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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1787 (BATTERY, CHARGING SYSTEM AND STARTING SYSTEM - NON-HYBRID)REPAIR INSTRUCTIONSGENERATOR REPLACEMENT (V6)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 2010 GMC Sierra, 2010 GMC Cab & Chassis Sierra, 2010 Chevrolet Silverado, and 2010 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
    GM1877576Courtesy of GENERAL MOTORS CORP.
  1. Install the generator into the generator bracket.
  2. Position the heater outlet, and AC compressor/condenser hoses as necessary.
    3. CAUTION: Refer to Fastener Caution .
  3. Install the generator bolts.

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

    4. Fig 2: View Of Engine Wiring Harness & Components
    GM1876492Courtesy of GENERAL MOTORS CORP.
  4. Install the engine wiring harness lead (4) to the generator stud.
  5. Install the engine wiring harness nut (3) to the generator.

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

  6. Position the engine wiring harness boot (6) over the generator stud.
  7. Connect the engine wiring harness electrical connector (5) to the generator.
    8. Fig 3: View Of Heater Outlet Hose & Clamp Bolt
    GM1877575Courtesy of GENERAL MOTORS CORP.
  8. Install the heater outlet hose clamp bolt (1) at the generator bracket.

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

    9. Fig 4: View Of A/C Compressor & Condenser Hose Bracket & Bolt
    GM1877551Courtesy of GENERAL MOTORS CORP.
  9. Install the A/C compressor and condenser hose bracket bolt (2).

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

    10. Fig 5: View Of Engine Wiring Harness & Components
    GM1876999Courtesy of GENERAL MOTORS CORP.
  10. Instal the engine wiring harness clip (1) to the A/C compressor/condenser hose bracket.
  11. Install the drive belt. Refer to Drive Belt Replacement .
  12. Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement .
  13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery)  or Battery Negative Cable Disconnection and Connection (Dual Batteries)  or Battery Negative Cable Disconnection and Connection (Auxiliary Battery) .
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.