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How to Replace (Without Air Conditioning) the Alternator Opel Vivaro A

Engine Electrics 4 illustrations ~510 words

Remove

  1. 1. Disconnect battery negative lead
  2. 2. Release fluid reservoir for power steering from upper front panel • Release clip, then pull upwards
  3. 3. For M9R 630 engine, remove intercooler pipe (1) from vehicle • Release 2x clip (2)
  1. 4. For M9R 780, M9R 782, M9R 784, M9R 786 or M9R 788 engine, remove intercooler pipe (1) from vehicle • Release 3x clip (2) • Disconnect harness connector (3) • Release charge pressure sensor from support frame – Pull off
  1. 5. Raise vehicle
  2. 6. Remove engine and transmission undershield from vehicle • Remove 8x bolt
  3. 7. Remove splash panel, right side • Release washer hose (if installed) from 2x clip • Remove 2x bolt, screw
  1. 8. Remove ribbed V-belt from engine • Rotate tension roller clockwise, then lock using Locating Pin KM-6130 (1)
  1. 9. Rotate tension roller clockwise, then remove locating pin KM-6130
  2. 10. Remove tension roller (1) from engine • Remove 2x bolt (2)
  3. 11. Remove guide roller (4) from engine • Remove cover (3) • Remove bolt
  1. 12. Disconnect positive lead from alternator • Remove nut
  2. 13. Release alternator from auxiliary support bracket • Release lower bolt

Note. The lower bolt cannot be removed at this stage.

  1. 14. Lower vehicle
  2. 15. Release alternator (3) from auxiliary support bracket (2) • Remove bolt (1)
  1. 16. Reposition alternator from auxiliary support bracket
  2. 17. Remove lower bolt from alternator
  3. 18. Disconnect harness connector (2) from alternator (1)
  1. 19. Remove alternator from engine compartment

Install

  1. 20. Install new alternator to engine compartment
  2. 21. Connect harness connector (2) to alternator (1)
  1. 22. Install lower bolt to alternator; do not tighten at this stage
  2. 23. Position alternator to auxiliary support bracket
  3. 24. Secure alternator (3) to auxiliary support bracket (2) • Install bolt (1) 25 Nm
  1. 25. Raise vehicle
  2. 26. Secure alternator to auxiliary support bracket • Secure lower bolt 25 Nm
  3. 27. Connect positive lead to alternator • Install nut
  4. 28. Install new guide roller (4) to engine • Install bolt 44 Nm • Install cover (3)
  5. 29. Install new tension roller (1) to engine • Install 2x bolt (2) 25 Nm
  1. 30. Rotate tension roller clockwise, then lock using Locating Pin KM-6130
  2. 31. Install new ribbed V-belt to engine • Rotate tension roller clockwise, then remove Locating Pin KM-6130 (1)
  1. 32. Install splash panel, right side • Install 2x bolt 8 Nm , screw 6 Nm • Secure washer hose (if Installed) to 2x clip
  1. 33. Install engine and transmission undershield to vehicle • Install 8x bolt 8 Nm
  2. 34. Lower vehicle
  3. 35. For M9R 630 engine, install intercooler pipe (1) to vehicle • Secure 2x clip (2)
  1. 36. For M9R 780, M9R 782, M9R 784, M9R 786 or M9R 788 engine, install intercooler pipe (1) to vehicle • Secure 3x clip (2) • Secure charge pressure sensor to support frame – Push on • Connect harness connector (3)
  1. 37. Secure fluid reservoir for power steering to upper front panel • Secure to clip
  2. 38. Connect battery negative lead
  3. 39. Program all volatile memories

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