- Remove the lower flywheel housing cover.
- Inspect the flywheel for signs of unusual wear such as chipped or missing gear teeth or the flywheel being bent.
- Start the engine and gently touch the outside diameter of the rotating flywheel ring gear with chalk or crayon to show the high point of tooth runout after the engine is turned off. Turn the engine off and rotate the flywheel so the marked teeth are in the area of the starter pinion gear.
- Disconnect the negative battery cable to prevent accidental cranking of the engine. Refer to Battery Cable Replacement in Engine Electrical.
- Measure the clearance between the top of the ring gear tooth and the bottom of the pinion tooth using the width of a wire gage or standard feeler stock. Normal clearance is 0.5 to 1.5 mm (0.02 to 0.06 in).
- If clearance is less than 0.5 mm (0.02 in), and the starter whines after firing, shim the starter away from the flywheel.
- If the pinion clearance is more than 1.5 mm (0.06 in) and the starter whines during cranking, shim the starter toward the flywheel.
- Install the mounting bolts.
- Install the negative battery cable and test for noise. Refer to Battery Cable Replacement in Engine Electrical.
- Add or reduce the amount of shims if noise continues.
Add 1.0 mm (0.04 in) shims, one at a time, to both long bolts between starter mounting pads and the engine until the noise problem is corrected. Do not use more than 2 shims total.
Add 0.33 mm (0.014 in) shims between the outboard starter mounting pad and the engine mount until the noise stops. Do not add more than 4 shims total.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Tighten
| • | Mounting bolts (diesel) to 45 N·m (33 lb ft). |
| • | Mounting bolts (gas) to 40 N·m (30 lb ft). |
