Generator Replacement 3.8L

The Delphi CS130D (K68) 105 ampere generator is serviced as a complete unit only.

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



4. Remove the bolts (1, 3) and stud (2) from the generator.
5. Disconnect the electrical connector from the generator.
6. Position aside the protective boot from the generator output BAT terminal for access.
7. Remove the generator output BAT terminal nut and remove the positive battery lead from the generator.
8. Remove the generator.

1. Position the generator to the engine.




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. Install the positive battery lead to the generator.
3. Install the generator output BAT terminal nut.

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

4. Install the protective boot to the generator output BAT terminal.
5. Connect the electrical connector to the generator.

Important: Do not tighten the stud.

6. Install the generator stud (2) to the generator bracket.

Important: Do not tighten the bolts.

7. Install the generator bolts (1, 3) to the generator bracket.
8. Tighten the generator bolts and stud in the order described. The following is a mandatory torque sequence:

Tighten

1. Tighten the generator bolt (1) to 50 N·m (37 lb ft).
2. Tighten the generator stud (2) to 50 N·m (37 lb ft).
3. Tighten the generator rear bracket bolt (3) to 50 N·m (37 lb ft).
9. Install the generator rear brace. Refer to Generator Brace Replacement .
10. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.8L.
11. Connect the negative battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .

Generator Replacement 3.1L

1. Disconnect the negative battery cable. 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. Place the coolant recovery reservoir aside for access. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
4. Remove the generator rear brace nut (4).
5. Remove the bolts (1, 2, 3) from the generator.
6. Disconnect the electrical connector from the generator.
7. Remove the protective boot from the generator output BAT terminal.
8. Remove the generator output BAT terminal nut and remove the positive battery lead from the generator.
9. Remove the generator.

1. Position the generator to the engine.

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. Install the positive battery lead to the generator.
3. Install the generator output BAT terminal nut.

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

4. Install protective boot to the generator output BAT terminal.
5. Connect the electrical connector to the generator.




Important: Do not tighten the bolts.

6. Install the generator bolts (2, 3) to the generator.

Important: Do not tighten the bolt.

7. Install the generator pivot bolt (1) to the generator.
8. Tighten the generator bolts in the order described. The following is a mandatory torque sequence:

Tighten

1. Tighten the generator pivot bolt (1) to 50 N·m (37 lb ft).
2. Tighten the generator bolt (2) to 50 N·m (37 lb ft).
3. Tighten the generator bolt (3) to 50 N·m (37 lb ft).
9. Install the generator rear brace nut (4).

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

10. Install the coolant recovery reservoir . Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
11. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.1L.
12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .