Volkswagen Cars 2000-05

Flywheel/Flexplate & Ring Gear

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Removal & Installation




NOTE
The flywheel bolts are stretch bolts and cannot be used again once they have been removed. Make sure new bolts are on hand before removing the flywheel.

  1. On automatic transaxles, mark the flywheel so it can be installed with the same face towards the transaxle.
  2.  
  3. The flywheel bolts are secured with a thread locking compound and will be difficult to remove. Use VW tool 558 or an equivalent locking tool to hold the flywheel from turning.
  4.  
  5. Remove the bolts and remove the flywheel. Clean the thread locking compound out of the bolt holes in the crankshaft with a tap.
  6.  
  7. Before installing the automatic transaxle flywheel:

    Temporarily install the flywheel with only 2 bolts.
     
    Use a depth caliper to measure the distance between the outer face of the ring gear and the cylinder block.
     
    The distance must be 1.20-1.28 inches (30.6-32mm). Remove the flywheel and change the shims as required.
     
    Install the flywheel and apply a thread locking compound to the bolts. Torque the bolts in the sequence shown to 22 ft. lbs. (30 Nm). After tightening all the bolts, tighten them an additional 1 / 4 turn in the same sequence.
     

  8.  


NOTE
The flywheel bolts are stretch bolts and cannot be used again once they have been removed. Make sure new bolts are on hand before removing the flywheel.

  1. Remove the engine and/or transaxle as necessary.
  2.  
  3. On automatic transaxles, mark the flywheel so it can be installed with the same face towards the transaxle and carefully keep track of the location the shim and thrust plate and where they were removed from.
  4.  
  5. Use VW tool 558, or an equivalent, locking tool to hold the flywheel from turning.
  6.  
  7. Remove the bolts and remove the flywheel. If necessary clean the bolt holes in the crankshaft with a tap.
  8.  

To Install :


NOTE
New bolts must be installed! If measuring drive plate installed height using a new bolt, Do NOT torque above 44 ft. lbs. (60 Nm) until completion.

  1. Before installing the automatic transaxle drive plate:
  2.  
    1. Temporarily install the flywheel with 3 bolts.
    2.  
    3. Use a depth caliper to measure the distance between the outer face of the ring gear and the cylinder block.
    4.  


The distance must be:



1.8L engines: 1.024-1.102 inches (26-28mm)
 
2.0L (9A) DOHC engines: 1.20-1.28 inches (30.6-32mm)
 
2.0L (ABA) SOHC engines: 0.768-0.831 inch (19.5-21.1mm)
 
2.8L VR6 engines: 0.618-0.650 inch (15.7-16.5mm)
 
2.8L SOHC (AFC) V6 engines: 0.713-0.776 inch (18.1-19.7mm)
 
2.8L 5V DOHC V6 engines: 0.484 inch (12.3mm)
 

  1. Remove the flywheel and replace the shim as needed. Only one shim can be used, they cannot be stacked.
  2.  

  1. Install the flywheel/drive plate using new bolts and torque evenly using a crisscross pattern as follows:
  2.  

1.8L engine:

Manual transmission:



Step 1: 44 ft. lbs. (60 Nm)
 
Step 2: 180° ( 1 / 2 turn)
 

Automatic transmission:



Step 1: 44 ft. lbs. (60 Nm)
 
Step 2: 90° ( 1 / 4 turn)
 

2.0L DOHC (9A) engine:



Step 1: 37 ft. lbs. (50 Nm)
 
Step 2: 74 ft. lbs. (100 Nm)
 

2.0L SOHC (ABA) engine:



Step 1: 44 ft. lbs. (60 Nm)
 
Step 2: 90° ( 1 / 4 turn)
 

2.8L VR6 engine:



Step 1: 44 ft. lbs. (60 Nm)
 
Step 2: 90° ( 1 / 4 turn)
 

2.8L V6 engine:

Manual transmission:



Step 1: 44 ft. lbs. (60 Nm)
 
Step 2: 180° ( 1 / 2 turn)
 

Automatic transmission:



Step 1: 44 ft. lbs. (60 Nm)
 
Step 2: 90° ( 1 / 4 turn)
 

 
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