Document ID: 1953122 Page 1 of 2

2009 Chevrolet Express - AWD | Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical | Specifications |
Document ID: 1953122

Fastener Tightening Specifications

Specification
Application Metric English
Auxiliary Battery Cable (6.6L) 15 N·m 11 lb ft
Auxiliary Generator Bolt (6.6L) 50 N·m 37 lb ft
Auxiliary Generator Bracket Bolt (6.6L) 50 N·m 37 lb ft
Auxiliary Positive Battery Cable Bolt (6.6L) 17 N·m 13 lb ft
Auxiliary Positive Battery Cable Nut (6.6L) 8 N·m 71 lb in
Battery Cable to Starter Nut (6.6L) 9 N·m 80 lb in
Battery Hold Down Retainer Bolt 18 N·m 13 lb ft
Battery Tray Bolt -- Auxiliary 25 N·m 18 lb ft
Battery Tray Bolt -- Primary 9 N·m 80 lb ft
Coolant Recovery Reservoir/Surge Tank Bolt 11 N·m 97 lb in
Drive Belt Tensioner Bolt (6.6L) 50 N·m 37 lb ft
Engine Harness Bolt (6.6L) 10 N·m 89 lb in

ca
Engine Wiring Harness Ground Bolt 16 N·m 12 lb ft

rd
Engine Wiring Harness Nut (6.6L) 3.4 N·m 30 lb in

ia
Generator Bolt 50 N·m 37 lb ft

gn
Generator Bracket Bolt (4.8L, 5.3L, 6.0L, 6.6L) 50 N·m 37 lb ft

.c
Generator Bracket Bolt/Nut (4.3L) 41 N·m 30 lb ft

om
Generator Cable Nut (4.8L, 5.3L, 6.0L) 9 N·m 80 lb in
Generator Extension Bracket Bolt (6.6L) 50 N·m 37 lb ft
Generator Nut (4.3L) 12 N·m 106 lb in
Generator Output (BAT) Nut (4.8L, 5.3L, 6.0L) 18 N·m 13 lb ft
Ground Strap to Front of Dash Nut (4.8L, 5.3L, 6.0L) 9 N·m 80 lb in
Junction Block Nut (4.8L, 5.3L, 6.0L) 10 N·m 89 lb in
Negative Battery Cable to Auxiliary Battery (6.6L) 15 N·m 11 lb ft
Negative Battery Cable Ground Lead to Crossmember Nut (4.3L) 10 N·m 89 lb in
Negative Battery Cable to Inner Fender Panel Nut 10 N·m 89 lb in
Negative Battery Cable Lead to Engine Block Bolt 25 N·m 18 lb ft
Negative Battery Terminal Bolt 17 N·m 13 lb ft
Negative Ground Lead (6.6L) 10 N·m 89 lb in
Oil Fill Tube Bracket Bolt (4.3L) 25 N·m 18 lb ft
Oil Indicator Tube Bracket Bolt (6.6L) 21 N·m 15 lb ft
Positive Battery Cable Bolt (6.6L) 17 N·m 13 lb ft
Positive Battery Cable to Battery Bolt (4.3L) 17 N·m 13 lb ft
Positive Battery Cable to Junction Block Nut (6.6L) 8 N·m 71 lb in
Positive Battery Cable to Underhood Bussed
© 2010 General MotorsElectrical Center
Corporation. (UBEC)
All rights Nut
reserved.

http://localhost:9001/si/showDoc.do?docSyskey=1953122&pubCellSyskey=37499&pub... 11/18/2010
Document ID: 1953122 Page 2 of 2

(4.3L) 5 N·m 44 lb in
Positive Cable Nut (6.6L) 9 N·m 80 lb in
Positive Extension Cable to Intake Air Heater Nut (6.6L) 4 N·m 34 lb in
Positive Extension Cable to Junction Block Nut (6.6L) 8 N·m 71 lb in
Positive Lead to Starter Solenoid Nut (4.8L, 5.3L, 6.0L) 10 N·m 89 lb in
Starter Bolt (4.3L, 4.8L, 5.3L, 6.0L) 50 N·m 37 lb ft
Starter Bolt (6.6L) 78 N·m 58 lb ft
Starter Solenoid Nut (4.3L) 9 N·m 80 lb in
Starter Solenoid Nut (4.8L, 5.3L, 6.0L) 3.4 N·m 30 lb in
Transmission Cover Bolt (4.8L, 5.3L, 6.0L) 9 N·m 80 lb in

ca
rd
ia
gn
.c
om

http://localhost:9001/si/showDoc.do?docSyskey=1953122&pubCellSyskey=37499&pub... 11/18/2010
Document ID: 2086012 Page 1 of 1

2009 Chevrolet Express - AWD | Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical | Specifications |
Document ID: 2086012

Battery Usage
Application Specification
GAS
Cold Cranking Amperage 600 A
Amp Hour Rating 63 AH
Reserve Capacity Rating 110 minutes
Replacement Battery Number 78-6YR
DIESEL
Cold Cranking Amperage 770 A
Amp Hour Rating 63 AH
Reserve Capacity Rating 120 minutes
Replacement Battery Number 78-7YR

ca
rd
ia
gn
.c
om

http://localhost:9001/si/showDoc.do?docSyskey=2086012&pubCellSyskey=37556&pub... 11/18/2010
Document ID: 2086014 Page 1 of 1

2009 Chevrolet Express - AWD | Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical | Specifications |
Document ID: 2086014

Generator Usage
Generator Usage - P4 (K68)
Application GAS Specification
Generator Model P4 (K68)
Rated Output 105 Amps
Load Test Output 85 Amps

Generator Usage - DR44G (K63)

Application GAS Specification
Generator Model DR44G (K63)
Rated Output 145 Amps
Load Test Output 105 Amps

Generator Usage - DR44G

Application DIESEL Specification

ca
Generator Model DR44G

rd
Rated Output 145 Amps

ia
Load Test Output 105 Amps

gn
.c
om

http://localhost:9001/si/showDoc.do?docSyskey=2086014&pubCellSyskey=37509&pub... 11/18/2010
Document ID: 2069921 Page 1 of 3

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2069921

Battery Negative Cable Disconnection and Connection

Removal Procedure
1. Turn OFF all the lamps and accessories.
2. Turn the ignition OFF.

Warning: Refer to Battery Disconnect Warning in the Preface section.

ca
rd
ia
gn
.c
om
3. Remove the battery negative cable bolt in order to disconnect the negative battery cable
from the battery.

http://localhost:9001/si/showDoc.do?docSyskey=2069921&pubCellSyskey=37733&pub... 11/18/2010
Document ID: 2069921 Page 2 of 3

4. If applicable, remove the auxiliary battery negative cable bolt in order to disconnect the
negative battery cable from the auxiliary battery.

Installation Procedure
Warning: Refer to Battery Disconnect Warning in the Preface section.

Caution: Refer to Fastener Caution in the Preface section.

ca
rd
ia
gn
.c
om
Note: Clean any existing corrosion from the battery terminal bolt flange and the battery
cable end.

1. Install the negative cable terminal bolt and cable to the battery and Tighten to 14 N·m
(123 lb in) .

http://localhost:9001/si/showDoc.do?docSyskey=2069921&pubCellSyskey=37733&pub... 11/18/2010
Document ID: 2069921 Page 3 of 3

Important: Clean any existing corrosion from the battery terminal bolt flange and the
battery cable end.

ca
rd
2. If applicable, install the negative cable terminal bolt and cable to the auxiliary battery and
tighten to 14 N·m (123 lb in) .

ia
gn
.c
om

http://localhost:9001/si/showDoc.do?docSyskey=2069921&pubCellSyskey=37733&pub... 11/18/2010
Document ID: 2070681 Page 1 of 2

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2070681

Battery Current Sensor Replacement

Removal Procedure
1. Disconnect the instrument panel (I/P) harness electrical connector (1) from the battery
current sensor.
2. Remove the negative battery cable. Refer to Battery Negative Cable Replacement .

ca
rd
ia
gn
.c
om
3. Cut the tie straps and electrical tape attaching the battery current sensor to the battery
cable.
4. Squeeze the negative battery cable branches together.

Important: Note the position of the battery current sensor prior to removal.

5. Slide the battery current sensor (1) off of the negative battery cable.

Installation Procedure

http://localhost:9001/si/showDoc.do?docSyskey=2070681&pubCellSyskey=139013&pub... 11/18/2010
Document ID: 2070681 Page 2 of 2

Important: Ensure that the tape tab is pointing away from the battery prior to installation.

ca
1. Slide the NEW battery current sensor (1) up onto the negative battery cable.

rd
2. Using NEW tie straps and electrical tape, attach the battery current sensor to the negative
battery cable.

ia
3. Install the negative battery cable. Refer to Battery Negative Cable Replacement .

gn
4. Connect the I/P harness electrical connector (1) to the battery current sensor.

.c
om

http://localhost:9001/si/showDoc.do?docSyskey=2070681&pubCellSyskey=139013&pub... 11/18/2010
Document ID: 2071098 Page 1 of 3

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2071098

Battery Negative Cable Replacement (With LMM

Primary)
Removal Procedure
1. Disconnect the battery negative cable from the battery . Refer to Battery Negative Cable
Disconnection and Connection .

ca
rd
ia
gn
.c
om
2. Disconnect the battery negative cable lead from the inner fender panel.

3. Disconnect the battery negative cable lead from the engine block.

http://localhost:9001/si/showDoc.do?docSyskey=2071098&pubCellSyskey=37760&pub... 11/18/2010
Document ID: 2071098 Page 2 of 3

4. Remove the battery negative cable from the vehicle.

Installation Procedure

ca
rd
ia
1. Install the battery negative cable to the vehicle.

gn
Caution: Refer to Fastener Caution in the Preface section.

.c
om

2. Connect the battery negative cable lead to the engine block and tighten to 25 N·m
(18 lb ft) .

http://localhost:9001/si/showDoc.do?docSyskey=2071098&pubCellSyskey=37760&pub... 11/18/2010
Document ID: 2071098 Page 3 of 3

3. Connect the negative cable lead to the inner fender panel.

Tighten

ca
Tighten the nut that retains the negative cable to the inner fender well to 10 N·m (89 lb in).

rd
4. Connect the negative cable to the battery. Refer to Battery Negative Cable Disconnection and

ia
Connection .

gn
Tighten

.c
Tighten the negative cable terminal bolt to 14 N·m (123 lb in).

om

http://localhost:9001/si/showDoc.do?docSyskey=2071098&pubCellSyskey=37760&pub... 11/18/2010
Document ID: 2071100 Page 1 of 2

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2071100

Battery Negative Cable Replacement (With LMM

Auxiliary)
Removal Procedure

ca
rd
ia
gn
.c
om
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Disconnect the battery negative cable from the auxiliary battery. Refer to Battery Negative
Cable Disconnection and Connection .
3. Disconnect the negative ground leads from the frame.
4. Remove the battery negative cable from the vehicle.

Installation Procedure

http://localhost:9001/si/showDoc.do?docSyskey=2071100&pubCellSyskey=37760&pub... 11/18/2010
Document ID: 2071100 Page 2 of 2

1. Install the battery negative cable to the vehicle.

Caution: Refer to Fastener Caution in the Preface section.

ca
rd
2. Connect the negative ground leads to the frame and tighten to 10 N·m (89 lb in) .
3. Connect the battery negative cable to the auxiliary battery and tighten to 14 N·m

ia
(123 in lb) .

gn
.c
om

http://localhost:9001/si/showDoc.do?docSyskey=2071100&pubCellSyskey=37760&pub... 11/18/2010
Document ID: 2071102 Page 1 of 5

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2071102

Battery Negative Cable Replacement (With LY2, LMF or

LY6)
Removal Procedure
1. On all models, disconnect the battery negative cable from the battery . Refer to Battery
Negative Cable Disconnection and Connection .

ca
rd
ia
gn
.c
om
2. Disconnect the battery negative cable lead from the inner fender panel.

3. On models with 5.3L engine, disconnect the battery negative cable lead from the frame.

http://localhost:9001/si/showDoc.do?docSyskey=2071102&pubCellSyskey=37760&pub... 11/18/2010
Document ID: 2071102 Page 2 of 5

4. On all models, disconnect the battery negative cable lead from the engine block.

ca
rd
ia
gn
.c
om
5. On models with 4.8L and 6.0L engine, disconnect the battery negative cable lead from the
frame.

http://localhost:9001/si/showDoc.do?docSyskey=2071102&pubCellSyskey=37760&pub... 11/18/2010
Document ID: 2071102 Page 3 of 5

6. On all models, remove the battery negative cable from the vehicle.

ca
Installation Procedure

rd
ia
gn
.c
om

1. On all models, install the negative cable to the vehicle.

http://localhost:9001/si/showDoc.do?docSyskey=2071102&pubCellSyskey=37760&pub... 11/18/2010
Document ID: 2071102 Page 4 of 5

2. On models with 4.8L and 6.0L engine, connect the negative cable to the frame.

Caution: Refer to Fastener Caution in the Preface section.

ca
rd
ia
gn
.c
om

3. On all models, connect the negative cable to the engine block and tighten the bolt to 25 N·m
(18 lb ft) .

http://localhost:9001/si/showDoc.do?docSyskey=2071102&pubCellSyskey=37760&pub... 11/18/2010
Document ID: 2071102 Page 5 of 5

4. On models with 5.3L engine, connect the negative cable lead to the frame.

ca
rd
ia
gn
.c
om
5. On all models, connect the negative cable lead to the inner fender panel and tighten the nut
to 10 N·m (89 lb in) .
6. Connect the negative cable to the battery. Refer to Battery Negative Cable Disconnection and
Connection .

http://localhost:9001/si/showDoc.do?docSyskey=2071102&pubCellSyskey=37760&pub... 11/18/2010
Document ID: 2071106 Page 1 of 4

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2071106

Battery Negative Cable Replacement (With LU3 and

RVS)
Removal Procedure

ca
rd
ia
gn
.c
om
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection .
2. Disconnect the battery current sensor (1) harness connector.
3. Remove the negative battery cable ground bolt (2) from the inner fender panel.
4. Remove the negative battery cable ground lead (3) from the inner fender panel.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

http://localhost:9001/si/showDoc.do?docSyskey=2071106&pubCellSyskey=37760&pub... 11/18/2010
Document ID: 2071106 Page 2 of 4

6. Remove the negative battery cable ground lead bolt (2) at the crossmember.
7. Remove the negative battery cable ground (1) from the crossmember.

ca
rd
8. Remove the negative battery cable ground bolt (2) from the engine block.

ia
9. Remove the negative battery cable ground (1) from the block.
10. Lower the vehicle.

gn
11. Remove the negative battery cable from the vehicle.

.c
Installation Procedure

om

http://localhost:9001/si/showDoc.do?docSyskey=2071106&pubCellSyskey=37760&pub... 11/18/2010
Document ID: 2071106 Page 3 of 4

1. Install the negative battery cable to the vehicle.

2. Raise the vehicle.
3. Position the negative cable ground lead (1) to the engine block.

Caution: Refer to Fastener Caution in the Preface section.

4. Install the negative cable ground bolt (2) to the engine block and tighten the bolt to 25 N·m
(18 lb ft) .

ca
rd
ia
gn
5. Install the negative cable ground lead (1) to the crossmember.

.c
6. Install the negative cable ground bolt (2) at the crossmember and tighten to 10 N·m
(89 lb in) .

om

7. Lower the vehicle.

8. Position the negative cable ground (3) to the inner fender panel.

http://localhost:9001/si/showDoc.do?docSyskey=2071106&pubCellSyskey=37760&pub... 11/18/2010
Document ID: 2071106 Page 4 of 4

9. Install the negative cable ground bolt (2) to the inner fender panel and tighten to 14 N·m
(123 lb in) .
10. Connect the battery current sensor (1) harness connector.
11. Connect the negative cable to the battery. Refer to Battery Negative Cable Disconnection and
Connection .

ca
rd
ia
gn
.c
om

http://localhost:9001/si/showDoc.do?docSyskey=2071106&pubCellSyskey=37760&pub... 11/18/2010
Document ID: 2071302 Page 1 of 6

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2071302

Battery Positive Cable Replacement (With LMM

Primary)

Removal Procedure
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection .
2. Disconnect the positive battery cable from the battery.

ca
rd
ia
gn
.c
om
3. Remove the positive cable nut from the junction block and disconnect the cable.

http://localhost:9001/si/showDoc.do?docSyskey=2071302&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071302 Page 2 of 6

4. Remove the positive cable nut from the generator and disconnect the cable .
5. Remove the engine cover. Refer to Engine Cover Replacement .

ca
rd
6. Disconnect the wiring harness clips and the positive cable from the glow plug module.

ia
7. Remove the battery positive cable from the engine harness clip.

gn
.c
om

8. Remove the battery positive cable from the engine harness clips (1).
9. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .

http://localhost:9001/si/showDoc.do?docSyskey=2071302&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071302 Page 3 of 6

10. Remove the battery positive cable bolt (1) and clip (2) from the frame.
11. Remove the battery positive cable retaining clip from the transmission line bracket.

ca
rd
ia
gn
.c
om
12. Remove the positive battery cable nut (7) from the starter and disconnect the cable (8).
13. Remove the positive battery cable.

Installation Procedure
1. Position the positive cable to the vehicle using the same cable routing as in removal.

Caution: Refer to Fastener Caution in the Preface section.

http://localhost:9001/si/showDoc.do?docSyskey=2071302&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071302 Page 4 of 6

2. Position the positive cable (8) to the starter and install the nut (7) and tighten to 10 N·m
(89 lb in) .
3. Install the positive cable retaining clip to the transmission line bracket.

ca
rd
ia
gn
.c
om
4. Install the battery positive cable nut (1) and clip (2) to the frame.
5. Lower the vehicle.

http://localhost:9001/si/showDoc.do?docSyskey=2071302&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071302 Page 5 of 6

6. Install the positive cable to engine harness clips (1).

7. Install the positive cable to the engine harness clip.

ca
rd
ia
gn
.c
om
8. Connect the positive cable to the glow plug module and connect the wiring harness clips.
9. Install the engine cover. Refer to Engine Cover Replacement .

http://localhost:9001/si/showDoc.do?docSyskey=2071302&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071302 Page 6 of 6

10. Install the positive battery cable to the generator and tighten the nut 10 N·m (89 lb in) .

ca
rd
ia
gn
.c
om
11. Install the positive cable to the junction block and tighten the nut to 8 N·m (71 lb in) .
12. Connect the positive cable to the battery and tighten the terminal to 14 N·m (123 lb in) .
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection .

http://localhost:9001/si/showDoc.do?docSyskey=2071302&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071306 Page 1 of 5

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2071306

Battery Positive Cable Replacement (With LMM

Auxiliary)
Removal Procedure
Warning: Refer to Battery Disconnect Warning in the Preface section.

ca
rd
ia
gn
.c
om
1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable
Disconnection and Connection.

http://localhost:9001/si/showDoc.do?docSyskey=2071306&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071306 Page 2 of 5

2. Remove the auxiliary positive battery cable to the frame clips (1).
3. Remove the auxiliary positive battery cable to chassis harness clips (2).

ca
rd
ia
gn
.c
om
4. Remove the auxiliary positive battery cable to frame clips (1).
5. Remove the auxiliary positive battery cable to crossmember clips (2).
6. Remove the auxiliary positive battery cable to frame clip (3).

http://localhost:9001/si/showDoc.do?docSyskey=2071306&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071306 Page 3 of 5

7. Remove the auxiliary positive battery cable nut from the junction block.
8. Disconnect the auxiliary positive battery cable wiring harness clips.
9. Remove the auxiliary positive battery cable from the vehicle.

ca
rd
Installation Procedure

ia
1. Position the auxiliary positive battery cable and connect the wiring harness clips.

gn
.c
Caution: Refer to Fastener Caution in the Preface section.

om

2. Position the auxiliary positive battery cable to the junction block and tighten the cable nut to

http://localhost:9001/si/showDoc.do?docSyskey=2071306&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071306 Page 4 of 5

8 N·m (71 lb in).

ca
rd
ia
gn
.c
om
3. Install the auxiliary positive battery cable to frame clip (3).
4. Install the auxiliary positive battery cable to crossmember clips (2).
5. Install the auxiliary positive battery cable to frame clips (1).

http://localhost:9001/si/showDoc.do?docSyskey=2071306&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071306 Page 5 of 5

6. Install the auxiliary positive battery cable to the chassis harness clips (2).
7. Install the auxiliary positive battery cable to the frame clips (1).

ca
rd
8. Connect the auxiliary positive battery cable to the auxiliary battery and tighten the terminal
to 14 N·m (123 lb in).

ia
9. Connect the auxiliary negative battery cable. Refer to Battery Negative Cable Disconnection

gn
and Connection.

.c
om

http://localhost:9001/si/showDoc.do?docSyskey=2071306&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071327 Page 1 of 8

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2071327

Battery Positive Cable Replacement (With LY2, LME or

LY6)

Removal Procedure

ca
rd
ia
gn
.c
om
1. On all models, remove the bolt retaining the coolant recovery reservoir or surge tank.
2. Position the coolant recovery reservoir or the surge tank aside.
3. Disconnect the battery negative cable from the battery. Refer to Battery Negative Cable
Disconnection and Connection .

http://localhost:9001/si/showDoc.do?docSyskey=2071327&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071327 Page 2 of 8

4. Disconnect the battery positive cable from the battery.

5. On models equipped with the 4.8L, or 6.0L engine, disconnect the positive lead to the
junction block.

ca
rd
ia
6. On models equipped with 4.8L, 5.3L or 6.0L engine, unclip the battery positive cable from the
engine harness clip (1).

gn
7. Unclip the battery positive cable from the engine harness retainer (2).

.c
om

8. On all models, raise the vehicle. Refer to Lifting and Jacking the Vehicle .
9. Disconnect the positive lead at the starter solenoid.

http://localhost:9001/si/showDoc.do?docSyskey=2071327&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071327 Page 3 of 8

10. On models with 4.8L and 6.0L engine, remove the battery positive cable retainer clips (1).
11. Remove the positive cable to the chassis harness clips (2).

ca
rd
ia
gn
.c
om
12. Remove the positive cable retainer clips (1) from the frame.
13. Remove battery positive cable retainer clips (2) from crossmember.

http://localhost:9001/si/showDoc.do?docSyskey=2071327&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071327 Page 4 of 8

14. On all models, lower the vehicle.

15. On models equipped with the 4.8L, 5.3L or 6.0L engine, unclip the battery positive cable from
the fan shroud.

ca
rd
ia
gn
.c
om
16. On all models, disconnect the positive lead to the generator.
17. Remove the positive cable from the vehicle. Note the location of the retaining clips.

Installation Procedure

http://localhost:9001/si/showDoc.do?docSyskey=2071327&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071327 Page 5 of 8

1. On all models, install the positive cable to the vehicle.

Ensure the cable is routed correctly and installed in the retainer clips.

ca
rd
Caution: Refer to Fastener Caution in the Preface section.

ia
2. Connect the positive lead to the generatoroutput (BAT) terminal and tighten the nut to

gn
10 N·m (89 lb in) .

.c
om

3. On models equipped with the 4.8L, 5.3L or 6.0L engine, clip the positive cable to the fan
shroud.
4. On all models, raise the vehicle. Refer to Lifting and Jacking the Vehicle .

http://localhost:9001/si/showDoc.do?docSyskey=2071327&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071327 Page 6 of 8

5. On models with 4.8L and 6.0L engine, install the positive cable retainer clips (2) to the
crossmember.
6. Install the positive cable retainer clips (1) to the frame.

ca
rd
ia
gn
.c
om
7. Install the positive cable to the chassis harness clips (2).
8. Install the positive cable retainer clips (1).

http://localhost:9001/si/showDoc.do?docSyskey=2071327&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071327 Page 7 of 8

9. Install the positive lead to the starter solenoid and tighten the nut to 10 N·m (89 lb in) .
10. On all models, lower the vehicle.

ca
rd
ia
gn
.c
om
11. On models equipped with 4.8L, 5.3L or 6.0L engine, clip battery positive cable to the engine
harness retainer (2).
12. Clip the positive cable to the engine harness clip (1).

http://localhost:9001/si/showDoc.do?docSyskey=2071327&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071327 Page 8 of 8

13. On models equipped with the 4.8L, or 6.0L engine, install the positive lead to the junction
block and tighten the nut to 10 N·m (89 lb in) .
14. On all models, connect the battery positive cable to the battery and tighten to 14 N·m

ca
(123 lb in) .
15. Connect the battery negative cable to the battery. Refer to Battery Negative Cable

rd
Disconnection and Connection .

ia
gn
.c
om

16. Install the coolant recovery reservoir or surge tank and tighten the bolt to 11 N·m
(97 lb in) .

http://localhost:9001/si/showDoc.do?docSyskey=2071327&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071337 Page 1 of 4

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2071337

Battery Positive Cable Replacement (With LU3)

Removal Procedure
1. Unbolt and reposition the coolant recovery reservoir. Refer to Coolant Recovery Reservoir
Replacement .
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection .

ca
rd
ia
gn
.c
om
3. Loosen the positive battery cable bolt (4) in order to disconnect the positive battery cable (3)
from the battery.
4. Remove the nut (2) retaining the positive battery cable (1) to the junction block.
5. Remove the positive battery cable clip (5) from the battery tray.
6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

http://localhost:9001/si/showDoc.do?docSyskey=2071337&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071337 Page 2 of 4

7. Remove the positive battery cable retainer (2) to frame bolt (1).

ca
8. Remove the battery terminal nut (3) on the starter solenoid (1).

rd
9. Remove the positive battery cable (2) from the starter solenoid.

ia
10. Lower the vehicle.

gn
.c
om

11. Reposition the positive battery cable boot (2) at the generator.
12. Remove the generator nut (3).
13. Remove the positive battery cable (1) from the generator.
14. Remove the positive battery cable from the vehicle.

Installation Procedure

http://localhost:9001/si/showDoc.do?docSyskey=2071337&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071337 Page 3 of 4

1. Install the positive battery cable to the vehicle.

2. Install the positive cable (1) to the generator.

ca
Caution: Refer to Fastener Caution in the Preface section.

rd
3. Install the generator nut (3) and tighten to 10 N·m (89 lb in) .

ia
4. Position the positive cable boot (2) at the generator.

gn
5. Raise and support the vehicle.
6. Install the positive cable (2) to the starter solenoid battery terminal (1).

.c
om

7. Install the battery terminal nut (3) onto the starter solenoid battery terminal (1) and tighten
to 10 N·m (89 lb in).

http://localhost:9001/si/showDoc.do?docSyskey=2071337&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071337 Page 4 of 4

8. Install the positive cable retainer (2) to frame bolt (1) and tighten to 13 N·m (115 lb in) .
9. Lower the vehicle.

ca
rd
ia
gn
.c
om
10. Install the positive battery cable (1) to the junction block and tighten to 13 N·m
(115 lb in) .
11. Install the positive battery cable clip (5) from the battery tray.
12. Install the positive battery cable to the battery and tighten the bolt to 14 N·m (123 lb in) .
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection .
14. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement .

http://localhost:9001/si/showDoc.do?docSyskey=2071337&pubCellSyskey=37759&pub... 11/18/2010
Document ID: 2071388 Page 1 of 3

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2071388

Battery Positive Cable Extension Cable Junction Block

Replacement
Removal Procedure
1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable
Disconnection and Connection .

ca
rd
ia
gn
.c
om
2. Remove the positive extension cable nut from the junction block and disconnect the cable.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
4. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.

http://localhost:9001/si/showDoc.do?docSyskey=2071388&pubCellSyskey=146470&pub... 11/18/2010
Document ID: 2071388 Page 2 of 3

5. Remove the positive extension cable nut from the intake air heater and disconnect the cable.
6. Disconnect the wiring harness clips.
7. Remove the battery positive cover from the underhood bused electrical center (UBEC).
8. Remove the positive extension cable nut from the UBEC terminal stud.
9. Remove the positive extension cable.

Installation Procedure
1. Position the positive extension cable and connect the wiring harness clips.

Caution: Refer to Fastener Caution in the Preface section.

ca
rd
ia
gn
.c
om
2. Position the positive extension cable to the UBEC terminal stud and tighten the nut to 9 N·m
(80 lb in) .
3. Install the battery positive cover to the UBEC.

http://localhost:9001/si/showDoc.do?docSyskey=2071388&pubCellSyskey=146470&pub... 11/18/2010
Document ID: 2071388 Page 3 of 3

4. Position the positive extension cable to the intake air heater and tighten the nut to 4 N·m
(34 lb in) .

ca
Tighten

rd
Tighten the positive extension cable to intake air heater nut.

ia
5. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .

gn
6. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .

.c
om

7. Position the positive extension cable to the junction block and tighten the cable nut to 8 N·m
(71 lb in) .
8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection .

http://localhost:9001/si/showDoc.do?docSyskey=2071388&pubCellSyskey=146470&pub... 11/18/2010
Document ID: 2128064 Page 1 of 3

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2128064

Battery Replacement (Primary)

Removal Procedure
Warning: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply
levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of
personal injury while working near a battery, observe the following guidelines:
• Always shield your eyes.
• Avoid leaning over the battery whenever possible.
• Do not expose the battery to open flames or sparks.
• Do not allow battery acid to contact the eyes or the skin.
- Flush any contacted areas with water immediately and thoroughly.
- Get medical help.

1. Remove the fender brace.

ca
rd
ia
gn
.c
2. Disconnect the battery negative cable from the negative battery terminal. Refer to Battery
om
Negative Cable Disconnection and Connection.
3. Disconnect the battery positive cable from the positive battery terminal. Refer to Battery
Positive Cable Replacement.

http://localhost:9001/si/showDoc.do?docSyskey=2128064&pubCellSyskey=37462&pub... 11/18/2010
Document ID: 2128064 Page 2 of 3

4. Remove the battery hold-down retainer bolt and retainer.

5. Remove the battery from the vehicle.
6. Inspect the battery for:

ca
• Damage

rd
• Worn or corroded cables and connectors

ia
• Damage or foreign objects in the battery carrier

gn
7. If damage is noted, find and correct the cause.
8. Clean any corrosion form the battery cables and connectors.

.c
9. Clean the battery tray and remove any foreign objects from the tray.

om
Installation Procedure

http://localhost:9001/si/showDoc.do?docSyskey=2128064&pubCellSyskey=37462&pub... 11/18/2010
Document ID: 2128064 Page 3 of 3

1. Install the battery into the battery tray.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the battery hold-down retainer and bolt and tighten to 18 N·m (12 lb ft).

ca
rd
ia
gn
3. Connect the battery positive cable and the positive battery cable terminal to the battery.

.c
Refer to Battery Positive Cable Replacement.
4. Connect the battery negative cable and the negative battery cable terminal to the battery.

om
Refer to Battery Negative Cable Disconnection and Connection.
5. Install the fender brace.

http://localhost:9001/si/showDoc.do?docSyskey=2128064&pubCellSyskey=37462&pub... 11/18/2010
Document ID: 2128065 Page 1 of 4

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2128065

Battery Tray Replacement (Primary)

Removal Procedure
1. Remove the coolant recovery reservoir bolt and reposition the reservoir.

ca
rd
ia
gn
2. Disconnect the battery negative cable from the battery negative terminal. Refer to Battery

.c
Negative Cable Disconnection and Connection.

om
3. Disconnect the battery positive cable from the battery positive terminal. Refer to Battery
Positive Cable Replacement.
4. Remove the battery limiter from the vehicle if equipped.
5. Remove the fender brace.

http://localhost:9001/si/showDoc.do?docSyskey=2128065&pubCellSyskey=37692&pub... 11/18/2010
Document ID: 2128065 Page 2 of 4

6. Remove the battery hold-down bolt and retainer.

7. Remove the battery.

ca
rd
8. Remove the battery tray bolts.

ia
9. Disconnect the vacuum hoses.
10. Disconnect the vacuum pump electrical connector.

gn
11. Remove the battery tray from the vehicle.

.c
Installation Procedure

om

http://localhost:9001/si/showDoc.do?docSyskey=2128065&pubCellSyskey=37692&pub... 11/18/2010
Document ID: 2128065 Page 3 of 4

1. Install the battery tray to the vehicle.

2. Connect the vacuum pump hoses and electrical connector.

Caution: Refer to Fastener Caution in the Preface section.

3. Install the battery tray bolts and tighten to 9 N·m (80 lb in).

ca
rd
ia
4. Install the battery.

gn
5. Install the battery hold-down retainer and bolt and tighten to 18 N·m (12 lb ft).
6. Install the fender brace.

.c
7. Install the battery limiter to the vehicle if equipped.

om

8. Install the positive battery cable to the battery and tighten to 17 N·m (13 lb ft).
9. Install the battery negative cable to the battery. Refer to Battery Negative Cable
Disconnection and Connection.

http://localhost:9001/si/showDoc.do?docSyskey=2128065&pubCellSyskey=37692&pub... 11/18/2010
Document ID: 2128065 Page 4 of 4

Tighten the terminal bolt to 17 N·m (13 lb ft).

10. Install the coolant recovery reservoir and tighten to 11 N·m (97 lb in).

ca
rd
ia
gn
.c
om

http://localhost:9001/si/showDoc.do?docSyskey=2128065&pubCellSyskey=37692&pub... 11/18/2010
Document ID: 2069922 Page 1 of 3

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2069922

Auxiliary Battery and Tray Replacement

Removal Procedure
1. Disconnect the primary battery and the auxiliary battery negative cables. Refer to Battery
Negative Cable Disconnection and Connection
2. Disconnect the auxiliary battery positive cable from the auxiliary battery.

ca
rd
ia
gn
.c
om
3. Remove the lower auxiliary battery tray to frame bolts (3).
4. Loosen, but DO NOT REMOVE the upper battery tray to frame bolts (1).
5. Lift the battery and tray assembly (2) from the upper frame bolts (1).

http://localhost:9001/si/showDoc.do?docSyskey=2069922&pubCellSyskey=171528&pub... 11/18/2010
Document ID: 2069922 Page 2 of 3

6. Remove the battery retainer bolt and retainer (3).

7. Remove the battery (1) from the battery tray (2).

Installation Procedure

ca
rd
ia
1. Install the battery (1) into the battery tray (2).

gn
.c
Warning: Refer to Fastener Caution in the Preface section.

om
2. Install the battery bolt and retainer (3) and tighten to 18 N·m (12 lb ft) .

3. Lift the battery and tray assembly (2) onto the upper auxiliary battery tray bolts (1). Do not

http://localhost:9001/si/showDoc.do?docSyskey=2069922&pubCellSyskey=171528&pub... 11/18/2010
Document ID: 2069922 Page 3 of 3

tighten the upper bolts at this time.

4. Install the lower battery tray bolts (3) and tighten to 25 N·m (18 lb ft) .
5. Connect the positive battery cable to the auxiliary battery and tighten the bolt to 14 N·m
(123 lb in) .
6. Connect the negative battery cable to the auxiliary battery and to the primary battery. Refer
to Battery Negative Cable Disconnection and Connection .

ca
rd
ia
gn
.c
om

http://localhost:9001/si/showDoc.do?docSyskey=2069922&pubCellSyskey=171528&pub... 11/18/2010
Document ID: 2128066 Page 1 of 3

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2128066

Engine Ground Strap Replacement

Removal Procedure

ca
rd
ia
gn
1. Remove the engine cover. Refer to Engine Cover Replacement.

.c
om
Remove the engine wiring harness ground bolt.

2. Reposition the engine wiring harness ground and ground strap.

http://localhost:9001/si/showDoc.do?docSyskey=2128066&pubCellSyskey=37696&pub... 11/18/2010
Document ID: 2128066 Page 2 of 3

3. Remove the ground strap nut from the stud at the front of dash.
4. Remove the ground strap from the stud.

Installation Procedure

ca
rd
ia
gn
.c
1. Install the ground strap to the stud.

om
Caution: Refer to Fastener Caution in the Preface section.

2. Install the ground strap nut to the stud at the front of dash and tighten to 9 N·m (80 lb in).

http://localhost:9001/si/showDoc.do?docSyskey=2128066&pubCellSyskey=37696&pub... 11/18/2010
Document ID: 2128066 Page 3 of 3

3. Position the ground strap and engine wiring harness ground.

4. Install the engine wiring harness ground bolt and tighten to 16 N·m (12 lb ft).
5. Install the engine cover. Refer to Engine Cover Replacement.

ca
rd
ia
gn
.c
om

http://localhost:9001/si/showDoc.do?docSyskey=2128066&pubCellSyskey=37696&pub... 11/18/2010
Document ID: 2128288 Page 1 of 5

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2128288

Starter Replacement (4.8L/5.3L/6.0L)

Removal Procedure
Warning: Refer to Battery Disconnect Warning in the Preface section.

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection.
2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.

ca
rd
ia
gn
.c
om
3. Remove the right transmission cover bolt, if equipped.
4. Disconnect the oil level sensor electrical connector.

http://localhost:9001/si/showDoc.do?docSyskey=2128288&pubCellSyskey=37552&pub... 11/18/2010
Document ID: 2128288 Page 2 of 5

5. Remove the starter bolts.

6. Slide the starter forward until the starter clears the transmission.

ca
rd
7. Remove the starter solenoid nut.

ia
8. Remove the starter lead from the solenoid stud.
9. Remove the starter lead nut.

gn
10. Remove the positive cable from the starter stud.
11. Place the starter on a workbench.

.c
om

12. Unsnap the transmission cover from the starter, if equipped.

http://localhost:9001/si/showDoc.do?docSyskey=2128288&pubCellSyskey=37552&pub... 11/18/2010
Document ID: 2128288 Page 3 of 5

13. If necessary, remove the starter shield.

ca
Installation Procedure

rd
ia
gn
.c
om

1. If necessary, install the starter shield.

http://localhost:9001/si/showDoc.do?docSyskey=2128288&pubCellSyskey=37552&pub... 11/18/2010
Document ID: 2128288 Page 4 of 5

2. Snap the transmission cover to the starter, if equipped.

Caution: Refer to Fastener Caution in the Preface section.

ca
rd
ia
gn
.c
om

3. Install the positive cable to the starter stud.

4. Install the starter lead nut and tighten to 10 N·m (89 lb in)..
5. Install the starter solenoid lead to the solenoid stud.
6. Install the starter solenoid nut and tighten to 3.4 N·m (30 lb in).

http://localhost:9001/si/showDoc.do?docSyskey=2128288&pubCellSyskey=37552&pub... 11/18/2010
Document ID: 2128288 Page 5 of 5

7. Slide the starter rearward.

8. Install the starter bolts and tighten to 50 N·m (37 lb ft).

ca
rd
ia
gn
.c
om
9. Install the right transmission cover bolt, if equipped and tighten to 9 N·m (80 lb in).
10. Connect the oil level sensor electrical connector.
11. Lower the vehicle.
12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection.

http://localhost:9001/si/showDoc.do?docSyskey=2128288&pubCellSyskey=37552&pub... 11/18/2010
Document ID: 2128289 Page 1 of 3

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2128289

Starter Replacement (6.6L)

Removal Procedure
Warning: Refer to Battery Disconnect Warning in the Preface section.

ca
rd
ia
gn
.c
om
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection.
2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
3. Remove the engine wiring harness nut (4).
4. Remove the engine wiring harness lead (1) from the starter.

http://localhost:9001/si/showDoc.do?docSyskey=2128289&pubCellSyskey=37552&pub... 11/18/2010
Document ID: 2128289 Page 2 of 3

5. Remove the positive battery cable nut (7).

6. Remove the positive battery cable lead (8) from the starter.

ca
rd
7. Remove the starter motor bolts.

ia
8. Remove the starter motor.

gn
Installation Procedure

.c
om

1. Install the starter motor.

http://localhost:9001/si/showDoc.do?docSyskey=2128289&pubCellSyskey=37552&pub... 11/18/2010
Document ID: 2128289 Page 3 of 3

Warning: Refer to Fastener Caution in the Preface section.

2. Install the starter motor bolts and tighten to 78 N·m (58 lb ft).

ca
3. Install the positive battery cable lead (8) to the starter.

rd
4. Install the positive battery cable nut (7) and tighten to 9 N·m (80 lb in).

ia
gn
.c
om

5. Install the engine wiring harness lead (1) to the starter.

6. Install the engine wiring harness nut (4) and tighten to 3.4 N·m (30 lb in).
7. Lower the vehicle.
8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection.

http://localhost:9001/si/showDoc.do?docSyskey=2128289&pubCellSyskey=37552&pub... 11/18/2010
Document ID: 2134828 Page 1 of 2

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2134828

Starter Replacement (V6)

ca
rd
ia
gn
.c
om
Callout Component Name

Preliminary Procedures
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection
and Connection
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle
Battery Terminal Nut

Caution: Refer to Fastener Caution in the Preface section.

1

Tighten
9 N·m (80 lb in)
Starter Bolt (Qty: 2)
2
Tighten
50 N·m (37 lb ft)

Starter

Procedure

http://localhost:9001/si/showDoc.do?docSyskey=2134828&pubCellSyskey=37552&pub... 11/18/2010
Document ID: 2134828 Page 2 of 2

• Disconnect the S terminal harness connector from the starter.

Note: Orient the B+ terminal Harness anti rotation tab to the starter
orientation slot.

3 • Remove the B+ terminal harness from the starter.

Note: The starter motor bracked shield snaps into place on the starter
solenoid.

• Remove the starter motor bracket shield from the starter.

ca
rd
ia
gn
.c
om

http://localhost:9001/si/showDoc.do?docSyskey=2134828&pubCellSyskey=37552&pub... 11/18/2010
Document ID: 2128294 Page 1 of 2

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2128294

Generator Bracket Replacement (4.8L/5.3L/6.0L)

Removal Procedure

ca
rd
ia
gn
1. Remove the generator. Refer to Generator Replacement.

.c
2. Remove the power steering pump. Refer to Power Steering Pump Replacement.

om
3. Remove the generator bracket bolts.
4. Remove the generator bracket.

Installation Procedure
Warning: Refer to Fastener Caution in the Preface section.

http://localhost:9001/si/showDoc.do?docSyskey=2128294&pubCellSyskey=37625&pub... 11/18/2010
Document ID: 2128294 Page 2 of 2

1. Install the generator bracket.

2. Install the generator bracket bolts and tighten to 50 N·m (37 lb ft).
3. Install the power steering pump. Refer to Power Steering Pump Replacement.

ca
4. Install the generator. Refer to Generator Replacement.

rd
ia
gn
.c
om

http://localhost:9001/si/showDoc.do?docSyskey=2128294&pubCellSyskey=37625&pub... 11/18/2010
Document ID: 2128295 Page 1 of 7

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2128295

Generator Bracket Replacement (6.6L)

Removal Procedure
Warning: Refer to Battery Disconnect Warning in the Preface section.

1. Remove the cooling fan. Refer to Fan Replacement.

2. Remove the drive belt. Refer to Drive Belt Replacement.
3. Disconnect the generator electrical connector.

ca
rd
ia
gn
.c
om
4. Remove the generator bolts (1).
5. Remove the generator (2).
6. Remove the positive battery cable from the generator, perform the following:
6.1. Slide the boot down to access the terminal stud.
6.2. Remove the positive cable nut.
6.3. Remove the positive cable.
7. Disconnect the right engine wiring main harness connector.

http://localhost:9001/si/showDoc.do?docSyskey=2128295&pubCellSyskey=37625&pub... 11/18/2010
Document ID: 2128295 Page 2 of 7

8. Remove the 2 right engine wiring harness bracket bolts and position aside.

ca
rd
ia
gn
.c
om
9. Remove the 2 wiring harness routing bolts.

http://localhost:9001/si/showDoc.do?docSyskey=2128295&pubCellSyskey=37625&pub... 11/18/2010
Document ID: 2128295 Page 3 of 7

10. Remove the oil indicator tube bracket bolt.

ca
rd
ia
gn
.c
om
11. Remove the drive belt tensioner bolt and tensioner.

http://localhost:9001/si/showDoc.do?docSyskey=2128295&pubCellSyskey=37625&pub... 11/18/2010
Document ID: 2128295 Page 4 of 7

12. Remove the bolts and nut and the generator mounting bracket.
13. Transfer any parts as needed.

ca
Installation Procedure

rd
ia
Caution: Refer to Fastener Caution in the Preface section.

gn
.c
om

1. Position the generator mounting bracket and install the bolts and tighten to 50 N·m
(37 lb ft).

http://localhost:9001/si/showDoc.do?docSyskey=2128295&pubCellSyskey=37625&pub... 11/18/2010
Document ID: 2128295 Page 5 of 7

2. Position the drive belt tensioner and install the bolt and tighten to 50 N·m (37 lb ft).

ca
rd
ia
gn
.c
om
3. Install the oil indicator tube bracket bolt and tighten to 21 N·m (15 lb ft).

http://localhost:9001/si/showDoc.do?docSyskey=2128295&pubCellSyskey=37625&pub... 11/18/2010
Document ID: 2128295 Page 6 of 7

4. Install the 2 wiring harness routing bolts and tighten to 10 N·m (89 lb in).

ca
rd
ia
gn
.c
om
5. Position the right engine wiring harness bracket and install the 2 bolts and tighten to 10 N·m
(89 lb in).
6. Connect the right engine wiring harness connector.
7. Install the positive cable to the auxiliary generator, perform the following:
7.1. Install the positive cable.
7.2. Install the positive cable nut and tighten to 9 N·m (80 lb in).
7.3. Slide the boot to cover the terminal stud.

http://localhost:9001/si/showDoc.do?docSyskey=2128295&pubCellSyskey=37625&pub... 11/18/2010
Document ID: 2128295 Page 7 of 7

8. Position the generator.

9. Install the generator bolts (1) and tighten to 50 N·m (37 lb ft).
10. Connect the generator electrical connector.

ca
11. Install the drive belt. Refer to Drive Belt Replacement.
12. Install the cooling fan. Refer to Fan Replacement.

rd
ia
gn
.c
om

http://localhost:9001/si/showDoc.do?docSyskey=2128295&pubCellSyskey=37625&pub... 11/18/2010
Document ID: 2128322 Page 1 of 2

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2128322

Generator Bracket Replacement (4.3L)

Removal Procedure

ca
rd
ia
gn
1. Remove the generator. Refer to Generator Replacement.

.c
2. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.

om
3. Remove the generator bracket bolts and nut.
4. Remove the generator bracket.

Installation Procedure
Caution: Refer to Fastener Caution in the Preface section.

http://localhost:9001/si/showDoc.do?docSyskey=2128322&pubCellSyskey=37625&pub... 11/18/2010
Document ID: 2128322 Page 2 of 2

1. Install the generator bracket.

2. Install the generator bracket bolts and nut and tighten to 41 N·m (30 lb ft).
3. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.

ca
4. Install the generator. Refer to Generator Replacement.

rd
ia
gn
.c
om

http://localhost:9001/si/showDoc.do?docSyskey=2128322&pubCellSyskey=37625&pub... 11/18/2010
Document ID: 2128300 Page 1 of 4

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2128300

Auxiliary Generator Bracket Replacement

Removal Procedure
Warning: Refer to Battery Disconnect Warning in the Preface section.

1. Remove the fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement.
2. Disconnect the auxiliary generator electrical connector.
3. Remove the drive belt. Refer to Drive Belt Replacement.

ca
rd
ia
gn
.c
om
4. Remove the positive battery cable from the auxiliary generator, perform the following:
4.1. Slide the boot (4) down to access the terminal stud.
4.2. Remove the positive cable nut (1).
4.3. Remove the positive cable.

http://localhost:9001/si/showDoc.do?docSyskey=2128300&pubCellSyskey=37727&pub... 11/18/2010
Document ID: 2128300 Page 2 of 4

5. Remove the auxiliary generator bolts (3).

6. Remove the auxiliary generator (4).

ca
rd
ia
gn
.c
om
7. Remove the auxiliary generator bracket bolts.
8. Remove the auxiliary generator bracket.

Installation Procedure

http://localhost:9001/si/showDoc.do?docSyskey=2128300&pubCellSyskey=37727&pub... 11/18/2010
Document ID: 2128300 Page 3 of 4

1. Install the auxiliary generator bracket.

Caution: Refer to Fastener Caution in the Preface section.

ca
rd
2. Install the auxiliary generator bracket bolts and tighten to 50 N·m (37 lb ft).

ia
gn
.c
om

3. Install the auxiliary generator (4).

4. Install the auxiliary generator bolts (3) and tighten to 50 N·m (37 lb ft).

http://localhost:9001/si/showDoc.do?docSyskey=2128300&pubCellSyskey=37727&pub... 11/18/2010
Document ID: 2128300 Page 4 of 4

5. Install the positive cable to the auxiliary generator, perform the following:
5.1. Install the positive cable.

ca
5.2. Install the positive cable nut (1) and tighten to 9 N·m (80 lb in).
5.3. Slide the boot (4) up to cover the terminal stud.

rd
6. Install the drive belt. Refer to Drive Belt Replacement.

ia
7. Connect the auxiliary generator electrical connector (3).

gn
8. Install the radiator fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement.

.c
om

http://localhost:9001/si/showDoc.do?docSyskey=2128300&pubCellSyskey=37727&pub... 11/18/2010
Document ID: 2069923 Page 1 of 5

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2069923

Generator Replacement (With LU3)

Removal Procedure

ca
rd
ia
gn
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and

.c
Connection.

om
2. Remove the drive belt. Refer to Drive Belt Replacement.
3. Unbolt and reposition the oil level indicator tube. Refer to Oil Level Indicator and Tube
Replacement.
4. Unbolt and reposition the oil fill tube. Refer to Oil Filler Tube Replacement.
5. Disconnect the engine wiring harness electrical connector (1) from the generator.
6. Remove the oil fill tube bracket stud (2).
7. Reposition the engine wiring harness clip.

http://localhost:9001/si/showDoc.do?docSyskey=2069923&pubCellSyskey=37565&pub... 11/18/2010
Document ID: 2069923 Page 2 of 5

8. Reposition the positive battery cable boot (2) at the generator.

9. Remove the generator nut (3).
10. Remove the positive battery cable (1) from the generator.

ca
rd
ia
gn
.c
om
11. Remove the oil fill tube bracket bolt (2) and bracket (1).

http://localhost:9001/si/showDoc.do?docSyskey=2069923&pubCellSyskey=37565&pub... 11/18/2010
Document ID: 2069923 Page 3 of 5

12. Remove the generator bolts (2) and generator (1).

ca
Installation Procedure

rd
Caution: Refer to Fastener Caution in the Preface section.

ia
gn
.c
om

1. Install the generator (1) and bolts (2) and tighten to 50 N·m (37 lb ft).

http://localhost:9001/si/showDoc.do?docSyskey=2069923&pubCellSyskey=37565&pub... 11/18/2010
Document ID: 2069923 Page 4 of 5

2. Install the oil fill tube bracket (1) and bolt (2) and tighten to 25 N·m (18 lb ft).

ca
rd
ia
gn
.c
om
3. Install the positive cable (1) to the generator.
4. Install the generator nut (3) and tighten to 10 N·m (89 lb in).
5. Position the positive cable boot (2) at the generator.

http://localhost:9001/si/showDoc.do?docSyskey=2069923&pubCellSyskey=37565&pub... 11/18/2010
Document ID: 2069923 Page 5 of 5

6. Position the engine wiring harness clip to the generator bracket.

7. Install the oil fill tube bracket stud (2) and tighten to 25 N·m (18 lb ft).
8. Connect the engine wiring harness electrical connector (1) to the generator.

ca
9. Position and install the oil fill tube. Refer to Oil Filler Tube Replacement.
10. Position and install the oil level indicator tube. Refer to Oil Level Indicator and Tube

rd
Replacement.

ia
11. Install the drive belt. Refer to Drive Belt Replacement.
12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and

gn
Connection.

.c
om

http://localhost:9001/si/showDoc.do?docSyskey=2069923&pubCellSyskey=37565&pub... 11/18/2010
Document ID: 2069927 Page 1 of 3

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2069927

Generator Replacement (WithLY2, LMF and LY6)

Removal Procedure

ca
rd
ia
gn
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and

.c
Connection.

om
2. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory.
3. Disconnect the generator electrical connector (3).

4. Remove the generator

© cable from the
2010 General generator,
Motors perform
Corporation. All rightsthe following:
reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2069927&pubCellSyskey=37565&pub... 11/18/2010
Document ID: 2069927 Page 2 of 3

4.1. Slide the boot down revealing the terminal stud.

4.2. Remove the generator cable nut from the terminal stud.
4.3. Remove the generator cable.

ca
rd
5. Remove the generator bolts.

ia
6. Remove the generator from the bracket.

gn
Installation Procedure

.c
om

1. Install the generator to the bracket.

http://localhost:9001/si/showDoc.do?docSyskey=2069927&pubCellSyskey=37565&pub... 11/18/2010
Document ID: 2069927 Page 3 of 3

Caution: Refer to Fastener Caution in the Preface section.

2. Install the generator bolts and tighten to 50 N·m (37 lb ft).

ca
3. Install the generator cable to the generator, perform the following:

rd
3.1. Install the generator cable.

ia
3.2. Install the generator cable nut to the terminal stud and tighten to 10 N·m (89 lb in).

gn
3.3. Slide the boot over the terminal stud.

.c
om

4. Connect the generator electrical connector (3).

5. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory.
6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection.

http://localhost:9001/si/showDoc.do?docSyskey=2069927&pubCellSyskey=37565&pub... 11/18/2010
Document ID: 2069935 Page 1 of 2

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2069935

Generator Replacement (With LMM)

Removal Procedure
1. Disconnect the negative battery. Refer to Battery Negative Cable Disconnection and
Connection.
2. Remove the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement.
3. Remove the drive belt. Refer to Drive Belt Replacement.

ca
rd
ia
gn
.c
om
4. Remove the generator bolts (1).
5. Remove the generator front support bracket attached to the generator bracket and the
generator.
6. Reposition the generator to access wiring.
7. Remove the positive battery cable nut from the generator.
8. Disconnect the generator electrical connector.
9. Remove the generator (2).

Installation Procedure

http://localhost:9001/si/showDoc.do?docSyskey=2069935&pubCellSyskey=37565&pub... 11/18/2010
Document ID: 2069935 Page 2 of 2

1. Install the generator (2) to the generator bracket.

2. Connect the generator electrical connector.
3. Install the positive battery cable to the generator stud.

ca
rd
Caution: Refer to Fastener Caution in the Preface section.

ia
4. Install the cable nut to the generator stud and tighten to 10 N·m (89 lb in).

gn
5. Install the generator bolts (1) and tighten to 50 N·m (37 lb ft).
6. Install the generator front support bracket and attach it to the generator and the generator

.c
bracket.
7. Install the drive belt. Refer to Drive Belt Replacement.

om
8. Install the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement.

http://localhost:9001/si/showDoc.do?docSyskey=2069935&pubCellSyskey=37565&pub... 11/18/2010
Document ID: 2128349 Page 1 of 2

2009 Chevrolet Express - AWD| Express, Savana (VIN G/H) Service Manual | Engine | Engine Electrical |
Repair Instructions | Document ID: 2128349

Auxiliary Generator Replacement

Removal Procedure
Warning: Refer to Battery Disconnect Warning in the Preface section.

1. Remove the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement.
2. Remove the drive belt. Refer to Drive Belt Replacement.
3. Disconnect the auxiliary generator electrical connector.
4. Remove the positive cable from the auxiliary generator, perform the following:
4.1. Slide the boot down to access the terminal stud.
4.2. Remove the positive cable nut.
4.3. Remove the positive cable.

ca
rd
ia
gn
.c
5. Remove the auxiliary generator bolts (3).
6. Remove the auxiliary generator (4). om
Installation Procedure
Caution: Refer to Fastener Caution in the Preface section.

http://localhost:9001/si/showDoc.do?docSyskey=2128349&pubCellSyskey=37726&pub... 11/18/2010
Document ID: 2128349 Page 2 of 2

1. Position the auxiliary generator (4).

2. Install the auxiliary generator bolts (3) and tighten to 50 N·m (37 lb ft).
3. Install the positive cable to the auxiliary generator, perform the following:

ca
3.1. Position the positive cable.

rd
3.2. Install the positive cable nut and tighten to 10 N·m (89 lb in).

ia
3.3. Slide the boot to cover the terminal stud.

gn
4. Connect the generator electrical connector.
5. Install the drive belt. Refer to Drive Belt Replacement.

.c
6. Install the upper shroud. Refer to Engine Coolant Fan Upper Shroud Replacement.

om

http://localhost:9001/si/showDoc.do?docSyskey=2128349&pubCellSyskey=37726&pub... 11/18/2010