Flywheel Inspection

CAUTION:

Secure the steering wheel using tape or a cable to prevent the steering shaft from rotating after disconnecting the steering shaft. If the steering wheel rotates after the steering shaft and the steering gear and linkage are disconnected, the internal parts of the clock spring could be damaged.
Do not rework the dual-mass flywheel if it is distorted.
Do not clean the dual-mass flywheel with any kind of fluid. Clean the dual-mass flywheel with a dry cloth only.
Do not clean the gap between the primary and secondary mass. Only clean the bolt connection surface and the clutch surface.

Perform the following procedures.
1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO] .)
2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO] .)
3. Remove the PCM cover No.1. (See PCM REMOVAL/INSTALLATION .)
4. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION .)
5. Remove the battery tray and PCM component. (See BATTERY REMOVAL/INSTALLATION [MZR 2.3 DISI TURBO] .)
6. Remove the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
7. Remove the charge air cooler cover. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
8. Remove the charge air cooler. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
9. Remove the fuel pump resistor. (See FUEL PUMP RESISTOR REMOVAL/INSTALLATION .)
10. Remove the front tires. (See GENERAL PROCEDURES (SUSPENSION) .)
11. Remove the splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION .)
12. Remove the aerodynamic under cover No.2. (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION .)
13. Remove the WU-TWC bracket. (See EXHAUST SYSTEM REMOVAL/INSTALLATION .)
14. Remove the starter. (See STARTER REMOVAL/INSTALLATION .)
15. Remove the front auto leveling sensor. (See AUTO LEVELING SENSOR REMOVAL/INSTALLATION .)
16. Drain the transaxle oil into a suitable container. (See TRANSAXLE OIL REPLACEMENT .)
17. Remove the manual transaxle. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION .)
18. Remove the clutch cover and clutch disc. (See CLUTCH UNIT REMOVAL/INSTALLATION .)
Inspect the dual-mass flywheel runout.

Fig 1: Inspecting Dual-Mass Flywheel Runout
- If it is more than the maximum specification, replace the dual-mass flywheel. (See CLUTCH UNIT REMOVAL/INSTALLATION .)
Flywheel maximum runout
- 1.5 mm {0.059 in}
Remove the dual-mass flywheel. (See CLUTCH UNIT REMOVAL/INSTALLATION .)
Visually inspect the ring gear on the dual-mass flywheel.

Fig 2: Inspecting Ring Gear On Dual-Mass Flywheel
- If there is any damage, replace the dual-mass flywheel. (See CLUTCH UNIT REMOVAL/INSTALLATION .)
Inspect the dual-mass flywheel.
- Cracks
- Worn ring gear teeth
- Chipped or cracked ring gear teeth
- Surface that contacts the clutch disc for scratches, nicks, and discoloration.
- If there is any malfunction, correct slight scratches and discoloration using sandpaper.
  
  Fig 3: Correcting Slight Scratches And Discoloration Using Sandpaper
Visually inspect the secondary mass.
- If there is any damage, replace the dual-mass flywheel.
Inspect the welded area of the dual-mass flywheel for grease leakage.

Fig 4: Inspecting Welded Area Of Dual-Mass Flywheel For Grease Leakage
- If there is grease leakage, replace the dual-mass flywheel. (See CLUTCH UNIT REMOVAL/INSTALLATION .)
Inspect for locating dowels touching the primary mass of the dual-mass flywheel.

Fig 5: Inspecting For Locating Dowels Touching Primary Mass Of Dual-Mass Flywheel
CAUTION:
- Make sure that the three locating dowels are installed.
- If the locating dowels are touching the primary mass of the dual-mass flywheel, replace the dual-mass flywheel with a new one.
Verify that the center of the dual-mass flywheel does not move.
1. Rotate the dual-mass flywheel or attempt to move it up and down, and left and right to verify that the center of the dual-mass flywheel does not move.
  
  Fig 6: Indicating Center Of Dual-Mass Flywheel Does Not Move
  - If there is any movement as indicated by the arrows in the figure, replace the dual-mass flywheel with a new one. (See CLUTCH UNIT REMOVAL/INSTALLATION .)
Verify that the secondary mass rotates by 15 teeth or more.

Fig 7: Inspecting Secondary Mass Rotates By 15 Teeth Or More
- If it rotates by 15 teeth or more, replace the dual-mass flywheel.
Inspect the dual-mass flywheel for the amount of guide pin projection.

Fig 8: Inspecting Dual-Mass Flywheel For Amount Of Guide Pin Projection
- If not within the specification, replace the dual-mass flywheel.
Rotate the secondary mass left and right and verify that it rotates within a range of three teeth without resistance.

Fig 9: Inspecting Secondary Mass Rotates Within Range Of Three Teeth Without Resistance
- If there is any malfunction, replace the dual-mass flywheel.