Alternator: Service and Repair

REMOVAL

All vehicles
1. Disconnect the battery ground cable.

WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.







2. Remove the air cleaner outlet pipe.







3. Remove the intake air resonator.







4. Disconnect the generator electrical connectors.
5. Remove the accessory drive belt.
6. Lower the vehicle.

Vehicles without returnless fuel system







7. Disconnect the fuel supply and return lines.

Vehicles with returnless fuel system







8. Disconnect the fuel supply line from the fuel injection supply manifold.

All vehicles







9. Detach the generator.
1 Loosen the generator lower bolt.
2 Detach the generator.







10. Remove the generator.

CAUTION: There is a very limited amount of space in which to remove the generator. Do not overstress or damage any hoses or cables.

INSTALLATION







1. To install, reverse the removal procedure.

WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.