Valve Body, Removing and Installing
Valve body, removing and installing, 09G, 6 Speed A/T
Special tools and workshop equipment required
^ V.A.G 1331 Torque wrench
Note:
^ Always replace valve body if it has collected dirt or if it is faulty.
^ Be familiar with the rules for cleanliness when working on the automatic transmission.
^ General repair instructions.
Removing
- Disconnect battery:
- Remove oil pan.
- Remove ATF screen.
- Make a hand-drawn diagram similar to illustration with all solenoid valves and their connectors and mark all connectors in appropriate color. Also mark corresponding wiring in appropriate color.
Note:
^ This diagram is essential to help avoid inadvertently interchanging the connectors at the solenoid valves during re-installation of the valve body.
^ Interchanging of the connectors would, in some circumstances, lead to destruction of the transmission.
- Use a small screwdriver to carefully pry out retaining tabs of connectors at solenoid valves (- 1 - to - 8 -) and disconnect connectors.
Note: If the connectors are damaged, the wiring harness with 14-pin connector and/or the valve body with solenoid valves must be replaced.
- Remove three bolts (2 x -D- and -E-).
- Carefully disconnect/pull apart following connectors:
1 - Connector at Sender 1 for hydraulic pressure - G193 -
2 - Connector to Sensor for transmission input RPM - G182 -
4 - Connector at Sender 2 for hydraulic pressure - G194 -
6 - Connector to Sender for transmission output RPM - G195 -
- Carefully remove Transmission fluid temperature sensor - G93 - - 8 - together with bracket - 7 - from valve body.
Note: For reinstallation purposes, note the attachment of the bracket at transmission fluid temperature sensor - G93 -.
- Disengage wiring harness at bracket -C-.
Note: If the connectors are damaged (depending on the faulty connector), the wiring harness with 8-pin connector and/or the Sensor for transmission input RPM - G182 - and/or the Sender for transmission output RPM - G195 - must be replaced.
- Remove gear lever -A- at selector shaft.
Note:
^ Carefully hold the gear lever -A- secure with universal pliers -B- so that the torque is not transferred to the Multi-function TR switch - F125 -.
^ Watch the slide on the valve body in which the gear lever engages, to ensure that it is not damaged.
- Unscrew securing bolts (arrows) on valve body in a diagonal sequence and carefully take out valve body. Bolts must be replaced.
- Remove brackets - 1 - and - 2 -.
3 - Designation of valve body, in this example, A2
Note:
^ The bolts are of different lengths and must be replaced. Note when re-installing.
^ Only loosen the securing bolts (arrows) indicated in the illustration.
^ If other bolts are loosened, this may affect the operation of the valve body or the valve body will come apart.
^ When removing the valve body, secure the shock absorber piston -E- against falling out or remove it together with the two springs. Installing
Note:
^ The routing of the wiring must be noted precisely to avoid it being pinched or damaged when the valve body is installed.
^ Damaged or pinched wires must always be replaced.
- Route wiring harness -C- (with 8-pin connector) as illustrated in specified indentation in valve body.
Distance - a - must be maintained, to prevent the wiring harness -C- being in contact with the transmission during travel and being chafed by it.
- Route wiring harnesses -A-, -B- and -D- over edge of transmission, as illustrated.
- Make sure that shock absorber piston -E- is installed in transmission in illustrated location.
Note:
^ If the shock absorber piston -E- has been removed, it and the two springs must be cleaned and reinstalled in the same way, Item 27, 26, 25.
^ To reinstall, fit the two springs into each other, coat the outer wall of the shock absorber piston and the aperture in the transmission with ATF and place all components in the transmission.
^ Press the shock absorber piston into the transmission and secure it against falling out until the valve body is installed.
- Install valve body without exerting force.
Note:
^ The wiring harnesses must not be pinched by the valve body. Pinched wiring must always be replaced.
^ All bolts for securing the valve body must be replaced.
- Screw down brackets for wiring harness - 1 - and - 2 - hand-tight with corresponding bolt.
- Tighten remaining valve body bolts (arrows) hand-tight.
Note lengths of bolts:
(Arrow): Bolt M6 x 21
(Arrow -A-): Bolt M6 x 16
(Arrow -B-): Bolt M6 x 28
Note:
^ If the wire - 3 - (to Sensor for transmission input RPM - G182 -) is too short to be able to screw down the connector - 2 - at the specified location on the valve body, it has been routed incorrectly or is being pinched by the valve body. The valve body must be removed again and the wire must be routed correctly.
^ Pinched wires must be replaced.
- Make sure that no wires are actually being pinched.
- Tighten valve body bolts (arrows) starting from outside and working in, to their final tightening torque.
- Engage wiring harness in bracket (arrow -B-).
- Install gear lever - 2 - on selector shaft - 5 -.
Note: When doing so, make sure that the gear lever bolt - 2 - engages in the slide - 1 - (arrow -A-). If necessary move the slide out of or into the valve body, as appropriate.
- Install washer - 4 - and nut - 3 - on selector shaft.
Note:
^ The centering collar of the nut must face toward the washer and run into the washer when screwed on.
^ The wiring harness must be routed under the gear lever.
- Tighten nut to 10 Nm.
Note:
^ When doing so, carefully hold the gear lever -A- secure with universal pliers -B- so that the torque is not transferred to the Multifunction TR switch - F125 -.
^ Watch the slide on the valve body, in which the gear lever engages, to ensure that it is not damaged.
- Connect connectors - 1 - to - 8 - on solenoid valves as indicated in hand-drawn diagram. Note colors of wires and connectors.
- Route wiring harness -B- as illustrated.
Note: Interchanging of the connectors would, in some circumstances, lead to destruction of the transmission.
- Connect connector - 2 -.
- Connect connector - 6 -.
Note: The mating piece of a connector must be of the same color as the connector itself.
- Install bracket - 7 - on Transmission fluid temperature sensor - G93- - 8-.
- Install sensor - G93 - together with bracket in valve body and tighten bolt (M6) -E- to 11 Nm.
- Connect connectors - 1 - and - 5 - directly onto pressure senders.
- Connect connectors - 2 - and - 6 - on valve body -D- to 7 Nm (M5 bolts).
Note:
^ If the wire - 3 - (to sensor - G182 -) is too short to be able to fasten the connector - 2 - at the specified location on the valve body, it has been routed incorrectly or is being pinched by the valve body. The valve body must be removed again and the wire must be routed correctly.
^ Pinched wires must be replaced.
- Engage wiring harness -B- in bracket -C- and route it as illustrated.
- Install ATF screen.
- Install oil pan.
- Connect battery:
- Fill with ATF, check ATF level and top off.
Tightening torque
