Regulator Harness Alternator Connector Replacement

Instructions for how to replace the regulator harness alternator connector in 2nd and 3rd Generation Revels.

Step 1: Battery Shut Down

1. Ensure your house batteries are off by turning all the breakers off.
   -On a 1st Gen system the breakers are located on the front of the bench seat.
   
   -On 2nd Gen and 3rd Gen systems, the breakers are located in the rear battery compartment.
   
2. Ensure the van is NOT running before proceeding.

Step 2: Regulator Harness - Field Wire Plug Removal

1. In some images, the alternator is removed. You do NOT need to remove the alternator or disconnect any power/ground wires to install the new alternator pig tail.
2. Remove the field wire connector from the back of the alternator by depressing the tab, and pulling the connector out from the alternator.
   
3. Take the new pig tail connector and line up the connector to the original connector. Mark the original connector wire BELOW the butt connector. This is where we will cut the old connector off.
   
4. Using a pair of wire cutters, cut the old connector off.
   

Step 3: Installing New Connector

1. Strip approx. 3/8" of insulation from the wire as shown.
   
2. Slide the butt connector on the pigtail onto the wire you just cut until the wire is fully seated into the butt connector.
3. Using a pair of wire crimpers, crimp the butt connector onto the wire. Ensure you have a good crimp, and tug the wire to make sure it does not pull out of the butt connector.
   
4. After you have checked to ensure the crimp is good, use a heat gun or torch to heat shrink the butt connector.
   

Step 4: Reinstalling the Connector into the Alternator

1. Insert the connector into the alternator. Ensure the connector is fully seated into the alternator by giving the connector a slight tug.
   
2. Once the connector is installed, you can turn all the breakers back on.