Fault Finding, Power Transmission

Service
Workshop Manual
Polo Classic 2002 ➤
Fault finding, Power transmission
Edition 11.2007
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups AG. Volkswagen AG d
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Repair Group
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30 - Clutch
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34 - Controls, housing
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg SAR5R010820

Fault finding, Power transmission - Edition 11.2007
Contents
30 - Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Complaints regarding clutch and clutch mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Checking clutch mechanism (slave cylinder is bolted from outside on clutch housing) . . . . 7
1.2 Checking clutch mechanism (slave cylinder is located inside clutch housing) . . . . . . . . . . 8
34 - Controls, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Complaints regarding the selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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atio
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Contents i
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nf
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orm
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or c
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ii Contents
30 – Clutch
1 Complaints regarding clutch and
clutch mechanism
Note
Checking clutch mechanism ⇒ page 7 .
Before carrying out any clutch repairs, the customer complaint

must always be checked and the cause traced. When doing this,
check whether the complaint is actually attributable to the clutch
or whether adjustment of the selector mechanism is the cause of
the problem.
The repair measures listed in this fault finding programme are to
be carried out as described in the relevant workshop manuals.
Complaint Fault description Measure
Clutch pedal does not return to orig‐ ♦ Air in line system – Bleed line system; replenish
inal position brake fluid.
♦ Line system, master or slave – Renew defective part, bleed line
cylinder leaking. system; replenish brake fluid.
AG. Volkswagen AG d
agen oes
olksw ♦ Return spring (if fitted)not defec‐ – Renew return spring.
y V gu
b
rised tive. ara
ntee
ho
aut or
a
ss ♦ Actuator elements in bell hous‐ c – Clean, lubricate bearing points.
ing stiff. Repair bearing as necessary.
ce
e
nl
pt
du
an
itte
y li
♦ Clutch release bearing canted – Renew guide sleeve and re‐

erm
ab
on guide sleeve, worn. lease bearing.

ility
ot p
wit
, is n
♦ Diaphragm spring of pressure – Renew pressure plate.

h re
hole
plate broken.
spec
es, in part or in w
t to the co

rrectness of i
Actuation pressure at clutch pedal ♦ Over-centre spring defective. – Renew over-centre spring.
l purpos
too high
♦ Return spring (if fitted) too – Allocate return spring according
nform
ercia
strong, incorrect return spring. to ⇒ Electronic parts catalogue

“ETKA” .
m
at
om
ion
♦ Clutch release pressure in‐ – Explain situation to customer

c
in t
or
creased due to wear in clutch (release pressure rises as wear

his
ate
friction linings. increases).

do
priv
cum
for
– Renew clutch plate if distance

en
ng
t.
yi
from lining to rivet is less than
Co
Cop py
0.1 mm.
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♦ Actuator elements in bell hous‐ – Clean, lubricate bearing points.
co Vo
by lksw
cted
ing stiff. Repair bearing bushes as nec‐
agen
Prote AG.
essary.
♦ Clutch release bearing canted – Renew defective parts.
on guide sleeve, worn.
♦ Contact surface of release bear‐ – Renew defective parts.

ing/release lever worn/scored.
1. Complaints regarding clutch and clutch mechanism 1


♦ Pressure plate has incorrect – Allocate according to ⇒ Elec‐
spring rating. tronic parts catalogue “ETKA” .
♦ Clutch plate stiff/sticking on – Check splines on hub for dam‐

spline. age (burrs). Renew clutch plate
as necessary.
– Clean splines of hub and input

shaft of corrosion and lubrica‐
agen AG tion
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agen AG and lubricate with
does
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olksw grease -G 000 100-
not
gu . Move
ed b clutch plate back andaraforth, re‐
nte
oris move excess grease. eo
h
aut ra
Manual gearboxs 02K only:
s – Lubricate contact points lightly c
ce
♦ Clutch push rod and release with -G 000 100- .
e
nl
pt
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plate (pressure plate) stiff.
an
itte
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– Lubricate clutch push rod lightly.
erm
ab
ility
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hole
spec
es, in part or in w
Noises when clutch is depressed “Only Sharan:” – Clean, lubricate bearing points.
t to the co
♦ Clutch pedal stiff, bearing points Repair bearing as necessary.
misaligned.
rrectness of i
♦ Over-centre spring bearing dry,
stiff, misaligned.
l purpos
♦ Return spring (if fitted) causing – Grease bearing points.
nform
ercia
noises.
m
at
om
♦ Release bearing defective, – Always renew noisy release
ion
c
guide for release bearing not bearings.
in t
or
OK, contact surface worn.
his
ate
– Renew guide sleeves if dam‐
do
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c
aged.
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for
en
ng
t.
♦ Contact surface (diaphragm – Renew pressure plate.
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spring ends) of pressure plate . C rig
ht ht
defective (bent, broken). Re‐ – Check and, if necessary, renew
rig by
opy Vo
lease bearing off-centre. release bearing and guide
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cted agen
sleeve.
Prote AG.
– Check position of release lever.
– Check locating sleeves.

♦ Needle roller bearing in crank‐ – Renew, lubricate with MoS2
shaft (if fitted) defective. Offset grease.
engine/gearbox.
♦ Clutch plate installed wrong way – Rectify installation position.
round.
♦ Incorrect clutch plate installed. – Allocate clutch plate according

to ⇒ Electronic parts catalogue
“ETKA” .

Scratching noises when engaging ♦ Air in system, clutch does not – Bleed system; check system, re‐
forwards or reverse gear, selector separate fully. plenish brake fluid.
mechanism sticking, catching, stiff,
gear selection not possible, clutch
has no function
2 Rep. Gr.30 - Clutch


♦ Master/slave cylinder, lines – Renew defective part, top up
leaking. brake fluid, bleed system.
♦ Travel of clutch pedal insuffi‐ – Explain situation to customer.

cient (carpet, foot mat under
pedal), clutch does not fully de‐
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agen press. oes
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db ara
ir se ♦ Pressure plate unevenntedue
ho e o to – Check parts, renew as necessa‐
aut faulty installation, clutch plate
ra
c
ry, observe position of centring
ss warped due to improper han‐ pins.
ce
le
dling.
un
pt
an
– If scratching still occurs, check
d
itte
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splines of clutch plate on input
erm
ab
shaft for ease of movement,
ility
ot p
check needle roller bearing in
wit
is n
crankshaft, repair transmission
h re
ole,
if necessary.
spec
♦ Diaphragm spring ends broken – Renew pressure plate.
t to the co
off or bent (faulty installation, re‐
lease bearing offset). – Check and, if necessary, renew
release bearing, guide sleeve.
rrectne
ss
Manual gearbox 02K only – Renew push rod, check release
o
cial p
f
♦ Push rod too short due to wear. bearing, renew as necessary.
inform
mer
– Lubricate contact points of push

atio
m
rod/release bearing lightly with

o
n
c
i
grease -G 000 100- .
or
n thi
te
sd
a
♦ Clutch plate too thick. – Allocate clutch plate according

iv
o
pr

um
r
fo
“ETKA” .
en
ng
t.
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op
♦ Lining seized on flywheel – Lightly rub down friction surfa‐
C py
t. rig
(parked up for long period, high ces of clutch linings or, in event
gh ht
pyri by
level of humidity). of heavy corrosion, renew part
co Vo
by lksw
cted
completely.
agen
Prote AG.
♦ Clutch plate stiff/sticking on – Check splines on hub for dam‐

spline. Hub corroded, damaged age. Renew clutch plate as nec‐
during installation. Hub profile essary.
misaligned on one side.
– Remove corrosion and deposits
of grease from hub and shaft.
Lubricate shaft lightly with
grease -G 000 100- .
– Move clutch plate back and

forth, remove excess grease.
– Check position of locating

sleeves if hub profile is mis‐
aligned.
– Check and, if necessary, renew

release bearing, guide sleeve,
pressure plate and needle roller
bearing.
♦ Pressure plate lift insufficient – Allocate pressure plate accord‐
(incorrect pressure plate instal‐ ing to ⇒ Electronic parts cata‐
led). logue “ETKA” .


♦ Needle roller bearing in crank‐ – Renew needle roller bearing
shaft (if fitted) defective. Input and lubricate with MoS2 grease.
shaft picked up by crankshaft
when clutch is depressed. – Check locating sleeves and re‐
new if necessary.
– Check input shaft.

♦ Engine/gearbox
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agen Aexces‐
G do – Insert locating sleeves before in‐
wage
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olks (locating sleeves missing)
es n
ot g stalling gearbox.
d b causing carrier plate of clutch uara
ir se nte
ho plate to bend. Needle roller – Check
eo clutch plate, pressure
ut
ss
a bearing in crankshaft (if fitted) plate
ra
c and needle roller bearing
defective. for damage and renew as nec‐
ce
le
un
essary.
pt
an
d
itte
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♦ Linings flown off due excessive‐ – Renew clutch plate. Explain sit‐
rm
ab
ly high speed (changing down uation to customer.
pe
ility
when speed is too high).
ot
wit
, is n
h re
♦ Linings flown off due to clutch
hole
spec
being allowed to slip too much
es, in part or in w
when pulling away.
t to the co
rrectness of i
l purpos
Load change jolts from acceleration ♦ Assembly mounting too soft. – Explain situation to customer.
and abrupt reduction in engine Allocate mounting according to
nform
ercia
speed ⇒ Electronic parts catalogue

m
“ETKA” , renew as necessary.
a
com
tion in
♦ Lumpy engine (not running – Check, rectify engine setup.
r
te o
smoothly).
thi
s
iva
do
r
rp
♦ Clutch plate installed with damp‐ – Explain situation to customer.

um
fo
en
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er to prevent loose gears rat‐

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tling.
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♦ Needle roller bearing in crank‐ – Renew needle roller bearing
cop Vo
by lksw
cted
shaft (if fitted) defective. Offset and lubricate with MoS2 grease.
agen
Prote AG.
engine/gearbox.
– Check locating sleeves and re‐
new if necessary.

Clutch slipping, no propulsion or ♦ Wrong clutch plate, wrong pres‐ – Allocate clutch plate and pres‐
propulsion poor sure plate installed. sure plate according to ⇒ Elec‐
tronic parts catalogue “ETKA” .
♦ Clutch plate worn, burnt, pres‐ – Renew clutch plate.
sure plate overheated, scores,
pressure plate warped from faul‐ – Renew pressure plate.
ty installed, contact pressure of
pressure plate insufficient, driv‐ – Explain situation to customer.
ing fault, natural wear.
♦ Actuator elements on gearbox – Clean, lubricate bearing points.

stiff. Repair as necessary.


♦ Clutch plate, pressure plate, fly‐ – Renew clutch plate.
wheel oily. Shaft seal from en‐
gine or gearbox defective. – Clean contact surfaces and
Grease on contact surfaces due pressure plate and clean fly‐
to excessive greasing of hub. wheel.
– Renew shaft seal, remove ex‐

cess grease from input shaft.
Manual gearbox 02K only – Renew seal, clutch plate.
♦ Seal for push rod in input shaft
leaking. Bearing bush for push – Check bearing bush for push
rod in input shaft misaligned. rod, renew as necessary.
– Clean pressure plate, flywheel.

♦ Clutch plate installed wrong way – Rectify installation, check clutch
round. plate, renew as necessary.
♦ Flywheel depth too great or ex‐ – Allocate flywheel according to ⇒

cessive erosion on lining contact Electronic parts catalogue “ET‐
surface. KA” .
– Check clutch plate, pressure

plate, renew as necessary.
♦ Slave cylinder with release – Renew slave cylinder with re‐
bearing leaking. lease bearing.
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Complaint ss
au
Fault description Measure
ac
ce
e
Clutch jolts, ♦ Air in system – Bleed system, check brake fluid

nl
pt
du
assembly shakes level, check for leaks.

an
itte
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erm
ab
– Renew defective part.

ility
ot p
wit
♦ Engine not running well – Check, rectify engine setup.

, is n
h re
hole
spec
♦ Driving fault, pulling away speed – Explain situation to customer.

es, in part or in w
too low.
t to the co
♦ Incorrect clutch plate installed. – Allocate clutch plate according

rrectness of i
“ETKA” .
l purpos
♦ Assembly mounting too soft, – Allocate assembly mounting ac‐

misaligned. cording to ⇒ Electronic parts
catalogue “ETKA” .
nf
ercia
orm
♦ Clutch lining, contact surface of – Check shaft seal of gearbox in‐

m
atio
m
pressure plate and flywheel oily put shaft or crankshaft, renew as

o
n in
c
(oil seeping from clutch hous‐ necessary.

or
thi
ing).
te
sd
iva
– Renew clutch plate, clean pres‐

o
r
rp
cu
sure plate and flywheel.

o
m
f
en
ng
t.
yi
♦ Release bearing canted on – Renew release bearing and
Co
op py
guide sleeve, seized (one-sided guide sleeve.
t. C rig
gh ht
yri
pressure on diaphragm spring of
p by
o Vo
pressure plate). – Check actuator elements and
c by lksw
cted agen
bearings for actuator elements.
Prote AG.


♦ Contact surface of pressure – Check contact surface of clutch
plate has only one-sided lift due lining to flywheel, pressure plate
to canted release bearing. and diaphragm spring, renew
pressure plate as necessary.
♦ Housing of pressure plate war‐
ped during assembly. Contact – Renew release bearing and
surface of pressure plate has guide sleeve.
only one-sided lift.
♦ Input shaft has been packed – Clean grease off pressure plate
with too much grease (signs of and flywheel, renew if there are
grease on clutch plate, pressure signs of damage (rattle marks,
plate and flywheel). signs of overheating, scores).
– Remove traces of grease from

hub and shaft, lubricate shaft
lightly with grease -G 000 100- .
n AG. Volkswagen AG do – Move clutch plate back and
swage es n
olk ot gforth, remove excess grease.
byV ua
ed ran
h
♦
or Slave cylinder with release
is – Checktee threaded connections of
aut
bearing is not flat on bell hous‐ slave cylinder
or
ac to bell housing.
ss ing.
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
“Knocking” noise when depressing ♦ Slow mass/input shaft is accel‐ – Explain situation to customer.
hole
spec
clutch erated by abrupt clutch depres‐
es, in part or in w
sion. Teeth of meshed gear
t to the co
wheels strike; on clutch plates
with damper, noise is amplified
due to damper coming into con‐
rrectness of i
tact.
l purpos
nf
ercia

rm
m
atio
m
Noises at idle ♦ Torsional damper spring bro‐ – Renew clutch plate.

o
n in
c
ken.
or
thi
te
sd
iva
♦ Clutch plate installed without – Install clutch plate with damper.

r
rp
cu
o
damper (rattling at idle).

f
en
ng
t.
yi Co
op py
♦ Pressure plate warped, broken, – Renew pressure plate.
t. C rig
gh ht
yri
unbalanced.
p by
co Vo
by lksw
cted agen
Prote AG.
♦ Lumpy engine (not running – Check engine setup, rectify as
smoothly). necessary.
♦ Engine/gearbox offset too great – Insert locating sleeves before in‐

(locating sleeves missing). stalling gearbox.
♦ Intermediate plate rubbing on – Mount intermediate plate on

flywheel. sealing flange and position on
locating sleeves.

1.1 Checking clutch mechanism (slave cyl‐

inder is bolted from outside on clutch
housing)
– Check if clutch is slipping.
Renew clutch if necessary
“1” The pedal return function must not be hindered by additional
foot mats or foot mats pushed underneath.
“2” Check level of brake fluid in brake fluid reservoir
Note
♦ The clutch hydraulics is connected to the brake fluid reservoir

via a supply hose -arrow 1- and clip -arrow 2-.
♦ If no or very little brake fluid is in this chamber, the system may
be leaking.
“3” Check clutch hydraulics for external leaks:

• The clutch system must be bled
♦ Master cylinder
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♦ Supply hose agen oes
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♦ Line between master cylinder
rise
d and slave cylinder nte
tho eo
♦ Connecting points (clip
ss a fit and threaded connections) also in
u ra
c
areas that cannot be seen.
ce
le
un
pt
an
♦ Slave cylinder
d
itte
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erm
ab
Symptoms for external leaks are, for example, signs of fluid in or

ility
ot p
on noise damper under gearbox.

wit
is n
h re
“4” Check for correct routing of line between master cylinder and
ole,
spec
slave cylinder. The line must not be kinked or trapped.

t to the co
“5” Depress clutch pedal. To do this, the pedal must be depressed

and held over the entire pedal travel in five different positions for
approx. 20 seconds (tests different application pressures in the
rrectne
hydraulic system). A second person thereby checks whether any

fluid escapes at the positions mentioned in “3”. The first position
also checks whether the clutch pedal drops on its own when pres‐
ss
sure is maintained.
o
cial p
f inform
“6” Remove slave cylinder from gearbox. Do not open lines and
mer
check boot for signs of leaking brake fluid.

atio
om
n
c
i
or
Carefully pull boot off plunger -arrow-.

thi
te
sd
va
“7” Check function of clutch mechanism during a road test

i
o
pr
cum
r
fo
en
ng
t.
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Cop py
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co lksw
by
cted agen
Prote AG.

1.2 Checking clutch mechanism (slave cyl‐

inder is located inside clutch housing)
Note
. Volkswagen AG
gen AG d
Only the bleeder -A- is visible
Vol when the slave cylinder is olocated
ksw
a oes
n t
inside the clutch housing.
sed by gu
ara
n
ri tee
ho
ut or
– Check if clutch
ss is slipping.
a ac
ce
e
nl
Renew clutch if necessary
pt
du
an
itte
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“1” The pedal return function must not be hindered by additional
erm
ab
foot mats or foot mats pushed underneath.
ility
ot p
wit
, is n
“2” Check level of brake fluid in brake fluid reservoir
h re
hole
spec
es, in part or in w
t to the co
Note
♦ Note that the clutch hydraulics is connected to the brake fluid
rrectness of i
reservoir via a supply hose -arrow 1- and clip -arrow 2-.
l purpos
♦ If no or very little brake fluid is in this chamber, the system may

be leaking.
nform
ercia
“3” Check clutch hydraulics for external leaks:

m
at
om
ion
c
• The clutch system must be bled

in t
or
his
te
♦ Master cylinder
a
do
priv
cum
or
♦ Line between master cylinder and slave cylinder

f
en
ng
t.
yi Co
♦ Supply hose Cop py
t. rig
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yri
♦ Connecting points (clip fit and threaded connections) also in p by
o Vo
by c lksw
areas that cannot be seen. Prote
cted AG.
agen
Symptoms for external leaks are, for example, signs of fluid in or

on noise damper under gearbox.
“4” Check for correct routing of line between master cylinder and
slave cylinder. The line must not be kinked or trapped.
“5” Depress clutch pedal. To do this, the pedal must be depressed
and held over the entire pedal travel in five different positions for
approx. 20 seconds (tests different application pressures in the
hydraulic system). A second person thereby checks whether any
fluid escapes at the positions mentioned in “3”. The first position
also checks whether the clutch pedal drops on its own when pres‐
sure is maintained.
“6” Remove gearbox. Remove slave cylinder and check for signs
of leaking brake fluid.

Note that on some slave cylinders -A- the supply line is separate
-arrow-.
“7” Check function of clutch mechanism during a road test.
lkswage es n
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d ran
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pt
an
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ility
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wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
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Prote AG.

34 – Controls, housing
1 Complaints regarding the selector
mechanism
Before carrying out any selector mechanism repairs, the custom‐
er complaint must always be checked and the cause traced.
When doing this, check whether the complaint is actually attrib‐
utable to the selector mechanism or its adjustment. It may be
necessary to check whether the complaint originates from the
clutch and clutch mechanism ⇒ page 1 .
The repair measures listed in this fault finding programme are to
be carried out as described in the relevant workshop manuals.
Complaint AG. Volkswagen AG d Fault description Measure
agen oes
ksw
Scratching noises when bengaging
yV
ol ♦ Adjustment of selector
not
gu mecha‐ – Checking and rectifying.
forwards or reverse gear,
rised selector nism. ara
nte
mechanism sticking, utho catching, stiff, eo
ra
gear selection not
ss a possible, clutch c
has no function
ce
le
un
pt
an
♦ Bearing for selector level and – Grease selector mechanism, re‐
d
itte
y li
selector mechanism not lubrica‐ new defective parts.
erm
ab
ted, misaligned.
ility
ot p
wit
is n
♦ Needle roller bearing in crank‐ h re – Renew needle roller bearing

ole,
shaft (if fitted) defective. Input and lubricate with MoS2 grease.
spec
shaft picked up by crankshaft

t to the co
when clutch is depressed. – Check locating sleeves and re‐

new if necessary.
rrectne
– Check input shaft.

♦ Synchronisation and/or selector – Repair gearbox.
ss
mechanism in gearbox defec‐

o
cial p
tive.
inform
mer
atio
om
n
c
i
or
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10 Rep. Gr.34 - Controls, housing

Fault Finding, Power Transmission

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Fault Finding, Power Transmission

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Service

Service Department. Technical Information

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Copyright © 2015 Volkswagen AG, Wolfsburg SAR5R010820

Checking clutch mechanism ⇒ page 7 .

Before carrying out any clutch repairs, the customer complaint

♦ Clutch release bearing canted – Renew guide sleeve and re‐

on guide sleeve, worn. lease bearing.

♦ Diaphragm spring of pressure – Renew pressure plate.

Complaint Fault description Measure

strong, incorrect return spring. to ⇒ Electronic parts catalogue

♦ Clutch release pressure in‐ – Explain situation to customer

creased due to wear in clutch (release pressure rises as wear

friction linings. increases).

– Renew clutch plate if distance

♦ Contact surface of release bear‐ – Renew defective parts.

1. Complaints regarding clutch and clutch mechanism 1

Complaint Fault description Measure

♦ Clutch plate stiff/sticking on – Check splines on hub for dam‐

– Clean splines of hub and input

Complaint Fault description Measure

♦ Return spring (if fitted) causing – Grease bearing points.

♦ Release bearing defective, – Always renew noisy release

guide for release bearing not bearings.

OK, contact surface worn.

– Renew guide sleeves if dam‐

– Check position of release lever.

– Check locating sleeves.

♦ Incorrect clutch plate installed. – Allocate clutch plate according

Complaint Fault description Measure

2 Rep. Gr.30 - Clutch

Complaint Fault description Measure

♦ Travel of clutch pedal insuffi‐ – Explain situation to customer.

check needle roller bearing in

crankshaft, repair transmission

♦ Diaphragm spring ends broken – Renew pressure plate.

– Lubricate contact points of push

rod/release bearing lightly with

♦ Clutch plate too thick. – Allocate clutch plate according

to ⇒ Electronic parts catalogue

♦ Clutch plate stiff/sticking on – Check splines on hub for dam‐

– Move clutch plate back and

– Check position of locating

– Check and, if necessary, renew

1. Complaints regarding clutch and clutch mechanism 3

Complaint Fault description Measure

– Check input shaft.

when pulling away.

speed ⇒ Electronic parts catalogue

“ETKA” , renew as necessary.

♦ Clutch plate installed with damp‐ – Explain situation to customer.

er to prevent loose gears rat‐

Complaint Fault description Measure

♦ Actuator elements on gearbox – Clean, lubricate bearing points.

4 Rep. Gr.30 - Clutch

Complaint Fault description Measure

– Renew shaft seal, remove ex‐

– Clean pressure plate, flywheel.

♦ Flywheel depth too great or ex‐ – Allocate flywheel according to ⇒

– Check clutch plate, pressure

Clutch jolts, ♦ Air in system – Bleed system, check brake fluid

assembly shakes level, check for leaks.

– Renew defective part.

♦ Engine not running well – Check, rectify engine setup.