Clutch in van and what is this bolt for?

[Gizmoman]

The TDI input shaft is different from the vanagon one.  That is why you need the WBX (waterboxer - gas vanagon) disc which will fit the TDI flywheel and pressure plate. 

Got it, thanks

[libbydiesel]

http://www.thesamba.com/vw/forum/viewtopic.php?t=549444

[Gizmoman]

Just wanted to run this by everyone one more time. . .
228 mm TDI FLYWHEEL -

Website - http://www.fourseasontuning.com/product.php?id=931&product_code=028105269b.ess

Vanagon 228 mm CLUTCH AND PRESSURE PLATE KIT  -
Website - http://www.partsgeek.com/catalog/1989/volkswagen/vanagon/clutch/clutch_kit.html

Don't want to be a PITA but - well, I guess I just am sometimes.

Are these the bits required?
The pressure plate looks beefier than what I have now and so does the disc.
Hopefully I can get these on the way and stop bugging everyone with this.

[libbydiesel]

What you need is the TDI/VR6/G60 flywheel and TDI/VR6/G60 pressure plate along with the WBX disc.  I do not think the WBX pressure plate will work, but I'd have to compare the WBX PP and the TDI one to recall why.  I think I have both in the parts bin, but I'd have to look.

Flywheel:
http://www.idparts.com/catalog/product_info.php?products_id=996

Pressure plate:
http://www.partsgeek.com/ss/?i=1&ssq=W0133-1612589&x=24&y=5

Clutch disc:
http://www.partsgeek.com/catalog/1989/volkswagen/vanagon/clutch/clutch_disc.html

[Gizmoman]

OK, I was close anyway
I am curious about the Valeo kit http://www.partsgeek.com/catalog/1989/volkswagen/vanagon/clutch/clutch_kit.html as it "appears" to be beefier than the Sachs.
Can you check the compatibility if you get a chance? If not - understood. You've already walked me through this to a clear solution. Many thanks Libby.

Also, I will be sure to remove the tabs from the pressure plate, and check bolt lengths and housing clearances.

Cheers

[Syncroincity]

You don't need to remove the tabs, just tap them down flush; you'll see it once you get it in your hands. While minor, it would create a slight imbalance in the PP if you grind them off.

The bellhouse clearancing is also minor, just hold the flywheel in roughly where it resides and you'll see where it could interfere. You'll also need to take off a few mm's from the gear end of the starter... I can't remember exactly where; the tip or the flat edge, it will be apparent when you dry-fit the motor.

[Gizmoman]

You don't need to remove the tabs, just tap them down flush; you'll see it once you get it in your hands. While minor, it would create a slight imbalance in the PP if you grind them off.

The bellhouse clearancing is also minor, just hold the flywheel in roughly where it resides and you'll see where it could interfere. You'll also need to take off a few mm's from the gear end of the starter... I can't remember exactly where; the tip or the flat edge, it will be apparent when you dry-fit the motor.

Noted.
As for the Vanagon 228 mm pressure plate bolting up to the G60 flywheel , maybe I can get a local auto parts to get them so I can check fit at the counter. Not sure if they will do that but it beats ordering them and having to send it back if they don't match up.
I am probably over-thinking everything here (again) but the Vanagon pressure plate just looks stronger than the Sachs G60.

Also, thanks for the tip on the starter nose. Nothing worse than having to stab in a motor twice

[libbydiesel]

The vanagon disc does work with the tdi/g60 flywheel and pressure plate provided you clearance the bell-housing and starter as outlined in the thread I linked.  I'm sure about that.  The only question I have is why the gas vanagon pressure plate doesn't work.  I believe the gasser flywheel is a different depth and the pressure plate matches it. 

[libbydiesel]

I looked in my spare parts bin and it is quite obvious why the WBX PP will not work with the TDI flywheel.  The depth of the friction surface from the surface that the PP bolts to is twice as deep on the WBX, approx. 25mm vs 12.5mm on the TDI flywheel.

[R.O.R-2.0]

Where would one find this pilot bearing? Is it a common part or custom made?

theres one in the end of the crank in my Jetta ;-p

[Gizmoman]

I looked in my spare parts bin and it is quite obvious why the WBX PP will not work with the TDI flywheel.  The depth of the friction surface from the surface that the PP bolts to is twice as deep on the WBX, approx. 25mm vs 12.5mm on the TDI flywheel.

Thanks Libby - I am now 331 bucks lighter

Now I'll get back to fabbing the support bracket to brace the Laminova inter-cooler and K14/manifold to the block. This was a suggestion from a member and I'm heeding it.
I'll post photos soon.

Thanks again everyone!