Volkswagen Jetta Hybrid 2013 Workshop Manual
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Volkswagen Jetta Hybrid 2013 Workshop Manual

Volkswagen Jetta Hybrid 2013 Workshop Manual

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Jetta Hybrid 2013 ➤
7-speed dual clutch gearbox 0CG
Edition 08.2012
Service Department. Technical Information

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Summary of Contents for Volkswagen Jetta Hybrid 2013

  • Page 1 Service Workshop Manual Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG Edition 08.2012 Service Department. Technical Information...
  • Page 2 In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2012 Volkswagen AG, Wolfsburg D4B8026F80B...

  • Page 3: Table Of Contents

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Contents 00 - Technical data ........... .
  • Page 4 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Overview - mechatronic unit ..........

  • Page 5: Technical Data

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 00 – Technical data Identification (VRL004662; Edition 08.2012) ⇒ “1.1 Gearbox identification”, page 1 Gearbox identification The “7-speed dual clutch gearbox 0CG” is installed in the Jetta models 2011 ▶. Allocation ⇒...

  • Page 6: Technical Data

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Technical data ⇒ “2.1 Allocation gearbox - engine”, page 2 ⇒ “2.2 Calculation of gear ratios”, page 2 ⇒ “2.3 Capacities”, page 3 Allocation gearbox - engine Dual clutch gearbox...

  • Page 7: Capacities

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Capacities The 7-speed dual clutch gearbox has two separate and different oil systems. One for the gearbox oil section -arrow A- and one for the hydraulic fluid section -arrow B-.

  • Page 8: Overview - Power Transmission

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Overview - power transmission ⇒ “2.4.1 Overview - power transmission - front-wheel drive”, page 2.4.1 Overview - power transmission - front-wheel drive The 7-speed dual clutch gearbox 0CG is configured as a 5-shaft gearbox.

  • Page 9: Safety Instructions

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Safety instructions ⇒ “3.1 General safety regulations”, page 5 ⇒ “3.2 Safety precautions when working on vehicles with high- voltage system”, page 5 ⇒ “3.3 Safety precautions during road tests in which test and measuring equipment is used”, page 7...
  • Page 10 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 voltage system” ⇒ Electrical system; Rep. gr. 93 ; General warning instructions for work on the high-voltage system . WARNING You can suffer an electric shock. An electric shock can be fatal.

  • Page 11: Safety Precautions During Road Tests In Which Test And Measuring Equipment Is Used

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Safety precautions during road tests in 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 se‐...

  • Page 12: Safety Precautions When Working On Mechatronic Unit For Dual Clutch Gearbox J743

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Safety precautions when working on mechatronic unit for dual clutch gear‐ box -J743- WARNING System is under pressure! ♦ The mechatronic unit for dual clutch gearbox -J743- has a pressure accumulator that maintains a system pressure of up to 60 bar.

  • Page 13: Notes On Tow-Starting/Towing

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Notes on tow-starting/towing Caution Danger of irreparable damage to gearbox. ♦ If the vehicle has to be towed, the selector lever must be in the “N” position and the vehicle must not be towed at a speed no greater than 50 km/h and for a distance not ex‐...

  • Page 14: Repair Instructions

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Repair instructions ⇒ “4.1 General notes”, page 10 ⇒ “4.2 Rules for cleanliness”, page 11 ⇒ “4.3 General repair notes”, page 11 General notes Gearbox ♦ The torque of the engine is transmitted to the dual clutch via the electric drive motor -V141- .

  • Page 15: Rules For Cleanliness

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Gearbox oil The 7-speed dual clutch gearbox has two separate and different oil systems. One for the gearbox oil section -arrow A- and one for the hydraulic fluid section -arrow B-.
  • Page 16 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 agnostic tester in Guided fault finding Vehicle self- modes. diagnosis Test instruments Various functions are available in the operating modes Guided ⇒ page 13 functions Guided fault finding...

  • Page 17: Working With Vehicle Diagnostic Testers

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 4.3.1 Working with vehicle diagnostic testers • Only work with vehicle diagnostic testers from Volkswagen. Various functions are available in the operating modes Guided . The 3 most important functions...

  • Page 18: Clutch

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 30 – Clutch Clutch ⇒ “1.1 Assembly overview - dual clutch”, page 14 ⇒ “1.2 Removing and installing the dual clutch”, page 16 ⇒ “1.3 Renewing input shaft seal”, page 23 ⇒...
  • Page 19 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 10 - Large engaging lever for “K 1” ❑ With engagement bearing ❑ Removing and installing ⇒ “2.2 Removing and installing clutch engagement mechanism”, page 29 11 - Upper section of guide sleeve ❑...

  • Page 20: Removing And Installing The Dual Clutch

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Removing and installing the dual clutch Special tools and workshop equipment required ♦ Hook -3438- ♦ Engine bung set -VAS 6122- ♦ Support device -T10323- ♦ -T10356/5- from assembly tool -T10356- ♦...
  • Page 21 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Removing dual clutch Prerequisites: • Gearbox removed and secured to engine and gearbox support ⇒ page 76 • Mechatronic unit for dual clutch gearbox -J743- built into gear‐...
  • Page 22 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – 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‐...
  • Page 23 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Remove retaining ring -arrow- for clutch. If retaining ring cannot be removed: Note If the retaining ring cannot be removed it is because the clutch ♦ has »clamped« the retaining ring at the bottom.
  • Page 24 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Remove clutch together with puller -T10373- . Installing dual clutch Caution Risk of damage to clutch and other components! • The positions of the engagement bearings must be set correctly.
  • Page 25 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Position support bracket -T10323- parallel to gearbox flange as shown in illustration. – If necessary, balance out gaps using -T10356/5- from assem‐ bly tool -T10356- , for example.
  • Page 26 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 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 to contact ♦...

  • Page 27: Renewing Input Shaft Seal

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Turn clutch by hand. It should be possible to turn it without difficulty. Note If the clutch is difficult to turn or if the clutch lining is being ♦...
  • Page 28 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 ♦ 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 29: Renewing Seal For Inner Input Shaft

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Lever out outer oil seal. 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 oil.
  • Page 30 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Procedure • Dual clutch is removed ⇒ page 16 • Clutch engagement mechanism is removed ⇒ page 29 Caution Risk of damage to clutch and other components! • Renew dual clutch if it is oily.
  • Page 31 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Drive in new oil seal to stop on tool using thrust piece - T10421- . – Install clutch engagement mechanism ⇒ page 29 – Install dual clutch ⇒...

  • Page 32: Clutch Mechanism

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Clutch mechanism ⇒ “2.1 Assembly overview - clutch engagement mechanism”, page 28 ⇒ “2.2 Removing and installing clutch engagement mechanism”, page 29 ⇒ “2.3 Adjusting clutch engagement mechanism”, page 32 Assembly overview - clutch engagement mechanism 1 - Shim for “K 1”...

  • Page 33: Removing And Installing Clutch Engagement Mechanism

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 10 - Lower section of guide sleeve ❑ Small small engaging lever “K 2” ❑ Is removed and installed together with small engaging lever and upper section of guide sleeve Removing and installing clutch engage‐...
  • Page 34 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Note The hinge mounting -1- is not removed. ♦ Only replace the ball pin -2- when it is worn ⇒ page 34 ♦ Installing Install in reverse order of removal, observing the following: WARNING The position of the engagement bearings “K 1”...
  • Page 35 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Observe the following when installing a new engaging lever »K 2«: The new engaging lever »K2« with upper and lower section of guide sleeve will be delivered in transport position -illustration- and must be set to installation position prior to installation.

  • Page 36: Adjusting Clutch Engagement Mechanism

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Continuation for all: – Install »small« engaging lever together with upper and lower section of guide sleeve. Insert and tighten new bolts. – Insert »large« engaging lever with measured shims for “K 1”...
  • Page 37 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Note There is no need to adjust anything if all the named parts have ♦ only been removed and reinstalled. The retaining ring must be renewed in each case.
  • Page 38 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 • Specified tightening torque ⇒ “2.1 Assembly overview - clutch engagement mechanism”, page 28 Caution Risk of damage to clutch and other components! • Mounting for engaging lever and entire mechanism of en‐...
  • Page 39 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 1st step: 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.
  • Page 40 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – In the opposite position, determine dimension “B 2 ” to retaining ring. Note Do not measure on retaining ring joint. The retaining ring could be pushed away and falsify the reading.
  • Page 41 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Insert large engaging lever. Caution Risk of false measurements. ♦ Do not insert any shim! – Check that engaging lever is seated correctly. – Place gauge block -T10466- on large engagement bearing.
  • Page 42 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – In the opposite position, determine dimension “A 1 b ” to gauge block -T10466- . • Example: Dimension “A 1 b ” = 5.01 mm – Calculate mean value from dimension “A 1 a ” and “A 1 b ”.
  • Page 43 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Select required shim from the table with the help of the part number -magnifying glass- and have it ready for installation. Calculated thick‐ Available shims Part number of shim...
  • Page 44 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 6th step: Determine dimension “A 2” for clutch engaging lever “K 2” Note The upper section of the guide sleeve cannot be removed or in‐ stalled alone. It is always removed or installed together with lower section of guide sleeve and »small«...
  • Page 45 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 If the engaging lever is 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.
  • Page 46 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Place gauge block -T10466- on small engagement bearing. Flat side faces upwards. – To ensure that gauge block -T10466- sits properly on engage‐ ment bearing, press down and turn gauge block.
  • Page 47 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – In the opposite position, determine dimension “A 2 b ” to gauge block -T10466- . • Example: Dimension “A 2 b ” = 4.75 mm – Calculate mean value from dimension “A 2 a ” and “A 2 b ”.
  • Page 48 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – From the shims supplied, measure the required shim and have it ready for installation. Calculated thickness of shim Available shims Thickness in mm 0.31 … 0.90 0.80 0.91 …...

  • Page 49: Controls, Housing

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 34 – Controls, housing Selector mechanism ⇒ “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 ⇒...

  • Page 50: Jetta Hybrid

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 1 - Selector lever handle ❑ With gaiter and cover. ❑ Do not remove handle without reason. ❑ For emergency release, only the cover needs to be unclipped ⇒...

  • Page 51: Emergency Release From Position P

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 ❑ Qty. 3 ❑ Renew after each removal. ❑ 8 Nm +90° 8 - Bolt ❑ For gearbox selector lever. ❑ Renew after each removal. ❑ 10 Nm +90°...

  • Page 52: Removing And Installing Selector Lever Handle

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Procedure – Unclip selector lever cover and push it aside. – Depress brake pedal or set handbrake. – Press onto yellow plastic part -arrow-. Caution Risk of damage to selector mechanism.

  • Page 53: Moving Push-Button To Installation Position In The Handle

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Unclip cover on both sides using removing wedge -3409- and pull gaiter inside out over selector lever handle. – Disconnect connector from selector lever cover. – Push sleeve upwards in -direction of arrow- to release knob.
  • Page 54 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 There are 2 ways of moving the push button into the installation position, »with« 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- at the front.

  • Page 55: Removing And Installing Selector Mechanism

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Using a screwdriver, for example, press small lever -1- for tie rod into groove -2-. When doing this, push-button -3- is pushed back into installation position. -I- Push button in pressed position...
  • Page 56 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Removing – Move selector 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.
  • Page 57 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Pull air damper -1- upwards out of rubber bushes -arrows-. Continuation for all vehicles WARNING You can suffer an electric shock. An electric shock can be fatal.
  • Page 58 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Pull off securing clip -1- for selector lever cable. Securing clips for selector lever cable must always be renewed. – Remove selector lever cable -2- from gearbox selector lever, e.g.
  • Page 59 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Remove nuts -arrows- inside vehicle. – If fitted, remove bracket -A-. – Remove selector mechanism -B- together with selector lever cable and selector housing downwards. Thread selector lever cable out of cable support bracket while doing so.
  • Page 60 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Removing – Move selector 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.
  • Page 61 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Pull air damper -1- upwards out of rubber bushes -arrows-. Continuation for all vehicles WARNING You can suffer an electric shock. An electric shock can be fatal.
  • Page 62 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Pull off securing clip -1- for selector lever cable. Securing clips for selector lever cable must always be renewed. – Remove selector lever cable -2- from lever/selector shaft, e.g.

  • Page 63: Checking Selector Mechanism

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Carefully pull selector mechanism with Bowden cable out of the centre tunnel. Ensure that the cord remains accessible from the engine compartment after being pulled by the Bow‐...

  • Page 64: Checking And Adjusting Selector Lever Cable

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 When selector lever is shifted to position “N” at speeds above 5 km/h, solenoid for selector lever lock must not engage and block selector lever. Selector lever can be shifted into a driving range.
  • Page 65 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Move selector lever to position “P” position. Vehicles with secondary air system – Unclip cover for air damper -1- upwards from mountings -arrows- and remove it. – Disconnect air hoses -1- and -2- from air damper -3-. To do this, press retaining ring -arrow- together on both sides and pull hoses off.
  • Page 66 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Pull air damper -1- upwards out of rubber bushes -arrows-. Continuation for all vehicles WARNING You can suffer an electric shock. An electric shock can be fatal.
  • Page 67 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Using removal lever -80 - 200- lever selector lever cable -2- off gearbox selector lever. – If necessary, pull off securing clip -1- for selector lever cable.

  • Page 68: Renewing Oil Seal For Selector Shaft

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Tighten adjustment screw -arrow-. The position of the selector lever cable must not change while doing so. This completes the adjustment. – Continue installation in reverse order of removal. Install power and control electronics for electric drive -JX1- ⇒...

  • Page 69: Removing And Installing Gearbox

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Removing and installing gearbox ⇒ “2.1 Removing gearbox”, page 65 ⇒ “2.2 Installing gearbox”, page 69 ⇒ “2.3 Specified torques for gearbox”, page 72 Removing gearbox – The gearbox is removed together with the engine ⇒ Rep. gr.
  • Page 70 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 ♦ Workshop hoist -VAS 6100- • Engine/gearbox assembly has been removed and attached to scissor-type assembly platform -VAS 6131- . – Disconnect connector -1- from selector valve -2- of mecha‐...
  • Page 71 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Release and disconnect connector -A- from vacuum pump for brakes -V192- -B-. – Remove vacuum pump for brakes -V192- -B- together with bracket from gearbox and tie it up to side of engine.
  • Page 72 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Unscrew engine/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.

  • Page 73: Installing Gearbox

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Unbolt cable support bracket -1- from gearbox -arrows-, speci‐ fied torque ⇒ page 45 – Remove gearbox bracket -1- from gearbox -arrows A and B-, specified torque ⇒...
  • Page 74 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Inspect needle bearing -arrow- in electric drive motor -V141- and renew it if necessary ⇒ Rep. gr. 10 ; Separating electric drive motor -V141- and engine and ⇒ Rep. gr. 10 ; Connecting electric drive motor -V141- and engine .
  • Page 75 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 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 ♦...

  • Page 76: Specified Torques For Gearbox

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Install drive motor rotor position sender 1 -G713- -C- to gear‐ box -arrows- ⇒ Electrical system, hybrid vehicles; Rep. gr. 93 ; Electric drive motor; Removing and installing drive motor rotor position sender 1 -G713- .

  • Page 77: Transporting Gearbox

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Transporting gearbox Special tools and workshop equipment required ♦ Hook -10 - 222 A /2- ♦ Shackle -10 - 222 A /12- ♦ Workshop hoist -VAS 6100- 3. Transporting gearbox...
  • Page 78 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Seal gearbox so that it is oil-tight. Caution Risk of damage to gearbox. Before repairs, the breather of the mechatronic unit for dual clutch gearbox -J743- (-arrow A-) and the gearbox breather (-arrow B-) must be sealed so that no oil can escape.
  • Page 79 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – 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‐...

  • Page 80: Installing To Engine And Gearbox Support

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Installing to engine and gearbox support Special tools and workshop equipment required ♦ Support plate -VW 309- ♦ Gearbox support -VW 353- ♦ Lifting tackle -2024 A- ♦ Eye bolt -3368- ♦...
  • Page 81 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Lifting gearbox into engine and gearbox support Requirement: • Gearbox is oil-tight ⇒ page 74 The gearbox and gearbox support -VAS 6100- are lifted into en‐ gine and gearbox support -VAS 6095- using workshop hoist -VW 353- .

  • Page 82: Assembly Mountings

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Assembly mountings ⇒ “5.1 Assembly overview - assembly mountings”, page 78 Assembly overview - assembly mountings 1 - Bolt ❑ Specified torque ⇒ Rep. gr. 10 ; Assembly mountings;...
  • Page 83 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 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 mountings 15 - Bolt ❑...
  • Page 84 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Special tools and workshop equipment required ♦ Support bracket -10 - 222 ♦ 2 x spindle -10 - 222 A /11- ♦ 2 x adapters -10 - 222 A / ♦...
  • Page 85 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Disconnect air hoses -1- and -2- from air damper -3-. To do this, press retaining ring -arrow- together on both sides and pull hoses off. – Pull air damper -1- upwards out of rubber bushes -arrows-.
  • Page 86 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Remove bracket for power and control electronics for electric drive -JX1- ⇒ Electrical system, hybrid vehicles; Rep. gr. 93 ; High-voltage cables; Removing and installing high-voltage wiring harness for hybrid battery -PX1- .
  • Page 87 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 To take the weight of the engine/gearbox assembly, fit the support bracket as follows: Adapter -10 - 222 A /31-2- Swivel joint -T40091/3- Adapter -10 - 222 A /31-1-...
  • Page 88 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Loosen bolts -1- for gearbox bracket by approx. one turn and unscrew bolts -2-. – Then lower engine and gearbox slightly using the spindles of engine support bracket -10 - 222 A- .
  • Page 89 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Caution Risk of damaging thread in gearbox bracket if bolts are started at an angle. ♦ Before starting the bolts -arrows-, gearbox bracket -1- and support arm of gearbox mounting must be perfectly aligned parallel to each other.

  • Page 90: Gearbox Oil

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Gearbox oil ⇒ “6.1 Draining and filling gearbox oil”, page 86 Draining and filling gearbox oil Special tools and workshop equipment required ♦ Used oil collection and extraction unit -V.A.G 1782- ♦...
  • Page 91 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Measure length of breather pipe attached to adapter for oil filling -VAS 6262 A- and, if necessary, shorten it. In order to ensure that the breather pipe of the adapter for oil filling -VAS 6262 A- does not contact the bottom of some oil bottles, the pipe must be shortened to the length -a-.
  • Page 92 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Vehicles with secondary air system – Unclip cover for air damper -1- upwards from mountings -arrows- and remove it. – Disconnect air hoses -1- and -2- from air damper -3-. To do this, press retaining ring -arrow- together on both sides and pull hoses off.
  • Page 93 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Pull air damper -1- upwards out of rubber bushes -arrows-. Continuation for all vehicles WARNING You can suffer an electric shock. An electric shock can be fatal.
  • Page 94 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Remove bracket for power and control electronics for electric drive -JX1- ⇒ Electrical system, hybrid vehicles; Rep. gr. 93 ; High-voltage cables; Removing and installing high-voltage wiring harness for hybrid battery -PX1- .
  • Page 95 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Connect adapter -VAS 6262/4- to filling hose and attach to bleeder hole in gearbox. – Flip bottle over and fill the exact required oil capacity; For oil capacities refer to ⇒...

  • Page 96: Mechatronic Unit

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Mechatronic unit ⇒ “7.1 Overview - mechatronic unit”, page 92 ⇒ “7.2 Removing and installing mechatronic unit”, page 94 ⇒ “7.3 Setting mechatronic unit to removal position by hand”, page...
  • Page 97 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 ❑ Do not remove valve block from mechatronic unit ⇒ page 93 ❑ ⇒ “3.4 Safety precautions when working on mechatronic unit for dual clutch gearbox J743 ”, page 8 ❑...

  • Page 98: Removing And Installing Mechatronic Unit

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 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:...
  • Page 99 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 ♦ Assembly lever -T10407- ♦ Allocate engine bung set according to ⇒ Electronic parts cata‐ logue “ETKA” . ♦ Allocate sealing cap -0AM 325 120 A- according to ⇒ Elec‐...
  • Page 100 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Remove radiator cowling ⇒ Rep. gr. 19 ; Radiator/radiator fan; Removing and installing radiator cowling . WARNING Hot steam/hot coolant can escape - risk of scalding. ♦ On a warm engine, the cooling system is under high pres‐...
  • Page 101 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Disconnect air hoses -1- and -2- from air damper -3-. To do this, press retaining ring -arrow- together on both sides and pull hoses off. – Pull air damper -1- upwards out of rubber bushes -arrows-.
  • Page 102 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Remove bracket for power and control electronics for electric drive -JX1- ⇒ Electrical system, hybrid vehicles; Rep. gr. 93 ; High-voltage cables; Removing and installing high-voltage wiring harness for hybrid battery -PX1- .
  • Page 103 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Caution Risk of damaging gearbox components beyond repair. ♦ Do not under any circumstances touch the contacts in the gearbox connector by hand. The resulting static discharge could destroy the control unit and, consequently, the me‐...
  • Page 104 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Note The following work step serves to lift off both engaging levers of the dual clutch from the plungers of 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‐...
  • Page 105 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – To prevent assembly lever -T10407- from slipping out while it is being turned, press it against gearbox housing if necessary using a screwdriver. Note The assembly lever -T10407- remains inserted between the ♦...
  • Page 106 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Unscrew bolts -arrows 2- diagonally. – Unscrew bolts -arrows 1-. – Pull mechatronic unit -B- together with valve block -A- off gearbox. Caution Risk of damaging mechatronic unit for dual clutch gearbox - J743- .
  • Page 107 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 N - Neutral position R - Reverse gear 1 - First gear 2 - Second gear 3 - Third gear 4 - Fourth gear 5 - Fifth gear...
  • Page 108 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 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 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Fit mechatronic unit together with valve block to gearbox. – Tighten bolts for mechatronic unit ⇒ page 94 Caution Risk of damaging clutches. ♦ If the engaging levers strike the clutch actuators of the...
  • Page 110 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Install bracket -A- at front of gearbox -arrows-. – Connect connector -1- to selector valve -2- of mechatronic unit and install wiring harness to retainer at front of gearbox.
  • Page 111 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Remove sealing cap -arrow- from breather connection of me‐ chatronic unit for dual clutch gearbox -J743- . • If a large quantity of hydraulic fluid (more than 20 ml) has es‐...

  • Page 112: Setting Mechatronic Unit To Removal Position By Hand

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 • After the high-voltage system has been re-energised, bleed hydraulic clutch mechanism of disengagement clutch using ⇒ Vehicle diagnostic tester in mode. Guided functions Note The disengagement clutch in the electric drive motor -V141- sep‐...
  • Page 113 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Procedure Sometimes, the mechatronic unit cannot be removed. In this case, the gear actuator is »caught« at the »top left« of the gearbox housing -arrow-. The »sticking« gear actuator must now be pressed by hand into a »removal position«.

  • Page 114: Gears, Shafts

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 35 – Gears, shafts Parking lock ⇒ “1.1 Removing and installing parking lock cover”, page 110 ⇒ “1.2 Removing and installing parking lock”, page 112 Removing and installing parking lock...
  • Page 115 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Disconnect air hoses -1- and -2- from air damper -3-. To do this, press retaining ring -arrow- together on both sides and pull hoses off. – Pull air damper -1- upwards out of rubber bushes -arrows-.

  • Page 116: Removing And Installing Parking Lock

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Remove bracket for power and control electronics for electric drive -JX1- ⇒ Electrical system, hybrid vehicles; Rep. gr. 93 ; High-voltage cables; Removing and installing high-voltage wiring harness for hybrid battery -PX1- .
  • Page 117 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – 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: –...

  • Page 118: Final Drive - Differential

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 39 – Final drive - differential 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...
  • Page 119 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 ♦ Multipurpose tool -VW 771- ♦ Thrust piece -3305- ♦ Socket -T10107 A- ♦ Used oil collection and extraction unit -V.A.G 1782- ♦ Sealing grease -G 052 128 A1-...
  • Page 120 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 Removing Note Observe ⇒ “4 Repair instructions”, page 10 ♦ Do not loosen the centre bolt of the drive shaft. ♦ – Remove front left wheel. – Remove noise insulation beneath engine/gearbox ⇒ General body repairs, exterior;...
  • Page 121 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Remove bolt for left flange 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: Renewing Right Oil Seal

    Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Drive in new oil seal to stop, being careful not to cant oil seal. – Insert flange shaft. – Tighten securing bolt for flange shaft to specified torque. When doing this, press flange shaft against gearbox so that bolt en‐...
  • Page 123 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 ♦ 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 –...
  • Page 124 Jetta Hybrid 2013 ➤ 7-speed dual clutch gearbox 0CG - Edition 08.2012 – Unscrew bolt in intermediate shaft using socket and extended bit 6 mm -T10107 A- or a commercially available 6 mm socket. – Pull out intermediate shaft. – Pry seal out using assembly lever.

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