GENERATOR REMOVAL


  1. DISCONNECT NEGATIVE BATTERY CABLE

  2. REMOVE ENGINE COVER


    1. A0138OOE01

      Disengage the 3 claws and remove the engine cover.

  3. REMOVE ENGINE UNDER COVER


    1. A013649

      Remove the 9 bolts.

    2. Remove the 5 screws and engine under cover.

  4. REMOVE FRONT BUMPER COVER

    A0138CFE01

    1. Apply protective tape to the outer circumference of the front bumper cover, as shown in the illustration.

    2. Using a clip remover, remove the clip.

    3. Remove the 3 bolts, 5 screws and 2 clips.

    4. A01360O

      Disengage the 13 claws and remove the front bumper cover.

    5. A0136YZ

      Remove the 2 clips.

  5. DRAIN ENGINE COOLANT

    Note

    To avoid the danger of being burned, do not remove the reservoir tank cap sub-assembly while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.


    1. A01375N

      Remove the drain plug and clip, then drain the engine coolant.

    2. Disconnect the radiator by uncoupling the radiator hose No.2.

    3. A01379O

      Remove the hose clamp, disconnect the water by-pass hose.

    4. Remove the reservoir tank cap sub-assembly.

      A01389E

  6. REMOVE SUPPORT RH SUB-ASSEMBLY

  7. REMOVE SUPPORT LH SUB-ASSEMBLY

  8. DISCONNECT COOLING FAN MOTOR CONNECTOR


    1. A0137JZ

      Disconnect the cooling fan motor connector.

  9. DISCONNECT RESISTOR CONNECTORS (w/ Air Conditioning System)


    1. A0137ZT

      Disconnect the 2 resistor connectors.

  10. DISCONNECT WATER BY-PASS HOSE


    1. A01379O

      Remove the hose clip, and disconnect the water by-pass hose from the radiator assembly.

  11. DISCONNECT RADIATOR HOSE


    1. A0137E8

      Disconnect the radiator hose and clamp from the radiator assembly.

  12. DISCONNECT RADIATOR HOSE NO.2


    1. A0135SS

      Disconnect the radiator hose No.2 and clamp from the radiator assembly.

  13. DISCONNECT CONDENSER ASSEMBLY (w/ Air Conditioning System)


    1. A0136TM

      Remove the 2 bolts, and disconnect the condenser assembly from the radiator assembly.

  14. REMOVE FRONT CROSS MEMBER SUB-ASSEMBLY


    1. A0138MG

      Remove the 6 bolts and front cross member sub-assembly.

  15. REMOVE RADIATOR ASSEMBLY


    1. Remove the radiator assembly.

      Note

      Do not allow the cooler condenser assembly and radiator assembly to come into contact with each other.

    2. A01369K

      Remove the claws, bolt, and the fan assembly from the radiator assembly.

    3. A0137Q1

      Remove the 2 radiator support cushions and 2 grommets from the radiator assembly.

  16. REMOVE V-RIBBED BELT


    1. A0135ZX

      While releasing the belt tension by turning the belt tensioner clockwise, remove the V-ribbed belt from the belt tensioner.

    2. A01366Y

      While turning the belt tensioner, align with its holes, and then insert the 3 mm (0.1181 in.) hexagon wrench into the holes to fix the V-ribbed belt tensioner.

  17. REMOVE V-RIBBED BELT TENSIONER SUB-ASSEMBLY


    1. A0137H7

      Remove the 3 bolts and V-ribbed belt tensioner sub-assembly.

  18. REMOVE TURBO INSULATOR NO.1


    1. A0137BH

      Remove the 7 bolts and turbo insulator No.1.

  19. REMOVE MANIFOLD HEAT SHIELD


    1. A0138LO

      Remove the 2 bolts and manifold heat shield.

  20. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. A0136ILE01

      Remove the 2 nuts and 2 exhaust manifold converter clamps.

    2. Remove the 2 nuts, exhaust manifold converter sub-assembly, catalytic converter support bracket, and converter separator insulator No.1.

  21. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY

  22. REMOVE OIL LEVEL GAUGE GUIDE


    1. A0137BX

      Remove the bolt and oil level gauge guide.

    2. A013776

      Remove the 2 O-rings from the oil level gauge guide.

  23. REMOVE STUD BOLT


    1. A0138ZOE01

      Using a "trox" socket wrench (E7), remove the stud bolt.

  24. DISCONNECT WIRE HARNESS


    1. A0137P9E01

      Disconnect the engine oil pressure switch connector.

    2. A0138SIE01

      w/ Air Conditioning System:


      1. Disconnect the wire harness from the generator assembly.

      2. Disconnect the compressor connector.

  25. REMOVE GENERATOR ASSEMBLY (w/o Air Conditioning System)


    1. A013920

      Disconnect the generator connector.

    2. Remove the terminal cap.

    3. Remove the nut and disconnect the wire harness from terminal B.

    4. Remove the 4 bolts and generator assembly with generator bracket No.2.

    5. Using a hexagon socket wrench, remove the bolt and V-ribbed belt idler assembly No.1 from the generator bracket No.2.

    6. Remove the 2 bolts and generator bracket No.2 from the generator assembly.

  26. REMOVE GENERATOR ASSEMBLY (w/ Air Conditioning System)


    1. A0137E9E01

      Disconnect the generator connector.

    2. Remove the terminal cap.

    3. Remove the nut and disconnect the wire harness from terminal B.

    4. Remove the 4 bolts and generator assembly.