Remove, install flywheel

AR03.30-W-8002B

10.1.07

ENGINE 541.9 in MODEL 950, 952, 953, 954

ENGINE 542.9 in MODEL 950, 952, 954

W03.30-1013-06

Shown on engine 541.9 without
code (G02) Torque converter clutch (WSK)

1 Flywheel

2 Bolt

3  Drifts

4 Dowel pin

B15 Crankshaft angle position sensor

L Shank length

Modification notes

26.4.05

Grease ring gear, deleted

Step 7

	Removing
1.1	Remove clutch	Vehicles without code (G02) Torque converter clutch (TCC) with single-plate clutch.	AR25.10-W-0050B
		Vehicles without code (G02) Torque converter clutch (TCC) with double-plate clutch.	AR25.10-W-0050BA
1.2	Remove torque converter clutch	Vehicles with code (G02) torque converter clutch (WSK)	AR25.40-W-0100A
2	Pull crankshaft angle position sensor (B15) out of the timing case
3	Remove cover of TDC inspection hole at timing case
4	Attach cranking device to timing case		*BA01.60-N-1009-01B
			*407589006300
5	Lockup flywheel (1) with cranking device		*407589006300
6	Remove two opposite bolts (2) on flywheel (1)		*422589020900
7	Screw drifts (3) into freed up threaded holes for removed bolts		*403589026300
8	Unscrew remaining bolts (2) at flywheel (1)		*422589020900
9	Remove flywheel (1) over drifts (3)	 Screw two bolts (M101.5) into opposite threaded holes and pull out flywheel (1).
			*403589026300
	Checking
10	Measure bolts (2)	 If permissible shank length (L) is exceeded, replace bolt (2) concerned	*BE03.30-N-1004-03C
11	Check coupling friction surface on flywheel (1)	 Only for vehicles without code (G02) Torque converter clutch (WSK). If burned, scored or cracked: 
		Rework flywheel (1) or	AR03.30-W-8022B
		install new flywheel (1).
12	Check ring gear of flywheel (1) for wear	 If worn: 
		Replace ring gear of flywheel (1).	AR03.30-W-8312B
13	Check flange or race on flywheel (1) for galling due to radial sealing ring	 If there is galling on the flange or race: 
		Install new race on flywheel (1).	AR03.30-W-8350A
14	Check locating bearing in flywheel (1)	 Only for vehicles without code (G02) Torque converter clutch (WSK). If wear is found: 
		Replace locating bearing in flywheel (1).	AR03.30-W-8401B
	Install
15	Install flywheel (1) over the drifts (3)	 Pay attention to installation position of dowel pin (4). Remove both bolts (M101.5) at flywheel (1).
			*403589026300
16	Remove bolts (2) at flywheel (1)	 Lightly lubricate bolts (2). Do not tighten down bolts (2).
			*422589020900
17	Remove both drifts (3)		*403589026300
18	Screw in remaining two bolts (2) on flywheel (1) and tighten all bolts (2)	 Lightly lubricate bolts (2).
			*BA03.30-N-1001-01F
			*422589020900
19	Press in locking bush and crankshaft angle position sensor (B15) all the way.	 Replace O-ring and inspect locking bush; replace if necessary.
20.1	Install clutch	Vehicles without code (G02) Torque converter clutch (TCC) with single-plate clutch.	AR25.10-W-0050B
		Vehicles without code (G02) Torque converter clutch (TCC) with double-plate clutch.	AR25.10-W-0050BA
20.2	Install torque converter clutch	Vehicles with code (G02) torque converter clutch (WSK)	AR25.40-W-0100A
21	Remove cranking device to timing case		*407589006300
22	Attach cover of TDC inspection hole at timing case		*BA01.60-N-1001-01B

Check values for flywheel

Number	Designation			Engine 541.9, 542.9 without code G02


BE03.30-N-1004-03C	Bolt, flywheel	Thread Ø	M	161.5
		Length of shank when new	mm	74.0
		Permissible shank length	mm	75,0

 Timing case

Number	Designation		Engine 541.9, 542.9


BA01.60-N-1001-01B	Bolt, end cover of TDC inspection hole to timing case	Nm	25
BA01.60-N-1009-01B	Bolt, engine cranking device to timing case	Nm	25

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

Number	Designation			Engine 541.9, 542.9


BA03.30-N-1001-01F	Bolt, flywheel to crankshaft	Stage 1	Nm	210
		Stage 2	°	90

422 589 02 09 00

403 589 02 63 00

407 589 00 63 00

Socket

Cranking device

Drift

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