Generator Replacement 4.3L

Warning: Refer to Battery Disconnect Warning in the Preface section.




1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
2. Remove the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement.
3. Remove the drive belt. Refer to Drive Belt Replacement.
4. Remove the engine wiring harness clip (1) from the air conditioning (A/C) compressor/condenser hose bracket.



5. Remove the A/C compressor and condenser hose bracket bolt (2).



6. Remove the heater outlet hose clamp bolt (1) at the generator bracket.



7. Disconnect the engine wiring harness electrical connector (5) from the generator.
8. Reposition the engine wiring harness boot (6).
9. Remove the engine wiring harness nut (3) from the generator.
10. Remove the engine wiring harness lead (4) from the generator stud.



11. Remove the generator bolts.
12. Reposition the heater outlet, and AC compressor/condenser hoses as necessary in order to remove the generator.
13. Remove the generator from the generator bracket.

1. Install the generator into the generator bracket.
2. Position the heater outlet, and AC compressor/condenser hoses as necessary.

Caution: Refer to Fastener Caution in the Preface section.

3. Install the generator bolts.

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




4. Install the engine wiring harness lead (4) to the generator stud.
5. Install the engine wiring harness nut (3) to the generator.

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

6. Position the engine wiring harness boot (6) over the generator stud.
7. Connect the engine wiring harness electrical connector (5) to the generator.



8. Install the heater outlet hose clamp bolt (1) at the generator bracket.

Tighten
Tighten the bolt to 25 N·m (18 lb ft).




9. Install the A/C compressor and condenser hose bracket bolt (2).

Tighten
Tighten the bolt to 25 N·m (18 lb ft).




10. Instal the engine wiring harness clip (1) to the A/C compressor/condenser hose bracket.
11. Install the drive belt. Refer to Drive Belt Replacement.
12. Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement.
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.

Generator Replacement 6.6L

Warning: Refer to Battery Disconnect Warning in the Preface section.




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. Reposition the engine wiring harness boot (2) in order to access the terminal stud.
4. Remove the engine wiring harness nut (1).
5. Remove the engine wiring harness terminal (3) from the generator.
6. Reposition the engine wiring harness out of the way.



7. Disconnect the engine wiring harness electrical connector (1) from the generator (2).



8. Remove the generator bolts (1).
9. Remove the generator.

1. Install the generator.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the generator bolts (1).

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




3. Connect the engine wiring harness electrical connector (1) to the generator (2).



4. Install the engine wiring harness terminal (3) to the generator.
5. Install the engine wiring harness nut (1).

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

6. Position the engine wiring harness boot (2) in order to cover the terminal stud.
7. Install the drive belt. Refer to Drive Belt Replacement.
8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.

Generator Replacement 4.8L, 5.3L, 6.0L, and 6.2L

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
2. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement.
3. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory.
4. Disconnect the engine harness electrical connector (3) from the generator.



5. Reposition the generator battery jumper cable boot (3).
6. Remove the generator battery jumper cable nut (2) from the generator.
7. Remove the generator battery jumper cable terminal (1) from the generator stud.



8. Remove the generator bolts.
9. Remove the generator.

1. Install the generator.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the generator bolts.

Tighten
Tighten the bolts to 55 N·m (41 lb ft).




3. Install the generator battery jumper cable terminal (1) to the generator stud.
4. Install the generator battery jumper cable nut (2) to the generator.

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

5. Position the generator battery jumper cable boot (3).



6. Connect the engine harness electrical connector (3) to the generator.
7. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory.
8. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement.
9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.