1. Gather Tools and Materials:
- Replacement alternator
- Socket wrench set
- Combination wrench set
- Screwdriver
- Safety glasses
- Gloves
2. Disconnect the Battery:
- Open the hood and locate the negative (-) battery terminal.
- Loosen the negative terminal nut using the wrench and remove the cable.
- This step is crucial to prevent any electrical accidents during the repair.
3. Remove the Serpentine Belt:
- Locate the serpentine belt tensioner near the alternator.
- Use the wrench to loosen the tensioner pulley and remove the serpentine belt.
4. Disconnect Electrical Connectors:
- Identify the electrical connectors attached to the alternator.
- Use a screwdriver to release the locking tabs on these connectors and carefully detach them.
5. Remove Mounting Bolts:
- Locate the mounting bolts securing the alternator to the engine.
- Use the appropriate wrench size to loosen and remove the bolts.
6. Detach the Alternator:
- Once the mounting bolts are removed, carefully slide the alternator out from its position.
7. Transfer Necessary Parts:
- In some cases, you may need to transfer parts like brackets or pulleys from your old alternator to the replacement one.
8. Install the New Alternator:
- Position the new alternator in place and secure it using the mounting bolts.
- Tighten the bolts securely.
9. Reconnect Electrical Connectors:
- Reattach the electrical connectors that you disconnected earlier.
- Make sure they are firmly connected.
10. Reinstall the Serpentine Belt:
- Place the serpentine belt back into its proper position and use the tensioner pulley to adjust the tension.
11. Reconnect the Battery:
- Reconnect the negative battery cable to its terminal and tighten the nut.
12. Test the Alternator:
- Start the engine and check if the battery light turns off.
- Use a voltmeter to verify if the alternator is charging properly (usually between 13.5 to 14.5 volts).
13. Clean Up:
- Clean up any tools or materials used during the repair.
- Dispose of any removed parts appropriately.
14. Test Drive:
- Take the vehicle for a short drive to ensure that the alternator is functioning correctly.
By following these steps, you should be able to successfully replace the alternator on your 1991 Chevy Cavalier. Remember to take necessary safety precautions and if you encounter any difficulties or have doubts, it's best to consult a professional mechanic for assistance.
