Volkswagen Touareg 2003 Workshop Manual

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Workshop Manual

Touareg 2003 ➤

Automatic gearbox 09D Volkswagen R GmbH

Engine ID

CBW

A

Edition 06.2010

Service

Service Department. Technical Information

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.

List of Workshop Manual Repair GroupsList of Workshop Manual

Repair GroupsList of Workshop Manual Repair Groups

Repair Group

00 - Technical data

32 - Torque converter

37 - Controls, housing

38 - Gears, control

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.

Service

No reproduction without prior agreement from publisher.

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Contents

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

1 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Suggestions and criticism of this workshop manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Information about 6-speed automatic gearbox 09D, general repair notes . . . . . . . . . . . . . . 2

1.3 Brief overview - driveline guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.5 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.6 Seals and sealing rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.7 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.8 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.9 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.10 Guided fault finding, vehicle self-diagnosis and testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Identification codes, engine allocation, Touareg 2003 ► . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4 Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

32 - Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1 Proper handling and installation of torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.1 Checking torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.2 Removing and installing torque converter oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.3 Draining torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.4 Installing torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

37 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1 Connecting »tester« . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.1 Connecting vehicle diagnosis, testing and information system VAS 5051 . . . . . . . . . . . . 13

2 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.1 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.2 Dismantling and assembling selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.3 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.4 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.5 Removing and installing selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.6 Removing and installing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.7 Signal magnet for Tiptronic switch F189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.8 Removing and installing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.9 Releasing selector lever without electrical current (emergency release) . . . . . . . . . . . . . . 26

2.10 Removing and installing selector lever position P solenoid N380 . . . . . . . . . . . . . . . . . . . . 27

2.11 Removing and installing selector lever lock solenoid N110 . . . . . . . . . . . . . . . . . . . . . . . . 28

2.12 Removing and installing selector lever locked in position P switch F319 . . . . . . . . . . . . . . 29

2.13 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3 Renewing needle bearing for starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.1 Renewing needle bearing for starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4.1 Removing and installing gearbox, vehicles with V10 TDI engine . . . . . . . . . . . . . . . . . . . . 36

4.2 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5 Checking ATF level and topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5.1 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5.2 Checking ATF level and topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6 ATF lines and ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

6.1 Assembly overview - ATF lines, vehicles with V10 TDI engine . . . . . . . . . . . . . . . . . . . . . . 46

6.2 Removing and installing ATF lines and ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6.3 Cleaning ATF lines and ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Touareg 2003 ➤

Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010

Contents i

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6.4 Bleeding ATF system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

7 Control unit for automatic gearbox J217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

7.1 Removing and installing automatic gearbox control unit J217 . . . . . . . . . . . . . . . . . . . . . . 51

8 Renew seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

8.1 Renewing output shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

8.2 Renewing oil seals for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

38 - Gears, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

1 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

1.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

1.3 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

2 Removing and installing ATF strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

2.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

2.3 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

3 Overview - removing and installing valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3.1 Removing and installing valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3.2 Removing and installing gearbox output speed sender G195 . . . . . . . . . . . . . . . . . . . . . . 63

4 Removing, installing and adjusting multifunction switch F125 . . . . . . . . . . . . . . . . . . . . . . 64

4.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

4.2 Installing and adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Touareg 2003 ➤

Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010

ii Contents

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.

00 – Technical data

1 General repair notes

1.1 Suggestions and criticism of this workshop manual

This workshop manual

This workshop manual was made for you. It should support you

and be an aid to you. If you use ⇒ ELSA, you can send us sug‐

gestions, »praise and criticism« from anywhere in the world.

– One can do this by clicking the ⇒ Feedback button

-at the top in the menu bar-.

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. But to do so, we

need your comments.

One example of a reader's suggestion which has been »imple‐

mented« is the chapter „Definitions“ in the workshop manual ⇒

Touareg 2003 ➤

Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010

1. General repair notes 1

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.

Automatic gearbox 001; Rep. gr. 39 ; Final drive, differential; Ad‐

justing final drive; Definitions for the Polo 2002.

– Go ahead and »Click« click the link! Have a look.

If you find this chapter useful, or would like such a chapter in this

workshop manual or have additional suggestion, write to us.

So once more:

We make great effort to implement your suggestions for the work‐

shop manuals. But to do so, we need your comments. If we don't

know what is bothering you, we can't improve it.

– Use the ⇒ Feedback button -at the top in the menu bar-.

1.2 Information about 6-speed automatic

gearbox 09D, general repair notes

Design and function of gearbox

For more information about design and function, see ⇒ Self-study

programme No. 300 ; 6-speed automatic gearbox 09D .

In addition, you can find out more about automatic gearboxes us‐

ing the ⇒ CD ROMs ⇒ Multimedia training; Power transmission

parts 1 to 3 .

1.3 Brief overview - driveline guide

1 - Transfer box

❑ ⇒ Rep. gr. 34 ; Remov‐

ing and installing trans‐

fer box

❑ ⇒ Rep. gr. 34 ; Remov‐

ing and installing trans‐

fer box; Transporting

transfer box

2 - Propshafts

❑ ⇒ Rep. gr. 39 ; Remov‐

ing and installing prop‐

shafts

3 - Rear final drive

❑ ⇒ Rep. gr. 39 ; Remov‐

ing and installing rear fi‐

nal drive

4 - Front final drive

❑ ⇒ Rep. gr. 39 ; Remov‐

ing and installing front fi‐

Touareg 2003 ➤

Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010

2 Rep. gr.00 - Technical data

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.

nal drive

1.4 Tools

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.

The catalogue is also available on ⇒ CD-ROM and can be ordered

the usual way from Bertelsmann.

Uncertainty often occurs with smaller bolts having low tightening

forces. Torque wrench 2...10 Nm -V.A.G 1783- can be used with

these bolts.

1.5 Gearbox

♦ If gearbox covers have been unbolted or gearbox has no fluid,

do not run engine or tow vehicle.

♦ First thoroughly clean connecting points and surrounding

areas and then loosen bolts.

♦ When installing the gearbox, ensure that dowel sleeves be‐

tween the engine and gearbox are correctly located.

♦ Place removed parts on a clean surface. Cover parts to pre‐

vent soiling. Use plastic sheeting and paper. Use lint-free

cloths only!

♦ If repair work cannot be performed immediately, carefully cov‐

er or seal components.

♦ Install only clean parts; do not remove new parts from pack‐

aging until immediately before installing.

♦ Do not run engine or tow vehicle with pan removed or when

there is no ATF in gearbox.

♦ With gearbox removed, secure torque converter against falling

out.

♦ After installing, check ATF level ⇒ page 42 .

Touareg 2003 ➤

Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010

1. General repair notes 3

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.

1.6 Seals and sealing rings

♦ Always renew O-rings, seals and gaskets.

♦ When seals have been removed, check contact surface on

housings or shafts for burrs and damage and rectify as nec‐

essary.

♦ Before installing seals, moisten outer circumference of seal

and sealing lip with ATF depending on installation location.

♦ Only use ATF for automatic transmission components. Other

lubricants cause faults to occur in the gearbox hydraulics.

♦ Open side of oil seal faces oil.

♦ After installing, check ATF level ⇒ page 42 .

1.7 Oil

Caution

Be careful when working with oil. Dispose of drained oil ac‐

cording to regulations. Remember: one drop of oil will contam‐

inate 1,000 litres of water.

Do not mix any additives into the oil or use a substitute oil.

Oil which has been drained out cannot be filled again.

The ATF is obtainable as a spare part.

Container size 1.0 l - Part No. -G 055 025 A2-

Capacity ⇒ page 8 .

1.8 Nuts and bolts

♦ Loosen and tighten securing bolts and nuts for covers and

housings diagonally.

♦ Torque settings are specified for unoiled bolts and nuts.

♦ Threads of bolts secured with locking fluid must be cleaned

with a wire brush. Then insert bolts with locking fluid -

AMV 185 101 A1- .

♦ Use a thread chaser to clear residual locking fluid from all

threaded holes into which self-locking bolts are to be screwed.

Otherwise there is a danger of bolts shearing when subse‐

quently being removed.

♦ Always renew self-locking bolts and nuts.

♦ Torque settings are specified for unoiled bolts and nuts.

1.9 Electrical components

You have probably at some time received an electrical shock

when touching a metal object. This is due to the electrostatic

charge of the human body. This charge can disturb the function

of electrical components of the gearbox and of the selector mech‐

anism.

Touareg 2003 ➤

Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010

4 Rep. gr.00 - Technical data

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Note

Before beginning work on electrical components, touch an earth‐

ed object, for example a water pipe or lifting platform. Please do

not touch connectors directly.

1.10 Guided fault finding, vehicle self-diag‐

nosis and testing

Before making repairs to the gearbox, determine the cause of the

fault as precisely as possible with the aid of „guided fault finding“.

Carry out Guided fault finding using the vehicle diagnosis,

testing and information system -VAS 5051- .

Touareg 2003 ➤

Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010

1. General repair notes 5

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2 Gearbox identification

The 6-speed automatic gearbox 09D is installed in the Touareg.

Allocation ⇒ page 7 .

The gearbox code appears on the type plate to the left on the

bottom of the gearbox.

Example:

1 - Identification code

2 - Automatic gearbox 09D

The gearbox code also ap‐

pears on the vehicle identifica‐

tion plates.

Touareg 2003 ➤

Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010

6 Rep. gr.00 - Technical data

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3 Identification codes, engine alloca‐

tion, Touareg 2003 ►

If parts are required for repair work, it is essential that reference

is made to the gearbox code of the automatic gearbox.

„6-speed 09D four-wheel drive automatic gearbox“

Identification code JXW

Engine 5.0 l - 258 kW

V10 TDI

Touareg 2003 ➤

Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010

3. Identification codes, engine allocation, Touareg 2003 ► 7

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4 Capacity

General information on Volkswagen oils can be found in ⇒ Elsa‐

Win; Internet (globe); Language; Technical information; Gearbox

oils .

Capacities Automatic gearbox 09D

Initial filling of gearbox by

manufacturer

about 9 l

(filled for life)

Filling entire system

(gearbox including ATF

cooling system)

about 12 l

(filled for life)

Lubricant ATF

The ATF is obtainable as a spare part.

Container size 1.0 l - Part No. -G 055 025 A2-

Touareg 2003 ➤

Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010

8 Rep. gr.00 - Technical data

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32 – Torque converter

1 Proper handling and installation of

torque converter

– Always secure torque converter.

An unsecured torque converter may slide out when the gearbox

is tipped.

Therefore, always work with care.

1.1 Checking torque converter

– Check torque converter hub for scoring -arrow-.

The torque converter is welded and must be renewed if damaged.

1.2 Removing and installing torque convert‐

er oil seal

Special tools and workshop equipment required

♦ Oil seal extractor lever -VW 681-

♦ Thrust piece -3295-

Touareg 2003 ➤

Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010

1. Proper handling and installation of torque converter 9

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1.2.1 Removing

– Apply oil seal extractor lever -VW 681- directly behind sealing

lip of oil seal to avoid damaging stop ring.

1.2.2 Installing

– Apply ATF to circumference and sealing lips of oil seal.

Installation position:

Open side of oil seal faces gearbox.

– Using thrust piece -3295- , drive in torque converter oil seal to

stop of thrust piece.

1.3 Draining torque converter

Special tools and workshop equipment required

♦ Oil extraction unit -V.A.G 1358 A-

♦ Oil extraction probe -V.A.G 1358 A/1-

If ATF has become fouled by abraded material or if a major over‐

haul of gearbox is being performed, drain torque converter as

follows:

– Extract ATF from torque converter using oil extractor -

V.A.G 1358 A- and probe -V.A.G 1358 A- .

Touareg 2003 ➤

Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010

10 Rep. gr.32 - Torque converter

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1.4 Installing torque converter

– Lubricate torque converter hub and lips of torque converter

seal each with one drop of ATF (and not more).

– Push torque converter into gearbox to stop.

– Now turn the torque converter while gently pressing it towards

the gearbox.

The torque converter can be felt to slip further into the gearbox

when the notch in the torque converter hub slips into the follower

of the pump gear.

When the torque converter is fitted, the outer lip of the oil seal may

become »inverted«.

– Therefore, pull torque converter 5 mm back out of gearbox

again.

This will bring the lip into its »proper position«.

– Then push torque converter into gearbox to stop.

The torque converter is properly installed when the gearbox can

be pushed against the engine flange »without force«.

– If this is not the case, fit the torque converter again. Then check

the installation dimension ⇒ page 12 .

Touareg 2003 ➤

Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010

1. Proper handling and installation of torque converter 11

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Installation dimension

• The torque converter is correctly installed when the distance

-a- between the contact surfaces at the threaded holes of the

torque converter and the torque converter housing is at least

19 mm.

– Ensure that the torque converter does not slide »forwards«

during the installation of the gearbox.

– If this is not the case, check the installation of the torque con‐

verter as follows:

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.

The torque converter is properly installed when the gearbox can

be pushed against the engine flange »without force«.

Torque setting for drive plate to torque converter ⇒ page 36

– After installing gearbox, check ATF level and top up

⇒ page 42 .

Touareg 2003 ➤

Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010

12 Rep. gr.32 - Torque converter

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37 – Controls, housing

1 Connecting »tester«

Volkswagen offers various devices such as

♦ Vehicle diagnosis, testing and information system -VAS 5051-

♦ Vehicle diagnosis, testing and information system -VAS

5051B-

♦ Tester -VAS 5051/11A-

♦ Vehicle diagnosis and service information system -VAS 5052-

♦ Diagnostic system -VAS 5053-

The operation of these »devices« is described in the respective

user's manuals.

The following description refers to the vehicle diagnosis, testing

and information system -VAS 5051- ⇒ page 13 .

1.1 Connecting vehicle diagnosis, testing

and information system -VAS 5051-

Special tools and workshop equipment required

♦ Vehicle diagnosis, testing and information system -VAS 5051-

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- or -

VAS 5051/3- onto diagnosis connection.

Touareg 2003 ➤

Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010

1. Connecting »tester« 13

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– Switch on tester -arrow-.

The »tester« is ready for use when it is possible to choose be‐

tween the buttons 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.

Touareg 2003 ➤

Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010

14 Rep. gr.37 - Controls, housing

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2 Repairing selector mechanism

WARNING

Before working on vehicle with engine running, move selector

lever to position „P“ and apply parking brake.

2.1 Checking selector mechanism

The starter must not operate in the selector lever positions „R“,

„D“ or „S“.

On right-hand drive vehicles, the starter must operate in selector

lever positions „P“ and „N“ only when the button in the selector

lever handle is not pressed.

When selector lever is shifted to position „N“ at speeds above 5

km/h, solenoid for selector lever lock must not engage and block

selector lever. Selector lever can be shifted into a driving gear.

When the vehicle is moving at speeds below 5 km/h (almost sta‐

tionary) and the selector lever is shifted to position „N“, the sole‐

noid for selector lever lock should only engage after about 1

second. Selector lever cannot be shifted out of „N“ position until

brake pedal is depressed.

2.1.1 Selector lever in „P“ position and ignition

switched on

• Brake pedal not depressed:

Selector lever is locked and cannot be shifted out of „P“ position

when the button is pressed. Solenoid for selector lever lock blocks

selector lever.

• Brake pedal depressed:

Solenoid for selector lever lock releases selector lever. It is pos‐

sible to shift into a driving gear. Slowly shift selector lever from

„P“ through to „S“, checking whether selector lever position in

dash panel insert corresponds to selector lever position.

2.1.2 Selector lever in „N“ position and ignition

switched on

• Brake pedal not depressed:

Selector lever is locked and cannot be shifted out of „N“ position

with the push button pressed. Solenoid for selector lever lock

blocks selector lever.

• Brake pedal depressed:

Solenoid for selector lever lock releases selector lever. It is pos‐

sible to shift into a driving gear.

2.1.3 Selector lever in position „Tiptronic“

• Shift selector lever into Tiptronic gate.

The illuminated „D“ symbol in the selector mechanism cover must

go out and the „+“ and „-“ symbols must light up.

When the selector lever is shifted into the Tiptronic gate, the se‐

lector lever position display in the dash panel insert must change

from „P R N D S“ to „6 5 4 3 2 1“.

Touareg 2003 ➤

Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010

2. Repairing selector mechanism 15

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2.1.4 Ignition and light switched on

The respective symbol in the shift mechanism cover lights up.

2.1.5 Selector lever position display

Simultaneous illumination of all selector lever position display

segments indicates that the gearbox is in gearbox emergency

running mode.

– Check and adjust selector lever cable ⇒ page 20 .

2.2 Dismantling and assembling selector mechanism

1 - Selector lever handle

❑ Removing and installing

⇒ page 17

2 - Clip

3 - Insert

4 - Emblem

❑ Self-adhesive

5 - Sleeve

6 - Cover

❑ With selector indicator

❑ Removing and installing

⇒ page 23

7 - Printed circuit board

❑ With Tiptronic switch -

F189-

8 - Cover strip/frame

❑ Removing and installing

⇒ page 25

❑ Note signal magnet for

Tiptronic switch -F189-

in cover strip

⇒ page 24

9 - Cable

❑ Removing and installing

⇒ page 29

10 - Selector lever lock sole‐

noid -N110-

❑ Removing and installing

⇒ page 28

11 - Selector lever position P

solenoid -N380-

❑ Removing and installing ⇒ page 26

12 - Bolt, 20 Nm

❑ Qty. 4

13 - Retainer

14 - Retainer

15 - Selector mechanism

❑ With selector lever lock solenoid -N110- and selector lever position P solenoid -N380- .

❑ Releasing selector lever without electrical current (emergency release) ⇒ page 26

Touareg 2003 ➤

Automatic gearbox 09D Volkswagen R GmbH - Edition 06.2010

16 Rep. gr.37 - Controls, housing

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Volkswagen Touareg 2003 Workshop Manual

Volkswagen Touareg 2003 Workshop Manual

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