Flywheel and Flywheel Housing – Remove and Install


Flywheel

Removal Procedure

Remove the electric starting motor.


Remove two setscrews from position (X) on the flywheel (1).
Install Tooling in position (X) on the flywheel (1).
Attach a suitable lifting device to the flywheel (1). Support the weight of the flywheel. The flywheel can weigh 70.6 kg (155 lb).
If necessary, remove the four setscrews (2) that secure the housing for the pilot bearing (3) to the flywheel (1). Remove the housing for the pilot bearing (3). Remove the remaining setscrews (4).
Use the lifting device to remove the flywheel from the engine.


Inspect the flywheel (1) and the ring gear (5) for wear or damage. Replace any worn components or damaged components. To remove the flywheel ring gear (5). Place the flywheel assembly on a suitable support.
Use a hammer and a punch in order to remove the ring gear (5) from the flywheel (1). Identify the orientation of the teeth on the flywheel ring gear.

Installation Procedure


If the flywheel ring gear was removed, to install the ring gear (5) to the flywheel (1). Identify the orientation of the teeth (6) on the new ring gear (5).
The chamfered side of the ring gear teeth (6) must face toward the starting motor when the flywheel is installed. This will ensure the correct engagement of the starting motor.
Heat the flywheel ring gear (5) in an oven to a maximum temperature of 250 °C (482 °F) prior to installation. Do not use a torch to heat the ring gear.
Ensure that the orientation of the ring gear (5) is correct and quickly install the ring gear onto the flywheel (1). Inspect the crankshaft rear seal for leaks. If there are any oil leaks, replace the crankshaft rear seal.


Install:
- a suitable lifting device to the flywheel (1). The flywheel can weigh 70.6 kg (155.6 lb). 
- Tooling in position (X) on the crankshaft. Use the lifting device to position the flywheel (1) onto Tooling. If necessary, install the pilot bearing (3) and the setscrews (2) to the flywheel (1).
- setscrews (4) to the flywheel (1). Remove Tooling. 
- the remaining setscrews (4) to the flywheel (1). Use a suitable tool to prevent the flywheel from rotating. Tighten the setscrews (2) and (4) to a torque of 120 N·m (88 lb ft). Remove the lifting device from the flywheel (1).
Check the run out of the flywheel.
- the electric starting motor.


Flywheel Housing

Removal Procedure

Standard Housing

Remove the flywheel.
Install a suitable lifting device to the flywheel housing in order to support the flywheel housing. The flywheel housing can weigh 32 kg (70.5 lb).


Remove the two M12 setscrews (2) and six M10 setscrews (3) from the flywheel housing (1).
Use the lifting device in order to remove the flywheel housing (1) from the cylinder block.


If the engine has an aluminum oil pan, remove the dust seal (5).
If necessary, remove the two dowels (4) from the cylinder block.

Wet Back End Housing

Remove the flywheel.
Install a suitable lifting device to the flywheel housing in order to support the flywheel housing. The flywheel housing can weigh 32 kg (70.5 lb).


Remove the two M16 setscrews (2). Remove the two M12 setscrews (4). Remove the four M10 setscrews (3) from the flywheel housing (1).
Use the lifting device in order to remove the flywheel housing (1) from the cylinder block.


If the engine has an aluminum oil pan, remove the dust seal (6).


Remove the joint (7). Discard the joint.
If necessary, remove the two dowels (5) from the cylinder block.
Remove the oil seal (8) from the flywheel housing (1). Discard the oil seal.

Installation Procedure

Standard Housing

Ensure that the flywheel housing is clean and free from damage. If necessary, replace the flywheel housing.

Engine with an aluminum oil pan

Engine with a cast iron oil pan

Inspect the crankshaft rear seal (8) for leaks. If there are any oil leaks, replace the crankshaft rear seal. Clean the rear face of the cylinder block. If necessary, install the two dowels (4) to the cylinder block.
Install:
- Tooling to the cylinder block. If the engine has an aluminum oil pan, install the dust seal (5). If the engine has a cast iron oil pan, apply a bead of Tooling to positions (X).


- a suitable lifting device to the flywheel housing. The flywheel housing can weigh 32 kg (70.5 lb). Use the lifting device to align the flywheel housing (1) with Tooling. 
- the flywheel housing to the cylinder block.
- the two M12 setscrews (2) and four M10 setscrews (3). Remove Tooling. 
- the remaining two M10 setscrews (3). Tighten the setscrews (3) to a torque of 63 N·m (46 lb ft). Tighten the setscrews (2) to a torque of 78 N·m (57.5 lb ft). Check the alignment of the flywheel housing (1) with the crankshaft.
- the flywheel.

Wet Back End Housing

Ensure that the flywheel housing is clean and free from damage. If necessary, replace the flywheel housing.


Install a new oil seal (8) to the flywheel housing (1).
Press the oil seal into the flywheel housing from the rear. Ensure that the front edge of the oil seal is flush with the joint face of the flywheel housing .
Inspect the crankshaft rear seal (9) for leaks. If there are any oil leaks, replace the crankshaft rear seal.

Engine with an aluminum oil pan

Engine with cast iron oil pan

Clean the rear face of the cylinder block. If necessary, install the two dowels (5) to the cylinder block. Install: 
- the Tooling to the cylinder block. Align a new joint (7) with Tooling. 
- the joint to the cylinder block. If the engine has an aluminum oil pan, install the dust seal (6). If the engine has a cast iron oil pan, apply a bead of Tooling to positions (X).
- a suitable lifting device to the flywheel housing. The flywheel housing can weigh 32 kg (70.5 lb).


Use the lifting device to align the flywheel housing (1) with Tooling. 
- the flywheel housing to the cylinder block.
- the two M16 setscrews (2), two M12 setscrews (4) and two M10 setscrews (3). Remove Tooling. 
- the remaining two M10 setscrews (3). Tighten the M16 setscrews (2) to a torque of 190 N·m (140 lb ft). Tighten the M12 setscrews (4) to a torque of 115 N·m (85 lb ft). Tighten the M10 setscrews (3) to a torque of 63 N·m (46 lb ft). Check the alignment of the flywheel housing (1) with the crankshaft.
- the flywheel.