Flywheel: Service and Repair

Replacing The Flywheel

Special Tools: 999 5112, 999 5678

Replacing flywheel

NOTE: As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information is always correct.

Removal

Preparations
- Removing the transmission
- Remove the clutch

NOTE: The figures display a dual mass flywheel, but the method is the same for the single mass flywheels.

Removing the flywheel







- Remove the engine speed (RPM) sensor with the bracket. Place it to one side.
- Slacken off all the screws for the flywheel. Remove all the screws except for one.
- Remove gear sector 999 5112.
- Detach the flywheel from the crankshaft. Remove the remaining screw.
- Remove the flywheel.

Checking the crankshaft seal







- Check the crankshaft seal for leakage.
- To replace the crankshaft seal, refer to the car model and year.

Installation

Installing the flywheel

NOTE: Ensure that the mating surfaces on the crankshaft and flywheel are completely clean.

- Use tool 999 5678, which consists of 3 studs with nuts.

- Install







- The 3 studs belonging to tool 999 5678, distributed as shown in the above figure.
- the flywheel.

NOTE:
- Check that the locating pin on the crankshaft is positioned opposite the hole in the flywheel.
- Only applies to cars with dual mass flywheels: There is a marking in the form of a shallow hole (see the arrow). The marking indicates the direction to the guide hole on the flywheel.

- Locate gear sector 999 5112 against the flywheel.
- Alternately tighten the nuts on the flywheel to the crankshaft. Use the three nuts which belong to tool 999 5678.

CAUTION: The flywheel must lie against the crankshaft flange before the screws are installed. There is a risk that excess locking fluid on the screws will come between the mating surfaces.

- Install 7 new screws. Tighten crosswise. Tighten to 45 Nm.
- Remove the 3 nuts and studs.
- Install the remaining 3 new screws for the flywheel. Tighten to 45 Nm. Then angle-tighten all 10 screws crosswise. Tighten to 65 degrees.
- Install the engine speed (RPM) sensor with the bracket. Tighten to 10 Nm.

Finishing
- Install the clutch
- Install the transmission