- Replacement Alternator
- Shop towels
Remove Negative Battery Cable Step 2 - Release the serpentine belt tensioner to remove the belt. Please visit - Removing Serpentine Belt
Remove Serpentine Belt
Alternator Main Power Step 4 - Using a socket remove the main power cable lead mounting nut from the alternator.
Remove Alternator Main Power Cable Mounting Nut Step 5 - After the nut has been removed, grasp the main power cable and lift it from the alternator terminal.
Main Power Cable Step 6 - Locate the alternator wiring harness, grasp the dust boot and pull it back enough to access the electrical connector.
Pull Dust Boot Back Step 7 - While releasing the safety clip on the side of the connector, pull to remove the wiring harness.
Remove Wiring Harness Connector Step 8 - After clearing any wiring or hoses, use a wrench or socket to remove the upper alternator mounting bolt and bracket.
Remove Top Mounting Bolt Step 9 - Locate and remove the lower mounting bolt.
Remove Bottom Mounting Bolt Step 10 - After the mounting bolts have been removed, grasp the alternator and move it back and forth, this will help release the press fit (lower mounting bracket) used to hold the alternator in place.
Move Alternator Back and Forth Step 11 - Once the alternator becomes loose in the engine bay, gently lift to remove. (Note: This step can take some trial and error depending on application.)
Failed Alternator Step 12 - Match the new alternator to the old unit, including electrical plug to ensure a proper installation.
Match New Alternator Step 13 - Most alternator mounting brackets include a press fit sleeve that must be moved slightly outward to make installation possible.
Press Fit Sleeve Step 14 - Using a large punch gently hammer the sleeve outward to allow room for the new alternator. (Note: Without this step reinstallation will be difficult.)
Punch Alternator Bracket Sleeve Step 15 - The sleeve will look like this once moved, creating a gap in which to lower the alternator into.
Sleeve Moved Step 16 - Gently lower the new alternator into the engine bay.
Install Alternator Step 17 - Once the alternator is in place, reinstall the lower mounting bolt, leave it hand tight until the installation of the upper bolt, then tighten completely.
Installing Lower Mounting Bolt Step 18 - Reinstall any brackets removed in the process.
Reinstall Bracket Step 19 - Hand thread in the upper mounting bolt and tighten, then tighten the lower bolt as well.
Reinstall Upper Mounting Bolt Step 20 - After all mounting bolts are tight, reinstall the wiring harness along with the rubber dust boot.
Reconnect Wiring Harness Step 21 - Reinstall main charge cable and mounting nut, gently tighten the cable into place (do not over tighten), reinstall rubber dust boot, also, reinstall any wiring harness position clips.
Install Charge Cable Step 22 - Check the condition of the serpentine belt, replace if needed and reinstall. Please visit - Serpentine Belt Replacement
Reinstall Serpentine Belt Step 23 - Gently touch the negative cable to the battery post, there should be a small spark, tighten the cable end. (Note: If a large spark is generated the alternator charge cable is grounded and needs to be rechecked.) Once the job is complete the alternator operation should be tested. Please Visit - Alternator Testing
Reconnect Negative Battery Cable Helpful Information When an alternator fails the battery warning light will come on, the battery to lose charge causing the engine to stall and not crank over.