Alternator: Service and Repair

Generator, Removing and Installing


WARNING!
Before working on electrical system, disconnect battery Ground (GND) strap.


NOTE:
- Obtain radio code before disconnecting battery.
- Be sure to activate vehicle features (radio, clock, electric window regulator, engine) when the battery is re-connected.







- Remove cover above the battery (arrows).







- Disconnect battery Ground (GND) strap (arrow) with the ignition switched off.


Vehicles With 6-Cylinder Engine

Vehicles With 2.8L engine

Special Tools and Equipment







- 3204 drift

Removing







- Remove both bolts -1- on air intake channel and pull up on the rear part of the intake channel -2-.







- Remove the sound-proofing material (arrows).
- Bring the lock carrier into service position.

Tensioning roller with hex socket insert:







- Swing ribbed belt tensioner in direction of arrow to release tension on ribbed belt using a 17 mm ring spanner.
- Position tensioning device by inserting 3204 drift into the alignment bore (arrows).

Tensioning roller with socket head:







- Swing ribbed belt tensioner in direction of arrow to release tension on ribbed belt using a socket head wrench (10 mm).
- Position tensioning device by inserting 3204 drift into alignment bore -1- and -2-.

All:
- Remove ribbed belt from generator pulley.







- Remove the air guide -3- at the rear of the generator.
- Unbolt line for terminal 30/B+ -1- from generator.
- Unscrew terminal D+ -2-.







- Unbolt retaining clamp -1- for refrigerant lines above the torque support.







- Cut cable ties -2-, open bracket -1- for starter and generator wire, remove wire.







- Unbolt torque support-1-and stop for torque support -2-.
- Unbolt bracket for refrigerant line.
- Unbolt electrical coolant pump, where installed.







- Remove bolts -1- and -3-.
- Remove generator -4- downward and out.


WARNING!
When removing, refrigerant lines may only be pushed aside very carefully.


Installing
Installation is reverse of removal, noting the following:







- Make sure the ribbed belt is seated and installed correctly.
1 - Generator
2 - Ribbed belt
3 - Power steering vane pump
4 - Viscous fan
5 - A/C compressor
6 - Crankshaft
7 - Tensioner roller
- Start engine and check path of belt.

Tightening torques

Component Nm
Generator to engine M8 22
M10 45
Terminal 30/B+ to generator 16
Terminal D+ to generator 4
Torque support to oil pan (upper part) 40
Torque support stop at chassis 23
Mounting clamp for refrigerant lines 10