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Changing the complete clutch

Changing the complete clutch

Removing the clutch and inspecting it after removal


1. Remove the gearbox as described in Removal or Gearbox removal 4-cyl, diesel

2. Fit 83 94 868 Flywheel locking attachment or 83 92 987 Flywheel locking attachment for Z19 to block the flywheel.


3. Macro Remove the screws securing the pressure plate and remove the clutch.

4. Check the flywheel surface in contact with the clutch plate. A blue tone and hairline cracks are no cause for concern. If the surface is deeply scored however, the flywheel should be changed.

5. Check the pressure plate for cracks or distortion. If it is uneven, it should be changed.

6. Check the release bearing for noise, wear and the like.

7. Check driven plate wear and change if necessary.


Fitting


1. Place the driven plate and pressure plate on the flywheel and loosely fit the screws.

Z19: the convex side should face the gearbox.

Important

Cars with self-adjusting pressure plate: Clutch plate and pressure plate are matched in pairs and must therefore be replaced as a pair.



2. Centre the driven plate with respectively 87 92 327 Centring tool, driven plate or 83 95 964 Centring tool, driven plate, 2.2 diesel and tighten the bolts alternately.

Z19l: Apply Thread locking adhesive, Loctite 270 to the threads.

Tightening torque, diesel 30 Nm (22 lbf ft)

Tightening torque, other models 22 Nm (16 lbf ft)

3. Remove flywheel locking attachment

4. Fit the gearbox. See Installation or Gearbox installation 4-cyl, diesel . Lubricate the primary shaft splines. See List of lubricants and sealing compounds .