Identifying The Circlip For The Dual Clutch

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

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-- Select the 2 mm thick ring from the circlips delivered and install it -arrow-.

NOTE:

For the initial measurement, temporarily insert 2 mm thick circlip. After the measurement has been determined, replace it with the final circlip.

First Measurement

The :T10303 remains installed.

-- Install the :VW387 on the transmission flange.

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-- Place the tip of dial indicator ion the input shaft and shown in the illustration.

-- Set the dial gauge to "0" with 2 mm pretension.

-- Raise the double clutch upward until stop and note the measurement.

Second Measurement

The :T10303 remains installed.

-- Place dial gauge measuring tip on inner clutch pack carrier hub, as show in the illustration.

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NOTE:

Do not place the measuring on the circlip.

-- Set the dial gauge to "0" with 2 mm pretension.

-- Raise the dual clutch all the way upward.

-- Read and note the measurement result.

The new circlip is determined according to the following formula:

Circlip = 2. Measurement - 1. Measurement + 1.85 = Thickness of the circlip to be installed.

-- Write down the result.

The new circlips are staggered in 0.1 mm increments.

-- Measure all the circlips and determine the one that is the closest match to the result.

Determined Measurement For The New Circlip	New Circlip
2.27 mm	2.3 mm
2.24 mm	2.2 mm

NOTE:

If the measurement determined for the new circlip is 2 mm, the circlip that was inserted temporarily remains installed.

-- Remove the 2 mm circlip and replace it with the circlip that was measured.

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-- Dispose of any remaining circlips.

NOTE:

Circlips must only be installed one time.

-- Insert the pump shaft by lifting the pump shaft and turning it slightly -arrow- so that it slides all the way into the splines.

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-- Insert the drive plate into the dual clutch.

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The protruding tab on the drive plate -arrow- must be installed between the marked teeth or the marking applied to the outer clutch plate carrier.

-- Install the new drive plate circlip.

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Installation position: The drive plate tab and the color-marked teeth or the markings that were applied later to the outer clutch plate carrier must lie between the ends of the circlip.

-- Using a screwdriver, check to make sure the circlip is completely engaged.

-- Remove the :T10303 between the dual clutch and the housing.

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-- Install the clutch end cover. Refer to CLUTCH END COVER, REMOVING AND INSTALLING .

When The Installation Is Completed, The Clutch Is Adjusted Correctly

-- Install the transmission. Refer to TRANSMISSION, INSTALLING, 2.0L - 155 KW - GASOLINE ENGINE .

-- Fill the transmission fluid. Refer to TRANSMISSION FLUID, DRAINING AND FILLING .

-- After installing the transmission, perform the Basic Setting using the Guided Functions using the Vehicle Diagnostic Tester.