Generator Replacement Delphi KG9

1. Disconnect the battery ground (negative) cable from the battery. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the drive belt from generator. Refer to Drive Belt Replacement in Engine Mechanical - 3.4L.
3. Remove the windshield wiper system module cover. Refer to Wiper Motor Replacement and Wiper Motor Crank Arm Replacement in Wipers/Washer Systems.
4. Remove the windshield wiper motor crank arm link from the wiper motor and move aside. Refer to Wiper Motor Replacement and Wiper Motor Crank Arm Replacement in Wipers/Washer Systems.
5. Position the wiper arms to a vertical position on windshield.
6. Remove the engine mount strut bracket bolts and rotate engine forward. Refer to Rotating the Engine for Service Access in Engine Mechanical - 3.1L, 3.4L.
7. Disconnect the electrical connector from the generator.
8. Remove the following from the generator output BAT terminal:

8.1.

Boot

8.2.

Nut

8.3.	Battery (positive) lead

9. Remove the generator front brace. Refer to Generator Brace Replacement .
10. Remove the generator rear brace. Refer to Generator Brace Replacement .
11. Remove the generator bolt (pivot bolt) and nut from the generator.
12. Place a floor jack at the center front of the frame.

Notice: Make sure that lowering the frame does not interfere with the bumper fascia or subsequent fascia damage may result.

13. Remove the front frame bolts. Refer toFrame Replacement in Frame and Underbody.
14. Lower the frame 76 mm (3 in).
15. Remove the generator.

1. Install the generator.
2. Raise the frame using the floor jack.
3. Install new front frame bolts. Refer toFrame Replacement in Frame and Underbody.
4. Remove the floor jack.
5. Install the generator bolt (pivot bolt) to the generator.

Tighten
Tighten the generator bolt (pivot bolt) to 50 N·m (37 lb ft).

6. Install the generator rear brace. Refer to Generator Brace Replacement .
7. Install the generator front brace. Refer to Generator Brace Replacement .
8. Install the battery (positive) lead to the generator output BAT terminal with the nut.

Tighten
Tighten the battery (positive) lead BAT nut to 25 N·m (18 lb ft).

9. Install the boot .
10. Connect the electrical connector to the generator.
11. Rotate the engine rearward and install engine mount strut bracket bolts. Refer to Rotating the Engine for Service Access in Engine Mechanical - 3.1L, 3.4L.
12. Install the windshield wiper motor crank arm link to wiper motor. Refer to Wiper Motor Replacement and Wiper Motor Crank Arm Replacement in Wipers/Washer Systems.
13. Install the windshield wiper system module cover. Refer to Wiper Motor Replacement and Wiper Motor Crank Arm Replacement in Wipers/Washer Systems.
14. Install the drive belt to the generator. Refer to Drive Belt Replacement in Engine Mechanical - 3.4L.
15. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection .
16. Inspect the front end toe-in alignment. Refer toFront Toe Adjustment in Wheel Alignment.

Generator Replacement Valeo K68

1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the drive belt from generator. Refer to Drive Belt Replacement in Engine Mechanical - 3.4L.
3. Remove the windshield wiper system module cover. Refer to Wiper Motor Replacement and Wiper Motor Crank Arm Replacement in Wipers/Washer Systems.
4. Remove the windshield wiper motor crank arm link from the wiper motor and move aside. Refer to Wiper Motor Replacement and Wiper Motor Crank Arm Replacement in Wipers/Washer Systems.
5. Position the wiper arms to a vertical position on the windshield.
6. Remove the engine mount strut bracket bolts and rotate engine forward. Refer to Rotating the Engine for Service Access in Engine Mechanical - 3.1L, 3.4L.
7. Disconnect the electrical connector from the generator.
8. Remove the nut and the battery positive lead from the generator output BAT terminal.



9. Remove the generator front brace. Refer to Generator Brace Replacement .
10. Remove the generator rear brace. Refer to Generator Brace Replacement .
11. Remove the generator mounting bolts.
12. Remove the generator bolt (pivot bolt) and nut from the generator. Set the generator aside.
13. Remove the generator bracket from the engine. Refer to Generator Bracket Replacement .
14. Remove the generator.

1. Position the generator to the engine and set the generator aside.
2. Install the generator bracket to the engine. Refer to Generator Bracket Replacement .
3. Install the generator bolt (pivot bolt) to the generator. Hand tighten.
4. Install the generator rear brace. Refer to Generator Brace Replacement .
5. Install the generator front brace. Refer to Generator Brace Replacement .

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

6. Tighten the generator bolt (pivot bolt).

Tighten
Tighten the generator pivot bolt to 50 N·m (37 lb ft).

7. Install the battery positive lead to the generator output (BAT) terminal with the nut.

Tighten
Tighten the battery positive lead (BAT) nut to 15 N·m (11 lb ft).

8. Connect the electrical connector to the generator.
9. Rotate the engine rearward and install engine mount strut bracket bolts. Refer to Rotating the Engine for Service Access in Engine Mechanical - 3.1L, 3.4L.
10. Install the windshield wiper motor crank arm link to the wiper motor. Refer to Wiper Motor Replacement and Wiper Motor Crank Arm Replacement in Wipers/Washer Systems.
11. Install the windshield wiper system module cover. Refer to Wiper Motor Replacement and Wiper Motor Crank Arm Replacement in Wipers/Washer Systems.
12. Install the drive belt to the generator. Refer to Drive Belt Replacement in Engine Mechanical - 3.4L.
13. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection .