Pinpoint Test A : Excessive Noise

WARNING: This page is about a different variant/trim than selected.

A1 CHECK THE TRANSMISSION AT IDLE (A)
- Start the engine.
- Press the clutch pedal fully.
Is the noise apparent when the clutch is operated?

Yes GO to A2

No There is a problem with the transmission. REFER to: Manual Transmission . .

A2 CHECK THE TRANSMISSION AT IDLE (B)
- Run the engine at idle.
Are the noises coming from the pedal box?

Yes CHECK the clutch pedal and bushings.

No GO to A3. REFER to: Clutch Controls .

A3 CHECK THE CLUTCH RELEASE BEARING
- Remove the clutch slave cylinder/release bearing assembly. REFER to: Clutch Slave Cylinder - 6-Speed Manual Transmission - B6 .
- Check the release bearing for wear and corrosion.
Are there signs of wear or corrosion?

Yes INSTALL a new clutch release bearing. REFER to: Clutch Slave Cylinder - 6-Speed Manual Transmission - B6 .

No CHECK the crankshaft for excessive end float. Are there still noises? GO to A4

A4 CHECK THE ROTATION OF THE SECONDARY MASS OF THE DUAL MASS FLYWHEEL

NOTE: Do not rework or machine the dual mass flywheel if it is distorted.

NOTE: Do not clean the dual mass flywheel with any kind of liquid. Use only a dry cloth to clean the flywheel.

NOTE: Do not clean the gap between the primary and secondary mass of the dual mass flywheel. Only clean the bolt connection surface and the clutch surface.

NOTE: Discoloration is not a reason in itself to install a new dual mass flywheel.

Remove the clutch disc and clutch pressure plate. REFER to: Clutch Disc and Pressure Plate .

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Can the secondary mass of the dual mass flywheel be turned freely by more than 15 teeth?

Can spring resistance be felt in both directions?

Yes	INSTALL a new dual mass flywheel. REFER to: Flywheel .

GO to A5

A5 CHECK THE SPRING RESISTANCE
- Move the secondary mass of the dual mass flywheel in both directions.
Can spring resistance be felt in both directions?

Yes GO to A6

No INSTALL a new dual mass flywheel. REFER to: Flywheel .

A6 CHECK THE ROTATION OF THE DUAL-MASS FLYWHEEL

Secure the primary side of the dual mass flywheel.

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Move the secondary side of the dual mass flywheel by hand left and right several times prior to moving on.

Twist the secondary side of the dual mass flywheel by hand in a clockwise direction until spring resistance is felt and release.

Mark the rest position on the primary and secondary sides of the dual mass flywheel.

Twist the secondary side of the dual mass flywheel by hand in a counterclockwise direction until spring resistance is felt and release.

Mark the new rest position on the primary side of the dual mass flywheel.

Count the number of teeth between the marks for both directions on the dual mass flywheel ring gear.

Are more than 5 teeth counted?

Yes	INSTALL a new dual mass flywheel. REFER to: Flywheel .

GO to A7

A7 CHECK THE DUAL MASS FLYWHEEL

Carry out a visual inspection of the dual mass flywheel.

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Is the dual mass flywheel free of faults?

Yes

GO to A8

No	INSTALL a new dual mass flywheel. REFER to: Flywheel .

A8 CHECK THE FLYWHEEL RING GEAR

Carry out a visual inspection of the dual mass flywheel ring gear.

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Is the dual mass flywheel ring gear OK?

Yes

GO to A9

No	INSTALL a new dual mass flywheel. REFER to: Flywheel .

A9 CHECK THE TRANSMISSION BELL HOUSING FOR GREASE LEAKAGE

Visually inspect the transmission bell housing for traces of grease.

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Are there traces of circulated grease greater than 10 grams, 50 mm backwards from the front edge of the bell housing?

Yes	INSTALL a new dual mass flywheel. REFER to: Flywheel .

GO to A10

A10 CHECK THE GUIDE PINS OF THE DUAL MASS FLYWHEEL

NOTE: The guide pins should protrude by 0.4528in (11.5mm) +/- 0.0197in (.5mm).

CHECK the installation of the guide pins of the dual mass flywheel.

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Are the guide pins present and are they all the same length?

Yes

GO to A11

No	INSTALL a new dual mass flywheel. REFER to: Flywheel .

A11 CHECK FOR DISCOLORATION OF THE DUAL MASS FLYWHEEL DUE TO OVERHEATING

Check the dual mass flywheel for discoloration due to overheating.

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Is any discoloration evident in the marked area?

Yes	INSTALL a new dual mass flywheel. REFER to: Flywheel .

No	The dual mass flywheel is OK.