Clutch, Servicing

Clutch, servicing





Special tools and workshop equipment required
^ 3067 Flywheel retainer
^ 3176 Centering mandrel
^ VAG 1331 Torque wrench

Note:
^ Observe the general repair instructions.
^ Replace clutch plates and pressure plates with damaged or loose rivets.
^ Select the correct clutch plate and pressure plate according to engine code:
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^ Clean input shaft splines and (in the case of used clutch plates) the hub splines.
^ Remove corrosion and apply only a very thin coating of grease G 000 100 to the splines. Then move clutch plate on input shaft until hub moves freely on shaft. Excess grease must be removed.
^ Pressure plates are protected against corrosion and are greased. Only the contact surface may be cleaned, otherwise the service fife of the clutch will be reduced.
^ If the clutch has burnt out, thoroughly clean the bellhousing, flywheel and parts of the engine facing the transmission to reduce the smell of burnt linings.





- Remove transmission to work on clutch.
A - Colored marking on dual mass flywheel
^ If components are marked, white marking -A- on dual mass flywheel must coincide with white marking -13- on pressure plate.

B - Colored marking on pressure plate
^ If components are marked, white marking -A- on dual mass flywheel must coincide with white marking -13- on pressure plate.
1 - Flywheel/dual mass flywheel
^ Make sure that centering pins are a tight fit
^ Contact surface for clutch lining must be free of grooves, oil and grease
2 - Bolt for flywheel
^ Always replace
^ Vehicles without dual mass flywheel 60 Nm +turn 90° further
^ Vehicles with dual mass flywheel
- Bolt length 22 mm 60 Nm + turn 90° further
- Bolt length 42 mm 60 Nm + turn 180° further
3 - Clutch plate
^ Installation position:
- Spring pack (coil springs) toward pressure plate and transmission
- Clutch lining must make full contact with flywheel
- Marking Getriebeseite (if present) goes toward pressure plate and transmission
^ Do not grease
^ Clutch plate diameter
^ Centering
^ Lightly grease splines
4 - Pressure plate
^ Removing and installing
^ Check ends of diaphragm spring
^ Checking spring connection and riveted fastenings
^ If components are marked, assemble with white marking on flywheel -A- aligning with white marking on pressure plate -B-.
5 - Bolt, 25 Nm
^ Loosen and tighten gradually over several stages in diagonal sequence
6 - Needle bearing
^ Removing and installing:

Fig. 1 Centering clutch plate and removing and installing pressure plate:

- Loosen and tighten bolts gradually over several stages in diagonal sequence -25 Nm.
- Reverse position of counterhold 3067 when removing.
- Installation position of clutch plate: Spring pack (coil springs) or marking Getriebeseite toward pressure plate and transmission.
- Do not insert mounting bolts until clutch lining and contact surface of pressure plate must make full contact with flywheel.
- Use mandrel 3176 to center clutch plate.
- If components are marked, assemble with white marking on dual-mass flywheel -A- aligning with white marking on pressure plate -B-.

Fig. 2 Checking ends of diaphragm spring:

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

Note: When performing repairs always match up clutch pressure plate and clutch plate by checking engine code (see Parts Supplier).

Fig. 3 Checking spring connection and riveted fastenings:

- Check spring connection between pressure plate and cover for cracks and make sure rivet fastenings are seated tightly.
- Replace clutches with damaged springs or loose riveted fastenings arrows-.