Generator Replacement

REMOVAL PROCEDURE

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.

CAUTION: Failure to observe Step 1 may result in a serious personal injury. It a tool is shorted at the generator lead, the tool will become hot. enough to cause a serious burn.




1. Disconnect the negative (-) battery cable.
2. Remove the air cleaner hose.
3. Slide the Evaporative Emission (EVAP) canister from the mounting bracket at the inner fender.
4. Remove the generator electrical connector (1) from the back of the generator (2).
5. Remove the rubber protector, the nut and the generator battery terminal wire from the generator battery terminal.
6. Loosen the lower generator mounting bolt.
7. Remove the upper generator mounting bolt (3) and the drive belt from the vehicle.
8. Remove the lower generator mounting bolt and the generator from the vehicle.

INSTALLATION PROCEDURE




1. Install the generator (2) to the vehicle.
2. Install the upper and lower mounting bolts (3) finger tight.
3. Install the drive belt to the generator pulley.





4. Adjust the drive belt tension to obtain the specified deflection with 10 kg (22 lbs) (thumb pressure) of force applied.

USED DRIVE BELT DEFLECTION
6 to 8 mm (0.24 to 0.31 inch)

NEW DRIVE BELT DEFLECTION
5 to 7 mm (0.20 to 0.27 inch)

NOTICE: Refer to Fastener Notice in Cautions and Notices.

5. Tighten the upper and lower generator mounting bolts.

Tighten
Tighten the generator mounting bolts to 33 N.m (24 lb ft).

6. Install the generator electrical connector to the back of the generator.
7. Install the generator battery terminal wire. Secure the battery terminal wire with one nut.

Tighten
Tighten the generator battery terminal retaining nut to 10 N.m (89 lb in).

8. Install the rubber protector over the generator battery terminal.
9. Install the EVAP canister to the mounting bracket at the inner fender.
10. Connect the negative (-) battery cable-to-negative battery terminal.

Tighten
Tighten the negative (-) battery cable-to-negative battery terminal retainer to 5.5 N.m (48.68 lb in).