Alternator: Service and Repair

Generator,

WARNING: HYDROGEN AND OXYGEN GASES ARE PRODUCED DURING NORMAL BATTERY OPERATION. THIS GAS MIXTURE CAN EXPLODE IF FLAMES, SPARKS OR LIGHTED SUBSTANCES ARE BROUGHT NEAR THE BATTERY (10655). WHEN CHARGING OR USING A BATTERY IN AN ENCLOSED SPACE, ALWAYS PROVIDE VENTILATION AND SHIELD YOUR EYES. WARNING: KEEP BATTERIES OUT OF REACH OF CHILDREN. BATTERIES CONTAIN SULFURIC ACID. AVOID CONTACT WITH SKIN, EYES OR CLOTHING. ALSO, SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION. IN CASE OF ACID CONTACT WITH THE SKIN, EYES OR CLOTHING, FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF FIFTEEN MINUTES. IF ACID IS SWALLOWED, DRINK LARGE QUANTITIES OF MILK OR WATER, FOLLOWED BY MILK OF MAGNESIA, A BEATEN EGG, OR VEGETABLE OIL. CALL A PHYSICIAN IMMEDIATELY.






Removal

1. Disconnect battery ground cable.
2. Disconnect the wire harness attachments to the integral generator. Pull the two connectors straight out.






3. Disengage the accessory drive belt from the generator pulley.
4. Remove the generator mounting bolts and remove generator.

Installation






1. Position the integral generator on the engine.
2. Install the upper generator mounting bolt. Tighten upper mounting bolt to 21-29 N.m (16-21 lb-ft).
3. Install the lower generator mounting bolt. Tighten lower mounting bolt to 40-55 N.m (30-40 lb-ft)
4. Install the accessory drive belt over the generator pulley.
5. Connect the engine control sensor wiring to the generator. Tighten output terminal nut to 9-12 N.m (80-106 lb-in).
6. Connect battery ground cable.