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Generators & Regulators - Testing & Specifications: Removal & Installation Volvo S80 I

Charging System 6 illustrations ~586 words

Removal & Installation

  1. Turn ignition to OFF position. Disconnect negative battery cable from battery. See «BATTERY DISCONNECT/CONNECT»(ref-165022-S02040893862004082400000) under TROUBLESHOOTING. Raise and support vehicle.
  2. Remove drive belt. See appropriate procedure under «REMOVAL & INSTALLATION»(ref-161143-S07862303862004040100000) in SPECIFICATION & DRIVE BELT ROUTING article in COOLING SYSTEM (MECHANICAL).
  3. Remove power steering pump. See appropriate MANUAL & POWER STEERING article in STEERING.
  4. On vehicles with A/C, go to next step. On vehicles without A/C, remove upper generator mounting bolt. (Scheme 2) Remove lower bolt. Remove B+ terminal nut and cable. Disconnect generator harness connector. Remove generator.
  5. On vehicles with A/C, loosen lower compressor mounting bolts until there is clearance. (Scheme 3) Disconnect B+ terminal nut and cable. Disconnect generator harness connector. Remove generator mounting bolts. Carefully pry front panel forward. Pull generator upward and away.
  6. To install on all vehicles, position generator. Loosely install upper mounting bolt. Connect B+ terminal nut and cable. Connect generator harness connector. Install lower generator bolt (upper bolt for A/C compressor).
  7. On vehicles equipped with A/C, tighten 2 lower compressor bolts to specification. See «TORQUE SPECIFICATIONS»(ref-165022-S19748487232004082000000). On all vehicles, tighten 3 generator bolts to specification. See «TORQUE SPECIFICATIONS»(ref-165022-S19748487232004082000000).
  8. To complete installation, reverse removal procedure. Before connecting battery, read procedure thoroughly. See «BATTERY DISCONNECT/CONNECT»(ref-165022-S02040893862004082400000) under TROUBLESHOOTING. Connect negative battery cable to terminal. Start vehicle and check belt running and generator operation.

Scheme 2

Scheme 2
Scheme 2

Scheme 3

Scheme 3
Scheme 3

Removal & Installation (With Fixed Pulley)

  1. Remove generator. See «GENERATOR»(ref-165022-S08175594892004082000000).
  2. Using wrench (951 2036) hold nut. (Scheme 4) Use twelve toothed dowel (115 9079) on rotor shaft. Remove nut. Remove pulley.
  3. To install, thread pulley onto rotor shaft. Thread nut. Use wrench (951 2036) and twelve toothed dowel (115 9079).
  4. On all vehicles, tighten pulley to specification. See «TORQUE SPECIFICATIONS»(ref-165022-S19748487232004082000000). Start vehicle and check belt running and generator operation.

Scheme 4

Scheme 4
Scheme 4

Removal & Installation (With Freewheel)

  1. Remove generator. See «GENERATOR»(ref-165022-S08175594892004082000000). Remove dust cover.
  2. Insert special tool (999 5760). (Scheme 5) Insert twelve toothed dowel (115 9080).
  3. Disconnect pulley from rotor shaft. Remove pulley. Test pulley. See «GENERATOR BELT PULLEY»(ref-165022-S40133785702004082000000) under BENCH TESTING.
  4. To install, reverse removal procedure. Tighten pulley to specification. See «TORQUE SPECIFICATIONS»(ref-165022-S19748487232004082000000). Test pulley. See «GENERATOR BELT PULLEY»(ref-165022-S24773947782004082000000) under ON-VEHICLE TESTING. Start vehicle and check belt running and generator operation.

Scheme 5

Scheme 5
Scheme 5
  1. Turn ignition to OFF position and remove key. Remove drive belt. See appropriate procedure under «REMOVAL & INSTALLATION»(ref-161143-S07862303862004040100000) in SPECIFICATION & DRIVE BELT ROUTING article in COOLING SYSTEM (MECHANICAL). On vehicles equipped with 6-cylinder engine, remove generator. See «GENERATOR»(ref-165022-S08175594892004082000000).
  2. On all vehicles, use wrench (951 2036) to hold nut. (Scheme 6) Use twelve point socket (951 2849) on rotor shaft. Remove nut. Remove pulley.
  3. To install, thread pulley onto rotor shaft. Thread nut. Use wrench (951 2036) and twelve point socket (951 2849). Tighten pulley to specification. See «TORQUE SPECIFICATIONS»(ref-165022-S19748487232004082000000).
  4. To complete installation, reverse removal procedure. Start vehicle and check belt running and generator operation.

Scheme 6

Scheme 6
Scheme 6
  1. Turn ignition to OFF position and remove key. Remove drive belt. See appropriate procedure under «REMOVAL & INSTALLATION»(ref-161143-S07862303862004040100000) in SPECIFICATION & DRIVE BELT ROUTING article in COOLING SYSTEM (MECHANICAL). On vehicles equipped with 6-cylinder engine, remove generator. See «GENERATOR»(ref-165022-S08175594892004082000000).
  2. Insert counterhold (999 5760). (Scheme 7) Insert twelve toothed wrench (951 2849). Disconnect pulley from rotor shaft. Remove pulley.
  3. To install, thread pulley onto rotor shaft. Thread nut. Use counterhold (951 5760) and twelve tooth wrench (951 2849). Tighten pulley to specification. See «TORQUE SPECIFICATIONS»(ref-165022-S19748487232004082000000).
  4. To complete installation, reverse removal procedure. Start vehicle and check belt running and generator operation.

Scheme 7

Scheme 7
Scheme 7

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