Volkswagen Golf Variant / Jetta. Manual - part 223

Clutch, Servicing, Gasoline

⇒ “4.1 Clutch, Servicing”, page 67
⇒ “4.2 Clutch, Removing and Installing”, page 68

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

⇒ page 71

 Alignment Tool - Clutch Plate - 3176- .

4.1

Clutch, Servicing

Note

♦

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 trans‐

mission may make noises (loose rattling).

4. Clutch, Servicing, Gasoline    

67

❑ 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.

❑ Removing and instal‐

ling. Refer to

⇒ “4.2 Clutch, Remov‐

ing and Installing”, page

68

 .

❑ Only replace together

with the SAC pressure

plate

❑ Installation position. Re‐

fer to

⇒ Fig. ““Clutch Plate In‐

stalled Position”“ ,

page 69

3 - SAC Pressure Plate

❑ SAC = “Self Adjusting

Clutch”

❑ Only replace together

with the clutch plate

❑ Allocation. Refer to the

Parts Catalog.

❑ Removing and instal‐

ling. Refer to

⇒ “4.2 Clutch, Remov‐

ing and Installing”, page

68

 .

❑ Checking the ends of the diaphragm spring. Refer to

⇒ Fig. ““Check the Ends of the Diaphragm Spring”“ , page 69

❑ Checking the spring connection and rivet connections. Refer to

⇒ Fig. ““Checking the Spring Connections and Rivet Connections”“ , page 69

4 - Bolt

❑ M6: 13 Nm
❑ M7: 20 Nm
❑ Loosen or tighten in small steps and in a diagonal sequence.

4.2

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

68

♦

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
• “Getriebeseite” (transmission side) -arrow- faces the trans‐

mission.

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 -arrows A- for damage and

make sure the rivet connections -arrows B- are tight.

4. Clutch, Servicing, Gasoline    

69

sure Plates
• Both edges -A- of the adjusting ring must be located between

both notches -arrows B-.

• If the adjusting ring takes on a different position with new pres‐

sure plates, pressure plate and clutch plate must not be in‐

stalled.

• With used clutches, the adjusting ring may take on a position

outside of the notches.

Note

♦

Replace clutch plates and pressure plates if the rivets are

damaged or loose.

♦

Replace the pressure plate and the clutch plate together.

♦

Allocate the clutch plate and pressure plate to match the en‐

gine 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 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.

70