GM Service Manual Online
For 1990-2009 cars only

Removal Procedure


    Object Number: 71685  Size: SH
  1. Remove the bolt retaining the coolant recovery reservoir or surge tank.
  2. Move the coolant recovery reservoir or the surge tank aside.
  3. 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.

  4. Disconnect the battery negative cable from the battery. Refer to Battery Negative Cable Disconnection and Connection .

  5. Object Number: 105205  Size: SH
  6. Disconnect the battery positive cable from the battery.
  7. If equipped with the 6.5L engine, disconnect the positive lead to the junction block.

  8. Object Number: 184054  Size: SH
  9. Disconnect the positive lead to the starter solenoid.

  10. Object Number: 105195  Size: SH
  11. Disconnect the positive lead to the generator.
  12. Remove the cable from the vehicle. Note the location of the retaining clips.

Installation Procedure

  1. Install the cable to the vehicle.
  2. Ensure the cable is routed correctly and installed in the retainer clips.


    Object Number: 105195  Size: SH

    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.

  3. Connect the positive lead to the generator.
  4. Tighten
    Tighten the generator output (BAT) nut to 18 N·m (13 lb ft).


    Object Number: 184054  Size: SH
  5. Install the positive lead to the starter solenoid.
  6. Tighten
    Tighten the positive lead to starter solenoid to 10 N·m (89 lb in).


    Object Number: 105205  Size: SH
  7. If equipped with the 6.5L engine, install the positive lead to the junction block.
  8. Tighten
    Tighten the junction block nut to 10 N·m (89 lb in).

  9. Connect the battery positive cable to the battery.
  10. Tighten
    Tighten the battery terminals to 17 N·m (13 lb ft).

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

  12. Object Number: 71685  Size: SH
  13. Install the coolant recovery reservoir or surge tank and the bolt.
  14. Tighten
    Tighten the coolant recovery reservoir or surge tank bolt to 11 N·m (97 lb in).