Alternator: Service and Repair

Generator Replacement

Removal Procedure




1. Disconnect the negative battery cable.
2. Remove the drive belt.
3. Remove the fuel injector sight shield.
4. Remove the engine mount strut bracket.
5. Remove the air conditioning (A/C) liquid line clamp bolt (2) from the upper radiator support.




6. Remove the coolant recovery reservoir bolts (1).
7. Remove the reservoir (2) tabs from the upper radiator support, position the reservoir out of the way.




8. Reposition the battery positive junction block cable boot (1).
9. Remove the battery positive junction block cable to generator nut (2).
10. Remove the battery positive junction block cable terminal (3) from the generator stud.




11. Disconnect the engine wiring harness electrical connector (1) from the generator (2).




12. Remove the power steering reservoir inlet hose clip (1) from the power steering fluid reservoir hose clip bracket (2).




13. Loosen the idler pulley (1) bolt and slide the pulley out as far as possible.




14. Remove the generator bolts (2).
15. Remove the A/C compressor/evaporator hose bracket (1) from against the generator.
16. Remove the power steering fluid reservoir hose clip bracket (3) from against the generator.
17. Remove the generator (4) and idler pulley (5) together from the vehicle.
18. Remove the idler pulley from the generator.

Installation Procedure




1. Install the idler pulley (5) to the generator.
2. Install the generator (4) and idler pulley together to the vehicle.
3. Install the power steering fluid reservoir hose clip bracket (1) onto one of the generator bolts, and install the bolt finger tight.
4. Install the A/C compressor/evaporator hose bracket (2) onto the other generator bolt, and install the bolt finger tight.

Notice: Refer to Fastener Notice.

5. Tighten the idler pulley/generator bolts (2) in the following sequence:

1. Idler pulley bolt
2. Generator bolts

Tighten the bolts to 50 N.m (37 lb ft).




6. Install the power steering reservoir inlet hose clip (1) to the power steering fluid reservoir hose clip bracket (2).




7. Connect the engine wiring harness electrical connector (1) to the generator.




8. Install the battery positive junction block cable terminal (3) to the generator stud.
9. Install the battery positive junction block cable to generator nut (2).

Tighten the nut to 22 N.m (16 lb ft).

10. Position the battery positive junction block cable boot (1) over the stud.




11. Install the coolant recovery reservoir (2) tabs into the appropriate slots in the upper radiator support.
12. Install the coolant recovery reservoir bolts (1).

Tighten the bolts to 5 N.m (44 lb in).




13. Install the A/C liquid line clamp bolt (2) at the upper radiator support.

Tighten the bolt to 9 N.m (80 lb in).

14. Install the engine mount strut bracket.
15. Install the fuel injector sight shield.
16. Install the drive belt.
17. Connect the negative battery cable.