Alternator: Service and Repair

Removal
1. Disconnect battery ground cable.
2. Remove alternator drive belt.
3. Remove upper adjusting bolt.
4. Remove connector from B+ terminal by removing retaining nut.
5. Raise vehicle on a hoist.
6. Disconnect voltage regulator connector.
7. On naturally aspirated vehicles, perform the following:
a. Remove RH wheel and tire assembly.
b. Remove RH ball joint clamp bolt.
c. Separate knuckle from ball joint.





d. Pull halfshaft out of transaxle and position as shown.

CAUTION: Use care not to damage oil seal.





8. Remove retaining nuts and separate catalytic converter from front exhaust pipe. Disconnect two rubber exhaust hangers and lower exhaust assembly. Wire exhaust assembly into position as shown.
9. Remove alternator through bolt.





10. Carefully move alternator to the LH side of the vehicle and remove alternator between transaxle and catalytic converter.




Installation

1. Install alternator in vehicle.
2. Install alternator through bolt.
3. Connect voltage regulator connector.
4. Connect catalytic converter to front exhaust pipe. Tighten nuts.
5. Connect rubber exhaust hangers.
6. On naturally aspirated vehicles, perform the following:
a. Install new circlip on halfshaft.
b. Position halfshaft into transaxle and align splines.
c. Push inward on knuckle assembly until halfshaft is fully seated in transaxle.
d. Position ball joint into knuckle assembly.
e. Install ball joint clamp bolt. Tighten to 43-54 Nm (32-40 lb-ft).
f. Install RH wheel and tire assembly.
7. Lower vehicle.
8. Connect B+ terminal and install retaining nut.
9. Install upper adjusting bolt.
10. Install alternator drive belt and adjust tension.
11. Connect battery ground cable.