Volkswagen Workshop Service and Repair Manuals

Modifications to clutch for Golf syncro saloon with 1.9 ltr. - 66 kW turbo diesel engine =>Page 30-26

(Gearbox removed)

Notes:

• ◆ Before replacing the clutch and pressure plate note fault finding transmission No.9 - Defects on the clutch and clutch mechanism
• ◆ Replace clutch plates and pressure plates with damaged or loose rivets
• ◆ Ensure correct clutch plate and pressure plate is selected according to engine code letters from Parts list

• Flywheel
• ◆ Ensure centring pins are a tight fit
• ◆ Contact surface for clutch lining must be free of grooves, oil and grease
• ◆ Removing and installing

=> Repair group13

• Clutch plate
• ◆ Diameter
  =>from Page 00-3
• ◆ Note installation position, spring cage faces to pressure plate
• ◆ Centring => Fig.1

Note:

Remove corrosion from input shaft splines and clutch plate hub splines, clean and apply only a very thin coating of grease Part No.: G 000 100 to the input shaft splines.

The clutch plate must move to and fro freely on shaft.

Excess grease must be removed.

• Pressure plate
• ◆ Removing and installing => Fig.1
• ◆ Check ends of diaphragm spring
  => Fig.2

Note:

Pressure plates are protected against corrosion. Only the contact surface may be cleaned.

• Twelve point bolt, 20 Nm
• ◆ Loosen and tighten gradually and diagonally

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

• ‒ Loosen and tighten bolts gradually and diagonally.
• ‒ Reverse position of retainer 3067 when removing.

Note:

Pressure plate contact surface and clutch plate must make full contact with flywheel. Tighten bolts diagonally and evenly to prevent damage to the centralising holes in the pressure plate housing and the centralising pins in the flywheel.

→ Fig.2     Checking ends of the diaphragm spring (arrows)

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

For Golf syncro saloon with 1.9 ltr. - 66 kW turbo diesel engine the clutch diameter has been modified:

Clutch

• ◆ → A twin-mass flywheel -1- has been fitted to the 1.9 ltr. - 66 kW turbo diesel engine.

• ‒ Removing and installing flywheel

=> Repair group13

• ◆ The clutch plate -2- has a diameter of 219 mm.

Installation position:

The shorter end of the hub (arrow) faces to pressure plate -3-.

• ◆ The pressure plate -3- is attached to flywheel with multi point socket head bolts -4-.

Tightening torque

Pressure plate multi point socket head bolts -4- to flywheel: 13 Nm.

• ‒ Removing and installing clutch plate =>Page 30-25