Flywheel: Service and Repair

Flywheel

Special tools:
999 5112 GEAR SECTOR 999 5112 Gear Sector
999 5678 Special screw 999 5678 Special Screw

Replacing flywheel

Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Removal

Preparations
Removing the transmission: see Transmission, removing Transmission, Removing.
To remove the clutch: for gasoline see Clutch disc and pressure plate Service and Repair.

Note! The illustrations display a dual mass flywheel, but the method is the same for the single mass flywheels.

Removing the flywheel




Remove the engine speed (RPM) sensor with the bracket. Place it to one side.
Slacken off all the screws for the flywheel. Remove all the screws except for one.
Remove 999 5112 GEAR SECTOR 999 5112 Gear Sector.
Detach the flywheel from the crankshaft. Remove the remaining screw.
Remove the flywheel.

Checking crankshaft seal




Check the crankshaft seal for leakage.
To replace the crankshaft seal, refer to the car model and year.

Installation

Installing the flywheel





Note! Ensure that the mating surfaces on the crankshaft and flywheel are completely clean.

Use: 999 5678 Special screw 999 5678 Special Screw , consisting of 3 x studs with nuts.

Install:
- 3 x studs belonging to 999 5678 Special screw 999 5678 Special Screw distributed as illustrated
- the flywheel.

Note! Check that the locating pin on the crankshaft is positioned opposite the hole in the flywheel.

Note! Only applies to cars with dual mass flywheels: There is a marking in the form of a shallow hole (see the arrow). The marking indicates the direction to the guide hole on the flywheel.

Locate 999 5112 GEAR SECTOR 999 5112 Gear Sector against the flywheel.
Alternately tighten the nuts on the flywheel to the crankshaft. Use the three nuts which belong to 999 5678 Special screw 999 5678 Special Screw.

Caution! The flywheel must lie against the crankshaft flange before the screws are installed. There is a risk that excess locking fluid on the screws will come between the mating surfaces.

Install 7 new screws. Tighten. See the relevant specifications.
Remove the 3 nuts and studs.
Install the remaining 3 new screws for the flywheel. Tighten. See the relevant specifications.
Install the engine speed (RPM) sensor with the bracket. Tighten.

Finishing
To install the clutch: for gasoline see Clutch disc and pressure plate Service and Repair.
To install the transmission, see Transmission, installing Transmission, Installing.