Flywheel: Service and Repair

WM 136019 Removing and installing flywheel








Preliminary work

Preliminary work
1. Remove engine.
2. Remove transmission.

Caution
Clutch pressure plate not loosened and tightened correctly.
Pressure plate can be deformed.

-> Always loosen and tighten screws crosswise and in several stages.
-> Always replace screws.

Remove clutch.

Removal

Removing flywheel





Component overview

Caution
Removing and installing flywheel
Leaks
Risk of damage to the flywheel and adjacent components

-> Be very careful during removal and installation.
-> Get another person to help because of the weight.

1. Remove flywheel.
1.1. Loosen and unscrew the nine cheese head bolts (M10 x 62) while countering at the crankshaft pulley using special tool holding wrench 9548. Carefully take off flywheel.
2. Check clutch plate for wear.

Information
Check the friction surface of the flywheel. The flywheel must be replaced if it is damaged or discolored.

3. Check pressure plate and flywheel for wear; e.g. scoring or blueing on contact surfaces. Replace components if necessary.

Installation

Installing flywheel

Caution
Use solvent naphtha or acetone to clean/degrease components.
Harmful to skin and eyes.

-> Always observe the manufacturer's specifications.
-> Wear appropriate (gasoline-resistant) protective gear, such as apron, gloves and goggles.

1. Remove protective wax on new parts with acetone or solvent naphtha.

Caution
Removing and installing flywheel
Leaks
Risk of damage to the flywheel and adjacent components

-> Be very careful during removal and installation.
-> Get another person to help because of the weight.

2. Correctly position flywheel together with guide bearing at the crankshaft flange (dowel pin -arrow- and insert the nine internal-serration screws (M10 x 62).





Crankshaft flange dowel sleeve

3. Screw in the screws evenly and tighten to the specified torque in the correct sequence -1- to 9-. Counter at the crankshaft pulley using special tool holding wrench 9548.
-> Tightening torque: 85 Nm (63 ftlb.)





Tightening sequence for flywheel

Subsequent work

Subsequent work

Caution
Clutch pressure plate not loosened and tightened correctly.
Pressure plate can be deformed.

-> Always loosen and tighten screws crosswise and in several stages.
-> Always replace screws.

1. Install clutch.
1.1. Center clutch plate with centering mandrel 9102 on flywheel, position pressure plate together with ring gear and fix in place using the nine cheese head bolts (M8 x 40) -1-.





Pressure plate

1.2. Screw in cheese head bolts evenly and crosswise and tighten to the specified torque. To counter, position toothed segment p201 b on stud.
-> Final tightening: 23 Nm (17 ftlb.)
2. Mount transmission.
3. Install engine.