Alternator: Service and Repair

Generator, Removing And Installing

CAUTION!
Disconnect the battery Ground (GND) strap before working on the electrical system.

NOTE:
- Before disconnecting the battery, determine the correct coding for the anti-theft radio.
- Once the battery is reconnected, check and activate the vehicle's electrical equipment (radio, clock, comfort and convenience features, etc.).

Vehicles with 6-cylinder gasoline engines

Special tools, test equipment and auxiliary items

3204 drift

Removing

- Remove two bolts -1- on air intake duct and then lift up back portion of air intake duct -2-.

- Remove noise insulation panel (arrows).
- Remove front bumper.
- Move lock carrier to service position.
- Remove cover for engine and ribbed belt.

- Rotate tensioner for ribbed belt toward right using box wrench until both holes are in alignment (lower arrows), and secure in place using 3204 drift.
- Remove ribbed belt from generator pulley

Vehicles with air conditioning
(Except 2.7 Liter/84 kW engine, 5V twin-turbo)

- Remove mounting clamp -1- for refrigerant lines above torque arm.

All vehicles

- Detach cable for starter and generator from bracket -1-.

To do this, cut both tie wraps -2- open and then release the snap catches.

- Disconnect air duct from generator fitting -3-.
- Disconnect wire on terminal 30/B+ by removing nut -2-.
Tightening torque: 16 Nm (12 ft lb)
- Disconnect wire on terminal D+ by removing nut -1-.
Tightening torque: 4 Nm (35 in. lb)

- Remove socket head bolt -1- and lock nut -2-.
Tightening torque: 45 Nm (33 ft lb)
- Loosen bolt -3-.
Tightening torque: 22 Nm (16 ft lb)
- Remove generator -4- from below.

CAUTION!
When removing the generator, be careful not to damage the refrigerant lines.

Installing
- To make it easier to install generator onto mount, drive bushing for mounting bolt back approx. 1 mm.
- Install generator in reverse order of removal.

- Make sure ribbed belt is properly seated and correctly routed.

1 - Without air conditioning
2 - With air conditioning