Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 612
♦ Cover or plug unpacked components if repairs cannot be per‐
formed immediately.
♦ Only install clean components: Remove the replacement parts
from their packaging just prior to installing them.
♦ Always replace seals and gaskets.
♦ Coat O-rings with ATF before inserting to prevent crushing
rings during installation.
♦ After installing check the ATF level and if necessary fill. Refer
⇒ “7 Automatic Transmission Fluid”, page 73
3.3
General Repair Information
♦ Carefulness, cleanliness and the correct tools are required for
transmission repairs to be successful. The usual basic safety
precautions also, naturally apply when carrying out vehicle re‐
pairs.
♦ A number of generally applicable instructions for individual re‐
pair operations, which are otherwise mentioned at various
points in the repair procedure, are summarized here. They
apply to this repair manual.
Guided Fault Finding, On Board Diagnostics (OBD) and Test In‐
struments
♦ Before servicing the transmission, determine the cause of the
fault using the Vehicle Diagnostic Tester in
Guided Fault
Finding
,
Vehicle Self-Diagnosis
and
Test Instru-
ments
.
Tools
A complete list of special tools and workshop equipment used in
the repair manual can be found at the beginning of each repair
section and in its corresponding binder: Listed “Special tools and
workshop equipment”.
Often times there are questions when a bolt has a low tightening
specification. Use Torque Wrench 1783 - 2-10Nm - VAG1783- to
tighten these bolts.
Transmission
♦ Do not run the engine and do not tow the vehicle if the trans‐
mission cover is removed or if there is no transmission fluid
inside the transmission.
♦ Always clean the connection points and the area around them
first, and then loosen them.
♦ When installing transmission, make sure centering sleeves
are correctly seated between engine and transmission.
♦ With the transmission removed, secure the torque converter
so that it cannot fall out.
Electrical Components
You have probably received an electrical shock at one time, when
touching a metal item. The reason behind this is the electrostatic
charge to the human body. This charge can damage the electrical
components on the transmission and the selector mechanism.
– Touch a grounded object, such as, a water pipe or a vehicle
hoist, before working on electrical components. Do not touch
connector or »open« electronic components directly.
3.4
Seals, Sealing Rings
♦ Always replace the O-rings, seals and gaskets.
♦ Flange shaft, torque converter and selector shaft seals are il‐
lustrated as shaft seals.
♦ After removing the seals, check the sealing surfaces on the
housing or shaft for burrs resulting from removal or damage.
♦ Coat O-rings with ATF before inserting to prevent crushing
rings during installation.
♦ Use ATF only. Other types of lubrication cause faults to occur
in the transmission hydraulics.
♦ Before installing the seal rings, lightly oil the outer circumfer‐
ence and coat the space between the sealing lips -arrow- with
ATF.
♦ The open side of the seals point toward the fluid to be sealed
in.
♦ Check the ATF level. Refer to
⇒ “7 Automatic Transmission Fluid”, page 73
3.5
Bolts and Nuts
♦ Loosen or tighten bolts and nuts on the covers or housings
diagonally.
♦ The tightening specifications stated apply to non-oiled nuts
and bolts.
♦ Use a wire brush to clean the threads of bolts that were
screwed in with locking compound. Install the bolts with Lock‐
ing Fluid - AMV 185 101 A1- .
♦ Threaded holes with self-locking bolts or bolts coated with
locking fluid must be cleaned, for example using a thread tap.
Otherwise there is a risk that the bolts will shear the next time
they are removed.
♦ Always replace self-locking nuts and bolts.
4
Technical Data
⇒ “4.1 Transmission/Engine Allocation”, page 7
⇒ “4.2 Capacities”, page 7
4.1
Transmission/Engine Allocation
Use the transmission code letters if a repair requires replacement
parts.
“Automatic Transmission 09G”
Code letters »PAL« »QNQ«
»PPU«
Engine
1.6L - 81 kW
1.8L - 125 kW
4.2
Capacities
Capacities
“Automatic Transmission”
Original filling by the manufacturer
Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
Filling after draining in Service
Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
Change
♦ No change
♦ Permanent fill; only change after repairs such as
when removing the ATF pan
Lubricant
ATF is available as a replacement part. Therefore the
part numbers are also located in the Parts Catalog.
5
Electrical Components
⇒ “5.1 Component Location Overview - Electrical Components”,
5.1
Component Location Overview - Electrical Components
1 - Transmission Control Mod‐
ule - J217-
❑ Installed location, re‐
moving and installing.
Refer to
❑ Can be checked in “Gui‐
ded Fault Finding” using
Vehicle Diagnostic
Tester .
2 - Engine Control Module
(ECM)
❑ The control module
sends and receives data
from the Data bus
❑ Component location
and removing and in‐
stalling. Refer to ⇒ En‐
gine Mechanical, Fuel
Injection and Ignition;
Rep. Gr. 24 ; Engine
Control Module; Engine
Control Module - J623- ,
Removing and Instal‐
ling .
3 - Multifunction Transmission
Range Switch - F125-
❑ Component location.
Refer to
❑ Removing and instal‐
ling. Refer to
⇒ “2.9 Multifunction Switch, Removing and Installing”, page 37
❑ Adjusting. Refer to
⇒ “2.10 Multifunction Transmission Range Switch, Adjusting”, page 40
❑ Can be checked in “Guided Fault Finding” using Vehicle Diagnostic Tester .
4 - Valve Body
❑ Component location. Refer to
⇒ Fig. ““Valve Body”“ , page 10
❑ Removing and installing. Refer to
⇒ “2.2 Valve Body, Removing and Installing”, page 90
.
❑ The components can be checked in “Guided Fault Finding” using Vehicle Diagnostic Tester
❑ Allocation. Refer to the Parts Catalog.
5 - Sensor Wiring Harness
❑ 8-pin wiring harness
❑ With Transmission Fluid Temperature Sensor - G93-
❑ Component location. Refer to
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