Removal and Replacement
WM 444019 Mounting tyres (removing and installing tyres) - for vehicles with and without TPM
Tools
Tyre removal/mounting machine
Only use recommended tyre removal/mounting machine and auxiliary equipment (special mounting lever, bead holding-down device). Refer to Tools and Equipment.
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- Information media
- WEST.
- Main group: 4 - Running gear/Tool type: Workshop Equipment/Dealer Classification: All
WE 1084 Tyre removal/mounting machine
Auxiliary equipment
Auxiliary equipment
Requirements/information on removing/mounting tyres
Information
- Tyre temperature during removal/mounting must be approx. 20 °C (at least 15 °C). Allow enough time to heat the vehicle/tyres 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 tyre temperature is approx. - 15 °C, approx. 3 hours are required to heat the tyres to the required temperature.
- Before removal/mounting, it is important to establish whether a Tyre Pressure Monitoring system (TPM) is fitted. The tyre valve serves as the distinguishing feature. Without TPM: rubber valve. With TPM: aluminium valve. If a TPM system is fitted, read the special information on the Tyre Pressure Monitoring system (see module in this main information).
- Vehicles with TPM: Before changing a tyre, 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 tyre 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 tyre during removal/mounting. If this is not observed, damage will occur that will render a tyre 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 tyre 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 tyre/rim, true running, superficial damage and deformation).
- If you intend to continue using the tyre, check it for damage (sealing face between tyre/rim, ply damage, tyre beads, sidewalls and tread depth).
- The rubber valve must generally be replaced when a tyre change is necessary. In vehicles with TPM (aluminium valve), the valve only needs to be replaced in exceptional cases. This is elaborated further in: "Special information on TPM" (module in this main information).
- When mounting tyres, pay particular attention to the direction of rotation and the inside/outside.
- When replacing only one tyre on an axle, make sure that the tread depth of the new tyre does not differ from that of the other tyre 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 tyres 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 tyre, 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.
Wheel electronics unit (shown as an example)
Component overview for TPM valve/wheel electronics
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
- Tyre sealant (tyre 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) => Countering TPM valve while tightening .
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 T 20) 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 tyres (removing and installing tyres)
Removing tyres
For correct tyre removal/mounting, follow the instructions provided for the tyre removal/mounting machine.
See Requirements/information on removing/mounting tyres.
1. Fit and clamp a clean disc wheel on the tyre removal/mounting machine.
Check that the tyre is seated securely and without damage (as described in the instructions provided for the tyre removal/mounting machine).
2. Unscrew the valve insert and release the air so that the tyre is depressurised.
3. Set the tyre bead press-off tool (in accordance with the tyre size).
Setting the tyre bead press-off tool
3.1. Set the tyre bead press-off tool to the inch graduation (rough setting in accordance with the tyre size).
3.2. Then adjust the setting precisely (the press-off roller must not touch the rim when positioned on the tyre). If this is not the case, the rim flange may be damaged by the press-off rollers.
4. Loosen the lower and upper tyre bead (press the tyre off the rim).
4.1. The wheel must be turned anti-clockwise (anti-clockwise rotation of the mounting table) when pressing the tyre off the rim (loosening the tyre bead). Otherwise, excessive forces occur on the fastening bolts of the machine which can break the bolts.
First press off the lower tyre bead and then the upper tyre bead (to ensure that the wheel remains seated securely on the machine).
Coat the tyre beads with mounting paste even at this stage of the procedure to make it easier to press the tyre bead off.
4.2. Loosen the two bead press-off tools again (by moving them back to their original position).
5. Before removing the tyre, coat the tyre beads with mounting paste again if necessary to facilitate removal.
Information
- Always use a bead holding-down device for removing the upper tyre bead (second tyre bead).
- Use the Wulstboy bead holding-down device (type 2 in section 6.2) for tyre/wheel combinations that are difficult to remove.
6. Removal
6.1. Removing upper tyre bead - type 1
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 tyre bead, and then guided over the mounting shoe and pushed down.
Lift the tyre 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 tyre bead can become jammed and be damaged irreparably.
- The mounting lever must be the same distance from the inside of the tyre 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) tyre bead must be in the deep bed during removal.
- The tyre bead must not be pressing against the wheel electronics unit.
6.2. Removing upper tyre bead using bead holding-down device type 2 = Wulstboy
Removal using Wulstboy
Valve/wheel electronics unit at approx. 12 o'clock position.
Use the upper plastic press-off roller on the mounting machine to press the upper tyre bead approx. 4 to 5 cm below the rim flange (max. 5 cm/the belt edge of the tyre 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". Move the arm of the bead holding-down device to the 1 o'clock position.
Turn the wheel slowly in a clockwise direction (clockwise rotation) and insert the blocks of the bead holding-down device.
Remove the upper press-off roller on the mounting machine from the tyre and fit the mounting head on the rim flange. Insert the mounting lever (with plastic protection) -1- and lever the upper tyre bead over the mounting head.
Continue turning the disc wheel slowly (clockwise rotation) until the bead holding-down device (Wulstboy) is just in front of the mounting head. Remove the Wulstboy using holding-down device 9539. Continue turning the disc wheel slowly (clockwise rotation) until the upper bead is completely removed.
6.3.
7. Removing lower tyre bead:
Removing tyres
Valve/wheel electronics unit at 12 o'clock position.
Pull the tyre upwards and push it into the rim bed underneath the second tyre 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 tyre 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 tyre is removed.
8. Set the mounting lever and tyre 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 tyres
NOTICE
Wheel electronics
- Wheel electronics unit and valve may have been fitted incorrectly.
- Wheel electronics units may not have been assigned correctly.
-> Read and follow the installation instructions for the wheel electronics units. => 443219 Removing and installing wheel electronics
-> Check that the wheel electronics units are assigned correctly. => 443200 Tyre Pressure Monitoring (TPM) system not active after changing wheels
Information
- For correct tyre mounting, follow the instructions provided for the tyre removal/mounting machine.
- Always use approved tyres and tyre sizes (specification code/speed index/load capacity). This data can be found in the applicable/current Technical Information.
- Tyre temperature during removal/mounting must be approx. 20 °C (at least 15 °C). Allow enough time to heat the vehicle/tyres 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 tyre temperature is approx. - 15 °C, approx. 3 hours are required to heat the tyres to the required temperature.
- The wheel electronics must not be treated with compressed air, tyre mounting paste, cleaning agents or any other solvents.
- Disc wheels with wheel electronics must not be cleaned with a high-pressure power cleaner before tyres have been fitted.
- Do not expose filter surface of wheel electronics. Remove soiling with a lint-free cloth. Do not apply tyre mounting paste to the wheel electronics unit. All traces of tyre mounting paste must be removed from the wheel electronics unit.
- During fitting, ensure that the tyre bead is not pressed against the wheel electronics unit.
- Huge tension can be transferred to the tyre bead when the mounting paste dries quickly. It is therefore absolutely essential to mount the upper and lower tyre bead quickly and without delay.
1. Complete preparatory steps for mounting tyres:
- Remove abraded rubber particles from the disc wheel and check for damage. => 441202 Checking disc wheels.
- Fit and clamp the clean wheel as described in the instructions provided for the tyre 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 tyre mounting paste.
- If you intend to continue using the tyre, check it for damage (sealing face between tyre/rim, ply damage, tyre beads, sidewalls and tread depth).
- As a general rule, check the bead area (mounting and sealing face) for damage before mounting tyres (even new tyres). Ensure that this area is perfectly clean to prevent any slow air leaks (loss of tyre pressure) in this area (after mounting the tyre). A loss of tyre pressure often goes unnoticed on vehicles without TPM. Serious consequence: Reduced driving dynamics and the tyre can be damaged irreparably as a result of increased kneading action (overheating).
2. Coat the rim and tyre (both bead areas) with sufficient tyre mounting paste - TIP TOP Universal, Order No. 593 0601 - or Contifix. Absolute cleanliness is essential (clean brush/clean tyre mounting paste). Make sure that there are no traces of tyre mounting paste on the wheel electronics unit.
3. Fitting lower tyre bead (first tyre bead).
Place the tyre 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 tyre, lower bead, Figure 1
Push the lower tyre bead (first tyre bead) partly over the rim flange and guide it through the mounting head => Mounting tyre, lower tyre bead, Figure 2. Turn the disc wheel slowly in a clockwise direction (clockwise rotation of mounting table) until the lower tyre bead is completely fitted.
Mounting tyre, lower tyre bead, Figure 2
4. Fitting upper tyre bead (second tyre bead) using bead holding-down device. This presses the tyre bead into the deep bed.
Information
- Always use a bead holding-down device for mounting the upper tyre bead (second tyre bead).
- There are two types of bead holding-down devices. These are described in sections 4.1 and 4.2 below.
- Use the Wulstboy bead holding-down device (type 2 in section 4.2) for tyre/wheel combinations that are difficult to mount.
4.1. Fitting upper tyre bead (second tyre bead) using bead holding-down device type 1 = special tool 9539
Mounting tyre, upper bead using holding-down device 9539
Position the mounting head -1- approx. 15 cm to the right of the valve -2-.
Hold the upper tyre bead (second tyre 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 tyre bead is completely fitted.
4.2. Fitting upper tyre bead (second tyre bead) using bead holding-down device type 2 = Wulstboy
Inserting Wulstboy blocks
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 tyre bead approx. 4 to 5 cm below the rim flange (max. 5 cm/the belt edge of the tyre 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.
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 tyre 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 tyres.
5.1. Remove entire wheel from tyre fitting unit.
WARNING
High tyre seating pressure
- Risk of squashing or bruising
-> Use a tyre filling cage.
5.2. Fill the tyre (without the valve insert) with air immediately in the tyre filling cage (while the tyre mounting paste is still fully effective). Continue filling the tyre until the tyre beads slide/jump over the humps (max. 3.3 bar/48 psi).
Tyre filling cage
If the tyre is not seated correctly when the maximum permitted tyre seating pressure (max. 3.3 bar/48 psi) is applied, coat the wheel and tyre again with tyre mounting paste TIP TOP Universal or Contifix and repeat the procedure.
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 tyre to the setting pressure of 4.0 bar (58 psi). Check that the tyre bead is seated correctly. The tyre must be lying evenly against the rim all the way around.
Set the prescribed tyre pressure. => 4405IN Wheels and tyres/tyre pressure. Screw on valve cap.
6. Balance the wheel => 440594 Balancing/optimising wheels.
7. Perform a test drive. Avoid extreme driving manoeuvres (acceleration, braking) during the test drive to prevent the tyre from turning on the rim.
This can happen if the tyre 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 (Tyre Pressure Monitoring system).
Before starting the test drive (with "ignition on"), select the mounted set of wheels under Main menu > Tyre 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-storey car park, bridge and other concrete, highly metallic surfaces).
7.2. Rough running performance and vibrations
7.3. Vehicle handling.