Flywheel — removal, repair and installation (VW Golf 2)

1. Remove the clutch.

2. Lock the flywheel using a lever or a steel protractor inserted into the teeth of the ring gear.

3. Loosen the bolts and remove the flywheel from the crankshaft (photo 1.152).



4. Remove the cover plate (photo 1.153).

Flywheel repair

5. If the teeth of the flywheel ring gear are damaged, the ring gear must be replaced with a new one.

6. It is necessary to heat the ring to such a temperature that it can be removed from the flywheel. Another way is to cut the ring. The new ring is put on after it has been heated, since it is connected to the flywheel by shrinkage. Correctly fitting the ring is beyond the capabilities of most car enthusiasts. It is necessary to use the services of a company that has a furnace for heating the ring.



7. Deep wear marks on the clutch lining mating surface, cracks on the surface or damaged threads require the installation of a new flywheel.

8. If a new flywheel is to be installed, the ignition timing point must be marked. The new flywheel only has a TDC mark in the form of "0" on the outer surface. Therefore, it is necessary to make the appropriate ignition timing mark for this model. This point will later be used to set the ignition timing. Therefore, it is best to transfer this mark from the old wheel. The wheels (gears) must be placed next to each other, based on the holes that attach the flywheel to the crankshaft and on the TDC mark. The holes fit together only in one position,

Flywheel installation

9. Install the flywheel cover plate onto the locking couplings and screw it to the rear seal cover. The plate is secured with three M6 bolts.

10. Clean the working surfaces of the flywheel and crankshaft, then set the clutch pressure (box 020) or flywheel (box 084) onto the shaft. Note that the bolt holes only match in one position of the wheel.

11. Coat the threads of the new bolts with protective fluid before unscrewing, then insert them and tighten them crosswise. Before final tightening, it is necessary to lock the flywheel.

12. Put on and press the clutch.

13. In models with an automatic transmission, check the drive disk according to the description for the flywheel. Here, you will also need the ignition timing designation. Secure the drive plate together with the adjusting and spacer washers. Tighten the new crankshaft bolts to the specified torque. Using a caliper, check the distance o g of the drive disk to the cylinder block. If this distance is not within the range of 30.5... 32.1 mm, it is necessary to remove the drive plate and, if necessary, install new adjusting washers. It is necessary to ensure that the beveled cut on the washer is facing the drive disk. If the distance is normal, remove the bolts, coat the threads with a liquid locking substance and tighten to the specified torque.