Volkswagen Jetta Hybrid (2013 year). Manual - part 18

⇒ “2.1 Removing gearbox”, page 65
⇒ “2.2 Installing gearbox”, page 69
⇒ “2.3 Specified torques for gearbox”, page 72

2.1

Removing gearbox

10 ; Removing and installing engine; Removing engine .

Remove gearbox from engine as follows:
Special tools and workshop equipment required
♦ Bits XZN 12 -T10099-

♦ Socket -T10061-

♦ Shackle -10 - 222 A /12-

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2. Removing and installing gearbox    

65

 

scissor-type assembly platform -VAS 6131- .

– Disconnect connector -1- from selector valve -2- of mecha‐

tronic unit and pull wiring harness off retainer on front of

gearbox.

– Remove high-voltage wiring harness for drive motor -PX2- to‐

gether with terminal box -1- from gearbox ⇒  Electrical system,

and installing high-voltage wiring harness for drive motor -

PX2- .

– Also remove cable retainer -1- for high-voltage wiring harness

for drive motor -PX2- from gearbox -arrows- ⇒  Electrical sys‐

tem, hybrid vehicles; Rep. gr.  93 ; High-voltage cables; Re‐

moving and installing high-voltage wiring harness for drive

motor -PX2- .

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66

 

– Remove vacuum pump for brakes -V192- -B- together with

bracket from gearbox and tie it up to side of engine.

– Release and disconnect connector -D- from drive motor rotor

position sender 1 -G713- -C-.

– Unscrew bolts -arrows- and pull out drive motor rotor position

sender 1 -G713- .

WARNING

Risk of soiling.
Thoroughly clean all joints and surrounding areas before dis‐

mantling.
In the procedure below the hydraulic system of the mecha‐

tronic unit will be opened. Soiling will cause the system to fail!

– Unscrew union nut -1- for hydraulic line -3- from engine.
– Then, pull retaining clip -2- out of valve block/mechatronic unit.
– Pull hydraulic line -3- simultaneously out of engine and valve

block/mechatronic unit.

• Seal hydraulic line connections immediately with suitable seal‐

ing plugs to ensure that as much hydraulic fluid as possible

remains in the hydraulic line.

• Also seal the connections on engine and valve block/mecha‐

tronic unit with suitable sealing plugs.

• For allocation of sealing plugs and hydraulic fluid refer to ⇒ 

Electronic parts catalogue “ETKA” .

– Unscrew bolts -1 ... 7- securing gearbox on engine.

Note

♦

For unscrewing bolts -3- and -4- bits XZN 12 -T10099/1- can

be used.

♦

Bolts -8- and -9- are left screwed in.

– Screw guide pins -T10515- into engine as shown in illustration.

Note

For reasons of clarity, the gearbox is removed in the illustration.

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2. Removing and installing gearbox    

67

 

-T10061- . Note coolant line -A- while doing so.

– Press gearbox off dowel sleeves in engine.

– Carefully pull gearbox off engine. Ensure to not damage con‐

nections -arrow 1- on electric drive motor -V141- and the drive

motor temperature sender -G712- -arrow 2- while doing so.

Note

If necessary, change position of gearbox using spindles of gear‐

box support -3282- while pulling gearbox off engine.

If gearbox is to be sent:
– Remove bracket -A- at front of gearbox -arrows-.

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