Remove/install a flywheel

AR03.30-B-8002TJ

Remove/install a flywheel

12.02.16



Remove

1

Remove the clutch

AR25.10-B-0050TJ

2

Remove the closing cover from the distribution housing (5) and install the cranking device (4)

 Lock the cranking device (4) by inserting the pin.

AR03.30-B-1600-03A



*BA01.60-B-1003-01A



*904589046300

3

Extract the crankshaft position sensor (B15) from the distribution housing (5)

Do not undo the electrical connection.

4

Loosen two opposite screws (1)



*904589011000

5

Screw the dowel pins (3) onto the threaded holes



*904589026300

6

Remove the remaining screws (1)



*904589011000

7

Remove the flywheel (2) from the dowel pin (3)

 On the installed flywheel (2), install two screws (M8  80 or M10  80) at opposite threaded holes and remove the flywheel (2).



Check

8

Check the surface of the clutch for burned spots, stretch marks and cracks

 If necessary:



Machine the flywheel (2)

AR03.30-B-8022TJ

or replace the flywheel (2).

9

Inspect the flange on the flywheel (2) for wear tracks caused by the radial seal

 If necessary:



Replace the rear radial seal and

AR03.20-B-3063TJ

Replace the engine flywheel (2).

10

Check the rack for wear

 If necessary:



replace the flywheel rack (2)

AR03.30-B-8312TJ

or replace the flywheel (2).

11

Check the guide bearing on the flywheel (2)

 If necessary:



Replace the guide bearing on the flywheel (2).

AR03.30-B-8401TJ

12

Measure the shaft length (L) of the screws (1)

If the allowable shaft length (L) is exceeded, replace the respective screw (1).

*BE03.30-B-1001-02D



Installing

13

Install the flywheel (2) on the dowel pins (3)

 Note the mounting position of the adjustment pin on the crankshaft.

Remove both screws (M880 or M1080).

14

Lubricate the screws (1) with motor oil and insert them

 Do not tighten the screws (1) yet.

15

Loosen the dowel pins (3)

16

Apply motor oil to both remaining screws (1) and insert them, tighten all screws (1)



*BA03.30-B-1001-01C

17

Remove the cranking device (4) from the distribution housing (5) and install the closing cover

The cranking device (4) should be removed before starting the engine, otherwise the sprocket or the distribution housing (5) will be destroyed.

AR03.30-B-1600-03A



*BA01.60-B-1002-01A

18

Fit the crankshaft position sensor (B15) until the stop on the distribution housing (5)

 Check the sleeve of the crankshaft position sensor (B15), if necessary, replace it.

19

Install the clutch

AR25.10-B-0050TJ

Número

Denominação

Engine 924.9, 926.9

BE03.30-B-1001-02D

Anti-vibration pulley fastening bolts to the crankshaft

M14x1.5

length (L), new bolt

mm

59.5...60.0

length (L), max. used bolt

mm

61.0

M16x1.5

length (L), new bolt

mm

-

length (L), max. used bolt

mm

-

Número

Denominação

Engine 924.9; 926.9

BA01.60-B-1002-01A

Inspection window closing cover to timing case

Nm

25

BA01.60-B-1003-01A

Rotary device bolt on the timing case

Nm

25

Número

Denominação

Engine 924.9; 926.9

BA03.30-B-1001-01C

Crankshaft flywheel

First stage

Nm

125

Second stage

degrees

90...100