Flywheel starter ring gear

Refit

1. Using an old flywheel retaining bolt with saw cuts at 45 °to bolt shank, clean old adhesive from thread of flywheel bolt holes in crankshaft.
2. Clean flywheel and mating face of crankshaft.
3. Clean dowel and dowel hole.
4. Fit flywheel to crankshaft.
5. Fit flywheel locking pin tool 18G 1523.
6. Fit NEW bolts securing flywheel to crankshaft and working in a diagonal sequence tighten bolts to 100 Nm.
7. Fit CKP sensor. See ENGINE MANAGEMENT SYSTEM - EDC, Repairs.
8. Fit clutch assembly. See CLUTCH, Repairs.

FLYWHEEL STARTER RING GEAR

Service repair no - 12.53.19

Remove

1. Remove engine flywheel. See this section.

2. Drill a 3 mm diameter hole at root of 2 teeth.
3. Apply a cold chisel in root of one of ring gear teeth, strike chisel with hammer to break ring gear.

WARNING: Suitable eye protection must be worn.

4. Remove starter ring gear.

Refit

1. Clean flywheel and starter ring gear.
2. Heat new starter ring gear evenly to 350°C, indicated when the ring is a light blue colour.
3. Locate ring gear on flywheel and press ring gear hard against flange on flywheel.
4. Ensure ring gear is correctly seated around the complete circumference of flywheel and allow to cool.
5. Fit flywheel. See this section.