- Battery polarity should be checked before any connections, such as jumper cables or battery charger leads, are made. Reversing the battery connections will damage the diodes in the alternator. It is recommended that the battery cables be disconnected before connecting a battery charger.
- The battery must never be disconnected while the alternator is running.
- Always disconnect the battery ground lead before working on the charging system, especially when replacing an alternator.
- Do not short across or ground any alternator or regulator terminals.
- If electric arc welding has to be done to the car, first disconnect the battery and alternator cables. Never start the car with the welding unit attached.
REMOVAL & INSTALLATION
Types 1 and 2/1600
The generator (alternator) can be removed without removing the engine on these models by loosening the fan housing and lifting it up enough to remove the four generator (alternator) to fan housing bolts.
Although it is possible to remove the generator/alternator with the engine installed in the vehicle, this procedure is much easier with the engine already removed from the car. Access to several of the fan shroud fasteners can be extremely tight.
- Disconnect the battery.
- Disconnect the leads from the generator (alternator) and mark them for reassembly.
- Remove the air cleaner housing and the carburetor or air flow sensor (fuel injected models). Refer to Fuel System for more information.
- Slide the accelerator cable out through the fan housing and remove the cable's guide tube.
- Separate the generator (alternator) pulley halves, noting the number and position of the pulley shims, and remove the belt from the pulley.
- Remove the retaining strap from the generator (alternator).
- Remove the cooling air thermostat. See the end of this section for details.
- Remove the hot air hoses from the fan housing.
- Remove any wires and hoses which may hinder lifting the fan housing up.
- On 1971 Type 2s and on all Type 1s except the 1970 model, use a 10mm wrench to remove the bolt that holds the oil cooler cover to the front (flywheel side) of the engine and the bolt that holds the fan housing to the oil cooler flange. Remove the oil cooler cover and flange.
- Remove the screws at both sides of the fan housing and on 1971 Type 2s and all Type 1s except 1970 models, pry off the clip and disconnect the fan housing flap linkage from the left control flap.
- Lift up the fan housing enough to remove the four 10mm head bolts that hold the generator (alternator) to the fan housing and remove the generator (alternator) from the vehicle.
- Remove the fan from the generator (alternator) by unscrewing the special nut and pulling the fan off the keyed generator (alternator) shaft. Note the position of any shims found on Type 2 generators, from chassis number 219000001, as these shims are used to maintain a gap of 0.047 in. between the fan and the fan cover. The Type 1 gap is 0.08 in.
- Reverse the above steps to install. When installing the generator (alternator) the cooling air intake slot in the fan cover must face downward and the generator (alternator) pulley must align with the crankshaft pulley.
- Disconnect the negative battery cable.
- Disconnect the alternator wiring harness at the voltage regulator and starter.
- Pull out the dipstick and remove the oil filler neck. Disconnect the heater blower from the front of the alternator on 1980-81 Type 2.
- Loosen the alternator adjusting bolt and remove the drive belt.
- Remove the right rear engine cover plate and the alternator cover plate.
- Disconnect the warm air duct at the right side, and remove the heat exchanger bracket and connecting pipe from the blower.
- Disconnect the cool air intake elbow at the alternator. Remove the attaching bolt and lift out the alternator from above.
- Reverse the above procedure to install, taking care to ensure that the rubber grommet on the intake cover for the wiring harness is installed correctly. After installation, adjust the drive belt so that the moderate thumb pressure midway on the belt depresses the belt about 1/2 in.
- Remove the cooling air intake cover and disconnect the battery.
- Loosen the fan belt adjustment and remove the fan belt. Removal of the belt is accomplished by removing the nut in the center of the generator pulley and removing the outer pulley half.
- Remove the two nuts which hold the generator securing strap in place and then remove the strap.
- Disconnect the generator wiring.
- Remove the generator.
- Installation is the reverse of the above. Install the generator so that the mark on the generator housing is in line with the notch on the clamping strap. The generator pulley must be aligned with the crankshaft pulley. Make sure that the boot which seals the generator to the air intake housing is properly placed.
The factory procedure recommends removing the engine to remove the alternator. However, it is possible to reach the alternator by first removing the right heater box which will provide access to the alternator.
- Disconnect the battery.
- The following is the alternator removal and installation procedure after removing the engine; however, all bolts and connections listed below must be removed, except the engine cooling fan, if the right heater box is removed to gain access to the alternator.
- Remove the engine.
- Remove the dipstick, if necessary and the rear engine cover plate.
- Remove the fan belt.
- Remove the lower alternator bolt and the alternator cover plate.
- Disconnect the wiring harness from the alternator.
- Remove the allen head screws which attach the engine cooling fan, then remove the fan.
- Remove the rubber elbow from the fan housing.
This elbow must be in position upon installation because it provides cooling air for the alternator.
- Remove the alternator adjusting bracket.