Alternator: Service and Repair

GENERATOR

REMOVAL

WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM.

1. Disconnect negative battery cable at battery.
2. Raise and support vehicle.




3. A heat shield (1) is used over the right engine mount (3). Remove two heat shield mounting bolts (2). The heat shield must be removed to gain access to generator support bracket nut (refer to following step).




4. Loosen, but do not remove generator support bracket nut (4).
5. Remove bolt (3).
6. Unsnap plastic insulator cap from B+ output terminal.
7. Remove B+ terminal mounting nut at rear of generator. Disconnect terminal from generator.
8. Disconnect field wire connector at rear of generator by pushing on connector tab.
9. Lower vehicle.
10. Remove generator drive belt.




11. Partially drain some engine coolant and remove upper radiator hose.
12. Remove two generator mounting bolts (1).
13. Remove generator (2) from vehicle.

INSTALLATION

Rear Wheel Drive (RWD)




1. Position generator (2) to engine and install 2 mounting bolts (1). Do not tighten bolts (1) at this time.
2. Raise and support vehicle.




3. Position support bracket (1) to generator and install bolt (3). Tighten all bolts / nut.




4. Install heat shield (1) and two heat shield mounting bolts (2).
5. Snap field wire connector into rear of generator.
6. Install B+ terminal eyelet to generator output stud. Tighten mounting nut.
7. Lower vehicle.

CAUTION:
- Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
- When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump may be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment.

8. Install generator drive belt.
9. Install upper radiator hose and fill cooling system with coolant.
10. Install negative battery cable to battery.