Caution: New flywheel/drive plate mounting bolts will be required during installation.
Removal
Models with manual transmission
1. Remove the transmission (see Section 7A), then remove the clutch assembly as described in Section 6.
2. Lock the flywheel ring gear with a tool similar to the one shown (see illustration). Alternatively, bolt a metal strip to the flywheel and crankcase. Make alignment marks on the flywheel and crankshaft using paint or a suitable marker.
3. Unscrew the mounting bolts and remove the flywheel. Do not drop it - the component is very heavy.
Models with automatic transmission
4. Remove the transmission as described in Section 7B.
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5. Lock the drive disk as described in step 2, then loosen its mounting bolts.
6. Remove the bolts and the retaining plate, centering ring and drive plate from the end of the crankshaft, noting the location of each component.
Inspection
7. On manual transmission models, inspect the flywheel for scratches on the contact surface with the clutch disc. If this area is worn, the flywheel can be reground, but it is preferable to replace it. Check the flywheel ring gear teeth for wear and chipping. On models with a standard flywheel, the ring gear can be replaced, but this task should be entrusted to a specialist. On heavy flywheels, such replacement is not possible.
8. On models with automatic transmission, carefully inspect the drive disc and its ring teeth for damage and signs of wear.
9. If there is any doubt about the condition of the flywheel/drive disc, contact your Opel dealer for advice.
Installation
Models with manual transmission
10. Clean the contact surfaces of the flywheel and crankshaft and remove all traces of locking compound from the threads of the holes in the crankshaft.
11. Install the flywheel and insert new mounting bolts. If installing the same component, align the marks made before removal.
12. Lock the flywheel and tighten its mounting bolts to the required tightening torque (see Specifications), then tighten the bolts to the desired angle (see Specifications), using the socket and extension rod, and finally to the desired angle (see Specifications). It is recommended to use a corner template to ensure accuracy (see illustrations). If a template is not available, use white paint to mark the bolt head and flywheel with alignment marks - these will help you ensure that the bolt is turned to the correct angle.
13. Install the clutch as described in Section 6, then remove the locking tool and install the transmission (see Section 7A).
Models with automatic transmission
14. Clean the contact surfaces of the drive disc and crankshaft and remove all traces of locking compound from the threads of the holes in the crankshaft.
15. Place the drive disc in the working position together with the centering ring and mounting plate, then screw in the new mounting bolts.
16. Tighten the mounting bolts to the tightening torque specified in the Specifications and tighten them to the required angles (see point 12), then remove the locking tool and install the transmission as described in Section 7B.
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