ION 2006-2007

Alternator

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Diagnosis & Testing



Whenever troubleshooting the charging system, always check for obvious problems before proceeding, such as loose belts, bad electrical or battery connections, blown fuses, broken wires, etc. The battery must be in good condition and in the proper state of charge.

When performing the following tests, inspect the serpentine accessory drive belt to make sure it is properly tensioned. Also, make sure the ignition is OFF before connecting or disconnecting test equipment.

Carbon Pile Load Alternator Test
  1. Make sure the battery is properly charged (on original type batteries, a green eye should be visible through the built-in hydrometer) and that all battery and alternator connections are clean and tight.
  2.  
  3. Install the red tester cable to the positive battery terminal and the black cable to the negative battery terminal.
  4.  
  5. Clamp the ammeter connection to one of the battery terminals.
  6.  
  7. Start the engine, then run at 2000 rpm and observe the voltmeter; if the voltage is uncontrolled or exceeds 16 volts, the alternator is bad.
  8.  
  9. If the voltage is below 16 volts, turn the carbon pile load tester ON and, while maintaining 2000 rpm, adjust the tester to obtain a maximum current reading on the ammeter. Do not allow the voltage to fall below 13 volts.
  10.  
  11. If the output current is greater than 60 amps or within 15 amps of the rated alternator voltage, the alternator is good.

    Click image to see an enlarged view

    Fig. Typical carbon pile load tester

  12.  

System Function Test
  1. Turn the ignition key to the OFF position and verify that the charge lamp (which looks like a battery and is located in the left lamp grouping of the instrument cluster) is not illuminated.
  2.  
  3. Turn the ignition key to the ON position and verify that the charge lamp illuminates. If the lamp does not illuminate, check that the battery contains the proper voltage (and charge if necessary), then make sure the alternator and battery connections are clean and tight.
  4.  
  5. Start the engine and verify that the charge lamp extinguishes and remains unlit as long as the engine is running.
  6.  

Removal & Installation



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the drive belt.
  6.  
  7. Remove the supercharger.
  8.  
  9. Disconnect the alternator connectors.
  10.  
  11. Remove the alternator bolts.
  12.  
  13. Remove the alternator from the vehicle.

    Click image to see an enlarged view

    Fig. Exploded view of the alternator mounting-2.0L engine

  14.  

To install:

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Install the alternator on the engine.
  4.  
  5. Install the alternator bolts. Tighten to 18 ft. lbs. (25 Nm).
  6.  
  7. Connect the positive battery harness to the alternator battery terminal. Tighten the nut to 15 ft. lbs. (25 Nm).
  8.  
  9. Connect the alternator harness connectors.
  10.  
  11. Install the supercharger.
  12.  
  13. Install the drive belt.
  14.  
  15. Connect the negative battery cable.
  16.  

2.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Throttle body air duct
     
    Accessory drive belt
     
    Alternator electrical connectors
     
    Alternator bolts
     
    Alternator

    Click image to see an enlarged view

    Fig. Exploded view of the alternator-2.2L engine

     

  4.  

To install:

  1. Install or connect the following:

    Alternator and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Alternator electrical connectors
     
    Accessory drive belt
     
    Throttle body air duct
     
    Negative battery cable
     

  2.  

2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt
     
    Air duct
     
    Alternator electrical connectors
     
    Alternator bolts
     
    Alternator

    Click image to see an enlarged view

    Fig. Exploded view of the alternator mounting-2.4L engine

     

  4.  

To install:

  1. Install or connect the following:

    Alternator and torque the bolts to 16 ft. lbs. (22 Nm)
     
    Alternator electrical connectors
     
    Accessory drive belt
     
    Throttle body air duct
     
    Negative battery cable
     

  2.  

 
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