Volkswagen Jetta Hybrid 2013 Workshop Manual Download Page 3

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Contents

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

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1

Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2

Calculation of gear ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4

Overview - power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1

General safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2

Safety precautions when working on vehicles with high-voltage system . . . . . . . . . . . . . .

3.3

Safety precautions during road tests in which test and measuring equipment is used . . . .

3.4

Safety precautions when working on mechatronic unit for dual clutch gearbox J743 . . . .

3.5

Notes on tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4.1

General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4.2

Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.3

General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.1

Assembly overview - dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.2

Removing and installing the dual clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.3

Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.4

Renewing seal for inner input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.1

Assembly overview - clutch engagement mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.2

Removing and installing clutch engagement mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.3

Adjusting clutch engagement mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

1.1

Assembly overview - selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

1.2

Emergency release from position P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

1.3

Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1.4

Moving push-button to installation position in the handle . . . . . . . . . . . . . . . . . . . . . . . . . . 49

1.5

Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

1.6

Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

1.7

Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

1.8

Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

2.1

Removing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

2.2

Installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

2.3

Specified torques for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Installing to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

5.1

Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

6.1

Draining and filling gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Mechatronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Jetta Hybrid 2013 ➤

7-speed dual clutch gearbox 0CG - Edition 08.2012

Contents

Summary of Contents for Jetta Hybrid 2013

Page 1: ...ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n...

Page 2: ...al Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups Repair Group 00 Technical data 30 Clutch 34 Controls housing 35 Gears shafts 39 Final drive differential Tech...

Page 3: ...ness 11 4 3 General repair notes 11 30 Clutch 14 1 Clutch 14 1 1 Assembly overview dual clutch 14 1 2 Removing and installing the dual clutch 16 1 3 Renewing input shaft seal 23 1 4 Renewing seal for...

Page 4: ...o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 7 1 Overview mechatronic unit 92 7 2 Removing and installing mechatronic unit 94 7 3 Setting mechatronic unit to removal position by hand 1...

Page 5: ...e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 00 Technical data 1 Identification VRL004662 Edition 08 2012 1 1 Gearbox identification page...

Page 6: ...gearbox 0CG Gearbox Identification code NDR Allocation Model Jetta 2011 Engine 1 4 l TSI 110 kW Ratios Final drive I for 1st to 4th gear 71 16 4 438 Z2 Z1 Final drive II for 5th and 6th gear 71 22 3...

Page 7: ...or the 7 speed dual clutch gearbox 0CG which is available through the replacement parts system must be used Electronic parts catalogue ET KA Other oils will lead to malfunctions or failure of the gear...

Page 8: ...a g e n A G 2 4 Overview power transmission 2 4 1 Overview power transmission front wheel drive page 4 2 4 1 Overview power transmission front wheel drive The 7 speed dual clutch gearbox 0CG is confi...

Page 9: ...or lever into position P and apply parking brake Please note the following to avoid personal injury and damage to or destruction of electrical and electronic components Connect and disconnect measurin...

Page 10: ...nician before any work is done on the high voltage system and before any repair work is done on the body The types of work for which this is necessary are indicated in the table Work for which the hig...

Page 11: ...n which test and measuring equipment is used Please note the following if test and measuring equipment is re quired during a road test WARNING Accident hazard as a result of distraction and inadequate...

Page 12: ...The mechatronic unit for dual clutch gearbox J743 has a pressure accumulator that maintains a system pressure of up to 60 bar The cover of the mechatronic unit for dual clutch gearbox J743 and the pr...

Page 13: ...c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 3 5 Notes on tow starting towing Caution Danger of irreparable damage to gearbox If the...

Page 14: ...gearbox Through opposed hydraulic actuation of two multi plate dry clutches it is operated like an automatic gearbox In other words the gears are engaged automatically or manually via the Tiptronic sy...

Page 15: ...int free cloths for cleaning Seal open lines and connections immediately using suitable and only new sealing plugs Allocate sealing plugs according to Electronic parts catalogue ETKA Place removed par...

Page 16: ...resulting from removal or for other signs of damage Thoroughly clean housing joint surfaces before assembly Lightly lubricate outer circumference and sealing lip of oil seals with gearbox oil before i...

Page 17: ...switched on You cannot generate any faults using this function Please al ways perform the Adapt installation information function after the following activities Following installation of a gear selec...

Page 18: ...dual clutch Caution Risk of damage from clutch adjustment device The clutch is self adjusting Shocks can have an effect on this adjusting device Do not allow clutch to fall into gear box during instal...

Page 19: ...per section of guide sleeve Small small engaging lever K 2 Is removed and installed together with small engaging lever and lower section of guide sleeve 12 Small engaging lever for K 2 Is removed and...

Page 20: ...n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 2 Removing and installing the dual clutch Special tools and workshop equipment required Ho...

Page 21: ...fluid has escaped it must be replenished through the breather connection of the mechatronic unit if necessary For allocation of the sealing plugs hydraulic fluid and filling equipment refer to Electr...

Page 22: ...alogue ET KA Note Breather 2 and breather cap 1 form one replacement part and are fitted together onto breather connection 3 Once the gearbox has been installed in the vehicle the sealing plugs must b...

Page 23: ...bottom In this case push the clutch down slightly see following de scription and release the load on the retaining ring Never strike the clutch or shaft with a hammer Position support bracket T10323...

Page 24: ...the following tasks Clutch has been renewed Engaging levers were renewed Small ball pin for engaging lever K 2 has been renewed Engagement bearings were renewed If you have performed any of the above...

Page 25: ...Bolts A secure with nut as required Press on clutch as far as it will go Note Place a hand on the clutch when pressing it on A slight rattling will be felt Rattling indicates that the clutch is being...

Page 26: ...y V o l k s w a g e n A G Note By pressing on the clutch sits at the bottom against the limit stop on the input shaft This is not the optimum position Clutch should only be pulled up far enough for it...

Page 27: ...roperly seated and undamaged page 20 A mathematical error could have been made Check meas urements again page 32 If no fault can be found the clutch may have been moved out of position due to transpor...

Page 28: ...n t C o p y r i g h t b y V o l k s w a g e n A G Tube VW 415 A Puller hooks T20143 2 Sealing grease G 052 128 A1 Procedure Dual clutch is removed page 16 Clutch engagement mechanism is removed page 2...

Page 29: ...eal Caution Risk of damaging the clutch Only drive in oil seal until it is flush in order to avoid closing off oil drilling located behind it Otherwise bearing can no longer be supplied with enough oi...

Page 30: ...oved page 29 Caution Risk of damage to clutch and other components Renew dual clutch if it is oily Note There are 2 oil seals in gearbox at clutch end Both oil seals can be renewed without gearbox bei...

Page 31: ...oesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e...

Page 32: ...tch engagement mecha nism page 32 2 Large engaging lever for K 1 With engagement bear ing Removing and installing 2 2 Removing and in stalling clutch engage ment mechanism page 29 3 Hinge mounting For...

Page 33: ...mall small engaging lever K 2 Is removed and installed together with small engaging lever and upper section of guide sleeve 2 2 Removing and installing clutch engage ment mechanism Removing Dual clutc...

Page 34: ...it is worn page 34 Installing Install in reverse order of removal observing the following WARNING The position of the engagement bearings K 1 and K 2 must only be adjusted after the following work Du...

Page 35: ...nsport position illustration and must be set to installation position prior to installation Setting engaging lever K2 to installation position Hold upper section of guide sleeve with one hand With the...

Page 36: ...e engagement bearing with the hemispherical side of the shim facing downwards The small shim goes under the small engagement bearing Therefore insert shim first The shim and the small engagement beari...

Page 37: ...re tolerances in the engagement system of the gearbox and in the gearbox itself Even within the dual clutch there are tolerances These tolerances must be taken into ac count separately during adjustme...

Page 38: ...echanism page 28 Caution Risk of damage to clutch and other components Mounting for engaging lever and entire mechanism of en gagement bearing must be dry and free of oil or grease If ball pin is worn...

Page 39: ...p Determine dimension B for clutch K 1 and K 2 Place ruler T40100 upwards across end of shaft onto gear box flange Caution Risk of false measurements The ruler T40100 should remain in this position fo...

Page 40: ...ne dimension B2 to retaining ring Note Do not measure on retaining ring joint The retaining ring could be pushed away and falsify the reading Example dimension B2 2 58 mm Calculate mean value from dim...

Page 41: ...engagement bearing Flat side faces upwards To ensure that gauge block T10466 sits properly on engage ment bearing press down and turn gauge block Engagement bearing will turn with gauge block T10466...

Page 42: ...ension B the height tolerance of the engagement bearing for clutch K 1 is now cal culated according to the following calculus Dimension A 1 Dimension B Actual height tolerance of clutch engagement bea...

Page 43: ...allation Calculated thick ness of shim mm Available shims Thickness in mm Part number of shim 1 21 1 60 1 50 0AM 141 383 1 61 1 80 1 70 0AM 141 383 A 1 81 2 00 1 90 0AM 141 383 B 2 01 2 20 2 10 0AM 14...

Page 44: ...ne It is always removed or installed together with lower section of guide sleeve and small engaging lever Observe the following when installing a new engaging lever K 2 The new engaging lever K2 with...

Page 45: ...in installation position the holes of the lower section of guide sleeve are at right angles to the engaging lever and the sleeve moves freely Continuation for all Install small engaging lever togethe...

Page 46: ...block T10466 sits properly on engage ment bearing press down and turn gauge block Engagement bearing will turn with gauge block T10466 Place digital 300 mm depth gauge VAS 6594 on top of ruler and pos...

Page 47: ...on B the height tolerance of the engagement bearing for clutch K 2 is now cal culated according to the following calculus Dimension A 2 Dimension B Actual height tolerance of clutch engagement bearing...

Page 48: ...stallation Calculated thickness of shim mm Available shims Thickness in mm 0 31 0 90 0 80 0 91 1 10 1 00 1 11 1 30 1 20 1 31 1 50 1 40 1 51 1 70 1 60 1 71 1 90 1 80 1 91 2 10 2 00 2 11 2 30 2 20 2 31...

Page 49: ...m 1 1 Assembly overview selector mechanism page 45 1 2 Emergency release from position P page 47 1 3 Removing and installing selector lever handle page 48 1 4 Moving push button to installation positi...

Page 50: ...E313 with selec tor lever sensors control unit J587 Tiptronic switch F189 selector lever locked in position P switch F319 and se lector lever lock sole noid N110 Testing is carried out via Vehicle dia...

Page 51: ...or lever in position P The selector lever can only be shifted out of position P with ignition switched on engine running with brake pedal depressed and with selector lever button pressed page 59 If th...

Page 52: ...nism If parts of the selector mechanism are damaged the se lector mechanism must be renewed completely The solenoid releases the selector lever With solenoid released press button on selector lever ha...

Page 53: ...allation position must be re stored page 49 If the selector lever handle is installed with push button pressed the selector lever handle and the tie rod 3 of the selector mechanism will be destroyed N...

Page 54: ...ith and without installation guard Both of them are described here Place handle with installation guard in installation position When using the installation guard make sure that it has an eyelet arrow...

Page 55: ...chanism until the handle has been fitted This makes it possible to check whether the small lever engages in the tie rod when the push button is pressed 1 5 Removing and installing selector mech anism...

Page 56: ...or lever to position P position Remove selector lever handle page 48 pulling off connector 2 from cover in process Remove centre console General body repairs interior Rep gr 68 Centre console Removing...

Page 57: ...high voltage technician before any work is done on the high voltage system and before any repair work is done on the body All work on vehicles with a high voltage system must only be carried out by el...

Page 58: ...A with the selector lever cable from the gearbox To do so remove bolts arrows These bolts must be renewed Specified torque of bolts arrows Item 7 page 46 Caution Risk of damage to selector lever cabl...

Page 59: ...heat shield beneath selector mechanism Install exhaust system and align it free of stress Rep gr 26 Cleansing exhaust emissions Assembly overview cleansing exhaust emissions Attach tunnel bridges at...

Page 60: ...or lever to position P position Remove selector lever handle page 48 pulling off connector 2 from cover in process Remove centre console General body repairs interior Rep gr 68 Centre console Removing...

Page 61: ...high voltage technician before any work is done on the high voltage system and before any repair work is done on the body All work on vehicles with a high voltage system must only be carried out by el...

Page 62: ...the cable support bracket Do not use a sharp edged lever The selector lever cable could otherwise be damaged If necessary remove the cable support bracket A with the selector lever cable from the gea...

Page 63: ...le through opening in centre tunnel Have the second mechanic pull cord with Bowden cable through tunnel from engine compartment until Bowden cable can be attached to cable support bracket Remove cord...

Page 64: ...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 Selector...

Page 65: ...t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Move selector lever to position P position Vehicles with secondary air...

Page 66: ...ician before any work is done on the high voltage system and before any repair work is done on the body All work on vehicles with a high voltage system must only be carried out by electrically instruc...

Page 67: ...ism and selector lever cable glide easily when changing gear Selector lever cable not damaged Adjusting selector lever cable Loosen adjustment screw arrow for selector lever cable Shift gearbox select...

Page 68: ...ent Continue installation in reverse order of removal Install power and control electronics for electric drive JX1 Electrical system hybrid vehicles Rep gr 93 Power and control elec tronics for electr...

Page 69: ...d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 Removing and installing gearbox 2 1 Removing gearbox page 65 2 2 Installing gearbox page 69 2 3 Specified torques for gearbox page 72 2...

Page 70: ...assembly platform VAS 6131 Disconnect connector 1 from selector valve 2 of mecha tronic unit and pull wiring harness off retainer on front of gearbox Remove high voltage wiring harness for drive moto...

Page 71: ...ng In the procedure below the hydraulic system of the mecha tronic unit will be opened Soiling will cause the system to fail Unscrew union nut 1 for hydraulic line 3 from engine Then pull retaining cl...

Page 72: ...gearbox connecting bolts arrows working from engine side and using e g socket multi point bit XZN 14 T10061 Note coolant line A while doing so Press gearbox off dowel sleeves in engine Carefully pull...

Page 73: ...arbox page 73 Secure gearbox to assembly stand page 76 Installing gearbox page 69 2 2 Installing gearbox The gearbox is installed together with the engine Rep gr 10 Removing and installing engine Inst...

Page 74: ...elected properly anymore Screw guide pins T10515 into engine as shown in illustration Align gearbox with engine and push it carefully towards en gine Adjust position of gearbox using spindles of gearb...

Page 75: ...hydraulic line 3 by pulling on it Screw union nut 1 for hydraulic line on engine and tighten it to specified torque Item 6 page 92 If the gearbox has been sealed so that no oil can escape e g after a...

Page 76: ...ectric vacuum pump Install high voltage wiring harness for drive motor PX2 to gearbox Electrical system hybrid vehicles Rep gr 93 High voltage cables Removing and installing high voltage wiring harnes...

Page 77: ...ot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A...

Page 78: ...aped it must be replenished through the breather connection of the mechatronic unit if necessary For allocation of the sealing plugs hydraulic fluid and filling equipment refer to Electronic parts cat...

Page 79: ...a g e n A G Order a new breather cap arrow for mechatronic unit for dual clutch gearbox J743 because it must be renewed after the gearbox has been installed Electronic parts catalogue ET KA Note Breat...

Page 80: ...t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 Installing to engine and gearbox support Special tools and workshop equipment required S...

Page 81: ...i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Lifting gearbox into engine and gearbox support...

Page 82: ...gr 10 Assembly mountings Assembly overview assembly mountings 4 Pendulum support Removing and installing Rep gr 10 Assem bly mountings Assem bly overview assembly mountings 5 Bolt Specified torque Rep...

Page 83: ...A G 13 Engine support Removing and installing Rep gr 10 Assembly mountings Assembly overview assembly mountings 14 Bolt Specified torque Rep gr 10 Assembly mountings Assembly overview assembly mountin...

Page 84: ...pport bracket 10 222 A 2 x spindle 10 222 A 11 2 x adapters 10 222 A 28 2 x adapters 10 222 A 28 2 Adapter 10 222 A 31 Hook rail T40091 2 from engine support basic set T40091 Mounting T40093 5 from en...

Page 85: ...h voltage system Electrical system hybrid vehicles Rep gr 93 General warning instructions for work on the high voltage system The system must first be de energised by a high voltage technician before...

Page 86: ...oving and installing high voltage wiring harness for hybrid battery PX1 Unscrew bolts arrows for lock carrier bracket on left and right Unscrew lower mounts from adapter 10 222 A 28 and re place with...

Page 87: ...travel Place engine support bracket 10 222 A on suspension strut turrets and with the aid of a 2nd mechanic prevent it from tipping T40091 1 Push item 5 on left and right from front through adapter 10...

Page 88: ...ox one turn and unscrew bolts 2 Then lower engine and gearbox slightly using the spindles of engine support bracket 10 222 A At most 4 turns are sufficient to remove the gearbox console Do not lower f...

Page 89: ...rolley jack or gearbox jack Do not remove support bracket 10 222 A until the bolts securing the assembly mounting have been tightened to specified torque Pull gearbox upwards using spindle of engine s...

Page 90: ...n A G 6 Gearbox oil 6 1 Draining and filling gearbox oil page 86 6 1 Draining and filling gearbox oil Special tools and workshop equipment required Used oil collection and extraction unit V A G 1782 A...

Page 91: ...ft green area in the magnifying glass of the adapter for oil filling VAS 6262 A If dimension a is greater than 210 mm Mark dimension a on the breather pipe and shorten pipe e g with pipe cutter VAS 60...

Page 92: ...h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Vehicles with secondary air system Unclip cover for...

Page 93: ...General warning instructions for work on the high voltage system The system must first be de energised by a high voltage technician before any work is done on the high voltage system and before any r...

Page 94: ...uch oil is put in the gearbox the latter will not function correctly Caution Risk of damage to gearbox Only the gearbox oil for the 7 speed dual clutch gearbox 0CG which is available through the repla...

Page 95: ...ch to bleeder hole in gearbox Flip bottle over and fill the exact required oil capacity For oil capacities refer to page 3 After filling remove oil filling adapter VAS 6262 A Clean area around breathe...

Page 96: ...gearbox J743 on gear box housing Qty 3 M8 x 35 Renew after each re moval Specified torque and tightening sequence page 94 2 Bolt For securing mecha tronic unit for dual clutch gearbox J743 on gear bo...

Page 97: ...precautions when working on mechatronic unit for dual clutch gearbox J743 page 8 7 2 Removing and installing mechatronic unit page 94 7 3 Setting mechatronic unit to removal position by hand page 108...

Page 98: ...n A G Mechatronic unit for dual clutch gearbox J743 specified torque and tightening sequence Note Renew bolts arrows 1 and arrows 2 Tighten bolts in 4 stages as follows Stage Bolts Specified torque 1...

Page 99: ...x J743 removed or when there is no gearbox oil in the gearbox Note Observe 4 Repair instructions page 10 The clutch is self adjusting Shocks can have an effect on this adjusting device Even if the mec...

Page 100: ...risk of scalding On a warm engine the cooling system is under high pres sure Cover filler cap on expansion tank with a cloth and open it carefully to release pressure Open filler cap arrow on expansi...

Page 101: ...gh voltage system Electrical system hybrid vehicles Rep gr 93 General warning instructions for work on the high voltage system The system must first be de energised by a high voltage technician before...

Page 102: ...to fail Unscrew union nut 1 for hydraulic line 3 from engine Then pull retaining clip 2 out of valve block mechatronic unit Pull hydraulic line 3 simultaneously out of engine and valve block mechatron...

Page 103: ...x connector by hand The resulting static discharge could destroy the control unit and consequently the me chatronic unit Touch earth connection without gloves in order to discharge yourself Disconnect...

Page 104: ...f the mechatronic unit If this is not done the engaging levers will jam the mechatronic unit at the plungers and prevent the mechatronic unit from being re moved Insert assembly lever T10407 under plu...

Page 105: ...ing Caution Risk of damaging gearbox components beyond repair Do not touch or remove the mechatronic unit for dual clutch gearbox J743 until you have electrostatically dis charged yourself by touching...

Page 106: ...ion position by hand page 108 Installing The breather connection of the mechatronic unit is sealed with a sealing plug or sealing cap 0AM 325 120 A so that no oil can escape Order sealing plugs via th...

Page 107: ...t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G N Neutral position R Reverse gear 1 First gear 2 S...

Page 108: ...h t b y V o l k s w a g e n A G Adjusting gear actuator Caution Risk of damaging mechatronic unit for dual clutch gearbox J743 When levering out the plungers do not use the sensors as an anchor point...

Page 109: ...ressure and the self adjusting device of the clutch will become active Self adjustment cannot be reversed Both clutch actuators must be engaged correctly in retainers of clutch engaging levers Do not...

Page 110: ...o retainer at front of gearbox Note Check the O ring arrow on the hydraulic line for damage and renew it if necessary Refer to Electronic parts catalogue ETKA The O ring must be green It is suitable f...

Page 111: ...the old mechatronic unit so that no oil can escape when it is sent for reconditioning The oil in the old mechatronic unit must not be drained off Further installation is carried out in reverse order o...

Page 112: ...draulic clutch mechanism of disengagement clutch using Vehicle diagnostic tester in Guided functions mode Note The disengagement clutch in the electric drive motor V141 sep arates the combustion engin...

Page 113: ...king lock cover 1 page 110 Caution Risk of causing permanent damage by mechatronic unit falling out After the next work step the mechatronic unit is free and could fall out If it has not already been...

Page 114: ...ng lock 1 1 Removing and installing parking lock cover page 110 1 2 Removing and installing parking lock page 112 1 1 Removing and installing parking lock cover Note Only if you cannot set the mechatr...

Page 115: ...high voltage system Electrical system hybrid vehicles Rep gr 93 General warning instructions for work on the high voltage system The system must first be de energised by a high voltage technician befo...

Page 116: ...support bracket Unscrew bolt 3 and remove gearbox selector lever 4 Unscrew bolts 2 and remove parking lock cover 1 Installing In the event of leaks on the oil seal for the selector shaft or on the par...

Page 117: ...Remove parking lock cover 1 page 110 Unscrew bolts 2 and pull parking lock 1 off dowel sleeves arrows If the parking lock cannot be pulled off by hand Fit multipurpose tool VW 771 with extractor hook...

Page 118: ...tial 1 Oil seals 1 1 Fitting location overview seals page 114 1 2 Renewing left oil seal page 114 1 3 Renewing right oil seal page 118 1 1 Fitting location overview seals 1 Renewing input shaft seal R...

Page 119: ...not guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n...

Page 120: ...eel housing liner Removing and installing wheel housing liner If present undo bolts securing front left vehicle level sender G78 and remove sender from suspension link Turn steering wheel to left lock...

Page 121: ...shaft by screwing 2 bolts into flange and counterholding flange shaft with a lever Bolt has a 6 mm hexagon socket The bolt can also be removed and installed with a commercially available 6 mm socket...

Page 122: ...Drive shaft Removing and installing drive shaft Install coupling rod and wishbone Running gear axles steering Rep gr 40 Subframe Removing and installing anti roll bar If gearbox oil has escaped when r...

Page 123: ...y V o l k s w a g e n A G Socket T10107 A Used oil collection and extraction unit V A G 1782 Sealing grease G 052 128 A1 Removing Note Observe 4 Repair instructions page 10 Remove noise insulation be...

Page 124: ...areful not to cant seal If necessary it is possible to press a new dust ring onto the in termediate shaft using tube 2010 Do not use a hammer Insert intermediate shaft Tighten securing bolt for interm...

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Volkswagen Jetta Hybrid 2013, Workshop Manual

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