DESCRIPTION
A conventional 3-phase Bosch 115-amp generator is used, utilizing 6 positive and 6 negative diodes to rectify current. Three additional diodes are used in exciter circuit and to turn off charge indicator light. An internal Integrated Circuit (IC) voltage regulator controls charging system voltage. A fan is mounted on generator shaft to cool the generator.
BELT TENSION
Belt tension can be tested using Belt Tension Tester (9574). Press belt tension tester against generator belt. Tension for a used belt should be 33-50 lbs. (15-23 kg) with cold engine.
Engine blower/generator drive belt tension is increased by removing shims between generator pulley halves and decreased by installing shims between pulley halves. Shims provided for adjustment are available in.5 and.7 mm thicknesses. The.7 mm thickness shim is identified by 2 mm diameter drill hole. (Scheme 1)
TROUBLE SHOOTING
Note. See TROUBLE SHOOTING article in GENERAL INFORMATION.
ON-VEHICLE TESTING
Testing information is not available from manufacturer at time of publication. Generator is grounded through Brown wire (D-). Exciter/charge indicator light circuit (D+) uses Blue wire. Red wire at generator terminal B+ is routed to generator, from battery positive terminal on starter.
Removal
- Disconnect negative battery cable. Remove drive belts. Remove generator/blower housing hold-down strap. (Scheme 1) Remove blower housing from engine.
- Remove generator-to-housing retaining nuts. Disconnect wiring from generator. Remove large nut and press off blower wheel using Puller (VW 202).
Installation
To install, reverse removal procedure. Apply Loctite 270 to blower wheel retaining nut and tighten nut to 10 ft. lbs. (14 N.m). Ensure generator wiring is routed properly through housing with wires leading to right side of engine. Tighten chassis ground nuts on crankcase to 17 ft. lbs. (23 N.m)
Note. After reinstallation or repairs, retighten blower housing hold-down strap after running engine to operating temperature.
OVERHAUL
Generator overhaul is not recommended by manufacturer. Replace voltage regulator or generator as necessary.
Scheme 1
TORQUE SPECIFICATIONS
| Application | Ft. Lbs. (N.m) |
|---|---|
| Generator Fan (Impeller) | 10 (14) |
| Ground Cable | 17 (23) |
| INCH Lbs. (N.m) | |
| Engine Blower/Generator Housing Strap | 71 (8.0) |
TORQUE SPECIFICATIONS
Charging System Wiring Diagram (911). Scheme 2
Poses Online