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  • The screeching starter could be the the big hint here, it's possible that the starter pinion ( the small gear in the end of the starter motor) isn't engaging with the ring gear of the flywheel and binding up causing an electrical overload.
    There are probably damaged sectors on the ring gear, what you need to do to check this is remove the starter, check the pinion isn't mangled, then put it in a vice and connect a battery to observe that the pinion mechanism is engaging properly, (you will need to put it in a vice to secure it when you power it up, as the starter produces a shit load of torque and could injure you if you try to hold it by hand!)
    Next check the ring gear........ using a glamorous assistant, rotate the engine at least one whole revolution by hand, whilst inspecting the ring gear through the hole vacated by the starter motor.
    You are looking for chewed up sections on the ring gear.
    4cyl engines usually stop at the two same places in their rotation every time they're switched off, so when started the starter nearly always engages at the same two sectors of the ring gear.

    Depending on the mechanical aptitude of the aforementioned glamorous assistant, you may have to do the turning whilst they video the ring gear with a mobile phone.
    A damaged ring gear will require replacement, you'll need to separate gearbox from the engine, remove the clutch (inspect the clutch and probably replace it while your there) remove the flywheel, now remove the ring gear from it, by cutting it between the teeth with a sharp cold chisel ( it's easier if you CAREFULLY drill through the ring gear to weaken it, without drilling into the flywheel!)
    To fit the new ring gear to the flywheel, evenly heat the ring gear to @ 350C, this will expand the ring gear to enable you to press it by hand (use welder's gloves) onto the flywheel.
    Some ring gears will have chamferd teeth on one side, the chamfer is to enable the starter to engage more easily, so this this side is to face the starter.
    I suggest you sneak into the kitchen whilst no one is looking and using the oven to heat up the ring gear,it will probably change colour to a bluish hue, it wont hurt to hurl the flywheel in the freezer while you heating the ring gear.
    Cooling the flywheel will cause it to contract, buying you a little more time to fit the hot ring gear.
    Quickly place the hot ring gear onto the cooled flywheel, tap it into place with a copper or leather faced hammer if need be. (if you don't have such a hammer, you can use a steel faced hammer with a bit of brass, cooper or aluminum bar as a drift, so as not to damage the ring gear.)
    Put it to one side to cool all by itself. Slap the whole lot back together.....happy days!
    I cannot put enough emphasis on the fact that you need to move quickly once you take the ring gear out of the oven, getting stuck half on/ half off is not an option.

    Of course, you may have two separate problems, an electrical problem as well as a damaged ring gear.
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