Alternator: Service and Repair

CAUTION: Observe notes on disconnecting and connecting battery. Service Precautions

- Switch off ignition.
- Disconnect battery ground wires.
- Remove alternator drive belt.




- Remove upper section of intake filter housing with mass air flow sensor.




- Remove bracket for coolant hose.




- Unfasten hose clip (1) and remove cooling air hose. Unfasten screw in retaining clip (2) on hydraulic line and remove retaining clip.




- Unfasten cable ties (1 and 2) on cover of distributor cap.




- Unfasten connections on alternator.




NOTE: Connections illustrated here on removed alternator.
- Disconnect plug connection (1).
- Unfasten nut (2).




- Unfasten screws (1 to 3). Remove tensioning roller for ribbed vee belt.




- Unfasten screws (1 to 3).




- Unfasten oil filter screw connection on bracket and place oil filter to one side.
- Mark sequence of ignition leads on the distributor cap and remove ignition leads from the distributor cap.
- Place ignition leads (2) to one side.
- Remove distributor cap.




- Pull out alternator.




- Screw alternator into radiator shroud. Remove alternator by lifting upwards.

CAUTION: Avoid damage to radiator fins!




Installation Note: First insert alternator in radiator shroud with pulley wheel.

CAUTION: Do not damage radiator fins!




- Replace alternator pulley:
- Unfasten nut with special tool 12 7 110, bracing alternator shaft with internal hex wrench or internally-splined wrench