Volkswagen Golf Variant, Jetta. Manual - part 6

This allows the value to be found even more accurately, because

the inaccuracy caused by “tilting” on the engagement bearing is

minimised.
– Calculate average of both measurements onto gauge block -

T10374- .

– Note down this value and call it “A2”.
Example:

Dimension “A2” = 2,50+2,542 = 2.52

Example: “A2” = 2.52 millimetres
Next calculation:
“A2” minus “B” plus height of gauge block -T10374- = Depth of

engagement bearing of clutch 2.
Height of gauge block -T10374- is always the same. On inside, it

is: 36.20 mm.
Sample calculation:
2.52 mm minus 2.96 mm plus 36.20 mm = 35.76 mm.
You have now calculated value for how deep engagement bear‐

ing is actually seated inside gearbox.
Depth of bearing in each gearbox should be 34.35 millimetres.
Subtract nominal dimension “34.35 millimetres” from this actual

value. This gives result for actual gap of clutch 2.
– Continue the calculation:
Calculated value (in example: 35.76 mm) minus nominal dimen‐

sion = gap of clutch.
Sample calculation:
35.76 mm minus “34.35 millimetres” = gap of clutch 2 = 1.41mm.
Now tolerances in dual clutch must be introduced into this calcu‐

lation. Procedure for this is very simple:
– Please read off value of clutch tolerance of “new” clutch.
A value between minus 0.40 and plus 0.40 millimetres is provided

with a new clutch.
– Make a note of this value.
Example 1: “- 0.40” is indicated on your clutch.
The previous calculation for “K 2”: “your calculated” gap minus

value of clutch 2 =
1.41 mm minus 0.40 = 1.01 mm.
Example 2: “+ 0.20” is indicated on your clutch.
Then, the last calculation of “K 2” is as follows: 1.41 mm plus 0.20

= 1.61 mm.
– Refer to table to find correct shim.

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

1. Removing and installing the dual clutch    

21

 

metres)

from

to

 

0.31

0.90

0.8

0.91

1.10

1.0

1.11

1.30

1.2

1.31

1.50

1.4

1.51

1.70

1.6

1.71

1.90

1.8

1.91

2.10

2.0

2.11

2.30

2.2

2.31

2.50

2.4

2.51

2.70

2.6

2.71

3.30

2.8

– From the supplied shims, select the one that is required.

WARNING

Later on, only insert this 1 shim. Not 2 shims.

With this, you also have found “correct” shim for “K 2”. Please

install this shim during subsequent clutch installation. This shim

should be under small engagement bearing.

1.3

Installing dual clutch

Special tools and workshop equipment required
♦ Support device -T10323-

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

22

 

♦ Thrust piece -T10376-

♦ Adhesive -AMV 195 KD1 01-
Perform the following steps:

Caution

Do not oil or grease anything!

Before clutch is installed, position of engagement bearings “K 1

and K 2” must be set 

⇒ page 12

 .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

1. Removing and installing the dual clutch    

23

 

– Install small engaging lever with clip.
Sleeve with its retaining plate fits only in one position.

Only a few, “older gearboxes” do not have a clip.
“New” clutches always have one clip.
– Check engaging lever is properly seated.
– Screw on engaging lever with 2 new bolts.
Torque setting: 8 Nm + 90°

Note

Mounting for engaging lever and entire mechanism of engage‐

ment bearing must be dry and free from oil or grease. If neces‐

sary, clean these components with a cloth.

– Insert 2nd, “larger” engaging lever.
This “larger” lever is for clutch “K 1”.
– Check both engaging levers are seated correctly.

Caution

Before continuing with assembly, check whether clutch needs

to be adjusted.
Do not continue with the assembly before the clutch has been

adjusted!
Adjust positions of engagement bearings 

⇒ page 12

 .

Golf Variant 2007 ➤ , Golf Variant 2010 ➤ , Jetta 2005 ➤ , Jetta 2011 ➤

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