Disconnect the battery negative (earth) lead.
Remove the auxiliary drivebelt.
1.4 and 1.6 litre petrol engine
Remove the plastic cover, unscrew the nut and disconnect the wiring from the alternator
Disconnecting the wiring connector
Remove the lower mounting bolt, and also the upper securing bolt and nut from the alternator
Undo the upper securing bolt and nut
Carefully lift the alternator upwards from the engine. Take care not to damage the surrounding components, as there is little room to manoeuvre the alternator.
1.8 and 2.0 litre petrol engine
Undo the securing bolt from the coolant expansion tank, lift out from securing clip and move to one side
Remove the securing bolt...
...and lift the tank off from the securing clip
Lift the power steering reservoir from its retaining bracket and move to one side
Lift reservoir from the retaining bracket
Undo the securing bolt from the wiring loom bracket, and move the wiring to one side (disconnect the multi-plug)
Unbolt the wiring clip . . .
. . . then disconnect the block connector
Undo the bolt from the power steering reservoir bracket to release the earth cable (to aid the removal of the alternator, carefully bend the earth bracket down)
Unbolt the earth cable . . .
. . . then carefully bend the bracket down
Undo the two retaining bolts from the canister purge valve and move to one side
Disconnect the wiring connector, and move the canister to one side
Remove the plastic cover, unscrew the nut and disconnect the wiring from the back of the alternator.
Unscrew and remove the alternator mounting bolt nearest the engine
. Unscrew the other retaining bolt until it has fully disengaged from the bracket (it will not be possible to remove the bolt from the alternator at this stage)
Remove the bolt . . .
. . . and remove the lower bolt as far the inner wing
Carefully lift the alternator from the engine, turning it with the pulley facing upwards. Take care not to damage the surrounding components on removal, as there is little room to manoeuvre the alternator
Turn and lift the alternator out with the pulley facing upwards
Remove the engine undershield.
On vehicles with air conditioning, undo the four bolts from the air conditioning compressor and remove to one side.
Do not disconnect the refrigerant pipes.
Remove the plastic cover, unscrew the nut and disconnect the wiring from the alternator.
Undo the two pulley bracket bolts, then loosen the three generator coupling bolts and remove the coupling
Undo the two pulley bolts . . .
. . . loosen the three coupling bolts . . .
. . . and remove the coupling from the alternator
Unscrew the alternator mounting bolts and carefully lift the alternator from the engine
If you are renewing the alternator, take the old one with you. Make sure that the new or rebuilt unit is identical to the old alternator. Look at the terminals – they should be the same in number, size and location as the terminals on the old alternator. Finally, look at the identification markings – they will be stamped in the housing, or printed on a tag or plaque affixed to the housing. Make sure that these numbers are the same on both alternators.
Many new/rebuilt alternators do not have a pulley installed, so you may have to switch the pulley from the old unit to the new/rebuilt one. When buying an alternator, ask about the installation of pulleys – some auto-electrical specialists will perform this service free of charge.
One of the mounting bolts on the 1.8 litre and 2.0 litre petrol engine will need to be put in place before refitting the alternator (see paragraph 12).
Refitting is the reverse of the removal procedure, referring where necessary to the relevant Chapters of this manual. Tighten all nuts and bolts to the specified torque wrench settings.
| Coupling bolts (diesel engine)
| Mounting bolts:
| Petrol engine
| Diesel engine
| Mounting nuts (petrol engine)
| Pulley bracket bolts (diesel engine)