How do I install an alternator? - Civic Honda Cars & Trucks

Here is the procedure....



The CS130D alternator, used on these engines, is serviced as a complete assembly only.

1. Disconnect the negative battery cable.
2. Remove the serpentine drive belt.
3. Remove the alternator from brace.
4. Remove the electrical connector from the alternator.
5. Remove the retaining bolts from the alternator.
6. Remove the protective boot from the alternator output "BAT" terminal and remove the nut. Disconnect the battery positive lead from the alternator.
7. Remove the alternator from the vehicle.

To install:

1. Position the replacement alternator to the engine bracket.
2. Connect the battery positive lead to the alternator output "BAT" terminal and install the nut. Tighten the nut to 15 ft. lbs. (20 Nm). Install the protective boot over the terminal.
3. Hand start the alternator front lower bolt and tighten to 37 ft. lbs. (50 Nm).
4. Install the alternator brace stud through the alternator flange and the bracket and tighten the brace stud to 22 ft. lbs. (30 Nm).
5. If equipped with the CS 144 alternator, install the inboard alternator bolt through the flange and into the alternator brace assembly and tighten to 37 ft. lbs. (50 Nm).
6. If equipped with the CS 130D alternator, tighten the rear brace bolt to 22 ft. lbs. (30 Nm).
7. Plug in the electrical connector to the alternator.
8. Install the alternator front brace.
9. Install the serpentine drive belt to the alternator pulley.
10. Connect the negative battery terminal.

Remove the battery ground (negative) cable from the battery.

Remove the accessory drive belt.

Remove the alternator B+ terminal nut.

Remove the alternator B+ lead.

Remove the alternator electrical connector.

Remove the drive belt from the alternator.

Remove the alternator mounting bolts.

Remove the alternator from the vehicle.

To Install:

Install the alternator to the alternator bracket.

Install the alternator bolts. Tighten the alternator bolts to 37 ft. lbs. (50 Nm).

Install the drive belt.

Install the alternator electrical connector.

Install the alternator B+ lead.

Install the alternator B+ terminal nut. Tighten the alternator B+ terminal nut to 15 ft. lbs. (20 Nm).

Install the battery ground (negative) cable to the battery.

Hope this was helpful :-)

- Scott

This answer covers:
2005 Chrysler 300 6cyl VIN "G" 3.5L SFI HO (72% of 2005 300's)
2005 Chrysler 300 6cyl VIN "R" 2.7L MFI DOHC (28% of 2005 300's)
2005 Dodge Magnum 5.7L engine

Alternator

Removal & Installation


WARNING - Precautions Section:
Disconnect negative cable from battery before removing battery output wire (b+ wire) from alternator. Failure to do so can result in injury or damage to electrical system.

2.7L Engine

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect negative battery cable.
3. Remove alternator drive belt.
4. Disconnect alternator field circuit plug.
5. Remove B+ terminal nut and wire.
6. Remove 2 lower mounting bolts.
7. Remove alternator.

To install:

1. Install alternator.
2. Install upper bolt mounting bolt.
3. Install 2 lower mounting bolts.
4. Tighten bolts to 48 ft. lbs. (65 Nm).
5. Install B+ terminal nut and wire. Tighten nut to 115 inch lbs. (13 Nm).
6. Connect alternator field circuit plug.
7. Install alternator drive belt.
8. Connect negative battery cable.

3.5L Engines

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect negative battery cable.
3. Remove alternator drive belt.
4. Remove bracket bolts.
5. Remove upper mounting bolt.
6. Raise and support vehicle.
7. Remove middle splash pan.
8. Disconnect alternator field circuit plug.
9. Remove B+ terminal nut and wire.
10. Remove lower mounting bolts.
11. Remove alternator.

To install:

1. Install alternator.
2. Install lower mounting bolts. Loosen install the upper mounting bolt.
3. Tighten lower mounting bolts to 48 ft. lbs. (65 Nm).
4. Connect alternator field circuit plug.
5. Install B+ terminal nut and wire. Tighten nut to 115 inch lbs. (13 Nm).
6. Install middle splash pan.
7. Lower vehicle.
8. Remove loose installed upper bolt.
9. Install bracket and bracket bolt.
10. Install upper mounting bolt and bracket.
11. Tighten upper mounting bolt to 48 ft. lbs. (65 Nm).
12. Tighten the bracket bolt to 40 ft. lbs. (54 Nm).
13. Install alternator drive belt.
14. Connect negative battery cable.

5.7L Engines

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect negative battery cable at battery.
3. Remove alternator drive belt.
4. Raise and support vehicle.
5. Unsnap plastic insulator cap from B+ output terminal.
6. Remove B+ terminal mounting nut at rear of alternator. Disconnect terminal from alternator.
7. Disconnect field wire connector at rear of alternator by pushing on connector tab.
8. Remove alternator support bracket nut and bolt. Remove support bracket. See Figure 1.
9. Remove 2 alternator mounting bolts. See Figure 2.
10. Remove alternator from vehicle.

Fig. 1 Alternator Support Bracket - 5.7L engine



Fig. 2 Alternator Mounting Bolts - 5.7L engine

REMOVAL & INSTALLATION 2.2L Engines
CHRYSLER ALTERNATOR

1. Disconnect the negative battery cable.
2. Label and disconnect the wiring (for easy installation).
3. Remove the air conditioning compressor drive belt, if equipped.
4. Loosen the alternator adjusting bracket bolt and adjusting bolt. Remove the alternator belt.
5. Remove the bracket and mounting bolts.
6. Remove the pivot bolt and nut.
7. Lift the alternator from the vehicle.

When lifting the alternator out of the vehicle on some years with A/C, clearance may be restricted by the condenser cooling fan assembly or the A/C compressor and mounting bracket assembly, if so, removal of one of these items will be necessary.
To install:

1. Position the alternator against the engine.
2. Install the pivot bolt and nut.
3. Install the mounting bracket bolts, and adjusting bolt.
4. Install drive belts and adjust to specification.
5. Tighten all the mounting bolts and nuts.
6. Connect all alternator terminals.
7. Connect the negative battery cable.

BOSCH ALTERNATOR

1. Disconnect the negative battery cable.
2. Disconnect the wiring and label for easy installation.
3. Remove the air conditioning compressor drive belt.
4. Loosen the alternator adjusting bracket locknut and adjusting screw. Remove the alternator belt.
5. Remove the bracket locknut and mounting bolt.
6. Remove the pivot bolt and nut.
7. Remove the alternator from the engine.

To install:

1. Position the alternator against the engine.
2. Install pivot bolt and nut.
3. Set the mounting bracket in place and install the bracket mounting bolt and locknut.
4. Install the drive belts and adjust to specification.
5. Tighten all the mounting bolts and nuts.
6. Connect all alternator terminals.
7. Connect the negative battery cable.

Removal & Installation 3.0L (2V) To Remove:

1. Disconnect the battery ground cable
2. Remove the accessory drive belt
3. Remove the fasteners and move the degas bottle aside.
4. Disconnect the wiring from the alternator.
5. Remove the brace and the alternator mounting bolt.
6. Remove the alternator from the engine.

To Install:

1. Install the alternator on the engine. Tighten the lower and right brace bolt to 18 lb-ft. (25 Nm) and the left brace bolt to 35 lb-ft. (48 Nm).
2. Connect the wiring to the alternator.
3. Install the degas bottle in the original position.
4. Install the drive belt.
5. Connect the negative battery cable.

3.0L (4V) To Remove:

1. Disconnect the battery ground cable.
2. Remove the accessory drive belt.
3. Remove the power steering hose bracket nut from the alternator mounting bolt.
4. Remove the upper alternator mounting bolts. NOTE: The left side bolt will come out with the alternator.
   
5. Raise and safely support the vehicle.
6. Remove the right front wheel.
7. Remove the right inner fender splash shield.
8. Remove the screws and the alternator splash shield
9. Remove the torque converter inspection cover.
10. Install the flywheel holding tool.
    
11. Remove the bolt and the crankshaft pulley. NOTE: The crankshaft pulley bolt has a reverse thread. The crankshaft pulley and bolt are a molded composite and are one piece.
    
12. Lower the alternator to allow access to the electrical connectors.
13. Disconnect the crankshaft sensor.
14. Release the oxygen sensor connector locator from the bracket.
15. Remove the lower alternator bolt.
16. Disconnect the regulator electrical connector.
17. Disconnect the remaining wiring from the alternator and remove the alternator

To Install:

1. Position the alternator on the engine while making the necessary electrical connections.
2. Connect the voltage regulator electrical connector.
3. Install oxygen sensor connector locator in bracket.
4. Connect crankshaft sensor.
5. Raise alternator and install upper alternator bolts (left side bolt is installed with alternator). Torque upper and lower bolts to 18 lb-ft. (25Nm).
6. Position the wiring harness locator and install nut.
7. Install the alternator splash shield and the screws.
8. Position crankshaft pulley and install bolt (reverse thread). Torque to 74 lb-ft. (100Nm)
9. Remove the flywheel holding tool.
10. Install the inner fender splash shield.
11. Install the right front wheel.
12. Install the torque converter inspection cover.
13. Lower the vehicle.
14. Install the power steering hose bracket nut from the alternator mounting bolt.
15. Install accessory drive belt.
16. Connect the battery ground cable.

REMOVAL & INSTALLATION
2.2L Engines
CHRYSLER ALTERNATOR

1. Disconnect the negative battery cable.
2. Label and disconnect the wiring (for easy installation).
3. Remove the air conditioning compressor drive belt, if equipped.
4. Loosen the alternator adjusting bracket bolt and adjusting bolt. Remove the alternator belt.
5. Remove the bracket and mounting bolts.
6. Remove the pivot bolt and nut.
7. Lift the alternator from the vehicle.
   

When lifting the alternator out of the vehicle on some years with A/C, clearance may be restricted by the condenser cooling fan assembly or the A/C compressor and mounting bracket assembly, if so, removal of one of these items will be necessary.

To install:

1. Position the alternator against the engine.
2. Install the pivot bolt and nut.
3. Install the mounting bracket bolts, and adjusting bolt.
4. Install drive belts and adjust to specification.
5. Tighten all the mounting bolts and nuts.
6. Connect all alternator terminals.
7. Connect the negative battery cable.

BOSCH ALTERNATOR

1. Disconnect the negative battery cable.
2. Disconnect the wiring and label for easy installation.
3. Remove the air conditioning compressor drive belt.
4. Loosen the alternator adjusting bracket locknut and adjusting screw. Remove the alternator belt.
5. Remove the bracket locknut and mounting bolt.
6. Remove the pivot bolt and nut.
7. Remove the alternator from the engine.

To install:

1. Position the alternator against the engine.
2. Install pivot bolt and nut.
3. Set the mounting bracket in place and install the bracket mounting bolt and locknut.
4. Install the drive belts and adjust to specification.
5. Tighten all the mounting bolts and nuts.
6. Connect all alternator terminals.
7. Connect the negative battery cable.

2.5L Engines
2.5L engines were equipped with either Chrysler or Bosch alternators.

1. Disconnect the negative battery cable.
2. Remove the drive belts.
3. Remove the adjusting bracket-to-engine mounting bolt.
4. Remove the adjusting locking bolt and nut, then remove the mounting bracket.
5. Position the alternator to gain access to the wiring.
6. Disconnect the wiring and label for easy installation.
7. Remove the pivot bolt, nut, and washers.
8. Remove the alternator assembly from the engine.
   

To install:

1. Position the alternator assembly against the engine.
2. Loosely install the pivot bolt, washers, and nut.
3. Attach all wiring connectors to the alternator.
4. Position the mounting bracket in place, then install engine mounting bolt.
5. Loosely install the adjusting locking bolt and nut.
6. Install the drive belts, and adjust to specification.
7. Tighten all mounting bolts and nuts.
8. Connect the negative battery cable.
   

2.6L Engines
2.6L engines were equipped with Mitsubishi alternators.

1. Disconnect the negative battery cable.
2. Disconnect the wiring and label for easy installation.
3. Remove the adjusting strap mounting bolt.
4. Remove the drive belts.
5. Remove the support mounting bolt and nut.
6. Remove the alternator assembly.

To install:

1. Position the alternator assembly against the engine, then install the support bolt.
2. Install the adjusting strap mounting bolt.
3. Install the alternator belts and adjust to specification.
4. Tighten all the support bolts and nuts.
5. Connect all of the wiring terminals to the alternator.
6. Connect the negative battery cable.

3.0L Engines
The 3.0L engines were equipped with either the Nippondenso or Bosch alternators.

1. Disconnect the negative battery cable.
2. Install a 1 / 2 in. breaker bar in the tensioner slot. Rotate counterclockwise to release belt tension and remove poly-V belt.
3. Remove the alternator mounting bolts (2).
4. Remove the wiring and remove alternator.
   

To install:

1. Position the alternator onto the engine, then install the wiring.
2. Set the alternator against the mounting bracket and install the mounting bolts.
3. Rotate the tensioner counterclockwise and install poly-V belt.
4. Connect the negative battery cable.
   

3.3L and 3.8L Engines
The 3.3L and 3.8L engines were equipped with the Nippondenso alternators.

1. Disconnect the negative battery cable.
2. Remove the alternator drive belt, by relieving the tension on the dynamic tensioner.
3. Loosen the nut on the support bracket at the exhaust manifold, do not remove it.
4. Remove the alternator tensioner/power steering bracket bolt.
5. Remove the tensioner stud nut and remove the tensioner.
6. Remove the alternator mounting bolts.
7. Remove the power steering reservoir from the mounting bracket, do not disconnect the hoses, and position it out of the way.
8. Remove the alternator support bracket bolts. Remove the intake plenum to alternator bracket bolt and remove the alternator support bracket from the engine.
9. Remove the alternator from the engine and disconnect the electrical leads.
   

To install:

1. Install the alternator in position on the engine and connect the electrical leads.
2. Install the alternator support bracket, tighten the retaining bolts to 40 ft. lbs. (54 Nm).
3. Install the power steering reservoir on the mounting bracket.
4. Install the alternator mounting bolts, tighten the bolts to 40 ft. lbs. (54 Nm).
5. Install the tensioner and tensioner mounting stud. Install the retaining nut on the exhaust manifold.
6. Install the alternator belt, insert a 1 / 2 in. extension into the square hole in the tensioner and turn the tensioner. Tighten the tensioner bolt.
7. Connect the negative battery cable.

Hope this help (remember comment and rated this).

2001 Chevrolet Metro 1.3L MFI SOHC 4cyl

Alternator - Removal & Installation

1. Before servicing the vehicle, refer to the precautions section.
2. Remove or disconnect the following:
   Negative battery cable Air cleaner assembly Alternator electrical connectors Accessory drive belt Upper and lower mounting bolts Alternator
   

To install:

1. Install or connect the following:
   Alternator and the bolts, do not tighten the bolts at this time
   
2. Install the alternator belt and adjust the tension until a deflection of 0.24-0.31 inch (6-8mm) deflection with 22 lbs. (10 kg) of pressure exerted when installing a used belt. On a new belt the belt deflection should be 0.20-0.27 inch (5-7mm) with 22 lbs. (10 kg) of pressure exerted.
   Alternator electrical connectors, then torque the alternator bolts to 17 ft. lbs. (23 Nm) Air cleaner assembly Negative battery cable
   

1. Before servicing the vehicle, refer to the precautions section.
2. Remove or disconnect the following:
   Negative battery cable Accessory drive belt Alternator electrical connectors Alternator
   

To install:

1. Install the alternator and hand-tighten the bolts.
2. Install the alternator belt and adjust the tension until a deflection of 0.24-0.31 inch (6-8mm) deflection with 22 lbs. (10 kg) of pressure exerted when installing a used belt. On a new belt the belt deflection should be 0.20-0.27 inch (5-7mm) with 22 lbs. (10 kg) of pressure exerted.
3. Install or connect the following: Upper alternator bolt to 18 ft. lbs. (25 Nm) Lower alternator bolt to 40 ft. lbs. (54 Nm) Alternator electrical connectors Accessory drive belt Negative battery cable
   
   
   Fig. Exploded view of the alternator-Metro and Prizm models
   

Hope thats help (remember rated this).

2000 Ford Truck Expedition 4WD 4.6L EFI 8cyl

Alternator - REMOVAL & INSTALLATION

4.2L Engine

1. Disconnect the negative battery cable.
2. Disconnect 2 alternator and voltage regulator electrical harness connectors at the alternator. To disconnect push-on type terminals, depress the lock tab and pull straight off.
3. Remove the positive battery cable nut and remove the positive battery cable at the alternator.
4. Rotate the drive belt tensioner away from the drive belt and remove the drive belt from the alternator pulley.
5. Remove 3 alternator retaining bolts and remove the alternator.

To install:

1. Place the alternator on the engine and install 3 alternator retaining bolts. Tighten the bolts to 18-22 ft. lbs. (20-30 Nm).
2. Rotate the drive belt tensioner away from the drive belt and install the drive belt on the alternator pulley.
3. Connect 2 alternator and voltage regulator electrical harness connectors.
4. Connect the positive battery cable to the alternator and install the nut and washer. Tighten the nut to 84 inch lbs. (10 Nm).
5. Connect the negative battery cable.
6. Start the engine and check for proper charging system operation.

4.6L, 5.4L and 6.8L Engines



Fig. 1 Detach the connectors from the alternator



Fig. 2 Remove the nut and the battery cable from the post on the rear of the alternator



Fig. 3 Remove the 2 front alternator mounting bolts and ...



Fig. 4 Remove the alternator from the engine by carefully lifting it up and...



Fig. 5 ... out of the engine compartment

1. Disconnect the negative battery cable.
2. Rotate the drive belt tensioner away from the drive belt and remove the drive belt from the alternator pulley.
3. Detach the electrical harness connectors at the alternator assembly.
4. Disconnect the positive battery cable and remove the nut and washer.
5. Remove 2 front alternator bolts.
6. Remove the rear alternator support bracket retaining bolts and the support bracket.
7. Remove the alternator from the vehicle.

To install:

1. Place the alternator in position and loosely install 2 front alternator retaining bolts.
2. Install the alternator bracket and 3 alternator bracket bolts. Tighten to 84 inch lbs. (10 Nm).
3. Tighten 2 front alternator retaining bolts to 19 ft. lbs. (26 Nm).
4. Connect 2 electrical harness connectors to the alternator assembly.
5. Connect the positive battery cable and install the nut and washer. Tighten the nut to 72 inch lbs. (8 Nm).
6. Rotate the drive belt tensioner away from the drive belt and install the drive belt on the alternator pulley.
7. Connect the negative battery cable.
8. Start the engine and check for proper charging system operation.

5.8L and 7.5L Gasoline Engines and 7.3L Diesel Engine

1. Disconnect the battery ground cable.
2. Label and detach the connectors from the alternator.
3. Release the tensioner and remove the drive belt from the alternator pulley.
4. Remove the alternator retaining bolts.
5. Remove the alternator from the vehicle.

To install:

1. Position the alternator and install the retaining bolts. Tighten the retaining bolts to 15-21 ft. lbs. (21-29 Nm).
2. Install the drive belt.
3. Attach the alternator connectors.
4. Connect the battery ground cable.

I really hope help you with this (remember rated this help) Good luck.

A good repair manuel to get which has picture step by step, Hanyes auto repair manuel at any aut part store for 20 bucks is a great investment.
.0l Engines The 3.0L engines were equipped with either the Nippondenso or Bosch alternators.
1. Disconnect the negative battery cable.
2. Install a 1/2 in, breaker bar in the tensioner slot. Rotate counter-clock- wise to release belt tension and remove poly-V belt.
3. Remove the alternator mounting bolts (2)
4. Remove the wiring and remove alternator.
To Install:
5. Position the alternator onto the engine, then install the wiring.
6. Set the alternator against the mounting bracket and install the mounting bolts.
7. Rotate the tensioner counterclockwise and install poly-V belt.
8. Connect the negative battery cable. 3.3L and 3.8L Engines
The 3.3L and 3.8L engines were equipped with the Nippondenso alternators. 1. Disconnect the negative battery cable.
2. Remove the alternator drive belt, by relieving the tension on the dynamic tensioner
3. Loosen the nut on the support bracket at the exhaust manifold, do not remove it.
4. Remove the alternator tensioner/power steering bracket bolt.
5. Remove the tensioner stud nut and remove the tensioner.
6. Remove the alternator mounting bolts.
7. Remove the power steering reservoir from the mounting bracket, do not disconnect the hoses, and position it out of the way.
8. Remove the alternator support bracket bolts, Remove the intake plenum to alternator bracket bolt and remove the alternator support bracket from the engine.
9. Remove the alternator from the engine and disconnect the electrical leads.
To Install:
10. Install the alternator in position on the engine and connect the electrical leads.
11. Install the alternator support bracket, tighten the retaining bolts to 40 ft. lbs. (54 Nm). Install the power steering reservoir on the mounting bracket.
13. Install the alternator mounting bolts, tighten the bolts to 40 ft. lbs. (54 Nm).
14. Install the tensioner and tensioner mounting stud. Install the retaining nut on the exhaust manifold.
15. Install the alternator belt, insert a 1/2 in. extension into the square hole in the tensioner and turn the tensioner. Tighten the tensioner bolt.
16. Connect the negative battery cable.

2005 Ford Mustang 4.0L SFI SOHC 6cyl
Ford Mustang 1999-2005
Alternator - Removal & Installation

3.8L And 4.0L Engines

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Disconnect the negative battery cable.
3. Remove the accessory drive belt.
4. Disconnect the alternator electrical connectors.
5. Remove the alternator shield (4.0L engine).
6. Remove the alternator mounting bolts.
7. Remove the alternator from the vehicle.
8. Installation is the reverse of the removal procedure.

To install:

1. Position the alternator onto engine. Tighten the lower bolt to 35 ft. lbs. (47 Nm) and the upper bolt to 18 ft. lbs. (25 Nm).
2. Install the alternator shield (4.0L engine).
3. Connect the alternator electrical connectors.
4. Install the accessory drive belt.
5. Connect the negative battery cable.

4.6L Engines (Non-Supercharged)

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Disconnect the negative battery cable.
3. Remove the air intake scoop bracket, if equipped.
4. Remove the accessory drive belt.
5. Remove the upper alternator bracket.
6. Disconnect the alternator electrical connectors.
7. Remove the alternator bolts.
8. Remove the alternator from the vehicle.
9. Installation is the reverse of the removal procedure.

To install:

1. Position the alternator onto engine. Tighten the mounting bolts to 18 ft. lbs. (25 Nm).
2. Connect the alternator electrical connectors.
3. Install the upper alternator bracket. Tighten the bolts to 89 inch lbs. (10 Nm).
4. Install the accessory drive belt.
5. Install the air intake scoop bracket, if equipped.
6. Connect the negative battery cable.

4.6L Engines (Supercharged)

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Disconnect the negative battery cable.
3. Remove the accessory drive belt.
4. Raise the vehicle.
5. Disconnect the alternator electrical connectors.
6. Remove the alternator bolts.
7. Remove the alternator from the vehicle.
8. Installation is the reverse of the removal procedure.

To install:

1. Position the alternator onto engine. Tighten the lower bolt to 18 ft. lbs. (25 Nm) and the upper bolt to 37 ft. lbs. (50 Nm).
2. Connect the alternator electrical connectors.
3. Lower the vehicle.
4. Install the accessory drive belt.
5. Connect the negative battery cable.
6. Installation is the reverse of the removal procedure.

More details about this model in Autozone.com (free register).

I hope help you with this (remember rated this help). Good luck.