Removal and Replacement
WM 444019 Mounting tires (removing and installing tires) - for vehicles with and without Tire Pressure Monitoring (TPM) systemTools
Tire removal/mounting machine
Only use recommended tire removal/mounting machine and auxiliary equipment (special mounting lever, bead holding-down device).
Search criteria in PIWIS (PPN):
^ Information media
^ WEST (Workshop Equipment and Special Tools Manual).
^ Main group: 4 - Running gear/Tool type: Workshop Equipment/Dealer Classification: All
WE 1084 Tire removal/mounting machine
Auxiliary equipment
Auxiliary equipment
1 - Special mounting lever with plastic protection.
2 - Holding-down device 9539 - for holding down the tire bead.
3 - Wulstboy - for holding down the tire bead (alternative to holding-down device 9539/item 2)
4 - Adhesive weight remover - commercially available
Requirements/information on removing/mounting tires
Information:
^ Tire temperature during removal/mounting must be approx. 20°C (at least 15°C). Allow enough time to heat the vehicle/tires in a suitable environment if necessary (at room temperature of more than 15°C). Example: If the room temperature of the workshop is approx. 20°C and the tire temperature is approx. - 15°C, approx. 3 hours are required to heat the tires to the required temperature.
^ Before removal/mounting, it is important to establish whether a Tire Pressure Monitoring system (TPM) is fitted! The tire valve serves as the distinguishing feature. Without TPM: rubber valve. With TPM: aluminum valve. If a TPM system is fitted, read the special information on the Tire Pressure Monitoring system (see module in this main chapter).
^ Vehicles with TPM: Before changing a tire, read out the remaining life span of the wheel electronics unit (battery capacity) using the PIWIS Tester. The value you read out gives an indication as to whether or not it needs to be replaced (not a 100% value). If the values are considerably lower than expected for the next tire change, talk to the customer and determine whether he/she is happy to have the wheel electronics unit(s) replaced at this time.
^ Use only TIP TOP Universal, Order No. 593 0601 (3.5 kg bucket) or Contifix as the removal/mounting paste (sliding compound). Use sufficient sliding compound.
^ No large point load for wheel (rim) and tire during removal/mounting. If this is not observed, damage will occur that will render a tire unusable (ready for disposal) and/or require a new rim.
^ Before removal/mounting, check the mounting head (of the mounting machine) for damage (scoring, soiling). Clean or replace the mounting head if necessary to prevent paint damage and pressure marks on the rim flange.
^ All parts that touch the disc wheel and tire are made of plastic to prevent damage to paintwork during removal/mounting. Protect the rim flange with adhesive tape if necessary. The mounting lever can also be covered with adhesive tape in order to avoid damaging the area around the spokes (during removal).
^ If you do not have a mounting lever with plastic protection, use a rim flange protector (assembly aid) and avoid letting it slip on to the rim flange.
^ Check the disc wheel for damage (sealing face between tire/rim, true running, superficial damage and deformation).
^ If you intend to continue using the tire, check it for damage (sealing face between tire/rim, ply damage, tire beads, sidewalls and tread depth).
^ The rubber valve must generally be replaced when a tire change is necessary. In vehicles with TPM (aluminum valve), the valve only needs to be replaced in exceptional cases. This is elaborated further in: "Special information on TPM" (module in this main chapter).
^ When mounting tires, pay particular attention to the direction of rotation and the inside/outside.
^ When replacing only one tire on an axle, make sure that the tread depth of the new tire does not differ from that of the other tire by more than 30%!
Special notes for Tire Pressure Monitoring (TPM)
Information:
^ If the old wheels are still in the vicinity after assembly work (for example changing winter tires and/or wheels from another vehicle with TPM), these will still be detected by the system. If one or more of these wheels has a minimum pressure of more than 0.5 bar below the required pressure, this can trigger a warning in the instrument cluster. In this case, remove the other wheels or use the PIWIS Tester to tune the vehicle to be outside the radio range of these wheels.
^ Before changing a tire, read out the remaining life span of the wheel electronics unit (battery capacity) using the PIWIS Tester.
^ For vehicles with a TPM, the valve and wheel electronics unit -A- are only replaced in exceptional cases. The following points can make replacement necessary.
Component overview for TPM valve/wheel electronics
-A- - Wheel electronics
-B- - Valve complete (No. 2 to No. 7)
-1- - Self-locking (Torx) fastening screw
-2- - Valve cap (plastic)
-3- - Valve insert
-4- - Union nut
-5- - Washer chamfered on both sides
-6- - Bead seat sealing ring
-7- - Valve
The valve -B- must be replaced if:
^ The wheel electronics unit -A- is removed
^ The self-locking fastening screw -1- is loose
^ The union nut -4- is loose
^ The valve -7- is leaking at the valve seat
^ The valve -7- (valve body) is bent or broken.
The wheel electronics unit -A- must be replaced if:
^ The housing is visibly deformed
^ The filter surface (on the bottom) is so soiled that it cannot be cleaned by wiping
^ Tire sealant (tire sealing liquid) has been used
Instructions for fitting the TPM valve are provided below.
1. Loosely fit the wheel electronics unit -A- at the valve -7- (do not tighten screw -1- ). Insert this assembly into the valve bore (of the rim) with the bead seat sealing ring -6-.
Fit washer, chamfered on both sides, -5- and screw on the union nut -4- until it is seated correctly.
TPM valve
Wheel electronics
2. Tighten valve and wheel electronics unit.
2.1. Block the valve at the bore in the base of the valve using a suitable assembly pin. This is necessary in order to counter while tightening the union nut. Tighten the union nut to 4 Nm (3 ftlb.). The union nut must be tightened in one step (without interruption until the prescribed tightening torque is reached). It must not be tightened again afterwards!
2.2. After fitting the valve, remove the assembly pin (used to counter the valve).
2.3. Press the wheel electronics unit -A- slightly into the rim bed (this adjusts the angle of inclination of the valve with respect to the wheel electronics unit).
Carefully tighten the self-locking fastening screw (Torx T20) to the required tightening torque of 4 Nm (3 ftlb.). The wheel electronics unit should now be lying evenly against the rim.
Countering TPM valve while tightening
Removing/mounting tires (removing and installing tires)
Removing tires
For correct tire removal/mounting, follow the instructions provided for the tire removal/mounting machine.
See Requirements/information on removing/mounting tires!
1. Fit and clamp a clean disc wheel on the tire removal/mounting machine.
Check that the tire is seated securely and without damage (as described in the instructions provided for the tire removal/mounting machine).
2. Unscrew the valve insert and release the air so that the tire is depressurized.
3. Set the tire bead press-off tool (in accordance with the tire size).
Setting the tire bead press-off tool
3.1. Set the tire bead press-off tool to the inch graduation (rough setting in accordance with the tire size).
3.2. Then adjust the setting precisely (the press-off roller must not touch the rim when positioned on the tire). If this is not the case, the rim flange may be damaged by the press-off rollers.
4. Loosen the lower and upper tire bead (press the tire off the rim).
4.1. The wheel must be turned anti-clockwise (anti-clockwise rotation of the mounting table) when pressing the tire off the rim (loosening the tire bead). Otherwise, excessive forces occur on the fastening bolts of the machine which can break the bolts. First press off the lower tire bead and then the upper tire bead (to ensure that the wheel remains seated securely on the machine). Coat the tire beads with mounting paste even at this stage of the procedure to make it easier to press the tire bead off.
4.2. Loosen the two bead press-off tools again (by moving them back to their original position).
5. Before removing the tire, coat the tire beads with mounting paste again if necessary to facilitate removal.
6. Removing upper tire bead:
Valve/wheel electronics unit at 12 o'clock position.
Fit the mounting head on the rim flange.
The mounting lever (with plastic protection) is pushed into the deep bed underneath the upper tire bead, and then guided over the mounting shoe and pushed down.
Lift the tire bead out of the rim bed by turning the wheel clockwise. Check the following while doing this:
^ Check that the bead lip is facing outwards and is fully visible. Otherwise, the tire bead can become jammed and be damaged irreparably.
^ The mounting lever must be the same distance from the inside of the tire and the valve during the entire removal procedure.
^ Constantly check that the plastic protection (on the mounting lever) is positioned correctly in order to protect the rim.
^ The lower (second) tire bead must be in the deep bed during removal.
^ The tire bead must not be pressing against the wheel electronics unit.
7. Removing lower tire bead:
Valve/wheel electronics unit at 12 o'clock position.
Pull the tire upwards and push it into the rim bed underneath the second tire bead using the mounting lever (plastic protection). Make sure that the valve/wheel electronics unit is not damaged.
Check the position of the mounting lever. The mounting lever must be the same distance from the inside of the tire and the valve during the entire removal procedure. Constantly check that the plastic protection (on the mounting lever) is positioned correctly in order to protect the rim.
Turn the wheel slowly clockwise until the tire is removed.
Removing tires
8. Set the mounting lever and tire aside (in a safe/clean place).
Detach the disc wheel from the machine, remove it and lay it carefully aside (store in a safe place).
Mounting tires
Information:
^ For correct tire mounting, follow the instructions provided for the tire removal/mounting machine.
^ Always use approved tires and tire sizes (specification code/speed index/load capacity). This data can be found in the applicable/current Technical Information.
^ Tire temperature during removal/mounting must be approx. 20°C (at least 15°C). Allow enough time to heat the vehicle/tires in a suitable environment if necessary (at room temperature of more than 15°C). Example: If the room temperature of the workshop is approx. 20°C and the tire temperature is approx. - 15°C, approx. 3 hours are required to heat the tires to the required temperature.
^ The wheel electronics must not be treated with compressed air, tire mounting paste, cleaning agents or any other solvents.
^ Disc wheels with wheel electronics must not be cleaned with a high-pressure power cleaner before tires have been fitted.
^ Do not expose filter surface of wheel electronics. Remove soiling with a lint-free cloth. Do not apply tire mounting paste to the wheel electronics unit. All traces of tire mounting paste must be removed from the wheel electronics unit.
^ During fitting, ensure that the tire bead is not pressed against the wheel electronics unit.
^ Huge tension can be transferred to the tire bead when the mounting paste dries quickly. It is therefore absolutely essential to mount the upper and lower tire bead quickly and without delay.
1. Complete preparatory steps for mounting tires:
^ Remove abraded rubber particles from the disc wheel and check for damage.
^ Fit and clamp the clean wheel as described in the instructions provided for the tire removal/mounting machine.
^ For vehicles with TPM, check the valve and wheel electronics unit for damage. Replace these components if they are damaged or if they do not comply with specifications (special information on TPM).
^ Always replace the rubber valve (on vehicles without TPM). Use a commercially available insertion tool and tire mounting paste.
^ If you intend to continue using the tire, check it for damage (sealing face between tire/rim, ply damage, tire beads, sidewalls and tread depth).
^ As a general rule, check the bead area (mounting and sealing face) for damage before mounting tires (even new tires). Ensure that this area is perfectly clean to prevent any slow air leaks (loss of tire pressure) in this area (after mounting the tire). A loss of tire pressure often goes unnoticed on vehicles without TPM. Serious consequence: Reduced driving dynamics and the tire can be damaged irreparably as a result of increased kneading action (overheating).
2. Coat the rim and tire (both bead areas) with sufficient tire mounting paste - TIP TOP Universal, Order No. 593 0601 - or Contifix. Absolute cleanliness is essential (clean brush/clean tire mounting paste). Make sure that there are no traces of tire mounting paste on the wheel electronics unit.
3. Fitting lower tire bead (first tire bead).
Place the tire at the correct position on the disc wheel (check direction of rotation and inside/outside position).
Push in mounting arm and position on top of the rim flange. The mounting head must be offset by 180° with respect to the valve.
Mounting tire, lower bead, Figure 1
Push the lower tire bead (first tire bead) partly over the rim flange and guide it through the mounting head. Turn the disc wheel slowly in a clockwise direction (clockwise rotation of mounting table) until the lower tire bead is completely fitted.
Mounting tire, lower tire bead, Figure 2
4. Fitting upper tire bead (second tire bead) using bead holding-down device. This presses the tire bead into the deep bed.
Information:
^ Always use a bead holding-down device for mounting the upper tire bead (second tire bead).
^ There are two types of bead holding-down devices.
^ Use the Wulstboy bead holding-down device for tire/wheel combinations that are difficult to mount.
4.1. Fitting upper tire bead (second tire bead) using bead holding-down device type 1 = special tool 9539
Position the mounting head -1- approx. 15 cm to the right of the valve -2-.
Hold the upper tire bead (second tire bead) in the deep bed using the bead holding-down device 9539 and turn the disc wheel slowly at the same time (clockwise rotation of mounting table) until the upper tire bead is completely fitted.
Mounting tire, upper bead using holding-down device 9539
4.2. Fitting upper tire bead (second tire bead) using bead holding-down device type 2 = Wulstboy
Position the mounting head approx. 15 cm to the right of the valve.
Use the upper plastic press-off roller (on the mounting machine) to press the upper tire bead approx. 4 to 5 cm below the rim flange (max. 5 cm/the belt edge of the tire must not be deformed by the plastic press-off roller). This makes space for the bead holding-down device blocks.
Fit the bead holding-down device (Wulstboy) into the middle of the "wheel/rotary plate" -1-. Move the arm -2- of the bead holding-down device to the 1 o'clock position.
Inserting Wulstboy blocks
Turn the wheel slowly in a clockwise direction (clockwise rotation) and insert the blocks -3- of the bead holding-down device.
Continue turning the disc wheel slowly (clockwise rotation) until the upper bead is completely fitted.
After fitting the upper tire bead, loosen the bead holding-down device by turning the disc wheel anti-clockwise (anti-clockwise rotation) and remove the blocks using the upper press-off roller.
5. Filling/setting tires.
5.1. Remove entire wheel from tire fitting unit.
Warning: High tire seating pressure - max. 3.3 bar permitted.
^ Risk of personal injury as a result of irreversible damage to tires/wheels.
--> Tires must be filled in the filling cage.
--> Do not exceed tire seating pressure (max. 3.3 bar).
5.2. Fill the tire (without the valve insert) with air immediately in the tire filling cage (while the tire mounting paste is still fully effective). Continue filling the tire until the tire beads slide/jump over the humps (max. 3.3 bar).
If the tire is not seated correctly when the maximum permitted tire seating pressure (max. 3.3 bar) is applied, coat the wheel and tire again with tire mounting paste TIP TOP Universal or Contifix and repeat the procedure.
Tire filling cage
5.3. Screw in new valve insert. Counter at the valve body when tightening. Required tightening torque is 0.2 Nm/0.1 ftlb to 0.35 Nm/0.2 ftlb. (20 to 35 Ncm/1.6 to 3 inlb.). A safety valve screw-on tool with tightening control (e.g. from Butler) is ideal for this.
Fill tire to the setting pressure of 4.0 bar. Check that the tire bead is seated correctly. The tire must be lying evenly against the rim all the way around.
Set the prescribed tire pressure. Screw on valve cap.
6. Balance the wheel.
7. Perform a test drive. Avoid extreme driving maneuvers (acceleration, braking) during the test drive to prevent the tire from turning on the rim.
This can happen if the tire mounting paste is not completely dry. Optimum balancing will be impaired as a result.
Observe the following criteria during the test drive:
7.1. TPM function (Tire Pressure Monitoring system).
Before starting the test drive (with 'ignition on'), select the mounted set of wheels under Main menu > Tire pressure > Settings in the instrument cluster. The control unit then learns the wheel positions again while you drive the vehicle.
The system starts learning as soon as you accelerate above 25 km/h (16 mph). The learning time is normally about 30 seconds, but can take several minutes when the vehicle is driven in a metallic environment (e.g. multi-story car park, bridge and other concrete, highly metallic surfaces).
7.2. Rough running performance and vibrations
7.3. Vehicle handling.