Battery-Alternator-Fuse Box Connections

First, the negative battery post. Then remove the belt that runs the alternator. There are two electrical connections to remove. Sometimes it helps to partially remove the alternator from its mounting to get to the electrical connections.

Ready to remove alternator, now. Some are held in place rigid and held by 2 bolts. Some are adjustable with a pivot bolt on one side and an adjusting bolt on the other side-anyway, remove the alternator mounting bolts, and remove alternator. Some are open and come right out. Some are sneaky tough, and you almost have to stand on your head to get them out. to install, just reverse your method of removal.

The early GM products would build up restance in the wire that went from the alternator to the starter. The easy cure for this is to install a 10 guage wire directly from the Alternator Batt. lug directly to the battery postive post. Do this using the correct end connectors.. do not just wrap the wire around the termanel. This was a big problem on these cars. especially the Diesel cars. Always disconnect the battery ground terminal before you work on this.

1. Disconnect the negative battery cable.
   
2. Label and disengage the electrical connections from the alternator.
   
3. On the 2.5L engines, loosen the adjusting bolts and remove the alternator belt.
   
4. If equipped with a serpentine belt, loosen the tensioner and turn it counterclockwise to remove the belt.
   
5. Unfasten the alternator mounting bolts, then detach the alternator air inlet connector (3.1L engine only) and remove the alternator from the engine.
   

To install:

1. 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.
   

1. If equipped with the 3.1L engine, attach the alternator air inlet connector.
   
2. Install the serpentine or alternator belt, as applicable. For details, please refer to Section 1 of this manual.
   
3. Engage the alternator electrical connections. Tighten the "Bat" terminal nut to 65 inch lbs. (7 Nm).
   
4. Check the belt tension, then adjust if necessary.
   
5. Connect the negative battery cable, then check the alternator for proper operation.
   

One of those secondaries will be the feeder for the ignition switch. The other may be for the fuse box, or may be for something else that is powered at all times-like the headlight switch. Here's how to clean it up:
First take off the negative battery cable-negative first to avoid sparking. Now you can pull off the positive. Most new positive battery cables only come with one "pigtail" or secondary insulated wire. But if you tell the parts person you have a Volvo and the year, they may have a cable specifically for your car with two secondaries. Or you could try the dealer for the right cable.
Barring that, if you just want to fix your old cable without buying a new one, you could take the stripped wire and crimp a new eyelet connector on the end and wrap the bare portion with several wraps of electrical tape. Now put the big cable terminal on the battery post, take off the nut on the tightener bolt, put the eyelet connector over the bolt, and tighten the nut down on the bolt. Now both secondary wires are attached? Put the negative post on and tighten it down. To avoid corrosion at the posts you can smear a little petroleum jelly (vaseline) on the post and cable connections, if you want.

Inspect/Test/Service/Replace Follow service manual procedures given by the manufacturer for the generator you are working on for disassembling, inspecting, testing, and rebuilding AC generators. Remember, improper connections to an AC generator can destroy it.
AC generator removal varies according to the engine size, engine placement, and vehicle accessories (such as power steering and air conditioning). The following is the typical procedure for removal and replacement of the AC generator.

• Place fender covers over the fenders
• Disconnect the battery ground cable

CAUTION
Never attempt to remove the alternator or disconnect any wires to the alternator without first disconnecting the battery negative cable.It's a good practice to wrap the cable with tape or insert the cable inside a rubber hose to prevent accidental contact with the battery terminal.Always wear safety glasses when working around the battery.

• Disconnect and label the wiring harness connections to the alternator (Painters Masking tape works very well for labeling Automotive wiring).
• Loosen the alternator pivot bolt.
• Remove the bolt that attaches the alternator to the adjustment arm.
• Rotate the alternator to loosen the drive belt and disengage the belt from the pulley. Be careful that any spacers that are used in mounting are kept with their original bolts. This will make correct reinstallation much easier.
• While supporting the alternator remove the pivot bolt.
• Remove the alternator from the vehicle.

To reinstall the alternator, reverse the removal procedure.
To adjust the belt tension, leave the pivot and adjusting arms loose. Look up the belt tension specification for the vehicle you are working on. Using a belt tension gauge on the belt apply pressure to the alternator until the correct belt tension registers on the gauge and tighten the mounting and adjustment bolts to the specified torque specification.

CAUTION
Over tightening of the alternator drive belt will cause the unit to whine and premature failure of the alternator drive end bearing, the water pump or the engine crankshaft

Inspect/Test/Service/Replace Follow service manual procedures given by the manufacturer for the generator you are working on for disassembling, inspecting, testing, and rebuilding AC generators. Remember, improper connections to an AC generator can destroy it.
AC generator removal varies according to the engine size, engine placement, and vehicle accessories (such as power steering and air conditioning). The following is the typical procedure for removal and replacement of the AC generator.

• Place fender covers over the fenders
• Disconnect the battery ground cable

CAUTION
Never attempt to remove the alternator or disconnect any wires to the alternator without first disconnecting the battery negative cable.It's a good practice to wrap the cable with tape or insert the cable inside a rubber hose to prevent accidental contact with the battery terminal.Always wear safety glasses when working around the battery.

• Disconnect and label the wiring harness connections to the alternator (Painters Masking tape works very well for labeling Automotive wiring).
• Loosen the alternator pivot bolt.
• Remove the bolt that attaches the alternator to the adjustment arm.
• Rotate the alternator to loosen the drive belt and disengage the belt from the pulley. Be careful that any spacers that are used in mounting are kept with their original bolts. This will make correct reinstallation much easier.
• While supporting the alternator remove the pivot bolt.
• Remove the alternator from the vehicle.

To reinstall the alternator, reverse the removal procedure.
To adjust the belt tension, leave the pivot and adjusting arms loose. Look up the belt tension specification for the vehicle you are working on. Using a belt tension gauge on the belt apply pressure to the alternator until the correct belt tension registers on the gauge and tighten the mounting and adjustment bolts to the specified torque specification.

CAUTION
Over tightening of the alternator drive belt will cause the unit to whine and premature failure of the alternator drive end bearing, the water pump or the engine crankshaft

THE FUSE LINK TO ALTERNATOR. YOU HAVE TO DISCONNECT NEGATIVE BATTERY CABLE BUT FIRST TURN OFF RADIO BEFORE DISCONNECTING NEGATIVE BATTERY CABLE.TELL ME WHAT SIZE MEGA FUSE YOU REPLACING 40 AMP FUSE IN FUSE BOX..FORD CARRIES MEGA FUSE 175 AMP FUSE A MEGE FUSE DOES SAME JOB FUSE LINK.YOU NEED TO REPLACE FUSE LINK.FUSE LINK IS HEAVY GAUGE WIRES TWISTED TOGETHER THEN USE ROSIN CORE SOLDER AND SOLDER WIRES TOGETHER.WRAP A LOT OF ELECTRIC TAPE AROUND SOLDER WIRES TO KEEP FROM GROUNDING STARTING A ELECTRICAL FIRE. FUSE LINK LOCATED IN THE WIRE FROM THE BATTERY TO THE ALTERNATOR YOU WILL SEE WORDS FUSE LINK ON THE LINK.

Locate the alternator on the engine. The alternator will be placed somewhere on the engine so that the pulley on one end of the alternator can be attached to the main belt of the engine. The belt will turn the pulley of the alternator and create the electrical charge to recharge the battery as the engine runs.

Step 2 Ensure that no other parts of the engine will prevent you removing the alternator. If there are other parts that you must remove, carefully remove them before attempting to remove the alternator. Make sure that you keep all the screws, nuts, bolts and other parts together for any other items that you remove, as you will need to use them to replace those items after changing your alternator.

Step 3 Unscrew and remove the battery terminals. It is always wise to disconnect the battery when working on the electrical system of the vehicle. Make sure you place the terminals in such a way as to prevent them from touching the metal frame of the vehicle. If there is any doubt, wrap the terminals with a small amount of electrical tape.

Step 4 Find the alternator mounting bolt or bolts. There is usually 1 bolt that attaches the alternator to the engine and is placed at a pivot point on the alternator, so that the alternator may be positioned against the fan belt to a greater or lesser of a degree as needed to generate the charging current for the recharge of the battery.

Step 5 Loosen the mounting bolt at the bottom of the alternator and rotate the alternator back away from the fan belt. Continue loosening the bolt until it is free from the engine. Remove it and place it aside for use in remounting the new alternator.

Step 6 Lift the alternator out of the engine cavity and place it on the engine so that you may disconnect the electrical connections for final removal. Locate the point at which the charging circuit attaches to the alternator.

Step 7 Move the rubber covering shroud away from the terminal on the alternator and, using the small crescent wrench, remove the nut from the bolt and carefully wrap the terminal ends of the wire with a small amount of electrical tape. This will complete the removal of the alternator

Yes, very easy...here is the steps to do it:

To Remove:

1. Disconnect battery negative cable.
2. Remove air cleaner inlet pipe.
3. Disconnect alternator electrical connections.
4. Loosen (but do not remove) pivot bolt and tensioner mounting bolt.
5. Remove drive belt form alternator pulley.
6. Remove tensioner mounting bolt and belt tensioner.
7. Remove pivot bolt, loosen adjusting bracket bolt and rotate bracket up.
8. Remove alternator.

To Install:

1. Place alternator on engine.
2. Install (but do not tighten) pivot bolt.
3. Rotate bracket down on top of alternator.
4. Install belt tensioner and install bolt loosely.
5. Install drive belt on alternator pulley.
6. Tighten tensioner bolt to 14-19 ft lb (19-26 Nm).
7. Tighten pivot bolt and bracket bolt to 28-38 ft lb (38-51 Nm).
8. Connect alternator electrical connections.
9. Install air cleaner inlet pipe.
10. Connect battery negative cable.

2.7L Engine

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   
   Negative battery cable from the shock tower Accessory belt splash shield and loosen the belt Alternator electrical connectors A/C pressure switch and clutch electrical connectors Engine oil dipstick Alternator
   

To install:

1. Install or connect the following:
   
   Alternator and torque the bolts to 40 ft. lbs. (54 Nm) Engine oil dipstick tube A/C pressure switch and clutch electrical connectors Alternator electrical connectors Drive belt and splash shield Negative battery cable
   

1. Before servicing the vehicle, refer to the Precautions section.
2. Raise vehicle and support.
3. Remove the accessory drive belt splash shield.
4. Loosen the accessory drive belt.
5. Remove the lower mounting bolt.
6. Lower the vehicle.
7. Remove the electrical connections from the alternator.
8. Disconnect the electrical connector to the A/C pressure switch and A/C clutch.
9. Remove the engine oil dip stick.
10. Remove the 2 upper mounting bolts.
11. Remove the alternator.

To install:

1. Install the alternator.
2. Install the 2 upper bolts, but do not tighten.
3. Install the engine dip stick tube.
4. Connect the A/C pressure switch and A/C clutch electrical connectors.
5. Connect the electrical connections to the alternator.
6. Raise vehicle and support.
7. Install the lower bolt. Tighten bolt to 40 ft. lbs. (54 Nm).
8. Install the accessory drive belt.
9. Install the accessory drive belt splash shield.
10. Lower the vehicle.
11. Install the 2 upper mounting bolts. Tighten bolts to 40 ft. lbs. (54 Nm).
12. Connect the negative battery cable.

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