Volkswagen Golf Variant / Jetta. Manual - part 507

 

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Volkswagen Golf Variant / Jetta. Manual - part 507

 

 

❑ 20 Nm
❑ Remove grease already present
❑ Grease using the Grease for Clutch Disc Shaft Splines - G 000 100-

8 - Transmission
9 - Hex Bolt

❑ 20 Nm

10 - Bracket

❑ For hose/line assembly

11 - Clutch Slave Cylinder

❑ Removing and installing. Refer to 

⇒ “2.10 Clutch Slave Cylinder, Removing and Installing”, page 39

 .

4.2

Clutch Release Lever with Release

Bearing and Guide Sleeve, Removing

and Installing

Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-
Clutch Release Lever with Release Bearing and Guide Sleeve,

Removing and Installing
– Remove the bolts -arrows-.
– Remove clutch release lever with release bearing and guide

slide from input shaft and ball joint pin.

Install in reverse order of removal.
• The spring -item 4- 

⇒ Item 4 (page 43)

 must be engaged into

the clutch release lever.

♦ Information and tightening specification: -item 2-

⇒ Item 2 (page 43)

 .

Guide Sleeve, Removing and Installing
• The clutch release lever is removed.
– Remove the guide sleeve -3- upward out of release bearing

-2-.

– Rotate the guide sleeve -3- opposite release bearing -2- in di‐

rection of -arrow- approximately 90° in direction of -arrow- until

the tabs on the guide sleeve align with the grooves -4- on the

release bearing.

– Pull the guide sleeve out of release bearing in this position.
Install in reverse order of removal.

44

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.

4. Clutch Release Mechanism, Servicing    

45

Clutch, Servicing

Special tools and workshop equipment required
♦ Flywheel Retainer - 3067-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Alignment Tool - Clutch Plate - 3190A-
♦ 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 smaller di‐

ameter, or engines with a needle bearing -arrow- in the crank‐

shaft.”“ , page 49

 Alignment Tool - Clutch Plate - T10086- .

♦ Grease for Clutch Disc Shaft Splines - G 000 100-
(Transmission removed)

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).

Replace clutch plates and pressure plates if the rivet connections are damaged or loose.

Allocation. Refer to the Parts Catalog.

46

❑ Make sure it fits secure‐

ly on the centering pins

❑ There must not be any

grooves, oil or grease

on the clutch plate con‐

tact surface.

❑ Removing and instal‐

Gr.  13 .

2 - Clutch Plate

❑ Allocation. Refer to the

Parts Catalog.

❑ Dual mass flywheel in‐

stallation position: the

shorter hub end faces

the pressure plate.

❑ The word

“Getriebeseite” (trans‐

mission) always faces

the pressure plate and

toward transmission.

❑ Installation position with

a single flywheel: the

spring cage faces to‐

wards the pressure

plate

❑ Centering. Refer to

⇒ Fig. ““Centering the

Clutch Plate and Re‐

moving and Installing

Pressure Plate”“ ,

page 48

❑ Centering 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 smaller diameter, or engines with a needle bearing -arrow- in the crankshaft.”“ , page 49

❑ Lightly grease the splines

Note

Clean the input shaft splines and (on

used clutch plates) the hub splines.

Remove any corrosion and then ap‐

ply a very thin coat of Grease for

Clutch Disc Shaft Splines - G 000

100- on the driveshaft 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.

3 - Pressure Plate

❑ Removing and installing. Refer to

⇒ Fig. ““Centering the Clutch Plate and Removing and Installing Pressure Plate”“ , page 48

 .

❑ Removing and installing 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 smaller diameter, or engines with a needle bearing -arrow- in the crankshaft.”“ , page 49

5. Clutch, Servicing    

47

 

 

 

 

 

 

 

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