Volkswagen Front Wheel Drive 1974-1989 Repair Guide

Flywheel

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3

For Rabbit, Scirocco, Golf and Jetta models equipped with manual transaxles, please refer to the clutch procedures in Drive Train for flywheel removal and installation.

  1. Remove the transaxle from the vehicle.
  2.  
  3. Mark the flywheel so it can be installed in the same position. As you are removing the flywheel, also make a note as to which side the shim and washer faces. These shims/washers may either have notches cut into them or have a chamfered edge and must be installed correctly.
  4.  
  5. The flywheel bolts are secured with a thread locking compound and can be difficult to remove. VW tool 558 or an equivalent flywheel locking tool can be used to keep the flywheel from turning.
  6.  
  7. Remove the bolts, then remove the flywheel. Clean the thread locking compound out of the bolt holes in the crankshaft with a tap.
  8.  

Bolts with a raised shoulder and stretch-type bolts must be replaced anytime they are removed. Be sure to install new ones.



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Fig. Fig. 1: Make a note as to which side the shim (2) and washer (1) face



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Fig. Fig. 2: Bolts with and without shoulder. Bolts with the shoulder must always be replaced



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Fig. Fig. 3: A depth caliper can be used to check the flywheel-to-engine block clearance. On 5-cylinder models, it will also be necessary to measure the raised area inside the flywheel

To install:
  1. On Quantum, Fox and Dasher models equipped with manual transaxles, coat the threads of the flywheel bolts with Loctite® or a similar thread locking compound. Tighten to 55 ft. lbs. (75 Nm) for bolts without shoulders or 74 ft. lbs. (100 Nm) for bolts with shoulders. Remember, shoulder bolts cannot be reused, always replace them.
  2.  
  3. On automatic transaxle models, the flywheel-to-engine block clearance must be checked:
    1. Temporarily install the flywheel with only 2 bolts.
    2.  
    3. On 4-cylinder models, 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 (30.6-32.0mm). Remove the flywheel and change the shims as required.
    4.  
    5. On 5-cylinder models, use a depth caliper to measure the distance between the raised rim above the ring gear and the cylinder block on both sides. This is the outside measurement. Now use the depth caliper to measure from the raised rim (above the ring gear) to the raised area inside the flywheel. This is the inside measurement. Subtract the outside measurement from the inside measurement. It should be between 0.677-0.741 inches (17.2-18.8mm). If not, remove the flywheel and change the shim as required.
    6.  

  4.  
  5. Install the flywheel and apply Loctite® or a similar thread locking compound to the bolts. On 1985 and later Jetta and Golf models, stretch-type bolts are used. Tighten them to 22 ft. lbs. (30 Nm) plus an additional 1 / 4 turn. On other models, tighten the bolts without shoulders to 55 ft. lbs. (75 Nm) and the bolts with shoulders to 74 ft. lbs. (100 Nm). Once again, keep in mind that shoulder bolts and stretch-type bolts cannot be reused, always replace them.
  6.  
  7. Install the transaxle.
  8.  

 
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