Alternator: Service and Repair

WARNING: BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL INJURY. DO NOT ALLOW FLAMES, SPARKS OR LIGHTED TOBACCO TO COME NEAR THE BATTERY. WHEN CHARGING OR WORKING NEAR A BATTERY, ALWAYS SHIELD YOUR FACE AND PROTECT YOUR EYES. ALWAYS PROVIDE VENTILATION.

WARNING: WHEN LIFTING A PLASTIC-CASED BATTERY, EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE ACID TO SPEW THROUGH THE VENT CAPS, RESULTING IN PERSONAL INJURY. LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS.

WARNING: KEEP BATTERIES OUT OF REACH OF CHILDREN. BATTERIES CONTAIN SULFURIC ACID. AVOID CONTACT WITH SKIN, EYES OR CLOTHING. ALSO, SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION. IN CASE OF ACID CONTACT WITH THE SKIN, EYES OR CLOTHING, FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES. IF ACID IS SWALLOWED, DRINK LARGE QUANTITIES OF MILK OR WATER, FOLLOWED BY MILK OF MAGNESIA, A BEATEN EGG OR VEGETABLE OIL. CALL A PHYSICIAN IMMEDIATELY.

NOTE: The voltage regulator (VR) is the only internally serviceable component on this generator (GEN).

Removal




1. Disconnect the battery ground cable.

2. Remove the accessory drive belt from the generator pulley.

3. Remove the power steering line bracket and heater hose support bracket from the generator.

4. Remove the upper generator bolts.

5. Partially raise the vehicle on a hoist.

6. Remove the right front wheel.

7. Remove the lower fender splash shield retainers and position the shield out of the way.

8. Remove the generator splash shield.

9. Raise the vehicle.

10. Disconnect the electrical connector and remove the battery positive cable from the generator.

11. Position an adjustable stand to the subframe.

12. Remove the right subframe bolts.

13. Remove the lower generator bolt.

14. Lower the subframe to provide clearance.

15. Remove the generator.

Installation




1. NOTE: Do not tighten the lower bolt Install the generator and the lower bolt.

2. Raise the subframe and install the subframe bolts. Tighten the bolts to 90 Nm (66 lb-ft).

3. Remove the adjustable stand.

4. Lower the vehicle.

5. Install the upper generator bolts and tighten them to 25 Nm (18 lb-ft).

6. Install the power steering line bracket and the heater hose support bracket. Tighten the nut to 20 Nm (15 lb-ft).

7. Install the accessory drive belt.

8. Partially raise the vehicle.

9. Tighten the lower generator bolt to 25 Nm (18 lb-ft).

10. Connect the generator electrical connector.

11. Install the battery positive B + cable and nut. Tighten the cable nut to 10 Nm (89 lb-in).

12. Install the generator splash shield.

13. Install the fender splash shield and the retainers.

14. Install the right front wheel.

15. Lower the vehicle.

16. Connect the negative battery cable.