The removal and installation instructions serve as a guide only. Some vehicles may require you to remove other equipment in order to access the generator, drive belts and brackets.

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. Refer to Negative Battery Cable in Battery Cable Replacement .
2. Remove the front wheelhouse panel.
3. Remove the front intake air duct from the air filter housing.
4. Remove the wiring connectors from the back of the generator.
5. Remove the ground strap. Refer to Engine Ground Strap Replacement .
6. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical.
7. Remove the following components:

•	The generator mounting bolts

•	The generator mounting washers

•	The generator mounting nuts

8. Remove the generator mounting brackets.

Important: Replace the pulley of the new generator if the pulley diameter is not exactly the same as the one being removed from the vehicle.

9. Remove the generator pulley from the generator.

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 pulley to the generator.

Tighten
Tighten the generator shaft nut to 100 N·m (75 lb ft).

2. Use the following components in order to install the generator to the mounting bracket:

•	The generator mounting bolts

•	The generator mounting washers

•	The generator mounting nuts

3. Install the V-belts onto the generator pulley.
4. Secure the generator to the mounting bolts.

CS-Series Generators: (6.0L) and (7.0L) Gasoline Engines

•	Tighten the top mounting bolt to 45 N·m (33 lb ft).

•	Tighten the bottom mounting bolt to 45 N·m (33 lb ft).

•	Tighten the rear mounting bolt to 40 N·m (30 lb ft).

21-SI 200 Series Generator: (7.2L) Diesel Engine

•	Tighten the top mounting bolt to 88 N·m (65 lb ft).

•	Tighten the bottom mounting bolt to 71 N·m (52 lb ft).

5. Install the drive belt.
6. Install the ground strap. Refer to Engine Ground Strap Replacement .
7. Install the wiring connectors to the back of the generator.



8. Hold the hex-shaped base on the output terminal.

Tighten

•	Tighten the generator output terminal nut on a CS-130 series generator to 8 N·m (71 lb in).

•	Tighten the generator output terminal nut on a CS-144 series generator to 8 N·m (71 lb in).

9. Hold the hex-shaped base on the output terminal.




Tighten

•	Tighten the generator output terminal nut on a 21-SI 200 series generator to 11 N·m (97 lb in).

•	Tighten the generator relay terminal nut on a 21-SI 200 series generator to 2 N·m (18 lb in).

•	Tighten the generator indicator terminal nut on a 21-SI 200 series generator to 2 N·m (18 lb in).

10. Connect the negative battery cable. Refer to Negative Battery Cable in Battery Cable Replacement .
11. Install the front air duct to the air filter housing.
12. Install the front wheelhouse panel.