General Repair Information

General Repair Information, 01J, CVT A/T FWD:

Transmission
^ Observe rules for cleanliness when working on the transmission.
^ Do not run engine with the end cover removed or without sufficient ATF and do not tow vehicle.
^ Install only clean components: Unpack replacement parts immediately prior to installation.
^ After installation the transmission, check fluid level, fill if necessary.

O-rings, gaskets, seals
^ Always replace O-rings, gaskets and sealing rings.
^ After removing gaskets and seals, always inspect the contact surfaces at housing or shaft for burrs resulting from removal or for other signs of damage.
^ Thoroughly clean housing joint surfaces before assembling.
^ Lightly lubricate the outside surface and sealing lip of oil seals with ATF before installing.
^ Lightly lubricate O-rings with ATF before inserting to prevent them being trapped and damaged when assembling.
^ Use only ATF in the parts of the transmission where ATF is the specified lubricant. Other lubricating substances cause functional problems in the hydraulic transmission module.
^ The open side of the oil seals face toward the fluid to be sealed in.
^ When pressing in new seals, 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 installation, check fluid level, fill if necessary: ATF in planetary gear, gear oil in front final drive. Filling quantities and specifications go to Capacities.

Nuts, bolts
^ Loosen the bolts in reverse sequence to the specified tightening sequence.
^ Nuts and bolts which secure covers and housings should be tightened in stages according to the specified sequence and tightening method.
^ Nuts and bolts which secure covers and housings should be loosened and tightened diagonally in stages if no tightening sequence is specified.
^ The tightening torques stated apply to non-oiled nuts and bolts.
^ Always replace self-locking nuts and bolts.
^ Using a wire brush, clean threads of bolts which are secured with locking compound. Then insert bolts with locking fluid AMV 185 101 A1.
^ Threaded holes into which self-locking bolts or bolts coated with locking fluid are threaded in, must be cleaned (e.g. using threaded tap). Otherwise there is the danger that the bolts may shear when removed.

Circlips
^ Do not over-stretch circlips.
^ Always replace damaged or over-stretched circlips.
^ Circlips must be fully seated in groove.

Bearings
^ Install needle bearings with the lettering on the bearing (the side with thicker metal) facing the drift.
^ Lubricate bearings with gear oil or ATF, depending on installation location.
^ Do not interchange inner and outer bearing races with those from other bearings of the same size.
^ Always replace tapered roller bearings on one shaft together and use new bearings from the same manufacturer.

Shims
^ Use a micrometer to measure the shims at several points. Different tolerances make it possible to obtain the exact shim thickness required.
^ Check for burrs and signs of damage. Install shims which are in perfect conditions.

Guided Fault Finding
Always perform Guided Fault Finding using the Diagnostic Operation System VAS 5051 A before starting disassembly and assembly work.