Removal and Replacement

Generator:

GENERATOR

REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

2. REMOVE ENGINE UNDER COVER (for 2WD)
3. REMOVE ENGINE UNDER COVER (for 4WD)
4. REMOVE COOL AIR INTAKE DUCT SEAL
5. REMOVE ENGINE ROOM SIDE COVER LH
6. REMOVE ENGINE ROOM SIDE COVER RH
7. REMOVE V-BANK COVER
8. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
9. REMOVE NO. 1 AIR CLEANER INLET
10. DRAIN ENGINE COOLANT
11. REMOVE RADIATOR RESERVOIR ASSEMBLY
12. REMOVE V-RIBBED BELT

13. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY

a. Remove the bolt, pulley cover plate and idler pulley.

14. REMOVE COMPRESSOR ASSEMBLY
a. Remove the compressor with pulley for 2WD or 4WD.

15. REMOVE GENERATOR ASSEMBLY

a. Detach the clamp, and remove the bolt from the generator.
b. Disconnect the generator connector.
c. Detach the rubber cap, and then remove the nut and battery cable.

d. Remove the nut, bolt and generator bracket.

e. Remove the 2 bolts and generator.

INSTALLATION

1. INSTALL GENERATOR ASSEMBLY

a. Install the generator with the 2 bolts.

Torque: 43 N.m (438 kgf.cm, 32 ft.lbf)

b. Install the bracket with the bolt and nut.

Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)

c. Install the battery cable with the nut.

Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)

d. Install the bracket of the wire harness to the generator with the bolt.
e. Attach the clamp of the wire harness to the generator.
f. Connect the cable to the generator, and then attach the rubber cap.

2. INSTALL COMPRESSOR ASSEMBLY
a. Install the compressor with pulley for 2WD or 4WD.

3. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

a. Install the idler pulley and pulley cover plate with the bolt.

Torque: 43 N.m (438 kgf.cm, 32 ft.lbf)

4. INSTALL V-RIBBED BELT
5. INSTALL RADIATOR RESERVOIR ASSEMBLY
6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
7. ADD ENGINE COOLANT
8. INSPECT FOR COOLANT LEAK
9. CHARGE REFRIGERANT
10. INSTALL NO. 1 AIR CLEANER INLET
11. WARM UP ENGINE
12. CHECK FOR LEAKAGE OF REFRIGERANT
13. INSTALL V-BANK COVER
14. INSTALL ENGINE ROOM SIDE COVER RH
15. INSTALL ENGINE ROOM SIDE COVER LH
16. INSTALL COOL AIR INTAKE DUCT SEAL
17. INSTALL ENGINE UNDER COVER (for 4WD)
18. INSTALL ENGINE UNDER COVER (for 2WD)

19. PERFORM INITIALIZATION
a. Perform initialization.

NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.