Alternator removal Is it necessary to remove the radiator to get the alternator off of the engine? Does anyone know how to do it without taking the radiator out? This is the northstar engine.

Here is the procedure. Let me know if you have questions.

Removal & Installation

1. Before servicing the vehicle, refer to the Precautions Section.
2. Disconnect the negative battery cable.
3. Drain and recycle the engine coolant.
4. Raise and support the vehicle.
5. Remove the lower splash shields.
6. Disconnect the lower radiator hose and the degas return hose.
7. Remove the lower center support bolt.
8. Lower the vehicle.
9. Disconnect the remaining coolant hose connections.
10. Position the hood latch assembly out of the way.
11. Remove the two bolts and the center support.
12. Remove the two top bolts retaining the cooling fan to the radiator.
13. Remove the upper radiator support brackets, and remove the radiator from the vehicle.
14. To install, reverse removal procedure. Tighten all fasteners to 89 inch lbs. (10 Nm).
15. Start the engine and check for leaks, repair if necessary.

If you are on the fence about changing your alternator yourself, let me say: Don't do it!!! This is not a novice job. I spent about 4 hours getting it out and about 3 putting it back together, including about a 1 hr trip to the parts store. I'd say I lost 1-2 hours for having no manual or guide on how to do this work. If you are intent on doing this yourself, the next paragraph will describe the steps necessary. You'll have to fill in your own curse words during the exercise! LOL

1. Remove the lower plastic cowling to allow undercarriage access
2. Remove the upper plastic cowling to see the radiator
3. Loosen the radiator overflow tank
4. Remove the stabilizer bar that runs front to rear over the serpentine belt
5. Remove the stabilizer bar mounting bracket that is attached to the engine just above the alternator
6. Remove the steel body bar that runs left-to-right in front of the engine (I didn't find this until late, costing me extra time) You will need to remove the cover to the fuses to get at one of the bolts. 4 18mm bolts.
7. Remove the bolts and body nuts that attach the front grill and upper bumper to the chassis
8. Optional - Remove the air breather assembly if you need more room on the right side of the car - it's an easy pull
9. Remove the upper radiator hose
10. Remove the upper radiator clamps
11. Remove the engine fan tray
12. Optional - remove the radiator Or
13. Tilt the radiator back with not enough room to properly work
14. Remove the alternator
15. That's it. Now Reverse the steps.

Here are a few notes:

Fan tray - held to radiator by an upper and lower clip. Also, there are two hoses bolted to it on the right side along with the power cables..

Radiator - if you are going to leave it in and work around it, you need to lift it from it's center supports so that it can be tilted towards the front of the car. You run the risk of damaging the radiator as is not enough room to maneuver the alternator out without striking it.

You will need a second person to pull back on the radiator during the alternator removal. I used a bottle jack and a piece of lumber to push it forward as I had no helper. The only way to get the radiator leaning far enough to work was to also have the front grill pivoting forward as well. In reality, you need the bottom section as far forward as possible and less so the upper.

Air Conditioner - In every step of removing anything, the AC hoses were in the way. Sure would have been much easier if I could have pulled those hoses off.

Alternator - Has 3 bolts. Reach one from under the car. It is the pivot bolt. It is a 15mm bolt and nut. Best with a helper as the nut is best held from above and the bolt from under. Next bolt was removed from above. It is located on the alternator face. It took me a while to realize that there was a third bolt that is at a 45 degree angle upwards on the front side of the unit. It's also the battery ground wire location. Also remove the hot wire and the 2 wire connector.

Try this link. I found it to be pretty self-explanatory.
http://www.ehow.com/how_5418653_replace-oldsmobile-aurora-alternator.html

The other option, but be warned could cause damage to the motor mounts, is to use a cherry picker to lift the engine up enough to clear the alternator from the engine bay.

For 2002 Hyundai Sonata 2.7L MFI DOHC 6cyl check this procedure...
Alternator - Removal

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   Negative battery cable Radiator mounting bolts, 1.6L only Alternator drive belt Alternator wiring harness connectors Alternator. It may be necessary to raise the radiator
   
   
   Fig. Exploded view of the alternator-XG 300
   

Removal & Installation

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   Negative battery cable Alternator drive belt Alternator wiring harness connectors Alternator. It may be necessary to raise the radiator

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   Negative battery cable Radiator mounting bolts, 1.6L only Alternator drive belt Alternator wiring harness connectors Alternator. It may be necessary to raise the radiator
   
3. Install or connect the following:
   Alternator and reposition the radiator, if raised Alternator wiring harness connectors Alternator drive belt
4. Adjust the alternator belt and torque the bolts to the following specifications:
   1. Accent: Pivot bolt to 14-18 ft. lbs. (19-25 Nm) and adjustment bolt to 14-20 ft. lbs. (19-28 Nm).
   2. 2.0L and 2.5L Sonata, Elantra and Tiburon: Pivot bolt to 14-18 ft. lbs. (19-25 Nm) and adjustment bolt to 105-132 inch lbs. (12-15 Nm).
   3. 2.4L Sonata: Pivot bolt to 26-41 ft. lbs. (34-54 Nm) and the adjustment bolt to 14-18 ft. lbs. (19-25 Nm).
   4. 3.0L Sonata and XG 300: Pivot bolt to 14-18 ft. lbs. (19-25 Nm) and adjustment bolt to 11-16 ft. lbs. (15-22 Nm).
5. Install the radiator mounting bolts, if removed.
6. Connect the negative battery cable.

Hope helps (remember rated this).

Disconnect battery.
Remove under engine shroud if it's still there.
The alternator is at the front of the engine down low on the radiator side.
Loosen drive belt, the alternator can be removed by patient use of a 14mm wrench, the wires should be removed before dropping the alternator out. Frankly I forget whether they are in a jack or screwed on.
It is necessary to turn the alternator sideways to get it out.
Have fun!

The thermostat is under the alternator.

If you have a memory saver to keep radio & PCM settings, install it now.

Remove negative battery cable from battery. Remove positive cable from alternator and disconnect harness plug from alternator.

Remove accessory belt noting how it is installed for later reinstallation.

Remove engine lifting hook in front of alternator.

Remove (3) bolts holding alternator on.

Drain coolant from radiator (may want to start this as first step as it takes a while). Loosen pressure cap to aid in system draindown.

Remove radiator hose from thermostat housing.

Remove two bolts from housing and remove from engine.

Reinstall is reverse keeping in mind the following:

Cleanliness counts where thermostat housing seals to engine.
Thermostat spring should point into engine.
If the thermostat has a bleed port, it should go to the 12 o'clock position (up).

Removal & Installation

4.2L Engine

1. Remove the necessary coolant from the radiator.
2. Remove the alternator, as outlined in the Engine Electrical Section.
3. Loosen the outlet hose clamp at the thermostat housing. Remove the outlet hose from the thermostat housing.
4. Remove the thermostat housing bolts.
5. Remove the thermostat housing from the engine block.
6. Clean all of the surfaces of the thermostat housing.
7. Clean the sealing surface of the engine block.

TO INSTALL

1. Install the thermostat housing to the engine block.
2. Install the thermostat housing bolts and tighten to 89 inch lbs. (10 Nm).
3. Lubricate the inner diameter of the radiator hose with engine coolant.
4. Install the outlet hose to the thermostat housing. Secure the hose with the clamp.
5. Install the alternator.
6. Fill the cooling system with specified coolant and concentration.
7. Inspect all sealing surfaces for leaks after starting the engine.

Thanks for using FixYa - a 4 THUMBS rating is appreciated for answering your FREE question.

1. Remove the necessary coolant from the radiator.
   
2. Remove the alternator, as outlined in the Engine Electrical Section.
   
3. Loosen the outlet hose clamp at the thermostat housing. Remove the outlet hose from the thermostat housing.
   
4. Remove the thermostat housing bolts.
   
5. Remove the thermostat housing from the engine block.
   
6. Clean all of the surfaces of the thermostat housing.
   
7. Clean the sealing surface of the engine block.
   

To install:


Thermostat mounting—4.2L engine

1. Install the thermostat housing to the engine block.
   
2. Install the thermostat housing bolts and tighten to 89 inch lbs. (10 Nm).
   
3. Lubricate the inner diameter of the radiator hose with engine coolant.
   
4. Install the outlet hose to the thermostat housing. Secure the hose with the clamp.
   
5. Install the alternator.
   
6. Fill the cooling system with specified coolant and concentration.
   
7. Inspect all sealing surfaces for leaks after starting the engine.
   

Removal

1. Remove or disconnect the following:
   
   Negative battery cable Radiator mounting bolts, 1.6L only Alternator drive belt Alternator wiring harness connectors Alternator. It may be necessary to raise the radiator

Fig. Exploded view of the alternator-XG 300 and XG 350


Removal & Installation

1. Remove or disconnect the following:
   Negative battery cable Alternator drive belt Alternator wiring harness connectors Alternator. It may be necessary to raise the radiator
   


Fig. Exploded view of the alternator-XG 300 and XG 350

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   
   Negative battery cable Radiator mounting bolts, 1.6L only Alternator drive belt Alternator wiring harness connectors Alternator. It may be necessary to raise the radiator
   
   
   
   Fig. Exploded view of the alternator-XG 300
   
   
   
   Fig. Exploded view of the alternator-XG 350
   
   
3. Install or connect the following:
   
   Alternator and reposition the radiator, if raised Alternator wiring harness connectors Alternator drive belt
   
4. Adjust the alternator belt and torque the bolts to the following specifications:
   1. Accent: Pivot bolt to 14-18 ft. lbs. (19-25 Nm) and adjustment bolt to 14-20 ft. lbs. (19-28 Nm).
   2. 2.0L and 2.5L Sonata, Elantra and Tiburon: Pivot bolt to 14-18 ft. lbs. (19-25 Nm) and adjustment bolt to 105-132 inch lbs. (12-15 Nm).
   3. 2.4L Sonata: Pivot bolt to 26-41 ft. lbs. (34-54 Nm) and the adjustment bolt to 14-18 ft. lbs. (19-25 Nm).
   4. 3.0L Sonata and XG 300: Pivot bolt to 14-18 ft. lbs. (19-25 Nm) and adjustment bolt to 11-16 ft. lbs. (15-22 Nm).
5. Install the radiator mounting bolts, if removed.
6. Connect the negative battery cable.

I hope hrlp you with this. Good luck and remember rated this help-