How do you replace alternator 2001 Volvo s40?

Answer 1

Loud noises from the front of the Volvo alternator can be either bad bearings or a bad clutch inside the pulley. The alternator is very expensive, the pulley is around $75 from Volvo and with the right tools is easy to replace once the alternator is off the car. After running the engine for 5 or so minutes, shut it off, and carefully (!) place your hand on the pulley. If it is very hot, the problem is the pulley clutch, if not, it is likely the bearing and the alternator needs to be rebuilt or replaced.

Remove positive cable connecting battery. Once you do this you will have to re-program the radio. You may want to go on-line and find your radio code. Without the code you will not be able to use your radio after reconnecting the battery cable.

Remove belt shield over Power Steering pump by aligning holes in pulley.

Use 13mm wrench on tensioning pulley take tension off belt (don't try to wedge wrench, it WILL slip, broken fingers can result, hold wrench (turn clockwise)) and slip belt off of power steering pump. Note the EXACT routing of the serpantine belt, take a picture, draw a picture. There is no underhood diagram and it isn't intuitive.

Remove 2 brackets, 1 from manifold and 1 from AC compressor going to power steering pump. You can't remove bolt on AC compressor that's holding the bracket, just slide it out at least 3/4".

Align holes in pulley with remaining 3 bolts holding power steering pump onto bracket and remove bolts. Remove power steering pump and move out of the way, do not disconnect hoses.

Loosen, do not remove, 2nd bolt holding AC compressor to engine block. This will permit AC compressor to move far enough (1/16" or so) to allow removal of alternator.

Remove 2 (1 faston and one bolted) terminals from alternator.

Remove 3 bolts holding alternator to the engine. Remove alternator.

When installing the new alternator, install all bolts loosely until all are started, then tighten bolts. The bracket from the AC compressor will usually end up on the wrong side of the alternator, don't worry, with the bolt to the compressor loose, the bracket can slip by the manifold. Connect 2 wires to new alternator, install the plastic insulator you dropped when you removed the output wire.

Re-install power steering pump. Take tension off of belt idler pulley, slip belt on to power steering pump pulley and let idler put tension on belt. Use a flash light or good trouble lamp and assure the belt is correctly on all pulleys.

Install shield on power steering pump, check all bolts (including the one you loosened on the AC compressor). Reconnect positive battery terminal.

Start engine. Program radio.