Remove/install a flywheel · ar0330g8002n · Mercedes-Benz WIS

AR03.30-G-8002N

Remove/install a flywheel

14.12.2018

Engine

470.9, 471.9 in model 800.110/112

Modification notes

14.02.2018	Screw/bolt for flywheel		BE03.30-N-1001-03L
23.09.2018	Work procedure completely revised.

1	Flywheel
2	Bolts
3	Drift
4	Dowel pin
5	Electrical connector
6	Screw
7	Timing case
B600	Crankshaft position sensor

W03.30-1098-06

1	Flywheel
8	Assembly device for commercial vehicle pressure plates

W03.30-1122-12

Topical note	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
	Remove
1	Remove clutch.	Only if installed.
		with Mercedes PowerShift 3	AR25.10-G-0050N
		 with shift mechanism, manual See information from body manufacturer.
2	Disconnect electrical connector (5) at crankshaft position sensor (B600).
3	Remove the screw (6) and the crankshaft position sensor (B600) from the timing case (7).
4	Attach turning device to timing case (7) and lock flywheel (1) with turning device.		AR03.30-G-1600-03N
		 Bolt, turning device to timing case	*BA01.60-N-1002-01N
		 Turning device	*904589046300
5	Loosen screws (2) and then remove two opposing screws (2) on the flywheel (1).	 Socket wrench bit	*422589020900
6	Screw centering pins (3) into the threaded holes.	 Drift	*403589026300
7	Remove the remaining screws (2) from the flywheel (1).
8	Remove turning device at timing case (7).		AR03.30-G-1600-03N
9	Attach assembly device for commercial vehicle pressure plates (8) to flywheel (1).
	000 588 00 61 00 Assembly device		WS01.00-N-3033B
	000 588 00 61 07 Bracket		WS01.00-N-3036B
	000 588 00 61 04 Adapter		WS01.00-N-3037B
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 screws (2).
	Screw for flywheel changed		BT03.30-W-0009-01H
			AR03.30-W-8002-02H
		Bolt for flywheel	*BE03.30-N-1001-03L
		If permissible shank length is exceeded,
		
		Replace screw/bolts (2).
13	Check clutch friction surface at flywheel (1).	If scorch marks, score marks or cracks are present,
		
		replace flywheel (1).
14	Check ring gear at flywheel (1) for wear.	If wear is present,
		
		replace flywheel (1).
15	Check flange at flywheel (1).	If galling is present due to radial shaft sealing ring,
		
		replace flywheel (1).
16	Check guide bearing in flywheel (1).	If there is wear or when replacing the flywheel (1),
		
		replace guide bearing in flywheel (1).
			AR03.30-G-8401N
17	Check rear radial shaft sealing ring.	If wear or damage exists,
		
		Replace rear radial shaft sealing ring.
			AR03.20-G-3063N
	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 assembly device for commercial vehicle pressure plates (8).	 Install flywheel (1) over the drifts (3). Note installation position of dowel pin (4).
20	Wet thread of screws (2) with engine oil and screw in screws (2).	 Do not tighten bolts (2) yet.
21	Remove assembly device for commercial vehicle pressure plates (8) from flywheel (1).
22	Remove both punch drifts (3).
23	Wet thread of remaining two screws (2) with engine oil and screw in remaining two screws (2).
24	Attach turning device to timing case (7) and lock flywheel (1) with turning device.		AR03.30-G-1600-03N
		 Bolt, turning device to timing case	*BA01.60-N-1002-01N
		 Turning device	*904589046300
25	Tighten all screws (2) in a diagonal pattern.	 Bolt, flywheel to crankshaft	*BA03.30-N-1002-01V
26	Press crankshaft position sensor (B600) into timing case (7) and tighten screw (6).	 Replace sealing ring on crankshaft position sensor (B600) and wet with engine oil.
		 Bolt, crankshaft position sensor to timing case	*BA07.04-N-1001-01H
27	Connect electrical connector (5) to crankshaft position sensor (B600).
28	Install clutch.	Only if installed.
		with Mercedes PowerShift 3	AR25.10-G-0050N
		 with shift mechanism, manual See information from body manufacturer.
29	Remove turning device at 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
BA01.60-N-1001-01N	Screw/bolt, cap of TDC inspection hole to timing case	Nm	30

 Timing case

Number	Designation		Engine 470.9, 471.9
BA01.60-N-1002-01N	Bolt, turning device to timing case	Nm	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

904 589 04 63 00

Turning device

422 589 02 09 00

Socket wrench bit

403 589 02 63 00

Drift

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