Generator

Generator

Special tools, testers and auxiliary items required

• Hose clip pliers (VAS 6362)

• Workshop crane drip tray (VAS 6208)

Removing

- With ignition switched off, disconnect battery ground (ND) wire. Refer to => [ Battery, Disconnecting and Connecting ] Battery, Disconnecting and Connecting.

- Drain coolant.

- Move lock carrier to service position. Radiator Support

- Unplug connector - 1 - for Mass Air Flow (MAF) Sensor (G70).





- Detach air hose - 4 - at intake manifold.

- Detach bracket for electrical connectors - 2 - and - 3 - at top section of air cleaner housing.

- Remove screws - arrows -.

- Remove right upper section of air filter housing.

- Remove air duct - 1 -.





- Remove screws - arrows -.

- Remove lower section of right air cleaner housing.

• Place a rag under separating point to catch escaping coolant.





- Detach coolant hose - arrow - at right on engine.

- Next, carefully remove engine cover at rear and center upward - arrows 1 -.





- Then remove engine cover forward from intake manifold - arrows 2 -.

- To loosen the poly V-belt, apply pressure to tensioner in direction of the - arrow - using a 30 mm box-end wrench.





- Detach ribbed belt from generator pulley.

- Release tensioner.

- Place Workshop Crane Drip Tray (VAS 6208) under engine.





- Detach coolant hose (front) at auxiliary radiator - arrow - and allow coolant to drain off.

- Remove bolts - 1 - and - 2 -.

- Detach coolant hoses - arrows -.





- Remove bolts - 1 - and - 2 -.

- Remove auxiliary radiator.

- Detach wire- 1 - at generator.





- Disconnect electrical connector - 2 -.

- Remove screws - arrows -.





• If alternator sticks in holder, turn bolt back in again down to the last 2 turns.

• Tap carefully on bolt heads with flat side of hammer to release threaded bushings of generator mount.

- Pivot the alternator slightly down to left.

• Two technicians are required for remaining procedures for removing generator.


Coolant will drain out.

- Detach coolant hose - 2 - from hose flange at generator.





- Mark installation position of hose flange on generator.

- Remove bolt - 1 - and remove bracket.

- Detach both hose flanges from generator.

- Remove generator.

Installing

Install in reverse order of removal, observing the following:

• Replace O-ring

• Secure all hose connections using standard hose clamps.

- slightly drive back sleeves for retaining bolts in order for easier installation of generator.

• Tight sleeves for generator mount must be made smooth-running, otherwise clamping force of sleeve is too little despite correct torque.

- First fit poly V-belt onto pulley for vibration damper, then onto the remaining pulleys, and lastly onto the tensioning roller.





• When installing poly V-belt, make sure it is properly seated on pulleys.

- Install right auxiliary radiator.

- Connect battery. Required actions, refer to => [ To connect, connect terminal clamp of ground (GND) wire by hand to battery negative terminal and tighten nut. ] Battery, Disconnecting and Connecting.

- Fill coolant.

- Start engine and check belt routing.

- Install lock carrier with attachments.

- Install front bumper cover.

Tightening Specifications