2004 Chevrolet Optra Base, AutomaticFACTORY OEM SERVICE PROCEDURE

Assembly Procedure

    Fig 1: View Of Generator Through-Bolts
    GM1241906Courtesy of GENERAL MOTORS CORP.
  1. Install the new ring in the slip ring end frame.
  2. Install the stator.
    3. Fig 2: View Of Generator Through-Bolts
    GM1241906Courtesy of GENERAL MOTORS CORP.
  3. Position the rotor assembly shaft with the drive end frame in the slip ring end assembly until the gap between the outer lace and the end frame casting is 1.9 mm (0.075 in).
    4. NOTE: Refer to Fastener Notice .
  4. Install the generator through-bolts.

    Tighten:  Tighten the generator through-bolts to 10 N.m (89 lb in)  .

    5. Fig 3: View Of Generator Drive End And Drive End Bearing Nut
    GM1241907Courtesy of GENERAL MOTORS CORP.
  5. Position the fan, the collars, and the pulley on the rotor shaft and secure with the nut.

    Tighten:  Tighten the generator drive end bearing nut to 81 N.m (60 lb ft)  .

  6. Install the generator. Refer to Generator Replacement (1.6L)  or Generator Replacement (1.8L/2.0L) .
    7. Fig 4: View Of Stator And Components
    GM1241902Courtesy of GENERAL MOTORS CORP.
  7. Weld the brush holder terminal to the regulator terminal, if removed.
  8. Fix the brush holder with the retainer pin, and weld the regulator/brush holder assembled terminal to the rectifier terminal.
  9. Apply silicone grease between the bridge and the end frame for radiation purposes.
  10. Fasten the screws holding the rectifier regulator/brush holder assembly to the end frame.
  11. Punch the new baffle with the pin into the brush.
    12. Fig 5: View Of Stator Connections And Rectifier Bridge Terminals
    GM1241901Courtesy of GENERAL MOTORS CORP.
Factory Service Tools

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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.

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