Alternator: Service and Repair

Removing And Installing Three-Phase Generator

Tools







Technical values







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. Remove drive belt.

Removing the three-phase generator

INFORMATION: 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).







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







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







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







5. Unscrew fastening screws -A and B- of coolant hoses.

INFORMATION: 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 there is no more than minimal damage to the protective cap.







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







7. Release -a- and pull off plug.
8. Unscrew fastening nut for B+ lead and remove the B+ lead.







9. Unscrew the three fastening screws -1 and 2- and support the three-phase generator with your hand.
10. Remove the three-phase generator through the opening - wheel housing liner with air-cleaner box removed.

Installing the three-phase generator

INFORMATION: Additional assembly operations must be performed if a new three-phase generator has to be fitted.







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







2. Position the three fastening screws -1 and 2- and tighten them. - Tightening torque: 17 ftlb.
3. Additional assembly operations must be performed if a new three-phase generator has to be fitted.







4. Insert the plug -6- until the locking tab -A- is felt to engage.
5. Clip the line into the two retaining clips -7-.
6. Tighten electrical B+ lead with fastening nut -5-. - Tightening torque: 11 ftlb.

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







7. Position protective cap and press it on, ensuring it fits securely and is sealed against moisture.







8. Replace sealing rings. Push in coolant connections on the three-phase generator and screw into place using fastening screws -A and B-. - Tightening torque: 7.5 ftlb.
9. Connect coolant lines and position holding clamps.







10. Secure ground lead to three-phase generator with fastening screw -3-. - Tightening torque: 15 ftlb.
11. Attach clip -4- of the electrical lead to the three-phase generator.







12. Position the impact bracket and screw into place with the fastening screws -8-. - Tightening torque: 7.5 ftlb.

Perform additional assembly work when replacing the three-phase generator

Additional assembly work when replacing three-phase generator

INFORMATION: 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 immobilise 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. Install right air-cleaner box.
4. Install right wheel housing liner.
5. Connect the battery and carry out the work instructions.
6. Fit engine guard.