Service Manual Update - Generator Replacement

This bulletin is being issued to revise the Generator Replacement procedure in the Engine Mechanical sub-section of the Service Manual. The addition of radiator removal has been added to this procedure in order to provide sufficient room to remove the generator through the top of the engine compartment.

Please replace the current information in the Service Manual with the following information.

The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page.

Removal Procedure

1. Remove the rear seat cushion. Refer to Seats and Carpet.
2. Disconnect the negative battery cable. Refer to Battery Disconnect Caution in General Information.
3. Remove the radiator. Refer to Radiator Replacement in Engine Cooling.
4. Remove the accessory drive belt from the power steering pulley.
5. Remove the accessory drive belt from the generator.
6. Remove the upper generator bolts.
7. Disconnect the battery lead.



8. Disconnect the voltage regulator connector.
9. Disconnect the ground strap.
10. Remove the power steering line bracket to gain access to the generator.
11. Raise and suitably support the vehicle.



12. Remove the lower generator bolts.
13. Remove the air inlet duct.
14. Remove the generator through the top left side of the engine compartment.

Installation Procedure

1. Install the generator through the top left side of the engine compartment.
2. Install the air inlet duct.
3. Install the lower generator bolts.

Tighten
Tighten the lower generator bolts to 38 N·m (28 lb ft).

4. Install the ground strap.
5. Install the power steering line bracket.
6. Install the generator mounting bolts.

Tighten
Tighten the generator mounting bolts to 47 N·m (35 lb ft).

7. Install the generator output terminal nut.

Tighten
Tighten the generator output terminal nut to 20 N·m (15 lb ft).




8. Connect the voltage regulator connection.
9. Install the accessory drive belt.
10. Install the radiator. Refer to Radiator Replacement in Engine Cooling.
11. Connect the negative battery cable.
12. Install the rear seat cushion. Refer to Seats and Carpet.

Removal Procedure

1. Remove the rear seat cushion. Refer to Seat Cushion Replacement -- Rear in Seats.

Caution: Refer to Battery Disconnect Caution in Cautions and Notices.

2. Disconnect the negative battery cable.
3. Remove the upper radiator shroud.
4. Remove the air inlet duct.
5. Remove the radiator. Refer to Radiator Replacement in Engine Cooling.
6. Remove the accessory drive belt from the generator. Refer to Drive Belt Replacement in Engine Mechanical.
7. Disconnect the electrical connector from the generator.
8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



9. Remove the lower splash shield.
10. Remove the generator mounting bolts.
11. Remove the nuts and the studs.
12. Lower the vehicle.
13. Remove the power steering hose from the reservoir.



14. Remove the generator through the top left side of the engine compartment.

Installation Procedure

1. Install the generator through the top left side of the engine compartment.
2. Connect the power steering hose to the reservoir.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

Notice: Refer to Fastener Notice in Cautions and Notices.

4. Install the generator mounting studs and nuts.

Tighten
Tighten the lower generator bracket to block nuts to 38 N·m (28 lb ft).

5. Install the generator mounting bolts.

Tighten
Tighten the generator mounting bolts to 50 N·m (37 lb ft).

6. Install the lower splash shield.
7. Lower the vehicle.



8. Connect the electrical connector.
9. Install the accessory drive belt. Refer to Drive Belt Replacement in Engine Mechanical.
10. Install the radiator. Refer to Radiator Replacement in Engine Cooling.
11. Install the upper radiator shroud.
12. Install the air inlet duct.
13. Connect the negative battery cable.
14. Install the rear seat cushion. Refer to Seat Cushion Replacement -- Rear in Seats.

Removal Procedure

1. Remove the rear seat cushion. Refer to Seat Cushion Replacement -- Rear in Seats.

Caution: Refer to Battery Disconnect Caution in Cautions and Notices.

2. Disconnect the negative battery cable.
3. Remove the upper radiator shroud.
4. Remove the air inlet duct.
5. Remove the radiator. Refer to Radiator Replacement in Engine Cooling.
6. Remove the accessory drive belt from the generator. Refer to Drive Belt Replacement in Engine Mechanical.
7. Disconnect the electrical connector from the generator.
8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



9. Remove the lower splash shield.
10. Remove the generator mounting bolts.
11. Remove the nuts and the studs.
12. Lower the vehicle.
13. Remove the power steering hose from the reservoir.



14. Remove the generator through the top left side of the engine compartment.

Installation Procedure

1. Install the generator through the top left side of the engine compartment.
2. Connect the power steering hose to the reservoir.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

Notice: Refer to Fastener Notice in Cautions and Notices.

4. Install the generator mounting studs and nuts.

Tighten
Tighten the lower generator bracket to block nuts to 38 N·m (28 lb ft).

5. Install the generator mounting bolts.

Tighten
Tighten the generator mounting bolts to 50 N·m (37 lb ft).

6. Install the lower splash shield.
7. Lower the vehicle.



8. Connect the electrical connector.
9. Install the accessory drive belt. Refer to Drive Belt Replacement in Engine Mechanical.
10. Install the radiator. Refer to Radiator Replacement in Engine Cooling.
11. Install the upper radiator shroud.
12. Install the air inlet duct.
13. Connect the negative battery cable.
14. Install the rear seat cushion. Refer to Seat Cushion Replacement -- Rear in Seats.