Note: Use new flywheel mounting bolts when installing. Some models are equipped with a pot-shaped flywheel.
Removal
1. Remove the clutch (Section 6) and starter (Section 5).
2. If the engine is in the vehicle, remove the release bearing and guide sleeve as described in Section 6.
3. Although the flywheel bolt holes are offset so that the flywheel will only install in one position, make marks between the flywheel and the end of the crankshaft to facilitate installation.
4. Lock the flywheel from turning by pinching the ring gear with a large screwdriver or other suitable tool. If the engine is in a car, the easiest way to get to it is through the starter hole.
5. Unscrew the mounting bolts and remove the flywheel (see illustration).
Inspection
6. After removing the flywheel, inspect it as follows.
7. If the teeth on the flywheel starter ring are badly worn, or if some of them are missing, it is necessary to remove the ring and install a new one.
8. The old ring can be broken with a chisel by making a small cut between the two teeth with a hacksaw. Be careful not to damage the flywheel and protect your eyes.
9. The new ring gear must be heated to 180-230°C, so if there is no special heating means, contact the dealer or an engine repair specialist. The new ring gear must not be overheated, otherwise the metal hardening will change.
10. The heated crown is simply placed on the flywheel and left to cool - when cooling, the metal will shrink and the crown will be fixed.
11. If the contact surface of the clutch friction disc on the flywheel has a large wear, or small cracks are visible upon careful inspection (caused by overheating), this flywheel surface can be reground. But this is provided that the total thickness of the flywheel does not decrease too much. Consult an engine repair specialist and if this is not possible, simply replace the flywheel.
Installation
12. Perform installation in reverse order, paying attention to the following.
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13. Align the previously made marks on the flywheel and crankshaft, install new flywheel mounting bolts. Tighten them in two stages to the tightening torque specified in the Specifications, fixing the flywheel as you did when removing it (see illustrations).
14. Where necessary, install the release bearing, guide sleeve and clutch as described in Section 6.
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