Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 495
Centering the Clutch Disc, Removing And Installing the Pressure
Plate on Engines with a Crankshaft with a Smaller Diameter, or
Engines with a Needle Bearing in the Crankshaft.
Note
Ignore arrows -A and B-.
Continuation for All
When Installing, Tighten Bolts as Follows So Pressure Plate Does
Not Distort (Causing Shuddering on Acceleration):
– Install the pressure plate on the centering pins.
– Install all bolts evenly, by hand, until the bolt heads touch the
clutch pressure plate.
– Tighten the bolt diagonally in small steps.
– Install the transmission. Refer to
⇒ “2.2 Transmission, Installing”, page 92
.
Tightening Specifications
♦ Pressure plate on the flywheel. Refer to
⇒ “2.2.2 Overview - Clutch, with Dual Mass Flywheel, LuK”,
.
2.3.3
Clutch, Removing and Installing, with
Single Flywheel
Special tools and workshop equipment required
♦ Flywheel Retainer - 3067-
♦ Alignment Tool - Clutch Plate - T10097-
♦ Torque Wrench 5-50Nm - VAG1331-
♦ Clutch Disc Shaft Spline Lubricant - G 000 100-
Removing
• Transmission is removed.
– Insert the -3067- to loosen the bolts.
When Removing, Loosen the Bolts as Follows so that the Clutch
Pressure Plate Does Not Distort (Causing Shuddering on Accel‐
eration):
– Loosen all bolts clockwise one after the other in stages of 90°
until clutch pressure plate is free.
– Remove the pressure plate and the clutch plate.
Installing
Note
♦
Allocate clutch pressure plate and clutch plate according to the
engine code. Refer to the Parts Catalog.
♦
Clean the input shaft splines and (on used clutch plates) the
hub splines. Remove any corrosion and then apply a very thin
coat of Grease for Clutch Disc Shaft Splines - G 000 100- on
the splines. Then move the clutch plate back and forth on the
input shaft until the hub moves freely on the shaft. Remove
any excess grease.
♦
The clutch pressure plates are corrosion-protected and
greased. With the exception of the friction surface on the clutch
plate, do not clean the clutch pressure plate. This will shorten
the service life of the clutch considerably.
♦
The friction surfaces on the clutch pressure plate and on the
flywheel must be cleaned thoroughly (degreased).
♦
To reduce odor caused by a burnt clutch, thoroughly clean the
transmission housing around the clutch as well as the engine
on the transmission side.
♦
The clutch plate linings must sit completely on the flywheel and
on the clutch pressure plate friction surface. Install the bolts.
♦
Tighten the bolts diagonally in small steps so as to not damage
the centering holes in the pressure plate and the centering pins
on the flywheel.
♦
Make sure the alignment sleeves for centering the engine/
transmission are installed inside the cylinder block. Install
them if necessary.
♦
If the alignment sleeves are missing, it will be difficult to shift,
there will be clutch problems and the transmission may make
noises (loose rattling).
• Clutch plate installed location: The labeling
“Getriebeseite” (transmission side) or the shorter end of the
hub with the spring cage faces the pressure plate.
Check the Ends of the Diaphragm Spring
• Wear up to half the thickness of the diaphragm spring
-arrows- is permitted.
Check the Spring Connection and Rivet Connections
– Check the spring connection between the pressure plate and
the cover for cracks and make sure the rivet connections are
tight.
– Replace the pressure plate if the springs are damaged or if the
rivet connections -arrows- are loose.
Checking the Pull-Springs and Rivet Connection
I - Pull-spring OK
• Slight offset in the outer area -arrows A-.
II - Pull-springs damaged
• The clutch pressure plates must be replaced if the pull-spring
is bent or broken off -arrow B-.
– Check the spring connections -arrows A- for damage and
make sure the rivet connections -arrows B- are tight.
• Replace a clutch pressure plate with severely kinked or broken
spring connections and loose rivet connections.
– Make sure the rivet connections -arrows B- fit correctly on all
pull-springs -arrows A-.
– Tighten all bolts clockwise to the final tightening specification.
• Replace any clutch pressure plates that have loose rivet con‐
nections -arrow B-.
Checking the Metal Ring
– Check the metal ring in the clutch pressure plate -arrow- for
damage.
• Replace any clutch pressure plates that have a broken metal
ring.
– Use the -3067- when installing.
– Tighten the bolt diagonally in small steps.
– Install the transmission. Refer to
⇒ “2.2 Transmission, Installing”, page 92
Tightening Specifications
♦ Pressure plate on the flywheel. Refer to
⇒ “2.2.3 Overview - Clutch, with Single Flywheel”, page 44
.
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