N Body Ecotec Alternator Removal and Replacement

[killman]

The Haynes manual has some really nice Ecotec details such as the engine section but has completely missed dealing with many things related to the Ecotec in the final N-Body manual. One of those missing things is R & R of the Ecotec alternator. This repair How-To covers the following cars with the vin “F” L61 Ecotec engine; 2002-2005 Pontiac Grand Am SE, 2002-2004 Olds Alero GX/GL, and the 2004-2005 Chevy Classic (fleet “Malibu” with 4th VIN “N”) These instructions will allow you to remove the alternator without jacking the car but with the engine coolant cool and in a Walmart parking lot if needed.

Tools needed:

1/4″ drive ratchet or a 3/8″ female to 1/4″ male drive adapter
1/4″ drive 3″ extension (other extensions may be handy)
3/8″ drive ratchet
3/8″ drive 3″ extension (other extensions may be handy)
10 mm 3/8″ drive socket
13 mm 3/8″ drive socket
5/16″ or 8 mm socket or boxed end wrench to remove battery terminals
1/4″ flathead screwdriver
1/8″ flathead screwdriver
3/8″ thin head breaker bar about 12″ long (Craftsman or Snap-On knock off) or a rented alternator belt/pulley tool from a FLAPS
brass wire brush (toothbrush size is better)
dielectric gel (a packet of “light bulb grease” or “electrical connector grease” from the FLAPS)
1/4″ torque wrench (with proper adapter or 1/4″ 13 mm socket) or 3/8″ torque wrench with a max scale of 75 ft-lbs
Channel Lock style tongue and groove pliers, Vise Grips, or other pliers to remove hose clamps and maybe the coolant drain plug
6 qt clear plastic $1 Sterilite “shoe box” or a low profile clean drain pan

Optional tools:

*** coolant funnel or the cut off top of a 2 L soda bottle (especially if your pouring aim sucks) ***
*** Air duster or compressed air would be helpful especially for the dipstick tube base ***
*** Adjustable lighted mirror might be handy ($10 Craftsman lighted mirror works fine) ***
*** 13 mm Gearwrench stubby ratchet for the positive post alternator bolt ***
*** telescoping magnetic pickup tool for the bolts out of reach on the access cover ***
*** clean shop rag to cover the open throttle body and for cleanup ***

How to R & R the N-Body Ecotec Alternator:

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