Attachment III - Technical Instructions

CAPRI ALTERNATOR DRIVE PULLEY AND BELT INSPECTION/REPLACEMENT INSTRUCTIONS

NOTE:
THESE INSTRUCTIONS REPLACE AND SUPERSEDE TECHNICAL SERVICE BULLETIN ARTICLE NO. 92-6-10.

INSPECTION PROCEDURE





1. Check vehicle build date (see Figure 1) and verify that vehicle is affected by this program. The build date is stamped on either strut tower in the engine compartment. The numbers are approximately 8 mm high in red or yellow ink. The build date is a four-digit code which shows the month then the date but not the year. The year is shown in the VIN. For example: 0509 = May 9th, 1201 = December 1st. Affected vehicles have build dates from February 1, 1991 through January 28, 1992.

2. If vehicle is affected, inspect alternator drive pulley color.

a. If pulley has a bright plated look (silver or gold color), replace both the pulley and the alternator drive belt per Replacement Procedure below. Do not replace bright plated pulleys on vehicles with build dates outside the limits of this program.

b. If the pulley is black and the alternator drive belt is not cogged, replace both the pulley and the alternator drive belt per Replacement Procedure below.

c. If the pulley is black AND the alternator drive belt is cogged, do not replace the pulley or the belt. Instead, retension the belt already on the vehicle as specified in Replacement Procedure below (Steps 9 through 12). IT IS VERY IMPORTANT THAT BELT IS CORRECTLY TENSIONED.

REPLACEMENT PROCEDURE





1. Disconnect the battery negative terminal.

2. Disconnect the electrical wire and connector from the alternator.

3. Loosen the power steering pump drive belt adjustment bolt and remove the drive belt.

4. Remove the alternator lower mounting bolt, upper adjusting bolt and drive belt.

NOTE:
IT MAY BE NECESSARY TO REMOVE OR LOOSEN THE RIGHT HAND FRONT ENGINE SPLASH SHIELD TO REMOVE THE ALTERNATOR LOWER MOUNTING BOLT.

5. Rotate the alternator downward so that the alternator pulley is accessible from beneath the vehicle.

6. Hold the alternator pulley firmly and remove the pulley-securing nut and washer.

NOTE:
THE ALTERNATOR PULLEY CAN BE HELD FIRMLY BY GRASPING IT TIGHTLY WITH THE ORIGINAL ALTERNATOR BELT.

7. Install the new larger diameter alternator pulley, part number F2JY-10344-A.

a. Reinstall the existing nut and washer.

b. Tighten the alternator pulley - securing nut to 63-93 lb.ft. (84-138 N-m).

c. Throw away the original alternator pulley and belt.

8. Attach the alternator by installing the mounting bolt and adjusting bolt. Position the new alternator drive belt, part number F2JY-8620-A, over the pulleys.

CAUTION:
DO NOT USE ANY BELT OTHER THAN THE ONE PROVIDED FOR THIS OWNER NOTIFICATION PROGRAM. DO NOT REUSE THE OLD ALTERNATOR BELT.

9. Move the alternator to obtain the correct belt tension.

NOTE:
APPLY MODERATE THUMB PRESSURE (ABOUT 22 LBS., 10KG) MIDWAY BETWEEN THE ALTERNATOR DRIVE PULLEY AND THE WATER PUMP PULLEY - SEE FIGURE 2. THE NEW BELT DEFLECTION SHOULD BE 0.25-0.35" (6-9 mm).

10. Tighten the alternator mounting bolt to 27-38 lb.ft. (32-52 N-m) and the adjusting bolt to 14-19 lb.ft. (19-26 N-m).

11. Install the powersteering pump drive belt and adjust it to the correct tension.

12. Run the engine for 10 minutes with the air conditioner and headlamps on. THEN RETENSION THE BELT

NOTE:
IT IS IMPORTANT THAT THE BELT IS PROPERLY TENSIONED BEFORE VEHICLE IS RELEASED.

NOTE:
THE ALTERNATOR DRIVE BELT WILL SIT HIGH IN THE WATER PUMP PULLEY AND DRIVE PULLEY. THIS IS NORMAL.