Volvo Cars 1999-05

Alternator

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Removal & Installation



4-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  


NOTE
Make a note of the anti-theft radio code

  1. Remove or disconnect the following:

    Engine splash guards, if equipped
     
    Negative battery cable
     
    Drive belt
     
    Power steering pump
     
    Mounting bracket
     
    Connector and wiring
     
    Upper mounting screw
     
    Upper screws for the air conditioning (A/C) compressor. Move the screws approximately 30 mm forward.
     
    Lower screws for the air conditioning (A/C) compressor
     
    Alternator
     

  2.  


    Click image to see an enlarged view

    Fig. Typical alternator mounting

    Typical alternator mounting

  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Make a note of the anti-theft radio code

  2.  
  3. Remove or disconnect the following:

    Engine splash guards, if equipped
     
    Negative battery cable
     
    Drive belt
     
    Power steering pump
     
    Mounting bracket
     
    Connector and wiring
     
    Upper alternator mounting bolt
     
    Upper bolts for the air conditioning (A/C) compressor
     
    Lower bolts for the A/C compressor
     
    Alternator

    Click image to see an enlarged view

    Fig. Typical alternator mounting

    Typical alternator mounting
     

  4.  

To install:

Install or connect the following:



Alternator
 
Upper bolt. Do not tighten
 
Mounting bracket
 
Two bolts for the air conditioning compressor
 
Tighten bolts to 18 ft. lbs. (25 Nm)
 
Connector and wiring
 
Power steering pump
 
Drive belt
 
Negative battery cable
 
Engine splash guards, if equipped
 

5-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt
     
    Power steering pump
     
    Alternator harness connectors
     
    Alternator
     

  4.  

To install:

Install or connect the following:



Alternator
 
Alternator harness connectors
 
Power steering pump
 
Accessory drive belt
 
Negative battery cable
 

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

    Negative battery cable
     
    Air intake between the radiator and the air cleaner housing, if equipped
     
    Charge air pipe over the engine, if equipped
     
    Engine cooling fan
     
    Charge air pipe from cooling system
     
    Accessory drive belt
     
    Bolt and nut that run through the upper mounting
     
    Lower bolts
     
    Connector and wiring
     
    Alternator
     

  4.  

To install:

Install or connect the following:



Alternator, and tighten mounting bolts and bolts common to the alternator and compressor to 18 ft. lbs. (24 Nm)
 
Alternator connector and wiring
 
Lower bolts
 
Bolt and nut that run through the upper mounting
 
Accessory drive belt
 
Charge air pipe from cooling system
 
Engine cooling fan
 
Charge air pipe over the engine, if equipped
 
Air intake between the radiator and the air cleaner housing, if equipped
 
Negative battery cable
 

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

    Negative battery cable
     
    Accessory drive belt
     
    Power steering pump
     
    Turbo hose from air conditioning assembly
     
    Radiator hose from radiator
     
    Mounting bolts common to alternator and compress
     
    Alternator connector and wiring
     
    Alternator mounting bolts
     
    Alternator
     

  4.  

To install:

Install or connect the following:



Alternator, and tighten mounting bolts and bolts common to the alternator and compressor to 18 ft. lbs. (24 Nm)
 
Alternator connector and wiring
 
Radiator hose to radiator
 
Turbo hose to air conditioning assembly
 
Power steering pump
 
Accessory drive belt
 
Negative battery cable
 

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

    Negative battery cable
     
    Accessory drive belt
     
    Air cleaner assembly
     
    Oil dipstick assembly
     
    Throttle body
     
    Bolts common to the alternator and compressor
     
    Alternator connector and wiring
     
    Alternator mounting bolts
     
    Alternator
     

  4.  

To install:

Install or connect the following:



Alternator, and tighten mounting bolts and bolts common to the alternator and compressor to 18 ft. lbs. (24 Nm)
 
Alternator connector and wiring
 
Throttle body
 
Oil dipstick assembly
 
Air cleaner assembly
 
Accessory drive belt
 
Negative battery cable
 

6-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt
     
    Alternator harness connectors
     
    Alternator
     

  4.  

To install:

Install or connect the following:



Alternator
 
Alternator harness connectors
 
Accessory drive belt
 
Negative battery cable
 

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

    Negative battery cable
     
    Accessory drive belt
     
    Power steering pump
     
    Upper mounting bolts
     
    Bolts common to the alternator and compressor
     
    Lower bolts on the alternator and the upper bolts on the compressor
     
    Connector and wiring
     
    Alternator
     

  4.  

To install:

Install or connect the following:



Alternator
 
Connector and wiring
 
Bolt in the upper mounting. Do not tighten
 
Bolts common to the alternator and compressor (the lower bolts on the alternator and the upper bolts on the compressor). Do not tighten
 
Tighten the lower bolts for the compressor to 18 ft. lbs. (24 Nm)
 
Tighten the bolts common to the alternator and the compressor to 18 ft. lbs. (24 Nm)
 
Tighten the bolt and nut that run through the upper mounting to 18 ft. lbs. (24 Nm)
 
Power steering pump
 
Accessory drive belt
 
Negative battery cable
 

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

    Negative battery cable
     
    Air cleaner assembly
     
    Power steering pump
     
    Turbo hose from air conditioning assembly
     
    Radiator hose from the radiator
     
    Accessory drive belt
     
    Alternator connector and wiring
     
    Mounting bolts common the alternator and compressor
     
    Alternator mounting bolts
     
    Alternator
     

  4.  

To install:

Install or connect the following:



Alternator, and tighten mounting bolts and bolts common to the alternator and compressor to 18 ft. lbs. (24 Nm)
 
Alternator connector and wiring
 
Accessory drive belt
 
Radiator hose to radiator
 
Turbo hose to air conditioning assembly
 
Power steering pump
 
Negative battery cable
 

Diagnosis & Testing



The alternator provides power consuming components with current while the engine is running and maintains battery charge. The alternator is mounted on the front edge of the engine. The output of the alternator depends on engine speed. When the engine is idling, the alternator operates at approximately half of maximum output. When the engine is idling with many power consuming components engaged, the alternator may be unable to maintain full battery charge.

The alternator creates an alternating current which is converted to a direct current in the rectifier bridge. The alternator also utilizes a built-in voltage regulator.

  1. Check that the wiring is in good condition.
  2.  
  3. Check for any abnormal noise from the alternator while the engine is running.
  4.  
  5. Check the accessory drive belt for wear or slipping.
    NOTE
    With the engine running at 2500 RPM, headlights on and fan blower on high, the alternator output voltage should be 13.9-14.6 volts at 68°F.

  6.  

Installation



4-Cylinder Engines

Install or connect the following:



Alternator
 
Upper bolt. Do not tighten.
 
Mounting bracket
 
Two bolts for the air conditioning compressor. Do not tighten.
 
Tighten the screws to 18 ft. lbs. (25 Nm)
 
Connector and wiring
 
Power steering pump
 
Drive belt
 
Negative battery cable
 
Engine splash guards, if equipped
 

6 Cylinder Engines

Install or connect the following:



Alternator
 
Connector and wiring
 
Bolt in the upper mounting. Do not tighten
 
Bolts common to the alternator and compressor (the lower bolts on the alternator and the upper screws on the compressor). Do not tighten
 
Tighten the lower bolts for the compressor to 18 ft. lbs. (24 Nm)
 
Tighten the bolts common to the alternator and the compressor to 18 ft. lbs. (24 Nm)
 
Tighten the screw and nut that run through the upper mounting to 18 ft. lbs. (24 Nm)
 
Power steering pump
 
Accessory drive belt
 
Negative battery cable
 

Install or connect the following:



Alternator, and tighten mounting bolts and bolts common to the alternator and compressor to 18 ft. lbs. (24 Nm)
 
Alternator connector and wiring
 
Accessory drive belt
 
Radiator hose to radiator
 
Turbo hose to air conditioning assembly
 
Power steering pump
 
Negative battery cable
 

Install or connect the following:



Alternator
 
Alternator harness connectors
 
Accessory drive belt
 
Negative battery cable
 

5 Cylinder Engines

Install or connect the following:



Alternator, and tighten mounting bolts and bolts common to the alternator and compressor to 18 ft. lbs. (24 Nm)
 
Alternator connector and wiring
 
Radiator hose to radiator
 
Turbo hose to air conditioning assembly
 
Power steering pump
 
Accessory drive belt
 
Negative battery cable
 

Install or connect the following:



Alternator, and tighten mounting bolts and bolts common to the alternator and compressor to 18 ft. lbs. (24 Nm)
 
Alternator connector and wiring
 
Throttle body
 
Oil dipstick assembly
 
Air cleaner assembly
 
Accessory drive belt
 
Negative battery cable
 

Install or connect the following:



Alternator
 
Alternator harness connectors
 
Power steering pump
 
Accessory drive belt
 
Negative battery cable
 

Removal



5 Cylinder Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt
     
    Power steering pump
     
    Alternator harness connectors
     
    Alternator
     

  4.  

6-Cylinder Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt
     
    Alternator harness connectors
     
    Alternator
     

  4.  

 
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