AC_Tensioner_Work_Instruction_Paragraph_5.7.4.pdf

POWER PACK AC BELT DRIVE TENSIONER REMOVAL/INSTALLATION

Tools and Special Tools Ratchet, 1/2 inch drive Ratchet, 3/8 inch drive Socket, 13 mm, 3/8 inch drive Socket, 13 mm, 3/8 inch drive Socket, 24 mm, 1/2 inch drive Socket, Allen head, 8 mm, 3/8 inch drive Wrench, 24 mm Wrench, torque, 3/8 inch drive

Materials Marker, paint Sealant, Loctite 242

1. Loosen bolt (Item 4) on back of mounting bracket (Item 3) using 24 mm wrench, 1/2 inch drive ratchet, and 1/2 inch drive 24 mm socket (Figure 1).

2. Remove bolt (Item 1) and washer (Item 2) from mounting bracket (Item 3) using 3/8 inch drive ratchet and 3/8 inch drive 13 mm socket (Figure 1).

3. Remove bolt (Item 4) and washer (Item 5) securing automatic tensioner (Item 6) to mounting bracket (Item 3).

Remove automatic tensioner (Figure 1).

Figure 1. Tensioner Removal.

1 2

POWER PACK AC BELT DRIVE TENSIONER REMOVAL/INSTALLATION – Continued

AC Belt Drive Tensioner Assembly

NOTE

Ensure that pin on back of tensioner is properly aligned with hole in adapter plate.

1. Apply Loctite 242 to threads of bolt. Install bolt (Table 1, Item 1) to secure tensioner (Item 2) to adapter plate (Item 3) by hand (Figure 2).

Figure 2. Tensioner and Adapter Plate.

Table 1. Parts List – Tensioner Installation.

ITEM NO NOMENCLATURE PART NO NIIN QTY

1 Bolt, Allen head R2002809 1

2 Tensioner R0140865 1

3 Adapter Plate R0161627 1

AC Belt Drive Tensioner Installation

1. Loosely install bolt (Table 2, Item 1), two washers (Item 2) and lock nut (Item 3) to secure adapter plate, tensioner and spacer plate to engine bracket. Hand tight (Figure 3).

NOTE

Ensure bolt is installed to center position hole on adapter plate and engine bracket.

2. Install bolt (Item 4) and washer (Item 5) to secure adapter plate in position on engine bracket using 3/8 inch drive ratchet and 3/8 inch drive 13 mm socket (Figure 3).

3. Tighten bolt (Item 1) and lock nut (Item 3) using 24 mm wrench, 1/2 inch drive ratchet, and 1/2 inch drive 24 mm socket.

Figure 3. Belt Tensioner Installation.

2 1

Table 2. Parts List – Tensioner Installation.

ITEM NO NOMENCLATURE PART NO NIIN QTY

1 Bolt R2002712/R2002433 NSL/015575631 1

2 Flat Washer R2003046 01-557-6579 2

3 Lock nut R2020313 01-653-8190 1

4 Bolt R2002625 01-547-6220 1

5 Washer R2003015 01-557-6797 1

4. Raise two adjustable feet (Figure 4, Item 2) and tighten nuts (Item 1) on engine mounting bracket (Item 3).

Figure 4. Engine Mounting Bracket.

5. Tighten bolt (Figure 5, Item 1) using 3/8 inch drive ratchet and 3/8 inch drive 8 mm Allen head socket to secure tensioner (Item 2) to adapter plate (Item 3).

Figure 5. Tensioner Final Install.

6. Adjust cooling tube to ensure tensioner does not touch tube. Loosen nuts on clamps on cooling tube to open gap as wide as possible using 3/8 inch drive ratchet and 3/8 inch drive 13 mm socket (Figure 6).

Figure 6. Tube Spacing.

Loosen Tube Clamp Here

Ensure Gap is wide as possible

NAME OF REMOVED AND

DISPOSITION ITEMS

(QUANTITY)

PART NUMBER NIIN PICTURE

Tensioner assembly (1) R0091262 01-577-9840

END TASK