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 1/2 TON VAN V8-5.7L VIN RREPAIR AND DIAGNOSISSTARTING AND CHARGINGCHARGING SYSTEMALTERNATORSERVICE AND REPAIRGENERATOR BRACKET REPLACEMENT
2002 Chevrolet Express 1/2 Ton Van V8-5.7L VIN R
Generator Bracket Replacement
2002 Chevrolet Express 1/2 Ton Van V8-5.7L VIN RSECTION Generator Bracket Replacement
REMOVAL PROCEDURE
1. Disconnect the battery negative cable.
2. Remove the engine cover.
3. Remove the coolant recovery reservoir.
4. Remove the air cleaner assembly and the air inlet duct from the throttle body.
5. Remove the engine oil and the transmission fluid level indicators.
6. Remove the screw holding the oil level indicator tube and the transmission fluid fill tube to the oil fill tube lower support.
7. Remove the upper section of the oil level indicator tube.
8. Remove the nut holding the transmission fluid fill tube to the rear of the right cylinder head.
9. Remove the upper section of the transmission fluid fill tube.
10. Remove the screw holding the oil fill tube to the oil fill tube lower support.
11. Remove the oil fill tube.
12. Remove the bolts holding the heater outlet and inlet hoses to the oil fill tube lower support.
13. Remove the engine wiring harness retainer from the stud at the oil fill tube lower support.
14. Remove the stud and the bolt for the oil fill tube lower support.
15. Remove the oil fill tube lower support.
16. Remove the upper fan shroud section.
17. Remove the drive belt.
18. Remove the generator.
19. Remove the drive belt tensioner.
20. Remove the drive belt idler pulley.
21. Remove the 2 bolts and nut holding the generator mounting bracket to the engine.
22. Slide the generator mounting bracket off of the stud.
INSTALLATION PROCEDURE
1. Slide the generator mounting bracket on the stud.
NOTE: Refer to Fastener Notice in Service Precautions.
2. Install the 3 bolts and the nut.
Tighten
Tighten the generator mounting bracket bolts and the nut to 41 N.m (30 lb ft).
3. Install the drive belt idler pulley.
4. Install the drive belt tensioner.
5. Install the generator.
6. Install the drive belt.
7. Install the upper fan shroud section.
8. Install the oil fill tube lower support the bolt and the stud.
Tighten
Tighten the oil fill tube lower support stud and the bolt to 25 N.m (18 lb ft).
9. Install the engine wiring harness retainer on the stud.
10. Install the heater inlet and outlet hose brackets and the bolts to the oil fill tube lower support.
Tighten
Tighten the heater hose bracket bolts to 5 N.m (44 lb in).
11. Install the oil fill tube into the right valve rocker arm cover.
12. Install the screw holding the oil fill tube to the oil fill tube lower support.
13. Install the transmission fluid fill upper tube in the lower tube.
14. Install the nut holding the transmission fluid fill tube to the rear of the right cylinder head.
Tighten
Tighten the transmission fluid fill tube nut to 10 N.m (88 lb in).
15. Apply sealer GM P/N 12346004, or equivalent on the area of the upper section of the oil level indicator tube where it fits into the lower section.
16. Install the upper section of the oil level indicator tube into the lower section.
17. Install the bolt holding the oil level indicator tube and the transmission fluid fill tube to the oil fill tube lower support.
Tighten
Tighten the oil level indicator tube and the transmission fluid fill tube to lower support bolt to 5 N.m (44 lb in).
18. Install the engine oil level indicator and the transmission fluid level indicator.
19. Install the air inlet duct to the throttle body and the air cleaner assembly.
20. Install the coolant recovery reservoir.
21. Install the engine cover.
22. Connect the battery negative cable.
1. Disconnect the battery negative cable.
2. Remove the engine cover.
3. Remove the coolant recovery reservoir.
4. Remove the air cleaner assembly and the air inlet duct from the throttle body.
5. Remove the engine oil and the transmission fluid level indicators.
6. Remove the screw holding the oil level indicator tube and the transmission fluid fill tube to the oil fill tube lower support.
7. Remove the upper section of the oil level indicator tube.
8. Remove the nut holding the transmission fluid fill tube to the rear of the right cylinder head.
9. Remove the upper section of the transmission fluid fill tube.
10. Remove the screw holding the oil fill tube to the oil fill tube lower support.
11. Remove the oil fill tube.
12. Remove the bolts holding the heater outlet and inlet hoses to the oil fill tube lower support.
13. Remove the engine wiring harness retainer from the stud at the oil fill tube lower support.
14. Remove the stud and the bolt for the oil fill tube lower support.
15. Remove the oil fill tube lower support.
16. Remove the upper fan shroud section.
17. Remove the drive belt.
18. Remove the generator.
19. Remove the drive belt tensioner.
20. Remove the drive belt idler pulley.
21. Remove the 2 bolts and nut holding the generator mounting bracket to the engine.
22. Slide the generator mounting bracket off of the stud.
INSTALLATION PROCEDURE
1. Slide the generator mounting bracket on the stud.
NOTE: Refer to Fastener Notice in Service Precautions.
2. Install the 3 bolts and the nut.
Tighten
Tighten the generator mounting bracket bolts and the nut to 41 N.m (30 lb ft).
3. Install the drive belt idler pulley.
4. Install the drive belt tensioner.
5. Install the generator.
6. Install the drive belt.
7. Install the upper fan shroud section.
8. Install the oil fill tube lower support the bolt and the stud.
Tighten
Tighten the oil fill tube lower support stud and the bolt to 25 N.m (18 lb ft).
9. Install the engine wiring harness retainer on the stud.
10. Install the heater inlet and outlet hose brackets and the bolts to the oil fill tube lower support.
Tighten
Tighten the heater hose bracket bolts to 5 N.m (44 lb in).
11. Install the oil fill tube into the right valve rocker arm cover.
12. Install the screw holding the oil fill tube to the oil fill tube lower support.
13. Install the transmission fluid fill upper tube in the lower tube.
14. Install the nut holding the transmission fluid fill tube to the rear of the right cylinder head.
Tighten
Tighten the transmission fluid fill tube nut to 10 N.m (88 lb in).
15. Apply sealer GM P/N 12346004, or equivalent on the area of the upper section of the oil level indicator tube where it fits into the lower section.
16. Install the upper section of the oil level indicator tube into the lower section.
17. Install the bolt holding the oil level indicator tube and the transmission fluid fill tube to the oil fill tube lower support.
Tighten
Tighten the oil level indicator tube and the transmission fluid fill tube to lower support bolt to 5 N.m (44 lb in).
18. Install the engine oil level indicator and the transmission fluid level indicator.
19. Install the air inlet duct to the throttle body and the air cleaner assembly.
20. Install the coolant recovery reservoir.
21. Install the engine cover.
22. Connect the battery negative cable.
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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.