GM Service Manual Online
For 1990-2009 cars only

Generator Replacement 1.6L

Removal Procedure

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


    Object Number: 1289188  Size: SH
  1. Disconnect the negative battery cable.
  2. Disconnect the intake air temperature (IAT) sensor electrical connector from the air intake tube.
  3. Remove all the clamps from the air cleaner outlet hose and set aside the tube.

  4. Object Number: 1289189  Size: SH
  5. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
  6. Disconnect the harness connector from the back of the generator and the generator lead to the battery.
  7. Remove the power steering pump drive belt by lowering the vehicle and turning the automatic tensioner roller bolt clockwise to relieve tension on the belt. Refer to Power Steering Pump Belt Replacement.
  8. Push up the power steering reservoir and set it aside.

  9. Object Number: 1289204  Size: SH
  10. Remove the bolt of the generator upper engine connecting bracket to the engine.

  11. Object Number: 1289242  Size: SH
  12. Raise and suitably support the vehicle and remove the nut and washers which hold the generator lower bracket-to-generator bolt. Work the bolt loose and remove the generator.

  13. Object Number: 1289257  Size: SH
  14. Remove the generator lower support bracket nut, the bolt, and the washer.

Installation Procedure


    Object Number: 1289225  Size: SH
  1. Install the generator to the generator lower bracket and insert the generator bolt.
  2. Caution: Refer to Fastener Caution in the Preface section.

  3. Install the nut and washers on the generator lower bracket-to-generator bolt.
  4. Tighten
    Tighten the generator lower bracket-to-generator nut to 25 N·m (18 lb ft).


    Object Number: 1289204  Size: SH
  5. Install the upper generator support bracket bolt and the washer.
  6. Tighten
    Tighten the generator upper support bracket bolt to 20 N·m (15 lb ft).

  7. Connect the harness connector to the back of the generator and the generator lead to the battery.

  8. Object Number: 1289189  Size: SH
  9. Route the power steering pump drive belt. Refer to Power Steering Pump Belt Replacement.
  10. Relieve the tension on the belt by first applying downward pressure on the automatic tension roller bolt and releasing pressure once the belt is in place.
  11. Install the power steering reservoir.

  12. Object Number: 1289188  Size: SH
  13. Install the air cleaner outlet hose and connect the IAT electrical connector.
  14. Connect the negative battery cable.

Generator Replacement 1.8L/2.0L

Removal Procedure

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


    Object Number: 1289768  Size: SH
  1. Disconnect the negative battery cable.
  2. Disconnect the intake air temperature (IAT) sensor electrical connector from the air intake tube.
  3. Remove all the clamps from the air cleaner outlet hose, and set aside the tube.

  4. Object Number: 1289189  Size: SH
  5. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
  6. Disconnect the harness connector from the back of the generator and the generator lead to the battery.
  7. Remove the power steering pump drive belt by lowering the vehicle and turning the automatic tensioner roller bolt clockwise to relieve tension on the belt. Refer to Power Steering Pump Belt Replacement.
  8. Push up the power steering reservoir and set it aside.

  9. Object Number: 1289225  Size: SH
  10. Remove the generator upper mounting bolts to the intake manifold/cylinder head support bracket, the intake manifold strap bracket, and the intake manifold-to-cylinder body strap bracket.

  11. Object Number: 1289242  Size: SH
  12. Raise and suitably support the vehicle and remove the nut and washers which hold the generator lower bracket-to-generator bolt. Work the bolt loose and remove the generator.

  13. Object Number: 1289257  Size: SH
  14. Remove the generator lower support bracket bolts.
  15. Carefully remove the generator with the lower bracket attached.
  16. Remove the generator lower support bracket nut, the bolt, and the washer.

Installation Procedure

    Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1289225  Size: SH
  1. Install the generator to the generator lower bracket and insert the generator bolt.
  2. Tighten
    Tighten the generator lower bracket-to-generator nut to 25 N·m (18 lb ft).


    Object Number: 1289270  Size: SH
  3. Install the generator and the lower support bracket assembly to the engine block.
  4. Tighten
    Tighten the generator and the lower bracket-to-engine block bolts to 37 N·m (27 lb ft).


    Object Number: 1289225  Size: SH
  5. Install the generator-to-intake manifold and cylinder head support bracket bolts.
  6. Tighten
    Tighten the generator-to-intake manifold and cylinder head support bracket bolts to 37 N·m (27 lb ft).

  7. Install the generator-to-intake manifold strap bracket bolts and the intake manifold-to-cylinder body strap bracket bolts over the starter.
  8. Tighten
    Tighten the generator-to-intake manifold strap bracket bolt and the intake manifold-to-cylinder body strap bracket bolts to 22 N·m (16 lb ft).


    Object Number: 1289204  Size: SH
  9. Connect the harness connector to the back of the generator, and the generator lead to the battery.

  10. Object Number: 1289189  Size: SH
  11. Route the power steering pump drive belt. Refer to Power Steering Pump Belt Replacement.
  12. Relieve tension on the belt by first applying downward pressure on the automatic tension roller bolt and releasing pressure once the belt is in place.
  13. Install the power steering reservoir.

  14. Object Number: 1289768  Size: SH
  15. Install the air cleaner outlet hose and connect the IAT electrical connector.
  16. Connect the negative battery cable.

Generator Replacement 2.0L Diesel Engine

Removal Procedure

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


    Object Number: 1962615  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: 1962618  Size: SH
  7. Remove the EGR vacuum tank.

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

Installation Procedure


    Object Number: 1821743  Size: SH
  1. Install the generator.
  2. Caution: Refer to Fastener Caution 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).

    Object Number: 1962618  Size: SH
  5. Install the EGR vacuum tank.

  6. Object Number: 1821742  Size: SH
  7. Install the accessory drive belt. Refer to Drive Belt Replacement.

  8. Object Number: 1962615  Size: SH
  9. Install the charge air cooler inlet hoses. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement.
  10. Install the engine cover. Refer to Engine Cover Replacement.
  11. Connect the negative battery cable.