Alternator: Service and Repair

Removal





1. Disconnect the battery ground cable.
Remove the battery cover.
2. Remove the air cleaner assembly (including fit body paintwork protection sheets to the adjacent working area).
3. Remove the twin fan and motor assembly from behind the radiator.
4. Remove the supercharger drive belt.
5. Remove the supercharger drive belt tensioner. Service and Repair
6. Check that the belt wear indicator (accessory drive) is within the limit marks.





7. Remove the drive belt from the generator and accessory drive,
1. Use a spanner e.g. Churchill JD-230 or Snap On XDHM 1415, on the centre bolt of the belt tensioner idler pulley, to turn the adjuster assembly to the left against spring tension. Whilst holding the tensioner against spring tension, remove the drive belt from the generator pulley. Release the tensioner slowly and remove the spanner.
2. Disconnect the belt from the other pulleys, as necessary, to move it clear of the generator.
8. Raise the vehicle on a ramp.





9. Remove the air intake ducting from the generator. The ducting comprises two sections; the upper section is retained by two screws to the sump body assembly and the lower (horizontal) section is retained by one screw.





10. Disconnect the generator harness.
Disconnect the harness multi-plug.
Remove the protective boot from the positive terminal, remove the terminal nut and disconnect the cable from the terminal.





11. Remove the lower mounting bolt and reposition the harness mounting bracket.





12. From above the vehicle, reposition the supercharger water pump for access.
1. Reposition the pump harness multiplug from the retaining bracket.
2. Remove the two nuts which secure the U-bracket around the pump.
3. Remove the U-bracket from the pump.
4. Reposition the pump to allow access for removing the generator.

Generator:

13. Remove the upper securing bolt and withdraw the generator from the mounting bracket.





14. Carefully, manoeuvre the generator forward towards the radiator.





15. Change the position of the generator and remove it upwards between the engine and the radiator.





16. Move the spacing bush rearwards slightly in the generator mounting bracket, to ease fitting the new generator.
1. Position a suitable length bolt through the bush, fit a tubular spacer or socket spanner, fit a nut and tighten the assembly to move the bush slightly. Remove the nut, bolt and spacer.


Installation





1. Fit the generator to the engine.
1. From above, position the generator and fit the upper mounting bolt and nut, but do not fully tighten.





2. Fit the generator lower mounting.
1. From below, reposition and align the harness clip to the generator lower mounting.
2. Fit the lower mounting bolt and nut, tighten to 38-48 Nm.





3. Connect the harness.
2. Secure the main positive cable to the generator positive terminal.
3. Fit the boot to the terminal.
4. Reconnect the generator harness multi-plug.





4. Refit the air intake ducting to the generator. The upper section is retained by two screws to the sump body assembly and the lower (horizontal) section is retained by one screw.
5. Lower the vehicle on the ramp.
6. Fully tighten the generator upper mounting bolt, to 18-24 Nm.





7. Reposition the supercharger water pump.
1. Reposition the pump to the mounting bracket.
2. Fit the U-bracket to the pump.
3. Fit the two nuts which secure the U-bracket around the pump.
4. Reposition the pump harness multiplug to the retaining bracket.





8. Refit the drive belt to the generator.
1. Pass the drive belt around the idler pulley.
2. Using spanner (Churchill JD-230 or Snap On XDHM 1415) on the centre bolt of the belt tensioner idler pulley, rotate the adjuster against spring tension.
3. Whilst holding the tensioner against spring tension, pass the drive belt over the generator pulley and check that it is correctly located on the other pulleys. Release the tensioner slowly and remove the spanner. Check the alignment of the belt.
9. Fit the supercharger drive belt tensioner.
10. Fit the supercharger drive belt.
11. Refit the fan and motor assembly.
12. Refit the air cleaner assembly.
13. Reconnect the battery ground cable and fit the battery cover. Reset the radio information and the clock.