General, Technical

General Repair Notes: - 01J, Continuously Variable Transmission (CVT)

Transmission
^ Observe rules of cleanliness for working on the transmission.
^ Do not run engine with 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 and axle oil in front final drive.

O-rings, seals, gaskets
^ Always replace O-rings, gaskets and seals.
^ After removing gaskets, examine contact surface on housing/shaft for burr 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 faults 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 or axle oil in front final drive.

Bolts and nuts
^ Loosen bolts in reverse of tightening sequence.
^ 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 with locking fluid AMV 185 101 A1.
^ Threaded holes into which self-locking bolts or bolts coated with locking fluid are installed, 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-tensioned.
^ 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 outer or inner races of bearings of the same size.
^ Always replace taper roller bearings on one shaft together and use new bearings from a single manufacturer.

Adjustment shims
^ Use a micrometer to measure 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 Diagnostic Operation System VAS 5051 A before starting disassembly and assembly work.