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Home >> Chevrolet >> 2004 >> Optra Base, Automatic >> Repair and Diagnosis >> Electrical >> Charging Systems >> Engine Electrical System >> Repair Instructions >> Generator Replacement (1.8L/2.0L) >> Installation Procedure
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Installation Procedure

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

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

  2. Fig 2: View Of Generator, Lower Bracket And Bolts
    GM1289270Courtesy of GENERAL MOTORS CORP.
  3. Install the generator and the lower support bracket assembly to the engine block.

    Tighten:  Tighten the generator and the lower bracket-to-engine block bolts to 37 N.m (27 lb ft)  .

  4. Fig 3: View Of Lower Bracket To Generator Bolt
    GM1289225Courtesy of GENERAL MOTORS CORP.
  5. Install the generator-to-intake manifold and cylinder head support bracket bolts.

    Tighten:  Tighten the generator-to-intake manifold and cylinder head support bracket bolts to 37 N.m (27 lb ft)  .

  6. Install the generator-to-intake manifold strap bracket bolts and the intake manifold-to-cylinder body strap bracket bolts over the starter.

    Tighten:  Tighten the generator-to-intake manifold strap bracket bolt and the intake manifold-to-cylinder body strap bracket bolts to 22 N.m (16 lb ft)  .

  7. Fig 4: View Of Upper Engine Connecting Bracket And Bolt
    GM1289204Courtesy of GENERAL MOTORS CORP.
  8. Connect the harness connector to the back of the generator, and the generator lead to the battery.
  9. Fig 5: Turning Automatic Tensioner Roller Bolt Clockwise
    GM1289189Courtesy of GENERAL MOTORS CORP.
  10. Route the power steering pump drive belt. Refer to Power Steering Pump Belt Replacement .
  11. Relieve tension on the belt by first applying downward pressure on the automatic tension roller bolt and releasing pressure once the belt is in place.
  12. Install the power steering reservoir.
  13. Fig 6: Intake Air Temperature Sensor
    GM1289768Courtesy of GENERAL MOTORS CORP.
  14. Install the air cleaner outlet hose and connect the IAT electrical connector.
  15. Connect the negative battery cable.