Generator Replacement 2.4L

Caution: Refer to Battery Disconnect Caution in the Preface section.




1. Disconnect the negative battery cable.
2. Disconnect the intake air temperature (IAT) sensor connector.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .



4. Disconnect the harness connector from the generator.
5. Remove the generator upper bracket mounting bolts and the generator-to-intake manifold strap bracket bolts.



6. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
7. Remove the serpentine accessory drive belt. Refer to Drive Belt Replacement .
8. Disconnect the generator lead-to-starer motor wire from the generator.




Important: Do not remove the generator through bolt, nut and washers at this stage.

9. Loosen the nut and washers which hold the generator lower bracket-to-generator bolt.
10. Remove the generator lower support bracket bolts.
11. Carefully remove the generator with the lower support bracket.



12. Remove the generator-to-lower support bracket through bolt, nut and washer.

Important: Do not tighten the generator through bolt at this stage.

1. Install the generator lower support bracket to the generator and insert the through bolt.

Notice: Refer to Fastener Notice in the Preface section.




2. Install the generator and the lower support bracket assembly to the engine block.

Tighten
Tighten the generator lower support bracket bolts to 25 N·m (18 lb ft).

3. Tighten the generator-to-generator lower support bracket through bolt.

Tighten
Tighten the generator through bolt to 40 N·m (30 lb ft).




4. Connect the generator lead-to-starer motor wire to the generator.
5. Install the serpentine accessory drive belt. Refer to Drive Belt Replacement .
6. Lower the vehicle.



7. Install the generator upper bracket and the generator-to-intake manifold strap bracket.
8. Install the generator upper bracket mounting bolts and the generator-to-intake manifold strap bracket bolts.

Tighten

•	Tighten the generator upper bracket retaining bolts (1) to 25 N·m (18 lb ft) and the bolt (2) to 35 N·m (26  lb ft).

•	Tighten the generator-to-intake manifold strap bracket retaining bolt (3) to 35 N·m (26 lb ft) and the bolt (4) to 25 N·m (18 lb ft).




9. Connect the harness connector to the generator.
10. Install the air cleaner assembly and connect the IAT sensor connector. Refer to Air Cleaner Assembly Replacement .
11. Connect the negative battery cable.

Generator Replacement 2.0L Diesel

Caution: Refer to Battery Disconnect Caution in the Preface section.




1. Disconnect the battery negative cable.
2. Remove the engine cover. Refer to Engine Cover Replacement .
3. Remove the charge air cooler inlet hoses. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement .



4. Remove the accessory belt. Refer to Drive Belt Replacement .



5. Disconnect the generator connector.
6. Remove the generator B+ wiring harness.
7. Remove the generator.

1. Install the generator.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the generator lead-to-starter motor wire retaining nut.

Tighten

•	Tighten the generator bolt to 30 N·m (22.1  lb ft).

•	Tighten the generator B+ wiring harness retaining nut to 25 N·m (18.4 lb ft).

Generator Replacement 3.2L

Caution: Refer to Battery Disconnect Caution in the Preface section.




1. Disconnect the negative battery cable.
2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.



4. Rotate the accessory drive belt tensioner clockwise to reduce the belt tension.
5. While holding the tensioner in the reduced tension position, disconnect the belt.



6. Remove the cooling fan assembly. Refer to Engine Cooling Fan Replacement.



7. Remove the nut which secures the generator-to-battery lead wire (1) from the generator.
8. Disconnect the wiring harness connector (2) from the generator.
9. Remove the generator upper mounting bolts.



10. Loosen the accessory drive belt idler.
11. Support the generator and remove the through bolt.
12. Remove the generator.

Important: Do not tighten the accessory drive belt idler pulley-to-generator through bolt at this stage.

1. Position the generator and hand tighten the accessory drive belt pulley-to-generator through bolt.

Notice: Refer to Fastener Notice in the Preface section.




2. Install the generator upper mounting bolts (3).

Tighten

•	Tighten the generator-to-battery lead wire retaining nut to 58 N·m (43 lb ft).

•	Tighten the accessory drive belt idler pulley-to-generator through bolt to 50 N·m (37 lb ft).

3. Install the generator-to-battery lead wire (1) retaining nut to the generator.

Tighten
Tighten the generator-to-battery lead wire retaining nut to 15 N·m (11 lb in).

4. Connect the wiring harness connector (2) to the generator.



5. Rotate the accessory drive belt tensioner clockwise.
6. While holding the tensioner in the reduced tension position, install the belt.



7. Install the cooling fan assembly. Refer to Engine Cooling Fan Replacement.



8. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
9. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
10. Connect the battery negative cable.