Remove/install flywheel / drive plate

AR03.30-P-8001A

Remove/install flywheel / drive plate

12.12.08

1.3.94

Technical modification: stretch-shank bolt replaced by a straight stretch shank bolt.

Refer to step 4

1.5.95

Bolts for clutch plate, flywheel, sheet metal two-mass flywheel made uniform

Step 4

 

Remove/install

1.1

Remove manual transmission

Model 163

AR26.10-P-0020GH

Model 170, 202, 208, 210

AR26.10-P-0020A

1.2

Remove automatic transmission

AR27.10-P-0500A

2

Remove clutch

AR25.10-P-0050A

3

Install retaining lock (03) for crankshaft/ring gear

 Use M690 bolts otherwise thread in rear end cover will be damaged.

AR03.30-P-5000HA

4

Unscrew bolts (1)



*000589011000

 Stretch shank bolts

*BA03.30-P-1004-01B

 Straight stretch shank bolts

*BA03.30-P-1006-01B

 Torx screws


Replace Torx screws and straight stretch shank bolt; see technical modification 

*BA03.30-P-1007-01B



Bolt for two-mass flywheel altered

BT03.30-P-0001-01A



Bolts for clutch plate, flywheel, sheet metal two-mass flywheel made uniform

Engine 111, 604, 605, 606

BT03.30-P-0002-01A

 Installation:
If no angle tightener is available, the bolts (1) can be turned by the specified angle in a single stroke, using a socket wrench and locking handle (10).

 Do not use a flexi-rod torque wrench for tightening to angle degrees in order to avoid any angle errors.

5

Check bolts (stretch shank bolts) for flywheel/clutch plate



AR03.30-P-8001-01HA

6.1

Remove the flywheel (96) or two-mass flywheel

 If manual transmission fitted

A certain installation position is prescribed by the straight pin (2).

 The flywheel, two-mass flywheel are balanced individually and can be replaced without balancing.

6.2

Take off drive plate (98) and washers (3)

 If automatic transmission fitted

A certain installation position is prescribed by the straight pin (2).

 The clutch plate is balanced and can be replaced without balancing.

7

Install in the reverse order

8

Perform default initialization.

 If a new flywheel is installed, perform initialization in the ME control unit with STAR Diagnosis in the menu point "Control unit adaptation".

Number

Designation

Engine 111 with a two-mass flywheel

Engine 111 with flywheel or driven plate

BE03.30-P-1001-01A

Flywheel or drive plate bolts (1st version)

Thread dia.  (D)

M

101

101

Stretch shank (d)

New

mm

8.5-0.2

8.5-0.2

min

mm

8.0

8.0

Shank length (L)

New

mm

57.0  0.2

22.00.2

max.

mm

-

22.5

See picture

AR03.30-P-8001-01HA

AR03.30-P-8001-01HA

Number

Designation

Engine 103

Engine 104

Engine 111

BA03.30-P-1004-01B

Stretch shank bolt for flywheel to crankshaft

Stage 1

Nm

30

45

40

Stage 2

°

90

90

90

BA03.30-P-1006-01B

Straight stretch shank bolt for flywheel to crankshaft

Stage 1

Nm

-

-

45

Stage 2

°

-

-

90

BA03.30-P-1007-01B

Bolt, flywheel or two-mass flywheel / drive plate to crankshaft

Stage 1

Nm

-

45

45

Stage 2

°

-

90

90