replacing the alternator
Give yourself an hour or two
This replacement should take a just over an hour at most. Especially if you have already removed the old one.
Make sure it is the alternator
If you are still trying to determine whether or not your alternator is bad, check out the alternatorr diagnosing steps below. Another great way to be completely sure it’s the alternatorr is to remove it, and take it to your local parts store – they will be able to verify on their testing machine, and help you get a new replacement.
Pulley instructions
Use pulley from old alternator if this alternator does not have a pulley or pulley supplied is different from the one on alternator being replaced. NOTICE! When changing the pulley, keep the alternator in the horizontal position and do not apply any pressure to end of the shaft. Internal damage will occur if the shaft is pushed back and turned.
If there were spacers: when the fan and pulley were removed, make sure all spacers are replaced when installing the fan and pulley on this alternator. Hold the shaft by placing a hex wrench in the hexagonal hole in the shaft while removing or installing the pulley. Tighten the pulley nut to 95-108 Nm (70-80 Ibs ft).
Improper belt tension can cause premature alternator failure. Use a torque wrench to tighten mounting bolts to specified torque. Follow vehicle or engine manufacturer's specifications carefully for belt tension and mounting bolts torque. DO NOT OVER TIGHTEN BELT!
Disconnect the battery
Disconnect the negative battery cable – which is always the black cable.
Identify and label the cables
"POS" Terminal - Output terminal connects to the Positive (+) Battery terminal.
"R" Terminal - Relay terminal carries half systems voltage and may be used for certain types of control relays, charge indicators, tachometers or similar devices. The current draw should not exceed four (4) amperes. Notice! Do not install the remote sense lead to this terminal.
"I" Terminal - Indicator lamp/Ignition terminal carries full system voltage. Current draw should not exceed one (1) ampere. It is recommended current is not drawn from this terminal.
Ground Screw - Ground lead ensures alternator is grounded and is strongly recommended for optimum performance.
"Remote Sense" Terminal - Monitors batteries system voltage at the Batteries or a common distribution point. The Sense terminal is the fourth terminal and is identified with a "remote sense" label on the back cover plate. Notice! Do not connect anything but the remote sense line to this terminal.
- If installing a remote sense alternator in a vehicle without a remote sense line, connect a lead from the Voltage Sense terminal to the Positive (+) Battery terminal or the common distribution point at the Starter Solenoid Battery (+) terminal.
- If installing a non-remote sense alternator in a vehicle that has a remote sense line, disconnect and secure the wire from the battery. Notice! Be careful not to ground the leads open end and if it has a fuse it should be deactivated.
- Only connect the sense line to the remote sense terminal. The "R" Terminal is Not the Remote Sense Terminal!
Check for shims
Before removing the alternator, do a quick visual inspection, look for any shims that might have been added to help align the alternator pulley to the belt. Note their position and save them, you will need to put them back in the same position once you install the new starter.
Remove the alternator
Loosen the bolts holding the alternator in place, and then support the alternator while you remove the bolts. You can then remove the alternaotr from the engine frame.
Instal new alternator
Make sure you use all shims in the same position they were previously in, tighten bolts to fasten the alternaotr to the engine frame - use manufacturer torque specifications for proper tightening.
Connect leads
Instal all leads back to the correct terminals and ensure all leads are hooked back up or contained where they can not ground.
NOTE:
This Alternator may have more terminals than the alternator it is replacing had or used. It will function properly by only hooking up the leads that were used on the alternator being replaced.
Reconnect battery terminals
Reconnect battery cable, connecting positive connections first.
troubleshoot your alternator
CHECK THE BATTERY
1. A battery and alternator work together. First check if the battery is functioning. There are three main indicators to know if the battery has gone bad. First, look for any leaks on or around the battery. If there is no visible battery acid, check to see if the battery should be cleaned. Finally, pull the battery out of the car to see if there is any noticeable bulging.
CHECK CABLES + CONNECTIONS
2. Having a constant connection with the terminals is important for the car to function properly. Check for any visible corrosion or rust on either the terminal or cable clamp. Look for problems with the cables if there are any cracks or fraying along the cable. Finally check for burnt or loose connections on or around the terminals.
CHECK BELT/TENSIONER
3. The alternator belt drives the alternator.Check the belt for cracks or glazing, which hinder them from performing their job to the fullest. If the belt is not cracked, feel to see if it is loose allowing it to have more movement than designed. Finally, look to see if the belt has been contaminated by a fluid. If so, fix the leak then replace the belt.
CHECK DASH LIGHT
4. Cars have a built in feature that will signal when the alternator or battery has gone bad. To find this, turn the key to the on position and look for a battery or "ALT" icon on the dash. If the key is on but no lights appear, check all connections and replace the battery.
CHECK THE CORE
5. The alternator core itself can sometimes indicate that it is causing the problem. Look to see if the core is burnt, cracked or covered in oil. If any of these are the case, replace the core immediately.
CONSULT YOUR OWNERS MANUAL
In the event that no solution was reached, seek wiring and installation instructions. These can be attained from a store, online or call our hotline for free information.