Generators & Regulators: Removal & Installation

REMOVAL & INSTALLATION

Note. Manufacturer recommends that generators should be serviced as a unit and not overhauled.

Removal - Non-Supercharged

Open the engine compartment hood to service position and install body protection covers. Disconnect the battery ground cable and remove the battery cover. See «BATTERY DISCONNECT PROCEDURE»(ref-164580-S13051001112004081000000) under MISCELLANEOUS.
Remove the 2 bolts which secure the air intake tube to the throttle body. Disconnect the air intake tube from the throttle body. (Scheme 5)
Release the 5 clips which secure the air cleaner cover. (Scheme 6) Disconnect the airflow meter connector.
Disconnect the breather pipe from the "A" bank valve cover. Remove and discard the "O" ring from the breather pipe. Remove the air intake tube/airflow meter/air cleaner cover assembly. (Scheme 7) Remove and discard the air intake tube-to-throttle body rubber seal.
Cut and remove the strap which secures the vacuum pipe to the intake manifold elbow.
Remove the air filter element. Remove the nut which secures the base of the air cleaner assembly to the rubber mounting. Release the assembly from the lower rubber mountings. Release the intake tube from the assembly by moving it into the grommet in the inner fender. Remove the air cleaner assembly. (Scheme 8)
Raise and support vehicle. Disconnect both the high and low speed cooling fans and reposition the harnesses from the retaining clips. Reposition the A/C line from the clip on the radiator fan assembly. Lower vehicle.
Remove the 2 radiator fan assembly nuts and remove fan assembly from the radiator. (Scheme 9)
Check that the accessory drive belt wear indicator is within the limit marks. see scheme 8
Using Spanner Wrench (Churchill JD-230 or Snap-On XDHM 1415) on the center bolt of the belt tensioner idler pulley, turn the adjuster assembly to the left against spring tension. While holding the tensioner against spring tension, remove the drive belt from the generator pulley. Release the tensioner slowly and remove the spanner wrench. Remove belt from all other pulleys. (Scheme 10) Raise and support vehicle.
Remove the generator cooling ducts from the generator. The ducting is comprised of the lower cooling duct/air intake and the upper cooling duct. (Scheme 11) The upper section is retained by 2 screws and the lower section is retained by one screw.
Remove the protective boot from the positive main output terminal and remove the terminal nut. Remove the cable from the terminal and where fitted, remove the suppression module positive cable from the terminal. Where fitted, remove the nut which secures the suppression module negative cable and remove the cable from the generator. Remove the generator 3-pin connector, lower generator mounting bolt and generator harness retaining clip. (Scheme 12) Reposition generator harness to the side and lower vehicle.
Remove the upper generator mounting bolt. (Scheme 13)
Carefully, move the generator forward towards the radiator. Change the position of the generator and remove it upwards between the engine and the radiator. (Scheme 14)
Position a suitable length bolt through the generator mounting bushing, fit a tubular spacer and nut. (Scheme 15) Tighten the assembly to move the bush slightly. Remove the nut, bolt and spacer.

Installation

Install generator to the engine. (Scheme 14) Position the generator and install the upper mounting bolt and nut, but do not fully tighten. (Scheme 13)
Raise and support vehicle. Reposition and align the generator harness retaining clip to the generator lower mounting. (Scheme 16) Install the lower mounting bolt and nut. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-164580-S04605585612004081000000).
Install the suppression module negative harness connector to the generator negative terminal. Install and tighten the terminal nut. Install the suppression module positive harness connector and positive main output connector to the generator positive terminal. Install and tighten the terminal nut. Install the boot to the positive main output terminal and install the generator 3-pin connector. (Scheme 17)
Install the generator cooling ducts to the generator. (Scheme 11) The upper section is retained by 2 screws and the lower section is retained by one screw. Lower the vehicle.
Tighten the generator upper mounting bolt to specification. See «TORQUE SPECIFICATIONS»(ref-164580-S04605585612004081000000).
Install engine drive belt around all pulleys except the generator. Using Spanner Wrench (Churchill JD-230 or Snap-On XDHM 1415) on the center bolt of the belt tensioner idler pulley, turn the adjuster assembly to the left against spring tension. While holding the tensioner against spring tension, install the drive belt around the generator pulley. Release the tensioner slowly and remove the spanner wrench. (Scheme 10)
Install the fan assembly to the radiator. Install the 2 radiator fan assembly nuts and tighten. (Scheme 9)
Raise and support vehicle. Connect both the high and low speed cooling fans and reposition the harnesses to the retaining clips. Reposition the A/C line to the clip on the radiator fan assembly. Lower vehicle.
Install the air cleaner assembly into the rubber mountings and install the nut that secures the base of the air cleaner. Install the intake tube into the air cleaner assembly. (Scheme 8)
Install a NEW air intake tube-to-throttle body seal. Install a NEW "O" ring to the "A" bank breather pipe and install the air intake tube/airflow meter/air cleaner cover assembly. (Scheme 7)
Secure the 5 air cleaner cover clips and connect the airflow meter connector. (Scheme 6)
Connect the air intake tube to the throttle body and install the 2 bolts which secure the air intake tube to the throttle body. (Scheme 5)
Install a NEW strap to secure the vacuum pipe to the intake manifold elbow.
Connect battery. See «BATTERY RECONNECT PROCEDURE»(ref-164580-S32475472932004081000000) under MISCELLANEOUS.

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Removal - Supercharged

Drain the cooling system. For 2001 models, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING - VEHICLES WITH: SUPERCHARGER»(ref-198529-S00617077792005101800000). For 2002 models, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING - VEHICLES WITH: SUPERCHARGER»(ref-198529-S00617077792005101800000).
Open the engine compartment hood to service position and install body protection covers. Disconnect the battery ground cable and remove the battery cover. See «BATTERY DISCONNECT PROCEDURE»(ref-164580-S13051001112004081000000) under MISCELLANEOUS.
Remove the 2 bolts which secure the air intake tube to the throttle body. Disconnect the air intake tube from the throttle body. (Scheme 5)
Release the 5 clips which secure the air cleaner cover. (Scheme 6) Disconnect the airflow meter connector.
Disconnect the breather pipe from the "A" bank valve cover. Remove and discard the "O" ring from the breather pipe. Remove the air intake tube/airflow meter/air cleaner cover assembly. (Scheme 7) Remove and discard the air intake tube-to-throttle body rubber seal.
Cut and remove the strap which secures the vacuum pipe to the intake manifold elbow.
Remove the air filter element. Remove the nut which secures the base of the air cleaner assembly to the rubber mounting. Release the assembly from the lower rubber mountings. Release the intake tube from the assembly by moving it into the grommet in the inner fender. Remove the air cleaner assembly. (Scheme 8)
Raise and support vehicle. Disconnect both the high and low speed cooling fans and reposition the harnesses from the retaining clips. Reposition the A/C line from the clip on the radiator fan assembly. Lower vehicle.
Remove the 2 radiator fan assembly nuts and remove fan assembly from the radiator. (Scheme 9)
Check that the supercharger drive belt wear indicator is within the limit marks. see scheme 8
Remove supercharger drive belt by fitting a 1/2 inch square drive ratchet or bar into square opening on front face of tensioner. Rotate tensioner assembly to the right (viewed from front) against spring tension. While holding the tensioner against spring tension, remove supercharger drive belt from tensioner pulley. Release tensioner slowly and remove bar. Disconnect supercharger drive belt from other pulleys and remove it from rear of tensioner. (Scheme 19)
Remove the supercharger belt tensioner. (Scheme 20)
Check that the accessory drive belt wear indicator is within the limit marks. see scheme 8
Using Spanner Wrench (Churchill JD-230 or Snap-On XDHM 1415) on the center bolt of the belt tensioner idler pulley, turn the adjuster assembly to the left against spring tension. While holding the tensioner against spring tension, remove the drive belt from the generator pulley. Release the tensioner slowly and remove the spanner wrench. Remove belt from all other pulleys. (Scheme 10) Raise and support vehicle.
Remove the generator cooling ducts from the generator. The ducting is comprised of the lower cooling duct/air intake and the upper cooling duct. (Scheme 11) The upper section is retained by 2 screws and the lower section is retained by one screw.
Remove the protective boot from the positive main output terminal and remove the terminal nut. Remove the cable from the terminal and where fitted, remove the suppression module positive cable from the terminal. Where fitted, remove the nut which secures the suppression module negative cable and remove the cable from the generator. Remove the generator 3-pin connector, lower generator mounting bolt and generator harness retaining clip. (Scheme 12) Reposition generator harness to the side.
Reposition the electric water pump connector from the electric water pump retaining bracket. Remove the 2 electric water pump-to-bracket retaining nuts. (Scheme 18) Remove the electric water pump from the mounting bracket and reposition to allow access for removing the generator.
Remove the upper generator mounting bolt. (Scheme 13)
Carefully, move the generator forward towards the radiator. Change the position of the generator and remove it upwards between the engine and the radiator. (Scheme 14)
Position a suitable length bolt through the generator mounting bushing, fit a tubular spacer and nut. (Scheme 15) Tighten the assembly to move the bush slightly. Remove the nut, bolt and spacer.

Install generator to the engine. (Scheme 14) Position the generator and install the upper mounting bolt and nut, but do not fully tighten. (Scheme 13)
Raise and support vehicle. Reposition and align the generator harness retaining clip to the generator lower mounting. (Scheme 16) Install the lower mounting bolt and nut. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-164580-S04605585612004081000000).
Install the suppression module negative harness connector to the generator negative terminal. Install and tighten the terminal nut. Install the suppression module positive harness connector and positive main output connector to the generator positive terminal. Install and tighten the terminal nut. Install the boot to the positive main output terminal and install the generator 3-pin connector. (Scheme 17)
Install the generator cooling ducts to the generator. (Scheme 11) The upper section is retained by 2 screws and the lower section is retained by one screw. Lower the vehicle.
Tighten the generator upper mounting bolt to specification. See «TORQUE SPECIFICATIONS»(ref-164580-S04605585612004081000000).
Install the electric water pump to the mounting bracket. Install the 2 electric water pump-to-bracket retaining nuts. Reposition the electric water pump connector to the electric water pump retaining bracket. (Scheme 18)
Install engine drive belt around all pulleys except the generator. Using Spanner Wrench (Churchill JD-230 or Snap-On XDHM 1415) on the center bolt of the belt tensioner idler pulley, turn the adjuster assembly to the left against spring tension. While holding the tensioner against spring tension, install the drive belt around the generator pulley. Release the tensioner slowly and remove the spanner wrench. (Scheme 10)
Install the supercharger belt tensioner. (Scheme 20)
Install supercharger drive belt to all pulleys except the tensioner pulley. Insert a 1/2 inch square drive ratchet or bar into square opening on front face of tensioner. Rotate tensioner assembly to the right (viewed from front) against spring tension. While holding the tensioner against spring tension, install supercharger drive belt to tensioner pulley. Release tensioner slowly and remove bar. (Scheme 19)
Install the fan assembly to the radiator. Install the 2 radiator fan assembly nuts and tighten. (Scheme 9)
Raise and support vehicle. Connect both the high and low speed cooling fans and reposition the harnesses to the retaining clips. Reposition the A/C line to the clip on the radiator fan assembly. Lower vehicle.
Install the air cleaner assembly into the rubber mountings and install the nut that secures the base of the air cleaner. Install the intake tube into the air cleaner assembly. (Scheme 8)
Install a NEW air intake tube-to-throttle body seal. Install a NEW "O" ring to the "A" bank breather pipe and install the air intake tube/airflow meter/air cleaner cover assembly. (Scheme 7)
Secure the 5 air cleaner cover clips and connect the airflow meter connector. (Scheme 6)
Connect the air intake tube to the throttle body and install the 2 bolts which secure the air intake tube to the throttle body. (Scheme 5)
Install a NEW strap to secure the vacuum pipe to the intake manifold elbow.
Connect battery. See «BATTERY RECONNECT PROCEDURE»(ref-164580-S32475472932004081000000) under MISCELLANEOUS.

Scheme 18

Scheme 19

Scheme 20

Removal

Disconnect battery. See «BATTERY DISCONNECT PROCEDURE»(ref-164580-S13051001112004081000000) under MISCELLANEOUS.
Remove generator from vehicle. See «GENERATOR»(ref-164580-S14525330372004081000000).
Remove the retaining nut from the positive main output terminal stud and remove the insulator. (Scheme 21)
Remove the retaining nut and screw that retain the ground tab. Remove the ground tab. (Scheme 22)
Remove the 2 remaining nuts which secure the rear cover and remove the cover. (Scheme 23)
Remove the rubber cover from the brush holder. (Scheme 24)
Remove the brush holder retaining screws. Taking care not to damage the brushes, remove the brush holder. (Scheme 25)
Remove the 2 long and one short voltage regulator retaining screws. (Scheme 26) Remove the regulator.

Check that the rubber gasket for the brush holder is correctly located. (Scheme 27)
Check that the NEW regulator is of the same type and is not damaged. (Scheme 28)
Locate and align the New regulator. Install, but do not tighten the two long and one short voltage regulator retaining screws. (Scheme 26)
Using a plastic rod, hold the brushes fully into the brush holder. Very carefully slide the holder into position taking care not to damage brushes. (Scheme 29)
Install the brush holder retaining screws. Tighten the brush holder and voltage regulator retaining screws.
Install the brush holder rubber cover. (Scheme 24)
Install the rear cover and the ground tag. (Scheme 30)
Install the screw to secure the ground tab and install the 3 nuts to secure the rear cover. (Scheme 31) Tighten the ground tab screw and 3 rear cover retaining nuts.
Install the insulator to the positive main output terminal stud. Ensure that the locating flat on the insulator aligns with the locating flat in the rear cover. (Scheme 21) Install the retaining nut to the positive main output terminal.
Install the generator to the vehicle. See «GENERATOR»(ref-164580-S14525330372004081000000).
Connect battery. See «BATTERY RECONNECT PROCEDURE»(ref-164580-S32475472932004081000000) under MISCELLANEOUS.