Clutch, servicing: Notes

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Observe general repair instructions, see GENERAL REPAIR INSTRUCTIONS .

CAUTION:

Replacement clutch pressure plates are greased and protected against corrosion. Only their friction surfaces are to be cleaned. Further cleaning will lead to corrosion and shorten service life.
Assemble the clutch so that the flywheel dowel pin(s) align with the bore(s) or slot(s) in the pressure plate. Otherwise the TDC marking on the flywheel will be incorrect.
Always refer to the engine code and engine number when consulting the parts catalog microfiche for replacement clutch discs and pressure plates.

NOTE: The transmission must be removed to carry out work on the clutch, see TRANSMISSION, REMOVING AND INSTALLING .

The following list pertains to Fig 1.

Bolt
- M7 x 40
- 20 N.m (15 ft lb)
Flywheel
- Two versions, see FLYWHEEL VERSIONS
- Removing, see CLUTCH, REMOVING AND INSTALLING
- Installing, see INSTALLING
- Make sure dowel pin(s) seat properly
- Clutch lining friction surface must be free of grooves, oil and grease
Clutch disc
- Aligning, see VEHICLES WITH 1.8 OR 1.9 LITER ENGINE
- Diameter CODE LETTERS, ENGINE/TRANSMISSION APPLICATIONS, RATIOS, CAPACITIES
WARNING:
- Friction materials such as clutch linings may contain asbestos fibers.
- DO NOT create dust by grinding, sanding or by cleaning with compressed air.
- Avoid breathing asbestos fibers and asbestos dust. Breathing asbestos may result in serious diseases and cause injury or death.
Clutch push rod
- Grease in area of guide bushing in input shaft
Snap ring
Release plate
- Lightly lubricate pressure plate contact surface and clutch pushrod socket with G 000 100 grease
Bolt
- Pressure plate to crankshaft
- Removing and installing, see appropriate Engine Mechanical article.
Intermediate plate
- Installation position, see INSTALLING
Pressure plate
- Two versions, see FLYWHEEL VERSIONS
- Removing and installing, see CLUTCH, REMOVING AND INSTALLING
- Maximum distortion of pressure plate inner surface: 0.2 mm (0.008 in.)
- Replace pressure plate that has damaged or loose rivets
  CAUTION:
  - Pressure plates are treated against corrosion and greased. Only the friction surface must be cleaned.
  - When assembling the clutch make sure the flywheel dowel pin(s) and the bore(s) or slot(s) in the pressure plate are aligned.

Fig 1: Exploded View Of Clutch Components

Courtesy of VOLKSWAGEN OF AMERICA, INC.