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HOMESERVICE MANUALSCHEVROLET2005AVEO LS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISENGINE MECHANICALSTARTERBATTERY, CHARGING SYSTEM AND STARTING SYSTEMREPAIR INSTRUCTIONSGENERATOR REPLACEMENTINSTALLATION PROCEDURE
2005 Chevrolet Aveo LS, 4D Sedan, Standard

Installation Procedure

2005 Chevrolet Aveo LS, 4D Sedan, StandardSECTION Installation Procedure
    Fig 1: Removing And Installing Generator, Nuts And Bracket-To-Generator Bolts
    GM1241862Courtesy of GENERAL MOTORS CORP.
  1. Install the generator at the generator lower bracket and insert the generator bolts.
    2. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the nut and the washers on the generator lower bracket-to-generator bolts.

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

    3. Fig 2: Installing Generator, Lower Support Bracket Assembly, And Bolts
    GM1241863Courtesy of GENERAL MOTORS CORP.
  3. Install the generator and the lower support bracket assembly to the engine block with the bolts.
  4. Secure the generator to the shackle bracket with the bolt.

    Tighten:  Tighten the generator shackle bracket bolt to 25 N.m (18 lb ft).

    5. Fig 3: View Of Generator Voltage Regulator
    GM1241861Courtesy of GENERAL MOTORS CORP.
  5. Connect the harness connector to the back of the generator.
  6. Install the generator lead to the battery and fasten the lead with the nut.

    Tighten:  Tighten the generator battery lead nut to 15 N.m (11 lb ft).

    7. Fig 4: Locating Intake Ducting To Engine
    GM1241530Courtesy of GENERAL MOTORS CORP.
  7. Install the air intake tube and the connector.
    8. Fig 5: View Of Valve Cover Breather Hose
    GM1241458Courtesy of GENERAL MOTORS CORP.
  8. Install the IAT electrical connector to the air intake tube.
  9. Connect the negative battery cable.
RENDER: 1.0x

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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.