Removal and Replacement

Generator Removal and Installation

Removal

1. Disconnect the negative battery cable.
2. Disconnect the manifold air temperature (MAT) sensor electrical connector the air intake tube.




3. Remove all the clamps from the air cleaner outlet hose, and set aside the tube.
4. Raise and suitably support the vehicle.
5. Disconnect the harness connector from the back of the generator, and the generator lead to the battery.
6. Remove the serpentine accessory drive belt by lowering the vehicle and turning the automatic tensioner roller bolt clockwise to relieve tension on the belt. Refer to Serpentine Accessory Drive Belt Removal and Installation.




7. Push up the power steering reservoir and set it aside.




8. Remove the generator upper mounting bolts to the intake manifold/cylinder head support bracket, the intake manifold strap bracket, and the intake manifold-to-cylinder body strap bracket.




9. Raise and suitably support the vehicle and remove the nut and washers which hold the generator lower bracket-to-generator bolt. Work the bolt loose and remove the generator.
10. Remove the generator lower support bracket bolts.
11. Carefully remove the generator with the lower bracket.




12. Remove the generator lower support bracket nut, the bolt, and the washer.

Installation




1. Install the generator to the generator lower bracket and insert the generator bolt.

Tighten: Tighten the generator lower bracket-to-generator nut to 25 Nm (18 ft. lbs.).




2. Install the generator and the lower support bracket assembly to the engine block (as shown).

Tighten: Tighten the generator and the lower bracket-to-engine block bolts to 37 Nm (27 ft. lbs.).




3. Install the generator-to-intake manifold and cylinder head support bracket bolts, the generator-to-intake manifold strap bracket bolt, and the intake manifold-to-cylinder body strap bracket bolts over the starter.

Tighten:
Tighten the generator-to-intake manifold and cylinder head support bracket bolts to 37 Nm (27 ft. lbs.).
Tighten the generator-to-intake manifold strap bracket bolt and the intake manifold-to-cylinder body strap bracket bolts to 22 Nm (16 ft. lbs.).

4. Route the serpentine accessory drive belt. Refer to Serpentine Drive Belt Removal and Installation.
5. Relieve tension on the belt by first applying downward pressure on the automatic tension roller bolt and releasing pressure once the belt is in place.




6. Install the power steering reservoir.
7. Install the air cleaner outlet hose and connect the MAT electrical connector.




8. Connect the negative battery cable.