Peugeot 205 Manual

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


Removal
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 a similar arrangement to that shown in illustration 8.10. Alternatively, bolt a strap between the flywheel and the cylinder block/crankcase. Do not attempt to lock the flywheel in position using the locking pin described in Section 3.

3 Slacken and remove the flywheel retaining bolts, and discard them; they must be renewed whenever they are disturbed.

4 Remove the flywheel. Do not drop it, as it is very heavy. If the locating dowel is a loose fit in the crankshaft end, remove and store it with the flywheel for safe-keeping.

Inspection
5 If the flywheel’s clutch mating surface is deeply scored, cracked or otherwise damaged, the flywheel must be renewed.

However, it may be possible to have it surface-ground; seek the advice of a Peugeot dealer or engine reconditioning specialist.

6 If the ring gear is badly worn or has missing teeth, it must be renewed. This job is best left to a Peugeot dealer or engine reconditioning specialist. The temperature to which the new ring gear must be heated for installation is critical and, if not done accurately, the hardness of the teeth will be destroyed.

Refitting
7 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.

8 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.

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

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

11 Refit the clutch as described in Chapter 6.

Remove the locking tool, and refit the transmission as described in Chapter 7A.


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