Clutch - service

Make

Volkswagen

Model

Polo Mk4

Section

5-speed manual gearbox 02R › Clutch, control › Clutch - service

Clutch and gearboxClutch - service

Clutch - service

Special tools and workshop equipment required t  Lock -3067- t  Centring pin -3190 A- t  Torquemeter   Note t  Replace clutch plates and pressure plates with damaged or loose rivets t  Select correct clutch plate and pressure plate according to parts list and engine code

1 -

Flywheel

q	Ensure centring pins are a tight fit.

q	Contact surface for clutch lining must be free of grooves, oil and grease.

q	Remove and install → Rep. Gr.13.

2 -	Clutch plate

q	Diameter → Chapter.

q	Installation position of the flywheel of the Bi-Mass motor: The shortest extremety of the cube -arrow- shall point towards the pressure plate.

q	Installation position of the flywheel of the simple motor: the housing of the springs shall point towards the pressure plate.

q	Center → Fig.

q	Lightly grease splines.

  Note

Clean input shaft slots and on used clutch plates, the hub slots, remove corrosion and apply only a very thin coating of grease “G 000 100” to input shaft slots. Then move clutch plate to and fro on input shaft until hub moves freely on shaft. Excess grease must be removed

3 -

Plate

q	Remove and install → Fig.

q	Check ends of diaphragm spring .

  Note

Plates are greased and protected against corrosion. Only the contact surface may be cleaned, otherwise the service life of the clutch will be considerably reduced

4 -

Screw

q	Check using Electronic Parts Catalogue.

q

20 Nm.

q	Loosen and tighten gradually and diagonally.

Centre clutch plate and remove and install plate –  Loosen and tighten bolts gradually and diagonally. –  Install Lock -3067- for removal   Note Plate contact surface (trim) 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

Check ends of diaphragm spring l  Wear up to half the thickness of the diaphragm spring is permitted

07 Transmission