Overhaul

Removing and installing double-mass flywheel








Preliminary work

Preliminary work for double-mass flywheel

1. Remove manual transmission.
2. Remove clutch.

Removing double-mass flywheel - 3.8 l

Component overview





Overview of double-mass flywheel, 3.8 l

^ 1 - Double-mass flywheel, 3.8 l
^ 2 - Fastening screw for double-mass flywheel, (8 M10 screws)
^ 3 - Clutch plate
^ 4 - Clutch pressure plate
^ 5 - Fastening screw for clutch pressure plate, (6 M8 screws)

Information
The toothed segment 9538/1 must be bored to [diameter] 15 mm to guarantee a perfect fit and to avoid damaging the thread in the crankcase.

1. To counter, fit toothed segment 9538/1 to the crankcase using an M12 x 50 hexagon-head bolt (fine thread).





Toothed segment 9538/1

2. Loosen and unscrew fastening screws on flywheel. Carefully take off flywheel (watch the thread!). Undo fastening screw for toothed segment.





Flywheel, 3.8 l

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

3. Inspect the friction surface of the flywheel visually.

Installing double-mass flywheel

Information
Before re-installing the flywheel, clean the friction surface of the flywheel using a clean, lint-free cloth soaked in acetone or solvent naphtha).

1. Position double-mass flywheel on the crankshaft's dowel pin and press on to the crankshaft flange. Insert all fastening screws (8).
2. Align toothed segment 9538/1 and tighten fastening screw again.
3. Screw in and tighten fastening screws in diagonally opposite sequence. -> Initial tightening: 19 ftlb.; -> Final tightening - torque angle: 120°
4. Remove toothed segment.

Subsequent work

Subsequent work for double-mass flywheel

1. Install clutch.
2. Install manual transmission.