Servicing clutch

Notes:

• ◆ Observe the general repair instructions .
• ◆ Before renewing the clutch plate and pressure plate

=> Fault-finding No. 9 - Defects on the clutch and clutch mechanism.

• ◆ Replace clutch plates and pressure plates with damaged or loose rivets.
• ◆ Select the correct clutch plate and pressure plate according to engine code:

=> Parts List

• ◆ Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease G 000 100 to the splines. Then move clutch plate to and fro on input shaft until hub moves freely on shaft. Excess grease must be removed.
• ◆ Pressure plates are protected against corrosion and greased. Only the contact surface may be cleaned, otherwise the service life of the clutch will be considerably reduced.
• ◆ If the clutch has burnt out, thoroughly clean the bell housing, flywheel and parts of the engine facing the gearbox in order to reduce the smell.

• ‒ Remove gearbox to work on clutch .

•     A -    Coloured marking on dual mass flywheel
• ◆ If components are marked: white marking -A- on dual mass flywheel must coincide with white marking -B- on pressure plate.
•     B -    Coloured marking on pressure plate
• ◆ If components are marked: white marking -A- on dual mass flywheel must coincide with white marking -B- on pressure plate.

• Flywheel/dual mass flywheel
• ◆ Make sure that centring pins are a tight fit.
• ◆ Contact surface for clutch lining must be free of grooves, oil and grease
• ◆ Removing and installing:

=> 4-cylinder engine (5-valve), Mechanics; Repair Group 13; Removing and installing sealing flanges and flywheel/drive plate; Removing and installing dual mass flywheel/drive plate

=> 4-cylinder engine (5-valve turbo), Mechanics; Repair Group 13; Removing and installing sealing flanges and flywheel/drive plate; Removing and installing dual mass flywheel/drive plate

=> 4-cylinder diesel direct injection engine (TDI), Mechanics; Repair Group 13; Removing and installing sealing flanges and flywheel/drive plate

=> 6-cylinder Engine (2-valve), Mechanics; Repair Group 13; Crankshaft group; Removing and installing flywheel/drive plate, Installation dimensions

=> 6-cylinder Engine (5-valve), Mechanics; Repair Group 13; Dismantling and assembling cylinder block, crankshaft and flywheel; Removing and installing flywheel/drive plate, Installation dimensions

• Bolt for flywheel
• ◆ Replace
• ◆ Vehicles without dual mass flywheel 60 Nm + turn 90o further
• ◆ Vehicles with dual mass flywheel 60 Nm + turn 180o further

• Detach clutch plate
• ◆ Installation position:
• ‒ Spring pack (coil springs) towards pressure plate and gearbox
• ‒ Clutch lining must make full contact with flywheel
• ‒ Marking "Getriebeseite" (if present) goes towards pressure plate and gearbox
• ◆ Do not grease
• ◆ Clutch plate diameter => from Page 00-3
• ◆ Centring =>Fig.1
• ◆ Lightly grease splines

• Pressure plate
• ◆ Removing and installing => Fig.1
• ◆ Check ends of diaphragm spring => Fig.2
• ◆ Checking spring connection and riveted fastenings => Fig.3
• Release and tighten bolt - 25 Nm
• ◆ Loosen and tighten gradually in several stages working diagonally
• Needle bearing
• ◆ Removing and installing

=> 4-cylinder engine (5-valve), Mechanics; Repair Group 13; Removing and installing crankshaft; Removing and installing needle roller bearing in crankshaft

=> 4-cylinder engine (5-valve turbo), Mechanics; Repair Group 13; Removing and installing crankshaft; Removing and installing needle roller bearing in crankshaft

=> 4-cylinder diesel direct injection engine (TDI), Mechanics; Repair Group 13; Removing and installing crankshaft; Removing and installing needle roller bearing in crankshaft

=> 6-cylinder engine (2-valve), Mechanics; Repair Group 13; Crankshaft group; Removing and installing needle bearing in flywheel

=> 6-cylinder Engine (5-valve), Mechanics; Repair Group 13; Dismantling and assembling cylinder block, crankshaft and flywheel; Removing and installing needle bearing in flywheel

→ Fig.1    Centring clutch plate and removing and installing pressure plate

• ‒ Installation position of clutch plate: spring pack (coil springs) or marking "Getriebeseite" towards pressure plate and gearbox.

Notes:

• ◆ The clutch plate lining and the contact surface of the pressure plate must make full contact with the flywheel before the securing bolts are inserted.
• ◆ Tighten securing bolts evenly and in diagonal sequence to avoid damaging centring holes in pressure plate and centring pins on flywheel.

• ‒ When assembling, ensure that white marking (if provided) on dual-mass flywheel coincides with white marking on pressure plate.
• ‒ Loosen and tighten bolts gradually in several stages working diagonally. Tightening torque: 25 Nm.
• ‒ Reverse position of retainer 3067 when removing.
• ‒ Use mandrel 3176 to centre clutch plate.

→ Fig.2    Checking ends of the diaphragm spring

• ◆ Wear up to half the thickness of the diaphragm spring is permitted.

Note:

When performing repairs always match up clutch pressure plate and clutch plate by checking engine code (see Parts Catalogue).

→ Fig.3    Checking spring connection and riveted fastenings

• ‒ Check spring connection between pressure plate and cover for cracks and make sure rivet fastenings are seated tightly.
• ‒ Renew clutches with damaged springs or loose riveted fastenings -arrows-.