REMOVAL AND INSTALLATION

Removal steps <<A>> 1. Alternator drive belt <<B>> >>A<< 2. Crankshaft pulley centre bolt <<B>> >>A<< 3. Crankshaft pulley washer <<B>> >>A<< 4. Crankshaft pulley

1. caution To reuse the alternator drive belt, draw an arrow indicating the rotating direction on the back of the alternator drive belt using chalk to install the same direction. Turn the alternator drive belt auto-tensioner to anti-clockwise, and insert the L-shaped hexagon wrench to the alternator drive belt auto-tensioner hole in order to fix the auto-tensioner. 2.Remove the alternator drive belt.

1. caution Use only the specified special tools, or a damaged pulley damper could result. Use the following special tools to support the crankshaft pulley: Front hub and flange yoke holder (MB990767) Pin (MD998719)

2. caution Provide one punch mark on the head of the crankshaft pulley centre bolt each time the bolt is removed. Replace the bolt that already has three punch marks (The evidence of having been tightened three times). Loosen the crankshaft pulley centre bolt and remove the crankshaft pulley washer and crankshaft pulley.

1. caution Before installing the crankshaft pulley centre 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. Wipe the dirt on the crankshaft pulley washer using a rag. 2.Using a rag, wipe the dirt on the crankshaft pulley, the front flange, the crankshaft sprocket, the thread hole of the crankshaft and then remove the grease. 3.Install the front flange and crankshaft pulley. 4.Apply an adequate and minimum amount of engine oil to the threads of crankshaft pulley centre bolt and the outer surface of washer.

5.Use the following special tools as during removal to support the crankshaft pulley: Front hub and flange yoke holder (MB990767) Pin (MD998719) 6.Tighten the crankshaft pulley centre bolt to the specified torque. Tightening torque: 110 N·m

7.Make a paint mark on the crankshaft pulley centre bolt. 8. caution If the crankshaft pulley centre bolt is turned less than 60 degrees, proper fastening performance may not be achieved. Be careful to tighten the crankshaft pulley centre bolt exactly 60 degrees. If the crankshaft pulley centre bolt is overtightened (exceeding 60 degrees), loosen the crankshaft pulley centre bolt completely and then retighten it by repeating the tightening procedure from step 6. Make a paint mark on the crankshaft pulley centre bolt end at a position 60 degrees from the paint mark made on the washer in the direction of tightening the crankshaft pulley centre bolt. 9.Turn the crankshaft pulley centre bolt another 60 degrees and make sure that the paint marks on the washer and crankshaft pulley centre bolt are aligned. 10.Loosen the crankshaft pulley centre bolt fully. 11.Tighten the crankshaft pulley centre bolt to the specified torque again. Tightening torque: 110 N·m 12. caution If the crankshaft pulley centre bolt is turned less than 60 degrees, proper fastening performance may not be achieved. Be careful to tighten the crankshaft pulley centre bolt exactly 60 degrees. If the crankshaft pulley centre bolt is overtightened (exceeding 60 degrees), loosen the crankshaft pulley centre bolt completely and then retighten it by repeating the tightening procedure from step 6. Make a paint mark on the crankshaft pulley centre bolt end at a position 60 degrees from the paint mark made on the washer in the direction of tightening the crankshaft pulley centre bolt.