Product Safety - Transmission Mount Attachment Bolt

GMDAT has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 Chevrolet Optra model vehicles. It has been identified that in extremely rare instances, the transmission mounting bolt was not properly torqyed and may come loose.

Dealers are to inspect for a properly torqued bolt and retighten or replace as required.

Involved are certain 2004 Chevrolet Optra model vehicles built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.]

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the program bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this program. Any dealer not receiving a computer listing with the program bulletin has no involved vehicles currently assigned.

These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this program.

Parts required to complete this recall are being provded by the supplier.

1. Open the hood.
2. Set the torque wrench to measure 70 N·m (52 lb ft).



3. Set the torque wrench to the transmission mount bolt (1), clockwise direction.
4. Carefully attempt to tighten the transmission mounting bolt (1).




Important: 

•	If in Step 4 the torque wrench clicks before the bolt turns, continue with Step 5.

•	If in Step 4 a bolt turns before the torque wrench clicks, the bolt is loose. In this case, inspect the crack of the transmission mount/bolt or inspect whether the bolt turns continuously without tightening.

If the above symptoms could be found, continue with Step 7 to replace the transmission mount assembly.

5. Set the torque wrench (1) to measure 110 N·m (81 lb ft) of torque.
6. Set the torque wrench (1) to tighten the bolt, clockwise direction.

Tighten
Tighen the transmission mounting bolt to 110 N·m (81 lb ft).

7. Remove the battery from the battery tray.



8. Remove the ECM connector and put the ECM wiring harness away for work space. (1.6 DOHC - Siemens EMS)



9. Remove the RON switch mounting bracket (1) for work space. (1.8 DOHC - Delphi EMS).



10. Remove the engine fuse box assembly.
11. Place the engine support fixture.



12. Remove the transmission mount retaining bolts (2) (4 EA) and nut (1) (1 EA).
13. Remove the transmission mount assembly.



14. Install the new transmission mount assembly with bolts and nut.

Tighten

•	Tighten the transmission mount to bracket bolt to 65 N·m (48 lb ft) (1).

•	Tighten the transmission mount to bracket nut to 65 N·m (48 lb ft) (1).

•	Tighten the transmission mount to body bolts to 55N·m (41 lb ft) (2).

15. Remove the engine support fixture.



16. Install the engine fuse box assembly with bolts.
17. Connect the ECM connector (1.6 DOHC -- Siemens EMS).
18. Install the RON switch bracket with bolt (1.8 DOHC -- Delphi EMS).
19. Install the battery onto the battery tray.
20. Close the hood.
21. Perform IACV or MTIA reset procedures.
22. Reset digital clock and input audio security code.

Submit a Product Program Claim with the information indicated below:

Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission.

All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles.

Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.