Changing Alternator/Generator in 2002 Sedona

[Inky]

1. Disconnect battery ground.
2. Disconnect horn, sensor, fans, etc.
3. Remove support piece above radiator, and remove hood latch support in front of radiator.
4. Disconnect air conditioner condenser. (Be careful as pressure is released.)
5. Cap connection from Step 4. (I used tape.)
6. Disconnect radiator hoses. (For the lower hose, it is easier to remove it where it enters the engine block since there is very little room at the bottom of the radiator itself. Some coolant will be lost.)
7. Disconnect oil cooler hoses from cooler (2) and from radiator assembly (2). (It's pretty easy to tell which one goes where. However, if you're afraid you'll get mixed up, label them.) Cap them. (I used plastic wrap and rubber bands.)
8. Unbolt oil cooler.
9. Remove anything else attaching radiator/condenser/oil cooler to vehicle (if any).
10. Pick entire assembly up and out of vehicle.
11. Hook one end of a Bungee cord to the belt just above the alternator's pully. Hook the other end to the bottom of the front bumper. (Keeping tension on the belt will prevent it from slipping off the other pullies.)
12. Remove the wire bolted to the alternator. Also remove wires plugged into alternator.
13. Remove the plug from the AC compressor (since the wire gets in the way).
14. Loosen the idler beneath the alternator. Slide it a bit away from it's support. (It's not necessary to completely remove it.)
15. Remove the 2 alternator bolts and the one on the alternator support. (The rear bolt cannot be fully removed with the alternator still in place. Slide it out as far as possible.)
16. Slide the alternator forward, watching that the rear bold doesn't get hung up.
17. Remove the rear bolt and place into the new alternator before installing. (NOTE: The pully size on the new alternator may be different than the old one. If so, switch it out. Use an impact wrench or visit a local garage to have this done.)
18. Installation is reverse of removal. (BE CAREFUL TO REPLUG ALL WIRES AND HOSES! New O-rings are recommended for AC system. Also add compressor oil if any is lost.)
19. Top up coolant and oil if necessary.
20. Fully recharge battery.
21. With AC off, start vehicle and check for leaks.
22. Add more coolant if necessary. (Check before vehicle gets hot. Be careful!)
22. Have AC evacuated, leak tested, and rechaged.

[krempep]

Simplier method less costly method:

2. Do not mess with the A/C connections this method has enough flexibility to manuver the alternator without distubing the connections too much.
3. Remove support piece above radiator, and remove hood latch support in front of radiator.
4. remove only the upper coolant hose and bracket to the engine.
5. No need to disconnect the the coolant lines. Just remove the brackets that mount them to the car body opposite the alternator. This will give you flexibility to move the radiator and mounting bolts.
6. Remove each of the fan housings. This should give you sufficient space to work on the alternator itself and remove it.
7. loosen the tension pulley, the one toward the firewall, no need to remove it but no big deal. Then loosen the bolt below it to help put the belt back on later.
8. Remove the alternator, disconnect the electrical and remove the mounting bracket that mounts to the engine. The long bolt on the bottom does not come all the way out but you can still remove the alternator with it wedged in the hole. Remember to put this one in first when you reinstall the new on;
9. Work the altermator carefully around the front of the engine and remove from the right side.
10. Installation is the reverse of these instructions.
11. Replace the lost coolant about a liter.
Should take about 3-4 hours depending on how difficult it is to remove the fans.

[krempep]

5. Correction. No need to remove A/C lines. Remove upper Coolant hoses from Radiator .

[krempep]

This works for 2003-04 and 05. as well.