Volkswagen Workshop Service and Repair Manuals

Clutch - repair

Special tools and workshop equipment required

t	Lock -3067-

t	Torque wrench - 5 to 50Nm (enc. 1/2") -VAG 1331-

t	Guide Pin -T 10086-

t	Guide Pin or VW 3190A -3190A-

Note t  Change clutch discs and plates with damaged or loosened riveted unions. t  The clutch disc and plate must correspond each other according to the Electronic Parts Catalogue and the engine prefixes.

1 -	Engine flywheel

q	Pay attention on the perfect fitting of the guide pins

q	The contact surface of the clutch disc shall be free of oil and grease, and should not have grooves

q	Remove and install → Motor; Rep. Gr.13

2 -	Clutch disc

q	Installation position: the spring case shall be facing the clutch plate

q	centralization for vehicles with gasoline engine → Fig.

q	centralization for vehicles with gasoline engine → Fig.

q	Apply a slight coat of grease on the splines

t	Clean the splines on the primary shaft and the clutch disc hub used.

t	Eliminate corrosion and apply a very fine coat of grease on the primary shaft splines. Move the clutch disc on the primary shaft to one side and other until the hub slides smoothly on the shaft. Eliminate the excess grease. Refer to → Chemical Materials Manual

3 -	Clutch plate

q	Remove and install on vehicles with gasoline engine → Fig.

q	Remove and install on vehicles with gasoline engine → Fig.

q	Check membrane spring height → Fig.

The clutch plates are greased and protected against corrosion. Clean the contact surface only; otherwise, the clutch lifetime will be significantly reduced.

4 -

Screw

q

20 Nm

q	Loosen and tighten in a cross and phased pattern

Centralize the clutch disc using the Guide pin -T 10086- and remove and install the clutch plate - vehicles with gasoline engine –  Loosen and tighten screws in a cross and phased pattern. –  To remove, install Lock - 3067-.   Note t  The clutch plate and clutch disc contact surfaces must be completely seated on the engine's flywheel. t  Tighten evenly the fastening screws, in a cross pattern, to prevent damages on the membrane spring of the clutch plate and the guide pins of the engine's flywheel.

Centralize the clutch disc using the Guide pin or VW 3190A -3190A- and remove and install the clutch plate - vehicles with diesel engine –  Loosen and tighten screws in a cross and phased pattern. –  To remove, install Lock - 3067-.   Note t  The clutch plate and clutch disc contact surfaces must be completely seated on the engine's flywheel. t  Tighten evenly the fastening screws, in a cross pattern, to prevent damages on the membrane spring of the clutch plate and the guide pins of the engine's flywheel.

Membrane spring height measurement –  Install clutch → Item.

–  Fasten centesimal dial gauge support somewhere on the crankcase. –  Reset centesimal dial gauge to zero in one of the clutch plate membrane spring tabs. –  Measure height of each tab and write down the values. –  Consider the highest and lowest values found. –  The sum of obtained values on the right and left of the zero point at the centesimal dial gauge should not be higher than 0.80 mm; otherwise, replace it.