Fixing Audi A3 rattle under car at idle | Replace 2009 Audi A3 1.9 Tdi dual mass flywheel & clutch

This video is about fixing an Audi A3 with a rattle under the car at idle. The vehicle is a 2009 Audi A3 1.9 Tdi Sportback with 167000 miles. It had a rattle sounding like it was coming from underneath the car, which was most noticeable in neutral with foot off the clutch and the engine at idle. There were no obvious driveability issues.

The video gives an overview of steps required to replace the dual mass flywheel and clutch. After these had been replaced, the rattle went. The flywheel was to blame but the clutch was pretty much worn out so that was replaced too.

I did this work on my own, without a lift, so hopefully if you're in a similar situation this video will be of interest to you.

Briefly the work involved:
-Removing air intake, air filter housing, battery housing.
-Remove gear shift linkage and cables.
-Remove clutch slave cylinder (although none of the lines needed to be undone)
-Remove starter motor
-Remove LH driveshaft
-Disconnect RH driveshaft at gearbox end (RH driveshaft doesn't need to be removed).
-Support engine with an engine support beam.
-Disconnect the DPF from the turbo. Support it so it can stay in place whilst the engine is lowered.
-Undo the left hand engine/gearbox mount
-Lower the engine down
-Remove the gearbox.
-Remove clutch.
-Remove dual mass flywheel.
-Clean up.
-Put it all back together with new parts.

I'm not going to list every single tool used, but here are the essential, potentially non-standard items:
-12 point / triple square bit set.
-Torque wrench with range up to 200 Nm.
-Big breaker bar.
-24mm 12 point socket.
-Transmission jack.
-Clutch alignment tool https://amzn.to/2MisBD4
-Engine support beam

Timestamps / Chapters
0:00 Introduction
0:46 Rattle
3:02 Wheel removal
3:20 Loosening driveshaft bolt
4:51 Battery & air intake
7:32 Gear cables
10:00 Support bracket
11:25 Clutch slave cylinder
11:43 Summary - gear linkage and slave cylinder
12:48 Driveshaft
14:26 Drain gear oil
14:54 Engine support beam
15:55 Intake and exhaust
17:42 Gearbox out
19:00 Flywheel out
20:02 Wear on 167k clutch
20:36 New parts
23:22 Flywheel in
23:43 Release bearing sleeve
24:29 Clutch alignment tool setup
25:34 Gearbox back
27:00 Reassembly 1
29:10 EGR cleaning
30:42 Shift mechanism
31:12 Reassembly 2
32:26 No more rattle
33:00 Summary

Thanks for watching and please consider subscribing to the channel if you haven't already.
See you next time!
andrewfixes.com

#audia3 #flywheel #clutch