Flywheel (manual transmission) (Audi 100 C4)

As already mentioned, a conventional or dual flywheel can be installed (dual mass flywheel). To disconnect the flywheel, hold it in a suitable manner by the toothed ring, inserting a screwdriver, or with a special device, as shown in the figure, and at this time loosen the flywheel bolts.

Another way is to screw a metal strip to the cylinder block flange, as described earlier.





On the inside of the flywheel, you can find a toothed ring. Thanks to it, when the flywheel rotates, impulses are sent to the sensor, and the electronic control unit generates a signal about the engine speed. The toothed ring is screwed to the flywheel and can be removed when replacing the flywheel. The flywheel bolts should not be reused.



The flywheel working surface should be thoroughly wiped with a rag and checked for grooves. Small burrs can be removed with an abrasive material.

If it is necessary to remove the needle bearing at the end of the crankshaft (only with manual transmission), it is necessary to use the puller (A). The middle part should engage under the edge of the bearing. Removal should be carried out with the flywheel removed.



The side of the bearing with the inscriptions must be visible from the outside. When installing, the new bearing must be hammered in (having greased it well) into the hole using a suitable punch (mandrel), as shown in the figure.



The installation depth of the needle bearing (a) is 1.5 mm. This distance is most easily achieved by using a 1.5 mm thick washer, placing it in the hole from the top side of the bearing. Then hit the washer, driving it flush with the shaft. Do not allow the washer to jam, otherwise it will not be possible to remove it.





If the flywheel working surface has grooves, for example, when replacing a slipping clutch, the flywheel must be replaced. If the teeth of the ring gear are worn, the starter pinion must be checked, as it may also be damaged.

When installing the flywheel, the following tightening torques must be observed:

• If a standard flywheel is installed, the bolts must be tightened to 60 Nm and then tightened from this position by ¼ turn (90°).
• If a dual flywheel is installed, the bolts must be tightened to 40 Nm and from this position, tightened by half a turn (180°).
• In both cases, the crankshaft must be supported in a suitable manner.
• After installing the flywheel, you need to install the clutch and tighten the bolts.

(This article was copied from an online resource «AUDImanual»)