Alternator Replacement

Fig. 5 Alternator Mounting. 1989-91 5.7L Single Cam 16 Valve Engine:

Fig. 6 Alternator Mounting. 1992 5.7L Single Cam 16 Valve Engine:

1. Disconnect battery ground cable, then remove intake air duct.
2. Disconnect regulator electrical connector and battery lead from rear of alternator.
3. On 1989-91 models, rotate serpentine belt tensioner using a 1/2 inch breaker bar to release belt tension, then remove serpentine drive belt.
4. On 1992-93 models, using a suitable socket and handle on tensioner pulley bolt, lift tensioner upward in the clockwise direction, then remove serpentine drive belt.
5. On all models, remove alternator rear mounting bolt and nut, then remove alternator rear mounting bracket, Figs. 5 and 6.
6. Remove two bolts from alternator upper mounting, then remove upper mounting bracket.
7. Remove two bolts from alternator lower mounting, then remove lower mounting bracket.
8. Remove alternator from vehicle.
9. Reverse procedure to install, noting the following:
a. Do not tighten alternator mounting bolts until all mounting brackets and bolts have been installed.
b. Torque alternator lower and upper mounting bolts to 37 ft. lbs.
c. Torque alternator rear mounting bolt to 17 ft. lbs. and rear mounting nut to 24 ft. lbs.
d. On 1989-91 models, position serpentine drive belt over pulleys, then rotate tensioner using a 1/2 breaker bar.
e. On 1992-93 models, lift tensioner using a suitable socket and handle on pulley bolt, then position serpentine drive belt over pulleys and release tensioner.
f. On 1989-91 models, check serpentine drive belt tension using a suitable belt tension gauge. Belt tension should be 120 to 140 lbs. on 1989 models, 60 to 90 lbs. on 1990-91 models. If not replace serpentine drive belt or tensioner as necessary.
g. On 1992-93 models, check to ensure belt tension indicator marks are within limit lines on belt tensioner indicator.