Generator device (VW Passat B5)

Generator

• 1 - poly V-belt,
• 2 - generator,
• 3 - voltage regulator,
• 4 - screws,
• 5 - protective cover,
• 6 - screws

Generator installed on models with 1.6-I and 1.8-I engines with power steering and air conditioning

• 1 - bracket,
• 2 - bolt M8x90, 25 Nm,
• 3 - nut, 30 Nm,
• 4 - generator,
• 5 - voltage regulator,
• 6 - screws,
• 7 - protective cover,
• 8 - screws,
• 9 - poly V-belt,
• 10 - bolt M8x85, 25 Nm,
• 11 - bolt M8x85, 25 Nm,
• 12 - tension mechanism roller,
• 13 - bolt 25 Nm,
• a - to the generator

Warning: Fasten the wire (B+ arrow) with a tightening torque of 15±1 Nm. If the tightening torque of the wire is less than required, the following malfunctions may occur:

• the battery charge level decreases;
• the operation of electrical equipment is disrupted;
• sparking poses a fire hazard;
• an increase in voltage in the vehicle's on-board network, leading to failure of the electronic control units.

Tighten the blue wire (D+) to a torque of 3.2±0.2 Nm.

Generator bracket for diesel vehicles with power steering and air conditioning

• 1 - bracket,
• 2 - nut, 30 Nm,
• 3 - bolt 25 Nm,
• 4 - tension mechanism roller,
• 5 - bolt M8x85, 25 Nm,
• 6 - washer,
• a - to the generator

Generator bracket for 2.3L vehicles with power steering

• 1 - bolt, 25 Nm,
• 2 - bracket,
• 3 - bolt M8x60, 25 Nm,
• 4 - washer,
• 5 - bolt M8x60, 25 Nm,
• 6 - bolt M8x60, 25 Nm,
• a - to the generator

Vehicles are equipped with alternators. Depending on the model and the electrical equipment installed on the vehicle, alternators of varying power may be installed. When installing additional electrical equipment, check that the alternator has sufficient power to power this equipment.

The generator is driven by a V-belt from the engine crankshaft.


The generator is a three-phase synchronous electric machine with electromagnetic excitation. To convert alternating current into direct current, a diode rectifier is built into the generator. The voltage is regulated by a built-in microelectronic voltage regulator.

When the generator is operating, the electric current flowing through the excitation winding creates a magnetic flux around the rotor poles. When the rotor rotates, the south and north poles of the rotor pass under each stator tooth, and the working magnetic flux passing through the stator teeth changes in magnitude and voltage. This variable magnetic flux creates an electromotive force in the stator winding. The wedge-shaped rotor pole pieces are selected in such a way that it allows obtaining a nearly sinusoidal shape of the electromotive force curve.

At high generator rotor speed, when the generator voltage becomes higher than 13.6–14.6 V, the voltage regulator locks and the current does not pass through the excitation winding. The generator voltage drops, the regulator unlocks and again passes the current through the excitation winding. The higher the generator rotor speed, the longer the regulator locks, and therefore the more the voltage at the generator output decreases. The process of locking and unlocking the regulator occurs with a high frequency, so the voltage fluctuations at the generator output are not noticeable, and it can practically be considered constant, maintained at a level of 13.6–14.6 V.

When checking the generator, as well as when operating the vehicle, it is necessary to follow a number of simple rules in order not to damage the generator:

Do not operate the generator with the battery disconnected from the generator terminal. Without a battery, dangerous overvoltage pulses occur in the vehicle's on-board network when any electrical consumers are disconnected. These overvoltage pulses can damage the vehicle's electronic equipment, including the voltage regulator and the generator's rectifier block diodes.

Do not check the generator's performance for a spark, even by briefly connecting the positive clamp of the generator to ground. In this case, a significant current flows through the diodes and they are damaged. The generator voltage can only be controlled with a voltmeter.

The negative terminal of the battery must always be connected to the vehicle's ground, and the positive terminal must be connected to the generator clamp. Incorrect (reverse) connection of the battery will immediately cause increased current to flow through the generator diodes, and they will fail.

Do not test diodes with a voltage higher than 12 V or with a megohmmeter, as it has too high a voltage for diodes and they will be broken during testing (a short circuit will occur). When checking the insulation of electrical wiring with a megohmmeter, it is necessary to disconnect all wires from the generator.

It is necessary to disconnect all wires from the generator and from the battery when electric welding any body parts.

It is necessary to check the circuits and components of electrical equipment and troubleshoot any faults with the engine not running and the battery disconnected.