Removing and installing dual mass flywheel/drive plate — AUDI

Special tools and workshop equipment required

Clamping bolt 3242

Removing dual mass flywheel

Gearbox removed

Important
The engine must only be turned at the crankshaft, in the direction of engine rotation (clockwise).
Set crankshaft to TDC marking of No. 3 cylinder by turning at central bolt of toothed belt sprocket in direction of engine rotation.
Notch -B- opposite mark -A-

Unscrew plug for TDC marking from cylinder block.

Note:

There is a TDC bore in the crankshaft directly behind the plug (it is possible to feel the hole).

Important
Do not rotate the crankshaft while feeling for the TDC hole with your finger - risk of injury.
Screw clamping bolt 3242 into the hole of the removed plug and tighten.
Remove clutch thrust plate.

=> Manual Gearbox; Repair group 30
Manual Gearbox

Mark position of dual mass flywheel relative to engine.
Unbolt dual mass flywheel.

Installing

Installation is carried out in the reverse order; note the following:

Note:

The needle bearing is located in the flywheel and must be driven in if a new flywheel is installed =>Page
13-43
.

Fit new bolts and tighten.
Install clutch thrust plate.

=> Manual Gearbox; Repair group 30
Manual Gearbox

Remove clamping bolt 3242.
Screw plug for TDC marking into cylinder block with new O-ring seal.

Tightening torques:

Component · Nm
Flywheel to crankshaft
Bolt length · 22.5 mm · 60 + 90°1)2)
Bolt length · 35.0 mm · 60 + 180°2)3)
Bolt length · 43.0 mm · 60 + 180°2)3)
Plug in cylinder block · 10

1)
90°corresponds to a quarter of a turn

2)
Replace bolts

3)
180°= 1 / 2 turn

Removing drive plate

Gearbox removed

Important
The engine must only be turned at the crankshaft, in the direction of engine rotation (clockwise).
Set crankshaft to TDC marking of No. 3 cylinder by turning at central bolt of toothed belt sprocket in direction of engine rotation.
Notch -B- opposite mark -A-

Unscrew plug for TDC marking from cylinder block.

Note:

There is a TDC bore in the crankshaft directly behind the plug (it is possible to feel the hole).

Important
Do not rotate the crankshaft while feeling for the TDC hole with your finger - risk of injury.
Screw clamping bolt 3242 into the hole of the removed plug and tighten.
Mark position of drive plate relative to engine.
Unbolt drive plate.

Installing

Fit drive plate with packing plate -2- and 3.0 mm or 4.0 mm shim -1-.
Insert at least 3 of the old securing bolts and tighten to 30 Nm.

Measure dimension -a- at three points and calculate average value.
Specification for automatic gearbox 01F/01K:
18.1 ... 19.7 mm

If specification is not attained:

Remove drive plate again and fit with different shim -1-. Retighten bolts to 30 Nm.
Measure distance again.

If specification is attained:

Fit new bolts and tighten.

Remove clamping bolt 3242.
Screw plug for TDC marking into cylinder block with new O-ring seal.

Tightening torques:

Component · Nm
Drive plate to crankshaft
Bolt length · 22.5 mm · 60 + 90°1)2)
Plug in cylinder block · 25

1)
90°corresponds to a quarter of a turn

2)
Replace bolts