Camaro, Firebird, 1999 - 2002

Alternator

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Removal & Installation



3.8L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt
     
    Alternator electrical connectors
     
    Evaporative Emissions (EVAP) canister purge solenoid
     
    Rear alternator brace-to-alternator bolt
     
    Both front alternator bolts
     
    Alternator

    Click image to see an enlarged view

    Fig. Exploded view of the alternator and related components-3.8L engine

     

  4.  

To install:

Install or connect the following:



Alternator. Torque the upper (drive belt tensioner) bolt to 22 ft. lbs. (30 Nm) and the lower bolt to 37 ft. lbs. (50 Nm).
 
Rear alternator brace-to-alternator bolt. Torque the bolt to 22 ft. lbs. (30 Nm).
 
EVAP canister purge solenoid
 
Alternator electrical connectors. Torque the battery cable nut to 16 ft. lbs. (22 Nm).
 
Accessory drive belt
 
Negative battery cable
 

5.7L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt
     
    Alternator rear inner brace
     
    Transmission oil cooler line clips
     
    Alternator bolts
     
    Alternator electrical connectors
     
    Alternator

    Click image to see an enlarged view

    Fig. Exploded view of the alternator and related components-5.7L engine

     

  4.  

To install:

Install or connect the following:



Alternator
 
Alternator bolts. Torque the bolts to 37 ft. lbs. (50 Nm).
 
Transmission oil cooler line clips
 
Alternator rear inner brace. Torque the nut to 18 ft. lbs. (25 Nm).
 
Alternator electrical connectors. Torque the battery cable nut to 16 ft. lbs. (22 Nm).
 
Accessory drive belt
 
Negative battery cable
 

Camaro & Firebird
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the accessory drive belt.
  4.  
  5. Raise and suitably support the vehicle.
  6.  
  7. Remove the positive cable from the generator:
  8.  
  9. Slide the boot down revealing the positive terminal stud.
  10.  
  11. Remove the positive cable nut from the generator output stud.
  12.  
  13. Remove the positive cable.
  14.  
  15. Remove the generator rear bracket mounting bolt.
  16.  
  17. Remove the transmission oil cooler lines from the oil cooler clip.
  18.  
  19. Remove the front generator mounting bolts and oil cooler clip.
  20.  
  21. Disconnect the generator electrical connector.
  22.  
  23. Remove the generator from the vehicle.

    Click image to see an enlarged view

    Fig. Showing location of generator on Camaro & Firebird with 5.7L V8 engines

  24.  

To install:

  1. Install the generator to the vehicle.
  2.  
  3. Connect the generator electrical connector.
  4.  
  5. Install the front generator mounting bolts and oil cooler clip. Tighten the generator mounting bolts to 50 Nm (37 ft. lbs.).
  6.  
  7. Install the transmission oil cooler lines to the oil cooler clip.
  8.  
  9. Install the generator rear bracket mounting bolt. Tighten the rear bracket mounting bolt to 25 Nm (18 ft. lbs.).Install the positive cable to the generator:
  10.  
  11. Install the positive cable.
  12.  
  13. Install the positive cable nut to the generator output stud. Tighten the positive cable nut to the generator output stud to 22 Nm (16 ft. lbs.).
  14.  
  15. Slide the boot over the positive terminal stud.
  16.  
  17. Lower the vehicle.
  18.  
  19. Install the accessory drive belt.
  20.  
  21. Connect the negative battery cable.
  22.  

Testing



Load Test
  1. With the engine running, turn on the blower motor and the high beams (or other electrical accessories to place a load on the charging system).
  2.  
  3. Increase and hold engine speed to 2000 rpm.
  4.  
  5. Measure the voltage reading at the battery.
  6.  
  7. The voltage should increase at least 0.5 volts from the voltage test. If the voltage does not meet specifications, the charging system is malfunctioning.
  8.  

No-Load Test
  1. Connect a tachometer to the engine.
    CAUTION
    Ensure that the transmission is in Park and the emergency brake is set. Blocking a wheel is optional and an added safety measure.

  2.  
  3. Turn off all electrical loads (radio, blower motor, wipers, etc.)
  4.  
  5. Start the engine and increase engine speed to approximately 1500 rpm.
  6.  
  7. Measure the voltage reading at the battery with the engine holding a steady 1500 rpm. Voltage should have raised at least 0.5 volts, but no more than 2.5 volts.
  8.  
  9. If the voltage does not go up more than 0.5 volts, the alternator is not charging. If the voltage goes up more than 2.5 volts, the alternator is overcharging.
    NOTE
    Usually under and overcharging is caused by a defective alternator, or its related parts (regulator), and replacement will fix the problem; however, faulty wiring and other problems can cause the charging system to malfunction. Many automotive parts stores have alternator bench testers available for use by customers. An alternator bench test is the most definitive way to determine the condition of your alternator.

  10.  
  11. If the voltage is within specifications, proceed to the next test.
  12.  

Voltage Test
  1. Make sure the engine is OFF, and turn the headlights on for 15-20 seconds to remove any surface charge from the battery.
  2.  
  3. Using a DVOM set to volts DC, probe across the battery terminals.
  4.  
  5. Measure the battery voltage.
  6.  
  7. Write down the voltage reading and proceed to the next test.
  8.  

 
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