How to change clutch kit on VW Jetta Mk2 (19E, 1G2, 165) – replacement guide
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Recommended replacement interval for the part category Clutch kit : 100000km
Important!
This replacement procedure can be used for:
VW Jetta II (19E, 1G2, 165) 1.3,
VW Jetta II (19E, 1G2, 165) 1.3 Cat,
VW Jetta II (19E, 1G2, 165) 1.3
…
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The steps may slightly vary depending on the car design.
This video shows the replacement procedure of a similar car part on another vehicle
All the parts you need to replace – Clutch Kit for Jetta II (19E, 1G2, 165) and other VW models
Take care to prevent the gearbox from being unsupported (hanging).
Step 41
Clean the gearbox mount fasteners. Use a wire brush. Use WD-40 spray.
Step 42
Unscrew the gearbox mount fasteners. Use a drive socket #18. Use a ratchet wrench.
Step 43
Unscrew the fastener that connects the gearbox mount to the car body. Use a drive socket #13. Use a ratchet wrench.
Step 44
Remove the gearbox mount.
Step 45
Unscrew the fasteners that connect the bottom gearbox mount to the gearbox. Use a combination spanner #16.
Step 46
Remove the bottom gearbox mount.
Step 47
Unscrew the fasteners that connect the gearbox to the engine block. Use a drive socket #18. Use a ratchet wrench.
Step 48
Move the gearbox aside.
Replacement: clutch kit – VW JETTA II (19E, 1G2, 165). Tip from AUTODOC:
Make sure the gearbox is reliably secured.
Step 49
Remove the support from under the gearbox.
AUTODOC recommends:
Replacement: clutch kit – VW JETTA II (19E, 1G2, 165). Lower the transmission jack smoothly, without jerks, to avoid damaging components and mechanisms.
Step 50
Remove the gearbox.
Step 51
Remove the release bearing. Use a crowbar.
Step 52
Unscrew the pressure plate fasteners. Use 12-point socket No.9. Use a ratchet wrench.
Step 53
Remove the pressure plate together with the clutch disc. Use a crowbar.
Step 54
Clean the clutch kit mounting seats. Use all-purpose cleaning spray.
Step 55
Install the new pressure plate together with the clutch disc.
Step 56
Screw in the pressure plate fasteners. Use 12-point socket No.9. Use a ratchet wrench.
Screw in the pressure plate fasteners. Use 12-point socket No.9. Use a ratchet wrench.
Step 59
Install the engine flywheel locking tool. Use a clutch tool kit.
Step 60
Tighten the pressure plate fasteners. Use 12-point socket No.9. Use a torque wrench. Tighten it to 27 Nm torque.
Step 61
Remove the flywheel locking tool.
Step 62
Treat the release bearing mounting seat. Use a multipurpose grease.
Step 63
Install the new release bearing.
Step 64
Support the gearbox. Use a hydraulic transmission jack.
Step 65
Install the gearbox.
Replacement: clutch kit – VW JETTA II (19E, 1G2, 165). Tip from AUTODOC:
Take care to prevent the gearbox from being unsupported (hanging).
Step 66
Refit the gearbox to its mounting seat.
Step 67
Screw in the fasteners that connect the gearbox to the engine block. Use a drive socket #18. Use a ratchet wrench.
Step 68
Tighten the fasteners that connect the gearbox to the engine block. Use a drive socket #18. Use a torque wrench. Tighten it to 64 Nm torque.
Step 69
Install the lower gearbox mount.
Step 70
Screw in the fasteners that connect the gearbox mount to the gearbox. Use a combination spanner #16.
Step 71
Tighten the fasteners that connect the gearbox mount to the gearbox. Use a combination spanner #16. Use a torque wrench. Tighten it to 64 Nm torque.
Step 72
Install the gearbox mount.
Step 73
Screw in the fasteners that connect the gearbox mount to the car body. Use a drive socket #18. Use a ratchet wrench.
Step 74
Tighten the fasteners that connect the gearbox mount to the car body. Use a drive socket #13. Use a torque wrench. Tighten it to 38 Nm torque.
Step 75
Tighten the fasteners that connect the gearbox mount to the gearbox. Use a drive socket #18. Use a torque wrench. Tighten it to 69 Nm torque.
Step 76
Remove the support from under the gearbox.
AUTODOC recommends:
Replacement: clutch kit – VW JETTA II (19E, 1G2, 165). Lower the transmission jack smoothly, without jerks, to avoid damaging components and mechanisms.
Step 77
Install the gearbox mount.
Step 78
Screw in the fasteners that connect the gearbox mount to the subframe. Use a drive socket #13. Use a ratchet wrench.
Step 79
Tighten the fasteners that connect the gearbox mount to the subframe. Use a drive socket #13. Use a torque wrench. Tighten it to 49 Nm torque.
Step 80
Tighten the fasteners that connect the gearbox mount to the gearbox. Use a combination spanner #16. Use a drive socket #16. Use a torque wrench. Tighten it to 75 Nm torque.
Step 81
Tighten the fasteners that connect the gearbox to the engine block. Use a drive socket #18. Use a torque wrench. Tighten it to 64 Nm torque.
Step 82
Attach the gear shift cable retaining clip.
Step 83
Screw in the gear shift cable fastener. Use a drive socket #13. Use a ratchet wrench.
Step 84
Screw in the fastener of the cable bracket. Use a drive socket #16. Use a ratchet wrench.
Step 85
Tighten the fastener of the cable bracket. Use a drive socket #16. Use a torque wrench. Tighten it to 22 Nm torque.
Step 86
Clean the CV joint mounting seat. Use all-purpose cleaning spray.
Step 87
Install the drive shaft.
Step 88
Screw in the fasteners of the CV axle inner joint. Use XZN #8. Use a ratchet wrench.
Step 89
Clean the splines of the drive shaft CV joint. Use a wire brush. Use WD-40 spray.
Step 90
Install the steering knuckle on the CV axle.
Step 91
Attach the ball joint to the control arm. Use a pin punch.
Step 92
Screw in the fastener connecting the ball joint to the control arm. Use a drive socket #13. Use a ratchet wrench.
Step 93
Tighten the fasteners of the CV axle inner joint. Use XZN #8. Use a torque wrench. Tighten it to 42 Nm torque.
Step 94
Install the fastening nut.
Step 95
Screw in the nut of the CV axle. Use a drive socket #30. Use a ratchet wrench.
Step 96
Tighten the fasteners connecting the ball joint to the control arm. Use a drive socket #13. Use a torque wrench. Tighten it to 55 Nm torque.
Step 97
Attach the transmission sensor connector.
Step 98
Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 99
Clean the brake disk surface. Use a brake cleaner.
AUTODOC recommends:
Replacement: clutch kit – VW JETTA II (19E, 1G2, 165). After applying the spray, wait a few minutes.
Step 100
Install the wheel.
AUTODOC recommends:
Important! Hold the wheel while screwing in the fastening bolts. VW JETTA II (19E, 1G2, 165)
Step 101
Screw in the wheel bolts. Use wheel impact socket #17.
Step 102
Lower the car.
Step 103
Tighten the drive shaft nut. Use a drive socket #30. Use a torque wrench. Tighten it to 175 Nm torque.
Step 104
Tighten the wheel bolts using a criss-cross pattern. Use wheel impact socket #17. Use a torque wrench. Tighten it to 120 Nm torque.
Step 105
Remove the jacks and chocks.
Step 106
Remove the engine support beam.
Step 107
Tighten the fasteners that connect the gearbox to the engine block. Use a drive socket #18. Use a torque wrench. Tighten it to 64 Nm torque.
Step 108
Tighten the engine starter fasteners. Use a drive socket #13. Use a torque wrench. Tighten it to 29 Nm torque.
Step 109
Attach the engine wiring harness.
Step 110
Connect the ground wire.
Step 111
Screw on the ground wire fastener. Use a combination spanner #13.
Step 112
Treat the engine wiring harness connectors. Use dielectric grease.
Step 113
Connect the engine wiring harness connector.
Step 114
Attach the clutch cable.
Step 115
Install the battery tray.
Step 116
Screw in the battery tray fasteners. Use a drive socket #10. Use a ratchet wrench.
Step 117
Install the battery.
Step 118
Screw in the battery fastener. Use a drive socket #13. Use a ratchet wrench.
Step 119
Attach the terminals to the battery.
Replacement: clutch kit – VW JETTA II (19E, 1G2, 165). Tip from AUTODOC:
Be careful! Do not mix up the positive and the negative terminals of the car battery.
Step 120
Screw in the fasteners of the battery terminals. Use a drive socket #10. Use a ratchet wrench.
Step 121
Treat the battery terminals. Use dielectric grease.
Step 122
Run the engine for a few minutes. This is necessary in order to make sure that the component operates properly.
Step 123
Shut off the engine.
Step 124
Remove the fender protection cover.
Step 125
Close the hood.
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