Peugeot 205 Manual

Flywheel/driveplate - removal, inspection and refitting
XU series engine in-car repair procedures / Flywheel/driveplate - removal, inspection and refitting


Removal
Flywheel (models with manual transmission)
1 Remove the transmission as described in Chapter 7A, then remove the clutch assembly as described in Chapter 6.

2 Prevent the flywheel from turning by locking the ring gear teeth with a screwdriver or similar tool.

3 Slacken and remove the flywheel retaining bolts, and remove the flywheel from the end of the crankshaft. Be careful not to drop it; it is heavy. If the flywheel locating dowel is a loose fit in the crankshaft end, remove it and store it with the flywheel for safe-keeping. Discard the flywheel bolts; new ones must be used on refitting.

Driveplate (models with automatic transmission)
4 Remove the transmission as described in Chapter 7B. Lock the driveplate as described in paragraph 2. Mark the relationship between the torque converter plate and the driveplate, and slacken all the driveplate retaining bolts.

5 Remove the retaining bolts, along with the torque converter plate and the two shims (where fitted). Note that the shims are of different thickness, the thicker one being on the outside of the torque converter plate.

Discard the driveplate retaining bolts; new ones must be used on refitting.

6 Remove the driveplate from the end of the crankshaft. If the locating dowel is a loose fit in the crankshaft end, remove it and store it with the driveplate for safe-keeping.

Inspection
7 On models with manual transmission, examine the flywheel for scoring of the clutch face, and for wear or chipping of the ring gear teeth. If the clutch face is scored, the flywheel may be surface-ground, but renewal is preferable. Seek the advice of a Peugeot dealer or engine reconditioning specialist to see if machining is possible. If the ring gear is worn or damaged, the flywheel must be renewed, as it is not possible to renew the ring gear separately.

8 On models with automatic transmission, check the torque converter driveplate carefully for signs of distortion. Look for any hairline cracks around the bolt holes or radiating outwards from the centre, and inspect the ring gear teeth for signs of wear or chipping. If any sign of wear or damage is found, the driveplate must be renewed.

Refitting
Flywheel - models with manual transmission
9 Clean the mating surfaces of the flywheel and crankshaft. Remove any remaining locking compound from the threads of the crankshaft holes, using the correct-size tap, if available.

10 If the new flywheel retaining bolts are not supplied with their threads already precoated, apply a suitable thread-locking compound to the threads of each bolt (see illustration).

13.10 Apply thread locking compound to the flywheel bolts if not already
13.10 Apply thread locking compound to the flywheel bolts if not already pre-coated

11 Ensure that the locating dowel is in position. Offer up the flywheel, locating it on the dowel, and fit the new retaining bolts.

12 Lock the flywheel using the method employed on dismantling, and tighten the retaining bolts to the specified torque.

13 Refit the clutch as described in Chapter 6, and refit the transmission as described in Chapter 7A.

Driveplate - models with automatic transmission
14 Carry out the operations described above in paragraphs 9 and 10, substituting УdriveplateФ for all references to the flywheel.

15 Locate the driveplate on its locating dowel.

16 Offer up the torque converter plate, with the thinner shim positioned behind the plate and the thicker shim on the outside, and align the marks made prior to removal.

17 Fit the new retaining bolts, then lock the driveplate using the method employed on dismantling. Tighten the retaining bolts to the specified torque wrench setting.

18 Refit the transmission as described in Chapter 7B.


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