Alternator: Service and Repair

Generator (GEN) - 132kW Engine, Removing And Installing

CAUTION: Before beginning repairs on the electrical system:
- Obtain the anti-theft radio security code.
- Switch the ignition off.
- Disconnect the battery Ground (GND) strap.
- After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows according to Owner's Manual.

Removing
- Disconnect electrical connections at throttle valve control module -J338 and charge pressure sender -G31.
- Disconnect air hose -1 - at throttle valve control module.







- Disconnect vacuum hose -2- (going to activated charcoal filter) at throttle valve control module.







- Unscrew nut (with washer) -2- and pull out activated charcoal filter -3- from the top. (Peg -1- on filter is only a push fit).
- Place activated charcoal filter on engine cover panel.

CAUTION: Before removing ribbed belt, mark the direction of rotation with chalk or felt pen. If the belt rotates in the wrong direction when it is reinstalled, it can break. Ensure that the belt is properly seated in the pulleys when installing.







- To loosen ribbed belt turn tensioning element in direction of arrow.
- Remove ribbed belt.

NOTE:







The tensioning element may be secured with a mandrel of dia. 4.5 mm and about 55 mm long. On vehicles without headlight washer system connecting rod support 3090 may also be used.







Ribbed belt on vehicles without air conditioner







Ribbed belt on vehicles with air conditioner

NOTE: Engines with an air conditioner compressor are installed with a double ribbed belt.







- Unscrew nut and disconnect wire -1- (terminal 30/B+). Unplug connector -2-.
- Unbolt wire clamp -3-.
- Loosen the two generator securing bolts and lift out generator.

Installing

NOTE: Before installing, knock in threaded collars for generator securing bolts (about 1 mm).

- Installation is performed in the reverse sequence.
- Make sure that ribbed belt is correctly routed and properly seated.







- Screw on nut to secure wire -1- (terminal 30/B+) and plug in connector -2-.
- Bolt on wire clamp -3-.