136019 Removing And Installing Dual-mass Flywheel - Turbo

WM 136019 Removing and installing dual-mass flywheel - Turbo

Tools





Technical values






Preliminary work

1. Remove manual transmission.
=> 343519 Removing and installing transmission - section on "Removing"
2. Remove the clutch.
=> 305019 Removing and installing clutch - section on "Removing"

Removing dual-mass 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

CAUTION

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 internal serration screws (M10 x 29) on the flywheel. Carefully remove the flywheel (it is quite heavy - so be careful).
2.1. Replace internal serration screws.

Information

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

3. Visually inspect the friction surface on the dual-mass flywheel.

Installing dual-mass flywheel

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.

CAUTION

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.

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 internal serration screws (M10 x 29) and tighten them evenly and crosswise.
3. Position special tool toothed segment 9538/1 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 ten internal serration screws evenly and crosswise according to tightening specifications.
=> Initial tightening: 25 Nm (19 ftlb.)
=> Final tightening - torque angle: 120°
5. Remove toothed segment 9538/1.

Subsequent work

1. Install the clutch.
=> 305019 Removing and installing clutch - section on "Installing"
2. Install manual transmission.
=> 343519 Removing and installing transmission - section on "Installing"