Generator Replacement Gasoline Engines

The removal and installation instructions serve only as a guide. Additional operations may be required on some vehicles to remove other equipment in order to gain access to the generator, the drive belt, and the brackets.

Caution: Failure to observe Step 1 in this procedure may result in an injury from the live battery lead at the generator.

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.
2. Disconnect the 4-wire connector from the generator.
3. Disconnect the battery lead from the back of the generator.
4. Remove the drive belt. Refer to Drive Belt Replacement 4.3L, Drive Belt Replacement 5.7L, or Drive Belt Replacement 7.4L in Engine Mechanical.



5. Remove the three generator mounting bolts.
6. Remove the generator from the generator mounting bracket.

1. Loosely install the generator into the generator mounting bracket.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.




2. Install the three generator mounting bolts.

Important: The generator mounting bolts must be torqued in the following sequence:

Tighten

1. Tighten the right mounting bolt to 50 N·m (37 lb ft).
2. Tighten the left mounting bolt to 50 N·m (37 lb ft).
3. Tighten the mounting bracket bolt at the back of the generator to 25 N·m (18 lb ft), for 105 ampre generators,50 N·m (37 lb ft), for 124 and 145 ampre generators.
3. Install the drive belt. Refer to Drive Belt Replacement 4.3L, Drive Belt Replacement 5.7L, or Drive Belt Replacement 7.4L in Engine Mechanical.
4. Connect the4-wire connector to the generator.
5. Connect the battery lead to the back of the generator.

Tighten
Tighten to battery terminal nut to 8 N·m (71 lb in).

6. Connect the negative battery cable.

Generator Replacement Diesel Engines

The removal and installation instructions serve only as a guide. Additional operations may be required on some vehicles to remove other equipment in order to gain access to the generator, the drive belt, and the brackets.

Caution: Failure to observe Step 1 in this procedure may result in an injury from the live battery lead at the generator.

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.
2. Disconnect the 4-wire connector from the generator.
3. Disconnect the battery lead from the back of the generator.
4. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical.



5. Remove the three generator mounting bolts. (Note: L 65 engines with 105 ampre generators use only two mounting bolts.)
6. Remove the generator from the generator mounting bracket.

1. Install the generator into the generator mounting bracket.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.




2. Install the generator mounting bolts.

Tighten

1. Tighten the top mounting bolt to 50 N·m (37 lb ft).
2. Tighten the bottom mounting nut to 50 N·m (37 lb ft).
3. Tighten the mounting bracket bolt at the back of the generator to 50 N·m (37 lb ft).
3. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical.
4. Connect the4-wire connector to the generator.
5. Connect the battery lead to the back of the generator.

Tighten
Tighten to battery terminal nut to 8 N·m (71 lb in).

6. Connect the negative battery cable.