Volkswagen Jetta Hybrid (2013 year). Manual - part 11

Risk of false measurements.

♦ Do not insert any shim!

– Check that engaging lever is seated correctly.

– Place gauge block -T10466- on large engagement bearing.

Flat side faces upwards.

– To ensure that gauge block -T10466- sits properly on engage‐

ment bearing, press down and turn gauge block.

• Engagement bearing will turn with gauge block -T10466- .

– Place digital 300 mm depth gauge -VAS 6594- on top of ruler

and position depth gauge rod on outer input shaft.

• Ruler -T40100- is lying upwards across end of shaft on gear‐

box flange.

Caution

Risk of false measurements.

♦ The ruler -T40100- should remain in this position for the

following measurements. Do not turn over, do not remove.

– Set depth gauge to “0”.

– Position depth gauge rod on gauge block -T10466- , as show

in diagram.

– In this position, determine dimension “A 1a” to gauge block -

T10466- .

• Example: Dimension “A 1a” = 5.03 mm

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• Example: Dimension “A 1b” = 5.01 mm
– Calculate mean value from dimension “A 1a” and “A 1b”.

Formula: A 1a + A 1b 2

Example:
• 5,03 + 5,012 = 5.02 mm
• Result: Dimension “A 1” = 5.02 mm
3rd step: Calculate height tolerance of clutch engagement bear‐

ing “K 1”

Note

On the basis of dimension “A 1” and dimension “B”, the height

tolerance of the engagement bearing for clutch “K 1” is now cal‐

culated according to the following calculus.

 

Dimension “A 1”

–

Dimension “B”

=

Actual height tolerance of clutch engagement bearing “K

1”

Example:
• 5.02 mm - 2.60 mm = 2.42 mm
• Result: Height tolerance of clutch engagement bearing “K 1”

= 2.42 mm

4th step: Calculate clutch tolerance of clutch “K 1”.
– Read clutch tolerance value from new clutch.
• Example: Read off clutch tolerance value on clutch

“K 1 = +0.2”, as shown in diagram.

• Result: Clutch tolerance of clutch “K 1” = + 0.20 mm.
5th step: Determine thickness of shim “SK 1”

Note

On the basis of the clutch tolerance “K 1”, the thickness of shim

“SK 1” is now calculated according to the following calculus.

 

Height tolerance of engagement bearing “K 1”

–/+ Clutch tolerance of clutch “K 1”
=

Calculated thickness of shim “SK 1”

Example:
• 2.42 mm + 0.20 mm = 2.62 mm
• Result: Calculated thickness of shim “SK 1” = 2.62 mm

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Calculated thick‐

ness of shim

mm

Available shims

Thickness in mm

Part number of shim

1.21 … 1.60

1.50

0AM 141 383

1.61 … 1.80

1.70

0AM 141 383 A

1.81 … 2.00

1.90

0AM 141 383 B

2.01 … 2.20

2.10

0AM 141 383 C

2.21 … 2.40

2.30

0AM 141 383 D

2.41 … 2.60

2.50

0AM 141 383 E

2.61 … 2.80

2.70

0AM 141 383 F

2.81 … 3.00

2.90

0AM 141 383 G

3.01 … 3.20

3.10

0AM 141 383 H

3.21 … 3.40

3.30

0AM 141 383 J

3.41 … 3.80

3.50

0AM 141 383 K

Example:
• Result: Calculated thickness of shim “SK 1” = 2.62 mm
• Chosen shim thickness = 2.70 mm = part number 0AM 141

383 F

Caution

Risk of damaging the clutch!

♦ Only use this shim when installing.

– Remove gauge block -T10466- and large engaging lever

again.

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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« engaging lever.

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.
Setting engaging lever »K2« to installation position:

– Hold upper section of guide sleeve with one hand. With the

other hand turn the lower section of guide sleeve in

-direction of arrow- until the sleeve moves freely.

Note

Apply high force to hold both sections, as this is necessary for

turning the lower section of the guide sleeve.

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