Clutch housing, servicing: Notes
WARNING: This page does not describe the selected car, but rather 21 other vehicles, including the 2002 Volkswagen Cabrio, 2001 Volkswagen Cabrio, 2000 Volkswagen Cabrio, 1999 Volkswagen Jetta, and 1999 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
The following list refers to items in Fig 1.
- Oil drain plug
- Without magnet
- 25 N.m (18 ft lb)
- Dowel sleeve
- Qty: 2
- Shim S2
- Always 1 mm thick (0.04 in.)
- Outer race of tapered roller bearing for differential
- Removing and installing, see DIFFERENTIAL, DISASSEMBLING AND ASSEMBLING
- When replacing: adjust differential, see DIFFERENTIAL, ADJUSTING
- Magnet
- Retained in housing joint surface
- Install with AMV 188 200 03 sealant
- Shim S3
- Adjustment summary, see ADJUSTMENT SUMMARY
- Outer race for output shaft tapered roller bearing
- Removing and installing, see OUTPUT SHAFT, DISASSEMBLING AND ASSEMBLING
- When replacing: adjust output shaft, see OUTPUT SHAFT, ADJUSTING
- Needle bearing for input shaft
- Removing, see Extracting input shaft needle bearing
- Installing, see Driving in input shaft needle bearing
- Bolt
- With locking teeth
- 25 N.m (18 ft lb)
- Relay lever
- Spring
- Relay lever bracket
- Slide piece
- Bushing
- Removing, see Extracting bushing for starter
- Installing, see Driving in bushing for starter
- Can be replaced with transmission installed
- Threaded plug
- Green: for 1.8 liter, 1.9 liter Turbo Diesel or 2.0 liter engines with 210 mm clutch
- White: for engines with 200 mm clutch-not applicable for USA/Canada
CAUTION: Use care when transmission or clutch components are being replaced. It is essential that the parts installed are correct for the specific application.
Installation of the wrong plug results in the following malfunctions:- White plug w/210 mm clutch: destruction of test instrument TDC sensor, damaged flywheel markings, parts of TDC sensor scattered in clutch housing.
- Green plug w/200 mm clutch: test instrument provides no reading, or an imprecise, fluctuating reading.
- Plug
- Clutch housing
- Modified version starting with transmission number 13 09 3, see INSTALLING
- Input shaft oil seal
- Removing, see Prying out input shaft oil seal
- Installing, see Driving in input shaft oil seal
- Fill space between sealing lips with multipurpose grease
- Can be replaced with transmission removed (not disassembled)
CAUTION: The clutch housing and oil seal for vehicles with the 2.0 liter, 85 kW (115 hp) engine correspond to an increased output shaft diameter. - Sleeve
- Removing, see Using screwdriver to pry out sleeve
- Installing, see Driving in sleeve
- Drive flange oil seal
- Replacing, see DRIVE FLANGE OIL SEALS, REMOVING AND INSTALLING
- Consult parts catalog microfiche for drive flange and oil seal applications