1. Clutch module.
2. Lip seal for dual mass flywheel.
3. Needle bearing for dual mass flywheel: check and replace if necessary. If the drive shaft is damaged, always replace the needle bearing. Depending on the design, needle bearings with a full set of rollers or needle bearings with every fourth roller missing are installed. This is not a defect of the needle bearing.
4. Dual mass flywheel with transfer plate: ensure that the centering pins are securely installed; there should be no grooves, oil or grease on the mating surface of the clutch lining.
5. Clutch driven disc: installation position: the inscription "Gearbox side" faces the pressure plate; if available: damping package (coil springs) facing the pressure plate.
6. Pressure plate: self-aligning; replace the pressure plate and clutch disc only together; check the pressure plate for warpage; check the ends of the membrane spring; check springs and riveted joints; checking the steel ring; there should be no grooves, oil or grease on the mating surface of the clutch lining.
7. Bolt: 22 Nm and 90° turn; always subject to replacement; for fastening the pressure plate on the dual mass flywheel; loosen or tighten according to installation instructions.
The distinctive feature of the manufacturer Sachs
Pressure plate with "arrow" position sensor or Sachs inscription.
Check the plastic disc "A" of the dual mass flywheel from Sachs
The dual-mass flywheel must be equipped with a "white" plastic disc "A." It should be located under the copper-colored sliding washer "B" and above the radial shaft seal "C." If the "white" plastic disc "A" is missing, the dual-mass flywheel must be replaced. Measuring the degree of wear of the plastic disc "A".
Measuring the wear of a plastic disc in a dual mass flywheel manufactured by Sachs
Clean the copper-coloured sliding washer "A" and the radial shaft seal "B" at the measuring point. Press sliding washer "A" toward radial shaft seal "B." Using a depth gauge, measure the distance "x" from the top of copper-colored sliding washer "A" to the top of radial shaft seal "B" along the outer edge. Dimension "x" min. 2.5 mm. If dimension "x" is less than 2.5 mm, the dual mass flywheel must be replaced.
Checking the needle bearings in the dual mass flywheel on a vehicle with a 4-cylinder TDI engine (except for the 125 kW TDI engine)
Depending on the design, needle bearings with a full set of rollers or needle bearings with every fourth roller missing are installed. This is not a defect of the needle bearing. Needle bearings where every 4th "arrow" roller is missing must be replaced. New needle bearings have a full set of rollers. On all other vehicles, the absence of the fourth roller is not a defect of the needle bearing. Do not replace the needle bearing!
Check the pressure plate for deformation, cracks and signs of burning
A. Lekalo. V. Template sheet for the feeler gauge. Deformation of the clutch pressure plate is permissible within 0.8 mm.
Checking the ends of the membrane spring
Permissible wear is max. 0.3 mm.
Check springs and riveted joints
The tension springs are normal. The slight bends in the outer area of the "arrow A" are a sign of the series.
Damaged springs Pressure plates with bent or cracked springs "arrow B" must be replaced.
Check the riveted connections "arrow B" of all springs "arrow A" for tightness.
Replace pressure plates with loose riveted connections "arrow B".
Checking the steel ring
Check the steel ring in the pressure plate "arrow" for damage. Replace pressure plates with a broken steel ring.
Removal and installation the clutch disc and pressure plate manufacturer Sachs
Remove the clutch module.
Clutch pressure plate. Risk of damage to the pressure plate and dual mass flywheel. Pressure plate "3" may only be removed and installed in a pre-compressed state. Pre-compressed pressure plates are deformed when bolts "2" are loosened or tightened, which leads to jerking when starting off. To compress pressure plate "3" using a hydraulic press, the dual-mass flywheel may only be supported by the sliding washer "arrow A." Supporting the dual-mass flywheel against transfer plate "1" will damage it (deformation). In this case, it is necessary to replace the dual mass flywheel. Install the clutch module so that the pressure plate "VW 510" is adjacent to the sliding washer "arrow A" in the dual mass flywheel. Install mont. device "T10254/3" on the spring tongues of the pressure plate "3" and press on them using a press. Compression stroke - dimension "x" 8...9 mm. Unscrew all 6 bolts "2" and release the press. Remove pressure plate "3" and clutch driven disc.
Installation
Installation in reverse order. Check the clutch pressure plate for deformation. Center the clutch driven disc using the T40171 centering tool. Install the pressure plate onto the mounting pins.
Clutch disc mounting position: damper package (coil springs) or an inscription "Getriebeseite" (side of the checkpoint) must face the gearbox. Install the clutch module so that the "VW 510" pressure plate is flush with the "arrow A" sliding washer in the dual mass flywheel.
Clutch pressure plate. Risk of damage to the dual mass flywheel. To compress pressure plate "1" using a hydraulic press, dual-mass flywheel "3" may only be supported by the sliding washer "arrow A." Supporting the dual-mass flywheel against the transfer plate "arrow B" will damage it (deformation). In this case, it is necessary to replace the dual mass flywheel. Install mont. device "T10254/3" over the centering mandrel "T40171". Apply pressure with the press until the pressure plate "1" lies against the dual-mass flywheel "3" "arrows C". Screw in all 6 bolts "2" one after the other and tighten to the specified torque. Release the pressure from the press. Install the clutch module.
[The original article is available on the website AudiManual.ru]