Headlamps/Headlights and/or Interior Lights Flicker Intermittently (Replace Generator Voltage Regulator)

This bulletin is being revised to add the 2007 model year and update the part number. Please discard Corporate Bulletin Number 05-06-03-003B (Section 06 - Engine/Propulsion System).

Some customers may comment that the headlamps and/or interior lights flicker intermittently. This condition may occur when other accessories are engaged and may be most noticeable in the fog or at idle.

This condition may be caused by fluctuations in generator output.

Do NOT replace the entire generator.

Replace the generator voltage regulator following the service procedure below.

Important: The generator does not need to be removed from the vehicle to perform this procedure.

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect.
2. Loosen the drive belt and remove the belt from the generator pulley. Refer to Drive Belt Replacement in Engine Mechanical - 3.5 or Engine Mechanical 3.9.
3. Disconnect the electrical connectors off the back of the generator. If equipped, remove nut holding power steering lines to generator and reposition power steering lines aside.
4. Remove all three mounting bolts on the generator. Keep the mounting bolts in a safe place for use in Step 10. The generator can be rested on the mounting bracket for support in Steps 5-9.
5. Remove the end cover and brush protector.
6. Remove the old voltage regulator.
7. Install the new voltage regulator.
8. Install the new brush protector, included in the kit.
9. Install a new end cover, included in the kit.
10. Reinstall the three generator mounting bolts. (Make sure that dielectric grease is still present on metal contact areas of mounting bolt holes. If not, place a thin film of dielectric grease on metal contacts.)

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

11. Connect the electrical connectors. If equipped, install the nut holding the power steering lines on the back of the generator.
12. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.5 or Engine Mechanical 3.9.
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect.
14. Test generator function using VAT-40.
15. Make sure that the battery is fully charged. Refer to Battery Charging in SI.

For vehicles repaired under warranty, use: