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I have a couple of questions about installing the clutch and flywheel on a 1.9 CIH:
1) When installing the flywheel-to-crank bolts, one of the six has a longer "shaft" (unthreaded section, same size otherwise). I don't see any instructions relating to this in the factory manual, but I recall a thread that said the longer stud has to be in the "correct" position to ensure the flywheel is exactly centered. There is one hole in the flywheel/crank that is slightly offset. Is this the hole the longer-shafted bolt goes into?
2) Is it REALLY necessary to use new flywheel bolts, as the manual suggests? The original bolts look good, and I have been careful to re-torque them to the recommended 43 ft-lbs, after cleaning the threads and using 242 LocTite. This is a low performance engine, and I doubt it will see much abuse, at least by me.
3) The manual recommends torquing the pressure plate-to-flywheel bolts to 36 ft-lbs. When I tried this, two of the four original 8 mm bolts started to stretch beyond yield. I noticed that the threads in the flywheel are somewhat counter-sunk, and the bolts (assuming that they are the original; they DO have the proper spring washers) are only grade 8.8 (in metric, which I think is only grade 5 in SAE). So I installed new, slightly longer grade 8.8 bolts with the spring washers, and three bolts tightened up nicely at 36 ft-lbs. But the fourth bolt started to stretch at about 30 ft-lbs. I replaced it again, and only went to 34 ft-lbs, and it seems OK. So, my question is, should these have been a higher grade bolt (metric equivalent to grade 8, whatever that is)? Or is the 36 ft-lbs of torque too high? It seems pretty high for only 8 mm bolts.
Any other hints about replacing the clutch and flywheel? I already replaced the rear engine seal, and I greased up the pilot bearing (the manual says to check for roughness, which it wasn't, and lubricate with bearing grease). My release bearing has only 40k miles on it, and was smooth, so I haven't planned to replace that. This thread might prove to be useful to those about to perform a clutch replacement.
Thanks!
1) When installing the flywheel-to-crank bolts, one of the six has a longer "shaft" (unthreaded section, same size otherwise). I don't see any instructions relating to this in the factory manual, but I recall a thread that said the longer stud has to be in the "correct" position to ensure the flywheel is exactly centered. There is one hole in the flywheel/crank that is slightly offset. Is this the hole the longer-shafted bolt goes into?
2) Is it REALLY necessary to use new flywheel bolts, as the manual suggests? The original bolts look good, and I have been careful to re-torque them to the recommended 43 ft-lbs, after cleaning the threads and using 242 LocTite. This is a low performance engine, and I doubt it will see much abuse, at least by me.
3) The manual recommends torquing the pressure plate-to-flywheel bolts to 36 ft-lbs. When I tried this, two of the four original 8 mm bolts started to stretch beyond yield. I noticed that the threads in the flywheel are somewhat counter-sunk, and the bolts (assuming that they are the original; they DO have the proper spring washers) are only grade 8.8 (in metric, which I think is only grade 5 in SAE). So I installed new, slightly longer grade 8.8 bolts with the spring washers, and three bolts tightened up nicely at 36 ft-lbs. But the fourth bolt started to stretch at about 30 ft-lbs. I replaced it again, and only went to 34 ft-lbs, and it seems OK. So, my question is, should these have been a higher grade bolt (metric equivalent to grade 8, whatever that is)? Or is the 36 ft-lbs of torque too high? It seems pretty high for only 8 mm bolts.
Any other hints about replacing the clutch and flywheel? I already replaced the rear engine seal, and I greased up the pilot bearing (the manual says to check for roughness, which it wasn't, and lubricate with bearing grease). My release bearing has only 40k miles on it, and was smooth, so I haven't planned to replace that. This thread might prove to be useful to those about to perform a clutch replacement.
Thanks!
