Alternator: Service and Repair

Generator, Removing And Installing


CAUTION!
Disconnect the battery Ground (GND) strap before working on the electrical system.


NOTE:
- Before disconnecting the battery, determine the correct coding for the anti-theft radio.
- Once the battery is reconnected, check and activate the vehicle's electrical equipment (radio, clock, comfort and convenience features, etc.).


Vehicles with 4-cylinder gasoline engines

Removing

1.8 Liter/110 kW, 5V Turbo







- Disconnect air duct -1- for charge air cooler from throttle valve.







- Pivot ribbed belt tensioner in direction of arrow and remove ribbed belt from generator pulley.
- Slowly release pressure on tensioner.







- Secure viscous clutch with 5 x 60 mm bolt and remove mounting bolt for viscous clutch.
Tightening torque: 45 Nm (33 ft lb)
- Remove viscous clutch.







- Remove socket-head bolt -1-.
Tightening torque: 25 Nm (18 ft lb)
- Remove nut -2- from bolt.
Tightening torque: 45 Nm (33 ft lb)
- Pivot generator slightly to side and remove bolt from below.







- Release wiring harness from cable tie (arrow).
- Disconnect wire on terminal 30/B+ by removing nut -2-.
Tightening torque: 16 Nm (12 ft lb)
- Disconnect wire on terminal D+ by removing nut -1-.
Tightening torque: 4 Nm (35 in. lb)
- Carefully push radiator hose to side and lift generator up and out.

Installing

- To make it easier to install generator onto mount, drive bushing for mounting bolt back approx. 1 mm.
- Install generator in reverse order of removal.







- Make sure ribbed belt is properly seated and correctly routed.

1 - Without air conditioning
2 - With air conditioning