Contents: Removal ⇓ Installation ⇓
Removal
1. Raise the vehicle and support it on stands. Remove the transmission (see chapter 7).
2. On a model with a manual transmission, remove the clutch basket and friction disc (see chapter 8). Now is the time to check and, if necessary, replace the clutch disc and release bearing.
3. Mark the position of the flywheel relative to the rear wall of the engine with paint or a center punch to facilitate further installation (figure 14.3).
4. Remove the flywheel mounting bolts from the crankshaft (see Figure 14.3). If the shaft rotates, lock the flywheel by inserting a strong screwdriver into the flywheel ring gear.
Note: Do not rotate the crankshaft after removing the flywheel, as this will disrupt their relative position. If you need to turn the shaft or remove it, then use a center punch to make marks on the flywheel and on the end of the shaft next to one of the bolt holes.
5. Remove the flywheel from the shaft. On automatic transmission models, also remove the retaining ring and adapter behind the faceplate. Remember which side these parts are installed on to avoid any difficulties during assembly. Please note: the flywheel is heavy - support it when you remove the last bolt. Be careful, the flywheel ring gear may have a sharp edge - wear work gloves.
6. Wash away dirt and oil from the flywheel. Inspect its surface for cracks and broken crown teeth. Place the flywheel on a level surface and check it for warpage (to do this, apply it to the surface of the edge of a steel ruler). Minor warping can be corrected by grinding in a machine shop.
7. Clean and inspect the mating surfaces of the flywheel (faceplate) and crankshaft. If the rear engine oil seal is leaking, replace it before installing the flywheel (see paragraph 15).
Installation
8. Use a tap to drill the bolt holes in the end of the shaft. Remove any dirt and thread sealant residue from them. Clean the bolts as well.
Note: If the thread sealant cannot be completely removed from the bolt, replace the bolt. Do not apply sealant to new bolts.
9. On models with a manual transmission, install the clutch assembly onto the flywheel. On models with automatic transmission, install the adapter, faceplate and pressure ring. Align the flywheel using the marks made before disassembly. Apply thread sealant to the old bolts (there is no need to apply it to new bolts).
10. Lock the flywheel by inserting a strong screwdriver into the ring gear. Install and tighten the flywheel mounting bolts gradually, in three to four passes, in a cross pattern until the required tightening torque is achieved.
11. The rest of the assembly is carried out in the sequence opposite to disassembly.