Toyota
Dodge Durango
 Service Manual
Charging System » Removal and installation
Generator

REMOVAL

WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM.

(1) Disconnect negative battery cable at battery.

(2) Remove generator drive belt. Refer to Group 7, Cooling System for procedure.

(3) Unsnap plastic cable protector cover from B+ mounting stud (4.7L V-8 engine only).

(4) 3.9L/5.2L/5.9L Engines: Remove generator pivot and mounting bolts/nut (Fig. 1). Position generator for access to wire connectors.

(5) 4.7L Engine: Remove 3 generator mounting bolts (Fig. 2). Position generator for access to wire connectors.

(6) Remove B+ terminal mounting nut at rear of generator (Fig. 3) or (Fig. 4). Disconnect terminal from generator.

(7) Disconnect field wire connector at rear of generator by pushing on connector tab and pulling connector from generator.

(8) Remove generator from vehicle.

Fig. 1 Remove/Install Generator-3.9L/5.2L/5.9L Engines Fig. 1 Remove/Install Generator-3.9L/5.2L/5.9L Engines

1 - MOUNTING BOLT

2 - GENERATOR

3 - MOUNTING BRACKET

4 - MOUNTING BOLT/NUT

Fig. 2 Remove/Install Generator-4.7L V-8 Engine Fig. 2 Remove/Install Generator-4.7L V-8 Engine

1 - LOWER BOLTS

2 - REAR BOLT

3 - GENERATOR

Fig. 3 Generator Connectors-Typical Bosch Fig. 3 Generator Connectors-Typical Bosch

1 - FIELD WIRE CONNECTOR

2 - FIELD WIRES

3 - B+ (OUTPUT TERMINAL)

Fig. 4 Generator Connectors-Typical Denso Fig. 4 Generator Connectors-Typical Denso

1 - FIELD WIRES

2 - B+ (OUTPUT TERMINAL)

3 - FIELD WIRE CONNECTOR

INSTALLATION

(1) Position generator to engine and snap field wire connector into rear of generator.

(2) Install B+ terminal to generator mounting stud. Tighten mounting nut to 8.5 N*m (75 in. lbs.) torque.

(3) Install generator mounting fasteners and tighten as follows:

  • Generator mounting bolt-3.9L/5.2L/5.9L engines-41 N*m (30 ft. lbs.) torque.
  • Generator pivot bolt/nut-3.9L/5.2L/5.9L engines-41 N*m (30 ft. lbs.) torque.
  • Vertical mounting bolt 4.7L engine-55 N*m (40 ft. lbs.)
  • Long horizontal mounting bolt 4.7L engine-55 N*m (40 ft. lbs.)
  • Short horizontal mounting bolt 4.7L engine-74 N*m (55 ft. lbs.)

CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.

CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump will be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment, or refer to Belt Schematics in Group 7, Cooling System.

(4) Install generator drive belt. Refer to Group 7, Cooling System for procedure.

(5) Snap cable protector cover to B+ mounting stud (if equipped).

(6) Install negative battery cable to battery.

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