Clutch, With Dual Mass Flywheel, SACHS: Installing

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Install in reverse order of removal. Note the following:

NOTE:

Allocate the pressure plate and the clutch disc to match the engine code.

Clean the input shaft splines and (on used clutch plates) the hub splines. Remove any corrosion and then apply a very thin coat of Lubricant G 000 100 on the splines. Then move the clutch plate back and forth on the input shaft until the hub moves freely on the shaft. Remove any excess grease.

The clutch pressure plates are corrosion-protected and greased. With the exception of the friction surface on the clutch plate, do not clean the clutch pressure plate. This will shorten the service life of the clutch considerably.

The friction surfaces on the clutch pressure plate and on the flywheel must be cleaned thoroughly (degreased).

To reduce odor caused by a burnt clutch, thoroughly clean the transmission housing around the clutch as well as the engine on the transmission side.

Only use compressed air to clean the dual mass flywheel.

The clutch plate linings must sit completely on the flywheel and on the clutch pressure plate friction surface. Install the bolts.

Tighten the bolts diagonally in small steps so as to not damage the centering holes in the pressure plate and the centering pins on the flywheel.

Make sure the alignment pins for centering the engine/transmission are installed inside the cylinder block. Install them if necessary.

If the alignment pins are missing, it will be difficult to shift, there will be clutch problems and the transmission may make noises (loose rattling).

Fig 1: Identifying Installation Position Of Clutch Disc At Dual-Mass Flywheel

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"Getriebeseite" (transmission side) and the spring cage faces the transmission.

Fig 2: Checking Ends Of Diaphragm Spring

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Wear up to half the thickness of the diaphragm spring -arrows- is permitted.

Fig 3: Checking Pull-Springs And Rivet Connection

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I - Pull-spring OK

Slight offset in the outer area -arrows A-.

II - Pull-springs damaged

The clutch pressure plates must be replaced if the pull-spring is bent or broken off -arrow B-.

Fig 4: Checking Spring Connections And Rivet Connections

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-- Check the spring connections between the pressure plate and the cover for cracks and make sure the rivet connections are tight.

Replace the pressure plate if the spring connections are damaged or if the rivet connections -arrows- are loose.

-- Install the Flywheel Retainer 3067.

Fig 5: Identifying Flywheel Retainer 3067 Repositioned For Installation

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Fig 6: Crankshafts With Smaller Diameter Or Needle Bearing

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Fig 7: Centering Clutch Plate And Removing And Installing Pressure Plate

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NOTE:

Ignore arrows -A and B-.

Continuation for All:

When installing, tighten bolts as follows, so the pressure plate does not distort (causing shuddering on acceleration):

Fig 8: Checking Pressure Plate Does Not Distort

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-- Make sure the stop pin (position sensor) -arrow- moves easily.

-- Install the pressure plate on the centering pins.

-- Install all bolts evenly, by hand, until the bolt heads touch the pressure plate.

When doing this, the stop pin -arrow- must lift off from the pressure plate.

-- Tighten the bolts in small steps and in a diagonal pattern to prevent damaging the centering holes of the pressure plate and the centering pins of the dual mass flywheel.

-- Install the transmission, refer to TRANSMISSION, INSTALLING .