GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2003 🢒 ION 🢒 Engine 🢒 Engine Electrical 🢒 Generator Replacement

Removal Procedure
  1. Disconnect negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 2.2L (L61).
  3. Remove the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls - 2.2L (L61).
  4. Disconnect the generator connectors.

    5. Object Number: 758471 Size: SH
  5. Remove the generator bolts.
  6. Remove the generator from the vehicle.

Installation Procedure

    Object Number: 758471 Size: SH
  1. Position the generator on the engine.

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the generator bolts.

    3. Tighten
    Tighten the generator bolts to 22 N·m (16 lb ft).

  3. Connect the positive battery harness to the generator battery terminal.

    4. Tighten
    Tighten the generator terminal nut to 20 N·m (15 lb ft).

  4. Connect the generator harness connectors.
  5. Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls - 2.2L (L61)
  6. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 2.2L (L61).
  7. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .