GM 30016320
Alternator

When repairing the Alternator begin by taking the generator out of the vehicle while marking alignment points between the front and rear housings for assembly purposes. First use the bearing puller (J 22912-O1) to extract the rear bearing from the rotor before moving on to take off all four generator housing bolts at the front housing. Work with clean shop cloths between the rotor and vise as you gently remove the front housing together with the rotor from the rear housing. To begin assembly place the front housing with rotor into the vise to face its drive pulley upwards then take out the drive pulley's retaining nut followed by the drive pulley washer and finally the drive pulley itself. Start by removing the rotor combined with its spacer section from the front housing then carefully take out both the front bearing and retainer. The resistance measurement between slip rings on the rotor and stator leads needs the digital multimeter (J 39200) and vernier caliper (J 26900-5) to determine proper brush length. Proceed with replacements based on any recorded measurements which show replacement necessity. To start the procedure connect brushes with the regulator before soldering the brush lead wires followed by installing the brush lead wire cover. Put everything back together while torquing the battery terminal nut to 10 n.m and drive pulley nut to 65 n.m and generator housing bolts to 30 n.m. The generator requires its rotor to move smoothly before placing it back onto the vehicle.

The generator replacement requires beginning with disconnecting the negative Battery Cable to prevent severe injuries that could result from tool shorts at the generator lead. You should first take out the air cleaner assembly then remove the rubber insulator, the nut and the electrical connector from generator b+ terminal. The generator becomes removable once the upper mounting bolt and Drive Belt lose their place before extracting the two lower generator mounting bolts. To install the generator place it back onto the vehicle first before tightening the lower bolts and then finish by leaving the upper bolt loose. For used belts set the desired deflection between 6-8 mm (0.24-0.31 in) while new belts need adjustments between 5-7 mm (0.20-0.27 in) during belt installation across the pulleys by applying 10 kg (22 lb) weight. Apply 23 n.m (17 lb ft) of torque when you finish adjusting the generator mounting bolts. Secure the electrical connector over the generator b+ terminal using the provided nut along with a rubber insulator before locking the connector nut with a torque of 8 n.m (71 lb in). Put everything back for the air cleaner assembly before reconnecting the negative Battery Cable and fastening it to 15 n.m (11 lb in).