The following general information has been assembled as a guide for alternator removal and installation. Refer to the appropriate Original Equipment Manufacturer’s service manual for specific information pertaining to alternator removal and installation procedures and safety precautions for your vehicle.
- Disconnect the negative battery cable from the vehicle. CAUTION: Personal injury or damage to the vehicle or its components may occur if this step is not performed.
- Identify each wire connection and note the location of each on the alternator.
- Disconnect the wires from the alternator.
- Loosen the alternator pivot bolt. Do not remove the bolt at this time.
Loosen the tension assembly’s lock nut or bolt and turn the adjustment bolt so that drive belt tension is reduced far enough to allow belt removal.
- Some vehicles may be equipped with an automatic, spring-loaded tensioner. Rotate the spring-loaded tensioner using the appropriate tool far enough to allow drive belt removal.
- Remove the drive belt(s) from the alternator.
- Support the alternator and remove the bolts holding the alternator in place. Set the bolts and alternator aside. Be sure to note bracket orientation and fastener length and location before removing the alternator.
- Inspect the condition of the wiring and connectors. Inspect for frayed wire ends, continuity, loose or broken connectors, corrosion, and pliability. Repair or replace as necessary.
- Physically compare the replacement alternator to the original. Compare the case and pulley offsets, pulley size and type, pivot and adjustment hole locations, and wire connector locations or rear housing clocking with the original alternator.
- Install the mounting bracket(s). Do not completely tighten the bolts at this time.
- Support the alternator and fasten it into position. Do not completely tighten the bolts at this time.
- Install the drive belt(s). If the drive belt(s) was found to be worn, stretched, cracked, oily, or glazed during the charging system inspection, replace the belt(s).
- Set the belt tension while tightening the mounting and adjusting bolts. Be sure to set the belt tension and torque the mounting bolts to the vehicle manufacturer’s recommended specifications. CAUTION: DO NOT pry or hit the alternator housing to adjust belt tension.
- Check the drive belt alignment between the alternator pulley and drive pulley(s). Be sure there is no interference between the drive belt(s) and other components.
- Re-connect the wire connector(s) to their proper location on the alternator. Be sure there is no interference between the wire harness and other components.
- Re-inspect that all components are correctly installed, all threaded fasteners properly torqued and there is no interference between components.
- Re-connect the battery negative cable.
- Start the engine and be sure there is no interference between components. Let the engine idle for 10 minutes to break-in the drive belt(s). Readjust the drive belt(s) using the “used” tension specification.
- Shut the engine off and re-inspect that all components are correctly installed, all fasteners properly torqued and there is no interference between components.
- Re-test the charging system to verify it is performing to the vehicle manufacturer’s specifications.