Generator Replacement

REMOVAL PROCEDURE
The Delphi AD237 (KG7) generator is serviced as a complete unit only.




1. Disconnect the battery ground (negative) cable.
2. Remove the drive belt.
3. Drain the engine coolant.
4. Remove the battery tray.
5. Remove the engine cooling fan assembly.
6. Remove the thermostat housing and the radiator hose.
7. Remove the outboard generator bolt.
8. Loosen the inboard generator bolt.
9. Remove the idler pulley bolt and the idler pulley.




10. Disconnect the wiring harness connector from the generator.
11. Reposition the protective boot from the generator output BAT terminal for access.
12. Remove the generator output BAT terminal nut and disconnect the battery (positive) lead from the generator.
13. Remove the generator.

INSTALLATION PROCEDURE




1. Position the generator to the engine.
2. Connect the wiring harness connector to the generator.

NOTE: Refer to Fastener Notice in Cautions and Notices.

3. Connect the battery (positive) lead and install the generator output BAT terminal nut.

Tighten
Tighten the generator output BAT terminal nut to 20 N.m (15 lb ft).

4. Press the protective boot on to the generator output BAT terminal.
5. Place the outboard generator bolt into the generator housing.




6. Position the generator on the inboard generator bolt and finger tighten the outboard bolt.
7. Install the idler pulley and idler pulley bolt.
8. Tighten the bolts in the order described. The following is a mandatory torque sequence:
8.1. Tighten the idler pulley bolt.

Tighten
Tighten the idler pulley bolt to 50 N.m (37 lb ft).

8.2. Tighten the generator bolts.

Tighten
Tighten the generator bolts to 50 N.m (37 lb ft).

9. Install the battery tray.
10. Install the thermostat housing and the radiator hose.
11. Install the engine cooling fan assembly.
12. Fill the engine with engine coolant.
13. Install the drive belt.
14. Connect the battery ground (negative) cable.