GM Celebrity/Century/Ciera/6000 1982-1996 Repair Guide

Alternator

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PRECAUTIONS



  1. When installing a battery, make sure that the positive and negative cables are not reversed.
  2.  
  3. When jump-starting the car, be sure that like terminals are connected. This also applies to using a battery charger. Reverse polarity will burn out the alternator and regulator in a matter of seconds.
  4.  
  5. Never operate the alternator with the battery disconnected or on an otherwise uncontrolled open circuit.
  6.  
  7. Do not short across or ground any alternator or regulator terminals.
  8.  
  9. Do not try to polarize the alternator.
  10.  
  11. Do not apply full battery voltage to the field (brown) connector.
  12.  
  13. Always disconnect the battery ground cable before disconnecting the alternator lead.
  14.  
  15. Always disconnect the battery (negative cable first) when charging it.
  16.  
  17. Never subject the alternator to excessive heat or dampness. If you are steam cleaning the engine, cover the alternator.
  18.  
  19. Never use arc-welding equipment on the car with the alternator connected.
  20.  

REMOVAL & INSTALLATION



See Figures 1, 2, 3 and 4

SI Series
4-CYLINDER ENGINES
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the two-terminal plug and the battery leads from the rear of the alternator.
  4.  
  5. Remove the adjusting bolt from the alternator.
  6.  
  7. Remove the drive belt.
  8.  
  9. Remove the upper alternator bracket.
  10.  
  11. Loosen and remove the alternator pivot bolt, remove the alternator.
  12.  

To install:
  1. Position the alternator and install the pivot bolt.
  2.  
  3. Install upper mounting bracket, insert the adjusting bolt.
  4.  
  5. Place belt into position.
  6.  
  7. Be sure to adjust the tension of the drive belt properly, then tighten the adjusting bolt(s).
  8.  
  9. Install alternator terminal plug and battery leads to the alternator.
  10.  
  11. Connect the negative battery cable, tighten the cable bolt to 11 ft. lbs. (15 Nm).
  12.  

6-CYLINDER GASOLINE ENGINES
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the two-terminal plug and the battery leads from the rear of the alternator.
  4.  



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Fig. Fig. 1: Unplug the field terminal connector from the alternator



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Fig. Fig. 2: Loosen the nut to disconnect the "BAT" lead

  1. Remove the adjusting bolt from the alternator.
  2.  
  3. Move the alternator to loosen the drive belt, then remove the belt.
  4.  



Click image to see an enlarged view

Fig. Fig. 3: Remove the adjusting bolt to release the belt

  1. On some models you may need to remove the upper alternator bracket.
  2.  
  3. Remove the alternator pivot bolt and remove the alternator.
  4.  



Click image to see an enlarged view

Fig. Fig. 4: After disconnecting all terminals and removing the mounting bolts, pull the alternator from its bracket

To install:
  1. Position the alternator and install the pivot bolt.
  2.  
  3. Insert upper mounting bracket with the adjusting bolt.
  4.  
  5. Place the belt into position.
  6.  
  7. Be sure to adjust the tension of the drive belt properly, then tighten the adjusting bolt.
  8.  
  9. Install the terminal plug and battery leads to the alternator.
  10.  
  11. Connect the negative battery cable, tighten the cable bolt to 11 ft. lbs. (15 Nm).
  12.  

DIESEL ENGINES
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the two-terminal plug and the battery leads from the rear of the alternator.
  4.  
  5. Fit the end of a ratchet extension into the square hole of the belt tensioner bracket. Attach a ratchet to the extension. Lever the tensioner towards the firewall side of the engine compartment and remove the serpentine drive belt from the alternator.
  6.  
  7. Remove the alternator brace bolt from the rear of the alternator.
  8.  
  9. Remove both alternator attaching bolts and remove the alternator.
  10.  

To install:
  1. Install the alternator with both attaching bolts.
  2.  
  3. Install the brace and insert bolt from the rear of alternator.
  4.  
  5. Install belt.
  6.  
  7. Tighten the adjusting bolt(s).
  8.  
  9. Install the terminal plug and battery leads to the alternator.
  10.  
  11. Connect the negative battery cable, tighten the cable bolt to 11 ft. lbs. (15 Nm).
  12.  

CS Series

CAUTION
Failure to disconnect the negative battery cable when working on the CS alternator can result in personal injury. If a tool is shorted at the alternator output or battery terminal, the tool will heat up enough to cause skin damage.

2.2L ENGINE

See Figure 5

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the electrical connector at the alternator.
  4.  



Click image to see an enlarged view

Fig. Fig. 5: Alternator mounting on the 2.2L engine

  1. Lift or rotate the tensioner using a 15mm socket to remove the belt.
  2.  
  3. Loosen and remove all the bolts to alternator.
  4.  
  5. Remove bolts from brace(s) to alternator.
  6.  
  7. Remove the nut from alternator battery terminal BAT.
  8.  
  9. Remove the alternator.
  10.  

To install:
  1. Install the alternator with mounting bolts. Tighten the front bolts to, 37 ft. lbs. (50 Nm) and rear bolts 18 ft. lbs. (25 Nm).
  2.  
  3. Connect battery positive lead and nut to alternator output BAT terminal. Tighten nut 71 inch lbs. (8 Nm).
  4.  
  5. Insert electrical connector to alternator.
  6.  
  7. Install drive belt by lifting or rotating tensioner using a 15mm socket.
  8.  
  9. Connect the negative battery cable, tighten the cable bolt to 11 ft. lbs. (15 Nm).
  10.  

2.5L ENGINE

See Figure 6

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the belt by lifting or rotating the tensioner using a 15mm socket.
  4.  
  5. Disconnect the electrical connector at the alternator.
  6.  



Click image to see an enlarged view

Fig. Fig. 6: Alternator mounting on the 2.5L engine

  1. Remove the nut from alternator battery terminal BAT.
  2.  
  3. Remove the rear attaching bolt, front attaching bolt and rear brace.
  4.  
  5. Remove the alternator.
  6.  

To install:
  1. Install the alternator with mounting bolts but do not tighten.
  2.  
  3. Install the rear brace and attaching bolt.
  4.  
  5. Tighten the long bolts 37 ft. lbs. (50 Nm), short bolts 18 ft. lbs. (25 Nm), rear bolts 18 ft. lbs. (25 Nm).
  6.  
  7. Connect battery positive lead and nut to alternator output BAT terminal. Tighten nut 71 inch lbs. (8 Nm).
  8.  
  9. Insert electrical connector to alternator.
  10.  
  11. Install drive belt by lifting or rotating tensioner using a 15mm socket.
  12.  
  13. Connect the negative battery cable, tighten the cable bolt to 11 ft. lbs. (15 Nm).
  14.  

3.1L ENGINE

See Figure 7

  1. Disconnect the negative battery cable.
  2.  
  3. Detach the electrical connector at the alternator.
  4.  
  5. Disconnect the belt shield bolt, remove shield (if equipped).
  6.  
  7. Lift or rotate tensioner using a breaker bar.
  8.  
  9. Untighten and remove the nuts, bolt along with the stud for alternator braces.
  10.  



Click image to see an enlarged view

Fig. Fig. 7: Alternator mounting used on the 3.1L engine

  1. The alternator bolts may be removed now.
  2.  
  3. Remove the nut from alternator battery terminal BAT.
  4.  
  5. Remove the alternator, bracket bolts and the bracket.
  6.  

To install:
  1. Install bracket to alternator, tighten to 37 ft. lbs. (50 Nm).
  2.  
  3. Position the alternator. Install the BAT lead and nut on alternator. Tighten to 71 inch lbs. (8 Nm).
  4.  
  5. Install the alternator bolt, do not tighten.
  6.  
  7. Install the brace stud, nuts and bolts to alternator.
  8.  

Make sure when tightening the brace stud, it does not bind the alternator.

  1. Tighten the alternator pivot to 37 ft. lbs. (50 Nm), the other bolts to 18 ft. lbs. (25 Nm), Install brace nuts and studs to 18 ft. lbs. (25 Nm).
  2.  
  3. Lift or rotate tensioner with breaker bar and install the belt. Install the bolt shield, tighten to 89 inch lbs. (10 Nm).
  4.  
  5. Connect the electrical connector at alternator.
  6.  
  7. Connect the negative battery cable, tighten the cable bolt to 11 ft. lbs. (15 Nm).
  8.  

3.3L ENGINE
  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the electrical connector at the alternator.
  4.  
  5. Lift or rotate the tensioner to remove the belt.
  6.  
  7. Loosen and remove all the bolts to alternator.
  8.  
  9. Next remove bolts from brace(s) to alternator.
  10.  
  11. Remove the nut from alternator battery terminal BAT, remove alternator.
  12.  

To install:
  1. Connect battery positive lead and nut to alternator output BAT terminal. Tighten nut to 71 inch lbs. (8 Nm).
  2.  
  3. Install the alternator with mounting bolts but do not tighten.
  4.  
  5. After inserting all bolts, tighten the long bolts to 37 ft. lbs. (50 Nm), short bolts to 18 ft. lbs. (25 Nm), and the brace bolt to 37 ft. lbs. (50 Nm). Make sure when tightening brace bolt, it does not bind the alternator.
  6.  
  7. Install drive belt by lifting or rotating tensioner using a 15mm socket.
  8.  
  9. Insert electrical connector to alternator.
  10.  
  11. Connect the negative battery cable, tighten the cable bolt to 11 ft. lbs. (15 Nm).
  12.  

 
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