136019 Removing and installing dual-mass flywheel

WM 136019 Removing and installing dual-mass flywheel

Tools





Technical values





Preliminary work

1. Remove manual transmission.
-> 34351900 Removing and installing transmission.

Information

Loosen and tighten screws on the component according to specifications.

2. Remove the clutch.
-> 305019 Removing and installing clutch Service and Repair.

Removing flywheel

Component overview





Overview of dual-mass flywheel





1. Position special tool toothed segment 9538/1 -1- for countering at the starter ring gear and place it on the cast strut.





Toothed segment position for loosening screws

NOTICE

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. Loosen and unscrew ten M10 x 29 (internal serration) fastening screws. Carefully remove the flywheel (it is quite heavy - so be careful).
2.1. Replace fastening screws.

Information

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

3. Visually inspect the friction surface on the flywheel.

Installing flywheel

NOTICE

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.

WARNING

Caustic fluids

- Danger of chemical burns

-> Avoid contact with caustic fluid.
-> Wear personal protective gear.
-> Ensure that there is good ventilation.
-> If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

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

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).

2. Position the dual-mass flywheel on the crankshaft dowel pin and press it onto the crankshaft flange.
2.1. Fit ten new M10 x 29 (internal serration) fastening screws and tighten them evenly and crosswise.
3. Toothed segment 9538/1 must be used for countering at the starter ring gear.
3.1. Place toothed segment -1- on the cast strut. Turn the flywheel slightly to the right to do this.





Toothed segment position for tightening screws

4. Tighten fastening screws evenly and crosswise to the prescribed tightening torque.
=> Initial tightening: 25 Nm (19 ftlb.)
=> Final tightening - torque angle: 120°
5. Remove the toothed segment.

Subsequent work

Information

Loosen and tighten screws on the component according to specifications.

1. Install the clutch.
-> 305019 Removing and installing clutch Service and Repair.
=> Initial tightening: 15 Nm (11 ftlb.)
=> Final tightening - torque angle: 45°
2. Install manual transmission.
-> 34351900 Removing and installing transmission.