The experts at Haldex offer these tips (Be sure to place vehicle in neutral and disconnect batteries before working on the electrical system):
Test the batteries before installing the alternator: Batteries must be in good condition, have the proper capacity and be fully charged.
Inspect all wire and battery cables: These and connections must be tight and free of corrosion.
Inspect the fan and pulley: A damaged fan will affect the cooling of the alternator, decreasing its life. A damaged pulley may cause the drive belts to slip. A fan and pulley out of balance can cause premature failure.
Properly torque the fan and pulley in place: Install the fan and pulley and torque the pulley nut to 70−80 ft.-lbs. This will locate the rotor properly in the alternator.
Use proper mounting hardware: Use grade 5 bolts and self-locking nuts when mounting the alternator. Use hardened flat washers under the bolts and lock nuts. Do not use lock washers.
If alternator fails to charge after proper installation: It may be necessary to increase the engine speed until the regulator turns on. Units in inventory, dissembled or serviced may need to have their magnetism reestablished. To magnetize the rotor, connect the alternator to the electrical system. With the engine off momentarily, connect a jumper lead from the battery positive to the relay terminal of the alternator. This will restore the magnetism in the rotor and the alternator will begin operating correctly.
Alternator operation: Reliable test equipment should always be used.
Do not test the alternator by disconnecting the battery lead to see if it sparks. This will damage the alternator and void the warranty.
