Volkswagen Golf Variant / Jetta. Manual - part 221

together.

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

flywheel.

– Remove the pressure plate and the clutch plate.
Installing
Install in reverse order of removal while. Note the following:

Note

♦

Allocate thrust plate and clutch disc according to the engine

code. Refer to the Parts Catalog.

♦

Check whether there are centering sleeves for the engine/

transmission in the cylinder block; install 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 and the spring cage face the trans‐

mission.

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

-arrows- is permitted.

3. Clutch, Servicing, Diesel    

59

the cover for cracks and make sure the rivet connections are

tight.

• Replace the pressure plate if the spring connections are dam‐

aged or if the rivet connections -arrows- are loose.

Note

♦

Replace clutch plates and pressure plates if the rivets are

damaged or loose.

♦

Allocate clutch disc and thrust plate using the engine code.

Refer to the Parts Catalog.

♦

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

splines, remove corrosion and apply a very thin coating of

Grease for Clutch Disc Shaft Splines - G 000 100- to the

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

shaft until the hub moves freely on the shaft. Remove any ex‐

cess 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.

– Move the Flywheel Retainer - 3067- during installation.

Engines Having A Crankshaft with A Smaller Diameter -arrow-,

or Engines Having A Needle Bearing -arrow- in the Crankshaft

60

Plate on Engines with A Crankshaft with A Smaller Diameter, or

Engines with A Needle Bearing in the Crankshaft.

Note

Ignore arrows -A and B-.

Continuation for All

When Installing, Tighten Bolts As Follows So Pressure Plate

Does Not Distort (Causing Shuddering on Acceleration):
– Make sure the stop pin (position sensor) -arrow- moves easily.
– Position the pressure plate on the centering pins.
– Install all the bolts evenly, by hand, until the bolt heads contact

the pressure plate.

• When doing this, the stop pin -arrow- must lift off from the

pressure plate.

– Tighten the bolts in small steps and in diagonal sequence to

prevent damaging the centering holes of the pressure plate

and the centering pins of the dual mass flywheel -item 4-

⇒ Item 4 (page 62)

 .

– Install the transmission.

3.3

Clutch, Servicing, “Sachs”

3. Clutch, Servicing, Diesel    

61

❑ Removing and instal‐

Gr.  13 .

❑ Make sure it fits secure‐

ly on the centering pins

❑ Keep the clutch lining

contact surface free of

grooves, oil and grease.

2 - Clutch Plate

❑ Allocation. Refer to the

Parts Catalog.

❑ Only replace together

with the pressure plate

❑ Removing and instal‐

ling. Refer to

⇒ “3.2  Sachs Clutch,

Removing and Instal‐

ling”, page 58

 .

❑ Installation position. Re‐

fer to

⇒ Fig. ““Clutch Plate In‐

stalled Position”“ ,

page 59

 .

3 - Pressure Plate

❑ With adjustment mech‐

anism

❑ Allocation. Refer to the

Parts Catalog.

❑ Only replace together

with the clutch plate

❑ Removing and instal‐

ling. Refer to

⇒ “3.2  Sachs Clutch,

Removing and Instal‐

ling”, page 58

 .

❑ Checking the ends of the diaphragm spring. Refer to

⇒ Fig. ““Check the Ends of the Diaphragm Spring”“ , page 59

❑ Checking the spring connections and rivet connections. Refer to

⇒ Fig. ““Checking the Spring Connections and Rivet Connections”“ , page 60

4 - Bolt

❑ M6 bolt: 13 Nm
❑ M7 bolt: 20 Nm
❑ Allocation. Refer to the Parts Catalog.
❑ Loosen or tighten in small steps and in diagonal sequence

3.4

“LuK” Clutch, Removing and Installing

Removing
– Remove the transmission.
– Insert Flywheel Retainer - 3067- to loosen the bolts.
– Loosen the bolt diagonally in small steps.
– Remove the pressure plate and the clutch plate.

62