Before You Begin:
* Safety First: Disconnect the negative (-) battery terminal before starting any work on the electrical system. This prevents accidental shorts and shocks.
* Gather Tools: You'll need a socket set (metric), wrenches (metric), a ratchet, possibly a breaker bar for stubborn bolts, a battery terminal cleaner, a jack and jack stands (essential for proper access), possibly a pulley puller (depending on the alternator's design), and possibly a torque wrench. Gloves and safety glasses are also recommended.
* Repair Manual: A Haynes or Chilton manual for your specific year and model Malibu is invaluable. It will provide detailed instructions and diagrams specific to your vehicle.
General Steps (This is a simplified overview. Refer to your repair manual for specifics):
1. Prepare the Vehicle: Raise the front of the vehicle and securely support it with jack stands. Never work under a vehicle supported only by a jack.
2. Access the Alternator: The location varies slightly depending on the engine, but the alternator is typically located near the front of the engine, often on the passenger side. You'll likely need to remove some components for access; this might include:
* Removing the serpentine belt: This usually involves loosening the tensioner pulley. Consult your repair manual for the proper procedure. Use a belt tensioner tool if necessary.
* Removing other components: You may need to loosen or remove other parts (e.g., air intake components, shrouds) to gain better access to the alternator's mounting bolts.
3. Disconnect Electrical Connections: Carefully disconnect the wiring harness connectors from the alternator. Take photos or make notes of the connections to ensure proper reassembly. Note the location and orientation of any electrical components you disconnect.
4. Remove the Alternator: Remove the mounting bolts holding the alternator in place. It may be held in by two or three bolts. You might need a breaker bar for stubborn bolts.
5. Install the New Alternator: Carefully install the new alternator, ensuring it's correctly aligned with its mounting points. Tighten the mounting bolts to the specified torque (found in your repair manual).
6. Reconnect Electrical Connections: Carefully reconnect the wiring harness connectors to the new alternator, making sure they're securely fastened.
7. Reinstall Components: Reinstall any components you removed earlier to access the alternator (e.g., air intake, shrouds).
8. Install Serpentine Belt: Carefully reinstall the serpentine belt, making sure it's properly routed around all the pulleys.
9. Lower the Vehicle: Lower the vehicle from the jack stands.
10. Reconnect Battery: Reconnect the negative (-) battery terminal.
11. Check Functionality: Start the engine and check the charging system. Use a multimeter to check the voltage at the battery terminals; it should be around 13.5-14.5 volts when the engine is running.
Important Considerations:
* Proper Torque: Use a torque wrench to tighten all bolts to the manufacturer's specifications. Over-tightening can strip threads or damage components.
* Belt Routing: Ensure the serpentine belt is properly routed. An incorrectly routed belt can lead to premature wear or damage to other components.
* Disposal: Dispose of the old alternator properly; check with your local auto parts store or recycling center for proper disposal methods.
If you're not comfortable performing this repair yourself, take your vehicle to a qualified mechanic. Improper installation can lead to serious damage and potential safety hazards.
