Safety Glasses
Nitrile Gloves
Sockets
Ratchets
Wrenches
Alternators
Voltmeters
The steps for this alternator replacement are demonstrated on a 2003 Ford Taurus, but procedures will vary slightly from one vehicle to the next. Before you get started, check your vehicle’s service manual for manufacturer-recommended disassembly and installation steps. If you’re not completely comfortable doing this yourself, we’d be happy to recommend a professional technician in your area.
Step 1: Disconnect the Battery
Start this procedure by disconnecting the negative battery cable.
Step 2: Loosen and Remove the Belt
Loosen the belt tensioner so the belt can be removed from the alternator and other pulleys. If your vehicle has an automatic tensioner, use a ratchet or breaker bar to temporarily relieve tension on the belt by pivoting the tensioner arm. Manual tensioners can be loosened until the belt can be removed. While the belt is loose, it’s a good idea to inspect it for wear or signs of glazing, which can diminish the belt’s ability to turn the alternator pulley and keep your battery charged.
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Do It Right: Your vehicle should have a belt routing diagram under the hood, on the radiator support, or elsewhere in the engine compartment to demonstrate how to route the belt during reinstallation. Taking a picture of the belt routing before removal can also provide a reference when re-installing the belt. |
Step 3: Disconnect the Voltage Regulator Plug
Disconnect the voltage regulator connector from the back of the alternator.
Step 4: Remove the Alternator Positive Cable
Using a socket and ratchet, remove the nut from the positive cable on the alternator, and then remove the positive cable and set it aside.
Step 5: Remove the Alternator Brace Bolt
Remove the nut and bolt on the alternator brace (if so equipped).
Step 6: Remove the Alternator’s Lower Mounting Bolt
Locate and remove the alternator’s lower mounting bolt.
Step 7: Remove the Old Alternator
After the brace bolt and mounting bolt are removed, lift the old alternator out of the engine bay.
Step 8: Install the New Alternator
Position the new alternator so you can start threading the lower mounting bolt in place. Then replace the upper bolt and nut on the alternator brace. Tighten the bolts to the manufacturer-recommended torque specification.
Step 9: Reconnect the Voltage Regulator Connector
Once your alternator is secured, reconnect the voltage regulator connector or plug to the back of the new alternator.
Step 10: Reattach the Alternator Positive Cable
Reattach the positive lead and nut to the post on the alternator, and tighten the nut to manufacturer’s specifications.
Step 11: Route the Serpentine Belt Around the Pulleys
Route the serpentine belt around the pulleys as indicated on your vehicle’s belt routing diagram, or reference the picture you took in Step 2. If your vehicle has a self-adjusting tensioner pulley, you’ll need to use a breaker bar or ratchet to relieve tension and slide your belt back into place.
If you have a threaded belt tensioner, increase the tension by turning the bolt until the belt is taut and there is no more than 3/4" deflection between pulleys with the longest span. Be sure there is no interference with the belt and that all tools have been removed from the engine bay.
Step 12: Reattach the Negative Battery Cable
Reattach the ground cable to the battery post and tighten it securely.
The automotive repair work depicted in this series is performed under the direction of the manufacturer of the product featured. Prior to undertaking any of the demonstrated repairs on your vehicle, we suggest you consult with a certified mechanic or another professional who can adequately advise you of the proper repair or remedy required. O’Reilly Automotive Stores, Inc. and its affiliates (“O’Reilly”) disclaims any responsibility for injury or damage resulting from a viewer’s attempt to recreate the repairs shown in this series.