Clutch kit 036141025P 036141032P， 036141015AA, 036141015Q 03C141015， 03C141015D，3000 951 518，3000951518 3000 951 703，3000951703, 3000 951 773 for Audi A2 Skoda FABIA Volkswagen Golf 56 POLO 9N 6R1.4FSI

I. Preparation and Safety Standards

• Disconnect the battery negative terminal to prevent short circuits during operation.

• Socket Wrench Set: 8-19mm, including a ratchet wrench.

• Dedicated Centering Tool: The 1.4 FSI input shaft splines are relatively fine; a dedicated tool is mandatory to ensure concentricity.

• Torque Wrench: Must be precise to Nm.

• Release Bearing Installation Tool: If applicable.

• Support Stand or Jack: Used to support the gearbox.

• Confirm that the clutch disc (friction plate), pressure plate, release bearing, and guide sleeve are complete. It is highly recommended to replace the guide sleeve.

II. Removal of Old Clutch (Brief)

1. Remove Gearbox: Follow the standard procedure to remove the gearbox (note the position of the starter motor and shift cables on 1.4 FSI models).

2. Mark Pressure Plate: Mark the pressure plate and flywheel (if not replacing the flywheel) to observe wear patterns.

3. Loosen Bolts Diagonally: Loosen the pressure plate bolts in a diagonal sequence, performing this in 2-3 stages to prevent deformation of the pressure plate.

4. Remove Old Parts: Remove the pressure plate and friction disc.

5. Inspect Flywheel: Check if the flywheel ring gear is intact and if the friction surface has grooves or heat spots. If wear is severe, resurfacing or replacement is required.

III. Installation of New Clutch (Core Steps)

• Thorough Cleaning: Clean the flywheel and pressure plate surfaces completely with solvent to ensure no oil or water residue.

• Lubricate Guide Sleeve: The 1.4 FSI release bearing is either hydraulic (CSC) or cable-operated. Apply a small amount of high-temperature grease (G000650 or similar) to the guide sleeve before installation.

• Confirm Direction: Check the markings on the friction disc.

• "Gearbox Side" or "Getriebe Seite": Faces the gearbox.

• "Flywheel Side" or "Schwungrad Seite": Faces the flywheel.

• Note: The 1.4 FSI friction disc is usually asymmetrical. Installing it backward will cause failure to disengage or damage to the input shaft.

• Place Pressure Plate: Align the new pressure plate with the locating dowels and place it on the flywheel.

• Insert Centering Tool: Place the friction disc and insert the dedicated centering tool through the disc splines and into the pilot bearing in the center of the flywheel.

• Key Point: Move the friction disc up, down, left, and right to ensure the centering tool rotates easily without sticking.

• Pre-tighten: Manually thread in all pressure plate bolts.

• Tighten Diagonally: Tighten in a diagonal sequence, performing this in 2-3 stages.

• Torque Standard: Final torque is typically 25 Nm - 30 Nm (refer to the service manual for specifics, as it varies slightly by year).

• Remove Tool: Once bolts are fully tightened, remove the centering tool.

• For 1.4 FSI models (specifically Golf 5/6, Fabia), the release bearing is usually integrated inside the gearbox or within the hydraulic slave cylinder.

• Ensure the release bearing circlip is fully seated in the groove during installation.

• Check that the release bearing slides smoothly on the guide sleeve.

IV. Gearbox Installation and Verification

1. Install Gearbox: Carefully slide the gearbox into place, aligning with the engine locating dowels.

• Note: If sliding is difficult, never use brute force or a pry bar. Retract and check alignment; otherwise, the disc splines or pressure plate diaphragm spring will be damaged.

2. Tighten Gearbox Bolts: Tighten the engine-to-gearbox connecting bolts to standard torque (usually 40 Nm + 90° or similar, depending on the specific model).

3. Reconnect Components: Refit the starter motor, shift cables, battery negative terminal, etc.

V. 1.4 FSI Specific Precautions (Pitfall Guide)

• Some 1.4 FSI models use a Dual Mass Flywheel (DMF). If the DMF has excessive backlash, noise, or cracks, it must be replaced. Never just replace the clutch disc, as the new clutch will burn out quickly due to flywheel free play.

• If it is a Single Mass Flywheel (SMF), check for face runout. If runout exceeds 0.2mm, resurfacing is recommended.

• For models using a Concentric Slave Cylinder (CSC), such as the Golf 5/6 or Polo 6R, the clutch hydraulic system must be bled after installation. Failure to do so will result in incomplete disengagement (difficulty shifting gears).

• The 1.4 FSI input shaft is thin, making alignment difficult. It is recommended to use a dedicated centering tool with needle bearings or an old input shaft.

• After installation, avoid high-rev starts with the clutch slipping for the first 500 km to allow the friction disc to fully bed in with the flywheel.

1. Flywheel Inspection: SMF vs. DMF

• Current Status: Depending on the model and configuration, the 1.4 FSI engine may be equipped with a Single Mass Flywheel (SMF) or a Dual Mass Flywheel (DMF).

• Action:

• If DMF: Check for excessive backlash, abnormal noise, or cracks. If any issues exist, it must be replaced. Never replace only the clutch disc; otherwise, the new clutch will burn out rapidly due to the flywheel's excessive free play.

• If SMF: Check the friction surface for heat spots (blue spots), grooves, or warping. If wear exceeds limits, resurfacing is recommended.

2. Critical Detail: Pilot Bearing vs. Guide Sleeve

• Core Hazard: The 1.4 FSI gearbox input shaft is long and has extremely high requirements for concentricity.

• Action:

• Pilot Bearing: Every time the clutch is replaced, it is highly recommended to replace the pilot bearing in the center of the flywheel. If the bearing is dry or seized, severe shudder will occur during takeoff.

• Guide Sleeve: This is the most easily overlooked component (located in the center of the gearbox housing where the release bearing slides). If the guide sleeve is worn, the release bearing will suffer uneven wear, causing difficulty shifting or noise. Always inspect and apply dedicated high-temperature grease (such as VW G000650).

3. Lubrication Boundaries: Distinguish "Apply" vs. "Forbid"

• Where to Apply Oil:

• Inside the friction disc hub: Apply a small amount of high-temperature grease (Molybdenum Disulfide).

• Gearbox input shaft splines: Apply a small amount of high-temperature grease.

• Release Fingers: If using an older cable-operated release bearing, apply a thin layer of high-temperature grease to the diaphragm spring release fingers (prevents squeaking).

• Where Oil is Strictly Forbidden:

• Friction disc facing (lining): Not a single drop is allowed.

• Flywheel surface.

• Pressure plate surface.

• Note: New friction discs usually have anti-rust oil from the factory. They must be thoroughly cleaned with solvent and dried before installation.

4. Installation Direction: Gearbox Side / Flywheel Side

• Action: Carefully observe the markings on the side of the friction disc.

• "Gearbox Side" / "Getriebe Seite": Faces the gearbox.

• "Flywheel Side" / "Schwungrad Seite": Faces the flywheel.

• Consequence: The 1.4 FSI friction disc is usually asymmetrical (damper springs have different depths). If installed backward, it will cause the clutch to fail to disengage (cannot shift gears) or result in an abnormal engagement point.

References：

1. Core Technical Basis

• VW OEM Workshop Manuals (ELSA / ETKA): The core parameters within this content (such as the pressure plate bolt torque of 25-30 Nm, bolt tightening sequence, and grease specification VW G000650) are derived from official VW Group repair guidelines for the PQ25/PQ35 platforms and 1.4 FSI (BKG/BXW) engines.

• Universal Mechanical Principles: The descriptions regarding "Centering," "Flywheel Face Runout," and "Friction Disc Orientation (Gearbox/Flywheel Side)" adhere to general mechanical engineering standards for automotive clutch repair.

2. Vehicle Adaptation Experience

• 1.4 FSI Engine Characteristics: Specific requirements regarding the pilot bearing, input shaft length, and Dual Mass Flywheel (DMF) for this engine (and its matched manual transmission) are specifically emphasized.

• Platform Differences: The text distinguishes between different operational specifications for the older cable-operated release bearings (e.g., early Polo 9N, Audi A2) and the newer hydraulic (CSC) systems (e.g., Golf 6, Polo 6R).

3. Industry Practical "Pitfall" Guide

• Common Failure Point Summary: Precautions mentioned in the content—such as "hydraulic system bleeding," "abnormal noise caused by guide sleeve wear," and "shudder caused by an uneven flywheel"—are high-frequency causes of rework summarized by service technicians during actual repairs on these specific models.