Volkswagen 2014 Jetta Hybrid User manual

Jetta Hybrid
Quick Reference
Specification Book
2014

VW Jetta Hybrid Quick Reference Specication Book • February 2014 i
2014 Volkswagen Jetta Hybrid
Quick Reference Specification Book
TABLE OF CONTENTS
General Information ...................................................... 1
Decimal and Metric Equivalents ...........................................1
Distance/Length....................................................................1
Tightening Torque .................................................................2
Nm-to-lb·ft (ft·lb) ...................................................................2
Nm-to-lb·in (in·lb), kg·cm......................................................3
N·cm-to-lb·in (in·lb), kg·cm...................................................3
kg·cm-to-lb·in (in·lb), N·cm...................................................4
Warnings and Cautions ........................................................4
WARNINGS ..........................................................................4
CAUTIONS ...........................................................................7
Vehicle Identication..................................................... 9
VIN on Lower Edge of Windshield...........................................9
VIN on Longitudinal Member Extension ................................10
Vehicle Data Label.................................................................11
Type Plate..............................................................................12
VIN Decoder ..........................................................................13
Sales Codes ................................................................. 14
Engine Codes ........................................................................14
Transmission Codes ..............................................................14
Vehicle Lifting .............................................................. 15
Hoist and Jack Mounting Points .........................................15
Front ......................................................................................15
Rear.......................................................................................16
ENGINE
Engine – 1.4L CNLA..................................................... 17
General Information – 1.4L CNLA.......................................17
Engine Number......................................................................17
Vehicles with a Four Digit Engine Code: ...............................17
Engine Data...........................................................................18

ii VW Jetta Hybrid Quick Reference Specication Book • February 2014
Engine Assembly – 1.4L CNLA...........................................20
Engine and Transmission Mount Overview ...........................20
Engine Bracket Tightening Specications .............................22
Pendulum Support Tightening Specications ........................23
DSG Transmission to Engine Tightening Specications........24
Fastener Tightening Specications........................................24
Crankshaft, Cylinder Block – 1.4L CNLA............................26
Cylinder Block Overview, Belt Pulley Side.............................26
Crankshaft Flange to Drive Motor - Tightening Sequence
and Tightening Specication ...........................................27
Ribbed Belt Transmission Side Sealing Flange -
Tightening Specications and Sequence ........................28
Pistons and Connecting Rods Overview ...............................29
Sealing Flange Belt Pulley Side Overview ............................30
Ribbed Belt Pulley Side Sealing Flange - Tightening
Specications and Sequence..........................................31
Crankshaft Dimensions .........................................................31
Piston Dimension...................................................................31
Cylinder Bore Dimension.......................................................31
Piston Ring End Gap .............................................................32
Piston Ring Groove Clearance ..............................................32
Cylinder Head, Valvetrain – 1.4L CNLA..............................34
Camshaft Housing Overview .................................................34
Camshaft Housing Tightening Specication and
Sequence ........................................................................35
Cylinder Head Overview........................................................36
Cylinder Head Loosening Sequence .....................................37
Cylinder Head Tightening Specication and Sequence.........38
Toothed Belt Guards Overview..............................................39
Toothed Belt Overview...........................................................40
Valve Dimensions ..................................................................42
Lubrication – 1.4L CNLA.....................................................43
Crankcase Ventilation Overview............................................43
Oil Separator Tightening Specication and Sequence .........44
Engine Oil Cooler Overview .................................................45
Oil Filter/Oil Pressure Switch Overview.................................46
Oil Pan/Oil Pump Overview ...................................................48
Lower Section of Oil Pan, Tightening Specications and
Sequence ........................................................................50
Upper Section of Oil Pan Tightening Specications and
Sequence ........................................................................51
Cooling System – 1.4L CNLA .............................................52
Coolant Pump/Thermostat Overview, Version 1....................52

VW Jetta Hybrid Quick Reference Specication Book • February 2014 iii
Thermostat Housing to Coolant Pump - Tightening
Specication and Sequence............................................53
Coolant Thermostat Cover to Coolant Thermostat -
Tightening Specication ..................................................54
Coolant Pump/Thermostat Overview, Version 2....................55
Tightening Sequence and Torque Specication from
Coolant Thermometer Housing to Coolant Pump ...........56
Engine Coolant Temperature Sensors -G62- and -G83-
Overview .........................................................................57
Low Temperature Circuit Coolant Pump -V468- Overview ....58
Coolant Hose Overview.........................................................59
Radiator and Coolant Fan Overview .....................................60
Fuel Supply – 1.4L CNLA ...................................................62
Accelerator Pedal Mechanism Overview...............................62
Leak Detection Pump -V144- Assembly Overview ................63
Canister Installed in Engine Compartment Overview ............64
EVAP Canister Installed on Right Rear Side Overview .........66
Externally Installed Fuel Filter Overview ...............................68
Fuel Delivery Unit/Fuel Level Sensor Overview ....................69
Fuel Tank Overview ...............................................................70
Turbocharger – 1.4L CNLA.................................................72
Charge Air System Overview.................................................72
Turbocharger and Mahle Charge Pressure Actuator
-V465- Overview .............................................................74
Air Guides with Screw-Type Clamps .....................................78
Multiport Fuel Injection – 1.4L CNLA ..................................80
Air Filter Housing Overview ...................................................80
Fuel Rail with Fuel Injectors Overview ..................................82
High Pressure Pump Overview .............................................83
High Pressure Pump Tightening Specication and
Sequence ........................................................................84
Intake Manifold Overview ......................................................86
Intake Manifold Tightening Specications .............................87
Oxygen Sensor Overview......................................................88
Exhaust System, Emission Controls – 1.4L CNLA .............90
Emissions Control Overview..................................................90
Installing the Catalytic Converter - Tightening
Specication and Sequence............................................91
Mufer Overview....................................................................92
Secondary Air Injection System Overview.............................94
Ignition/Glow Plug System – 1.4L CNLA ............................96
Ignition System Overview ......................................................96
Technical Data .......................................................................97

iv VW Jetta Hybrid Quick Reference Specication Book • February 2014
TRANSMISSION
Direct Shift Gearbox (DSG) Transmission – 0CG..... 98
General Information............................................................98
Transmission Code Letters, Reading ....................................98
Transmission Allocation Codes..............................................99
Clutch (DSG) – 0CG.........................................................100
Clutch Engaging Mechanism Overview...............................100
Dual Clutch Overview ..........................................................102
Controls, Housing (DSG) – 0CG ......................................104
Assembly Mounts Overview ................................................104
Mechatronic Overview .........................................................106
Direct Shift Gearbox (DSG) Mechatronic -J743-
Tightening Specication and Sequence .......................107
Selector Mechanism Overview ............................................108
Transmission Tightening Specications...............................109
Gears, Shafts (DSG) – 0CG .............................................110
FastenerTightening Specications.......................................110
Rear Final Drive, Differential (DSG) – 0CG...............111
Seals Component Overview ................................................ 111

General
Information
VW Jetta Hybrid Quick Reference Specication Book • February 2014 1
GENERAL INFORMATION
Decimal and Metric Equivalents
Distance/Length
To calculate: mm x 0.03937 = in.
mm in. mm in. mm in. mm in.
0.002 0.00008 0.01 0.0004 0.1 0.004 1 0.04
0.004 0.00016 0.02 0.0008 0.2 0.008 2 0.08
0.006 0.00024 0.03 0.0012 0.3 0.012 30.12
0.008 0.00031 0.04 0.0016 0.4 0.016 4 0.16
0.010 0.00039 0.05 0.0020 0.5 0.020 5 0.20
0.020 0.00079 0.06 0.0024 0.6 0.024 6 0.24
0.030 0.00118 0.07 0.0028 0.7 0.028 70.28
0.040 0.00157 0.08 0.0031 0.8 0.031 8 0.31
0.050 0.00197 0.09 0.0035 0.9 0.035 90.35
0.060 0.00236 0.10 0.0039 1.0 0.039 10 0.39
0.070 0.00276 0.20 0.0079 2.0 0.079 20 0.79
0.080 0.00315 0.30 0.0118 3.0 0.118 30 1.18
0.090 0.00354 0.40 0.0157 4.0 0.157 40 1.57
0.100 0.00394 0.50 0.0197 5.0 0.197 50 1.97
0.200 0.00787 0.60 0.0236 6.0 0.236 60 2.36
0.300 0.01181 0.70 0.0276 7.0 0.276 70 2.76
0.400 0.01575 0.80 0.0315 8.0 0.315 80 3.15
0.500 0.01969 0.90 0.0354 9.0 0.354 90 3.54
0.600 0.02362 1.00 0.0394 10.0 0.394 100 3.94
0.700 0.02756 2.00 0.0787 20.0 0.787
0.800 0.03150 3.00 0.1181 30.0 1.181
0.900 0.03543 4.00 0.1575 40.0 1.575
1.000 0.03937 5.00 0.1969 50.0 1.969
2.000 0.07874 6.00 0.2362 60.0 2.362
3.000 0.11811 7.00 0.2756 70.0 2.756
4.000 0.15748 8.00 0.3150 80.0 3.150
5.000 0.19685 9.00 0.3543 90.0 3.543
6.000 0.23622 10.00 0.3937 100.0 3.937
7.000 0.27559 20.00 0.7874
8.000 0.31496 30.00 1.1811
9.000 0.35433 40.00 1.5748
10.000 0.39370 50.00 1.9685
20.000 0.78740 60.00 2.3622
30.000 1.18110 70.00 2.7559
40.000 1.57480 80.00 3.1496
50.000 1.96850 90.00 3.5433
60.000 2.36220 100.00 3.9370
70.000 2.75591
80.000 3.14961
90.000 3.54331
100.000 3.93701

2 VW Jetta Hybrid Quick Reference Specication Book • February 2014
Tightening Torque
Nm-to-lb·ft (ft·lb)
To calculate: Nm x 0.738 = lb·ft
Nm lb·ft
(ft·lb) Nm lb·ft (ft·lb) Nm lb·ft (ft·lb)
10 755 41 100 74
11 8 56 41 105 77
12 957 42 110 81
13 10 58 43 115 85
14 10 59 44 120 89
15 11 60 44 125 92
16 12 61 45 130 96
17 13 62 46 135 100
18 13 63 46 140 103
19 14 64 47 145 107
20 15 65 48 150 111
21 15 66 49 155 114
22 16 67 49 160 118
23 17 68 50 165 122
24 18 69 51 170 125
25 18 70 52 175 129
26 19 71 52 180 133
27 20 72 53 185 136
28 21 73 54 190 140
29 21 74 55 195 144
30 22 75 55 200 148
31 23 76 56 205 151
32 24 77 57 210 155
33 24 78 58 215 159
34 25 79 58 220 162
35 26 80 59 225 166
36 27 81 60 230 170
37 27 82 60 235 173
38 28 83 61 240 177
39 29 84 62 245 181
40 30 85 63 250 184
41 30 86 63 260 192
42 31 87 64 270 199
43 32 88 65 280 207
44 32 89 66 290 214
45 33 90 66 300 221
46 34 91 67 310 229
47 35 92 68 320 236
48 35 93 69 330 243
49 36 94 69 340 251
50 37 95 70 350 258
51 38 96 71 360 266
52 38 97 72 370 273
53 39 98 72 380 280
54 40 99 73 390 288
55 41 100 74 400 295

General
Information
VW Jetta Hybrid Quick Reference Specication Book • February 2014 3
Nm-to-lb·in (in·lb), kg·cm
To calculate: Nm x 8·85 = lb·in • Nm x 10.20 = kg·cm
Nm lb·in
(in·lb) kg·cm Nm lb·in (in·lb) kg·cm
1910 26 230 265
2 18 20 27 239 275
327 31 28 248 286
4 35 41 29 257 296
5 44 51 30 266 306
6 53 61 31 274 316
762 71 32 283 326
8 71 82 33 292 337
980 92 34 301 347
10 89 102 35 310 357
11 97 112 36 319 367
12 106 122 37 327 377
13 115 133 38 336 387
14 124 143 39 345 398
15 133 153 40 354 408
16 142 163 41 363 418
17 150 173 42 372 428
18 159 184 43 381 438
19 168 194 44 389 449
20 177 204 45 398 459
21 186 214 46 407 469
22 195 224 47 416 479
23 204 235 48 425 489
24 212 245 49 434 500
25 221 255 50 443 510
N·cm-to-lb·in (in·lb), kg·cm
To calculate: N·cm x 0.089 = lb·in • N·cm x 0.102 = kg·cm
N·cm lb·in
(in·lb) kg·cm N·cm lb·in (in·lb) kg·cm
50 4 5 250 22 25
60 5 6 300 27 31
70 6 7350 31 36
80 78 400 35 41
90 8 9450 40 46
100 910 500 44 51
110 10 11 550 49 56
120 11 12 600 53 61
130 12 13 650 58 66
140 12 14 700 62 71
150 13 15 750 66 76
160 14 16 800 71 82
170 15 17 850 75 87
180 16 18 900 80 92
190 17 19 950 84 97
200 18 20 1000 89 102

4 VW Jetta Hybrid Quick Reference Specication Book • February 2014
kg·cm-to-lb·in (in·lb), N·cm
To calculate: kg·cm x 0.868 = lb·in • kg·cm x 9.81 = N·cm
kg·cm lb·in
(in·lb) N·cm kg·cm lb·in (in·lb) N·cm
5 4 49 110 95 1079
6 5 59 120 104 1177
76 69 130 113 1275
8778 140 122 1373
98 88 150 130 1471
10 998 160 139 1569
20 17 196 170 148 1667
30 26 294 180 156 1765
40 35 392 190 165 1863
50 43 490 200 174 1961
60 52 588 210 182 2059
70 61 686 220 191 2157
80 69 785 230 200 2256
90 78 883 240 208 2354
100 87 981 250 217 2452
Warnings and Cautions
WARNINGS
• Some repairs may be beyond your capability. If you lack the skills,
tools and equipment, or a suitable workplace for any procedure
described in this manual, we suggest you leave such repairs to an
authorized dealer service department or other qualied shop.
• Do not reuse any fasteners that have become worn or deformed
during normal use. Many fasteners are designed to be used only
once and become unreliable and may fail when used a second
time. This includes, but is not limited to, nuts, bolts, washers, self-
locking nuts or bolts, circlips and cotter pins. Always replace these
fasteners with new parts.
• Never work under a lifted car unless it is solidly supported on
stands designed for the purpose. Do not support a car on cinder
blocks, hollow tiles or other props that may crumble under
continuous load. Never work under a car that is supported solely
by a jack. Never work under the car while the engine is running.
• If you are going to work under a car on the ground, make sure
the ground is level. Block the wheels to keep the car from rolling.
Disconnect the battery negative (-) terminal (ground strap) to
prevent others from starting the car while you are under it.