Valve Body, Removing and Installing
Valve body,
Valve body, removing and installing
Special tools and equipment
^ VAG 1756 Angle wrench
^ VAG 1331 Torque wrench
Removing
- Observe general repair instructions
- Check whether a coded radio is installed. If so obtain anti-theft coding.
- With ignition switched off disconnect battery Ground strap.
- Remove oil pan.
- Remove oil strainer.
- Make a sketch (similar to illustration) of all sensors and solenoid valves along with their respective connections.
- Before connections of sensors and solenoid valves are disconnected, mark sensors and solenoid valves along with their respective connections.
Note:
^ The sketch and markings are absolutely necessary to prevent interchanging of sensor and solenoid valve connections when reinstalling the valve body.
^ Interchanging the connections can destroy the transmission.
- Carefully pry out retaining tabs of connections on solenoid valves -2- to -9- using a small screwdriver and disconnect connectors.
Note: If a connection is damaged, the wiring harnesses or the valve body with solenoid valves must be replaced.
- Disconnect connections of hydraulic pressure sensors -1- and -4-.
- Disconnect connections -2- and -5-.
- Remove bolts -3- of retainers.
Note: If a connection is damaged, the wiring harnesses or the Sensor for transmission RPM -G182-, or the Sender for transmission output RPM -G195- must be replaced.
- Remove bolt -6-.
- Carefully remove Transmission fluid temperature sensor -G93- -7-, along with retainer out of valve body.
Note: For the reinstallation, note the mounting of the Transmission fluid temperature sensor -G93- retainer.
- Unclip wiring harness on retainer -8-.
- Remove selector lever -1- on selector shaft.
Note:
^ Carefully hold the selector lever -1- with a pair of pliers -2-, so that the torque is not transmitted to the Multi-function TO switch -F125-.
^ Ensure the slide valve -3- on the valve body (in which the selector lever engages) is not damaged.
- Remove securing screws (arrows, arrows -A- and arrows -B-) of valve body using cross-over sequence and carefully remove valve body.
- Remove retainers -1- and -2-.
3 Valve body designation, in this example A2
Note:
^ The bolts/screws are of various lengths and must be replaced in their original locations.
^ Only the bolts/screws (arrows) as marked may be removed.
^ Loosening other bolts/screws can affect the function of the valve body or separate the valve body.
- When removing valve body secure damper piston -2- to prevent it falling out or remove it along with both springs beforehand.
Installing
Note: The routing of the wiring harnesses must be observed exactly, otherwise they may become trapped when installing the valve body.
- Route wiring harness -5- in prescribed channels in transmission as per illustration.
The distance -a- must be observed so that the wiring harness -5- does not lie against the planetary gearbox and be damaged when the vehicle is in use.
- Route wiring harnesses -1-, -3-, -4- and -5- over edge of transmission as per illustration.
- Secure wiring harnesses to transmission with tape.
- Ensure damper piston -2- is installed in position as illustrated.
Note: If the camper piston -2- was removed, it must be cleaned along with both springs and reinstalled in the same way.
- Moisten damper piston and mounting in transmission with ATF.
- Insert springs into one another and insert into damper piston.
- Insert damper piston with springs into mounting in transmission.
- To prevent damper piston from falling out, push it into transmission until valve body is installed, if necessary.
- Position valve body, using no force.
- Ensure that wiring harnesses -1-, -3-, -4- and -5- are not trapped by valve body.
Note:
^ The bolts/screws are of various lengths and must be replaced in their original locations.
^ Observe different lengths of bolts/screws:
Bolts/screws (arrows) M6 x 21
Bolts/screws (arrows -A-) M6 x 16
Bolts/screws (arrows -B-) M6 x 28
- Tighten retainer for wiring harnesses -1- and -2- using new bolts/screws hand tight.
- Tighten remaining valve body new bolts/screws (arrows, arrows -A and arrows -B-) hand tight.
Note: If the wires -3-, -5- and -9- are too short to connect the sensors or too short to be secured to the prescribed locations on the valve body, then the wiring harnesses have been routed incorrectly or are trapped by the valve body. The valve body must be removed again and the wires must be re-routed correctly.
- Ensure that wires -3-, -5- and -9- are not trapped.
- Tighten new bolts (arrows, arrows -A- and arrows -B-) from inside to outside to prescribed torque
- Hook wiring harness -3- into retainer -7- (arrows -B-).
- Install selector lever -2- onto selector shaft -6-.
- Make sure that selector lever -2- pin engages into slide valve -1- (arrow -A-). Reposition slide valve as necessary.
- Install washer -5- and nut -4- onto selector shaft -6-.
Note:
^ The centralizing shoulder of the nut must face the washer and run into the washer when tightened.
^ The wiring harness must be routed below the selector lever.
- Tighten nut to prescribed torque
Note:
^ Carefully hold the selector lever -1- with a pair of pliers -2-, so that the torque is not transmitted to the Multi-function TO switch -F125-.
^ Ensure the slide valve -3- on the valve body (in which the selector lever engages) is not damaged.
- Reconnect connections to respective solenoid valves -2- to -9- as per previous markings.
Note:
^ Interchanging the connections can destroy the transmission.
^ If a connection is damaged, the wiring harnesses or the valve body with solenoid valves must be replaced.
- Route wiring harness -1- as per illustration.
- Reconnect connections -2- and -5-.
Note: The opposing connector must have the same markings as that being connected.
- Install retainer to Transmission fluid temperature sensor -G93- -7-.
- Install sensor -G93- together with retainer into valve body.
- Tighten bolt/screw -6- to 11 Nm.
- Reconnect connections horizontally onto hydraulic pressure sensors -1- and -4-.
- Tighten retainer bolts/screws -3-for connections
Note: If the wires are too short to be secured, then they have been routed incorrectly or are trapped by the valve body. The valve body must be removed again and the wires must be re-routed correctly.
- Hook wiring harness into retainer -8- and route as shown in illustration.
- Install oil strainer.
- Install oil pan.
- Fill with ATF, check ATF level and top off.
- Connect battery Ground strap.
- Enter radio code.
- Initialize power windows, set correct time on clock.
- Connect VAS 5051 and advance through programs until "Functions/selecting component" is displayed.
- Press "Drive (Repair group. 01; 10...26; 28...39)".
- Press "6-speed automatic transmission O9G".
- Press "self-diagnosis".
- Press "Functions".
- Press "Initiate basic (default) setting".