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REMOVAL & INSTALLATION
3.0L Engine
Disconnect the battery negative cable from the battery terminal.
Remove the Pre-volume chamber.
Remove the serpentine drive belt from the generator.
Raise and safely support the vehicle securely on jackstands.
Unscrew the terminal nuts and remove the electrical leads from the generator.
Remove the generator air-cooling duct.
Remove the upper nut from the generator and AIR injection crossover pipe
Remove the lower bolt and nut.
Disconnect the generator from the engine-with the generator loose, push the upper mounting bolt out of the generator and bracket.
Lower the vehicle.
Remove the generator from the vehicle.
To install:
Place the generator into the vehicle.
Raise and safely support the vehicle securely on jackstands.
Mount the generator to the engine-with generator loosely installed onto engine, insert the upper mounting bolt.
Install the lower bolt and nut and tighten to 30 ft. Lbs. (40 Nm).
Install the upper nut to the generator and AIR injection crossover pipe, and tighten the nut to 30 ft. Lbs. (40 Nm).
Install the generator air-cooling duct.
Connect the electrical leads and terminal nuts to the generator. Tighten the field coil terminal nut to 31 inch lbs. (3.5 Nm). Tighten the battery terminal nut to 71 inch lbs. (8 Nm).
Lower the vehicle and install the serpentine belt to the generator.
Install the pre-volume chamber.
Connect the negative battery cable.
Seville With 4.6L Engine
On some models, the generator is water-cooled. When this is the case, the repair procedure is as follows:
Disconnect the negative battery cable.
Remove the accessory drive belt.
Drain and recycle the engine coolant.
Remove the radiator.
NOTE
If your vehicle is equipped with air conditioning, refer to the information regarding the implications of servicing your A/C system yourself. Only an MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.
Remove the A/C condenser.
Raise and safely support the vehicle securely.
Disconnect the coolant inlet and outlet hoses from the generator.
Detach the electrical connections from the generator. The regulator, the battery output, and the heated windshield (if equipped) will need to be unplugged.
Remove the generator fasteners from the generator.
Remove the generator from the vehicle.
To install:
Attach the generator to the engine and tighten the fasteners to 37 ft. Lbs. (50 Nm).
Attach the electrical connections for the regulator, battery output, and the heated windshield.
Tighten the battery output cable to 15 ft. Lbs. (20 Nm).
Reconnect the coolant inlet and outlet hoses to the generator.
Lower the vehicle.
Install the A/C condenser.
Install the radiator.
Install the accessory drive belt.
4.5L and 4.9L Engine
Disconnect the negative battery cable.
Remove the generator harness connector and battery charging wire on the back of the generator. Heated windshield 3-phase connector and clip if equipped.
Release the tension from the drive belt land remove the belt from the generator pulley. Do not remove the belt from any other component pulleys.
Remove the volts, ABS ground strap, and generator from the vehicle.
To install:
Install the generator and ground strap to the mounting bracket with bolts tightened to 20 ft. Lbs. (27 Nm).
Raise the drive belt tensioner. Position the drive belt over the generator pulley and release the tensioner.
Attach the generator harness connector and battery-charging wire to the generator output stud. Do not route the battery charging wire to rest against the cruise control servo. Tighten to 15 ft. Lbs. (20 Nm). Do not overtighten.
Connect the negative battery cable.
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Tuesday, January 19th, 2010 AT 1:34 PM
