Alternator: Service and Repair

Remove And Install Generator







DANGER:
- Risk of explosion from hydrogen gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury with caustic burns to eyes and skin from battery electrolyte or from handling damaged
lead-acid batteries
- No fire, sparks, open flames or smoking.
- Wear acid protection gloves, clothes and goggles. Pour battery electrolyte only into suitable and appropriately marked containers.

1 Disconnect ground cable of battery

CAUTION: Do not connect quiescent current retention device otherwise this may cause damage to the control module.

2 Remove right engine suction fan duct in front of air cleaner
3 Unscrew retainer oil line (1) of rack-and-pinion steering at longitudinal member and place to the side
4 Remove poly V-belt (2)
5 Unhinge front left coolant hose at bracket on the body
6 Unhinge from below coolant hose at bracket at alternator (G2)
7 Unscrew bolts (3) of alternator (G2)

Generator Screw - 42 N.m

8 Rotate alternator (G2) with electrical lines toward top
9 Detach cap (6) at terminal 30
10 Unbolt nut of electrical line (5) terminal 30

Nut, Terminal B+ To Generator - 18 N.m

11 Release clutch of electrical line (4) terminal 61 and detach.
12 Take generator (G2) down and out
13 Press distance sleeves (7) toward front, until they are flush with the bracket

NOTE: Through this the alternator can be slightly mounted

14 Install in the reverse order
15 Perform basic programming
16 Read out fault memory with STAR DIAGNOSIS and erase if necessary.