Alternator: Service and Repair

WM 272219 Removing and installing generator

Technical values





Preliminary work

1. Before the generator can be removed, the battery must be disconnected and the terminal covered. -> 90 Work instructions after disconnecting the battery
2. Remove air box for throttle housing (intake manifold). -> 243519 Removing and installing air box for throttle housing (intake manifold) - section on "Removing" Service and Repair
3. Remove air cleaner housing lid. -> 242455 Replacing air-cleaner element Service and Repair
4. Remove belt tensioner. -> 137319 Removing and installing belt tensioner - section on "Removing" Service and Repair

Removing generator





Overview of generator

1. Release the connector -1- and unplug it -arrow A- ( -arrow B- ).





Disconnecting electric connections on the generator (similar illustration)

2. Screw off fastening nut -2- and pull off the B+ line -3- ( -arrow C- ).
3. Unscrew fastening screws -3- and remove the generator to the side -arrow-. Press the generator out of the bracket using a lever if necessary.





Removing generator

4. Lift generator up and out. Press the upper cooling water hose aside if necessary.

Installing generator

Information

- Before installing the new generator, tap the threaded bushings -d- out by approx. 4 mm -arrows-.





Threaded bushing on generator

1. Insert the generator -3- from above.
2. Place the generator in installation position -arrow- and secure with the fastening screws -arrows 3-. => Tightening torque: 20 Nm (15 ftlb.)





Securing the generator

3. Connect the B+ line -3- to the generator -arrow A- and secure with the fastening nut -2-. => Tightening torque: 15 Nm (11 ftlb.)





Securing electric connections on the generator (similar illustration)

4. Plug in connector -1- ( -arrow B- ) until it engages securely.

Subsequent work

1. Install the belt tensioner. -> 137319 Removing and installing belt tensioner - section on "Installing" Service and Repair
2. Install air cleaner housing lid. -> 242455 Replacing air-cleaner element Service and Repair
3. Install air box for throttle housing (intake manifold). -> 243519 Removing and installing air box for throttle housing (intake manifold) - section on "Installing" Service and Repair
4. Connect the battery and carry out the work instructions. -> 90 Work instructions after disconnecting the battery