Safety First:
* Disconnect the negative battery cable first. This prevents accidental short circuits.
* Wear safety glasses to protect your eyes from flying debris.
* Use jack stands if you need to lift the vehicle. Never work under a vehicle supported only by a jack.
* Have the correct tools on hand before you begin.
Tools You'll Likely Need:
* Socket wrench set (metric)
* Ratchet and extensions
* Wrenches (metric)
* Pliers
* Screwdrivers (possibly Phillips and flathead)
* Battery terminal cleaner
* New alternator (make sure you get the correct one for your specific engine)
* Possibly a pulley puller (depending on the alternator design)
* Torque wrench (recommended for proper tightening)
Procedure:
1. Locate the Alternator: The alternator is typically located on the front of the engine, near the passenger side (right side). Consult your repair manual for the exact location on your specific model.
2. Disconnect the Electrical Connections:
* Carefully disconnect the positive (+) and negative (-) wires from the alternator. Take note of which wire goes where. A camera photo can be helpful.
* Often there's a small wire connector as well. Disconnect this.
3. Remove the Alternator Belt: You'll need to loosen the tensioner pulley to remove the serpentine belt. The tensioner is usually located near the alternator. Consult your repair manual to determine the correct procedure for releasing tension on your model. Some require a special tool while others can be loosened using a wrench or socket on a specific bolt.
4. Remove the Alternator Mounting Bolts: These are usually two or three bolts securing the alternator to the engine block or bracket. Remove them carefully.
5. Remove the Alternator: Once the bolts are removed, the alternator should be relatively easy to remove. You might need to gently wiggle it free.
6. Install the New Alternator:
* Position the new alternator in the same location as the old one.
* Install the mounting bolts and tighten them securely, but don't overtighten. Use a torque wrench if you have one.
* Reconnect the positive (+) and negative (-) wires and the small wire connector. Make sure they are securely connected.
7. Reinstall the Serpentine Belt: Carefully route the serpentine belt around all the pulleys, ensuring it's seated correctly on each pulley. Consult your repair manual for the correct routing. Re-tension the belt using the tensioner pulley.
8. Reconnect the Battery Cable: Reconnect the negative (-) battery cable.
9. Test the Alternator: Start the engine and check the battery voltage with a voltmeter. The voltage should be around 13.5-14.5 volts. If it's not, there may be a problem with the new alternator or the wiring.
Important Considerations:
* Belt Routing: Getting the serpentine belt routed correctly is crucial. A misrouted belt can cause damage to other components. Your repair manual will have a diagram.
* Tightening Torque: Use a torque wrench to ensure you tighten the bolts to the manufacturer's specifications to avoid damaging the alternator or engine block.
* Pulley Removal: Some alternators might have a pulley that needs to be removed before the alternator itself can come off. This often requires a pulley puller.
This is a general overview. Always refer to a repair manual specific to your 1996 Jeep Cherokee Sport for detailed instructions and torque specifications. If you're not comfortable performing this repair yourself, it's best to take it to a qualified mechanic.
