GM Service Manual Online
For 1990-2009 cars only
Makes 馃 GMC_Truck 馃 2008 馃 TopKick C-Series (Conventional) C4/C5 馃 Engine 馃 Engine Controls and Fuel - 8.1L 馃 Generator Replacement

Generator Replacement LG4

Removal Procedure
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Replacement .
  2. Remove the drive belts. Refer to Drive Belt Replacement .

    3. Object Number: 801023 Size: SH
  3. Remove the generator mounting bolts.
  4. Remove the generator.
  5. Disconnect the wiring connectors from the back of the generator.

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 801023 Size: SH
  1. Install the generator pulley.

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

  2. Connect the wiring connectors to the back of the generator.

    3. Hold the hex-shaped base on the output terminal when you tighten the nut.

    Tighten
    Tighten the generator output terminal nut to 12 N路m (100 lb in).

  3. Install the generator to the mounting bracket with mounting bolts.

    4. Object Number: 206221 Size: SH
  4. Tighten the generator mounting bolts.

    5. Tighten
    Tighten the mounting bolts to 88 N路m (65 lb ft).

  5. Install the drive belt. Refer to Drive Belt Replacement for the 7.8L engine.
  6. Connect the negative battery cable. Refer to Battery Negative Cable Replacement .

Generator Replacement L18

Removal Procedure

    Object Number: 742248 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the drive belt. Refer to Drive Belt Replacement for the 8.1L engine.
  3. Reposition the wiring harness boot.
  4. Remove the harness lead nut and lead from the generator stud.
  5. Disconnect the generator electrical connector.

    6. Object Number: 742240 Size: SH
  6. Remove the generator bolts.
  7. Remove the generator.

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 742240 Size: SH
  1. Install the generator.
  2. Install the generator bolts.

    3. Tighten
    Tighten the generator bolts to 50 N路m (37 lb ft).


    Object Number: 742248 Size: SH
  3. Connect the generator electrical connector.
  4. Install the harness lead and nut to the generator stud.

    5. Tighten
    Tighten the harness lead nut to 9 N路m (80 lb in).

  5. Position the wiring harness boot.
  6. Install the drive belt. Refer to Drive Belt Replacement for the 8.1L engine.
  7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

Generator Replacement LG5

Removal Procedure

    Object Number: 868023 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Disconnect the wiring connectors from the back of the generator.
  3. Remove the drive belt. Refer to Drive Belt Replacement .
  4. Remove the generator mounting bolts.
  5. Remove the generator .

Installation Procedure

    Object Number: 868023 Size: SH
  1. Install the generator .

    2. Notice: Refer to Fastener Notice in the Preface section.

  2. Install the generator mounting bolts.

    3. Tighten
    Tighten the mounting bolts to 50 N路m (37 lb ft).

  3. Install the drive belt. Refer to Drive Belt Replacement .
  4. Connect the wiring connectors to the back of the generator.

    5. Tighten
    Tighten the generator output terminal nut to 11 N路m (97 lb in).

  5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

Generator Replacement LMM

Removal Procedure

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


    Object Number: 1869602 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement .
  3. Remove the drive belt. Refer to Drive Belt Replacement .
  4. Disconnect the engine wiring harness electrical connector (3) from the generator.
  5. Reposition the engine wiring harness boot (7).
  6. Remove the generator terminal nut (6).
  7. Remove the engine wring harness terminal (5) from the generator.

    8. Object Number: 1869603 Size: SH
  8. Remove the generator bolts (4).
  9. Remove the generator (1).

Installation Procedure

    Object Number: 1869603 Size: SH
  1. Install the generator (1).

    2. Notice: Refer to Fastener Notice in the Preface section.

  2. Install the generator bolts (4).

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


    Object Number: 1869602 Size: SH
  3. Install the engine wring harness terminal (5) to the generator.
  4. Install the generator terminal nut (6).

    5. Tighten
    Tighten the nut to 25 N路m (18 lb ft).

  5. Position the engine wiring harness boot (7).
  6. Connect the engine wiring harness electrical connector (3) to the generator.
  7. Install the drive belt. Refer to Drive Belt Replacement .
  8. Install the air cleaner. Refer to Air Cleaner Assembly Replacement .
  9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .