Generator Replacement 1.6L

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Remove the air cleaner hose.
3. Slide the Evaporative Emission (EVAP) canister from the mounting bracket at the inner fender.
4. Remove the generator electrical connector (1) from the back of the generator.
5. Remove the rubber protector, the nut and the generator battery terminal wire from the generator battery terminal.



6. Remove the upper and lower generator mounting bolts (3).
7. Remove the generator from the vehicle while disengaging the drive belt from the generator pulley.

1. Install the generator to the vehicle.
2. Install the upper and lower generator mounting bolts (3) finger tight.
3. Install the drive belt to the generator pulley.



4. Adjust the drive belt tension to obtain the specified deflection with 10 kg (22 lbs) of force applied.

Used Drive Belt Deflection
6 to 8 mm (0.24 to 0.31 inch)

New Drive Belt Deflection
5 to 7 mm (0.20 to 0.27 inch)

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

5. Tighten the upper and lower generator mounting bolts.

Tighten
Tighten the generator mounting bolts to 23 N·m (17 lb ft).

6. Install the generator electrical connector to the back of the generator.
7. Install the generator battery terminal wire. Secure the battery terminal wire with one nut.

Tighten
Tighten the generator battery terminal retaining nut to 10 N·m (89 lb in).

8. Install the rubber protector over the generator battery terminal.
9. Install the EVAP canister to the mounting bracket at the inner fender.
10. Install the air cleaner hose.
11. Connect the negative battery cable.

Tighten
Tighten the negative battery cable-to-negative battery terminal retainer to 15 N·m (11 lb ft).

Generator Replacement 2.0L

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Remove the air cleaner hose.
3. Remove the drive belt from the generator pulley. Refer to Generator and Air Conditioning Compressor and Power Steering Pump Belt Replacement in Engine Mechanical.
4. Disconnect the power steering pressure switch connector.
5. Disconnect the generator electrical connector.
6. Remove the rubber protector, the nut and the electrical connector from the generator B+ terminal.
7. Remove the 2 vacuum lines from the top of the EVAP canister.
8. Slide the EVAP canister from the bracket on the inner fender and position aside.
9. Remove the upper and lower generator mounting bolts.
10. Remove the generator from the vehicle.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1. Install the generator to the vehicle. Secure the generator with the upper and lower mounting bolts.

Tighten
Tighten the generator mounting bolts to 23 N·m (17 lb ft).

2. Connect the electrical connector to the generator B+ terminal. Secure the connector with one nut and the rubber protector.

Tighten
Tighten the electrical connector nut to 10 N·m (89 lb in).

3. Connect the generator electrical connector.
4. Connect the power steering pressure switch connector.
5. Slide the EVAP canister into the bracket on the inner fender.
6. Connect the 2 vacuum lines to the top of the EVAP canister.
7. Install the drive belt to the generator pulley. Refer to Generator and Air Conditioning Compressor and Power Steering Pump Belt Replacement in Engine Mechanical.
8. Install the air cleaner hose.
9. Connect the negative battery cable.

Tighten
Tighten the negative battery cable-to-negative battery terminal retainer to 15 N·m (11 lb ft).

Generator Replacement 2.5L

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Remove the air cleaner hose.
3. Disconnect the generator electrical connector.
4. Remove the rubber protector, the nut and the electrical connector from the generator B+ terminal.



5. Remove the adjusting bolt (1) and pivot bolt (2) and move the generator (3) aside.
6. Remove the bolts and the upper generator bracket.
7. Remove the generator from the vehicle.

1. Install the generator to the vehicle.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the generator upper bracket to the vehicle. Secure the generator bracket with the bolts.

Tighten
Tighten the generator upper bracket bolts to 45 N·m (32 lb ft).





Important: Do not torque the bolts until the drive belt tension is correct.

3. Install the adjusting bolt (1) and pivot bolt (2) to the generator.
4. Install the drive belt to the pulleys.
5. Remove slack from the belt by pulling on the generator in order to obtain 9-11 mm (0.35- 0.43 in) of belt deflection under 10 kg (22 lbs) of force.
6. Secure the generator with the adjusting bolt and pivot bolt.

Tighten
Tighten the generator bolts to 23 N·m (17 lb ft).

7. Connect the electrical connector to the generator B+ terminal. Secure the connector with one nut and the rubber protector.

Tighten
Tighten the electrical connector nut to 8 N·m (71 lb in).

8. Connect the generator electrical connector.
9. Install the air cleaner hose.
10. Connect the negative battery cable.

Tighten
Tighten the negative battery cable-to-negative battery terminal retainer to 8 N·m (71 lb in).