Question about 2004 Suzuki Aerio

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How to remove alternator

I need to replace the alternator,how do you remove it.

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  • Anonymous Mar 30, 2009

    how to remove alternator from skoda fabia

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Park vehicle on level ground.
2. Remove battery from vehicle.
3. Remove air cleaner outlet hose, engine under cover ( right side ) and exhaust pipe # 2 .
4. Disconnect " B " terminal wire and coupler from the Alternator ( Generator ) .
5. Remove Alternator ( Generator ) belt.

6. Remove power steering pump. Do not disconnect hoses.
6. Remove Alternator ( Generator ) cover.
7. Remove Alternator ( Generator ) bracket mounting bolts.
8. Remove Alternator ( Generator ).

Power Steering pump has three bolts- 2 behind the pulley at 12 and 6 o'clock and one bolt on the back.

Once you get the power steering pump out of the way you can remove the last bolt on the alternator


Ok...I did not remove axle or disconnect hoses on power steering...I did unbolt power steering pump and moved off to side.

after that I disconnected sensor on throttle body and very carefully lifted alternator through the top where your air intake assembly would have been at, right next to A.C. refrigerant lines.It takes a minute , you HAVE TO BE CAREFUL NOT TO DAMAGE SENSOR!!

However it is a lot faster that taking off drive shaft and exhaust pipe!

If you go to AutoZone .com they have exploded diagrams of the parts you have to take off and they will show you bolt locations, the power steering pump bolt at 6 o'clock drove me crazy.

P.S. Get a ratcheting 12 mil wrench, it's a life and knuckle saver!!

Posted on Jun 30, 2012

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect the following:
    • Negative battery cable
    • Air cleaner outlet hose and air cleaner assembly
    • Power steering return pipe clamp bolt
    • Right side drive shaft
    • Right engine under cover
    • Serpentine drive belt
    • Power steering suction hose
    • Union bolt
    • Power steering high pressure pipe and gasket
    • Power steering pressure switch connector
    • Power steering pump bolts
    • Power steering pump
    • B terminal wire and connector from the alternator
    • Alternator cover
    • Alternator mounting bolts
    • Alternator
To install:
  1. Install or connect the following:
    • Alternator
    • Alternator mounting bolts. Tighten to upper bolt to 16 ft. lbs. (23 Nm); and lower bolt to 37 ft. lbs. (50 Nm).
    • Alternator cover
    • B terminal wire and connector to the alternator
    • Power steering pump and bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
    • Power steering pressure switch connector
    • Power steering high pressure pipe and gasket
    • Union bolt and tighten to 26 ft. lbs. (55 Nm)
    • Power steering suction hose
    • Serpentine drive belt
    • Right engine under cover
    • Right side drive shaft
    • Power steering return pipe clamp bolt
    • Air cleaner outlet hose and air cleaner assembly
    • Negative battery cable
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect the following:
    • Negative battery cable
    • Serpentine accessory drive belt by turning the automatic tensioner roller bolt clockwise to relieve tension on the belt
    • Harness connector from the back of the alternator
    • Alternator lead to the battery
    • Alternator bolts and alternator
To install:
  1. Install or connect the following:
    • Alternator
    • Alternator mounting bolts. Tighten to upper bolt to 26 ft. lbs. (35 Nm); and lower bolt to 30 ft. lbs. (40 Nm).
    • Alternator lead to the battery
    • Harness connector to the back of the alternator
    • Serpentine accessory drive belt. Relieve tension on the belt by first applying downward pressure on the automatic tension roller bolt and releasing pressure once the belt is in place.
    • Negative battery cable how to remove alternator - 0900c1528019bbda.jpgAlternator mounting—Verona
5-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect the following:
    • Negative battery cable
    • Accessory drive belt
    • Power steering pump
    • Turbocharger hose
    • Alternator harness connectors
    • Alternator 0900c1528019bbdb.jpgAlternator mounting
To install:
Install or connect the following:
  • Alternator
  • Alternator harness connectors
  • Turbocharger hose
  • Power steering pump
  • Accessory drive belt
  • Negative battery cable
6-Cylinder Engines
  1. Disconnect the battery negative lead.
  2. Raise the car.
  3. Remove the lower cover plate.
  4. Drain the coolant.
  5. Install the lower splash guard.
  6. Lower the car.
  7. Remove the upper engine coolant hose.
  8. Remove the auxiliary belt.
  9. Remove the power steering pump.
  10. Disconnect the turbocharger hose from the cooling system. Push the hose to one side.
  11. Remove the right-hand headlamp.
  12. Detach the bumper cover on the right-hand side.
  13. Remove the bolts from the front panel on the right-hand side as illustrated.
  14. Remove the bolt that runs through the upper mounting and the lower bolts.
  15. With AC, slacken off the lower bolts for the compressor, to provide clearance.
  16. Disconnect the battery positive lead.
  17. Disconnect the connector.
  18. Remove the alternator .
  19. Turn the alternator into position.
  20. Carefully pry the front panel forwards.
  21. Pull the alternator upwards and out.
To install:
  1. Position the alternator. Install the bolt through the upper mounting. Do not tighten.
  2. Connect the cable and the connector.
  3. Install the lower bolts for the alternator (upper bolts for the compressor).
  4. With AC, tighten the 2 lower bolts for the compressor.
  5. Tighten the 3 bolts for the alternator.
  6. Install:
    • The front panel
    • The bumper cover
    • The right-hand headlamp
    • The turbocharger hose
    • The power steering pump
    • The accessory drive belt
    • The engine coolant hose. Top up the coolant
    • The battery negative lead
8-Cylinder Engines
  1. Disconnect the battery negative cable.
  2. Remove the auxiliary drive belt.
  3. Detach the rear ignition coil cover on the right-hand side. Pull straight up and fold it aside.
  4. Remove the right-hand halfshaft.
  5. Remove the cover to the wheel arch
  6. Remove the plastic nuts.
  7. Removing the fuel line brackets
  8. Remove the bolts and nuts.
  9. Move the fuel lines to the side.
  10. Lift the alternator out through the wheel arch. 0900c1528019bbdc.jpgAlternator mounting—8-cylinder engines
To install:
  1. Lift the alternator into position.
  2. Install the bolts and connect the battery cable.
  3. Install the fuel lines
  4. Install the cover to the wheel arch
  5. Install the right-hand halfshaft
  6. Install the fuel pipe
  7. Press in the ignition coil cover.
  8. Install the auxiliary belt.
  9. Connect the battery negative cable.

Posted on Oct 16, 2008

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