Alternator: Service and Repair

Replacing the generator (GEN)

Removing the generator (GEN)
Open the hood.
Remove all the engine splash guards if installed.

Preparations




- Make a note of the anti-theft radio code
- Switch off the ignition
- Disconnect the battery negative terminal.

Removing the poly V-belts


Remove the power steering pump. Place the power steering pump to one side




- Remove the lower screw from the mounting bracket (A)
- Remove the bracket between the power steering pump and the intake manifold
- Remove the cable clip from the bracket
- Remove the connector assembly from the bracket
- Remove the mounting screws between the spokes on the pulley
- Lift out the pump. Place the pump to one side in the engine compartment
- Move the bracket (A) sideways.

Disconnect the electrical wiring from the generator (GEN)




- Remove the connector
- Remove the wiring clamp
- Remove the positive lead from the generator (GEN).

Removing the generator (GEN)




- Remove the upper mounting screw
- Remove the two upper screws for the air conditioning (A/C) compressor. Move the screws approximately 30 mm forward
- Remove the two lower screws for the air conditioning (A/C) compressor
- Lift the generator (GEN) out using a twisting movement.

Replacing the pulley and freewheel
Use special tool 999 5760 Counterhold 999 5760 Counterhold.
See Pulley and freewheel, replacing .

Installing the generator (GEN)




- Install the generator
- Insert the upper screw. Finger tighten
- Install the bracket (A)
- Insert the two screws for the air conditioning (A/C) compressor. Finger tighten
- Tighten the screws. Tighten to 25 Nm.

Installing electrical terminals and wiring for the generator (GEN)
- Position the wiring. Reconnect the positive lead for the battery
- Connect the connector
- Clamp the cable harness in position.

Installing the power steering pump




- Install the pump. Install the screws between the pulley spokes. Finger tighten.
Tighten the screws. Tighten to 25 Nm
- Install and secure the bracket. Install the bracket between the generator (GEN) and the intake manifold.
Tighten the screws. Tighten to 25 Nm
- Install the cable clamp and connector on the bracket.

Installing the poly V-belts


Installing the battery




- Switch on the ignition
- Connect the battery negative lead
- Re-enter the anti-theft radio code
- Set the clock.

Check the function
- Start the engine. Check the function
- Reinstall the engine splash guards, if applicable.