Audi Workshop Service and Repair Manuals

Servicing self-adjusting clutch (Sachs version) - exploded view   Caution On this type of clutch the pressure plate and clutch plate can only be renewed together. t  The gearbox has to be removed before working on the clutch → Chapter. t  Identification → Fig.. t  Select the correct clutch plate and pressure plate according to engine code → Electronic parts catalogue.

1 -

Bolt

q

22 Nm

q	Observe instructions for installation → Chapter

2 -	Pressure plate

q	Self-adjusting

q	Identification → Fig.

q	Pressure plate and clutch plate can only be renewed together.

q	Removing and installing → Chapter

q	Checking ends of diaphragm spring → Fig.

q	Checking spring connection and rivets → Fig.

q	Checking wire ring → Fig.

3 -	Clutch plate

q	Pressure plate and clutch plate can only be renewed together.

q	Installation position: Clutch lining must make full contact with flywheel

q	The marking “Getriebeseite” (gearbox side), if provided, faces towards pressure plate/gearbox.

q	If fitted, coil springs (damper assembly) face towards pressure plate and gearbox

q	Centralising → Anchor

q	Lightly grease splines → Anchor

q	Select diameter of clutch plate according to engine code → Electronic parts catalogue.

4 -	Bolt for flywheel

q	Always renew

q	Observe instructions for removal → Fig.

q	Bolt length: 22.5 mm; 60 Nm + 90° further

q	Bolt length: 43 mm; 60 Nm + 180° further

5 -	Dual-mass flywheel

q	Ensure that dowel pins fit tightly

q	Contact surface for clutch lining must be free of grooves, oil and grease

q	Observe instructions for removal → Fig.

6 -	Needle bearing

q	Removing and installing → Rep. Gr.13

Identification Pressure plate with position sender -arrow-.

Checking ends of diaphragm spring l  Wear up to half the thickness of the diaphragm spring is permissible.   Note Important: When performing repairs, always match up clutch pressure plate and clutch plate by checking engine code → Electronic parts catalogue.

Checking spring connection and rivet –  Check spring connections -arrows A- for damage and make sure riveted joints -arrows B- are seated tightly.   Note Renew pressure plate if spring connections are broken or badly bent, or if riveted joints are loose.

Checking wire ring –  Check that wire ring in pressure plate -arrow- is not damaged. Renew pressure plate if wire ring is broken.

Removing dual-mass flywheel   Note Do not use an impact wrench or pneumatic wrench to remove bolts -B-: this would severely damage the dual-mass flywheel. Bolts -B- must always be removed by hand. –  Rotate flywheel -A- so that bolts -B- are aligned centrally behind the holes -arrows-. –  When unscrewing bolts -B-, make sure the bolt heads do not contact the flywheel -arrows- because this would damage the flywheel when the bolts are turned further. –  Removing and installing dual-mass flywheel → Rep. Gr.13.