Operation CHARM: Car repair manuals for everyone.

With 2.0L Engine

1. Position the pressure plate and the intermediate plate.

Intermediate Plate:




2. Install the intermediate plate with the notch (arrow) pointing out away from the pressure plate.
3. Install new attachment bolts.
4. Hold the pressure plate in position with locking tool VW 558 or equivalent, and torque new bolts to 60 Nm (45 ft lbs) + 90°.

Snap Ring:




5. Position the release plate "B" and attach to the pressure plate with snap ring "A". Lock both ends of the snap ring in the bores in the pressure plate (arrows).
6. Coat the splines at the center of the clutch disc with a thin layer of lithium grease or equivalent. Then, move the clutch disc back and forth along the input shaft until the disc hub moves on the shaft with no resistance.

NOTE: Always remove any excess grease.

7. Install the clutch disc and flywheel to the pressure plate.



8. Insert centering tool 3178 and tighten flywheel bolts in an alternating diagonal pattern.
9. Install locking tool VW 558 to the flywheel and tighten the flywheel bolts to 20 Nm (15 ft lbs).
10. Install the transmission. Manual Transmission/Transaxle

CAUTION:
- Replacement clutch pressure plates are greased and protected against corrosion. Only their friction surfaces are to be cleaned, as further cleaning will lead to corrosion and shorten service life.

- Assemble the clutch so that the flywheel dowel pins align with the bores/slots in the pressure plate, otherwise the TDC marking on the flywheel will be incorrect.

- Always refer to the engine code and engine number for replacement clutch discs and pressure plates.