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 6.6L

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

1. Remove the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement .
2. Remove the drive belt. Refer to Drive Belt Replacement .



3. Remove the generator bolts (1).
4. Remove the generator front support bracket attached to the generator bracket and the generator.
5. Reposition the generator to access wiring.
6. Remove the positive battery cable nut from the generator.
7. Disconnect the generator electrical connector.
8. Remove the generator (2).

1. Install the generator (2) to the generator bracket.
2. Connect the generator electrical connector.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the positive battery cable to the generator stud.
4. Install the cable nut to the generator stud.

Tighten
Tighten the positive cable nut to 10 N·m (89 lb in).

5. Install the generator bolts (1).

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

6. Install the generator front support bracket and attach it to the generator and the generator bracket.
7. Install the drive belt. Refer to Drive Belt Replacement .
8. Install the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement .

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 .
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
4. Remove the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement .
5. Remove the drive belt from the generator. Refer to Drive Belt Replacement .
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 .
10. Install the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement .
11. Install the air cleaner. Refer to Drive Belt Replacement .
12. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement .
13. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .