Charging System - Charge Warning Lamp ON

27 10 02

July 14, 2010

2020793 Supersedes T.B. Group 27 number 09-04 Dated Nov.11, 2009 to update warranty table labor operation time units.





Vehicle Information

Condition

Generator, Intermittent Charge Warning Light ON, Low Voltage Indication on Gauge

^ Charge warning light ON.

^ Voltage display of the voltmeter drops to 0 volts.

^ Error messages in dash insert "consumer cut-off active".

After switching the ignition OFF and ON the complaint is gone.

Technical Background

Incorrect voltage regulator installed in Valeo generators. Valeo generator Part No. 021-903-016 between production dates 51/07-01/09.

Production Solution

Revised regulator Part No.059 903 803G starting with VIN 7L_9D034156.

Service

Procedure

^ Remove generator from vehicle, see Repair Manual group 27 in ElsaWeb.





^ Gently pry off the voltage regulator cover, see illustration 1.





^ Carefully remove cap (A) for the voltage regulator, see illustration 2.





^ Remove voltage regulator retaining bolts (2) and pin (3).

^ Remove voltage regulator.





Tip:
DO NOT apply grease to commutater, see illustration 4.

^ Position new voltage regulator and reposition bolts and pin.

Tip:
The Carbon brushes must not protrude from the opening of the protective cap. DO NOT depress regulator protective cap before tightening the regulator bolts.





^ Tighten voltage regulator bolts and pin to 2.6-4.8Nm (23-42 in. lbs.).

^ To release the carbon brushes, press down cap (A), until it is flush with the voltage regulator housing.

^ Install regulator cover previously removed in illustration 1.

^ Install the generator, see Repair Manual group 27 in ElsaWeb.








Warranty





Required Parts and Tools

No Special Tools required.

Additional Information

All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information.