Service Procedure
GENERATOR WIRING HARNESS REPLACEMENTCAUTION:
THE BATTERY NEGATIVE CABLE MUST BE DISCONNECTED FIRST TO PREVENT ARCING.
1. Disconnect the battery negative cable. (Record radio station presets.)
CAUTION:
MAKE SURE THE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED PRIOR TO LIFTING. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.
2. Raise vehicle.
CAUTION:
BE CAREFUL NOT TO CONTACT HOT EXHAUST PIPE.
3. Remove starter motor splash shield retainer by pulling out center pin with pliers (first design) or inserting a small screwdriver in the flat and rotate screwdriver to remove the center pin (second design). (Refer to illustration.)
4. With center pin removed, remove outer portion of the starter motor splash shield retainer.
5. Remove starter motor splash shield, by lifting upward and pulling backward at the top of the shield to remove shield from the starter motor.
6. Remove the generator splash shield attachment bolt and unclip the generator splash shield from the generator. (Refer to illustration.)
7. Pull back protective cover (rubber boot) on the generator wiring harness at the generator B + stud and remove generator wiring harness nut. (Refer to illustration View A)
NOTICE:
Always spray the starter motor solenoid B+ stud and nut with penetrating oil prior to removing the nut. Use extreme care when loosening the nut to prevent cracking the solenoid's phenolic end cap. A cracked end cap will allow debris and moisture to corrode the solenoid contacts.
8. Remove nut from the B+ stud on the starter motor solenoid, remove generator wiring harness (red wire) and discard harness. (Refer to illustration.)
Note:
To effectively torque generator B+ stud nut and starter motor solenoid B+ stud nut, it may be necessary to utilize a 12 Pt. socket with a click-type torque wrench with the appropriate scale.
NOTICE:
Do not over-torque the starter motor solenoid's B+ stud nut. Over-torquing will crack the solenoid's phenolic end cap, allowing debris and moisture to corrode the electrical contacts.
9. Install new generator wiring harness assembly (orange wire) on the starter motor solenoid's B+ stud and tighten nut.
Torque: 10 N-m (89 in.lbs.)
NOTICE:
Make sure generator wiring harness terminal crimp, at generator B+ stud faces away from generator. (Refer to illustration View A.)
10. On DOHC (LLO) engines, route the generator wiring harness behind intake manifold support bracket to the generator B+ stud and position terminal between the 10 and 11 o'clock position and tighten nut. (Refer to illustration.)
11. On SOHC (LKO) engines, route the generator wiring harness to the generator B + stud and position terminal between the 10 and 11 o'clock position and tighten nut.
Torque: 10 N-m (89 in.lbs.)
12. Install the protective cover (rubber boot) on the generator wiring harness assembly over the B+ terminal of the generator. The protective cover (rubber boot) must be properly installed to prevent moisture intrusion.
13. Install the generator splash shield by clipping shield to generator then install bolt and tighten. Make sure the EVO and generator wires are properly routed. (Refer to illustration.)
Torque: 10 N-m (89 in.lbs.)
14. Install starter motor splash shield and retainer. Make sure the engine wiring harness is routed on the outside of the starter motor splash shield. (Refer to illustration.)
NOTICE:
Inspect generator wiring harness (orange wire) and make sure it is not contacting starter motor or generator splash shields, or EVO and engine wiring harness conduit. (Refer to illustration.)
15. Lower vehicle.
16. Connect battery negative cable. (Reset clock and radio station presets, noted in step 1.)
Torque: 17 N-m (151 in.lbs.)
17. Affix the campaign completion label as outlined by "CAMPAIGN COMPLETION LABEL" in "Misc. Dealer Information."