VW 1.9 TDi Clutch & Flywheel Replacement
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- Опубликовано: 15 июл 2024
- How to replace the clutch on a VAG car based on the MK4 golf platform fitted with the 1.9 TDI
This particular car was a VW new Beetle from 2008 fitted with the 1.9 TDI engine. This is quite a ubiquitous drivetrain and fitted to a sleuth of cars including the Golf, Bora, Caddy, Ibiza, Leon, Toledo, Fabia, Octavia and Audi A3 to name a few. There might be slight variations between these cars but i think VW did maintain a fairly modular design between these cars.
0:00 Introduction
0:27 Opening Bonnet
0:38 Engine and battery cover removal
0:48 Battery Removal
2:24 Air filter housing removal
3:33 Battery tray removal
3:52 Wire track removal
4:50 Starter Removal Part 1
5:37 Gear linkage cables
6:20 Clutch slave cylinder
6:50 Speedometer sensor
7:00 Earth Cable
7:45 Upper Bell-housing bolts
8:10 Wheel Removal
8:24 Driveshaft Removal
12:52 Lower Engine Mount
14:10 Lower Bell-housing Bolts
14:27 Flywheel Cover Plate
14:47 Engine Brace
15:45 Gearbox Mount Removal
16:30 Attempt to remove gearbox with subframe in place
17:32 Removing subframe
18:45 Removing Gearbox
19:06 Pressure plate & flywheel removal
20:00 Installing new flywheel
21:27 Installing new clutch and pressure plate
22:45 Replacing release bearing
23:45 Reinstalling Gearbox
24:35 Reassembly
35:38 Startup and Test Drive 
Авто/Мото
This is hands down the best car repair tutorial I have ever seen. Often the most frustrating thing about a car repair is trying to disconnect those clips without breaking something and the closeup videos and descriptive guide is excellent!! Thank you!!
The detail in this video is great. Thanks for taking the time to do it properly. Makes a great tutorial for anyone attempting it.
Thanks for the comment
Atleast you used a sprung hub clutch with that single mass flywheel. I've seen so many people install a single mass flywheel with the non spring loaded clutch disc. Good job.
I think all came in the one kit?
Best fix-it mechanical video I’ve ever seen! 👍 Distilled to perfection. Thanx for this. Been looking for exactly this for weeks w no good ones found … until now! 🤩
Thank you very much for the comment!
Just did my first clutch on my partners 2008 1.9 Beetle, this video helped me along the way, thank you so much for putting it together, I've learned a lot!
Hi there, well done for the repair great to read that the video helped.
Thank you for all the work you put in to this! Fantastic video!
Sick video! I'm looking to do this clutch and flywheel replacement on my jetta tdi. Very helpful. Thanks for putting this video together. You're a boss!
Thanks for the comment, best of luck with the work on your Jetta
Unfortunately I’m about to do this to 99 beetle and I’m not looking forward to it. But.. this video made me feel just a little bit better about it
How did it go? I’m about to do a 2004 Beetle 1.8T Convertible
I just did my 99 D-bug , this video saved me hours of BS
well done mate. appreciate the effort you put into sharing this video.
sei veramente bravo,i meccanici come te sono sempre piu' rari
Man this is such nice replacement Video. Nice comments, nice views! Thanks a lot, hope you get More appreciation!!
Greetz vom polska👍🏼🇵🇱🇵🇱
Thank you very much for this comment, really makes the effort of making the video worthwhile when people find it useful.
By far the best vid for a MkIV 5spd excellent job
Thanks for the comment, great to read that as i would not be 100% confident working around VAG stuff.
Thanks a lot for your efforts - the work and the video editing...nice.
Thanks for the comment
Thank you so much for this video. It helped me do the clutch on my 2005 VW Beetle 2.0. It is very similar.
Incredibly helpful, you saved our Beetle.
You're welcome! Great to hear that you have got it running again.
@@peugeotCitroen2CV Silver Turbo S that would not budge even an inch but we bought her anyway! What a payoff thanks to you.
Hey thank you so much for this video! I was able to do everything to replace the clutch on my wife’s 99 New beetle 2.0 5speed.
Great to hear you were able to get the beetle running again, well done!
A lot of Work and determination. Amd a lot of Tools and Lifts.
Knowledge.
Good Job.
Thank you so much for this video!! You are amazing for sharing so much information and help thank you for all your hard work!
A million times, thank you. This has been a 3 week project for me. I did everything you did, I think I -may have missed something as now I cant get it started. The dash lights up but nothing when you turn the key to start it. If you have any ideas, I need all the help I can get! If not, once again, A MILLION THANK YOUS!! I was quoted 2000 to replace the flywheel/clutch. Im anxious to get it started to see if I did everything correctly! This is a 1998 Volkswagen beetle 1.9 5 spd
Hi, sorry for the late reply but did you get the car started in the end?
Very straight forward and easy to follow video, very much appreciate your time and effort in making it.
Thanks for the comment, glad you found the video useful
Best video on RUclips on the subject!!!
Thanks for the comment
Thanks ,saved me a lot of guess work .
Glad it helped
Can I just say thanks for this video. I've just removed the gearbox from my tdi beetle. Found the pressure plate had cracked all the way across in 3 places. This video really helped
This is an awesome video! Thank you very much for taking the time to film and post this video.
Thanks for the comment glad to see you found it useful
ottimo video
Thanks
good thanks
Thanks for the comment
WOW
Great video although what was the purpose of removing the track rod ends from the hub? You could have easily left them in and still removed the driveshaft.
Is there a brass coloured ring that looks to go on the shaft? Often cracks etc I don't know name of he part so wanted to ask if it sounded like something you know off I had clutch flywheel changed and guy showed me a ring part it was brass coloured and cracked down the side I need the name of the part to replace it on my mates car he asked me as I had my clutch changed but no one seems to know
Great video.. Did you have to make sure the vehicle was at TDC when doing this clutch/flywheel replacement? I ordered a solid flywheel/clutch kit and was nervous I didn't want to mess anything up on that end. Thanks.
HI there, thanks for the comment.
No there was no need to set the engine to TDC for this job.
@@peugeotCitroen2CV thank you!
Fantastic video and mechanic,all details matter. I wonder how many hours total to do this job.
Thanks for the comment.
With regards the hours, i did this over the Christmas break, the camera work added a fair bit of time to proceedings and i am generally not particularly fast at this. Think it might have been about 3-4 days doing a few hours here and there.
👏👏👏👏👏👏👏
Excellent work! Thanks for sharing this knowledge with us
One question, consider someone who is doing this job on the floor and uses a floor jack to support the oil pan. If the jack slips would the engine fall to the ground :O ?
Hi there, thanks for the comment
It depends on how you support the engine. I wouldnt recommend holding it up just on a jack. Use blocks of wood to supplement the jack, or an engine support bar along the top. If hypothetically the jack was on its own and slipped then the engine will fall, but there is still one engine mount and the exhaust/wires holding it in place. They would probably also get damaged so it is well worth being very careful when supporting the engine for removing the gearbox.
@@peugeotCitroen2CV thank you very much for your explanation!
Dog is super👍
Great video. How much time did it take?
Hi there,
I recall doing it over a weekend i was off work for christmas and agreed to help a mate out in changing this clutch over my time off. Probably took longer because of the videoing process, its a job that probably could be done in a day.
Is this similar to the 2.5l engine
Hi there,
I do not think it is, the 2.5 is it not a V6? Im thinking 2.5 TDI they sold here in possibly the A4 and A6 i think they didnt have the best reputation. Or are you on about the 2.5 petrol engine, we never got that here as far as i am aware.
VAG stuff isnt really my area of expertise.
I need your help!
Hey I broke off two of the three bolts from the gearbox mount bracket. Do you know the part number to buy them please!
Hi there, i do not know the part numbers but you can use this site which is very comprehensive, find your part number and then copy it into google it should give you various options to buy what you are after
www.catcar.info/audivw/?lang=en&l=c3RzPT17IjEwIjoiQnJhbmQiLCIyMCI6IlZXIn18fHN0PT0yMHx8YnJhbmQ9PXZ3
what is the reason for replacing the flywheel?
Why didn't you change the crankshaft oil seal?
The owner complained of a flywheel rattle, he buys/sells cars and wanted this to have a new solid flywheel apparently easier to sell.
Regarding the crankshaft oil seal, an ideal time to change it and if it was my own car i would probably have. However it was not leaking.
How was clutch after?
Hi there, the car drove very well after the clutch was changed. I drove it back to my mates house and he drove it for a few weeks after before selling it on, never heard any complaints about it.
Hey! Best video ever. Saved my @ss more than 10 times. Didnt even end up with extra bolts somehow! Lol
On the other hand, how did you get those tie rod ends off? I got one somehow by soaking it with pen oil and getting it red hot, but the other one wont budge even if my vise grips are tighter than sin. I dont want to replace the inner end either.
Let me know!
Part number?
Luk or sachs?
For 2006 skoda Octavia 1.9 tdi diesel alh 5 speed manual
Hi there
Sorry i cant remember any of those details, the owner of the car brought it round to me with the new clutch and flywheel sitting on the passenger footwell.
It came from a local motor factors so nothing particularly hard to come across.
@peugeotCitroen2CV ok bro but can you tell me tentatively which one is good brand sachs or luk for vw?
@@1.9tdilove71
Im not too sure, i don't work often on VW stuff. Join the forums/owners pages on facebook to judge what owners recommend.
Although either brand should be good, try and do some research to see what originally was fitted.
Where can you get the kit for that price
It was a local motor factors. I think from ringing around a few of them the prices were all in the same ballpark
@@peugeotCitroen2CV thanks for the reply much appreciated
How much would a mechanic charge for this job
I am not too sure, i do not do this as a full time job and dont go to mechanics myself. Rough estimate £150-300, it will vary depending on where you are from, and the cost of the parts you fit will be on top of that.
@@peugeotCitroen2CV Thank you much!
Hello. What is the engine code?
Sorry i dont know, it’s whatever the 1.9 PD the MK4 golf got, not sure what bhp. I was just told it was the ‘good engine’
Pretty sure it’s ALH.
This was my car. The engine code was BSW. Same engine as fitted to Skoda Fabia II
Does this model have a pilot bearing
It did not seem to have one
that engine mount bolt snap triggered my ptsd...
Haha, slightly better to hear it on removal than when its going in but it can still be scary.