Clutch, Servicing

Clutch, servicing

NOTE: Observe general repair instructions.

CAUTION: Replacement clutch pressure plates are greased and protected against corrosion. Only their friction surfaces are to be cleaned. Further cleaning results will lead to corrosion and shorten service life.
Assemble the clutch so that the flywheel dowel pin(s) align with the bore(s) slot(s) in the pressure plate. Otherwise the TDC marking on the flywheel will be incorrect.
Always refer to the engine code and engine number when consulting the parts catalog microfiche for replacement clutch discs and pressure plates.

NOTE: The transmission must be removed to carry out work on clutch. Refer to Manual Transmission/Transaxle - Service and Repair - Procedures Service and Repair






1. Bolt: M7 x 40 mm
Tighten to: 20 Nm (15 ft lb)

2. Flywheel
Two versions, see below.
Installation & removal, see below
Make sure that dowel pin(s) seat properly
Clutch lining friction surface must be free of grooves, oil and grease

3. Clutch disc
Aligning, refer to procedures below.
Diameter, refer to Transmission Identification.

WARNING: Friction materials such as clutch linings may contain asbestos fibers. DO NOT create dust by grinding, sanding or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust Breathing asbestos may result in serious diseases and cause injury or death.

4. Clutch push rod
Grease in area of guide bushing in input shaft

5. Snap ring

6. Release plate
Lightly lubricate pressure plate contact surface and clutch pushrod socket with G 000 100 grease

7. Bolt
Pressure plate to crankshaft
Removing and installing, Manual Transmission/Transaxle - Flywheel, M/T - Service and Repair - Procedures Service and Repair

8 Intermediate plate
Installation position, refer to procedure below.

9 Pressure plate
Two versions, refer to information below
Removing & installing, refer to procedure below.
Maximum distortion of pressure plate inner surface: 0.20 mm (0.008 inch)
Replace pressure plate that has damaged or loose rivets.

CAUTION: Pressure plates are treated against corrosion and greased. Only the friction surface must be cleaned. When assembling the clutch make sure that the flywheel dowel pin(s) and the hole(s) or slot(s) in the pressure plate are aligned.

Clutch, removing and installing






- Hold flywheel in place with VW 558 retainer.
- Loosen bolts and remove flywheel.
- Remove clutch disc






- Use screwdriver to free ends of snap ring -A- from bores -arrows- and remove.
- Remove release plate -B-.






- Hold pressure plate in place with VW 558 retainer and bolt -A- and remove.
- Remove pressure plate and intermediate plate.

Installing

- Position pressure plate and intermediate plate.






Installation position of intermediate plate: protrusion -arrow- points out away from pressure plate
- Install new attachment bolts.
- Hold pressure plate in position with VW 558 retainer (as during removal) and tighten attachment bolts.
For tightening information, refer to Engine.






- Position release plate -B- and attach to pressure plate with snap ring -A-. Lock both ends of snap ring wire in bores in pressure plate -arrows-.
- Coat splines at center of clutch disc with a thin layer of G 000 1000 grease.
- Move clutch disc back and forth along input shaft until disc hub moves on shaft with no resistance.

CAUTION: Always remove any excess grease.

- Mount clutch and pressure plate to flywheel.






- Insert centering tool 3178 and tighten flywheel bolts in an alternating diagonal pattern.

Install VW 558 retainer to flywheel (as during removal) to tighten flywheel bolts

Flywheel Versions

Up to December 1992:
Two alignment dowel pins: pin diameter: 6 mm (0.24 inch)






From December 1992:
Flywheel mass increased
One alignment dowel pin (arrow): pin diameter: 7 mm (0.28 inch)

Clutch Pressure Plate Versions

Up to December 1992:
Two recesses mate with flywheel alignment dowel pins to center flywheel






From December 1992:
One recess -arrow 1- mates with one flywheel alignment dowel pin
Circular shoulder -arrow 2- centers flywheel

CAUTION: The later style clutch pressure plate can only be installed together with the later style flywheel.