Alternator: Service and Repair

REMOVAL

Generator Location - 2.4L Turbo:

The generator is located above the oil filter and axle shaft.
1. Disconnect the negative battery cable.

Generator Heat Shield:

2. Remove the 2 bolts from the top of the heat shield on the generator.

Generator T-Bolt And Upper Pivot Bolt:

3. Remove nut from the upper T-bolt adjustment bracket.
4. Raise vehicle and support.
5. Remove the right front wheel.

Accessory Drive Splash Shield:

6. Remove the accessory drive splash shield.
7. Remove the axle retaining nut.

Axle Shaft:

8. Remove the lower control arm from the steering knuckle.
9. Remove the 2 bolts for the axle shaft bearing support.
10. Remove the axle shaft assembly. Put a container under the transmission to catch the transmission fluid from the transmission.

Lower Heat Shield Mounting:

11. Remove the lower heat shield bolt.
12. Remove the generator heat shield.

Battery Connection On Generator:

13. Unplug the field circuit from the generator.

Generator Field Connections:

14. Remove the B+ terminal nut and wire.
15. Loosen the accessory drive belt T-bolt.

Pencil Strut:

16. Remove the penal strut.

Lower Pivot Bolt:

17. Loosen the lower generator pivot bolt.
18. Remove the generator belt, refer to the Cooling section for more information.
19. Remove the generator from the lower mounting bracket and set generator to the side.

Lower Mounting Bracket:

20. Remove the lower mounting bracket for the generator.

Generator Removal/Installation:

21. Remove generator through the axle shaft hole.

INSTALLATION
1. Install generator through the axle shaft hole in wheel well.
2. Put generator on upper T-bolt and loosely install the nut.
3. Install the lower mounting bracket for the generator to the block and tighten bolts to 54 Nm (40 ft. lbs.).
4. Loose install the lower pivot bolt for the generator.
5. Install the B+ terminal nut and wire and tighten nut to 11.3 Nm (100 in. lbs.).
6. Plug in the field circuit to the generator.
7. Install the axle shaft assembly.
8. Install the 2 bolts for the axle shaft bearing support and tighten bolts to 54.2 Nm (40 ft. lbs).
9. Install the axle shaft into the steering knuckle.
10. Install the lower control arm to the steering knuckle and install the bolt and tighten bolts to 94.9 Nm (70 ft. lbs.).
11. Install the axle retaining nut and tighten nut to 244 Nm (180 ft. lbs.).
12. Install and tension the general or belt, refer to the Cooling section for more information.
13. Tighten the accessory drive belt T-bolt and tighten nut to 54 Nm (40 ft. lbs.).
14. Tighten the lower generator pivot bolt and tighten bolts to 54 Nm (40 ft. lbs.).
15. Install the pencil strut.
16. Install the generator heat shield.
17. Install the lower heat shield bolt and tighten bolt to 54.2 Nm (40 ft. lbs.).
18. Install the accessory drive splash shield.
19. Install the right front wheel.
20. Lower vehicle.
21. Tighten nut to the upper adjustment bracket and tighten to 25 Nm (18 ft. lbs.).
22. Install the 2 bolts to the heat shield on the generator and tighten bolts to 4.5 Nm (40 in. lbs.).
23. Connect the negative battery cable.