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 2.7L biturbo-engine







- 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.
- Remove front bumper.

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 both hose clamps -1- and remove hose -2- to charge air cooler downward and out.







- Unbolt line for terminal 30/B+ -2- from generator.
- Disconnect harness connector terminal D+ -1-.

Vehicles with automatic transmission







- Loosen ATF-lines, loosen bolt -1- to do so.

All:
- Loosen A/C lines, loosen bolt -2- to do so.
- Remove tube -5-, to do so remove bolts -3- and loosen hose clamps -4-.







- Remove bolts -1-.
- Remove socket head bolt -2-.
- Remove generator downward and out.

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
Mounting clamp for refrigerant lines 10
Bracket for ATF-lines 10
Hose clamps for air guide hoses 3.5