Kia Sorento 2003-05

Alternator

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Diagnosis & Testing



Visually check the alternator wiring and listen for abnormal noises. Check that the wiring is in good condition. Check that there is no abnormal noise from the alternator while the engine is running.

Removal & Installation



  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the accessory drive belt.
  6.  
  7. Disconnect the wiring to the alternator.
  8.  
  9. Remove the alternator mounting bolts.
  10.  
  11. Remove the alternator.
  12.  


    Click image to see an enlarged view

    Fig. Alternator mounting exploded view


To install:

  1. Install the alternator and insert a support bolt (Do not insert a nut this time).
  2.  
  3. After pushing the alternator forward, check to see if any spacers are required (a spacer thickness : 0.198 mm) between the alternator frontleg and front case.
  4.  
  5. If necessary, insert spacer(s), then insert and tighten nut securely.
  6.  
  7. Connect the alternator electrical connectors. Tighten the battery terminal connector nut to 60 inch lbs. (7 Nm).
  8.  
  9. Install the accessory drive belt.
  10.  
  11. Connect the negative battery cable.
  12.  

  1. Before servicing the vehicle, refer to the Precautions Section..
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the accessory drive belt.
  6.  
  7. Disconnect the wiring to the alternator.
  8.  
  9. Remove the alternator mounting bolts.
  10.  
  11. Remove the alternator.

    Click image to see an enlarged view

    Fig. Alternator mounting

  12.  

To install:

  1. Install the alternator and insert a support bolt (Do not insert a nut this time).
  2.  
  3. After pushing the alternator forward, check to see if any spacers are required (a spacer thickness of 0.198 mm is acceptable) between the alternator front leg and front case.
  4.  
  5. If necessary, insert spacer(s), then insert and tighten nut securely.
  6.  
  7. Connect the alternator electrical connectors. Tighten the battery terminal connector nut to 60 inch lbs. (7 Nm).
  8.  
  9. Install the accessory drive belt.
  10.  
  11. To adjust the drive belt tension, hang the belt on the pulley of the tensioner and install the tensioner.
    NOTE
    If the tensioner is already installed, loosen its mounting bolts to allow belt installation

  12.  
  13. Install the drive belt.
  14.  
  15. Adjust the belt tension to specification by turning the adjusting bolt clockwise or counterclockwise.
  16.  
  17. Air conditioning belt tension should be 0.28-0.039 inch. Alternator belt tension should be 0.39-0.051 inch. Power steering belt tension should be 0.31-0.051 inch.
  18.  
  19. Torque the tensioner assembly bolt to 33-36 ft. lbs. (45-50 Nm).
  20.  
  21. Connect the negative battery cable.
  22.  

 
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