Alternator: Service and Repair

Generator - 2.5L









Removal

NOTICE: Do not allow any metal object to come in contact with the generator housing and internal diode cooling fins. A short circuit may result and burn out the diodes. Failure to follow this instruction may result in component damage.

1. With the vehicle in NEUTRAL, position it on a hoist.

2. Disconnect the battery.

3. Remove the 5 bolts, 1 pushpin and the RH lower splash shield.

4. Rotate the front end accessory drive belt tensioner clockwise and position the accessory drive belt aside.

5. Remove the battery harness locator from the lower generator stud.

6. Remove the generator bolt.

7. Remove the 2 generator stud nuts.

8. Working from the top of the vehicle, press the locking tab to release the generator lower air duct from the generator and remove the lower air duct.

9. Position the generator B+ protective cover aside and remove the generator B+ terminal nut.

10. Position the generator B+ cable aside.

11. Disconnect the generator electrical connector.

12. Remove the generator.

13. Remove the 3 screws and the generator upper air duct.

Installation

1. Install the 3 screws and the generator upper air duct.
- To install, tighten to 4 Nm (35 lb-in).

2. Working from the top of the vehicle, install the generator and the generator stud.

3. Install the 2 generator stud nuts hand-tight.

4. Install the generator B+ cable and install the generator B+ terminal nut.
- To install, tighten to 12 Nm (106 lb-in).

5. Connect the generator electrical connector.

6. Position the generator B+ protective cover on the B+ terminal.

7. Working from under the vehicle, install the lower generator bolt hand-tight.

8. Tighten the 2 generator stud nuts.
- To install, tighten to 47 Nm (35 lb-ft).

9. Install the lower generator air duct.

10. Tighten the generator bolt.
- To install, tighten to 47 Nm (35 lb-ft).

11. Rotate the front end accessory drive belt tensioner clockwise and position the accessory drive belt onto the pulleys.

12. Install the 5 bolts, 1 pushpin and the RH lower splash shield.
- To install, tighten to 8 Nm (71 lb-in).

13. Position the harness locator on the generator stud.

14. Connect the battery.