Removing and installing flywheel / driving disc plate - AR03.30-P-8001HA

ENGINE 602.982 /983, 604, 605, 606 / 

Fig 1: Identifying Flywheel Driving Disc Plate Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Modification notes

1.3.94	Technical modification: Stretch shank bolt replaced by straight stretch shank bolt.	Step 4
1.5.95	Bolt for driven plate, flywheel, sheet metal two-mass flywheel standardized	Step 4

	Removing, installing
1.1	Remove manual transmission		AR26.10-P-0020A
1.2	Remove automatic transmission	Model 202, 210, 140	AR27.10-P-0500A
		Model 461	AR27.10-P-0500G
		Model 463	AR27.10-P-0500BD
2.1	Remove clutch	Manual transmission	AR25.10-P-0050A
3	Install retaining lock (3,4) for crankshaft/ring gear	Use bolts M6x90 otherwise the threads in the rear end cover will be damaged.	AR03.30-P-5000HA
4	Unscrew bolts (1, 1a, 1c)		Figure
		Stretch shank bolts (1)	*BA03.30-P-1004-01A
		Straight stretch shank bolts (1a)	*BA03.30-P-1005-01A
		Torx bolts (1c)	*BA03.30-P-1005-01A
		Replace torx bolts and straight stretch shank bolts, refer to technical modifications ↓
	Bolt for two-mass flywheel modified	Engine 605, 606	BT03.30-P-0001-01A
	Bolt for driven plate, flywheel, sheet metal two-mass flywheel standardized	Engine 602.982/983, 604, 605, 606	BT03.30-P-0002-01A
		Installation:  If no torquing angle wrench is available, the bolts can be torqued further by the specified angle in a single operation using a wrench and tommy arm (10). Do not use a flexi-rod torque wrench for tightening to angle degrees in order to avoid any angle errors.
5.1	Inspect bolts (stretch shank bolts) (1) for flywheel/ driven plate		AR03.30-P-8001-01HA
			*BE03.30-P-1001-01A
6	Take off flywheel (5), two-mass flywheel or flywheel (6) with driven plate (6a), or starter ring gear (7)	Straight pin (2) centers flywheel and driven plate Flywheels do not need to be balanced and must not be interchanged
		Arrangement of flywheel, two-mass flywheel, driven plate	GF03.30-P-8001-01A
7	Install in the reverse order

Flywheel, driven plate

Number	Designation				Engine 605, 606 with automatic transmission up to 4/95	Engine 605, 606 with manual transmission (TMS) up to 4/95
BE03.30-P-1001-01A	Flywheel or driven plate bolts (1st version)	Thread ø (D)		M	10x1	10x1
		Stretch shank ø (d)	when new	mm	8.5-0.2	8.5-0.2
			min	mm	8.0	8.0
		Length of shank (L)	when new	mm	22.0 ± 0.2	57.0 ± 0.2
			max.	mm	22.5	-
			See figure		AR03.30-P-8001-01HA	AR03.30-P-8001-01HA

Flywheel, driven plate

Number	Designation				Engine 604 up to 10/95	Engine 111 with two-mass flywheel
BE03.30-P-1001-01A	Flywheel or driven plate bolts (1st version)	Thread ø (D)		M	10x1	10x1
		Stretch shank ø (d)	when new	mm	8.5-0.2	8.5-0.2
			min	mm	8.0	8.0
		Length of shank (L)	when new	mm	22.0 ± 0.2	57.0 ± 0.2
			max.	mm	22.5	-
			See figure		AR03.30-P-8001-01HA	AR03.30-P-8001-01HA

Flywheel, driven plate

Number	Designation				Engine 111 with flywheel or driven plate	Engine 111 with metal two-mass flywheel
BE03.30-P-1001-01A	Flywheel or driven plate bolts (1st version)	Thread ø (D)		M	10x1	10x1
		Stretch shank ø (d)	when new	mm	8.5-0.2	8.5-0.2
			min	mm	8.0	8.0
		Length of shank (L)	when new	mm	22.0 ± 0.2	22.0 ± 0.2
			max.	mm	22.5	22.5
			See figure		AR03.30-P-8001-01HA	AR03.30-P-8001-01HA

Flywheel, driven plate, vibration damper, starter ring gear

Number	Designation			Engine 601, 602, 603 with/ without automatic transmission	Engine 604 with/without automatic transmission
BA03.30-P-1004-01A	Stretch shank bolt for flywheel to crankshaft	1st stage	Nm	35	35
		2nd stage	∠°	90	90
BA03.30-P-1005-01A	Straight stretch shank bolt for flywheel or two-mass flywheel to crankshaft	1st stage	Nm	45	45
		2nd stage	∠°	90	90

Flywheel, driven plate, vibration damper, starter ring gear

Number	Designation			Engine 605, 606 with manual transmission (TMF)	Engine 605, 606 with automatic transmission
BA03.30-P-1004-01A	Stretch shank bolt for flywheel to crankshaft	1st stage	Nm	40	35
		2nd stage	∠°	90	90
BA03.30-P-1005-01A	Straight stretch shank bolt for flywheel or two-mass flywheel to crankshaft	1st stage	Nm	45	45
		2nd stage	∠°	90	90

Fig 2: Identifying Torx Bit Set (000 589 01 10 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.