Alternator: Service and Repair

Gasoline Powered Engines

REMOVAL

CAUTION: Disconnect negative cable from battery before removing battery output wire from generator. failure to do so can result in injury.

1. Disconnect and isolate negative battery cable at battery.

CAUTION:
- Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
- 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 in engine compartment, or refer to Belt Schematics in Cooling System.

2. Remove generator drive belt. Refer to Cooling System for procedures.

Generator Electrical Connectors - Typical:

3. Unsnap plastic protective cover from B+ mounting stud.
4. Remove B+ terminal mounting nut at top of generator.
5. Disconnect field wire electrical connector at rear of generator by pushing on connector tab.

Generator - 2.4L:

6. 2.4L Engine: Remove 2 generator mounting bolts.

Generator - 3.7L:

7. 3.7L Engine: Remove 1 vertical generator mounting bolt and 2 horizontal mounting bolts.
8. Remove generator from vehicle.

INSTALLATION
1. 2.4L Engine: Position generator to engine and install 2 mounting bolts. Refer to torque specifications.
2. 3.7L Engine: Position generator to engine and install 3 mounting bolts. Tighten 2 horizontal mounting bolts to specified torque. Tighten 1 vertical mounting bolt to specified torque. Refer to torque specifications.
3. Snap field wire connector into rear of generator.
4. Install B+ terminal and nut to generator mounting stud. Refer to torque specifications.
5. Snap plastic protective cover to B+ terminal.

CAUTION:
- Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
- 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 in engine compartment, or refer to Belt Schematics in Cooling System.

6. Install drive belt Refer to Cooling System for belt routing, belt adjustment and bolt tightening procedures.
7. Install negative battery cable to battery.