Removal
Note: New flywheel/drive plate mounting bolts may be required during installation.
1. Remove the engine as described in Chapter 2G or gearbox as described in Chapter 7.
2. Where required, remove the clutch as described in Chapter 6.
3. To loosen the mounting bolts, it is necessary to lock the flywheel/drive faceplate. This can be done by securing the toothed device (by engaging with the starter ring gear teeth) on the cylinder head using one of the engine mounting bolts to the gearbox.
4. Gradually loosen the mounting bolts, then remove the flywheel/drive faceplate from the crankshaft. Note that the flywheel is keyed. On models with automatic transmission, remove the spacer discs.
Examination
5. If the teeth on the flywheel starter ring gear are badly worn or some are missing, the drive faceplate assembly must be replaced, since on models with an automatic transmission the ring gear is welded to the faceplate.
6. On models with a manual transmission, it is possible to replace the toothed ring. This work is best done at a service station, since the temperature to which the ring must be heated is very critical. If it is not maintained, the strength of the teeth may be compromised.
7. If on models with a manual transmission there are deep nicks, cracks or other damage on the flywheel surface that contacts the clutch disc, the flywheel must be replaced. However, it is possible to grind the flywheel surface; consult an engine restoration specialist.
8. Manufacturers recommend checking the length of the flywheel bolts to determine if replacement is necessary, however, some owners may choose to replace all the bolts if desired.
9. Measure the length of each bolt from the base of the head to the end of the shaft (see fig. 14.9). If the bolt length exceeds the maximum value permitted by technical specifications, the bolts must be replaced.
Fig. 14.9. Measuring the flywheel/faceplate bolt
d Minimum diameter = 8.0 mm
L Max length = 22.5mm
10. Similarly, measure the diameter of the bolt on the shank between the base of the bolt head and the start of the thread. If the diameter is less than the minimum allowable, the bolt must also be replaced.
Installation
11. Begin installation by cleaning the mating surfaces of the crankshaft and flywheel/drive plate.
12. Place the flywheel on the crankshaft, placing it on the keys (on models with automatic transmission, make sure the spacer plates are in place), then install the mounting bolts (see paragraphs 8-10, inclusive).
13. Lock the flywheel using the method used during removal, then gradually tighten the mounting bolts in a diagonal order. Tighten the bolts in several stages, as specified in the Technical Specifications - i.e. tighten all bolts to stage 1, then tighten the bolts to stage 2, etc.
14. Where required, install the clutch as described in Chapter 6.
15. Install the engine as described in Chapter 2G or gearbox as described in Chapter 7.