Generators & Regulators: Removal & Installation Kia Sedona I

Removal

Note. When battery is disconnected, vehicle computer may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See appropriate COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

1. Disconnect negative battery cable. (Scheme 7)
2. Remove the 10 rosebud clips that attach the cover assembly upper shroud to the upper radiator support. (Scheme 8)
3. Loosen the clamp securing the air cleaner assembly to the fresh air duct assembly.
4. Remove the fresh air duct assembly. (Scheme 9)
5. Detach wire harness retainers from upper radiator support.
6. Detach hood release cable retainer from upper radiator support. (Scheme 10)
7. Disconnect connectors from both horns.
8. Remove hood latch to upper radiator support bolts.
9. Remove bolts from each end of the upper radiator support and remove support. (Scheme 11)
10. Disconnect electrical connectors from both engine cooling fans.
11. Remove cooling fan bolts and remove both cooling fans from radiator beginning with the driver side fan.
12. Insert a piece of cardboard behind the radiator to protect radiator fins when removing the generator. (Scheme 12)
13. Loosen lock nut on drive belt tensioner pulley. (Scheme 13)
14. From under vehicle, loosen belt tension using adjustment bolt "B". (Scheme 14) NOTE: One generator connector is a male/female connector and the other is a 12 mm nut/bolt connector.
15. Disconnect electrical connections at back of generator. (Scheme 15)
16. Remove generator brace bolts and remove generator brace.
17. Loosen lower mounting bolt from generator. (Scheme 16) NOTE: Lower mounting bolt can interfere with body before clearing generator. Bolt will be removed along with generator.
18. Loosen but do not remove upper mounting bolt.
19. Remove bolts securing upper generator bracket to engine. (Scheme 17)
20. Slide generator straight up until it clears the lower mounting bolt hole, then remove the lower mounting bolt. (Scheme 18) NOTE: Due to tight fit, removal may require shifting the engine to the right so the mounting bolt will clear the body. Loosen the passenger side motor mount if needed. Retighten motor mount after removal.
21. Carefully remove generator by sliding unit to right and lifting from vehicle.

Installation

1. Verify that the cardboard used to protect the radiator is still in place next to the radiator. (Scheme 12) NOTE: Verify that upper mounting bracket is attached and set snug against the body of the generator. Insert, but DO NOT start lower mounting bolt prior to installing generator onto lower mounting bracket. (Scheme 19) Manufacturer does not provide bolt torque specifications.
2. Install and tighten upper generator bracket bolts. (Scheme 17)
3. Install generator brace and brace bolts. Tighten all generator mounting bolts. See «TORQUE SPECIFICATIONS»(ref-153347-S24361747212003040200000).
4. Remove protective cardboard.
5. Install the drive belt. see scheme 22
6. Turn adjustment bolt "B" to set belt tension to specified deflection. (Scheme 14) See «BELT ADJUSTMENT»(ref-153347-S28853711052004092000000) table.
7. Tighten pulley lock nut "A" to specification. (Scheme 14) See «TORQUE SPECIFICATIONS»(ref-153347-S13595391462003040200000).
8. Connect generator electrical connectors. (Scheme 15)
9. Install both cooling fans, beginning with passenger side fan. Reconnect electrical connectors. NOTE: Hoses and cables should be arranged below radiator support prior to installation of support.
10. Install upper radiator support, using caution not to pinch hood release cable in left radiator mount. (Scheme 11)
11. Attach wiring harness retaining clips and hood release cable retainer to upper radiator support.
12. Install bolts securing hood latch to upper radiator support.
13. Connect horn electrical connectors.
14. Install fresh air duct. (Scheme 9)
15. Tighten the clamp securing the air cleaner assembly to the fresh air duct assembly.
16. Attach the upper cover assembly shroud to the upper radiator support using the 10 rosebud clips. (Scheme 8)
17. Connect negative battery cable.

BELT ADJUSTMENT

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Note. When removing solder from rectifier leads, DO NOT use soldering iron for more than 5 seconds. Rectifier may be damaged by excessive heat.