Volkswagen Golf / Golf GTI / Golf Variant. Service manual - part 493

2.2.3

Overview - Clutch, with Single Flywheel

1 - Flywheel

❑ Make sure it fits secure‐

ly on the centering pins

❑ Keep the clutch lining

contact surface free of

grooves, oil and grease

❑ Removing and instal‐

ling. Refer to ⇒  Engine

Mechanical, Fuel Injec‐

tion and Ignition; Rep.

Gr.  13 ; Cylinder Block,

Transmission Side; Fly‐

wheel, Removing and

Installing .

2 - Clutch Plate

❑ Allocation. Refer to the

Parts Catalog.

❑ Centering. Refer to

⇒ “2.3.3 Clutch, Remov‐

ing and Installing, with

Single Flywheel”,

page 52

3 - Pressure Plate

❑ Check the ends of the

diaphragm spring. Refer

to

⇒ Fig. ““Check the Ends

of the Diaphragm

Spring”“ , page 53

❑ Checking the spring

connections and rivet

connections. Refer to

⇒ Fig. ““Check the

Spring Connection and

Rivet Connections”“ ,

page 54

❑ Removing and instal‐

ling. Refer to 

⇒ “2.3.3 Clutch, Removing and Installing, with Single Flywheel”, page 52

 .

4 - Bolt

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

2.3

Clutch, Removing and Installing

⇒ “2.3.1 Clutch, Removing and Installing, with Dual Mass Fly‐

wheel, Sachs”, page 45
⇒ “2.3.2 Clutch, Removing and Installing, with Dual Mass Fly‐

wheel, LuK”, page 48
⇒ “2.3.3 Clutch, Removing and Installing, with Single Flywheel”,

page 52

2.3.1

Clutch, Removing and Installing, with

Dual Mass Flywheel, Sachs

Special tools and workshop equipment required
♦ Flywheel Retainer - 3067-
♦ Centering Pin - 3176-
♦ Alignment Tool - Clutch Plate - T10097-
♦ Torque Wrench 5-50Nm - VAG1331-
♦ Clutch Disc Shaft Spline Lubricant - G 000 100-

♦ 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 Small‐

er Diameter, or Engines with a Needle Bearing in the Crank‐

shaft.”“ , page 48

 -3176- .

Removing
• Transmission removed.
– Insert the -3067- to loosen the bolts.
When Removing, Loosen the Bolts as Follows so that the Clutch

Pressure Plate Does Not Distort (Causing Shuddering On Accel‐

eration):
– Loosen the bolt diagonally in small steps.

• When loosening, the stop -2- and the bolt -1- must loosen up

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. Note the following:

Note

♦

Allocate clutch pressure plate and clutch plate according to the

engine code. Refer to the Parts Catalog.

♦

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

hub splines. Remove any corrosion and then apply a very thin

coat of Grease - G 000 100- for clutch disc shaft splines on 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 clutch pressure plates are corrosion-protected and

greased. With the exception of the friction surface on the clutch

plate, do not clean the clutch pressure plate. This will shorten

the service life of the clutch considerably.

♦

The friction surfaces on the clutch pressure plate and on the

flywheel must be cleaned thoroughly (degreased).

♦

To reduce odor caused by a burnt clutch, thoroughly clean the

transmission housing around the clutch as well as the engine

on the transmission side.

♦

Only use compressed air to clean the dual mass flywheel.

♦

The clutch plate linings must sit completely on the flywheel and

on the clutch pressure plate friction surface. Install the bolts.

♦

Tighten the bolts diagonally in small steps so as to not damage

the centering holes in the pressure plate and the centering pins

on the flywheel.

♦

Make sure the alignment sleeves 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 transmission may make

noises (loose rattling).

Clutch Plate Installed Position
• “Getriebeseite” (transmission side) and the spring cage face

the transmission.

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

-arrows- is permitted.

Checking the Pull-Springs and Rivet Connection
I - Pull-spring OK
• Slight offset in the outer area -arrows A-.
II - Pull-springs damaged
• The clutch pressure plates must be replaced if the pull-spring

is bent or broken off -arrow B-.

Checking the Spring Connections and Rivet Connections
– Check the spring connections between the pressure plate and

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.

– Use the -3067- when installing.