Volkswagen Workshop Service and Repair Manuals

Modifications to clutch for vehicles with 1.9 ltr. 81 kW turbo diesel engine =>Page 30-28

(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
• ◆ Select correct clutch plate and pressure plate according to parts list and engine code.

• 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
  =>Page 00-3
• ◆ Note installation position, spring cage faces to pressure plate
• ◆ Centring => Fig.1
• ◆ Lightly grease splines

Note:

Clean input shaft splines and on used clutch plates, the hub splines, remove corrosion and apply only a very thin coating of grease Part No: G 000 100 to the input shaft splines. Then move clutch plate to and fro on input shaft until hub moves 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 and greased. Only the contact surface may be cleaned, otherwise the service life of the clutch will be considerably reduced.

• 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.

→ Fig.2     Checking ends of the diaphragm spring

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

For vehicles with 1.9 ltr. 81 kW turbo diesel engine the clutch has been modified:

Clutch

• ◆ → A twin mass flywheel -1- has been fitted to the 1.9 ltr. 81 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 30-27