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Volkswagen Jetta Hybrid 2014 Quick Reference
Volkswagen Jetta Hybrid 2014 Quick Reference

Volkswagen Jetta Hybrid 2014 Quick Reference

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2014 Volkswagen Jetta Hybrid
Quick Reference Specification Book
TaBle of ConTenTS
General Information ...................................................... 1
Decimal and Metric Equivalents ...........................................1
Distance/Length ....................................................................1
Tightening Torque .................................................................2
Nm-to-lb·ft (ft·lb) ...................................................................2
Nm-to-lb·in (in·lb), kg·cm ......................................................3
N·cm-to-lb·in (in·lb), kg·cm ...................................................3
kg·cm-to-lb·in (in·lb), N·cm ...................................................4
Warnings and Cautions ........................................................4
WARNINGS ..........................................................................4
CAUTIONS ...........................................................................7
Vehicle Identification ..................................................... 9
VIN on Lower Edge of Windshield ...........................................9
VIN on Longitudinal Member Extension ................................10
Vehicle Data Label ................................................................. 11
Type Plate ..............................................................................12
VIN Decoder ..........................................................................13
Sales Codes ................................................................. 14
Engine Codes ........................................................................14
Transmission Codes ..............................................................14
Vehicle Lifting .............................................................. 15
Hoist and Jack Mounting Points .........................................15
Front ......................................................................................15
Rear .......................................................................................16
CHASSIS
Brake System ............................................................... 17
General Information ............................................................17
Front Brakes ..........................................................................17
Rear Brakes, Torsion Beam Rear Suspension ......................17
Rear Brakes, Multi-link Rear Axle ..........................................17
Master Cylinder and Brake Booster ......................................17
VW Jetta Hybrid Quick Reference Specification Book • February 2014
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Summary of Contents for Volkswagen Jetta Hybrid 2014

  • Page 1 2014 Volkswagen Jetta Hybrid Quick Reference Specification Book TaBle of ConTenTS General Information ............1 Decimal and Metric Equivalents ...........1 Distance/Length ..............1 Tightening Torque ..............2 Nm-to-lb·ft (ft·lb) ..............2 Nm-to-lb·in (in·lb), kg·cm ............3 N·cm-to-lb·in (in·lb), kg·cm ...........3 kg·cm-to-lb·in (in·lb), N·cm ...........4 Warnings and Cautions ............4...
  • Page 2 Front Brakes, FS III ...............18 Front Brakes, FN 3 ..............19 Rear Drum Brakes ..............21 Rear Disc Brakes ..............22 Anti-lock Brake System (ABS) ..........24 ABS Mark 70 (ABS/ASR) Overview ........24 ABS Mark 60 EC (ABS/EDS/ASR/ESP) Overview ....26 Right Front ABS Wheel Speed Sensor -G45-/Left Front ABS Wheel Speed Sensor -G47- Overview ....28 Right Rear ABS Wheel Speed Sensor -G44-/Left Rear ABS Wheel Speed Sensor -G46-, Twist Beam Rear...
  • Page 3 Front Brake Caliper Overview, FN 3 ........60 Bosch ZOH 38 Rear Brakes Overview ........61 CI 38 Rear Brakes Overview ..........62 Suspension, Wheels, Steering ........64 Front Suspension ...............64 Drive Axle with CV Joint VL 100 Overview ......64 Drive Axle Overview, with CV Joint VL 107 ......66 Drive Axle Overview with Triple Roller Joint AAR3300i ..68 Drive Axle Overview with Triple Roller Joint AAR2600i ..70 Front Suspension and Control Arm Overview .......72...
  • Page 4 Power Steering Gear Overview ...........106 Steering Column Overview ..........107 Steering Wheel with Airbag Overview .........108 Electrical System ............109 Communication ..............109 Fastener Tightening Specifications ........109 Electrical Equipment ............110 Battery, Starter, Generator, Cruise Control ....... 110 Battery -A- Overview ............110 Generator Overview ............
  • Page 5 Drive Motor -V141- Cover..........138 Bolt Tightening Specification for the Wiring Guide -1-..139 Tightening Specifications for the Potential Equalization Cable to Electric Drive Power and Control Electronics -Jx1- -1- .................140 Tightening Specifications for the Potential Equalization Cable -2- on the Electro-Drive Drive Motor -V141- ..141 Body ................
  • Page 6 Rear Bumper Cover Guides Overview ........176 Rear Bumper Carrier Overview ...........177 Glass, Window Regulators ..........178 Front Door Window Overview ..........178 Rear Door Window Overview ..........179 Exterior Equipment ............180 Front Wheel Housing Liner Overview ........180 Rear Wheel Housing Liner Assembly Overview ....181 Manual Exterior Mirror Assembly Overview ......182 Power Exterior Mirror Assembly Overview ......183 Sill Panel Cover Assembly Overview ........184...
  • Page 7 GEnErAL InformAtIon Decimal and Metric Equivalents Distance/Length To calculate: mm x 0.03937 = in. 0.002 0.00008 0.01 0.0004 0.004 0.04 0.004 0.00016 0.02 0.0008 0.008 0.08 0.006 0.00024 0.03 0.0012 0.012 0.12 0.008 0.00031 0.04 0.0016 0.016 0.16 0.010 0.00039 0.05 0.0020 0.020...
  • Page 8 Tightening Torque nm-to-lb·ft (ft·lb) To calculate: Nm x 0.738 = lb·ft lb·ft lb·ft lb·ft (ft·lb) (ft·lb) (ft·lb) VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 9 nm-to-lb·in (in·lb), kg·cm To calculate: Nm x 8·85 = lb·in • Nm x 10.20 = kg·cm lb·in lb·in kg·cm kg·cm (in·lb) (in·lb) n·cm-to-lb·in (in·lb), kg·cm To calculate: N·cm x 0.089 = lb·in • N·cm x 0.102 = kg·cm lb·in lb·in n·cm kg·cm n·cm...
  • Page 10 kg·cm-to-lb·in (in·lb), n·cm To calculate: kg·cm x 0.868 = lb·in • kg·cm x 9.81 = N·cm lb·in lb·in kg·cm n·cm kg·cm n·cm (in·lb) (in·lb) 1079 1177 1275 1373 1471 1569 1667 1765 1863 1961 2059 2157 2256 2354 2452 Warnings and Cautions WArnInGS •...
  • Page 11 • Never run the engine unless the work area is well ventilated. Carbon monoxide kills. • Remove rings, bracelets and other jewelry so they cannot cause electrical shorts, get caught in running machinery, or be crushed by heavy parts. • Tie back long hair. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near machine tools or running engines.
  • Page 12 WArnInGS (cont’d) • Batteries give off explosive hydrogen gas during charging. Keep sparks, lighted matches and open flame away from the top of the battery. If hydrogen gas escaping from the cap vents is ignited, it ignites the gas trapped in the cells and causes the battery to explode.
  • Page 13 • Place jack stands only at locations specified by manufacturer. The vehicle lifting jack supplied with the vehicle is intended for tire changes only. Use a heavy duty floor jack to lift the vehicle before installing jack stands. • Battery acid (electrolyte) can cause severe burns. Flush contact area with water, seek medical attention.
  • Page 14 CAUtIonS (cont’d) • Label battery cables before disconnecting. On some models, battery cables are not color coded. • Disconnecting the battery may erase fault code(s) stored in control module memory. Check for fault codes prior to disconnecting the battery cables. •...
  • Page 15 VEHICLE IDEntIfICAtIon VIn on Lower Edge of Windshield Æ The VIN is on the left side of the vehicle in the area of the windshield wiper mount. It is visible from outside. VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 16 VIn on Longitudinal member Extension The Vehicle Identification Number (VIN) is located on the extension Æ of the longitudinal member VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 17 Vehicle Data Label Æ The vehicle data label is located in the left rear of vehicle in the spare wheel well. The vehicle data sticker can also be found in the customer’s service schedule. VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 18 type Plate Æ The type plate is visible at the bottom of the B-pillar when the left front door is open. The type plate contains the following vehicle information: A – Vehicle Identification Number (VIN) B – Variable specifications (axle loads, total permissible weights, permissible towing weights) C –...
  • Page 19 VIn Decoder 2014 Volkswagen VIN Decoder (except Routan) Series: k= Jetta SportWagen w/5 A= CC Sport w/Man Trans, Spd Man Trans E = 2014 Passat S, Tiguan w/Auto L= Jetta SEL/TDI w/Auto Trans Trans B= CC Sport/Sport+ w/Auto m= Jetta SportWagen w/6...
  • Page 20 SALES CoDES Engine Codes CnLA 1.4L 4-cylinder 4V transmission Codes 7-speed direct shift VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 21 VEHICLE LIftInG Hoist and Jack Mounting Points front Position the support plate in the side member vertical Æ reinforcement area VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 22 rear Position the support plate in the side member vertical Æ reinforcement area VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 23 BrAkE SyStEm General Information front Brakes Engine Version Pr number front Wheel Brake 1.4l 110 kW 1ZA/1ZB/1LV FN 3 (16) 2.0L 85 kW 1ZM/1ZQ FS III (15”) 2.5L 125 kW 1ZP/1ZE FN 3 (15”) 2.0L 103 kW TDI 1ZP/1ZE FN 3 (15”) 2.0L 147 kW 1ZA/1ZB/1LV FN 3 (16”)
  • Page 24 front Brakes, fS III Item Pr number 1Zm/1ZQ Brake caliper FS III (15”) Brake pad, thickness without backing plate Brake rotor Diameter in Brake rotor, thickness Brake caliper, piston Diameter in VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 25 front Brakes, fn 3 Item Pr number 1ZE/1ZP Brake caliper FN 3 (15”) Brake pad, thickness without backing plate Brake rotor Diameter in Brake rotor, thickness Brake caliper, piston Diameter in VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 26 front Brakes, fn 3 (cont’d) Item Pr number 1LV/1ZA/1ZB Brake caliper FN 3 (16”) Brake pad, thickness Brake pad, wear limit without back plate Brake rotor Diameter in Brake rotor thickness Brake rotor, wear limit Brake caliper, piston Diameter in VW Jetta Hybrid Quick Reference Specification Book •...
  • Page 27 rear Drum Brakes Item Pr number Wheel brake cylinder Brake pad, width Brake pad, thickness Brake pad, minimum thickness Brake drum Diameter in Brake drum, wear limit Diameter in 231.5 VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 28 rear Disc Brakes Item Pr number 1kS/1kt Brake caliper Bosch Brake pad, thickness without backing plate Brake rotor Diameter in Brake rotor, thickness Brake caliper, piston Diameter in VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 29 VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 30 Anti-lock Brake System (ABS) ABS mark 70 (ABS/ASr) overview 1 - Brake Line 14 Nm … 2 - Brake Line 14 Nm … 3 - Brake Booster with master Brake Cylinder 4 - Brake Line 14 Nm … 5 - Brake Line 14 Nm …...
  • Page 31 10 - Bracket 11 - ABS Hydraulic Unit -n55- 12 - Bolt 5.5 Nm … 13 - ABS Control module -J104- 14 - Brake Line 14 Nm … 15 - Brake Line 14 Nm … 16 - Brake Line 14 Nm …...
  • Page 32 ABS mark 60 EC (ABS/EDS/ASr/ESP) overview 1 - ABS Hydraulic Unit -n55- 2 - ABS Control module -J104- 3 - Brake Booster with master Brake Cylinder 4 - Bolt 2 Nm +/- 0.8 Nm … Always replace if removed … 5 - Brake Line 14 Nm …...
  • Page 33 10 - Brake Booster with master Brake Cylinder 11 - Brake Line 14 Nm … 12 - Brake Line 14 Nm … 13 - Hex Bolt 8 Nm … 14 - rubber Insulation 15 - Bracket 16 - Bolt 8 Nm …...
  • Page 34 right front ABS Wheel Speed Sensor -G45-/Left front ABS Wheel Speed Sensor -G47- overview 1 - right front ABS Wheel Speed Sensor -G45-/ Left front ABS Wheel Speed Sensor -G47- 2 - Bolt 8 Nm … 3 - Wheel Bearing Unit 4 - Drive Axle VW Jetta Hybrid Quick Reference Specification Book •...
  • Page 35 right rear ABS Wheel Speed Sensor -G44-/Left rear ABS Wheel Speed Sensor -G46-, twist Beam rear Suspension and Drum Brakes overview 1 - right rear ABS Wheel Speed Sensor -G44-/ Left rear ABS Wheel Speed Sensor -G46- 2 - Bolt 8 Nm …...
  • Page 36 right rear ABS Wheel Speed Sensor -G44-/Left rear ABS Wheel Speed Sensor -G46-, twist Beam rear Suspension and Disc Brakes overview 1 - right rear ABS Wheel Speed Sensor -G44-/ Left rear ABS Wheel Speed Sensor -G46- 2 - Bolt 8 Nm …...
  • Page 37 right rear ABS Wheel Speed Sensor -G44-/Left rear ABS Wheel Speed Sensor -G46, multi-Link rear Axle overview 1 - right rear ABS Wheel Speed Sensor -G44-/ Left rear ABS Wheel Speed Sensor -G46- 2 - Bolt 8 Nm … 3 - Wheel Bearing Unit VW Jetta Hybrid Quick Reference Specification Book •...
  • Page 38 Steering Angle Sensor -G85-, on the Steering Column overview 1 - Bolt 30 Nm + 90° turn … Always replace if removed. … 2 - Steering Wheel 3 - Bolt 1.5 Nm … 4 - Steering Angle Sensor -G85- 5 - Steering Column VW Jetta Hybrid Quick Reference Specification Book •...
  • Page 39 VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 40 Mechanical Components front Brakes overview, fS III without Brake Pad Wear Indicator 1 - Bolt 70 Nm + 90° turn … Always replace if removed … 2 - Wheel Bearing Housing 3 - right front ABS Wheel Speed Sensor -G45-/ Left front ABS Wheel Speed Sensor -G47- 4 - Bolt 8 Nm...
  • Page 41 9 - Bolt 12 Nm … 10 - Brake Pads 11 - Brake Caliper 12 - Bearing Bushing 13 - Guide Pins 30 Nm … 14 - Cap 15 - Adapter Sleeve 16 - Brake Hose with ring Connection and Banjo fitting 35 Nm …...
  • Page 42 front Brakes overview, fS III with Brake Pad Wear Indicator 1 - Bolt 12 Nm … 2 - Brake rotor 3 - Bolt 4 Nm … 4 - Brake Pads 5 - Harness Connector 6 - Brake Caliper 7 - Guide Pins 30 Nm …...
  • Page 43 11 - Cap 12 - Bolt 13 - Bracket 14 - Wheel Bearing Housing 15 - right front ABS Wheel Speed Sensor -G45-/ Left front ABS Wheel Speed Sensor -G47- 16 - Bolt 8 Nm … 17 - Wheel Bearing/Wheel Bearing Unit 18 - Cover Plate VW Jetta Hybrid Quick Reference Specification Book •...
  • Page 44 front Brakes overview, fn 3 15/16 inch, without Brake Pad Wear Indicator 1 - Bolt 4 Nm … 2 - Brake rotor 3 - Brake Pads 4 - Spring 5 - Brake Carrier 6 - Brake Caliper 7 - Guide Pins 30 Nm …...
  • Page 45 10 - Bolt 200 Nm … Clean if using again … 11 - Wheel Bearing Housing 12 - right front ABS Wheel Speed Sensor -G45-/ Left front ABS Wheel Speed Sensor -G47- 13 - Bolt 8 Nm … 14 - Cover Plate 15 - Bolt 12 Nm …...
  • Page 46 front Brakes overview, fn 3 15/16 inch with Brake Pad Wear Indicator 1 - Bolt 4 Nm … 2 - Brake rotor 3 - Brake Pads 4 - Spring 5 - Brake Carrier 6 - Brake Caliper 7 - Guide Pins 30 Nm …...
  • Page 47 11 - Bolt 12 - Bracket 13 - Wheel Bearing Housing 14 - right front ABS Wheel Speed Sensor -G45-/ Left front ABS Wheel Speed Sensor -G47- 15 - Bolt 8 Nm … 16 - Cover Plate 17 - Bolt 12 Nm …...
  • Page 48 Brake Cylinder overview 1 - Dust Cap 2 - Bleed Valve 8 Nm … 3 - Wheel Brake Cylinder VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 49 Drum Brakes overview 1 - Axle Beam 2 - Parking Brake Cable 3 - Bolt 8 Nm … 4 - right rear ABS Wheel Speed Sensor -G44-/ Left rear ABS Wheel Speed Sensor -G46- 5 - Stub Axle 6 - Brake Carrier with Brake Shoes 7 - Bolt 30 Nm + 90°...
  • Page 50 Drum Brakes Assembly overview 1 - Spring Plate 2 - Pressure Spring 3 - Brake Shoe 4 - Wedge 5 - Upper return Spring 6 - Contact Spring 7 - Wheel Brake Cylinder 8 - Bolt 8 Nm … 9 - Spring Pin 10 - Brake Carrier 11 - Brake Shoe with Parking Brake Lever 12 - Pressure rod...
  • Page 51 VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 52 multi-link rear Axle overview (Bosch ZoH 38 Brakes) 1 - right rear ABS Wheel Speed Sensor -G44-/ Left rear ABS Wheel Speed Sensor -G46- 2 - Bolt 8 Nm … 3 - Bolt 90 Nm + 90° turn … Always replace if removed …...
  • Page 53 11 - Bolt 4 Nm … 12 - Brake Pads 13 - Brake Carrier with Different Guide Pins and Protective Cap 14 - Brake Pad retaining Plate 15 - ake Pad retaining Plate 16 - Brake Caliper 17 - Bolt 35 Nm …...
  • Page 54 multi-Link rear Axle overview (CI 38 Brakes) 1 - Bolt 90 Nm + 90° turn … Always replace if removed … 2 - Bolt 8 Nm … 3 - rear ABS Wheel Speed Sensor 4 - Axle Beam 5 - Brake Cover Plate 6 - Bolt 12 Nm …...
  • Page 55 11 - Bolt 4 Nm … 12 - Brake Pads 13 - Brake Carrier with Different Guide Pins and Protective Cap 14 - Brake Caliper 15 - Bolt 35 Nm … Always replace if removed … 16 - Parking Brake Cable 17 - Brake Line 14 Nm …...
  • Page 56 twist Beam rear Suspension overview (Bosch ZoH 38 Brakes) 1 - right rear ABS Wheel Speed Sensor -G44-/ Left rear ABS Wheel Speed Sensor -G46- 2 - Bolt 8 Nm … 3 - Axle Beam 4 - Stub Axle 5 - Brake Cover Plate 6 - Bolt 30 Nm + 90°...
  • Page 57 11 - Bolt 8 Nm … 12 - Brake Pads 13 - Brake Carrier with Different Guide Pins and Protective Cap 14 - Brake Pad retaining Plate 15 - Brake Pad retaining Plate 16 - Brake Caliper 17 - Bolt 35 Nm …...
  • Page 58 twist Beam rear Suspension overview (CI 38 Brakes) 1 - Bolt 8 Nm … 2 - rear ABS Wheel Speed Sensor 3 - Axle Beam 4 - Stub Axle 5 - Brake Cover Plate 6 - Bolt 30 Nm + 90° turn …...
  • Page 59 13 - Brake Carrier with Different Guide Pins and Protective Cap 14 - Brake Caliper 15 - Parking Brake Cable 16 - Bolt 35 Nm … Always replace if removed … 17 - Brake Line 14 Nm … 18 - Brake Hose 19 - Bolt 90 Nm + 90°...
  • Page 60 Parking Brake overview 1 - Handle for Parking Brake Lever 2 - trim for Parking Brake Lever 3 - Parking Brake Lever 4 - nut 20 Nm … 5 - Compensator 6 - Adjusting nut 7 - Parking Brake Indicator Lamp Switch -f9- 8 - Parking Brake Cables VW Jetta Hybrid Quick Reference Specification Book •...
  • Page 61 Brake Pedal overview 1 - Bracket 2 - nut 25 Nm … Always replace if removed … 3 - Bearing Bushing 4 - nut 25 Nm … Always replace if removed … 5 - Stop Buffer 6 - Brake Pedal 7 - Cover 8 - Bearing Shell 9 - mount...
  • Page 62 Hydraulic Components Brake Booster/Brake master Cylinder overview 1 - Pedal Assembly 2 - nut 25 Nm … Always replace if removed … 3 - Seal 4 - Brake Booster 5 - Seal 6 - Brake master Cylinder 7 - nut 25 Nm …...
  • Page 63 10 - Brake Line 14 Nm … 11 - Brake Line 14 Nm … 12 - Sealing Plug 13 - Sealing Plug 14 - mounting Pin 15 - Brake fluid reservoir 16 - Cap 17 - Vacuum Line 18 - Vacuum Sensor -G608- VW Jetta Hybrid Quick Reference Specification Book •...
  • Page 64 Brake System Vacuum Pump -V192- overview 1 - Bolt 7 Nm … 2 - Brake System Vacuum Pump -V192- 3 - Bracket 4 - Buffer 5 - Bolt 25 Nm … VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 65 front Brake Caliper overview, fS III 1 - Dust Cap 2 - Bleeder valve 10 Nm … Apply a thin coat of assembly paste -G 052 150 A2- to the threads … before installing. 3 - Caps 4 - Guide Pins 30 Nm …...
  • Page 66 front Brake Caliper overview, fn 3 1 - Dust Cap 2 - Bleeder valve 10 Nm … Apply a thin coat of assembly paste -G 052 150 A2- to the threads … before installing. 3 - Caps 4 - Guide Pins 30 Nm …...
  • Page 67 Bosch ZoH 38 rear Brakes overview 1 - Brake Caliper with Parking Brake Cable Lever 2 - Bleeder Valve 10 Nm … Apply a thin coat of Assembly Paste -G 052 150 A2- to the threads … before installing. 3 - Dust Cap 4 - Bolt 35 Nm …...
  • Page 68 CI 38 rear Brakes overview 1 - Cap 2 - Piston with Automatic Adjustment 3 - Seal 4 - Brake Caliper 5 - Bleeder Valve 10 Nm … Apply a thin coat of Assembly Paste -G 052 150 A2- to the threads …...
  • Page 69 VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 70 SUSPEnSIon, WHEELS, StEErInG Front Suspension Drive Axle with CV Joint VL 100 overview 1 - outer CV Joint 2 - Bolt There are different versions … Refer to the Parts Catalog. … Always replace if removed … 3 - right Drive Axle 4 - Clamp 5 - CV Boot VW Jetta Hybrid Quick Reference Specification Book •...
  • Page 71 6 - Clamp 7 - Plate Spring 8 - thrust ring 9 - Locking ring Always replace if removed … 10 - CV Boot 11 - Clamp Always replace if removed … 12 - Left Drive Axle 13 - Locking Plate 14 - Internal multi-Point Bolt First tighten diagonally to 10 Nm, then tighten diagonally again to …...
  • Page 72 Drive Axle overview, with CV Joint VL 107 1 - outer CV Joint 2 - Bolt There are different versions … Refer to the Parts Catalog. … Always replace if removed … 3 - Locking ring Always replace if removed …...
  • Page 73 13 - Locking Plate 14 - Cover 15 - Inner CV Joint 16 - Seal 17 - Locking ring 18 - Cover 19 - Internal multi-Point Bolt 70 Nm … First tighten diagonally to 10 Nm, then tighten diagonally again to …...
  • Page 74 Drive Axle overview with triple roller Joint AAr3300i 1 - outer CV Joint 2 - Bolt There are different versions … Refer to the Parts Catalog. … Always replace if removed … 3 - Locking ring Always replace if removed …...
  • Page 75 11 - CV Boot for triple roller Joint 12 - Clamp Always replace if removed … 13 - triple roller Star with rollers 14 - Locking ring Always replace if removed … 15 - Internal multi-Point Bolt 70 Nm … First tighten diagonally to 10 Nm, then tighten diagonally again to …...
  • Page 76 Drive Axle overview with triple roller Joint AAr2600i 1 - outer CV Joint 2 - Bolt There are different versions … Refer to the Parts Catalog. … Always replace if removed … 3 - right Drive Axle 4 - Left Drive Axle 5 - Clamp Always replace if removed …...
  • Page 77 11 - Clamp Always replace if removed … 12 - CV Boot for triple roller Joint 13 - Clamp Always replace if removed … 14 - Locking ring Always replace if removed … 15 - Joint 16 - Locking ring Always replace if removed …...
  • Page 78 front Suspension and Control Arm overview 1 - Bolt 15 Nm + 90° turn … Replace after removal … 2 - Body, front 3 - Suspension Strut 4 - nut 65 Nm … 5 - Internal multi-Point Bolt 6 - nut 70 Nm + 90°...
  • Page 79 9 - Ball Joint 10 - nut 100 Nm … 11 - Control Arm 12 - font Bonded rubber Bushing 13 - rear Bonded rubber Bushing 14 - Coupling rod VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 80 Stabilizer Bar overview 1 - Stabilizer Bar There are different versions. … Refer to the Parts Catalog … 2 - Coupling rod 3 - nut 65 Nm … 4 - Subframe 5 - Bolt 20 Nm + 90° turn … Replace after removal …...
  • Page 81 VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 82 Subframe overview 1 - Subframe 2 - nut 3 - Intermediate Plate Replace after removal … 4 - Bolt 70 Nm + 180° turn … M12 x 1.5 x 100 … Replace after removal … 5 - Bolt 70 Nm + 180° turn …...
  • Page 83 8 - Bolt 70 Nm + 180° turn … M12 x 1.5 x 80 … Replace after removal … 9 - Bolt 100 Nm + 90° turn … M14 x 1.5 x 70 … Replace after removal … 10 - Bolt 50 Nm + 90°...
  • Page 84 Suspension Strut overview 1 - nut 60 Nm … Replace after removal … 2 - Suspension Strut Bearing 3 - Axial Groove Ball Bearing 4 - Coil Spring 5 - Protective Sleeve 6 - Stop Buffer 7 - Shock Absorber VW Jetta Hybrid Quick Reference Specification Book •...
  • Page 85 VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 86 Wheel Bearing overview 1 - Cover Plate 2 - Wheel Hub with Wheel Bearing There are different versions … 3 - Bolt There are different versions … Replace after removal … 4 - Bolt 12 Nm … 5 - Hex Socket Head Bolt 8 Nm …...
  • Page 87 9 - Wheel Bearing Housing With integrated brake carrier … 10 - Wheel Bearing Housing With bolted brake carrier … VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 88 Rear Suspension rear Suspension Axle Beam, Subframe and Crossbrace overview 1 - Subframe 2 - Backing Plate 3 - nut 70 Nm + 90° turn … Replace after removal … 4 - Bolt Follow the tightening sequence: … 1. 90 Nm + 90° turn …...
  • Page 89 7 - Bolt Always replace if removed. … 8 - Bonded rubber Bushing 9 - nut 70 Nm + 180° turn … Replace after removal … 10 - Bolt 50 Nm + 45° turn … Replace after removal … 11 - Bracket 12 - Bolt Always replace if removed …...
  • Page 90 Bluemotion Vehicles Subframe Components overview 1 - Subframe 2 - Bolt 3 - Bracket 4 - nut 20 Nm … 5 - trim Panel 2 Nm … 6 - Angle Bracket VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 91 Left rear Level Control System Sensor -G76- overview 1 - Subframe 2 - Lower transverse Link 3 - Bolt 5 Nm … M5 x 20 … 4 - Left rear Level Control System Sensor -G76- VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 92 Shock Absorber and Coil Spring overview, multi-Link rear Suspension 1 - Upper Spring Support 2 - Coil Spring 3 - Low Spring Support 4 - Bolt 180 Nm … 5 - Bolt 50 Nm + 45° turn … Replace after removal …...
  • Page 93 Stabilizer Bar Assembly multi-Link rear Suspension 1 - Stabilizer Bar There are different versions of the suspension … 2 - Bearing 3 - Clamp 4 - Bolt 25 Nm + 45° turn … Replace after removal … 5 - Wheel Bearing Housing 6 - nut 45 Nm …...
  • Page 94 Subframe, transverse Link and tie rod overview, multi-Link rear Suspension 1 - Eccentric Bolt 2 - nut 95 Nm … Replace after removal … 3 - Eccentric Washer 4 - Eccentric Bolt 5 - Eccentric Washer 6 - nut 95 Nm …...
  • Page 95 8 - Bolt Follow the tightening sequence: … 1 - 90 Nm + 90° turn … 2 - Loosen one full turn (360°) … 3 - 90 Nm + 180° turn … Replace after removal … 9 - Lower transverse Link 10 - nut 70 Nm + 180°...
  • Page 96 Wheel Bearing Housing and trailing Arm overview, multi-Link rear Suspension 1 - Bolt 50 Nm + 45° turn … Replace after removal … 2 - Bracket 3 - Bolt 90 Nm + 45° turn … Replace after removal … 4 - Coupling rod 5 - Bolt 90 Nm + 45°...
  • Page 97 8 - right rear ABS Wheel Speed Sensor -G44-/Left rear ABS Wheel Speed Sensor -G46- 9 - Wheel Bearing Housing 10 - Bonded rubber Bushing 11 - nut 45 Nm … Replace after removal … 12 - Bolt 4 Nm …...
  • Page 98 rear Suspension overview 1 - Spring Seat 2 - Coil Spring 3 - Base Plate 4 - Bolt 40 Nm + 90° turn … Replace after removal … 5 - Shock Absorber 6 - Bolt 50 Nm + 45° turn …...
  • Page 99 Shock Absorber overview 1 - Gas-filled Strut 2 - Protective tube 3 - Stop Buffer 4 - Shock Absorber mount 5 - nut 25 Nm … Replace after removal … 6 - Cap VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 100 Wheel Bearing and Disc Brake overview 1 - Axle Beam 2 - Stub Axle 3 - Brake Carrier with Brake Shoes 4 - Bolt 30 Nm + 90° turn … Replace after removal … 5 - Wheel Hub with Wheel Bearing 6 - Bolt 180 Nm + 180°...
  • Page 101 Wheel Bearing and Drum Brake overview 1 - Axle Beam 2 - Stub Axle 3 - Brake Carrier with Brake Shoes 4 - Bolt 30 Nm + 90° turn … Replace after removal … 5 - Wheel Hub with Wheel Bearing 6 - Bolt 180 Nm + 180°...
  • Page 102 Wheels, Tires, Wheel Alignment tire Pressure monitoring Sensor overview 1 - tire Pressure monitoring Sensor 2 - Valve Insert 3 - Sealing Washer 4 - Seal 5 - Disc Wheel 6 - Union nut 8 Nm … 7 - Valve Cap VW Jetta Hybrid Quick Reference Specification Book •...
  • Page 103 VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 104 Alignment Specifications with torsion Beam rear Suspension front Suspension Basic Sport PR numbers Total toe (wheels not pressed) 10’ ± 10′ 10’ ± 10′ Camber (wheels in straight ahead -30′ ± 30′ -40′ ± 30′ position) Maximum permissible difference Maximum 30’ Maximum 30’...
  • Page 105 front Suspension Comfort Heavy Duty Toe out angle with steering wheel 1°12′ ± 20′ 1°7′ ± 20′ turned 20° to left and right Caster 7° 27′ ± 30′ 7° 18′ ± 30′ Maximum permissible difference Maximum 30’ Maximum 30’ between both sides Standing height 389 ±...
  • Page 106 Alignment Specifications, multi-Link rear Suspension front Suspension Basic PR numbers Total toe (wheels not pressed) 10’ ± 10′ Camber (wheels in straight ahead position) -30′ ± 30′ Maximum permissible difference between both sides Maximum 30’ Toe out angle with steering wheel turned 20° to left and 1°19′...
  • Page 107 front Suspension Sport Comfort Heavy Duty Maximum permissible difference Maximum Maximum Maximum between both sides 30’ 30’ 30’ Standing height 364 ± 389 ± 399 ± 10 mm 10 mm 10 mm Depending on the manufacturer, the toe out angle difference can also be indicated negatively in the alignment computer.
  • Page 108 Steering Electromechanical Steering Gear overview 1 - Electrical Wire 2 - Universal Joint 3 - Bolt 30 Nm … M8 x 35 … Always replace if removed. … 4 - torx® Bolt 6 Nm … 5 - Heat Shield 6 - Power-Assisted Steering Gear 7 - Left Wheel Bearing Housing 8 - Power Steering Pump 9 - Bolt...
  • Page 109 10 - Subframe 11 - right Wheel Bearing Housing tightening Sequence for the Steering Gear to Subframe Steps Bolts Tightening specification/ additional turn Pre tighten the bolts -1, 2 Install all the way in by hand. and 3- after each other Pre-torque the bolts -1 and Tighten lastly to 10 Nm in diagonal 2- after each other...
  • Page 110 Electromechanical Steering Gear overview 1 - right tie rod End 2 - nut 70 Nm … 3 - Clamp 4 - Boot 5 - Clamp Replace … 6 - tie rod’ 100 Nm … 7 - Spring Clamp 8 - Left tie rod End VW Jetta Hybrid Quick Reference Specification Book •...
  • Page 111 Hydraulic Power Steering overview 1 - rubber Bushing 2 - Clamp Replace after removal … 3 - Heat Shield 4 - nut 6 Nm … 5 - Bolt 23 Nm … 6 - Seal 7 - Wheel Bearing Housing 8 - nut 20 Nm + 90°...
  • Page 112 Power Steering Gear overview 1 - right tie rod End 2 - nut 70 Nm … 3 - Clamp 4 - Boot 5 - Clamp Replace … 6 - right tie rod 100 Nm … 7 - Power-Assisted Steering Gear 8 - Left tie rod End VW Jetta Hybrid Quick Reference Specification Book •...
  • Page 113 Steering Column overview 1 - Assembly Carrier with Bracket 2 - Steering Column 3 - Brake Pedal Crash Brace 4 - Bolt 20 Nm … Follow tightening sequence, refer to Repair Manual … 5 - Bolt 20 Nm … Follow tightening sequence, refer to Repair Manual …...
  • Page 114 Steering Wheel with Airbag overview 1 - Steering Column 2 - Steering Wheel 3 - Bolt 30 Nm + 90° turn … Replace after removal … VW Passat Quick Reference Specification Book • February 2014...
  • Page 115 ELECtrICAL SyStEm Communication Fastener Tightening Specifications Component Amplifier-to-body nut Antenna amplifier-to-C-pillar screw FM frequency filter in positive wire-to-C-pillar Frequency crossover Front mid-range speaker Radio-to-center console screw Roof antenna-to-body nut Satellite radio-to-rear shelf Satellite tuner antenna-to-body nut Subwoofer in rear shelf VW Jetta Hybrid Quick Reference Specification Book •...
  • Page 116 Electrical Equipment Battery, Starter, Generator, Cruise Control Battery -A- overview 1 - nut 6 Nm … 2 - nut 6 Nm … 3 - fuse Holder 4 - Positive Cable Battery terminal 5 - Battery -A- 6 - Clamping Plate 7 - Bolt 20 Nm …...
  • Page 117 9 - Ground Cable 10 - Battery monitoring Control module -J367- 11 - Ground Cable Battery terminal 12 - nut 20 Nm … no illustration Battery tray bolts: 9 Nm … VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 118 Generator overview 1 - Bolt 23 Nm … 2 - ribbed Belt 3 - ribbed Belt Pulley 4 - Generator -C- 5 - Voltage regulator -C1- 6 - Bolt 2 Nm … 7 - Bolt 2 Nm … 8 - nut 3.2 Nm …...
  • Page 119 Starter overview 1 - Starter -B- 2 - Connection, B+ wire to Starter -B- 3 - nut 20 Nm … 4 - Bolt M10 = 40 Nm … M12 = 75 Nm … 5 - Cap 6 - nut 20 Nm …...
  • Page 120 Instrument Horn overview 1 - Low tone Horn -H7- 2 - nut 10 Nm … Tightening specification bolt to longitudinal member: 20 Nm … 3 - nut 10 Nm … Tightening specification bolt to longitudinal member: 20 Nm … 4 - High tone Horn -H2- VW Passat Quick Reference Specification Book •...
  • Page 121 Windshield Wiper/Washer System Starter overview 1 - Joint-free Windshield Wiper 2 - Windshield Wiper Arm 3 - nut 20 Nm … 4 - Bolt 5 Nm … 5 - Windshield Wiper motor with Wiper motor Control module -J400- 6 - Wiper frame with Linkage no illustration Windshield wiper motor -v- bolts for the wiper frame with linkage: 8 …...
  • Page 122 Exterior Lights, Switches tail Lamp LED Bulbs in rear Lid overview 1 - tail Lamp Assembly Housing in rear Lid 2 - Left Back-Up Lamp Bulb -m16-/right Back-Up Lamp Bulb -m17- 3 - nut 3 Nm … 4 - Bulb Holder VW Passat Quick Reference Specification Book •...
  • Page 123 front fog Lamp, Jetta overview 1 - front Bumper Cover 2 - fog Lamp Housing 3 - Bolt 2 Nm … 4 - Ventilation Hose 5 - Left front fog Lamp Bulb -L22-/right front fog Lamp Bulb -L23- 5 - Cap VW Jetta Hybrid Quick Reference Specification Book •...
  • Page 124 front fog Lamp, Jetta GLI overview 1 - fog Lamp Housing 2 - Bolt 2 Nm … 3 - Left front fog Lamp Bulb -L22-/right front fog Lamp Bulb -L23- 4 - front Bumper Cover VW Passat Quick Reference Specification Book • February 2014...
  • Page 125 VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 126 Halogen Headlamps overview 1 - Cap 2 - Cap 3 - Left Low Beam Headlamp Bulb -m29-/right Low Beam Headlamp Bulb -m31- 4 - Left front Side marker Lamp Bulb -m33-/right front Side marker Lamp Bulb -m34- 5 - Left Daytime running Lamp Bulb -L174-/right Daytime running Lamp Bulb -L175- 6 - Bolt 8 Nm...
  • Page 127 11 - Left front turn Signal Bulb -m5-/right front turn Signal Bulb -m7- 12 - Left Position Lamp Bulb -m1-/right Position Lamp Bulb -m3- 13 - Left High Beam Headlamp Bulb -m30-/right High Beam Headlamp Bulb -m32- VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 128 HID Headlamps and Cornering Lamp overview 1 - Cap 2 - Cap 3 - Left Cornering Lamp Bulb -L148- or right Cornering Lamp Bulb -L149- 4 - Left front turn Signal Bulb -m5-/right front turn Signal Bulb -m7- 5 - Left Headlamp Beam Adjustment motor -V48- and right Headlamp Beam Adjustment motor -V49- 6 - Left HID Headlamp Bulb -L13-/right HID Headlamp Bulb -L14- 7 - Bolt...
  • Page 129 13 - Bolt 1.4 Nm … 14 - Bolt 1.4 Nm … 15 - Left Headlamp Power output Stage -J667-/right Headlamp Power output Stage -J668- 16 - Bolt 5 Nm … 17 - Carrier, front End 18 - Cornering Lamp And Headlamp range Control module -J745- VW Jetta Hybrid Quick Reference Specification Book •...
  • Page 130 High-mounted Brake Lamp overview 1 - High-mounted Brake Lamp 2 - Bolt 2 Nm … VW Passat Quick Reference Specification Book • February 2014...
  • Page 131 Steering Column Switch module overview, Valeo 1 - Steering Column Electronics Control module -J527- 2 - Steering Column Combination Switch -E595- 3 - Steering Column Switch mount 4 - Shear Bolts 15 Nm … 5 - Steering Lock Housing- 6 - Ignition Switch and Lock Cylinder 7 - Bolt 1.5 Nm …...
  • Page 132 Steering Column Switch module overview, kostal 1 - Steering Column Electronics Control module -J527- 2 - Steering Column Combination Switch -E595- 3 - Steering Column Switch mount 4 - Shear Bolts Break-off torque: approximately 15 Nm … 5 - Bolt 2.5 Nm …...
  • Page 133 Steering Column Switch module overview, kESSy 1 - Steering Column Electronics Control module -J527- Bolts: 1.5 Nm … 2 - Steering Column Combination Switch -E595- 3 - Steering Column Switch mount 4 - Shear Bolts Break-off torque: approximately 15 Nm …...
  • Page 134 trailer Socket -U10-, overview 1 - trailer Socket -U10- 2 - Bolt 2 Nm … 3 - towing recognition Control module -J345- 4 - Bolt 1.2 Nm … Interior Lights, Switches Fastener Tightening Specifications Component Alarm Horn Nut Frame bolts Front Interior Lamp VW Passat Quick Reference Specification Book •...
  • Page 135 Wiring relay Panels, fuse Panels and E-Boxes Component Location overview 1 - Vehicle Electrical System Control module -J519- relay carrier 2 - fuse Panel Behind the Instrument Panel on the Driver Side 3 - Bolt 2.5 Nm … 4 - nut 6 Nm …...
  • Page 136 Electrical Drive Electric Drive Power and Control Electronics -JX1- overview 1 - Bolt 7 Nm … 2 - Cover 3 - Bolt 20 Nm … 4 - Bolt 9 Nm … 5 - High Voltage Connection Cover Plate 6 - Bolt 9 Nm …...
  • Page 137 9 - Cable Bracket 10 - Electric Drive Power and Control Electronics -JX1- Tightening Specifications, High Voltage Contacts 1 - High Voltage Contacts -arrows- 20 Nm … 2 - threaded Connection -2- and -3- 5 Nm … VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 138 Tightening Specifications for the Electric A/C Compressor -V470- fuse 1 - Bolts -arrows- 2.7 Nm … 2 - Tightening Specifications for Terminal 30/Terminal 31 Nut 20 Nm … VW Passat Quick Reference Specification Book • February 2014...
  • Page 139 VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 140 Hybrid Battery Unit -AX1- overview 1 - nut 5 Nm … 2 - reinforcement 3 - nut 5 Nm … 4 - reinforcement 5 - Cap 6 - Bolt 4 Nm … 7 - Cover 8 - Bolt 4 Nm …...
  • Page 141 12 - Exhaust Air Duct 13 - Bolt 2 Nm … 14 - Bolt 4 Nm … 15 - Cover Plate 16 - Battery fan 1 -V457- 17 - right Air Guide Duct 18 - Bolt 4 Nm … 19 - Air Guide Duct 20 - Lower Supply Air Duct 21 - Bolt 4 Nm...
  • Page 142 Tightening Specifications, High Voltage Contacts 1 - High Voltage Contacts -2- 20 Nm … 2 - threaded Connection -arrows- 5 Nm … If microencapsulated bolts -arrows- were used: replace. … Bolt tightening specification for the Battery Regulation Control … Module -J840-: 5 Nm VW Passat Quick Reference Specification Book •...
  • Page 143 Tightening Specifications, High Voltage Contacts Electro-Drive Drive motor -V141-. 1 - High Voltage Contacts -2- 20 Nm … 2 - threaded Connection -3- 5 Nm … VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 144 Bolt Tightening Specification for the Electro- Drive Drive motor -V141- Cover. 1 - Bolt -2- 20 Nm … - Bolt tightening specification for the Electro-Drive Drive Motor V141- cover: 20 Nm … - Bolt tightening specification for the Electro-Drive Drive Motor -V141- connection box: 20 Nm …...
  • Page 145 Bolt Tightening Specification for the Wiring Guide -1-. - Bolt -arrow- 20 Nm … VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 146 Tightening Specifications for the Potential Equalization Cable to Electric Drive Power and Control Electronics -Jx1- -1- - Bolt to Electric Drive Power and Control Electronics -JX1--3- tightening specification 9 Nm … - nut -2- 20 Nm … VW Passat Quick Reference Specification Book • February 2014...
  • Page 147 Tightening Specifications for the Potential Equalization Cable -2- on the Electro-Drive Drive motor -V141- - Bolt tightening specification -1-: 8 Nm … - Bolt tightening specification -3-: 8 Nm … - Bolt tightening specification -4-: 20 Nm … VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 148 BoDy Body Dimensions Body, front Component 5.0 ± 0.5 1.9 ± 0.5 2.5 ± 0.5 2.0 ± 1.0 0.0 ± 0.5 4.9 ± 0.5 0.5 ± 0.5 0.5 ± 0.5 3.2 ± 1.5 0.5 – 1.6 ± 0.5 VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 149 Body, Center Component 3.5 ± 0.5 0.0 ± 0.8 0.0 ± 1.0 4.2 ± 0.5 4.5 ± 0.5 5.1 ± 0.5 0.8 ± 1.0 3.5 ± 0.5 VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 150 Body, rear Component 1.0 ± 0.5 0.5 ± 0.5 3.7 ± 0.5 0.0 – 0.5 ± 0.5 2.0 ± 0.5 2.5 ± 0.5 0.5 ± 0.5 0.0 ± 0.5 3.5 ± 0.5 0.8 + 0.5 5.0 ± 0.5 VW Passat Quick Reference Specification Book • February 2014...
  • Page 151 Body Exterior Body front Bulkhead overview 1 - Bulkhead 2 - Body flange 3 - PUr Adhesive Sealant 4 - Bolt 25 Nm … VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 152 front fender overview 1 - fender 2 - Bolt 6 Nm … 3 - fender End Plate 4 - noise Insulation, fender End Plate 5 - foam Piece 6 - fender Brace 7 - Bolt 6 Nm … VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 153 VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 154 Lock Carrier overview 1 - Lock Carrier with Attachments 2 - Air Guide Channel 3 - Bolt 2 Nm … 4 - Bolt 8 Nm … 5 - Bracket 6 - Air Ducts 7 - Bolt 8 Nm … 8 - Bolt 60 Nm …...
  • Page 155 12 - Bolt 8 Nm … 13 - Center Guide 14 - Air Ducts 15 - Bolt 12 Nm … 16 - Support 17 - Bracket VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 156 noise Insulation overview, Gasoline 1 - noise Insulation 2 - Bolt 2 Nm … 3 - front Bumper Cover VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 157 noise Insulation overview, Diesel 1 - noise Insulation 2 - Bolt 2 Nm … 3 - Bolt 6 Nm … 4 - front Bumper Cover VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 158 tunnel Bridge overview 1 - front tunnel Bridge 2 - Hex nut 20 Nm … 3 - rear tunnel Bridge VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 159 Underbody trim Panel overview 1 - Underbody trim Panel 2 - nut 2 Nm … 3 - Cover VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 160 right rear Underbody trim Panel 1 - right rear Underbody trim Panel 2 - Bolt 2.7 Nm … 3 - nut 2 Nm … VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 161 Hood, Lids fuel filler Door Unit overview 1 - Connector 2 - fuel tank Lid Unlock motor -V155- 3 - fuel filler Door Unit 4 - Bolt 1.5 Nm … 5 - Water Drain Hose VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 162 Hood overview 1 - Hood 2 - Adjusting Buffer 3 - Center Seal 4 - Hood Catch 5 - Insulation 6 - Hinge 7 - Support rod 8 - Hood Latch 9 - Bolt 22 Nm … 10 - nut 22 Nm …...
  • Page 163 Hood release Lever and Bracket overview 1 - Bracket 2 - Cable 3 - Expanding nut 4 - Bolt 1.5 Nm … 5 - Hood release Lever VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 164 rear Lid Hinge overview 1 - rear Lid 2 - Bolt 9 Nm … 3 - Hinge 4 - Gas-filled Strut 5 - Electric Wire 6 - Bolt 9 Nm … 7 - Spring VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 165 front Doors, Central Locking System Door Handle and Door Lock overview 1 - Door Lock 2 - Bolt 4 Nm … 3 - Bracket 4 - Lock Cylinder 5 - Backing 6 - Cover 7 - Door Handle 8 - Bolt 1 Nm …...
  • Page 166 front Door overview 1 - Door 2 - Cable 3 - Bracket 4 - Door Handle 5 - Lock Cylinder 6 - Backing 7 - Cover 8 - outer Window Shaft Seal 9 - Bracket 10 - rivet 11 - Bolt 18 Nm …...
  • Page 167 16 - Bolt 9 Nm … 17 - Door Strap 18 - Inner Window recess Seal 19 - Door Window VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 168 Door Hinge overview 1 - Door 2 - Bolt 40 Nm … Always replace … 3 - Door Hinge 4 - Bolt 23 Nm … 5 - Cover 6 - Bolt 40 Nm … Always replace … 7 - Door Hinge 8 - Bolt 40 Nm …...
  • Page 169 10 - Door Strap 11 - Bolt 9 Nm … 12 - Bolt 40 Nm … Always replace … VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 170 rear Doors Door Handle and Door Lock overview 1 - Bolt 18 Nm … 2 - Dock Lock 3 - Cable 4 - Cable 5 - Bracket 6 - Bolt 1 Nm … 7 - Door Handle 8 - Cap 9 - Backing VW Jetta Hybrid Quick Reference Specification Book •...
  • Page 171 VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 172 rear Door overview 1 - Door 2 - outer Window Shaft Seal 3 - Bracket 4 - Door Handle 5 - Cable 6 - Backing 7 - Cap 8 - fixed Door Window 9 - Dock Lock 10 - Bolt 18 Nm …...
  • Page 173 15 - Door Strap 16 - Bolt 9 Nm … 17 - Bolt 4 Nm … 18 - Angle Bracket 19 - Inner Window recess Seal 20 - Door Window VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 174 Door Hinge overview 1 - Door 2 - Bolt 40 Nm … Always replace … 3 - Door Hinge 4 - Bolt 23 Nm … 5 - Cap 6 - Bolt 40 Nm … Always replace … 7 - Door Hinge 8 - Bolt 40 Nm …...
  • Page 175 9 - Bolt 30 Nm … 10 - Door Strap 11 - Bolt 9 Nm … VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 176 Sunroof Sunroof overview 1 - Sunroof Glass Panel (one-piece safety glass) 2 - Bellows 3 - Bolt 7 Nm … 4 - Bolt 1 Nm … 5 - Guide Piece 6 - Sunshade 7 - Assembly Unit 8 - Bolt 8 Nm …...
  • Page 177 VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 178 Bumpers front Bumper Cover overview 1 - front Bumper Cover 2 - Bolt 2.7 Nm … 3 - Bolt 2 Nm … 4 - Bolt 2 Nm … 5 - Bolt 2 Nm … VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 179 front Bumper Cover Guides overview 1 - Center Guide 2 - Side Guide 3 - Bolt 2.7 Nm … 4 - Bolt 8 Nm … VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 180 front Bumper Carrier overview 1 - front Bumper Carrier 2 - Bolt 8 Nm … 3 - foam Piece 4 - nut 8 Nm … 5 - Bolt 60 Nm … VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 181 rear Bumper Cover overview 1 - Center Guide 2 - rear Bumper Cover 3 - Bolt 2.7 Nm … 4 - Bolt 2.7 Nm … 5 - Bolt 2.7 Nm … 6 - Bolt 2.7 Nm … 7 - Side Guide 8 - Angle Bracket VW Jetta Hybrid Quick Reference Specification Book •...
  • Page 182 rear Bumper Cover Guides overview 1 - Center Guide) 2 - Bolt 4 Nm … 3 - Bolt 4 Nm … 4 - Bolt 4 Nm … 5 - Side Guide 6 - Angle Bracket VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 183 rear Bumper Carrier overview 1 - rear Bumper Carrier 2 - Bolt 20 Nm … 3 - foam Piece VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 184 Glass, Window regulators front Door Window overview 1 - Clip 2 - Door Window 3 - front Door 4 - Window regulator 5 - nut 8 Nm … 6 - Window regulator motor 7 - Bolt High equipment (AW1): 3 Nm …...
  • Page 185 rear Door Window overview 1 - Door Window 2 - fixed Door Window 3 - Bolt 5.5 Nm … 4 - Window regulator 5 - nut 8 Nm … 6 - Window regulator motor 7 - Bolt High equipment (AW1): 3 Nm …...
  • Page 186 Exterior Equipment front Wheel Housing Liner overview 1 - Wheel Housing Liner 2 - Bolt 2 Nm … 3 - Expanding nut VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 187 rear Wheel Housing Liner Assembly overview 1 - Wheel Housing Liner 2 - Bolt 2 Nm … 3 - Expanding nut 4 - Expanding nut VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 188 manual Exterior mirror Assembly overview 1 - mirror Housing 2 - mirror Base Plate 3 - trim 4 - mirror Glass 5 - Adjusting Unit 6 - Insulation 7 - Bolt 12 Nm … VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 189 Power Exterior mirror Assembly overview 1 - mirror Housing 2 - mirror Base Plate 3 - Adjusting Unit with Exterior rearview mirror motor 4 - Bolt 2 Nm … 5 - trim 6 - mirror Glass 7 - Electric Wire with Connector 8 - Bolt 12 Nm …...
  • Page 190 Sill Panel Cover Assembly overview 1 - Sill Panel Cover 2 - Bolt 2 Nm … 3 - Expanding nut VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 191 Body Interior Interior Equipment Tightening Specifications Component Center console storage compartment screws Steering column trim screws Driver side instrument panel cover screws Glove compartment screws Glove compartment decorative trim screws Eyeglass compartment screws Sunvisor mount screw Roof grab handle bracket bolts Rear center console trim bracket bolts, Comfort and Highline Front console side mounting bracket screws...
  • Page 192 Passenger Protection, Airbags, Seat Belts front three-Point Seat Belt Assembly overview 1 - Bolt 40 Nm … 2 - Seat Belt Height Adjuster 3 - Seat Belt Guide ring 4 - Seat Belt Guide 5 - Automatic Belt retractor 6 - Belt End fitting 7 - Bolt 40 Nm …...
  • Page 193 Airbag Control module -J234- Assembly overview 1 - Airbag Control module -J234- 2 - nut 9 Nm … 3 - nut 9 Nm … 4 - Connector VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 194 front Seat Assembly overview, Basis 1 - Wiring Harness 2 - front Seat Cushion 3 - Positioning Aids 4 - Positioning Aids 5 - Passenger occupant Detection System Pressure Sensor -G452- 6 - Adhesion Surfaces 7 - Bolt 1.5 Nm …...
  • Page 195 front Seat Assembly overview, Comfort 1 - Wiring Harness 2 - front Seat Cushion 3 - Positioning Aids 4 - Passenger occupant Detection System Pressure Sensor -G452- 5 - Positioning Aids 6 - Adhesion Surfaces 7 - Bolt 1.5 Nm …...
  • Page 196 front Seat Assembly overview, Sport 1 - Wiring Harness 2 - front Seat Cushion 3 - Positioning Aids 4 - Positioning Aids 5 - Passenger occupant Detection System Pressure Sensor -G452- 6 - Adhesion Surfaces 7 - Bolt 1.5 Nm …...
  • Page 197 VW Jetta Hybrid Quick Reference Specification Book • February 2014...
  • Page 198 Interior trim Instrument Panel Central tube Assembly overview 1 - nut 9 Nm … 2 - Bolt 1.5 Nm … 3 - Bolt 20 Nm … 4 - nut 4.5 Nm … 5 - Instrument Panel Central tube 6 - front Passenger Side Deformation Element 7 - mount with Extensor 8 - nut 20 Nm...
  • Page 199 9 - Bolt 20 Nm … 10 - threaded Plate 11 - Bolt 20 Nm … 12 - nut 20 Nm … 13 - mount with Extensor 14 - Driver Side Deformation Element 15 - Center Deformation Element 16 - Bolt 20 Nm …...
  • Page 200 Seat frames manual front Seat Assembly overview 1 - Backrest 2 - Headrest 3 - Door Sill Side Seat trim 4 - Bolt 40 Nm … 5 - Cover 6 - Seat Height Adjuster 7 - Backrest Adjuster 8 - Cover 9 - Storage Compartment 10 - Cover 11 - Seat forward/Back Adjustment Handle...
  • Page 201 Partial Power front Seat Assembly overview 1 - Backrest 2 - Headrest 3 - Door Sill Side Seat trim 4 - Bolt 40 Nm … 5 - Cover 6 - Seat Height Adjuster 7 - Backrest Adjustment Button 8 - Cover 9 - Seat forward/Back Adjustment Handle 10 - Cover 11 - Lower Seat frame...
  • Page 202 manual Lower Seat frame Assembly overview 1 - Seat Cushion 2 - Lower Seat frame 3 - Bracket 4 - Bolt 8 Nm … 5 - Expanding rivet 6 - Handle 7 - Handle 8 - Cover 9 - Seat trim 10 - Bolt 20 Nm …...
  • Page 203 Partial Power Lower Seat frame Assembly overview 1 - Seat Cushion 2 - Lower Seat frame 3 - Bracket 4 - Bolt 8 Nm … 5 - Expanding rivet 6 - Handle 7 - Seat trim 8 - tunnel Side Seat trim 9 - Seat Belt Latch 10 - Bolt 20 Nm...
  • Page 204 Seat Height Adjustment Assembly overview 1 - Bolt 6.5 Nm … 2 - Seat Height Adjusting Lever 3 - Clip 4 - Seat Height Adjustment Handle 5 - Lower Seat frame 6 - Lock Washer 7 - Seat Height Adjuster 8 - Bolt 10 Nm …...
  • Page 205 HEAtInG, VEntILAtIon & AIr ConDItIonInG General, Technical Data refrigerant oil Distribution Component Approximate % of total amount of oil in component A/C compressor Condenser Suction hose Evaporator Fluid reservoir refrigerant r134a Vapor Pressure table temperature in °C Pressure in bar (positive pressure) of r134a -0.61 -0.49...
  • Page 206 Heating, Ventilation Fastener Tightening Specifications Component Auxiliary heater heating element screw Auxiliary heater heating element connector strip 9 ±1 Auxiliary heater heating element voltage supply nuts 6 ±1 Fresh air blower bolt From 1K-7M 119 727 Through 1K-7M 119 726 VW Jetta Hybrid Quick Reference Specification Book •...
  • Page 207 Air Conditioning refrigerant Circuit Components overview 1 - Condensor 2 - A/C Compressor 3 - Hex Head nut 6 Nm … 4 - Bracket 5 - High Pressure Sensor -G65- 6 - Expansion Valve 7 - Evacuating and Charging Valve 8 - Evacuating and Charging Valve VW Jetta Hybrid Quick Reference Specification Book •...
  • Page 208 Fastener Tightening Specifications Component A/C compressor bolts Climatic Heating and A/C unit bracket (item 3) screws Heating and A/C unit bracket (items 5, 11) screws Climatronic Heating and A/C unit bracket (item 3) screws Heating and A/C unit bracket (items 5, 11) screws Climatronic control module 1.5 ±...