How to replace alternator on 2003 KIA Rio ?

Alternator

Removal & Installation

1. Before servicing the vehicle, refer to the Precautions Section.
2. Disconnect the negative battery cable.
3. Temporarily loosen the water pump pulley bolts, 1.6L (VIN 3) engine only.
4. Remove the front air intake inlet pipe bolts, 1.8L engine only.
5. Remove the top hose from the air intake inlet pipe, 1.8L engine only.
6. Remove the air intake inlet pipe clamp and the pipe, 1.8L engine only.
7. Remove the power steering pump, 2.0L engine only.
8. Remove the power steering pump bracket, 2.0L engine only.
9. Remove the alternator B terminal cover cap.
10. Disconnect the alternator electrical connections.
11. Loosen, but do not remove the alternator pivot bolt and the tensioner mounting bolt.
12. Remove the drive belt(s); relieve tension on the belt by rotating the adjustment bolt.
13. Remove the water pump pulley, 1.6L (VIN 3) engine only.
14. Remove the power steering pump, 1.6L (VIN 3) engine only.
15. Remove the power steering pump bracket, 1.6L (VIN 3) engine only.
16. Remove the alternator tensioner mounting bolt and the belt tensioner.
17. Remove the alternator pivot bolt.
18. Loosen the bolt at the base of the adjusting bracket and rotate the bracket up.
19. Remove the alternator.
    
    
    

    

    Fig. Alternator mounting-1.5L and 1.6L (VIN 5) engine shown

    
    
    
    

    

    Fig. Alternator mounting-2.0L and 1.6L (VIN 3) engines shown

    
    
    
    

    

    Fig. Alternator mounting-2.4L and 2.7L engine

To install:

1. Before servicing the vehicle, refer to the Precautions Section.
2. Install the alternator.
3. Install the alternator pivot bolt and hand-tighten at this time.
4. Rotate the adjusting bracket into position, place the belt tensioner into position. Hand-tighten the mounting bolt.
5. Install the drive belt.
6. Adjust the belt tension by rotating the adjustment bolt.
7. The belt deflection for 1.5L, 1.6L (VIN 5), 2.4L and 2.7L engines, is as follows:
   1. New belt: 0.22-0.28 in. (5.5-7mm).
   2. Used belt: 0.24-0.28 in. (6-7mm).

   
   
8. The belt deflection for 1.6L (VIN 3) engine is as follows :
   1. New belt: 0.13-0.15 in. (3.3-3.7mm).
   2. Used belt: 0.17-0.19 in. (4.2-4.7mm).

   
   
9. The belt deflection for the 2.0L engine, is as follows:
   1. New belt: 0.22-0.31 in. (5.5-8mm).
   2. Used belt: 0.33-0.45 in. (8.5-11.5mm).

   
   
10. The belt deflection for the 1.8L engine, is as follows:
    1. New belt: 0.23-0.31 in. (6-8mm).
    2. Used belt: 0.28-0.35 in. (7-9mm).

    
    
11. Tighten the tensioner bolt to 14-19 ft. lbs. (19-26 Nm) and the pivot bolt to 28-38 ft. lbs. (38-51 Nm).
12. Connect the alternator electrical connections.
13. Install the alternator B terminal cover cap.
14. Install the power steering pump and adjust the power steering belt tension, 2.0L and 1.6L (VIN 3) engines only.
15. Install the water pump pulley, 2006 1.6L engine only.
16. Install the air intake inlet pipe and fasten the clamp, 1.8L engine only.
17. Install the top hose to the air intake inlet pipe, 1.8L engine only.
18. Install the front air intake inlet pipe bolts, 1.8L engine only.
19. Connect the negative battery cable.

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All motor mounts need to be removed and jack the engine up till it almost hits the cowl.

Remove the air duct from the air cleaner to the throttle body by using a screwdriver to loosen the clamps and pulling the hose off. Loosen the power steering belt by using a socket to turn the tensioner bolt to relieve the tension on the belt. Remove the belt. Remove the power steering pump and bracket using a socket.

Disconnect the negative battery terminal using a wrench. Loosen the two bolts securing the alternator to the block, but do not remove them yet. Loosen the tension on the alternator belt by using a socket and turning the tensioner bolt. Lift the belt off.

Remove the alternator's top bolt, and swing the alternator out toward the fender. Remove the electrical connectors on the back of the alternator. Use a wrench to remove the heavy battery wire and just pull the plastic field plug out of its socket. Remove the remaining bolts in the alternator. Remove the alternator and tensioner.

Bolt up the alternator and tensioner, which share the same bracket. Install the bolts loosely. Install the electrical battery wire and field plug on the back of the alternator. Use a wrench to tighten the battery wire nut.

Tighten the two bolts in the alternator and the bolt in the tensioner using a socket. Install the alternator belt and turn the tensioner bolt with a socket until sufficient tension is applied to the belt.

Install the power steering pump and bracket and tighten the bolts with a socket. Install the power steering belt and rotate the tensioner bolt with a socket until sufficient tension is applied. Install the air duct from the air cleaner to the throttle body and tighten the clamps with the screwdriver. Connect the negative battery terminal and tighten with a wrench.

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Removing the Old Alternator from KIA Rio:----

• Start by loosening the water pump bolts. Do not remove them at this point. Next, remove the alternator B terminal cover cap by pulling it off and sliding it down the wire out of the way. Remove all the electrical connections to the alternator, including the plug. Loosen, but do not remove, the alternator pivoting bolt and the tensioner mounting bolt. This will allow you to pivot the alternator in the direction to relieve tension on the drive belt. Remove the water pump pulley and then remove the power steering pump to get it out of the way. Remove the power steering pump bracket to make clearance for the alternator removal. Remove the alternator tensioner mounting bolt and then the belt tensioner itself. Finish removing the alternator pivoting bolt. Loosen the bolt of the adjusting bracket enough to rotate the bracket upward. At this point, you'll be able to remove the alternator.

  An alternative method to remove the alternator is by bracing the engine with a floor jack and wood block. Disconnect the engine mount and raise the jack up approximately one inch to give enough clearance for the removal of the alternator.

  To reinstall, reverse the procedure. Be sure enough tension is applied to the belt to ensure that it is functioning properly. A rule of thumb for belt tension is only being able to twist it a half turn to expose the ribs of the belt.

  Test the alternator and belt reinstallation after replacing. It's also a good idea to recharge the battery--especially if it died due to alternator failure.