Volkswagen Workshop Service and Repair Manuals

Note:

For repairs to the clutch:

=> 5 Speed manual gearbox 020; Repair group 30; servicing clutch

=> 5 Speed manual gearbox 02A; Repair group 30; servicing clutch

=> 5-Speed manual gearbox 02K; Repair group 30; Servicing clutch; Removing and installing clutch

• Oil seal
• ◆ To remove oil seal, remove sealing flange
• ◆ Install with T10071 and T10071/1
• ◆ Lightly oil sealing lip
• Woodruff key
• ◆ Ensure tight fit

• 25 Nm
• Sealing flange
• Gasket
• ◆ Renew
• Cylinder block
• ◆ Removing and installing crankshaft
• ◆ Dismantling and assembling pistons and conrods
  => Page 13-42
• 60 Nm + 1/4 turn (90 °) further
• ◆ Renew
• Plate
• ◆ Observe fitting position
• Pressure plate/drive plate
• ◆ Removing and installing pressure plate =>Fig. 1
• ◆ Removing and installing drive plate

• Intermediate plate
• ◆ Must be located on dowel sleeves
• ◆ Do not damage/bend when assembling
• 10 Nm
• Sealing flange with oil seal
• ◆ Only renew complete
• ◆ Use protective sleeve supplied when installing
• ◆ To remove and install remove sump
• ◆ Do not additionally oil or grease the oil seal sealing lip
• ◆ Before installing, remove oil remains from crankshaft journal with a clean cloth
• ◆ Remove protective sleeve first after sealing flange has been slid onto crankshaft journal

• Oil seal
• ◆ Renewing => Page 13-31
• Intermediate shaft
• ◆ First remove distributor
• ◆ Axial clearance max. 0.25 mm
• O-ring
• ◆ Renew if damaged
• Sealing flange intermediate shaft

→ Fig.1     Removing and installing pressure plate