- 1). Locate the negative battery cable terminal on the battery and remove the retaining bolt with a wrench. Lift the cable off the battery and set it aside for now.
- 2). Locate the belt tensioner for the alternator belt: It is located on the front-center part of the engine. Loosen the lock nut on the front of the tensioner (the one on the center of the tensioner pulley) with a socket and ratchet, but do not remove it. Turn the jack screw at the top of the tensioner counterclockwise, releasing the tension on the belt.
- 3). Slide the belt off the alternator pulley and lay it aside. Locate the electrical connectors on the back of the alternator. Remove the nut from the stud terminal on the back of the alternator, using a wrench, then slide the cable off the terminal. Depress the locking tab on the push-in connector, near the top of the alternator, and pull it out of the connector on the alternator body. Lay it aside for now.
- 4). Remove the top mounting bolt from the alternator with a socket and ratchet, then set the bolt aside. Move to the lower mounting bolt; remove the nut from the front of the bolt with a wrench, then use a ratchet to back the bolt out of the alternator. Remove the alternator from the van.
- 5). Position the new alternator in the engine compartment, slide the lower mounting bolt in place from the rear and install the nut on the front. Torque the nut to 62 pounds-feet with a torque wrench. Install the upper bolt and torque it to 21 pound-feet.
- 6). Plug the electrical connector into its slot on the alternator, making sure it locks into place. Install the second cable on the stud terminal at the rear of the alternator, followed by the retaining nut. Torque the nut to 18 pound-feet with a torque wrench.
- 7). Slide the alternator belt over the pulley on the new alternator, then turn the jack screw on the tensioner clockwise, raising the adjuster pulley until the belt is tight. Tighten the nut in the center of the pulley to lock the tensioner in place.
- 8). Install the negative battery cable on the negative battery terminal and tighten the retaining bolt with a wrench. Close the hood.
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