Volkswagen Jetta Hybrid (2013 year). Manual - part 4

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‐

ceeding 50 km.

Note

It is not possible to tow-start the engine.

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3. Safety instructions    

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⇒ “4.1 General notes”, page 10
⇒ “4.2 Rules for cleanliness”, page 11
⇒ “4.3 General repair notes”, page 11

4.1

General notes

Gearbox
♦ The torque of the engine is transmitted to the dual clutch via

the electric drive motor -V141- . The electric drive motor -

V141- and the dual clutch are joined together by a toothed

connection. The electric drive motor -V141- is provided with a

disengagement clutch. The disengagement clutch in the elec‐

tric drive motor -V141- separates the combustion engine from

the electric drive motor -V141- .

♦ The gearbox is structured like a 7-speed manual gearbox.

Through opposed hydraulic actuation of two multi-plate dry

clutches, it is operated like an automatic gearbox. In other

words, the gears are engaged automatically or manually via

the Tiptronic system. There is no clutch pedal.

♦ When the ignition is switched off, both clutches are disengag‐

ed. In sub-gearbox 1 the 1st gear is engaged. In sub-gearbox

2 the reverse gear is engaged.

In some vehicles, a cover is fitted over the engaging levers.
The cover prevents dirt getting in.
Specified torque: 8 Nm

Selector mechanism
The feedback for the gearbox concerning the selector lever po‐

sition is not transferred by mechanical means via the selector

lever cable and the multifunction switch anymore, as is the case

for the automatic gearbox. The information concerning selector

lever positions or shifting operations are transferred to the gear‐

box control unit via a separate control unit in the selector mech‐

anism and the CAN data bus. That is, gears are shifted without

any mechanical cables being involved. Only for selector lever po‐

sition “P” the parking lock is engaged mechanically via the selec‐

tor lever cable.

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the hydraulic fluid section -arrow B-.
Only the gearbox oils available through the replacement parts

system must be used for the dual clutch gearbox 0CG. Other oils

will lead to malfunctions or failure of the gearbox, part number ⇒ 

Electronic parts catalogue “ETKA” .
Do not mix »additives« in oil.
Oil which has been drained out cannot be added again.
The oil level in the gearbox cannot be checked. The oil level can

only be adjusted by changing the gearbox oil, e.g. in the event of

leaks on the gearbox

⇒ “6.1 Draining and filling gearbox oil”, page 86

 .

4.2

Rules for cleanliness

♦ Carefully clean connection points and the surrounding area

with engine cleaner or brake cleaner and dry thoroughly before

opening.

♦ Clean the gearbox and gearbox components using e.g. clean‐

ing solution -D 009 401 04- .

♦ Use lint-free cloths for cleaning.
♦ Seal open lines and connections immediately using suitable

and only new sealing plugs. Allocate sealing plugs according

to ⇒  Electronic parts catalogue “ETKA” .

♦ Place removed parts on a clean surface and cover them over.

Use plastic sheeting and paper. Use lint-free cloths only!

♦ If repair work cannot be performed immediately, cover new

parts which have been removed from their packing.

♦ Install only clean parts; do not remove new parts from pack‐

aging until immediately before installing.

♦ Protect disconnected electrical connections from dirt and wa‐

ter and only reconnect in dry condition.

♦ Always make sure that no dirt can enter an »open« gearbox.
♦ If gearbox covers have been unbolted or gearbox has no fluid,

do not run engine. Do not tow vehicle.

♦ If repair work cannot be performed immediately, cover opened

parts carefully.

4.3

General repair notes

♦ To ensure flawless and successful gearbox repairs, the great‐

est care and cleanliness as well as the use of good and proper

tools are essential. Of course, the basic rules for safety also

apply during repair work.

♦ A number of generally applicable instructions for the various

repair procedures - which were previously repeated at numer‐

ous places in the Workshop Manual - are summarised here.

They apply to this workshop manual.

Guided fault finding, vehicle self-diagnosis and testing
♦ Before performing repairs on the gearbox, determine the

cause of the fault as accurately as possible using vehicle di‐

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4. Repair instructions    

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, 

Vehicle self-

diagnosis

 and 

Test instruments

 modes.

Various functions are available in the operating modes 

Guided

functions

 and 

Guided fault finding

 

⇒ page 13

 .

Special tools
For a complete list of special tools used in this workshop manual,

see ⇒  "Workshop equipment and special tools" .
Gearbox
♦ Do not run engine or tow vehicle with sump removed or when

there is no gearbox oil in the gearbox.

♦ Thoroughly clean all joints and surrounding areas before dis‐

mantling.

♦ When installing, ensure that the dowel sleeves are fitted cor‐

rectly.

O-rings, seals, gaskets
♦ Always renew O-rings, seals and gaskets.
♦ Oil seals are also called radial oil seals.
♦ After removing gaskets and seals, always inspect contact sur‐

face of housing or shaft for burrs resulting from removal or for

other signs of damage.

♦ Thoroughly clean housing joint surfaces before assembly.
♦ Lightly lubricate outer circumference and sealing lip of oil seals

with gearbox oil before installing.

♦ Coat O-rings with oil to prevent pinching of rings during as‐

sembly.

♦ Never use any other types of lubrication in the gearbox oil

section. Otherwise there is a risk of malfunctions in the hy‐

draulic gearbox control.

♦ The open side of the oil seal faces the side with fluid filling.
♦ Press in new oil seals so that sealing lip does not contact the

shaft in the same place as the old seal (make use of insertion

depth tolerances).

♦ Observe rules for cleanliness 

⇒ page 11

 .

Locking devices
♦ Do not overstretch retaining rings.
♦ Always renew retaining rings which have been damaged or

overstretched.

♦ Retaining rings must locate properly in grooves.
Nuts and bolts
♦ Loosen bolts in sequence opposite to the tightening sequence.
♦ Securing bolts and securing nuts which secure covers and

housings should be loosened and tightened diagonally in

stages if no tightening sequence is specified.

♦ Renew self-locking nuts.
♦ Threads of bolts secured with locking fluid must be cleaned

with a wire brush. Then insert bolts with locking fluid -

AMV 185 101 A1- .

♦ Specified torques settings are specified for unoiled bolts and

nuts.

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