Alternator: Service and Repair

Removal
1. Disconnect battery and cover terminals or battery. Remove righthand seat. Open rear wall cover behind the seats.
2. Open engine compartment lid and disconnect cable connector of the B+ leads to the generator and to the starter at the B+ disconnection point.
3. Slacken drive belt at the tensioning pulley and remove belt.
4. Loosen and unscrew right-hand fastening screw (looking in direction of travel).




5. Loosen left-hand fastening screw (with idler pulley) 3 turns. A gentle tap on the fastening screw loosens the threaded bushing in the generator arm (use aluminium mandrel).



6. Take generator out of the slotted generator bracket in upward direction. Unscrew fastening screw and remove with deflection roller.
7. The generator must be turned clockwise so that the swivel arm is near the crankcase and the holding arm projects beyond the fastening eye.




8. Carefully pull the generator forward a little and disconnect electrical connections, or press plug connection to the generator housing, release (arrow A) and pull off. Take out generator to the front.


Installation

Tightening torques:
Hexagon nut a/f 24 M16x1.5 65 ± 5Nm
(48 ± 3.5 ft lb)
Hexago-head bolts M10 45 Nm (33 ft lb)
Hexagon nut a/f 13 M8 15 Nm (11 ft lb)

The line to the generator must be on top when the cable lug of the B+ lines to the generator and to the starter is reconnected to the B+ connector. Engage plug connection and route wire carefully.

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, screw driver 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 screw driver insert and the torque wrench.

Tool for holding the free-wheel pulley

For 2.7L Boxster and 3.2L Boxster S (manual transmission only)
2.7L as from Engine No. 65 Y 02460
3.2L as from Engine No. 67 Y 00936

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




A/f 17 multi-tooth adapter

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