Alternator: Service and Repair

REMOVAL

WARNING: DISCONNECT BOTH NEGATIVE CABLES FROM BOTH BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM.

1. Disconnect both negative battery cables at both batteries.
2. Remove generator drive belt.
3. Unsnap plastic insulator cap from B+ output terminal.

Fig. 7 Diesel Generator Connectors:

4. Remove B+ terminal mounting nut at rear of generator. Disconnect terminal from generator.
5. Disconnect field wire connector at rear of generator by pushing on connector tab.

Fig. 6 5.9L Diesel Generator:

6. Remove upper mounting bracket bolt.
7. Remove lower mounting bracket bolt and nut.
8. Remove generator from vehicle.


INSTALLATION
1. Position generator to upper and lower mounting brackets and install upper bolt and lower bolt / nut.
2. Tighten all bolts / nut to 41 Nm (30 ft. lbs.).
3. Snap field wire connector into rear of generator.
4. Install B+ terminal eyelet to generator output stud. Tighten mounting nut to 12 Nm (108 in. lbs.) torque.

CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.

CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump will be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat.

5. Install generator drive belt.
6. Install both negative battery cables to both batteries.