Clutch, With Dual Mass Flywheel, Manufactured By SACHS: Installing

WARNING: This page is about a different car, the 2013 Volkswagen Beetle and 2012 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Install in reverse order of removal. Note the following:

NOTE:

Allocate the clutch pressure plate and clutch disc according to the engine code.

Clean the input shaft splines and (on used clutch discs) the hub splines. Remove any corrosion and then apply a very thin coat of Grease for Clutch Plate Splines G 000 100 on the splines. Then move the clutch disc 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 disc, 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 disc 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).

Fig 1: Identifying Installation Position Of Clutch Disc At Dual-Mass Flywheel

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"Getriebeseite" -arrow- is the (transmission side) mark and is installed facing the transmission.

Fig 2: Checking Ends Of Diaphragm Spring

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Wear that is up to half the thickness of the diaphragm spring -arrows- is permitted.

Fig 3: Checking Pull-Springs And Rivet Connection

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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-.

-- Make sure the rivet connections -arrows B- fit correctly on all pull-springs -arrows A-.

Fig 4: Check Connections Of Springs And Rivet Connections

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Replace any clutch pressure plates that have loose rivet connections -arrows B-.

-- Install the flywheel retainer 3067.

Fig 5: Centering Clutch Plate And Removing And Installing Pressure Plate

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-- Install the clutch pressure plate on the centering pins.

-- Center the clutch disc using the Thrust Piece 3190 A.

When installing, tighten bolts as follows so pressure plate does not distort (causing shuddering on acceleration):

Fig 6: Checking Pressure Plate Does Not Distort

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-- 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 bolts in small steps and in diagonal sequence to prevent damaging the centering holes of the pressure plate and the centering pins of the dual mass flywheel.

When doing this, the stop pin -arrow- must lift off from the pressure plate.

For transmission installing, refer to TRANSMISSION, INSTALLING .