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ElantraClub - For Elantra Owners and Enthusiasts _ The Kia Zone _ Alpha alternator
Posted by: bhorste Aug 11 2013, 08:54 PM
The wife's Rio has been sitting for a couple of weeks because of her recovery from the c-section. I went to fire it up today so we could drive it and the battery was dead. No big deal, I have a charger. Threw the charger on there, tried to fire it up, didn't hardly turn over. Okay, looks like the battery is the original so I'll get around to replacing it. Threw the charger on again just in case, and got it to turn over and fire. Alternator belt starts squealing immediately, then started smoking. Shut the car off, looked for the source of the smoke, and also found bits of belt dust everywhere. I'm thinking perhaps the alternator has seized, so I'm going to have to replace it as well.
Just how big a PIA is this going to be? I'm thinking that I'm going to go ahead and do the timing belt and water pump while I'm in there, but just looking at it makes me think it's going to be a multi-day project. Has anyone done one on a Rio/Accent? This is an '03, if it helps you out.
Posted by: roydjt Aug 11 2013, 09:56 PM
The Elantra alternator replacement is pretty simple. I haven't done it myself, but I've read about members doing the job in pretty short order. If you're savvy enough to do the timing belt, the alternator should be a breeze.
-Roy
Posted by: Bobzilla Aug 12 2013, 09:11 AM
03 is pre-Accent sharing, so I'm not sure. I believe it is on the same side as the alpha/beta/theta (down low passenger side.). If it's typical asian, it'll be 12mm retention bolts, 10mm for the power wire and it'll likely have to comeout the bottom.
Posted by: bhorste Aug 12 2013, 06:31 PM
Actually, it's not that low. It's accessible from the top, but because of the intake/air conditioning hoses I don't think it'll come out through the top.
Posted by: bhorste Aug 15 2013, 11:40 AM
So I'm elbow-deep in it now... doing the alternator, battery, timing belt and water pump. The car, as expected, is mounting terrific resistance to my efforts. Right now, my problem is trying to get the power steering pump loosened enough to remove that belt (it's the outer of the 2 anyway). The trick is the bolt labeled 7 in this picture:
It seems that the head of it is buried where I can't get at it, and the nut on the other side is restricted access due to the exhaust manifold. After lunch, I guess I'm going to try to locate the head of the bolt and give the air tools another go at it (or perhaps my breaker bar), but failing that, any suggestions?
Posted by: blupupher Aug 15 2013, 11:52 AM
Are you trying to get to the bolt from up top? Try coming at it from the wheel well if possible.
Looks like it is low like where the alternator is in the Elantra. Turn the wheel (or remove it) and move the splash shield in the wheel well and see if it is there.
Not sure if it the same, but worth a try.
Posted by: bhorste Aug 15 2013, 12:05 PM
Looks like it is low like where the alternator is in the Elantra. Turn the wheel (or remove it) and move the splash shield in the wheel well and see if it is there.
Not sure if it the same, but worth a try.
I think it's up too high to get at from the wheel well, but I'll take a look in a bit (read: after we get the kids down for a nap). I did take the wheel off, knowing that it's definitely going to be easier to get at the timing sprocket from that end. Stay tuned.
Posted by: Bobzilla Aug 15 2013, 12:15 PM
You are replacing that belt as well right? Cut it. The new one you can get on by starting it by hand then turning hte pulley to seat it. If this is one of the pre-smart t-belt jobs, you'll have to support the engine and take the side mount off. When you do that, you can use the jack to raise and lower the engine to make certain bolts easier to get to.
Posted by: bhorste Aug 15 2013, 12:21 PM
That might not be a bad idea... provided I've got something burly enough to cut the belt. I'm hoping I can do it the "normal" way, though.
Posted by: bhorste Aug 15 2013, 01:36 PM
Power steering pump has been defeated. Turns out, the bolt is only accessible from the top, provided you have the pulley turned just right so you can access the bolt through one of the two holes in the pulley. Next up, alternator. Trying to figure out the best way to get at the bottom bolt and then remove/replace... looking like through the bottom. Ack.
Posted by: bhorste Aug 15 2013, 07:06 PM
Well, now I've got a real snag... the head snapped off the alternator mounting bolt. I'm going to surf the mall and find some sort of screw extractor set and hope that that and a new can of PB'laster will save my bacon.
The good thing is that my wife isn't driving again yet after the c-section. The car can sit immobile for another month and a half, but I'm going to try really hard to have it back on the road by next weekend.
Posted by: bhorste Aug 29 2013, 10:25 PM
So I'll be headed back under the car tomorrow... hopefully to remove that freakin' bolt that busted off. Might have to bust out the 6" long drill bit so I can get a run at the bolt from the far side of the obstructions.
Posted by: bhorste Aug 30 2013, 01:10 PM
Still haven't gotten the bolt out. Maybe some JB weld on a grade 8 bolt and stick it to the end of the broken bolt? The alternator (whose bearings are INDEED seized) is just flopping in there by this bolt. Vinnie and Bob, I'm looking specifically at you guys for some real suggestions.
Posted by: Bobzilla Aug 30 2013, 01:59 PM
Take the side engine mount loose and drop it down so you can get to it easier with an e-zee out?
Posted by: bhorste Aug 30 2013, 03:48 PM
I'm not sure just how far down it'll drop with the mount loose. Plus, that won't change its position relative to all the other crap in the way (halfshaft, wire for O2 sensor, etc.). Might give it a try later this evening, with a smaller board between jack/oil pan (oh yeah, have to work around that nonsense, too).
Posted by: bhorste Sep 14 2013, 02:42 PM
This thing is still fighting me, which is remarkable. I've snapped 3 drill bits on this project (including a DeWalt cobalt 5/16 bit) but chewed up most of the threaded tab on the alternator... and it still won't let go. I don't know whether to smash something or just sit here and cry quietly in frustration.
Any futher hints/suggestions?
Posted by: Vinnie Sep 14 2013, 03:38 PM
So #7 bolt is still stuck in there?
That oil pump bracket - that's what holds it all onto the engine right?
Worst case scenario - VERY worst case....
How comfortable are you doing timing belts?
You get that bracket off - you can put it into a vise very lightly tight - drill it out or replace the bracket.
One way or another - not all hope is lost - you've got this.
Posted by: bhorste Sep 14 2013, 04:31 PM
I'm trying to get this finished so I can move on to the timing belt/water pump... and I'm not terribly comfortable trying to take that bracket off. It looks like it's held on by oil pan bolts among others.
The big problem is just that there is NO room anywhere around it. I'm going to have another go at it with a smaller drill bit in a little here... need a quick post-dinner nap. I WILL have that damn alternator in my hands this evening, so I can devote post-work, pre-Lions time to the rest of the job tomorrow... okay, and probably during-Lions time as well as post-Lions time. Really gotta get this job done; the wife goes back to work in just over a week.
Posted by: bhorste Sep 15 2013, 03:01 PM
Okay, we've got ourselves a good news/bad news situation:
Good news: the alternator is no longer attached to the block.
Bad news: it is not out of the engine bay. Also, I had to use a cutoff wheel to cut through the threaded tab.
Good news: I think there's a way to get it out.
Bad news: it involves removing the oil filter. Also, not sure if I'll be able to get the new alternator in this way.
Will be heading back out in a bit to try to pull it... but I will probably just get a new oil filter for the car (it's about due anyway) and try to make it happen that way.
Posted by: bhorste Sep 15 2013, 05:09 PM
The old alternator is OUT! It involved undoing the motor mount and moving the motor up and down about 6 times, but I managed to drop it out the bottom. Just took it back to get the core; they never even opened the box to look at it. WINNING!
Of course, now the real fun will be getting the new one in, with all 3 tabs intact.
Posted by: bhorste Sep 17 2013, 10:15 PM
The new alternator is IN!!!! A big shout-out of thanks to member hourang for driving the hugely long distance (just down the block) to be an extra set of hands and helping to fnagle the beast into position and put the accessory belts on (which was an entirely different bear of an issue).
After having to do some creative engineering to get the new battery to fit (new one is ~1" shorter than the old one, not enough threads on the hooks) - which involved getting out my brand-new B&D circular saw and cutting down a piece of wood to go under the battery - I buttoned everything back up that was needed to make the car run, pressurized the fuel system, turned the key and...
IT PURRED LIKE A KITTEN!
I'm amazed the bearings on that alternator didn't fail sooner, with all the noise it made. The new one is quiet, there's no belt squeal, it's very nice.
The water pump/timing belt are on hold until I can find another weekend to take care of the whole deal. The important thing is that the wife has her car back on the road, which she will after I re-install the splash guard and take it down off the jackstand.
Overall, I'd have to answer my initial question by saying, yes... changing that altertnator was a major PIA.
Posted by: slowgls Sep 17 2013, 10:23 PM
Glad you got it together.
Posted by: bhorste Sep 17 2013, 10:34 PM
Thanks... not looking forward to eventually getting after the timing belt/water pump. The motor mount tab on the block is right above the water pump pulley. Don't think it comes off, either. Ought to add intrigue, if nothing else.
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