GENERATOR REMOVAL


  1. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  3. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH


    1. A01588F

      Remove the 3 bolts and screw.

    2. Turn the clip indicated by the arrow in the illustration to remove the front fender splash shield sub-assembly LH.

  4. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH


    1. A0159SG

      Remove the 3 bolts and 2 screws.

    2. Turn the clip indicated by the arrow in the illustration to remove the front fender splash shield sub-assembly RH.

  5. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. A0157XJ

      Remove the 10 bolts and No. 1 engine under cover.

  6. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    Tech Tips

    Collect the coolant in a container and dispose of it according to the regulations in your area.


    1. Loosen the radiator drain cock plug.

    2. Remove the radiator reservoir cap to drain the coolant in the radiator.

    3. Loosen the oil filter bracket drain cock plug to drain the coolant in the engine.

      A015DKUE01

    4. Tighten the radiator drain cock plug by hand.

    5. A0158UW

      Tighten the oil filter bracket drain cock plug.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  7. REMOVE FRONT FENDER APRON SEAL FRONT RH


    1. A015AN4

      Remove the 3 clips and front fender apron seal front RH.

  8. REMOVE FRONT FENDER APRON SEAL REAR RH


    1. A015D4I

      Remove the 4 clips and front fender apron seal rear RH.

  9. REMOVE V-RIBBED BELT (w/ Viscous Heater)


    1. A0155TJ

      Loosen the lock nut and turn the bolt counterclockwise.

    2. Remove the V-ribbed belt.

  10. REMOVE NO. 1 IDLER PULLEY (w/ Viscous Heater)


    1. A015A7A

      Remove the bolt, cover, No. 1 idler pulley and collar.

  11. REMOVE NO. 3 IDLER PULLEY (w/ Viscous Heater)


    1. A015C7J

      Remove the nut and No. 3 idler pulley.

  12. REMOVE V-RIBBED BELT


    1. A015CL0

      Using a wrench to the V-ribbed belt tensioner bracket, turn the wrench clockwise and remove the V-ribbed belt.

  13. REMOVE INTERCOOLER ASSEMBLY (w/ Intercooler)

    Click here

  14. REMOVE NO. 1 COOL AIR INLET (w/o Intercooler)


    1. A015E40

      Loosen the No. 1 air hose clamp.

    2. Disconnect the turbo pressure sensor connector, intake air temperature sensor connector and vacuum hose.

    3. A0158C6

      Remove the 3 nuts, bolt and No. 1 cool air inlet.

    4. Remove the gasket from the air tube RH.

  15. REMOVE NO. 2 COOL AIR INLET (w/o Intercooler)


    1. A015B0X

      Loosen the No. 2 air hose clamp.

    2. A015A93

      Remove the 3 nuts, bolt and No. 2 cool air inlet.

    3. Remove the gasket from the air tube LH.

  16. DISCONNECT WATER HOSE SUB-ASSEMBLY (w/ Viscous Heater)


    1. A01579DE01

      Disconnect the 2 water hoses.

  17. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A0156LC

      Disconnect the wire harness clamp from the No. 2 engine oil level dipstick guide.

    2. A015C0GE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Disconnect the ventilation hose from the cylinder head cover RH.

    3. Remove the 2 bolts and No. 2 engine oil level dipstick guide.

    4. Remove the O-ring from the No. 2 engine oil level dipstick guide.

  18. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A0159QI

      Loosen the hose clamp.

    2. Disconnect the mass air flow meter connector and using a clip remover, detach the wire harness clamp from the air cleaner cap.

    3. Detach the 4 clamps and remove the air cleaner cap.

  19. REMOVE NO. 1 AIR CLEANER HOSE


    1. A015DGT

      Loosen the hose clamp and remove the No. 1 air cleaner hose.

  20. REMOVE INTAKE AIR CONNECTOR


    1. A015852E04
      Text in Illustration
      *A w/ Viscous Heater

      w/ Viscous Heater:

      Disconnect the 2 connectors from the viscous with magnet clutch heater and water temperature sensor.

    2. w/o Viscous Heater:

      Disconnect the connector from the water temperature sensor.

    3. Using a clip remover, detach the 3 wire harness clamps.

    4. A015DJJ

      Loosen the 2 hose clamps and remove the 2 bolts and intake air connector.

  21. REMOVE NO. 1 AIR HOSE


    1. A0158SB

      Loosen the hose clamp and remove the No. 1 air hose.

  22. REMOVE NO. 3 AIR TUBE


    1. A0159U8

      Disconnect the wire harness from the clamp.

    2. Remove the nut and ground wire.

    3. A0155HD

      Remove the bolt and disconnect the wire harness bracket.

    4. A01572L

      Loosen the hose clamp and remove the bolt and No. 3 air tube.

  23. REMOVE HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)


    1. A0158HY

      Remove the 4 bolts and disconnect the 4 water hose ends, and then remove the heater water pipe.

  24. REMOVE NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY


    1. A015D8F

      Loosen the hose clamp.

    2. Remove the bolt and No. 1 air cleaner pipe.

  25. REMOVE NO. 1 AIR TUBE ASSEMBLY


    1. A0158LS

      Remove the bolt and No. 1 air tube.

    2. Remove the O-ring.

  26. REMOVE GENERATOR ASSEMBLY


    1. Disconnect the 4 connectors.

    2. A0156Q6

      Disconnect the 6 wire harness clamps.

    3. Remove the terminal cap.

    4. Remove the nut and disconnect the generator wire.

    5. Remove the bolt and disconnect the wire harness bracket from the belt tensioner.

    6. A0158KF

      Loosen the clamp and remove the bolt.

    7. A015BKO

      Remove the 2 bolts and No. 1 intake air connector bracket.

    8. Remove the No. 1 intake air connector pipe from the No. 1 inlet compressor elbow.

    9. A015DQ2

      Remove the 3 bolts and 2 nuts.

    10. Using an E7 "TORX" socket wrench, remove the 2 stud bolts and generator.