Tools You'll Likely Need:
* Socket wrench set (metric)
* Ratchet and extensions
* Wrenches (metric)
* Pliers
* Screwdrivers (Phillips and possibly flathead)
* Battery terminal cleaner
* New alternator (ensure you get the correct replacement for your vehicle)
* Jack and jack stands (Crucially important for safety)
* Wheel chocks
* Gloves
* Safety glasses
Procedure:
1. Disconnect the Battery: This is the MOST important step. Disconnect the negative (-) terminal first, then the positive (+) terminal. This prevents electrical shorts and potential injury.
2. Access the Alternator: On most 1996 Grand Ams, the alternator is located on the front of the engine, typically on the passenger side. You'll likely need to remove some components for better access. This might include:
* Air intake system: Disconnect and remove the air filter housing and intake tube(s).
* Serpentine belt: This is almost certainly necessary. You'll need a belt wrench or a suitable tool to loosen the tensioner pulley to remove the belt. Note the routing of the belt carefully before removal, as you'll need to put it back the same way.
* Possibly other components: Depending on your specific engine and access, you might need to remove other smaller parts to gain sufficient clearance. Refer to your repair manual.
3. Remove the Alternator:
* Disconnect the electrical connections: There will be at least two wires connected to the alternator – a larger wire and a smaller wire. Carefully disconnect them, noting which goes where. Take pictures if it helps.
* Remove the mounting bolts: The alternator is held in place by several bolts. Carefully remove these bolts.
* Remove the alternator: Once the bolts are out, carefully remove the alternator. It may be somewhat heavy.
4. Install the New Alternator:
* Mount the new alternator: Carefully position the new alternator in its mounting location.
* Reconnect the mounting bolts: Securely tighten the mounting bolts to the specified torque (check your repair manual).
* Reconnect the electrical connections: Reconnect the electrical wires to the new alternator, making sure they're securely attached.
* Install the serpentine belt: Carefully route the serpentine belt back onto the pulleys in the correct order (refer to your repair manual for the correct routing). Make sure the belt is properly seated on all pulleys.
5. Reconnect and Test:
* Reconnect the air intake system: Reassemble all components you removed earlier in the process.
* Reconnect the battery: Reconnect the positive (+) terminal first, then the negative (-) terminal.
* Start the engine: Start the engine and check for any warning lights. Also check the alternator's output voltage using a multimeter – it should be around 13.5-14.5 volts while the engine is running.
Important Considerations:
* Safety First: Always use jack stands and chocks to ensure your vehicle is securely supported. Never work under a vehicle supported only by a jack.
* Repair Manual: A factory repair manual specific to your 1996 Pontiac Grand Am 2.4L is highly recommended. It will provide detailed diagrams, torque specifications, and procedures.
* Electrical Safety: Be extremely careful when working with electrical components. Disconnect the battery before starting any work.
* Belt Tension: Ensure the serpentine belt has the correct tension after reinstallation. An improperly tensioned belt can lead to premature wear or failure.
This is a general guide. If you are not comfortable performing this repair yourself, it's best to take your car to a qualified mechanic. Improperly installing the alternator can lead to further damage to your vehicle.
