GM Service Manual Online
For 1990-2009 cars only

Generator Replacement 4.8L, 5.3L, and 6.0L

Removal Procedure


    Object Number: 663672  Size: SH

    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 Battery Negative Cable Disconnection and Connection .
  2. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory .
  3. Disconnect the generator electrical connector (3).

  4. Object Number: 395686  Size: SH
  5. Remove the generator cable from the generator, perform the following:
  6. 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: 385810  Size: SH
  7. Remove the generator bolts.
  8. Remove the generator.

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 385810  Size: SH
  1. Install the generator.
  2. Install the generator bolts.
  3. Tighten
    Tighten the generator bolts to 50 N·m (37 lb ft).


    Object Number: 395686  Size: SH
  4. Install the generator cable to the generator, perform the following:
  5. 3.1. Install the generator cable.
    3.2. Install the generator cable nut to the terminal stud.

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

    3.3. Slide the boot over the terminal stud.

    Object Number: 663672  Size: SH
  6. Connect the generator electrical connector (3).
  7. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory .
  8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

Generator Replacement 4.3L

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.

  1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
  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.
  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 - 4.3L.
  6. Remove the heater hose pipe from the generator.

  7. Object Number: 374484  Size: SH
  8. Remove the oil fill tubes from the support bracket.

  9. Object Number: 184032  Size: SH
  10. Remove the support bracket from the generator bracket.

  11. Object Number: 360237  Size: SH
  12. Remove the generator mounting bolts.
  13. Remove the generator from the engine.

  14. Object Number: 184024  Size: SH
  15. Disconnect the electrical connectors.

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 184024  Size: SH
  1. Connect the electrical connectors to the generator.
  2. Tighten
    Tighten the generator output (BAT) terminal nut to 18 N·m (13 lb ft).


    Object Number: 360237  Size: SH
  3. Install the generator to the engine.
  4. Install the generator mounting bolts.
  5. 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).

    Object Number: 184032  Size: SH
  6. Install the oil fill tube support bracket to the generator bracket.
  7. Install the oil fill tube support bracket bolt and stud.
  8. Tighten
    Tighten the oil fill tube support bracket bolt and stud to 25 N·m (18 lb ft).


    Object Number: 374484  Size: SH
  9. Install the oil fill tube to the support bracket.
  10. Install the oil fill tube screw to the support bracket.
  11. Tighten
    Tighten the oil fill tube screw to 5 N·m (44 lb in).

  12. Install the heater hose pipe to the generator.
  13. Install the drive belt to the generator. Refer to Drive Belt Replacement in Engine Mechanical - 4.3L.
  14. Install the upper fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.
  15. Install the air cleaner. Refer to Drive Belt Replacement in Engine Controls - 4.3L.
  16. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
  17. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .