Generator Replacement 4.8L, 5.3L, and 6.0L

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. Remove the generator cable from the generator, perform the following:

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.




5. Remove the generator bolts.
6. Remove the generator.

Notice: Refer to Fastener Notice in the Preface section.




1. Install the generator.
2. Install the generator bolts.

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




3. Install the generator cable to the generator, perform the following:

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.




4. Connect the generator electrical connector (3).
5. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory .
6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

Generator Replacement 4.3L

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. 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: Refer to Fastener Notice in the Preface section.




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 bracket to the generator bracket.
5. Install the oil fill tube support bracket bolt and stud.

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




6. Install the oil fill tube to the support bracket.
7. Install the oil fill tube screw to the support bracket.

Tighten
Tighten the oil fill tube screw to 5 N·m (44 lb in).

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