Volkswagen Jetta Hybrid (2013 year). Manual - part 12

lever and the sleeve moves freely.

Continuation for all:
– Install »small« engaging lever together with upper and lower

section of guide sleeve. Insert and tighten new bolts.

– Insert »small« engagement bearing without shim.

Caution

Risk of false measurements.

♦ Do not insert any shim!

• Small engagement bearing only fits in one position due to 8

grooves.

– By turning, check whether small engagement bearing has

been installed correctly and that grooves are seated correctly.

Jetta Hybrid 2013 ➤

2. Clutch mechanism    

41

 

– 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 2a” to gauge block -

T10466- .

• Example: Dimension “A 2a” = 4.79 mm

Jetta Hybrid 2013 ➤

42

 

• Example: Dimension “A 2b” = 4.75 mm
– Calculate mean value from dimension “A 2a” and “A 2b”.

Formula: A 2a + A 2b 2

Example:
• 4,79 + 4,752 = 4.77 mm
• Result: Dimension “A 2” = 4.77 mm
7th step: Calculate height tolerance of clutch engagement bearing

“K 2”

Note

On the basis of dimension “A 2” and dimension “B”, the height

tolerance of the engagement bearing for clutch “K 2” is now cal‐

culated according to the following calculus.

 

Dimension “A 2”

–

Dimension “B”

=

Actual height tolerance of clutch engagement bearing “K

2”

Example:
• 4.77 mm - 2.60 mm = 2.17 mm
• Result: Height tolerance of clutch engagement bearing “K 2”

= 2.17 mm

8th step: Calculate clutch tolerance of clutch “K 2”
– Read clutch tolerance value from new clutch.
• Example: Read off clutch tolerance value on clutch “K 2 = –

0.2”, as shown in illustration.

• Result: Clutch tolerance of clutch “K 2” = – 0.20 mm.
9th step: Determine thickness of shim “SK 2”

Note

On the basis of the clutch tolerance “K 2”, the thickness of shim

“SK 2” is now calculated according to the following calculus.

 

Height tolerance of engagement bearing “K 2”

–/+ Clutch tolerance of clutch “K 2”
=

Calculated thickness of shim “SK 2”

Example:
• 2.17 mm – 0.20 mm = 1.97 mm
• Result: Calculated thickness of shim “SK 2” = 1.97 mm

Jetta Hybrid 2013 ➤

2. Clutch mechanism    

43

 

Calculated thickness of shim

mm

Available shims

Thickness in mm

0.31 … 0.90

0.80

0.91 … 1.10

1.00

1.11 … 1.30

1.20

1.31 … 1.50

1.40

1.51 … 1.70

1.60

1.71 … 1.90

1.80

1.91 … 2.10

2.00

2.11 … 2.30

2.20

2.31 … 2.50

2.40

2.51 … 2.70

2.60

2.71 … 3.30

2.80

Example:
• Result: Calculated thickness of shim “SK 2” = 1.97 mm
• Chosen shim thickness = 2.00 mm

Caution

Risk of damaging the clutch!

♦ Only use this shim when installing.

The adjusting work has now been completed and the »small« en‐

gaging lever has already been installed.
– Install dual clutch 

⇒ page 20

 .

♦ Lower section of guide sleeve with small engaging lever to

gearbox housing 

⇒ Item 9 (page 28)

 .

Jetta Hybrid 2013 ➤

44