Volkswagen Jetta Hybrid (2013 year). Manual - part 28

 .

Caution

Risk of damaging clutches.

♦ If the engaging levers strike the clutch actuators of the

mechatronic unit hard, these will be placed under excess

pressure 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 damage rubber grommets of clutch actuators when

doing this.

• Rubber grommets must seal properly against mechatronic

unit.

– Carefully and slowly turn assembly lever -T10407- in clock‐

wise direction and remove it.

• The plungers must slide slowly into the mountings.
– Pull out plungers by hand until they are properly seated in

mountings.

– Install gearbox input speed sender 3 -G641- .
– Pay attention to sender. Clip must not be damaged.
• Sender lug must be fully and firmly in contact with gearbox

housing. If sender is »loose« because the clip is broken, renew

mechatronic unit.

– Connect mechatronic unit connector.

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and install wiring harness to 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 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)

 .

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

caped, 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-.

Note

♦

If the mechatronic unit is removed, fit sealing plugs onto 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 of removal. Ob‐

serve the following when installing:
– Fill gearbox oil 

⇒ page 86

 .

– Check selector lever cable adjustment and adjust it if neces‐

sary 

⇒ page 60

 .

Install power and control electronics for electric drive -JX1- ⇒ 

electronics for electric drive -JX1- .
– Re-energise high-voltage system and carry out documenta‐

tion ⇒  Electrical system, hybrid vehicles; Rep. gr.  93 ; Re-

energising high-voltage system .

– Move lock carrier back from service position ⇒  General body

from service position .

Removing and installing radiator cowling .

Draining and filling coolant .

gr.  66 ; Noise insulation .

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⇒ 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- .

–

Initiate basic adjustment

 

⇒ page 13

 .

Specified torques
♦

⇒ Fig. ““ Mechatronic unit for dual clutch gearbox -J743- -

specified torque and tightening sequence”“ , page 94

7.3

Setting mechatronic unit to removal position by hand

• Only if you cannot set the mechatronic unit to removal position

with the vehicle diagnostic tester , you must set the unit by

hand to this position.

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