Volkswagen Workshop Service and Repair Manuals

(Gearbox removed)

Modifications to clutch for Diesel engine vehicles =>Page 30-38

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

Modifications to clutch for Diesel engine vehicles =>Page 30-38

• Clutch plate
• ◆ Diameter
  =>from 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.

Modifications to clutch for Diesel engine vehicles =>Page 30-38

• 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 counter-hold 10-201 when removing.

The special tool 10-213 has been superseded by 10-213 A when reordering.

Note:

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

→ The clutch has been modified on vehicles with a Diesel engine:

• ◆ The Diesel engine has a two-part flywheel -1- fitted. The outer diameter and the diameter in the area of the clutch plate is smaller than the flywheel used in conjunction with a petrol engine.

• ‒ Removing and installing flywheel

=> Repair group13

• ◆ The clutch plate -2- also has a smaller diameter =>from Page 00-3 .

Installation position:

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

• ‒ Centralizing clutch plate => Fig.1

• ◆ The pressure plate -3- has been matched to the flywheel and the clutch plate.

• ‒ Removing and installing pressure plate => Fig.1

Tightening torque

Pressure plate socket head bolts -4- to flywheel: 10 Nm.

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

• ‒ Loosen and tighten bolts gradually and diagonally.
• ‒ Reverse position of counter-hold tool 3386 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 centring holes in the pressure plate housing and the centring pins in the flywheel.