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Old 02-05-2009, 06:11 PM   #4
bsansa
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Join Date: Oct 2004
Location: Fort Wayne, Indiana
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Re: Alternator Replacement '00 Intrigue - here's how

Here are the steps straight out of a repair manual (looks like rncotton is right on):

Removal & Installation
3.5L Engine
To Remove:

Disconnect the negative, then the positive battery cables.
Remove the battery from the vehicle.
Remove the battery tray using the following procedure:
Remove the four battery tray bolts.
Remove the battery tray from the vehicle.
Remove the serpentine drive belt.
Remove the cooling fan assembly using the following procedure:
Remove the wishbone-shaped engine mount strut by removing the bolts and nuts at the engine mount bracket and on the upper radiator support.
Remove the strut from the vehicle.
Disconnect the cooling fan harness from the engine wiring harness.
Reposition the wiring harness at the upper radiator support.
Remove the cooling fan shroud bolts.
Remove the right side radiator bracket.
Remove the cooling fan shroud with the electric cooling fan motors and fans as an assembly.
Remove the thermostat housing and the radiator hose using the following procedure.
Partially drain the engine coolant.
Use hose clamp pliers to remove the radiator hose clamp to the water inlet housing and disconnect the radiator hose.
Use hose clamp pliers to remove the heater hose clamp to the water inlet housing and disconnect the heater hose from the water inlet housing.
Use hose clamp pliers to remove the surge tank inlet hose clamp from the water inlet housing and disconnect the surge tank hose from the water inlet housing.
Remove the water inlet housing bolts and remove the water inlet housing.
Remove the outboard generator bolt and loosen the inboard bolt.
Remove the idler pulley bolt and idler pulley.
Unplug the electrical connector from the alternator.
Pull back the protective boot from the alternator "BAT" terminal, remove the nut and disconnect the heavy "BAT" wire from the alternator terminal stud.
Remove the alternator from the vehicle.

Alternator mounting (3.5L engine)




To Install:

Position the alternator to the engine.
Plug in the electrical connectors and install the heavy "BAT" wire to the alternator terminal stud. Tighten the nut to 15 ft. lbs. (20 Nm). Press the protective boot back in place over the stud terminal and nut assembly.
Install the outboard alternator bolt into the alternator housing.
Install the inboard alternator bolt and then finger-tighten the outboard bolt.
Install the idler pulley and idler pulley bolt.
Tighten the bolts in the following torque sequence:
Tighten the idler pulley bolt to 37 ft lbs. (50 Nm).
Tighten the alternator bolts to 37 ft. lbs. (50 Nm).
Install the water inlet and thermostat housing and the radiator hose, observing the following:
Inspect and clean the mating surfaces on the thermostat cover and its mounting surface on the engine.
Use RTV Sealer GM #1052366 or equivalent on the mounting bolts since the threaded openings are open to the cooling system and the torque requirement is low.
Install the water inlet and thermostat housing and tighten the bolts to 80 inch lbs. (9 Nm).
Connect the surge tank inlet hose to the water inlet housing.
Connect the heater hose to the water inlet housing.
Connect the radiator hose to the water inlet housing.
Install the cooling fan assembly and tighten the radiator bracket bolts to 80 inch lbs. (9 Nm). Plug in the wiring harness at the upper radiator support. Plug in the cooling fan wiring harness to the engine wiring harness.
Install the engine mount strut bracket to the upper radiator support first, insert the through bolt. Attach the engine side of the strut to the engine mount strut bracket on the engine and install the through bolt. Thread the nuts on the through bolts and tighten to 35 ft. lbs. (48 Nm).
Install the battery tray and tighten the bolts to 44 inch lbs. (5 Nm).
Install the battery.
Install the serpentine drive belt.
Connect the positive, then the negative battery cables.
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