2004 Chevrolet Optra Base, StandardFACTORY OEM SERVICE PROCEDURE

Installation Procedure

    Fig 1: View Of Lower Bracket To Generator Bolt
    GM1289225Courtesy of GENERAL MOTORS CORP.
  1. Install the generator to the generator lower bracket and insert the generator bolt.
    2. NOTE: Refer to Fastener Notice .
  2. Install the nut and washers on the generator lower bracket-to-generator bolt.

    Tighten:  Tighten the generator lower bracket-to-generator nut to 25 N.m (18 lb ft)  .

    3. Fig 2: View Of Upper Engine Connecting Bracket And Bolt
    GM1289204Courtesy of GENERAL MOTORS CORP.
  3. Install the upper generator support bracket bolt and the washer.

    Tighten:  Tighten the generator upper support bracket bolt to 20 N.m (15 lb ft)  .

  4. Connect the harness connector to the back of the generator and the generator lead to the battery.
    5. Fig 3: Turning Automatic Tensioner Roller Bolt Clockwise
    GM1289189Courtesy of GENERAL MOTORS CORP.
  5. Route the power steering pump drive belt. Refer to Power Steering Pump Belt Replacement .
  6. Relieve the tension on the belt by first applying downward pressure on the automatic tension roller bolt and releasing pressure once the belt is in place.
  7. Install the power steering reservoir.
    8. Fig 4: View Of Air Cleaner Outlet Hose
    GM1289188Courtesy of GENERAL MOTORS CORP.
  8. Install the air cleaner outlet hose and connect the IAT electrical connector.
  9. Connect the negative battery cable.
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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