Alternator, Disassemble and Assemble
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Vacuum pump bolts, vacuum pump with O-ring
| .P. C7322.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Multi-plug (arrow), cable fastening bolt (1)
| .P. D7528.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Rubber cap (arrow), nut of connection "B", cable
Note installation position of insulating sleeve.
| .P. C7324.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON11.tif | 0,75 | 0,75 | tiff;; Important! |
Mark position of drive and slip ring bearings relative to stator.
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Bolts (arrows)
| .P. C7325.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Carefully lever out drive bearing, slip ring bearing upwards.
| .P. C7207.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Nuts (arrows)
| .P. C7208.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Carefully lever of stator, stator with diode plate.
| .P. C7211.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Nut from pulley, spring ring, pulley, fan, spacer ring, drive bearing from rotor
| .P. C7209.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Remove ball bearing from rotor with remover.
| .P. C5911.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Remove bearing cover of drive bearing (arrows).
| .P. C7212.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Ball bearing from drive bearing, with suitable installer sleeve if necessary.
| .P. C7213.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Edge seal ring out of slip ring bearing.
| .P. C7214.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Carefully bend diode plate away from stator.
Unsolder stator winding (arrows) from diode plate.
Hold cable with flat-nosed pliers while soldering - conducts heat away.
| .P. C7215.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON11.tif | 0,75 | 0,75 | tiff;; Important! |
Mark installation position of insulating sleeve.
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Insulating sleeve (1), unsolder connection (arrow), carbon brush plate from diode plate.
| .P. D7526.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON04.tif | 0,75 | 0,75 | tiff;; Assemble |
Press ball bearing (1) onto rotor shaft with suitable installer sleeve.
| .D. ICON11.tif | 0,75 | 0,75 | tiff;; Important! |
Twist protector (arrow) of ball bearing points upwards.
| .P. D7525.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON04.tif | 0,75 | 0,75 | tiff;; Assemble |
If necessary, lubricate ball bearing - Bearing Grease
19 41 574 (90 001 812), press ball bearing into drive bearing.
Bearing cover to drive bearing (arrows).
| .P. C7212.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON04.tif | 0,75 | 0,75 | tiff;; Assemble |
Rotor in drive bearing, spacer ring, fan, pulley, spring ring, nuts - torque 55 Nm/41 lbf. ft.
| .P. C7209.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON04.tif | 0,75 | 0,75 | tiff;; Assemble |
Place carbon brush plate with retaining plate above positioning screw on diode plate, solder connection (arrow), insulating sleeve (1) on positioning screw.
| .P. D7526.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON04.tif | 0,75 | 0,75 | tiff;; Assemble |
Solder stator winding to diode plate.
Ensure that cables are correctly routed.
| .P. C7215.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Stator with diode plate in slip ring bearing.
Seal ring in slip ring bearing.
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Press back carbon brushes, drive bearing with rotor in slip ring bearing, bolts (arrows).
| .P. C7325.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON11.tif | 0,75 | 0,75 | tiff;; Important! |
Insert insulating sleeve (arrow), note installation position of
O-ring when installing vacuum pump.
| .P. C7219.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Vacuum pump - 7 Nm/5 lbf. ft.,
Fill engine oil (approx. 5 cm3) in oil intake aperture, cable connections to alternator.
| .D. ICON06.tif | 0,75 | 0,75 | tiff;; Inspect |
Alternator pulley must be able to be turned easily by hand.
Alternator - see corresponding operation.
| .P. C7322.tif | 9 | 7,5 | tiff;; |