2.0L Diesel Engines
Clutch
=> [ Sachs ]
=> [ LuK ]
Special tools, testers and auxiliary items required
• Flywheel Retainer (3067)
• Centering Pin (T10097)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Centering Mandrel (3176) (For crankshafts with a smaller diameter, or with a needle bearing, refer to => [ Centering the Clutch Disc, Removing/Installing
the Pressure Plate with a Crankshaft with a Smaller Diameter, or a
Needle Bearing. ])
• Grease for Clutch Plate Splines (G 000 100)
Sachs
Removing
- Remove the transmission.
- Install the flywheel retainer (3067) to loosen the bolts.
- Loosen the bolt diagonally and in small steps.
• When loosening, the stop - 2 - and the bolt - 1 - must loosen up together.
- If the stop does not loosen: push the bolt toward the dual mass flywheel.
- Remove the pressure plate and the clutch disc.
Installing
Installation is performed in the reverse order of removal while observing the following:
• Allocate the pressure plate and the clutch disc to match the engine code. Refer to the Parts Catalog.
• Check whether there are alignment sleeves for the engine/transmission in the cylinder block; install 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 Disc Installed Position
• "Getriebeseite" (transmission side) and the spring cage face the transmission.
Checking the Ends of the Diaphragm Spring
• Wear up to half the thickness of the diaphragm spring - arrows - is permitted.
Checking the Spring and Rivet Connections
- Check the spring connections between the pressure plate and the cover for cracks and make sure the rivet connections are tight.
• Replace the pressure plate if the spring connections are damaged or if the rivet connections - arrows - are loose.
• Replace the clutch disc and pressure plate if the rivets are damaged or loose.
• Allocate the clutch disc and pressure plate to match the engine code. Refer to the Parts Catalog.
• Clean the input shaft splines and (on used clutch discs) the hub splines, remove the corrosion and apply a very thin coating of grease for clutch plate splines (G 000 100) to 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 pressure plate is corrosion-protected and lubricated. Only the running surfaces may be cleaned. Otherwise the service life of the clutch will be shortened considerably.
• The pressure plate contact surface and the clutch disc lining must completely touch the flywheel. Install the bolts.
- Remove the flywheel retainer (3067) when installing.
Crankshafts with a Smaller Diameter - arrow -, or a Needle Bearing - arrow -.
Centering the Clutch Disc, Removing/Installing the Pressure Plate with a Crankshaft with a Smaller Diameter, or a Needle Bearing.
• Ignore arrows - A and B -.
Continuation for all Vehicles:
When installing, tighten the bolts as follows so the pressure plate does not distort (causing shuddering on acceleration):
- Make sure the stop pin (position sensor) - arrow - moves easily.
- Position the pressure plate on the alignment pins.
- Install all the bolts evenly, by hand, until the bolt heads contact the pressure plate.
• When doing this, the stop pin - arrow - must lift off from the pressure plate.
- Tighten the bolts in small steps and in a diagonal sequence to prevent damaging the centering holes of the pressure plate and the centering pins of the dual mass flywheel => [ (Item 4) Bolt ] Sachs.
- Install the transmission.
LuK
Removing
- Remove the transmission.
- Install the flywheel retainer (3067) to loosen the bolts.
- Loosen the bolt diagonally and in small steps.
- Remove the pressure plate and the clutch disc.
Installing
Installation is performed in the reverse order of removal while observing the following:
• Allocate the pressure plate and the clutch disc to match the engine code. Refer to the Parts Catalog.
• Check whether there are alignment sleeves for the engine/transmission in the cylinder block; install 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 Disc Installed Position
• "Getriebeseite" (transmission side) faces the transmission.
Checking the Ends of the Diaphragm Spring
• Wear up to half the thickness of the diaphragm spring - arrows - is permitted.
Checking the Spring and Rivet Connections
- Check the spring connections - arrows A - for damage and make sure the rivet connections - arrows B - are tight.
Only check the position of the adjustment mechanism with a new pressure plate.
• Both edges - A - of the adjusting ring must be located between both notches - arrows B -.
• If the adjusting ring takes on a different position with a new pressure plate, the pressure plate and clutch disc must not be installed.
• With used clutches, the adjusting ring may take on a position outside of the notches.
• Replace the clutch disc and pressure plate if the rivets are damaged or loose.
• Replace the pressure plate and the clutch disc together.
• Allocate the clutch disc and pressure plate to match the engine code. Refer to the Parts Catalog.
• Clean input shaft splines and (on used clutch discs) the hub splines, remove corrosion and apply a very thin coating of grease for clutch plate splines (G 000 100) to 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 pressure plate is corrosion-protected and lubricated. Only the running surfaces may be cleaned. Otherwise the service life of the clutch will be shortened considerably.
• The pressure plate contact surface and the clutch disc lining must completely touch the flywheel. Install the bolts.
- Remove the flywheel retainer (3067) when installing.
Crankshafts with a Smaller Diameter - arrow -, or a Needle Bearing - arrow -
Centering the Clutch Disc, Removing/Installing the Pressure Plate with a Crankshaft with a Smaller Diameter, or a Needle Bearing.
• Ignore arrows - A and B -.
Continuation for all Vehicles:
- Position the pressure plate on the alignment pins.
- Install all the bolts evenly, by hand, until the bolt heads contact the pressure plate.
- Tighten the bolts in small steps and in a diagonal sequence to prevent damaging the centering holes of the pressure plate and the centering pins of the dual mass flywheel => [ (Item 4) Bolt ] LuK.
- Install the transmission.