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. Refer to Cooling System for procedure.

Fig.2 Generator B+ Cable And Field Wire Connections (Typical - 4.0L Engine Shown):

3. Unsnap cable protector cover from B+ mounting stud (Fig. 2).
4. Disconnect (unsnap) 2-wire field connector at rear of generator (Fig. 2).

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

Fig.4 Remove/Install Generator - 4.0L 6-Cylinder Engine:

5. Remove generator mounting bolts (Fig. 3) or (Fig. 4).
6. Remove generator from vehicle.

INSTALLATION
1. Position generator to engine and install mounting bolts.
2. Tighten generator mounting bolts as follows:
- Vertical mounting bolt 4.7L engine-40 Nm (29 ft. lbs.)
- Long horizontal mounting bolt 4.7L engine-55 Nm (41 ft. lbs.)
- Short horizontal mounting bolt 4.7L engine-55 Nm (41 ft. lbs.)
- Generator mounting bolts 4.0L engine-55 Nm (41 ft. lbs.)
- B+ terminal nut-11 Nm (95 in. lbs.)
3. Snap 2-wire field connector into rear of generator.
4. Snap cable protector cover to B+ mounting stud.

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.

5. Install generator drive belt.
6. Install negative battery cable to battery