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  1. #1
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    Replacing alternator 2002 chevy Malibu - 44k reps!

    Have the alternator all set...removed the belt tensioner to make room, and now I can't manage to fit the alternator + belt tensioner on at the same time.


    Wat do?
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  2. #2
    Lifter vancityrider's Avatar
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    To replace the alternator in a 2002 Chevrolet Malibu, you need to measure the width and diameter of Chevy alternator’s pulley and also count the number of ribs on it. You need to make sure that the configuration of the old and new alternator pulley has the same configuration, as they differ from model to model.

    Removing the old alternator

    Using a wrench you need to disconnect the cable of negative battery. For better access you can remove the coolant reservoir, using a socket and ratchet. You can see the reservoir at the front and to the right of the engine compartment.

    If your Malibu has a belt guard at the top of the belt, remove it with the help of a ratchet and socket. You can locate the belt guard between the power steering pump and the water pump. To release the belt tension , rotate the belt tensioner pulley.

    You need to slip the belt off the alternator pulley. If you have a 2.4 liter engine model, remove the front bolt and top two mounting bolts. If you have a 3.1 liter engine model, remove the front mounting and top mounting bolts from the alternator. If you have a 3.1 liter engine model , you need to unscrew the mounting nut from the back of the alternator.

    From the alternator you need to unplug the connector and using a wrench, detach the wire from the rear of the alternator. If yours is a 3.1 liter engine model, to work the alternator out of the engine compartment, use a ratchet and a socket to unscrew the power steering line clip.

    Installing the new alternator

    In the engine compartment, set the new alternator in it’s mounting position. If you have a 3.1 liter engine model, install the power steering line clip with the help of a ratchet and socket. You need to plug the electrical wire harness and the single wire along with the retaining nuts at the rear of the alternator using a wrench.

    At the back of the alternator install the mounting nut. To tighten the mounting nut use universal joint, ratchet with ratchet extension and a deep well socket. If you have a 2.4 liter engine install the two top alternator mounting bolts and the front bolt. If you have a 3.1 liter engine model, install the front and top bolts to the alternator. Depending on your particular model, you need to rotate the belt tensioner pulley using either a long 13mm box wrench or 3/8-inch drive breaker bar. Then slip the belt to the alternator pulley.

    If your Malibu has a belt guard, then attach it to the top of the belt using the socket and ratchet. Also install the coolant reservoir if you had to remove it.

    Finally using the wrench, connect the negative battery cable.
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  3. #3
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    or




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    2002 Malibu? OP is a phaggot.

    Ok got that out of the way...here's all I can offer.

    Unit Repair
    Service the CS-130D generator as a complete unit.

    Removal Procedure


    1. Disconnect the negative battery cable.
    2. Remove the drive belt from generator.
    3. Remove the generator electrical connections.
    4. Remove the power steering line clip.
    5. Remove the generator mounting nuts and bolts.
    6. Remove the generator.

    Installation Procedure

    1. Install the generator. NOTE: Refer to Fastener Notice in Service Precautions.
    2. Install generator bolts. Tighten
    Tighten the generator bolts to 50 N.m (37 lb ft) .
    Tighten the generator nuts to 30 N.m (22 lb ft) .

    3. Install the generator electrical connections.
    4. Install the power steering line clip.
    5. Install the drive belt.
    6. Connect the negative battery cable.
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  5. #5
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    Components Required

    The components that are required to carry out this installation procedure are ratchet, wrench set, socket set, ratchet extension, 3/8-inch breaker bar, and socket.

    The alternators that are present in different models of this vehicle are different from each other.

    So, first measure the alternator pulley diameter, width, and also make a note of the number of pulley ribs. Check out if the alternator that you are replacing has got the same configuration as that of the new alternator or not. Because replacing the wrong unit will break or damage the alternator belt eventually.
    Steps to be Followed

    First, remove the old alternator from the vehicle. Place the new alternator in the corresponding mounting position. Using the socket and ratchet, carry out the installation of power steering clip. Using the wrench, make the proper connections at the back side of the new alternator.

    Install the front and top volts to the alternator using the socket and ratchet. Turn the belt pulley with the thirteen mm box wrench, which will depend upon the particular edition. At the top of the alternator, attach the belt guard.

    Finally, install the coolant reservoir, and then, using the wrench fix the negative battery cable. This is the last step in the installation process.

    Now that you have learnt how to change 2002 Chevrolet Malibu alternator, you can do the replacement on your own.
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  6. #6
    Registered User -stew-'s Avatar
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    The belt tensioner is like a loaded spring brah, you should never have to remove it. You just have to pry on it in the right direction to slip the belt on. Sooo, put tensioner back in, wiggle alternator into place (it can be a bitch and a puzzle but it will go back in) then using a pry bar or a wrench on the nut of the tensioner, load the tension in what ever direction it swings to get the belt back into place.
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  7. #7
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    It depends on what model you have, but most are the same.

    Disconnect the battery!

    Loosen the tensioner for the serpentine belt and pull the belt off the alternator pulley.

    Remove the bolt holding the alternator at the 4:00 o'clock position
    Remove the nut at the right rear side of the alternator
    Remove the bolt at the next to it nearer you. All bolts have 15mm heads, but you're going to need a deep well socket to get the nut off.

    Pull out the alternator and remove the plug from it and also remove the red wire attached to the back. You're going to need a 13mm socket and a 13mm flat wrench.

    Replace the alternator by reversing the steps above.

    Reattach the serpentine belt
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