GM Lumina/Grand Prix/Cutlass Supreme/Regal 1988-1996

Alternator

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REMOVAL & INSTALLATION



See Figures 1 and 2

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the serpentine drive belt, as outlined in Routine Maintenance of this repair guide.
  4.  
  5. Unfasten the rear bracket/heat shield nuts from the exhaust manifold.
  6.  
  7. Remove the rear bracket/heat shield bolts from the block, near the water pump.
  8.  
  9. Unfasten the rear bracket/heat shield retaining nuts at the alternator, then remove the bracket/heat shield.
  10.  



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Fig. Fig. 1: Unfasten the necessary nuts and bolts in order to remove the rear bracket/heat shield

  1. Detach the electrical connections from the alternator, including the battery positive lead and the nuts from the alternator output (BAT) terminal.
  2.  
  3. Unfasten the front attaching bolts, then remove the alternator from the vehicle.
  4.  



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Fig. Fig. 2: Remove the front attaching bolts, then remove the alternator (generator) from the vehicle

To install:
  1. Position the alternator in the vehicle, then secure using the retaining bolts. Tighten the long bolt to 37 ft. lbs. (50 Nm) and the short bolt to 18 ft. lbs. (25 Nm).
  2.  
  3. Fasten the battery positive lead and nut to the alternator output terminal and tighten to 70 inch lbs. (8 Nm).
  4.  
  5. Attach the electrical connector to the alternator.
  6.  
  7. Position the rear bracket/heat shield, then install the retaining bolt at the alternator. Tighten the bolt to 18 ft. lbs. (25 Nm).
  8.  
  9. Fasten the rear bracket/heat shield bolts to the block, near the water pump. Tighten to 63 ft. lbs. (85 Nm). Install the bracket/shield-to-exhaust manifold nuts and tighten to 37 ft. lbs. (50 Nm).
  10.  
  11. Install the serpentine drive belt, as outlined in Routine Maintenance of this repair guide.
  12.  
  13. Connect the negative battery cable.
  14.  

See Figure 3

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the electrical center fuse block shield.
  4.  
  5. Remove the serpentine belt, as outlined in Routine Maintenance of this repair guide.
  6.  
  7. Label and detach the alternator electrical connector(s). Unfasten the nut and the battery positive connector from the alternator.
  8.  
  9. Unfasten the alternator brace bolt and the rear and front retaining bolts.
  10.  


WARNING
Be very careful not to damage the A/C compressor and condenser hose when removing the alternator.

  1. Lift the alternator out between the engine lifting eyelet and the A/C compressor and condenser hose, to the passenger side, then up and out.
  2.  



Click image to see an enlarged view

Fig. Fig. 3: Alternator mounting-2.3L engine

To install:
  1. Position the alternator in the vehicle, then install the front attaching bolt, but do not tighten at this time. Install rear and brace retaining bolts.
  2.  
  3. Tighten the long bolt to 40 ft. lbs. (54 Nm), the short bolt to 19 ft. lbs. (26 Nm) and the brace bolt to 18 ft. lbs. (25 Nm).
  4.  
  5. Fasten the battery positive connector and nut to the alternator.
  6.  
  7. Attach the alternator electrical connector, then install the serpentine belt and fuse block shield.
  8.  
  9. Connect the negative battery cable and check for proper operation.
  10.  

See Figure 4

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the serpentine belt, as outlined in Routine Maintenance of this repair guide.
  4.  
  5. Detach the electrical connector(s) from the back of the alternator.
  6.  
  7. Unfasten the nut and the battery positive lead from the alternator output (BAT) terminal.
  8.  
  9. Remove the rear then the front attaching bolts and remove the heat shield.
  10.  
  11. Carefully remove the alternator assembly, making sure all wires are disconnected.
  12.  



Click image to see an enlarged view

Fig. Fig. 4: On the 2.5L engine, you must remove the heat shield in order to remove the alternator from the vehicle

To install:
  1. Position the alternator into the mounting bracket and install the front mounting bolts but do not tighten at this time.
  2.  
  3. Install the heat shield and the rear the rear mounting bolt.
  4.  
  5. Tighten the long bolts to 37 ft. lbs. (50 Nm) and the short bolt and heat shield bolt to 20 ft. lbs. (27 Nm).
  6.  
  7. Attach the electrical connector(s).
  8.  
  9. Install the serpentine belt, as outlined in Routine Maintenance of this repair guide.
  10.  
  11. Connect the negative battery cable.
  12.  

2.8L and 3.1L Engines
1998-93 VEHICLES

See Figures 5, 6, 7 and 8

  1. Disconnect the negative battery cable.
  2.  
  3. If necessary for access to the alternator, remove the air cleaner assembly.
  4.  
  5. Remove the serpentine belt, as outlined in Routine Maintenance of this repair guide.
  6.  
  7. Label and detach the electrical connector(s) from the back of the alternator.
  8.  



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Fig. Fig. 5: After removing the serpentine belt, detach the electrical connector from the rear of the alternator

  1. Remove the rear and front attaching bolts, and unfasten the brace-to-alternator bolt.
  2.  



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Fig. Fig. 6: Unfasten the front and rear mounting bolts...



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Fig. Fig. 7: ... then remove the brace-to-alternator bolt

  1. Carefully remove the alternator assembly, making sure all wires are disconnected.
  2.  

If the alternator brace is removed, the studs must be retightened before installation or damage to the brace may result.

Click image to see an enlarged view

Fig. Fig. 8: Alternator (generator) removal and installation-1992 3.1L engine shown

To install:
  1. Position the alternator into the mounting bracket.
  2.  
  3. If necessary, attach the battery positive lead and nut to the alternator output terminal. Tighten to 71 inch lbs. (8 Nm).
  4.  
  5. Install the brace-to-alternator bolt, but do not tighten at this time.
  6.  
  7. Install the front and rear mounting bolts. Tighten the bolts as follows:
    1. Long bolt to 35 ft. lbs. (47 Nm)
    2.  
    3. Short bolt to 18 ft. lbs. (25 Nm)
    4.  
    5. Bracket bolt to 18 ft. lbs. (25 Nm)
    6.  

  8.  
  9. Check that tightening of the brace bolts did not bind the alternator.
  10.  
  11. Attach the electrical connector(s).
  12.  
  13. Install the serpentine belt, as outlined in Routine Maintenance of this repair guide.
  14.  
  15. If removed, install the air cleaner.
  16.  
  17. Connect the negative battery cable.
  18.  

1994-96 VEHICLES

See Figure 9

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the serpentine belt at the alternator, as outlined in Routine Maintenance of this repair guide.
  4.  
  5. Unfasten the bolt/screw from the alternator.
  6.  
  7. Remove the power steering gear pipe clip and nut.
  8.  
  9. Remove the stud from the alternator.
  10.  
  11. Detach the electrical connector from the alternator.
  12.  
  13. Loosen the alternator front and rear braces from the upper intake manifold.
  14.  
  15. Unfasten the nut and battery positive lead from the alternator output (BAT) terminal.
  16.  
  17. Remove the alternator from the vehicle.
  18.  



Click image to see an enlarged view

Fig. Fig. 9: Alternator mounting-1996 3.1L engine shown

To install:
  1. Position the alternator in the mounting bracket.
  2.  
  3. Attach the battery positive lead and the nut to the alternator output terminal. Tighten the nut to 15 ft. lbs. (20 Nm).
  4.  
  5. Hand start the alternator front and rear braces to the intake manifold.
  6.  
  7. Attach the electrical connector to the alternator. The connector will snap into place when it is correctly installed.
  8.  
  9. Install the retaining bolts/screws to the alternator. Tighten to 37 ft. lbs. (50 Nm).
  10.  
  11. Fasten the alternator front and rear brace nuts to the intake manifold, then tighten the nuts to 18 ft. lbs. (25 Nm). Make sure the alternator does not bind when tightening the brace nuts.
  12.  
  13. Install the stud on the alternator, then tighten to 18 ft. lbs. (25 Nm).
  14.  
  15. Fasten the power steering gear pipe clip and nut.
  16.  
  17. Install the drive belt on the alternator as outlined in Routine Maintenance of this repair guide.
  18.  
  19. Connect the negative battery cable.
  20.  

3.4L Engine

Vehicles with the 3.4L engine will also be equipped with an alternator cooling fan behind the right side headlight, used to cool the unit through a duct hose.

AUTOMATIC TRANSAXLE VEHICLES THROUGH 1994



See Figures 10, 11 and 12

  1. Remove the air cleaner assembly.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the serpentine belt, as outlined in Routine Maintenance of this section.
  6.  
  7. Remove the coolant recovery reservoir and set it aside.
  8.  
  9. Unfasten the upper alternator stud nut and remove the power steering pipe retaining clip from the stud.
  10.  
  11. Loosen the upper alternator stud.
  12.  
  13. Raise and safely support the vehicle.
  14.  
  15. Remove the front tire and wheel assemblies.
  16.  
  17. Unfasten the right engine splash shield upper retaining clips, then pull down the shield.
  18.  
  19. Remove the upper alternator stud.
  20.  
  21. Remove the cotter pin and lower ball joint castle nut from the right lower ball joint, then separate the lower ball joint from the lower control arm.
  22.  
  23. Remove the metal halfshaft shield retaining screws, then remove the shield.
  24.  
  25. If equipped, detach the knock sensor electrical connector.
  26.  
  27. Disconnect the right halfshaft from the transaxle.
  28.  
  29. Remove the front exhaust pipe and converter assembly.
  30.  
  31. Unfasten the lower alternator mounting bolt.
  32.  
  33. Remove the alternator rear brace-to-alternator bolt. The bolt can best be accessed using a 4 ft. (1.2m) extension through the left side wheel well opening.
  34.  
  35. Remove the alternator rear brace nut from the engine. The nut can be best accessed through the right wheel well behind the alternator.
  36.  
  37. Remove the alternator from the mounting bracket.
  38.  
  39. Detach the electrical connector from the alternator.
  40.  
  41. Unfasten the battery wire nut from the alternator stud, then disconnect the battery positive lead from the alternator output terminal.
  42.  
  43. Remove the alternator from the vehicle.
  44.  



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Fig. Fig. 10: Removal and installation of the alternator shield-1993 3.4L engine with an automatic transaxle



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Fig. Fig. 11: Alternator mounting-1993 3.4L engine shown

To install:
  1. Attach the alternator electrical connector and battery wire to the alternator. Tighten the mounting nut on the battery wire to 71 inch lbs. (8 Nm).
  2.  
  3. Position the alternator and loosely install the mounting bolts. If the replacement alternator does not fit into the bracket, remove the adhesive-backed shim from the rear of the alternator bracket.
  4.  



Click image to see an enlarged view

Fig. Fig. 12: If the replacement alternator does not fit properly, remove the shim from the rear of the bracket

  1. Install the alternator rear brace, cooling duct bracket and mounting. Access the bolt through the left wheel opening using a 4 ft. (1.2m) extension.
  2.  
  3. Tighten the mounting bolts as follows:
    1. Rear brace bolt to 18 ft. lbs. (25 Nm)
    2.  
    3. Rear brace nut to 37 ft. lbs. (50 Nm)
    4.  
    5. Lower mounting bolt to 37 ft. lbs. (50 Nm)
    6.  

  4.  
  5. Install the front exhaust pipe and converter assembly.
  6.  
  7. Connect the right halfshaft to the transaxle.
  8.  
  9. Install the metal drive axle shield and retaining screws.
  10.  
  11. If equipped, attach the knock sensor electrical connector.
  12.  
  13. Connect the lower ball joint to the lower control arm, then tighten the castle nut to 63 ft. lbs. (85 Nm).
  14.  
  15. Loosely install the upper alternator mounting stud.
  16.  
  17. Install the right engine splash shield, and secure with the retaining clips.
  18.  
  19. Install the tire and wheel assemblies, then carefully lower the vehicle.
  20.  
  21. Tighten the alternator mounting stud to 18 ft. lbs. (25 Nm).
  22.  
  23. Install the power steering pipe retaining clip and mounting nut.
  24.  
  25. Install the coolant recovery reservoir.
  26.  
  27. Install the serpentine belt, as outlined in Routine Maintenance of this repair guide.
  28.  
  29. Connect the negative battery cable.
  30.  
  31. Install the air cleaner assembly.
  32.  

MANUAL TRANSAXLE VEHICLES THROUGH 1994
See Figures 11, 12 and 13
  1. Remove the air cleaner assembly.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the serpentine belt, as outlined in Routine Maintenance of this repair guide.
  6.  
  7. Remove the coolant recovery reservoir.
  8.  
  9. Unfasten the upper alternator stud nut, and remove the power steering pipe retaining clip from the stud.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Remove the right front wheel and tire assembly.
  14.  
  15. Unfasten the right engine splash shield upper retaining clips and pull down the shield.
  16.  
  17. Remove the plastic outboard halfshaft shield retaining screws and the shield.
  18.  
  19. Unfasten the alternator rear brace-to-alternator bolt and nut.
  20.  
  21. Detach the electrical connector from the alternator.
  22.  
  23. Unfasten the battery wire nut from the alternator stud and disconnect the battery positive lead form the alternator output terminal.
  24.  
  25. Remove the cotter pin and lower ball joint castle nut from the right lower ball joint and separate the lower ball joint from the lower control arm.
  26.  
  27. Disconnect the right halfshaft from the transaxle.
  28.  
  29. Remove the metal outer drive axle shield.
  30.  
  31. Remove the rear engine mount bracket brace mounting bolts with the metal inner halfshaft shield attached.
  32.  
  33. Unfasten the alternator mounting stud and lower mounting bolt, then remove the alternator.
  34.  



Click image to see an enlarged view

Fig. Fig. 13: Alternator shield mounting-1993 3.4L engine with manual transaxle

To install:
  1. Position the alternator, then loosely install the mounting bolts. If the replacement alternator does not fit into the bracket, remove the adhesive-backed shim from the rear of the alternator bracket.
  2.  
  3. Tighten the lower mounting bolt to 37 ft. lbs. (50 Nm) and the mounting stud to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the rear engine mount bracket brace retaining bolts and the inboard halfshaft shield.
  6.  
  7. Install the metal drive axle shield and retaining screws.
  8.  
  9. Attach the right halfshaft to the transaxle.
  10.  
  11. Connect the lower ball joint to the lower control arm and tighten the castle nut to 63 ft. lbs. (85 Nm).
  12.  
  13. Attach the alternator electrical connector and battery wire to the alternator. Tighten the mounting nut on the battery wire to 71 inch lbs. (8 Nm).
  14.  
  15. Install the alternator rear brace, cooling duct bracket and mounting nut and bolt. Tighten the rear brace bolt to 18 ft. lbs. (25 Nm) and the rear brace nut to 37 ft. lbs. (50 Nm).
  16.  
  17. Install the plastic outboard halfshaft shield.
  18.  
  19. Position the right engine splash shield and secure with the retaining clips.
  20.  
  21. Install the tire and wheel assembly, then carefully lower the vehicle.
  22.  
  23. Fasten the power steering pipe retaining clip and mounting nut.
  24.  
  25. Install the coolant recovery reservoir.
  26.  
  27. Install the serpentine belt, as outlined in Routine Maintenance this information.
  28.  
  29. Connect the negative battery cable, then install the air cleaner assembly.
  30.  

1995-96 VEHICLES

See Figure 14

  1. Remove the air cleaner and duct.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the cross brace.
  6.  
  7. Remove the coolant recovery reservoir.
  8.  
  9. Remove the serpentine belt, as outlined in Routine Maintenance of this repair guide.
  10.  
  11. Disconnect the power steering gear pipe from the clip mounting to the alternator upper stud.
  12.  
  13. Unfasten and remove the alternator upper stud and nut.
  14.  
  15. Raise and safely support the vehicle.
  16.  
  17. Remove the right tire and wheel.
  18.  
  19. Unfasten the right engine splash shield upper retaining clips, then pull down the shield.
  20.  
  21. Remove the front exhaust pipe and converter.
  22.  
  23. Detach the alternator splash shield fastened to the cowl.
  24.  
  25. Install a suitable jacking fixture to support the engine.
  26.  
  27. Unfasten the rear two cradle bolts.
  28.  
  29. Remove the intermediate shaft lower pinch bolt at the steering gear.
  30.  
  31. Unfasten the right front cradle bolt, then remove the right side tie rod.
  32.  
  33. Remove the alternator splash shield at the drive axle.
  34.  
  35. Detach the alternator electrical connectors.
  36.  
  37. Remove the alternator cooling duct and rear brace.
  38.  
  39. Unfasten the alternator rear brace nut at the engine, then remove the alternator from the vehicle.
  40.  



Click image to see an enlarged view

Fig. Fig. 14: Alternator mounting and location-1996 3.4L engine shown

To install:
  1. Position the alternator in the vehicle, then install the lower bolt. Tighten the bolt to 37 ft. lbs. (50 Nm).
  2.  

The part should fit together easily. Tightening the bolts and nuts must NOT bind the alternator.

  1. Install the alternator rear brace, bolt and nut. Tighten the rear brace nut to 37 ft. lbs. (50 Nm) and the bolt to 18 ft. lbs. (25 Nm).
  2.  
  3. Connect the cooling duct.
  4.  
  5. Attach the electrical connectors to the alternator.
  6.  
  7. Attach the alternator splash shield at the drive axle.
  8.  
  9. Install the right side tie rod. Tighten the nut to 63 ft. lbs. (85 Nm).
  10.  
  11. Install the right front cradle bolt.
  12.  
  13. Fasten the intermediate shaft lower pinch bolt to the steering gear.
  14.  
  15. Raise the cradle, then install the rear cradle bolts.
  16.  
  17. Remove the jacking fixture.
  18.  
  19. Attach the alternator splash shield to the cowl.
  20.  
  21. Install the front exhaust pipe.
  22.  
  23. Fasten the right engine splash shield using the retaining clips.
  24.  
  25. Install the right tire and wheel assembly, then carefully lower the vehicle.
  26.  
  27. Fasten the alternator upper stud and nut and tighten to 18 ft. lbs. (25 Nm).
  28.  
  29. Attach the power steering gear pipes to the clip mounted on the alternator stud.
  30.  
  31. Install the serpentine belt, as outlined in Routine Maintenance of this repair guide.
  32.  
  33. Install the coolant recovery reservoir.
  34.  
  35. Fasten the cross brace.
  36.  
  37. Connect the negative battery cable, then install the air cleaner and duct assembly.
  38.  
  39. Bleed the power steering system, as outlined in Suspension & Steering of this repair guide.
  40.  

3.8L Engine

See Figures 15 and 16

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the serpentine belt, as outlined in Routine Maintenance of this repair guide.
  4.  
  5. Unfasten the alternator retaining bolts.
  6.  
  7. Detach the electrical connector from the alternator.
  8.  
  9. Unfasten the nut and the positive battery lead from the alternator output (BAT) terminal.
  10.  
  11. Remove the alternator from the vehicle.
  12.  
  13. If removing, unfasten the brace-to-engine bolt.
  14.  



Click image to see an enlarged view

Fig. Fig. 15: The alternator on this 1992 3.8L engine is retained by a long and a short bolt



Click image to see an enlarged view

Fig. Fig. 16: Alternator and brace mounting-1996 3.8L engine shown

To install:
  1. If removed, fasten the brace-to-engine bolt.
  2.  
  3. Position the alternator in the vehicle.
  4.  
  5. Attach the battery positive lead and nut to the alternator output terminal. Tighten the nut to 71 inch lbs. (8 Nm).
  6.  
  7. Attach the electrical connector to the alternator.
  8.  

Make sure that tightening the bolts does not bind the alternator.

  1. Install the alternator mounting bolts and tighten them to 20 ft. lbs. (27 Nm).
  2.  
  3. Install the serpentine belt, as outlined in Routine Maintenance of this repair guide.
  4.  
  5. Connect the negative battery cable.
  6.  

 
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