Alternator: Service and Repair

Removal
1. Open the driver's door, or both doors if necessary, to allow the side windows to drop. Ensure that the doors remain open until after the battery has been disconnected.







2. Disconnect the battery ground cable. Remove the battery cover.
3. Remove the air cleaner assembly (including fit body paintwork protection sheets to the adjacent working area).
4. Remove the fan and motor assembly from behind the radiator.
- Check that the belt wear indicator is within the limit marks.
- Raise the vehicle on a ramp.







5. Remove the air intake ducting from the generator. The ducting comprises two sections; each is retained by two screws and a clip.







6. 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 bolt of the belt tensioner idler pulley, to turn the adjuster 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 slowly and remove the spanner.
- Disconnect the belt from the other pulleys, as necessary, to move it clear of the generator.







7. Disconnect the generator harness.
(1) Disconnect the harness multi-plug.
(2) Remove the protective boot from the positive terminal, remove the terminal nut and disconnect the cable from the terminal. Disconnect the suppressor module positive cable from the positive terminal.
(3) Remove the nut which secures the suppression module negative cable and disconnect the cable from the generator. Reposition the suppression module harness clear of the generator.







8. Remove the lower mounting bolt.







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







10. Carefully, manoeuvre the generator forward towards the radiator.







11. Change the position of the generator and remove it upwards between the engine and the radiator.


Installation







1. Move the spacing bush rearwards 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.







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







3. Fit the generator lower mounting.
(1) From below, reposition and align the harness clip to the generator lower mounting.
(2) Fit the lower mounting bolt and nut, tighten to 38-48 Nm.







4. Connect the harness.
(1) Reposition the suppression 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 & main positive cable to the generator positive terminal.
(3) Fit the boot to the terminal.
(4) Reconnect the generator harness multi-plug.
5. Lower the vehicle on the ramp.
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.
9. Refit the air cleaner assembly.
10. Reconnect the battery Service and Repair