EBSCO Auto Repair Reference Center REMOVAL & INSTALLATION Except 2.3L (VIN A, D and 3) Disconnect the negative battery cable. Label and disengage the electrical connections from the alternator. On the 2.5L engines, loosen the adjusting bolts and remove the alternator belt. If equipped with a serpentine belt, loosen the tensioner and turn it counterclockwise to remove the belt. Unfasten the alternator mounting bolts, then detach the alternator air inlet connector (3.1L engine only) and remove the alternator from the engine. Fig. 1: After removing the belt and detaching the electrical connections, unfasten the front retaining bolts Fig. 2: Now unfasten the rear mounting bolts and remove the alternator from the vehicle To install: Fasten the alternator to the mounting bracket, using the retaining bolts, washers and nuts. Tighten the retainers to the specifications listed in the accompanying figures. Fig. 3: Position the alternator bracket on the engine and secure if removed — 2.4L engine shown If equipped with the 3.1L engine, attach the alternator air inlet connector. Install the serpentine or alternator belt, as applicable. For details, please refer to Section 1 of this manual. Engage the alternator electrical connections. Tighten the "Bat'' terminal nut to 65 inch lbs. (7 Nm). Check the belt tension, then adjust if necessary. Connect the negative battery cable, then check the alternator for proper operation. 2.3L (VIN A, D and 3) Engines 1988–90 VEHICLES Disconnect the negative battery cable. NOTE: To avoid personal injury when rotating the serpentine belt tensioner, use a tight fitting 13mm wrench that is at least 24 inch (61cm) long. Tool J 37059 can also be used to do this. Loosen the tensioner pulley bolt, turn the pulley counterclockwise and remove the serpentine belt from the alternator pulley. Tag and disconnect the two vacuum lines at the front of the engine. Remove the vacuum harness retaining bracket, then position the harness aside. Detach the injector harness, alternator connector and the battery lead from the alternator. Position the harness out of the way. Fig. 4: 1990 2.3L engine alternator mounting — without A/C Fig. 5: 2.3L engine alternator mounting — with A/C Unfasten and remove the two rear alternator mounting bolts. Remove the front alternator bolt and the engine harness clip. Remove the alternator from the vehicle between the engine lifting eyelet and the A/C compressor and condenser hose, to the right (passenger) side of the radiator filler neck. To install: Position the alternator in the vehicle, then install and hand-tighten the front mounting bolt and the engine harness clip. Install the two rear mounting bolts, then tighten them to 19 ft. lbs. (26 Nm). Tighten the front alternator bolt to 37 ft. lbs. (50 Nm). Install the serpentine belt. For details, please refer to Section 1 of this manual. Attach the injector harness wiring, alternator connector and the alternator battery lead. Install the vacuum harness and the retaining clip. Connect the two hoses to the vacuum harness as tagged during removal, then connect the negative battery cable. 1991–95 VEHICLES Disconnect the negative battery cable at the battery. NOTE: To avoid personal injury when rotating the serpentine belt tensioner, use a tight fitting 13mm wrench that is at least 24 inch (61cm) long. Tool J 37059 can also be used to do this. Loosen the tensioner pulley bolt, turn the pulley counterclockwise and remove the serpentine belt from the alternator pulley. Label and disconnect the oil/air separator hose and the vacuum harness at the front of the engine. NOTE: When removing and installing the lower alternator mounting bolts, shield the radiator core from possible tool damage to the fins and tubes. Unfasten the lower alternator bolts located at the rear of the alternator. There is one 13mm head hex sized bolt and one 10mm hex head sized bolt. Remove the upper alternator bolt. Partially remove the alternator, then detach the alternator electrical connector and battery lead, and remove the alternator from the vehicle. To install: Position the alternator into the engine compartment, then attach the electrical connector and battery lead. Install and hand-tighten the upper retaining bolt. Install the two lower (rear) alternator mounting bolts. Tighten the bolts to 19 ft. lbs. (26 Nm) Tighten the upper (front) alternator bolt to 37 ft. lbs. (50 Nm). Install the serpentine belt. For details, please refer to Section 1 of this manual. Connect the oil/air separator hose and the vacuum harness as tagged during removal. Connect the negative battery cable at the battery. EBSCO Auto Repair Reference Center