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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) >> Removal Procedure
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Removal Procedure

    Fig 1: Intake Air Temperature Sensor
    GM1289768Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Battery Disconnect Caution .
  1. Disconnect the negative battery cable.
  2. Disconnect the intake air temperature (IAT) sensor electrical connector from the air intake tube.
  3. Remove all the clamps from the air cleaner outlet hose, and set aside the tube.
    4. Fig 2: Turning Automatic Tensioner Roller Bolt Clockwise
    GM1289189Courtesy of GENERAL MOTORS CORP.
  4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  5. Disconnect the harness connector from the back of the generator and the generator lead to the battery.
  6. Remove the power steering pump drive belt by lowering the vehicle and turning the automatic tensioner roller bolt clockwise to relieve tension on the belt. Refer to Power Steering Pump Belt Replacement .
  7. Push up the power steering reservoir and set it aside.
    8. Fig 3: View Of Lower Bracket To Generator Bolt
    GM1289225Courtesy of GENERAL MOTORS CORP.
  8. Remove the generator upper mounting bolts to the intake manifold/cylinder head support bracket, the intake manifold strap bracket, and the intake manifold-to-cylinder body strap bracket.
    9. Fig 4: View Of Generator, Nut, Washers And Bolt
    GM1289242Courtesy of GENERAL MOTORS CORP.
  9. Raise and suitably support the vehicle and remove the nut and washers which hold the generator lower bracket-to-generator bolt. Work the bolt loose and remove the generator.
    10. Fig 5: View Of Generator, Support Bracket, Nut, Washer And Bolt
    GM1289257Courtesy of GENERAL MOTORS CORP.
  10. Remove the generator lower support bracket bolts.
  11. Carefully remove the generator with the lower bracket attached.
  12. Remove the generator lower support bracket nut, the bolt, and the washer.
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