SAFARI

ENGINE

Fig. 1

Fig. 2

Fig. 3

FLYWHEEL/RING GEAR/CRANKSHAFT PULLEY

REMOVAL OF FLYWHEEL

(Clutch removed)

1 Remove speed sensor on clutch housing.

2 Lock flywheel suitably.

3 Unlock lock plates and unscrew fastening bolts

from flywheel.

4 Tap with plastic mallet and remove flywheel.

INSTALLATION OF FLYWHEEL

1 Position flywheel on crankshaft flange.

2 Align all holes on flywheel with tapped holes of

crankshaft flange.

3 Place new lock plates and screw in flywheel mounting

bolts after oiling their threads.Tighten them uniformly

cross-wisetospecifiedtorque. Fig. 1.

4 Lock flywheelmounting screws by staking lockplates

on bolt heads.

5. Fit thespeedsensor andtightenwithspecifiedtorque.

INSPECTION AND REPAIR OF FLYWHEEL

1 Check starter ringgear forwear anddamage. Replace

if necessary.

2 Clean flywheel and check for cracks, scoring, burns

and unevenness.

3 If necessary, grind friction face just to clear defect

after removing dowels meant for pressure plate.

Grinding should be done over entire friction face. In

any case, thickness of flywheel shouldnot be reduced

beyond specified limit. Fix new dowels.

REPLACEMENT OF STARTER RING GEAR

(Flywheel removed)

1 Quickly heat starter ringgear withwelding flame and

press it out.

2 Heat new ring gear to 180 deg C – 230 deg C (Yellow

annealing colour). Press in ring gear upto contact

surface of flywheel.

3 Maximum lateral runout of ring gear should not

exceed specified value after pressing.

REMOVAL OF CRANKSHAFT PULLEY

1 Slacken and remove V-belt driving water pump/

alternator.

2 Lockcrankshaft at flywheel suitablyandremovepulley

mounting bolt. Fig. 2.

3 Mount suitable two leg puller with spacer & pull

out the pulley.

4 Examine woodruff key and replace if necessary.

5 Remove oil slinger (if fitted).