Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 495

Centering the Clutch Disc, Removing And Installing the Pressure

Plate on Engines with a Crankshaft with a Smaller Diameter, or

Engines with a Needle Bearing in the Crankshaft.

Note

Ignore arrows -A and B-.

Continuation for All
When Installing, Tighten Bolts as Follows So Pressure Plate Does

Not Distort (Causing Shuddering on Acceleration):
– Install the pressure plate on the centering pins.
– Install all bolts evenly, by hand, until the bolt heads touch the

clutch pressure plate.

– Tighten the bolt diagonally in small steps.
– Install the transmission. Refer to

⇒ “2.2 Transmission, Installing”, page 92

 .

Tightening Specifications
♦ Pressure plate on the flywheel. Refer to

⇒ “2.2.2 Overview - Clutch, with Dual Mass Flywheel, LuK”,

page 43

 .

2.3.3

Clutch, Removing and Installing, with

Single Flywheel

Special tools and workshop equipment required
♦ Flywheel Retainer - 3067-
♦ Alignment Tool - Clutch Plate - T10097-
♦ Torque Wrench 5-50Nm - VAG1331-
♦ Clutch Disc Shaft Spline Lubricant - G 000 100-
Removing
• Transmission is removed.
– Insert the -3067- to loosen the bolts.
When Removing, Loosen the Bolts as Follows so that the Clutch

Pressure Plate Does Not Distort (Causing Shuddering on Accel‐

eration):
– Loosen all bolts clockwise one after the other in stages of 90°

until clutch pressure plate is free.

– Remove the pressure plate and the clutch plate.

Installing

Note

♦

Allocate clutch pressure plate and clutch plate according to the

engine code. Refer to the Parts Catalog.

♦

Clean the input shaft splines and (on used clutch plates) the

hub splines. Remove any corrosion and then apply a very thin

coat of Grease for Clutch Disc Shaft Splines - G 000 100- on

the splines. Then move the clutch plate 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

plate, 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.

♦

The clutch plate 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).

• Clutch plate installed location: The labeling

“Getriebeseite” (transmission side) or the shorter end of the

hub with the spring cage faces the pressure plate.

Check the Ends of the Diaphragm Spring
• Wear up to half the thickness of the diaphragm spring

-arrows- is permitted.

Check the Spring Connection and Rivet Connections
– Check the spring connection between the pressure plate and

the cover for cracks and make sure the rivet connections are

tight.

– Replace the pressure plate if the springs are damaged or if the

rivet connections -arrows- are loose.

Checking the Pull-Springs and Rivet Connection
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-.

– Check the spring connections -arrows A- for damage and

make sure the rivet connections -arrows B- are tight.

• Replace a clutch pressure plate with severely kinked or broken

spring connections and loose rivet connections.

– Make sure the rivet connections -arrows B- fit correctly on all

pull-springs -arrows A-.

– Tighten all bolts clockwise to the final tightening specification.
• Replace any clutch pressure plates that have loose rivet con‐

nections -arrow B-.

Checking the Metal Ring
– Check the metal ring in the clutch pressure plate -arrow- for

damage.

• Replace any clutch pressure plates that have a broken metal

ring.

– Use the -3067- when installing.
– Tighten the bolt diagonally in small steps.
– Install the transmission. Refer to

⇒ “2.2 Transmission, Installing”, page 92

 .

Tightening Specifications
♦ Pressure plate on the flywheel. Refer to

⇒ “2.2.3 Overview - Clutch, with Single Flywheel”, page 44

 .