Alternator: Service and Repair

Generator Replacement (With L61 and LE5)

Removal Procedure





1. Disconnect negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair) .
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair) for the 2.2L (L61) engine or Air Cleaner Assembly Replacement (Service and Repair) for the 2.4L engine.
3. Remove the drive belt. Refer to Drive Belt Replacement (Service and Repair) for the 2.2L (L61) engine or Drive Belt Replacement (Service and Repair) for the 2.4L engine.
4. Lower the vehicle.
5. Remove the generator terminal nut (2).
6. Remove the engine harness terminal (1) from the generator.




7. Remove the generator upper bolts.
8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair) .
9. Cut the tie straps and reposition the coolant heater cord, if equipped.
10. Remove the generator lower bolt.




11. Disconnect the generator electrical connector (3).
12. Remove the generator.



Installation Procedure





1. Raise the generator into position.
2. Connect the generator electrical connector (3).




3. Install the generator lower bolt until snug.
4. Position the coolant heater cord and secure with NEW tie straps, if equipped.
5. Lower the vehicle.
6. Install the generator upper bolts until snug.

Notice: Refer to Fastener Notice (Fastener Notice) .

7. Tighten the generator bolts.

Tighten the bolts to 22 N.m (16 lb ft).





8. Install the engine harness terminal (1) to the generator.
9. Install the generator terminal nut (2).

Tighten the nut to 20 N.m (15 lb ft).

10. Install the drive belt. Refer to Drive Belt Replacement (Service and Repair) for the 2.2L (L61) engine or Drive Belt Replacement (Service and Repair) for the 2.4L engine.
11. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair) for the 2.2L (L61)or Air Cleaner Assembly Replacement (Service and Repair) for the 2.4L engine.
12. Connect negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair) .