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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1533 (BATTERY, CHARGING SYSTEM AND STARTING SYSTEM)REPAIR INSTRUCTIONSGENERATOR REPLACEMENT (4.8L, 5.3L, 6.0L, AND 6.2L)INSTALLATION PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Installation Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Installation Procedure
WARNING: This page is about a different car, the 2009 GMC Sierra, 2009 Chevrolet Silverado, and 2009 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Generator & Bolts
    GM1702916Courtesy of GENERAL MOTORS CORP.
  1. Install the generator.
    2. CAUTION: Refer to Fastener Caution .
  2. Install the generator bolts.

    Tighten:  Tighten the bolts to 55 N.m (41 lb ft).

    3. Fig 2: View Of Battery Jumper Cable Terminal, Nut & Bolt
    GM1702914Courtesy of GENERAL MOTORS CORP.
  3. Install the generator battery jumper cable terminal (1) to the generator stud.
  4. Install the generator battery jumper cable nut (2) to the generator.

    Tighten:  Tighten the nut to 9 N.m (80 lb in).

  5. Position the generator battery jumper cable boot (3).
    6. Fig 3: View Of Engine Harness Retainer Nut & Electrical Connectors
    GM1696891Courtesy of GENERAL MOTORS CORP.
  6. Connect the engine harness electrical connector (3) to the generator.
  7. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory .
  8. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement .
  9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) , Battery Negative Cable Disconnection and Connection (With Auxiliary Battery)  or Battery Negative Cable Disconnection and Connection (With Dual Batteries) .
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.