Flywheel: Service and Repair

Replacing the flywheel

Special tools:
999 5112 GEAR SECTOR 999 5112 Gear Sector
999 5678 Special screw 999 5678 Special Screw

Removal

Preparations
To remove the transmission, see Removing the transmission Removing the Transmission.
To remove the clutch, see Pressure plate / clutch driven plate, replacing Service and Repair.

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 GEAR SECTOR 999 5112 Gear Sector.
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 Special screw 999 5678 Special Screw , which consists of 3 studs with nuts.

Install:
- The 3 studs belonging to tool 999 5678 Special screw 999 5678 Special Screw , distributed as illustrated
- the flywheel.

Note! Check that the locating pin on the crankshaft is positioned opposite the hole in the flywheel.

Note! 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 GEAR SECTOR 999 5112 Gear Sector against the flywheel.
Alternately tighten the nuts on the flywheel to the crankshaft. Use the three nuts which belong to tool 999 5678 Special screw 999 5678 Special Screw.

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 to 65°.
Install the engine speed (RPM) sensor with the bracket. Tighten to 10 Nm.

Finishing
To install the clutch, see Pressure plate / clutch driven plate, replacing Service and Repair.
To install the transmission, see Transmission, installing Transmission, Installing.