Alternator: Service and Repair

Removing And Installing Three-phase Generator







- 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 fastening screws -a- and remove both covers -arrow B-.
3. Release connector -arrow A- and pull out -arrow B-.







4. Release air cleaner cover -arrow C- and pull upwards -arrow D-.
5. Release fastening clamp -A- and pull intake hose off throttle body -arrow B-.







6. Pull intake hose away to the right -arrow C-.
7. Release vent hose -arrows D- and pull it off -arrow E-.
8. Remove air filter cover with intake 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 the running direction-b-onthe drive belt.







10. Slacken the tensioning roller with the pressure screw (M8 x 50) -c- (-arrow A-) and remove the tensioning belt -arrow B-.
11. Unscrew the fastening nuts -1- and remove the tensioning roller.







12. Release connector -arrow A- and pull out -arrow B-.







13. Pull off protective cap -arrow C-.
14. Unscrew fastening nuts -2- and remove the B+ lead -arrow D-.
15. Unscrew fastening screws -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 clamp 3094.







17. Unscrew fastening screws -4- and pull out the two water hoses along with the flange -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 bushing -d- out by approx. 4 mm.
- Check the seal on the neck of the water hose and replace it if necessary.

1. Attach the flange with the water hoses -arrow- and tighten with the fastening screw -4-.







2. Loosen the hose clamps 3094 on the water hoses and remove them.
3. Position the generator in installation position -arrow- and secure with the fastening screws -3-.







4. Connect the B+ lead to the generator -arrow A- and secure with the fastening nuts -2-.







5. Fit the protective cap -arrow B-.
6. Push on plug -arrow C- until the locking tab -D- can be felt to engage.
7. Position tensioning roller in installation position -arrow- and place the drive belt on the tensioning roller and belt pulley on generator.







8. Tighten tensioning roller with fastening screws -1-.
9. Check installation position and direction of rotation -b- of the drive belt.







10. Unscrew the pressure screw -c- and tension the drive belt -arrow-.
11. Insert the vent hose -arrow A- until you feel the locking tabs-B-engage.







12. Insert the air cleaner.







13. Connect the intake hose to the throttle body -arrow A-.
14. Fit the cover of the air cleaner housing-arrow B into position and secure with the retaining clips-arrow C-.
15. Tighten the fastening clamp -D-.
16. Connect plug -arrow A- until locking tab- -B engages.







17. Fit engine cover-arrow A- until locking tabs are felt to engage.







18. Fit the covers -arrow B- and secure with the fastening clips -a-.
- Connect the battery and carry out the work instructions.
19. Start engine and check the belt.

Tightening torques







Tools