Removal, Installation and Inspection of Clutch

Clutch release bearing, manual transmission housing. 1.8 L engines 1 – manual transmission 2 – ball stud, 25 N•m Apply MoS grease

2. 3 – input shaft seal ring of manual transmission. Insert to the stop. 4 – guide sleeve. The seal ring on the sleeve cannot be replaced separately. In the area of the clutch release bearing, apply MoS grease

2. 5 – retaining spring. Mounted on the clutch release bearing lever. 6 – bolt, 20 N•m 7 – clutch release bearing lever. In the area of the clutch release bearing, apply MoS grease

2. 8 – clutch release bearing. Do not wash the bearing, only wipe it. If the bearing makes noise during operation, replace it. 9 – bolt, 20 N•m 10 – slave cylinder 11 – pushrod. Apply MoS grease to the end of the pushrod

2. 12 – mounting bolt. Locks the release lever when installing the manual transmission. Unscrew after the manual transmission is installed.

CAUTION

If the mounting bolt is not available, an M8 x 35 bolt may be used.

Clutch release bearing, manual transmission housing. 1.6 L engines 1 – cover. Removal: Pierce with a sharp drift and remove by prying. Installation: Sealing surfaces must be free of grease. Press the new cover in evenly around the circumference with a suitable mandrel. 2 – clutch release bearing. Can be replaced without removing the manual transmission. 3 – clutch release lever. Removal: Remove the retaining clip (5). Remove shaft (9) from the side. The lever can only be installed in one position. 4 – bushing 5 – retaining clip 6 – needle bearing 7 – bushing 8 – seal ring 9 – clutch release shaft 10 – manual transmission cover 11 – oil filler plug, 25 N•m

Engines except 1.6 L

(Procedures for 1.6 L engines are described below) REMOVAL

PROCEDURE

1. Remove the manual transmission. Refer to subsection Manual Transmission Removal and Installation.

2. To prevent the flywheel from turning when loosening the mounting bolts, hold it with tool AUDI–3067 or a screwdriver and rod.

CAUTION

Tool AUDI-3067 is shown in the installation position in the illustration. It must be turned over for removal. A centering mandrel AUDI-3190A or a standard centering pin, such as HAZET 2174, is required to install the clutch.

3. Loosen the pressure plate mounting bolts crosswise, each by 1 – 1.5 turns, until the plate is released.

CAUTION

If the bolts loosen immediately, the pressure springs may be damaged.

4. After loosening, remove the bolts completely.

5. Remove the pressure plate and clutch disc.

CAUTION

Do not drop the pressure plate or clutch disc. Otherwise, the clutch may judder or be difficult to disengage after installation.

6. Wipe the clutch release bearing clean without washing it.

7. Wipe the flywheel with a rag dampened with gasoline. INSPECTION

When installing used clutch components, they must be inspected beforehand.

8. Check the pressure plate for hot spots and scoring.

9. Check the pressure springs for damage (indicated by arrows). Wear up to half the spring thickness is permitted.

10. Check the spring connections between the pressure plate and cover for cracks. Check riveted connections for strength. If connections are loose or damaged, replace the clutch.

11. Check the contact surface of the pressure plate for cracks, overheating and wear. If the pressure plate is deformed by up to 0.2 mm inward, it can still be used. Check with a straightedge and feeler gauge.

12. Check the flywheel for cracks, heat checking and scoring.

13. Replace a clutch disc that is oily or has mechanical damage with a new one.

14. Check the thickness of the clutch disc friction linings and check the linings for cracks.

15. In a service shop, the clutch disc can be checked for runout. Axial runout of the disc must not exceed 0.8 mm (measured at 2.5 mm from the edge).

CAUTION

This check is only necessary when a used clutch disc is installed and there were problems with its operation. If necessary, the disc may be carefully straightened.

16. Check the clutch release bearing by hand in the installed position. Lightly compress the bearing and rotate it. The bearing must rotate easily. Damage to the clutch release bearing during operation is indicated by noise when the clutch pedal is pressed. Replacing the bearing is recommended. INSTALLATION

CAUTION

If new clutch components are installed, check the pressure plate and clutch disc against the parts catalog to confirm they are correct, to prevent incorrect installation.

17. Before installing the new pressure plate, remove the protective anti-corrosion layer from the working surface only. Do not remove grease from other areas under any circumstances, as this may significantly reduce clutch service life.

18. Check that the centering pins on the flywheel are secure.

19. Clean the splines of the clutch disc of rust. Apply a thin layer of MoS2 grease to the splines of the transmission input shaft. Service information specifies AUDI G 000 for this.

100. Then move the clutch disc on the shaft and check that it moves freely. Be sure to remove any excess grease. 20.

CAUTION

When installing the clutch disc, make sure the spring cage faces the pressure plate. If a clutch for a dual-mass flywheel is installed, there are no spring cages. In this case, install the clutch so that the friction lining contacts the flywheel. The hub must not contact the flywheel. The short end of the hub faces the pressure plate.

21. Center the clutch disc on the pressure plate using an alignment arbor, such as HAZET 2174 or AUDI–3176 (indicated by arrows). If the clutch disc is not centered, the input shaft cannot be installed in its working position. An old transmission input shaft can be used as a centering arbor.

22. Install the pressure plate onto the corresponding centering pins.

CAUTION

The pressure plate must fully contact the flywheel and must not be cocked. Otherwise, the centering pins and holes may be damaged. Only then insert the mounting bolts. Never draw the pressure plate to the flywheel with the bolts, otherwise the centering holes in the pressure plate and the centering pins on the flywheel may be damaged.

23. Install the pressure plate bolts and tighten them in a crisscross pattern, turning each by 1 – 1.5 turns, until the pressure plate is secured. Torque: 20 N·m.

CAUTION

For versions with internal hex bolts, tighten the bolts to 13 N·m torque.

24. Remove the centering arbor.

25. Install the transmission. Refer to the Transmission Removal and Installation subsection. Engines 1.6 L REMOVAL

26. Remove the transmission. Refer to the Transmission Removal and Installation subsection.

27. To prevent the flywheel from rotating while loosening the mounting bolts, lock it with tool AUDI–558 or with a screwdriver and a drift.

CAUTION

Mark the position of the flywheel relative to the pressure plate so they can be installed in the same position. If the flywheel is installed incorrectly, the TDC mark on the flywheel will be out of position.

28. Loosen the flywheel mounting bolts one at a time, by 1 – 1.5 turns each.

CAUTION

If the bolts loosen immediately, the pressure springs may be damaged.

29. If the bolts loosen immediately, the pressure springs may be damaged.

30. Remove the clutch disc.

CAUTION

Do not drop the pressure plate or clutch disc. Otherwise, the clutch may judder or be difficult to disengage after installation.

31. Using a screwdriver, pry the retaining ring (A) of the release diaphragm (B) out of the holes (indicated by arrows).

32. Remove the release diaphragm (B).

33. Separate the pressure plate from the flywheel. Hold the pressure plate with tool AUDI 558 using the bolt (A). If the specified tool is not available, hold the pressure plate with a screwdriver and a drift.

34. Remove the pressure plate and the intermediate plate.

35. Wipe the flywheel with a rag moistened with gasoline. INSPECTION

When installing used clutch components, they must be inspected beforehand.

36. Inspect the riveted connections on the pressure plate. Replace the plate if the rivet connections are damaged or loose.

37. Inspect the friction surface of the pressure plate for cracks, signs of overheating and wear. If the pressure plate is distorted by up to 0.2 mm inward, it can still be used. Check with a straightedge and feeler gauge.

38. Wipe oil off the friction surfaces of the pressure plate and flywheel.

39. Replace an oil-contaminated or worn clutch disc with a new one.

CAUTION

A faulty clutch release bearing is indicated by noise when the clutch pedal is pressed during driving. The bearing is located behind the cover on the outside of the manual transmission and can be replaced without removing the manual transmission.

INSTALLATION

CAUTION

If new clutch components are installed, check the pressure plate and clutch disc against the parts catalog to confirm they are correct, to prevent incorrect installation.

40. Before installing the new pressure plate, remove the protective anti-corrosion layer only from the contact and friction surfaces. Do not remove grease from other areas under any circumstances, as this may significantly reduce clutch service life.

41. Install the pressure plate with the intermediate plate onto the crankshaft.

CAUTION

Pay attention to the installation position of the intermediate plate. The raised section (arrow in the illustration) points away from the pressure plate. Install new mounting bolts and lock the pressure plate as during removal, using tool AUDI–556 or a screwdriver and mandrel.

42. Secure the pressure plate with a torque wrench to 60 N·m, then turn the bolts an additional 90° (1/4 turn) with a standard wrench.

CAUTION

Bolts take a permanent set when tightened, so replace them with new ones every time they are loosened.

43. Insert the release diaphragm and secure it with the retaining ring on the pressure plate. Insert both ends of the wire into the holes of the pressure plate.

44. Clean the splines of the clutch disc of rust. Apply a thin layer of MoS2 grease to the splines of the transmission input shaft. Service information specifies AUDI G 000 for this.

100. Then move the clutch disc on the shaft and check that it moves freely. Be sure to remove any excess grease.

45. Check that the centering pins on the flywheel are secure. If any pin on the flywheel is loose, it must be replaced.

46. Check that the centering pins on the flywheel are secure. If any pin on the flywheel is loose, it must be replaced.

CAUTION

If the flywheel is installed incorrectly, the TDC mark on it will be in the wrong position. The flywheel must fully contact the clutch pressure plate. Only then insert the mounting bolts. Do not cock the flywheel, otherwise the pins and centering holes may be damaged. Never draw the clutch cover to the flywheel with the bolts, otherwise the pins and centering holes may be damaged.

47. If tool AUDI 3178 was used, remove it.

48. Install the transmission. Refer to the Transmission Removal and Installation subsection.