Volkswagen Jetta 2013 User Manual
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Service
Repair Manual
Jetta Hybrid 2013 ➤
Direct Shift Gearbox
Edition 01.2016
Service Department. Technical Information
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List of Workshop Manual Repair Groups
Re pa ir G ro up
00 - General, Technical Data
30 - Clutch
34 - Controls, Housing
35 - Gears, Shafts
39 - Final Drive, Differential
Service
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2016 Volkswagen AG, Wolfsburg D4B8026057D
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Jetta Hybrid 2013 ➤
Direct Shift Gearbox - Edition 01.2016
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Transmission Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 High Voltage Vehicles Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Road Test with Testing Equipment Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Mechatronic Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.5 Towing Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Guidelines for Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Transmission/Engine Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Gear Ratio Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5 Overview - Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.1 Overview - Powertrain, Front Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 Clutch Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1 Overview - Clutch Engaging Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Clutch Engaging Mechanism, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3 Clutch Engaging Mechanism, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.1 Overview - Dual Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.2 DSG® Clutch, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.3 Dual Clutch, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4 Input Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.5 Inner Input Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
34 - Controls, Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1 Mechatronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.1 Overview - Mechatronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.2 Mechatronic, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.3 Mechatronic, Moving into Removal Position by Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2 Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.1 Overview - Selector Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.2 Emergency Release from P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.3 Selector Lever Handle, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.4 Button in Handle, Moving Into Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.5 Selector Mechanism, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.6 Gearshift Mechanism, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.7 Selector Lever Cable, Checking and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.8 Selector Shaft Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3 Transmission, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.1 Transmission, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.2 Transmission, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.3 Transmission Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Contents i
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Jetta Hybrid 2013 ➤
Direct Shift Gearbox - Edition 01.2016
4 Transmission, Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5 Securing on Engine and Transmission Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6 Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6.1 Overview - Subframe Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7 Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.1 Transmission Fluid, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
8 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
35 - Gears, Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
39 - Final Drive, Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1 Parking Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.1 Parking Lock Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.2 Parking Lock, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.1 Overview - Component Location Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.2 Left Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.3 Right Seal, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
ii Contents
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00 – General, Technical Data
Jetta Hybrid 2013 ➤
Direct Shift Gearbox - Edition 01.2016
1 Identification
(Edition 01.2016)
⇒ “1.1 Transmission Identification”, page 1
1.1 Transmission Identification
The “7-speed DSG® transmission 0CG” is installed in the Jetta
from MY 11. Allocation. Refer to
⇒ “4.1 Transmission/Engine Allocation”, page 12 .
Note
The transmission code letters are also included on the vehicle data labels.
NDR - Transmission Code
⇒ “4.1 Transmission/Engine
Allocation”, page 12
01. 06.12 - Build date:
06/01/2013
14 - Plant Code
13:59 - Time
0026 - Serial Number
1. Identification 1
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Jetta Hybrid 2013 ➤
Direct Shift Gearbox - Edition 01.2016
2 Safety Precautions
⇒ “2.1 General Safety Precautions”, page 2
⇒ “2.2 High Voltage Vehicles Safety Precautions”, page 2
⇒ “2.3 Road Test with Testing Equipment Safety Precautions”,
page 3
⇒ “2.4 Mechatronic Safety Precautions”, page 3
⇒ “2.5 Towing Notes”, page 5
2.1 General Safety Precautions
To Avoid Injury and Damage to the Vehicle, Observe the Follow‐
ing:
There is a risk of injury and accident from accidentally engag‐
ing a gear when the engine is running.
♦ Move the selector lever into “P” and set the parking brake
WARNING
before working on a running engine.
Observe the following to Prevent Personal Injury and Damage to
the Electrical/Electronic Components:
♦ Connect and disconnect test equipment only when the ignition
is off.
Caution
Risk of damaging electronic components when disconnecting
the battery.
♦ Follow the steps when disconnecting the battery. Refer to
⇒ Electrical Equipment; Rep. Gr. 27 ; Battery, Discon‐
necting and Connecting .
2.2 High Voltage Vehicles Safety Precau‐
tions
Note
Check with the importer if there are any questions regarding the
titles “hybrid electrically instructed person”, “high voltage techni‐
cian”, “high voltage expert”” or the term hybrid system.
Before beginning work on the high voltage system, a high voltage
technician must de-energize the high voltage system. Refer to ⇒
Electrical System Hybrid; Rep. Gr. 93 ; High Voltage System, DeEnergizing .
The procedures required for de-energizing the high voltage sys‐
tem are listed in “Working on the High Voltage System”. Refer to
⇒ Electrical System Hybrid; Rep. Gr. 93 ; High Voltage System
General Warnings .
2 Rep. Gr.00 - General, Technical Data
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WARNING
Jetta Hybrid 2013 ➤
Direct Shift Gearbox - Edition 01.2016
Beware of the danger of electrocution.
An electrical shock can result in death.
Follow the High Voltage System General Warnings. Refer to
⇒ Electrical System Hybrid; Rep. Gr. 93 ; High Voltage System
General Warnings .
♦ A high voltage technician must de-energize the high volt‐
age system before any can work can be performed on the
high voltage system or before any servicing work can be
performed on the body. The table “de-energizing the high
voltage system” lists all the work procedures for which this
procedure is necessary. Refer to ⇒ Electrical System Hy‐
brid; Rep. Gr. 93 ; General Warnings When Working On
The High Voltage System .
♦ Only hybrid electrically instructed persons may perform all
work on a vehicle with a high voltage system. All work
must be performed by a high voltage technician.
WARNING
Handling the high voltage cables:
♦ Do not lean on or set tools on the high voltage system or
any of its components.
♦ When working near high voltage components and high
voltage cables, do not use tools that generate heat or that
have sharp edges.
♦ Do not weld, solder or use hot air or thermal adhesive
equipment when working near high voltage components
and cables because they are sources of heat.
♦ Do not excessively bend or flex high voltage cables.
♦ Always contact a high voltage technician if there are ques‐
tions or if something is not clearly understood.
2.3 Road Test with Testing Equipment Safety Precautions
Performing Road Tests While Using Testing Equipment:
WARNING
Distraction and testing equipment that is not secured properly
can cause accidents.
The passenger airbag could pose a risk if it deploys in a colli‐
sion.
• Operating testing equipment while driving is a distraction.
• Testing equipment that is not secured probably increases
the risk of injury.
♦ Always secure testers on the rear seat with a strap and
have a second person on the rear seat operate them.
2.4 Mechatronic Safety Precautions
2. Safety Precautions 3
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Jetta Hybrid 2013 ➤
Direct Shift Gearbox - Edition 01.2016
WARNING
The system is under pressure.
The pressure reservoir holds a maximum pressure of 60 bar (870 psi). The pump software adjusts the pressure.
The pump shuts off when this pressure is reached. The pump turns back on when the pressure falls below 42
bar (609 psi) caused by shifting. A pressure of up to approximately 75 bar (1087 psi) could be produced should
the software be faulty. The pressure relief valve opens automatically when this pressure is reached.
Note
4 Rep. Gr.00 - General, Technical Data
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2.5 Towing Notes
Caution
Danger of causing damage to the transmission.
♦ When towing the vehicle, move the selector lever into “N”.
Do not tow the vehicle further than 50 km (31 miles) and
do not drive faster than 50 km/h (31 mph).
Note
It is not possible to tow-start the engine.
Jetta Hybrid 2013 ➤
Direct Shift Gearbox - Edition 01.2016
2. Safety Precautions 5
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Jetta Hybrid 2013 ➤
Direct Shift Gearbox - Edition 01.2016
3 Repair Information
⇒ “3.1 General Information”, page 6
⇒ “3.2 Guidelines for Clean Working Conditions”, page 8
⇒ “3.3 General Repair Information”, page 8
3.1 General Information
Transmission
♦ The Electro-Drive Drive Motor - V141- transfers the engine
torque to the double clutch. The Electro-Drive Drive Motor V141- and the dual clutch are connected via splines. The
Electro-Drive Drive Motor - V141- has a disengagement
clutch. The decoupler in Electro-Drive Drive Motor - V141separates the internal combustion engine from the ElectroDrive Drive Motor - V141- .
♦ The transmission is built like a 7-speed manual transmission.
The alternating hydraulic actuation of the two dry multi-plate
clutches permits operation similar to that of an automatic
transmission. This means the gears are automatically or man‐
ually shifted via the Tiptronic mode. Clutch pedal is not avail‐
able.
♦ Both clutches are open when the ignition is off. 1st gear on
sub-transmission 1 and reverse gear on sub-transmission 2
are engaged.
Some Vehicles Have A Cover Over the Engaging Levers.
The cover prevents dirt from getting in.
Bolt tightening specification: 8 Nm
6 Rep. Gr.00 - General, Technical Data
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Direct Shift Gearbox - Edition 01.2016
Transmission Assembly Overview
1 - Dual clutch
2 - Right Stub Shaft
3 - Cable Mounting Bracket
4 - Gearshift Lever
5 - Transmission ventilation cap
6 - Parking lock cover
7 - Valve block
8 - DSG Transmission Mechatronic - J743- Bleed Unit
9 - DSG Transmission Mechatronic - J743-
Selector Mechanism
In contrast to the automatic transmission, the selector lever po‐
sition is no longer transmitted mechanically to the transmission
via the selector lever cable and Multi-Function Transmission
Range. Selector lever positions and shifts are transmitted via a
separate control module in the selector mechanism to the trans‐
mission control module via the CAN-Bus. The shifter occurs
without a cable. The selector lever cable is mechanically brought
into the park brake in the selector lever position “P”.
Transmission Fluid
The 7-speed DSG® transmission has two separate, different fluid
systems. One for the transmission fluid -arrow A- and one for the
hydraulic fluid -arrow B-.
Only transmission fluids specific to the DSG® transmission 0CG
may be used. They are available as a replacement part. Using
other oils can lead to function problems or can even cause the
transmission to fail, for the specification. Refer to the Parts Cat‐
alog.
Do not mix any »additives« into the oil.
Do not re-use drained transmission fluid.
Caution
Be very careful when working with transmission fluid. Dispose
of drained transmission fluid correctly.
It is not possible to check the transmission fluid level in the trans‐
mission. The only way to adjust the transmission fluid level is to
replace the transmission fluid, for example, if the transmission is
leaking fluid. Refer to
⇒ “7.1 Transmission Fluid, Draining and Filling”, page 111 .
Jetta Hybrid 2013 ➤
3. Repair Information 7
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Jetta Hybrid 2013 ➤
Direct Shift Gearbox - Edition 01.2016
3.2 Guidelines for Clean Working Condi‐
tions
♦ Always clean connection places and surrounding areas with
engine or brake cleaner before loosening and dry cleaned pla‐
ces.
♦ Clean the transmission and transmission components using
for example Cleaning Solution - D 009 401 04- .
♦ Use lint-free towels.
♦ Seal all open lines and connections immediately with new
plugs from the Repair Kit - 5C0 998 152- . Refer to the Parts
Catalog.
♦ Place removed parts on a clean surface and cover them. Use
foil and paper. Use a lint-free cloth.
♦ Carefully cover or plug unpacked components if repairs can‐
not be performed immediately.
♦ Only install clean components: Remove the replacement parts
from their packaging just prior to installing them.
♦ Protect the disconnected connectors from dirt and moisture
and only connect when they are dry.
♦ Make sure no dirt can get into the transmission when it is open.
♦ Do not run the engine when the cover is removed from the
transmission or when there is no transmission fluid in the
transmission. Do not tow the vehicle.
♦ Cover all opened components carefully if it necessary to per‐
form a repair.
3.3 General Repair Information
♦ Carefulness, cleanliness and the correct tools are required for
transmission repairs to be successful. The usual basic safety
precautions also, naturally apply when carrying out vehicle re‐
pairs.
♦ Some general repair information that applies to several pro‐
cedures throughout this manual is summarized here. They
apply to this repair manual.
Guided Fault Finding, On Board Diagnostics (OBD) and Test In‐
struments
♦ Before servicing the transmission, determine as best as pos‐
sible the cause of the fault using the Vehicle Diagnostic Tester
in Guided Fault Finding , Vehicle Self-Diagnosis and
Test Instruments
The Guided Functions button and the Guided Fault Find-
ing button offer various functions. Refer to
⇒ “3.3.1 Working with Tester”, page 10 .
Special Tools and Equipment
.
For a complete list of special tools used in the Repair Manual.
Refer to Workshop Equipment and Special Tools.
Transmission
♦ Do not run engine or tow the vehicle when the oil pan is re‐
moved or when there is no transmission fluid.
♦ Always clean the connection locations and the area around
them before loosening.
8 Rep. Gr.00 - General, Technical Data
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.
Direct Shift Gearbox - Edition 01.2016
♦ During installation, make sure that the alignment bushings are
fitted correctly.
O-Rings, Gaskets, Seals
♦ O-rings, gaskets and seals must be replaced.
♦ Seals are also called shaft seals.
♦ After removing gaskets, examine contact surface on housing/
shaft for burr resulting from removal or for other signs of dam‐
age.
♦ Clean the housing separating surface thoroughly before as‐
sembling.
♦ Lightly coat the seals with ATF along outer circumference and
along the sealing lip.
♦ Coat O-rings with transmission fluid before inserting to prevent
crushing rings during installation.
♦ Do not use any other lubricants in the gear oil area. Otherwise
there is a danger of malfunction of the transmission hydraulics.
♦ The open side of the seals point toward the fluid to be sealed
in.
♦ When installing the new shaft seals, make sure the sealing lip
does not run on the same point as the sealing lip of the old
seal (use insertion depth tolerances).
♦ Follow the guidelines for clean working conditions. Refer to
⇒ “3.2 Guidelines for Clean Working Conditions”, page 8 .
Fasteners
♦ Do not overstretch the circlips.
♦ Replace damaged or stretched circlips.
♦ The circlips must fit completely inside the groove.
Adjusting Shims
♦ Measure the shims at several locations with a micrometer cal‐
iper. It is possible to measure the necessary shim thickness
by the different tolerances.
♦ Check for burrs and damage.
♦ Only install perfect shims.
Jetta Hybrid 2013 ➤
3. Repair Information 9
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.
Jetta Hybrid 2013 ➤
Direct Shift Gearbox - Edition 01.2016
Bolts and Nuts
♦ Loosen the bolts opposite the tightening sequence.
♦ Nuts and bolts which secure covers and housings should be
loosened and tightened diagonally and in steps if no tightening
sequence is specified.
♦ Replace the self-locking nuts.
♦ Use a wire brush to clean the threads of bolts that were
screwed in with locking compound. Install the bolts with Lock‐
ing Fluid - AMV 185 101 A1- .
♦ The tightening specifications stated apply to non-oiled nuts
and bolts.
3.3.1 Working with Tester
• Use only Volkswagen Vehicle Diagnostic Testers .
The Guided Functions button and the Guided Fault Find-
ing button offer various functions. The 3 most important functions
are:
♦ Adapting installation information
♦ Reading measurements for mandatory reporting
♦ Performing basic measurement
Adapting Installation Information
The Mechatronic recognizes other control modules in the vehicle
by signals from the Data bus. Pressing the Adapt Installation
Information button tells the Mechatronic to forget all communi‐
cation partners.
All active partners are recognized the next time the ignition is
turned on.
Faults cannot be »created« with this function. Always use the
Adapt Installation Information after the following tasks:
♦ After installing a gearshift mechanism.
♦ After a different control module is installed, for example, en‐
gine, ABS or Gateway.
♦ After working on the steering wheel paddle.
Reading Measurements for Mandatory Reporting
It is necessary to upload the measurements before contacting the
Technical Service Center.
Save the measurements in the diagnostic log so that all the nec‐
essary transmission data is available for analyzing the faults.
Performing Basic Measurement.
This is how the Mechatronic learns the important settings. Also
important adjustments are learned new or reset to the preprog‐
rammed points. Among others, these are the synchronizing points
and the corner points for the engaging lever and the gear selector.
WARNING
Do not perform a basic measurement without cause or without
being requested.
10 Rep. Gr.00 - General, Technical Data
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.
– Press the J743 Perform Mechatronic Basic Measure-
ment screen button only:
♦ If the “Guided Fault Finding” requests it
♦ After a fault stored in the Diagnostic Trouble Code (DTC)
memory was corrected
♦ After a dual clutch was installed
♦ Or after a Mechatronic was installed
Jetta Hybrid 2013 ➤
Direct Shift Gearbox - Edition 01.2016
3. Repair Information 11
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.
Jetta Hybrid 2013 ➤
Direct Shift Gearbox - Edition 01.2016
4 Technical Data
⇒ “4.1 Transmission/Engine Allocation”, page 12
⇒ “4.2 Gear Ratio Calculation”, page 12
⇒ “4.3 Capacities”, page 13
4.1 Transmission/Engine Allocation
DSG Transmission 0CG
Transmission Codes NDR PLC PMY
Allocation Type
Gear Ratios Final drive I
Z2: Z
1
Z2: Z
1
Use the transmission code when ordering replacement parts for a repair. Refer to the Parts Catalog.
Engine
for 1st to 4th gear
Final drive II
for 5th gear and
6th gear
Final drive III
for 7th gear and re‐
verse gear
Jetta from MY 2011 Jetta from MY 2011 Jetta from MY 2011
1.4L TSI - 110 kW 1.4L TSI - 110 kW 1.4L TSI - 110 kW
71 : 16 = 4.438 71 : 16 = 4.438 71 : 16 = 4.438
71 : 22 = 3.227 71 : 22 = 3.227 71 : 22 = 3.227
71 : 17 = 4.176 71 : 17 = 4.176 71 : 17 = 4.176
DSG Transmission 0CG
Transmission Codes PWK PZV QHT
Allocation Type
Engine
Gear Ratios Final drive I
Jetta from MY 2011 Jetta from MY 2011 Jetta from MY 2011
1.4L TSI - 110 kW 1.4L TSI - 110 kW 1.4L TSI - 110 kW
71 : 16 = 4.438 71 : 16 = 4.438 71 : 16 = 4.438
for 1st to 4th gear
Z2: Z
1
Final drive II
71 : 22 = 3.227 71 : 22 = 3.227 71 : 22 = 3.227
for 5th gear and
6th gear
Z2: Z
1
Final drive III
71 : 17 = 4.176 71 : 17 = 4.176 71 : 17 = 4.176
for 7th gear and re‐
verse gear
Use the transmission code when ordering replacement parts for a repair. Refer to the Parts Catalog.
4.2 Gear Ratio Calculation
Example:
7. Gear Final Drive
Drive gear ZG1 = 49 ZA1 = 17
Driven gear ZG2 = 32 ZA2 = 71
i = Z2 : Z1 (Z1 = Number of teeth on the drive gear, Z2 = number
of teeth on the driven gear)
iG = gear ratio = ZG2 : ZG1 = 32 : 49 = 0.653
iA = axle ratio = ZA2 : ZA1 = 71 : 17 = 4.176
i
= total ratio= iG x iA = 0.653 x 4.176 = 2.730
total
12 Rep. Gr.00 - General, Technical Data
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.
Direct Shift Gearbox - Edition 01.2016
4.3 Capacities
The 7-speed DSG® transmission has two separate, different fluid
systems. One for the transmission fluid -arrow A- and one for the
hydraulic fluid -arrow B-.
Capacities Transmission Fluid
Initial filling Refer to ⇒ Fluid Capacity Tables; Rep. Gr.
03
Change No change required
Lubricant Transmission fluid for DSG transmission
0CG
For the part number. Refer to the Parts Cat‐
alog.
Capacities Hydraulic Fluid in DSG Transmission Me‐
chatronic - J743-
Initial filling Refer to ⇒ Fluid Capacity Tables; Rep. Gr.
03
Change Change not possible
Checking the hydraulic fluid level for the
DSG Transmission Mechatronic - J743- is
not possible 1).
Lubricant Hydraulic oil
For the part number. Refer to the Parts Cat‐
alog.
Jetta Hybrid 2013 ➤
1)
It is possible to fill hydraulic fluid via the Mechatronic vent.
Caution
Danger of causing damage to the transmission.
♦ Use only the transmission fluid specifically for the 7-speed
DSG transmission 0CG. It is available as a replacement
part. Refer to the Parts Catalog.
♦ Using other fluids can cause malfunctions or transmission
failure.
♦ Checking the hydraulic fluid level in the DSG Transmis‐
sion Mechatronic - J743- is not possible. The vent on the
DSG Transmission Mechatronic - J743- must be sealed
tight before performing any assembly work.
♦ Hydraulic fluid that has leaked out of the DSG Transmis‐
sion Mechatronic - J743- may not refilled.
♦ Seal off all openings with new plugs from the Repair Kit -
5C0 998 152- whenever the hydraulic pipe between the
valve block on the DSG Transmission Mechatronic - J743and the connection for the decoupler for the Electro-Drive
Drive Motor - V141- is removed. After installing the hy‐
draulic pipe, add hydraulic fluid via the vent for the Me‐
chatronic , if necessary. For the correct hydraulic fluid,
sealing plugs and disposable syringe from the Repair Kit
- 5C0 998 152- . Refer to the Parts Catalog.
♦ If transmission fluid has leaked out, then it is necessary to
perform a transmission fluid replacement. It is not possible
to check the fluid level.
♦ Under filling or overfilling both fluid systems will impair the
function of the transmission.
4. Technical Data 13
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.
Jetta Hybrid 2013 ➤
Direct Shift Gearbox - Edition 01.2016
5 Overview - Powertrain
⇒ “5.1 Overview - Powertrain, Front Wheel Drive”, page 14
5.1 Overview - Powertrain, Front Wheel Drive
The 7-speed DSG transmission 0CG has 5 shafts. Two input
shafts and three output shafts.
A1 - Input Shaft 1
A2 - Input Shaft 2
B1 - Output Shaft 1
B2 - Output Shaft 2
B3 - Output Shaft 3
C - Front Final Drive
K1 - Clutch 1
K2 - Clutch 2
M - Engine
T1 - Sub-Transmission 1
❑ With 1st, 3rd, 5th and
7th gears
T2 - Sub-Transmission 2
❑ With 2nd, 4th, 6th and
reverse gears
14 Rep. Gr.00 - General, Technical Data
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Jetta Hybrid 2013 ➤
Direct Shift Gearbox - Edition 01.2016
30 – Clutch
1 Clutch Mechanism
⇒ “1.1 Overview - Clutch Engaging Mechanism”, page 15
⇒ “1.2 Clutch Engaging Mechanism, Removing and Installing”,
page 16
⇒ “1.3 Clutch Engaging Mechanism, Adjusting”, page 19
1.1 Overview - Clutch Engaging Mechanism
1 - Shim for “K 1”
❑ For determining thick‐
ness. Refer to
⇒ “1.3 Clutch Engaging
Mechanism, Adjusting”,
page 19 .
2 - Large Engaging Lever “K 1”
❑ With engaging bearing
❑ Removing and instal‐
ling. Refer to
⇒ “1.2 Clutch Engaging
Mechanism, Removing
and Installing”,
page 16 .
3 - Engaging Lever Support
❑ For the large engaging
lever “K 1”
❑ Cannot be replaced
4 - Small Engaging Bearing for
“K 2”
5 - Shim for “K 2”
❑ For determining thick‐
ness. Refer to
⇒ “1.3 Clutch Engaging
Mechanism, Adjusting”,
page 19 .
6 - Guide Sleeve Upper Sec‐
tion
❑ For the small engaging
lever “K 2”
❑ Is removed and installed
together with the small
engaging lever and the
guide sleeve lower sec‐
tion
7 - Small Engaging Lever for “K 2”
❑ Is removed and installed together with the guide sleeve upper section and lower section
❑ Removing and installing. Refer to
⇒ “1.2 Clutch Engaging Mechanism, Removing and Installing”, page 16 .
8 - Ball Stud
❑ For the small engaging lever “K 2”
❑ Removing and installing. Refer to ⇒ page 20 .
1. Clutch Mechanism 15
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Jetta Hybrid 2013 ➤
Direct Shift Gearbox - Edition 01.2016
9 - Bolt
❑ 8 Nm +90° turn
❑ Replace after removing
10 - Guide Sleeve Lower Section
❑ For the small engaging lever “K 2”
❑ Is removed and installed together with the small engaging lever and the guide sleeve upper section
1.2 Clutch Engaging Mechanism, Remov‐
ing and Installing
Removing
• The dual clutch is removed. Refer to
⇒ “2.2 DSG® Clutch, Removing”, page 33 .
– Remove the large engaging lever with the small engaging
bearing.
Note
The guide sleeve upper section cannot be removed or installed
separately. It is always removed and installed together with the
guide sleeve lower section and the small engaging lever.
– Remove the bolts and the small engaging lever with the guide
sleeve upper and lower sections.
16 Rep. Gr.30 - Clutch
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.
Replace the ball stud -2- only if it is worn down. Refer to
⇒ page 20 .
WARNING
The hinge -1- cannot be removed.
Jetta Hybrid 2013 ➤
Direct Shift Gearbox - Edition 01.2016
Installing
Install in reverse order of removal. Note the following:
WARNING
It is necessary to adjust the position of the “K 1” and “K 2” en‐
gaging bearing after performing the following:
The hinge cannot be removed.
It is necessary to adjust the position of the “K 1 and K 2” en‐
gaging bearings first if one of the above mentioned procedures
was performed. Refer to
⇒ “1.3 Clutch Engaging Mechanism, Adjusting”, page 19 .
It is not necessary to perform any adjustment if all the mentioned
components are removed and installed again individually.
♦ The dual clutch was replaced.
♦ The engaging levers were replaced.
♦ The ball stud for the “K 2” engaging lever was replaced.
♦ The engaging bearings were replaced.
Note
• The engaging lever support -1- and ball stud -2- are installed.
• Replace the ball stud -2- only if it is worn down. Refer to
⇒ page 20 .
1. Clutch Mechanism 17
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Jetta Hybrid 2013 ➤
Direct Shift Gearbox - Edition 01.2016
Note the Following When Installing A New Engaging Lever »K 2«:
A new engaging lever »K 2« with guide sleeve upper and lower
sections are in their transportation position when they are deliv‐
ered -illustration-. It is necessary to first move them into their
installation position before installing them.
Bringing the engaging lever »K 2« into the installed position as
follows:
– Hold the guide sleeve upper section with one hand. Turn the
guide sleeve lower section in direction of -arrow- with the other
hand until the sleeve moves freely.
Note
Hold both parts securely because a lot of force is needed to turn
the guide sleeve lower section.
In the installed position, the holes in the guide sleeve lower sec‐
tion are at a right angle to the engaging lever and the sleeve can
be moved freely.
– It is necessary to adjust the position of the engaging bearing
“K 1” and “K 2” when installing a new engaging lever. Refer to
⇒ “1.3 Clutch Engaging Mechanism, Adjusting”, page 19 .
18 Rep. Gr.30 - Clutch
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Continuation for All
– Install the small engaging lever with the upper and lower sec‐
tions of the guide sleeve. Install new bolts and tighten them.
– Install the large engaging lever with the selected shims for “K
1” and “K 2” and with the small engaging bearing.
• The large shim in the large engaging bearing with the halfround side facing down.
• The small shim belongs under the small engaging bearing. In‐
stall the shim first.
• The shim and the small engaging bearing fit only in one posi‐
tion due to the 8 grooves.
– Turn and make sure the parts are installed correctly and fit
correctly in the grooves.
– Make sure both engaging levers fit correctly.
Direct Shift Gearbox - Edition 01.2016
– Install the dual clutch. Refer to
⇒ “2.3 Dual Clutch, Installing”, page 37 .
Tightening Specifications
♦ For the guide sleeve lower section together with the small en‐
gaging lever to transmission housing. Refer to
⇒ “1.1 Overview - Clutch Engaging Mechanism”, page 15 .
Jetta Hybrid 2013 ➤
1.3 Clutch Engaging Mechanism, Adjusting
It is necessary to adjust the position of the “K 1” and “K 2” en‐
gaging bearing after performing the following:
♦ The dual clutch was replaced.
♦ The engaging levers were replaced.
♦ The ball stud for the “K 2” engaging lever was replaced.
♦ The engaging bearings were replaced.
Note
♦
It is not necessary to perform any adjustment if all the men‐
tioned components are removed and installed again individu‐
ally.
♦
The locking ring must be replaced in each case.
1. Clutch Mechanism 19
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Jetta Hybrid 2013 ➤
Direct Shift Gearbox - Edition 01.2016
Short Description
♦ The position of the engaging bearing is comparable to clutch
play on a manual transmission. The engaging system in the
7-speed DSG® transmission 0CG and in the transmission it‐
self have tolerances. There are also tolerances within the dual
clutch. These tolerances must be taken into account sepa‐
rately when performing the adjustments.
♦ The following procedure describes how all necessary meas‐
urements are determined from the transmission side in order
to select the correct shim. In addition to this, the tolerances in
the dual clutch already determined by the manufacturer. The
transmission side tolerances and the tolerances in the dual
clutch determine the thickness of the shim.
♦ Follow the work sequence.
Special tools and workshop equipment required
♦ Digital Depth Gauge - 300mm - VAS6594-
♦ Gauge - Clutch Bearings - T10466-
♦ Ruler (2 pc.) - T40100-
Procedure
• The dual clutch is removed. Refer to
⇒ “2.2 DSG® Clutch, Removing”, page 33 .
• The transmission flange must be even so that it has a good
surface for the ruler.
• The DSG Transmission Mechatronic - J743- is installed in the
transmission.
Caution
Danger of damaging the dual clutch and other components.
• The mount for the engaging lever and the entire mechan‐
ical system for the engaging bearing must be dry and free
from oil and grease.
If Ball Stud Is Worn Down
– Remove the ball stud using pliers.
20 Rep. Gr.30 - Clutch
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Direct Shift Gearbox - Edition 01.2016
– Install the new ball stud by hand. Use a plastic hammer and
drift gently, if necessary.
Note
Tap the drift with the plastic hammer gently to avoid damaging
the ball stud.
Continuation for All
Note
If dimension “B” was already measured, then step “2” of the
measurement can be made now. Refer to ⇒ page 23 .
– Install the previous locking ring -arrow- for the outer input
shaft.
Jetta Hybrid 2013 ➤
Step 1: Measure Dimension “B” for Clutch “K 1” and “K 2”.
– Place Ruler (2 pc.) - T40100- across the end of the shaft on
the transmission flange.
There is the risk of incorrect measurements.
♦ The Ruler (2 pc.) - T40100- should stay in this position for
Caution
the following measurements. Do not move it or take if off.
1. Clutch Mechanism 21
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.
Jetta Hybrid 2013 ➤
Direct Shift Gearbox - Edition 01.2016
– Place the Digital Depth Gauge - 300mm - VAS6594- on top of
the Ruler (2 pc.) - T40100- and position the depth slide on the
outer input shaft.
– Set the depth gauge to “0”.
– Position the depth slide on the locking ring, as illustrated.
– Measure dimension “B1 ” on the locking ring in this position.
• Example: measurement “B1 ” = 2.62 mm
– Measure dimension “B2 ” on the opposite side of the locking
ring.
Note
Do not measure on the end of the locking ring. The locking ring
could get pushed away and this would invalidate the measure‐
ment.
• Example: dimension “B2 ” = 2.58 mm
– Calculate the mean value from “B1 ” and “B2 ”.
Formula: B1 + B2 2
Example:
• 2.62 + 2.582 = 2.60 mm
• Result: dimension “B” = 2.60 mm
Note
If the dual clutch is being installed according to this measurement,
then it must be removed now. Refer to ⇒ page 36 .
22 Rep. Gr.30 - Clutch
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.
Direct Shift Gearbox - Edition 01.2016
– Remove the locking ring -arrow- from the outer input shaft and
throw it away.
Caution
Do not re-use the locking ring.
Step 2: Measure Dimension “A 1” for the Clutch Engaging Bearing
“K 1” .
– Install the large engaging lever.
– Make sure the engaging lever fits correctly.
– Place the Gauge - Clutch Bearings - T10466- on the large en‐
– Press and turn the Gauge - Clutch Bearings - T10466- to make
• The engaging bearing turns with the Gauge - Clutch Bearings
Caution
There is the risk of incorrect measurements.
♦ Do not install the shim.
gaging bearing. The flat side faces up
sure it seats correctly on the engaging bearing.
- T10466- .
Jetta Hybrid 2013 ➤
1. Clutch Mechanism 23
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Jetta Hybrid 2013 ➤
Direct Shift Gearbox - Edition 01.2016
– Place the Digital Depth Gauge - 300mm - VAS6594- on top of
the ruler and position the depth slide on the outer input shaft.
• The Ruler (2 pc.) - T40100- lies straight across the transmis‐
sion flange over the end of the shaft.
Caution
There is the risk of incorrect measurements.
♦ The Ruler (2 pc.) - T40100- should stay in this position for
the following measurements. Do not move it or take if off.
– Set the depth gauge to “0”.
– Position the depth slide on the Gauge - Clutch Bearings -
T10466- , as illustrated.
– Measure dimension “A 1a ” on the Gauge - Clutch Bearings -
T10466- .
• Example: measurement “A 1a ” = 5.03 mm
– Measure dimension “A 1b ” on the other side of the Gauge -
Clutch Bearings - T10466- .
• Example: measurement “A 1b ” = 5.01 mm
– Calculate the average 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
Step 3: Measuring the Height Tolerance for the Engaging Bearing
of Clutch “K 1”.
Note
Using dimension “A 1” and dimension “B”, calculate the height
tolerance for clutch “K 1” engaging bearing as follows:
Dimension “A 1”
– Dimension “B”
= Height tolerance for clutch “K 1” engaging bearing
Example:
• 5.02 mm - 2.60 mm = 2.42 mm
• Result: height tolerance for clutch “K 1” engaging bearing =
2.42 mm
24 Rep. Gr.30 - Clutch
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Direct Shift Gearbox - Edition 01.2016
Step 4: Measuring the Clutch Tolerance for Clutch “K 1”.
– Read the clutch tolerance value on the new clutch.
• Example: clutch tolerance read on the clutch “K 1 = +0.2”, as
illustrated.
• Result: clutch “K 1” clutch tolerance = + 0.20 mm.
Step 5: Measuring the Thickness of Shim “SK 1”.
Note
Using the clutch tolerance of clutch “K 1”, now the thickness of
shim “SK 1” can be calculated as follows:
Height tolerance for the engaging bearing “K 1”
–/+ Clutch tolerance for clutch “K 1”
= Calculated thickness for shim “SK 1”
Example:
• 2.42 mm + 0.20 mm = 2.62 mm
• Result: calculated shim thickness “SK 1” = 2.62 mm
Jetta Hybrid 2013 ➤
– Select the shim from the table using the part number
-magnifying glass- on the shim and lay it nearby for installation.
Calculated Shim
Thickness
mm
1.21 to 1.60 1.50 0AM 141 383
1.61 to 1.80 1.70 0AM 141 383 A
1.81 to 2.00 1.90 0AM 141 383 B
2.01 to 2.20 2.10 0AM 141 383 C
2.21 to 2.40 2.30 0AM 141 383 D
2.41 to 2.60 2.50 0AM 141 383 E
2.61 to 2.80 2.70 0AM 141 383 F
2.81 to 3.00 2.90 0AM 141 383 G
3.01 to 3.20 3.10 0AM 141 383 H
3.21 to 3.40 3.30 0AM 141 383 J
3.41 to 3.80 3.50 0AM 141 383 K
Example:
• Result: calculated shim thickness “SK 1” = 2.62 mm
• Selected shim thickness = 2.70 mm = part number 0AM 141
383 F
Caution
There is a risk of damaging the clutch.
♦ Later installed only this shim.
Available Shim
Thicknesses in mm
Shim Part Number
1. Clutch Mechanism 25
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Jetta Hybrid 2013 ➤
Direct Shift Gearbox - Edition 01.2016
– Remove the Gauge - Clutch Bearings - T10466- and large en‐
gaging lever.
Step 6: Calculating Dimension “A 2” for Clutch “K 2” Engaging
Bearing
Note
The guide sleeve upper section cannot be removed or installed
separately. It is always removed and installed together with the
guide sleeve lower section and the small engaging lever.
Note the Following When Installing A New Engaging Lever »K 2«:
A new engaging lever »K 2« with guide sleeve upper and lower
sections are in their transportation position when they are deliv‐
ered -illustration-. It is necessary to first move them into their
installation position before installing them.
Bringing the engaging lever »K 2« into the installed position as
follows:
26 Rep. Gr.30 - Clutch
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