Volvo Truck 2003-05

Alternator

Print

Removal & Installation



8-Cylinder Engines
  1. Disconnect the battery negative cable.
  2.  
  3. Remove the auxiliary drive belt.
  4.  
  5. Detach the rear ignition coil cover on the right-hand side. Pull straight up and fold it aside.
  6.  
  7. Remove the right-hand halfshaft.
  8.  
  9. Remove the cover to the wheel arch
  10.  
  11. Remove the plastic nuts.
  12.  
  13. Removing the fuel line brackets
  14.  
  15. Remove the bolts and nuts.
  16.  
  17. Move the fuel lines to the side.
  18.  
  19. Lift the alternator out through the wheel arch.

    Click image to see an enlarged view

    Fig. Alternator mounting-8-cylinder engines

    Alternator mounting-8-cylinder engines
  20.  

To install:

  1. Lift the alternator into position.
  2.  
  3. Install the bolts and connect the battery cable.
  4.  
  5. Install the fuel lines
  6.  
  7. Install the cover to the wheel arch
  8.  
  9. Install the right-hand halfshaft
  10.  
  11. Install the fuel pipe
  12.  
  13. Press in the ignition coil cover.
  14.  
  15. Install the auxiliary belt.
  16.  
  17. Connect the battery negative cable.
  18.  

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
     
    Turbocharger hose
     
    Alternator harness connectors
     
    Alternator

    Click image to see an enlarged view

    Fig. Alternator mounting

    Alternator mounting
     

  4.  

To install:

Install or connect the following:



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

6-Cylinder Engines
  1. Disconnect the battery negative lead.
  2.  
  3. Raise the car.
  4.  
  5. Remove the lower cover plate.
  6.  
  7. Drain the coolant.
  8.  
  9. Install the lower splash guard.
  10.  
  11. Lower the car.
  12.  
  13. Remove the upper engine coolant hose.
  14.  
  15. Remove the auxiliary belt.
  16.  
  17. Remove the power steering pump.
  18.  
  19. Disconnect the turbocharger hose from the cooling system. Push the hose to one side.
  20.  
  21. Remove the right-hand headlamp.
  22.  
  23. Detach the bumper cover on the right-hand side.
  24.  
  25. Remove the bolts from the front panel on the right-hand side as illustrated.
  26.  
  27. Remove the bolt that runs through the upper mounting and the lower bolts.
  28.  
  29. With AC, slacken off the lower bolts for the compressor, to provide clearance.
  30.  
  31. Disconnect the battery positive lead.
  32.  
  33. Disconnect the connector.
  34.  
  35. Remove the alternator .
  36.  
  37. Turn the alternator into position.
  38.  
  39. Carefully pry the front panel forwards.
  40.  
  41. Pull the alternator upwards and out.
  42.  

To install:

  1. Position the alternator. Install the bolt through the upper mounting. Do not tighten.
  2.  
  3. Connect the cable and the connector.
  4.  
  5. Install the lower bolts for the alternator (upper bolts for the compressor).
  6.  
  7. With AC, tighten the 2 lower bolts for the compressor.
  8.  
  9. Tighten the 3 bolts for the alternator.
  10.  
  11. Install:

    The front panel
     
    The bumper cover
     
    The right-hand headlamp
     
    The turbocharger hose
     
    The power steering pump
     
    The auxiliaries belt
     
    The engine coolant hose. Top up the coolant
     
    The battery negative lead
     

  12.  

  1. Disconnect the battery negative lead.
  2.  
  3. Raise the car.
  4.  
  5. Remove the lower cover plate.
  6.  
  7. Drain the coolant.
  8.  
  9. Install the lower splash guard.
  10.  
  11. Lower the car.
  12.  
  13. Remove the upper engine coolant hose.
  14.  
  15. Remove the auxiliary belt.
  16.  
  17. Remove the power steering pump.
  18.  
  19. Disconnect the turbocharger hose from the cooling system. Push the hose to one side.
  20.  
  21. Remove the right-hand headlamp.
  22.  
  23. Detach the bumper cover on the right-hand side.
  24.  
  25. Remove the bolts from the front panel on the right-hand side as illustrated.
  26.  
  27. Remove the bolt that runs through the upper mounting and the lower bolts.
  28.  
  29. With AC, slacken off the lower bolts for the compressor, to provide clearance.
  30.  
  31. Disconnect the battery positive lead.
  32.  
  33. Disconnect the connector.
  34.  
  35. Remove the alternator .
  36.  
  37. Turn the alternator into position.
  38.  
  39. Carefully pry the front panel forwards.
  40.  
  41. Pull the alternator upwards and out.
  42.  

To install:

  1. Position the alternator. Install the bolt through the upper mounting. Do not tighten.
  2.  
  3. Connect the cable and the connector.
  4.  
  5. Install the lower bolts for the alternator (upper bolts for the compressor).
  6.  
  7. With AC, tighten the 2 lower bolts for the compressor.
  8.  
  9. Tighten the 3 bolts for the alternator.
  10.  
  11. Install:

    The front panel
     
    The bumper cover
     
    The right-hand headlamp
     
    The turbocharger hose
     
    The power steering pump
     
    The accessory drive belt
     
    The engine coolant hose. Top up the coolant
     
    The battery negative lead
     

  12.  

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



6 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
 
Accessory drive belt
 
Radiator hose to radiator
 
Turbo hose to air conditioning assembly
 
Power steering pump
 
Negative battery cable
 

 
label.common.footer.alt.autozoneLogo