How to properly install a flywheel on an engine

Tips for replacing the flywheel on a VAZ 2109

It’s not for nothing that VAZ cars are considered long-lived on domestic roads.
And that is to say - they have been used as “folk” for several decades, and many copies have actually become real technical rarities. However, long-term (or multi-decade) use of any mechanism requires an attentive approach to it, competent technical support, repair and replacement of spare parts. Moreover, it is obvious that replacing entire units will cost more than replacing individual elements. So, for example, if extraneous knocks, creaks and other sounds are heard during engine operation, the car should be diagnosed to find out the cause. And, quite possibly, you can eliminate it yourself. Thus, one of the elements of the vehicle’s propulsion system can be considered the VAZ flywheel, and more specifically, the crown of the VAZ flywheel. Replacing the entire flywheel can cost a hefty sum, while replacing the flywheel crown yourself will take relatively little time and require a small amount of investment.

Replacing the flywheel crown is a multi-level process, including:

You will find detailed instructions on how to remove the clutch basket and gearbox in the relevant materials on our website. Here is some advice for those who no longer need to explain elementary truths.

To remove the gearbox quickly and without additional costs (including the cost of draining the oil and refilling it), you can perform just a few steps: unscrew the trailing arms or “sabers” (even at this stage the transverse travel of the struts is sufficient to disconnecting the gearbox from the engine; now it is enough to remove the starter, disconnect the rocker, gearbox supports and ground contacts of the reverse sensor - and place the removed transmission on the floor, providing the most convenient access to the clutch and flywheel.

Advice: to carry out work on dismantling the flywheel, the latter must be properly fixed. This is best done using a clamp specially designed for this purpose, or a homemade device made in the likeness of this industrial part. Only after this should you begin to unscrew the flywheel bolts.

Before removing the flywheel, record (and it is best to make special notes) the relative position of the flywheel relative to the crankshaft. This will help during subsequent installation, because position matters.

Tip: It is best to put a new ring on the flywheel while it is warm. You can use a regular fire or, if you have such a system in your garage, a heater, which could help heat the crown to the desired temperature (approximately at the limit of human physical capabilities).

Advice: it should be remembered that the crown on the flywheel is always put on with an internal chamfer to the latter. The easiest way to place the crown on the flywheel is by gently tapping it with a hammer.

When assembling the flywheel, the bolts are tightened with a force of 62-89 N*m, when installing the basket - 19-31 N*m, and all bolts, in order to avoid deformation of the units, are tightened in a checkerboard pattern. But the transverse arm and stabilizer fasteners are tightened only under load (that is, after the car is lowered from the lift to the ground).

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Repair work

If you decide to do everything yourself, follow the following sequence of actions.

1. Drive onto an overpass or pit. This will make it more convenient for you to work.
2. Raise the front of the car using a reliable jack and securely fix the nine.
3. Remove the wheels.
4. Disconnect the clutch housing ground and clutch cable. Next you will have to remove the transmission.
5. To do this, remove the starter by disconnecting the wires, terminals and unscrewing the three mounting nuts.
6. Disconnect the speedometer cable and reverse cable.
7. Remove the brace fastenings to the suspension arms and move them to the sides.
8. Disconnect the ball joints from the swing arms. To do this, you need to remove the cotter pin, unscrew the nut, and knock out the support pin. Then the two nuts are unscrewed and the hinge is disconnected.
9. Using a pry bar, press out the tip of the inner CV joint. Be sure to plug the hole formed in the gearbox using improvised means, otherwise oil will begin to pour out of the gearbox.
10. Remove the lower clutch housing protection. There are only 3 bolts holding it in place.
11. Make supports from bars, bricks for the box and engine.
12. Remove the rear supports.
13. Unscrew the remaining fasteners and pull the gearbox horizontally. Be careful not to deform the pressure spring lobes with the input shaft.

Replacing the flywheel crown. The instructions are universal, can be applied to VAZ

The flywheel is one of the most important parts of any car, be it a truck or a passenger car. But often it can wear out, either from time and high mileage, or from a low-quality spare part, or rather a part called the “crown”. The problem may manifest itself as follows: you turn the key, but instead of starting, the car makes a metallic grinding noise and does not start...

Maybe by the way, try to grab it, but somehow “slip”! That is, “intermittent” startup. Many car owners begin to delve into this malfunction, and the first thing they look at is the starter, its gear and bendix.

Secondly, look at the flywheel itself . To be honest, this toothed disc has a simple design. Essentially, this is a large metal disk on which a special crown is placed; these are the teeth that engage with the starter.

Flywheel in a VAZ 2109 transmission

The VAZ 2109 flywheel is part of the transmission of this car. It is located between the engine and the clutch. This unit is the output point of the internal combustion engine (ICE) and the input point of the car drive; it is connected to the drive shaft of the gearbox (Gearbox). In a car, the flywheel performs three functions:

1. Increases the uniformity of rotation of the engine crankshaft, smoothes out fluctuations in the amount of torque transmitted from the pistons of the combustion chambers through the crank mechanism to the crankshaft of the internal combustion engine. The fact is that with each revolution of the crankshaft, two explosive acts of combustion of the fuel-air mixture take place in the car’s cylinders, and if not for the flywheel, the crankshaft would twitch violently twice for each revolution. The flywheel smoothes out these pulsations, accumulating and releasing kinetic energy of rotational motion.
2. Provides transmission of torque from the engine to the gearbox. This unit is the primary, driving disk of the clutch mechanism. When the clutch pedal is released, the driven disk is pressed against the flywheel, ensures rotation of the gearbox output shaft and causes the driving front wheels of the VAZ 2109 to rotate.
3. When starting a car, the flywheel transmits torque from the starter to the engine crankshaft. When the ignition key is turned to the “starter” position, the starter gear engages with the ring teeth, thus spinning the flywheel and crankshaft. An ignition spark is supplied to the cylinders and the engine starts. The ignition key returns to the “ignition” position and the starter gear disengages from the ring gear.

Flywheel for VAZ 2108-099, 2113-2115, Kalina

Dear customers, in order to avoid errors when sending a flywheel, please indicate the model and year of manufacture of your car in the “Comment” line.

If we consider the structure and principle of operation of the internal combustion engine, we will have to deal with such a product as the flywheel. In terms of its design, it is not anything complicated, but the functions it performs are extremely important, and it is impossible to do without it.

The engine flywheel is a component of several independent systems. Its functions include:

— reduction of vibrations when rotating the engine crankshaft. In this case, the flywheel acts as part of the engine;

— transmission of torque to the gearbox from the power unit. The flywheel is, among other things, the primary clutch disc;

— transmission of torque to the crankshaft from the starter. Through the flywheel crown, torque is supplied from the starter to spin the crankshaft and start the engine.

As an element of an internal combustion engine, this is its very first application.

1 – connecting rod journal, 2 – counterweight, 3 – flywheel with crown 4 – main journal, 5 – crankshaft.

Removal, installation and troubleshooting of the flywheel on VAZ 2108, VAZ 2109, VAZ 21099 cars

First remove the gearbox and clutch from the VAZ 2108, VAZ 2109, VAZ 21099 (see section 5 “Transmission”).

1. Remove the six flywheel mounting bolts. At the same time, use a screwdriver to hold the flywheel from turning, having first screwed in one of the gearbox mounting bolts.

2. Together with the last bolt, holding the flywheel, remove the bolt locking plate.

3. Remove the flywheel from the crankshaft flange.

4. Check the condition of the flywheel rim teeth and, if damaged, replace the flywheel.

5. Replace or repair the flywheel if the contact surfaces of the clutch driven disc or...

6.... risks and scuff marks were found on the crankshaft flange. The flywheel can be checked and repaired in a workshop that has special equipment. The non-flatness of surface 3 (Fig. 4.4) of the contact of the clutch driven disc should not exceed 0.06 mm. The non-parallelism of the contact surfaces of the driven clutch disk and surface 2 for fastening the clutch should not exceed 0.1 mm. The flywheel runout on surfaces 3 and 1 should not exceed 0.1 mm. To remove deep marks and burrs, the surface 3 of the flywheel can be machined, and the layer of metal removed should not exceed 1 mm. Simultaneously with surface 3, it is necessary to grind surface 2, maintaining the size between them (0.5+0.1) mm. When grooving, maintain the parallelism of surfaces 3 and 1.

Clutch repair and replacement - the best price in St. Petersburg, excellent quality

Prices for repairing clutches, gearboxes, replacing sensors, seals and other things

carries out clutch repairs in St. Petersburg on domestic and imported cars. Our experienced, qualified craftsmen will repair this unit of any degree of complexity, be it a complete replacement of the clutch assembly or repair of its individual element (for example, replacing a rocker).

At the same time, we guarantee all car owners the impeccable quality of all work performed and the spare parts and consumables used in them, as well as short deadlines and competitive prices for all our services!

Clutch replacement in St. Petersburg - a few words about this element of the car

The main purpose of the clutch is to regulate torque, in terms of its transmission from the engine flywheel to the transmission. In simple terms, this element allows you to smoothly disconnect and dock the engine flywheel with the transmission at the right moments. This device comes in two main types:

In addition, the clutch can be:

Clutch repair prices

Replacing the clutch - cost and signs of trouble with this unit

Symptoms that should alert the driver and which may indicate that clutch replacement is just around the corner:

As for the price of replacing the clutch, it, of course, depends on the severity of the breakdown and on the number of parts of the assembly that require replacement (up to a complete replacement of the clutch assembly).

Clutch repair - the price depends on the complexity of the task and the broken element of the unit

Of course, this is not the cheapest service - clutch replacement, and the price for it, by definition, cannot be symbolic, because this procedure is very labor-intensive and responsible, since a faulty clutch can provoke a serious accident when the car is moving.

However, a complete replacement of the clutch assembly is not always required; sometimes the situation allows us to limit ourselves to updating one of its individual elements, such as:

Clutch replacement in St. Petersburg - contact the professionals

Of course, motorists are always tempted to try their own hand at repairing their “iron horse,” but the clutch is not the unit with which you can start your car mechanic experiments, because the safety of your driving this car is at stake! Therefore, it is better to entrust such important tasks as replacing a clutch disc or cylinder, its fork, cable and slides to our qualified craftsmen, who will accurately determine the cause of the malfunction and quickly eliminate it.

And finally, we want to give a simple recommendation, following which you will significantly extend the working life of your clutch, and you will not have to change it every year: try not to keep your foot on its pedal all the time, even if it seems to you that your foot does not touch its surface. After all, even the lightest pressure on the pedal wears out the driven disc. But even the most careful handling of car systems will not extend their service life indefinitely, and sooner or later you will need to replace the entire clutch or its individual elements (link, cable, cylinder, disc, basket, and so on).

Guarantee

We provide a special guarantee:

• one year - original spare parts
• month – non-original spare parts
• one year – completed work (installation of original spare parts)
• three months – completed work (installation of non-original spare parts)

*Price depends on modification. For more information about the cost of replacing a clutch for specific brands of cars, please call +7(812)309-26-56.

Sudden movement of the car when the clutch is engaged

A characteristic symptom of a malfunction of the clutch system is a situation when the car starts to move quite abruptly (even if the driver releases the pedal as smoothly and calmly as possible). This problem most often occurs when there is mechanical damage and severe wear of individual clutch elements, including damper springs, friction linings and the driven disc.

It is worth noting other common signs that may indicate the need to repair or replace the clutch in a VAZ 2109. For example, when the pedal falls through without returning to its original position. In addition, there may be problems associated with the occurrence of extraneous noise that occurs during operation of the clutch system.

Advantages of clutch repair at the GREK car service center?

The main advantages of our company include:

Vast professional experience. Working in the field of automotive service and repairing clutch systems in domestic cars for more than 10 years, we have gained amazing experience and knowledge that allows us to do our work with the highest quality possible. The best components. Our specialists repair and replace damaged parts using branded KRAFT-TECH brand components from Turkey. We are the official representatives of this brand in Russia. Affordable prices. The cost of car service "GREK" is the most affordable. On average, the duration of work to replace or repair clutch elements on a VAZ 2109 is about half an hour. To get a consultation or make an appointment for diagnostics, call us today!

Nuances of the work

Following all the recommendations from the automaker's manual does not guarantee that everything is done simply and quickly. Not every car owner has the opportunity to drive the car onto a pit or overpass. A lift is perfect for carrying out work, but not everyone has one either.

When you contact any service, the replacement will be made within a couple of hours, but for such a service you will need to pay a considerable amount. It may take a whole day to do the work yourself. Maybe more if you don't have experience in car repairs.

Most of the time is spent on disassembly and assembly. The operation to replace the node will take you no more than half an hour. Later in the article we will look at the process of replacing a clutch without a pit/lift.

Removing transmission elements

Repairing and replacing the VAZ 2109 flywheel are procedures of medium complexity and can be done on your own if you have some experience. In addition, you will need a workshop with an inspection pit, a standard set of plumbing tools, a gas burner to warm up the crown when installing it, and a torque wrench for tightening the bolts with a calibrated force.

How to remove the flywheel with minimal effort? The design of the VAZ 2109 gearbox and clutch makes it possible to dismantle them without draining the oil and disassembling the gearbox. To remove the transmission, perform the following operations:

Place the removed flywheel on a round podium so that the crown hangs above the working surface of your bench. Gently knock down the crown using a drift and a medium-sized hammer, without applying excessive force. Some car enthusiasts try to help themselves by heating the part. Replacing the flywheel crown on a VAZ 2109 does not require this - it heats up along with the flywheel, and the coefficient of thermal expansion of the parts practically coincides and no thermal gap is formed.

How to change a flywheel without heating? Unfortunately, no way. The reverse installation of the crown involves the use of heat shrinkage. In order to install the new crown in place, it is necessary to heat it to approximately 200 degrees. This can be done with a portable gas burner. Smoothly move the burner flame along the rim of the crown, ensuring uniform heating of the part to the specified temperature. The procedure will take you approximately 10-15 minutes.

Once the crown is properly warmed up, grab it with pliers and place it on the flywheel with the chamfer facing down. Using light hammer blows, press the part until it fits snugly against the flange. Let cool quietly in the air.

Replacing the ring gear on the engine flywheel

Let's look at how to replace a worn ring gear on the engine flywheel of VAZ 2108, 2109, 21099, 2105, 2107. Wear on the ring teeth is one of the reasons for the inability to start the engine.
The starter simply turns idle. The Bendix teeth simply have nothing to grab onto. Wear on the teeth on the flywheel of VAZ 2108, 2109, 21099, 2105, 2107 cars usually appears on both sides (since the engine crankshaft stops mainly in two positions). Therefore, in some cases, it is advisable not to replace the ring gear with a new one, but simply rotate it relative to the flywheel 90 degrees, placing the sides with intact teeth under the Bendix. The factory crown may still serve, but the new part may be too soft and fail in a matter of months.

Wear of the teeth of the car engine flywheel ring gear

The procedure for replacing the flywheel ring gear on VAZ 2108, 2109, 21099 vehicles

Before replacement, you should remove the gearbox, the clutch “basket” and the flywheel itself.

— Heat the ring gear to a temperature of 150-200 degrees

This can be done using a gas burner, blowtorch, fire, etc. We heat the crown, trying to heat the flywheel itself as little as possible.

— We knock the crown off the flywheel with a hammer

The crown only gets knocked in one direction (from the collar on the flywheel into which it rests).

We knock the ring gear off the flywheel

— Heat the new ring gear on fire to 150-200 degrees

— We put it on the flywheel

Using light blows of a hammer, we ensure that the crown is seated on the flywheel until it touches the shoulder. The heated crown fits onto the flywheel easily. If it is difficult, then you should remove it and warm it up a little more. There is no need to score with force.

DIY replacement process

If you still have a great need to replace the flywheel crown with your own hands, perhaps my instructions will help you.

First, let's define the difficulties, let's assume that the flywheel has already been removed:

1) The crown sits firmly, you can’t just remove it, you need to heat it and then knock it down.

2) It is important to plant the new crown evenly, just like the old one was attached. We also heat it up to dress it, but the main thing is not to overheat it.

Well let's get started.

We shoot down

First, we need to heat the flywheel, and then knock off the damaged crown from it. Of course, many don’t bother and just “hit it cold”, but it may not work on all models, I mean that if it works on a VAZ, then on a foreign car it can stall. Therefore, the easiest way is to put the flywheel in the oven and heat it to 200 - 250 degrees. He will lie there for about 20 - 30 minutes.

After this, take a soft chisel, preferably made of copper or brass, and use a hammer to remove the crown, simply knock it down (and to be honest, a heated one can be removed by hand). If we talk about the VAZ, then it has a side on one side, you need to hit it from it. If everything is done correctly, it will come off in a few blows with a hammer.

We stretch

This is where it gets more complicated - you won’t be able to simply hammer in a new crown (on a cold one), you will split it or damage it. It is MANDATORY to heat it up! The main thing is not to overheat, because you can change the metal if you heat it red hot, thereby reducing the strength.

My advice to you is to put it in the oven again and heat it up (250 degrees), you can put it on one or two electric stoves, but I don’t advise you to use direct fire.

Incomplete shutdown

Many experienced motorists can quickly determine that there is a significant problem when the clutch begins to “lead.” This happens due to its incomplete engagement, while the main symptom may be the appearance of a crunching noise at the moment when the driver engages the gear, but the car has not yet moved.

Most often, the cause of such a malfunction is the deformation of various structural elements of the clutch, for example, the driven disk or release levers. An excessive increase in clutch pedal free play may also be a possible factor.

Main signs of clutch failure

1. The clutch is slipping
2. Difficulty shifting gears
3. Incomplete engagement or disengagement of the clutch
4. Feeling jerks and impacts when starting from a stop
5. Extraneous noise is heard when the clutch is depressed
6. The clutch pedal travel has become longer

To avoid unnecessary problems, at the first sign of a malfunction you should contact a car service center in Kirov to replace the clutch.

It is impossible to name a specific mileage after which it is time to change the clutch. Too many factors influence its service life:

• driving style - a sharp start and frequent slipping, and even more so, participation in races significantly reduces the period of operation;
• quality of the unit - original parts are always more durable than inexpensive analogues;
• foreign liquids or small solid objects can damage even a new unit;
• errors during installation and adjustment inevitably lead to reduced performance.

Wear of linings due to incorrect clutch settings

Clutch repair

Repairing a clutch does not always mean replacing it. Failures may occur in the control system. In such cases, the clutch also stops working. The car may even stop moving because torque is not transferred from the engine to the transmission. The car will have to be taken to the service station on a tow truck or towed. But repairing such faults is much simpler than replacing the entire unit. In most cases, repairing such breakdowns does not require removing the gearbox. The most common failure of a mechanical control system is a broken clutch cable. In hydraulic systems, cylinders usually fail, they leak or no longer hold operating pressure. Clutch hose leaks occur less frequently.

Clutch diagnostics

Clutch diagnostics , as well as its repair and replacement, is one of the areas of work of our car service in the city of Kharkov. If, when trying to move the car, there are jerks or noise when changing gears. If the gears stop turning on, or turn on, but the car does not move. In such situations, by contacting our car service center, you can be sure of positive repair results. The technical qualifications of our specialists are marked by the Original Sachs Service certificate. We use high-quality spare parts for the clutch system in our work. They fully correspond to the quality of parts supplied to mass production. This allows you to guarantee proper operation of the clutch after replacing it. The warranty period is 6 months.

Clutch replacement is most often done when the linings on the disc wear out. If the disc is not replaced, the metal rivets will scratch the clutch basket and flywheel.

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