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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Golf IV (1997 release)

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Volkswagen Golf 4
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Coupling disk on cars with engines 1,4 and 1,6-I
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Coupling



Flywheel and clutch disk on models with engines 1,8-I



1 - a flywheel;
2 - disc clutch;
3 - pressure plate;
4 - a bolt, 25 Nm

Hydraulic clutch (the engine 1,8-I)

1 - popolnitelny tank of brake system;
2 - hydraulic hose;
3 - the clutch master cylinder;
4 - earring;
5 - the clutch pedal;
6 - Self-locking hexagon nut, 25 Nm. When you install a new nut should be used;
7 - an arm;
8 - the pipeline;
9 - a support;
10 - a protective cap;
11 - bleeder valve;
12 - the working cylinder of coupling;
13 - bolt flange, 25 Nm;
14 - the transmission housing;
15 - Spring bracket;
16 - Clip;
17 - the pipeline;
18 - Connect the pipeline;
19 - O-ring. Before installation grease sealing ring with brake fluid;
20 - spring bracket

The clutch of cars with engines 1,4- / 1,6-I

1 - a bolt, 20 Nm. Tightening bolts evenly crosswise produce;
2 - a flywheel. The surface is matched with the clutch disk should not have grooves and it should be no oil and grease. Flywheels are used in two sizes. They are distinguished by the color designation in the screw plugs in the clutch housing;
3 - disc clutch. Lubricate splines clutch grease based on molybdenum disulfide. A lubricant layer should be thin and uniform, as otherwise when the clutch is excessive lubricant dropped on the clutch surface, which can disrupt its operation;

4 - Push rod clutch. It is necessary to lubricate the guide bush in the area in the drive shaft;
5 - a lock ring;
6 - plate. The support surface of the plate in contact with the push rod, brush a thin layer of grease on the basis of molybdenum disulphide;
7 - a bolt, 60 Nm + tighten on a corner 90 ?. When installing it is necessary to use new bolts;
8 - a steel plate;
9 - pressure plate. Minimum wear inside - 0.2 mm

The mechanism clutch models 1,4- / 1,6-I

1 - cover. To remove a pointed punch punch cap and, using a punch as a lever to remove it. To install degrease the mating surface of the cover. Using the appropriate holder, replace the cover;
2 - clutch. Replacement of the bearing can be made without removing the gearbox;
3 - the lever of the clutch. Remove the safety spring clip 5 and remove the shaft 9;
4 - the plug;
5 - spring safety bracket;
6 - a support;
7 - the plug;
8 - a sealing ring;
9 - shaft;
10 - the transmission housing;
11 - oil filler plug

The clutch on vehicles with engines of 1,8- / 1,9- / 2,3-l

1 - gearbox housing;
2 - a stud with a ball, 25 Nm. The ball tip is lubricated with grease based on molybdenum disulfide;
3 - a sealing ring drive shaft. Installation of the sealing ring is made up to the stop;
4 - the directing plug. O-ring guide sleeve can not be replaced individually. The surface mating with the release bearing, brush a thin layer of grease on the basis of molybdenum disulphide;
5 - spring latch;
6 - a bolt, 20 Nm;
7 - the lever of the clutch. All contact surfaces of the lever grease with a thin layer of grease on the basis of molybdenum disulphide;

8 - clutch. Do not wash the release bearing in a solvent, as it will be washed out of the grease. The bearing makes noise during rotation, to be replaced;
9 - a bolt, 20 Nm;
10 - the working cylinder of coupling;
11 - a pusher. At the head of the pusher applied grease based on molybdenum disulfide;
12 - mounting screw. Mounting screw holding the lever when installing clutch gearbox. After you install the gearbox you need to unscrew the screw. As the set screw can be used bolt M8h35

The clutch located between the engine and the transmission and intended for separation and connection of the engine crankshaft and the gearbox input shaft. Clutch is a part of the transmission to ensure retention of the car relative to the road in gear, smooth pick-up and the car gearshift without the noise and the risk of damaging parts.

When the clutch, ie, When the clutch pedal in the upper position, the cup spring leading part of coupling moves the pressure plate in the direction of the motor. In this clutch disc provided with friction linings, is sandwiched between the pressure plate and the flywheel and the torque transmitted from the engine to the gearbox. When you press the clutch pedal thrust bearing clutch pressure plate moves back. This releases the clutch disc, after which the motor shaft and the transmission shaft can rotate independently of each other.

All models installed dry single-plate clutch, which consists of a disk clutch pressure plate, a diaphragm spring, and the thrust bearing housing.

Clutch disc moves freely in the slots of the primary shaft of the gearbox and is clamped between the flywheel and pressure plate forces generated by diaphragm spring. On both sides of the clutch disc friction linings riveted. The leading portion of the clutch disc is connected to the hub through the details of the torsional vibration damper, which provides a resilient connection between them.

The need for vibration damper caused by the following. When a sudden change in the vehicle speed, running over bumps in the road, sharp inclusion of coupling, as well as due to the irregular operation of the engine in the vehicle transmission having dynamic loads that cause twisting (unwinding) shafts of the transmission. Uneven motor torque can cause significant congestion in the transmission due to the occurrence of torsional vibrations and resonance when the frequencies of transmitted loads to the natural frequency of the transmission. Elastic vibrations transmission lead not only to the appearance of noise in the mechanisms and units, but also to hazardous vibration, and sometimes to the breakage of parts when the oscillation amplitude reaches a high value. The energy of the torsional vibration damper absorbs.

Releaser mounted on a front side of a transmission. Moving the bearing is made clutch lever. Pressing the clutch pedal moves the piston in the master cylinder and compresses the fluid that is passed through the hose to the clutch slave cylinder. Under the pressure of the piston moves the clutch slave cylinder and actuates the release lever. The lever moves the clutch release bearing, which acts on the spring pressure plate and puts pressure plate from the clutch disc. Adjusting the clutch automatically.

Depending on the design of the flywheel mounted on the engine, different clutch discs. If the flywheel consists of two sections with a spring and damping system, the set clutch disc without springs shock absorber. If the engine is equipped with a flywheel, which consists of one piece, then set the clutch disc with springs shock absorber (classic clutch disc).

If the car is a flywheel, consisting of two sections, set the clutch disc without springs shock absorber.

If the flywheel is composed of one piece, then set the clutch disc with springs shock absorber, the spring must be by the pressure plate.

Inserting a disc

PERFORMANCE ORDER
1. Grease slots clutch disc with a thin layer of grease on the basis of molybdenum disulphide. A lubricant layer should be thin and uniform, as otherwise when the clutch is excessive lubricant dropped on the clutch surface, which can disrupt its operation.
2. Tightening bolts produce gradually and evenly in diagonal sequence.
3. On models with a flywheel with twice the mass of used screws with hexagon socket, tightening torque 13 Nm that.




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