Repairing clutch: VW 1.8 (BBU)

VW
Golf Variant
2007
Golf Variant
2010
Jetta
2005
Jetta
2011
Power transmission
6-speed manual gearbox 0AJ
Edition
05.2013
Repairing clutch
Special tools and workshop equipment required
Counterhold
3067
Torque wrench
V.A.G 1331
Centring mandrel
3190 A
For engines having a crankshaft of smaller diameter or having needle bearings
Fig.
in the crankshaft -
centring mandrel
T10086
Grease for clutch plate splines
G 000 100
(Gearbox removed)
Note
Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary.
If dowel sleeves are not fitted, difficulties shifting gears, clutch problems and possible noises from the gearbox (rattling of gears which are not engaged) could occur.
Renew clutch plates and pressure plates with damaged or loose rivets.
Allocation
Electronic Parts Catalogue
.
Flywheel
Ensure that centring pins fit tightly
Contact surface for clutch lining must be free of grooves, oil and grease
Removing and installing
Rep. gr.
13
Clutch plate
Allocation
Electronic Parts Catalogue
.
Installation position with dual-mass flywheel: shorter end of hub faces pressure plate.
Text
“Getriebeseite”
(gearbox side) always faces pressure plate and gearbox.
Installation position with single piece flywheel: spring cage faces pressure plate
Centring
Fig.
Centring for engines having a crankshaft of smaller diameter or having needle bearings in the crankshaft -
Fig.
Lightly grease splines
Note
Clean input shaft splines and, on used clutch plates, hub splines; remove corrosion and apply only a very thin coat of
grease for clutch plate splines
G 000 100
to the input shaft splines. Then move clutch plate to and fro on input shaft until hub moves freely on shaft. Remove excessive grease.
Pressure plate
Removing and installing
Fig.
Removing and installing for engines having a crankshaft of smaller diameter or having needle bearings in the crankshaft -
Fig.
Check ends of diaphragm spring
Fig.
Checking spring connections and riveted connections
Fig.
Contact surface for clutch lining must be free of grooves, oil and grease
Note
Pressure plates are protected against corrosion and greased. Clean contact surface only; otherwise the service life of the clutch will be considerably reduced.
Bolt
M6: 13 Nm
M7: 20 Nm
Allocation
Electronic Parts Catalogue
.
Loosen or tighten diagonally in small steps
Centring clutch plate and removing and installing pressure plate
Loosen and tighten bolts diagonally in small steps to prevent damage to thrust plate centring holes and flywheel centring pins.
Reverse position of
counterhold
3067
when removing.
For engines having a crankshaft of smaller diameter
arrow
or having an needle bearing
arrow
in the crankshaft
Centring clutch disc and removing and installing pressure plate for engines having a crankshaft of smaller diameter or having a needle bearing in the crankshaft
Loosen or tighten bolts diagonally in stages.
Reverse position of
counterhold
3067
when removing.
Continuation for all
Note
Pressure plate contact surface and clutch plate lining must make full contact with flywheel.
Tighten securing bolts diagonally and evenly to prevent damage to pressure plate centring hole and flywheel centring pins.
Checking ends of diaphragm spring
arrows
Wear up to half the thickness of the diaphragm spring is permitted.
Check spring connection and riveted fastenings.
Check spring connection between pressure plate and cover for cracks as well as rivet connections for secure seating.
If pressure plate has damaged springs or loose rivet connections
arrows
, it must be renewed.