89k303 six-speed automatic transmission 09d.pdf

Self-Study ProgramCourse Number 89K303

Six-Speed AutomaticTransmission 09D

Volkswagen of America, Inc.Service TrainingPrinted in U.S.A.Printed 3/2003Course Number 89K303

©2003 Volkswagen of America, Inc.

All rights reserved. All Information contained inthis manual is based on the latest informationavailable at the time of printing and is subject to the copyright and other intellectual propertyrights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights arereserved to make changes at any time withoutnotice. No part of this document may bereproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recordingor otherwise, nor may these materials be modified or reposted to other sites without the prior expressed written permission of the publisher.

All requests for permission to copy and redistribute information should be referred toVolkswagen of America, Inc.

Always check Technical Bulletins and theVolkswagen Worldwide Repair InformationSystem for information that may supersede anyinformation included in this booklet.

Trademarks: All brand names and product namesused in this manual are trade names,servicemarks, trademarks, or registered trademarks; andare the property of their respective owners.

i

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Transmission Overview, Technical Data

Selector Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Selector Lever Positions, Selector Lever Position and Gear Display inInstrument Panel Insert, Tiptronic, Selector Lever Tiptronic, Gear Display inthe Instrument Panel Insert, Selector Lever Lock and Ignition Key RemovalLock, Shift Lock Solenoid N110, Selector Lever Park Position SolenoidN380, Ignition Switch Key Lock Solenoid

Automatic Transmission Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Component Overview, Component Functions, Torque Converter withLockup Clutch and ATF Pump, Torque Converter Clutch (TCC), The ATFPump, The Lepelletier Arrangement, The Simple Planetary Gear Set, TheDual Planetary Gear Set, The Multi-Disc Clutches, The Multiple DiscBrakes, The Free-Wheel, The Parking Lock, the Hillholder Function,Emergency Running Mode, Power Flow in the Touareg

Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26System Overview, Sensors, Sensor for Transmission RPM G182, Senderfor Transmission Output RPM G195, Multifunction Transmission Range(TR) Switch F125, Transmission Fluid Temperature Sensor G93, Sender -1-G193 and Sender -2- G194 for Hydraulic Pressure, Tiptronic Switch F189,Actuators, Solenoid Valves

Self-Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Knowledge Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Page

New!

Important/Note!

The Self-Study Program provides you with informationregarding designs and functions.

The Self-Study Program is not a Repair Manual

For maintenance and repair work, always refer to thecurrent technical literature

1

Introduction

This Self-Study Program provides you withthe design and function of the new 6-speedautomatic transmission, which is installed inthe Touareg.

The 09D 6-speed automatic transmissionprovides:

• six forward speeds to help lower fuelconsumption

• excellent acceleration values and lownoise output.

Introduction

The 09D 6-Speed Automatic

Transmission

The 09D 6-speed automatic transmissionwas developed at the famous Japanesemanufacturer of automatic transmissions,AISIN Co., LTD, where it is manufactured.

In the development of the control modulesoftware, the Volkswagen engineers haveused their years of experience regardingfuzzy logic-controlled driving programs whichrely on driving situations and driver input.

This 6-speed automatic transmission, whichhas a very compact construction, is beingused for the first time in the VolkswagenTouareg.

Introduction

2

ManufacturerSpare Parts Number

AISIN Model Number

Production Date

Gearbox Codes

Serial Number of the Manufacturer 89K303_003

3

Special transmission features include:

• fuzzy logic-controlled shifting programsthat depend on driver and driving situa-tions as well as shifting programs thatdepend on vehicle inputs

• a controlled torque converter clutch

• lifetime ATF filling

• The hill-holder function secures the vehi-cle from rolling back and permits hills tobe approached comfortably.

• selector lever and steering wheelTiptronic switches

Introduction

ElectricalConnections

Gearbox Ventilation

ATF Cooler Connections Multifunction Switch

89K303_005Technical Data

89K303_004

The Self-Study Program is not a Repair ManualFor maintenance and repair work, always refer to the current technical literature

The Selector Lever Positions

P - ParkBefore the selector lever can be moved outof the Park position, the ignition must beswitched on.

In addition, the foot brake and the lockingbutton on the selector lever must bepressed.

R - ReverseThe locking button on the selector levermust be pressed to shift into reverse.

N - NeutralThe transmission is idling in this position. Nopower is being transmitted to the wheels.

If the selector lever is in this position for along time, the foot brake must be pressedagain to activate the lever.

D - DriveIn the Drive position, the forwards gears areswitched automatically.

S - SportThe control module selects gears automati-cally according to a "sporty" switching charac-teristic curve.

The individual gears are held longer.

Selector lever position and gear dis-play in instrument panel insert

After the ignition is switched on, the currentselector lever position is displayed in theinstrument panel insert.

In positions "D" and "S", the gear selected inthe transmission is also displayed.

Selector Lever

4

Locking Button

89K303_007

89K303_006

5

Tiptronic

The Tiptronic function in the Touareg allowsfor greater driver control. It is actuatedthrough the selector lever and displayed inthe instrument panel insert.

Selector lever Tiptronic

The Tiptronic channel is selected by movingthe selector lever to the right out of the "D"position.

This allows the Transmission Control Moduleto enter the Tiptronic mode. The driver cannow actively select gears.

Gear display in the instrument panelinsert

The current gear is displayed in Tiptronicmode.

Selector Lever

"+" Move Up a Gear

"-" Move Down a Gear

Tiptronic Channel 89K303_009

5

3

6

4

2

1

89K303_008

Selector Lever Lock and Ignition

Key Removal Lock

Shift Lock Solenoid N110

This is located in the front on the selectorlever frame. It prevents the selector leverfrom moving out of the positions "P" and "N"when the brake is not being applied.

How it works

Once the ignition has been switched on, themagnet for the selector lever lock is ener-gized by the Transmission Control Module,locking the selector lever.

If the Transmission Control Module receivesthe signal "brake applied" via the CAN databus, it cuts off current to the magnet andthe selector lever can be moved.

Effects of a signal drop-out

If one of the two signals fails or if the mag-net is faulty, the selector lever can be movedout of "P" and "N" without applying the brakeif the ignition is switched on.

Selector Lever

6

Selector LeverFrame


89K303_011

89K303_010

Components:

E408 Access/Start Authorization ButtonE415 Access/Start Authorization SwitchF319 Selector Lever Park Position Lock SwitchJ217 Transmission Control ModuleJ518 Access/Start Control ModuleN110 Shift Lock SolenoidN376 Ignition Switch Key Lock SolenoidN380 Selector Lever Park Position Solenoid

7

Selector Lever Park Position Solenoid N380

This is located on the selector lever frame,as is the magnet for the selector lever lock.

It prevents the selector lever from movingout of the "P" position when the ignition isswitched off.

The ignition must be switched on to activatethe lock button.

How it works

The Selector Lever Park Position SolenoidN380 is without power when the ignition isswitched off, locking the selector lever in the"P" position.

After the ignition is switched on, the magnetN380 receives power from terminal 15 andthe lock is lifted.

F319 signals to the access and start autho-rization control device that the selector leveris in the "P" position.

Effects of a signal drop-out

If one of the signals fails or the magnet forselector lever lock "P" is defective, then theselector lever cannot be moved out of the"P" position.

N380 has to be manually unlocked beforemoving the vehicle. To disable N380, thecenter console covering must be removedand the magnet actuated by hand.

The selector lever has to be simultaneouslymoved out of the "P" position.

Selector Lever

Selector Lever Park Position Solenoid N380

Selector Lever Park Position Switch F319

Press Magnetto Actuate

89K303_013

89K303_012

Components:

E408 Access/Start Authorization ButtonE415 Access/Start Authorization SwitchF319 Selector Lever Park Position Lock SwitchJ217 Transmission Control ModuleJ518 Access/Start Control ModuleN110 Shift Lock SolenoidN376 Ignition Switch Key Lock SolenoidN380 Selector Lever Park Position Solenoid

Ignition Switch Key Lock Solenoid N376

The Ignition Switch Key Lock Solenoid N376is located inside the Access/StartAuthorization Switch E415 and prevents theignition key from being removed when theselector lever is in a driving position. Theignition key removal lock works electro-mechanically.

How it works

Ignition Switch Key Lock Solenoid N376 con-tains two spring-loaded locking pins whichengage into the inside tract of the insertedignition key whenever the selector lever isnot in the "P" position (N376 without power).

The ignition key cannot be withdrawn.

When the selector lever is in the "P" position,a signal travels from the Selector Lever ParkPosition Lock Switch F319 to theAccess/Start Control Module J518.

The control module then sends current tothe Ignition Switch Key Lock Solenoid N376.This causes the magnets to retract the lock-ing pins from the inside tract of the ignitionkey.

The ignition key can be withdrawn.

Selector Lever

8

Inside Tract

Access/Start Authorization Switch E415

Ignition Switch Key Lock Solenoid N376

89K303_016

Ignition Switch Key Lock Solenoid N376 Without Power

Locking Pins Locked in Place

Access/Start Control Module

J518

89K303_015

Ignition Switch Key Lock Solenoid N376 With Power

Locking Pins Removed

Access/Start Control Module

J518

89K303_014

9

Electrical Circuit

If the ignition is switched off and the selec-tor lever is in the "P" position, a signal travelsfrom the Selector Lever Park Position LockSwitch F319 to the Access/Start ControlModule J518.

The control module then sends current tothe magnet for the ignition key removal lockN376. The locking pins are removed, and theignition key can be withdrawn.

If the selector lever is not in the "P" positionwhen the engine of a vehicle with start/stopbuttons is switched off, the instrument panelinsert emits an optical and acoustical warn-ing.

This informs the driver that the selector leveris not in the "P" position.

Effects of signal drop-out

The electro-mechanical lock cannot bereleased if either the signal from the selectorlever to the Access/Start Control ModuleJ518 or the signal from the control moduleto the Access/Start Authorization SwitchE415 fails. The key cannot be withdrawn.

In these circumstances, the ignition lock hasan emergency release for the ignition key.

Press the emergency release button with apen or similar object to activate the emer-gency release for the ignition key.

While keeping the button pressed, turn theignition key to the left and remove it.

Selector Lever

89K303_018

Emergency Release Button(press to release)

89K303_017

Components:

E408 Access/Start Authorization ButtonE415 Access/Start Authorization SwitchF319 Selector Lever Park Position Lock SwitchJ217 Transmission Control ModuleJ285 Control Module with Indicator Unit in

Instrument Panel InsertJ518 Access/Start Control ModuleN110 Shift Lock SolenoidN376 Ignition Switch Key Lock SolenoidN380 Selector Lever Park Position Solenoid

Automatic Transmission Design

10

Torque Converter K3 Clutch K1 ClutchSimplePlanetary Gear Set

Starter Ring Gear

TransmissionInput Shaft

ATF Pump Drive ATF Pump B1 BrakeSensor forTransmissionRPM G182

Torque Converter Clutch (TCC)

Component Overview

11


K2 ClutchDual Planetary Gear Set (Ravigneaux)

B2 Brake Parking LockOil PanFree-wheel Sender forTransmissionOutput RPM G195

Parking Lock Wheel

Drive Shaft

89K303_019

Component Functions

The transmission housing is made of analuminum alloy.

The six forward gears and the reverse gearare switched using a Lepelletier arrangementof the planetary gear sets.

To switch the gears,

• three multi-disc clutches,

• two multiple disc brakes

are switched on or off using the electro-mechanic-hydraulic control module in thevalve body.

The Transmission Control Module initiatesgear changes and monitors the process forproblems.

Signals from the various sensors are used tocontrol actuator activation.

Activation takes place depending on driver,driving situation and the shift program.

Torque converter with lockup clutchand ATF pump

The torque converter uses transmission fluidto allow the vehicle to start and for torquemultiplication. This converter is also equippedwith a Torque Converter Clutch (TCC).

This TCC can be used from an engine speedof 1000 rpm or higher. The TransmissionControl Module closes this clutch, allowingengine torque to transfer directly to thetransmission input shaft.

The transmission is adapted for use withdifferent engines in the Touareg by varying

• the number of installed disc pairs for thebrakes and the clutches

• the size of the torque converter and

• the geometric shape of the torque con-verter housing.

The individual gears remain the same for allengines.

A transfer transmission flanged onto thetransmission distributes the torque to theaxle drives.


12

ATF PumpTorque Converter

Torque Converter Lockup Clutch

Starter Ring Gear 89K303_020

13


The Transmission Control Module controlsthe TCC Solenoid Valve N91. This solenoidvalve either opens or closes the TCC,depending on the engine speed and torque.

When the TCC is closed, engine torque istransmitted directly through to the transmis-sion without any slip.

To close the TCC, N91 opens the oil reser-voir upstream of the TCC. This decreases thepressure in the oil reservoir, allowing theTCC to close.

When N91 closes the oil flow again, allowingpressure to increase upstream of the TCC,the TCC will open.


Starter Ring GearATF Pump Drive

Torque Converter 89K303_023


TCCClosed

Solenoid Valve 4, N91

89K303_022

TCCOpen


89K303_021

The ATF pump

The ATF pump is a gear pump and is drivenby the ATF pump drive of the torque convert-er. It pulls the ATF from the oil pan of thetransmission through the oil sieve.

The ATF pump generates the workingpressure for:

• the application of the multi-disc clutchesand multiple disc brakes,

• the lubrication circulation system and

• the coolant circulation system.

The ATF is cooled by a separate radiator. Thisradiator is located in front of the engineradiator (as seen in the driving direction).


14

89K303_026

ATF RadiatorEngine Radiator

Engine

ATF Pump inAutomaticTransmission

89K303_025

Drive

Pressure Side Suction Side89K303_024

15

The Lepelletier Arrangement

The Lepelletier arrangement is based on theRavigneaux design - a simple planetary gearset and a subsequent dual planetary gearset.

Lepelletier's brilliant idea was to drive thesun wheels and the planetary carriers of thedual planetary gear set at different speeds.

Due to the different input speeds in the dualplanetary gear set, the potential number ofgear ratios almost doubles, from five to nine.

The sun wheels of the dual planetary gearset are driven with the output speed of thesimple planetary gear set.

The planetary carriers of the dual planetarygear set are driven with the transmissioninput speed. As a result, the sun wheels andthe planetary carriers have different speeds.

In this automatic transmission, six forwardand one reverse gear bring Lepelletier'sidea to life.


Transmission Input Shaft Simple PlanetaryGear Set

Dual PlanetaryGear Set (Ravigneaux)

Drive Shaft

Output Speed,Simple Planetary Gearset

Sun Wheel of Dual Planetary Gear Set

Planetary Carrier

89K303_027

The Simple Planetary Gear Set

The simple planetary gear set consists of:

• a sun wheel,

• an internal gear and

• 3 planetary wheels, which are guided bythe planetary carriers.

The input torque is guided through thesimple planetary gear set on two paths:

• from the transmission input shaft withouttransmission via the clutch K2 on theplanetary carrier of the dual planetarygear set and

• through the simple planetary gear setwith transmission to clutches K1 and K3


16

Planetary GearPlanetary Carrier

Sun Wheel

Internal Gear

89K303_029

Transmission Input Shaft K3 K1 K2

Simple Planetary Gear Set 89K303_028

17

The Dual Planetary Gear Set

The dual planetary gear set, also known as theRavigneaux planetary gear set, consists of:

• an internal gear

• a planetary carrier

• two sun wheels with different diameters

• short and long planetary wheels.

The multi-disc clutch K1 connects the inter-nal gear of the simple planetary gear set andthe large sun wheel of the dual planetarygear set.

The multi-disc clutch K3 connects theplanetary carrier of the simple planetarygear set and the small sun wheel of thedual planetary gear set.

The multi-disc clutch K2 connects thetransmission input shaft and the planetarycarriers of the dual planetary gear set.


PlanetaryCarrier

SmallSun Wheel

Dual PlanetaryGear Set

LargeSun Wheel 89K303_031

LargeSun Wheel

SmallSun Wheel

ShortPlanetary Gear

LongPlanetary Gear

Planetary Carrier

Internal Gear

89K303_030

The Multi-Disc Clutches

The multi-disc clutches drive the two sunwheels and the planetary carriers of the dualplanetary gear set when they are closed.

Depending on the gear to be switched, theyare placed under ATF pressure by theTransmission Control Module via a solenoidvalve in the valve body; this closes them.

Each multi-disc clutch is supplied with ATFpressure by another solenoid valve.

The number of installed disc pairs per clutchvaries with the maximum torque that can betransmitted.

The multi-disc clutch K1

K1 is closed in gears 1 to 4 and is controlledby the Solenoid Valve 3, N90.


K2 is closed in gears 4 to 6. It is controlledby the Solenoid Valve 9, N282.


18

89K303_035

89K303_034

89K303_033

89K303_032

19


K3 is controlled by the Solenoid Valve 5,N92, and is closed in gears 3, 5 and R.


89K303_037

Multi-DiscPairs

89K303_036

The Multiple Disc Brakes

The multiple disc brakes secure parts of theplanetary gear sets when they are closed.

To do this, they are submitted to ATF pres-sure by the Transmission Control Module viaa solenoid valve or via the manual slider.

The multiple disc brakes are locked into thetransmission housing by the notches in theirexterior discs.

The multiple disc brake B1

B1 brakes the small sun wheel of the dualplanetary gear set. It is closed in gears 2 to6 and is controlled by the Solenoid Valve 10,N283.

The multiple disc brake B2

B2 brakes the planetary carriers of the dualplanetary gear set. It is controlled without asolenoid valve using the selector lever viathe manual slider. It is closed in Reverseand, in the Tiptronic mode, in 1st gear.


20

89K303_041

ExteriorDiscs

89K303_040

89K303_039

InteriorDiscs

89K303_038

21

The Free-Wheel

The free-wheel connects the planetary carri-ers of the dual planetary gear set with thetransmission housing.

Free-wheeling works in "D"- 1st gear and"S" - 1st gear, "tension" in the lockingdirection. In Tiptronic mode, 1st gear "thrust"secures free-wheeling of the multiple discbrake B2. This permits "engine braking".

If the exterior ring turns clockwise when theinterior ring is braked, the bodies stand upand form a torsion-free connection betweenthe interior and exterior rings.

Free-wheeling is "locked". If the turningdirection switches to counterclockwise, thisconnection breaks down.


89K303_044

Exterior Ring

Interior Ring

89K303_043

Free

Locked

89K303_042

The Parking Lock

The parking lock mechanically secures thevehicle from rolling away. It is activated pure-ly mechanically using the selector lever cablewhen the vehicle is at a standstill.

It engages in the parking lock wheel on thedriveshaft and prevents turning of the drive-shaft and the vehicle wheels.

The clamp pushes the parking lock in thegear teeth of the parking lock wheel andsecures it.


22

89K303_046

Selector LeverCable Connection

Connecting Rodsfor Parking Lock

Connecting Rodsfor Parking Lock

Parking Lock Clamp

Selector Shaft Parking Lock Wheel 89K303_045

23

Hillholder Function

The hill-holder function secures the vehiclefrom rolling back and permits hills to beapproached comfortably.

How it works

If the Transmission Control Module detectsan incline due to the driving resistance whilesimultaneously detecting a driving speed of"zero", it switches into 2nd gear.

In 2nd gear, the vehicle cannot roll backbecause the internal gear of the dual plane-tary gear set would have to turn in reverseagainst the locking free-wheel.

Free-wheeling is released and the vehiclestarts comfortably only after the startingtorque is greater than the slope descendingforce.


Assignment table

The following table shows in which gear the individual multi-disc clutches and multiple discbrakes are closed.

89K303_047

*Engine braking

The braking force of the engine in particular driving situations - such as steepdownhills - can be taken advantage of by applying the 1st gear in Tiptronic mode.

The multiple disc brake B2 is closed in 1st gear only in Tiptronic mode.

Emergency Running Mode

If normal operation of the automatic trans-mission is no longer possible, the automatictransmission operates in emergency runningmode.

In emergency mode, the Torque ConverterClutch (TCC) is no longer closed and thetransmission is in 3rd gear for all forwarddriving conditions.

When the selector lever is switched to the"R" position, the manual slider is shifted, andReverse gear is applied.

The emergency running mode is indicated bythe display in the dash panel insert.

The failure of certain components will notlead to emergency running mode activation.For example, if the Tiptronic Switch fails, theTiptronic functions will simply be unavailable.

However, if a solenoid valve fails, the trans-mission may enter emergency running modeto protect its internal parts.


24

Manual Slider

89K303_048

25

Power Flow in the Touareg

The torque of the engine is transferred tothe automatic transmission by the torqueconverter.

The engine torque is transferred from thedriveshaft of the transmission to the transfercase. In the transfer case, the torque is dis-tributed between the front and rear axles,depending on the load.

The transfer case can be locked. This fixesthe torque distribution between the frontand rear axles. Each axle receives 50% ofthe torque.

In addition, there is a switchable reduction inthe transfer case. If this is activated, thedrive speed of the wheels is reduced by afactor of 2.7, increasing the drive torque.

From the transfer case, the torque istransferred between the front and rearaxles using drive shafts.

An electro-mechanical multi-disc clutch inthe transfer case can be activated, lockingthe rear axle differential to the transfer case.


EngineFront Axle Drive

AutomaticTransmission Transfer

Case

Rear Axle Drive

89K303_049

Electrical Components

26

Sensor for TransmissionRPM G182

Sender for TransmissionOutput RPM G195

Multi-function TransmissionRange (TR) Switch F125

Transmission FluidTemperature Sensor G93

Tiptronic Switch F189

Senders -1- and -2- forHydraulic Pressure,

Automatic TransmissionG193, G194

Data Link Connector

Transmission Control Module J217

System Overview

27


1

23 4 5

6

780 0

km/h20

30

4050

7080 90

60100

110120

130

140

160

180170

150

23 : 54 23 : 5423 : 54

Solenoid ValvesN88, N89


Solenoid ValvesN90, N91, N92,N93, N282, N283

Engine Control Module J623

Differential Lock Control Module J647

ABS Control Module (w/EDL) J104

Control Module with Indicator Unit in Instrument Panel Insert J285

CAN Data Bus

89K303_050

The Sensor for Transmission

RPM G182

The Sensor for Transmission RPM G182 islocated within the transmission. It is insertedin the housing of the ATF pump and uses aring gear on the turbine shaft to determinethe transmission input speed. It worksaccording to the Hall principle.

Signal Utilization

The Transmission Control Module uses thesignal to detect the difference between theengine speed and the transmission inputspeed.

Using this speed difference, the slip of theconverter bypass coupling is controlled up toa speed of 2000 rpm by the Solenoid Valve N91.

Effect of Signal Failure

The Torque Converter Clutch (TCC) is closedwithout slip.

The engine speed is used as the replace-ment speed.


28

89K303_052

Sensor for Transmission RPM G182

89K303_051

Sensors

29

Electric Circuit

G182 - Sensor for Transmission RPM

J217 - Transmission Control Module


Sensor for TransmissionRPM G182

Turbine Shaft

Ring Gear on Turbine Shaft 89K303_054

+

89K303_053

The Sender for Transmission Output

RPM G195

The Sender for Transmission Output RPM,G195 is located above the valve body and isscrewed onto the transmission housing.It determines the working speed of theautomatic transmission by scanning theouter teeth of the internal gear on the rearplanetary gear set. It works according to theHall principle.

Signal Utilization

The Transmission Control Module uses thetransmission output speed and a shift pro-gram to determine when gear shifts occur.


The speed signal of the ABS control moduleis used as the replacement speed.


30

89K303_055

31

Electric Circuit

G195 - Sender for Transmission OutputRPM G195



Sender for TransmissionOutput RPM G195

89K303_057

+

89K303_056

The Multifunction Transmission

Range (TR) Switch F125

The Multifunction Transmission Range (TR)Switch F125 is mounted on the exterior ofthe transmission. Its duty is to transfer theselector lever settings to the TransmissionControl Module.

The multifunction switch is connected withthe selector shaft and the selector levercable. If the multifunction switch is replaced,it must be indexed to the selector shaft. Ifthe switch is incorrectly set, the engine can-not be started.

Signal Utilization

The Transmission Control Module will use ashift program depending on the position ofthe multifunction switch.


As long as the difference between forwardand reverse gears can be determined, thereare no effects on the shift programs.

If the Reverse gear signal is defective, thetransmission enters the emergency runningmode.


32

89K303_058

33

Electric Circuit

F41 - Back-Up Switch

F125 - Multifunction Transmission Range(TR) Switch


J518 - Access/Start Control Module


Lever for Manual Slider Connection for Selector Lever Cable(lever/selector shaft)

Multi-function Transmission Range (TR) Switch F125

Selector Shaft

89K303_060

89K303_059

Transmission Fluid Temperature

Sensor G93

G93 is located in the valve body within theATF. It checks the ATF temperature andreports this to the Transmission ControlModule.

It is an NTC thermistor (NTC - negative tem-perature coefficient), i.e. the electrical resis-tance of the sender drops with increasingtemperature.

Signal Utilization

Starting at an ATF temperature of 302 ºF(150 ºC), the Torque Converter Clutch (TCC)is closed more frequently.

If this does not result in cooling of the ATF,reduction of the engine torque is initiatedstarting at 338 ºF (170 ºC).


Harder gear shifts may occur.


34

89K303_062

40

105

0-40 80 120 160

104

103

102

101

Example of an NTC Thermistor Characteristic Curve

Temperature ºC

Res

ista

nce

89K303_061

35

Electric Circuit

G93 - Transmission Fluid TemperatureSensor



Transmission FluidTemperature Sensor G93

89K303_064

89K303_063

Sender -1- G193 and Sender -2-

G194 for Hydraulic Pressure,

Automatic Transmission

G193 and G194 have the same design andare located in the valve body. They monitorthe ATF pressure behind the safety slides inthe valve body. This prevents brakes andclutches from applying incorrectly, possiblybinding the internal transmission compo-nents. They function as diaphragm pressuresenders.

If the ATF pressure reaches a critical value,the pressure membranes are bent, closingthe electrical circuit.

Signal Utilization

The signals are used to monitor the ATFpressure being delivered throughout thetransmission.

If the ATF pressure is incorrect, the clutchesare not activated.


Incorrect pressure signals can affect the shiftprograms of the Transmission ControlModule.


36

89K303_066

Electrical Connection

PressureMembrane

Oil Pressure89K303_065

37

Electric Circuit

G193 - Sender -1- for Hydraulic Pressure,Automatic Transmission

G194 - Sender -2- for Hydraulic Pressure,Automatic Transmission



Sender -1- for Hydraulic Pressure,Automatic Transmission G193

Sender -2- for Hydraulic Pressure,Automatic Transmission G194

89K303_068

89K303_067

Tiptronic Switch F189

The Tiptronic Switch F189 is located underthe selector lever covering on the plate. Aferromagnetic "contact maker" is attached toeach cover of the selector lever.

The combination of the contact maker onblind 2 and the three Hall sensors on theplate form the Tiptronic Switch F189. WhenCovers 1 and 2 are moved, the contact mak-ers change their position under the plate. Inthis way, a different Hall sensor is alwaysactivated - "switched" - and sends a signalto the Transmission Control Module.

Signal Utilization

In the Tiptronic channel, tipping "to the front"results in moving up a gear and tipping "tothe back" results in moving down a gear bythe control module for the automatic trans-mission.


38

"+" Move Up a Gear

"-" Move Down a Gear

Tiptronic Channel 89K303_009

39


If the signal drops out, the Tiptronic functionusing the selector lever can no longer beused.

Electric Circuit

F189 - Tiptronic Switch


J519 - Vehicle Electrical System ControlModule


Cover 1Cover 2

Plate

Hall Sensor

Selector Lever Cover

Contact Maker

89K303_071

89K303_070

Solenoid Valves

Solenoid valves are used as electrohydraulicswitching elements in the electronically con-trolled automatic transmission.

There are switching solenoid valves (yes/novalves) and control solenoid valves (modula-tion valves).


The Solenoid Valve 1, N88, works as ayes/no solenoid valve, opening or closing anATF channel. If the solenoid valve is open,the gears 4 to 6 can be activated.

The solenoid valve also improves the switch-ing transition from 5th to 6th gear.

If no current is supplied, the solenoid valveis closed.


The gears 4 to 6 can no longer be activated.

Electric Circuit


N88 - Solenoid Valve 1


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Actuators

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The Solenoid Valve 2, N89, is located in thevalve body. It works as a yes/no solenoidvalve, opening or closing an ATF channel.When the solenoid valve is opened, the ATFpressure on the TCC is increased.

If the Solenoid Valves N88 and N89 areopened simultaneously, the brake B2 closesso that the "engine brake" is effective inTiptronic mode, 1st gear.

If no current is supplied, the valve is closed.


If the signal to the Solenoid Valve 2 N89drops out, the maximum ATF pressure can-not be applied to the Torque ConverterClutch (TCC).

The "engine brake" feature will not function.

Electric Circuit





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The Solenoid Valve 3, N90, is located in thevalve body. It is a modulation valve that con-trols the ATF pressure to the multi-discclutch K1.

If no current is applied, the solenoid valveis closed.

In this switching state, the maximum ATFpressure is applied to the clutch.


If the solenoid valve is defective or if it can-not be activated, shifting of gears 1 to 4 maybe harsh.

Electric Circuit




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The Solenoid Valve 4, N91 is located in thevalve body. It is a modulation valve that con-trols the ATF pressure on the TorqueConverter Clutch (TCC).

If no current is applied, the Torque ConverterClutch (TCC) is open.


The TCC is open.

Electric Circuit





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The Solenoid Valve 5, N92, is integrated inthe valve body. It is a modulation valve thatcontrols the ATF pressure to the multi-discclutch K3.

If no current is applied, the solenoid valve isclosed.

In this switching state, the maximum ATFpressure is applied to the clutch.


If the solenoid valve is defective or if there isa fault in the circuit, shifting of gears 3, 5and R may be harsh.

Electric Circuit




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The Solenoid Valve 6, N93, is located in thevalve body. It is a modulation valve that con-trols the main ATF pressure in the transmis-sion, depending on the engine torque.

If no current is applied, the solenoid valve isclosed. The transmission will operate withthe maximum ATF pressure.


If the solenoid valve is defective or if there isa fault in the circuit, shifting of all gears maybe harsh.

Electric Circuit





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N282 is located in the valve body. It is amodulation valve that controls the ATFpressure to the multi-disc clutch K2.

If no current is applied, the solenoid valve isclosed.

In this switching state, the clutch is closedwith the maximum pressure.


If the solenoid valve is defective or if there isa fault in the circuit, shifting of gears 4 to 6may be harsh.

Electric Circuit




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The Solenoid Valve 10, N283, is located inthe valve body. It is a modulation valve thatcontrols the ATF pressure to the multiple-disc brake B1.

The solenoid valve closes depending on thecurrent strength.

If no current is applied, the brake is closedwith the maximum ATF pressure.


If the solenoid valve is defective or if there isa fault in the circuit, shifting of gears 2 and 6may be harsh.

Electric Circuit





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Shift Lock Solenoid, N110

The Shift Lock Solenoid N110 is located inthe selector lever frame. It is an electromag-net that prevents the selector lever frommoving out of the "P" position when the igni-tion is switched on.

To move the selector lever, the foot brakemust be pressed.

If the ignition is switched on, theTransmission Control Module suppliesthe magnet with power. The magnet blocksthe selector lever from moving.

If the foot brake is pressed, the control unitswitches off the power to the magnet sothat the selector lever can be moved.


If the solenoid valve is defective or if there isa fault in the circuit, the selector lever can bemoved without having to press the footbrake.

Electric Circuit


N110 - Shift Lock Solenoid


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Magnet for Shift LockSolenoid N110

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Diagnostics

For vehicle diagnostics, measurement andinformation systems VAS 5051 and VAS5052, the operating modes "Guided fault-finding" and "Vehicle self-diagnosis" areavailable

The operating mode Guided fault-finding"carries out a vehicle-specific check of allinstalled control units for trouble codes andautomatically compiles an individual test planfrom the results.

Together with the ELSA information, such aswiring diagrams or repair guidelines, this pro-vides a specific target for trouble-shooting.

Independent of this, you can compile yourown test plan.

The function and component selection incor-porates the tests that you select into thetest plan; these can be processed in thediagnostics procedure in any order.

Self-Diagnosis

VAS 5051

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+ -

VAS 5052 89K303_090

Components

F125 - Multi-Function Transmission Range(TR) Switch

F189 - Tiptronic Switch F319 - Selector Lever Park Position SwitchG93 - Transmission Fluid Temperature

SensorG182 - Sensor for Transmission RPMG193 - Sender 1 for Hydraulic Pressure,

Automatic TransmissionG194 - Sender 2 for Hydraulic Pressure,

Automatic TransmissionG195 - Sender for Transmission Output

RPM J217 - Transmission Control ModuleJ527 - Steering Column Electronic Systems

Control ModuleN88 - Solenoid Valve 1N89 - Solenoid Valve 2N90 - Solenoid Valve 3N91 - Solenoid Valve 4N92 - Solenoid Valve 5N93 - Solenoid Valve 6N110 - Shift Lock SolenoidN282 - Solenoid Valve 9N283 - Solenoid Valve 10N380 - Selector Lever Park Position Solenoid

Additional signals

F41 - Back-Up SwitchJ518 - Access/Start Control ModuleJ519 - Vehicle Electrical System Control

Module1 Self-diagnosis2 CAN data bus high3 CAN data bus low

Functional Diagram

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a

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Functional Diagram

+ +

p p

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New Tools

Setting gauge for multifunction switchT10173

This is required to set the multifunctionswitch when repairs are completed.

Pressure piece T10174

This is required to press a seal on the shaftfor the multifunction switch.

Pressure piece T10180

This is required to press a seal on the driveshaft.

Sleeve T10186

This must be placed on the serration of thedrive shaft before the gasket is installed toprevent damage during installation of thegasket.

Special Tools

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Notes

Notes

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Knowledge Assessment

An on-line Knowledge Assessment (exam) is available for this Self-Study Program.

The Knowledge Assessment may or may not be required for Certification. You can find thisKnowledge Assessment in the Learning Management Center at:

www.vwwebsource.com

For assistance, please call:

Certification Program Headquarters

1-877-CU4-CERT (1-877-284-2378)

(8:00 a.m. to 8:00 p.m. EST)

Or email: [email protected]

Volkswagen of America, Inc.3800 Hamlin RoadAuburn Hills, MI 48326Printed in U.S.A.March 2003

89k303 six-speed automatic transmission 09d.pdf

Documents

selector lever lock

transmission overview

selector lever tiptronic

selector lever positions

speedautomatic transmission

transmission rpm g182

technical dataselector

parking lock