Volkswagen Cars 2000-05

Flexplate (Driveplate)

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Removal & Installation



1.8L, 1.9L And 2.0L Engines
1.8L (Aug/Awm) And 2.0L (Bhw) Engines
  1. Remove the engine and transaxle assembly, as outlined in this section.
  2.  
  3. Position flywheel retainer 3067 in order to loosen and tighten the bolts, as shown in the illustration.
  4.  
  5. Remove the bolts, then remove the drive plate.

    Click image to see an enlarged view

    Fig. Position the tool to loosen (A) and tighten (B) the drive plate



    Click image to see an enlarged view

    Fig. Exploded view of the grooved washer (1) and shim (2)

  6.  

To install:

  1. Position the drive plate using grooved washer . Install new bolts and tighten to 22 ft. lbs. (30 Nm).
  2.  
  3. Check the dimension (a) at three points and calculate the specification. It should be 26-28mm) for 1.8L engines or 18.9-20.5mm for 2.0L engines.
    NOTE
    Measure on the milled surface of the cylinder block.

  4.  
  5. If the measurement is not within specifications:
    1. Remove drive plate again and use shim to achieve the proper specification. Re-tighten the bolts to 22 ft. lbs. (30 Nm).

      Click image to see an enlarged view

      Fig. Check the dimension (a) at three points and calculate the specification

    2.  

  6.  
  7. Tighten the drive plate bolts to 45 ft. lbs. (60 Nm), plus an additional 90° ( 1 / 4 rotation), the additional rotation may occur in several stages).
  8.  
  9. Remove the special tool.
  10.  
  11. Install the engine and transaxle assembly.
  12.  

Except 1.8L (Aug/Awm) And 2.0L (Bhw) Engines
  1. Remove the engine and transaxle assembly, as outlined in this section.
  2.  
  3. Fasten special tool VW558, or equivalent flywheel lock adapter to the driveplate with hex bolt (M8x45).
  4.  
  5. Install two M10 hex nuts between the VW558 and driveplate, as shown in the accompanying illustration.

    Click image to see an enlarged view

    Fig. Proper positioning of the flywheel lock adapter tool-A: to loosen bolts, B: to tightening mounting bolts

  6.  
  7. Remove the driveplate
  8.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the driveplate, washer with cut outs (1), shim (2) and bolts (3). You must use new bolts when installing the driveplate

  1. Install the driveplate using washer with cut-outs.
  2.  
  3. Install new bolts and tighten to 22 ft. lbs. (30 Nm).
  4.  
  5. Check dimension at three points, as shown in the illustration, and calculate average value. The proper specification is: 19.5-21.1mm (0.768-0.831 in.) for all engines except AEB/ATW engines. For AEB/ATW engines, the specification is 26-26 mm. If results are not within specifications, perform the following:
    1. Remove the driveplate and install a shim to bring the dimension within specifications.
    2.  
    3. Tighten the bolts to 22 ft. lbs. (30 Nm).

      Click image to see an enlarged view

      Fig. Check the dimension (a) at three points and calculate the average value

    4.  

  6.  
  7. Tighten the bolts (3) to 44 ft. lbs. (60 Nm) plus and additional 1 / 4 -turn (90° turn), in several steps.
  8.  
  9. Install the engine and transaxle assembly, as outlined in this section.
  10.  

2.8L (Afp) Engine

NOTE
This procedure requires the following special tools and equipment, or their equivalents:



3406 Counter-hold
 
VAG 1331 torque wrench (5-50 Nm)
 
VAG 1332 torque wrench (40-200 Nm)
 
Depth gauge
 
Auxiliary ruler
 

  1. Remove the engine and transaxle assembly, as outlined in this section.
  2.  
  3. Lock the vibration damper in position with locking bracket 3406.

    Click image to see an enlarged view

    Fig. Lock the vibration damper in position with locking bracket 3406

  4.  
  5. Loosen mounting bolts of drive plate in crosswise pattern and remove.
  6.  
  7. Remove the drive plate.
  8.  

To install:

  1. Place drive plate on crankshaft.
  2.  
  3. Insert at least 3 old mounting bolts and tighten to22 ft. lbs. (30 Nm).
  4.  
  5. Check dimension (a) at three points, as shown in the illustration, and calculate average value. The proper specification is: 15.7-1605mm. If results are not within specifications, perform the following:

    Click image to see an enlarged view

    Fig. Check dimension (a) at three points, as shown, and calculate the average value

  6.  
  7. Remove the drive plate again, then use a proper sized shim to obtain the proper dimension.
    NOTE
    Only one shim of the appropriate thickness may be used for compensation.



    Click image to see an enlarged view

    Fig. Use a suitable shim (1) to get the proper dimension

  8.  
  9. Once proper specifications are met, perform the following:
    1. Insert new mounting bolts and hand tighten.
    2.  
    3. Install drive plate; use new mounting bolts and tighten to 44 ft. lbs. (60 Nm) plus 1 / 4 turn (90°) in several steps.
    4.  

  10.  
  11. Install the engine and transaxle into the vehicle, as outlined in this section.
  12.  

2.8L (Atq) Engine
  1. Remove the engine and transaxle assembly, as outlined in this section.
  2.  
  3. Remove sealing plug from left side of cylinder block.
  4.  
  5. Turn crankshaft to TDC for cylinder 3. TDC mark on crankshaft must be visible or felt behind bore for sealing plug.
  6.  
  7. Screw crankshaft holder 3242, or equivalent tool, into hole, as shown, to prevent the crankshaft from turning.

    Click image to see an enlarged view

    Fig. Screw crankshaft holder 3242, or equivalent tool, into hole, as shown, to prevent the crankshaft from turning

  8.  
  9. Matchmark the installed position of shim, drive plate and washer to the crankshaft.
  10.  
  11. Loosen drive plate mounting bolts, in a criss-cross pattern, remove them.
  12.  
  13. Remove the drive plate.
  14.  

To install:

  1. Place drive plate with shim and washer onto crankshaft.
  2.  
  3. Insert at least 3 of the old mounting bolts and tighten to 22 ft. lbs. (30 Nm).
  4.  
  5. Check dimension (a) at three points and calculate the value. The proper specification is about 12.3mm. If specified value is not reached or is exceeded:
    1. Remove the drive plate again, then install an appropriate size shim .
      NOTE
      You may only use a single shim of the proper thickness.

    2.  
    3. Once the proper specification is attained, insert new bolts and tighten by hand.
    4.  

  6.  
  7. Tighten the bolts to 45 ft. lbs. (60 Nm) plus 1 / 4 turn (90° ) in several steps.
  8.  

2.8L (Bdf) Engine

NOTE
This procedure requires the use of the following special tools, or their equivalents:



T10069 Counter support
 
Torque wrench
 
Depth gauge
 
Straight edge
 

  1. Remove the engine and transaxle assembly, as outlined in this section.
  2.  
  3. Remove drive plate, by holding the vibration damper with counter support T10069, then removing the mounting bolts.

    Click image to see an enlarged view

    Fig. Remove drive plate, by holding the vibration damper with counter support T10069, then removing the mounting bolts

  4.  
  5. Loosen drive plate securing bolts using a criss-cross sequence and remove them.
  6.  
  7. Remove the drive plate.
  8.  

To install:

  1. Position the drive plate on crankshaft
  2.  
  3. Insert at least 3 old bolts and tighten them to 22 ft. lbs. (30 Nm).
  4.  
  5. Check dimension (a) at three points, as shown in the illustration, and calculate average value. The proper specification is: 15.7-1605mm. If results are not within specifications, perform the following:

    Click image to see an enlarged view

    Fig. Check dimension (a) at three points, as shown, and calculate the average value

    1. Remove the drive plate again, then use a proper sized shim to obtain the proper dimension.
      NOTE
      Only one shim of the appropriate thickness may be used for compensation.



      Click image to see an enlarged view

      Fig. Use a suitable shim (1) to get the proper dimension

    2.  

  6.  
  7. Once proper specifications are met, perform the following:
    1. Insert new mounting bolts and hand tighten.
    2.  
    3. Install drive plate; use new mounting bolts and tighten to 44 ft. lbs. (60 Nm) plus 1 / 4 turn (90°), in several steps.
    4.  

  8.  
  9. Install the engine and transaxle into the vehicle, as outlined in this section.
  10.  

4.0L Engine

NOTE
This procedure requires the use of the following tools, or their equivalents.



Counter-Holder Tool T10069
 
Torque Wrench (40 to 200 Nm) V.A.G 1332
 
Depth Gauge
 
Straight edge
 

  1. Remove the engine and transaxle assembly, as outlined in this section.
  2.  
  3. Remove drive plate. To do this, lock vibration damper with Counter-Holder Tool T10069.

    Click image to see an enlarged view

    Fig. To remove or install the drive plate, you must lock the vibration damper with Counter-Holder Tool T100069

  4.  
  5. Loosen the drive plate securing bolts in a criss-cross pattern and remove them .
  6.  
  7. Remove the drive plate.
  8.  

To install:

  1. Install the drive plate on crankshaft.
  2.  
  3. Insert at least 3 of the old securing bolts and tighten to 22 ft. lbs. (30 Nm).
  4.  
  5. Check the dimension (a) through holes for securing torque converter using a straight edge and depth gauge and calculate the average.

    Click image to see an enlarged view

    Fig. Check the dimension (a) through holes for securing torque converter using a straight edge and a depth gauge and calculate average

  6.  
  7. Compare the average (measured distance plus an additional thickness of straightedge) with specification. The proper specification is 18.1-19.7 mm. If the measurement is outside of the specification, perform the following:
    1. Remove the drive plate again, then use a suitable sized shim to get the proper dimension.
      NOTE
      Only one shim of the appropriate thickness may be used for compensation.

    2.  

  8.  
  9. Once the specification is achieved:
    1. Insert new securing bolts and tighten by hand.
    2.  
    3. Install drive plate. To do this, lock vibration damper with Counter-Holder Tool T10069.
    4.  
    5. Tighten the mounting bolts to 45 ft. lbs. (60 Nm), plus an additional 90° ( 1 / 4 turn). The additional turn may be performed in several steps.
    6.  

  10.  
  11. Install the engine and transaxle assembly.
  12.  

 
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