2004 Chevrolet Optra Base, AutomaticFACTORY OEM SERVICE PROCEDURE

Installation Procedure

    Fig 1: Identifying Fuel Tank Straps And Retaining Nuts
    GM1289371Courtesy of GENERAL MOTORS CORP.
  1. Raise the fuel tank into position.
  2. Install the fuel tank straps.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the fuel tank strap retaining nuts.

    Tighten:  Tighten the fuel tank strap retaining nuts to 20 N.m (15 lb ft)  .

  4. Install the parking brake cables support bracket.
    5. Fig 2: View Of Fuel Inlet And Return Lines
    GM1289369Courtesy of GENERAL MOTORS CORP.
  5. Install the fuel pump. Refer to Fuel Pump Replacement .
  6. Connect the fuel outlet line and the fuel return line.
    7. Fig 3: View Of Fuel Tank Filler Tube Clamp
    GM1289367Courtesy of GENERAL MOTORS CORP.
  7. Connect the fuel pump harness connector.
  8. Connect the fuel vapor line.
  9. Connect the fuel tank filler tube.
  10. Connect the fuel tank vent tube.
  11. Install the fuel tank filler tube clamp at the fuel tank.
    12. Fig 4: Identifying Front Muffler
    GM1289366Courtesy of GENERAL MOTORS CORP.
  12. Install the front muffler. Refer to Exhaust Muffler Replacement (Gasoline Engine Front) or Exhaust Muffler Replacement (Gasoline Engine Rear) in Engine Exhaust.
  13. Connect the negative battery cable.
  14. Fill the fuel tank.
  15. Perform a leak check of the fuel tank and the fuel line connections.
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.