Alternator: Service and Repair
GENERATOR REPLACEMENTREMOVAL PROCEDURE
The Delphi AD237 (KG7) 125 ampere generator is serviced as a complete unit only.
1. Disconnect the negative battery cable.
2. Remove the battery tray.
3. Remove the drive belt.
4. Remove the engine cooling fan assembly.
5. Remove the water inlet housing.
6. Remove the outboard generator bolt
7. Loosen the inboard generator bolt
8. Remove the idler pulley bolt and the idler pulley.
9. Disconnect the electrical connector from the generator.
10. Remove the protective boot from the generator output BAT terminal.
11. Remove the generator output BAT terminal nut.
12. Remove the generator output BAT terminal wire from the generator.
13. Remove the generator.
INSTALLATION PROCEDURE
1. Position the generator to the engine.
2. Install the generator output BAT terminal wire to the generator.
NOTE: Refer to Fastener Notice in Service Precautions.
3. Install the generator output BAT terminal nut.
Tighten
Tighten the nut to 20 N.m (15 lb ft).
4. Install the protective boot to the generator output BAT terminal.
5. Connect the electrical connector to the generator.
6. Install the outboard generator bolt into the generator housing.
7. Install the generator on the inboard generator bolt and finger tighten the outboard bolt.
8. Install the idler pulley and idler pulley bolt.
9. Tighten the bolts in the order described. The following is a mandatory torque sequence:
9.1. The idler pulley bolt.
Tighten
Tighten the bolt to 50 N.m (37 lb ft).
9.2. The inboard and outboard generator bolts.
Tighten
Tighten the bolts to 50 N.m (37 lb ft).
10. Install the water inlet housing.
11. Install the engine cooling fan assembly.
12. Install the battery tray.
13. Install the drive belt.
14. Connect the negative battery cable.
For a description of the RPO Code(s) shown in this article/image, refer to the RPO Code List found at Vehicle/Application ID. RPO Codes