NHTSA ID Number: 10073691
Manufacturer Communication Number: 0.03937=IN
TSB/Document Date: 2016-06-22
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TSB/Document ID: 0.03937=IN
Replacement Service Bulletin Number:
MFR Communication Date: 2014-02-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL
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MFR Component Subsystem:
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2014 Volkswagen
Jetta Hybrid
Quick Reference Specification Book
Table of Contents
General Information....................................................... 1
Decimal and Metric Equivalents............................................1
Distance/Length.....................................................................1
Tightening Torque..................................................................2
Nm-to-lb·ft (ft·lb)....................................................................2
Nm-to-lb·in (in·lb), kg·cm.......................................................3
N·cm-to-lb·in (in·lb), kg·cm....................................................3
kg·cm-to-lb·in (in·lb), N·cm....................................................4
Warnings and Cautions.........................................................4
WARNINGS...........................................................................4
CAUTIONS............................................................................7
Vehicle Identification...................................................... 9
VIN on Lower Edge of Windshield............................................9
VIN on Longitudinal Member Extension.................................10
Vehicle Data Label.................................................................. 11
Type Plate...............................................................................12
VIN Decoder...........................................................................13
Sales Codes.................................................................. 14
Engine Codes.........................................................................14
Transmission Codes...............................................................14
Vehicle Lifting............................................................... 15
Hoist and Jack Mounting Points..........................................15
Front.......................................................................................15
Rear........................................................................................16
CHASSIS
Brake System................................................................ 17
General Information.............................................................17
Front Brakes...........................................................................17
Rear Brakes, Torsion Beam Rear Suspension.......................17
Rear Brakes, Multi-link Rear Axle...........................................17
Master Cylinder and Brake Booster .......................................17
VW Jetta Hybrid Quick Reference Specification Book • February 2014
i
Front Brakes, FS III................................................................18
Front Brakes, FN 3.................................................................19
Rear Drum Brakes..................................................................21
Rear Disc Brakes....................................................................22
Anti-lock Brake System (ABS).............................................24
ABS Mark 70 (ABS/ASR) Overview.......................................24
ABS Mark 60 EC (ABS/EDS/ASR/ESP) Overview.................26
Right Front ABS Wheel Speed Sensor -G45-/Left Front
ABS Wheel Speed Sensor -G47- Overview.....................28
Right Rear ABS Wheel Speed Sensor -G44-/Left Rear
ABS Wheel Speed Sensor -G46-, Twist Beam Rear
Suspension and Drum Brakes Overview.........................29
Right Rear ABS Wheel Speed Sensor -G44-/Left Rear
ABS Wheel Speed Sensor -G46-, Twist Beam Rear
Suspension and Disc Brakes Overview...........................30
Right Rear ABS Wheel Speed Sensor -G44-/Left Rear
ABS Wheel Speed Sensor -G46, Multi-Link Rear Axle
Overview..........................................................................31
Steering Angle Sensor -G85-, on the Steering Column
Overview..........................................................................32
Mechanical Components.....................................................34
Front Brakes Overview, FS III without Brake Pad Wear
Indicator...........................................................................34
Front Brakes Overview, FS III with Brake Pad Wear
Indicator...........................................................................36
Front Brakes Overview, FN 3 15/16 inch, without Brake
Pad Wear Indicator.........................................................38
Front Brakes Overview, FN 3 15/16 inch with Brake Pad
Wear Indicator..................................................................40
Brake Cylinder Overview........................................................42
Drum Brakes Overview...........................................................43
Drum Brakes Assembly Overview..........................................44
Multi-link Rear Axle Overview (Bosch ZOH 38 Brakes)..........46
Multi-Link Rear Axle Overview (CI 38 Brakes).......................48
Twist Beam Rear Suspension Overview (Bosch ZOH 38
Brakes).............................................................................50
Twist Beam Rear Suspension Overview (CI 38 Brakes)........52
Parking Brake Overview.........................................................54
Brake Pedal Overview............................................................55
Hydraulic Components........................................................56
Brake Booster/Brake Master Cylinder Overview....................56
Brake System Vacuum Pump -V192- Overview.....................58
Front Brake Caliper Overview, FS III......................................59
ii
VW Jetta Hybrid Quick Reference Specification Book • February 2014
Front Brake Caliper Overview, FN 3.......................................60
Bosch ZOH 38 Rear Brakes Overview...................................61
CI 38 Rear Brakes Overview..................................................62
Suspension, Wheels, Steering.................................... 64
Front Suspension................................................................64
Drive Axle with CV Joint VL 100 Overview.............................64
Drive Axle Overview, with CV Joint VL 107............................66
Drive Axle Overview with Triple Roller Joint AAR3300i..........68
Drive Axle Overview with Triple Roller Joint AAR2600i..........70
Front Suspension and Control Arm Overview........................72
Stabilizer Bar Overview..........................................................74
Subframe Overview................................................................76
Suspension Strut Overview....................................................78
Wheel Bearing Overview........................................................80
Rear Suspension.................................................................82
Rear Suspension Axle Beam, Subframe and Crossbrace
Overview..........................................................................82
BlueMotion Vehicles Subframe Components Overview.........84
Left Rear Level Control System Sensor -G76- Overview.......85
Shock Absorber and Coil Spring Overview, Multi-Link
Rear Suspension..............................................................86
Stabilizer Bar Assembly Multi-Link Rear Suspension.............87
Subframe, Transverse Link and Tie Rod Overview,
Multi-Link Rear Suspension.............................................88
Wheel Bearing Housing and Trailing Arm Overview,
Multi-Link Rear Suspension.............................................90
Rear Suspension Overview....................................................92
Shock Absorber Overview......................................................93
Wheel Bearing and Disc Brake Overview...............................94
Wheel Bearing and Drum Brake Overview.............................95
Wheels, Tires, Wheel Alignment..........................................96
Tire Pressure Monitoring Sensor Overview............................96
Alignment Specifications with
Torsion Beam Rear Suspension.......................................98
Specified Values Valid for all Engine Versions........................99
Alignment Specifications, Multi-Link Rear Suspension........100
Specified Values Valid for all Engine Versions......................101
Fastener Tightening Specifications.......................................101
Steering.............................................................................102
Electromechanical Steering Gear Overview.........................102
Tightening Sequence for the Steering Gear to Subframe.....103
Electromechanical Steering Gear Overview.........................104
Hydraulic Power Steering Overview.....................................105
VW Jetta Hybrid Quick Reference Specification Book • February 2014
iii
Power Steering Gear Overview............................................106
Steering Column Overview...................................................107
Steering Wheel with Airbag Overview..................................108
Electrical System........................................................ 109
Communication..................................................................109
Fastener Tightening Specifications.......................................109
Electrical Equipment..........................................................110
Battery, Starter, Generator, Cruise Control........................ 110
Battery -A- Overview............................................................ 110
Generator Overview............................................................. 112
Starter Overview................................................................... 113
Instrument..........................................................................114
Horn Overview...................................................................... 114
Windshield Wiper/Washer System.................................... 115
Starter Overview................................................................... 115
Exterior Lights, Switches...................................................116
Tail Lamp LED Bulbs in Rear Lid Overview.......................... 116
Front Fog Lamp, Jetta Overview.......................................... 117
Front Fog Lamp, Jetta GLI Overview................................... 118
Halogen Headlamps Overview.............................................120
HID Headlamps and Cornering Lamp Overview..................122
High-Mounted Brake Lamp Overview...................................124
Steering Column Switch Module Overview, Valeo................125
Steering Column Switch Module Overview, Kostal...............126
Steering Column Switch Module Overview, KESSY.............127
Trailer Socket -U10-, Overview.............................................128
Fastener Tightening Specifications.......................................128
Wiring................................................................................129
Relay Panels, Fuse Panels and E-Boxes Component
Location Overview..........................................................129
Electrical Drive...................................................................130
Electric Drive Power and Control Electronics -JX1Overview........................................................................130
Tightening Specifications, High Voltage Contacts ...............131
Tightening Specifications for the Electric A/C Compressor
-V470- Fuse...................................................................132
Hybrid Battery Unit -AX1- Overview.....................................134
Tightening Specifications, High Voltage Contacts................136
Tightening Specifications, High Voltage Contacts
Electro-Drive Drive Motor -V141-. .................................137
Bolt Tightening Specification for the Electro-Drive
iv
VW Jetta Hybrid Quick Reference Specification Book • February 2014
Drive Motor -V141- Cover. ............................................138
Bolt Tightening Specification for the Wiring Guide -1-. ........139
Tightening Specifications for the Potential Equalization
Cable to Electric Drive Power and Control Electronics
-Jx1- -1-..........................................................................140
Tightening Specifications for the Potential Equalization
Cable -2- on the Electro-Drive Drive Motor -V141-........141
Body............................................................................. 142
Body Dimensions...............................................................142
Body, Front...........................................................................142
Body, Center.........................................................................143
Body, Rear............................................................................144
Body Exterior.....................................................................145
Body Front ........................................................................145
Bulkhead Overview...............................................................145
Front Fender Overview.........................................................146
Lock Carrier Overview..........................................................148
Noise Insulation Overview, Gasoline....................................150
Noise Insulation Overview, Diesel........................................151
Tunnel Bridge Overview.......................................................152
Underbody Trim Panel Overview..........................................153
Right Rear Underbody Trim Panel........................................154
Hood, Lids.........................................................................155
Fuel Filler Door Unit Overview..............................................155
Hood Overview.....................................................................156
Hood Release Lever and Bracket Overview.........................157
Rear Lid Hinge Overview......................................................158
Front Doors, Central Locking System................................159
Door Handle and Door Lock Overview.................................159
Front Door Overview............................................................160
Door Hinge Overview...........................................................162
Rear Doors........................................................................164
Door Handle and Door Lock Overview.................................164
Rear Door Overview.............................................................166
Door Hinge Overview...........................................................168
Sunroof..............................................................................170
Sunroof Overview.................................................................170
Bumpers............................................................................172
Front Bumper Cover Overview.............................................172
Front Bumper Cover Guides Overview.................................173
Front Bumper Carrier Overview............................................174
Rear Bumper Cover Overview..............................................175
VW Jetta Hybrid Quick Reference Specification Book • February 2014
v
Rear Bumper Cover Guides Overview.................................176
Rear Bumper Carrier Overview............................................177
Glass, Window Regulators................................................178
Front Door Window Overview...............................................178
Rear Door Window Overview...............................................179
Exterior Equipment............................................................180
Front Wheel Housing Liner Overview...................................180
Rear Wheel Housing Liner Assembly Overview...................181
Manual Exterior Mirror Assembly Overview..........................182
Power Exterior Mirror Assembly Overview...........................183
Sill Panel Cover Assembly Overview....................................184
Body Interior......................................................................185
Interior Equipment.............................................................185
Tightening Specifications......................................................185
Passenger Protection, Airbags, Seat Belts........................186
Front Three-Point Seat Belt Assembly Overview.................186
Front Seat Assembly Overview, Basis..................................188
Front Seat Assembly Overview, Comfort..............................189
Front Seat Assembly Overview, Sport..................................190
Interior Trim.......................................................................192
Instrument Panel Central Tube Assembly Overview............192
Seat Frames......................................................................194
Manual Front Seat Assembly Overview................................194
Partial Power Front Seat Assembly Overview......................195
Manual Lower Seat Frame Assembly Overview...................196
Partial Power Lower Seat Frame Assembly Overview.........197
Seat Height Adjustment Assembly Overview........................198
Heating, Ventilation & Air Conditioning................... 199
General, Technical Data....................................................199
Refrigerant Oil Distribution...................................................199
Refrigerant R134a Vapor Pressure Table.............................199
Heating, Ventilation............................................................200
Fastener Tightening Specifications.......................................200
Air Conditioning.................................................................201
Refrigerant Circuit Components Overview...........................201
Fastener Tightening Specifications.......................................202
vi
VW Jetta Hybrid Quick Reference Specification Book • February 2014
General Information
General
Information
Decimal and Metric Equivalents
Distance/Length
To calculate: mm x 0.03937 = in.
mm
0.002
0.004
0.006
0.008
0.010
0.020
0.030
0.040
0.050
0.060
0.070
0.080
0.090
0.100
0.200
0.300
0.400
0.500
0.600
0.700
0.800
0.900
1.000
2.000
3.000
4.000
5.000
6.000
7.000
8.000
9.000
10.000
20.000
30.000
40.000
50.000
60.000
70.000
80.000
90.000
100.000
in.
0.00008
0.00016
0.00024
0.00031
0.00039
0.00079
0.00118
0.00157
0.00197
0.00236
0.00276
0.00315
0.00354
0.00394
0.00787
0.01181
0.01575
0.01969
0.02362
0.02756
0.03150
0.03543
0.03937
0.07874
0.11811
0.15748
0.19685
0.23622
0.27559
0.31496
0.35433
0.39370
0.78740
1.18110
1.57480
1.96850
2.36220
2.75591
3.14961
3.54331
3.93701
mm
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
in.
0.0004
0.0008
0.0012
0.0016
0.0020
0.0024
0.0028
0.0031
0.0035
0.0039
0.0079
0.0118
0.0157
0.0197
0.0236
0.0276
0.0315
0.0354
0.0394
0.0787
0.1181
0.1575
0.1969
0.2362
0.2756
0.3150
0.3543
0.3937
0.7874
1.1811
1.5748
1.9685
2.3622
2.7559
3.1496
3.5433
3.9370
mm
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
in.
0.004
0.008
0.012
0.016
0.020
0.024
0.028
0.031
0.035
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
0.394
0.787
1.181
1.575
1.969
2.362
2.756
3.150
3.543
3.937
mm
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