Alternator: Service and Repair

REMOVAL

WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY.

1. Disconnect negative battery cable at battery
2. Remove generator drive belt.

Fig. 4 Generator Remove/Install:

3. Remove nuts from harness hold-down, battery terminal, ground terminal and 2 field minals. Remove wire connectors.

Fig. 3 Remove/Install Generator Connectors - Typical:

4. Remove the upper and lower generator mounting bolts.
5. A spacer is pressed into the rear mounting ear of the generator. Pry or drive this spacer rearward about 1/8 Inch to loosen generator from upper mounting bracket. This will allow generator to be tilted for removal.
6. Remove generator from vehicle.
7. Reverse removal procedures to install. Tighten generator hardware as follows:
- Generator upper mounting bolt - All engines 55 N.m (41 ft. lbs.)
- Generator lower mounting bolt - All engines - 55 N.m (41 ft. lbs.)
- Battery terminal nut - 8.5 N.m (75 in. lbs.)
- Ground terminal nut - 8.5 N.m (75 in. lbs.)
- Harness hold-down nut - 8.5 N.m (75 in. lbs.)
- Field terminal nuts - 2.8 N.m (25 in. lbs.)

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.