Flywheel: Service and Repair

WM 136019 Removing and installing flywheel (dual-mass flywheel) on DFI engines

Tools





Technical values






Preliminary work

1. Remove transmission. -> 343519 Removing and installing transmission - section on "Removing" 343519 Removing and installing transmission
2. Remove clutch pressure plate and clutch. -> 305019 Removing and installing clutch - section on "Removing" Service and Repair

Removing flywheel (dual-mass flywheel)

Information

- Clean the crankshaft stub before installing the flywheel (remove rust).

- Use a special metal-polishing pad (e.g. Never Dull) for this.





Clutch and flywheel

1. Block flywheel. To do this, attach a suitable toothed segment toothed segment 201a or toothed segment 9538/1 to a screw hole in the crankcase so that at least one tooth engages with the starter teeth. Place a washer (approx. 5 mm) under the segment if necessary. => Toothed segment





Toothed segment

WARNING

Danger of injury if flywheel falls down.

- Danger of injury to feet.

-> Wear protective gear (e.g. safety shoes, gloves).
-> Work carefully (get another person to help you to install and remove the flywheel, if necessary).

Information

- To make it easier to re-install a used flywheel, use a felt-tip pen to mark the crankshaft stub and flywheel before removing it. This makes it easier to install it again later.

- If the flywheel is stuck, loosen it by levering it at the sides with two screwdrivers and then remove it.

2. Remove flywheel. To do this, loosen the fastening screws crosswise. => Fastening screws





Fastening screws

3. Take off flywheel and clean flange.

Installing flywheel (dual-mass flywheel)

Information

- Clean the crankshaft stub before installing the flywheel (remove rust).

- Use a special metal-polishing pad (e.g. Never Dull) for this.

1. Clean flange and fit flywheel (align with removal marking if necessary). Fit the new fastening screws and tighten hand-tight.
2. Block flywheel. To do this, attach toothed segment 201a or toothed segment 9538/1 to a screw hole in the crankcase so that at least one tooth engages with the starter teeth. Place a washer (approx. 5 mm) under the segment if necessary. => Toothed segment





Toothed segment





Clutch and flywheel

3. Tighten the new fastening screws crosswise. => Fastening screws => Tightening torque: 60 Nm (44 ftlb.) => Torque angle: 90°





Fastening screws

Subsequent work

1. Install transmission. -> 343519 Removing and installing transmission - section on "Installing" 343519 Removing and installing transmission
2. Install clutch pressure plate and clutch. -> 305019 Removing and installing clutch - section on "Installing" Service and Repair