Alternator: Service and Repair

GENERATOR REMOVAL AND INSTALLATION






1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY

CAUTION: Turn the ignition switch to "LOCK". Disconnect the cable from the negative (-) terminal of the battery. Wait at least 90 seconds before proceeding with work.






2. REMOVE BATTERY CLAMP COVER

(a) Remove the clip.
(b) Disconnect the two claws of the battery clamp cover from the hole of the upper radiator support and the end of the No.2 air cleaner hose.






3. REMOVE AIR CLEANER COVER
Disconnect the two clips from the No.2 air cleaner hose by pulling the air cleaner cover, and remove the air cleaner cover.






. REMOVE NO.2 AIR CLEANER HOSE
Remove the bolt and air cleaner hose.






5. REMOVE DRIVE BELT
Loosen the belt tension by turning the drive belt tensioner counterclockwise,and remove the drive belt.

CAUTION: The pulley bolt for the belt tensioner has a LEFT HAND THREAD.

6. REMOVE ENGINE UNDER COVER
7. REMOVE RH REAR ENGINE SIDE UNDER COVER






8. DISCONNECT POWER STEERING (P/S) OIL COOLER PIPE FROM OIL PAN
Remove the three bolts, and disconnect the PS oil cooler pipe from the engine oil pan.






9. REMOVE GENERATOR
(a) Disconnect the generator connector.
(b) Remove the rubber cap and nut, and disconnect the generator wire.
(c) Disconnect the generator wire clamp from the generator.
(d) Remove the bolt and clamp, and disconnect the two oil cooler pipes from the bracket.
(e) Remove the bolt, nut, bracket and generator.






GENERATOR INSTALLATION


1. INSTALL GENERATOR
(a) Install the generator and bracket with the bolt and nut.
Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
(b) Connect the generator connector.
(c) Connect the generator wire with the nut and rubber cap.
(d) Install the generator wire clamp to the generator.
(e) Install the oil cooler pipes with the clamp and bolt.






2. INSTALL POWER STEERING (P/S) OIL COOLER PIPE
Install the PS oil cooler pipe to the engine oil pan with the three bolts.






3. INSTALL DRIVE BELT
Install the drive belt by turning the drive belt tensioner counterclockwise. Timing Components

CAUTION: The pulley bolt for the belt tensioner has a LEFT HAND THREAD.






4. INSTALL NO.2 AIR CLEANER HOSE
Install the air cleaner hose with the bolt.






5. INSTALL AIR CLEANER COVER
(a) Insert the end of the air cleaner cover to the portion of the air cleaner case.
(b) Fit the air cleaner cover to the air cleaner hose with the two clips.






6. INSTALL BATTERY CLAMP COVER
(a) Fit the two claws of the battery clamp cover to the hole of the upper radiator support and the end of the No.2 air cleaner hose.
(b) Install the battery clamp cover with the clip.
7. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
8. PERFORM ON-VEHICLE INSPECTION [1][2]Component Tests and General Diagnostics
9. INSTALL RH REAR ENGINE SIDE UNDER COVER
10. INSTALL ENGINE UNDER COVER