GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2000 🢒 Firefly (Canada) 🢒 General Information 🢒 Vibration Diagnosis and Correction 🢒 Engine Flywheel Replacement

Removal Procedure
  1. Remove the transaxle from the engine. For automatic Transmission Replacement transaxle equipped vehicles, refer to in Automatic Transmission.For manual transaxle Transmission Replacement equipped vehicles, refer to in Manual Transmission.
  2. For manual transaxle equipped vehicles, remove the clutch from the flywheel. Refer to Clutch Assembly Replacement Clutch.
  3. Inspect the ring gear for the following conditions:
    4. • Wear
    • Damage
    • Cracks
  4. In a vehicle that is equipped with a manual transaxle, replace the flywheel, if the surface that contacts the clutch disc exhibits the following conditions:
    5. • Damage
    • Excessive wear
    • Cracks
  5. Mark the flywheel-to-engine position.
  6. Remove the flywheel retaining bolts and the flywheel from the crankshaft.
  7. Remove the clutch pilot bearing from the crankshaft.
  8. Use a suitable solvent in order to clean the grease and the dirt from the flywheel outer surfaces.

Installation Procedure
  1. In a vehicle with a manual transaxle, install the clutch pilot bearing into the crankshaft.
  2. Install the flywheel to the crankshaft, aligning the flywheel-to-engine marks

    3. Notice: Apply the proper amount of the sealant to the fastener when assembling this component. Excessive use of the sealant can prohibit the component from being assembled properly or allow the fastener to loosen. A component or fastener that is not assembled properly can loosen or fall off leading to extensive engine damage.

  3. Apply GM P/N 1234593 or equivalent to the flywheel retaining bolt threads.

    4. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  4. Install the flywheel retaining bolts to the flywheel.

    5. Tighten

        • Automatic Transmission: Tighten the flywheel retaining bolts to 95 N·m (69 lb ft).
        • Manual Transmission: Tighten the flywheel retaining bolts to 78 N·m (57 lb ft).
  5. In a vehicle with a manual transaxle, install the clutch to the flywheel. Refer to Clutch Assembly Replacement in Clutch.
  6. Install the transaxle to the engine. In a Transmission Replacement vehicle with an automatic transaxle, refer to in Automatic Transmission/Transaxle.In Transmission Replacement a vehicle with a manual transaxle, refer to in Manual Transmission/Transaxle.