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.

Remove/Install Generator Connectors - Typical:

3. Remove nuts from harness hold-down, battery terminal, ground terminal and 2 field terminals. Remove wire connectors. A typical generator wiring harness is shown. Wiring harness routing as shown may be slightly different depending on vehicle model and/or engine.

Generator Remove/Install:

4. Remove upper and lower generator mounting bolts.
5. A slide bushing is pressed into the rear mounting ear of 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.

INSTALLATION
1. Position generator to engine and install wiring to rear of generator. Tighten all wiring fasteners as follows:
- 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.)
2. Install generator mounting fasteners and tighten as follows:
- Generator upper mounting bolt/nut-All engines-55 N.m (41 ft. lbs.)
- Generator lower mounting bolt-All engines-55 N.m (41 ft. 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.
3. Install generator drive belt.
4. Install negative battery cable to battery.