Rebuild

Do not carry out further dismantling if component is removed for access only.

12. Using an 8 mm Allen key to restrain alternator shaft, remove nut securing pulley using tool 18G 1653 .
13. Remove pulley.

Rebuild

14. Clean pulley and alternator shaft.
15. Position pulley to alternator shaft.
16. Fit alternator pulley nut; restrain shaft and using 18G 1653, tighten nut to 75 Nm.

Refit

1. Fit alternator to mounting bracket.
2. Fit 4 bolts securing alternator to mounting bracket and tighten to 25 Nm .

NOTE: Tighten 2 front alternator retaining bolts first.

3. Connect cables to alternator and tighten nuts.
4. Align PAS pipe support bracket to engine coolant rail, fit and tighten screw.
5. Connect heated oxygen sensor multiplug and secure to clip.
6. Fit radiator top mounting brackets to radiator, align brackets to bonnet locking panel and secure with bolts.
7. Fit drive belt. See this section.
8. Connect battery earth lead.

ALTERNATOR - ’T’ SERIES WITH AIR CONDITIONING

Service repair no - 86.10.02/20

Remove

1. Remove drive belt. See this section.
2. Position container beneath engine.

3. Loosen clip and disconnect radiator top hose from engine coolant elbow.
4. Loosen clip and disconnect coolant expansion tank return hose from engine coolant elbow.
5. Disconnect heated oxygen sensor multiplug.
6. Remove alternator terminal cover.
7. Loosen alternator terminal lead nuts from alternator and position aside.

8. Remove 2 front alternator to mounting bracket bolts.
9. Remove 2 rear alternator to mounting bracket bolts.
10. Remove alternator.