Alternator: Service and Repair
Removing And Installing Three-Phase Generator
Tools
Tools:
Preliminary work
Before the three-phase generator can be removed, the battery must be disconnected and the terminal covered.
Removing the three-phase generator
1. Remove engine cover -arrow A-.
2. Unscrew the two fixing clips -a- and remove both covers -arrows B-.
3. Release -arrow A- and pull off connector -arrow B-.
4. Release the air cleaner cover -arrows C- and lift it up and out -arrow D-.
5. Release clamp -arrow A- and pull suction hose off throttle housing -arrow B-.
6. Pull suction hose away to the right -arrow C-.
7. Release breather hose -arrows D- and pull it off -arrow E-.
8. Remove air cleaner cover and suction hose.
NOTE:
- Mark the running direction on the top before removing the drive belt.
- Only screw the pressure screw in far enough to remove the drive belt. Otherwise, the tensioning roller housing may be damaged.
9. Mark rolling direction -b- on the drive belt.
10. Slacken the tensioning roller with the pressure screw (M8 x 50) -arrow c- and remove the tensioning belt -arrow b-.
11. Unscrew the fastening screws -arrows 1- and remove the tensioning roller.
12. Release -arrow A- and pull off connector -arrow B-.
13. Pull off protection cap -arrow C-.
14. Unscrew fastening nut -arrow 2- and remove B+ line -arrow D-.
15. Unscrew fastening screws -arrows 3- and remove generator to the side -arrow-. Press generator out of the bracket using a lever if necessary.
16. Disconnect the two hoses with the hose clamps 3094.
17. Unscrew fastening screw -4- and pull out the two water hoses along with the adapter -arrow-.
18. Pull the generator upwards and remove it. Press the top coolant hose aside if necessary.
Installing the three-phase generator
NOTE:
- Before installing the generator, push the threaded bush -d- out by approx. 4 mm.
- Check the seal on the neck of the water line adapter and replace it if necessary.
1. Attach the adapter with the water lines -arrow- and tighten with the fastening screw -4-. Tightening torque 6.5 ft.lb.
2. Loosen the hose clamps 3094 on the water hoses and remove them.
3. Position generator in installation position -arrow- and secure with the fastening screws -arrows 3-. Tightening torque 15 ft.lb.
4. Connect the B + line to the generator -arrow A- and secure with the fastening nut -arrow 2-. Tightening torque 11 ft.lb.
5. Fit protection cap -arrow B-.
6. Push on the connector -arrow C- until the locking tab -arrow D- is felt to engage.
7. Position tensioning roller in installation position -arrow- and place the drive belt on the tensioning roller and the belt pulley on the generator.
8. Secure the tensioning roller with the fastening screws -arrows 1-. Tightening torque 15 ft.lb.
9. Check installation position and direction of rotation -b- of the drive belt.
10. Unscrew the pressure screw -arrow c- and tension the drive belt -arrow-.
11. Insert breather hose -arrow A- until the locking tabs -arrows Bare felt to engage.
12. Insert the air cleaner.
13. Connect the suction hose to the throttle body -arrow A-.
14. Insert the cover for the air cleaner housing -arrow B- and secure with the retaining clips -arrows C-.
15. Tighten clamp -arrow D-.
16. Push on the connector -arrow A- until the locking tab -arrow B- is felt to engage.
17. Fit engine cover -arrow A- until locking tabs are felt to engage.
18. Fit covers -arrows B- and secure with fixing clips -a-.
19. Connect the battery and carry out the work instructions.
20. Start engine and check the belt.