Alternator: Service and Repair

GENERATOR

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.

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.
2. Remove generator drive belt.




3. Unsnap plastic protective cover (1) from B+ mounting stud.
4. Remove B+ terminal mounting nut (2) at top of generator.
5. Disconnect field wire electrical connector (4) at rear of generator by pushing on connector tab.




6. 2.4L Engine: Remove 2 generator mounting bolts (1) and (2).




7. 3.7L Engine: Remove 1 vertical generator mounting bolt (2) and two horizontal mounting bolts (3).
8. Remove generator from vehicle.

INSTALLATION




1. 2.4L Engine: Position generator to engine and install two mounting bolts (1) and (2) and tighten to 57 N.m (42 ft. lbs.)




2. 3.7L Engine: Position generator to engine and install three mounting bolts (2) and (3). Tighten 2 horizontal mounting bolts to specified torque. Tighten 1 vertical mounting bolt and tighten to 40 N.m (29 ft. lbs.)




3. Snap field wire connector (4) into rear of generator.
4. Install B+ terminal (3) and nut (2) to generator mounting stud and tighten to 13 N.m (115 in. lbs.)
5. Snap plastic protective cover (1) to B+ terminal.
6. Install drive belt Refer to Cooling System for belt routing, belt adjustment and bolt tightening procedures.
7. Install negative battery cable to battery.