Generator Replacement Gasoline Engines

1. Disconnect the battery negative cable. Refer to Battery Cable Replacement in Engine Electrical.
2. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
3. Remove the air cleaner. Refer Air Cleaner Assembly Replacement 4.3L or Air Cleaner Assembly Replacement 5.0/5.7L or Air Cleaner Assembly Replacement 7.4L in Engine Controls.
4. Remove the upper fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.
5. Remove the drive belt from the generator. Refer to Drive Belt Replacement 4.3L or Drive Belt Replacement 5.0/5.7L or Drive Belt Replacement 7.4L in Engine Mechanical.
6. Remove the heater hose pipe from the generator.



7. Remove the oil fill tubes from the support bracket.



8. Remove the support bracket from the generator bracket.



9. Remove the generator mounting bolts.
10. Remove the generator from the engine.



11. Disconnect the electrical connectors.

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. Connect the electrical connectors to the generator.

Tighten
Tighten the generator output (BAT) terminal nut to 18 N·m (13 lb ft).




2. Install the generator to the engine.
3. Install the generator mounting bolts.

Tighten

•	Tighten the generator front mounting bolts to 50 N·m (37 lb ft).

•	Tighten the generator rear mounting bolt to 25 N·m (18 lb ft).




4. Install the oil fill tube support the generator bracket.



5. Install the oil fill tube to the support bracket.
6. Install the heater hose pipe to the generator.
7. Install the drive belt to the generator. Refer to Drive Belt Replacement 4.3L or Drive Belt Replacement 5.0/5.7L or Drive Belt Replacement 7.4L in Engine Mechanical.
8. Install the upper fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.
9. Install the air cleaner. Refer to Air Cleaner Assembly Replacement 4.3L or Air Cleaner Assembly Replacement 5.0/5.7L or Air Cleaner Assembly Replacement 7.4L in Engine Controls.
10. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
11. Connect the battery negative cable. Refer to Battery Cable Replacement in Engine Electrical.

Generator Replacement Diesel Engines

1. Disconnect the battery negative cable. Refer to Battery Cable Replacement in Engine Electrical.
2. Remove the surge tank. Refer to Surge Tank (Diesel) Replacement in Engine Cooling.
3. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls.
4. Remove the upper fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.
5. Remove the drive belt from the generator. Refer to Drive Belt Replacement in Engine Mechanical.



6. Remove the generator mounting bolts.
7. Remove the generator from the engine.



8. Disconnect the electrical connectors.

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. Connect the electrical connectors to the generator.

Tighten
Tighten the generator output BAT terminal nut to 18 N·m (13 lb ft).




2. Install the generator to the engine.
3. Install the generator mounting bolts.

Tighten

•	Tighten the generator front mounting bolts to 50 N·m (37 lb ft).

•	Tighten the generator rear mounting bolt to 25 N·m (18 lb ft).

4. Install the drive belt to the generator. Refer to Drive Belt Replacement in Engine Mechanical.
5. Install the upper fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.
6. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls.
7. Install the surge tank. Refer to Surge Tank (Diesel) Replacement in Engine Cooling.
8. Connect the battery negative cable. Refer to Battery Cable Replacement in Engine Electrical.