Alternator: Service and Repair

Removing And Installing Three-phase Generator

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 ftlb.







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 ftlb.







4. Connect the B +line to the generator -arrow A- and secure with the fastening nut -arrow 2-. Tightening torque: 11 ftlb.







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 ftlb.
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 B- are 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.