Generator

GENERATOR

REMOVAL AND INSTALLATION

Removal steps 1-16:

Required Special Tool:
* MD998781: Flywheel Stopper

REMOVAL SERVICE POINT

[[A]] CRANKSHAFT BOLT REMOVAL





1. Using special tool MD998781, hold the drive plate.





2. Remove the crankshaft bolt.

CAUTION: provide one punch mark on the head of the crankshaft bolt each time the bolt is removed. Replace the bolt that already has three punch marks. (the evidence of having been tightened three times)

INSTALLATION SERVICE POINT

]]A[[ GENERATOR INSTALLATION





1. Temporarily tighten the alternator to the alternator bracket.
2. In accordance with the tightening order shown in the illustration, tighten the installation bolts for the alternator to the specified torque.
Tightening torque: 47 ± 11 Nm (35 ± 7 ft-lb)

]]B[[ CRANKSHAFT BOLT INSTALLATION





CAUTION: before installing the crankshaft bolt, check the number of punch marks on its head. (the bolt is reusable if it is two or less.) If the bolt has three punch marks, replace it.

1. Using special tool MD998781, hold the drive plate.





2. Clean the bolt hole in crankshaft bolt and crankshaft pulley's seating surface.
3. Degrease the cleaned seating surface of the front flange and crankshaft pulley.
4. Install the front flange and crankshaft pulley.
5. Apply oil to the threads of crankshaft bolt and the outer surface of washer.
6. Tighten the crankshaft bolt to 200 Nm (148 ft-lb).
7. Loosen the crankshaft bolt fully.
8. Tighten the crankshaft bolt to 110 Nm (81 ft-lb).





9. Make a paint mark on the crankshaft bolt.

CAUTION:
^ If the nut is turned less than 60 degrees proper fastening performance may not be achieved. Be careful to tighten the nut exactly 60 degrees.
^ If the nut is overtightened (exceeding 60 degrees), loosen the nut completely and then retighten it by repeating the tightening procedure from step 6.

10. Make a paint mark on the bolt end at a position 60 degrees from the paint mark made on the crankshaft pulley in the direction of tightening the crankshaft bolt.
11. Turn the crankshaft bolt another 60 degrees and make sure that the paint marks on the crankshaft pulley and crankshaft bolt are aligned.