Generators & Regulators Porsche 911 Carrera 996 рестайлинг

DESCRIPTION & OPERATION

Note. This article applies to 911 Carrera, Carrera 4, GT3 and Turbo vehicles with a factory designation of 996.

Generator is a three-phase generator driven by engine accessory drive belt. Generator bracket holds generator, A/C compressor and is also an integral part of the engine cooling system. Bracket is a hollow cast unit with a seal joining two separate halves through which coolant flows when engine is running.

On vehicles equipped with a manual transmission, alternators are equipped with a freewheeling belt pulley. Freewheeling pulley eliminates belt derailing under certain conditions (allowing for elimination of the drive belt guide clip used on earlier applications), by allowing generator to free wheel when turning backwards (against normal engine rotation). Freewheeling pulley requires a 17 mm multi-toothed tool (PNA 721 048) for removal and installation purposes.

BELT TENSION

Serpentine belt tension is automatically adjusted by tensioner and no adjustment is required.

DRIVE BELT ROUTING

Serpentine belt is self-adjusting. For drive belt routing (Scheme 1)or (Scheme 2).

Scheme 1

Scheme 2

SERVICE PRECAUTIONS

The following precautionary measures must be taken before disconnecting or total discharge of the battery or serious electrical damage can occur

1. Never disconnect battery with engine running.
2. Ensure battery is securely connected before starting.
3. Do not use a boost charger to start engine.
4. When jump starting use jumper cables with overvoltage protection.
5. Always disconnect the battery before performing any welding.
6. Always ensure ignition is in the OFF position before disconnecting any electrical components. Except for the following: On vehicles equipped with alarm siren tilt sensor M536 (located next to battery) ignition must be in the ON position with all loads turned off before disconnecting battery to ensure alarm siren will not be triggered.
7. Before beginning testing, perform «PRELIMINARY INSPECTION»(/porsche/911-carrera/996-2000-2005/remont/charging-system/#generators-regulators__preliminary-inspection) .

PRELIMINARY INSPECTION

Verify customer complaint by operating system. Visually inspect for obvious signs of mechanical and electrical damage. Check generator belt tension and condition. Ensure that battery voltage is within specifications. Following manufacturers instructions for load tester, load test battery. Inspect for blown fuses and damaged relays. For fuse and/or relay identification, see TORQUE SPECIFICATIONS .

Verify ground connection integrity between engine, body, battery and generator. Check for damaged wiring harnesses and/or switches. Check for a broken or partially broken wire inside insulation, which could cause system malfunction but prove good in a continuity/voltage check with system disconnected. Ensure any aftermarket electronic equipment is properly installed. If fault is found, repair as necessary. If no fault is found, check for conditions that might cause an intermittent situation.

REMOVAL & INSTALLATION

Removal & Installation (911 Carrera & Carrera 4)

1. Disconnect battery and cover negative terminal. See «SERVICE PRECAUTIONS»(/porsche/911-carrera/996-2000-2005/remont/charging-system/#generators-regulators__service-precautions) under TROUBLE SHOOTING.
2. Remove air cleaner assembly. Remove hose clamp from throttle body for Mass Air Flow (MAF) sensor. Remove air cleaner housing mounting bolt, and disconnect MAF sensor harness connector. Remove air filter housing. (Scheme 3)
3. Relieve tension on belt tensioner and remove drive belt.
4. Disconnect vacuum switch-over valve harness connector and unclip switch-over valve from holder. (Scheme 4)
5. Remove holder for switch-over valve from intake manifold. Remove bolts (2). (Scheme 5) Ensure that O-ring comes off with switch-over valve. O-ring can be reused if not damaged.
6. Remove bolt holding left side of generator. Remove right bolt along with belt deflection roller. (Scheme 6) To remove right bolt, unscrew bolt by approximately 3 turns and tap bolt head back toward generator. This dislodges the pressed-in bushing. With bushing removed, remove right bolt completely.
7. Swivel generator so fastening eye is past its holder. Disconnect generator harness connector by pushing connector in while pushing down on release tab, then pull connector out. Disconnect B+ lead from generator. (Scheme 7) Pull generator out of engine compartment toward rear of vehicle.
8. To install, follow reverse order of removal. Place O-ring on switch-over valve carefully. Torque fasteners to specification. See «TORQUE SPECIFICATIONS»(/porsche/911-carrera/996-2000-2005/remont/charging-system/#generators-regulators__torque-specifications).

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

911 Turbo

1. Disconnect battery and cover negative terminal. See «SERVICE PRECAUTIONS»(/porsche/911-carrera/996-2000-2005/remont/charging-system/#generators-regulators__service-precautions) under TROUBLE SHOOTING.
2. Remove air cleaner assembly. Remove hose clamp from throttle body for Mass Air Flow (MAF) sensor. Loosen hose clamps for left and right charge air cooler (intercooler) pressure pipes. Remove air cleaner housing mounting bolt, and disconnect MAF sensor harness connector. Remove complete air filter housing. (Scheme 8)and (Scheme 9).
3. Remove pressure pipe to throttle body. Relieve tension on belt tensioner and remove drive belt.
4. Remove belt deflection roller from generator bracket. (Scheme 10)
5. Open plastic cover of B+ connection point and remove nut and disconnect B+ connection. (Scheme 11)
6. Remove bolt holding left side of generator. To remove right bolt, unscrew bolt by approximately 3 turns and tap bolt head back toward generator. This dislodges the pressed-in bushing. With bushing removed, remove right bolt completely.
7. Disconnect harness connector to generator by pushing connector in while pushing down on release tab then pull out. Disconnect B+ lead from generator. (Scheme 7) Lift generator up and out of engine compartment.
8. To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(/porsche/911-carrera/996-2000-2005/remont/charging-system/#generators-regulators__torque-specifications).

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Removal & Installation (GT3)

1. Disconnect battery and cover negative terminal. See «SERVICE PRECAUTIONS»(/porsche/911-carrera/996-2000-2005/remont/charging-system/#generators-regulators__service-precautions) under TROUBLE SHOOTING.
2. Remove bolt holding air cleaner, and remove air cleaner housing. (Scheme 12) Remove hose clamp on throttle body for Mass Air Flow (MAF) sensor. Remove MAF sensor harness connector.
3. Relieve tension on belt tensioner and remove drive belt.
4. Open plastic cover of B+ connection point and remove nut and disconnect B+ connection. (Scheme 11)
5. Remove belt deflection roller from generator bracket. (Scheme 10)
6. Remove bolt holding left side of generator. To remove right bolt, unscrew bolt by approximately 3 turns and tap bolt head back toward generator. This dislodges the pressed-in bushing. With bushing removed, remove right bolt completely.
7. Disconnect harness connector to generator by pushing connector in while pushing down on release tab then pull out. Disconnect B+ lead from generator. (Scheme 7) Lift generator up and out of engine compartment.
8. To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(/porsche/911-carrera/996-2000-2005/remont/charging-system/#generators-regulators__torque-specifications).

Scheme 12

GENERATOR BRACKET

It is necessary to bleed coolant system after servicing generator bracket. See SPECIFICATIONS & DRIVE BELT ROUTING - 911 (EXCEPT 911 TURBO) or SPECIFICATIONS & DRIVE BELT ROUTING - 911 TURBO article under COOLING SYSTEM (MECHANICAL) in ENGINE.

Removal & Installation (911 Turbo)

1. Drain engine coolant. Remove cap from coolant expansion tank. Remove right and left drain plugs. (Scheme 13) When coolant is drained, fit plugs with new seals and tighten to 90-121 INCH lbs. (10-15 N.m).
2. Remove air cleaner housing. Remove bolt holding air cleaner. see scheme 14 Remove hose clamp on throttle body. Remove Mass Air Flow (MAF) sensor harness connector.
3. Relieve tension on belt tensioner and remove drive belt.
4. Unclip cable for MAF sensor from expansion tank of power steering hydraulic pump. Detach holder from oil filler neck.
5. Remove bolts holding power steering hydraulic pump. (Scheme 14) Pull expansion tank of hydraulic pump up and out of its bracket with fluid lines still attached. Lay aside to the right.
6. Remove holder for oil filter bracket. Remove M6 bolt and M8 bolt. Lift holder up and out.
7. Open plastic cover of B+ electrical connection point and disconnect. (Scheme 15) Remove left side generator mounting bolt. To remove right bolt, unscrew bolt by approximately 3 turns. Then tap bolt head back toward generator. This dislodges pressed-in bushing. With bushing removed, remove right generator mounting bolt completely. Lift generator up and out of engine compartment.
8. Remove 3 A/C compressor mounting bolts from generator bracket. (Scheme 16) Throttle body can be swung upward to make better access to rear bolt. NOTE: Cover vehicle body to prevent damage.
9. Disconnect A/C compressor harness connector. Lift compressor with A/C lines still attached and lay aside.
10. Unclip coolant hose. Release safety bracket with a screwdriver and pull hose up and out of bracket. (Scheme 17)
11. Remove coolant outlet neck of cylinder bank 4-6. Remove hex bolts (2).
12. Remove generator bracket mounting bolts (4). (Scheme 18)
13. Remove hose clamp from coolant connecting hose. (Scheme 19) Remove generator bracket from engine compartment upward and to the right.
14. Separate halves of generator bracket by removing bolts (3). (Scheme 20) Ensure that dowel sleeves do not get lost. Clean bracket if necessary and fit with a new "O" ring. Use "O" ring lubricate to fit NEW seal.
15. To install, reverse removal procedure. Fit coolant hose with NEW "O" ring before connecting. (Scheme 21)and (Scheme 22). Use Loctite 574 thread sealer on front right bolt for generator bracket. (Scheme 23) Torque fasteners to specification. See «TORQUE SPECIFICATIONS»(/porsche/911-carrera/996-2000-2005/remont/charging-system/#generators-regulators__torque-specifications).

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

1. Drain engine coolant. Remove cap from coolant expansion tank. Remove right and left drain plugs. (Scheme 13) When coolant is drained, fit plugs with NEW seals and tighten to 90-121 INCH lbs. (10-15 N.m).
2. Remove air cleaner housing. Remove bolt holding air cleaner. (Scheme 12) Remove hose clamp on throttle body. Disconnect Mass Air Flow (MAF) sensor harness connector.
3. Relieve tension on belt tensioner and remove drive belt.
4. Unclip cable for MAF sensor harness from expansion tank of power steering hydraulic pump. Detach holder from oil filler neck.
5. Remove bolts holding power steering hydraulic pump. (Scheme 14) Pull expansion tank of hydraulic pump up and out of its bracket with fluid lines still attached. Lay aside to the right.
6. Open plastic cover of B+ electrical connection point and disconnect. (Scheme 15) Remove left side generator mounting bolt. To remove right generator mounting bolt, unscrew bolt by approximately 3 turns. Then tap bolt head back toward generator. This dislodges pressed-in bushing. With bushing removed, remove right bolt completely. Lift generator up and out of engine compartment.
7. Remove 3 A/C compressor mounting bolts from generator bracket. (Scheme 16) Throttle body can be swung upward to make better access to rear bolt. NOTE: Cover vehicle body to prevent damage.
8. Disconnect A/C compressor harness connector. Lift compressor with A/C lines still attached and lay aside.
9. Unclip coolant hose. Release safety bracket with a screwdriver and pull hose up and out of bracket. (Scheme 17)
10. Remove coolant outlet neck of cylinder bank 4-6. Remove hex bolts (2).
11. Remove bolts holding generator bracket (4). (Scheme 18)
12. Remove hose clamp from coolant connecting hose. (Scheme 19) Remove generator bracket from engine compartment upward and to the right.
13. Separate halves of generator bracket by removing bolts (3). (Scheme 20) Ensure that dowel sleeves do not get lost. Clean bracket if necessary and fit with a new O-ring. Use "O" ring lubricate to fit NEW seal.
14. To install, reverse removal procedure. Fit coolant hose with new O-ring before connecting. (Scheme 21)and (Scheme 22). Use Loctite 574 thread sealer on front right bolt for generator bracket. (Scheme 23) Use correct tightening torques. See «TORQUE SPECIFICATIONS»(/porsche/911-carrera/996-2000-2005/remont/charging-system/#generators-regulators__torque-specifications).

Remove drive belt. Remove belt pulley nut using a double offset wrench, screwdriver insert for internal serration screw or with a cross handle and torque wrench. Tighten belt pulley nut to specification. See TORQUE SPECIFICATIONS .

Remove drive belt. Using 17 mm multi-toothed tool (PNA 721 048) hold freewheel pulley while loosening pulley nut. see scheme 25 Counter-holding pulley with appropriate sized wrench, tighten pulley with multi-toothed tool. Tighten freewheel belt pulley nut to specification. See TORQUE SPECIFICATIONS.

Scheme 23

GENERATOR SPECIFICATIONS

Normal output (for all models) is 1,680 Watts.

TORQUE SPECIFICATIONS

GENERATOR & GENERATOR BRACKET TORQUE SPECIFICATIONS

WIRING DIAGRAMS

Note. See CHARGING SYSTEM in appropriate SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

Poses Online

See also:
• SPECIFICATIONS & DRIVE BELT ROUTING - 911 (EXCEPT 911 TURBO)
• SPECIFICATIONS & DRIVE BELT ROUTING - 911 TURBO
• PRELIMINARY INSPECTION
• TORQUE SPECIFICATIONS
• SERVICE PRECAUTIONS