Volkswagen Corrado (1993 year). Manual - part 112

CLUTCH 

Fig. 2:  Adjusting Shift Cables (Installing Cables)
Courtesy of Volkswagen United States, Inc.

         REMOVAL & INSTALLATION

         CLUTCH ASSEMBLY

NOTE:    Transaxle may be lowered out of vehicle without removing
         engine.

         Removal
         1) Disconnect negative battery cable. Disconnect electrical
connectors from transmission. Remove connecting tube to intercooler
(if equipped).
         2) Disconnect gearshift cables, cable supports and linkage
from transmission. Remove clutch slave cylinder and wire aside.
disconnect speedometer drive from transmission. Remove upper engine-
to-transaxle bolts.
         3) Remove 3 right side engine mount-to-engine bolts and one
left side transmission mount bracket through bolt. In vehicles with
ABS (Anti-Lock Brake System) it may be necessary to remove coolant
overflow reservoir to access left side through bolt.
         4) Remove radiator fan, cover and mount. Remove nut from

CLUTCH 

Fig. 3:  Viewing Clutch Components
Courtesy of Volkswagen United States, Inc.

         Inspection
         Inspect pressure plate springs ends for damage or scoring.
Scores up to .12" (3mm) deep are acceptable. Replace pressure plate
if:
 * Contact Surface Has Burns, Cracks Or Chatter Marks
 * Contact Surface Has Grooves Or Defective Spring Connections
 * Diaphragm Spring Has Deep Scores, Pointed Tips Or Are Bent Or
Broken
 * Pressure Plate Housing Is Distorted Or Broken
 * Pressure Plate Housing Spring Connections Are Defective
 * Pressure Plate Housing Dowel Pin Bores Are Deformed
 * Pressure Plate Housing Rivets Are Damaged Or Loose
 Replace clutch disk if;

CLUTCH 

NOTE:    Pressure plate has a protective grease coating. Remove
         contact surface grease only. Service life will be shortened
         if remaining portions of pressure plate protective grease
         are removed.

         Installation
         1) Replace input shaft "O" ring. See Fig. 4. Ensure clutch
disk slides on input shaft spines. Splines may be lightly greased.
Wipe off excess grease. If flywheel was removed, reinstall on engine.
Using flywheel lock or similar device, hold engine from turning.
Tighten flywheel bolts to specification. See TORQUE SPECIFICATIONS
table at end of article.
         2) Mount clutch disk and pressure plate on engine. Install
pressure plate bolts finger tight. Using Clutch Centering Plug (3190),
align clutch disk and pilot bushing holes. Tighten pressure plate
bolts to specification using a crisscross pattern.
         3) To install transaxle, reverse removal procedure. Plug
transaxle openings to prevent contamination or fluid loss. Push clutch
release lever rearward and temporarily install mounting pin or an 8 x
22 mm bolt through pivot arm. Remove pin or bolt after installation is
complete.
         4) Ensure gear carrier housing cover fits properly. To
install gearshift lever cables, see GEARSHIFT LEVER CABLES under
ADJUSTMENTS. Tighten nuts and bolts to specification. See TORQUE
SPECIFICATIONS table.

Fig. 4:  Exploded View Of Clutch Assembly Components
Courtesy of Volkswagen United States, Inc.

CLUTCH 

TORQUE SPECIFICATIONS TABLE

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Application                                             Ft. Lbs. (N.m)

Balance Weight-To-Mount Bolt  ...............................  22 (30)
Drive Axle-To-Flange Bolt  ..................................  33 (45)
Flywheel Bolt  ...................................  22 (30) + 1/4 Turn
Front Transaxle Mount Nut  ..................................  44 (60)
Gearshift Cable Bolt  .......................................  18 (25)
Gearshift Cable Support Bolt  ...............................  18 (25)
Left Transaxle Mount
 Bracket-To-Mount Bolt  .....................................  44 (60)
 Bracket-To-Transaxle Bolt  .................................  18 (25)
Pressure Plate Bolt  ........................................  15 (20)
Right Rear Transaxle Mount Bolt  ............................  18 (25)
Slave Cylinder Bolt  ........................................  18 (25)
Starter Bolt  ...............................................  44 (60)
Transaxle Support-To-Transaxle Bolt  ........................  44 (60)
Transaxle-To-Engine Bolt  ...................................  59 (80)

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END OF ARTICLE