Golf Mk4
| Repairing clutch |
| (Gearbox removed) |
Note| t | Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary. |
| t | If dowel sleeves are not fitted, difficulties shifting gear, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur. |
| t | Replace clutch plates and pressure plates with damaged or loose rivets. |
| t | Select clutch plate and pressure plate according to → Electronic parts catalogue “ETKA” and engine code. |
| t | Assemble clutch so that the flywheel centring pin grips in the pressure plate centring hole or centring slot. Otherwise TDC on flywheel will not be correct. |
| 1 - | Twelve point bolt, 20 Nm |
| q | Loosen or tighten diagonally and in steps |
| 2 - | Flywheel |
| q | Removing and installing → Rep. Gr.13 |
| q | Ensure that centring pins fit tightly |
| q | Contact surface for clutch lining must be free of grooves, oil and grease |
| q | TDC sender insertion depth must be adapted to suit the sizes of the various flywheels. Therefore, there are two different colour-coded plugs in the clutch housing. Allocation → Chapter. |
| 3 - | Clutch plate |
| q | Centring → Anchor |
| q | Diameter → Chapter |
| 4 - | Clutch push rod |
| q | Grease area of guide sleeve in input shaft. |
| 5 - | Retaining ring |
| 6 - | Release plate |
| q | Coat contact surface and clutch push rod mounting with a very thin coating of grease -G 000 100-. |
| 7 - | Securing bolt for pressure plate to crankshaft |
| q | Removing and installing → Rep. Gr.13. |
| 8 - | Intermediate plate |
| q | Installation position → Anchor |
| 9 - | Thrust plate |
| q | Removing and installing → Chapter |
| q | Maximum pressure plate distortion, inside: 0.2 mm. |
| q | Renew pressure plate with damaged or loose riveted connections. |