Alternator: Service and Repair

GENERATOR REMOVAL

WARNING: Disconnect negative cable from 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 negative battery cable at battery.

2. Remove generator drive belt.

Fig. 4 R+R Generator LHD:

3. Left Rand Drive (LHD) Vehicles Only: Remove generator pivot and mounting bolts/nut. Position generator for access to wire connectors

Fig. 5 R+R Generator RHD:

4. Right Rand Drive (RHD) Vehicles Only: Remove upper nut (generator adjustment nut) and bolt, belt adjustment bolts. Remove generator lower nut/bolt. Position generator for access to wire connectors.

Fig. 6 R+R Generator Connectors (Typical):

5. Remove nuts from harness hold-down, battery terminal, ground terminal and 2 field terminals. Remove wire connectors. A typical generator wiring harness is shown. Wiring harness routing shown may be slightly different depending on vehicle model and/or engine.

3. Remove generator from vehicle.

INSTALLATION

1. Position generator to engine and instal wiring to rear of generator. Tighten all wiring fasteners as follows:
^ Battery terminal nut - 8.5 Nm (75 in. lbs.)
^ Ground terminal nut - 8.5 Nm (75 in. lbs.)
^ Harness hold-down nut - 8.5 Nm (75 in. lbs.)
^ Field terminal nuts - 2.8 Nm (25 in. lbs.)

2. LHD Vehicles: Install generator fasteners and tighten as follows:
^ Generator upper mounting bolt - 55 Nm (41 ft. lbs.)
^ Generator lower pivot bolt/nut - 55 Nm (41 ft. lbs.)

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. Refer to belt routing label on vehicle.

3. LHD Vehicles: Install generator drive belt. Adjust tension to 800-900 N (180-200 lbs. force) on a new belt, 623-712 N (140-160 lbs. force) on a used belt.

4. RHD Vehicles: Install upper nut (generator adjustment nut) and both belt adjustment bolts. Install generator lower nut/bolt.

5. RHD Vehicles: On vehicles equipped with RHD, the generator is used to adjust the serpentine belt. Adjust tension to 800-900 N (180-200 lbs. force) on a new belt, 623-712 N (140-160 lbs. force) on a used belt.

6. Install negative battery cable to battery.