Removal
6. Follow the steps described in paragraph. points 1 and 2, if you haven't done so yet.
7. Disconnect the ground cable from the battery (see "Disconnecting the battery").
8. Loosen the upper and lower nuts/bolts (whichever is applicable) generator mounts and adjusting bar mounting bolt.
9. If necessary, turn the adjusting bolt to relieve tension on the drive belt, then remove the belt from the pulleys (figure 12.9).
Figure 12.9. Upper generator mount nut (1) and adjusting bolt (2) (xOD series engines)
Note: If the belt is to be reused, mark the direction of rotation on it before removing it. This will ensure that the belt is installed correctly.
Installation
10. When replacing a belt, ensure that the new belt is the correct type, and if installing a removed belt, follow the marks made during removal to ensure it is installed correctly. Place the belt on the pulleys and use the adjusting bolt to take up the belt slack.
11. Tighten the drive belt as described in the following paragraphs.
Stretching
Advice: Proper drive belt tension ensures reliable operation throughout its entire service life, while sagging prevents slippage and squealing. Be careful not to exceed the required tension as this may cause increased wear on the generator bearings.
12. Follow the steps described in paragraph. points 1 and 2, if you haven't done so yet.
13. The belt should be tensioned so that when pressing firmly with your thumb in the middle of the longest section between the pulleys there is a deflection of approximately 5.0 mm (see the note at the beginning of this paragraph).
14. To make adjustments, turn the adjusting bolt to achieve the correct tension. This should be done in a position where the mounting bolts hold the generator but still allow for slight movement.
15. Rotate the crankshaft two revolutions, check the tension again, and then tighten both generator mounting bolts/nuts. If applicable, also tighten the bolt securing the adjuster bar to the corresponding support bracket.
16. Connect the ground wire to the battery.
17. Secure the coolant hoses in their normal position (where necessary) and install the wheel arch liner. Install the wheel and lower the vehicle.