunction switch ⇒ page 64 Rep. gr.37 - Controls, housing...

  • Page 61: Gears, Control

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 38 – Gears, control Removing and installing oil pan Special tools and workshop equipment required ♦ Drip tray -V.A.G 1306- ♦ Torque wrench -V.A.G 1331- Removing – Remove gearbox noise insulation.

  • Page 62: Torque Settings

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Install oil pan with new gasket -1-. – Ensure that all spacer sleeves -2- are completely located in new gasket -1-. – Tighten pan bolts diagonally in several stages ⇒...

  • Page 63: Removing And Installing Atf Strainer

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Removing and installing ATF strainer Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1410- Removing – Remove oil pan ⇒ page 57 – Remove bolts -arrows-.

  • Page 64: Torque Settings

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Screw in bolt -B- half way (approx. 5 turns). Centre ATF strainer ATF strainer »can be felt« to centre in seat of valve body. – Centre ATF strainer and apply even pressure to corners -arrows- until it reaches stop inside valve body.

  • Page 65: Overview - Removing And Installing Valve Body

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Overview - removing and installing valve body Valve body and/or lines can be removed and installed both with gearbox installed and with gearbox removed. 1 - Solenoid valve 2 -N89- 2 - Connector of gearbox out‐...
  • Page 66 Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Only gearboxes with hydraulic pressure sender: – Carefully pull off connectors for hydraulic pressure sender 1 for automatic gearbox -G193- -1- and hydraulic pressure sender 2 for automatic gearbox -G194- -2-.

  • Page 67: Removing And Installing Gearbox Output Speed Sender G195

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Remove bolts of valve body diagonally. Torque setting: 8 Nm + 90°. – Install in reverse order of removal. – After installing, fill up ATF, check ATF level and top up ⇒...

  • Page 68: Removing, Installing And Adjusting Multifunction Switch F125

    Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 Removing, installing and adjusting multifunction switch -F125- Special tools and workshop equipment required ♦ Setting gauge -T10173- ♦ Torque wrench -V.A.G 1331- Removing For the sake of clarity, this procedure shows an removed gearbox.
  • Page 69 Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Place multifunction switch -F125- on selector shaft. – Tighten securing bolts -arrows B- for multifunction switch - F125- by hand. – Set setting gauge -T10173- on selector shaft.
  • Page 70 Touareg 2003 ➤ Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010 – Tighten securing bolts -arrows- for multifunction switch -F125- to 6 Nm. – Now remove setting gauge -T10173- from selector shaft. – Connect selector lever cable. Further installation is carried out in the reverse sequence.

Table of Contents