Generator and Ignition System Removal and Installation

REMOVAL AND INSTALLATION









- MB990767: Front Hub And Flange Yoke Holder
- MB991398: Spark Plug Wrench
- MB991883: Flywheel Stopper
- MD998719: Pin

REMOVAL SERVICE POINT

[[A]] CRANKSHAFT PULLEY CENTER BOLT REMOVAL









1. Use special tool MB991883 to secure the flywheel.
Use the special tool MB990767 and MD998719 to insert the pin into the crankshaft pulley hole and prevent it from rotating.
2. Remove the crankshaft pulley center bolt.

[[B]] SPARK PLUG REMOVAL





Using special tool MB991398, removal the spark plug.

INSTALLATION SERVICE POINTS

]]A[[ SPARK PLUGS INSTALLATION





Using special tool MB991398, tighten the spark plug to the specified torque.
Specified torque: 18± 2Nm (13± 1 ft-lb)


]]B[[ CRANKSHAFT PULLEY / CRANKSHAFT PULLEY WASHER / CRANKSHAFT PULLEY CENTER BOLT INSTALLATION









1. Use special tool MB991883 to secure the flywheel.
Use the special tool MB990767 and MD998719 to insert the pin into the crankshaft pulley hole and prevent it from rotating.





2. Wipe off the dirt on the crankshaft pulley washer and on the thread hole of the crankshaft using a rag.
3. Wipe off the dirt on the crankshaft pulley and the crankshaft sprocket using a rag, and then remove the grease from the portion shown in the illustration.
NOTE:
Remove grease to prevent the coefficient of friction of the pressing portion from declining due to adhesion of oil.

4. Install the crankshaft pulley.
5. Apply an appropriate and minimum amount of engine oil to the threaded portion of the crankshaft and lower part of the flange.
6. With off the chamfered side on the inside of the washer facing the bolt top, install the washer to the crankshaft pulley center bolt.
7. Tighten the crankshaft pulley center bolt to 250 Nm (164 ft-lb)
8. Loosen the crankshaft pulley center bolt fully.
9. Tighten the crankshaft pulley center bolt to 110 Nm (81 ft-lb).





10. As shown in the illustration "A," apply the paint mark to the crankshaft pulley on the extended line of the corner adjacent to the one of the crankshaft pulley center bolt corners.
11.
CAUTION:

- When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured.
- When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the beginning again according to the procedure.

Tighten the crankshaft pulley center bolt by 60° once more. Make sure the paint mark of crankshaft pulley center bolt is aligned with the paint mark of crankshaft pulley as shown in the illustration "B."

]]C[[ GENERATOR / POWER STEERING PUMP BRACKET INSTALLATION





1. Temporarily tighten power steering pump bracket bolts.
2.
CAUTION:
Always loosen the power steering pump bracket bolt, and temporarily install the generator. Then tighten each bolt.

Loosen the power steering pump bracket bolts and make the power steering pump bracket unfixed.
3. Temporarily install the generator with the generator bolts.
4. Tighten them to the specified torque according to the order as illustrated.
Specified torque

Power steering pump bracket:
M8 26± 3Nm (19± 2 ft-lb)
M10 44± 8Nm (33± 5 ft-lb)
Generator: 44± 10Nm (32± 7 ft-lb)