Removing and installing drive gears and two-part flywheel — VW

Note:

Servicing clutch:

=> 5-Speed Manual Gearbox 000.1 and 000.2; Repair Group 30; Servicing clutch
5-Speed Manual Gearbox 000.1 and 000.2
Servicing clutch

I
=>page
13-17

II
=>page
13-20

Part I

60 Nm
Flywheel housing
Clean sealing surfaces before installation
Coat sealing surfaces with AMV 188 001
Watch securing when mounting

Clamping sleeve
Crankshaft
Removing and installing
=> page
13-45

Wheel drive housing
Clean sealing surfaces before installation
Coat sealing surfaces with AMV 188 001
Watch securing when mounting

Clamping sleeve
Drive gear
Renew => page
13-31
Arrangement of drive gears
=> page
13-25

Sender wheel
For engine speed sender (G28)
Renew if damaged
Renew sender wheel each time screws are unscrewed
Removing and installing => Fig.
2

Sleeve
Threaded insert
Two-part flywheel
To remove and install, brace vibration damper with spanner 3447
With ring gear

125 Nm
50 Nm
Sealing ring
Renew => page
13-37

Spacer ring
Clamping sleeve

Part II

Wheel drive housing
Clean sealing surfaces before installation
Coat sealing surfaces with
AMV 188 001
Watch securing when mounting

Coolant connection piece
Sealing washer
Renew

Sealing plug
Intermediate gear
For driving camshaft
Arrangement of drive gears
=> page
13-25
Adjust axial clearance =>page
13-25

Bearing
For intermediate gear

Bearing bush
For intermediate gear
Removing => Fig.
1

Intermediate gear
For driving coolant pump
Arrangement of drive gears
=> page
13-25
Adjust axial clearance =>page
13-25

Shim
Available in various thicknesses
For adjusting axial clearance

Thrust washer
For gear bearing

60 Nm
Thrust washer
For gear bearing

Intermediate gear
For driving vane pump for power steering
Arrangement of drive gears
=> page
13-25
Adjust axial clearance =>page
13-25

60 Nm
Sealing cap

Fig.1
Removing bearing bush of gear

Press out on the hydraulic press with special tool VW 454 and VW 412, as well as the base plate VW 402.

Installation is also carried out on the hydraulic press in the reverse order.

Fig.2
Removing and installing sender wheel

Always renew the sender wheel -2- each time the screws are unscrewed -1-.
Tightening torque: 10 Nm + 90° (1/4 turn)

Note:

After securing the second time, the screw-on point of the countersunk screws in the sender wheel is so deformed that the screw heads on the crankshaft -3- make contact -arrows- and the sender wheel lies loose beneath the screws.