Installing the pulley with freewheel

WARNING: This page is about a different car, the 2004 Volvo S40, 2003 Volvo S40, 2002 Volvo S40, 2001 Volvo S40, and 2000 Volvo S40. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Installing Pulley With Freewheel

Courtesy of VOLVO CARS OF NORTH AMERICA.

Cleans the surfaces of the rotor shaft and pulley to facilitate installation
Install the pulley on the rotor shaft
Screw the pulley (counter-clockwise) into place using counterhold 9995760 . Counterhold the rotor shaft using socket 9995761 (Denso) or 9512849 (Bosch).

NOTE:

The rotor shaft and pulley are left-hand threaded.

Tighten the pulley. Tighten to 80 Nm
Install a new dust guard.

Checking the freewheel function (Poly v-belt removed)

Check the pulley freewheel as follows:

Rotate the pulley counter-clockwise and brake the pulley heavily.

The freewheel must grip the rotor shaft when it rotates counter-clockwise.

Stop the rotation.

When braking the pulley, the freewheel mechanism should must release so that the rotor shaft continues to rotate.

Fig 2: Checking Freewheel Function (Poly V-Belt Removed)

Courtesy of VOLVO CARS OF NORTH AMERICA.

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 other power consuming components are engaged.

Check that only a faint clicking sound is heard when the freewheel engages and disengages
switch off the engine. Check that the generator rotates for longer than the engine (freewheel sound).

In cold conditions, the battery charge warning lamp may light for a short while after start. This is because the freewheel needs to rotate to 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.

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

Check the pulley freewheel as follows

Rotate the pulley counter-clockwise and brake the pulley 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.