Removal
Remove the gearbox.
Loosen the pressure plate mounting bolts sequentially by 1-11/2 turns, removing the load from the pressure plate.
Caution: If the bolts are completely loosened at once, the diaphragm spring may be damaged.
To prevent the flywheel from turning when unscrewing the pressure plate mounting bolts, it must be secured with either the VAG 10-201 tool or a screwdriver.
After removing the load from the pressure plate, unscrew the bolts completely.
Remove the pressure plate and clutch disc.
Caution: When removing the pressure plate and clutch disc, handle them carefully. Do not drop them, otherwise it may be difficult to install the discs back in place.
Remove the clutch release bearing from the front gearbox cover.
Attention: Do not wash the bearing, just wipe it.
Wash the flywheel with a rag soaked in gasoline.
Examination
Check the pressure plate for burns and cracks.
Check the pressure spring for cracks -arrows-. Traces of wear along the edges of the pressure spring with a depth of 0.3 mm do not pose a danger.
Check the connection between the pressure spring and the cover for cracks. Check the reliability of the riveted connections. A clutch that has mechanical damage must be replaced.
Check the bearing surfaces of the pressure plate for cracks, burns and wear. A pressure plate with deflections up to 0.3 mm deep can be used. The check is performed with a check ruler and feeler gauge.
Check the flywheel for burns and cracks.
A clutch disc with oiling and mechanical damage should be replaced. Check the thickness of the friction linings and the absence of cracks on them.
In specialized workshops, the end runout of friction linings is checked. The runout should not exceed 0.5 mm (when replacing at a distance of 2.5 mm from the outer edge).
Note: This check is carried out if old discs are installed that had defects when engaging the clutch.
The clutch release bearing is checked as follows. The bearing is lightly compressed by hand and rotated. The bearing should rotate freely. Otherwise, it must be replaced.
A defective clutch release bearing can be identified without dismantling it. A sign of a defective bearing is noise in its operation when the clutch pedal is pressed.
Installation
Before installing a new clutch, completely remove the anti-corrosion lubricant from its working surfaces
Check the reliability of the centering pin fastening on the flywheel.
Insert the clutch disc and pressure plate into the flywheel. Install the pressure plate onto the pin. The clutch disc must be centered. Using a mandrel for this purpose (for example HAZET) or the primary shaft of the gearbox.
When installing the clutch drive disc, ensure that the spring separator faces the pressure plate.
Clean the splined connection of the clutch disc from corrosion and coat with a thin layer of Moly paste. In workshops, grease G 000 100 is used. Excess grease must be removed.
Tighten the pressure plate mounting bolts sequentially by 1-11/2 turns until it is secured. Tightening torque: 25 Nm.
When completing the work, remove the centering mandrel.
Install the gearbox.