TESTING
Note. Charge indicator lamp in the combined instrument panel is controlled by the driver information module via signals from the Controller area network. Check indicator according to wiring diagram. See WIRING DIAGRAMS .
PRELIMINARY INSPECTION
Verify customer complaint by operating system. Visually inspect for obvious signs of mechanical and electrical damage. Check generator belt tension and condition. Ensure that battery voltage is within specifications. Inspect for blown fuses and damaged relays. For fuse and/or relay identification, see WIRING DIAGRAMS .
Verify ground connection integrity between engine, body, battery and generator. Check for damaged wiring harnesses and/or switches. Check for a broken or partially broken wire inside insulation, which could cause system malfunction but prove good in a continuity/voltage check with system disconnected. Ensure any aftermarket electronic equipment is properly installed. If fault is found, repair as necessary. If no fault is found, check for conditions that might cause an intermittent situation.
- Turn ignition to OFF position. Disconnect negative battery cable from battery. See «BATTERY DISCONNECT/CONNECT»(ref-165023-S16470739112004082400000) under TROUBLESHOOTING.
- Remove air intake pipe between air cleaner housing and front panel. Remove vacuum valve from fan shroud. (Scheme 2) Remove air vent hose from control module box.
- Remove first section of right-hand charge air (intercooler) pipe. Remove ties holding wiring to fan shroud. Lift out hose for expansion tank from holders on top of fan shroud.
- Disconnect engine cooling fan harness connectors. On vehicles equipped with automatic transmission, remove upper oil cooler hose on oil cooler.
- On all vehicles, remove fan shroud bolts. Carefully lift up engine cooling fan, and remove.
- To install, reverse removal procedure.
Scheme 2
- Turn ignition to OFF position. Disconnect negative battery cable from battery. See «BATTERY DISCONNECT/CONNECT»(ref-165023-S16470739112004082400000) under TROUBLESHOOTING. Raise and support vehicle.
- On vehicles equipped with turbo engine, remove air intake between radiator and air cleaner housing. Remove charge air (intercooler) pipe over engine. (Scheme 3)
- On all vehicles, remove engine cooling fan. See «ENGINE COOLING FAN»(ref-165023-S10851534332004082400000). Remove charge air (intercooler) pipe from cooling system.
- On all vehicles, remove drive belt. For 2001 models, see «DRIVE BELT/BELT TENSIONER»(ref-161142-S14927310392004032500000) under REMOVAL & INSTALLATION in COOLING SPECIFICATIONS & DRIVE BELT ROUTING article in COOLING SYSTEM (MECHANICAL). For 2002-04 models, see «DRIVE BELT/BELT TENSIONER»(ref-161203-S28066364532004032500000) under REMOVAL & INSTALLATION in COOLING SPECIFICATIONS & DRIVE BELT ROUTING article in COOLING SYSTEM (MECHANICAL).
- On vehicles with A/C, go to next step. On vehicles without A/C, remove upper generator mounting bolt. (Scheme 4) Remove lower bolt. Remove B+ terminal nut and cable. Disconnect generator harness connector. Remove generator.
- On vehicles with A/C, loosen lower compressor mounting bolts until there is clearance. (Scheme 5) Disconnect B+ terminal nut and cable. Disconnect generator harness connector. Remove generator mounting bolts. Carefully pry front panel forward. Pull generator upward and away.
- To install on all vehicles, position generator. Loosely install upper mounting bolt. Connect B+ terminal cable and nut. Install lower generator bolt (upper bolt for compressor).
- On vehicles equipped with A/C, tighten 2 lower compressor bolts to specification. See «TORQUE SPECIFICATIONS»(ref-165023-S06711441702004082000000). On all vehicles, tighten 3 generator bolts to specification. See «TORQUE SPECIFICATIONS»(ref-165023-S06711441702004082000000).
- To complete installation, reverse removal procedure. Before connecting battery, read battery disconnect/connect procedure thoroughly. See «BATTERY DISCONNECT/CONNECT»(ref-165023-S16470739112004082400000) under TROUBLESHOOTING. Connect negative battery cable to terminal. Start vehicle and check belt running and generator operation.
