Removal
5. Disconnect the negative (-) terminal from the battery.
Attention! This will delete the recorded information from some devices, and the security code from the radio receiver, as well as all automatic settings for radio stations. Therefore, before disconnecting the battery, read the provisions of Chapter "Battery - removal and installation".
6. Disconnect the large diameter wires (terminal B+) and thin diameter wires (terminal D+) from the terminals on the rear side of the generator (see arrows in the illustration).
16.6 Disconnect the large diameter wires (terminal B+) and thin diameter wires (terminal D+) from the terminals on the rear side of the generator (see arrows). 1 - generator mounting bolts
Cars with 1.4-/1.6-liter petrol engine (E7J/K7M)
7. Mark the position of the right front wheel on the hub with paint. This will allow you to install the balanced wheel in its original position during assembly.
8. Loosen the wheel mounting bolts. The car must be on the ground.
9. Place the front of the car on jack stands and remove the front wheel.
10. Loosen the three bolts 1 securing the power steering pump (see illustration). There is no need to completely unscrew the bolts.
16.10 Loosen the three bolts 1 securing the power steering pump
11. Loosen the V-belt tension by loosening nut 2 (see illustration 16.10).
12. Remove the V-belt from vehicles with air conditioning.
13. Unscrew clamp bolt 3, unscrew support bolt 4, turn the generator towards the engine and remove the V-belt (see illustration).
16.13 Unscrew clamp bolt 3, unscrew support bolt 4, turn the generator towards the engine and remove the V-belt
14. Remove support bolt 4 through hole 5 in the right wheel arch (see illustration).
16.14 Remove support bolt 4 through hole 5 in the right wheel arch
15. Unscrew nut 6 of the ball joint pin of the tie rod end and press the pin out of the lever on the steering knuckle (see illustration 16.14).
16. Support the wishbone to prevent the axle shaft from sagging after the shock absorber strut is disconnected.
17. Unscrew the 2 bolts securing the upper support of the shock absorber strut to the mudguard (see illustration). To facilitate subsequent installation, it is recommended to outline the areas where the bolt heads are attached to the mudguard with a marker or felt-tip pen.
16.17 Unscrew the bolts 2 securing the upper support of the shock absorber strut to the mudguard
18. Lower the strut together with the steering knuckle and hub down as far as possible without bending the drive axle shaft. This is necessary to remove the generator through the wheel arch of the removed right wheel.
19. Remove the generator.
Installation
20. Put the generator in place and secure it with bolts 3 and 4, without tightening them completely (see illustration 16.13).
21. Install a new V-belt for the alternator and power steering pump drive.
22. Connect the large diameter wires (terminal B+) and thin diameter wires (terminal D+) to the generator terminals.
23. Secure the upper shock absorber strut support to the mudguard, using the marks made during removal. Tighten the strut mounting bolts to 30 Nm.
24. Insert the ball joint pin of the tie rod end into the hole in the transverse knuckle arm and screw a new self-locking nut onto the pin, applying a tightening force of 35 Nm.
25. Install the wheel, following the marks made before removal, and screw in the wheel bolts. Do not lubricate the bolts.
26. Lower the vehicle onto its wheels and tighten the wheel bolts in a cross pattern to 90 Nm.
Cars with 1.4-/1.6-liter petrol engine (K4J/K4M)
27. Mark the position of the right front wheel on the hub with paint. This will allow you to install the balanced wheel in its original position during assembly.
28. Loosen the wheel mounting bolts. The car must be on the ground.
29. Place the front of the car on jack stands and remove the front wheel. •
30. Remove, if necessary, the right wheel arch liner by unscrewing the mounting bolts.
31. Remove the alternator V-belt.
32. Disconnect the power steering line bracket near the radiator fan and push the fan aside slightly if necessary.
33. Disconnect the large diameter wires (terminal B+) and thin diameter wires (terminal D+) from the terminals on the rear side of the generator (see illustration 16.6).
34. Unscrew the three bolts 1 and remove the generator 2 (see illustration).
16.34 Unscrew the three bolts 1 and remove the generator 2
Installation
35. Place the generator in place and secure it with three bolts, applying a tightening torque of 21 Nm.
36. Lay the V-belt.
37. If necessary, install the radiator fan in its original position and secure the power steering pipe in the holder.
38. Connect the large diameter wires (terminal B+) and thin diameter wires (terminal D+) to the generator terminals.
39. Install the right wheel arch liner, if removed, and secure it with bolts.
40. Install the right wheel, following the marks made before removal, and screw in the wheel bolts. Do not lubricate the bolts.
41. Lower the vehicle onto its wheels and tighten the wheel bolts in a cross pattern to 90 Nm.
Cars with a 2.0 liter petrol engine (113 hp)
Removal
42. Remove the alternator drive V-belt.
In order to unscrew the generator support bolt, it is necessary to remove the ignition coils together with the bracket.
43. Unscrew the mounting bolts in sequence 1-3 and move the bracket down (see illustration).
16.43 Unscrew the mounting bolts in the sequence 1-3 Move the bracket down
44. Unscrew the upper and lower generator mounting bolts and remove it.
Installation
45. Place the generator in place and secure it with cleats.
46. Install the new V-belt and tighten it.
47. Connect the large diameter wire (terminal B+) to the generator terminal. The thin section wire (terminal D+) is connected to the connector.
48. Replace the bracket and ignition coils.
Cars with a 2.0-liter, 16-valve petrol engine (150 hp)
Removal
49. Remove the front part of the right wheel arch liner.
50. Disconnect the adsorber hose and unscrew the bolts securing the injection system control unit to the bracket (see arrows in the illustration). Place the control unit on the engine without disconnecting the wires from it.
16.50 Disconnect the adsorber hose and unscrew the bolts securing the injection system control unit to the bracket (see arrows)
51. Remove the V-belt, securing the belt tensioner with a suitable pin.
52. Remove the pin and release the belt tensioner.
53. Unscrew bolts D and E and remove the belt tensioner (see illustration). When unscrewing bolt E, make sure that its gasket does not fly off and get between the engine and the tensioner.
16.53 Unscrew bolts D and E and remove the belt tensioner
54. Disconnect the thick section wire (terminal B+) and the thin section wire (terminal D+) from the back of the generator.
55. Disconnect the power steering reservoir from the mounting bracket and set it aside without disconnecting the hoses from the reservoir.
56. Unscrew the generator mounting bolts and remove it. To unscrew the generator bolts, you will need a hex socket head and a wrench about 20 cm long.
Installation
57. Reinstall the generator.
58. Secure the power steering fluid reservoir to the bracket.
59. Replace the V-belt tensioner and tighten it to the following torques:
- bolt D - 25 Nm;
- bolt E - 65 Nm.
Don't forget to put a washer on bolt E.
60. Install the new V-belt.
61. Connect the hose to the adsorber and secure the fuel injection system control unit to the bracket.
62. Connect the electrical wires to the generator.
63. Install the removed part of the wheel arch liner.