Alternator: Service and Repair
GENERATOR
Removal and Installation
CAUTION: Do not allow any metal object to come in contact with the generator housing and internal diode cooling fins. A short circuit may result and burn out the diodes.
1. Disconnect the battery.
2. Remove the right intermediate axle shaft. See HALFSHAFT - FRONT DISASSEMBLY AND ASSEMBLY.
3. Remove the 6 lower splash shield bolts and the 2 pin-type retainers.
NOTE: The LH lower splash shield must be removed before the RH lower splash shield.
4. Remove the lower splash shields.
5. Remove the nut and position the bracket and wiring harness aside.
6. Rotate the front end accessory drive tensioner counterclockwise and position the accessory drive belt aside.
7. Position the generator B+ protective cover aside and remove the generator B+ terminal.
8. Disconnect the generator electrical connector.
NOTE: Discard the removed clip. A new harness tie-wrap with clip (P/N 1F20-61-147) must be used for installation.
9. Remove the clip and cable from the generator.
10. Remove the generator upper air duct bolt.
11. Loosen the 2 lower generator bolts and remove the generator upper air duct.
12. Remove the pin-type retainer from the generator shield.
13. Remove the bolt and the generator shield.
14. Remove the generator stud nut.
15. Remove the generator stud.
16. Remove the 2 generator bolts.
17. Position the generator aside and remove the 3 generator lower air duct nuts.
18. Remove the generator lower air duct.
19. Rotate the generator to gain enough clearance and remove it through the opening in the fender well.
20. If necessary, remove the 2 generator bracket bolts and the generator bracket.
21. To install, reverse the removal procedure.
NOTE:
- A new harness tie-wrap with clip (P/N 1F20-61-147) must be used for installation and attached on the cable 50mm from the splice.
- The clip must be installed to the bottom of the generator at (A).
- Make sure that the clip is fully seated.
- Make sure that the cable is properly routed and not twisted as shown.