Remove/install a flywheel

AR03.30-G-8002CH

Remove/install a flywheel

12.02.2019

Engine

457.9, 458.9 in model 000.001

1

Flywheel

2

Screw

3

Drift

4

Dowel pin

5

Turning device

6

Crankshaft position sensor

L

Shank length

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A



Remove

1

Remove clutch.

Engine without reinforced coupling

AR25.10-G-0050CH

Engine with reinforced coupling

AR25.10-G-0050CHA

2

Pull crankshaft position sensor (6) out of the timing case.

3

Attach turning device to the timing case.

AR03.30-G-1600-03CH

 Bolt, turning device to timing case

*BA01.60-N-1009-01K

 Turning device

*904589046300

4

Block flywheel (1) with the turning device.

 Turning device

*904589046300

5

Remove two opposite screws (2) from the flywheel (1).

 Socket wrench bit

*422589020900

6

Screw drifts (3) into the free threaded holes.

 Drift

*403589026300

7

Remove remaining screws (2) at flywheel (1).

 Socket wrench bit

*422589020900

8

Remove flywheel (1) over the drifts (3).

 Screw two screws (M10x1,5) into opposite threaded holes and pull out flywheel (1).

 Drift

*403589026300



Check

9

Measure screws (2).

Flywheel bolt

*BE03.30-N-1004-03J

If permissible shank length (L) is exceeded,



Replace screw/bolt (2).

10

Check clutch friction surface at flywheel (1).

If scorch marks, score marks, or cracks are detected,



rework flywheel (1) or replace if necessary.

AR03.30-G-8022CH

11

Check ring gear at flywheel (1) for wear.

If damage is identifiable



replace the flywheel's ring gear (1).

AR03.30-G-8312CH

12

Check flange or race on the flywheel (1) for galling caused by the radial shaft sealing ring.

If damage is identifiable



replace flywheel (1) or replace race on flywheel (1).

AR03.30-G-8350CH

13

Check guide bearing in flywheel (1).

If damage is identifiable



replace guide bearing in flywheel (1).

AR03.30-G-8401CH

14

Check rear radial shaft sealing ring for leak tightness.

If damage is identifiable



Replace rear radial shaft sealing ring.

AR03.20-G-3063CH

15

Check bush of the crankshaft position sensor (6).

 Visual inspection.

If damage is identifiable



replace bush of the crankshaft position sensor (6).



Install

16

Install flywheel (1) over the drifts (3).

 Note installation position of dowel pin (4).

 Drift

*403589026300

17

Remove both screws (M10x1,5) from the flywheel (1).

18

Wet screws (2) on the thread and on the contact surface slightly with engine oil.

19

Screw screws (2) into the free threaded holes on the flywheel (1) and tighten slightly by hand.

 Socket wrench bit

*422589020900

20

Remove both punch drifts (3).

21

Screw in remaining two screws (2) on the flywheel (1) and tighten all screws (2).

 Bolt, flywheel to crankshaft

*BA03.30-N-1001-01R

 Socket wrench bit

*422589020900

22

Remove the cranking device from the timing case.

AR03.30-G-1600-03CH

 Bolt, cap of TDC inspection hole to timing case

*BA01.60-N-1001-01K

23

Press in bush and crankshaft position sensor (6) with new sealing ring up to end stop.

24

Install clutch.

Engine without reinforced coupling

AR25.10-G-0050CH

Engine with reinforced coupling

AR25.10-G-0050CHA

Check values for flywheel

Number

Designation

Engine 457.9, 458.9

BE03.30-N-1004-03J

Flywheel bolt

Thread diameter

M

161,5

Length of shank when new

mm

74,0

Shank length

mm

75,0

 Timing case

Number

Designation

Engine 457.9, 458.9 in model 000.001

BA01.60-N-1001-01K

Bolt, cap of TDC inspection hole to timing case

Nm

25

 Timing case

Number

Designation

Engine 457.9, 458.9 in model 000.001

BA01.60-N-1009-01K

Bolt, turning device to timing case

Nm

25

 Flywheel, drive plate, vibration damper, starter ring gear

Number

Designation

Engine 457.9, 458.9 in model 000.001

BA03.30-N-1001-01R

Bolt, flywheel to crankshaft

Stage 1

Nm

210

Stage 2

°

90