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Service

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Workshop Manual
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Jetta 2013 ➤

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6-speed manual gearbox 0AJ

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Service Department. Technical Information


Service
List of Workshop Manual Repair Groups
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Repair Gssr o u p
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00 - Technical data
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30 - Clutch
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34 - Controls, housing

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35 - Gears, shafts
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39 - Final drive - differential

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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 © 2017 Volkswagen AG, Wolfsburg D4B8033B594


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Location on gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Identification code, assembly allocation and capacities AG. Volkswa.g.en. A ......................... 1
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2 Overview - power transmission . . . y.V.o.l . . . . . . . . . . . . . . . . . . . .s.n.ot.g.u . . . . . . . . . . . . . . . .
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3 Calculating overall gear ratio “i”orise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.nt.ee. . . . . . . . . . . . . 5
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4 General repair instructions ss a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c. . . . . . . . . . 6
4.1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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1 Fault finding, power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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2 Repairing clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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2.2 Assembly overview - pedal cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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2.3 Removing and installing over-centre spring (left-hand drive) . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Removing and installing over-centre spring (right-hand drive) . . . . . . . . . . . . . . . . . . . . . . 18

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2.5 Removing and installing clutch pedal (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.6 Removing and installing clutch pedal (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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2.7 Removing and installing mounting bracket (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34


2.8 Removing and installing mounting bracket (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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2.9 Removing and installing clutch master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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2.10 Removing and installing clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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2.11 Assembly overview - hydraulics (LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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2.12 Assembly overview - hydraulics (RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54


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2.13 Removing and installing clutch slave cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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3 Bleeding clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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4 Repairing clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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4.1 Assembly overview - clutch release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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4.2 Removing and installing clutch release lever, release bearing and guide sleeve . . . . . . . . cted
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5 Repairing clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.1 Installation position of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.2 Overview of selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.3 Assembly overview - gear knob and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.4 Removing and installing gaiter with gear knob and noise insulation . . . . . . . . . . . . . . . . . . 68
1.5 Assembly overview - Gear lever and selector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.6 Assembly overview - Selector cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.7 Removing cable end-piece from relay lever and installing . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.8 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.9 Removing and installing gear selector cable and gate selector cable . . . . . . . . . . . . . . . . 87
1.10 Adjusting selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2 Removing and installing gearbox, Jetta 2011 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.1 Removing gearbox, Jetta 2011 with 1.2 l engine and 1.4 l engine . . . . . . . . . . . . . . . . . . . . 92
2.2 Installing gearbox, Jetta 2011 with 1.2 l engine and 1.4 l engine . . . . . . . . . . . . . . . . . . . . 102
3 Transporting gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4 Checking gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.1 Overview - gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Contents i
Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

5.3 Assembly overview - Removing and installing cover for gearbox housing and 5th and 6th
gears . . . . . . . . . . . . . . . . . . . . . .e.n.A.G.. V. o.lk.s.w.ag. e.n.A.G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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5.4 Assembly overview - removing olksand installing clutch housing not . . . . . . . . . . . . . . . . . . . . . . . . 117
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5.5 Assembly overview - removing ris
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mechanism and selector utho forks . . . . . . . . . . . . . . . . . . . . . . . . . .ee. o.r . . . . . . . . . . . . . . . . . . 118
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5.6 Assembly sequence ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . 120

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Repairing gearbox housing and clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

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7 Assembly overview - gearbox housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
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8 Repairing gearbox housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
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9 Repairing selector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

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10 Dismantling and assembling selector forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
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35 - Gears, shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1 Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

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1.1 Dismantling and assembling input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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2 Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165


2.1 Dismantling and assembling output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

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39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173


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1 Renewing flange shaft oil seals with gearbox installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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1.1 Renewing oil seal for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
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1.2 Renewing seal for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

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2 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

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2.1 Dismantling and assembling differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177


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2.2 Adjusting differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
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ii Contents
Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

00 – Technical data lkswage


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1 Identification of gearbox utho
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Allocation

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Code letters and date of gearbox manufacture -arrow-

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Codes and production date of gearbox -arrow-
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Example: FVG 12 11 2
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Identification Day Month Year (2002) of
code manufacture
Additional data provide information about the production facility.

Note

The gearbox code also appears on the vehicle identification


plates.

1.2 Identification code, assembly allocation and capacities


Manual gearbox 6-speed, 0AJ
Identification code LHX NBW PRJ
Manufac‐ from 11.08 12.10 11.08
tured to 11.08 12.10
Allocation Model Jetta 2011 ► Jetta 2011 ► Jetta 2011 ►
Engine 1.4 l - 90 kW 1.2 l - 77 kW 1.2 l - 77 kW
1.4 l - 90 kW 1.4 l - 90 kW
Ratio Final drive 74 : 17 = 4.352 73 : 18 = 4.056 73 : 18 = 4.056
Z1 : Z2
Capacity of manual gear‐ 2.0 l 2.0 l 2.0 l
box
Drive shaft flange diame‐ 100 mm 100 mm 100 mm
ter

1. Identification of gearbox 1
Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

The following data can be found in the ⇒ Electronic parts cata‐


logue (ETKA) :
♦ Individual gear ratios
♦ Gear oil
♦ Clutch allocation

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Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

2 Overview - power transmission


Designation:
-Arrows- indicate direction of travel.

1 - Engine
2 - Clutch
3 - Manual gearbox
4 - Input shaft
5 - Output shaft
6 - Differential

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Ratio t. C rig
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-Arrows- indicate direction of travel.
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2. Overview - power transmission 3


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
VI - 6th gear
R - Reverse gear
A - Final drive

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4 Rep. gr.00 - Technical data


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6th gear Final drive

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Drive gear ZG1 = 51 ZA1 = 18

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Driven gear ZG2 = 36 ZA2 = 73

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iG = gear ratio = ZG2: ZG1= 36 : 51 = 0.706
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iA = final drive ratio = ZA 2: ZA1 = 73 : 18 = 4.506
itotal = overall ratio = iG x iA = 0.706 x 4.506 = 3.181

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1) Z1 = no. of teeth on driving gear, Z2 = No. of teeth on driven gear
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3. Calculating overall gear ratio “i” 5


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

4 General repair instructions


To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Also note the basic rules on safety when performing
repair procedures.
A series of instructions generally applicable to the various repair
procedures - which were previously repeated a number of times
at various places in the workshop manual - are summarised under
the topic “components” ⇒ page 6 . They apply for this particular
workshop manual.

4.1 Components

4.1.1 Gearbox
♦ When installing the manual gearbox, ensure that the dowel
sleeves between the engine and gearbox are correctly seated.
♦ When installing mounting brackets or waxed components,
clean the contact surfaces. G. Volkswasurfaces
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♦ Following thinstallation,
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♦ Capacity
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4.1.2 O-rings, seals and gaskets


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♦ Renew O-rings, seals and gaskets.


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♦ Seals for flange shafts, drive shaft and selector shaft are also
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referred to as oil seals.


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♦ When oil seals and gaskets have been removed, check con‐
t to the co

tact surface on housings or shafts for burrs and damage and


rectify as necessary.
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♦ Before installing shaft seals, lightly oil outer circumference and


half-fill space between sealing lips -arrow- with sealing grease
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- G 052 128 A1- .


♦ The open side of the oil seals faces toward the side with fluid
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♦ After renewing seals and gaskets, check oil level in gearbox


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and replenish if necessary ⇒ page 111 .


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♦ Lightly oil O-rings before installing; this prevents the rings be‐
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ing crushed when inserted.


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4.1.3 Sealant
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♦ Thoroughly clean housing joint surfaces before applying seal‐
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♦ Evenly apply a thin coat of sealing paste - AMV 188 200 03- .
♦ Breather holes must remain free of sealing paste.

6 Rep. gr.00 - Technical data


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

4.1.4 Locking devices

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♦ Do not overstretch retaining rings.

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♦ Installation position for retaining rings: At the top, the ring is

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es, in part or in w

t to the co
make it possible for the pliers to gain a better grip during re‐
moval and installation.
♦ Always renew retaining rings which have been damaged or

rrectness of i
overstretched.
l purpos

♦ Retaining rings must locate properly in grooves.


♦ Renew spring pins. Installation position: slit -A- should be in

nform
ercia

line with the line of force -arrow-.


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tion in
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Cop py
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cted
4.1.5 Nuts and bolts
agen
Prote AG.

♦ Loosen nuts or bolts in the order opposite to the tightening


sequence.
♦ Securing bolts and securing nuts which secure covers and
housings should be loosened and tightened diagonally in
stages if no tightening sequence is specified.
♦ Do not cant especially delicate parts, such as clutch pressure
plates. Loosen and tighten bolts and nuts in stages in a diag‐
onal sequence.
♦ Specified torques given are for unoiled nuts, bolts and screws.
♦ Always renew self-locking bolts and nuts.
♦ Ensure with threaded connections that contact surfaces as
well as nuts and bolts are rewaxed only after assembly, if nec‐
essary.
♦ Clean threads of bolts which are to be installed with locking
fluid using a wire brush. Then insert bolts with locking fluid -
AMV 185 101 A1- .
♦ Threaded holes into which self-locking bolts or bolts with lock‐
ing agent have been screwed must be cleaned (e.g. with a
screw tap). Otherwise there is a danger that the bolts will shear
off when refitted.
♦ Check pitch of thread, to ensure correct thread chaser is used
for cleaning and that threads are not damaged.

4. General repair instructions 7


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

4.1.6 Bearings
♦ Install needle bearings with lettered side (thicker metal) to‐
wards fitting tool.
♦ Lubricate all gearbox bearings with gear oil before installing.
♦ Tapered roller bearings fitted to one shaft must be renewed as
a set. Use same make of bearings.
♦ Heat inner races to about 100°C with the inductive heater -
VAS 6414- before installing.
♦ Do not interchange outer or inner races of bearings of the
same size. The bearings are matched in pairs.

4.1.7 Shims
♦ Measure shims at several points with a micrometer. The var‐
ious thicknesses make it possible to achieve the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Install only flawless shims.

4.1.8 Synchro-rings
♦ Do not interchange them. When reusing synchro-rings, always
fit to the same synchromeshed gear. n AG. Volkswagen AG age does
ksw not
♦ Check for wear and renew if necessary. by Vol gu
ara
ed nte
ris
♦ Check grooves -arrow 1- of synchro-ring
tho -A- and inner ring for eo
flat spots (worn grooves). ss au ra
c
ce
e

♦ If synchro-rings are coated, coating must not be damaged.


nl

pt
du

an
itte

y li

♦ If an intermediate ring -B- is installed, check the outer friction


erm

ab

surface -arrow 2- and inner friction surface -arrow 3- of this


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intermediate ring for »scoring«, »signs of abnormal wear« and


wit
, is n

»blue discolouration (due to overheating)«.


h re
hole

spec

♦ If the synchro-rings are coated, check cone of synchromeshed


es, in part or in w

gear for »scoring« and »signs of abnormal wear«.


t to the co

♦ Moisten synchromesh mechanism with gear oil before instal‐


ling.
rrectness of i
l purpos

nform
ercia

4.1.9 Gear wheels


m

at
om

♦ Heat sleeves for needle bearings to about 100°C with the in‐
on
c

in t

ductive heater - VAS 6414- before installing.


or

his
ate

♦ Heat synchro-hub with inductive heater - VAS 6414- to approx.


do
priv

100°C before installing. Press in to stop when installing so


um
for

en
g

there is no axial clearance.


n

t.
yi Co
op py
♦ Heat gears with inductive heater - VAS 6414- to approx. 100°
t. C rig
gh ht
yri
C before installing. Press in to stop when installing so there is p by
co Vo
no axial clearance.
by lksw
cted agen
Prote AG.
♦ Observe installation position

8 Rep. gr.00 - Technical data


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

4.1.10 Synchromeshed gears


♦ After assembly, check synchromeshed gears for slight play, or
for freedom of movement.

4.1.11 Clutch olksw


agen
AG. Volkswagen AG d
oes
not
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♦ Ensure that the pressure plate
rise
d does not cant: loosen and tight‐ nte
en bolts diagonally andut in several gradual stages.
ho eo
ra
s a c
s
♦ If the clutch has burnt out, thoroughly clean the clutch housing

ce
e
nl

as well as the friction surface of flywheel with a cloth to reduce

pt
du

an
the smell of burnt linings.
itte

y li
erm

ab
♦ When removing gearbox, remove clutch slave cylinder without

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disconnecting pipes.

wit
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h re
♦ Once the clutch slave cylinder has been removed with the hy‐
hole

spec
draulic line attached, do not depress clutch pedal. Otherwise
es, in part or in w

the piston will be pressed out of the clutch slave cylinder.

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4. General repair instructions 9


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

30 – Clutch
1 Fault finding, power transmission
Please note:
♦ ⇒ Fault finding, power transmission; Rep. gr. 30 ; Complaints
regarding clutch and clutch actuation
♦ ⇒ Fault finding, power transmission; Rep. gr. 34 ; Complaints
regarding selector mechanism
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
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ce
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nl

pt
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an
itte

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erm

ab
ility
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

10 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

2 Repairing clutch mechanism

2.1 Overview

Note

♦ If the vehicle has a radio with anti-theft coding, obtain code before disconnecting battery.
♦ Disconnect battery earth strap ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and connecting
battery .
♦ When reconnecting battery, refer to ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and connecting
battery .
♦ Grease all bearing points and contact surfaces. Allocate grease using ⇒ Electronic parts catalogue (ETKA) .

I - Assembly overview - pedal


cluster ⇒ page 12
II - Assembly overview - hy‐
draulics (LHD) ⇒ page 51
III - Assembly overview - hy‐
draulics (RHD) ⇒ page 54

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Repairing clutch mechanism 11


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

2.2 Assembly overview - pedal cluster

1 - Bulkhead
❑ With support for mount‐
ing bracket
2 - Seal
❑ Renew after removal
❑ Between mounting
bracket and bulkhead
❑ Self-adhesive
❑ Bond to mounting
bracket
3 - Mounting bracket
❑ For mounting clutch
pedal
❑ Is provided with damp‐
ing in some equipment
variants ⇒ page 13
❑ Removing and installing
⇒ page 34
4 - Bolt
5 - Over-centre spring
❑ Removing and installing
(LHD) ⇒ page 13 n AG. Volkswagen AG do
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❑ Removing and installing y Volks ot g
ua
(RHD) ⇒ page 18 ised b ran
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6 - Bearing bush aut or
ac
ss
7 - Bearing mounting
ce
le
un

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itte

8 - Clutch pedal
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ab

❑ Removing and installing


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(LHD) ⇒ page 23
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❑ Removing and installing


ole,

spec

(RHD) ⇒ page 29
urposes, in part or in wh

t to the co

9 - Support
❑ To remove and install, separate clutch master cylinder from clutch pedal
⇒ “2.5 Removing and installing clutch pedal (LHD)”, page 23
rrectne

10 - Seal
s

❑ Renew after removal


s o
cial p

❑ Between clutch master cylinder and mounting bracket


inform
mer

11 - Clutch master cylinder


atio
m

❑ Removing and installing after removal of mounting bracket ⇒ page 46


o

n
c

i
or

n thi

12 - Clutch position sender - G476-


te

sd
iva

❑ Removing and installing ⇒ page 48


pr

cum
r
fo

❑ Can be checked in “Guided Fault Finding” using vehicle diagnostic tester


en
ng

t.
yi Co
op
❑ The clutch position sender - G476- is identified as clutch pedal switch - F36- in “guided fault finding”
C py
t. rig
gh ht
yri by
13 - Clip cop Vo
by lksw
cted agen
❑ Pull out clip to stop to remove and install pipe/hose assembly or plastic line Prote AG.

14 - Supply hose
❑ Made of plastic ⇒ page 53

12 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

15 - Hexagon nut, 25 Nm
❑ Self-locking
❑ Qty. 3
❑ For mounting bracket to bulkhead
❑ Renew after removal
16 - Hexagon nut, 25 Nm
❑ Renew after removal
17 - Stop
❑ For clutch pedal

Mounting bracket with damping -arrows-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

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un

pt
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itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
2.3 Removing and installing over-centre
l purpos

spring (left-hand drive)


Special tools and workshop equipment required
nform
ercia

♦ Release tool - T10178-


m

a
com

tion in
r
te o

thi
s
iva

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rp

cum
fo

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ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2. Repairing clutch mechanism 13


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

Torque wrench - V.A.G 1331-

2.3.1 Removing
Vehicles with knee airbag

Note

The installation location of the knee airbag is above the pedal


cluster.

– First check whether a coded radio is fitted. If so, obtain anti-


theft code.
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .
Continuation for all
– Push driver seat as far back as possible and put steering wheel
in highest position.
– Remove trim and cover below trim on driver side ⇒ General
body repairs, interior; Rep. gr. 68 ; Compartments, covers andwagen AG. Volkswagen AG doe
trims . yV
olks s no
t gu
b ara
ed nte
Vehicles with knee airbag thoris e or
au ac
– Remove bracket for knee airbag together withsscrash bar ⇒
ce
le

General body repairs, interior; Rep. gr. 69 ; Airbag; Removing


un

pt

and installing knee airbag bracket.


an
d
itte

y li
erm

ab

Continuation for all


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wit

– Remove cable guide -2- from steering column.


is n

h re
ole,

– Remove footwell vent -3- ⇒ Heating, air conditioning; Rep. gr.


spec
urposes, in part or in wh

80 ; Repairing heating .
t to the co

Vehicles without knee airbag


rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

14 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
Attachment with 2 bolts
– Remove crash bar -1- (2 bolts).

Attachment with 1 bolt


– Remove crash bar -1- (1 bolt -2-).
Continuation for all

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
If fitted, remove damping -arrow- from lower area of clutch pedal s

ce
e
nl

mounting bracket.

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
or

– To do this, remove lock washers -A- for damping.


f

en
ng

t.
yi Co
– Pull off damping. Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2. Repairing clutch mechanism 15


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

– Push damping upwards in area of upper securing nut -1-


above clutch pedal -A- in -direction of arrow-.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne
– Unbolt clutch pedal -1- from mounting bracket -3- by removing
nut -2- and pulling out bolt -5-.

ss o
cial p

f in
Note

form
mer

atio
m

Clutch pedal remains hooked to operating rod of clutch master


o

n
c

cylinder.

i
or

n thi
te

sd
iva

o
r

– Swing clutch pedal down slightly and remove over-centre


p

cum
r
fo

spring -4- from mounting bracket.


en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.3.2 Installing
Install in the reverse order of removal, observing the following.

Note

Renew self-locking nuts.

16 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

– Insert over-centre spring -2- in mounting bracket from above


while holding end of spring with assembly tool - T10178- in
installation position.

• Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐
tically. AG. Volkswagen A gen G do
swa es
– Insert tip -A- of clutchy Vpedal in bearing recess of over-centre
olk not
gu
spring. edb ara
ris nt ee
th o
o
– Depress clutch
s au pedal slightly, push bolt through and tighten r ac
self-locking nut to specified torque ⇒ page 18 .
s
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

Some cars have damping -arrow- on the clutch pedal mounting


t to the co

bracket.
– Return it to installation position.
rrectne

Vehicles without knee airbag


ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2. Repairing clutch mechanism 17


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
Attachment with 2 bolts
– Install crash bar -1- and tighten the 2 bolts to specified torque
⇒ page 18 .

Attachment with 1 bolt


– Install crash bar -1- and tighten bolt -2- to specified torque
⇒ page 18 .
Continuation for all

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
s c
– Mount cable guide -2- on steering column. s
ce
e
nl

pt
du

– Install footwell vent -3- ⇒ Heating, air conditioning; Rep. gr.


an
itte

y li

80 ; Repairing heating .
erm

ab
ility
ot p

Vehicles with knee airbag


wit
, is n

h re

– Install bracket for knee airbag together with crash bar ⇒ Gen‐
hole

eral body repairs, interior; Rep. gr. 69 ; Airbag; Removing and


spec

installing knee airbag bracket .


es, in part or in w

t to the co

Continuation for all


– Install trim and cover below trim on drive side ⇒ General body
rrectness of i

repairs, interior; Rep. gr. 68 ; Compartments, covers and


trims .
l purpos

– Reconnect battery and perform work required after connecting


battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Discon‐
nf
ercia

necting and connecting battery .


rm
m

atio
om

n in
c

2.3.3 Specified torques


or

thi
te

sd
iva

Component Nm
r
rp

cu
o

m
f

en
ng

Clutch pedal to mounting bracket 25


t.
yi Co
♦ Renew self-locking nuts Cop py
t. rig
gh ht
pyri by
Crash bar to steering column mounting 10
co Vo
by lksw
cted
bracket (attachment with 2 bolts)
agen
Prote AG.

Crash bar to steering column mounting 20


bracket (attachment with 1 bolt)
♦ Renew bolts for crash bar

2.4 Removing and installing over-centre


spring (right-hand drive)
Special tools and workshop equipment required

18 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

♦ Pliers - T10005-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
♦ Release tool - T10178-

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
♦ Torque wrench - V.A.G 1331- Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2.4.1 Removing
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .
– Push driver seat as far back as possible and put steering wheel
in highest position.
– Remove trim and cover below trim on driver side ⇒ General
body repairs, interior; Rep. gr. 68 ; Compartments, covers and
trims .
Vehicles with knee airbag
– Remove bracket for knee airbag together with crash bar ⇒
General body repairs, interior; Rep. gr. 69 ; Airbag; Removing
and installing knee airbag bracket.

2. Repairing clutch mechanism 19


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

Continuation for all


– Remove footwell vent -3- ⇒ Heating, air conditioning; Rep. gr.
80 ; Repairing heating .
– Remove cable guide -2- from steering column.
n AG. Volkswagen A age G do
ksw es n
y Vol ot g
ua
b
ed ran
oris tee
th or
au ac
ss

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

– Remove crash bar -1- (bolt -2-).

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n
If fitted, remove damping -arrow- from lower area of clutch pedal

thi
te

sd
a

mounting bracket.
iv

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– To do this, remove lock washers -A- for damping.


– Pull off damping.

20 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

– Push damping upwards in area of upper securing nut -1-


above clutch pedal -A- in -direction of arrow-.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
– Unbolt clutch pedal -1- from mounting bracket -3- by removing

ility
ot p

nut -2- and pulling out bolt -5-.

wit
, is n

h re
hole

spec
es, in part or in w

Note

t to the co
Clutch pedal remains hooked to operating rod of clutch master
cylinder.

rrectness of i
l purpos

– Swing clutch pedal down slightly and remove over-centre


spring -4- from mounting bracket.

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri by
2.4.2 Installing
cop Vo
by lksw
cted agen
Prote AG.
Install in the reverse order of removal, observing the following.

Note

Renew self-locking nuts.

2. Repairing clutch mechanism 21


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

– Insert over-centre spring -2- in mounting bracket from above


while holding end of spring with assembly tool - T10178- in
installation position.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
– Receptacle -arrow- for tip -A- of clutchrispedal
ed must stand ver‐ ran
tee
tically. utho
or
a ac
ss
– Insert tip of clutch pedal -1- in bearing recess of over-centre

ce
le
un

spring.

pt
an
d
itte

y li
– Depress clutch pedal slightly, push bolt through and tighten
erm

ab
self-locking nut to specified torque ⇒ page 23 .

ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne
Some cars have damping -arrow- on the clutch pedal mounting
bracket. ss
– Return it to installation position.
o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

22 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

– Install crash bar -1- and tighten bolt -2- to specified torque
⇒ page 23 .

– Mount cable guide -2- on steering column.


– Install footwell vent -3- ⇒ Heating, air conditioning; Rep. gr.
80 ; Repairing heating . olksw AG. V agen AG
agen does
– Install trim and cover below trim on driveVoside
lksw ⇒ General body not
gu
repairs, interior; Rep. gr. 68 ; Compartments,
ed by covers and ara
nte
trims . oris eo
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Vehicles with knee airbag ss

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pt
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eral body repairs, interior; Rep. gr. 69 ; Airbag; Removing and
erm

ab
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2.4.3 Specified torques

t to the co
Component Nm
Clutch pedal to mounting bracket 25

rrectne
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ss
Crash bar to steering column mounting 20
o
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bracket f inform
mer

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2.5 Removing and installing clutch pedal


thi
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Special tools and workshop equipment required


t.
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Cop py
♦ Pliers - T10005-
t. rig
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2. Repairing clutch mechanism 23


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJag-eEdition
n AG. Volk06.2017
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l purpos

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2.5.1 Removing
AG.

Vehicles with knee airbag

Note

The installation location of the knee airbag is above the pedal


cluster.

– First check whether a coded radio is fitted. If so, obtain anti-


theft code.
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .
Continuation for all
– Push driver seat as far back as possible and put steering wheel
in highest position.
– Remove trim and cover below trim on driver side ⇒ General
body repairs, interior; Rep. gr. 68 ; Compartments, covers and
trims .
Vehicles with knee airbag
– Remove bracket for knee airbag together with crash bar ⇒
General body repairs, interior; Rep. gr. 69 ; Airbag; Removing
and installing knee airbag bracket.

24 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

Continuation for all


– Remove cable guide -2- from steering column.
– Remove footwell vent -3- ⇒ Heating, air conditioning; Rep. gr.
80 ; Repairing heating .
Vehicles without knee airbag

The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
Attachment with 2 bolts
– Remove crash bar -1- (2 bolts).

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erm

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If fitted, remove damping -arrow- from lower area of clutch pedal


mounting bracket.
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2. Repairing clutch mechanism 25


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017
. Volkswagen AG
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– To do this, remove lock washers
Vol
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– Push damping upwards in area of upper securing nut -1-

rrectne
above clutch pedal -A- in -direction of arrow-.

ss o
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f inform
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– Unbolt clutch pedal -1- from mounting bracket -3- by removing


nut -2- and pulling out bolt -5-.
– Swing clutch pedal forward slightly and remove over-centre
spring -4- from mounting bracket.

26 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

– Release clutch pedal from clutch master cylinder using pliers


- T10005- .
– Remove clutch pedal.

2.5.2 Installing
Install in the reverse order of removal, observing the following.

Note

Renew self-locking nuts.

– Attach retainer -2- to clutch master cylinder operating rod -1-.


– Press retainer into notch in clutch pedal -3- until it can be heard
to engage.

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Cop py
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2. Repairing clutch mechanism 27


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

• Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐
tically.
– Insert tip -A- of clutch pedal in bearing recess of over-centre
spring.
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– Depress clutch pedal slightly, push bolt through andVtighten
olks
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self-locking nut to specified torque ⇒ page 29 . ed by gu
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Some cars have damping -arrow- on the mounting bracket/clutch

h re
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hole

spec
es, in part or in w

– Return it to installation position.

t to the co
Vehicles without knee airbag

rrectness of i
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The crash bar -1- in front of clutch pedal -2- may be secured in
AG.

different ways.
Attachment with 2 bolts
– Install crash bar -1- and tighten the 2 bolts to specified torque
⇒ page 29 .

Attachment with 1 bolt


– Install crash bar -1- and tighten bolt -2- to specified torque
⇒ page 29 .
Continuation for all

28 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

– Mount cable guide -2- on steering column.


– Install footwell vent -3- ⇒ Heating, air conditioning; Rep. gr.
80 ; Repairing heating .
Vehicles with knee airbag
– Install bracket for knee airbag together with crash bar ⇒ Gen‐
eral body repairs, interior; Rep. gr. 69 ; Airbag; Removing and
installing knee airbag bracket .
Continuation for all
– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. gr. 68 ; Compartments, covers and
trims .
– Reconnect battery and perform work required after connecting
battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Discon‐
necting and connecting battery .

2.5.3 Specified torques


Component Nm
Clutch pedal to mounting bracket 25
♦ Renew self-locking nuts

Crash bar to steering column mounting 10


bracket (attachment with 2 bolts)
Crash bar to steering column mounting 20
bracket (attachment with 1 bolt) en AG. Volkswagen AG
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2.6 Removing
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ss and installing clutch pedal ac

(RHD)
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Special tools and workshop equipment required


erm

ab
ility
ot p

♦ Pliers - T10005-
wit
is n

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spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

♦ Release tool - T10178-


i
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t.
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ht. rig
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Prote AG.

2. Repairing clutch mechanism 29


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

♦ Torque wrench - V.A.G 1331-

AG. Volkswagen AG d
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2.6.1 Removing
es, in part or in w

t to the co
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.

rrectness of i
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .
l purpos

– Push driver seat as far back as possible and put steering wheel
in highest position.

nf
ercia

or
– Remove trim and cover below trim on driver side ⇒ General

m
m

atio
body repairs, interior; Rep. gr. 68 ; Compartments, covers and
om

n in
trims .
or c

thi
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sd
Vehicles with knee airbag
iva

o
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rp

cu
– Remove bracket for knee airbag together with crash bar ⇒
o

m
f

en
ng

General body repairs, interior; Rep. gr. 69 ; Airbag; Removing


t.
yi Co
op
and installing knee airbag bracket.
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Continuation for all co Vo
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– Remove cable guide -2- from steering column.
AG.

– Remove footwell vent -3- ⇒ Heating, air conditioning; Rep. gr.


80 ; Repairing heating .

– Remove crash bar -1- (bolt -2-).

30 Rep. gr.30 - Clutch


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r eJetta
ut
ho
or 2013 ➤ , Jetta 2015 ➤
a ac
ss 6-speed manual gearbox 0AJ - Edition 06.2017

ce
le
un

pt
an
If fitted, remove damping -arrow- from lower area of clutch pedal

d
itte

y li
mounting bracket.

erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
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cum
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en
ng

t.
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op
– To do this, remove lock washers -A- for damping. C py
t. rig
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yri
– Pull off damping.
p by
o Vo
by c lksw
cted agen
Prote AG.

– Push damping upwards in area of upper securing nut -1-


above clutch pedal -A- in -direction of arrow-.

2. Repairing clutch mechanism 31


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

– Unbolt clutch pedal -1- from mounting bracket -3- by removing


nut -2- and pulling out bolt -5-.
– Swing clutch pedal forward slightly and remove over-centre
spring -4- from mounting bracket.

– Release clutch pedal from clutch master cylinder using pliers


- T10005- .
– Remove clutch pedal.

AG. Volkswagen AG d
agen oes
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2.6.2 Installing
s
ce
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an
d
itte

Install in the reverse order of removal, observing the following.


y li
erm

ab
ility
ot p

wit
is n

Note
h re
ole,

spec

Renew self-locking nuts.


urposes, in part or in wh

t to the co

– Attach retainer -2- to clutch master cylinder operating rod -1-.


– Press retainer into notch in clutch pedal until it can be heard
rrectne

to engage.
ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

32 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

– Insert over-centre spring -2- in mounting bracket from above


while holding end of spring with assembly tool - T10178- in
. Volkswagen AG
installation position. swa
gen AG does
olk not
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pe

ility
ot

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Receptacle -arrow- for tip -A- of clutch pedal must stand ver‐

nform
ercia

tically.
m

a
com

ti
– Insert tip of clutch pedal -A- in bearing recess of over-centre

on in
spring.
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– Depress clutch pedal slightly, push bolt through and tighten

do
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rp

c
self-locking nut to specified torque ⇒ page 34 .

um
fo

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t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Some cars have damping -arrow- on the mounting bracket/clutch


pedal.
– Return it to installation position.

2. Repairing clutch mechanism 33


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

– Install crash bar -1- and tighten bolt -2- to specified torque
⇒ page 34 . wage
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ris
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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Mount cable guide -2- on steering column.
– Install footwell vent -3- ⇒ Heating, air conditioning; Rep. gr.

rrectness of i
80 ; Repairing heating .
l purpos

– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. gr. 68 ; Compartments, covers and
trims .

nform
ercia

Vehicles with knee airbag


m

a
com

tio
– Install bracket for knee airbag together with crash bar ⇒ Gen‐

n in
r

eral body repairs, interior; Rep. gr. 69 ; Airbag; Removing and


te o

thi
installing knee airbag bracket .

s
iva

do
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Continuation for all
fo

en
ng

t.
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– If disconnected, connect battery, and perform work required Cop py
after connecting battery ⇒ Electrical system; Rep. gr. 27 ;
t. rig
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yri by
Battery; Disconnecting and connecting battery . op Vo
by c lksw
cted agen
Prote AG.

2.6.3 Specified torques


Component Nm
Clutch pedal to mounting bracket 25
♦ Renew self-locking nuts

Crash bar to steering column mounting 20


bracket
♦ Renew bolt for crash bar

2.7 Removing and installing mounting


bracket (LHD)
Special tools and workshop equipment required
♦ Hose clamps to 25 mm - 3094-

34 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

♦ Torque wrench - V.A.G 1331-

♦ Spring-type clip pliers - VAS 6362-

AG. Volkswagen AG d
agen oes
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ce
♦ Sealing tool - T10249-
le
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es, in part or in w

t to the co
rrectness of i
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ercia

2.7.1 Removing
m

a
– First check whether a coded radio is fitted. If so, obtain anti-
com

tion in

theft code.
r
te o

thi

– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.


s
iva

do
r

27 ; Battery; Disconnecting and connecting battery .


rp

cum
fo

en
ng

– Completely remove air filter housing if it is located in proximity


t.
yi Co
op
of battery ⇒ Rep. gr. 24 ; Injection system; Removing and C py
t. rig
installing air filter .
gh ht
pyri by
Vo
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– Remove battery and battery tray ⇒ Electrical system; Rep. gr. cted agen
Prote AG.
27 ; Battery; Removing and installing battery

2. Repairing clutch mechanism 35


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

Note

♦ During the following work, ensure that no brake fluid lands on


longitudinal member or gearbox. If this does happen, clean the n AG. Volkswagen AG do
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affected areas thoroughly. byV
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♦ Place a lint-free cloth under the clutch master cylinder. utho tee
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– Clamp off supply hose to clutch master cylinder using hose

e
nl

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clamp - 3094- .

an
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erm

ab
– If necessary, loosen spring-type clip -3- with hose clip pliers -

ility
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VAS 6362- , and pull supply hose off clutch master cylinder.

wit
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– In addition, seal supply hose with sealing tool - T10249/1- .
hole

spec
es, in part or in w
– Release securing clip -2- using screwdriver or a pointed object

t to the co
and pull pipe/hose assembly or plastic line -1- off clutch master
cylinder.

rrectness of i
– Unclip clutch position sender - G476- from clutch master cyl‐
inder -arrow- and remove with electrical connector attached
l purpos

-4-.

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Note

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When performing work in the footwell, put cloths on the carpet to


or

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protect it from possible brake fluid spills.
te

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o

m
– Remove trim and cover below trim on driver side ⇒ General
f

en
ng

t.
body repairs, interior; Rep. gr. 68 ; Compartments, covers and
yi Co
op
trims .
C py
t. rig
gh ht
yri by
Vehicles with knee airbag
cop Vo
by lksw
cted agen
Prote AG.

Note

The installation location of the knee airbag is above the pedal


cluster.

– Remove bracket for knee airbag together with crash bar ⇒


General body repairs, interior; Rep. gr. 69 ; Airbag; Removing
and installing knee airbag bracket.
Continuation for all

– Remove cable guide -2- from steering column.


– Remove footwell vent -3- ⇒ Heating, air conditioning; Rep. gr.
80 ; Repairing heating .
Vehicles without knee airbag

36 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
Attachment with 2 bolts
– Unbolt crash bar (2 bolts).

Attachment with 1 bolt


– Remove crash bar -1- (1 bolt -2-).
Continuation for all

If fitted, remove damping -arrow- from lower area of clutch pedal


mounting bracket. agen
AG. Volkswagen AG d
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Vol ot g
d by ua
ran
e
ris tee
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au ac
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nl

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itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

– To do this, remove lock washers -A- for damping.


rm
m

atio
m

– Pull off damping.


o

n in
or c

thi
te

sd
iva

o
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rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2. Repairing clutch mechanism 37


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

– Push damping upwards in area of upper securing nut -1-


above clutch pedal -A- in -direction of arrow-.

– Remove securing nuts -1- and -2-.


The upper securing nut -1- is accessible between the relay
carrier and the steering column trim.
– Remove mounting bracket -3-.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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h
aut ra
ss c
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nl

pt

2.7.2 Installing
du

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itte

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erm

ab

Install in the reverse order of removal, observing the following.


ility
ot p

wit
, is n

h re
hole

Note
spec
es, in part or in w

t to the co

♦ Renew self-locking nut.


♦ Renew hose clips.
rrectness of i

♦ Allocate all components according to ⇒ Electronic parts cata‐


logue (ETKA) .
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
38
by c lksw
cted
Rep. gr.30 - Clutch
agen
Prote AG.
Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

Some cars have damping -arrow- on the clutch pedal mounting


bracket.
Vehicles without knee airbag

The crash bar -1- in front of clutch pedal -2- may be secured in
different ways.
Attachment with 2 bolts
– Install crash bar -1- and tighten the 2 bolts to specified torque
⇒ page 40 .

n AG. Volkswagen AG do
lkswage es n
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Attachment with 1thbolt
o tee
or
au ac
ss
– Install crash bar -1- and tighten bolt -2- to specified torque
ce
le

⇒ page 40 .
un

pt
an
d
itte

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Continuation for all


rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

– Mount cable guide -2- on steering column.


l purpos

– Install footwell vent -3- ⇒ Heating, Air conditioning; Rep. gr.


80 ; Repairing heating; Removing and installing left footwell
nform
ercia

vent .
m

a
com

Vehicles with knee airbag


ion in
r
te o

– Install bracket for knee airbag together with crash bar ⇒ Gen‐
thi
s
iva

eral body repairs, interior; Rep. gr. 69 ; Airbag; Removing and


do
r
rp

installing knee airbag bracket .


um
fo

en
ng

t.
Continuation for all
yi Co
Cop py
t. rig
– Install trim and cover below trim on drive side ⇒ General body
gh ht
yri by
repairs, interior; Rep. gr. 68 ; Compartments, covers and
cop Vo
by lksw
cted
trims .
agen
Prote AG.

2. Repairing clutch mechanism 39


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

– Push pipe/hose assembly or plastic line -1- with seal -2- onto
connection of clutch master cylinder -4- until securing clip -3-
engages audibly.
– Test line by tugging on it.
– After removing hose clamp - 3094- , return supply hose to its
original shape, if necessary.
– Bleed clutch mechanism ⇒ page 58 .
– Install battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Re‐
moving and installing battery .
– If completely removed beforehand, install air filter housing ⇒
Rep. gr. 24 ; Injection system; Removing and installing air
filter .

2.7.3 Specified torques


Component Nm
Mounting bracket to bulkhead 25
♦ Renew self-locking nuts.

Crash bar to steering column mounting 10


bracket (attachment with 2 bolts)
Crash bar to steering column mounting 20
bracket (attachment with 1 bolt)
♦ Renew bolts for crash bar AG. Volkswagen AG d
agen oes
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2.8 Removing and installing mounting bracket (RHD) d ara
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40 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

Special tools and workshop


equipment required

AG. Volkswagen AG d
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c

♦ Hose clamps to 25 mm - 3094-


or

thi
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sd
a

♦ Sealing tool - T10249-


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♦ Hook - 3438-
en
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♦ Torque wrench - V.A.G 1331-
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2.8.1 Removing
op Vo
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cted agen
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Vehicles with knee airbag
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .
Continuation for all
An insulation mat is installed in conjunction with some engines.
Appearance may be different from that illustrated.

2. Repairing clutch mechanism 41


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

– Remove heat shield from pipe/hose assembly -arrows-.

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Note

wit
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♦ During the following work, ensure that no brake fluid lands on

spec
urposes, in part or in wh

longitudinal member or gearbox. If this does happen, clean the

t to the co
affected areas thoroughly.
♦ Place a lint-free cloth under the clutch master cylinder.

rrectne
– Clamp off supply hose to clutch master cylinder using hose
clamp - 3094- .

ss o
cial p

f
– Pull supply hose off clutch master cylinder.

inform
mer

– In addition, for disconnecting, you can seal supply hose with

atio
sealing tool - T10249/1- .
om

n
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i
or

n thi
e

Release securing clip -1- with a screwdriver or pointed object


t

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– Pull pipe/hose assembly or plastic line -2- off clutch master


um
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en

cylinder.
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t.
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– Unclip clutch position sender - G476- from clutch master cyl‐
. C rig
ht ht
rig
inder -arrow- and remove with electrical connector attached py by
co Vo
-3-.
by lksw
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Note

When performing work in the footwell, put cloths on the carpet to


protect it from possible brake fluid spills.

– Remove trim and cover below trim on driver side ⇒ General


body repairs, interior; Rep. gr. 68 ; Compartments, covers and
trims .
Vehicles with knee airbag
– Remove bracket for knee airbag together with crash bar ⇒
General body repairs, interior; Rep. gr. 69 ; Airbag; Removing
and installing knee airbag bracket.
Continuation for all

Note

The installation location of the knee airbag is above the pedal


cluster.

Continuation for all

42 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

– Remove cable guide -2- from steering column.


– Remove footwell vent -3- ⇒ Heating, air conditioning; Rep. gr.
80 ; Repairing heating .

– Remove crash bar -1- (bolt -2-).

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If fitted, remove damping -arrow- from lower area of clutch pedal

an
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mounting bracket.

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– To do this, remove lock washers -A- for damping.
Co
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– Pull off damping.
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2. Repairing clutch mechanism 43


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

– Push damping upwards in area of upper securing nut -1-agen AG. Volkswagen AG do
above clutch pedal -A- in -direction of arrow-. Vol
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– Remove securing nuts -1- and -2-.

atio
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c

The upper securing nut -1- is accessible between the relay carrier
or

thi
and the steering column trim.
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– Remove mounting bracket -3-.
o

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2.8.2 Installing
Install in the reverse order of removal, observing the following.

Note

Renew self-locking nut.

44 Rep. gr.30 - Clutch


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6-speed
ed b manual gearbox 0AJ - Edition a06.2017
ran
ris tee
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u
Some cars have damping -arrow- on the clutch spedal
s a mounting ac
bracket.

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pt
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ot

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es, in part or in w

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a
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tion in
r
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do
r

– Install crash bar -1- and tighten bolt -2- to specified torque
rp

cum
fo

⇒ page 46 .

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
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– Mount cable guide -2- on steering column.


– Install footwell vent -3- ⇒ Heating, air conditioning; Rep. gr.
80 ; Repairing heating .
– Install trim and cover below trim on drive side ⇒ General body
repairs, interior; Rep. gr. 68 ; Compartments, covers and
trims .
Vehicles with knee airbag
– Install bracket for knee airbag together with crash bar ⇒ Gen‐
eral body repairs, interior; Rep. gr. 69 ; Airbag; Removing and
installing knee airbag bracket .
Continuation for all

2. Repairing clutch mechanism 45


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

– Press pipe/hose assembly -2- with seal into connection of


clutch master cylinder.
– Engage securing clip -1-.
n AG. Volkswagen AG do
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– Clip clutch position sender - G476- into clutch
ir se master cylinder
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utho
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ss
– After removing hose clamp - 3094- , return supply hose to its

ce
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nl
original position, if necessary.

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rrectness of i
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– If present, fold heat shield around the pipe/hose assembly


-arrows-.

nf
ercia

– Bleed clutch mechanism ⇒ page 58 .

orm
m

atio
– If disconnected, connect battery ⇒ Electrical system; Rep. gr.
om

n in
27 ; Battery; Disconnecting and connecting battery .
or c

thi
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sd
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2.8.3 Specified torques


Component Nm
Mounting bracket to bulkhead 25
♦ Renew self-locking nuts.

Crash bar to steering column mounting 20


bracket
♦ Renew bolt for crash bar

2.9 Removing and installing clutch master


cylinder
Special tools and workshop equipment required

46 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

♦ Pliers - T10005-

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2.9.1 Removing

ility
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– Remove mounting bracket:
hole

spec
♦ LHD ⇒ page 34
es, in part or in w

t to the co
♦ Right-hand drive vehicles ⇒ page 40
– Release retainer for clutch master cylinder operating rod using

rrectness of i
pliers - T10005- .
l purpos

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– Insert spacer -A- between clutch pedal and stop and press
ht
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clutch pedal to spacer.
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♦ Length of spacer = approx. 40 mm (e.g. 1/2" socket)

– Release retaining clip -B-, and pull clutch master cylinder out
of mounting bracket -arrow 1- and -arrow 2-.

2.9.2 Installing
• Move clutch pedal to rest position at stop.

2. Repairing clutch mechanism 47


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

– Attach retainer -2- to clutch master cylinder operating rod -1-.

– Insert spacer -A- between clutch pedal and stop and press
clutch pedal to spacer.
♦ Length of spacer = approx. 40 mm (e.g. 1/2" socket)

– Engage clutch master cylinder in mounting bracket -arrow 1-


and -arrow 2-.

– Push clutch master cylinder operating rod -1- in gen AG. Volkswagen AG
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– Install mounting bracket: ho eo
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♦ LHD ⇒ page 34
ce
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♦ Right-hand drive vehicles ⇒ page 40


itte

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spec
urposes, in part or in wh

t to the co

2.10 Removing and installing clutch position


sender - G476-
rrectne

Special tools and workshop equipment required


ss o
cial p

f inform
mer

atio
om

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c

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or

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Vo
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cted agen
Prote AG.

48 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

♦ Hose clamps to 25 mm ∅ - 3094-

2.10.1 Removing
LHD vehicles
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery . AG. Volkswagen AG d
agen oes
ksw n ol ot g
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– Completely remove air filter housing if it is located in proximity
ed
b ua
ran
ris
of battery ⇒ Rep. gr. 24 ; Injection system; Removing tho and tee
or
installing air filter . ss
au ac

ce
le

– Remove battery and battery tray ⇒ Electrical system; Rep. gr.


un

pt
an
d

27 ; Battery; Removing and installing battery


itte

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ab
Right-hand drive vehicles
pe

ility
ot

wit
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An insulation mat is installed in conjunction with some engines.

h re
hole

– Remove heat shield from pipe/hose assembly or plastic line

spec
-arrows-.
es, in part or in w

t to the co
Continuation for all

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
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do
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rp

cum
fo

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2. Repairing clutch mechanism 49


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

If a pipe/hose line or plastic line -1- with a round component is


installed directly beneath the clutch master cylinder, the pipe/
hose line or plastic line must be removed.

Note

During the following work,swensure


agen
AGthat
. Volksno brake dfluid
wagen AG
oes lands on
longitudinal memberbor yV
ogearbox.
lk If this does happen,notclean the
gu
affected areas thoroughly.
ris
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s au ac
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ce
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nl

pt
du

an
itte

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ility
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Clamp off supply hose to clutch master cylinder using hose
clamp, up to ∅ 25 mm - 3094- .

rrectness of i
l purpos

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t.
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Cop py
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– Release securing clip-2- with a screwdriver or a pointed object yri
gh by
ht
and pull out of clutch master cylinder to stop. cop Vo
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– Pull pipe/hose assembly or plastic line -1- out from clutch
AG.

master cylinder and seal hose.


– Disconnect connector -4-.
– Unclip clutch position sender - G476- from clutch master cyl‐
inder -arrow- and remove.

2.10.2 Installing
Install in the reverse order of removal, observing the following.

50 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

Note

♦ Renew hose clips.


♦ Allocate all components according to ⇒ Electronic parts cata‐
logue (ETKA) .

If the pipe/hose assembly or plastic line was removed:


– Push pipe/hose assembly or plastic line -1- with seal -2- onto
connection of clutch master cylinder -4- until securing clip -3-
engages audibly.
– Test pipe/hose line by tugging on it.
– After removing hose clamp - 3094- , return supply hose to its
original shape, if necessary.
– Bleed clutch mechanism ⇒ page 58 .
LHD vehicles
– Install battery tray and battery ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– If completely removed beforehand, install air filter housing ⇒
Rep. gr. 24 ; Injection system; Removing and installing air
filter . agen
AG. Volkswagen AG d
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2.11 Assembly overview - hydraulics (LHD)

an
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ility
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spec
urposes, in part or in wh

t to the co
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cial p

f inform
mer

atio
om

n
c

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or

n thi
te

sd
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o
pr

cum
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fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Repairing clutch mechanism 51


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

1 - Brake fluid reservoir


2 - Spring-type clip
❑ Not fitted
3 - Supply hose
❑ Made of plastic
⇒ page 53
4 - Clutch master cylinder
❑ Removing and installing
⇒ page 46
5 - Clip
❑ Pull out clip to stop to re‐
move and install pipe/
hose assembly or plas‐
tic line
❑ Pulled out to side on
some clutch master cyl‐
inders gen AG
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6 - Support db
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❑ To remove tho
and
ris install, eo
separate s a uclutch master ra
c
cylinders
from clutch
ce
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pedal
un

pt
an
d

⇒ “2.5 Removing and in‐


itte

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stalling clutch pedal


rm

ab
pe

ility

(LHD)”, page 23
ot

wit
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7 - Clutch pedal
h re
hole

spec

❑ Removing and installing


es, in part or in w

⇒ page 23
t to the co

8 - Hexagon nut
❑ Note and torque setting:
rrectness of i

⇒ Item 15 (page 13)


l purpos

9 - Seal / O-ring
❑ Pull onto line connection
nform
ercia

❑ Insert with brake fluid


m

❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 53


com

tion in

❑ For allocation refer to ⇒ Electronic parts catalogue (ETKA)


r
te o

thi
s
iva

10 - Pipe/hose or plastic line


do
r
rp

cum

❑ For allocation refer to ⇒ Electronic parts catalogue (ETKA)


fo

en
ng

t.
yi
❑ To remove, remove battery and battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and
Co
op py
installing battery .
. C rig
ht ht
rig by
py
11 - Bracket
co Vo
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cted agen
Prote
❑ Secured to body
AG.

12 - Seal / O-ring
❑ Pull onto line connection
❑ Insert with brake fluid
❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 53
❑ For allocation refer to ⇒ Electronic parts catalogue (ETKA)
13 - Clip
❑ Pull out clip to stop to remove and install pipe/hose assembly or plastic line
14 - Clutch slave cylinder
❑ Removing and installing ⇒ page 55

52 Rep. gr.30 - Clutch


n AG. Volkswagen AG do
lkswage es n
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tee 2013 ➤ , Jetta 2015 ➤
t or
au 6-speed manual gearbox ac 0AJ - Edition 06.2017
ss

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15 - Dust cap

pt
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16 - Bleeder valve

rm

ab
pe

ility
❑ Bleeding clutch mechanism ⇒ page 58

ot

wit
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17 - Gearbox hole

spec
18 - Hexagon bolt
es, in part or in w

t to the co
❑ Specified torque: ⇒ Item 9 (page 60)
19 - Bracket

rrectness of i
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Seals and O-rings for pipe/hose assemblies or plastic lines

nform
ercia

Item Material of line connection


m

1 Line connection with circumferential groove

a
com

tio
-arrow 1-

n in
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te o

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2 Line connection with shoulder -arrow 2-

s
iva

do
3 Line connection with shoulder -arrow 2- and cir‐
r
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fo

cumferential groove -arrow 3-

en
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t.
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op
• For line connection having circumferential groove -arrow 1-
C py
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gh
and -arrow 3-, a seal or O-ring must be set there.
ht
pyri by
Vo
co lksw
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cted agen
Prote AG.

Supply hose -1- of plastic


• The seals -2- must be located in supply hose housing.

2. Repairing clutch mechanism 53


AG. Volkswagen AG d
agen oes
olksw not
Jetta 2013 ➤ , Jetta 2015 ➤ d byV gu
ara
e
6-speed manual gearbox 0AJ - Edition
horis 06.2017 nte
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aut ra
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2.12 Assembly overview - hydraulics (RHD)

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d
itte

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rm

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1 - Brake fluid reservoir

pe

ility
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wit
2 - Seal

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hole
❑ For plastic supply hose

spec
es, in part or in w
❑ The seals must be loca‐

t to the co
ted in supply hose
3 - Supply hose

rrectness of i
❑ Plastic
l purpos

4 - Clutch master cylinder


❑ Removing and installing

nform
ercia

⇒ page 46
m

5 - Clip

a
com

tion in
❑ Pull out clip to stop to re‐
r
te o

move and install pipe/

thi
s
iva

hose assembly or plas‐

do
r
rp

c
tic line

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fo

en
g

❑ Pulled out to side on


n

t.
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op
some clutch master cyl‐ C py
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inders rig ht
py by
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6 - Seal / O-ring cted agen
Prote AG.
❑ Pull onto line connection
❑ Insert with brake fluid
❑ Seals/O-rings are adap‐
ted to configuration of
line connection
⇒ page 53
❑ For allocation refer to ⇒
Electronic parts cata‐
logue (ETKA)
7 - Support
❑ To remove and install,
separate clutch master
cylinder from clutch
pedal
⇒ “2.6 Removing and installing clutch pedal (RHD)”, page 29
8 - Clutch pedal
❑ Removing and installing ⇒ page 29
9 - Hexagon nut
❑ Note and torque setting: ⇒ Item 15 (page 13)
10 - Bracket
❑ Secured to body
11 - Pipe/hose or plastic line
❑ For allocation refer to ⇒ Electronic parts catalogue (ETKA)
❑ To remove, remove battery and battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and
installing battery .
12 - Bracket
❑ Secured to retainer for ABS/EDL
13 - Bracket
❑ For ABS/EDL

54 Rep. gr.30 - Clutch


AG. Volkswagen AG d
agen
olksw Jetta 2013 o➤es n, Jetta 2015 ➤
ot g
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e6-speed
d b manual gearbox 0AJ - Editionua
ra06.2017
nte
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14 - Seal / O-ring ss a c

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❑ Pull onto line connection

nl

pt
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itte
❑ Insert with brake fluid

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ab
❑ Seals/O-rings are adapted to configuration of line connection ⇒ page 53

ility
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wit
❑ For allocation refer to ⇒ Electronic parts catalogue (ETKA)

, is n

h re
hole
15 - Clip

spec
es, in part or in w
❑ Pull out clip to stop to remove and install pipe/hose assembly or plastic line

t to the co
16 - Clutch slave cylinder
❑ Removing and installing ⇒ page 55

rrectness of i
17 - Bleeder valve l purpos
❑ Bleeding clutch mechanism ⇒ page 58
18 - Dust cap

nform
ercia

19 - Gearbox
m

at
om

ion
20 - Hexagon bolt
c

in t
or

his
e

❑ Specified torque: ⇒ Item 9 (page 60)


at

do
priv

c
21 - Bracket

um
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri
2.13 Removing and installing clutch slave
p by
o Vo
by c lksw
cted
cylinder
agen
Prote AG.

Special tools and workshop equipment required


♦ Torque wrench - V.A.G 1331-

2.13.1 Removing
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .
– Completely remove air filter housing if it is located above clutch
slave cylinder ⇒ Rep. gr. 24 ; Injection system; Removing and
installing air filter .
– Remove relay lever together with cable end-piece from gear‐
box ⇒ page 81 .

2. Repairing clutch mechanism 55


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

– Remove gearbox selector lever -A- by removing nut


-arrow 4-.

– Remove cable support bracket from gearbox -arrows-.


– Then raise and secure gear selector cable and gate selector
cable.
– Place a lint-free cloth under clutch slave cylinder.

AG. Volkswagen AG d
agen oes
– Pull clip -A- for pipe/hose assembly or plastic line out of clutch olks
w not
yV gu
slave cylinder as far as it will go. se
d b ara
nte
ri
ho eo
– Pull pipe/hose assembly or plastic line out of retainer -C-.aut ra
c
ss
– Pull pipe/hose assembly or plastic line -B- out of clutch slave
ce
e
nl

pt
du

cylinder, and seal opening.


an
itte

y li
erm

ab
– Unbolt clutch slave cylinder -arrows- and remove.
ility
ot p

wit
, is n

Caution h re
hole

spec
es, in part or in w

Do not operate clutch pedal any more.


t to the co
rrectness of i

2.13.2 Installing
l purpos

Install in the reverse order of removal, observing the following.


nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

56 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

– Install clutch slave cylinder and tighten bolts -arrows- to speci‐


fied torque ⇒ Item 9 (page 60) .
– Insert pipe/hose assembly or plastic line -B- into clutch slave
cylinder as far as stop.
– Push securing clip -A- into pipe/hose assembly or plastic line
to stop.
– Test pipe/hose line by tugging on it.
– Press pipe/hose assembly or plastic line into retainer -C- to
stop on gearbox.
– Bleed clutch mechanism after installing clutch slave cylinder
⇒ page 58 .
Assembling selector mechanism ⇒ page 82 .
Adjust selector mechanism ⇒ page 89 .
– If completely removed beforehand, install air filter housing ⇒
Rep. gr. 24 ; Injection system; Removing and installing air
filter .
– Connect battery earth ⇒ Electrical system; Rep. gr. 27 ; Bat‐
tery; Disconnecting and connecting battery .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Repairing clutch mechanism 57


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

3 Bleeding clutch mechanism


Special tools and workshop equipment required
♦ Brake filling and bleeding equipment - VAS 5234- or

♦ Brake filling and bleeding unit - V.A.G 1869-

Note
AG. Volkswagen AG d
agen oes
Prefilling system is not necessary! Volksw not
gu
d by ara
ise nte
or
Specifications for brake fluid ⇒ Brake systems;aut Rep. gr. 47 ;
h eo
ra
Bleeding brake system . ss c
ce
e
nl

pt

– Completely remove air filter housing if it prevents access to


du

an
itte

clutch slave cylinder ⇒ Rep. gr. 24 ; Injection system; Re‐


y li
erm

ab

moving and installing air filter .


ility
ot p

– Connect brake filling and bleeding equipment - VAS 5234- or


wit
, is n

h re

-V.A.G 1869- .
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
58
AG.
Rep. gr.30 - Clutch
Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

To bleed system, use 670 mm bleeder hose - V.A.G 1238/B3- if


necessary.
– Connect bleeder hose to collector bottle of brake bleeding
equipment.
– Connect bleeder hose to bleeder -arrow-.
– Pressurise system to 2 bar.
– Open bleeder valve.
– Bleed off about 100 cm3 brake fluid.
– Close bleeder valve.
– Rapidly operate pedal from stop to stop 10 to 15 times.
– Open bleeder valve.
– Bleed off an additional 50 cm3 brake fluid.
AG. Volkswagen AG d
– Close bleeder valve. lksw
agen oes
not
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by
– Depress clutch pedal several times after completion of isbleed‐
ed ara
nte
ing process. ut
hor eo
a ra
s c
– If completely removed beforehand, install air filters housing ⇒

ce
e

Rep. gr. 24 ; Injection system; Removing and installing air


nl

pt
du

an
filter .
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

3. Bleeding clutch mechanism 59


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

4 Repairing clutch release mechanism

4.1 Assembly overview - clutch release mechanism

1 - Release bearing
❑ Remove and install to‐
gether with clutch re‐
lease lever
⇒ Item 3 (page 60)
and guide sleeve
⇒ Item 5 (page 60)
❑ Removing and installing
⇒ page 61
❑ Do not wash out bear‐
ing; wipe only gen AG
. Volkswagen AG
swa does
❑ Renew noisy bearings yV
olk not
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2 - Bolt, 5 Nm + turnth90°
or further
is
e or
u
❑ Renew after ss removal
a ac

ce
e
nl

3 - Clutch release lever pt


du

an
itte

❑ Remove and install to‐ y li


erm

ab
gether with release ility
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bearing wit
, is n

⇒ Item 1 (page 60) and


h re

guide sleeve
hole

spec

⇒ Item 5 (page 60)


es, in part or in w

t to the co

❑ Removing and installing


⇒ page 61
❑ Remove old grease
rrectness of i

4 - Retaining spring
l purpos

❑ Secure to clutch release


lever
nform
ercia

5 - Guide bush
m

at
om

❑ Remove and install to‐


ion
c

gether with release


in t
or

bearing
his
ate

do
riv

⇒ Item 1 (page 60) and


p

clutch release lever


um
for

en
g

⇒ Item 3 (page 60)


n

t.
yi Co
op
❑ Removing and installing ⇒ page 61
C py
ht. rig
rig ht
py by
6 - Input shaft seal co Vo
by lksw
cted agen
❑ Lever out with a screwdriver
Prote AG.

❑ Driving in ⇒ page 138


7 - Ball-head pin, 20 Nm
❑ Remove old grease
❑ Lubricate with clutch plate spline grease - G 000 100-
8 - Gearbox
9 - Hexagon bolt, 20 Nm
10 - Bracket
11 - Clutch slave cylinder
❑ Removing and installing ⇒ page 55

60 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

4.2 Removing and installing clutch release


lever, release bearing and guide sleeve
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

Removing and installing clutch release lever with release bearing


and guide sleeve.
– Unscrew bolts -arrows-.
– Pull clutch release lever with release bearing and guide sleeve
off input shaft and ball stud.
Install in reverse order of removal.
. gen AG Volkswa
gen AG
• Retaining spring ⇒ Item 4 (page 60) must olkbe
swahooked into clutch does no
t gu
release lever. ed
by
V
ara
is nte
or
♦ Note and torque setting: ⇒ Item
au 2 (page 60)
th eo
ra
ss c
ce
e
nl

pt
du

Remove and install guide sleeve. an


itte

y li
erm

ab
• Clutch release lever removed.
ility
ot p

wit
, is n

– Push guide sleeve -3- upwards out of release bearing -2-.


h re
hole

– Turn guide sleeve -3- about 90° in -direction of arrow- relative


spec
es, in part or in w

to release bearing -2- until locking lugs of guide sleeve align


t to the co

with grooves -4- of release bearing.


– Pull guide sleeve out of release bearing in this position.
rrectness of i

Install in reverse order of removal.


l purpos

nf
ercia

Remove and install release bearing.


rm
m

atio
m

• Clutch release lever removed.


o

n in
or c

– Press together locking lugs -arrows- on back of clutch release


thi
te

sd
a

lever and remove release bearing -A- from clutch release lev‐
iv

o
r
rp

cu

er.
o

m
f

en
ng

t.
– To install, press release bearing -A- into clutch release lever
yi Co
op
until locking lugs -arrows- engage.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4. Repairing clutch release mechanism 61


AG. Volkswagen AG d
agen oes
olksw not
yV gu
Jetta 2013 ➤ , Jetta 2015 ➤ ed b ara
nte
ris
6-speed manual gearbox 0AJ - Edition 06.2017 ut
ho eo
ra
s a c
s

ce
e
nl

pt
5 Repairing clutch

du

an
itte

y li
erm

ab
ility
ot p
Special tools and workshop

wit
, is n
equipment required

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Counterhold tool - 3067-


♦ Torque wrench - V.A.G 1331-
♦ Centring mandrel - 3190 A-
♦ For engines having a crankshaft of smaller diameter or having
needle bearings ⇒ page 64 in the crankshaft - centring man‐
drel - T10086-
♦ Grease for splines - G 000 100-
(Gearbox removed)

62 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

Note

♦ Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if nec‐
essary.
♦ If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gear‐
box (rattling of gears which are not engaged) could occur.
♦ Renew clutch plates and pressure plates with damaged or loose rivets.
♦ For allocation refer to ⇒ Electronic parts catalogue (ETKA)
n AG. Volkswagen AG do
lkswage es n
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byV ua
d
1 - Flywheel o
ir se
ran
tee
th or
❑ Ensure that centring au ac
ss
pins fit tightly

ce
e
nl

pt
❑ Contact surface for
du

an
itte

clutch lining must be

y li
erm

ab
free of grooves, oil and

ility
ot p

grease

wit
, is n

❑ Removing and installing

h re
hole

⇒ Rep. gr. 13

spec
es, in part or in w

2 - Clutch plate

t to the co
❑ For allocation refer to ⇒
Electronic parts cata‐

rrectness of i
logue (ETKA)
❑ Installation position with
l purpos

dual-mass flywheel:
shorter end of hub faces

nf
ercia

pressure plate.

orm
❑ Text
m

atio
m

“Getriebeseite” (gear‐
o

n in
c

box side) always faces


or

thi
e

pressure plate and


t

sd
iva

gearbox.

o
r
rp

cu
o

m
❑ Installation position with
f

en
ng

t.
yi
single piece flywheel:
Co
op py
spring cage faces pres‐
t. C rig
gh ht
yri
sure plate p by
co Vo
by lksw
❑ Centring ⇒ page 64
cted agen
Prote AG.

❑ Centring for engines


having a crankshaft of
smaller diameter or hav‐
ing needle bearings in
the crankshaft -
⇒ page 65
❑ Lightly grease splines

Note

Clean input shaft splines and, on


used clutch plates, hub splines. Re‐
move corrosion and apply only a
very thin coat of grease for clutch
plate splines - G 000 100- to the in‐
put shaft splines. Then, move the
clutch plate back and forth on the
drive shaft until the hub moves easi‐
ly on the shaft. Remove excess
grease.

5. Repairing clutch 63
Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

3 - Thrust plate
❑ Removing and installing ⇒ page 64
❑ Removing and installing for engines having a crankshaft wage
nof
AGsmaller
. Volkswagdiameter
en AG
doesor having needle bearings
in the crankshaft - ⇒ page 65 Volks not
gu
d by ara
❑ Check ends of diaphragm spring ⇒ page 65 oris
e nte
th eo
❑ Checking spring connections and riveted a connections ⇒ page 65
u ra
c
ss
❑ Contact surface for clutch lining must be free of grooves, oil and grease

ce
le
un

pt
an
d
itte

y li
Note
rm

ab
pe

ility
ot
Pressure plates are protected

wit
, is n

against corrosion and greased.

h re
hole

Clean contact surface only; other‐

spec
wise the service life of the clutch will
es, in part or in w

t to the co
be considerably reduced.

4 - Bolt

rrectness of i
❑ M6: 13 Nm
l purpos

❑ M7: 20 Nm
❑ For allocation refer to ⇒ Electronic parts catalogue (ETKA)

nform
ercia

❑ Loosen or tighten diagonally in small steps


m

a
com

tion in
r
te o

Centring clutch plate and removing and installing pressure plate

thi
s
iva

do
r

– Loosen and tighten bolts diagonally in small steps to prevent


rp

cum
fo

damage to thrust plate centring holes and flywheel centring

en
ng

t.
yi
pins.
Co
Cop py
t. rig
– Reverse position of counterhold - 3067- when removing.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

For engines having a crankshaft of smaller diameter -arrow- or


having an needle bearing -arrow- in the crankshaft

64 Rep. gr.30 - Clutch


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed
gen AG. manual
Volkswagegearbox
n AGd 0AJ - Edition 06.2017
wa oes
olks not
yV gu
Centring clutch plate and removing and installing ed pressure plate
b ara
nte
ris
for engines with a smaller crankshaft diameter,
tho or with a needle eo
bearing in the crankshaft au ra
c
ss

ce
le
– Loosen or tighten bolts diagonally in stages.

un

pt
an
d
itte

y li
– Reverse position of counterhold - 3067- when removing.

erm

ab
ility
ot p
Continuation for all

wit
is n

h re
ole,

spec
Note urposes, in part or in wh

t to the co
♦ Pressure plate contact surface and clutch plate lining must
make full contact with flywheel.

rrectne
♦ Tighten securing bolts diagonally and evenly to prevent dam‐
age to pressure plate centring hole and flywheel centring pins.

ss o
cial p

f in
Checking ends of diaphragm spring -arrows-

form
mer

atio
• Wear up to half the thickness of the diaphragm spring is per‐
om

mitted.

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Check spring connection and riveted fastenings.


– Check spring connection between pressure plate and cover
for cracks as well as rivet connections for secure seating.
– If pressure plate has damaged springs or loose rivet connec‐
tions -arrows-, it must be renewed.

5. Repairing clutch 65
Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

34 – Controls, housing
1 Repairing selector mechanism

1.1 Installation position of selector mechanism


Arrow -A- Gear selection movement
Arrow -B- Gate selection movement

A - Gear selector cable


B - Gate selector cable
C - Heat shield
❑ Remove before remov‐
ing selector mecha‐
nism.
1 - Gearbox selector lever
2 - Deflector lever

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

66 Rep. gr.34 - Controls, housing


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual n AG. Volk0AJ
gearbox
age
swagen AG
- Edition
does 06.2017
lksw n
o ot g
yV ua
edb ran
1.2 Overview of selector mechanism tho
ris tee
or
au ac
ss

ce
e
nl

pt
du
Note

an
itte

y li
erm

ab
♦ If the vehicle has a radio with anti-theft coding, obtain code before disconnecting battery.

ility
ot p

wit
, is n
♦ Before working on selector mechanism in engine compartment, disconnect earth strap from battery ⇒ Elec‐

h re
trical system; Rep. gr. 27 ; Battery; Disconnecting and connecting battery .

hole

spec
es, in part or in w
♦ When reconnecting battery, perform work required after connecting battery ⇒ Electrical system; Rep. gr.

t to the co
27 ; Battery; Disconnecting and connecting battery .
♦ For work on selector mechanism in engine compartment, remove complete air filter housing if it is located

rrectness of i
over selector mechanism ⇒ Rep. gr. 24 .
♦ Remove selector mechanism to renew selector cables ⇒ page 82 .
l purpos
♦ Do not kink selector cables.

nform
mercia

at
om

i
I - Assembly overview - gear

on
c

in t
lever knob and cover
or

his
e

⇒ page 68
at

do
priv

cum
II - Assembly overview - selec‐
for

en
g

tor lever and selector housing


n

t.
yi Co
⇒ page 70 Cop py
t. rig
gh ht
yri
III - Assembly overview - se‐ p by
o Vo
by c lksw
lector cables ⇒ page 77 Prote
cted AG.
agen

Removing and installing selector mechanism ⇒ page 82 .


Adjust selector mechanism ⇒ page 89 .

1. Repairing selector mechanism 67


Jetta 2013 ➤ , Jetta 2015 ➤
6-speed manual gearbox 0AJ - Edition 06.2017

1.3 Assembly overview - gear knob and cover

1 - Emblem
❑ Can be carefully levered
off gear knob of plastic
or leather
2 - Gear knob
❑ With gaiter
❑ Gear knob and gaiter
cannot be separated
from one another
❑ Always renew together
❑ Removing and installing
⇒ page 68
3 - Clamp
❑ For securing gear knob
to gear lever
❑ Renew after removal
❑ Secure to gear knob us‐
ing hose clip pliers -
V.A.G 1275-
4 - Frame for centre console
❑ In some equipment ver‐
sions, forms one part to‐
gether with upper centre
console
5 - Noise insulation
❑ Not fitted in all vehicles
❑ Arrow on noise insula‐
tion points in direction of
travel
n AG. Volkswagen AG do
❑ Because the locking lkswage es n
lugs are irregularly d byV
o ot g
ua
placed, noise insulation o
ir se
ran
tee
can be installed in only auth or
ac
one position ss
ce
e
nl

pt