Alternator: Service and Repair

REMOVAL

WARNING
^ BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL INJURY. DO NOT ALLOW FLAMES, SPARKS OR LIGHTED TOBACCO TO COME NEAR THE BATTERY. WHEN CHARGING OR WORKING NEAR A BATTERY, ALWAYS SHIELD YOUR FACE AND PROTECT YOUR EYES. ALWAYS PROVIDE VENTILATION.
^ WHEN LIFTING A PLASTIC-CASED BATTERY, EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE ACID TO SPEW THROUGH THE VENT CAPS, RESULTING IN PERSONAL INJURY. LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS.
^ KEEP BATTERIES OUT OF REACH OF CHILDREN. BATTERIES CONTAIN SULFURIC ACID. AVOID CONTACT WITH SKIN, EYES OR CLOTHING. ALSO, SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION. IN CASE OF ACID CONTACT WITH THE SKIN, EYES OR CLOTHING, FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES. IF ACID IS SWALLOWED, DRINK LARGE QUANTITIES OF MILK OR WATER, FOLLOWED BY MILK OF MAGNESIA, A BEATEN EGG OR VEGETABLE OIL. CALL A PHYSICIAN IMMEDIATELY.






1. Disconnect battery ground cable.

NOTE: The Generator (GEN) is not internally serviceable.

2. Disconnect the electrical connectors from the integral generator/voltage regulator.
3. Loosen the generator pivot bolt. Remove the mounting brace bolt from the generator.
4. Disengage the accessory drive belt from the generator pulley.
5. Remove generator brace.
6. Remove the generator pivot bolt and generator/voltage regulator.

INSTALLATION
1. Position the generator/voltage regulator on the engine.
2. Install the generator pivot and mounting brace bolts, but do not tighten the bolts until the drive belt is tensioned.
3. Install generator brace. Tighten retaining nut to 20-30 N.m (15-22 Lb-Ft). Tighten generator brace bolts to 8.5-11 N.m (76-97 Lb-In).
4. Install the accessory drive belt over the generator pulley.
5. Tighten the mounting brace bolt to 20-30 N.m (15-22 Lb-Ft) and pivot bolt to 40-55 N.m (30-40 Lb-Ft).
6. Connect the wiring harness to the generator/voltage regulator. Tighten generator output nut (B+) to 9-11 N.m (80-97 Lb-In).
7. Connect battery ground cable.