Flywheel: Service and Repair
New flywheel introduced on C70/S70/V70.Applies to following engines: B5204T3, B5234TX and B5254T
Special tools:
999 5112 GEAR SECTOR 999 5112 Gear Sector
999 5662 Compression tool 999 5662 Compression Tool
999 5663 Centering tool 999 5663 Centering Tool
999 5677 Counterhold 999 5677 Counterhold
999 5678 Special screw 999 5678 Special Screw
A new type of twin mass flywheel (TMS) was introduced in production during week 20 1997
A twin mass flywheel consists of two masses.
Torsion dampers with springs and friction elements are integrated into the flywheel.
This construction has the following advantages:
- The engine's tendency to variable power pickup is eliminated.
- The dampening effect of the twin mass flywheel minimizes clatter, idling rattle and noise at low engine speeds.
- Driveablity is improved as the pre-dampener element is no longer incorporated into the clutch driven plate but is integrated into twin mass flywheel.
Note! Introduced on all turbocharged engines.
Replacing flywheel
Remove transmission.
Removing transmission: Transmission, removal Transmission, Removal.
Caution! Changes to method in operation D5 as follows:
- Clamp hose running between brake fluid reservoir and clutch master cylinder using hose pliers.
- Before disassembling clutch line put paper under the adapter on the side of bell housing to catch any spilled fluid.
- Remove clutch line from adapter by pulling out the locking tongue which locks quick-release connector to adapter.
- Remove quick-release connector from adapter.
- Make sure that any brake fluid that leaks out is wiped off.
- Reinstall locking tongue in adapter.
- Attach a plastic bag with an elastic band to the open end of the clutch line to catch any fluid that runs out.
- Lift up pipe from holder on side of transmission and place it to one side.
- Remove ground lead from transmission.
- Remove clamps from engine cable harness.
- Then continue with operations D6 to D26 to remove transmission.
Removal of clutch
Secure clutch automatic adjustment.
- Before removal the automatic adjuster on the clutch must be locked.
- The three arrows in the illustration show where the clutch automatic adjuster can be locked.
Installing tool
Use counterhold: 999 5677 Counterhold 999 5677 Counterhold.
The three pins of counterhold lock automatic adjustment.
- Position counterhold as illustrated.
Ensure that all three pins fit in front of tension springs for automatic adjustment.
See inset.
- Press ring to clutch and slide out counterhold three hooks.
Secure hooks in outer edge middle holes to torque as illustrated. Lock flywheel.
Lock flywheel
Lock flywheel and remove flywheel sensor.
Flywheel must be locked before clutch can be removed.
- Lock flywheel with gear sector: 999 5112 GEAR SECTOR 999 5112 Gear Sector.
Visibly up on right of illustration.
- Remove flywheel sensor with holder.
Compress clutch
Use press tool: 999 5662 Compression tool 999 5662 Compression Tool , changed according to: Workshop Guide no.213, with conversion kit: 998 9741 Conversion kit 998 9741 Conversion Kit.
- Ensure that hooks engage properly but do not compress adjustment springs.
- Center press tool and position screws.
- Fasten press tool with one hand and hold in place with the other.
- Compress clutch to relieve automatic adjustment mechanism.
- If clutch is worn counterhold automatically turns plastic holder under spring counter-clockwise until it comes in line with marking on cover.
Marking two stamped arrows.
- Then continue to screw in press tool until diaphragm spring has pressed pressure plate to a free position.
Caution! Plate clicks out.
- Slacken off 6 screws crosswise attaching clutch to flywheel.
- Lift down clutch and clutch driven plate.
Relieve clutch
Screw center screws back on to press tool to relieve spring but do not move tool.
Caution! Do not put pressure on diaphragm spring longer than necessary. Relieve pressure on the diaphragm spring as soon as possible.
Replacing flywheel
Remove flywheel.
- Slacken off flywheel 10 screws crosswise and remove flywheel.
- Check for spillage at crankshaft seal and clean if necessary.
- Replacing crankshaft seal:.
Install flywheel
Installing flywheel.
Use tool: 999 5678 Special screw 999 5678 Special Screw , with 3 point pin screws with nuts.
- Ensure that crankshaft flange and flywheel mating surfaces are completely clean.
- Install 3 pin screws with spacing as illustrated.
Turn short thread length towards crankshaft.
- Install flywheel.
Note! Check that locating pin on crankshaft is positioned opposite hole in flywheel. Marking indicates position of locating hole.
- Locate gear sector: 999 5112 GEAR SECTOR 999 5112 Gear Sector.
- Pull flywheel in towards crankshaft with three tool nuts. 999 5678 Special screw 999 5678 Special Screw.
Corresponding part of nut should face flywheel.
Note! Flywheel should bear on crankshaft floor before other screws are installed there.
- Install other screws there.
Use new screws and tighten crosswise with: 45 Nm. .
- Slacken off 3 nuts and remove 3 studs.
- Install 3 new standard nuts and tighten with: 45 Nm .
- The angle-tighten all 10 screws crosswise: 65 degrees .
Install flywheel sensor with bracket.
Tighten screws to: 10 Nm .
Install clutch
Install centering tool.
Use centering tool: 999 5663 Centering tool 999 5663 Centering Tool , , changed according to: Workshop Guide no. 213, with conversion kit: 998 9742 Conversion kit 998 9742 Conversion Kit.
- Remove black cone from centering tool.
- Install centering drift in crankshaft center.
- Press in as far as possible.
- Use a wrench as a counterhold and then tighten the outer socket until the tool expander locks centering drift.
Make sure that centering drift is secure in crankshaft.
Install clutch driven plate and center
Install clutch driven plate.
Install clutch driven plate on centering tool.
Caution! Turn longer part of hub in towards flywheel. Marking on clutch driven plate.
- Screw on centering drift black cone and secure clutch driven plate.
- Tighten cone by hand to center the clutch driven plate.
- Damage to clutch driven plate can occur when tightening with tool.
Install clutch
Install clutch.
- Check that clutch automatic adjustment is secured with counterhold: 999 5677 Counterhold 999 5677 Counterhold according to: Removal of clutch and Installing tool.
- Compress clutch according to procedure: Compress clutch.
- Install clutch and locate guide pins.
Press tool center screw is hollow so the centering tool can be installed.
- Check that clutch is in contact with the flywheel all around its circumference.
- Carefully tighten 6 screws crosswise so that clutch is guided onto the guide pins and is in contact with flywheel all the way around its circumference.
- Tighten screws crosswise to: 25 Nm .
Remove tools
Remove press tool and counterhold.
- Unscrew center screw and remove press tool.
- Remove clutch driven plate centering cone.
- Slacken off socket and then tap on centering tools with a rubber mallet so expander is released.
Rubber mallet is used so as not to damage threads.
Remove center centering tools.
- Slacken off hooks and remove counterhold.
- Remove gear sector locking flywheel.
Install transmission
Install.
- Transmission.
Caution! Changes to method in operation E21 as follows:
Install.
- Wiring. Clamp cable trunks and ground lead.
- Install new quick-release connector on clutch line terminal.
- Lubricate rubber seal with a drop brake fluid before joining.
Caution! Ensure everything is clean when working with hydraulic components.
- Check that striker plate is located in adapter.
Then secure clutch line in adapter so that striker plate clicks into place.
- Install clutch line in holder on side of transmission as illustrated.
- Remove hose clip from hose in clutch master cylinder.
- Bleed system and fill brake fluid if required.
Use Volvo Genuine parts brake fluid only.
Now continue with operations E22 to E25.
Check and test driving
Check and test drive.
- Clean and check that everything is in position.
- Start up car and check first with gear in neutral.
- Shift gears quickly up and down a few times.
Then test drive car without putting pressure on clutch at first.
Once the engine has reached operating temperature and the clutch feels normal, drive the car changing gear quickly. No jolts or vibrations should be noticed.
Caution! Inform the customer that flywheel has been changed.