Generators & Regulators: Removal & Installation Volvo XC90 I

Removal & Installation (5-Cyl. - B5254T2)

1. Turn ignition to OFF position. Disconnect negative battery cable from battery. See «BATTERY DISCONNECT/CONNECT»(ref-164960-S37086177402004082000000) under TROUBLESHOOTING. Raise and support vehicle.
2. Remove drive belt. See «DRIVE BELT & BELT TENSIONER»(ref-161145-S11141476482004032500000) under REMOVAL & INSTALLATION in SPECIFICATIONS & DRIVE BELT ROUTING article in COOLING SYSTEM (MECHANICAL).
3. Remove power steering pump. See appropriate MANUAL & POWER STEERING article in STEERING. Disconnect turbocharger hose from cooling system. Push hose aside.
4. On vehicles without A/C, remove upper generator mounting screw. (Scheme 2) Remove lower screw. Remove generator.
5. On vehicles with A/C, loosen lower compressor mounting bolts until there is some clearance. (Scheme 3) Disconnect B+ terminal harness. Disconnect 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 harness. Install lower generator bolt (upper bolt for compressor).
7. On vehicles equipped with A/C, tighten 2 lower compressor bolts (M8) to specification. See «TORQUE SPECIFICATIONS»(ref-164960-S12236006142004081900000). On all vehicles, tighten 3 generator bolts (M8) to specification. See «TORQUE SPECIFICATIONS»(ref-164960-S12236006142004081900000).
8. To complete installation, reverse removal procedure. Connect negative battery cable to terminal. See «BATTERY DISCONNECT/CONNECT»(ref-164960-S37086177402004082000000) under TROUBLESHOOTING. Test function.

Scheme 2

Scheme 3

Removal & Installation (6-Cyl. - B6294T)

1. Turn ignition to OFF position. Disconnect negative battery cable from battery. See «BATTERY DISCONNECT/CONNECT»(ref-164960-S37086177402004082000000) under TROUBLESHOOTING. Raise and support vehicle.
2. Remove lower splash guard. Position container under engine drain cock. Loosen drain cock. Drain coolant. Close drain cock. Install lower splash guard. Lower vehicle. Remove upper engine coolant hose.
3. Remove drive belt. See «DRIVE BELT & BELT TENSIONER»(ref-161145-S11141476482004032500000) under REMOVAL & INSTALLATION in SPECIFICATIONS & DRIVE BELT ROUTING article in COOLING SYSTEM (MECHANICAL).
4. Remove power steering pump. See appropriate MANUAL & POWER STEERING article in STEERING. Disconnect turbocharger hose from cooling system. Push hose aside.
5. Ensure lighting switch is off. Pull locking plate straight up. (Scheme 4) Disconnect connector. Detach bumper cover on right-hand side. (Scheme 5) Remove screws from front panel on right-hand side.
6. On vehicles without A/C, remove upper generator mounting screw. (Scheme 2) Remove lower screw. Remove generator.
7. On vehicles with A/C, loosen lower compressor mounting bolts until there is some clearance. (Scheme 3) Disconnect B+ terminal harness. Disconnect harness connector. Remove generator mounting bolts. Carefully pry front panel forward. Pull generator upward and away.
8. To install on all vehicles, position generator. Loosely install upper mounting bolt. Connect B+ terminal harness. Install lower generator bolt (upper bolt for compressor).
9. On vehicles equipped with A/C, tighten 2 lower compressor bolts (M8) to specification. See «TORQUE SPECIFICATIONS»(ref-164960-S12236006142004081900000). On all vehicles, tighten 3 generator bolts (M8) to specification. See «TORQUE SPECIFICATIONS»(ref-164960-S12236006142004081900000).
10. To complete installation, reverse removal procedure. Top off coolant. Connect negative battery cable to terminal. See «BATTERY DISCONNECT/CONNECT»(ref-164960-S37086177402004082000000) under TROUBLESHOOTING. Test function.

Scheme 4

Scheme 5

Removal & Installation (With Fixed Pulley)

1. Remove generator. See «GENERATOR»(ref-164960-S18105285612004081900000).
2. Using wrench (951 2036) hold nut. (Scheme 6) Use twelve toothed dowel (115 9079) on rotor shaft. Remove nut. Remove pulley.
3. To install pulley and nut on vehicles equipped with engine (B5254T2), use ring wrench (951 2036) and twelve point socket (951 2849). (Scheme 7)
4. On vehicles equipped with engine (B6294T), thread pulley onto rotor shaft. Thread nut. Use wrench (951 2036) and twelve toothed dowel (115 9079).
5. On all vehicles, tighten pulley to specification. See «TORQUE SPECIFICATIONS»(ref-164960-S12236006142004081900000). Start vehicle and check belt running and generator operation.

Scheme 6

Scheme 7

Removal & Installation (With Freewheel)

1. Remove generator. See «GENERATOR»(ref-164960-S18105285612004081900000). Remove dust cover.
2. On vehicles equipped with engine (B5254T2), insert special tool (999 5760). (Scheme 8) Insert special tool (951 2849).
3. On Vehicles equipped with engine (B6294T), insert special tool (999 5760). (Scheme 7) Insert twelve toothed dowel (115 9080).
4. On all vehicles, disconnect pulley from rotor shaft. Remove pulley. Test pulley. See «GENERATOR BELT PULLEY»(ref-164960-S40865898762004081900000) under BENCH TESTING.
5. To install, reverse removal procedure. Tighten pulley to specification. See «TORQUE SPECIFICATIONS»(ref-164960-S12236006142004081900000). Test pulley. See «GENERATOR BELT PULLEY»(ref-164960-S11087834732004081900000) under ON-VEHICLE TESTING. Start vehicle and check belt running and generator operation.

Scheme 8