GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2001 🢒 Metro 🢒 Engine 🢒 Engine Electrical 🢒 Generator Replacement

Removal Procedure

    Object Number: 262446 Size: SH

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.

    2. Caution: Failure to observe Step 1 may result in a serious personal injury. If a tool is shorted at the generator lead, the tool will become hot enough to cause a serious burn.

  2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement 1.0L or to Air Cleaner Assembly Replacement 1.3L in Engine Controls.
  3. Remove the rubber insulator, the nut, and the electrical connector from the generator B+ terminal.
  4. Remove the upper mounting bolt (1).
  5. Remove the drive belt.
  6. Remove the 2 lower generator mounting bolts (2).
  7. Remove the generator.

Installation Procedure

    Object Number: 262446 Size: SH
  1. Install the generator to the vehicle.
  2. Install the lower mounting bolts (2). Do not tighten the bolts at this time.
  3. Install the upper mounting bolt (1). Do not tighten the bolt at this time.

    4. Object Number: 168876 Size: SH
  4. Install the drive belt to the pulleys.
  5. Adjust the drive belt in order to obtain the specified deflection with 10 kg (22 lb) of pressure exerted.

    6. Used Belt Deflection
    6-8 mm (0.24-0.31 in)

    New Belt Deflection
    5-7 mm (0.20-0.27 in)

  6. Tighten the generator mounting bolts.

    7. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

    Tighten
    Tighten the generator bolts to 23 N·m (17 lb ft).

  7. Connect the electrical connector to the generator B+ terminal. Secure the connector with the nut and with the rubber insulator.

    8. Tighten
    Tighten the electrical connector nut to 8 N·m (71 lb in).

  8. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement 1.0L or to Air Cleaner Assembly Replacement 1.3L in Engine Controls.
  9. Connect the negative battery cable.

    10. Tighten
    Tighten the negative battery cable to 15 N·m (11 lb in).