Volkswagen Jetta Hybrid (2013 year). Manual - part 19

⇒ page 45

 .

– Remove gearbox bracket -1- from gearbox -arrows A and B-,

specified torque

⇒ “5.1 Assembly overview - assembly mountings”,

page 78

 .

Transporting gearbox 

⇒ page 73

 .

Secure gearbox to assembly stand 

⇒ page 76

 .

Installing gearbox 

⇒ page 69

 .

2.2

Installing gearbox

10 ; Removing and installing engine; Installing engine .

Install gearbox to engine as follows:
• Electric drive motor -V141- is installed to engine.
• Gearbox support -3282- is inserted into support set -VAS

6131/2- of scissor-type assembly platform -VAS 6131- .

• Observe repair instructions 

⇒ page 10

 .

•

⇒ “2.3 Specified torques for gearbox”, page 72

Refer to procedure “Removing gearbox” for required special tools

⇒ page 65

 .

– Fit gearbox onto gearbox support -3282- and secure it in place.
– Check that there are dowel sleeves for centring engine and

gearbox in the cylinder block. Insert any missing dowel

sleeves.

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2. Removing and installing gearbox    

69

 

electric drive motor -V141- and engine .

Note

If the needle bearing in the electric drive motor -V141- is dam‐

aged, the gears cannot be selected 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 gearbox

support -3282- while doing so.

• Ensure to not damage connections -arrow 1- on electric drive

motor -V141- and the drive motor temperature sender -G712-

-arrow 2-.

• It must be possible to guide the engine and gearbox together

by hand until the engine flange and gearbox flange make con‐

tact all around.

Turn crankshaft slightly if necessary.
– Bolt gearbox to engine and remove guide pins -T10515- from

engine.

– If a new gearbox is installed: Install cable support bracket,

gearbox bracket und remaining bracket to gearbox

⇒ page 68

 .

– Connect connector -1- to selector valve -2- of mechatronic unit

and install wiring harness to retainer at front of gearbox.

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70

 

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 for use with hydraulic

fluids. Do not use any other O-ring.

♦

Only remove the sealing plugs on hydraulic line, engine and

valve block/mechatronic unit immediately before installation.

– Insert hydraulic line -3- into engine and valve block/mecha‐

tronic unit.

– Then, press retaining clip -2- into valve block/mechatronic unit.
– Check proper seating of 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 gearbox repair or after gearbox has been renewed:
– Remove plug -arrow B- from gearbox breather and install

breather cap.

If the gearbox oil has been drained off, the gearbox oil must now

be filled through the breather connection 

⇒ page 86

 .

– Remove plug -arrow A- from breather connection of mecha‐

tronic unit for dual clutch gearbox -J743- .

• If a large quantity of hydraulic fluid (more than 20 ml) has es‐

caped, e.g. when removing and installing the mechatronic unit

for dual clutch gearbox -J743- or when removing and installing

the electric drive motor -V141- , approx. 30 ml of hydraulic fluid

must be replenished through breather connection -3- at this

point.

• For allocation of hydraulic fluid and filling equipment refer to

⇒  Electronic parts catalogue “ETKA” .

– Fit breather cap -1- (is one replacement part together with

breather -2-) onto breather connection -3-.

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2. Removing and installing gearbox    

71

 

93 ; Electric drive motor; Removing and installing drive motor

rotor position sender 1 -G713- .

– Bolt vacuum pump for brakes -V192- -B- together with bracket

to gearbox ⇒  Brake systems; Rep. gr.  47 ; Vacuum system;

Assembly overview - electric 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 harness for drive motor -PX2- .

The gearbox is installed together with engine during continued

Installing engine .
• After the high-voltage system has been re-energised, bleed

hydraulic 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 engine from the electric drive motor -

V141- .

2.3

Specified torques for gearbox

Dual clutch gearbox to engine:

Item

Bolt

Nm

1, 2

M12 x 50

80

3, 4

M12 x 105

80

5, 6, 7

M10 x 50

40

8, 9

1)

M12 x 70

80

A

Dowel sleeve for centring

• Screwed in from engine side.

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