GM Service Manual Online
For 1990-2009 cars only

Generator Replacement 2.4L

Removal Procedure

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


    Object Number: 1758465  Size: SH
  1. Disconnect the negative battery cable.
  2. Disconnect the intake air temperature (IAT) sensor connector.
  3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .

  4. Object Number: 1758559  Size: SH
  5. Disconnect the harness connector from the generator.
  6. Remove the generator upper bracket mounting bolts and the generator-to-intake manifold strap bracket bolts.

  7. Object Number: 1775317  Size: SH
  8. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  9. Remove the serpentine accessory drive belt. Refer to Drive Belt Replacement .
  10. Disconnect the generator lead-to-starer motor wire from the generator.

  11. Object Number: 1775318  Size: SH

    Important: Do not remove the generator through bolt, nut and washers at this stage.

  12. Loosen the nut and washers which hold the generator lower bracket-to-generator bolt.
  13. Remove the generator lower support bracket bolts.
  14. Carefully remove the generator with the lower support bracket.

  15. Object Number: 1775320  Size: SH
  16. Remove the generator-to-lower support bracket through bolt, nut and washer.

Installation Procedure


    Object Number: 1775320  Size: SH

    Important: Do not tighten the generator through bolt at this stage.

  1. Install the generator lower support bracket to the generator and insert the through bolt.
  2. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1775318  Size: SH
  3. Install the generator and the lower support bracket assembly to the engine block.
  4. Tighten
    Tighten the generator lower support bracket bolts to 25 N·m (18 lb ft).

  5. Tighten the generator-to-generator lower support bracket through bolt.
  6. Tighten
    Tighten the generator through bolt to 40 N·m (30 lb ft).


    Object Number: 1775317  Size: SH
  7. Connect the generator lead-to-starer motor wire to the generator.
  8. Install the serpentine accessory drive belt. Refer to Drive Belt Replacement .
  9. Lower the vehicle.

  10. Object Number: 1758571  Size: SH
  11. Install the generator upper bracket and the generator-to-intake manifold strap bracket.
  12. Install the generator upper bracket mounting bolts and the generator-to-intake manifold strap bracket bolts.
  13. Tighten

        • Tighten the generator upper bracket retaining bolts (1) to 25 N·m (18 lb ft) and the bolt (2) to 35 N·m (26  lb ft).
        • Tighten the generator-to-intake manifold strap bracket retaining bolt (3) to 35 N·m (26 lb ft) and the bolt (4) to 25 N·m (18 lb ft).

    Object Number: 1760023  Size: SH
  14. Connect the harness connector to the generator.
  15. Install the air cleaner assembly and connect the IAT sensor connector. Refer to Air Cleaner Assembly Replacement .
  16. Connect the negative battery cable.

Generator Replacement 2.0L Diesel

Removal Procedure

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


    Object Number: 1820433  Size: SH
  1. Disconnect the battery negative cable.
  2. Remove the engine cover. Refer to Engine Cover Replacement .
  3. Remove the charge air cooler inlet hoses. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement .

  4. Object Number: 1821742  Size: SH
  5. Remove the accessory belt. Refer to Drive Belt Replacement .

  6. Object Number: 1821743  Size: SH
  7. Disconnect the generator connector.
  8. Remove the generator B+ wiring harness.
  9. Remove the generator.

Installation Procedure


    Object Number: 1821743  Size: SH
  1. Install the generator.
  2. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the generator lead-to-starter motor wire retaining nut.
  4. Tighten

        • Tighten the generator bolt to 30 N·m (22.1  lb ft).
        • Tighten the generator B+ wiring harness retaining nut to 25 N·m (18.4 lb ft).