Installing a flywheel on a VAZ 2106. Replacing and repairing a flywheel: the main difficulties

Welcome!

The engine flywheel is one of the most important parts in the design of a car engine, and therefore, if the flywheel is heavily worn, or if it is installed incorrectly, the car begins to “slip” when starting from a standstill - this means that when starting from a standstill or while driving, the speed is the engine will jump and the car itself will not accelerate, but will only roar.” Therefore, the flywheel must be changed in a timely manner, since driving on a worn one will bring pleasure but only bring discomfort.

Note!

To replace, you will need to stock up on: A screwdriver, as well as an L-shaped socket wrench and, if possible, take a torque wrench with you!

When should you replace the flywheel?

It must be replaced when:

How will the car behave with a worn flywheel?

• As noted earlier, the first thing that will most likely happen is that the clutch will slip on the worn flywheel.
• And also, most likely, when starting from a stop, the car will move, but this will be accompanied by strong vibration, which as a result will be transmitted to the entire car.

Flywheel replacement

Replacement requires a car lift, transmission rack and standard plumbing tools.

Replacing the flywheel VAZ 2106

The engine of classic Lada cars has a conventional single-mass flywheel. Let's look at how to remove the flywheel and the technological sequence for replacing it:

1. First you need to gain access to the flywheel. If the engine is removed, there will be no problems; if not, you need to remove the gearbox and clutch basket;
2. Next, you need to keep the flywheel from turning. To do this, use a special clamp, but a regular screwdriver will do;
3. Having removed the gearbox, you need to unscrew the six fastening bolts, then remove the flywheel;
4. Installing a new flywheel . Install the flywheel in the reverse order of dismantling. The flywheel bolts are tightened crosswise with a force of 60.1-87.4 N.m.

A lighter flywheel reduces top speed - a false myth.

Lightweight flywheel of the VAZ 2101, what was before.

The original flywheel weighed 7 kg.
To be precise and electronic - 6.873 kg. With such a weight of the flywheel, the VAZ 2101 looks like a dynamo))). Carelessly throwing the clutch at idle, the car takes off without stalling. It is very convenient for a minor student to drive uphill, along sand, etc. On the other hand, we pay for this with worse dynamics, that is, sluggish acceleration up a hill or tight acceleration when overtaking a truck, etc. With the original flywheel, the engine is quite inert compared to the installed lightweight flywheel. The engine picks up speed with a slight hesitation, but drops somehow slowly. On long climbs there is a gradual decrease in speed. The car goes uphill briskly, but

fades away smoothly, like a dynamo))) The engine not only has to expend additional energy when moving on a long climb, but also spin extra pounds when the climb is very long. In no case am I trying to show a bunch of minuses, just a cold assessment. Engineers calculated this flywheel weight for some reason, probably, like door locks, they are also designed for something, maybe to close doors with your feet, but times change and so do the requirements. With the advent of foreign cars, there is something to compare with.

Lightweight flywheel of the VAZ 2101, what happened after.

In my opinion, the maximum speed has increased, but since the speedometer shows a maximum of 160 km/h, and the speedometer needle rests against the stop, I cannot say a specific figure for the increase in speed, sorry. After the speedometer needle stops, the car picks up speed beyond control. Checkpoint 5th century from Fiat Polonez.

As for fuel economy, there are many opinions, but I can confidently assure you that fuel economy is observed. I ran out of fuel and noticed that I had driven more. I took measurements several times; my VAZ 2101 car with an engine capacity of 1300 cm2, with the same moderate driving around the city, fuel consumption decreased by 1 liter. With the original flywheel, consumption is 10-14 (depending on driving style). With a lightweight flywheel, consumption is 9-16. Yes, 16 is not a typo. The car shoots faster, and sporting interest forces you to keep the engine at exorbitant speeds, hence the overestimation of consumption, the blood boils, all that)))

After installing a lightweight flywheel, I noticed that the engine spins easier, reaches maximum speed faster, and the acceleration dynamics have greatly improved, as if I had increased the engine size. A lightweight flywheel does not make the engine more powerful, it only adds agility, i.e. the engine is able to reach maximum speed faster. I began to press harder into the seats when accelerating the car.

When driving in first gear, at idle, the car drives smoothly and does not jerk. Engine operation unchanged. With the same dynamic acceleration, I step on the gas pedal less. The car has a reserve of dynamism. I like how the engine revs quickly now. In addition, I leaned the mixture a little, the dynamics remained at the same level and I got a good gain in efficiency.

Look at the regular flywheel and the lightweight flywheel version.

The standard flywheel is shown on the left. The lightweight flywheel is shown on the right.

The maximum negative impact of centrifugal forces on vehicle dynamics is exerted by the weight of the outer radius of the flywheel. We reduced the weight by removing excess metal along the edge of the flywheel, leaving a shelf for attaching the clutch basket.

The inside of the flywheel is the real battlefield. The main focus of lightening the flywheel is on this side. The communists were generous guys, there was a lot of metal)))

By observing all the rules, tolerances and all other scientific terms that are not covered in this topic, you can achieve good results in lightening without losing the strength properties of the part.

The lightweight flywheel is not devoid of strength qualities, this is due to the appearance of stiffening ribs. The developed lightening scheme with our bright heads))) allows you to remove excess metal without weakening the product.

So here's a summary of what I got from installing a lightweight flywheel.

Intensive acceleration Feeling of more engine power Less fuel consumption Pleasant feeling of dynamism, presses you tighter into the seat Reduced time to overtake the “column leader” in front of you)))

On the Internet you can find different pricing policies for these parts.
I’ll say right away that the thing is worthwhile. Search, maybe you will find a more profitable offer, but if you are worried about whether installing a lightweight flywheel will give results or not, then I suggest you take a test drive. I give you a lightweight flywheel, you leave the amount below as a deposit, test it on your car and when you are pleased with the result, you make a decision. You know, you will leave a lightweight flywheel. This is why I suggest testing it first, knowing the result you got on your car. I suggest testing it and if you don't like it, get your money back. Ukrposhta
Ukrposhta - delivery both within the territory of Ukraine and beyond its borders.
If you are from Russia, Georgia, Belarus, etc., choose the Ukrposhta delivery service. Your order will arrive at the nearest post office in your city. Ukrposhta does not provide cash on delivery abroad. Cash on delivery is possible throughout Ukraine Nova Poshta, Intime
Nova Poshta is a very convenient and fast way to receive your order in your city. Possibility to pay for the order upon receipt, but in this case the delivery cost increases. More than 1000 branches in Ukraine. Intime - delivery within Ukraine from 1-3 days. Possibility to pay for your order upon receipt. Prices are slightly lower than those of Nova Poshta. Not every city has a branch.

Electronic money / plastic card Visa, Mastercard

When paying by electronic money or Visa, Mastercard, the delivery cost will be lower than when paying by cash on delivery, since there is no fee for sending money. After funds are credited to your account, this usually happens instantly, I will definitely contact you and inform you about the date of dispatch of your order. After sending, I will tell you the parcel number if it is sent by Ukrposhta, or the invoice number if it is Nova Poshta or Intime.

If this is your first time ordering online, I recommend choosing Interkassa or Wallet One. After payment you will be informed by E-mail about the status of the payment. I will definitely contact you and inform you about the delivery time and dispatch date. If you are interested in cash on delivery, then select this item. Choose a suitable carrier - Nova Poshta, Intime, Ukrposhta. COD ONLY FOR RESIDENTS OF UKRAINE.

PS The lightweight flywheel really brings the car to life. For example, having appreciated how a classic drives with a lightweight flywheel, I can no longer morally drive a stock one. Great for everyday driving. Try how the dynamics change for the better with a lightweight flywheel. We give you the opportunity to test and if something is wrong, return it.

Sincerely, the team of the project “Improvement of VAZ family cars”!

Flywheel as an energy accumulator

Heavy flywheels are installed on ordinary, custom cars with serial engines for one more reason - they act as an energy battery.

The fact is that at the lower end, power transfer in such cars from the piston to the crankshaft occurs in a very narrow range - 50 0.

In this case, four strokes in the engine occur in 720 0 (2 revolutions), of which the theoretical power stroke is only 180 0.

Due to the fact that the standard engine has low speeds and power transmission occurs in a very narrow range, even idling it is difficult.

This situation is corrected by a heavy flywheel, which, after 50° rotation of the shaft cranks, absorbs enough energy to then spin up further by inertia and help the engine.

The same is true for the operation of the unit at lower levels. Those. a heavy device on engines with operating speeds in the range of 2.5 - 4 thousand, and idle speeds from 0.8 to 1 thousand plays a positive role and it is not worth making it lighter if you do not simultaneously make design changes to other elements of the engine.

What characterizes a lightweight flywheel?

A lightweight flywheel is a product from which a certain amount of metal has been extracted.

For example, many VAZ car owners from the classic series lighten their flywheel by one and a half, two, or even 3.5 kilograms. At the same time, the factory weight of the device is about 7.5 kg.

With the latter option, the product will weigh about 4 kg and it is believed that this is the limit for VAZ cars, since going beyond it to a lesser extent can affect the strength characteristics of the flywheel itself. It's not worth the risk. Although, with the right approach, the weight of the product on a VAZ can be reduced to 3 kg, but more on that later.

But usually on VAZ models the weight of the flywheel is reduced by 1.5 kg, which cannot negatively affect its strength characteristics.

But everything is not as simple as it seems; there are many pitfalls that are important to know about.

How to properly install the flywheel on a VAZ 2106

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Flywheel replacement

How to properly replace the flywheel?

The flywheel is replaced after replacing the gearbox, clutch basket and the flywheel itself. If you don't have

time and suitable skills to replace the flywheel, we recommend contacting the AutoDrug car service center in Ufa. And if you prefer to perform such an operation yourself, the tips described below will be useful to you.

The gearbox can be dismantled according to a simplified procedure - for this there is no need to drain the oil and disconnect the drives. Next, two wire levers are removed, the starter is dismantled, the rocker, ground wires of the reverse sensors and two gearbox supports are disconnected.

After the levers are disconnected, the racks acquire sufficient lateral movement, which allows the transmission to be separated from the engine. The dismantled box can be placed in a convenient place, now we will have direct access to the flywheel and clutch. Fixing the flywheel is necessary to unscrew the bolts.

What spare parts are needed

• repair size pistons with rings (70ue);
• connecting rod and main bearings (15ue);
• camshaft 21213 (for the best “low-end” 35ue);
• split gear (in order to correctly set the 20ue marks) and a new chain (12ue);
• valves, guides and seals (20ue);
• valve springs (15ue), the purchase of which is often neglected;
• rocker depending on condition;
• cylinder head bolts (3ue);
• automatic chain tensioner (11ue);
• set of gaskets and seals (10ue);
• oil pump assembly (30ue);
• gear tensioner shoe (25ue);
• thermostat, pump and cooling pipes (20ue);
• BSZ (45ue) to provide a powerful spark, respectively + new wires with spark plugs (15ue);
• carburetor repair kit (4ue);
• filter (oil, fuel, air (5ue);

In total, work with parts and liquids, on average, will cost 470, provided high-quality spare parts are used, which will ultimately give a well-functioning engine with a long service life, as well as a power of about 85 hp.

Functions of the internal combustion engine flywheel

The flywheel is installed on the engine crankshaft and is located on the outside of the engine. Thus, it is structurally connected directly to the internal combustion engine, clutch and gearbox.

In the engine design, the flywheel performs several functions at once: 1. Damping torsional vibrations that occur during engine operation. The better the flywheel dampens vibration, the less stress on the transmission and the longer its service life.

Vibration damping with dual-mass flywheel

2. Transfer of rotational torque from the crankshaft to the clutch. The clutch driven disc is connected to the friction surface of the flywheel.

Flywheel with clutch basket

3. Transfer of rotational torque to the crankshaft from the starter. When the engine starts, the starter meshes with the flywheel gear to spin the crankshaft.

4. The flywheel accumulates part of the rotational energy and creates inertia that prevents the engine from stopping. Without such inertial “feeding”, the engine would simply stop at the moment when the pistons reach their dead spots.

Flywheel vibration depends on engine operation

Thus, a simple mechanism in principle turned out to be indispensable in ultra-modern cars. The only thing that has changed over the years is the design of the flywheel itself.

Removing and troubleshooting the flywheel:

1. Before starting work, remove the battery (see article) from the car, drain the oil from the gearbox and remove it.

2. Remove the gearbox and disassemble it.

3. Now that you have reached the flywheel, unscrew the six bolts securing it. But to do this, put back one bolt securing the gearbox and insert a screwdriver into the teeth of the flywheel with one hand so that it does not rotate while unscrewing the bolts.

4. While holding the flywheel with one hand, remove the bolt locking plate from the final bolt with the other.

5. Now carefully remove the flywheel from the crankshaft flange. 7. If everything is in order with the rim of the teeth, then switch your gaze to the adjacent surface of the driven disk; it should not have deep abrasions or other defects.

8. Also carry out a similar troubleshooting on the back side of the driven disk, or rather, look at the adjacent crankshaft flange.

If such distortions are visible in points 7 or 8, then the flywheel must be replaced with a new one or repaired - sanded using special equipment in a car repair shop.

9. To carry out an accurate check or repair of the clutch driven disc, take it to a car workshop that has the required equipment. Actions and recommendations for repairing the flywheel:

• The defect of the adjacent surface of the clutch disc (3) should not be more than 0.06 mm.
• The parallelism between the upper contact surface of the driven disk and the lower surface (2) for fastening the clutch should not be more than 0.1 mm.
• On the clutch disc planes (1 and 3), the runout should not be more than 0.1 mm.
• When cleaning the surface of the flywheel (3) from abrasions and scratches, you should know that the maximum possible removal of a layer of metal is no more than 1 mm.
• At the same time as side (3), surface (2) should also be sanded. To do this, maintain a step between them with a height of 0.5±0.1 mm. When grooving, keep the adjacent surfaces (1 and 3) parallel.

10. Once you have finished cleaning the surface of the flywheel, proceed to reinstall it. First of all, degrease the bolts and threaded holes under them, and then apply sealant to their threads. Reinstall the part in the order of removal, only align the holes on the crankshaft flange and the flywheel correctly (they are located asymmetrically).

Isn't it easier to buy a new one?

It may be simpler, but imagine the cost of this part. As a rule, if you change the whole thing, the price will be 5–6 times more expensive than buying just a crown. However, there are small problems - replacement is not an easy process and if you have never done it, you may simply install this part incorrectly, it will quickly wear off. Or you will “kill” the starter gear.

Therefore, the bottom line is that the replacement should be carried out by professionals, preferably at a service station, with a guarantee.

How to install a clutch disc: step-by-step instructions

The clutch performs the most important function - it ensures smooth gear shifting, so that the car starts smoothly, the transmission and engine function correctly and do not fail ahead of time.

Due to the fact that the clutch experiences increased loads, it has to be changed quite often, every 100,000 kilometers. How do you know when it's time to install a new clutch disc?

The following signs indicate that this element has become unusable: slippage appears, the clutch does not disengage completely, gears are difficult to shift, the clutch pedal becomes too tight or falls, and the car loses traction.

Not every car owner is well versed in how to properly replace this element. What happens if you install the clutch disc incorrectly? The result of such a repair will be the following: you will have to disassemble the unit again, because the disk will not be able to function properly and will begin to malfunction.

Nuances of proper installation

Correct installation of the flywheel implies, first of all, that the marks match. If, when removing the flywheel, the position of the assembly relative to the crankshaft and the sensor was not noted (it is located right between), this leads to a problem.

Experts say that the 20th tooth after a flywheel break, counted up clockwise, should be facing the crankshaft sensor, and the shaft itself should be at TDC.

Attention. You can check the position of the crankshaft from the back of the engine. There is a special sign there.

In addition, knowledge of how to properly install the flywheel will help you fully realize the capabilities of the car engine. At the factory, the system is initially equipped with a standard unit. For example, on a VAZ the unit is of the old format, dating back to the era of the Fiat prototype.

Naturally, this was the reason for modernization and alterations. And today innovative techniques come to the aid of the tuner.

Let's consider these possibilities.

Installation of a 2-mass flywheel makes it possible to shift the RVK (mesomerism of oscillations) to a rotation amplitude two times smaller than the idle speed of the internal combustion engine. In a 2-mass flywheel, the spring system is not located in the clutch, but between the cast iron parts.

Despite such a large number of positive properties, a 2-mass flywheel is rarely the choice of tuners, since it is expensive, cannot be repaired in a garage due to high-precision manufacturing, and for a number of other reasons.

Attention. Among other things, the 2-mass flywheel often fails. When starting the internal combustion engine or stopping the engine, a characteristic creaking, noise and vibration is heard, which indicates problems with the unit.

A more effective way to reduce the load on the gearbox would be to install a lightweight flywheel model. In this case, the actual weight of the product is reduced by the maximum possible amount. The new unit ultimately weighs 4-5 kg ​​less than the standard version.

Lightweight flywheel

Installing a lightweight node model involves a lot of nuances. First of all, this concerns the groove of the flywheel on both sides.

Summary: If for any reason the position of the shafts and flywheel is in doubt, it is recommended to do the following. Align the mark on the crankshaft with the mark on the lower timing belt casing. At the same time, a mark is placed on the flywheel, which should point to the crankshaft sensor. As for the camshaft mark, it should be at the level of the cylinder head edge.

Flywheel replacement

Replacement requires a car lift, transmission rack and standard plumbing tools.

Replacing the flywheel VAZ 2106

The engine of classic Lada cars has a conventional single-mass flywheel. Let's look at how to remove the flywheel and the technological sequence for replacing it:

1. First you need to gain access to the flywheel. If the engine is removed, there will be no problems; if not, you need to remove the gearbox and clutch basket;
2. Next, you need to keep the flywheel from turning. To do this, use a special clamp, but a regular screwdriver will do;
3. Having removed the gearbox, you need to unscrew the six fastening bolts, then remove the flywheel;
4. Installing a new flywheel . Install the flywheel in the reverse order of dismantling. The flywheel bolts are tightened crosswise with a force of 60.1-87.4 N.m.

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