M11 Series – Service Manual – 016-006   Flywheel Housing

Remove the transmission, clutch, and all related components, if equipped. Refer to the manufacturer’s instructions.

Remove the flywheel. Refer to Procedure 016-005.

CAUTION  Place a wooden block, the width of the oil pan, between the floor jack and oil pan to prevent damage to the engine.

Use a floor jack or a suitable lifting fixture to support the rear of the engine.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

Disconnect the battery cables.

Remove the starting motor. Refer to Procedure 013-020.

Remove the capscrews and both rear engine mounts.

Remove the four oil pan rear mounting capscrews.

Remove the rear crankshaft oil seal. Refer to Procedure 001-024.

Remove capscrews 1 and 2 and install two guide pins.

WARNING  This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift the component.

Remove the remaining capscrews.

Use a rubber hammer to loosen the flywheel housing.

NOTE: Do not damage the rear of the oil pan gasket when removing the flywheel housing.

Remove the flywheel housing.

Remove the gasket material from the flywheel housing oil seal gasket surface.

Clean the sealant from the cylinder block surface.

WARNING  When using a steam cleaner, wear safety glasses or a face shield as well as protective clothing. Hot steam can cause serious personal injury.

Use steam or solvent to clean the flywheel housing. Dry with compressed air.

Inspect all surfaces for nicks, burrs, or cracks.

Use fine crocus cloth to remove small nicks and burrs.

Inspect all threaded capscrew holes for damage.

Repair or replace the housing if the capscrew holes are damaged.

Install two guide pins in the cylinder block to help support and align the housing during installation.

Apply a 2 mm [1/16 in] bead of silicone sealant, on the mounting surface of the housing and around each capscrew hole.

Apply silicone sealant to each rear corner of the oil pan gasket and flywheel housing mating surface.

Install the flywheel housing over the guide pins.

NOTE: Do not damage the oil pan gasket when installing the flywheel housing.

The flywheel housing bore must be aligned with the crankshaft. Do not tighten the capscrews to the final torque value until the flywheel housing is aligned.

Install the capscrews. Remove the guide pins, and install the remaining two capscrews.

Use dial indicator gauge, and dial gauge attachment, to measure the bore alignment.

Adjust the dial indicator gauge to zero “0.”

Use the accessory driveshaft to rotate the crankshaft one complete revolution (360 degrees).

If the maximum bore alignment does not meet the specifications, use a rubber hammer to move the housing in the necessary direction, and repeat the measurement procedure.

If the bore alignment will not meet the specifications or the bore is not round, the housing must be replaced.

CAUTION  The tip of the gauge must not enter the capscrew holes or the gauge will be damaged.

Install the contact tip of the dial indicator gauge against the flywheel housing face.

Push the crankshaft toward the front of the engine.

Adjust the dial indicator gauge to zero “0.”

Monitor the dial indicator gauge while turning the crankshaft.

Use the accessory driveshaft to rotate the crankshaft one complete revolution (360 degrees) while keeping the crankshaft end thrust pushed forward.

If the maximum face alignment does not meet the specifications, the flywheel housing must be replaced.

Tighten all capscrews in the sequence shown.

Measure the bore and face alignment again.

If bore and face alignment does not meet the specifications, loosen the housing capscrews. Tighten the capscrews, and measure the bore and face alignment again.

Install the rear crankshaft oil seal. Refer to Procedure 001-024.

Install the four oil pan rear mounting capscrews.

Install the starting motor. Refer to Procedure 013-020.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

Connect the battery cables.

Install the flywheel and clutch, if equipped. Refer to Procedure 016-005.

Install the transmission and related components. Refer to the manufacturer’s instructions.

NOTE: If the engine already has a properly tapped hole in the flywheel housing, this step and the following drill-and-tap steps can be omitted.

The following steps is for installation of engine speed sensor in non-existing location.

Mark and center-punch engine speed sensor hole in the flywheel housing using the illustration.

Drill an 11/16-inch hole in the flywheel housing that was center punched in the previous step.

Tap the hole from the previous step use a 3/4-inch x 16 bottoming tap.

This step is completed because the starter tap meets the flywheel prior to completing the hole-threading process.

Install the engine speed sensor, into the flywheel housing.

NOTE: Perform this step only if the sensor would not seat.

Tap the hole drilled in the previous step use a 3/4-inch x 16 coarse-thread series (UNC) starter tap.