-
TRANSMISSION
Continuously Variable Transmission (CVT) 01J
00 GENERAL, TECHNICAL DATA
TRANSMISSION IDENTIFICATION
The Continuously Variable Transmission (CVT) "multitronic 01J
front wheel drive" is installed in conjunction with various engines
in the Audi A6 2005 >. Allocation --> Code letters,
transmission applications, ratios, equipment.
Location of code letters on transmission
Fig. 1: Identifying Code Letters And Serial Number Of
Transmission Stamped On Underside Of Transmission Housing Courtesy
of VOLKSWAGEN UNITED STATES, INC.
Code letters and serial number of transmission are stamped on
the underside of the transmission housing - arrow -.
CONTINUOUSLY VARIABLE TRANSMISSION (CVT) MULTITRONIC 01J FRONT
WHEEL DRIVE , GENERAL INFORMATION
Continuously Variable Transmission (CVT) "multitronic 01J front
wheel drive" , general information
Additional information about the function of this transmission
951103Continuously Variable Transmission
Example: FRC 03 07 01 I I I I Code letters Day Month Year (2001)
of manufacture
NOTE:� The code letters of the transmission are also listed on
the vehicle data
stickers.
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TRANSMISSION Continuously Variable Transmission (CVT) 01J
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(CVT) multitronic 01J.
Guided Fault Finding
Always perform "Guided Fault Finding" using Diagnostic Operation
System VAS 5051 before starting disassembly and assembly work.
CODE LETTERS, TRANSMISSION APPLICATIONS, RATIOS, EQUIPMENT
Code letters, transmission applications, ratios, equipment
CAPACITIES
Capacities
Planetary gearbox
* ATF change interval for planetary gear 4F.
ATF for CVT transmission can be obtained as replacement part,
container size:
� 1.0 L - Part No. G 052 180 A2
NOTE:� The continuously variable automatic transmission
multitronic 01J is also
called "Continuously Variable Transmission" , "CVT" for
short.
Multitronic 01J.MTransmission Code letters HHZ Manufactured from
to 09.2005Application Model Audi A6 2005 > Engine 3.2L FSI 4V
-188 kWInput gearing ratio 49 : 48 1.021Front final drive ratio 43
: 9 4.778Ring gear dia. mm 203Flange shafts Center dia. mm 88 Hole
circle dia. mm 104
Capacities Planetary gearbox MultitronicInitial filling approx.
7.5 L 01JChanging 4.5 to 5.0 L * See note Lubricant ATF for CVT
transmission
CAUTION: The Continuously Variable Automatic Transmission
Multitronic 01J requires a different ATF than shift automatics.
Only ATF for CVT
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ATF, checking or changing --> ATF level, checking and topping
off.
Front final drive
*Permanent fill: only fill after repair, up to 1.3 liters.
Multitronic gear oil is available as a replacement part and
comes in the following container size:
� 0.5 L - Part no.G 052 190 A2
Oil level in front final drive, checking --> Front final
drive, checking gear oil level.
TOWING INSTRUCTIONS
Towing instructions
REPAIR INSTRUCTIONS
Repair instructions
transmission which can be obtained as replacement pa rt must be
used in the planet gearbox.
Capacities Front final drive MultitronicInitial filling approx.
1.3 L 01JChanging No change * See note Lubricant multitronic gear
oil
CAUTION: The Continuously Variable Automatic Transmission
Multitronic 01J requires a different axle oil than shift
automatics. Only axle oil for Multitronic which can be obtained as
a replacement part must be used in front final drive.
CAUTION: When towing, selector lever must be in position "N" and
vehicle must not to be towed for more than 50 km or at a speed in
excess of 50 km/h as otherwise transmission would be destroyed.
NOTE:� Tow-starting the engine, e.g. when the battery is too
weak or the starter is
faulty, is not possible.
CAUTION: Before work is done with engine running, place selector
lever in "P" position and press parking brake button to engage
electromagnetic parking brake.
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The maximum possible care and cleanliness and proper tools are
essential to ensure satisfactory and successful transmission
repairs. The usual basic safety precautions also, naturally apply
when carrying out vehicle repairs.
A number of generally applicable instructions for individual
repair procedures, which are otherwise mentioned at various points
in the article, are summarized here. They apply to this
article.
Special tools and equipment
For a complete list of special tools used in the article. See
Special Tools.
Transmission
� Observe rules of cleanliness for working on the transmission
--> Rules for cleanliness when working on transmission.
� Do not run engine with the end cover removed or without ATF
filling and do not tow vehicle.
� Only install clean parts: Remove packing from replacement
parts immediately prior to installation and not before.
� After installing, the following fluid levels must be checked
and topped off if necessary: ATF in planetary gear --> ATF
level, checking and topping off and axle oil in front final drive
--> Front final drive, checking gear oil level. Capacities and
specifications --> Capacities.
O-rings, seals, gaskets
� Always replace O-rings, gaskets and seals.
� After removing gaskets, examine contact surface on
housing/shaft for burrs resulting from removal or for other signs
of damage.
� Thoroughly clean housing joint surfaces before assembling.
� To install, thinly coat gaskets along outer circumference and
on sealing lip with ATF.
� Lightly lubricate O-rings with ATF when installing to prevent
the rings from being pinched when components are assembled.
� Only use ATF for automatic transmission components. Other
types of lubrication cause malfunctions to occur in the
transmission hydraulics.
� Open sides of oil seals face fluid side.
� When pressing in new gaskets, make sure the sealing lip does
not run on the same point as the sealing lip of the old seal (use
insertion depth tolerances).
� After installing, the following fluid levels must be checked
and topped off if necessary: ATF in planetary gear --> ATF
level, checking and topping off or axle oil in front final drive
--> Front final drive, checking gear oil level. Capacities and
specifications --> Capacities.
Bolts and nuts
� Loosen bolts in reverse of tightening sequence.
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� Nuts and bolts which secure covers and housings should be
tightened in stages according to specified sequence and tightening
method.
� Loosen and tighten bolts and nuts for securing covers and
housings in a diagonal sequence and in stages, when no tightening
sequence is specified.
� The tightening torques stated apply to unoiled bolts and
nuts.
� Replace self-locking bolts and nuts.
� Clean threads of bolts that were applied with locking fluid
using a wire brush. Then insert bolts and apply AMV 185 101 A1.
� Threaded holes into which self-locking bolts or bolts coated
with locking fluid are screwed, must be cleaned (e.g. tap).
Otherwise there is a risk that the bolts will shear the next time
they are removed.
Locking elements
� Do not over-stretch circlips.
� Always replace circlips which have been damaged or
over-stretched.
� Circlips must be properly seated in the base of the
groove.
Bearings
� Install needle bearings with the lettering on the bearing (the
side with thicker metal) facing towards the drift.
� Insert bearing with axle oil or ATF, depending on installation
location.
� Do not interchange the outer or inner races of bearings of the
same size.
� Always replace the taper roller bearings on one shaft together
and use new bearings from a single manufacturer.
Shims
� Use a micrometer to measure the shims at several points.
Varying tolerances make it possible to measure the required shim
thickness exactly.
� Inspect for burrs and signs of damage. Install only shims that
are in perfect condition.
Guided Fault Finding
Always perform Guided Fault Finding using the Diagnostic
Operation System VAS 5051 before starting disassembly and assembly
work.
RULES FOR CLEANLINESS WHEN WORKING ON TRANSMISSION
Rules for cleanliness when working on transmission
� Carefully clean all joints and adjacent areas before
disconnecting.
� Place removed parts on a clean surface and cover them. Use
sheeting or paper. Do not use fluffy cloths!
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� Carefully cover or plug unpacked components if repairs cannot
be performed immediately.
� Only install clean parts: Remove packing from replacement
parts immediately prior to installation and not before.
37 AUTOMATIC TRANSMISSION - CONTROLS, HOUSING
ELECTRICAL/ELECTRONIC COMPONENTS AND INSTALLED LOCATIONS
Fig. 2: Connecting Data Link Connector (DLC) Courtesy of
VOLKSWAGEN UNITED STATES, INC.
Data Link Connector (DLC)
� Location: Diagnostic connector is located below lower
instrument panel cover on drivers side.
Fig. 3: Identifying Sensors Of Soiling And Metal Shavings
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Courtesy of VOLKSWAGEN UNITED STATES, INC.
Transmission Control Module (TCM) J217
� Location: Transmission Control Module (TCM) J217 is on the
back end of transmission, secured directly to hydraulic control
module.
The following components are integrated in Transmission Control
Module (TCM) J217 :
A - Transmission Output Speed (RPM) Sensor G195 and Transmission
Output Speed (RPM) Sensor 2 G196
B - Transmission Fluid Temperature Sensor G93
C - Multi-Function Transmission Range (TR) Switch F125
D - Transmission Input Speed (RPM) Sensor G182
E - Automatic Transmission Hydraulic Pressure Sensor 1 G193
F - Automatic Transmission Hydraulic Pressure Sensor 2 G194
Removing and installing Transmission Control Module (TCM) J217
--> Transmission Control Module (TCM) J217 , removing and
installing.
Fig. 4: Identifying Hydraulic Control Module Components Courtesy
of VOLKSWAGEN UNITED STATES, INC.
Hydraulic control module
� Location: Hydraulic control module is bolted to back end of
transmission. Transmission Control Module (TCM) J217 is fastened
directly to hydraulic control module.
NOTE:� Transmission Control Module (TCM) J217 is monitored with
On Board
Diagnostics (OBD).
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A - Automatic Transmission Pressure Regulating Valve 1 N215
electrical connector
B - Automatic Transmission Pressure Regulating Valve 2 N216
electrical connector
C - Solenoid Valve 1 N88 electrical connector
Removing and installing hydraulic control module -->
Hydraulic control module, removing and installing.
The following valves are integrated into hydraulic control
module (not depicted here).
� Automatic Transmission Pressure Regulating Valve 1 N215
(clutch solenoid valve)
� Automatic Transmission Pressure Regulating Valve 2 N216
(solenoid valve gear)
� Solenoid Valve 1 N88 (clutch cooling/safety shut-off)
� Clutch cooling valve
� Minimum pressure valve
� Pressure relief valve
� Clutch control valve
� Pressure control valve
Fig. 5: Selector Lever Sensor System Control Module J587 And
Tiptronic Switch F189 Courtesy of VOLKSWAGEN UNITED STATES,
INC.
Selector Lever Sensor System Control Module J587 and Tiptronic
Switch F189
� Location: Selector Lever Sensor System Control Module J587 and
Tiptronic Switch F189 are housed in the same component - arrow
-.
Selector Lever Sensor system Control Module J587 and Tiptronic
Switch F189 , removing and installing --> Selector Lever Sensor
System Control Module J587 with Tiptronic Switch F189 , removing
and installing.
NOTE:� Valves are monitored via On Board Diagnostic (OBD).
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Fig. 6: Identifying Shift Lock Solenoid N110 Electrical
Connector And Releasing Retainer And Pulling Out Shift Lock
Solenoid N110 From The Front Courtesy of VOLKSWAGEN UNITED STATES,
INC.
Shift lock solenoid N110
� Location: Shift Lock Solenoid N110 - 1 - is clipped onto shift
mechanism.
Shift Lock Solenoid N110 , removing and installing --> Shift
lock solenoid N110 , removing and installing.
Fig. 7: Removing/Installing Microswitch Off Courtesy of
VOLKSWAGEN UNITED STATES, INC.
Transmission Park Selector Switch F305
� Location: Transmission Park Selector Switch F305 consisting of
2 micro switches is installed in shift mechanism.
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Assembly: --> Transmission Park Selector Switch F305 ,
removing and installing.
Fig. 8: Kick Down Switch F8 Courtesy of VOLKSWAGEN UNITED
STATES, INC.
Kick Down Switch F8
Location:
A specific value from Throttle Position (TP) Sensor G79 and
Accelerator Pedal Position Sensor 2 G185 is saved in engine control
module.
Accelerator pedal position sensors are integrated in accelerator
module - arrow -.
NOTE:� If accelerator pedal position sensor is faulty,
accelerator module must be
replaced --> 20 - FUEL SUPPLY SYSTEM .
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Fig. 9: Cruise Control Switch -E45- Courtesy of VOLKSWAGEN
UNITED STATES, INC.
Cruise control switch E45
� Location: Cruise control switch is located on steering column
switch.
Steering column switch, removing and installing --> 94 -
LIGHTS, SWITCHES - EXTERIOR .
Fig. 10: Transmission Range (TR) Selector Lever Display -Y6-
Courtesy of VOLKSWAGEN UNITED STATES, INC.
Transmission Range (TR) Display Y6
� Location: Transmission Range (TR) Display Y6 is integrated in
instrument cluster.
NOTE:� A completely lit display warns of a simple malfunction. �
A blinking display warns of a critical malfunction. � No display
indicates a wiring fault or a faulty Transmission Range (TR)
Display Y6. � If Transmission Range (TR) Display Y6 is faulty,
instrument cluster must
be replaced --> 90 - INSTRUMENTS .
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Fig. 11: Releasing Retaining Spring And Removing Selector Lever
Transmission Range (TR) Position Display Y26 Upward Courtesy of
VOLKSWAGEN UNITED STATES, INC.
Selector Lever Transmission Range (TR) Position Display Y26
� Selector Lever Transmission Range (TR) Position Display Y26 -
1 - is clipped into center console.
Selector Lever Transmission Range (TR) Position Display Y26 ,
removing and installing --> Selector Lever Transmission Range
(TR) Position Display Y26 , removing and installing.
SELECTOR MECHANISM, SERVICING
Selector mechanism, servicing
Ignition key lock, checking
� To reach position "ignition on" , briefly turn ignition key
lightly toward right.
� Press brake pedal and hold.
� It must be possible to shift selector lever out of position
"P" without "catching" while locking button on selector lever
handle is pressed.
� Switch ignition off.
� It should not be possible to remove the ignition key when
selector lever is in any other position than "P".
� Place selector lever in position "P".
� Remove ignition key.
CAUTION: Before work is done with engine running, place selector
lever in "P" position and press parking brake button to engage
electromagnetic parking brake.
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� It must be possible to remove ignition key only in position
"P".
� Selector lever cannot be shifted out of position "P" with the
locking button pressed and foot brake operated.
If ignition key removal lock does not function as described,
check Access/Start Authorization Switch E415 using Vehicle
Diagnostic, Testing and Information System VAS 5051 in "Guided
Fault Finding" function.
Selector mechanism, checking
� In selector lever positions "S" , "D" , "R" and "Tiptronic
gate" the starter motor will not operate.
� If selector lever position "N" is selected at speeds greater
than 5 km/h, the selector lever lock solenoid must not engage and
block the selector lever. Selector lever can be shifted into
driving gear.
� For speeds below 2 km/h (almost standstill) and shifting into
selector lever position "N" , the shift lock solenoid must only
engage after approx. 1 second. Selector lever can only be shifted
out of position "N" with the brake pedal operated.
Selector lever in "P" position and ignition switched on:
� Do not operate brake pedal.
� Selector lever is locked and cannot be shifted out of "P"
position. Shift Lock Solenoid N110 blocks selector lever.
� Press brake pedal and hold.
� Shift Lock Solenoid N110 releases selector lever. It is
possible to shift into a driving gear. Shift selector lever slowly
from "P" position through "R, N, D, S" and check whether the
Transmission Range (TR) Display Y6 in the instrument cluster shows
the correct selector lever position.
Selector lever in "N" position and ignition switched on:
� Do not operate brake pedal.
� After a brief pause: Selector lever is locked and cannot be
shifted out of position "N" without pressing the button on selector
lever handle. Shift Lock Solenoid N110 blocks selector lever.
� Operate brake pedal.
� Shift Lock Solenoid N110 releases selector lever. Selection of
position "D" is possible.
Selector lever in position "D" , ignition switched on:
� Shift selector lever into "Tiptronic gate".
� Lit "D" symbol in Selector Lever Transmission Range (TR)
Position Display Y26 must go out and "+" and "" symbols must light
up.
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� The Transmission Range (TR) Display Y6 in the instrument
cluster should switch from "PRNDS" to "654321" when the selector
lever is shifted into "Tiptronic gate".
If specified values are not obtained:
� Adjust selector lever cable --> Selector lever cable,
adjusting. � Check ignition key removal lock --> Ignition key
lock, checking.
Selector mechanism, component overview
Fig. 12: Selector Mechanism Components, Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.
1 - Lock washer
2 - Noise insulation
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3 - Retaining clip
� Secures selector lever cable to shift mechanism casing
4 - Selector lever cable
� Do not bend or kink
� Removing and installing --> Selector lever cable, removing
and installing � In case of damaged rubber boot, selector lever
cable must be replaced
� Lightly lubricate ball socket with polycarbamide grease G 052
142 A2 before installing.
� When installing, make sure rubber sleeve on transmission side
is not twisted
� Adjusting --> Selector lever cable, adjusting
5 - Locking screw, 13 Nm
6 - Selector lever cable screws
� To remove selector lever cable, move plastic retaining spring
at selector mechanism forward slightly and put screws upward, only
as far as necessary.
7 - Shift lock solenoid N110
� Removing and installing --> Shift lock solenoid N110 ,
removing and installing
8 - Selector Lever Transmission Range (TR) Position Display
Y26
� Removing and installing --> Selector Lever Transmission
Range (TR) Position Display Y26 , removing and installing
9 - Clamp
� For securing selector lever handle to selector lever
� Removing and installing --> Selector lever handle, removing
and installing
10 - Selector lever boot
� Separate from selector lever handle --> Separating selector
lever boot from selector lever handle
11 - Selector lever handle
� Removing and installing --> Selector lever handle, removing
and installing
12 - Trim ring
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� Removing and installing --> Separating selector lever boot
from selector lever handle
13 - 1.2 Nm
14 - Selector Lever Sensor System Control Module J587 with
Tiptronic Switch F189
� Removing and installing --> Selector Lever Sensor System
Control Module J587 with Tiptronic Switch F189 , removing and
installing
15 - Transmission Park Selector Switch F305
� Removing and installing --> Transmission Park Selector
Switch F305 , removing and installing
16 - 10 Nm
17 - Selector lever housing
� Can only be replaced as complete unit
� Removing and installing --> Selector mechanism, removing
and installing
18 - Shift mechanism bottom cover
19 - 10 Nm
Selector lever handle, Selector Lever Transmission Range (TR)
Position Display Y26 , component overview
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Fig. 13: Selector Lever Handle Components, Selector Lever
Transmission Range Position Display Y26 , Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.
1 - Clamp
� For securing selector lever handle to selector lever
� Removing and installing --> Selector lever handle, removing
and installing
2 - Trim ring
� Removing and installing --> Separating selector lever boot
from selector lever handle
3 - Selector lever handle
� Removing and installing --> Selector lever handle, removing
and installing
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4 - Selector lever boot
� Separate from selector lever handle --> Separating selector
lever boot from selector lever handle
5 - Selector Lever Transmission Range (TR) Position Display
Y26
� Removing and installing --> Selector Lever Transmission
Range (TR) Position Display Y26 , removing and installing
Shift mechanism, operating manual release
� Remove front ashtray insert.
Fig. 14: Prying Off Cover Cap In Ashtray Housing Using
Screwdriver Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Pry cover cap in ashtray housing out using screwdriver - arrow
-.
NOTE:� When the battery is disconnected or has been discharged,
the selector
lever cannot be shifted out of the "P" position. � By operating
the manual release the Shift Lock Solenoid N110 will release
the selector lever when there is no power supply.
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Fig. 15: Pressing On Manual Release Lever Using A Screwdriver
And Simultaneously Shift The Selector Lever Out Of Position
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Press on manual release lever - arrow - , e.g. with a
screwdriver, and at the same time, remove selector lever from "P"
position.
Selector lever handle, removing and installing
Special tools, testers and auxiliary items required
Fig. 16: Identifying Hose Clamp Pliers V.A.G 1275 Courtesy of
VOLKSWAGEN UNITED STATES, INC.
� Hose clamp pliers V.A.G 1275
Fig. 17: Unclipping Mounting Frame For Selector Lever Boot From
Center Console Courtesy of VOLKSWAGEN UNITED STATES, INC.
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Removing
� Place selector lever in position "N".
� Unclip mounting frame for selector lever boot - 1 - from
center console and lift it upward and off - arrows -.
Fig. 18: Securing The Interlock Button In Pulled-Out Position
Using A Cable Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Secure lock button in pulled-out position using a cable tie -
arrow - as shown in illustration.
Fig. 19: Selector Lever Boot, Selector Lever Handle And Clamp
Courtesy of VOLKSWAGEN UNITED STATES, INC.
NOTE:� The selector lever handle is removed together with the
selector lever boot.
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� Flip selector lever boot - 1 - upward and over the selector
lever handle - 2 -. � Open clamp - arrow - and pull off selector
lever handle together with selector lever boot, without
touching the lock button.
Fig. 20: Securing The Interlock Button In Pulled-Out Position
Using A Cable Courtesy of VOLKSWAGEN UNITED STATES, INC.
Installing
� Place selector lever handle completely onto selector lever -
lock button faces toward driver.
� When doing this, handle must engage into ring groove of
selector lever.
� Remove cable tie or assembly aid, thereby the lock button
mechanism engages in the vertical groove of the selector lever. If
necessary, press the lock button into the selector lever
handle.
NOTE:� To install selector lever handle, lock button must be
pulled out as far as
stop and secured with a cable tie - arrow - or using the
assembly aid included with new handle.
� If the lock button was not secured, it must not be pulled out
from the handle using mechanical aids. Apply compressed air gun to
bottom of handle and press lock button out with compressed air.
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Fig. 21: Selector Lever Boot, Selector Lever Handle And Clamp
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Clamp selector lever handle - 2 - to the selector lever, using
clamp - arrow -. To do this, use the hose clamp pliers V.A.G
1275.
� Clip retaining frame for selector lever boot - 1 - onto center
console.
Separating selector lever boot from selector lever handle
Fig. 22: Removing Selector Lever Boot From Selector Lever Handle
Courtesy of VOLKSWAGEN UNITED STATES, INC.
Removing
� Remove selector lever handle --> Selector lever handle,
removing and installing. � Bind the spring tabs - 1 - of selector
lever handle together with a cable tie - 3 - , as shown in the
illustration.
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� Push sleeve - 2 - of selector lever boot over retaining tabs
on spring tabs - arrow -. � Remove cable tie and remove sleeve with
selector lever boot from selector lever.
Installing
Install in reverse order, paying attention to the following:
Installation position of selector lever boot:
� The longer side of the frame for selector lever boot faces
toward driver side.
� Install selector lever handle --> Selector lever handle,
removing and installing.
Selector Lever Transmission Range (TR) Position Display Y26 ,
removing and installing
Fig. 23: Unclipping Mounting Frame For Selector Lever Boot From
Center Console Courtesy of VOLKSWAGEN UNITED STATES, INC.
Removing
� Place selector lever in position "N".
� Unclip mounting frame for selector lever boot - 1 - from
center console and lift it upward and off - arrows -.
� Flip selector lever boot upward.
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Fig. 24: Releasing Retaining Spring And Removing Selector Lever
Transmission Range (TR) Position Display Y26 Upward Courtesy of
VOLKSWAGEN UNITED STATES, INC.
� Release retaining spring - 2 - and remove Selector Lever
Transmission Range (TR) Position Display Y26 - 1 - - arrow -.
� Disconnect electrical connector.
Installing
Installation is in the reverse order of removal.
Selector mechanism, component overview
NOTE:� Lubricate bearing areas and slide surfaces with
polycarbamide grease G
052 142 A2 .
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Fig. 25: Selector Mechanism Components, Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.
1 - Selector lever cable rubber boot
� Check whether selector lever cable rubber boot on lower shift
mechanism cover is engaged correctly and properly sealed
2 - Selector lever cable
� Do not bend or kink
� Removing and installing --> Selector lever cable, removing
and installing � In case of damaged rubber boot, selector lever
cable must be replaced
� Lightly lubricate ball socket with polycarbamide grease G 052
142 A2 before installing.
� When installing, make sure rubber sleeve on transmission side
is not twisted
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� Adjusting --> Selector lever cable, adjusting
3 - Selector lever cable screws
� To remove selector lever cable, move plastic retaining spring
at selector mechanism forward slightly and put screws upward, only
as far as necessary.
4 - Shift lock solenoid N110
� Removing and installing --> Shift lock solenoid N110 ,
removing and installing
5 - Selector Lever Sensor System Control Module J587 with
Tiptronic Switch F189
� Removing and installing --> Selector Lever Sensor System
Control Module J587 with Tiptronic Switch F189 , removing and
installing
6 - 1.2 Nm
7 - 10 Nm
8 - Selector lever housing
� Can only be replaced as complete unit
� Removing and installing --> Selector mechanism, removing
and installing
9 - Retaining clip
� Secures selector lever cable to shift mechanism casing
10 - Shift mechanism bottom cover
11 - 10 Nm
Shift lock solenoid N110 , removing and installing
Removing
� Place selector lever in position "S".
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Fig. 26: Pulling Climatronic Control Module J255 (Control Head)
Out Of Mounting Frame Courtesy of VOLKSWAGEN UNITED STATES,
INC.
� Grasp at bottom of recesses on Climatronic Control Module J255
(operation and display unit).
� Remove Climatronic Control Module J255 (operation and display
unit) from installation frame - arrows -.
� Lay Climatronic Control Module J255 (operation and control
unit) on a cloth on center console to avoid damaging surface.
Fig. 27: Disconnecting Electrical Harness Connectors In Sequence
By Releasing Catches Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Disconnect electrical connectors in sequence - A to D - by
releasing tab - F -. � Disconnect electrical connector - E -.
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Fig. 28: Removing Gap Cover Above Ashtray Courtesy of VOLKSWAGEN
UNITED STATES, INC.
� Remove gap cover over ashtray - arrow -.
Fig. 29: Housing For Front Ashtray And Bolts Courtesy of
VOLKSWAGEN UNITED STATES, INC.
� Open front ashtray.
� Remove front ashtray insert.
� Remove bolts - 1 - and - 2 -. � Remove front ashtray housing -
3 - - arrow -.
� If equipped, disconnect electrical connector.
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Fig. 30: Identifying Shift Lock Solenoid N110 Electrical
Connector And Releasing Retainer And Pulling Out Shift Lock
Solenoid N110 From The Front Courtesy of VOLKSWAGEN UNITED STATES,
INC.
� Disconnect electrical connector - 1 - at Shift Lock Solenoid
N110. � Release catches - arrow A - and remove Shift Lock Solenoid
N110 forward - arrow B -.
Installing
� Selector lever in "S" position.
Fig. 31: Manual Release Lever Courtesy of VOLKSWAGEN UNITED
STATES, INC.
� Pull manual release lever - arrow - upward.
NOTE:� Shown with selector mechanism removed to provide a better
illustration.
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Fig. 32: Placing Shift Lock Solenoid N110 Into Guide At An Angle
From Above Courtesy of VOLKSWAGEN UNITED STATES, INC.
� At the same time, position Shift Lock Solenoid N110 at an
angle in guide from above.
� Press Shift Lock Solenoid N110 into guide until it
engages.
� Shift Lock Solenoid N110 ball head - 2 - must engage in
operating lever on selector mechanism.
Installation is in reverse order of removal.
Torque specification
Selector Lever Sensor System Control Module J587 with Tiptronic
Switch F189 , removing and installing
Removing
� Remove selector lever handle --> Selector lever handle,
removing and installing. � Remove front and rear center consoles
--> 68 - INTERIOR EQUIPMENT .
NOTE:� When manual release lever is raised, Shift Lock Solenoid
N110 operating
lever - 1 - swings into installation position.
Component NmFront ashtray housing to center console frame 3
NOTE:� Selector Lever Sensor System Control Module J587 with
Tiptronic Switch
F189 are combined in one component. � Tiptronic Switch F189
magnets are secured to cover.
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Fig. 33: Selector Lever Sensor System Control Module J587 With
Tiptronic Switch F189 And Bolts Courtesy of VOLKSWAGEN UNITED
STATES, INC.
� Disconnect electrical connector - 1 -. � Remove screws -
arrows - and remove Selector Lever Sensor System Control Module
J587 with
Tiptronic Switch F189.
Installing
Installation is in reverse order of removal. Note the
following:
� Install rear and front center consoles --> 68 - INTERIOR
EQUIPMENT . � Install selector lever handle --> Selector lever
handle, removing and installing.
Torque specification
Selector mechanism, removing and installing
Removing
Component NmSelector Lever Sensor System Control Module J587
with Tiptronic Switch F189 to selector lever housing
1.2
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Fig. 34: Removing Rear Cross Member Courtesy of VOLKSWAGEN
UNITED STATES, INC.
� Remove rear crossmember - arrows -.
Fig. 35: Removing Front Transverse Beam Courtesy of VOLKSWAGEN
UNITED STATES, INC.
� Remove front crossmember - arrows -.
Fig. 36: Vehicle Floor Cover Left And Right Courtesy of
VOLKSWAGEN UNITED STATES, INC.
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� Remove left and right vehicle floor cover - 1 -.
Fig. 37: Loosening Clamping Sleeves Courtesy of VOLKSWAGEN
UNITED STATES, INC.
� Loosen clamping sleeves - 1 - and - 2 -.
Fig. 38: Removing/Installing Mounting Bolts For Front Exhaust
Pipes Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Remove bolts - 1 - and - 2 - at front exhaust pipe rear
bracket.
NOTE:� Flex joint in front exhaust pipe must not be bent more
than 10 ° , otherwise
it may be damaged.
NOTE:� Disregard - 3 - .
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Fig. 39: Left And Right Exhaust System Pipes Tied Up To Body
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Tie left and right exhaust system pipes up to body - arrows
-.
Fig. 40: Heat Shield Courtesy of VOLKSWAGEN UNITED STATES,
INC.
� Remove heat shield - arrow -.
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Fig. 41: Identifying Quick-Release Fasteners & Noise
Insulation Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Loosen quick-release connectors - 2 - and remove rear noise
insulation.
Fig. 42: Removing Support Bracket For Selector Lever Cable
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Mark installation position of support bracket for selector
lever cable.
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� Remove bolt - 1 - support bracket for selector lever cable. �
Press selector lever cable ball joint - 2 - off from selector shaft
lever.
Fig. 43: Disconnecting Selector Mechanism Electrical Connectors
And Removing Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Remove front and rear center consoles --> 68 - INTERIOR
EQUIPMENT . � Disconnect electrical connectors - 2 - and - 4 -. �
Remove screws - 1 - , - 3 - , - 5 - and - 6 -.
� Press retaining clamps - arrows - inward and lower selector
mechanism downward.
Installing
Installation is in reverse order of removal. Note the
following:
� Install selector lever bracket according to marking on
console.
� Adjust selector lever cable --> Selector lever cable,
adjusting. � Install exhaust system and align free of tension
--> 26 - EXHAUST SYSTEM, EMISSION
CONTROLS . � Install rear crossmember --> 40 - FRONT
SUSPENSION .
NOTE:� Do not bend or kink the selector lever cable.
NOTE:� A second technician is required when detaching shift
mechanism below
vehicle.
NOTE:� Lightly grease ball socket of selector lever cable with
polycarbamide
grease G 052 142 A2 before installing. � Do not bend or kink the
selector lever cable.
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� Install front crossmember --> 50 - BODY - FRONT . � Install
front and rear center consoles --> 68 - INTERIOR EQUIPMENT . �
Check shift mechanism --> Selector mechanism, checking.
Torque specification
Transmission Park Selector Switch F305 , removing and
installing
Transmission Park Selector Switch F305 consists of two micro
switches. The two micro switches create the signal that the
electronic ignition key removal lock needs to release the key only
in selector lever position P.
The first switch is closed when the Shift Lock Solenoid N110 is
not active in selector lever position "P" (with brake pedal not
depressed) and also selector lever manual release below ashtray is
not actuated.
The second switch is closed when the button on selector lever
handle is not actuated in selector lever position "P".
Following points must be observed before replacing Transmission
Park Selector Switch F305 :
1. Both switches are switched electrically in sequence, that is,
both switches must be closed for ignition key to be removed.
Switches can be checked using Vehicle Diagnosing, Testing and
Information System VAS 5051 in Guided Fault Finding. After
performing tests on vehicle system, you must select test program
F305 - Gear selector position P switch via function/component
selection (drive/multitronic 01J front wheel drive/01-On Board
Diagnostic (OBD) capable systems/02 - Transmission
Electronics/Electrical components).
2. And electrical test on the switch is also possible. If a
continuity test is performed with a multimeter, note that in this
case, there is a resistance value of approx. 470 Ohm when both
switches are closed.
Removing
� Remove selector mechanism --> Selector mechanism, removing
and installing
Component NmShift mechanism to body 10
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Fig. 44: Selector Lever Sensor System Control Module J587 With
Tiptronic Switch F189 And Bolts Courtesy of VOLKSWAGEN UNITED
STATES, INC.
� Remove screws - arrows - and remove Selector Lever Sensor
System Control Module J587 with Tiptronic Switch F189.
Fig. 45: Removing/Installing Microswitch Off Courtesy of
VOLKSWAGEN UNITED STATES, INC.
� Disconnect connector - D - and remove from Shift Lock Solenoid
N110. � Disconnect connector - E - and remove upward. � Press tab -
C - in direction - arrow 1 -. � Remove micro switch - B - in
direction - arrow 2 -.
� Disengage electrical line at selector mechanism - arrow A
-.
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Fig. 46: Removing/Installing Selector Rod And Shift Selector
Lever Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Unclip covers - A - on both sides of selector mechanism. �
Press parking lock button - C - down and hold. � Remove selector
rod - B - upward and shift selector lever in direction of - arrow -
until it engages in
selector lever position "S".
Fig. 47: Removing/Installing Transmission Park Selector Switch
F305 Courtesy of VOLKSWAGEN UNITED STATES, INC.
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� Press retaining screws - A - with a screwdriver through rear
clip opening forward in direction - arrow -.
� Remove micro switch - B - forward. � Disengage electrical
wiring from tab - arrow C - and remove micro switch from shift
mechanism.
Fig. 48: Removing/Installing Transmission Park Selector Switch
F305 Courtesy of VOLKSWAGEN UNITED STATES, INC.
Installing
Installation is in reverse order of removal. Note the
following:
� Guide micro switch on longer electrical line into opening
under parking lock button in selector mechanism.
� Insert micro switch - B - in shift gate.
� Engage electrical line in tab - arrow C -. � Press retaining
screws - A - with a screwdriver opposite direction of - arrow - to
stop.
NOTE:� Retaining screws - A - must not be removed. They must
only be pressed
forward far enough so micro switch - B - can be removed.
NOTE:� Micro switch must lie flush on all sides.
NOTE:� Retaining screws - A - secure micro switch - B - in shift
gate. � Ignition key removal lock does not function correctly if
micro switch is not
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Fig. 49: Removing/Installing Microswitch Off Courtesy of
VOLKSWAGEN UNITED STATES, INC.
� Secure electrical line - arrow A - at selector mechanism
according to illustration. � Install micro switch - B -.
� Position connector - D - on Shift Lock Solenoid N110. � Engage
connector - E - from above.
inserted correctly or properly secured.
NOTE:� Ignition key removal lock does not function correctly if
micro switch is not
inserted correctly or properly secured.
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Fig. 50: Removing/Installing Selector Rod And Shift Selector
Lever Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Clip in covers - A - on both sides of selector mechanism. �
Install Selector Lever Sensor System Control Module J587 with
Tiptronic Switch F189 --> Selector
Lever Sensor System Control Module J587 with Tiptronic Switch
F189 , removing and installing � Install selector mechanism -->
Selector mechanism, removing and installing
Selector lever cable, assembly overview
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Fig. 51: Selector Lever Cable, Assembly Overview Courtesy of
VOLKSWAGEN UNITED STATES, INC.
1 - 9 Nm
2 - Selector shaft lever
� With mass damper
3 - 23 Nm
4 - Lock nut, 13 Nm
5 - Selector lever cable
� Do not bend or kink
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� Removing and installing --> Selector lever cable, removing
and installing � In case of damaged rubber boot, selector lever
cable must be replaced
� Lightly lubricate ball socket with polycarbamide grease G 052
142 A2 before installing.
� When installing, make sure rubber sleeve on transmission side
is not twisted
� Adjusting --> Selector lever cable, adjusting
6 - Selector lever cable locking screw, 13 Nm
7 - Selector lever cable screws
� To remove selector lever cable, move plastic retaining spring
at selector mechanism forward slightly and put screws upward, only
as far as necessary.
8 - Retaining clip
� Secures selector lever cable to shift mechanism casing
9 - Selector lever cable rubber boot
� Check whether selector lever cable rubber boot on lower shift
mechanism cover is engaged correctly and properly sealed
10 - 23 Nm
11 - Selector lever cable console
12 - Bracket for selector lever cable
Selector lever cable, removing and installing
Removing
� Place selector lever in position "S".
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Fig. 52: Removing Rear Cross Member Courtesy of VOLKSWAGEN
UNITED STATES, INC.
� Remove rear crossmember - arrows -.
Fig. 53: Removing Front Transverse Beam Courtesy of VOLKSWAGEN
UNITED STATES, INC.
� Remove front crossmember - arrows -.
Fig. 54: Vehicle Floor Cover Left And Right Courtesy of
VOLKSWAGEN UNITED STATES, INC.
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� Remove left and right vehicle floor cover - 1 -.
Fig. 55: Loosening Clamping Sleeves Courtesy of VOLKSWAGEN
UNITED STATES, INC.
� Loosen clamping sleeves - 1 - and - 2 -.
Fig. 56: Removing/Installing Mounting Bolts For Front Exhaust
Pipes Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Remove screws - 1 - and - 2 - at front exhaust pipe rear
bracket.
NOTE:� Flex joint in front exhaust pipe must not be bent more
than 10 ° , otherwise
it may be damaged.
NOTE:� Disregard - 3 - .
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Fig. 57: Left And Right Exhaust System Pipes Tied Up To Body
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Tie left and right exhaust system pipes up to body - arrows
-.
Fig. 58: Heat Shield Courtesy of VOLKSWAGEN UNITED STATES,
INC.
� Remove heat shield - arrow -.
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Fig. 59: Identifying Quick-Release Fasteners & Noise
Insulation Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Loosen quick-release connectors - 2 - and remove rear noise
insulation.
Fig. 60: Removing Support Bracket For Selector Lever Cable
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Mark installation position of support bracket for selector
lever cable.
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� Remove bolt - 1 - support bracket for selector lever cable. �
Press selector lever cable ball joint - 2 - off from selector shaft
lever.
Fig. 61: Identifying Lock Washers, Noise Insulation, Rubber
Sleeve, Bottom Cover For Selector Mechanism And Nuts Courtesy of
VOLKSWAGEN UNITED STATES, INC.
� Pry out lock washers - 1 -. � Slide noise insulation - 2 -
forward. � Remove rubber boots - 3 - from lower selector mechanism
cover - 4 -. � Remove nuts - 5 -.
� Swing lower selector mechanism cover and noise insulation
forward.
NOTE:� Do not bend or kink the selector lever cable.
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Fig. 62: Identifying Plastic Securing Spring, Pin, Screwdriver
And Selector Lever Cable Courtesy of VOLKSWAGEN UNITED STATES,
INC.
� Remove selector lever cable retaining clamp - 1 - on shift
mechanism downward. � Pull plastic securing spring - 2 - slightly
to front and push pins - 3 - upward with a screwdriver only as
far
as necessary.
� Remove selector lever cable - 4 - from shift mechanism.
Installing
Installation is in reverse order of removal. Note the
following:
Fig. 63: Inserting End Of Selector Lever Cable Into Joint Of
Selector Lever Courtesy of VOLKSWAGEN UNITED STATES, INC.
NOTE:� Make sure that pin is not pushed fully out.
NOTE:� Do not bend or kink the selector lever cable. � Lightly
grease ball socket of selector lever cable with polycarbamide
grease G 052 142 A2 before installing.
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� Slide selector lever cable into selector mechanism and secure
with retaining clamp - 1 -.
� Installation position: Angled end of retaining clamp points
toward rear.
� Insert end of selector lever cable - 4 - into selector lever
joint. � Press pin - 3 - downward - arrow -. � Check whether
plastic securing spring - 2 - has locked the pin. � Install
selector lever cable bracket on new selector lever cable.
� Install selector lever bracket according to marking on
console.
� Adjust selector lever cable --> Selector lever cable,
adjusting. � Install exhaust system and align free of tension
--> 26 - EXHAUST SYSTEM, EMISSION
CONTROLS . � Install rear crossmember --> 40 - FRONT
SUSPENSION .
� Install front crossmember --> 50 - BODY - FRONT . � Check
shift mechanism --> Selector mechanism, checking.
Torque specifications
Selector lever cable, adjusting
Special tools, testers and auxiliary items required
Fig. 64: Socket And Key T40031 Courtesy of VOLKSWAGEN UNITED
STATES, INC.
Component NmBracket to console 23Lower selector mechanism cover
to selector mechanism 10Selector lever cable lock nut 13
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� Socket and key T40031
Work procedure
Fig. 65: Unclipping Mounting Frame For Selector Lever Boot From
Center Console Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Unclip mounting frame for selector lever boot - 1 - from
center console and lift it upward and off - arrows -.
Fig. 66: Shifting Selector Lever To Position "S" Courtesy of
VOLKSWAGEN UNITED STATES, INC.
� Place selector lever in position "S".
NOTE:� Clamping screw is only accessible in selector lever
position "S".
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� Loosen selector lever cable locking screw approximately 1 turn
with a long hex socket head 5 mm.
Fig. 67: Removing Support Bracket For Selector Lever Cable
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Press selector shaft lever forward on transmission with end of
selector lever cable - 2 - to stop (position "S" on
transmission).
� Carefully move selector lever lightly toward front and rear
without shifting into another selector lever position, this
releases the tension on selector lever cable.
� Check exact setting of selector lever in position "S".
Fig. 68: Shifting Selector Lever To Position "S" Courtesy of
VOLKSWAGEN UNITED STATES, INC.
� Tighten selector lever cable locking screw - arrow - in this
position.
Installation is in reverse order of removal.
� Loosen locking screw approx. 1 turn - do not remove
completely
NOTE:� When tightening locking screw, selector lever must not be
moved forward
or back or adjustment will be incorrect.
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Torque specification
TRANSMISSION, REMOVING AND INSTALLING
Transmission, removing and installing
Fig. 69: Identifying Special Tools - Transmission, Removing And
Installing Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
� Hose clamps up to 25 mm dia. 3094
� Transmission support 3282
Component NmSelector lever cable locking screw 13
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� Adjustment plate 3282/30
� Engine/transmission jack V.A.G 1383 A
� Wooden block
Transmission, removing
� Lock carrier and torque support installed.
� Switch ignition off.
Fig. 70: Disconnecting Ground (GND) Strap At Battery Ground
(GND) Terminal Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Remove luggage compartment floor trim.
� Disconnect Ground (GND) lead - arrow - at the battery.
NOTE:� Reinstall cable ties that were loosened or cut off during
removal at same
locations during installation.
CAUTION: Observe procedures for disconnecting battery --> 27
- STARTER, GENERATOR, CRUISE CONTROL .
NOTE:� So that the front wheels can still be turned with the
battery disconnected,
the battery may only be connected when ignition key is
inserted.
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Fig. 71: Removing Rear Engine Cover Courtesy of VOLKSWAGEN
UNITED STATES, INC.
� Remove rear engine cover - arrows -.
Fig. 72: Removing Vacuum Hoses From T-Piece On Bulkhead Courtesy
of VOLKSWAGEN UNITED STATES, INC.
� Remove vacuum hoses - 1 - and - 2 - from T-connector on
bulkhead.
Fig. 73: Identifying Holding Plate, Intake Air Hose, Hose &
Air Duct Courtesy of VOLKSWAGEN UNITED STATES, INC.
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� Remove air intake hose - 1 - at Mass Air Flow (MAF) Sensor
G70. � Remove bolts for holding plate - 3 - for solenoid valves -
arrows -. � Disconnect hose - 4 - from air duct - 2 -.
Fig. 74: Removing Bolt And Disconnect Air Duct At Throttle Valve
Control Module Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Remove screw - arrow - and air duct - 2 - from Throttle Valve
Control Module J338. � If installed, disconnect hose - 1 - from air
duct.
Fig. 75: Removing Coolant Hoses Courtesy of VOLKSWAGEN UNITED
STATES, INC.
� Clamp off coolant hose - 2 - with a Hose Clamps Up to 25 mm
dia. 3094. � Remove coolant hose at coolant reservoir and seal
opening.
� Remove coolant reservoir - arrow - disconnect electrical
connector at Engine Coolant Level (ECL) Warning Switch F66 at
bottom of coolant reservoir.
� Lay aside coolant expansion tank with connected coolant hoses
- 1 - and - 3 -.
NOTE:� For sake of illustration, air guide is shown from the
rear with engine
removed.
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Fig. 76: Locating Electrical Connectors At Left Of Bulkhead
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Remove electrical connectors - 1 - and - 3 - at left of
bulkhead from bracket and disconnect. � Guide electrical wiring to
oxygen sensors downward.
Fig. 77: Removing Nut For Left Exhaust Pipe/Exhaust Manifold
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Remove nut - 2 - which is accessible from top for left exhaust
pipe/exhaust manifold.
NOTE:� Disregard - 2 - .
NOTE:� Shown from rear with engine removed to provide a better
illustration.
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Fig. 78: Locating Electrical Connectors At Right Of Bulkhead
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Remove electrical connectors - 1 - and - 3 - at right of
bulkhead from bracket and disconnect. � Guide electrical wiring to
oxygen sensors downward.
Fig. 79: Removing Nut For Right Exhaust Pipe/Exhaust Manifold
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Remove nut - 2 - which is accessible from top for right
exhaust pipe/exhaust manifold.
NOTE:� Disregard - 2 - .
NOTE:� Shown from rear with engine removed to provide a better
illustration.
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Fig. 80: Identifying Engine/Transmission Tightening Sequence
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Remove screws - 5 - and - 6 - accessible from top at
engine/transmission flange.
Fig. 81: Identifying Quick-Release Fasteners & Noise
Insulation Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Remove both front wheels.
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� Loosen quick-release connectors - 1 - and - 2 - and remove
noise insulation.
Fig. 82: Removing Left/Right Heat Shields For Drive Axles
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Remove left and right drive axle heat shield - 1 -. � Remove
left and right drive axles from transmission flange shaft.
Fig. 83: Removing Subframe Transverse Beam Courtesy of
VOLKSWAGEN UNITED STATES, INC.
� Remove crossmember from subframe - arrows -.
NOTE:� Secure brake discs with wheel bolts.
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Fig. 84: Removing Front Transverse Beam Courtesy of VOLKSWAGEN
UNITED STATES, INC.
� Remove front crossmember - arrows -.
Fig. 85: Loosening Clamping Sleeves Courtesy of VOLKSWAGEN
UNITED STATES, INC.
� Loosen clamping sleeves - 1 - and - 2 -.
NOTE:� To stabilize exhaust system, clamping sleeves remain in
installation
location and front exhaust pipes remain inserted in clamping
sleeves.
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Fig. 86: Removing/Installing Mounting Bolts For Front Exhaust
Pipes Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Remove bolts - 1 - and - 2 - at front exhaust pipe rear
bracket.
Fig. 87: Removing Bolt At Left Bracket For Front Exhaust Pipe
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Remove bolts - 1 - and - 2 -. � Remove front exhaust pipe left
bracket.
NOTE:� Flex joint in front exhaust pipe must not be bent more
than 10 ° , otherwise
it may be damaged.
NOTE:� Disregard - 3 - .
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Fig. 88: Removing Nut For Left Exhaust Pipe/Exhaust Manifold
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Free up oxygen sensor wiring.
� Remove nuts - 1 - and - 3 - which are accessible from bottom
for front exhaust pipe/left exhaust manifold.
� Remove front exhaust pipe with catalytic converter.
Fig. 89: Removing Bolt At Right Bracket For Front Exhaust Pipe
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Remove bolts - 1 - and - 2 - � Remove front exhaust pipe right
bracket.
NOTE:� For the sake of illustration, shown with engine
removed.
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Fig. 90: Removing Nut For Right Exhaust Pipe/Exhaust Manifold
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Free up oxygen sensor wiring.
� Remove nuts - 1 - and - 3 - which are accessible from bottom
for front exhaust pipe/right exhaust manifold.
� Remove front exhaust pipe with catalytic converter.
Fig. 91: Disconnecting Electrical Connector On Engine Speed
(RPM) Sensor G28 Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Disconnect Engine Speed (RPM) Sensor G28 electrical connector
- arrow -.
NOTE:� For the sake of illustration, shown with engine
removed.
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Fig. 92: Disengaging Electrical Harness Connector And
Disconnecting From Transmission Courtesy of VOLKSWAGEN UNITED
STATES, INC.
� Disengage electrical harness connector - 1 - and disconnect
from transmission. � Move wiring harness clear - arrows -.
Fig. 93: Removing ATF Line Bracket Courtesy of VOLKSWAGEN UNITED
STATES, INC.
� Remove right ATF line bracket at lower part of oil pan - arrow
-.
NOTE:� Observe the rules of cleanliness for working on automatic
transmissions --
> Rules for cleanliness when working on transmission .
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Fig. 94: Removing Bolt And ATF Lines From Transmission Courtesy
of VOLKSWAGEN UNITED STATES, INC.
� Remove bolt - arrow - and ATF lines from transmission. � Tie
ATF lines clear up to side.
Fig. 95: Placing Plunger Of Engine/Transmission Jack V.A.G 1383
A With Block Of Wood Inserted In Between Transmission At Bottom
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Place plunger of engine/transmission jack V.A.G 1383 A with a
block of wood inserted in between - 1 - on transmission at
bottom.
� Raise transmission slightly using engine/transmission jack
V.A.G 1383 A.
CAUTION: To continue procedure, torque support and lock carrier
must be installed.
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Fig. 96: Left Transmission Support, Bolts And Transmission
Mounting -- Vehicles With 8-Cyl. Engine Courtesy of VOLKSWAGEN
UNITED STATES, INC.
� Remove bolts - arrows - and remove tunnel crossmember. � Lower
transmission carefully.
Fig. 97: Identifying Transmission Support And Bolts Courtesy of
VOLKSWAGEN UNITED STATES, INC.
� Remove bolts - 2 - and remove transmission support - 1 - from
transmission.
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Fig. 98: Transmission Support 3282 Mounted On
Engine/Transmission Jack V.A.G 1383 A Courtesy of VOLKSWAGEN UNITED
STATES, INC.
� Mount transmission support 3282 on engine/transmission jack
V.A.G 1383 A.
� Place adjustment plate 3282/30 on the transmission support
3282 , as shown in the illustration.
� Align arms of transmission support to correspond with holes in
the adjustment plate.
� Attach support elements on adjustment plate, as
illustrated.
Fig. 99: Moving Engine/Transmission Jack V.A.G 1383 A With
Transmission Mount 3282 Under Transmission And Support Transmission
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Guide engine and transmission jack V.A.G 1383 A with
transmission support 3282 under transmission.
� Align adjusting plate parallel to transmission and secure
support to transmission with bolt M10x20 - arrow -.
� Raise transmission slightly using engine/transmission jack
V.A.G 1383 A.
NOTE:� Adjusting plate only fits in one position.
NOTE:� The arrow symbol on the adjusting plate points in the
direction of travel.
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Fig. 100: Placing Torque Support On Rubber Buffer For Torque
Support And Tightening Bolts Courtesy of VOLKSWAGEN UNITED STATES,
INC.
� Loosen bolts - arrow - on torque support stop. � Press torque
support stop upward and retighten bolts to 23 Nm.
Fig. 101: Identifying Engine/Transmission Tightening Sequence
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Remove bolts - 1 to 4 - and - 7 to 11 -. � Press transmission
off bushings - A - and carefully lower it far enough until selector
lever cable is
accessible.
NOTE:� Adjusting torque support stop prevents engine from
sinking down after
removing the front transmission.
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Fig. 102: Removing Support Bracket For Selector Lever Cable
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Mark installation position of support bracket for selector
lever cable.
� Remove bolt - 1 - support bracket for selector lever cable. �
Press selector lever cable ball joint - 2 - off from selector shaft
lever.
� Slowly lower transmission.
� Pay attention to clearance of drive axles when lowering
transmission.
Transmission, installing
Installation is in reverse order of removal. Note the
following:
� Check if alignment sleeves for centering engine/transmission
are in the cylinder block, and install if necessary.
� Before installing transmission, tie electrical wiring to one
side so that it cannot be trapped between engine
NOTE:� Do not bend or kink the selector lever cable.
NOTE:� Before installing an exchanged transmission, clean ATF
lines and ATF
cooler --> ATF lines and ATF cooler, cleaning and replace ATF
auxiliary filter --> ATF additional filter, removing and
installing .
� When performing repairs, replace self-locking nuts and bolts.
� Always replace bolts that are secured with tightening torque as
well as
sealing rings, gaskets and O-rings. � Clean input shaft splines
of transmission and damper unit splines on
flywheel, remove corrosion and apply only a very thin coating of
lubricant G 000 100 on splines. Excess grease must be removed.
� Secure all hose connections with hose clamps of the same type
as those equipped by the factory.
� When installing, bring all cable ties back to original
positions.
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and transmission.
� Raise engine far enough until selector lever cable can be
installed.
� Install selector lever bracket according to marking on
console.
Fig. 103: Moving Engine/Transmission Jack V.A.G 1383 A With
Transmission Mount 3282 Under Transmission And Support Transmission
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Carefully raise transmission and bring into installation
position using transmission support 3282.
� Attach transmission to engine with new bolts.
� Before inserting the lower set of bolts connecting
transmission with engine, lift transmission up slightly at
rear.
NOTE:� Do not bend or kink the selector lever cable. � Lightly
grease ball socket of selector lever cable with polycarbamide
grease G 052 142 A2 before installing.
NOTE:� The torque specifications apply only to lightly greased,
oiled, phosphated,
or black-finished nuts and bolts. � Additional lubricant such as
engine or transmission oil may be used, but
do not use graphite lubricant. � Do not use degreased parts. �
Tolerance for torque specification ± 15%.
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Fig. 104: Identifying Engine/Transmission Tightening Sequence
Courtesy of VOLKSWAGEN UNITED STATES, INC.
Torque specification, securing engine/transmission (transmission
flange pattern)
*Replace engine/transmission securing bolt.
*Bolt strength rating 10.9
� Install transmission support --> Transmission mounting and
transmission support, removing and installing.
Item Screw * See note Nm1, 10, 11 M10x45 45
2 * See note M10x80 653 M12x100 65
4, 8 M12x67 655, 6 M12x75 657 M10x90 459 M10x60 45A Alignment
sleeves for centering
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Fig. 105: Left Transmission Support, Bolts And Transmission
Mounting -- Vehicles With 8-Cyl. Engine Courtesy of VOLKSWAGEN
UNITED STATES, INC.
� Install tunnel crossmember - arrows -. � Install ATF lines
with new O-rings --> ATF lines, ATF cooler and auxiliary ATF
filter, component
overview, vehicles with 6-cyl. gasoline engine. � Install front
exhaust pipe and align exhaust system free of tension --> 26 -
EXHAUST SYSTEM,
EMISSION CONTROLS . � Install front crossmember --> 50 - BODY
- FRONT .
� Install subframe crossmember --> 40 - FRONT SUSPENSION . �
Fasten drive axles to flange shafts --> 40 - FRONT SUSPENSION
.
Fig. 106: Placing Torque Support On Rubber Buffer For Torque
Support And Tightening Bolts Courtesy of VOLKSWAGEN UNITED STATES,
INC.
� Loosen torque support bolts - arrows -. � Allow stop for
torque support to seat on torque support rubber buffer through its
own weight and
retighten bolts.
� Electrical connections and routing.
� Observe procedures for connecting battery --> 27 - STARTER,
GENERATOR, CRUISE CONTROL .
� Check adjustment of selector lever cable --> Selector lever
cable, adjusting. � Check oil level in front final drive -->
Front final drive, checking gear oil level. � Check ATF level and
top off --> ATF in planetary gear .
Torque specifications
Component NmBolts/nuts M6 9 M8 20 M1040
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Automatic transmission, transporting
Special tools, testers and auxiliary items required
Fig. 107: Transmission Lift Hook T40013 Courtesy of VOLKSWAGEN
UNITED STATES, INC.
� Attachment and holding rig T40013
Work procedure
Fig. 108: Identifying Transmission Lift Hook T40013 Used To
Transporting The Transmission Courtesy of VOLKSWAGEN UNITED STATES,
INC.
The transmission lift hook T40013 can be used when transporting
the transmission and for aligning transmission support 3282.
M1265Except for the following: Tunnel crossmember to chassis
40Heat shield for drive axle to transmission 23Torque support stop
to lock carrier 23
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� Mount and secure transmission lift hook T40013 on upper rib of
transmission housing as shown in the illustration.
Transmission, attaching to assembly stand
Fig. 109: Identifying Special Tools -- Transmission, Attaching
To Assembly Stand Courtesy of VOLKSWAGEN UNITED STATES, INC.
Special tools, testers and auxiliary items required
� Holding plate VW 309
� Holding fixture VW 313
� Transmission support VW 353
� Engine and Transmission Holder VW 540
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� Workshop crane VAS 6100
� Attachment and holding rig T40013
Securing transmission in vertical position
Fig. 110: Securing Transmission To Assembly Stand With Bolts
& Installing Transmission Support VW 353 Onto Holding Plate VW
309 Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Secure transmission to assembly stand with bolts - 1 - and - 2
-. � Screw transmission support VW 353 onto holding plate VW
309.
Fig. 111: Using Workshop Crane VAS 6100 To Insert Transmission
Into Holding Fixture VW 313 Courtesy of VOLKSWAGEN UNITED STATES,
INC.
� Using workshop crane VAS 6100 , insert transmission into
holding fixture VW 313.
CAUTION: Center of gravity of transmission is outside center of
rotation at holding fixture. To turn the transmission, a second
technician must hold the transmission housing to prevent
back-swing.
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Fig. 112: Securing Transmission In Horizontal Position Courtesy
of VOLKSWAGEN UNITED STATES, INC.
Securing transmission in horizontal position
� Bolt transmission onto engine/transmission holder VW 540 -
arrows -. � Using workshop crane VAS 6100 , insert transmission
into holding fixture VW 313.
Transmission mounting and transmission support, removing and
installing
Special tools, testers and auxiliary items required
Fig. 113: Identifying Engine/Transmission Jack V.A.G. 1383 A
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Engine/transmission jack V.A.G 1383 A
� Wooden block
Removing
CAUTION: Center of gravity of transmission is outside center of
rotation at holding fixture. To turn the transmission, a second
technician must hold the transmission housing to prevent
back-swing.
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Fig. 114: Identifying Quick-Release Fasteners & Noise
Insulation Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Loosen quick-release connectors - 2 - and remove rear noise
insulation.
Fig. 115: Removing/Installing Mounting Bolts For Front Exhaust
Pipes Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Remove front exhaust pipe rear bracket by removing bolts - 1
to 3 -.
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Fig. 116: Placing Plunger Of Engine/Transmission Jack V.A.G 1383
A With Block Of Wood Inserted In Between Transmission At Bottom
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Place plunger of engine/transmission jack V.A.G 1383 A with a
block of wood inserted in between - 1 - on transmission at
bottom.
� Raise transmission slightly using engine/transmission jack
V.A.G 1383 A.
Fig. 117: Removing Bolts On Tunnel Cross Member Courtesy of
VOLKSWAGEN UNITED STATES, INC.
� Remove tunnel crossmember bolts - arrows -.
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Fig. 118: Tunnel Cross-Member And Nuts Courtesy of VOLKSWAGEN
UNITED STATES, INC.
� Remove bolts - 1 - and - 2 - and slide tunnel crossmember back
slightly. � Remove transmission mounting between transmission and
tunnel crossmember.
Fig. 119: Identifying Transmission Support And Bolts Courtesy of
VOLKSWAGEN UNITED STATES, INC.
� Remove bolts - 2 - and remove transmission support - 1 - from
transmission.
Installing
Installation is in reverse order of removal.
Torque specifications
Component NmTransmission support to transmission 23Transmission
mount to transmission support 23Transmission mount to tunnel
crossmember 23Tunnel crossmember to chassis 40
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ATF IN PLANETARY GEAR
ATF level, checking and topping off
Special tools, testers and auxiliary items required
Fig. 120: VAS 5051 Vehicle Diagnosis, Testing and Information
System Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Vehicle Diagnosis, Testing and Information System VAS 5051
with Diagnostic cable VAS 5051/5A
Fig. 121: ATF Filler System F/CVT Transmission VAS 5162 Courtesy
of VOLKSWAGEN UNITED STATES, INC.
� ATF Filler System F/CVT Gearbox VAS 5162
� Old oil collecting and extracting device V.A.G 1782
� Safety glasses
Front exhaust pipe bracket to transmission 23Front exhaust pipe
to bracket 23
CAUTION: The Continuously Variable Automatic Transmission
Multitronic 01J
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Fig. 122: Identifying Illustration On Reservoir For ATF Filler
System F/CVT Transmission VAS5162 Courtesy of VOLKSWAGEN UNITED
STATES, INC.
Test conditions
� Transmission not in emergency operating mode.
� Move vehicle onto a lifting platform or over a work pit so
that it stands absolutely horizontal.
� Engine idling.
� Air conditioner and heating must be switched off.
requires a different ATF than shift automatics. Only ATF for CVT
transmission which can be obtained as replacement part must be used
in the planetary gear. ATF specifications --> Capacities .
NOTE:� The illustration on the reservoir for ATF Filler System
F/Cvt Gearbox VAS
5162 in upper left graphic refers to the use of special ATF for
CVT transmissions.
� The illustration also shows pictures of the steps required to
fill the transmission. These steps will be explained in the
following.
CAUTION:� Engine must not be started if only a small amount or
no ATF is in the
transmission after repair work or after significant ATF loss. �
In this case, a preliminary filling with 4.5 to 5 liters ATF must
be
performed.
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Fig. 123: Connecting Data Link Connector (DLC) Courtesy of
VOLKSWAGEN UNITED STATES, INC.
� Vehicle Diagnostic, Testing and Information System VAS 5051
connected, Vehicle Self-Diagnosis and vehicle system "02 -
Transmission electronics" selected.
� ATF temperature must not be higher than 30 ° C at start of
test, allow transmission to cool down if necessary.
Checking ATF temperature
Display on VAS 5051 :
NOTE:� The ATF level will vary according to the temperature of
the ATF. � Checking ATF level at too low ATF temperature leads to
overfilling. � If the ATF level is checked when the ATF temperature
is too high, this will
result in underfilling. � Over and underfilling lead to impaired
functioning of transmission. � ATF temperature is read off on the
Vehicle Diagnosis, Testing and
Information System VAS 5051.
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Fig. 124: Diagnostic System VAS 5051: Display Courtesy of
VOLKSWAGEN UNITED STATES, INC.
� In selection - 1 - , click on the diagnostic function "08 -
Read measuring value block".
Fig. 125: Diagnostic System VAS 5051: Display Courtesy of
VOLKSWAGEN UNITED STATES, INC.
Display on VAS 5051 :
1 - Enter display group, max. input value = 255
� In button field - 2 - , enter "10" for "Display group 10" and
confirm input by pressing Q button.
Display on VAS 5051 :
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Fig. 126: Diagnostic System VAS 5051: Display - Display Fields
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Read off ATF temperature indicated in display field - 3 -.
Checking ATF level and topping off
� Fill ATF Filler System F/Cvt Gearbox VAS 5162 with ATF for CVT
transmissions.
� ATF specification --> Capacities.
NOTE:� Engine keeps running at idle speed. � The ATF level is
checked at the ATF inspection plug. � ATF level is correct if a
little bit of fluid still escapes at the ATF check plug
between 35 ° and 45 ° C (50 ° C for hot countries) ATF
temperature (dependent on the fluid level when warming up).
CAUTION: The ATF filler tool must be clean and the ATF must not
be mixed with any other ATF oils!
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Fig. 127: Securing Filled Reservoir Of ATF Filler System F/CVT
Transmission VAS 5162 As High As Possible On Vehicle Courtesy of
VOLKSWAGEN UNITED STATES, INC.
� Secure filled reservoir of ATF Filler System F/Cvt Gearbox VAS
5162 as high as possible on the vehicle.
� While brake pedal is depressed, shift through all selector
lever positions ( "P" , "R" , "N" , "D" , "S" ) let each position
remain shifted at idle for approx. 2 seconds.
NOTE:� The shut-off valve on the ATF Filler System F/Cvt Gearbox
VAS 5162 must
be closed.
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Fig. 128: Identifying Quick-Release Fasteners & Noise
Insulation Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Loosen quick-release connectors - 2 - and remove rear noise
insulation. � Place old oil collecting and extracting device V.A.G
1782 beneath transmission.
CAUTION: Wear eye protection.
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Fig. 129: Identifying ATF Check Plug Courtesy of VOLKSWAGEN
UNITED STATES, INC.
� If an ATF temperature of 35 ° C is reached, remove ATF check
plug - B -.
If ATF continues to flow out of the ATF filler plug hole over
the overflow tube before the ATF reaches 40 ° C, the ATF level is
OK.
� Replace and tighten ATF check plug.
� Tightening torque: 20 Nm.
The ATF check is now completed.
� Press
-
Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Thread connection on shut-off valve of ATF Filler System F/Cvt
Gearbox VAS 5162 into opening of ATF check plug - B -.
Fig. 131: Securing Filled Reservoir Of ATF Filler System F/CVT
Gearbox VAS 5162 As High As Possible On Vehicle Courtesy of
VOLKSWAGEN UNITED STATES, INC.
� Rotate shut-off valve in direction of filler hose - lower
arrow -. ATF flows into transmission. � Hold a suitable container
beneath outlet of ATF Filler System F/Cvt Gearbox VAS 5162.
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Fig. 132: Checking ATF Level By Rotating Shut-Off Valve In
Direction Of Outlet Courtesy of VOLKSWAGEN UNITED STATES, INC.
� Check ATF level by rotating shut-off valve in direction of
outlet - lower arrow -.
ATF level is correct when ATF drips out only lightly from outlet
before 45 ° C is reached.
� If no additional ATF flows out, rotate shut-off valve back in
direction of filler hose and fill with more ATF; repeat check of
ATF level.
� After reaching correct ATF level, remove shut-off valve
again.
� Replace and tighten ATF check plug.
� Tightening torque: 20 Nm.
NOTE:� Approx. 5 cl of ATF will initially drain from the
internal oil level tube. This
is normal.
NOTE:� After removing shut- off valve, ATF drip