Generator and Drive Belt Tensioner Bracket Replacement

Removal Procedure

1. Remove the charge air cooler, condenser, fan, and radiator assembly. Charge Air Cooler, Condenser, Fan Motor, and Radiator Assembly Removal and Installation

Generator and Drive Belt Tensioner Bracket Replacement — figure 1

2. Air Cleaner Outlet Front Duct Clamp (1) » Loosen [2x]
3. Air Cleaner Outlet Front Duct (2) » Remove

Generator and Drive Belt Tensioner Bracket Replacement — figure 2

4. Air Cleaner Nut (2) » Remove
5. Disconnect the 2 electrical connectors (5) from the mass air flow sensor and the air cleaner.
6. Remove all wiring harness retainers from the air cleaner.

Generator and Drive Belt Tensioner Bracket Replacement — figure 3

7. Air Cleaner Housing Cover Bolt (1) » Remove [3x]
8. Air Cleaner Upper Housing (2) » Remove

Generator and Drive Belt Tensioner Bracket Replacement — figure 4

9. Air Cleaner Lower Housing (1) » Remove

Generator and Drive Belt Tensioner Bracket Replacement — figure 5

10. Radiator Inlet Hose Clip (1) » Disengage
11. Engine Wiring Harness Retainer (2) » Remove [2x]
12. Engine Wiring Harness Bracket Bolt (3) » Remove
13. Engine Wiring Harness Bracket (4) » Remove

Generator and Drive Belt Tensioner Bracket Replacement — figure 6

14. Electrical Connector (1) » Disconnect

Generator and Drive Belt Tensioner Bracket Replacement — figure 7

15. Battery Positive Cable Nut (1) @ Generator » Remove
16. Generator Battery Jumper Cable (2) » Remove

Generator and Drive Belt Tensioner Bracket Replacement — figure 8

17. Engine Front Cover Bolt (1) » Remove
18. Engine Front Cover (2) » Remove

Generator and Drive Belt Tensioner Bracket Replacement — figure 9

19. Rotate the accessory drive primary belt tensioner (1) clockwise to release the drive belt tension.
20. Slide the accessory drive primary belt (2) off of the belt idler pulley and slowly release the accessory drive primary belt tensioner (1).
21. Remove the accessory drive primary belt (2).

Generator and Drive Belt Tensioner Bracket Replacement — figure 10

22. Engine Wiring Harness Bracket Nut (1) » Remove [2x]
23. Engine Wiring Harness Bracket Bolt (2) » Remove

Generator and Drive Belt Tensioner Bracket Replacement — figure 11

24. Engine Wiring Harness Ground Bolt (1) » Remove
25. Ground Cable (2) » Position aside
26. Disconnect electrical connectors as needed, detach retainer at intake manifold and reposition the engine wiring harness channel (3) away from the front of the engine.

Generator and Drive Belt Tensioner Bracket Replacement — figure 12

27. Generator Bolt (1) » Loosen until disengaged
28. Generator Bolt (2) » Remove

Generator and Drive Belt Tensioner Bracket Replacement — figure 13

29. Generator (1) » Remove

Generator and Drive Belt Tensioner Bracket Replacement — figure 14

30. Air Conditioning Compressor Bolt (1) » Remove

Generator and Drive Belt Tensioner Bracket Replacement — figure 15

31. Air Conditioning Compressor Bolt (1) » Remove

Generator and Drive Belt Tensioner Bracket Replacement — figure 16

32. Air Conditioning Compressor Nut (1) » Remove
33. Air Conditioning Compressor Stud (2) » Remove
34. Reposition the air conditioning compressor, as needed.

Generator and Drive Belt Tensioner Bracket Replacement — figure 17

35. Drive Belt Idler Pulley (4) » Remove
36. Drive Belt Tensioner Bolt (1) » Remove
37. Drive Belt Tensioner (2) » Remove

Generator and Drive Belt Tensioner Bracket Replacement — figure 18

38. Generator and Air Conditioning Compressor Bracket Bolt (2) » Remove [4x]

39. Generator and Air Conditioning Compressor Bracket (1) » Remove Installation Procedure

40. Generator and Air Conditioning Compressor Bracket (1) » Install

41. Generator and Air Conditioning Compressor Bracket Bolt (2) » Install and tighten [4x] — Fastener Specifications

Generator and Drive Belt Tensioner Bracket Replacement — figure 19

3. Upon installation of the drive belt idler pulley, the retainer (3) and spacer (2) may detach from the pulley assembly (1). If reinstalling the idler belt pulley, ensure the proper orientation, as shown before reassembling the drive belt idler pulley.

4. Drive Belt Tensioner (2) » Install

Caution

Refer to Fastener Caution

5. Drive Belt Tensioner Bolt (1) » Install and tighten — Fastener Specifications

6. Drive Belt Idler Pulley (4) » Install and tighten — Fastener Specifications

7. Install the air conditioning compressor.

8. Air Conditioning Compressor Stud (2) » Install and tighten — Fastener Specifications

9. Air Conditioning Compressor Nut (1) » Install and tighten — Fastener Specifications

10. Air Conditioning Compressor Bolt (1) » Install and tighten — Fastener Specifications

11. Air Conditioning Compressor Bolt (1) » Install and tighten — Fastener Specifications

12. Generator (1) » Install

13. Generator Bolt (2) » Install and tighten — Fastener Specifications

14. Generator Bolt (1) » Install and tighten — Fastener Specifications

15. Position the engine wiring harness channel (3) at the front of the engine, attach retainer at intake manifold, and connect electrical connectors as needed.

16. Engine Wiring Harness Bracket Bolt (2) » Install and tighten — Fastener Specifications

17. Engine Wiring Harness Bracket Nut (1) » Install and tighten [2x] — Fastener Specifications

18. Ground Cable (2) » Install

19. Engine Wiring Harness Ground Bolt (1) » Install and tighten — Fastener Specifications

20. Install the accessory drive primary belt (2) to the vehicle.

21. Rotate the accessory drive primary belt tensioner (1) clockwise.

Note

Ensure the proper routing of the accessory drive primary belt.

22. Install the accessory drive primary belt (2) around all pulleys.

23. Slowly release the accessory drive primary belt tensioner (1).

24. Engine Front Cover (2) » Install

25. Engine Front Cover Bolt (1) » Install and tighten — Fastener Specifications

26. Generator Battery Jumper Cable (2) » Install

27. Battery Positive Cable Nut (1) @ Generator » Install and tighten Install and tighten — Fastener Specifications

28. Electrical Connector (1) » Connect

29. Engine Wiring Harness Bracket (4) » Install

30. Engine Wiring Harness Bracket Bolt (3) » Install and tighten — Fastener Specifications

31. Engine Wiring Harness Retainer (2) » Install [2x]

32. Radiator Inlet Hose Clip (1) » Install

33. Air Cleaner Lower Housing (1) » Install

34. Air Cleaner Upper Housing (2) » Install

35. Air Cleaner Housing Cover Bolt (1) » Install and tighten [3x] — Fastener Specifications

36. INstall all wiring harness retainers to the air cleaner.

37. Air Cleaner Nut (2) » Install and tighten — Fastener Specifications

38. Connect the 2 electrical connectors (5) to the mass air flow sensor and the air cleaner.

39. Air Cleaner Outlet Front Duct (2) » Install

40. Air Cleaner Outlet Front Duct Clamp (1) » Tighten [2x] — Fastener Specifications

41. Install the charge air cooler, condenser, fan, and radiator assembly. Charge Air Cooler, Condenser, Fan Motor, and Radiator Assembly Removal and Installation