Assuming this is a XG 350, the process is lengthly.
1. Remove the RH radiator cooling fan (two 10mm bolts at the top & wiring harness connector to it).
2. Lift vehicle to remove the Right Front wheel (then remove 4 10mm bolts securing the plastic splash shield & remove it)
3. Loosen the 14mm nut on the alternator belt tensioner pully
4. Loosen the tension on the belt by rotating (counter-clockwise) the 14mm bolt at the bottom of the idler pully and remove the belt.
5. remove the pully & the idler pully (three 12 mm bolts)
6. Loosen the 14mm nuts at the top and bottom mounting points of the alternator.
7. Using a floor jack (or vehicle lift), support the engine using a jack-stand & 2x4 piece of wood under the oil pan.
8. This is tricky - lift the engine 'SLIGHTLY' to take pressure off the front engine mount - loosen the 17 mm nut on top of the mount itself and observe engine movement. If the engine moves upward 'slightly' remove the 17mm nut - if not, raise the engine slight more until you see the mounting bracket rise off the mount.
9. Remove the remaining 17mm nut (deep well socket), and two 17mm bolts and remove the engine mount bracket.
10. Here's another tricky step. Some 350's bottom Alternator bolt bores are 'SLOTTED'... some are NOT. You'll need to determine wether you'll need to REMOVE the lower bolt, or just loosen the mounting sleeve at the bottom bolt. If it's 'sleeved', I use an air hammer to loosen the sleeve. If it's not slotted, I remove the lower bolt (it's the only way to remove the alternator and pry it off).
11. At the top is an "L" bracket which uses two 12mm bolts to attach it to the engine (head). One of the two 12mm bolts is difficult to get to -- do your best to remove it because the battery cable to the alternator is in the way.
12. Disconnect the alternator wiring (battery cable & regulator harness connector)
13. Lift the engine as high as it will go & pry the alternator off its lower mounting.
14. manuver the alternator upward taking care not to damage the radiator.
15. Installation is in reverse order.
NOTE: If your XG's lower mounting point was slotted, your task is easy. If it isn't, your task now becomes more difficult as you must align the new alternator to facillitate re-insertion of the lower bolt.
PS If not slotted, I use a telliscoping magnet to help re-insert the lower bolt.
Aug 09, 2010 |
2004 Hyundai XG350