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Generator, Z19

Generator, Z19

To remove


1. Remove the battery cover and disconnect the negative battery cable.


2. DTH Remove the upper engine cover and insulation.

3. DT: Remove the generator's upper retaining bolt.

DTH Remove the generator's two upper retaining bolts.


4. Raise the car.

5. Remove the lower engine cover.


6. Remove the front right wheel.

7. Remove the right-hand Front wing liner .


8. Release the load of the belt tensioner and lock it with 87 92 335 Lock pin .


9. Lift the poly-v-belt off the generator.

Important

Make a note of the belt's direction of rotation. The belt must be refitted for the same direction of rotation as previously.


10. Remove the bolt from the steering swivel member, lower the suspension arm and place a 83 95 238 Wedge between the suspension arm and the anti-roll bar.


11. Tap the drive shaft out of the intermediate shaft with a brass drift and large hammer. Move aside the drive shaft.


Warning

Use protective goggles to protect against flying splinters of metal.


12. Remove the generator's electrical connections (ring terminals).


13. DT: Remove the lower bracket.


DTH: Remove the generator's lower retaining bolt.

14. Lower the generator and lift it out.


To fit

DT


DTH



1. Lift the alternator into place.

DT: Fasten the lower bracket.

DT/DTH: Insert the lower bolt.

2. Lower the car.

3. DT: Fit the generator's upper bolt.

DTH: Fit the generator's upper bolts.

Tightening torque 60 Nm (44.5 lbf ft)

4. Raise the car.

5. DT: Tighten the bolts for the lower bracket.

Tightening torque

M8: 25 Nm (18.5 lbf ft)

M10: 50 Nm (37 lbf ft)

DT/DTH: Tighten the lower bolt.

Tightening torque 60 Nm (44.5 lbf ft)

6. Connect the ring terminals to the generator.

Tightening torque

M5: 5 Nm (3.7 lbf ft)

M8: 10 Nm (7.5 lbf ft)

7. Grease the drive shaft splines with 90 513 210 Universal paste and make sure the rubber seal is mounted on the shaft.

8. Fit the drive shaft to the intermediate shaft. Make sure the lock ring clicks into place.


9. Remove the wedge and connect the ball joint to the steering swivel member with a nut and bolt. The pin must be visible above the steering swivel member before the bolt is fitted. Tighten the nut.

Warning

Press up the pin carefully.

The groove in the pin must be visible in the screw hole in the spindle housing.

If the rubber gaiter is pressed down, it will not seal properly to the swivel pin.


Tightening torque 50 Nm (37 lbf ft)

10. Refit the poly-V belt.

Important

Make a note of the belt's direction of rotation. The belt must be refitted for the same direction of rotation as previously.


11. Release the tension of the belt tensioner and remove 87 92 335 Lock pin .

Note

Make sure that the belt is correctly positioned on all the pulleys.



12. Fit Front wing liner .


13. Fit the lower engine cover.


14. Fit the wheel.

15. Lower the car.

16. Connect the negative cable of the battery.

17. Fit the battery cover.


18. DTH Fit the insulation and upper engine cover.

19. When changing: check battery, see Battery check and charge battery if necessary, see "Charging the battery".

20. Reset the car; see Procedures after battery disconnection .