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The installation procedures for the 12V 120A and 12V 105A alternators of Chevrolet are basically the same. The core lies in ensuring power-off protection, firmly securing the alternator body accurately, making correct electrical connections, and adjusting the drive belt tension. Below is a universal and detailed installation guide applicable to most Chevrolet models:

First, turn off the vehicle engine and remove the key. Disconnect the negative cable of the storage battery to prevent electrical short circuits or electric shocks during installation.Prepare tools such as a socket wrench set, ratchet wrench, torque wrench, and cleaning rags. Meanwhile, clean the oil stains on the surface of the new alternator, check for no external damage, and confirm that the 12V voltage specification matches the vehicle.

Loosen the belt tensioner with a wrench and take off the drive belt. Mark the connection positions of the wires on the alternator, then disconnect the wiring connector and output cable. Finally, unscrew the mounting bolts of the alternator, take out the old alternator, and clean the dust and oil stains at the installation position with a rag.

Place the new alternator steadily into the installation position and align it with the bolt holes on the engine block. Initially tighten the mounting bolts without fully fastening them, leaving room for subsequent adjustment of the belt tension. The alternators of some Chevrolet models are equipped with 2 mounting bolts. It is recommended that the tightening torque refer to 26 lb-ft (approximately 35 N·m), and specific values should be in accordance with the vehicle's service manual.

Common terminals on Chevrolet alternators include B+, S, etc. Connect the wires according to the marked positions. A thick-gauge shielded wire should be directly connected from the B+ terminal to the positive pole of the storage battery to ensure stable power supply. The S terminal is connected to the alternator warning light, and some models are also equipped with an IG terminal which is connected to the ignition switch. Strictly follow the wiring method of the old alternator to avoid reverse connection. After wiring, tighten the terminal nuts and wrap the exposed connectors with insulating tape to prevent short circuits.

Fit the drive belt correctly onto the alternator pulley and the corresponding engine pulley, then adjust the belt tension by operating the belt tensioner. The standard for adjustment is that pressing the middle of the belt by hand should allow a deflection of 1 - 2 centimeters. An overly loose belt tends to slip and affect power generation, while an overly tight one will accelerate the wear of bearings and the belt itself.

Once the belt tension is properly adjusted, use a torque wrench to fully tighten the mounting bolts of the alternator to ensure there is no looseness or wobble of the alternator body. Then recheck to ensure that all wiring connectors are firmly plugged in, the terminals are not loose, and the belt is not misaligned or off-track.

Reconnect the negative cable of the storage battery and start the vehicle. Observe whether the charging indicator light on the instrument panel turns off. Use a multimeter to measure the output voltage of the alternator; the normal range should be 13.5 - 14.5V. Meanwhile, listen carefully for any abnormal noises during the operation of the alternator. If all indicators are normal, the installation is completed.

In addition to the key points mentioned in the previous installation steps, when installing these two specifications of alternators for Chevrolet, the following aspects regarding safe operation, parts matching, detailed operations and subsequent protection should also be noted to avoid component damage or potential safety hazards:

Throughout the entire process of disassembly and installation, it is essential to wear protective equipment such as insulated gloves and safety goggles. Some components in the engine compartment may have sharp edges, so work clothes are recommended to prevent scratches. After disconnecting the negative cable of the storage battery, it is advisable to wait for about 5 minutes to allow the capacitors in the circuit to discharge fully, so as to avoid short circuits caused by residual current.

If external battery boosting is required afterwards, the principle of connecting positive to positive must be followed. The negative terminal of the external battery should be connected to the engine ground wire, and reverse connection must be strictly prohibited; otherwise, it is likely to burn out the rectifier diodes inside the alternator.

Ensure that the new alternator not only matches the vehicle in terms of 12V voltage specification, but also fully aligns with the mounting holes and pulley specifications of the corresponding Chevrolet model. Although the installation procedures for the 120A and 105A alternators are identical, it is necessary to confirm that the alternator matches the load requirements of the vehicle's electrical system. This avoids malfunctions arising from mismatched power ratings.

Select tools of appropriate specifications. When tightening the mounting bolts, prioritize the use of a torque wrench and operate in accordance with the torque values specified in the vehicle's service manual. Never apply excessive force, as this may strip the bolt threads or crack the alternator housing. Store the removed bolts separately according to their original positions to prevent confusion and misalignment during installation.

During wiring, it is strictly forbidden to arbitrarily short-circuit the alternator terminals or make random ground connections. Firmly tighten the nut on the B+ terminal and remember to put on its rubber protective cover. Ensure that control wires such as those connected to the S terminal are fully inserted to avoid poor contact. Meanwhile, inspect the wires for cracks or aging; replace any defective wires promptly and wrap the connectors with insulating tape.

Do not modify the polarity of the alternator without authorization. When testing the internal diodes, avoid using a test pen with a voltage exceeding 12V to prevent damage to the internal electronic components.

After installation, if a battery fast charger is needed to charge the storage battery, disconnect the wires between the battery and the vehicle first. Never use the fast charger for direct boosting to start the vehicle, as this may damage the alternator.

If the vehicle requires welding work later, disconnect the storage battery wires in advance. This prevents the strong current generated during welding from damaging core components of the alternator, such as the voltage regulator.

During the test run, if the alternator produces abnormal noises such as sharp friction sounds or loud rumbling, or if the charging indicator light on the instrument panel remains illuminated, turn off the engine immediately for inspection. Check for issues such as misaligned belts, damaged bearings, or incorrect wiring.

If you are unfamiliar with the wiring routes or component structures, do not attempt to perform the operation forcefully. It is advisable to contact professional Chevrolet maintenance technicians to avoid exacerbating the malfunctions.

The precautions for installing these two specifications of Chevrolet 12V alternators (120A and 105A) as previously provided do not originate from a single specific official document or authoritative source. Instead, they are compiled and summarized based on the general maintenance knowledge of Chevrolet alternators, industry installation standards, and relevant content from multiple automotive maintenance platforms. Below is an explanation of the reference sources for the core information:

The precautions for disassembling and installing alternators for various Chevrolet models (such as the Aveo, Sail, and Cruze) on this platform repeatedly mention key points. These include performing power - off operations, handling the alternator with care to prevent housing damage, ensuring parts match the vehicle model, and inspecting wires for damage and aging. This serves as an important basis for the precautions related to safe operation and parts matching summarized earlier.

The articles on automotive alternator connection and installation published on Autohome clearly specify critical requirements. These cover disconnecting the negative terminal of the storage battery to prevent short circuits, ensuring firm connections of wiring terminals, and judging the normal operation via the charging indicator light and voltage test after installation. These requirements are highly consistent with the precautions regarding standardized wiring connections and test operation included in the summary.

The detailed introduction to installation steps on this platform emphasizes specifics like the standard for adjusting belt tension, cleaning the mounting surface, and conducting insulation treatment for wiring connections. It provides a reference for the precautions in the summary concerning belt adjustment and insulation protection for connectors.