Volkswagen Workshop Service and Repair Manuals

Note:

For repairs to the clutch:

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

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

• Oil seal
• ◆ To remove oil seal, remove sealing flange
• ◆ Install with 10-203
• ◆ 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 13-46
• 60 Nm + 1/4 turn (90 °) further
• ◆ Renew
• Plate
• ◆ Observe fitting position
• Pressure plate/drive plate
• ◆ Engine codes: 1Y, AAZ, AEY
• ◆ Removing and installing pressure plate =>Fig. 1

• Flywheel/drive plate
• ◆ Engine codes 1Z, AHU, AFN, AVG, ALE
• ◆ To remove and install flywheel counter-hold with 3067
• ◆ Removing and installing drive plate
• Intermediate plate
• ◆ Must be located on dowel sleeves
• ◆ Do not damage/bend when assembling
• Sealing flange with oil seal
• ◆ Only renew complete
• ◆ Lightly oil sealing lip of oil seal
• 10 Nm
• Oil seal
• ◆ Renewing => Page 13-37

• Intermediate shaft
• O-ring
• ◆ Renew if damaged
• Sealing flange intermediate shaft

→ Fig.1     Removing and installing pressure plate