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

1 - MOUNTING BOLT

2 - GENERATOR

3 - MOUNTING BRACKET

4 - MOUNTING BOLT/NUT

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

1 - LOWER BOLTS

2 - REAR BOLT

3 - GENERATOR

Fig. 3 Generator Connectors-Typical Bosch

1 - FIELD WIRE CONNECTOR

2 - FIELD WIRES

3 - B+ (OUTPUT TERMINAL)

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.

Battery temperature sensor

The battery temperature sensor is located under vehicle battery (Fig. 5) and is attached to a mounting hole on battery tray.

REMOVAL

(1) Remove battery. Refer to Group 8A, Battery for procedures.

Fig. 5 Battery Temperature Sensor Location

1 - BATTERY TEMPERATURE SENSOR

2 - BATTERY TRAY

(2) Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector.

(3) Pry sensor straight up from battery tray mounting hole.

INSTALLATION

(1) Feed pigtail harness through hole in top of battery tray and press sensor into top of battery tray.

(2) Connect pigtail harness.

(3) Install battery. Refer to Group 8A, Battery for procedures.

Specifications

Generator ratings

Torque chart

DESCRIPTION   TORQUE

Generator Mounting Bolt- 3.9L/5.2L/5.9L Engines . . . . . 41 N*m (30 ft. lbs.)

Generator Pivot Bolt- 3.9L/5.2L/5.9L Engines . . . . . 41 N*m (30 ft. lbs.)

Generator Vertical Mounting Bolt- 4.7L V-8 Engine . . . . . . . . . . 55 N*m (40 ft. lbs.)

Generator (long) Horizontal Mounting Bolt- 4.7L V-8 Engine . . . . . . . . . . 55 N*m (40 ft. lbs.)

Generator (short) Horizontal Mounting Bolt- 4.7L V-8 Engine . . . . . . . . . . 74 N*m (55 ft. lbs.)

Generator B+ Output Cable Terminal Nut . . . . . . . . . . . . 8.5 N*m (75 in. lbs.)