Generator Replacement (Delphi KG9)

REMOVAL PROCEDURE
1. Disconnect the battery ground (negative) cable from the battery. Refer to Battery Negative Cable Disconnect/Connect Procedure. Service and Repair
2. Remove the drive belt from generator.
3. Remove the windshield wiper system module cover.
4. Remove the windshield wiper motor crank arm link from the wiper motor and move aside.
5. Position the wiper arms to a vertical position on windshield.
6. Remove the engine mount strut bracket bolts and rotate engine forward.
7. Disconnect the electrical connector from the generator.
8. Remove the following from the generator output BAT terminal:
8.1. Boot
8.2. Nut
8.3. Battery (positive) lead
9. Remove the generator front brace.
10. Remove the generator rear brace.
11. Remove the generator bolt (pivot bolt) and nut from the generator.
12. Place a floor jack at the center front of the frame.

NOTICE: Make sure that lowering the frame does not interfere with the bumper fascia or subsequent fascia damage may result.

13. Remove the front frame bolts.
14. Lower the frame 76 m.m (3 in).
15. Remove the generator.

INSTALLATION PROCEDURE
1. Install the generator.
2. Raise the frame using the floor jack.
3. Install new front frame bolts.
4. Remove the floor jack.
5. Install the generator bolt (pivot bolt) to the generator.

Tighten
Tighten the generator bolt (pivot bolt) to 50 N.m (37 lb ft).

6. Install the generator rear brace.
7. Install the generator front brace.
8. Install the battery (positive) lead to the generator output BAT terminal with the nut.

Tighten
Tighten the battery (positive) lead BAT nut to 25 N.m (18 lb ft).

9. Install the boot.
10. Connect the electrical connector to the generator.
11. Rotate the engine rearward and install engine mount strut bracket bolts. Refer to Rotating the Engine for Service Access in Engine Mechanical -3.1L, 3.4L.
12. Install the windshield wiper motor crank arm link to wiper motor.
13. Install the windshield wiper system module cover.
14. Install the drive belt to the generator.
15. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure. Service and Repair
16. Inspect the front end toe-in alignment. Refer to Front Toe Adjustment in Wheel Alignment.