REMOVAL & INSTALLATION
| WARNING | Vehicles are equipped with air bag supplemental restraint system. Before attempting any repairs involving steering column, instrument panel or related components, see SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM in appropriate AIR BAG RESTRAINT SYSTEMS article. |
Removal & Installation (1.8L - ATC & AWP)
- Disconnect harness connector at throttle valve control module (J388), and charge pressure sender (G31). Disconnect air hose (1) at throttle valve control module. (Scheme 2) Disconnect vacuum hose (2) connecting charcoal filter-to-throttle valve control module at throttle valve control module.
- Unscrew nut (2), and pull out activated charcoal filter (3) from top. (Scheme 3) Place activated charcoal filter on engine cover panel.
- Using chalk or felt pen, mark serpentine belt direction of rotation. To loosen belt, turn tensioning element in direction of arrow. (Scheme 4)
- On vehicles without headlight washer system, secure tensioner with special tool (3090). (Scheme 5) On all other vehicles, tensioner may be secured with a mandrel (4.5 mm diameter and 55 mm long). On all vehicles, remove belt.
- Remove nut (1) from terminal 30/B+ connection. (Scheme 6) Disconnect electrical connector (2). Remove harness retainer (3). Remove M8 hex bolts connecting generator to bracket. Lift generator out from engine compartment.
- To install, reverse removal. Ensure belt is correctly routed and properly seated. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(ref-139129-S09205685402002042500000).
Scheme 2
Scheme 3
Scheme 4
Scheme 5
Scheme 6
Removal & Installation (1.8L - AMU & BEA)
- Remove right engine compartment trim pieces (arrows). (Scheme 7) Push clamp pin through expanding clip, and remove clip from trim. Release securing clip (3) to release trim (4). (Scheme 8)
- Unscrew nut (2), and pull out activated charcoal filter (3) from top. (Scheme 3) Place activated charcoal filter on engine cover panel.
- Loosen hose clamp (1), and pull hose (2) from intake pipe. (Scheme 8) Lay hose over to right.
- Using chalk or felt pen, mark serpentine belt direction of rotation. To loosen belt, turn tensioning element in direction of arrow. (Scheme 4)
- Tensioner may be secured with a mandrel (4.5 mm diameter and 55 mm long). On vehicles without headlight washer system, secure tensioner with special tool (3090). (Scheme 5) Remove belt.
- For better access to electrical connections on generator, loosen hex bolts (1), and slightly swivel bracket (2) upwards. (Scheme 9)
- Unscrew nut, and disconnect terminal 30/B+ wire (2). (Scheme 10) Unplug terminal 61 connector (1). Loosen two generator securing bolts, and lift out generator.
- To install, reverse removal. Ensure belt is correctly routed and properly seated. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(ref-139129-S09205685402002042500000).
Scheme 7
Scheme 8
Scheme 9
Scheme 10
Removal & Installation (With Freewheel)
- Remove generator. See «GENERATOR»(ref-139129-S32581917232002042500000). Using Adapter (3400), counter-hold securing nut. Turn generator shaft clockwise to remove.
- To install, turn generator shaft counterclockwise. (Scheme 11) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-139129-S09205685402002042500000). Clip protective cap onto freewheel pulley.
Scheme 11
Removal & Installation (Without Freewheel)
- Remove generator. See «GENERATOR»(ref-139129-S32581917232002042500000). Using Socket (3310), counter-hold securing nut. (Scheme 12) Turn generator shaft clockwise to remove.
- To install, turn generator shaft counterclockwise. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-139129-S09205685402002042500000).
Scheme 12
