Audi Workshop Service and Repair Manuals

Special tools, testers and auxiliary items required:

• ◆ Retainer 10-201
• ◆ Mandrel 3176
• ◆ Grease G 000 100

Notes:

• ◆ Observe general repair instructions
  .
• ◆ Before renewing the clutch plate and pressure plate

=> Fault-finding No. 9 - Defects on the clutch and clutch mechanism

• ◆ Replace clutch plates and pressure plates with damaged or loose rivets.
• ◆ Select the correct clutch plate and pressure plate according to engine code:

=> Parts catalogue

• ◆ Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease G 000 100 to the splines. Then move clutch plate to and fro on input shaft until hub moves freely on shaft. Excess grease must be removed.
• ◆ Pressure plates have an anti-corrosion coating and are greased. Only the contact surface may be cleaned, otherwise the service life of the clutch will be considerably reduced.
• ◆ If the clutch has burnt out, thoroughly clean the bellhousing, flywheel and parts of the engine facing the gearbox to reduce the smell of burnt linings.

• ‒ Before working on the clutch, the gearbox must be removed .

• Dual-mass flywheel
• ◆ White marking -A- must be aligned with marking -B- on pressure plate
• ◆ Ensure centring pins are tightly seated
• ◆ Contact surface for clutch lining must be free of grooves, oil and grease
• ◆ Removing and installing

=> 6-cylinder diesel direct injection engine (TDI), Mechanics; Repair group 13; Crankcase group; Removing and installing flywheel

• Bolt
• ◆ Vehicles with dual-mass flywheel: tighten bolt to 60 Nm, then turn a further 180°
• ◆ Always renew

=> 6-cylinder diesel direct injection engine (TDI), Mechanics; Repair group 13; Crankcase group; Removing and installing flywheel

• Clutch plate
• ◆ Install with spring pack (coil springs) or the word "Getriebeseite" towards pressure plate and gearbox
• ◆ Centring => Fig.1
• ◆ Do not grease
• ◆ Clutch plate diameter
  => from Page 00-3

• Pressure plate
• ◆ Removing and installing => Fig.1
• ◆ White marking -B- must be aligned with marking -A- on flywheel
• ◆ Checking ends of diaphragm spring => Fig.2
• ◆ Checking spring connection and riveted fastenings => Fig.3
• Bolt - 25 Nm
• ◆ Tighten gradually in diagonal sequence and in several stages
• Needle roller bearing
• ◆ Removing and installing

=> 6-cylinder diesel direct injection engine (TDI), Mechanics; Repair group 13; Crankcase group; Removing and installing flywheel

→ Fig.1    Removing and installing clutch

• ‒ Position of clutch plate: spring pack (coil springs) or marking "Getriebeseite" towards pressure plate and gearbox
• ‒ When assembling, make sure that white marking -A- on the dual-mass flywheel is aligned with white marking -B- on the pressure plate.
• ‒ Loosen and tighten bolts in stages and diagonally - 25 Nm.
• ‒ Reverse position of counter-hold tool 10-201 when removing.
• ‒ Use mandrel 3176 to centre clutch plate.

Notes:

• ◆ Clutch lining and contact surface of pressure plate must make full contact with flywheel before securing bolts are inserted.
• ◆ To avoid damaging centring holes in pressure plate and centring pins on flywheel, tighten securing bolts evenly and in several stages in diagonal sequence.

→ Fig.2    Checking ends of diaphragm spring

• ◆ Wear up to half the thickness of the diaphragm spring is permitted

Note:

When performing repairs always match up clutch pressure plate and clutch plate by checking engine code (see parts catalogue).

→ Fig.3    Checking spring connection and riveted fastenings

• ‒ Check spring connection between pressure plate and cover for cracks and make sure rivet fastenings are seated tightly.
• ‒ Renew clutches with damaged springs or loose riveted fastenings -arrows-.