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.
Jetta Hybrid 2013 ➤
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.
Jetta Hybrid 2013 ➤
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-.
Jetta Hybrid 2013 ➤
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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72
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