Volkswagen Golf Variant / Jetta. Manual - part 146

 

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Volkswagen Golf Variant / Jetta. Manual - part 146

 

 

⇒ Fig. ““Removing and Installing the Release Bearing”“ , page 46

❑ Lubricate release lever contact surface with MoS 2 grease.

9 - Collar Bolt

❑ 20 Nm

10 - Clutch Slave Cylinder

❑ Removing and Installing. Refer to 

⇒ “1.10 Clutch Slave Cylinder, Removing and Installing”, page 41

 .

11 - Plunger
12 - Bolt

❑ Secures the clutch release lever when installing transmission
❑ Remove after installing the transmission

Note

Use an M8 x 35 bolt if the assembly

bolt 

⇒ Item 12 (page 46)

 is missing.

Remove and Install the Clutch Release Lever with the Release

Bearing
– Unhook the spring -arrow 1-.
– Remove the clutch release lever -arrow 2- and release bear‐

ing.

– Install in reverse order of removal.

Removing and Installing the Release Bearing
– Press the tabs -arrows- together on backside of clutch release

lever and remove release bearing -A- out of clutch release

lever.

– To install, press the release bearing -A- into the clutch release

lever until the tabs -arrows- engage.

46

Clutch with Dual Mass Flywheel,

Servicing

⇒ “3.1 Determining Clutch Manufacturer”, page 47
⇒ “3.2 Sachs Clutch, Removing and Installing”, page 48
⇒ “3.3 Clutch, Sachs, Servicing”, page 50
⇒ “3.4 LuK Clutch, Removing and Installing”, page 51
⇒ “3.5 Clutch, Manufactured by LuK, Servicing”, page 53

3.1

Determining Clutch Manufacturer

Special tools and workshop equipment required
♦ Flywheel Retainer - 3067-
♦ Alignment Tool - Clutch Plate - 3190A-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Grease for Clutch Disc Shaft Splines - G 000 100-
Either a “Sachs” or a “LuK” clutch may be installed.
It is possible to tell which clutch the vehicle has with the trans‐

mission installed:
– Remove the noise insulation. Refer to ⇒  Body Exterior; Rep.

Gr.  50 ; Noise Insulation .

There are some openings -arrows- between the engine -A- and

the transmission -B- near the bottom of the oil pan.
– Check the outer contour of the flywheel through these open‐

ings.

– The outer contour of the flywheel can also be inspected by

removing the small cover plate -A-.

Round outer contour -arrows- = clutch made by Sachs = -A-
– Clutch, Removing and Installing, Sachs. Refer to

⇒ “3.2 Sachs Clutch, Removing and Installing”, page 48

 .

3. Clutch with Dual Mass Flywheel, Servicing    

47

⇒ “3.3 Clutch, Sachs, Servicing”, page 50

 .

Squared outer contour -arrows 1- and in addition, a pleat all the

way around -arrow 2- = clutch made by LuK = -B-
or

Round outer contour -arrows 1- and a circulated depression

-arrow 2- = Clutch manufacturer, LuK = -B-
– LuK Clutch, Removing and Installing. Refer to

⇒ “3.4 LuK Clutch, Removing and Installing”, page 51

 .

– LuK Clutch, Servicing. Refer to

⇒ “3.5 Clutch, Manufactured by LuK, Servicing”, page 53

 .

3.2

Sachs Clutch, Removing and Installing

⇒ “3.2.1 Removing”, page 48
⇒ “3.2.2 Installing”, page 48

3.2.1

Removing

– Remove the transmission.
– Insert the Flywheel Retainer - 3067- to loosen the bolts.
– Loosen the bolt diagonally in small steps.
• When loosening, the stop -2- and the bolt -1- must loosen up

together.

– If the stop does not loosen: push the bolt toward the dual mass

flywheel.

– Remove the pressure plate and the clutch plate.

3.2.2

Installing

Install in reverse order of removal while. Note the following:

48

Replace the pressure plate and the clutch plate together. Al‐

locate thrust plate and clutch disc according to the engine

code. Refer to the Parts Catalog.

Make sure the alignment bushings for centering the engine/

transmission are installed inside the cylinder block. Install

them if necessary.

If the alignment sleeves are missing, it will be difficult to shift,

there will be clutch problems and the transmission may make

noises (loose rattling).

Clutch Plate Installed Position
• “Transmission side” label faces the transmission.

Check the ends of the Diaphragm Spring
• Wear up to half the thickness of the diaphragm spring

-arrows- is permitted.

Checking the Spring Connections and Rivet Connections
– Check the spring connections between the pressure plate and

the cover for cracks and make sure the rivet connections are

tight.

Note

Replace clutch plates and pressure plates if the rivets are

damaged or loose.

Always replace the pressure plate and the clutch plate togeth‐

er.

Allocate clutch disc and thrust plate using the engine code.

Refer to the Parts Catalog.

To reduce odor caused by a burnt clutch, thoroughly clean the

clutch housing, the flywheel and the side of the engine facing

toward the transmission.

Clean the input shaft splines and (on used clutch plates) the

hub splines. Remove any corrosion and then apply a very thin

coat of Grease for Clutch Disc Shaft Splines - G 000 100- on

the splines. Then move the clutch plate back and forth on the

input shaft until the hub moves freely on the shaft. Remove

any excess grease.

The pressure plates are protected from corrosion and lubrica‐

ted. Only the running surfaces may be cleaned. Otherwise the

service life of the clutch will be shortened considerably.

The pressure plate contact surface and the clutch plate lining

must completely touch the flywheel. Install the bolts.

3. Clutch with Dual Mass Flywheel, Servicing    

49

 

 

 

 

 

 

 

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