Generator Replacement - Auxiliary

GENERATOR REPLACEMENT - AUXILIARY

REMOVAL PROCEDURE
The Denso G3A generator is serviced as a complete unit only.
1. Disconnect the battery negative cable.
2. Remove the auxiliary drive belt.




3. Disconnect the wiring harness connector from the auxiliary generator.
4. Reposition the protective boot from the auxiliary generator output BAT terminal for access.
5. Remove the auxiliary generator output BAT terminal nut and disconnect the positive lead from the auxiliary generator.




6. Remove the surge tank mounting nuts (2) and bolt (3).
7. Remove the overflow hose retainer from the mounting stud at the strut tower.
8. Carefully position aside the surge tank (1) in order to remove the auxiliary generator mounting bolt.

IMPORTANT: There are 3 shims (3) located between the auxiliary generator and the front of the auxiliary generator bracket.




9. Remove the auxiliary generator mounting bolts (1, 4) and nut (2).
10. Remove the auxiliary generator (5) from the vehicle.

INSTALLATION PROCEDURE




1. Position the auxiliary generator (5) to the engine.
2. Install the 3 shims (3) between the auxiliary generator and the front of the auxiliary generator bracket.
3. Install the generator mounting bolts (1, 4) and nut (2).




4. Position the surge tank (1) to the mounting studs.

IMPORTANT: Ensure that the overflow hose is properly routed through the retainer.

5. Position the overflow hose retainer to the mounting stud at the strut tower.

NOTE: Refer to Fastener Notice in Service Precautions.

6. Install the surge tank mounting nuts (2) and bolt (3).

Tighten
Tighten the surge tank nuts (2) and bolt (3) to 6 N.m (53 lb in).




7. Connect the wiring harness connector to the auxiliary generator.
8. Connect the battery positive lead and install the auxiliary generator output BAT terminal nut.

Tighten
Tighten the auxiliary generator output BAT terminal nut to 10 N.m (89 lb in).

9. Press the protective boot over the auxiliary generator output BAT terminal.
10. Install the auxiliary drive belt.
11. Connect the battery negative cable.