Alternator: Service and Repair

Removing And Installing Three-Phase Generator - Cayenne Tur...

Tools

Tools:

Preliminary work
1. Before the three-phase generator can be removed, the battery must be disconnected and the terminal covered.
2. Remove right wheel housing liner.
3. Remove right air cleaner housing.
4. Remove engine guard.
5. Drain coolant.
6. Detach lock mount, move it to the service position.
7. Remove drive belt.

Removing the three-phase generator







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).







1. Release hose connection on the turbocharger. To do this, pull out locking spring -1- on the turbocharger flange. Then undo hose clamp -2- of the pressure pipe on the turbocharger.







2. Disconnect the connection on the charge air cooler. To do this, remove locking clip -1- and pull off the line. Line -2- of the ambient air valve must also be disconnected on the right-hand side of the vehicle. To do this, remove the spring band clamp and pull off the line.







3. Remove coolant hose at the bottom right of the radiator. To do this, pull out the retaining clip on the coolant neck and remove the hose -arrow-. Then reconnect the retaining clip.







4. Disconnect the electrical plug of the air flow sensor. Release the hose clamp -arrow- on the underside of the air flow sensor and remove the intake bracket with the air valve module upwards.







5. Remove hose -arrow- from the control box of the bypass valve. If hose is tight, carefully lever off with a screwdriver.







6. Unscrew the three fastening screws -8- for the impact bracket and remove the impact bracket.







7. Unscrew ground lead fastening screw -1- and remove ground lead.







8. Unclip line to oil pressure switch and oil-level sensor using a release lever -A-.
9. Unclip the pressure pipe -Arrow B-.
10. Release plug on the oil pressure switch and pull it off -Arrow C-.







11. Unscrew fastening screw -2- of holder for three-phase generator leads.







12. Seal the coolant hoses -A and B- with a hose clamp to prevent them from leaking.







13. Unscrew fastening screws -3 and 4- of coolant connections.







14. Unscrew the fastening screws -5 and 6- and support the three-phase generator with your hand.







15. Pull three-phase generator forwards -Arrow A-.

NOTE: If the protective cap cannot be removed, use a knife to carefully cut if off the three-phase generator. Make sure that the plug connection and the electrical lead are not damaged and that the there is no more than minimal damage to the protective cap.







16. Pull off the protective cap for the electrical plug connection from the receptacle on the three-phase generator.







17. Release -Arrow B- and pull off -Arrow C- plug.







18. Unscrew fastening nut -7- and remove B+ lead.
19. Remove the three-phase generator through the opening - wheel housing liner with air-cleaner box removed.

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

NOTE: When tightening the B+ lead, make sure that no leads are trapped between the three-phase generator and the engine.







2. Tighten electrical B+ lead with fastening nut -7-. Tightening torque 11 ft.lb. To do this, pull the generator forward and position it so it cannot move when the B+ lead is tightened.







3. Push plug onto the generator -arrow- until it clicks into place.







4. Position the protective cover and press into place. Ensure that it fits securely and is sealed against moisture.







5. Move three-phase generator into the mounting position.
6. Screw in fastening screws in the order -6 and 5-.
7. Tighten fastening screws in the order -6 and 5-. Tightening torque 17 ft.lb.

NOTE: Additional assembly operations must be performed if installing a new three-phase generator.

8. Additional assembly operations must be performed if installing a new three-phase generator.







9. Secure the holder with generator leads to the three-phase generator using the fastening screw-2-. Tightening torque 7.5 ft.lb.







10. Clip in line to oil pressure switch and oil-level sensor -Arrow A-.
11. Clip in the pressure pipe -Arrow B-.
12. Push plug onto the oil pressure switch until it clicks into place -Arrow C-.







13. Push in coolant connections on the three-phase generator and secure with fastening screws -3 and 4-. Tightening torque 7.5 ft.lb.
14. Remove hose clamps on the coolant hoses.







15. Secure ground lead to the three-phase generator with the fastening screw -1-. Tightening torque 15 ft.lb.







16. Position the impact bracket and secure with the fastening screws -8-. Tightening torque 17 ft.lb.







17. Attach hose -arrow- to the control box of the bypass valve.







18. Insert the intake bracket with ambient air valve from above. Fasten the hose clamp -arrow- on the underside of the air flow sensor. Connect the electrical plug of the air flow sensor.







19. Push on the coolant line. The securing clip of the flange must audibly engage.







20. Connect the hose line to the charge air cooler. Ensure that locking clip -1- is mounted correctly. Then connect the line to the ambient air valve -2- and fit the spring-band clamp.







21. Secure hose connection to the turbocharger. To do this, connect pressure pipe -2- and tighten the hose clamp. Then fit the line from the charge air cooler. The connection piece must engage audibly. Ensure that sheetmetal clip -1- is fitted correctly.

Perform additional assembly work when replacing the three-phase generator

Additional assembly work when replacing three-phase generator

NOTE: The parts pack of a new three-phase generator contains all the parts required (insulator, PIN and socket).







1. Lay the lead of the new three-phase generator as for the old lead and clip into the three retaining clips -Arrows A-.
2. Trim the lead (with 2-pole plug) included in the engine wiring harness to the three-phase generator -arrow- such that, together with the new lead already laid from the three-phase generator, it can be joined without tension and without too much slack.
3. In the wiring harness, insulate and immobilize the wire to PIN 2 of the plug that was cut off.
4. In the wiring harness, remove the insulation of the wire to PIN 1 of the plug that was cut off and push new insulator -1- onto the wire.







5. Crimp new PIN -2- using repair kit for wiring harnesses NR.155-1 and repair kit for Cayenne wiring harnesses NR.155-2.
6. Insert wire with new PIN into the new socket -3- and lock.







7. Push the plug connection -1- together until it is felt to engage.
8. Tie the plug connection with a tie-wrap -2- to the nearby wiring harness.
9. Clip line holder -3- to the shaft tube.

Subsequent work
1. Install drive belt.
2. Fill in coolant.
3. Fasten lock mount.
4. Install right air-cleaner housing.
5. Install the right wheel housing liner.
6. Connect the battery and carry out the work instructions.
7. Fit engine guard.