Pulley and Freewheel Replacing

Pulley And Freewheel, Replacing

Special Tools: 951 2849, 999 5760, 999 5761

Removing The ABS Unit







- Detach the mounting on the side
- Remove the lower mounting screws. Remove the support
- Detach the mounting bracket (A) from the brake pipe on the fender liner
- Raise the ABS unit a little and move it to the side.

Removing The Auxiliaries Belt







- Remove the auxiliaries belt.

Installing The Special Tool







- Clean around the pulley
- Remove the protective cover (A)
- Install socket 999 5761 (Denso) or 951 2849 (Bosch) (Allen) on the rotor shaft as illustrated
- Install counterhold 999 5760 over the socket 999 5761 (Denso) or 951 2849 (Bosch). Press firmly into place in the track for the pulley.

Removing Pulley







NOTE: The pulley is lefthand threaded.

- Counterhold the rotor shaft using socket 999 5761 (Denso) or 951 2849 (Bosch).Twist off the pulley using counterhold 999 5760 (clockwise)
- Remove the pulley from the rotor shaft.

Installation

Installing Pulley







NOTE: The pulley is lefthand threaded.

- Clean the rotor shaft and the pulley
- Install the pulley on the shaft
- Screw the pulley (counter-clockwise) into place using counterhold 999 5760. Counterhold the rotor shaft using socket 999 5761 (Denso) or 951 2849 (Bosch)
- Tighten the pulley. Tighten to 80 Nm
- Install the protective cover.

Checking The Freewheel Function (Poly V-belt Removed)
Check the pulley freewheel as follows:

Rotate the pulley counter-clockwise and brake the pulley heavily.

The freewheel must grip the rotor shaft when it rotates counter-clockwise.
Stop the rotation.

When braking the pulley, the freewheel mechanism should must release so that the rotor shaft continues to rotate.

Installing The Auxiliaries Belt







- Install the auxiliaries belt.

Installing The ABS Unit







Install:
- the support and ABS unit. Tighten nuts and screws. Tighten to 23 Nm
- the clamp bracket. Tighten it to the fender liner. Tighten to 10 Nm.

Check the function.

Function Test
Check the pulley freewheel when the generator is secured in the car as follows.
- start the engine
- rev the engine to 3,000 rpm.

Ensure that no other power consuming components are engaged.

Check that only a faint clicking sound is heard when the freewheel engages and disengages

- switch off the engine. Check that the generator rotates for longer than the engine.

In cold conditions, the battery charge warning lamp may light for a short while after start. This is because the freewheel needs to rotate to warm up the bearing grease before it locks and engages the rotor shaft.

If the warning lamp remains lit, it may be an indication that the freewheel has not locked the pulley to the rotor shaft.