Clutch, servicing: Notes

WARNING: This page is about a different variant/trim than selected.

(Transmission removed)

Special tools and equipment required

3190 A Mandrel

Fig 1: 3190 A Mandrel

Courtesy of VOLKSWAGEN UNITED STATES, INC.

3067 Counter-hold tool

Fig 2: 3067 Counter-Hold Tool

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Replace clutch plates and pressure plates that have damaged or loose rivets
Select correct clutch plate and pressure plate according to parts list and engine code.

Fig 3: Identifying Flywheel, Clutch Plate, Pressure Plate & Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Flywheel

Ensure centering pins are a tight fit
Contact surface for clutch lining must be free of grooves, oil and grease
Removing and installing:

Refer to 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AWD, AWW, AWP, 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 1.9 LITER 4-CYL. 2V TDI ENGINE MECHANICAL, ENGINE CODE(S): ALH, 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 1.9 LITER 4-CYL. 2V TDI PD ENGINE MECHANICAL, FUEL INJECTION GLOW PLUG, ENGINE CODE(S): BEW, 13 ENGINE - CRANKSHAFT, CYLINDER BLOCK for 2.0 LITER 4-CYL. 2V ENGINE MECHANICAL, FUEL INJECTION & IGNITION, ENGINE CODE(S): AEG, AVH, AZG, BBW, BEV, 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 2.8 LITER VR6 2V ENGINE MECHANICAL, ENGINE CODE (S): AFP, 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 2.8 LITER VR6 4V ENGINE MECHANICAL, ENGINE CODE(S): BDF and 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 3.2 LITER VR6 4V ENGINE MECHANICAL, FUEL INJECTION IGNITION, ENGINE CODE(S): BJS

Fig 4: Identifying Flywheel, Clutch Plate, Pressure Plate & Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

2 - Clutch plate

Diameter. Refer to Code letters, transmission allocation, ratios, capacities
Installed position on two-part flywheel: Shorter hub end (arrow) points toward pressure plate
Installed position with single piece flywheel: spring cage faces pressure plate
Centering. See Centering clutch plate and removing and installing pressure plate

Lightly grease splines

NOTE: Clean input shaft splines and on used clutch plates, the hub splines. Remove corrosion and apply only a very thin coating of grease Part No: G 000 100 to the input shaft splines. Then move clutch plate back and forth on input shaft until hub moves freely. Excess grease must be removed.

Fig 5: Identifying Flywheel, Clutch Plate, Pressure Plate & Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

3 - Pressure plate

Removing and installing. See Centering clutch plate and removing and installing pressure plate
Check ends of diaphragm spring. See Checking ends of diaphragm spring

NOTE: Pressure plates are protected against corrosion and greased. Only the contact surface may be cleaned, otherwise the service life of the clutch will be considerably reduced.

4 - Bolt

Allocate using parts catalog
On two-part flywheel: 13 Nm
On single piece flywheel: 20 Nm
Loosen and tighten gradually and diagonally