The Denso G3A generator is serviced as a complete unit only.

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the auxiliary drive belt. Refer to Auxiliary Drive Belt Replacement in Engine Mechanical-4.6L.



3. Disconnect the wiring harness connector from the auxiliary generator.
4. Reposition the protective boot from the auxiliary generator output BAT terminal for access.
5. Remove the auxiliary generator output BAT terminal nut and disconnect the positive lead from the auxiliary generator.



6. Remove the surge tank mounting nuts (2) and bolt (3).
7. Remove the overflow hose retainer from the mounting stud at the strut tower.
8. Carefully position aside the surge tank (1) in order to remove the auxiliary generator mounting bolt.




Important: There are 3 shims (3) located between the auxiliary generator and the front of the auxiliary generator bracket.

9. Remove the auxiliary generator mounting bolts (1, 4) and nut (2).
10. Remove the auxiliary generator (5) from the vehicle.

1. Position the auxiliary generator (5) to the engine.
2. Install the 3 shims (3) between the auxiliary generator and the front of the auxiliary generator bracket.
3. Install the generator mounting bolts (1, 4) and nut (2).



4. Position the surge tank (1) to the mounting studs.

Important: Ensure that the overflow hose is properly routed through the retainer.

5. Position the overflow hose retainer to the mounting stud at the strut tower.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

6. Install the surge tank mounting nuts (2) and bolt (3).

Tighten
Tighten the surge tank nuts (2) and bolt (3) to 6 N·m (53 lb in).




7. Connect the wiring harness connector to the auxiliary generator.
8. Connect the battery positive lead and install the auxiliary generator output BAT terminal nut.

Tighten
Tighten the auxiliary generator output BAT terminal nut to 10 N·m (89 lb in).

9. Press the protective boot over the auxiliary generator output BAT terminal.
10. Install the auxiliary drive belt. Refer to Auxiliary Drive Belt Replacement in Engine Mechanical-4.6L.
11. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .