Remove/install a flywheel

AR03.30-G-8002H

Remove/install a flywheel

14.12.2018

Engine

470.9, 471.9, 473.9 in model 800.310/320

Modification notes

14.02.2018

Screw/bolt for flywheel

BE03.30-N-1001-03L

1

Flywheel

2

Bolts

3

Drift

4

Dowel pin

5

Electrical connector

6

Screw

7

Timing case

9

Crankshaft position sensor

1

Flywheel

8

Assembly device for commercial vehicle pressure plates

Topical note

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

AH00.00-P-0020-01A



Remove

1

Remove clutch

Engine 470.9, 471.9, 473.9 in model 800.310/320with Mercedes PowerShift 3

AR25.10-G-0050H

 Engine 470.9, 471.9, 473.9 in model 800.310/320with shift mechanism, manual
See information provided by vehicle manufacturer or engine supplier.

2

Disconnect electrical connection (5) at crankshaft position sensor (9)

3

Remove screw/bolt (6) and take crankshaft position sensor (9) out of the timing case (7)

4

Attach cranking device to the timing case (7) and block flywheel (1) with cranking device

AR03.30-G-1600-03N

 Bolt, turning device to timing case

*BA01.60-N-1002-01N

 Turning device

*904589046300

5

Loosen screw/bolts (2) and then remove two opposite screw/bolts (2) on the flywheel (1)

 Socket wrench bit

*422589020900

6

Screw drifts (3) into threaded holes

 Drift

*403589026300

7

Unscrew remaining screw/bolts (2) at flywheel (1)

8

Remove cranking device on timing case (7)

9

Attach assembly device for commercial vehicle pressure plates (8) to flywheel (1)

10

Remove flywheel (1) with assembly device for commercial vehicle pressure plates (8)

 Detach flywheel (1) over the  drifts (3).

11

Remove assembly device for commercial vehicle pressure plates (8) from flywheel (1)

Only if the flywheel (1) is replaced.



Check

12

Check shank length of screw/bolts (2)

AR03.30-W-8002-02H

Bolt for flywheel

*BE03.30-N-1001-03L

In case of exceeding the permissible shank length.



Replace screw/bolts (2).

13

Check coupling friction surface on flywheel (1)

If there are scorch marks, score marks or cracks.



replace flywheel (1).

14

Check ring gear on flywheel (1) for wear

If worn.



replace flywheel (1).

15

Check flange on flywheel (1)

For galling by the radial shaft sealing ring.



replace flywheel (1).

16

Check guide bearing in flywheel (1)

For wear or for replacing the flywheel (1).



Replace guide bearing in flywheel (1).

AR03.30-G-8401H

17

Check rear radial shaft sealing ring

If wear or damage present.



Replace crankshaft radial shaft sealing ring.

AR03.20-G-3063H



Install

18

Attach assembly device for commercial vehicle pressure plates (8) to flywheel (1)

Only if the flywheel (1) has been replaced.

19

Install flywheel (1) with the assembly device for commercial vehicle pressure plates (8)

 Install flywheel (1) over the drifts (3).
Observe installation position of dowel pin (4).

20

Wet screw/bolts thread (2) with engine oil and screw in screw/bolts (2)

 Do not tighten bolts (2) yet.

21

Remove assembly device for commercial vehicle pressure plates (8) from flywheel (1)

22

Remove both drifts (3)

23

Wet thread of the remaining screw/bolts (2) with engine oil and screw in remaining two screw/bolts (2)

24

Attach cranking device to the timing case (7) and block flywheel (1) with cranking device

AR03.30-G-1600-03N

 Bolt, turning device to timing case

*BA01.60-N-1002-01N

 Turning device

*904589046300

25

Tighten all screw/bolts (2) cross-wise

 Bolt, flywheel to crankshaft

*BA03.30-N-1002-01V

26

Push crankshaft position sensor (9) into the timing case (7) and tighten screw/bolt (6)

 Replace sealing ring on crankshaft position sensor (9) and wet with engine oil.

 Bolt, crankshaft position sensor to timing case

*BA07.04-N-1001-01H

27

Connect electrical connection (5) to crankshaft position sensor (9)

28

Install clutch

Engine 470.9, 471.9, 473.9 in model 800.310/320with Mercedes PowerShift 3

AR25.10-G-0050H

 Engine 470.9, 471.9, 473.9 in model 800.310/320with shift mechanism, manual
See information provided by vehicle manufacturer or engine supplier.

29

Remove cranking device on timing case (7)

AR03.30-G-1600-03N

 Screw/bolt, cap of TDC inspection hole to timing case

*BA01.60-N-1001-01N

Check values for flywheel

Number

Designation

Engine 470.9

Engine 471.9, 473.9

BE03.30-N-1001-03L

Bolt for flywheel

A 002 990 55 00

Bolt dimension

mm

-

M16x1,5x87-0,5

Permissible shank length

mm

-

 88,0

A 003 990 74 00

Bolt dimension

mm

M16x1,5x91-0,5

-

Permissible shank length

mm

 92,0

-

A 006 990 45 00

Bolt dimension

mm

M16x1,5x90-0,5

M16x1,5x90-0,5

Permissible shank length

mm

 92,0

 92,0

A 003 990 18 00

Bolt dimension

mm

M16x1,5x97-0,5

M16x1,5x97-0,5

Permissible shank length

mm

 98,0

 98,0

A 004 990 22 00

Bolt dimension

mm

M16x1,5x102-0,5

-

Permissible shank length

mm

 104,0

-

 Timing case

Number

Designation

Engine 470.9, 471.9

Engine 473.9

BA01.60-N-1001-01N

Screw/bolt, cap of TDC inspection hole to timing case

Nm

30

30

 Timing case

Number

Designation

Engine 470.9, 471.9

Engine 473.9

BA01.60-N-1002-01N

Bolt, turning device to timing case

Nm

30

30

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

Number

Designation

Engine 470.9, 471.9, 473.9

BA03.30-N-1002-01V

Bolt, flywheel to crankshaft

Stage 1

Nm

200

Stage 2

°

90

 Sensors

Number

Designation

Engine 470.9, 471.9, 473.9

BA07.04-N-1001-01H

Bolt, crankshaft position sensor to timing case

Nm

10