Generator, Generation II, Air-Cooled

Generator, Generation II, Air-Cooled

Special tools, testers and auxiliary items required

• Locking Pin (T10060 A)

• Tory TB 60 Socket (T40087)

Observe notes on contact corrosion => [ Contact Corrosion ] Contact Corrosion.

Removing

- With ignition switched off, disconnect battery Ground (ND) wire. Refer to => [ Battery, Disconnecting and Connecting ] Battery, Disconnecting and Connecting.








Risk of destroying if the running direction of a used ribbed belt is reversed.

• Before removing ribbed belt, marking running direction with chalk or a felt-tip pen for reinstallation.

- Move the tensioner clockwise - arrow - using the (T40087) to release the tension on the ribbed belt.

- Remove the ribbed belt and lock the tensioner using the (T10060 A).

- Remove screws - arrows -.






• If alternator sticks in holder, install screw again down as far as the last 2 turns.

• Carefully strike on bolt heads using flat side of hammer - doing this loosens sleeves of generator mount.

- Remove the right wheel housing liner..






- Remove bolts and remove the noise insulation in the front - 1 -.

- Loosen the air guide hose on the right side of the charge air cooler.

- Pull the clip - arrow - to unlock the tab - A - on the coupling.






- Remove the air guide pipe without using a tool.

- Remove bolts - 2 - and - 3 -.






- Remove the air guide pipe from the air guide hoses - 1 - and - 4 -.

• The air guide pipe remains in its installed position.

- Disconnect the electrical connector - 3 -.






- Remove the bolts - 1 and 4 -.

- Move the Electrohydraulic engine mount solenoid valve (N398) , the vacuum reservoir and the vacuum hoses still connected to the side.

- Detach wiring harnesses - 1 - and - 2 - from generator.






- Remove the generator - 1 - toward the right between the longitudinal member - 2 - and the stabilizer bar - 3 -.






Installing

Install in reverse order of removal, observing the following:

- Slightly drive back sleeves for retaining bolts in order for easier installation of generator.

• Tight sleeves for generator mount must be made smooth-running, otherwise clamping force of sleeve is too little despite correct torque.

- Install stabilizer bar.

- Fit poly V-belt over pulleys.






1. Generator

2. Idler pulley

3. Idler pulley

4. Coolant pump

5. Idler pulley

6. Vane pump

7. A/C Compressor

8. Tensioner for ribbed belt

9. Vibration damper


• When installing ribbed belt, be sure that it is seated correctly on belt pulleys.

- Install the bracket for the electrohydraulic engine mount solenoid valve and the vacuum reservoir.

- Install the air guide pipe.

- Connect battery. Refer to => [ Connecting ] Battery, Disconnecting and Connecting.

- Start the engine and verify that the belt is running properly.

Tightening Specifications