Alternator 20724 37300-2F000 FG15S029 2656070 LRA04303 373002F000 2656070， FG15S029 ALV1529BS， ALV1529GB， ALV1529KR for Kia Sorento 2.2 Sportage 2.0

I. Safety Preparation and Tool List

• Park the vehicle on level ground, engage the parking brake, and disconnect the negative (-) battery terminal (to prevent short circuits/electric shock).

• Wear insulated gloves to prevent tools from contacting live terminals.

II. Critical Pre-Installation Checks

• Mounting Surface Cleaning: Remove oil, dirt, and rust from the bracket and alternator flange to ensure a flat fit.

• New Alternator Pre-check: Verify the model number and pulley specifications. Rotate the pulley to ensure there is no binding or abnormal noise.

• Wiring and Terminals: Check that the B+ terminal nut and connector plug show no signs of burning/ablation, and ensure the wiring harness has no damage.

III. Installation Steps (Perform in Sequence)

• Place the new alternator into the mounting bracket. Insert the through-bolt and the mounting bolt, and hand-tighten them (do not fully tighten yet).

• Torque Tightening:

• Through-bolt: 49.0 - 63.7 N·m

• Mounting bolt: 24.5 - 34.3 N·m

• B+ terminal nut: 7.8 - 9.8 N·m

• Firmly insert the alternator harness connector (excitation/feedback plug) until a "click" sound is heard to confirm locking.

• Connect the B+ terminal cable. Torque the nut to 7.8 - 9.8 N·m to prevent heat generation from loose connections.

• Secure the wiring harness clips to prevent interference with the belt or high-temperature components.

• Use the tensioner tool to rotate the tensioner pulley counterclockwise and install the belt (follow the factory routing diagram to avoid misalignment).

• Release the tensioner and check that the belt is seated correctly in all pulley grooves.

• Tension Standard: Deflection should be 5-8mm for a new belt, or 8-12mm for an old belt (tested by applying 98N of force midway between two pulleys).

• Bolt Recheck: Double-check that all mounting bolts and terminal nuts meet the torque standards.

• Harness Routing: Ensure the harness does not contact the belt or exhaust manifold; leave a gap for heat dissipation.

• Battery Reconnection: Reconnect the negative terminal and ensure it is tight.

IV. Functional Testing and Troubleshooting

I. Electrical Safety "Iron Rules" (Preventing New Part Burnout)

• Action: Always disconnect the negative (-) battery terminal before removing or installing any alternator wiring harnesses.

• Consequence: The Sorento's electronic systems (ECM/BCM) are highly sensitive. Hot-plugging wires can easily cause voltage surges, directly damaging the new alternator's rectifier diodes or destroying the vehicle's ECU.

• Action: Before reconnecting the negative battery terminal, double-check that the alternator B+ terminal (thick wire) connects only to the battery positive terminal, with no breaks or misconnections in between.

• Consequence: Instant polarity reversal will cause the alternator's internal diodes to explode and may even ignite the wiring harness.

• Taboo: When testing the alternator, never disconnect the battery cables while the engine is running (the old "spark test" method is obsolete).

• Consequence: Modern vehicles have heavy electronic loads. Disconnecting the battery causes voltage to spike instantly to tens of volts, destroying the alternator regulator and electrical components throughout the vehicle.

II. Mechanical Installation Key Parameters (Torque and Positioning)

• Through-Mount Bolt (Long): 49.0 - 63.7 N·m

• Note: Engine bay space is tight on the Sorento. It is recommended to use a ratcheting torque wrench or an extension bar to ensure the torque meets specifications. Insufficient torque causes alternator vibration and noise; excessive torque may strip the threads.

• Pivot / Adjustment Bolt (Short): 24.5 - 34.3 N·m

• B+ Terminal Nut (Power Cable): 7.8 - 9.8 N·m

• Note: This is the most easily overlooked step. If loose, high current generates extreme heat, causing the terminal to melt or even start a fire.

• Action: Check that the B+ terminal's insulating sheath (red rubber cap) is intact and push it back to cover the nut after installation.

• Risk: Space behind the Sorento alternator is narrow. Exposed live wires can easily touch body metal or brackets, causing a ground short circuit.

III. Belt System "Invisible Traps"

• Critical: Must strictly follow the sticker diagram inside the engine bay or the repair manual.

• Common Error: The A/C compressor pulley and idler pulley are easy to route incorrectly. If routed wrong, the tensioner cannot apply correct tension, causing severe belt vibration, detachment, or alternator failure to charge.

• Action: While installing the new alternator, check the automatic tensioner.

• Judgment: Manually move the tensioner pulley to ensure it rotates smoothly without noise. If the tensioner base has cracks or the belt vibrates severely, the tensioner must be replaced along with the belt; otherwise, the new belt will wear out quickly.

• Action: After releasing the tensioner, use a flashlight to check the side of every pulley. Ensure the belt is not riding on the edge of the rim ("derailment").

• Consequence: The alternator pulley spins at high RPM; derailment will cut the belt within minutes.

IV. Special Tips for Sorento Models

• Symptom: On some newer Sorento models (especially those with Start/Stop), the battery light may illuminate after alternator replacement, or charging voltage may be low (<13V).

• Fix: This happens because the ECU remembers wear parameters from the old alternator. A professional diagnostic tool (such as KDS/HDS) is required to perform "Alternator Field Current Initialization" or "BMS Reset".

• Action: On the Sorento (especially 2.4L/2.0T models), there are usually A/C lines or intake manifold brackets above the alternator.

• Note: Do not forcefully pry during installation to avoid deforming lines and causing leaks. If wiring is too long, secure it with zip ties to ensure it does not get pulled into the belt during vehicle bumps.

References：

I. Core OEM Sources (Kia Official Workshop Manuals / Technical Specifications)

II. Industry Standards and Technical Norms