Generator Replacement Gas Engines: 4.3L, 5.0L, 5.7L, 7.4L

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
3. Remove the air cleaner assembly.

•	Refer to Air Cleaner Assembly Replacement in Engine Controls 4.3L

•	Refer to Air Cleaner Assembly Replacement in Engine Controls 5.0L/ 5.7L

•	Refer to Air Cleaner Assembly Replacement in Engine Controls 7.4L

4. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.



5. Remove the engine oil and the transmission fluid level indicators.
6. Remove the screw holding the oil level indicator tube and the transmission fluid fill tube to the oil fill tube lower support.
7. Remove the upper section of the oil level indicator tube.



8. Remove the nut holding the transmission fluid fill tube to the rear of the right cylinder head.
9. Remove the upper section of the transmission fluid fill tube.



10. Remove the screw holding the oil fill tube to the oil fill tube lower support.
11. Remove the oil fill tube.



12. Remove the bolts holding the heater outlet and inlet hoses to the oil fill tube lower support.



13. Remove the engine wiring harness retainer from the stud at the oil fill tube lower support.
14. Remove the stud and the bolt for the oil fill tube lower support.
15. Remove the oil fill tube lower support.
16. Remove the upper fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.
17. Remove the drive belt from the generator.

•	Refer to Drive Belt Replacement in Engine Mechanical 4.3L

•	Refer to Drive Belt Replacement in Engine Mechanical 5.0/5.7L

•	Refer to Drive Belt Replacement in Engine Mechanical 7.4L




18. Remove the generator mounting bolts.
19. Remove the generator from the engine.



20. 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 4.3L

•	Refer to Drive Belt Replacement in Engine Mechanical 5.0/5.7L

•	Refer to Drive Belt Replacement in Engine Mechanical 7.4L

5. Install the upper fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.



6. Install the oil fill tube lower support, the bolt and the stud.

Tighten
Tighten the oil fill tube lower support stud and the bolt to 25 N·m (18 lb ft).

7. Install the engine wiring harness retainer on the stud.



8. Install the heater inlet and outlet hose brackets and the bolts to the oil fill tube lower support.

Tighten
Tighten the heater hose bracket bolts to 5 N·m (44 lb in).




9. Install the oil fill tube into the right valve rocker arm cover.
10. Install the screw holding the oil fill tube to the oil fill tube lower support.



11. Install the transmission fluid fill upper tube in the lower tube.
12. Install the nut holding the transmission fluid fill tube to the rear of the right cylinder head.

Tighten
Tighten the transmission fluid fill tube nut to 10 N·m (88 lb in).




13. Apply sealer GM P/N 12346004, or equivalent on the area of the upper section of the oil level indicator tube where it fits into the lower section.
14. Install the upper section of the oil level indicator tube into the lower section.
15. Install the bolt holding the oil level indicator tube and the transmission fluid fill tube to the oil fill tube lower support.

Tighten
Tighten the oil level indicator tube and the transmission fluid fill tube to lower support bolt to 5 N·m (44 lb in).

16. Install the engine oil level indicator and the transmission fluid level indicator.
17. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.
18. Install the air cleaner assembly.

•	Refer to Air Cleaner Assembly Replacement in Engine Controls 4.3L

•	Refer to Air Cleaner Assembly Replacement in Engine Controls 5.0L/ 5.7L

•	Refer to Air Cleaner Assembly Replacement in Engine Controls 7.4L

19. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
20. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

Generator Replacement Diesel Engine: 6.5L

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 battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the surge tank. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement 4.3L or Air Cleaner Assembly Replacement 5.0L/ 5.7L or Air Cleaner Assembly Replacement 6.5L 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 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 assembly. Refer to Air Cleaner Assembly Replacement 4.3L or Air Cleaner Assembly Replacement 5.0L/ 5.7L or Air Cleaner Assembly Replacement 6.5L or Air Cleaner Assembly Replacement 7.4L 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 Negative Cable Disconnection and Connection .