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 MANUALSCHEVROLET2002EXPRESS 1 TON VAN V8-8.1L VIN GREPAIR AND DIAGNOSISSTARTING AND CHARGINGCHARGING SYSTEMALTERNATORSERVICE AND REPAIRGENERATOR REPLACEMENT
2002 Chevrolet Express 1 Ton Van V8-8.1L VIN G
Generator Replacement
2002 Chevrolet Express 1 Ton Van V8-8.1L VIN GSECTION Generator Replacement
REMOVAL PROCEDURE
CAUTION: Refer to Battery Disconnect Caution in Service Precautions.
1. Disconnect the negative battery cable (1).
2. Remove the drive belt.
3. Remove the fan shroud (upper).
4. Remove the indicator tube bracket bolts and reposition the bracket.
5. Remove the heater inlet pipe bolt from the bracket.
6. Remove the indicator tube bracket.
7. Remove the generator bolts (1).
5. Reposition the generator.
9. Reposition the positive cable boot at the generator.
10. Remove the positive cable nut.
11. Remove the positive cable from the generator.
12. Disconnect the generator electrical connector.
INSTALLATION PROCEDURE
1. Connect the generator electrical connector.
2. Install the positive cable to the generator.
NOTE: Refer to Fastener Notice in Service Precautions.
3. Install the positive cable nut.
4. Position the positive cable boot at the generator.
5. Install the generator.
6. Install the generator bolts (1).
Tighten
Tighten the generator bolts to 50 N.m (37 lb ft).
7. Install the indicator tube bracket.
8. Install the heater inlet pipe bolt to the bracket.
Tighten
Tighten the heater inlet pipe bolt to 5 N.m (44 lb in).
9. Position the bracket and install the indicator tube bracket bolts.
Tighten
Tighten the indicator tube bracket bolts to 25 N.m (18 lb ft).
10. Install the fan shroud (upper).
11. Install the drive belt.
12. Connect the negative battery cable (1).
CAUTION: Refer to Battery Disconnect Caution in Service Precautions.
1. Disconnect the negative battery cable (1).
2. Remove the drive belt.
3. Remove the fan shroud (upper).
4. Remove the indicator tube bracket bolts and reposition the bracket.
5. Remove the heater inlet pipe bolt from the bracket.
6. Remove the indicator tube bracket.
7. Remove the generator bolts (1).
5. Reposition the generator.
9. Reposition the positive cable boot at the generator.
10. Remove the positive cable nut.
11. Remove the positive cable from the generator.
12. Disconnect the generator electrical connector.
INSTALLATION PROCEDURE
1. Connect the generator electrical connector.
2. Install the positive cable to the generator.
NOTE: Refer to Fastener Notice in Service Precautions.
3. Install the positive cable nut.
4. Position the positive cable boot at the generator.
5. Install the generator.
6. Install the generator bolts (1).
Tighten
Tighten the generator bolts to 50 N.m (37 lb ft).
7. Install the indicator tube bracket.
8. Install the heater inlet pipe bolt to the bracket.
Tighten
Tighten the heater inlet pipe bolt to 5 N.m (44 lb in).
9. Position the bracket and install the indicator tube bracket bolts.
Tighten
Tighten the indicator tube bracket bolts to 25 N.m (18 lb ft).
10. Install the fan shroud (upper).
11. Install the drive belt.
12. Connect the negative battery cable (1).
RENDER: 1.0x
NO RELATED
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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.