Removal and Replacement

Removing and installing flywheel
Tools






Preliminary work for double-mass flywheel

1. Remove manual transmission.
2. Remove clutch.

Removing double-mass flywheel





Component overview
^ 1 - Double-mass flywheel
^ 2 - Fastening screw for double-mass flywheel, (8 M10 x 50 screws)
^ 3 - Clutch plate
^ 4 - Clutch pressure plate
^ 5 - Fastening screw for clutch pressure plate, (6 M8 screws)





Note: The toothed segment 9538/1 must be bored to [diameter] 15 mm to guarantee a perfect fit and to avoid damaging the thread in the crankcase.

1. To counter, fit toothed segment 9538/1 to the crankcase using an M12 x 50 hexagon-head bolt (fine thread).





2. Loosen and unscrew fastening screws on flywheel. Carefully take off flywheel (watch the thread!). Undo fastening screw for toothed segment.

Note: Check the friction surface of the flywheel. The flywheel must be replaced if it is damaged or discolored.

3. Inspect the friction surface of the flywheel visually.


Installing double-mass flywheel

Note: Before re-installation, clean the friction surface of the flywheel with a clean lint-free cloth that has been soaked in solvent naphtha or acetone.

1. Position double-mass flywheel on the crankshaft's dowel pin and press on to the crankshaft flange. Insert all fastening screws (8).
2. Align toothed segment 9538/1 and tighten fastening screw again.
3. Screw in and tighten fastening screws in diagonally opposite sequence. Initial tightening: 19 ft lb.; Final tightening - torque angle: 120°
4. Remove toothed segment.


Subsequent work for double-mass flywheel

1. Install clutch.
2. Install manual transmission.