GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Kodiak C-Series (Conventional) C6/C7/C8 🢒 Engine 🢒 Engine Electrical 🢒 Generator Replacement

Generator Replacement LG4

Removal Procedure
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Replacement .
  2. Remove the drive belts. Refer to Drive Belt Replacement .

    3. Object Number: 801023 Size: SH
  3. Remove the generator mounting bolts.
  4. Remove the generator.
  5. Disconnect the wiring connectors from the back of the generator.

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 801023 Size: SH
  1. Install the generator pulley.

    2. Tighten
    Tighten the generator shaft nut to 100 N·m (75 lb ft).

  2. Connect the wiring connectors to the back of the generator.

    3. Hold the hex-shaped base on the output terminal when you tighten the nut.

    Tighten
    Tighten the generator output terminal nut to 12 N·m (100 lb in).

  3. Install the generator to the mounting bracket with mounting bolts.

    4. Object Number: 206221 Size: SH
  4. Tighten the generator mounting bolts.

    5. Tighten
    Tighten the mounting bolts to 88 N·m (65 lb ft).

  5. Install the drive belt. Refer to Drive Belt Replacement for the 7.8L engine.
  6. Connect the negative battery cable. Refer to Battery Negative Cable Replacement .

Generator Replacement L18

Removal Procedure

    Object Number: 742248 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the drive belt. Refer to Drive Belt Replacement for the 8.1L engine.
  3. Reposition the wiring harness boot.
  4. Remove the harness lead nut and lead from the generator stud.
  5. Disconnect the generator electrical connector.

    6. Object Number: 742240 Size: SH
  6. Remove the generator bolts.
  7. Remove the generator.

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 742240 Size: SH
  1. Install the generator.
  2. Install the generator bolts.

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


    Object Number: 742248 Size: SH
  3. Connect the generator electrical connector.
  4. Install the harness lead and nut to the generator stud.

    5. Tighten
    Tighten the harness lead nut to 9 N·m (80 lb in).

  5. Position the wiring harness boot.
  6. Install the drive belt. Refer to Drive Belt Replacement for the 8.1L engine.
  7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

Generator Replacement 6.6L

Removal Procedure

    Object Number: 674573 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the air cleaner layer. Refer to Air Cleaner Replacement in Engine Controls - 6.6L.
  3. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 6.6L.
  4. Remove the outlet heater hose bracket bolts.
  5. Disconnect the generator electrical connector (1).

    6. Object Number: 660347 Size: SH
  6. Remove the generator bolts.
  7. Remove the generator.

    8. Object Number: 395686 Size: SH
  8. Remove the generator cable from the generator -- perform the following.
    9. 8.1. Slide the boot down revealing the terminal stud.
    8.2. Remove the generator cable nut from the terminal stud.
    8.3. Remove the generator cable.

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 395686 Size: SH
  1. Install the generator cable to the generator -- perform the following.
    2. 1.1. Install the generator cable.
    1.2. Install the generator cable nut to the terminal stud.

    Tighten
    Tighten the generator cable nut to 9 N·m (80 lb in).

    1.3. Slide the boot over the terminal stud.

    Object Number: 660347 Size: SH
  2. Install the generator.
  3. Install the generator bolts.

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


    Object Number: 674573 Size: SH
  4. Connect the generator electrical connector (1).
  5. Install the outlet heater hose bracket bolts.

    6. Tighten
    Tighten the heater hose bracket bolts to 25 N·m (18 lb ft).

  6. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 6.6L
  7. Install the air cleaner layer. Refer to Air Cleaner Replacement in Engine Controls - 6.6L.
  8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

Generator Replacement LG5

Removal Procedure

    Object Number: 868023 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Disconnect the wiring connectors from the back of the generator.
  3. Remove the drive belt. Refer to Drive Belt Replacement .
  4. Remove the generator mounting bolts.
  5. Remove the generator .

Installation Procedure

    Object Number: 868023 Size: SH
  1. Install the generator .

    2. Notice: Refer to Fastener Notice in the Preface section.

  2. Install the generator mounting bolts.

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

  3. Install the drive belt. Refer to Drive Belt Replacement .
  4. Connect the wiring connectors to the back of the generator.

    5. Tighten
    Tighten the generator output terminal nut to 11 N·m (97 lb in).

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