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Details service intervals and fluid change requirements for the transaxle.
Step-by-step instructions for checking the ATF level using diagnostic tools.
Step-by-step guide for draining and refilling the automatic transmission fluid.
Crucial safety warnings before and during valve body removal.
Step-by-step guide for removing and reinstalling the valve body assembly.
This document provides comprehensive servicing instructions for the automatic transmission (A/T) of the 2003 Volkswagen EuroVan MV, specifically focusing on the 01P transaxle model. It covers essential maintenance procedures, including fluid level checks, lubrication, draining and refilling, and adjustments for the selector lever cable and valve body assembly.
The primary function of this manual is to guide technicians through the proper servicing of the EuroVan's automatic transmission, ensuring its optimal performance and longevity. It emphasizes the importance of correct fluid levels, specific fluid types, and precise torque specifications for various components.
The manual outlines a detailed procedure for checking ATF (Automatic Transmission Fluid) levels. It highlights that the VW ATF (G 052 162 A2) is light yellow in color. A crucial note is provided regarding the replacement of the seal on the level plug every time the ATF level is checked. Specialized tools, such as the VAG Scan Tool (1551) and Diagnosis Cable (1551/1), are required to measure ATF temperature accurately. Before checking the ATF level, several prerequisites must be met: all fuses must be in good condition, battery voltage must be at least 11.5 volts, ground connections on the engine, transaxle, and body must be secure, and all electrical components must be switched off. The transaxle ATF temperature should not exceed 86°F (30°C) at the start of the test. The vehicle must be on a level surface, and the selector lever must be in the "P" (Park) position.
The procedure involves connecting the VAG 1924 ATF filling system and the VAS 5051 diagnostic system. Technicians are instructed to select "08 - read measured value blocks" and then display group 005 to monitor the ATF temperature. The initial ATF temperature must not be more than 86°F (30°C). The manual then details the use of the VAG Scan Tool (1551) to measure ATF temperature, guiding users through selecting "02 Transmission electronics" and then "Select function XX." After confirming the selection of "Read measured value block" (08) and "Display group number 005," the engine is started, and the vehicle is raised and supported. A drip tray is placed under the transaxle. The ATF is brought to a test temperature of 95-113°F (35-45°C). The ATF level plug (A) is then removed from the oil pan. If ATF drips out of the hole, no top-off is needed. A new seal (1) is installed, and the level plug is tightened to 11 ft. lbs. (15 N.m). If only the ATF from the overflow pipe runs out, the ATF needs to be topped off.
To top off the ATF, the plug securing cap (arrow) is pried off with a screwdriver. The manual notes that the securing cap locking device will be destroyed during this process, necessitating its replacement. The plug is pulled out of the filler pipe. Some transaxles may have a cap with a spring retainer, which can be reused. A critical warning is given that both insufficient and excessive amounts of ATF will negatively affect the transaxle's function. The transaxle is filled with ATF using the VAG 1924 ATF filling system until fluid runs out of the level hole. A new seal (1) is installed, and the level plug is tightened to 11 ft. lbs. (15 N.m). The sealing plug (3) is installed on the filler pipe until the spring retainer lock engages, or a new cap is installed to secure the plug.
For the final drive, fluid level checks are recommended at 40,000-mile intervals. The fluid is filled for life, meaning no changing is required. The procedure involves raising and supporting the vehicle and removing the filler plug on the side of the final drive. The gear oil level should be at the lower edge of the hole. If fluid is needed, G 50, SAE 75W-90 synthetic gear oil (G 052 145 S2) is added. The filler plug is then installed and tightened to 15 ft. lbs. (20 N.m).
The manual also provides fluid capacities: for the 01P transaxle, the refill capacity is 3.2 quarts (3.0 liters), and the dry-fill capacity is 5.6 quarts (5.3 liters) of VW ATF (G 052 162 A2). The final drive capacity for the 01P is 0.8 quarts (0.75 liters) of G 50, SAE 75W-90 (G 052 145 S2) synthetic oil.
The draining and refilling procedure for the transaxle involves raising and supporting the vehicle, placing a drip tray underneath, and removing the ATF level plug from the oil pan. The plug seal is removed, followed by the overflow pipe, allowing the ATF to drain. The overflow pipe is then screwed back in, and the level plug is screwed in hand-tight. The transaxle is refilled with the appropriate amount of ATF through the filler pipe using the VAG 1924 ATF filling system. After filling, the engine is started, and the transaxle is shifted through all selector lever positions while the vehicle is stationary. The ATF level is then checked and topped off as described in the "CHECKING FLUID LEVELS" section. The ATF level plug is tightened to 11 ft. lbs. (15 N.m).
The manual also addresses on-vehicle repairs, noting that various components can be serviced without removing the transaxle. These procedures are detailed under "ADJUSTMENTS" and "REMOVAL & INSTALLATION."
For selector lever cable adjustments, the manual specifies that numbers in parentheses refer to illustrations. The locking washer (6) is removed from the lever/selector shaft, and the cable is detached from the lever. The selector lever is moved from "P" to "1" position, and both the selector lever mechanism and cable must move freely. If not, they should be replaced. The locking washer must always be replaced after disassembly. To adjust the cable, the selector lever is placed in "P" position. The adjustment bolt (2) on the selector lever in the housing is loosened. The selector shaft lever is placed in "P" position on the transaxle, ensuring the locking lever engages the park lock wheel and both front wheels are locked. The adjustment bolt is then tightened to 15 ft. lbs. (20 N.m).
The locking cable adjustment requires the selector lever to be in "P" position and the ignition key turned to the end (ignition off). The locking cable nuts (1) and (2) at the frame are loosened. The locking lever (arrow) is pushed until it touches the selector lever, and the locking cable is secured in this position on the frame. After adjustment, proper ignition key operation must be verified.
For locking cable removal and installation, a caution is issued regarding battery disconnection: vehicle computer and memory systems may lose data, potentially causing driveability problems until relearn cycles are completed. The radio/cassette or radio/CD player is equipped with an anti-theft protection circuit, which will activate if the battery is disconnected. The radio will display "CODE" and remain inoperative until the correct code is entered, so the security code must be obtained beforehand. The selector lever is placed in "P" position, the negative battery cable is disconnected, and the selector lever handle, trim, cover, cover strips, and console are removed. The locking cable is removed from the frame and the locking lever ball head. The ignition switch trim is removed, and the locking cable clip (4) is pressed out of the ignition switch support. The locking cable (2) is removed from the ball head. The footwell vent console is removed, and the locking cable is taken out. Installation is the reverse of removal, ensuring proper routing and subsequent adjustment of the locking cable.
The valve body assembly removal and installation procedure includes a warning against running the engine or towing the vehicle with the oil pan removed or without ATF in the transaxle. Code letters stamped on a metal tab on the valve body are for identification and must remain with the valve body. A container is placed under the transaxle, and the level plug (1) and its seal are removed, followed by the overflow pipe (2), to drain the ATF. The overflow pipe is then screwed back in. The oil pan bolts, oil pan, gasket, and AFT screen are removed. To remove the conductor strip, a pry bar (3373) is used to pull the plug off the solenoid valve plug in the direction of the arrow, and bolt (1) is removed.
A critical note for valve body removal states that the manual selector valve (1) remains in the valve body and that manual selector valves of different valve bodies should not be interchanged. The valve body bolts and valve body are removed. The selector lever/shaft is shifted to "1" position, and the manual selector valve is pulled out just enough to unhook the operating rod (2). The manual selector valve is secured to prevent it from falling out. The steel spring and bolt for the manual selector valve must always be replaced. The steel spring (arrow) and lever are removed from the selector shaft in the transaxle. The steel spring and bolt are installed to the selector shaft but not tightened yet. The installation direction of the sealing plug is noted. The sealing plug is pulled out of the housing before removing and installing the free wheel to avoid damaging the sealing plug and "O" ring. Two new "O" rings are moistened with ATF and installed on the sealing plug, which is then inserted into the hole in the transaxle housing (arrow).
To adjust the operating rod for the manual selector valve, the selector shaft is moved to "P" position. The operating rod (2) with the manual selector valve (1) is pushed into the valve body onto the stop (direction of arrow), and bolt (3) is tightened to 35 INCH lbs. (4 N.m). The selector valve must be resting against the stop, and the bolt must be counter-held during tightening. The bolt and manual selector valve retaining clip must always be replaced. The valve body and bolts are installed, with bolts tightened to 44 INCH lbs. (5 N.m). The conductor strip is routed as shown, ensuring it is not kinked or twisted. Before installing the ATF screen, the seal is inserted into the valve body, and the ATF screen is firmly pressed onto the valve body. The oil pan, gasket, and bolts are installed, with bolts tightened to 106 INCH lbs. (12 N.m).
Torque specifications are provided for various components: Final Drive Filler Plug (15 ft. lbs. / 20 N.m), Selector Lever Cable Adjustment Bolt (15 ft. lbs. / 20 N.m), ATF Level Plug (133 INCH lbs. / 15 N.m), Oil Pan Bolt (106 INCH lbs. / 12 N.m), and Valve Body Bolt (44 INCH lbs. / 5 N.m).
General| Type | Automatic Transmission |
|---|---|
| Manufacturer | Volkswagen |
| Gears | 4 |
| Transmission Type | Automatic |
| Model Number | 01P |
| Drive Wheels | Front-Wheel Drive |
| Product Type | Automatic Transmission |
| Compatible Vehicles | Volkswagen Golf, Jetta, Passat |
