GM Camaro/Firebird 1993-1998 Repair Guide

Alternator

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TESTING



There are many possible ways in which the charging system can malfunction. Often the source of a problem is difficult to diagnose, requiring special equipment and a good deal of experience. However, when the charging system fails completely and causes the dash board warning light to come on or the battery to become dead the following items may be checked:

  1. The battery is known to be good and fully charged.
  2.  
  3. The alternator belt is in good condition and adjusted to the proper tension.
  4.  
  5. All connections in the system are clean and tight.
  6.  

REMOVAL & INSTALLATION



While internal alternator repairs are possible, they require specialized tools and training. Therefore, it is advisable to replace a defective alternator as an assembly, or have it repaired by a qualified shop.

3.4L Engine

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the serpentine drive belt.
  4.  
  5. Disconnect the positive battery cable from the alternator "BAT" terminal.
  6.  
  7. Detach the electrical connector from the alternator.
  8.  
  9. Remove the rear inner alternator brace nuts and bolt/screw, then remove the brace.
  10.  
  11. Unfasten the rear brace bolts/screws and the alternator retaining bolt/screws, then remove the alternator assembly from the mounting bracket.
  12.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the alternator and bracket mounting-3.4L engine

To install:
  1. Position the alternator assembly to the accessory mounting bracket and install the retaining bolts/screws. Tighten the rear brace bolt to 18 ft. lbs. (25 Nm) and the alternator mounting bolt to 37 ft. lbs. (50 Nm).
  2.  
  3. Install the alternator rear inner brace and secure with the retaining nuts and bolt/screw. Tighten the upper nut to 18 ft. lbs. (25 Nm) and the lower nut and bolt to 37 ft. lbs. (50 Nm).
  4.  
  5. Attach the electrical connector to the alternator assembly.
  6.  
  7. Connect the positive battery cable to the alternator assembly. Tighten the cable nut to 15 lbs. (20 Nm).
  8.  
  9. Install the serpentine drive belt assembly.
  10.  
  11. Connect the negative battery cable.
  12.  

3.8L Engine

See Figure 2

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the serpentine drive belt.
  4.  
  5. Detach the electrical connector from the alternator.
  6.  
  7. Disconnect the positive battery cable nut from the alternator "BAT" terminal.
  8.  
  9. Remove the charcoal canister solenoid from the alternator brace.
  10.  
  11. Unfasten the alternator brace bolt/screw attaching the alternator to the rear brace.
  12.  
  13. Unfasten the retaining bolts/screws securing the alternator to the drive belt tensioner, then remove the alternator from the vehicle.
  14.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the alternator and bracket mounting-3.8L engine

To install:
  1. Position the alternator to the drive belt tensioner and install the retaining bolts/screws. Tighten the upper bolt to 22 ft. lbs. (30 Nm) and the lower bolt to 37 ft. lbs. (50 Nm).
  2.  
  3. Install the charcoal canister solenoid to the alternator rear brace.
  4.  
  5. Install the rear brace bolt/screw attaching the alternator to the rear brace. Tighten to 22 ft. lbs. (30 Nm).
  6.  
  7. Connect the positive battery cable nut to the alternator "BAT" stud. Tighten the nut to 16 ft. lbs. (22 Nm).
  8.  
  9. Attach the electrical connector to the alternator.
  10.  
  11. Install the serpentine drive belt.
  12.  
  13. Connect the negative battery cable. Tighten the cable bolt/screw to 11 ft. lbs. (15 Nm).
  14.  

5.7L Engine

See Figure 3 through 8

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the serpentine drive belt.
  4.  



Click image to see an enlarged view

Fig. Fig. 3: Remove the serpentine drive belt from the alternator pulley

  1. Disconnect the positive battery cable from the alternator "BAT" terminal.
  2.  



Click image to see an enlarged view

Fig. Fig. 4: Loosen the retaining bolt, then remove the wire from the "BAT" terminal (see arrow)

  1. Detach the electrical connector from the alternator.
  2.  
  3. Remove the alternator rear brace bolt, the alternator upper and lower mounting bolts/screws and the nut from the alternator.
  4.  
  5. Remove the rear nut from the alternator rear inner brace, then remove the rear inner brace.
  6.  
  7. Remove the alternator from the accessory mounting bracket.
  8.  



Click image to see an enlarged view

Fig. Fig. 5: Unfasten the mounting bolts and/or braces ...



Click image to see an enlarged view

Fig. Fig. 6: ... then remove the alternator from the vehicle



Click image to see an enlarged view

Fig. Fig. 7: Exploded view of the alternator and bracket mounting-5.7L engine



Click image to see an enlarged view

Fig. Fig. 8: Rear view of the alternator, showing the "BAT" terminal (A) and electrical connection (B)

To install:
  1. Position the alternator to the accessory mounting bracket.
  2.  
  3. Install the alternator rear inner brace.
  4.  
  5. Install the rear nut to the alternator rear inner brace. Tighten the nut to 24 ft. lbs. (33 Nm).
  6.  
  7. Install the alternator and brace retaining bolts/screws. Tighten to 37 ft. lbs. (50 Nm).
  8.  
  9. Attach the electrical connector to the alternator.
  10.  
  11. Connect the positive battery cable to the alternator "BAT" stud. Tighten the cable nut to 16 ft. lbs. (22 Nm).
  12.  
  13. Install the serpentine drive belt.
  14.  
  15. Connect the negative battery cable. Tighten the cable bolt/screw to 11 ft. lbs. (15 Nm).
  16.  

 
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