Replacing the clutch Polo sedan

Self-Clutch Replacement Volkswagen Polo Sedan

Perhaps every motorist keeps in his memory the first driving lessons. A calm voice of an instructor explains: you squeeze the clutch, shift the gear, slowly release the clutch pedal, adding gas, go. You do not succeed, and so far quiet and serene voice of the teacher again uttered in a shorthand the same combination of words. And again the car stalls! The instructor starts to explain the principle of the clutch, but the words fly past your ears – the main thing: to continue driving. At any price.

Only after you pass all driving exams do you understand how important the clutch mechanism is on the car. Earlier it was a useless thing which took your nerves away, and now it turns out that you also have to take care of it. In fact it costs not cheap.

In sedan Volkswagen Polo the clutch service life is about 150 thou km. It is if to spend a resource of the device accurately. At “sporty” bravura style of driving the clutch may give up long before the specified term.

Clutch construction

The unit on Polo sedan is a standard dry single-disc clutch, the principle of which is based on friction force. The main purpose of the unit is to smoothly connect the engine flywheel to the transmission’s primary shaft. The flywheel is located on the crankshaft of the power plant. It connects to the slave disc, which is attached to the transmission, under the influence of the pressure plate.

The mechanism on the Polo sedan is triggered by the hydraulic actuator, which consists of the master and slave cylinders, connected by sockets, and a special bearing located in the sleeve on the clutch crankcase. The bearing is moved by a fork on the crankcase, which is controlled by the hydraulic actuator.

For effective operation of the clutch, the reservoir is filled with brake fluid, which ensures smooth sliding of the moving parts of the mechanism.

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The range of problems with the clutch on the car is quite wide. It is recommended to contact a service center for proper diagnosis of the malfunction.

Diagram of clutch mechanisms

The clutch can “drive” or slip – all these are the first signs of wear of the slave or pressure plates. It is not uncommon for air to enter the system. Air clogs usually result in the replacement of the master cylinder or one of the working cylinders.

Unusual noises in the mechanism indicate bearing wear. If the pedal begins to vibrate from clutch blows, as well as there are sharp jerks, the car will be more reliable to give in the hands of professionals, as there may be many reasons for the malfunction.

Replacement of the mechanism on the Volkswagen Polo sedan should be carried out as a complete set: both the discs and the bearing should be replaced with new samples. Whole parts without defects are also recommended to dismantle and replace with fresh elements, since their resource is already reduced. If this is not done, you will soon have to disassemble the clutch again and replace the old parts with new ones.

The work should be entrusted to craftsmen, because disassembling the mechanism on your own, which is quite time consuming and difficult, can damage vital “organs” of the car, from the chassis to the “engine” and the transmission. There is also a risk of incorrect reassembly of the device, which can turn into more serious problems for the car owner.

The unit kit for Polo sedan includes the following elements for replacement: a basket (220 mm), a disc (220 mm) and a release bearing with a fork. However, only non-original assemblies are available in stores, as the originals are sold separately.

Clutch parts

The most expensive element is the basket, or pressure plate. The original has the part number 03F141025 and is priced at 8000 rubles and higher.

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Clutch disc with part number 036141032T can be purchased for 6800 rubles. There is also part number 036141032H also for Polo sedan, but the part is more expensive – from 9600 rubles.

The cheapest bearing with code 02T141153F costs 2000 rubles with “cap”, but no more than 3000 rubles for original.

In addition to a set of wrenches and various heads in the work will need two screwdrivers – flat and Phillips – pliers, an assembly spatula, ratchet, dry rags and gloves.

The stumbling block in the procedure is the removal of the gearbox. The unit weighs a lot – about 40 kg, so to perform the work you will need an assistant or a solid support, which will hold the unit.

The first part of the work involves disassembling the gearbox:

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Dismantle air intake

Lift the car

Remove engine guard Unprotected vehicle

Disconnect wheel drives

Put chocks Suspend motor

Remove the gearbox ground

The second part – replacing the clutch:

    We mark the pressure plate with paint to be able to position the unit correctly during reassembly.

Mark the disc.

Remove discs.

Checking condition of discs.

Install the sprocket.

After connecting the pipes to the working cylinder adapter pump the hydraulic drive on Polo sedan to remove excess air from the system.

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You will need: a wrench x 14 (socket head is more convenient), a mounting spade, a marker and a mandrel for centering the drive plate.

1. Remove the gearbox (see here).

2. If you will be installing the former pressure plate, mark in any way (such as with a marker or paint) the relative position of the plate and flywheel housing to put the pressure plate in its former position (to maintain balance). 3. Holding the flywheel mounting spade (or large screwdriver) from turning, remove the six bolts securing the clutch pressure plate housing to the flywheel (for clarity, disassembly is shown on the removed engine). Loosen the bolts evenly: each bolt two turns of the wrench, going from bolt to bolt by diameter.

This is how the bolts secure the clutch pressure plate housing to the engine flywheel.

4. Remove the clutch pressure plate and slave plate from the flywheel, holding the slave plate,

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5. Inspect the clutch slave disc. Cracks on the parts of the slave disc are not allowed.

6. Check the degree of wear on the friction linings. If the rivet heads are recessed less than 0.3 mm, the friction linings surface is oily or the rivet joints are loose, the friction linings should be replaced.

The gearbox primary shaft oiling may be due to the oiling of the friction linings. It may need to be replaced.

7. Check that the damping springs are securely seated in the slipper hub seats by attempting to move them in the hub seats by hand. If the springs move easily in their seats or are broken, replace the disc.

8. Check the runout of the drive disc if visual inspection shows that it is warped. If runout is greater than 0.5 mm, replace the disc.

9. Inspect the flywheel friction surfaces.

10. and pressure plate, checking for deep grooves, burrs, dings, obvious signs of wear and overheating. Replace the defective parts. 11. If the riveted joints of the cowl and pressure plate parts are loose, replace the pressure plate assembly.

12. Visually inspect the condition of the pressure plate diaphragm spring. The presence of cracks in the diaphragm spring is not allowed. Places A contact spring blades with the clutch release bearing must be in the same plane and have no obvious signs of wear (no more than 0.8 mm). Otherwise, replace the pressure plate assembly.

13. Inspect the linking links of the guard and disc. If the links are deformed or broken, replace the pressure plate assembly.

14. Externally inspect the condition of the pressure spring support rings on the outside and inside of the pressure spring. The rings should be free of cracks and signs of wear. If not, replace the pressure plate assembly. 15. Before installing the clutch, check the ease of movement of the sliding disc on the splines of the transmission primary shaft. If necessary, eliminate the causes of jamming or replace defective parts.

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16. Apply a refractory grease to the splines of the idler disc.

17. When mounting the clutch, first use a mandrel to mount the slave disc and then the pressure plate guard, aligning the marks you made before removal.

Install the clutch disc so that the projecting part of the disc hub faces the diaphragm spring of the clutch cover.

18. and screw in the bolts securing the cowl to the flywheel.

19. Screw in the bolts evenly, one turn of the wrench each, in the order shown in the photo. 20. Remove the mandrel and install the gearbox (see here). 21. Check the operation of the clutch.

Instructions are valid for Volkswagen Polo sedan cars with 1.6L engines: 2010, 2011, 2012, 2013, 2014, 2015, 2016, 2017, 2018

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