My wife called me while on her way in to work yesterday to tell me her charge light was on. I figured it was just the battery going out on the car since it is about 8 years old now, but even if it was the alternator I knew she’d make it into work. I told her to I’d be up there later to check it out.
When I got there at about 10:00 I was expecting nothing more than just replacing the battery, so I took her car to Po Boys and had them run a check on the electrical system. The outcome was not so good. The alternator was totally shot. The cost of replacing it was going to be about $450 parts and labor ($250 for the alternator and $200 for the work). Well, I’m pretty broke, and I’m pretty handy with a set of wrenches, so I told my wife I’d put a new one on for her. So I called around and got a better price for an alternator (slightly under $200), went and picked it up, and got to work.
Now, I’m not used to working on newer vehicles. The only vehicle I’ve worked on in the last decade was my old Jeep, a 1987 YJ with a 258 inline-six… easy! Everything is right there for you to get to in an engine bay that could fit two of them in it. So I was a bit apprehensive about doing this job, but to save a few hundred bucks I was dead set on doing it.
It only took he 2 hours to get the job done, and that was with me working on the Vue in the parking lot of where she worked, without the proper tools, and taking a break for lunch. I decided to log what I did here so that if anyone else has to go through that they will be able to find a decent write-up of what is involved. It was actually pretty easy to do, just time consuming and awkward.
Here is how to replace an alternator on a 2003 Saturn Vue with a V6.
First thing to note is that the alternator is under the engine on the passengers side. You will be better off removing the tire so that you have room to work. Disconnect the negative battery cable, jack up the passengers side, chock the rear tires, pull the tire off, and take a look, you’ll be able to find the alternator pretty easily.
In order to gain access to the battery cables you’ll need to remove the battery cover, there are 3 Phillip’s head screws to undo and then the cover pulls right off. Once the cover is off take a 6mm wrench and undo the negative battery cable.
After you get the tire off you’ll have to remove the black plastic splash guard. It is attached with 6 or 7 plastic trim pins, which are easy to take out with a flat head screwdriver and a pair of needle nose pliers. Just pull the center pin out of the lock washer-pin and set them aside.
With the splash guard removed it is easy to see and maneuver around under there. You’ll need to locate the serpentine tensioner pulley, put a 15mm wrench on it, and crank it towards the firewall to lower the pulley. What that does is add slack to the belt so that you can pull the belt off the alternator pulley. It’s probably best to have someone do that from the top of the engine bay while you slip the belt from underneath, but it can be done alone from underneath if you have a long enough wrench.
Once the belt is slipped off the alternator pulley it’s time to disconnect the electrical connectors from the alternator. The main pigtail pulls out but will require you to bend back a tab to get it to pull. The tab is on the backside of the pigtail connector (where you can’t see it) you I had to use a small flat head screwdriver to bend the tab back while I pulled it. Then use a 10mm wrench to disconnect the nut from the ground wire and you are ready to remove the alternator bolts.
I used a 5/8 socket on a 3/8″ drive ratchet to remove the two alternator bolts. It’ll take a while to do since you can’t really get a lot of movement on the ratchet with all the stuff in the way. After a while though the bolts will come out and you’ll have to pry the alternator off the mounting area of the engine block.
Once the alternator is out, use a wire brush to clean the mounting area of the block and the threads to the mounting bolts, then reinstall the alternator just the opposite way you took it off. And that is all there is to it.
Like I said, it took me a total of 2 hours to figure it out, take a lunch break, and go from the moment of the car pulling into the work area until I handed my wife the keys when I was done.


