Outline of Alternator replacement procedure for a '04 4.2L
 

Hello all,


I'd like to post up a concise outline on the alternator replacement procedure for a '04 Rainier :) GM calls the alternator a generator but it's essentially the same part filling the same function.



1) Disconnect the negative battery cable.

2) Remove the accessory belt.

3) Disconnect the positive battery cable nut from the alternator.

4) Remove the A/C line mounting bracket bolt at the engine lift hook.

5) Remove the right engine lift hook bolts.

6) Remove the engine lift hook.

7) Remove the mounting bolts.

8) Remove the alternator.


--Installation--


1) Install the alternator and loosely install the mounting bolts.

2) Tighten the alternator mounting bolts to 37 ft. lbs. (50 Nm)

3) Connect the positive battery cable and secure with the nut; tighten the nut to 80 inch lbs. (9 Nm)

4) Install the engine lift hook and bolts; tighten the bolts to 37 ft. lbs. (50 Nm)

5) Install the A/C line bracket to the lift hook, then tighten the retaining bolt to 89 inch lbs. (10 Nm)

6) Install the accessory belt.

7) Connect the negative battery cable.


http://www.gmpartseast.com/diagrams/...-ts0220301.png
*diagram courtesy of gmpartsgiant.com; all rights reserved