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Charging System & Starting System: Generator: Removal: 1.6L

  1. Release the fuel pressure, refer to the fuel pressure release procedure.
  2. Remove air cleaner assembly cover.
  3. Disconnect the negative battery cable.
  4. Disconnect the electrical connectors from the fuel injectors.
  5. Remove the wiring harness from the fuel rail brackets.
  6. Remove the fuel line from the fuel rail.
  7. Remove the 2 bolts to the fuel rail at the lower manifold.
  8. Remove the fuel rail.
  9. Remove the lower intake manifold, see appropriate ENGINE MECHANICAL article.
  10. Disconnect the electrical connectors from the generator.
    Fig 1: Identifying Generator Connectors
    G01857975Courtesy of DAIMLERCHRYSLER CORP.
  11. Remove the power steering reservoir from the support bracket.
    Fig 2: Removing Power Steering Reservoir
    G01857976Courtesy of DAIMLERCHRYSLER CORP.
  12. Loosen the lower inboard generator mounting bolt.
  13. Raise vehicle and support.
  14. Remove the right splash shield.
    Fig 3: Removing Right Splash Shield
    G01857977Courtesy of DAIMLERCHRYSLER CORP.
  15. Remove the accessory drive belt, see COOLING SYSTEM MECHANICAL article.
    Fig 4: Removing Generator Belt
    G01857978Courtesy of DAIMLERCHRYSLER CORP.
  16. Loosen the lower outboard generator mounting bolt.
  17. Lower vehicle.
  18. Remove the 2 upper mounting bolts.
  19. Remove the generator.
    Fig 5: Removing Generator
    G01857979Courtesy of DAIMLERCHRYSLER CORP.
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