Contents: Removal ⬇ Installation ⬇
Removal
1. Open the hood.
2. Disconnect the battery terminals.
Note: On vehicles from 2004 onwards with stability control, the steering wheel angle sensor loses its basic setting after each battery disconnection and must be recalibrated.
Remove the ground wire.
Disconnect the exhaust pipe from the end panel.
Remove the front wheel on the right.
Raise the car.
Remove the right front wheel.
Unscrew the 4 mounting bolts.
Raise the car.
Remove the air duct on the right.
Unscrew the 3 mounting bolts (arrows).
Remove the poly V-belt cover.
Unscrew 3 mounting bolts 1.
Remove clamp 2.
Remove the poly V-belt.
Note: Indicate the direction of rotation.
Tension the poly V-belt tensioner using tool KM-913-A 2 in the direction of the arrow.
Insert the KM-61301 tool.
Lower the car.
Remove the engine cover.
Unscrew the oil filler pipe in the cover.
Unscrew the 2 mounting bolts.
Screw the oil filler neck into the cap.
Remove the air filter housing 1.
Disconnect 2 connectors of the wire harness of the hot-film air flow meter 4, tank ventilation valve 2.
Remove the tank vent valve from the clamps.
Remove the suction hose.
Remove the engine ventilation hose 3.
Unscrew the screw (arrow).
Remove the wiring harness fastener from the generator trim plate.
Remove the evaporative fuel hose.
Remove the pressure plate from the generator.
Remove ground wire 1 – unscrew nut 2.
Remove support screw 3.
Unscrew 2 mounting bolts 4, 5.
Raise the car.
Remove the poly V-belt tensioner.
Tighten the poly V-belt tensioner.
Remove the KM-6130 2 tool.
Loosen the tension in the poly V-belt tensioner.
Unscrew screw 1.
Disconnect 2 connectors of the lambda sensor wire harness, catalytic converter control unit 4, oil pressure relay 3.
Release the generator mountings.
Disconnect the generator bracket - unscrew the 2 mounting bolts at the top 1.
Unscrew nut 2.
Remove the generator bracket.
Unscrew the screw.
Remove the generator screw.
Remove the retaining clip, brake line and fuel line.
Remove the generator.
Remove the generator wiring harness - unscrew 2 nuts 1.
Remove the generator through the wheel well.
Installation
Install the generator.
Insert the generator.
Install the generator wiring harness.
Screw in 2 nuts.
Insert the generator bracket.
Insert the generator screw.
Tighten the fastening nut.
Tighten the adjusting screw.
Insert the mounting clamp.
Lower the car.
Install the generator pressure plate.
Remove the ground wire.
Tighten the mounting nut, 2 mounting bolts, tighten the support bolt to 20 Nm.
Attach the wiring harness bracket.
Tighten the screw to 20 Nm.
Raise the car.
Secure the generator.
Tighten the mounting nut to 35 Nm.
Secure the generator bracket – tighten the 2 mounting bolts to 35 Nm.
Connect the 2 wire harness connectors.
Install the poly V-belt tensioner.
Tighten the screw (35 Nm).
Tighten the poly V-belt tensioner using the KM-913-A tool.
Insert the KM-6130 tool.
Install the poly V-belt.
Note: Observe the direction of rotation and installation position.
Loosen the tension of the poly V-belt tensioner using the KM-913-A tool.
Remove KM-6130.
Secure the outlet pipe in the clamp.
Install the poly V-belt cover.
Tighten the 3 mounting bolts.
Insert the clamp.
Install the air duct on the right.
Tighten the 3 mounting bolts.
Lower the car.
Install the right front wheel.
Tighten the 4 mounting bolts.
Lower the car.
Secure the right front wheel.
Tighten the 4 mounting bolts to 110 Nm.
Install the air filter housing.
Tighten the screw.
Install the suction hose.
Install the engine ventilation hose.
Secure the tank vent valve.
Connect the 2 wire harness connectors.
Install the engine cover.
Unscrew the oil filler pipe in the cover.
Insert the retaining tabs.
Tighten the screws (8 Nm).
Screw the oil filler neck into the cap.
Connect the battery to the terminals.
Calibrate the steering wheel angle sensor.
Turn on the ignition.
Move the steering wheel from the far right position to the far left position once.
Program volatile memory.
Close the hood.
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