Generator, Water-Cooled

Generator, Water-Cooled

Special tools, testers and auxiliary items required

• Hose Clamps Up To 25 mm (3094)

• Drip Tray for VAS 6100 (VAS 6208)

• 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.

- Carefully remove engine cover successively from the 4 locking bolts- arrows -.








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.

- To release the tension the ribbed belt, move the tensioner in - direction of arrow - using the (T40087).

- Remove ribbed belt from tensioning roller.

- Remove the air filter housing.

- Loosen the clamps - 1, 2 and 3 - and remove the air guide hoses.






- Remove screws - 2 - and - 3 -.






• Ignore - item 1 -.

- Pry the cover - 3 - off the idler roller.






- Remove the bolt - 1 - and remove the idler roller - 2 -.

- Remove the bolts - arrows - from the generator - 1 -.






- Remove right front wheel.






- Remove screws and remove the noise insulation in the front - 1 - and in the rear - 2 -.

- Remove the right wheel housing liner..

- Remove the screw - arrow - and move the Fuel cooler pump (V166) with coolant hoses and electrical connector still connected to the side.






- Remove the generator from the bracket.

• 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.

- Place the (VAS 6208) under the generator.






- Clamp off coolant hoses - 3 - and - 4 - with hose clamps (3094) and then remove them.

- Disconnect the electrical connector - 1 -.

- Disconnect terminal 30/B+ - 2 - from the generator.

- Remove the generator to the right toward the wheel housing.

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 the fuel cooler pump (V166).

- Install the right wheel housing liner and the noise insulation..

- Install the front wheel.

- Install the idler roller.

- 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 charge air hoses and the charge air pipe.

- Install the air filter housing.

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

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

Tightening Specifications