Generator Replacement 3100 L82 (VIN M)

The CS130D generator is serviced as a complete unit only.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

Caution: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions:

1. Disconnect the negative battery cable from the battery terminal. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the drive belt from the generator. Refer to Drive Belt Replacement in Engine Mechanical - 3.1L.



3. Remove the bolts from the generator.



4. Remove the electrical connector from the generator.
5. Remove the nut and the battery positive lead from generator output BAT terminal.



6. Loosen the generator front and rear braces at the engine intake manifold.
7. Remove the generator.

1. Position the generator to the generator bracket.




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.

2. Connect the battery (positive) lead to the generator with the generator output BAT terminal nut.

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

3. Connect the electrical connector to the generator.



4. Hand start the generator front and rear brace nuts to the engine intake manifold.
5. Hand start the generator rear brace bolt to the generator.



6. Install generator bolts through the generator bracket and into the generator.

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




7. Tighten the generator front and rear brace nuts at the engine intake manifold.

Tighten
Tighten the brace nuts to 25 N·m (18 lb ft).

8. Tighten the generator rear brace stud to the generator.

Tighten
Tighten the rear brace stud to 25 N·m (18 lb ft).

9. install the drive belt to the generator. Refer to Drive Belt Replacement in Engine Mechanical - 3.1L.
10. Connect the negative battery cable with the negative battery terminal bolt to the battery terminal. Refer to Battery Negative Cable Disconnection and Connection .

Generator Replacement 3800 L36 (VIN K)

Caution: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions:

The CS130D generator is serviced as a complete unit only.

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.8L.



3. Remove the generator front brace. Refer to Generator Brace Replacement .



4. Disconnect the electrical connector from the generator.
5. Remove the bolts from the generator.
6. Remove the protective boot from the generator output BAT terminal.
7. Remove the generator output BAT terminal nut and disconnect the positive battery lead from the generator.
8. Remove the generator.

1. Install the generator.




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.

2. Connect the positive battery lead and install the generator output BAT terminal nut.

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

3. Install the protective boot to the generator output BAT terminal.



4. Hand start all the following bolts before tightening:

Install the generator front lower bolt.

Tighten
Tighten the generator front lower generator bolt to 50 N·m (37 lb  ft).

5. Install the generator brace stud through the generator flange and the generator bracket.

Tighten
Tighten the generator brace stud to 30 N·m (22 lb ft).




6. Install the generator rear brace bolt.

Tighten
Tighten the generator rear brace bolt to 30 N·m (22 lb ft).




7. Connect the electrical connector to the generator.



8. Install the generator front brace. Refer to Generator Brace Replacement .
9. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.8L.
10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

Generator Replacement 3800 Police and Taxi

The CS144 generator is serviceable.

Caution: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System. Failure to follow the correct procedure could cause the following conditions:

•	Air bag deployment

•	Personal injury

•	Unnecessary SIR system repairs

In order to avoid the above conditions, observe the following guidelines:

•	Refer to SIR Component Views in order to determine if you are performing service on or near the SIR components or the SIR wiring.

•	If you are performing service on or near the SIR components or the SIR wiring, disable the SIR system. Refer to Disabling the SIR System.

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.8L.
3. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.8L.
4. Remove the bolts from the generator.



5. Disconnect the electrical connector from the generator.
6. Remove the protective boot from the generator output BAT terminal.
7. Remove the generator output BAT terminal nut and disconnect the positive battery lead from the generator.
8. Remove the generator.

1. Install the generator to the vehicle.




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.

2. Connect the positive battery lead and install the generator output BAT terminal nut.

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

3. Press the protective boot on to the generator output BAT terminal.
4. Connect the electrical connector to the generator.



5. Hand start all the following bolts before tightening:

Install the generator front lower bolt.

Tighten
Tighten the generator front lower generator bolt to 50 N·m (37 lb  ft).

6. Install the generator brace bolt through the generator flange and into the drive belt tensioner bracket.

Tighten
Tighten the generator brace bolt to 30 N·m (22 lb ft).

7. Install the generator bolt through the flange and into the generator rear brace assembly.

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

8. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.8L.
9. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.8L.
10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .