Audi Workshop Service and Repair Manuals

Exploded view - servicing “Sachs” version clutch   Caution On this type of clutch the pressure plate and clutch plate can only be renewed together. t  Observe notes on clutch → Chapter. t  Identification → Fig.

1 -	Clutch module

q	Removing and installing → Chapter

2 -

Oil seal

q	For dual-mass flywheel

q	Pulling out → Fig.

q	Driving in → Fig.

3 -	Needle bearing

q	For dual-mass flywheel

q	Different versions → Fig.

q	Check and renew if necessary → Fig.

q	Pressing out → Fig.

q	Pressing in → Fig.

t	Always renew needle bearing if input shaft is damaged → Anchor

t	Depending on the version fitted, the needle bearing may have the full number of rollers, or every 4th roller may be missing. The missing rollers do not mean that the needle bearing is defective.

4 -	Dual-mass flywheel

q	With flange for drive plate

q	Ensure that dowel pins fit tightly

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

q	Removing and installing → Chapter „Removing and installing pressure plate and clutch plate (Sachs version)“

q	Checking plastic washer in dual-mass flywheel → Fig.

q	Measuring degree of wear on plastic washer → Fig.

5 -	Clutch plate

q	Removing and installing → Chapter

q	For correct version, refer to → Electronic parts catalogue

q	Installation position: marking “Getriebeseite” (gearbox side) faces towards pressure plate

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

6 -	Pressure plate

q	Self-adjusting

q	Identification → Fig.

q	Pressure plate and clutch plate can only be renewed together

q	For correct version, refer to → Electronic parts catalogue

q	Removing and installing → Chapter

q	Checking pressure plate for distortion → Fig.

q	Checking ends of diaphragm spring → Fig.

q	Checking springs and riveting → Fig.

q	Checking metal ring → Fig.

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

7 -

Bolt

q	22 Nm and then turn 90° further

q	Always renew

q	Secures pressure plate to dual-mass flywheel

q	Observe assembly instructions → Chapter for loosening or tightening

Identification of “Sachs” version Pressure plate with position sender -arrow- or “Sachs” lettering

Checking plastic washer -A- in “Sachs” version dual-mass flywheel l  There must be a white plastic washer -A- in the dual-mass flywheel. It should be located under the copper-coloured bearing washer -B- and above the oil seal -C-. l  If the white plastic washer -A- is missing, the dual-mass flywheel must be renewed. l  Measuring degree of wear on plastic washer -A- → Fig.

Measuring degree of wear on plastic washer in “Sachs” version dual-mass flywheel –  Clean copper-coloured bearing washer -A- and oil seal -B- at points to be measured. –  Press bearing washer -A- towards oil seal -B-. –  Maintain pressure and measure distance -x- from top surface of copper-coloured bearing washer -A- to top surface of oil seal -B- at outer edge using a depth gauge. l  Distance -x- = 2.5 mm (minimum) l  The dual-mass flywheel must be renewed if distance -x- is less than 2.5 mm.

Checking needle bearing in dual-mass flywheel on vehicles with 4-cylinder TDI engine (except 125 kW TDI)   Caution Check version of needle bearing in dual-mass flywheel. t  Depending on the version fitted, the needle bearing may have the full number of rollers, or every 4th roller may be missing. The missing rollers do not mean that the needle bearing is defective. t  The needle bearing of the type where every 4th roller is missing -arrows- must always be renewed on vehicles with 4-cylinder TDI engine (except 125 kW TDI) → Chapter. t  New needle bearings have the full number of rollers. t  On all other vehicles the missing needle rollers do not mean that the needle bearing is defective. Do not renew the needle bearing.

Checking pressure plate for distortion, cracks and burning A -  Straightedge B -  Feeler gauge l  Pressure plate distortion up to 1.0 mm is permissible.

Checking ends of diaphragm spring l  Wear up to 0.3 mm (maximum) is permissible.

Checking springs and riveting I -  Springs OK l  Slight kinking on the outside -arrows A- is normal on production parts. II -  Springs damaged l  Renew pressure plate if springs are broken or badly bent -arrow B-.

–  Check that riveting -arrows B- is secure at all springs -arrows A-. l  Renew pressure plate if rivets -arrows B- are loose.

Checking metal ring –  Check metal ring -arrow- in pressure plate for damage. l  Renew pressure plate if metal ring is broken.