Alternator Pulley / Clutch: Service and Repair

Pulley, replacing

Special tools:
115 9079 BIHEXAGON BIT ADAPTOR M10 115 9079 Bihexagon Bit Adapter M10
115 9080 BIHEXAGON BIT ADAPTOR M10X100 115 9080 Bihexagon Bit Adapter M10X100
951 2036 Ring wrench 951 2036 Ring Wrench
999 5760 Counterhold 999 5760 Counterhold

Replacing the pulley with freewheel/ fixed pulley

Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Removing a pulley with freewheel





Removing a pulley with freewheel
- remove the dust cover
- use tool 999 5760 Counterhold 999 5760 Counterhold as illustrated
- use a twelve toothed dowel, 115 9080 BIHEXAGON BIT ADAPTOR M10X100 115 9080 Bihexagon Bit Adapter M10X100 , as illustrated
Note! When removing: The rotor shaft and pulley are left-hand threaded.

- disconnect the pulley from the rotor shaft
- remove the pulley.

Installing the pulley with freewheel





Installing a pulley with freewheel
- slide the pulley onto the rotor shaft
- use tool 999 5760 Counterhold 999 5760 Counterhold on the pulley, as illustrated
- use a twelve toothed dowel, 115 9080 BIHEXAGON BIT ADAPTOR M10X100 115 9080 Bihexagon Bit Adapter M10X100 , as illustrated
Note! The rotor shaft and pulley are left-hand threaded.

- tighten the pulley. Tighten to 80 Nm (59 lbs.)
- install the dust cover.
Checking the function of the freewheel on the generator (GEN) in the car

Check the pulley freewheel as follows:
- start the engine
- rev the engine to 3,000 rpm.
Ensure that no extra power consuming components are connected.
Check that only a weak clicking sound is heard when the freewheel engages and disengages
- switch off the engine. Check that the generator rotates for longer than the engine.
If it is cold, the battery charge warning lamp may light shortly after start-up because the freewheel needs to rotate and 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.

Check
Checking the function of the freewheel on a removed generator (GEN)

Check the pulley freewheel as follows
- rotate the pulley counter-clockwise and brake heavily.
The freewheel should grip the rotor shaft when rotating counter-clockwise
- stop the rotation.
When braking the pulley, the freewheel mechanism should release so that the rotor shaft continues to rotate.
This method allows the function of the freewheel to be checked easily.

Removing a fixed pulley





Removing a fixed pulley
- use a wrench, 951 2036 Ring wrench 951 2036 Ring Wrench to hold the nut as illustrated
- use a twelve toothed dowel, 115 9079 BIHEXAGON BIT ADAPTOR M10 115 9079 Bihexagon Bit Adapter M10 , on the rotor shaft
- remove the nut and remove the pulley.

Installing a fixed pulley





Installing a fixed pulley
- thread the pulley onto the rotor shaft
- thread the nut
- use a wrench, 951 2036 Ring wrench 951 2036 Ring Wrench and a twelve toothed dowel, 115 9079 BIHEXAGON BIT ADAPTOR M10 115 9079 Bihexagon Bit Adapter M10 as illustrated
- tighten the pulley. Tighten to 65 Nm (48 ft. lb).





Function test
Start the car. Check that the generator (GEN) charges.