Installing flywheel (manual gearbox)

• Clean all the screw threads (1)  .

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• Use set of special tools 2 285 058 .

  Description
  Twist drill
  Thread cutter M12x1.5
  Deep stop
  Screw in tool

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• Assemble tool set.

  Number	Description
  1	Tool holder
  2	Thread cutter M12X1, 5

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• Mark the insertion depth (A)  on the thread cutter (1)  from the set of special tools 2 285 058 with a standard tool (2)  .

Screw-in depth of thread cutter
Screw-in depth	18 mm

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• Screw in the thread cutter (1)  from the set of special tools 2 285 058 up to the screw-in depth (2)  in the arrow direction.

Screw-in depth of thread cutter
Screw-in depth	18 mm

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• Make sure that the thread cutter is (1) not  pressed up against the timing chain (3)  .

• Make sure that the screw-in depth (2)  of the screw tap (1)  is not exceeded.

  The thread cutter (1)  must not come into contact with the timing chain (3)  .

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• Note the installation position of the magnet wheel (1)  .
• Position the magnet wheel (1)  on the crankshaft.

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• Position the flywheel (B)  .
• Replace flywheel bolts (1)  to (8)  .

  Parts:  Flywheel bolts

• Screw in new flywheel bolts by hand with the special tool 0 491 018 (11 4 180) .
• Make sure that the tightening sequence starts with the dowel pin (A)  .
• Tighten the new flywheel bolts in order from (1)  to (8)  using special tool 0 491 018 (11 4 180) (note the angle of rotation in the next step).

Flywheel to crankshaft
M12x1.5 Replace screws.	Tightening torque	45 Nm
	Angle of rotation	45°

• Apply all flywheel bolts (1)  with an angle of rotation of 45° by using the special tool 0 490 504 (00 9 120) .

• Remove special tool 0 493 938 (11 9 260) .

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• Loosen the transmission bolt (1)  .
• Thread out and remove special tools  0 494 793 (11 9 265)  and  0 496 171 (11 9 811)  with the conventional  5 mm washer.

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Follow-up work 

• Refer to INSTALLING CLUTCH .
• Refer to INSTALLING THE MANUAL TRANSMISSION .
• Refer to INSTALLING THE LEFT RADIAL SHAFT SEAL ON THE DIFFERENTIAL (GS6-58BG) .
• Refer to INSTALLING THE RIGHT RADIAL SHAFT SEAL ON THE DIFFERENTIAL (GS6-58BG) .
• Refer to INSTALLING THE LEFT OUTPUT SHAFT AT THE TRANSMISSION END .
• Refer to INSTALLING RIGHT OUTPUT SHAFT AT TRANSMISSION END .
• Refer to INSTALLING STARTER MOTOR .
• Refer to INSTALLING AND SECURING COMPLETE FRONT AXLE .
• Refer to SECURING MOUNTED PARTS ON THE FRONT AXLE SUPPORT .
• Refer to CONNECTING PURGE AIR LINE .
• Refer to CONNECTING CONNECTOR ON STEERING GEAR .
• Refer to FASTENING THE RUBBER MOUNT ON THE FRONT AXLE SUPPORT .
• Refer to SECURING THE ANTI-ROLL BAR ON THE LEFT AND RIGHT ON THE ANTI-ROLL BAR LINK .
• Refer to FASTENING THE CABLE FOR THE RIDE HEIGHT SENSOR .
• Refer to INSTALLING WHEEL ARCH COVER AT FRONT LEFT AND RIGHT .
• Refer to IF INSTALLED: INSTALLING UNDERBODY PROTECTION AT REAR .
• Refer to TOPPING UP THE OIL LEVEL IN THE MANUAL TRANSMISSION .
• Refer to INSTALLING FRONT UNDERBODY PROTECTION .
• Refer to INSTALLING THE FRONT LEFT AND RIGHT WHEELS .
• Refer to REMOVING THE MOUNTING FOR THE COOLANT RADIATOR ON THE LEFT AND RIGHT .
• Refer to SECURING THE STEERING SHAFT AT THE BOTTOM ON THE STEERING GEAR .
• Refer to TAKING ENGINE OUT OF INSTALLATION ORIENTATION .
• Refer to INSTALLING THE BATTERY .
• Refer to INSTALLING THE BATTERY COVER .
• Refer to INSTALLING SECOND UPPER BULKHEAD .
• Refer to INSTALLING THE RIGHT WINDSHIELD PANEL COVER .
• Refer to INSTALLING THE LEFT WINDSHIELD PANEL COVER .
• Refer to INSTALLING THE REAR HOOD SEAL .
• Refer to INSTALLING LEFT AND RIGHT WIPER ARM .
• Refer to INSTALLING ACOUSTIC COVER .
• Refer to INSTALLING INTAKE SILENCER HOUSING .
• Refer to INSTALLING INTAKE PORT .