Alternator: Service and Repair

Generator - 2.5L









Removal

NOTICE: Do not allow any metal object to come in contact with the generator housing and internal diode cooling fins. A short circuit may result and burn out the diodes. Failure to follow this instruction may result in component damage.

NOTE: The radial arm adapter is a serviceable item. Do not replace the generator if the radial arm adapter is the only concern.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.

2. Disconnect the battery. For additional information, refer to Battery, Mounting and Cables Battery Disconnect.

3. Remove the 4 RH lower splash shield screws.

4. Remove the 6 pushpins and the RH lower splash shield.

5. Rotate the Front End Accessory Drive (FEAD) belt tensioner clockwise and position the accessory drive belt aside.

6. Working from the top of the vehicle, press the locking tab to release the generator lower air duct from the generator and remove the lower air duct.

7. Remove the battery harness locator from the lower generator stud bolt.

8. Remove the lower generator bolt.

9. Remove the 2 generator stud nuts.

10. Position the generator B+ protective cover aside and remove the generator B+ terminal nut.

11. Position the generator B+ cable aside.

12. Disconnect the generator electrical connector.

13. Remove the 2 generator studs and remove the generator.

14. Remove the 3 screws and the generator upper air duct.

Installation

1. Position the generator upper air duct and install the 3 screws.
- Tighten to 4 Nm (35 lb-in).

2. Working from the top of the vehicle, position the generator and install the generator upper stud hand-tight.

3. Install the generator lower stud hand-tight.

4. Install the generator B+ cable and install the generator B+ terminal nut.
- Tighten to 12 Nm (106 lb-in).

5. Connect the generator electrical connector.

6. Position the generator B+ protective cover on the B+ terminal.

7. Working from under the vehicle, install the lower generator bolt hand-tight.

8. Working from the top of the vehicle, tighten the 2 generator studs to 24 Nm (18 lb-ft).

9. Tighten the 2 generator stud nuts to 47 Nm (35 lb-ft).

10. Tighten the generator bolt to 47 Nm (35 lb-ft).

11. Push the lower air duct onto the upper air duct until the locking tab is engaged.

12. Position the RH lower splash shield and install the 6 pushpins.

13. Position the RH wheel splash shield and install the 4 screws.
- Tighten to 8 Nm (71 lb-in).

14. Position the harness locator on the generator stud.

15. Connect the battery. For additional information, refer to Battery, Mounting and Cables Battery Disconnect.

16. Rotate the FEAD belt tensioner clockwise and position the accessory drive belt on the pulley.