Starter Generator Replacement

Starter Generator Replacement

Special Tools

EN-48932 - Hydraulic Belt Tensioner Compressor

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Removal Procedure

Danger: Ensure all High Voltage safety procedures are followed. Failure to follow the procedure exactly as written may result in serious injury or death.


Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.


The High Voltage Disabling procedure will perform the following tasks:


* Identify how to disable high voltage.

* Identify how to test for the presence of high voltage.

* Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.


Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:


* Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

* Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.


- Visually and functionally inspect the gloves before use.

- Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.


Failure to follow the procedures exactly as written may result in serious injury or death.


1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716).
2. Disable the high voltage System. Refer to High Voltage Disabling High Voltage Disabling.
3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement Service and Repair.
4. Reposition the secondary air injection pump inlet hose. Refer to Secondary Air Injection Pump Inlet Hose Replacement Secondary Air Injection Pump Inlet Hose Replacement.




5. Remove the radiator inlet hose bracket bolt (1) and the radiator inlet hose clamp (2).
6. Reposition the radiator inlet hose (3).





Note: Place a clean cloth in the starter generator coolant tubes to prevent coolant leakage.

7. Remove the starter generator hoses (1) and clamp the end of the hose using J - 38543 - hose clamp




8. Remove the starter generator battery cable cover nuts (1) and the starter generator battery cable cover (2).




9. Remove the starter generator battery cable terminal bolts (1) and reposition the generator starter generator battery cable.




10. Remove the starter generator battery connector (1).




11. Remove the spring tensioner stop bolt (1) and the spring tensioner stop.




12. Install the EN-48932 - compressor to the tensioner spring.
Note: Make sure the EN-48932 - compressor is not on the generator bracket.

13. Tighten the nut (1) on the EN-48932 - compressor (2) until the tensioner spring reaches its internal stop.

Note: Try not to remove the drive belt from the other pulleys.

14. Release the tension from the other drive belt spring tensioner and remove the drive belt from the starter generator pulley.




15. Remove the stud/nut (1) from the starter generator.
Note: If stud is seized, place 2 nuts on the end of the stud and remove with a socket.

16. Raise the vehicle.
17. Remove the starter generator bolts (2).

Installation Procedure




1. Position the generator to the engine.

Caution: Refer to Fastener Caution Fastener Caution.

2. For ease of service, replace the stud (1) with a bolt from the parts catalog and apply medium loctite to the bolt. Tighten to 58 Nm (41 lb ft).
3. Install the starter generator lower bolts (2) and tightren to 58 Nm (41 lb ft).




4. Remove the belt from the middle idler.
5. Install the drive belt onto the starter generator pulley.
6. Rotate the tensioner pulley clockwise and then install the belt around the middle idler.
7. Remove the EN-48932 - compressor from the tensioner spring.




8. Install the spring tensioner stop bolt (1) and the spring tensioner stop. Tighten to 9 Nm (80 lb in).
Note: Make sure the spring tensioner stop pin is aligned with the hole in the starter generator bracket.




9. Install the starter generator battery connector (1).




10. Install the starter generator battery cable to the starter generator assembly and tighten the nuts (1) to 9 Nm (80 lb in).




11. Install the starter generator battery cable cover nuts (1) and the starter generator battery cable cover (2). Tighten to 9 Nm (80 lb in).




12. Install the starter generator hoses and clamps (1) using J - 38543 - hose clamp.




13. Install the radiator inlet hose clamp (2) and tighten the bracket bolt (1) to 9 Nm (80 lb in).
14. Install the secondary air injection pump inlet PCV pipe. Refer to Secondary Air Injection Pump Inlet Hose Replacement Secondary Air Injection Pump Inlet Hose Replacement.
15. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement Service and Repair.
16. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716).
17. Enable the high voltage system. Refer to High Voltage Enabling High Voltage Enabling.