Volkswagen Jetta Hybrid (2013 year). Manual - part 26

pull hoses off.

– Pull air damper -1- upwards out of rubber bushes -arrows-.
Continuation for all vehicles

WARNING

You can suffer an electric shock.
An electric shock can be fatal.
Observe  general  warning  instructions  for  work  on  the  high-

93 ; General warning instructions for work on the high-voltage

system .

♦ The system must first be de-energised by a high-voltage

technician before any work is done on the high-voltage

system and before any repair work is done on the body.

♦ All work on vehicles with a high-voltage system must only

be carried out by electrically instructed persons. The work

must be supervised by a high-voltage technician.

WARNING

High voltage on high-voltage system of hybrid vehicle. Danger

of electric shock! Following procedure also requires work on

high-voltage system. De-energise high-voltage system now ⇒ 

high-voltage system .

– Remove power and control electronics for electric drive -JX1-

control electronics for electric drive -JX1- .

Jetta Hybrid 2013 ➤

7. Mechatronic unit    

97

 

High-voltage cables; Removing and installing high-voltage

wiring harness for hybrid battery -PX1- .

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

tronic unit and pull wiring harness off retainer on front of

gearbox.

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” .

Note

For reasons of clarity, the engine/gearbox assembly is removed

in illustration.

– Pull breather cap -1- off mechatronic unit. Breather -2- remains

attached to breather connection -3- for this.

• Breather -2- must be removed to prevent that hydraulic fluid

escapes from the mechatronic unit.

• The breather will be damaged during removal and must be

renewed.

• Breather connection -3- must now be sealed with a sealing

plug or sealing cap -0AM 325 120 A- so that no oil can escape.

Order sealing plugs via the ⇒  Electronic parts catalogue “ET‐

KA” .

Jetta Hybrid 2013 ➤

98

 

♦ Do not under any circumstances touch the contacts in the

gearbox connector by hand. The resulting static discharge

could destroy the control unit and, consequently, the me‐

chatronic unit.

– Touch earth connection (without gloves) in order to discharge

yourself.

– Disconnect connector -1- for mechatronic unit for dual clutch

gearbox -J743- . To do this, pull locking mechanism upwards

-arrow-.

– Unscrew nuts -2- and -3- from centre hex studs.
– Remove wire retainer from gearbox.

– Put used oil collection and extraction unit -V.A.G 1782- un‐

derneath.

– Unscrew oil drain plug of gearbox.
– Allow oil to drain off, then screw in oil drain plug firmly again.

– Using a screwdriver, carefully unclip gearbox input speed

sender 3 -G641- from housing in -direction of arrow-.

Jetta Hybrid 2013 ➤

7. Mechatronic unit    

99

 

the dual clutch from the plungers of the mechatronic unit. If this

is not done, the engaging levers will jam the mechatronic unit at

the plungers and prevent the mechatronic unit from being re‐

moved.

– Insert assembly lever -T10407- under plunger -2- between

gearbox housing and both engaging levers -1- -arrow-, as

shown in diagram.

– Insert assembly lever -T10407- just enough until groove is

flush with housing rib -arrows-, as shown in diagram. Do not

insert onto stop.

Note

The back of the assembly lever must rest against the gearbox

housing when doing this.

– Turn assembly lever -T10407- about its axis 90° in anti-clock‐

wise direction -arrow A- to lift off engaging lever from plungers

-1- -arrow B-.

Jetta Hybrid 2013 ➤

100