Removal and Installation

Generator - CS 121 DIF

Removal Procedure




1. Disconnect the negative battery cable.
2. Disconnect the intake air temperature (IAT) sensor electrical connector from the air intake tube.
3. Remove all the clamps from the air intake tube hose, and set aside the tube.




4. Raise and suitably support the vehicle.
5. Disconnect the harness connector from the back of the generator.
6. Remove the accessory drive belt by lowering the vehicle and turning the automatic tensioner roller bolt clockwise to relieve tension on the belt. Refer to Power Steering Pump.
7. Push up the power steering reservoir and set it aside.




8. Remove the generator upper mounting bolts to the intake manifold/cylinder head support bracket, the intake manifold strap bracket, and the intake manifold-to-cylinder body strap bracket.




9. Raise and suitably support the vehicle. Remove the nut and the washers which hold the generator lower bracket-to-generator bolt. Work the bolt loose and remove the generator.




10. Remove the generator lower support bracket bolts.
11. Carefully remove the generator with the lower bracket attached.
12. Remove the generator lower support bracket nut, the bolt, and the washer.

Installation Procedure




1. Install the generator to the generator lower bracket and insert the generator bolt.




2. Install the generator and the lower support bracket assembly to the engine block.

Tighten
Tighten the generator lower bracket-to-engine block bolts to 50 N.m (37 lb-ft).




3. Install the generator-to-intake manifold and cylinder head support bracket bolts, the generator-to-intake manifold strap bracket bolt, and the intake manifold-to-cylinder body strap bracket bolts over the starter.

Tighten
Tighten the generator-to-intake manifold and cylinder head support bracket bolts to 37 N.m (27 lb-ft). Tighten the generator-to-intake manifold strap bracket bolt and the intake manifold-to-cylinder body strap bracket bolts to 22 N.m (16 lb-ft).




4. Connect the harness connector to the back of the generator, if applicable.




5. Route the serpentine accessory drive belt. Refer to Power Steering Pump.
6. Relieve tension on the belt by first applying downward pressure on the automatic tension roller bolt and then releasing pressure once the belt is in place.
7. Install the power steering reservoir.




8. Install the air intake tube and connect the IAT sensor electrical connector.
9. Connect the negative battery cable.