Volkswagen Golf Variant 2010 User Manual

Service

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Manual

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Variant 2007

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Variant 2010

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2011

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u6-speed automatic gearbox 09G

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Edition 04.2010

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Service Department. Technical Information

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Servicent

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List of Workshop Manual Repairles

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Repair GroupsList of Workshopte

Manual Repair Groups

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Repair Group

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00 - Technical data

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32 - Torque converter

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37 - Controls, housing

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38 - Gears, control

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39 - Final drive - differential

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Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R005320

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1	Suggestions and criticism, general repair notes																													.	. . .	. . .	.	.		.	.	.	.		.	.	.	. .	.		. . . .	. .	.		.		.		.			.		. . . .	1
1.1	Suggestions and criticism of this workshop manual . .																															.	. .	.		.	.	.		.	.	.		. .	.	.	. . . .	.	.	.			.		.		.			. . . .	1
1.2	General repair notes											.		. .	. .	. . .		.		.	.	.		.	.	.	.	. .	. . .	.	. . .	. .	. .		.	.	.		.	.	.	.		. .	.	.	. . .	. .	.	.			.		.		.			. . . .	2
1.3	Gearbox . . . . .	.	.			.		.			.		.	.	. .	. . .	.	.		.	.	.			. .		. .	. .	. . .	.	. . .	. .	.	.		. .	.		.	.		. .		. .	.	.	. . .	. .	.	.			.		.		.			. . . .	2
1.4	Torque converter				.			.			.	.		. .	.	. . .	.	.		.	.		.		. .		. .	. .	. .	.	. . . .	.	. .	.		.	.	.		. .		.		. .	.	.	. . . .	.	.	.		.			.		.			. . . .	2
1.5	ATF . . . . . . . .	. .		.			.			.		.		. .	. .	. . .	.		.	.	.			.	. .		. .	. .	. .	.	. . . . .	.	.	.		.	.	.	.	.		.	.	. .	.		. . . .	. .	.		.	.			.			.		. . . .	2
1.6	Automatic gearbox control unit J217 with fuzzy logic .																															.	. .		.	.	.		.	.		.	.	. .	.		. . . .	. .		.		.			.		.			. . . .	2
1.7	Control units in vehicle													.	. .	. . .	.		. .		.			.	. .		. .	. .	. .	.	. . . . .		. .	.		.	.	.		. .		.		. .	.	.	. . .	. .	.	.		.			.		.			. . . .	2
1.8	Information on “09G gearbox”																.	.	.		.		.		. .		. . .	.	. .	V.	o. . . . .		. .	.		.	.	.		. .		.		. .	.	.	. . . .	.	.	.		.			.		.			. . . .	2
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1.9	Tools																											e n	A					A		G	d.oe																								2
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1.10	Gearbox																					o																						g.ua																	3
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1.11	Gaskets, seals and oil															s																													a																4
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1.12	Nuts and bolts															th																															o														4
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1.13	Electrical components													le																																		e													4
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										t	e					self-diagnosis and testing																																	n												5
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1.14 Guided fault finding, vehiclet																																	. .		.	.	.		.	. .		.		. .	.	.	. . .	. .	.	.		i. .					.			. . . .
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	Gearbox identification													. .	. .	. . .	.		. .		. .				. .		. . .	.	. .	.	. . . . . .		.	.		.	.	.	.	. .			.	. .	.		. . . .	. .	.		.	.			.	y.				. . . .
2.1	Gearbox codes	.n	o	t	p																																																								6
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	Capacities . . .l. .				.		.		.			.		. .	. .	. . .		.	. .		.			.	.	.	. . .		. . .	.	. . . . .		. .		.	.	.		.	. .		.		. .	.	.	. . .	. .	.	.		.			.		.
3.1	o																																																											p	7
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	Planetary gearbox and final drive																		.		. .				. .		. . .	.	. .	.	. . . . .		. .	.		.	.	.		. .		.		. .	.	.	. . .	. .	.	.		.			.		.			.c. . .
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4	n	allocation, ratios																																																										t	8
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	Codes, gearboxo																				.			.	.		. . .	.	. . .	.	. . . . .		.	.		.	.	.	.	.		.		. .	.	.	. . . .	.	.	.		.			.		.			. . . .t
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																																																												r.	9
32 - Torque converteri .		.		.			.		.				.	.	. .	. .	.		. .		.				. .		. . .		. .	.	. . . .		. .		.	.		.		. .		.		. .		.	. . .	. .		.		.				.			.
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1	Torque convertere																																																											t	9
					.			.	.			.		. .	.	. . .	.	.	.		. .				. .		. . .	.	. .	.	. . . . .		. .	.		.	.	.		. .		.		. .	.	.	. . . .	.	.	.		.			.		.			. .n. .
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1.1	o																																																											e	9
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	Identification of torque converter																		. .		.			.	.		. . .	.	. . .	.	. . . . .		.	.		.	.	.	.	.		.		. .	.	.	. . . .	.	.	.		.			.		.
1.2	u																																																											o	9
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	Draining torquelconverter														.	. . .	.		. .		. .				.	.	. . .		. . .	.	. . . . .		. .	.		.	.	.		. .		.		. .	.	.	. . .	. .	.	.		.			.		.			. .i. .
1.3	a																																																											n	9
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	Removing and installing torque converter oil seal																														. . . . .		. .		.	.	.		.	. .		.		. .	.	.	. . .	. .	.	.		.			.		.			.r. . .
1.4	e																																																											m	10
	m
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	Installing torque converter															. . .	.	.	. .		.			.	.		. . . .		. . .	.	. . . . .		. .		.	.	.		.	. .		.		. .	.	.	. . .	. .	.	.		.			.			.
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37 - Controls, housing		o																																																								i	n	o	11
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1	Connecting “tester”					t																																															d								11
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1.1										p																																								u											11
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	Connecting vehicle diagnosis, testing and information system VAS 5051																																														. .	. .e	.		.	.				.			.	. . .
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2															p									and their locations																							o.C														13
	Electrical and electronic componentso																																.	.		.	.	.	.	.		.		. .	.	.		.	.	.		.			.		.			. . . .
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3	Multifunction switch F125															t																															y														18
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3.1																			p																									y																	18
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	Removing multifunction switch F125y																						b		d. .		. . .	.	. .	. .	. . . . .		.	.		. .		.	.	. .	kl		.	. .	.	.	. . .	. .	.		.	.			.			.		. . . .
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3.2	Installing multifunction switch F125																								e	t	c						G.A					a																							19
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																								. . . . .or.P. . .						.	. . . . ..					.	.	.		. .		.		. .	.	.	. . . .	.	.	.		.			.		.			. . . .
3.3	Adjusting multifunction switch F125																							.	.	.	. . .		. . .	.	. . . . .		. .	.		.	.		.	. .		.		. .	.	.	. . .	. .	.	.		.			.		.			. . . .	20
4	Selector mechanism up to 02.2009																				.			.	.		. . .	.	. . .	.	. . . . .		.	.		.	.	.	.	.		.		. .	.	.	. . . .	.	.	.		.			.		.			. . . .	22
4.1	Overview of selector mechanism up to 02.2009																													.	. . . . .		. .		.	.	.		.	. .			.	. .	.		. . . .	. .		.		.			.	.				. . . .	22
4.2	Removing and installing selector mechanism with selector lever up to 02.2009																																																.	.		.				.			.	. . .	23
4.3	Removing and installing selector lever cable up to 02.2009																																			.	.	.		. .		.		. .	.	.	. . . .	.	.	.		.			.		.			. . . .	23
4.4	Checking selector lever cable .																	.	. .		.			.	.	.	. . .		. . .	.	. . . . .		.	.		.	.	.	.	.		.		. .	.	.	. . . .	.	.	.		.			.		.			. . . .	30
4.5	Adjusting selector lever cable .																.		. .		. .				. .		. . .	.	. .	.	. . . . . .		.	.		.	.	.	.	. .			.	. .	.		. . . .	. .	.		.	.			.			.		. . . .	30
4.6	Emergency release of selector lever																							.	.	.	. . .		. . .	.	. . . . .		. .		.	.	.		.	. .		.		. .	.	.	. . .	. .	.	.		.			.		.			. . . .	31
4.7	Removing and installing knob .																	.	. .		.			.	.	.	. . .		. . .	.	. . . . .		.	.		.	.	.	.	.		.		. .	.	.	. . . .	.	.	.		.			.		.			. . . .	32
4.8	Checking selector mechanism																.	.	.		. .				. .		. . .	.	. .	.	. . . . .		. .	.		.	.	.		. .		.		. .	.	.	. . . .	.	.	.		.			.		.			. . . .	33
5	Selector mechanism from 03.2009 onwards																												. . .	.	. . . . .		. .		.	.	.		.	. .		.		. .	.	.	. . .	. .	.	.		.			.		.			. . . .	35
5.1	Overview of selector mechanism in vehicles from 03.2009 onwards																																											. .	.	.	. . .	. .	.	.		.			.			.		. . . .	35
5.2	Removingandinstallingselectorleverandselectormechanismwithselectorlevercablefrom																																																												36
	03.2009 onwards				.			.	.				.	.	. .	. . .	.	.	.		. .				. .		. . .	.	. .	.	. . . . .		. .	.		.	.	.		. .		.		. .	.	.	. . . .	.	.	.		.			.		.			. . . .
5.3	Emergency release of selector lever																							.	.	.	. . .		. . .	.	. . . . .		. .		.	.	.		.	. .		.		. .	.	.	. . .	. .	.	.		.			.		.			. . . .	37

Contents i

Golf Variant 2007 , Golf Variant 2010 , Jettagen2005AG																							, JettagenA2011G
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6-speed automatic gearbox 09G - EditionV04.2010																											s	n
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6												th																									e
	Removing and installing gearbox, Jetta 2005 , Bora 2006 , Golf Variant 2007 , Jetta
												u																									o
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											a																										a
	Wagon 2008								l.e	s																											c															38
		.		.	.			. .			.	. .	.		. .		.	.	.	.	. .	. . . . .	. . . . . . . .	.	.	.	.	.	.		.	.	.		.	.	. . .		.p.		.			.		.		.			. . .
									s																													c
									n																														e
6.1												with 1.6 l - 75 kW and 2.0 l - 110 kW (FSI) engines																											t													38
	Removing gearbox, vehiclesd																																							. y. .						.		.			. . .
								u																																a
6.2						t	t	e			with 1.6 l - 75 kW and 2.0 l - 110 kW (FSI) engines																													n												45
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	Installing gearbox, vehiclesm																																						. . .b. .												. . .
					i																																						a
6.3	Removing gearbox,t			e	r							with 2.5 l, 110 kW engine																																		i						45
																																															t
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	Installing gearbox,svehicles with 2.5 l, 110 kW engine . . . . .																							. .		.	.	.	.		.	.	.		.	.	. . .		. .		.		.			.	.			h. . .
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7.1				Jetta 2011 with 2.0 l - 85 kW engine																																															h.	57
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7.2	Installing gearbox,a	Jetta 2011 with 2.0 l - 85 kW engine																																																		63
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9.1	Assembly overviewo- ATF cooler																																																			76
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10.1	Checking ATF level			e																																																78
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10.2	Topping up ATF						p																																	m	u											79
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10.3	Draining and filling ATF								g																																											80
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	Renewing oil seal for selector shaft . . .de.t																				. .	. . . . . .	. . . . . . .	.				k.l.		.		.	.		.	.	. . .		. .	.			.			.	.			.	. .
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2	ATF pan																					P	.G																													82
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2.1	Removing and installing ATF pan															.	.		. . .	.	. .	. . . . .	. . . . . . . .	.	.	.	.	.	.	.		.	.		.	.	. . .		. .	.			.			.	.			.	. .	82
3	ATF strainer . . . .		.	.	.		.	.	.	.	.	. . .			. .		.	.	. .	.	. .	. . . . . .	. . . . . . .	.	.	.	.	.	.	.		.	.		.	.	. . .		. .	.			.			.	.			.	. .	85
3.1	Removing and installing ATF strainer																		. .	.	. .	. . . . .	. . . . . . .	. .		.	. .		.	. .		.		.		.	. . .		. .	.			.			.	.			.	. .	85
4	Valve body . . . . .		.	.	.		.	.	. .		.	. . .			. .		.	.	. .	.	. .	. . . . . .	. . . . . . .	. .	.		. .	.	.	.		.		.	.	.	. . .		. .	.			.			.	.			.	. .	86
4.1	Assembly overview				.	.		. .	.	.		. . . .			.	.	.	.	. .	.	. .	. . . . . .	. . . . . . .	. .		.	. .		. .	.		.		.	.		. . .	.	. .	.			.			.	.			.	. .	87
4.2	Removing and installing valve body																	.	. .	.	. .	. . . . . .	. . . . . . .	.	.	.	.	.	.	.		.	.		.	.	. . .		. .	.			.			.	.			.	. .	91
4.3	Removing and installing wiring harness with 14-pin connector (for solenoid valves)																																										.			.	.			.	. .	103
4.4	Removing and installing wiring harness with 8-pin connector (for sender)																																			.	. . .		. .	.			.				.			.	. .	105
4.5	Removing and installing gearbox input speed sender G182																							. .		.	. .	.	.	.		.		.	.		. . .	.	. .	.			.			.	.			.	. .	106
4.6	Removing and installing gearbox output speed sender G195																							.		.	. .		.	. .		.		.		.	. . .		. .	.			.			.	.			.	. .	107
39 - Final drive - differential					.			.	. .		.	. .		.	.		.	.	. .		.	. . . . .	. . . . . .	.	.	.	.	.		. .			.		.	.	. .		. .	.			.				.			.	. . 109
1	Renewing oil seals for flange shafts																	.	. .	.	. .	. . . . . .	. . . . . . .	.	.	.	.	.	.	.		.	.		.	.	. . .		. .	.			.			.	.			.	. .	109
1.1	Renewing oil seal for flange shaft															.	.		. . .	.	. .	. . . . .	. . . . . . . .	.	.	.	.	.	.	.		.	.		.	.	. . .		. .	.			.			.	.			.	. .	109

ii Contents

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

00 – Technical data

1Suggestions and criticism, general repair notes

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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.

1. Suggestions and criticism, general repair notes 1

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

1.2General repair notes

To ensure flawless and successful gearbox repairs, the greatest care and cleanliness as well as the use of good and proper tools are essential. Obviously, the basic rules for safety also apply dur ing repair work.

A number of generally valid instructions applicable for the various repair procedures - which were formerly repeated a number of times at numerous places in the workshop manual - are summar ised here. They apply to this workshop manual.

1.3Gearbox

The “6-speed automatic gearbox 09G” has six hydraulically ac tuated forward gears. When the torque converter lock-up clutch closes, 2nd, 3rd, 4th, 5th and 6th gears become mechanically driven gears by eliminating torque converter slip.

1.4Torque converter

The torque converter is equipped with a lock-up clutch. The lockup clutch locks up depending on load and speed. The 2nd, 3rd, 4th, 5th and 6th gears can be driven mechanically (without slip).

1.5ATF

The ATF is filled for life. The ATF need not be changed during a

service.

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Self-study programme No. 291 ; Automatic gearbox 09G

1.9Tools

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.

2Rep. Gr.00 - Technical data

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aging until immediately before installing.

♦ If repair work cannot be performed immediately, carefully cov

er or seal components.

♦ Withgearboxremoved,securetorqueconverteragainstfalling

out.

Gearboxes with and without filler pipe

Here is an “example” with a filler pipe as it is installed in “older”

gearboxes. This pipe has been discontinued.

This “old” filler opening with the red cap is not needed because

ATF can be drained or filled as required through the bottom hole.

The “height” of this tube determines the level of the ATF.

The tube must be removed to drain the fluid.

♦After installation, check the ATF level and top uppage 77 .

♦Capacities page 7 .

1. Suggestions and criticism, general repair notes 3

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

1.11Gaskets, seals and oil

♦Always renew O-rings, seals and gaskets.

♦Before installing a radial oil seal, coat sealing lips and area between them with sealing grease -G 052 128- .

♦Open side of oil seal faces oil.

♦After installing, check ATF level.

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Nuts and bolts

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and housings diagonally.

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–Before beginning work on electrical components, touch an earthed object, for example a water pipe or lifting platform. Do nottouchconnectorsor“open”electroniccomponentsdirectly.

4Rep. Gr.00 - Technical data

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

1.14Guided fault finding, vehicle self-diag nosis and testing

Before making repairs to the automatic gearbox, determine the cause of the fault as precisely as possible with the aid of “guided fault finding”.

Guided fault finding is carried out using the vehicle diagno sis, testing and information system -VAS 5051B- page 11 .

The guided functions will guide you to the ATF temperature in the shortest way possible page 11 .

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1. Suggestions and criticism, general repair notes 5

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

2Gearbox identification

“6-speed automatic gearbox 09G” is fitted in Jetta 2005 , Bora 2006 , Golf Variant 2007 , Jetta Wagon 2008 and Jetta 2011.

The allocation of the gearbox to the vehicles can be found here: Codes, gearbox allocation, ratios page 8 .

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g

a

w

2.1

Gearbox codes

db

s

lk

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is

Code letters -arrow-

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Code letters -arrow 1-

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“6-speed automatic gearbox 09G” -arrow 2-

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Example:

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C.

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GGZ

08

05

02

y

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et

or

Identification

Day

Month

Year -2002-

code

of manufacture

The gearbox code also appears on the vehicle identification plates.

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6Rep. Gr.00 - Technical data

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

3Capacities

3.1Planetary gearbox and final drive

Capacities	“6-speed automatic gearbox 09G”
Initial filling	approx. 7.0 l
Change	Filled for life
	no change
Lubricant	ATF is available as a part. Therefore, the part number
	for it can be found in the Electronic parts catalogue
	“ETKA”.

.

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3. Capacities 7

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

4Codes, gearbox allocation, ratios

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

“Automatic gearbox 09G”

Identification

“HFS”, “HTN”,

“MAM”

“HFT”, “HTP”,

“HDN”, “HFU”,

“KGL”

code

“JTY”

“JUH”

“HRM”, “JUJ”

Engine

1.6 l - 75 kW

2.0 l - 85 kW

a2.0 l - 110 kW

2.5dl - 110 kW

2.5 l - 125 kW

o

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8Rep. Gr.00 - Technical data

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

32 – Torque converter

1Torque converter

1.1Identification of torque converter

Therearevarioustorqueconverters.Theyareidentifiedbycodes.

Torque converter/gearbox allocation Replacement parts cata logue ETKA

1.2Draining torque converter

Special tools and workshop equipment required ♦ -V.A.G 1358 A- Oil extraction unit

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A/1- Oil extraction probe

♦ -V.A.G 1358t

r

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– Extract ATF from torque converter using -V.A.G 1358 A- and

p

n

probe -V.A.G 1358 A/1- .

i

,

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1.3

s

uRemoving and installing torque convert

o

p

r

ier oil seal

p

l

a

c

Special toolsmand workshop equipment required

r

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♦ Thrust piecer-T10175-

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oitam

1. Torque converter 9

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

♦ Oil seal extractor lever -VW 681-

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Removingo

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or a c c e p t a

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t

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n– Pry out seal with lever -VW 681- .

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Installing

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.

– Drive in seal flushir

thrust piece -T10175- .

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1.4Installing torque converter

–Carefullypushontorqueconverterhubviaoilsealtofirststop.

–Turn torque converter towards gearbox using light pressure until notch in hub -arrow- engages in follower of pump gear and torque converter can be felt to slip in place.

The torque converter is properly inserted when it can easily be turned by hand and is seated equally deep in gearbox around the entire circumference.

Caution

If engine and gearbox are brought together with force because the torque converter is improperly fitted, both gearbox and tor que converter will be damaged.

10 Rep. Gr.32 - Torque converter

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011

Vo6lk-speedsw

automatic gearbox 09G - Edition 04.2010

G.

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37 –

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Volkswagen offers evarious devices such as

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Tester -VAS 5051/11A-

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Diagnosticssystem -VAS 5053-

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The operationuof these “devices” is described in the respective

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user's manuals.

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The following description refers to the vehicle diagnosis, testing

a

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and information system -VAS 5051- page 11 .

i

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Connecting vehicle diagnosis, testing

d

v

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and information system -VAS 5051-

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o

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.

Special tools and workshop equipment required

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♦ Vehiclediagnosis,testingandinformationsystem-VAS5051-

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P

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WARNING

♦During a road test, always secure testing and measuring equipment on the back seat.

♦These devices may be operated only by a passenger dur ing a test drive.

–Push connector of diagnosis cable -VAS 5051/1- -2- or - VAS 5051/3- onto diagnosis connection.

1. Connecting “tester” 11

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

– Switch on “tester” -arrow-.

The“tester”isreadyforusewhenitispossibletochoosebetween thebuttons Guided functions and Guided fault finding on the “right” of the screen.

Depending on equipment and version of the tester, other func tions may be “displayed” such as:

♦ElsaWin

♦Testing

♦Self-diagnosis

The “tester” is now ready for use.

–Switch on ignition.

–Touch a button on the screen to start the desired function.

12 Rep. Gr.37 - Controls, housing

.

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Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

2Electrical and electronic components and their locations

1 - Control unit for automatic gearbox -J217-

The control unit trans mits and receives data from the data bus.

Installation location in Jetta 2005 , Bora 2006 , Golf Variant 2007 , Jetta Wagon 2008 page 14

Installation location in Jetta 2011 with 2.0 l - 85 kW engine

page 15 .

Installation location in Jetta 2011 with 2.5 l - 125 kW engine

page 15 .

Can be checked using

“guided fault finding” of - VAS 5051-

2 - Engine control unit

The control unit trans

mits and receives data

from the data bus

Location and removing

and installing

Rep.

Gr. 23 for the respective

engine code letter

Rep. Gr. 24 for the re

db

spective engine code

e

is

r

letter

o

a

th

u

s

s

le

-F125-

3 - Multifunction switchun

d

Location itpage 15

m

t

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r

using

Can be checkedp e

“guided faulto

finding” of -

t

n

-

VAS 5051,i

s

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installing and adjusting page 18 .

Removing,h

l

o

w

4 - Valve bodyr

n

i

o

page 15

Locationa

t

r

p

Components can be checked using “guided fault finding” of -VAS 5051-

,

n

i

Electronic parts catalogue “ETKA”

Allocation

s

e

s

o

8-pin

5 - Wiring harness,u

p

r

p

For senders

l

a

i

c

With gearbox oil temperature sender -G93-

r

m

Locationc page 16

m

o

Removingtand installing page 105

r

o

e

Allocation pElectronic parts catalogue “ETKA”

a

v

i

r

u

r

m

f

6 - Gearbox oil temperature sender -G93-

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Location page 16

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Can be checked using “guidedy

fault finding” of -VAS 5051-

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7 - Wiring harness, 14-pin

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For solenoid valves

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h

2. Electrical and electronic components and their locations 13

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

Location page 16

Removing and installing page 103

Allocation Electronic parts catalogue “ETKA”

8 - Hydraulic pressure sender 1 for automatic gearbox -G193-

Not installed in all gearboxes

Allocation Electronic parts catalogue “ETKA”

Location page 16

9 - Hydraulic pressure sender 2 for automatic gearbox -G194-

Not installed in all gearboxes

Allocation Electronic parts catalogue “ETKA”

Location page 16

10 - Gearbox input speed sender -G182-

Location page 17

Removing and installing page 106

Can be checked using “guided fault finding” of -VAS 5051-

11 - Gearbox output speed sender -G195-

Location page 17

Removing and installing page 107

Can be checked using “guided fault finding” of -VAS 5051-

12 - Selector lever lock solenoid -N110-

Location: selector lever lock solenoid is located in the selector mechanism.

Can be checked using “guided fault finding” of -VAS 5051-

G.

Volksw

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en

en

A

A

G

d

13 - Tiptronic switch -F189-

o

g

o

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a

e

w

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s

V

lk

ot

g

y

u

Location page 17

is

b

an

d

a

e

r

r

t

o

e

Can be checked using “guided faultufinding” of -VAS 5051-

r

th

e

o

a

a

s

c

s

c

14 - Terminal 50 voltage supply relay -nJ682-

t

le

e

u

p

d

a

Current flow diagrams, Electrical fault finding and Fittingalocations.

In E box in engine compartmenti

t

e

n

l

t

y

r

m

i

15 - Diagnostic connection

p

i

y

e

b

t

l

t

i

Location page 17

n

o

s

i

h

w

i

t

r

,

e

e

-Y6-

s

16 - Selector lever position displayo

l

e

h

w

p

Location page 17

t

i

c

n

t

r

o

Removing and installingr Electrical system; Rep. Gr. 90 ; Gauges, instruments; Dash panel insert .

o

t

t

h

e

a

c

p

o

n

r

i

r

,

e

s

c

Automatic gearbox control unit -J217- -arrow- in Jetta 2005 ,

t

e

s

o

Bora 2006 , Golf Variant 2007u , Jetta Wagon 2008

p

r

p

Location: control unit is located in front left wheel housing.

l

a

i

c

r

– Wheel housing liner must be removed for removing and in

stalling.

m

c

m

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or

e

P

A

n

.G

14 Rep. Gr.37 - Controls, housing

o

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en

en

A

A

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d

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o

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u

b

d

a

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r

s

a

i

n

r

t

o

e

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011

th

e

u

o

r

le

a

a

s

6-speed automatic gearbox 09G - Edition 04.2010

c

s

c

n

e

t

u

p

d

a

e

n

Automatic gearbox control unit -J217- -A-it

in Jetta 2011 with 2.0

m

t

l - 85 kW engine

p

e

r

o

t

chamber on right.

Location: control unit is located in plenumn

s

i

,

e

– Plenum chamber cover must beoremoved for removal and in

l

chamber cover; Removing

stallation Rep. Gr. 50 ; Plenumw

h

and installing plenum chamberrcover .

n

i

o

t

r

a

p

n

i

,

s

e

s

o

p

r

u

p

l

a

i

c

Automatic gearbox control unit -J217m- -A- in Jetta 2011 with 2.5

r

l - 125 kW engine

e

o

m

Location:controlunitislocatedinfrontleftofenginecompartment

c

r

next to battery.

o

v

e

t

a

i

r

p

r

o

f

g

n

i

y

p

o

C

.

t

h

g

i

r

y

p

o

c

y

b

d

et

c

et

or

P

Multifunction switch -F125-

Location: multifunction switch is located on top of the gearbox.

h e

c o r

r e c t n e s s

n f o

Valve body

Location: valve body is bolted to underside of gearbox housing and covered by pan.

Solenoid valves -N88- , -N89- , -N90- , -N91- , -N92- , -N93- , -

N282and -N283- are attached to valve body.

2. Electrical and electronic components and their locations 15

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

Wiring harness, 8-pin

♦Wiring harness for senders

♦With integrated gearbox oil temperature sender -G93- -arrow-

Location: wiring harness is attached to valve body in gearbox.

Wiring harness, 14-pin

♦ Wiring harness for solenoid valves.

Location: wiring harness is attached to valve body in gearbox.

.

enAG

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a

w

s

lk

o

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b

d

e

is

r

o

th

u

a

s

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d

u

n

e

t

t

m

i

r

p

e

t

o

n

gearbox -G193- and

Hydraulic pressure sender 1 for automaticis

hydraulic pressure sender 2 for automaticl

gearbox -G194-

,

e

o

h

w

This sender is not installed in all gearboxes.n

i

r

Location:

o

r

t

a

p

sender 1 -G193- -1- and

Automatic gearbox hydraulic pressure,

n

i

automatic gearbox hydraulic pressure sender 2 -G194- -2- are

bolted into valve body.

e

o

s

p

r

u

p

l

a

i

c

r

e

m

m

o

c

r

o

e

t

a

v

i

r

p

r

o

f

g

n

i

y

p

o

C

.

t

h

g

i

r

y

p

o

c

y

b

d

et

c

et

or

P

V

o

								V
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A	n
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w

16 Rep. Gr.37 - Controls, housing

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011

o

swag

G.V lk wag

gearbox 09G - Edition 04.2010

A

6-speed automaticGdoe

en

en

A

s

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ot

o

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y

u

b

d

a

Gearbox input speed sender -oG182- and gearbox output speed

e

is

sender -G195-

r

u

th

a

s

s

in gearbox housing above valve

Location: senders are installedn

le

body.

e d

u

m

i

t

t

sender -G182-

1 - Gearbox input speede

p

r

o

t

speed sender -G195-

2 - Gearbox outputn

s

i

,

e

l

o

h

w

n

i

r

o

t

r

a

p

n

i

,

s

e

s

o

p

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u

p

l

a

i

c

r

e

m

m

o

r

n

i

o

c

Tiptronic switch -F189-

e

t

a

v

is integrated into selector mechanism.

Location: Tiptronic switcho

i

r

p

r

f

g

steering wheel, the buttons on the

In vehicles with a multifunctionp

n

i

y

steeringwheelandtheircableC.tconnectionsmustalsobechecked.

o

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g

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y

y

p

o

c

y

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kl

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d

s

w

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t

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g

c

et

or

e

P

A

.G

Diagnostic connection

Location: diagnosis connector -arrow- is located on left below driver storage compartment.

Selector lever position display -Y6-

Location: in dash panel insert

2. Electrical and electronic components and their locations 17

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

3Multifunction switch -F125-

Removing multifunction switch -F125- page 18

Installing multifunction switch -F125- page 19

Adjusting multifunction switch -F125- page 20

3.1Removing multifunction switch -F125-

Carry out procedure as follows:

– Move selector lever to position “N”.

–

Switch off ignition.

en

– In order to remove selector lever cable from gearbox, first reV

a

g

w

s

lk

lease cable -arrows 1- and then remove it from cable support

o

y

b

d

bracket -arrow 2-.

th

e

is

r

o

u

a

s

s

le

Note

d

u

n

e

m

i

t

t

r

on cable sup

♦ Do not use any pliers, otherwise securing tabsp

e

port bracket could break off.

n

o

t

s

i

♦ Do not bend or kink selector lever cable.l

,

e

o

h

w

n

i

r

o

t

r

a

– Lever cable -1- off lever -3- using an

open jaw spanner -2-.

i

p

n

,

– Pull connector off multifunction switchs-F125- .

s

e

o

p

r

u

p

l

a

i

c

r

e

m

m

o

c

r

o

e

t

a

v

i

r

p

r

o

f

g

n

i

y

p

o

C

.

t

–

Unscrew nut -1-.

h

ry

g

i

p

o

c

y

– Remove spring ring -2- and lever -3- from selector shaft -4-.

b

d

ce

et

AG.

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swagen

AG

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										t
										t
										o
										t
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										e
										c
										o
										r
										r
										e
										c
										t
										n
										e
										s
										s
										o
										f
										i
										n
										f
										o
										r
										m
										a
										t
										i
							n	i	n	o
						t
			d	s	i	h
	c	o

p y r i

18 Rep. Gr.37 - Controls, housing

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

–Carefully bend back hooks of lock washer -2- using a screw driver.

–Renew securing clip if hooks have broken off.

–Unscrew nut -1-.

–Remove bolts -5-.

–Pull multifunction switch -4-, together with washers -2- and -3-, off selector shaft -6-.

3.2Installing multifunction switch -F125-

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

e

g

a

w

s

lk

o

V

y

b

d

e

is

r

o

th

u

a

s

s

le

d

u

n

e

t

t

m

i

p

e

r

t

o

n

s

i

,

e

l

o

h

Carry out procedure as follows:

w

n

i

r

o

t

r

a

Install in the reverse order of removal, observing the following:

p

n

i

,

s

– Place multifunction switch -4- on selector shaft -6-.

e

s

o

p

– Tighten securing bolts -5- for multifunction switch hand-tight.

r

u

p

l

– Bend hooks of lock washer -2- back.a

i

c

r

e

– Put washers -2- and -3- on selector shaft -6-.

m

m

– Install washer -2- with hooks pointing up.o

c

r

– Install washer -2- with long, narrow guidesein long, narrow re t

o

a

	cesses of selector shaft -6-.	v
		i
		r
		p
		r
–	Tighten nut -1- to 7 Nm.	o
		f
		g
		n
		i
		y
		p
		o
– Secure nut -1- by bending up hooks on lock washerC.t-2-.
			h
			g
			i
			r
–	Renew securing clip if hooks have broken off.			y
				p	oc
					y
					b
					d
					et
					c
					et
					or

b
i
	l
		i
		t
		y
		w
				i
					t
					h
						r
						e
						s
						p
						e
						c
						t
						t
						o
						t
						h
						e
						c
						o
						r
						r
						e
						c
						t
						n
						e
						s
						s
						o
						f
						i
						n
						f
						o
						r
						m
						a
						t
						i
			n	i	n	o
		t
	i	h

3. Multifunction switch F125 19

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

–Push lever -3- onto selector shaft -4-.

–Use lever -3- to shift gearbox to “P” position, i.e. press lever -3- back (opposite direction of travel) to stop.

–Now use lever -3- to shift gearbox to “N” position. To do this, push lever -3- two detent positions forwards in direction of travel.

–Place spring ring -2- and nut -1- on selector shaft -4-.

–Tighten nut -1- to 13 Nm.

–Check selector mechanism page 33 .

3.3Adjusting multifunction switch -F125-

Special tools and workshop equipment required ♦ Setting gauge -T10173-

											t
									m	i	t
							p	e	r
						t
–	Move selector lever to position “N”.				o
				n
			s
			i
–	Do not kink selector lever cable.		,
			o
			e
			l
		h
3.3.1		w
		Adjustment prerequisitesr
		n
		i
		o

e

d

u

									en
								g
							a
						w
					s
				lk
			o
		V
	y
	b
	d
	e
	is
	r
	o
	th
	u
	a
	s
s
le
n

A

	t
• Selector lever cable is disconnectedp from selector shaft lever.
	r
	a
	n
• Selector shaft is set to “N” position.s
	i
	,
	e
	s
• Securing bolts for multifunction switch -F125- have been loos
	o
ened.	p
	p
	r
	u
	l
	a
• Selector shaft lever has been removed.e
	i
	c
	r
	m
	m
	o
	c
	r
	o
	e
	t
	a
	v
	i
	r
	p
	r
	o
	f
	g
	n
	i
	y
	p
	o
	C
	.
	t
	h
	g
	i
	r
	y
	p
	o
	c
	y
	b
	d
	et
		c
		et
		or
		P

											e
											n
											t
										.
										C
										o
										p
										y
										r
										i
									g
									h
									t
								b
								y
								V
							o
						kl
					s
				w
			a
		g
	e
A	n
.G

m

u

c

o

b
		i
		l
			i
			t
			y
			w
					i
					t
					h
						r
						e
						s
						p
						e
						c
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						t
						o
						t
						h
						e
						c
						o
						r
						r
						e
						c
						t
						n
						e
						s
						s
						o
						f
						i
						n
						f
						o
						r
						m
						a
						t
						i
				i	n	o
			t
d	s	i	h

20 Rep. Gr.37 - Controls, housing

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

Carry out procedure as follows:

– Placesettinggaugeonselectorshaft-2-andturnmultifunction switch -1- until setting gauge engages in lug on multifunction switch connector.

– Secure setting gauge on selectorA

shafte-n2- with bolt -3-.

o

en

G.

V

lksw

ag

A

G

d

g

o

a

e

w

s

s

n

lk

g

– Tighten bolts -arrows- to 6 Nm.

ot

o

V

y

u

b

d

a

e

r

–

s

a

Remove setting gauge.

n

i

r

t

o

e

th

e

o

u

r

–

a

a

Continuele

installation in reverse order of removal page 19 .e

s

c

s

c

n

t

u

p

d

a

t

e

n

l

i

t

y

m

i

r

a

e

b

t

p

o

n

s

i

,

e

l

o

h

w

n

i

r

o

t

r

a

p

n

i

,

s

e

s

o

p

r

u

p

l

a

i

c

r

e

m

m

o

c

r

t

o

h

t

s

i

a

e

r

o

d

v

i

c

p

u

r

m

f

o

e

g

n

n

i

t

p

.

C

y

o

o

C

p

y

.

t

r

h

g

g

h

i

i

t

r

y

b

p

o

c

y

y

V

o

kl

b

d

e

s

w

a

t

c

et

g

or

n

A

P

.G

n

i

n

t n e s s o f i n f o r

oitam

3. Multifunction switch F125 21

o

G.

V lksw

ag

en

en

A

A

G

d

g

o

a

e

w

s

s

n

lk

o

V

ot

Golf Variant 2007 , Golf Variant 2010i

y

, Jetta 2005 , Jetta 2011

b

d

e

s

r

6-speed automatic gearbox 09G -uEdition 04.2010

o

th

a

s

s

le

4

u

n

up to 02.2009

Selector mechanismit

t

e

d

m

r

t

p

e

WARNING

o

n

s

i

,

e

l

engine running, move selector

Before working on vehicle withh

o

w

handbrake.

lever into position “P” and applyi

n

r

o

t

r

a

p

Selector mechanism from

03.2009 onwards page 35 .

,

n

i

4.1

s

Overview ofpselector mechanism up to 02.2009

e

s

o

r

u

p

1 - Selector cover with knob

l

e

a

i

c

Do not remove knob

r

m

without reason. For

emergency release, on

ly the cover needs to be

unclipped page 31 .

Before removing knob,

pull button out past its

pressure point. Secure

button with cable tie or

appropriate wire against

being pressed in. This

will prevent the button

from being accidentally

pressed into the knob.

If button is pressed into

removed handle

–Always pull out button past the felt pressure point before installing knob.

2 - Selector mechanism with selector lever

Removing and installingpage 23

3 - Bolt with spring3 Nm

4 - Pin

Removing page 23

Do not grease

5 - Locking plate

Always renew after re moving

6 - Nut

9 Nm

Qty. 4

7 - Selector housingWith seal

8 - Selector lever cable

Cable must not be greased

Removing and installing page 23

Checking page 30

guarant ee

or a c c e p t a

n y

l i a

b

i l i t

y

w

i t

h

r e s p e c t

t o

t h e

c o r

r e c t n e s s o f i n

22 Rep. Gr.37 - Controls, housing

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

Adjusting page 30 9 - Hexagon nut with washer

8 Nm

Qty. 4

4.2Removing and installing selector mech anism with selector lever up to 02.2009

o

G.

V

lksw

ag

en

A

en

A

G

d

g

o

Carry out procedure as follows:V

a

e

ot

w

s

s

n

lk

y

o

g

b

u

d

a

e

r

s

a

i

n

r

t

o

e

Note

th

e

s

c

u

o

r

a

a

s

c

le

e

n

t

u

selector lever cable must be checked for

p

a

Following installation,e

y

t

d

n

l

t

i

ease of movement and be adjusted.

b

i

a

e

r

i

t

p

l

t

i

o

y

–

Removes

i

selector lever cable from gearbox page 23 .

h

n

w

i

t

r

–

,

centre console Rep. Gr. 68 ; Compartments, cov

e

Removeo

p

l

s

h

trims .

e

ers andw

t

n

c

t

i

– Remove selector lever cable from gearbox page 23 .

o

r

o

t

t

h

e

r

–

a

exhaust system below heat shield Rep. Gr. 26 ;

c

Removei

r

p

o

n

r

Removing and installing parts of exhaust system .

t

,

e

s

c

e

n

–

s

heat shield beneath selector mechanism.

Remover

s

p

e

s

u

o

–

Remove 4 nuts for selector mechanism “from above”.

n

i

f

p

l

i

a

f

r

o

c

r

Torque setting for nuts: 8 Nm

e

m

m

a

t

m

i

o

n

o

–

Take

selector mechanism out downwards.

n

i

r

o

c

t

– Check selector lever cable after installing page 30 .

s

i

h

t

e

d

a

o

r

v

4.3

i

c

p

Removing and installing selector lever

u

r

m

f

o

e

g

n

o

n

cable up to 02.2009

t

i

p

.

C

y

o

p

C

y

.

t

r

h

g

Carry out procedure as follows:y

b

i

g

h

i

t

r

p

o

y

V

c

y

o

kl

b

d

e

s

w

a

t

c

et

g

or

P

A

n

Note

.G

Following installation, selector lever cable must be checked for ease of movement and be adjusted.

Removing

–Move selector lever to position “S” position.

–In order to remove selector lever cable from gearbox, first re lease cable -arrows 1- and then remove it from cable support bracket -arrow 2-.

Note

♦Do not use any pliers, otherwise securing tabs on cable sup port bracket could break off.

♦Do not bend or kink selector lever cable.

4. Selector mechanism up to 02.2009 23

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

–Lever cable -1- off lever -3- using an open jaw spanner -2-.

–Raise vehicle.

To remove cable and/or selector mechanism, heat shield and, if necessary,partsofexhaustsystemmustberemoved Rep.Gr. 26 ; Removing and installing parts of exhaust system .

–Remove heat shield beneath selector mechanism.

–Remove -selector housingbeneath selector lever.

en

g

a

w

s

lk

o

V

y

b

d

e

is

r

o

th

u

a

s

s

le

d

u

n

e

t

t

m

i

r

p

e

t

o

n

s

i

,

e

l

o

h

w

n

i

r

o

t

r

a

p

n

i

,

s

e

s

o

p

r

u

p

l

a

i

c

r

e

m

m

o

c

r

o

e

t

a

v

i

r

p

r

o

f

g

n

i

y

p

o

C

.

t

h

g

i

r

y

p

o

c

y

b

d

et

c

et

or

P

								y
								V
							o
						kl
					s
				w
			a
		g
	e
A	n
.G

24 Rep. Gr.37 - Controls, housing

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

–Remove locking plate for selector lever cable. Always renew locking plate.

o

G.

V lksw

ag

en

en

A

A

G

d

g

o

a

e

w

s

s

n

lk

o

V

ot

y

b

d

e

is

r

o

th

u

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-Selector housingis pushed forwards slightly on cable --.

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To remove selectorClever cable, securing tab must be pushed fory

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wards in -direction ofgarrowir

1-.

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– At same time, -pin- is pushed up with a screwdriver

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-arrow 2-.

or

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–Please insert -screwdriver- from underneath whilst pushing securing tab forwards.

4. Selector mechanism up to 02.2009 25

Golf Variant 2007 , Golf Variant 2010 , Jetta 2005 , Jetta 2011 6-speed automatic gearbox 09G - Edition 04.2010

Clarification:

♦-1- Push tab forwards

♦-2- Push pin up

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26 Rep. Gr.37 - Controls, housing