GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Chevy K Silverado - 4WD 🢒 Engine 🢒 Engine Electrical 🢒 Generator Replacement

Generator Replacement 4.3L Engine

Removal Procedure

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.


    Object Number: 782177 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the drive belt. Refer to Drive Belt Replacement .
  3. Disconnect the generator electrical connector (3).

    4. Object Number: 395686 Size: SH
  4. Remove the generator cable from the generator, perform the following:
    5. 4.1. Slide the boot down revealing the terminal stud.
    4.2. Remove the generator cable nut from the terminal stud.
    4.3. Remove the generator cable.

    Object Number: 785526 Size: SH
  5. Remove the generator bolts.
  6. Remove the generator.

Installation Procedure

    Object Number: 785526 Size: SH
  1. Install the generator.

    2. 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.

  2. Install the generator bolts.

    3. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).


    Object Number: 395686 Size: SH
  3. Install the generator cable to the generator, perform the following:
    4. 3.1. Install the generator cable.
    3.2. Install the generator cable nut to the terminal stud.

    Tighten
    Tighten the nut to 9 N·m (80 lb in).

    3.3. Slide the boot over the terminal stud.

    Object Number: 782177 Size: SH
  4. Connect the generator electrical connector (3).
  5. Install the drive belt. Refer to Drive Belt Replacement .
  6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

Generator Replacement 4.8L, 5.3L, and 6.0L Engines

Removal Procedure

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.


    Object Number: 663672 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory .
  3. If necessary, remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement .
  4. Disconnect the generator electrical connector (3).

    5. Object Number: 395686 Size: SH
  5. Remove the generator cable from the generator. Perform the following:
    6. 5.1. Slide the boot down revealing the terminal stud.
    5.2. Remove the generator cable nut from the terminal stud.
    5.3. Remove the generator cable.

    Object Number: 385810 Size: SH
  6. Remove the generator bolts.
  7. Remove the generator.

Installation Procedure

    Object Number: 385810 Size: SH
  1. Install the generator.

    2. 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.

  2. Install the generator bolts.

    3. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).


    Object Number: 395686 Size: SH
  3. Install the generator cable to the generator. Perform the following:
    4. 3.1. Install the generator cable.
    3.2. Install the generator cable nut to the terminal stud.

    Tighten
    Tighten the nut to 9 N·m (80 lb in).

    3.3. Slide the boot over the terminal stud.

    Object Number: 663672 Size: SH
  4. Connect the generator electrical connector (3).
  5. If necessary, install the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement .
  6. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory .
  7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

Generator Replacement 6.6L Engine

Removal Procedure

    Object Number: 674573 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 6.6L.
  3. Disconnect the generator electrical connector (1).

    4. Object Number: 660347 Size: SH
  4. Remove the generator bolts.
  5. Remove the generator.

    6. Object Number: 395686 Size: SH
  6. Remove the generator cable from the generator, perform the following:
    7. 6.1. Slide the boot down revealing the terminal stud.
    6.2. Remove the generator cable nut from the terminal stud.
    6.3. Remove the generator cable.

Installation Procedure

    Object Number: 395686 Size: SH

    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.

  1. Install the generator cable to the generator, perform the following:
    2. 1.1. Install the generator cable.
    1.2. Install the generator cable nut to the terminal stud.

    Tighten
    Tighten the nut to 9 N·m (80 lb in).

    1.3. Slide the boot over the terminal stud.

    Object Number: 660347 Size: SH
  2. Install the generator.
  3. Install the generator bolts.

    4. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).


    Object Number: 674573 Size: SH
  4. Connect the generator electrical connector (1).
  5. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 6.6L
  6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

Generator Replacement 8.1L Engine

Removal Procedure

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.


    Object Number: 750525 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Disconnect the generator electrical connector (1).

    3. Object Number: 395686 Size: SH
  3. Remove the generator cable from the generator. Perform the following:
    4. 3.1. Slide the boot down revealing the terminal stud.
    3.2. Remove the generator cable nut from the terminal.
    3.3. Remove the generator cable.

    Object Number: 751563 Size: SH
  4. Remove the drive belt. Refer to Drive Belt Replacement - Accessory .
  5. Remove the generator bolts.
  6. Remove the generator.

Installation Procedure

    Object Number: 751563 Size: SH
  1. Install the generator.

    2. 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.

  2. Install the generator bolts.

    3. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).

  3. Install the drive belt. Refer to Drive Belt Replacement - Accessory .

    4. Object Number: 395686 Size: SH
  4. Install the generator cable to the generator. Perform the following:
    5. 4.1. Install the generator cable.
    4.2. Install the generator cable nut to the terminal.

    Tighten
    Tighten the nut to 9 N·m (80 lb in).

    4.3. Slide the boot over the terminal stud.

    Object Number: 750525 Size: SH
  5. Connect the generator electrical connector (1).
  6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .