Volkswagen Golf Variant / Jetta. Manual - part 221

 

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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

 

 

 

 

 

 

 

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