Cars with F engines
Removal
- Disconnect the cable from the negative terminal of the battery.
- Disconnect all electrical connectors from the generator.
- Disconnect the connector from the knock sensor.
- Disconnect the connector from the ignition coils.
- Loosen the tension on the generator drive belt by unscrewing the bolt securing the tension roller (pic. 15.3).
- Unscrew the bolt (2, fig. 15.3), nut and bolt (3) and remove the generator.
Pic. 15.3. Mounting elements for the generator on engine F: 1 - tension roller mounting bolt; 2 - generator mounting bolt; 3 - nut and bolt securing the generator
Installation
- Installation of the generator is carried out in the reverse order of removal.
- Adjust the belt tension. Do not install the previously removed belt, replace it with a new one.
Cars with Z engines
Removal
- When removing the generator, first remove the windshield washer fluid reservoir and lower the air conditioning compressor down.
- Place the vehicle on a two-post lift and disconnect the cable from the negative terminal of the battery.
Pic. 15.4. Location of the bolts for fastening the auxiliary equipment drive belt tensioning elements: A - bolts securing the tension roller of the generator drive belt; C - tension roller adjusting bolt; E - adjusting bolt of the water pump/air conditioning compressor drive belt; F - bolts securing the tension roller of the water pump/air conditioning compressor drive belt; G - air conditioning compressor mounting bolts
- Disconnect the connector and remove the injection system control unit along with the bracket.
- Remove the right front wheel, mudguard and under-engine skid plates.
- Loosen two bolts (A. fig. 15 4) fastening the tension roller of the generator drive belt.
- Loosen the adjusting bolt at the top (WITH) tension roller.
- Unscrew the nut of the upper mounting of the generator. On the right side of the front cylinder head, remove the air conditioning hose bracket.
- Remove the generator drive belt.
- Loosen the adjusting screw (E) air conditioning compressor drive belt.
- Loosen the locknut of the adjusting screw and turn it back as far as possible.
- Loosen two bolts (F) fastening the tension roller of the air conditioning compressor drive belt.
- Remove the air conditioning compressor drive belt.
- Remove the oil filter.
- Remove the 4 bolts securing the air conditioning compressor.
- Remove the compressor from the bracket and move it to the side without disconnecting the hoses from it.
- Disconnect all electrical connectors from the generator.
- Unscrew the nut of the lower mounting of the generator.
- Remove the windshield washer fluid reservoir.
- Disconnect the connector from the pump.
- Mark the location and disconnect the two tubes.
- Unscrew the bottom bolt securing the tank.
- Lower the car.
- Unscrew the top bolt securing the tank.
- Remove the reservoir with pump from the car.
- Remove the bolt from the top mounting of the generator.
- Raise the car and remove the generator, while raising the tension roller as much as possible.
Installation
- Installation of the generator is carried out in the reverse order of removal.
- To make it easier to screw on the generator upper mounting nut, install the generator with two bolts pre-installed on it.
- Install the air conditioning compressor onto the two bolts without tightening them. tighten the nut of the lower mounting of the generator and remove the compressor again to continue assembly
Pic. 15.5. Dimensions of the protective screen of the radiator of the cooling system
- If necessary, add oil to the engine.
- Adjust the belt tension. Do not install the previously removed belt, replace it with a new one.
Vehicles with G8T engines
Removal
- Place the vehicle on a two-post lift and disconnect the cable from the negative terminal of the battery.
- Remove the right mudguard and the under-engine skid plates.
- Disconnect, without removing, the oil cooler from the engine cooling system radiator.
- Install a radiator protective screen made independently from steel or aluminum sheet (pic. 15.5).
- Vehicles with air conditioning system
- Install lever Mot. 1370. grabbing the tension roller axis from behind (pic. 15.6).
- Lock the automatic tensioner. sliding it towards the rear of the car and remove the belt.
- Install the lock Mot. 1376.
- Remove lever Mot. 1370 and install the key Mot. 1368 (pic. 15.7).
- Unscrew the bolt and remove the eccentric adjusting roller.
- Disconnect the air conditioning hose from the power steering brace located between the engine and the power steering pump and remove the brace.
- Tongs Mot. 453-01, pinch the power steering pump supply hose.
- Disconnect the supply and high pressure hoses from the power steering pump.
- Remove the power steering pump.
Pic. 15.6. Relieving the tension of the accessory drive belt on the G8T diesel engine with air conditioning system
Pic. 15.7. Using special tools to remove the eccentric adjustment roller
Attention. Be sure to protect the generator from oil.
- Remove the three bolts securing the power steering pump bracket.
- Remove the power steering pump assembly with bracket
- Disconnect all electrical connectors from the generator.
- Remove the upper and lower generator mounting bolts.
- Remove the generator by moving its top through the space left by removing the power steering pump.
- Vehicles without air conditioning system
- Loosen the tension on the generator drive belt. To do this, use an internal hexagon to loosen the central bolt securing the tension roller a quarter turn, then turn the roller counterclockwise (pic. 15.8).
Pic. 15.8. Location of the central bolt securing the tension roller of the generator drive belt
- Remove the accelerator cable.
- Disconnect all electrical connectors from the generator.
- Unscrew the two generator mounting bolts and remove the generator.
Installation
- Installation of the generator is carried out in the reverse order of removal.
- On vehicles without an air conditioning system, use an internal hexagon to tighten the central bolt securing the tension roller until it stops and until there is no gap between the tension roller.
- Install a new belt and adjust its tension. Do not install the previously removed belt, replace it with a new one.
Vehicles with G9T engines
Removal
- Place the vehicle on a two post lift.
- Disconnect the cable from the negative terminal of the battery.
- Disconnect the connectors from the generator and air conditioning compressor.
- Remove the right front wheel, right wheel arch mudguard and engine oil pan protection.
- Remove the front bumper, windshield washer reservoir and the pipe leading from the heat exchanger to the throttle body.
- Loosen the belt tension by using a spanner to turn the axis of the tension roller clockwise and fix the roller using the device (pic. 15.9).
- Remove the accessory drive belt.
- Remove the accessory drive belt idler pulley (pic. 15.10).
- Unscrew the four bolts securing the air conditioning compressor and leave the compressor suspended on the hoses (pic. 15.11).
- Unscrew and remove the bolt of the lower mounting of the generator and unscrew the upper bolt without removing it (pic. 15.12).
- On the lower right side of the car, unscrew the vertically located torque rod mounting bolt.
- Unscrew without removing them from the exhaust gas pre-catalytic converter to the exhaust system.
- Remove the bolt from the top mounting of the generator. by lifting the power unit towards the front of the car, the bolt can be removed above the right side member and remove the generator
Installation
- Installation of the generator is carried out in the reverse order of removal.
- Install a new belt and adjust its tension. Do not install the previously removed belt, replace it with a new one.
Pic. 15.9. Loosen the accessory drive belt tension
Pic. 15.10. Accessory drive belt idler pulley location
Pic. 15.11. Location of the air conditioning compressor mounting bolts
Pic. 15.12. Location of generator mounting bolts