65 A (Valeo) With V-Belt

Generator (GEN), repairing - 65 A (Valeo) with V-belt







1 - Hex nut
- 40 Nm (30 ft lb)
2 - Washer
3 - Pulley
- Diameter 70 mm (2.75 in.)
- Removing/installing ~ Fig.5
4 - Spacer sleeve
5 - Washer
6 - Fan
- Note direction rotation marked with arrow
7 - Washer
8 - Spacer
9 - End plate
- Mark position in relation to Generator (GEN) housing
10 - Bearing (drive end)
- Removing/installing ~ Fig. 4
11 - Bearing securing plate
12 - Spacer
13 - Woodruff key
14 - Rotor
- Checking for short to ground ~ Fig. 6
- Checking winding for short or open circuit ~ Fig. 7
15 - Bearing (slip ring end)
- Removing/installing ~ Fig. 4
16 - Stator
- Removing/installing ~ Fig. 8
- Checking for short to ground ~ Fig.9
- Checking for open circuit ~ Fig.1O
17 - Metal ring
18 - Plastic bushing
- Always use new bushing
19 - Generator (GEN) housing
20 - Cover
21 - Diode plate
- Removing/installing ~ Fig. 8
- Checking ~ Fig. 11
22 - Voltage regulator
- Removing/installing ~ Fig. 2
- Replacing carbon brushes ~ Fig.3
23 - Stud
- For securing B+ and D+ wiring clamp, 3 Nm (27 in. lb)
24 - Suppressor
- ~ Fig. 1

Fig. 1 Suppressor Connection:

Terminal B+ arrow

Fig. 2 Removing/Installing Voltage Regulator:

Voltage regulator can be removed with Gene~ator (GEN)

Fig. 3 Generator (GEN) Carbon Brushes:

Length of new carbon brushes = 12 mm (0.47 in.)
Wear limit = 5 mm (0.2 in.)
Tolerance = +1 mm (0.0394 in.)

Fig. 4 Bearing, Removing/Installing:

1 - Separating tool, e.g. Kukko 15/0 or 17/0
2 - Puller, e.g. Kukko 18/0

Notes:
- When installing press bearing on over inner ring onto stop.
- Always use new bearing.

Fig. 5 Generator (GEN) Pulley, Removing/Installing:

- Secure pulley.
- Remove (unscrew) Hex nut.
- Tightening torque: 40 Nm (30 ft lb)

Fig. 6 Rotor - Checking For Short To Ground:

- Measure resistance using Fluke 83 tester.
- A resistance value must appear in the kilo-ohm display range.

Fig. 7 Rotor - Checking Windings For Short/Open Circuit:

- Press resistance measurement button on tester VAG 1315A.
Resistance value: 2.8 to 3.0 ohms

Open circuit: A resistance in the kilo-ohm range will flash in the display.

Winding short circuit: resistance is below specification.

Fig. 8 Stator And Diode Plate, Removing/Installing:

- Use long nose pliers to dissipate heat at solder points arrows.
- Unsolder stator winding.

Fig. 9 Stator - Checking For Short To Ground:

- Press resistance measurement button on tester VAG 1315A.
- Connect cables one after the other to measuring points 1 and 2; 1 and 3; 1 and 4.

A resistance in the kilo-ohm range must flash in the display.

Fig. 10 Stator - Checking For Open Circuit:

- Press resistance measurement button on tester VAG 1315A.
- Connect cables one after the other to winding ends 1 and 2; 1 and 3; 2 and 3.

At each point the reading must be approx. 0 Ohm.

There is an open circuit when a flashing resistance in the kilo-ohm range appears in the display.

Fig. 11 Diode Plate, Checking:

- Press resistance and voltage measurement buttons simultaneously on tester VAG 1315A.
- Checking positive diodes: Connect black test probe to positive heat sink 1 (corresponds to B+) and the red test probe to each of the collective points 2 one after the other.
- Checking negative diodes: Connect red test probe to negative heat sink 3 and black test probe to each of the collective points 2 one after the other.
- Checking exciter diodes: Connect black test probe to contact rail 4 (corresponds to D+) and red test probe on each collective points 2 one after the other.
For all checks 50-80 must be indicated 3 times. If this is not the case, replace diode plate.