generator JAGUAR X308 1998 2.G Service Manual

Generator and Regulator - Generator4.0L NA V8 - AJ27/3.2L NA V8 - AJ26
Removal and Installation
Removal

1. Disconnect the batt ery ground cable.
Remove the battery cover.
2. Remove the air cleaner assembly (including fit body paintwork
protection sheets to the adja cent working area); refer to
operation 19.10.05.
3. Remove the twin fan and moto r assembly from behind the
radiator; refer to operation 26.25.12.
4. Check that the belt wear indicator is within the limit marks.

5. Remove the drive belt from the generator and accessory
drive,
1. Use a spanner e.g. Churchill JD-230 or Snap On XDHM 1415, on the centre bo lt of the belt tensioner
idler pulley, to turn the adju ster assembly to the left
against spring tension.
2. Whilst holding the tensioner against spring tension, remove the drive belt from the generator pulley.
Release the tensioner sl owly and remove the
spanner.
Disconnect the belt from the ot her pulleys, as necessary,
to move it clear of the generator.
6. Raise the vehicle on a ramp; refer to Section 100-02

7. Remove the air intake ducting fr om the generator. The ducting
comprises two sections; the upper section is retained by two
screws to the sump body assembly and the lower (horizontal)
section is retained by one screw.
8. Disconnect the generator harness.
1. Disconnect the harness multi-plug.
2. Remove the protective boot from the positive
terminal, remove the termin al nut and disconnect the
cable from the terminal. Where fitted, disconnect the

suppression module positive cable from the positive
terminal.
3. Where fitted, remove the nut which secures the
suppression module negati ve cable and disconnect
the cable from the generator. Reposition the
suppression module harness clear of the generator.

9. Remove the lower mounting bolt and reposition the harness
mounting bracket.

10. Remove the upper securing bolt and withdraw the generator
from the mounting bracket.

11. Carefully, manoeuvre the ge nerator forward towards the
radiator.
12. Change the position of the ge nerator and remove it upwards
between the engine and the radiator.

Installation


13. Move the spacing bush rearward s slightly in the generator
mounting bracket, to ease fitting the new generator.
1. Position a suitable length bolt through the bush, fit a
tubular spacer or socket spanner, fit a nut and
tighten the assembly to move the bush slightly.
Remove the nut, bolt and spacer.

1. Fit the generator to the engine.
1. From above, position th e generator and fit the upper
mounting bolt and nut, but do not fully tighten.

2. Fit the generator lower mounting.
1. From below, reposition an d align the harness clip to
the generator lower mounting.
2. Fit the lower mounting bolt and nut, tighten to 38-48
Nm.
3. Connect the harness.
1. Reposition the suppres sion module harness and
connect the negative cable to the generator negative
terminal. Fit and tighten the terminal nut.

2. Secure the suppression module positive cable and
main positive cable to the generator positive
terminal.
3. Fit the boot to the terminal.
4. Reconnect the generator harness multi-plug.

4. Refit the air intake ducting to the generator. The upper section
is retained by two screws to the sump body assembly and the
lower (horizontal) section is retained by one screw.
5. Lower the vehicle on the ramp ; refer to Section 100-02.
6. Fully tighten the generator upper mounting bolt, to 18-24 Nm.

7. Refit the drive belt to the generator.
1. Pass the drive belt around the idler pulley.
2. Using spanner )Churchill JD-230 or Snap On XDHM 1415) on the centre bolt of the belt tensioner idler
pulley, rotate the adjuster against spring tension.
3. Whilst holding the tensioner against spring tension, pass the drive belt over the generator pulley and
check that it is correctly located on the other pulleys.
Release the tensioner slowly and remove the
spanner. Check the alignment of the belt.
8. Refit the fan and motor assembly ; refer to Operation 26.25.12.

9. Refit the air cleaner assembly; refer to Operation 19.10.05.
10. Reconnect the battery ground cable and fit the battery cover.
Reset the radio inform ation and the clock.

Generator and Regulator - Generator4.0L SC V8 - AJ26
Removal and Installation
Removal

1. Disconnect the batt ery ground cable.
Remove the battery cover.
2. Remove the air cleaner assembly (including fit body paintwork
protection sheets to the adja cent working area); refer to
operation 19.10.05.
3. Remove the twin fan and moto r assembly from behind the
radiator; refer to operation 26.25.12.
4. Remove the supercharger drive belt; refer to operation
18.50.08.
5. Remove the supercharger driv e belt tensioner; refer to
operation 18.50.24.
6. Check that the belt wear indica tor (accessory drive) is within
the limit marks.

7. Remove the drive belt from the generator and accessory
drive,
1. Use a spanner e.g. Churchill JD-230 or Snap On XDHM 1415, on the centre bo lt of the belt tensioner
idler pulley, to turn the adju ster assembly to the left
against spring tension.
2. Whilst holding the tensioner against spring tension, remove the drive belt from the generator pulley.
Release the tensioner sl owly and remove the
spanner.
Disconnect the belt from the ot her pulleys, as necessary,
to move it clear of the generator.
8. Raise the vehicle on a ramp; refer to Section 100-02

9. Remove the air intake ducting fr om the generator. The ducting
comprises two sections; the upper section is retained by two
screws to the sump body assembly and the lower (horizontal)
section is retained by one screw.
10. Disconnect the generator harness.

1. Disconnect the harness multi-plug.
2. Remove the protective boot from the positive
terminal, remove the termin al nut and disconnect the
cable from the terminal.

11. Remove the lower mounting bolt and reposition the harness
mounting bracket.

12. From above the vehicle, reposi tion the supercharger water
pump for access.
1. Reposition the pump harness multiplug from the
retaining bracket.
2. Remove the two nuts which secure the U-bracket around the pump.
3. Remove the U-bracket from the pump.
4. Reposition the pump to al low access for removing the
generator.

13. Remove the upper securing bolt and withdraw the generator
from the mounting bracket.
14. Carefully, manoeuvre the ge nerator forward towards the
radiator.

Installation


15. Change the position of the ge nerator and remove it upwards
between the engine and the radiator.

16. Move the spacing bush rearward s slightly in the generator
mounting bracket, to ease fitting the new generator.
1. Position a suitable length bolt through the bush, fit a
tubular spacer or socket spanner, fit a nut and
tighten the assembly to move the bush slightly.
Remove the nut, bolt and spacer.

1. Fit the generator to the engine.
1. From above, position th e generator and fit the upper
mounting bolt and nut, but do not fully tighten.
2. Fit the generator lower mounting.
1. From below, reposition an d align the harness clip to
the generator lower mounting.

2. Fit the lower mounting bolt and nut, tighten to 38-48
Nm.

3. Connect the harness.
1. Secure the main positive cable to the generator positive terminal.
2. Fit the boot to the terminal.
3. Reconnect the generator harness multi-plug.

4. Refit the air intake ducting to the generator. The upper section
is retained by two screws to the sump body assembly and the
lower (horizontal) section is retained by one screw.
5. Lower the vehicle on the ramp ; refer to Section 100-02.
6. Fully tighten the generator upper mounting bolt, to 18-24 Nm.

7. Reposition the superc harger water pump.
1. Reposition the pump to the mounting bracket.
2. Fit the U-bracket to the pump.
3. Fit the two nuts which secure the U-bracket around the pump.
4. Reposition the pump harness multiplug to the retaining bracket.
8. Refit the drive belt to the generator.
1. Pass the drive belt around the idler pulley.
2. Using spanner )Churchill JD-230 or Snap On XDHM

1415) on the centre bolt of the belt tensioner idler
pulley, rotate the adjuster against spring tension.
3. Whilst holding the tensioner against spring tension, pass the drive belt over the generator pulley and
check that it is correctly located on the other pulleys.
Release the tensioner slowly and remove the
spanner. Check the alignment of the belt.
9. Fit the supercharger drive belt tensioner; refer to operation
18.50.24.
10. Fit the supercharger drive belt ; refer to operation 18.50.08.
11. Refit the fan and motor asse mbly; refer to Operation
26.25.12.
12. Refit the air cleaner assembly; refer to Operation 19.10.05.
13. Reconnect the battery ground cable and fit the battery cover.
Reset the radio inform ation and the clock.

Generator and Regulator - Voltage Regulator
Removal and Installation
Removal

1. Disconnect the batt ery ground cable.
Remove the battery cover.
2. Remove the generator from the vehicle. Refer to Operation
86.10.02.

3. Remove the nut from the main terminal and remove the
insulator.

4. Remove the ground tag.
1. Remove the nut which secures the ground tag.
2. Remove the screw which secures the ground tag and remove the tag.
5. Remove the two remaining nuts which secure th e rear cover
and remove the cover.