Aveo 2006-2007

Alternator

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Diagnosis & Testing



Load Test
  1. With the engine running, turn on the blower motor and the high beams ( or other electrical accessories to place a load on the charging system).
  2.  
  3. Increase and hold engine speed to 2000 rpm.
  4.  
  5. Measure the voltage reading at the battery.
  6.  
  7. The voltage should increase at least 0.5 volts from the voltage test. If the voltage does not meet specifications, the charging system is malfunctioning.
    NOTE
    Usually under and overcharging is caused by a defective alternator, or its related parts (regulator), and replacement will fix the problem; however, faulty wiring and other problems can cause the charging system to malfunction. Further testing, which is not covered by this book, will reveal the exact component failure. Many automotive parts stores have alternator bench testers available for use by customers. An alternator bench test is the most definitive way to determine the condition of your alternator.

  8.  

No Load Test
  1. Connect a tachometer to the engine.
    CAUTION
    Ensure that the transmission is in Park and the emergency brake is set. Blocking a wheel is optional and an added safety measure.

  2.  
  3. Turn off all electrical loads (radio, blower motor, wipers, etc.)
  4.  
  5. Start the engine and increase engine speed to approximately 1500 rpm.
  6.  
  7. Measure the voltage reading at the battery with the engine holding a steady 1500 rpm. Voltage should have raised at least 0.5 volts, but no more than 2.5 volts.
  8.  
  9. If the voltage does not go up more than 0.5 volts, the alternator is not charging. If the voltage goes up more than 2.5 volts, the alternator is overcharging.
    NOTE
    Usually under and overcharging is caused by a defective alternator, or its related parts (regulator), and replacement will fix the problem; however, faulty wiring and other problems can cause the charging system to malfunction. Further testing, which is not covered by this book, will reveal the exact component failure. Many automotive parts stores have alternator bench testers available for use by customers. An alternator bench test is the most definitive way to determine the condition of your alternator.

  10.  
  11. If the voltage is within specifications, proceed to the next test.
  12.  

Voltage Test
  1. Make sure the engine is OFF , and turn the headlights on for 15-20 seconds to remove any surface charge from the battery.
  2.  
  3. Using a DVOM set to volts DC, probe across the battery terminals.
  4.  
  5. Measure the battery voltage.
  6.  
  7. Write down the voltage reading and proceed to the next test.
  8.  

Removal & Installation



  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the Intake Air Temperature (IAT) sensor connector.
  4.  
  5. Disconnect the air intake tube
  6.  
  7. Remove the accessory drive belt.
  8.  
  9. Remove the alternator wiring connector.
  10.  
  11. Remove the alternator.

    Click image to see an enlarged view

    Fig. Alternator mounting-1.6L engine

  12.  

To install:

  1. Position the alternator on the engine.
  2.  
  3. Install the alternator mounting bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  4.  
  5. Tighten the positive cable nut to 11 ft. lbs. (15 Nm).
  6.  
  7. Connect the wiring connector.
  8.  
  9. Install and tension the accessory drive belt.
  10.  
  11. Install the air intake tube.
  12.  
  13. Connect the IAT sensor connector.
  14.  
  15. Connect the negative battery cable.
  16.  

 
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