The Delphi AD237 (KG7) 125 ampere generator is serviced as a complete unit only.

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the battery tray. Refer to Battery Tray Replacement .
3. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.5L.
4. Remove the engine cooling fan assembly. Refer to Engine Cooling Fan Replacement in Engine Cooling.
5. Remove the thermostat housing and the radiator hose. Refer to Engine Coolant Thermostat Replacement in Engine Cooling.



6. Remove the outboard generator bolt.
7. Loosen the inboard generator bolt.
8. Remove the idler pulley bolt and the idler pulley.



9. Disconnect the electrical connector from the generator.
10. Reposition the protective boot from the generator output BAT terminal for access.
11. Remove the generator output BAT terminal nut and disconnect the battery positive lead from the generator.
12. Remove the generator.

1. Position the generator to the engine.



2. Connect the electrical connector to the generator.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Connect the battery positive lead and install the generator output BAT terminal nut.

Tighten
Tighten the generator output BAT terminal nut to 20 N·m (15 lb ft).

4. Press the protective boot on to the generator output BAT terminal.



5. Install the outboard generator bolt into the generator housing.
6. Install the generator on the inboard generator bolt and finger tighten the outboard bolt.
7. Install the idler pulley and idler pulley bolt.
8. Tighten the bolts in the order described. The following is a mandatory torque sequence:

8.1.	The idler pulley bolt.

Tighten
Tighten the idler pulley bolt to 50 N·m (37 lb ft).

8.2.	The generator bolts.

Tighten
Tighten the generator bolts to 50 N·m (37 lb ft).

9. Install the thermostat housing and the radiator hose. Refer to Engine Coolant Thermostat Replacement in Engine Cooling.
10. Install the engine cooling fan assembly. Refer to Engine Cooling Fan Replacement in Engine Cooling.
11. Install the battery tray. Refer to Battery Tray Replacement .
12. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.5L.
13. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .