Chevrolet Cobalt Service & Repair Manual: Alternator Pulley, Replace

Chevrolet Cobalt Service & Repair Manual / Electrical / Starter & Alternator / Alternator Pulley, Replace

Caution: Wear suitable eye protection and heavy leather gloves when removing and installing pulley.
Do not remove or install pulley with alternator in upright position.

Removal

1. Remove alternator as outlined in "Alternator/Generator."
2. Place alternator on secure horizontal surface.
3. On models equipped with bolted on pulley, perform following:
  a. Spray penetrating oil on alternator nut.
  b. Match an impact socket to nut located at front of alternator pulley.
  c. Hold alternator shaft directly behind pulley with heavy leather gloved hand.
  d. Slide socket attached to impact wrench onto alternator nut and remove nut.
  e. Remove pulley from shaft.
4. On models equipped with pressed on pulley, perform following:
  a. Take note of pulley installation position, measure distance between pulley and end of shaft.
  b. Install suitable alternator pulley remover and installer tool. Follow tool manufacturers instructions for tool operation.
  c. Press off alternator pulley.
5. On all models, remove washer and any spacers, as required.

Installation

1. Inspect and clean alternator shaft. File down any burs with a fine metal file.
2. Place alternator on secure horizontal surface.
3. On models equipped with pressed on pulley, perform following:
  a. Install spacers, as required.
  b. Press pulley to location noted on removal with a suitable alternator pulley remover and installer tool. Follow tool manufacturers instructions for tool operation.
4. On models equipped with bolted on pulley, perform following:
  a. Install lock washer and any spacers, as required.
  b. Install pulley onto shaft.
  c. Start nut onto alternator shaft.
  d. Hold alternator pulley with heavy leather gloved hand.
  e. Slide socket attached to impact wrench onto alternator nut and tighten nut until lock washer is fully closed.
5. On all models, inspect that pulley turns without binding and there are no abnormal noises when spinning.
6. Install alternator as outlined in "Alternator/Generator."
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