Removal
1. To remove the flywheel/drive shaft, you must first remove the transmission and clutch.
2. Using a suitable device, block the flywheel/drive plate from turning (see illustration). Use paint or a marker to mark the position of the flywheel relative to the crankshaft.
16.2a The flywheel is locked by the toothed ring using a specially shaped device
16.2b,c Options for installing a flywheel fixing device
3. Remove the mounting bolts and flywheel/drive plate - use an assistant if necessary as the flywheel is quite heavy.
Examination
4. Inspect the flywheel/drive disc for signs of wear or chipping of the ring gear teeth, and examine the condition of the working surface in contact with the clutch disc.
5. In some cases, if damage to the teeth or deep grooves and burrs are detected on the mating surfaces of the flywheel/drive disk, its crown can be replaced, and the flywheel/drive disk itself can be given for turning. However, it is highly recommended not to perform repairs outside the factory conditions - it would be wiser to replace the flywheel/drive disk.
6. If you are not sure about the condition of the flywheel/drive disk, seek advice from a car service specialist.
Installation
Note: New flywheel/drive plate mounting bolts will be required.
7. Clean the mating surfaces of the flywheel/drive plate and crankshaft - ensure that the threaded holes in the shaft flange are completely clear of any traces of old sealant.
8. Lubricate the threaded portion of the mounting bolts with a locking sealant, install the flywheel/drive plate and secure it with the bolts. When installing a used flywheel/drive plate, ensure that the alignment marks made during dismantling are correct.
9. Lock the flywheel using the method used during removal. Tighten all bolts evenly in a diagonal pattern in several steps to the first stage torque.
10. Tighten the fasteners to the corners of the 2nd, then, where required, the 3rd tightening stage, using a protractor attachment or first applying reference marks with paint.
11. Install the clutch assembly. Remove the flywheel locking device and install the transmission.
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