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.
- Remove right wheel housing liner.
- Remove air-cleaner box.
- Remove underbody sealing for the engine.
- Drain coolant.

NOTE: When the engine is being cleaned with high-pressure cleaning equipment, make sure that the high pressure blast is not directed directly onto the three-phase generator (risk of bearing damage).

Removing the three-phase generator
1. Remove the three fastening screws for the impact bracket -8- and remove the impact bracket.







NOTE: If the impact bracket is used, the routing of the wires may differ from this description.

2. Unscrew fastening screw -3- of ground lead and lay ground lead to one side.







3. Lever out fastening clips -4- for the electrical lead using a screwdriver.
4. Remove coolant hoses -A- and -B- with a hose clamp.







5. Unscrew the coolant connection on the three-phase generator.







6. Pull off the protective cap for the electrical plug connection from the mounting point on the generator.







NOTE: If the protective cap cannot be removed, use a knife to carefully cut if off the generator. Make sure that the plug connection and the electrical lead are not damaged and that the protective cap is only damaged slightly.

7. Press the electrical plug -a- and disconnect it.







8. Unscrew the screws for the B+ lead and remove the B+ lead.
9. Unscrew the three fastening screws and support the three-phase generator with your hand.







10. Remove the three-phase generator through the opening - wheel housing liner of the removed air-cleaner box.

Installing the three-phase generator
1. Insert the three-phase generator through the opening.
- wheel housing liner of the removed air-cleaner box
- and position it on the engine.







2. Position the three fastening nuts and tighten them.







3. Connect electrical plug connection and fit B+ lead.







NOTE: Check the condition of the protective cap; if it is damaged it must be repaired using body sealant.

4. Position protective cap and press it on, ensure that it fits securely and is sealed against moisture.







5. Screw on the coolant connection at the front on the three-phase generator.







6. Connect the coolant lines and position the holding clamps.
7. Screw ground lead -3- onto the three-phase generator.







8. Attach the clip -4- on the electrical lead to the three-phase generator.
9. Position the impact bracket and screw tight with the fastening screws -8-.
- Top up coolant.
- Install right air-cleaner box.
- Install the right wheel housing liner.
- Connect the battery and carry out the work instructions.
- Install underbody sealing for the engine.







Tightening torques