Three-Phase Generator

Removing and Installing Three-Phase Generator

NOTE: When the engine is being cleaned with high-pressure cleaning equipment, make sure that the high pressure blast is not directed directly onto the three-phase generator (risk of bearing damage).


Removing the Three-Phase Generator

1. Disconnect the battery and cover terminal or battery.

2. Remove the complete air cleaner assembly. Undo the fastening screw for the air cleaner housing and the hose clamp on the air flow sensor.

3. Undo the hose on the charge air cooler at the left and right on the pressure pipe.

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

5. Remove the pressure pipe to the throttle body.

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

7. Remove the deflection roller under the three-phase generator.

8. Disconnect the cable lug of the B+ lead to the three-phase generator at the B+ disconnection point.







9. Undo left fastening screw (in direction of travel) and remove.

10. Undo right fastening screw by three turns.

11. A gentle tap on the fastening screw loosens the threaded bushing in the three-phase generator arm (use aluminum mandrel). Unscrew fastening screw.

12. Remove three-phase generator and carefully pull a little to the rear.

13. Press the plug connection towards the three-phase generator housing, release and pull off.

14. Remove the three-phase generator towards the rear and disconnect the B+ lead.


Installing the Three-Phase Generator

1. Fasten B+ lead and install three-phase generator.







2. The B+ lead must be fastened onto the long wiring arrangement -(arrow)- of the three-phase generator (see Figure).

3. Install deflection roller and fit drive belt.

Tightening torque of the hexagon nut M16 x 1.5: 65 ± 5 Nm (48 ± 3.5 ftlb)

Tightening torque of the hexagon-head bolts M10: 46 Nm (34 ftlb.)

Tightening torque of the M8 hexagon nut: 15 Nm (11 ftlb.)

Tightening torque of the deflection roller M10: 46 Nm (34 ftlb.)

4. Install air flow sensor with air cleaner assembly and connect battery.

5. Perform a function test.


Undoing and Tightening the Belt Pulley

NOTE: The belt pulley can be undone or tightened using a standard commercially available tool.

- Double offset ring wrench a/f 24
- Screwdriver insert for internal serration screw a/f 10
- Cross handle and torque wrench

1. The hexagon nut a/f 24 must be countered with the ring wrench during tightening.

2. 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

NOTE: Only for vehicles with manual transmission.

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







2. A/f 17 multiple-tooth adapter: see tools.

3. Counter with a double ring wrench when tightening with the a/f 17 multiple-tooth adapter.

4. 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.