Removal, inspection and installation of the ZMZ-406 flywheel
The flywheel is removed to replace the crankshaft rear oil seal, to replace it if the toothed rim that serves to start the engine with a starter is damaged, and to grind the surface for the clutch disc
You will need: tools needed to remove the gearbox and clutch, as well as a 17 socket socket, a screwdriver.
Remove the gearbox (see Removal and installation of the GAZ-3110 gearbox).
The flywheel can only be installed on the crankshaft in one position, and the special hole in the flywheel must match the pin located on the crankshaft (Fig. 1).
However, to facilitate the installation of the flywheel, we recommend that you mark the relative position of the parts.
Using the “12” key, we unscrew the six bolts of the clutch pressure plate, holding the flywheel from turning with a screwdriver inserted between its teeth.
Remove the driven and pressure discs.
With a “17” head, we unscrew the six bolts securing the flywheel, holding it from turning with a screwdriver inserted between the teeth
Remove the washer
Remove the flywheel
Check the condition of the teeth of the flywheel rim, if they are damaged, replace the flywheel.
If there are marks or burrs on the contact surfaces of the clutch disc or crankshaft flange, replace or repair the flywheel
You can check and repair the flywheel in a workshop with special equipment.
Flywheel runout, measured at the toothed rim, must not exceed 0.5 mm.
To remove deep scratches and scuffs, the contact surface of the driven disk can be sanded, however, the layer of metal removed should not exceed 0.3 mm.
Install the flywheel in accordance with the marked marks and all removed components in the reverse order of removal.
Lubricate the threads of the flywheel mounting bolts with engine oil. Tighten the bolts evenly crosswise to 65 Nm (6.5 kgcm).
Be sure to replace the flywheel mounting bolts with new ones. Reuse of bolts is not allowed