Alternator Replacement Procedure

1. Install fender covers on the vehicle.

2. Record the radio station pre-sets.

3. Turn the ignition key to the OFF position and disconnect the negative cable from the battery.

4. Raise the vehicle on a hoist and remove the passenger side lower and side engine plastic covers.





5. Loosen the drive belt tension adjuster/idler pulley lock nut (see Figure 2).





6. Loosen the drive belt tension adjuster (see Figure 3) and remove the drive belt from the alternator pulley.





7. Remove the alternator wire harness support bracket bolt (see Figure 4).





8. Disconnect the alternator wire harness (S & L terminal) connector from the alternator (see Figure 5).

9. Disconnect the wire harness "eye-loop" terminal from the alternator "B" terminal (see Figure 5).

10. Disconnect the wire harness from the A/C compressor.

11. Re-position the alternator wire harness towards the passenger side inner wheel well to gain access to the alternator.





12. Remove the bolt that secures the upper alternator support bracket to the alternator (see Figure 6) and remove the bracket from the alternator.








13. Remove the four A/C compressor mounting bolts (see Figure 7) and carefully lower the A/C compressor assembly on to a support jack (see Figure 8) to gain access to the alternator.

CAUTION:
Do not allow the A/C compressor to hang from the A/C hoses or do not stretch the A/C hoses at any time.





14. Remove the alternator pivot mounting bolt (see Figure 9).





CAUTION:
When removing the pivot mounting bolt, hold on to the nut (located on the back side of the alternator) to avoid dropping the nut after the pivot bolt is removed. See Figure 11.





15. Remove the alternator from the vehicle (see Figure 10).

16. Position the new alternator in the vehicle and insert the pivot mounting bolt through the alternator.

17. Position the nut on the end of the pivot mounting bolt (see Figure 11). Tighten the pivot mounting bolt finger tight only at this time.

18. Re-install the A/C compressor assembly and tighten the four compressor mounting bolts to 45 - 60 N.m (4.6 - 6.1 kg-m, 33 - 44 ft-lb).

19. Re-install the upper alternator support bracket (see Figure 6). Finger tighten the mounting bolt at this time.

20. Install the other end of the alternator upper support bracket and the alternator wire harness support bracket to the engine and tighten the mounting bolt to 1 5.7 - 20.6 N.m (1.6 - 2.1 kg-m, 11.6 - 15.2 ft-lb).

21. Tighten the bolt that secures the upper support bracket to the alternator to 15.7 - 20.6 N.m (1.6 - 2.1 kg-m, 11.6 - 15.2 ft-lb).





22. Re-connect the wire harness (S & L terminal) connector to the alternator.

23. Re-connect the wire harness eye-loop terminal to the alternator "B" terminal and tighten the nut to 7.84-10.78 N.m (0.80-1.10 kg-m, 69.4 - 95.5 in-lb).

24. Tighten the alternator pivot mounting bolt to 44.1 - 52.0 N.m (4.5 - 5.3 kg-m, 32.5 - 38.3 ft-lb) making sure the pivot mounting bolt nut is correctly positioned (see Figure 11).

25. Re-connect the wire harness to the A/C compressor.

26. Re-install the drive belt.

27. Adjust the drive belt tension adjuster (see Figure 12) until the drive belt deflection is within 4.2 - 4.6 mm (0.165 - 0.181 in).

NOTE:
Check the drive belt deflection between the crankshaft and A/C compressor pulleys (see Figure 12) by pushing on the drive belt with a force of 98 N (10kg, 22 lb).

28. Tighten the drive belt tension adjuster/idler pulley lock nut to 25 - 32 N.m (2.6 - 3.3 kg-m, 19-24 ft-lb).

29. Re-install the lower and side engine plastic covers.

30. Re-connect the negative cable to the battery.

31. Re-program the radio station pre-sets.

32. Re-set the interior clock.

33. Start the vehicle and confirm the alternator charge light (in the instrument display) goes out and that the A/C system operates properly.