Alternator: Service and Repair

GENERATOR

REMOVAL

1. CAUTION: The generator must be protected from contamination. Failure to follow this instruction may cause premature failure of the generator.

Protect the generator with lint-free material to prevent contamination.

2. Remove the fuel pressure sensor.
3. Remove the accessory drive belt.
4. Lower the vehicle.







5. Remove the coolant expansion tank retaining bolt.







6. Disconnect the coolant expansion tank from the retaining clip and position aside.







7. Disconnect the power steering reservoir and position aside.







8. Disconnect and remove the engine wiring harness.







9. Remove the ground cable.







10. Disconnect the electrical connector and remove the evaporative emission canister purge valve.







11. Disconnect the vacuum lines from the evaporative emission canister purge valve.







12. Disconnect the lower evaporative emission canister vacuum line and remove the evaporative emission canister purge valve.







13. Disconnect the cylinder head temperature (CHT) sensor electrical connector.







14. Disconnect the ground cable and remove the engine lifting eye.







15. Disconnect the ground cable.







16. NOTE: Mark the position of the engine mount.

Remove the front engine mount retaining bolts.







17. Slide the engine towards the front of the vehicle and reinstall one of the bolts into the rear bolt hole to prevent the engine moving backwards.







18. Disconnect the generator electrical connectors.
- Remove the protective cap (if equipped).







19. Remove the generator bolt.







20. NOTE: The bolt must be fully disengaged from the bracket although it is not possible to remove the bolt at this stage.

Unscrew the generator bolt fully.







21. Remove the generator.
- Remove the bolt from the generator.

INSTALLATION



























1. NOTE: To aid installation, slide back the generator locking sleeves.

To install, reverse the removal procedure.