Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 903 (BATTERY, CHARGING SYSTEM AND STARTING SYSTEM)REPAIR INSTRUCTIONSGENERATOR REPLACEMENT (6.6L)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 2007 GMC Savana Special, 2007 GMC Savana Camper Special, 2007 GMC Savana, and 2007 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: View Of Auxiliary Generator & Bolts

Courtesy of GENERAL MOTORS CORP.

Install generator to engine.
Connect the generator electrical connector.

NOTE: Refer to Fastener Notice .

Install the positive battery cable to the generator, perform the following:
- Position the positive cable.
- Install the positive cable nut.
  Tighten: Tighten the positive cable nut to 9 N.m (80 lb in).
- Slide the boot down to cover the terminal stud.
Position the generator (2) to the mounting bracket.
Install the generator bolts (1).
Tighten: Tighten the generator bolts to 50 N.m (37 lb ft).
Install the generator front support bracket and attach to generator and generator bracket.
Install the drive belt. Refer to Drive Belt Replacement .
Install the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L) or Engine Coolant Fan Upper Shroud Replacement (6.6L) .

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.