Clutch release bearing, manual transmission housing. Engines 1.8 l
- 1 - manual transmission
- 2 - ball pin, 25 Nm. Coat with MoS2 grease.
- 3 - sealing ring of the manual transmission input shaft. Enter all the way.
- 4 - guide sleeve
The O-ring on the bushing cannot be replaced individually. Lubricate with MoS2 grease around the clutch release bearing.
- 5 - retaining spring. Attaches to the clutch release lever.
- 6 - bolt, 20 Nm
- 7 - clutch release bearing lever. Lubricate with MoS2 grease around the clutch release bearing.
- 8 - clutch release bearing. Do not wash the bearing, but only wipe it. If the bearing makes noise during operation, replace it.
- 9 - bolt, 20 Nm
- 10 - working cylinder
- 11 - pusher. Lubricate the end of the tappet with MoS2 grease.
- 12 - mounting bolt
Fixes the clutch release lever when installing a manual transmission. After installing the manual transmission, turn it out.
Warning: If a mounting bolt is not available, an M8 x 35 bolt may be used.
Clutch release bearing, manual transmission housing. Engines 1.6 l
- 1 - cover
Withdrawal: Punch with a sharp mandrel and remove by prying.
Installation: Sealing surfaces must be free of grease. Press the new cover around the circumference with a suitable mandrel.
- 2 - clutch release bearing. Can be replaced without removing the gearbox.
- 3 - clutch release lever
Withdrawal: Remove the retaining clip (5). Pull out the shaft from the side (9). The lever can only be inserted in one position.
- 4 - sleeve
- 5 - locking bracket
- 6 - needle bearing
- 7 - sleeve
- 8 - sealing ring
- 9 - clutch release shaft
- 10 - manual transmission cover
- 11 - filler cap for oil filling, 25 Nm
Engines other than 1.6L
(Description of work for 1.6L engines is given below)
Withdrawal
1. Remove the manual transmission, while referring to the subsection Removal and installation of manual transmission.
2. To prevent rotation of the flywheel when loosening the fastening bolts, it is necessary to hold it with an AUDI-3067 tool or a screwdriver and a rod.
Warning: The AUDI-3067 tool is shown in the installation position in the illustration. When removed, it must be turned over. Clutch installation requires an AUDI-3190A centering mandrel or a conventional centering rod such as HAZET 2174.
3. Turn away bolts of fastening of a pressure plate crosswise each on 1-1, 5 turns so that the disk was released.
Warning: If the bolts are loosened immediately, the compression springs may be damaged.
4. After loosening, the bolts are completely unscrewed.
5. Remove the pressure and driven clutch discs.
Warning: Do not drop pressure and driven discs. Otherwise, after assembly, the clutch may experience jerks and difficulty in disengaging.
6. Wipe the clutch release bearing without rinsing it.
7. Wipe the flywheel with a rag soaked in gasoline.
Examination
When installing used clutch parts, they must first be checked.
8. Check the pressure plate for overheating and burrs.
9. Check pressure springs for damage (indicated by arrows). Wear up to half the thickness of the spring is allowed.
10. Check the spring connections between pressure plate and cover for cracks. Check riveted joints for strength. Replace clutch if loose or damaged.
11. Check the adjacent surface of the pressure plate for cracks, overheating and wear. If there is a deformation of the pressure plate up to 0.2 mm inside, it can still be used. Checking is carried out with a ruler and a probe.
12. Check the flywheel for overheating cracks and burrs.
13. Oiled or mechanically damaged clutch disc, replace with a new one.
14. Check the thickness of the friction linings of the clutch disc and the presence of cracks in the linings.
15. Under workshop conditions, the clutch disc can be checked for runout. The end runout of the disc should not exceed 0.8 mm (measured at a distance of 2.5 mm from the edge).
Warning: This check is only necessary if a used disk is installed and there were deficiencies in its operation. If necessary, the disc can be carefully straightened.
16. Check by hand the clutch release bearing in the installed position. To do this, lightly squeeze the bearing and turn. The bearing should rotate easily. During operation, damage to the clutch release bearing is determined by the noise when the clutch pedal is depressed. It is recommended to replace the bearing.
Installation
Warning: If new clutch parts are being installed, the pressure plate and driven plate must be checked against the parts catalog to ensure they match to avoid incorrect installation.
17. Before installing a new pressure plate, the protective anti-corrosion layer should be removed only on the working side. In other places, the lubricant must not be removed in any case, otherwise this can lead to a significant reduction in the service life of the clutch.
18. Check the fastening of the centering pins on the flywheel.
19. Clean the splines of the driven disk from rust. Lubricate with a thin layer of MoS grease2 the splines of the input shaft of the manual transmission. The service station uses AUDI G 000 100 for this. After that, move the driven disk on the shaft, checking for ease of movement. Be sure to remove excess grease.
20.
Warning: When installing the driven plate, make sure that the spring separator points towards the pressure plate. If a dual-mass flywheel clutch is installed, there are no spring cages. In this case, the clutch is installed so that the friction lining rests against the flywheel. The hub should not be adjacent to the flywheel, the short end of the hub points towards the pressure plate.
21. Center the driven plate on the pressure plate using a rod, e.g. HAZET 2174 or AUDI-3176 (indicated by arrows). If the driven disk is not located in the center, the input shaft will not be able to take its working position. The old manual transmission input shaft can be used as a centering rod.
22. Install the pressure plate on the appropriate centering pins.
Warning: The pressure plate must be fully seated on the flywheel and must not warp. Otherwise, the centering pins and holes may be damaged. Only then insert the mounting bolts. Under no circumstances tighten the pressure plate with bolts, otherwise the centering holes of the pressure plate and the centering pins on the flywheel may be damaged.
23. Screw in the pressure plate mounting bolts and tighten them crosswise, turning 1–1.5 turns so that the pressure plate is fixed. Tightening torque: 20 Nm.
Warning: For versions with hexagon socket screws, they are tightened with a torque of 13 Nm.
24. Remove the centering rod.
25. Install the manual transmission, while referring to the subsection Removal and installation of manual transmission.
Engines 1.6 l
Withdrawal
26. Remove the manual transmission, while referring to the subsection Removal and installation of manual transmission.
27. To prevent the flywheel from rotating when the mounting bolts are loosened, it is necessary to fix it with an AUDI–558 tool or a mandrel screwdriver.
Warning: Mark the position of the flywheel in relation to the pressure plate so they can be reinstalled. If the flywheel is installed incorrectly, the TDC marking on the flywheel will lose its position.
28. Loosen the flywheel mounting bolts one by one by 1–1.5 turns.
Warning: If the bolts are loosened immediately, the compression springs may be damaged.
29. If the bolts are loosened immediately, the compression springs may be damaged.
30. Remove the driven disk.
Warning: Do not drop pressure and driven discs. Otherwise, after assembly, the clutch may experience jerks and difficulty in disengaging.
31. Pry with a screwdriver and remove from the holes (indicated by arrows) retaining ring (A) clutch release disc (IN).
32. Remove the clutch release disc (IN).
33. Disconnect the pressure plate from the flywheel, for which fix the AUDI 558 tool on the pressure plate with a bolt (A). If the specified tool is not available, the pressure plate can be held with a screwdriver and a mandrel.
34. Remove pressure plate and intermediate plate.
35. Wipe the flywheel with a rag soaked in gasoline.
Examination
When installing used clutch parts, they must first be checked.
36. Check the rivet connections on the pressure plate. Replace a disk with damaged or loose rivet joints with a new one.
37. Check the friction surface of the pressure plate for cracks, overheating and wear. If there is a deformation of the pressure plate up to 0.2 mm inside, it can still be used. Checking is carried out with a ruler and a probe.
38. Wipe the friction surfaces of the pressure plate and flywheel free of oil.
39. Replace oily or worn driven disc with a new one.
Warning: A sign of a damaged clutch release bearing is noise when the clutch pedal is depressed while 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
Warning: If new clutch parts are being installed, the pressure plate and driven plate must be checked against the parts catalog to ensure they match to avoid incorrect installation.
40. Before installing a new pressure plate, the protective anti-corrosion layer should only be removed on the adjacent and friction side. In other places, the lubricant must not be removed in any case, otherwise this can lead to a significant reduction in the service life of the clutch.
41. Install the pressure plate with intermediate plate on the crankshaft.
Warning: Pay attention to the installation position of the intermediate plate. Elevation (arrow on accompanying illustration) points away from the pressure plate. Screw in new mounting bolts and block the pressure plate as when removing with the AUDI–556 tool or with a screwdriver and mandrel.
42. Fasten the pressure plate with a torque wrench to 60 Nm and then tighten the bolts with a hard wrench at an angle of 90° (1/4 turn).
Warning: The bolts will permanently deform when tightened, so they must be replaced with new ones after each loosening.
43. Insert the clutch release disc and secure with the circlip to the pressure plate. Insert both ends of the wire into the holes in the pressure plate.
44. Clean the splines of the driven disk from rust. Lubricate with a thin layer of MoS grease2 the splines of the input shaft of the manual transmission. The workshop uses AUDIG 000 100 for this. After that, move the driven disk on the shaft, checking for ease of movement. Be sure to remove excess grease.
45. Check the fastening of the centering pins on the flywheel. If any pin on the flywheel is loose, it must be replaced.
46. Check the fastening of the centering pins on the flywheel. If any pin on the flywheel is loose, it must be replaced.
Warning: If the flywheel is installed incorrectly, the TDC marking on it is in the wrong position.
Warning: The flywheel must be in full contact with the clutch pressure plate. Only then are the mounting bolts inserted.
Warning: Do not twist the flywheel as it will otherwise the pins and centering holes may be damaged. Never tighten the clutch basket with bolts, as otherwise the pins and centering holes may be damaged.
47. If an AUDI 3178 tool was used, remove it.
48. Install the manual transmission, while referring to the subsection Removal and installation of manual transmission.
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