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Alternator

Starting and Charging › Charging System
Unified entry — merged from multiple cross-listed pages in the original manual.

Parts

PartAlternator
ManufacturerCHY
OEM part #5149275AA
Price$325.00
NotesAlternator Is Serviced Only As Assembly.

Labor

Replace — Alternator0.6 hr
Warranty 0.0 hrSkill B
Procedures
Alternator: Specificationsreference
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GENERATOR RATINGS
Generator - Installation6 steps
△ CAUTION
Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
△ CAUTION
When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump will be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment, or refer to Belt Schematics in Cooling System.
Fig. 1
Fig. 1
  1. Position generator (1) to engine and install three mounting bolts (2), (3) and (4). Tighten two horizontal mounting bolts (3) and (4) to 57 Nm (42 ft. lbs.). Tighten vertical mounting bolt (2) to 40 Nm (29 ft. lbs.)
  2. Snap field wire connector into rear of generator.
  3. Install B+ terminal and nut to generator mounting stud. Tighten nut to 13 Nm (115 in. lbs.)
  4. Snap plastic protective cover to B+ terminal.
  5. Install drive belt. Refer to Cooling System for belt routing, belt adjustment and bolt tightening procedures.
  6. Install negative battery cable to battery.
Generator Decoupler - Removal15 steps
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  1. Disconnect the negative battery cable.
  2. Remove the generator and accessory drive belt Generator - Removal.
  3. Position the Special Tool (VM.1048) (2) into the decoupler (1) (Figure 3).
  4. Determine if the end of generator shaft is hex shaped (2) (Figure 4).
  5. .or is splined (2) (Figure 5).
  6. If the hex is used, insert a 10MM deep socket (1) into tool (VM.1048) (Figure 8).
  7. If splined, insert a 5/16" 6-point hex driver (1), or a 10MM 12-point triple square driver into tool (VM.1048) (Figure 9).
  8. The generator shaft uses conventional right-hand threads to attach the decoupler. To break the decoupler loose from generator threads, rotate the end of tool (1) clockwise (Figure 8) or.,
  9. Rotate the end of tool (1) clockwise (Figure 8).
  10. After breaking it loose with the tool, unthread decoupler by hand from the generator. Litens Decoupler
  11. Disconnect the negative battery cable.
  12. Remove the generator and accessory drive belt Generator - Removal.
  13. Position the Special Tool A (Figure 10) into the decoupler. Align to the hex end of the generator shaft.
  14. The generator shaft uses conventional right-hand threads to attach the decoupler. To break the decoupler loose from generator threads, rotate the end of tool clockwise (Figure 11).
  15. After breaking loose the decoupler with the tool, unthread the decoupler by hand from the generator.
Generator Decoupler - Installation12 steps
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  1. Thread the decoupler pulley onto the generator shaft by hand (right-hand threads).
  2. Position the Special Tool (VM.1048) into the decoupler.
  3. Determine if the end of generator shaft is hex shaped or is splined. If hex is used, insert a 10MM deep socket (1) into the tool (VM.1048) (Figure 1) or.
  4. .if splined, insert a 5/16" 6-point hex driver (1), or a 10MM 12-point triple square driver into tool (VM.1048) (Figure 2).
  5. Do not use an adjustable, ratcheting "click type" torque wrench. Most "click type" wrenches will only allow torque to be applied in a clockwise rotation. Use a dial-type or beam-type wrench. Tighten in the counterclockwise rotation and tighten to 110 Nm (81 ft. lbs.).
  6. Install the accessory drive belt and generator Generator - Installation.
  7. Connect the negative battery cable. Litens Decoupler
  8. Thread the decoupler pulley onto the generator shaft by hand (right-hand threads).
  9. Position the Special Tool into decoupler. Align the tool to hex end of the generator shaft.
  10. Do not use an adjustable, ratcheting "click type" torque wrench. Most "click type" wrenches will only allow torque to be applied in a clockwise rotation. Use a dial-type or beam-type wrench. Tighten in the counterclockwise rotation and tighten to 110 Nm (81 ft. lbs.).
  11. Install the accessory drive belt, and generator Generator - Installation.
  12. Connect the negative battery cable.
Generator - Removal7 steps
△ CAUTION
Disconnect the negative battery cable before removing the battery output wire from generator. Failure to do so can result in injury or damage to electrical system.
△ CAUTION
Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
△ CAUTION
When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump will be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment, or refer to Belt Schematics in Cooling System.
Fig. 1
Fig. 1
  1. Disconnect and isolate negative battery cable at battery.
  2. Remove generator drive belt. Refer to Cooling System for procedures.
  3. Unsnap plastic protective cover from B+ mounting stud.
  4. Remove B+ terminal mounting nut at top of generator.
  5. Disconnect field wire electrical connector at rear of generator by pushing on connector tab.
  6. Remove one vertical generator mounting bolt (2) and two horizontal mounting bolts (3) and (4).
  7. Remove generator (1) from vehicle.
Alternator: Testing and Inspectionreference
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DIAGNOSIS AND TESTING - GENERATOR DECOUPLER
Generator Decoupler - Descriptionreference
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DESCRIPTION The generator decoupler is used only with certain engines. The decoupler is used in place of the standard generator drive pulley.
Factory service manual
From the 2008 KK factory manual — descriptions, specs, torque & procedures for this part.
GENERATOR TORQUE SPECIFICATIONS CHART📷 1
DESCRIPTIONN.mFt. Lbs.In. Lbs.
Generator Horizontal5742-
Mounting Bolts - 3.7L Generator Vertical 40 29 -
Mounting Bolt - 3.7L Generator Mounting 54 40 - Bolts - 2.8L Diesel Rear Generator Support Bracket Bolts (to engine) 28 - 250 - 2.8L Diesel
B+ Cable Terminal Nut1310115
Generator Decoupler11081-

Special tools

GENERATOR
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GENERATOR📷 1
The generator is belt-driven by the engine using a serpentine type drive belt. It is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced.
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GENERATOR📷 1
As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. Once the generator begins producing sufficient current, it also provides the current needed to energize the rotor.
The stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified DC current is delivered to the vehicle electrical system through the generator battery terminal.
Although the generators appear the same externally, different generators with different output ratings are used on this vehicle. Be certain that the replacement generator has the same output rating and part number as the original unit. Refer to SPECIFICATIONS and see Generator Ratings for amperage ratings and part numbers.
Noise emitting from the generator may be caused by: worn, loose or defective bearings; a loose or defective drive pulley; incorrect, worn, damaged or misadjusted fan drive belt; loose mounting bolts; a misaligned drive pulley or a defective stator or diode.
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REMOVAL - 2.8L DIESEL📷 1
CAUTION: Disconnect negative cable from battery before removing battery output wire from generator. Failure to do so can result in injury.
1. Disconnect and isolate negative battery cable at battery.
CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump will be rotating in the wrong
direction if the belt is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment, or refer to Belt Schematics in COOLING article .
  2.   Remove generator drive belt. Refer to COOLING article for procedures.
  3.   Unsnap plastic protective cover from B+ mounting stud.
  4.   Remove B+ terminal mounting nut at top of generator.
  5.   Disconnect field wire electrical connector at rear of generator by pushing on connector tab.
  6.   Remove four generator mounting bolts (2).
  7.   Remove generator (1) from vehicle.
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REMOVAL - 3.7L📷 1
CAUTION: Disconnect negative cable from battery before removing battery output wire from generator. Failure to do so can result in injury.
1. Disconnect and isolate negative battery cable at battery.
CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump will be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to
overheat. Refer to belt routing label in engine compartment, or refer to Belt Schematics in COOLING article .
  2.   Remove generator drive belt. Refer to COOLING article for procedures.
  3.   Unsnap plastic protective cover from B+ mounting stud.
  4.   Remove B+ terminal mounting nut at top of generator.
  5.   Disconnect field wire electrical connector at rear of generator by pushing on connector tab.
  6.   Remove one vertical generator mounting bolt (2) and two horizontal mounting bolts (3) and (4).
  7.   Remove generator (1) from vehicle.
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INSTALLATION - 2.8L DIESEL📷 1
1. Position generator (1) to engine and install four mounting bolts (2). Tighten all four bolts to 54 N.m (40 ft. lbs.). 2. Snap field wire connector into rear of generator. 3. Install B+ terminal and nut to generator mounting stud. Tighten nut to 13 N.m (115 in. lbs.) 4. Snap plastic protective cover to B+ terminal.
CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
CAUTION: When installing a serpentine accessory drive belt, the belt MUST be
routed correctly. The water pump will be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment, or refer to Belt Schematics in COOLING article .
5. Install drive belt. Refer to COOLING article for belt routing, belt adjustment and bolt tightening procedures. 6. Install negative battery cable to battery.
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INSTALLATION - 3.7L📷 1
1. Position generator (1) to engine and install three mounting bolts (2), (3) and (4). Tighten two horizontal mounting bolts (3) and (4) to 57 N.m (42 ft. lbs.). Tighten vertical mounting bolt (2) to 40 N.m (29 ft. lbs.) 2. Snap field wire connector into rear of generator. 3. Install B+ terminal and nut to generator mounting stud. Tighten nut to 13 N.m (115 in. lbs.) 4. Snap plastic protective cover to B+ terminal.
CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump will be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment, or refer
to Belt Schematics in COOLING article .
5. Install drive belt. Refer to COOLING article for belt routing, belt adjustment and bolt tightening procedures. 6. Install negative battery cable to battery.
PULLEY - GENERATOR DECOUPLER
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GENERATOR DECOUPLER📷 1
The generator decoupler is used only with certain engines. The decoupler is used in place of the standard generator drive pulley.
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GENERATOR DECOUPLER📷 1
The generator decoupler is used only with certain engines. The decoupler is a one-way clutch designed to help reduce belt tension fluctuation, vibration, reduce fatigue loads, improve belt life, reduce hubloads on components, and reduce noise. Dry operation is used (no grease or lubricants). The decoupler is not temperature sensitive and also has a low sensitivity to electrical load. The decoupler is a non-serviceable item and is to be replaced as an assembly. See Fig. 8.
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GENERATOR DECOUPLER📷 10
The generator decoupler is used only with certain engines.
1 - GENERATOR 2 - DECOUPLER (INA) 3 - MACHINED SPLINES
Two different type generator decoupler pulleys are used. One can be identified by the use of machined splines (3). See Fig. 9.
1 - DECOUPLER (LITENS) 2 - HEX OPENING
The other decoupler is equipped with a hex opening (2) and will not use splines. See Fig. 10.
Different special tools are required to service each different decoupler. Refer to following procedure.
INA Decoupler
1. Disconnect negative battery cable. 2. Remove generator and accessory drive belt. Refer to REMOVAL .
1 - INA DECOUPLER 2 - TOOL #8823 (VM.1048)
3. Position Special Tool #8823 (VM.1048) (2) into decoupler (1). See Fig. 11.
1 - GENERATOR SHAFT 2 - HEX
4. Determine if end of generator shaft is hex shaped (2). See Fig. 12.
1 - GENERATOR SHAFT 2 - SPLINES
5. Determine if end of generator shaft is splined (2). See Fig. 13.
1 - DEEP 10 MM SOCKET 2 - TOOL #8823 (VM.1048)
6. If hex is used, insert a 10-MM deep socket (1) into tool #8823 (VM.1048). See Fig. 14.
1 - DRIVER 2 - TOOL #8823 (VM.1048) 3 - 17 MM WRENCH
7. If splined, insert a 5/16" 6-point hex driver (1), or a 10-MM 12-point triple square driver into tool #8823 (VM.1048). See Fig. 15.
1 - DEEP 10 MM SOCKET 2 - TOOL #8823 (VM.1048)
8. The generator shaft uses conventional right-hand threads to attach decoupler. To break decoupler loose from generator threads rotate end of tool (1) clockwise. See Fig. 14.
1 - DRIVER 2 - TOOL #8823 (VM.1048) 3 - 17 MM WRENCH
9. Rotate end of tool (1) clockwise. See Fig. 14.
10. After breaking loose with tool, unthread decoupler by hand from generator.
Litens Decoupler
1. Disconnect negative battery cable. 2. Remove generator and accessory drive belt. Refer to REMOVAL .
3. Position Special Tool #8433 into decoupler. Align to hex end of generator shaft. See Fig. 18.
4. The generator shaft uses conventional right-hand threads to attach decoupler. To break decoupler loose from generator threads, rotate end of tool clockwise. See Fig. 19. 5. After breaking loose with tool, unthread decoupler by hand from generator.
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GENERATOR DECOUPLER📷 4
INA Decoupler
1. Thread decoupler pulley onto generator shaft by hand (right-hand threads). 2. Position Special Tool #8823 (VM.1048) into decoupler.
1 - 10-MM DEEP SOCKET 2 - TOOL # 8823 (VM.1048)
3. Determine if end of generator shaft is hex shaped or is splined. If hex is used, insert a 10-MM deep socket (1) into tool #8823 (VM.1048). See Fig. 20.
1 - DRIVER 2 - TOOL # 8823 (VM.1048) 3 - BACKUP WRENCH
4. If splined, insert a 5/16" 6-point hex driver (1), or a 10-MM 12-point triple square driver into tool #8823 (VM.1048). See Fig. 21.
5. Do not use an adjustable, ratcheting "click type" torque wrench. Most "click type" wrenches will only allow torque to be applied in a clockwise rotation. Use a dial-type or beam-type wrench. Tighten in counterclockwise rotation and tighten to 110 N.m (81 ft. lbs.). 6. Install accessory drive belt, and generator. Refer to INSTALLATION . 7. Connect negative battery cable.
Litens Decoupler
1. Thread decoupler pulley onto generator shaft by hand (right-hand threads). 2. Position Special Tool 8433 into decoupler. Align tool to hex end of generator shaft.
3. Do not use an adjustable, ratcheting "click type" torque wrench. Most "click type" wrenches will only allow torque to be applied in a clockwise rotation. Use a dial-type or beam-type wrench. Tighten in counterclockwise rotation and tighten to 110 N.m (81 ft. lbs.). 4. Install accessory drive belt, and generator. Refer to INSTALLATION . 5. Connect negative battery cable.
REGULATOR - VOLTAGE
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