Alternator: Service and Repair

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. Remove generator drive belt.
3. Unsnap plastic cable protector cover from B+ mounting stud.

Fig.3 Remove/Install Generator - 4.7L V-8 Engine:

4. Remove 3 generator mounting bolts (Fig. 3). Position generator for access to wire connectors.

Fig.4 Generator Connectors - Typical Denso:

5. Remove B+ terminal mounting nut at rear of generator (Fig. 4). Disconnect terminal from generator.
6. Disconnect field wire connector at rear of generator by pushing on connector tab and pulling connector from generator.
7. Remove generator from vehicle.

INSTALLATION
1. Position generator to engine and snap field wire connector into rear of generator.
2. Install B+ terminal to generator mounting stud. Tighten mounting nut to 12 Nm (108 in. lbs.) torque.
3. Install generator mounting fasteners and tighten as follows:
- Vertical mounting bolt 55 Nm (40 ft. lbs.)
- Long horizontal mounting bolt 55 Nm (40 ft. lbs.)
- Short horizontal mounting bolt 74 Nm (55 ft. lbs.)
4. Install generator drive belt.

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 will 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.

5. Snap cable protector cover to B+ mounting stud.
6. Install negative battery cable to battery.