VOLKSWAGEN GOLF IV

since 1997 of release

Repair and car operation



Foltsvagen Golf 4
+ 1. Maintenance instruction
+ 2. Engine
+ 3. Cooling system
+ 4. Fuel system
+ 5. Exhaust system
+ 6. Ventilation and heating system
- 7. Coupling
   + 7.1. Coupling disk
   + 7.2. A coupling disk on cars with engines 1,4 and 1,6-I
   + 7.3. Air removal from a hydraulic drive of coupling
   7.4. Main malfunctions of coupling
+ 8. Transmission
+ 9. Suspension brackets and power shafts
+ 10. Steering
+ 11. Wheels and tires
+ 12. Brake system
+ 13. Body
+ 14. Electric equipment and electroschemes






7. Coupling

GENERAL INFORMATION

Flywheel and coupling disk on models with the engine 1,8-I



1–flywheel;
2–coupling disk;
3–press disk;
4–bolt, 25 Nanometers

Hydraulic drive couplings (engine 1,8-I)

1–popolnitelny tank of brake system;
2–hydraulic hose;
3–main cylinder of coupling;
4–earring;
5–coupling pedal;
6–самоконтрящаяся six-sided nut, 25 Nanometers. At installation it is necessary to use a new nut;
7–arm;
8–pipeline;
9–support;
10-protective cap;
11-pumping union;
12-working cylinder of coupling;
13-a bolt with a fillet, 25 Nanometers;
14-transmission case;
15-spring bracket;
16-clip;
17-pipeline;
18-pipeline connection;
19-sealing ring of round section. Before installation grease a sealing ring with brake liquid;
20-spring bracket

Coupling of cars with engines 1,4-/1,6-I

1–bolt, 20 Nanometers. A tightening of bolts make evenly crosswise;
2–flywheel. The surface interfaced to a disk of coupling should not have flutes and on it there should be no an oil and greasing. Flywheels of two standard sizes are used. They differ on color in designation of carving jams in a coupling case;
3–coupling disk. Grease shlitsa of a disk of coupling with greasing on the basis of a molybdenum disulfide. The layer of greasing should be thin and uniform, otherwise at coupling work excessive greasing will be rejected on working surfaces of coupling that can break its work;

  4–a pushing bar of coupling. It is necessary to grease in the field of the directing plug in a power shaft;
5–lock ring;
6–plate. The basic surface of the plate contacting to pushing bar, grease with a thin layer of greasing on the basis of a molybdenum disulfide;
7–a bolt, 60 Nanometers + to tighten on a corner 90 °. At installation it is necessary to use new bolts;
8–steel plate;
9–press disk. The minimum wear inside – 0,2 mm

The mechanism of switching off of coupling on models 1,4-/1,6-I

1–cover. For removal by the pointed punch punch a cover and, using a punch as the lever, remove it. For installation degrease interfaced surfaces of a cover. Using the corresponding opravka, establish a cover into place;
2–bearing of switching off of coupling. Replacement of the bearing can be made, without removing a transmission;
  3–lever of switching off of coupling. Remove safety spring brackets 5 and take a shaft 9;
4–plug;
5–spring safety bracket;
6–support;
7–plug;
8–sealing ring;
9–shaft;
10-transmission case;
11-maslonalivny stopper

Coupling on cars with engines 1,8-/1,9-/2,3-l

1–transmission case;
2–a hairpin with a spherical tip, 25 Nanometers. The spherical tip is greased with greasing on the basis of a molybdenum disulfide;
3–sealing ring of a power shaft. Installation of a sealing ring is made against the stop;
4–the directing plug. The sealing ring of the directing plug is not replaced separately. A surface interfaced to the vyzhimny bearing, grease with a thin layer of greasing on the basis of a molybdenum disulfide;
5–spring latch;
6–bolt, 20 Nanometers;
7–lever of switching off of coupling. All contacting surfaces of the lever grease with a thin layer of greasing on the basis of a molybdenum disulfide;

  8–bearing of switching off of coupling. Do not wash out vyzhimny the bearing in solvent as from it greasing will be washed up. The bearing publishing noise at rotation, it is necessary to replace;
9–bolt, 20 Nanometers;
10-working cylinder of coupling;
11-pusher. Greasing is put on a head of a pusher on the basis of a molybdenum disulfide;
12-assembly screw. The assembly screw holds the lever of switching off of coupling at transmission installation. After transmission installation the screw is necessary for unscrewing. As the adjusting screw it is possible to use bolt М8х35

Coupling is located between the engine and a transmission and intended for separation and connection of a cranked shaft of the engine and primary shaft of a transmission. Coupling is an integral part of transmission for ensuring deduction of the car concerning the road by the included transfer, a smooth troganiye of the car from a place and gear shifting without noise and risk of damage of details.

At the included coupling i.e. when the pedal of coupling is in the top situation, the tarelchaty spring of a leading part of coupling moves press a coupling disk towards the engine. Thus the disk of coupling supplied with frictional slips, is clamped between a press disk and a flywheel, and the torque is transferred from the engine to a transmission. By pressing of a pedal of coupling the persistent bearing of coupling moves press a disk back. The coupling disk then the shaft of the engine and a shaft of a transmission can rotate independently from each other is thus released.

On all models dry one-disk coupling which consists of a disk of coupling, a press disk, a tarelchaty spring, a casing and the press bearing is established.

The coupling disk freely moves on shlitsa of primary shaft of a transmission and is clamped between a flywheel and a press disk effort which is created by a tarelchaty spring. From two parties of a disk of coupling приклепаны frictional slips. The leading part of a disk of coupling incorporates to a nave through details of a quencher of krutilny fluctuations which provides elastic communication between them.

Need of a quencher of krutilny fluctuations is caused by the following. At sharp change of speed of movement of the car, arrival on roughness of the road, sharp inclusion of coupling, and also owing to non-uniform operation of the engine in transmission of the car there are the dynamic loadings causing a twisting (raskruchivaniye) of shaft of transmission. Unevenness of a torque of the engine can cause considerable overloads in transmission owing to emergence of krutilny fluctuations and a resonance at coincidence of the frequencies, being transferred loadings to frequencies of own fluctuations of transmission. Elastic fluctuations of transmission lead not only to noise emergence in mechanisms and units, but also to dangerous vibrations, and sometimes and to breakages of details when the amplitude of fluctuations reaches big size. Energy of krutilny fluctuations is absorbed by a quencher.

The bearing is established by Vyzhimna from the forward party of a transmission. Moving of the bearing is made by the lever of switching off of coupling. The pressing of a pedal of coupling moves the piston in the main cylinder and compresses liquid which on a hose is transferred to the working cylinder of coupling. Under pressure the piston of the working cylinder of coupling moves and puts in action the lever of switching off of coupling. The lever of switching off of coupling moves vyzhimny the bearing which influences a spring of a press disk and takes away press a disk from a coupling disk. Adjustment of coupling occurs automatically.

Depending on a design of the flywheel established on the engine, various disks of coupling are used. If the flywheel consisting of two sections with a spring and dempfiruyushchy system is established, the coupling disk without springs of a quencher of fluctuations is established. If on the engine the flywheel consisting of one detail is established, the disk of coupling with springs of a quencher of fluctuations (a classical disk of coupling) is established.

If on the car the flywheel consisting of two sections is established, the coupling disk without springs of a quencher of fluctuations is established.

If the flywheel consists of one detail, the disk of coupling with springs of a quencher of fluctuations is established, and springs should be from a press disk.

Disk installation

PERFORMANCE ORDER
1. Grease shlitsa of a disk of coupling with a thin layer of greasing on the basis of a molybdenum disulfide. The layer of greasing should be thin and uniform, otherwise at coupling work excessive greasing will be rejected on working surfaces of coupling that can break its work.
2. A tightening of bolts make gradually and evenly in diagonal sequence.
3. On models with a flywheel with the doubled weight bolts with the internal shestigrannik, which moment of a tightening of 13 Nanometers are used.