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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 28 (BATTERY, CHARGING SYSTEM AND STARTING SYSTEM)REPAIR INSTRUCTIONSGENERATOR REPLACEMENTINSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Installation Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Installation Procedure
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2007 GMC Yukon XL, 2007 GMC Yukon, 2007 Chevrolet Tahoe, 2007 Chevrolet Suburban, and 2007 Chevrolet Avalanche. 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. NOTE: Refer to Fastener Notice .
  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 Generator & Related 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 .
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.