Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 494

Engines Having a Crankshaft with A Smaller Diameter -arrow-, or

Engines Having A Needle Bearing -arrow- in the Crankshaft

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):
– Make sure the stop pin (position sensor) -arrow- moves easily.
– Install the pressure plate on the centering pins.
– Install all bolts evenly, by hand, until the bolt heads touch the

pressure plate.

– Tighten the bolt diagonally in small steps.
• When doing this, the stop pin -arrow- must lift off from the

pressure plate.

– Install the transmission. Refer to

⇒ “2.2 Transmission, Installing”, page 92

 .

Tightening Specifications
♦ Refer to

⇒ “2.2.1 Overview - Clutch, with Dual Mass Flywheel, Sachs”,

page 41

 .

2.3.2

Clutch, Removing and Installing, with

Dual Mass Flywheel, LuK

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-

♦ On engines which have a crankshaft with a smaller diameter,

or engines with a needle bearing in the crankshaft. Refer to

⇒ Fig. ““Centering the Clutch Disc, Removing and Installing

the Pressure Plate On Engines with a Crankshaft with a Small‐

er Diameter, or Engines with a Needle Bearing in the Crank‐

shaft.”“ , page 48

 -3176- .

Removing
Transmission removed.
– Insert the -3067- to loosen the bolts.
– Loosen the bolt diagonally in small steps.
– Remove the pressure plate and the clutch plate.
Installing
Install in reverse order of removal. Note the following:

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.

♦

Only use compressed air to clean the dual mass flywheel.

♦

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 Position
• “Getriebeseite” (transmission side) faces the transmission.

Check the Ends of the Diaphragm Spring
• Wear up to half the thickness of the diaphragm spring

-arrows- is permitted.

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-.

Checking the Spring Connections and Rivet Connections
– Make sure the rivet connections -arrows B- fit correctly on all

pull-springs -arrows A-.

• Replace any clutch pressure plates that have loose rivet con‐

nections -arrows B-.

Only Check Position of Adjustment Mechanism with New Pres‐

sure Plates
• Both edges -A- of the adjusting ring must be located between

both notches -arrows B-.

• If the adjusting ring takes on a different position with new pres‐

sure plates, pressure plate and clutch plate must not be in‐

stalled.

• With used clutches, the adjusting ring may take on a position

outside of the notches.

– Use the -3067- when installing.

Engines Having a Crankshaft with a Smaller Diameter -arrow-, or

Engines Having a Needle Bearing -arrow- in the Crankshaft