Volkswagen Golf Variant / Jetta. Manual - part 220

 

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Volkswagen Golf Variant / Jetta. Manual - part 220

 

 

the secure clip engages.

– Pull on the line to make sure it is secure.
– After removing the Hose Clamps - Up To 25mm - 3094- , bring

the return hose back to its original shape.

– Bleed the clutch mechanism. Refer to

⇒ “1.10 Clutch Mechanism, Bleeding”, page 48

 .

Diesel Direct Injection System; Air Filter Housing, Removing

Removing and Installing .

2.4

Input Shaft Seal, Replacing

Special tools and workshop equipment required
♦ Puller - Crankshaft/Power Steering Seal - 1 - T20143/1-
♦ Seal Installer - Driveshaft - T40008-
♦ Sealing Grease - G 052 128 A1-
Procedure
• Remove the transmission.
– Remove the clutch slave cylinder and the release bearing.

Refer to

⇒ “2.2 Clutch Slave Cylinder with Release Bearing, Removing

and Installing”, page 52

 .

– Pry out input shaft seal using Puller - Crankshaft/Power Steer‐

ing Seal - 1 - T20143/1- .

Note

Be careful not to damage the contact surface for the seal on the

input shaft.

– Fill the space between the sealing and dust lip -arrow- halfway

with Sealing Grease - G 052 128 A1- .

– Lightly coat the outer circumference of the seal with transmis‐

sion fluid.

2. Clutch Release Mechanism, Servicing    

55

until it is flush.

– Install the clutch slave cylinder and the release bearing. Refer

to

⇒ “2.2 Clutch Slave Cylinder with Release Bearing, Removing

and Installing”, page 52

 .

• Install the transmission.

56

Clutch, Servicing, Diesel

⇒ “3.1 Determining Clutch Manufacturer”, page 57
⇒ “3.2  Sachs Clutch, Removing and Installing”, page 58
⇒ “3.3 Clutch, Servicing, Sachs ”, page 61
⇒ “3.4  LuK Clutch, Removing and Installing”, page 62
⇒ “3.5 Clutch, Servicing, LuK ”, page 65

Special tools and workshop equipment required
♦ Flywheel Retainer - 3067-
♦ Alignment Tool - Clutch Plate - T10097-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Grease for Clutch Disc Shaft Splines - G 000 100-

♦ On engines which have a crankshaft with a smaller diameter,

or engines with a needle bearing in the crankshaft. Refer to

⇒ Fig. ““Centering the Clutch Disc, Removing and Installing

the Pressure Plate on Engines with A Crankshaft with A Small‐

er Diameter, or Engines with A Needle Bearing in the Crank‐

shaft.”“ , page 61

 Alignment Tool - Clutch Plate - 3176- .

3.1

Determining Clutch Manufacturer

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 .

– Remove the noise insulation from the oil pan if necessary.
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 this opening.

3. Clutch, Servicing, Diesel    

57

removing -arrows- 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 58

 .

– Sachs clutch, servicing. Refer to

⇒ “3.3 Clutch, Servicing, Sachs ”, page 61

 .

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 62

 .

– LuK clutch, servicing. Refer to

⇒ “3.5 Clutch, Servicing, LuK ”, page 65

 .

3.2

“Sachs” Clutch, Removing and Installing

Removing
– Remove the transmission.
– Insert Flywheel Retainer - 3067- to loosen the bolts.

58

 

 

 

 

 

 

 

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