Alternator: Service and Repair

Removing and Installing Generator

Removal

1. Disconnect the battery and cover terminal or battery. Undo the fastening screw for the air cleaner housing and the hose clamp on the throttle body.

2. Disconnect the electrical plug connection on the air flow sensor and remove the complete air cleaner assembly.

3. Relieve the drive belt at the tensioning pulley and remove the belt.

4. Disconnect the electrical plug connection on the vacuum switchover valve and unclip the switchover valve from the holder.




5. Undo the holder at the intake distributor (2 screws) and remove. Pay attention to the sealing ring (vacuum line for brake booster) when removing.

6. Undo left fastening screw (in direction of travel) and unscrew.

7. Undo right fastening screw (with deflection roller) by three turns. A gentle tap on the fastening screw loosens the threaded bushing in the generator arm (use aluminium mandrel). Unscrew fastening screw and remove with deflection roller.

8. The generator must be turned clockwise so that the swivel arm is near the crankcase and the holding arm projects beyond the fastening eye.




9. Carefully pull the generator back a little and undo the electrical connections, or press the plug connection to the generator housing, release (arrow A) and pull off. Pull out generator to the rear.


Installation

Tightening torques:
Hexagon nut a/f24 M16x1.5 65 ± 5 Nm (48 ± 3.5 ftlb.)
Hexagon-head bolts M10 45 Nm (33 ftlb.)
Hexagon nut a/f13 M8 15 Nm (11.0 ftlb.)

NOTE: When carrying out installation, make sure that the sealing ring for the vacuum brake booster is replaced and carefully fitted.


Undoing and tightening the belt pulley

NOTE: The belt pulley can be undone and tightened using a standard commercially available tool. Tools: double offset ring wrench a/f 24, screwdriver insert for internal serration screw a/f 10, cross handle and torque wrench.

The hexagon nut a/f 24 must be countered with the ring wrench during tightening. The shaft is tightened to the prescribed tightening torque of 65 ± 5 Nm (48 ±3.5 ftlb.) using the screwdriver insert and the torque wrench.


Tool for holding the free-wheel pulley

For Carrera 996 (manual transmission only) from engine No. 66 Y 03208




Use an a/f 17 multiple-tooth adapter to hold the free-wheel pulley.

NOTE: Counter with a double ring wrench when tightening with the a/f 17 multiple-tooth adapter. The shaft is tightened to the prescribed tightening torque of 80 ± 5 Nm (59 ± 3.5 ftlb.) using the screwdriver insert (a/f 10 internal serration screw) and torque wrench.