You are on page 1of 86

Document ID: 2044844

2009 Chevrolet Aveo

Page 1 of 2

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Component Locator | Document ID: 2044844

Cylinder Head

(1) Spark Plug Coke Cover


(2) Engine Oil Cap
(3) Cylinder Head Cover
(4) Cylinder Head Cover Gasket
(5) Spark Plug Cable
(6) Spark Plug
(7) Ignition Coil (DIS) Bracket
(8) Ignition Coil (DIS)
(9) Camshaft Cap
(10) Camshaft (Intake)
(11) Camshaft (Exhaust)
2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2044844&from=sm

7/6/2010

Document ID: 2044844

Page 2 of 2

(12) Valve Tappet


(13) Valve Key
(14) Valve Spring Retainer
(15) Valve Spring
(16) Valve Stem Seal
(17) Cylinder Head
(18) Valve (Intake)
(19) Valve (Exhaust)
(20) Cylinder Head Gasket
(21) Cylinder Head Bolt
(22) Camshaft Position Sensor
(23) Coolant Outlet Case Gasket
(24) Coolant Outlet Case
(25) Coolant Temperature Sensor
(26) EGR Valve Gasket
(27) EGR Valve

http://localhost:9001/si/showDoc.do?docSyskey=2044844&from=sm

7/6/2010

Document ID: 2044848

2009 Chevrolet Aveo

Page 1 of 2

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Component Locator | Document ID: 2044848

Cylinder Block

(1) Piston Ring


(2) Piston
(3) Piston Pin Retainer
(4) Piston Pin
(5) Connecting Rod Cap Stud
(6) Connecting Rod
(7) Connecting Rod Bearing
(8) Connecting Rod Cap
(9) Dowel Pin
(10) Cylinder Block
(11) Timing Chain Cover
2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2044848&from=sm

7/6/2010

Document ID: 2044848

Page 2 of 2

(12) Crankshaft Front Oilseal


(13) Oil Pump Inner Rotor
(14) Oil Pump Outer Rotor
(15) Oil Pump Cover
(16) Oil Relief Valve
(17) Oil Relief Valve Spring
(18) Oil Relief Valve Cap
(19) Oil Relief Valve Retainer
(20) Oil Filter Stud
(21) Oil Filter
(22) Key
(23) Crankshaft
(24) Crankshaft Bearing Cap
(25) Oil Strainer
(26) Oil Pan
(27) Crankshaft Rear Oil Seal
(28) Cylinder Block Plate Plug
(29) Cylinder Block Plate Plug Gasket

http://localhost:9001/si/showDoc.do?docSyskey=2044848&from=sm

7/6/2010

Document ID: 2044849

2009 Chevrolet Aveo

Page 1 of 2

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Component Locator | Document ID: 2044849

Manifold and Air Charging System

(1) Resonator
(2) Resonator
(3) Air Filter Snorkel Hose
(4) Air Filter Lower Housing
(5) Air Filter Element
(6) Air Filter Upper Cover
(7) Air Outlet Hose
(8) Resonator
(9) Resonator
(10) Throttle Body
(11) IACV (Idle Air Control Valve)
2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2044849&from=sm

7/6/2010

Document ID: 2044849

Page 2 of 2

(12) Throttle Position Sensor


(13) Intake Manifold
(14) EGR Pipe
(15) EGR Pipe Gasket
(16) EGR Valve
(17) Thermostat Housing
(18) Coolant Outlet Case
(19) Fuel Rail
(20) Injector
(21) Exhaust Manifold
(22) Exhaust Manifold Heat Shield

http://localhost:9001/si/showDoc.do?docSyskey=2044849&from=sm

7/6/2010

Document ID: 2044850

2009 Chevrolet Aveo

Page 1 of 2

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Component Locator | Document ID: 2044850

Timing System and Mount

(1) Timing Chain


(2) Camshaft Sprocket (Intake)
(3) Camshaft Sprocket (Exhaust)
(4) Bushing
(5) Camshaft Sprocket Retaining Bolts
(6) Timing Chain Lever
(7) Timing Chain Tensioner
(8) Timing Chain Guide
(9) Crankshaft Sprocket
(10) Engine Mount Assembly
(11) Rear Mount Bracket
2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2044850&from=sm

7/6/2010

Document ID: 2044850

Page 2 of 2

(12) Transmission Rear Mount


(13) Transmission Mount Assembly
(14) Transmission Mount Bracket

http://localhost:9001/si/showDoc.do?docSyskey=2044850&from=sm

7/6/2010

Document ID: 2094866

2009 Chevrolet Aveo

Page 1 of 3

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - Off Vehicle | Document ID: 2094866

Valve Timing Inspection and Adjustment


Special Tools
EN-49073 Timing Chain Tensioner

Removal Procedure

1. Install the timing chain after aligning both the mark (1) on the camshaft sprocket and on the
timing chain.
2. Align both the timing mark (2) on the crankshaft sprocket and on the timing chain.

2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2094866&pubCellSyskey=123728&pubO... 7/6/2010

Document ID: 2094866

Page 2 of 3

3. Push the timing chain tensioner lever and fix the lever by installing the tensioner pin EN49073 (2).
Caution: Refer to Fastener Caution in the Preface section.

4. Assemble the timing chain guide (1).


Tighten
Tighten the timing chain guide retaining bolts to 10 Nm (7.4 lb in).
5. Assemble the timing chain lever (4).
Tighten
Tighten the timing chain lever retaining bolts to 10 Nm (7.4 lb in).
6. Assemble the timing chain tensioner (3).
Tighten
Tighten the timing chain tensioner retaining bolts to 12 Nm (8.8 lb in).

Installation Procedure

http://localhost:9001/si/showDoc.do?docSyskey=2094866&pubCellSyskey=123728&pubO... 7/6/2010

Document ID: 2094866

Page 3 of 3

Install the timing chain cover (1).


Tighten
Tighten the timing chain cover retaining bolts (M6 x 1.0) to 10.5 Nm (7.7 lb in).
Tighten the timing chain cover retaining bolts (M8 x 1.25) to 20 Nm (14.7 lb ft).

http://localhost:9001/si/showDoc.do?docSyskey=2094866&pubCellSyskey=123728&pubO... 7/6/2010

Document ID: 2091114

2009 Chevrolet Aveo

Page 1 of 4

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - Off Vehicle | Document ID: 2091114

Valve Clearance Adjustment


Measurement
1. Remove the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement.

2. Rotate the crankshaft pulley clockwise, aligning the pulley groove with the 0 point on the
cover.

3. Check that the camshaft sprocket and timing chain are aligned.
2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2091114&pubCellSyskey=180387&pubO... 7/6/2010

Document ID: 2091114

Page 2 of 4

4. Measure the valve clearance at positions (1), (2), (6) and (8). Rotate the crankshaft pulley
clockwise 360 degrees.
5. Measure the valve clearance at positions (3), (4), (5) and (7).
6. If the measured values are not within specifications, replace the valve tappets.
Specifications
Intake Side: 0.075-0.125 mm
Exhaust Side: 0.245-0.305 mm
7. Determine the tappet size. Refer to Determining Replacement Tappet Size.
8. Replace the valve tappets if necessary. Refer to Valve Stem Oil Seal and Valve Spring
Replacement.

Determine Replacement Tappet Size

http://localhost:9001/si/showDoc.do?docSyskey=2091114&pubCellSyskey=180387&pubO... 7/6/2010

Document ID: 2091114

Page 3 of 4

1. Remove the old tappet.


2. Measure the old tappet.
3. Perform the following calculation to determine the replacement tappet size.
Intake: value of removed tappet + measured clearance - 0.1 mm = new tappet size
Exhaust: value of removed tappet + measured clearance - 0.27 mm = new tappet size
Example:
Old tappet = 3.20 mm, clearance was 0.30 mm, Intake clearance value is 0.1 mm
3.20 mm + 0.30 mm - 0.1 mm = 3.40 mm
3.40 mm = 96449615 (part number)

Tappet Selection
Part Number

ID Number

Value (mm)

96449601

312

3.120.01

96449602

314

3.140.01

96449603

316

3.160.01

96449604

318

3.180.01

96449605

320

3.200.01

96449606

322

3.220.01

96449607

324

3.240.01

96449608

326

3.260.01

96449609

328

3.280.01

96449610

330

3.300.01

96449611

332

3.320.01

96449612

334

3.340.01

96449613

336

3.360.01

96449614

338

3.380.01

96449615

340

3.400.01

96449616

342

3.420.01

96449617

344

3.440.01

96449618

346

3.460.01

96449619

348

3.480.01

96449620

350

3.500.01

96449621

352

3.520.01

96449622

354

3.540.01

96449623

356

3.560.01

96449624

358

3.580.01

96449625

360

3.600.01

http://localhost:9001/si/showDoc.do?docSyskey=2091114&pubCellSyskey=180387&pubO... 7/6/2010

Document ID: 2091114

Page 4 of 4

96449626

362

3.620.01

96449627

364

3.640.01

96449628

366

3.660.01

96449629

368

3.680.01

96449630

370

3.700.01

96449631

372

3.720.01

96449632

374

3.740.01

96449633

376

3.760.01

96449634

378

3.780.01

96449635

380

3.800.01

96449636

382

3.820.01

96449637

384

3.840.01

96449638

386

3.860.01

96449639

388

3.880.01

96449640

390

3.900.01

http://localhost:9001/si/showDoc.do?docSyskey=2091114&pubCellSyskey=180387&pubO... 7/6/2010

Document ID: 2091678

2009 Chevrolet Aveo

Page 1 of 2

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - Off Vehicle | Document ID: 2091678

Camshaft Cleaning and Inspection

1. Measure the camshaft lift. Refer to Engine Mechanical Specifications.


2. Replace the camshaft if the measured value is not as specified.

3. Measure the outer diameter of each journal at the 4 different places. Refer to Engine
Mechanical Specifications.
4. Replace the camshaft if the measured value is not as specified.

2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2091678&pubCellSyskey=123743&pubO... 7/6/2010

Document ID: 2091678

Page 2 of 2

5. Measure the inner diameter of the cylinder head journal at the 2 places. Refer to Engine
Mechanical Specifications.
6. If necessary, replace the cylinder head.

http://localhost:9001/si/showDoc.do?docSyskey=2091678&pubCellSyskey=123743&pubO... 7/6/2010

Document ID: 2092147

2009 Chevrolet Aveo

Page 1 of 2

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - Off Vehicle | Document ID: 2092147

Cylinder Head Disassemble


Special Tools
EN-49074 Universal Valve Spring Compressor
EN-49075 Valve Spring Compressing Adapter

Note: Take extreme care to prevent any scratches, nicks or damage to the camshaft
surfaces.
1.
2.
3.
4.
5.

Remove
Remove
Remove
Remove
Remove

the
the
the
the
the

camshaft sprocket.
camshaft cap bolts in this sequence (1)-(4)-(2)-(3).
camshaft caps.
camshafts and oil seal rings.
valve tappet.

2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2092147&pubCellSyskey=123745&pubO... 7/6/2010

Document ID: 2092147

Page 2 of 2

6. Install the EN-49074 compressor and EN-49075 adapter .


7. Remove the valve key.

8. Remove the valves, springs (2), retainers (1), and seals (3).

http://localhost:9001/si/showDoc.do?docSyskey=2092147&pubCellSyskey=123745&pubO... 7/6/2010

Document ID: 2091687

2009 Chevrolet Aveo

Page 1 of 2

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - Off Vehicle | Document ID: 2091687

Cylinder Head Cleaning and Inspection


Inspection Procedure

Note: Take extreme care to prevent any scratches, nicks or damage to the cylinder head
surface.
1. Clean the sealing surfaces.
2. Inspect the cylinder head for the following:
Cracks, damage or pitting in the combustion chambers.
Debris in the oil galleries. Continue to clean the galleries until all debris is removed.
Coolant leaks or damage to the deck face sealing surface.
Damage to any gasket surfaces.
Damage to any threaded bolt holes.
Burnt or eroded areas in the combustion chamber.
Cracks in the exhaust ports and combustion chambers.
External cracks in the water passages.
Restrictions in the intake or exhaust passages.
Restrictions in the cooling system passages.
Rusted, damaged or leaking core plugs.
3. If the cylinder head is cracked or damaged, it must be replaced. No welding or patching of
the cylinder head is recommended.
4. Measure the clearance between the straight-edge and the cylinder head deck face using a
feeler gauge at four points along the straight-edge.
5. Check the sealing surfaces
deformation
and warping.
The
cylinder head sealing surfaces
2010for
General
Motors Corporation.
All rights
reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2091687&pubCellSyskey=123747&pubO... 7/6/2010

Document ID: 2091687

Page 2 of 2

(include the intake and exhaust sealing surfaces) must be flat within the specification. Refer
to Engine Mechanical Specifications.

6. Measure the height of the cylinder head from sealing surface to sealing surface. The cylinder
head height should be within specifications. Replace the cylinder head. If the cylinder head
height is out of specifications, replace the cylinder head. Refer to Engine Mechanical
Specifications.

http://localhost:9001/si/showDoc.do?docSyskey=2091687&pubCellSyskey=123747&pubO... 7/6/2010

Document ID: 2091163

2009 Chevrolet Aveo

Page 1 of 1

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - Off Vehicle | Document ID: 2091163

Valve Spring Inspection and Measurement


1. Inspect the valve springs. If the valve spring ends are not parallel, replace the valve spring.
2. Inspect the valve spring seating surface of the valve rotators for wear or gouges. Replace as
required.

3. Measure the valve spring free length. If it is out of specification, replace it. Refer to Engine
Mechanical Specifications.

4. Measure the valve spring right angles. If it is out of specification, replace it. Refer to Engine
Mechanical Specifications.
2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2091163&pubCellSyskey=123748&pubO... 7/6/2010

Document ID: 2091161

2009 Chevrolet Aveo

Page 1 of 2

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - Off Vehicle | Document ID: 2091161

Valve Stem and Valve Guide Clearance Inspection


Valve Inspection Procedure

1. Inspect the valve for damage from the head to tip for the following conditions:
pitting in the valve seat area (1)
lack of valve margin (2)
bending in the valve stem (3)
pitting or excessive wear in the stem (4)
worn valve key grooves (5)
worn valve tip (6)
2. Replace the valve if any of these conditions exist.

2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2091161&pubCellSyskey=135385&pubO... 7/6/2010

Document ID: 2091161

Page 2 of 2

Note: Valve guide is not removable. Replace the cylinder head if it is out of specification.
3. Measure the valve stem diameter (1) and valve guide inside diameter. If it is out of
specification, replace it. Refer to Engine Mechanical Specifications.

http://localhost:9001/si/showDoc.do?docSyskey=2091161&pubCellSyskey=135385&pubO... 7/6/2010

Document ID: 2092146

2009 Chevrolet Aveo

Page 1 of 3

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - Off Vehicle | Document ID: 2092146

Cylinder Head Assemble


Special Tools
EN-49074 Universal Valve Spring Compressor
EN-49075 Valve Spring Compressing Adapter

1. Install the valves, springs (2), retainers (1), and seals (3).

2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2092146&pubCellSyskey=123749&pubO... 7/6/2010

Document ID: 2092146

Page 2 of 3

2. Install the EN-49074 compressor and EN-49075 adapter .


3. Install the valve key.

Note: Do not scratch the valve tappet. Do not use gloves or tools, except special service
tools.
4. Install the valve tappet.
5. Coat and lubricate the camshaft bearing and camshaft surfaces with clean engine oil.

6. Install the camshafts (2, 3) on the cylinder head.


7. Install the camshaft bearing caps (1).
Caution: Refer to Fastener Caution in the Preface section.

http://localhost:9001/si/showDoc.do?docSyskey=2092146&pubCellSyskey=123749&pubO... 7/6/2010

Document ID: 2092146

Page 3 of 3

8. Install the camshaft bearing cap bolts and tighten in this sequence (2)-(3)-(1)-(4).
Tighten
Tighten the camshaft bearing cap bolts to 10 Nm (89 lb in).
9. Install the camshaft sprocket (4) and bolt (6)
Tighten
Tighten the camshaft sprocket bolt to 60 Nm (44 lb ft).

http://localhost:9001/si/showDoc.do?docSyskey=2092146&pubCellSyskey=123749&pubO... 7/6/2010

Document ID: 2094807

2009 Chevrolet Aveo

Page 1 of 4

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - On Vehicle | Document ID: 2094807

Drive Belt Replacement


Removal Procedure
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement
2. Lift the vehicle up.
3. Remove the front-right tire and wheel.

4. Remove the engine under cover.


5. Remove the power steering pump bracket retaining bolts and loosen the belt.
6. Remove the power steering pump-air compressor belt.

2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2094807&pubCellSyskey=176751&pubO... 7/6/2010

Document ID: 2094807

Page 2 of 4

7. Rotate the inner hex of the tensioner nut counterclockwise and loosen the nut.
8. Rotate the outer hex of the tensioner nut clockwise and put down the tensioner.
9. Remove the water pump-generator belt.

10. Remove the generator. Refer to Generator Replacement.


11. Remove the accessory tensioner (2).

Installation Procedure
Caution: Refer to Fastener Caution in the Preface section.

1. Install the accessory tensioner (2).

http://localhost:9001/si/showDoc.do?docSyskey=2094807&pubCellSyskey=176751&pubO... 7/6/2010

Document ID: 2094807

Page 3 of 4

Tighten
Tighten the accessory tensioner retaining bolts (1) to 33 Nm (24.3 lb ft).
2. Install the generator. Refer to Generator Replacement.

3. Rotate the outer hex of the tensioner nut counterclockwise and put up the tensioner.
4. Rotate the inner hex of the tensioner nut clockwise and tighten the nut, installing the water
pump-generator belt.

5. Install the power steering pump-air compressor belt (1), tightening power steering pump
bracket retaining bolts.
Tighten
Tighten the power steering pump bracket mounting bolts to 20 Nm (14.7 lb ft).

http://localhost:9001/si/showDoc.do?docSyskey=2094807&pubCellSyskey=176751&pubO... 7/6/2010

Document ID: 2094807

Page 4 of 4

6. Install the engine undercover.


7. Lower the vehicle.
8. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.

http://localhost:9001/si/showDoc.do?docSyskey=2094807&pubCellSyskey=176751&pubO... 7/6/2010

Document ID: 2094810

2009 Chevrolet Aveo

Page 1 of 4

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - On Vehicle | Document ID: 2094810

Drive Belt Tensioner Replacement


Removal Procedure
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
2. Lift the vehicle up.
3. Remove the front-right tire and wheel.

4. Remove the engine under cover.


5. Remove the power steering pump bracket retaining bolts and loosen the belt.
6. Remove the power steering pump-air compressor belt.

2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2094810&pubCellSyskey=176752&pubO... 7/6/2010

Document ID: 2094810

Page 2 of 4

7. Rotate the inner hex of the tensioner nut counterclockwise and loosen the nut.
8. Rotate the outer hex of the tensioner nut clockwise and put down the tensioner.
9. Remove the water pump-generator belt.

10. Remove the generator. Refer to Generator Replacement


11. Remove the accessory tensioner (2).

Installation Procedure
Caution: Refer to Fastener Caution in the Preface section.

1. Install the accessory tensioner (2).

http://localhost:9001/si/showDoc.do?docSyskey=2094810&pubCellSyskey=176752&pubO... 7/6/2010

Document ID: 2094810

Page 3 of 4

Tighten
Tighten the accessory tensioner retaining bolts (1) to 33 Nm (24.3 lb ft).
2. Install the generator. Refer to Generator Replacement.

3. Rotate the outer hex of the tensioner nut counterclockwise and put up the tensioner.
4. Rotate the inner hex of the tensioner nut clockwise and tighten the nut, installing the water
pump-generator belt.

5. Install the power steering pump-air compressor belt (1), tightening power steering pump
bracket retaining bolts.
Tighten
Tighten the power steering pump bracket mounting bolts to 20 Nm (14.7 lb ft).

http://localhost:9001/si/showDoc.do?docSyskey=2094810&pubCellSyskey=176752&pubO... 7/6/2010

Document ID: 2094810

Page 4 of 4

6. Install the engine undercover.


7. Lower the vehicle.
8. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.

http://localhost:9001/si/showDoc.do?docSyskey=2094810&pubCellSyskey=176752&pubO... 7/6/2010

Document ID: 2094821

2009 Chevrolet Aveo

Page 1 of 6

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - On Vehicle | Document ID: 2094821

Intake Manifold Replacement


Removal Procedure
1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection.
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.

3. Disconnect the power steering oil pressure switch connector (1) and the air conditioner
pressure sensor connector (2).

4. Disconnect the brake vacuum hose.

2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2094821&pubCellSyskey=123733&pubO... 7/6/2010

Document ID: 2094821

5.
6.
7.
8.
9.

Disconnect the
Disconnect the
Disconnect the
Disconnect the
Remove intake

Page 2 of 6

PCV breather hose.


intake temperature/pressure sensor connector.
accelerator cable.
canister hose from the intake manifold.
manifold front bracket upper retaining bolts (1).

10. Remove the fuel rail.


11. Remove the EGR pipe.

12. Disconnect the VGIS solenoid valve (3).


13. Remove the intake manifold rear bracket bolts (2).
14. Remove the intake manifold rear bracket (1).

http://localhost:9001/si/showDoc.do?docSyskey=2094821&pubCellSyskey=123733&pubO... 7/6/2010

Document ID: 2094821

Page 3 of 6

15. Remove the engine wiring harness from the intake manifold.
16. Remove the intake manifold (1).
17. Remove the intake manifold gasket.

Installation Procedure

1. Install the intake manifold (1) with the new gasket.


Caution: Refer to Fastener Caution in the Preface section.
2. Install the intake manifold bolts.

http://localhost:9001/si/showDoc.do?docSyskey=2094821&pubCellSyskey=123733&pubO... 7/6/2010

Document ID: 2094821

Page 4 of 6

Tighten
Tighten the intake manifold retaining bolts to 10 Nm (7.4 lb ft).

3. Install the intake manifold rear bracket (1).


4. Install the intake manifold rear bracket retaining bolts (2).
Tighten
Tighten the bracket upper bolts to 25 Nm (18.4 lb ft).
Tighten the bracket lower bolts to 50 Nm (36.8 lb ft).

5. Install the EGR pipe.


6. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement.

http://localhost:9001/si/showDoc.do?docSyskey=2094821&pubCellSyskey=123733&pubO... 7/6/2010

Document ID: 2094821

Page 5 of 6

7. Install the intake manifold front bracket upper retaining bolts (1).
Tighten
Tighten the intake manifold support bracket upper bolts to 2 Nm (1.5 lb ft).
8.
9.
10.
11.
12.

Connect
Connect
Connect
Connect
Connect

the
the
the
the
the

brake vacuum hose.


PCV breather hose.
intake temperature/pressure sensor connector.
accelerator cable.
canister hose from the intake manifold.

13. Connect the power steering oil pressure switch connector (1) and the air conditioner pressure
sensor connector (2).
14. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.

http://localhost:9001/si/showDoc.do?docSyskey=2094821&pubCellSyskey=123733&pubO... 7/6/2010

Document ID: 2094821

Page 6 of 6

15. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection.

http://localhost:9001/si/showDoc.do?docSyskey=2094821&pubCellSyskey=123733&pubO... 7/6/2010

Document ID: 2044861

2009 Chevrolet Aveo

Page 1 of 6

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - On Vehicle | Document ID: 2044861

Camshaft Timing Chain, Sprocket, and Tensioner


Replacement
Special Tools
EN-48356 Engine Fixture
EN-49073 Timing Chain Tensioner

Removal Procedure
1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection.
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
3. Remove the cylinder head cover. Refer to Valve Rocker Arm Cover Replacement.
4. Remove the accessory belt and tensioner. Refer to Drive Belt Replacement and Drive Belt
Tensioner Replacement.

5. Install the EN-48356 fixture .


6. Remove the engine mount. Refer to Engine Mount Replacement.
7. Remove the oil pan. Refer to Oil Pan Replacement.

2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2044861&pubCellSyskey=176754&pubO... 7/6/2010

Document ID: 2044861

Page 2 of 6

8. Remove the crankshaft pulley (2).


9. Remove the oil level gauge tube.

10. Remove the timing chain cover (1).

http://localhost:9001/si/showDoc.do?docSyskey=2044861&pubCellSyskey=176754&pubO... 7/6/2010

Document ID: 2044861

11.
12.
13.
14.

Remove
Remove
Remove
Remove

the
the
the
the

Page 3 of 6

timing chain tensioner (3).


left timing chain lever (4).
right timing chain guide (1).
timing chain.

Installation Procedure

1. Install the timing chain after aligning both the mark (1) on the camshaft sprocket and on the
timing chain.
2. Align both the timing mark (2) on the crankshaft sprocket and on the timing chain.

http://localhost:9001/si/showDoc.do?docSyskey=2044861&pubCellSyskey=176754&pubO... 7/6/2010

Document ID: 2044861

Page 4 of 6

3. Push the timing chain tensioner lever and fix the lever by installing the EN-49073 tensioner
(2).
Caution: Refer to Fastener Caution in the Preface section.

4. Assemble the timing chain guide (1).


Tighten
Tighten the timing chain guide retaining bolts to 10 Nm (7.4 lb in)
5. Assemble the timing chain lever (4).

http://localhost:9001/si/showDoc.do?docSyskey=2044861&pubCellSyskey=176754&pubO... 7/6/2010

Document ID: 2044861

Page 5 of 6

Tighten
Tighten the timing chain lever retaining bolts to 10 Nm (7.4 lb in)
6. Assemble the timing chain tensioner (3).
Tighten
Tighten the timing chain tensioner retaining bolts to 12 Nm (8.8 lb in)

7. Install the timing chain cover (1).


Tighten
Tighten the timing chain cover retaining bolts (M6 x 1.0) to 10.5 Nm (7.7 lb in).
Tighten the timing chain cover retaining bolts (M8 x 1.25) to 20 Nm (14.7 lb ft).

http://localhost:9001/si/showDoc.do?docSyskey=2044861&pubCellSyskey=176754&pubO... 7/6/2010

Document ID: 2044861

Page 6 of 6

8. Install the crankshaft pulley (2).


Tighten
Tighten the crankshaft pulley bolt to 85 Nm (62.7 lb ft).
9. Install the oil level gage tube.
Tighten
Tighten the oil level gage tube retaining bolt to 10.5 Nm (7.7 lb in).
10. Install the oil pan. Refer to Oil Pan Replacement
11. Install the engine mount. Refer to Engine Mount Replacement
12. Install the accessory belt and tensioner. Refer to Drive Belt Replacement and Drive Belt
Tensioner Replacement.

http://localhost:9001/si/showDoc.do?docSyskey=2044861&pubCellSyskey=176754&pubO... 7/6/2010

Document ID: 2094843

2009 Chevrolet Aveo

Page 1 of 3

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - On Vehicle | Document ID: 2094843

Valve Rocker Arm Cover Replacement


Removal Procedure

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection.
2. Disconnect the PCV hose.
3. Remove the cylinder head cover bracket and bolts.
4. Remove the spark plug cable cover (1).
5. Disconnect the spark plug cable.

2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2094843&pubCellSyskey=134194&pubO... 7/6/2010

Document ID: 2094843

Page 2 of 3

6. Remove the cylinder head cover retaining bolts.


7. Remove the cylinder head cover (1) with the gasket.

Installation Procedure

1. Install the cylinder head cover (1) with the gasket.


Caution: Refer to Fastener Caution in the Preface section.
2. Install the cylinder head cover retaining bolts.
Tighten
Tighten the cylinder head cover bolts to 10 Nm (7.4 lb ft).

http://localhost:9001/si/showDoc.do?docSyskey=2094843&pubCellSyskey=134194&pubO... 7/6/2010

Document ID: 2094843

Page 3 of 3

3. Connect the ignition cable.


4. Install the ignition cable cover (1).
5. Install the cylinder head cover bracket retaining bolts.
Tighten
Tighten the cylinder head cover bracket bolts to 10 Nm (7.4 lb ft).
Tighten the spark plugs cable cover bolts to 10 Nm (7.4 lb ft).
6. Connect the PCV hose.
7. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection.

http://localhost:9001/si/showDoc.do?docSyskey=2094843&pubCellSyskey=134194&pubO... 7/6/2010

Document ID: 2094847

2009 Chevrolet Aveo

Page 1 of 2

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - On Vehicle | Document ID: 2094847

Cylinder Head Replacement


Removal Procedure
1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection.
2. Drain the engine coolant. Refer to Cooling System Draining and Filling.
3. Relieve the fuel pressure. Refer to Fuel Pressure Relief.
4. Remove the cylinder head cover. Refer to Valve Rocker Arm Cover Replacement.
5. Remove the timing chain cover. Refer to Camshaft Timing Chain, Sprocket, and Tensioner
Replacement.
6. Remove the camshaft. Refer to Camshaft Replacement.
7. Remove the intake manifold. Refer to Intake Manifold Replacement.
8. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement.

9. Remove the cylinder head bolts (1).


10. Remove the cylinder head (2) with the gasket.

Cleaning Procedure
1.
2.
3.
4.

Clean
Clean
Clean
Clean

the
the
the
the

cylinder
cylinder
cylinder
cylinder

head sealing surface.


block sealing surface.
head cover bolts.
head cover bolt holes.

Installation Procedure

2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2094847&pubCellSyskey=123736&pubO... 7/6/2010

Document ID: 2094847

Page 2 of 2

1. Install the cylinder head assembly (2) and the NEW gasket.
Caution: Refer to Fastener Caution in the Preface section.
2. Install the cylinder head bolts (1).
Tighten
Tighten the cylinder head bolts to 22 Nm+ 82 degrees.
Install the exhaust manifold. Refer to Exhaust Manifold Replacement.
Install the intake manifold. Refer to Intake Manifold Replacement.
Install the camshaft. Refer to Camshaft Replacement.
Install the timing chain. Refer to Camshaft Timing Chain, Sprocket, and Tensioner
Replacement.
7. Install the cylinder head cover. Refer to Valve Rocker Arm Cover Replacement.
8. Refill the engine cooling system. Refer to Cooling System Draining and Filling.
9. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection.

3.
4.
5.
6.

http://localhost:9001/si/showDoc.do?docSyskey=2094847&pubCellSyskey=123736&pubO... 7/6/2010

Document ID: 2094849

2009 Chevrolet Aveo

Page 1 of 3

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - On Vehicle | Document ID: 2094849

Oil Pan Replacement


Removal Procedure

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection.
2. Drain the engine oil.
3. Remove the front exhaust pipe. Refer to Front Pipe Replacement.

4. Remove the oil pan retaining bolts.

2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2094849&pubCellSyskey=123737&pubO... 7/6/2010

Document ID: 2094849

Page 2 of 3

5. Remove the oil pan (1).


6. Remove the gasket between the oil pan and the sealing surface of the engine block.

Installation Procedure

1. Apply the liquid gasket to the oil pan.


Caution: Refer to Fastener Caution in the Preface section.
2. Install the oil pan (1) to the engine block and tighten the oil pan retaining bolts.
Tighten
Tighten the oil pan retaining bolts to 10.5 Nm (7.7 lb ft).

http://localhost:9001/si/showDoc.do?docSyskey=2094849&pubCellSyskey=123737&pubO... 7/6/2010

Document ID: 2094849

Page 3 of 3

3. Install the front exhaust pipe. Refer to Front Pipe Replacement.


4. Refill the engine oil.
5. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection.

http://localhost:9001/si/showDoc.do?docSyskey=2094849&pubCellSyskey=123737&pubO... 7/6/2010

Document ID: 2094853

2009 Chevrolet Aveo

Page 1 of 2

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - On Vehicle | Document ID: 2094853

Oil Pump Replacement


Special Tools
EN-49072 Crankshaft Front Seal Installer

Removal Procedure
1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection.
2. Remove the cylinder head cover. Refer to Valve Rocker Arm Cover Replacement.
3. Remove the front exhaust pipe. Refer to Front Pipe Replacement.
4. Remove the oil pan. Refer to Oil Pan Replacement.
5. Remove the timing chain cover. Refer to Camshaft Timing Chain, Sprocket, and Tensioner
Replacement.
6. Remove the gasket between the oil pan and the sealing surface of the engine block.

7. Remove the oil pump retaining bolts (1) from the timing chain cover.

Installation Procedure
Caution: Refer to Fastener Caution in the Preface section.

2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2094853&pubCellSyskey=123738&pubO... 7/6/2010

Document ID: 2094853

Page 2 of 2

1. Tighten the oil pump retaining bolts (1) to the timing chain cover and install the oil pump.
Tighten
Tighten the oil pump cover bolts to 10Nm (7.4 lb ft).
2. Install the timing chain cover. Refer to Camshaft Timing Chain, Sprocket, and Tensioner
Replacement.
Note: If the crankshaft front oil seal is damaged, replace it with new oil seal. When installing
the crankshaft front oil seal to the oil pump, make the oil seal groove faced toward the oil
pump case contact.
3.
4.
5.
6.
7.

Install the EN-49072 installer .


Install the oil pan. Refer to Oil Pan Replacement.
Install the cylinder head cover. Refer to Valve Rocker Arm Cover Replacement.
Install the spark plug cable cover.
Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection

http://localhost:9001/si/showDoc.do?docSyskey=2094853&pubCellSyskey=123738&pubO... 7/6/2010

Document ID: 2094855

2009 Chevrolet Aveo

Page 1 of 3

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - On Vehicle | Document ID: 2094855

Engine Mount Replacement


Special Tools
DW-110-060 Engine Assembly Support Fixture

Removal Procedure

1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
2. Support the engine assembly using DW-110-060 support fixture .

2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2094855&pubCellSyskey=134199&pubO... 7/6/2010

Document ID: 2094855

Page 2 of 3

3. Remove the engine mount bracket retaining bolts (2)/nuts (1).

4. Remove the engine mount retaining bolts (2).


5. Remove the engine mount assembly (1).

Installation Procedure

1. Install the engine mount assembly (1).


Caution: Refer to Fastener Caution in the Preface section.

http://localhost:9001/si/showDoc.do?docSyskey=2094855&pubCellSyskey=134199&pubO... 7/6/2010

Document ID: 2094855

Page 3 of 3

2. Install the engine mount retaining bolts (2).


Tighten
Tighten the engine mount retaining bolts to 55 Nm (40.5 lb ft).

3. Tighten the engine mount bracket retaining bolts (2)/nuts (1).


Tighten
Tighten the engine mount bracket retaining bolts/nuts to 65 Nm (47.9 lb ft).
4. Remove the DW-110-060 support fixture .
5. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.

http://localhost:9001/si/showDoc.do?docSyskey=2094855&pubCellSyskey=134199&pubO... 7/6/2010

Document ID: 2094860

2009 Chevrolet Aveo

Page 1 of 11

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - On Vehicle | Document ID: 2094860

Engine Replacement
Special Tools
DW010-010 Assembly Support Remover/Installer

Removal Procedure
1.
2.
3.
4.
5.

Discharge the air condition (A/C) system, if equipped.


Drain the power steering oil, if equipped.
Drain the engine coolant. Refer to Cooling System Draining and Filling.
Remove the battery and battery tray. Refer to Battery Tray Replacement.
Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.

6. Disconnect the radiator inlet and outlet hose (1).


7. Disconnect the heater core inlet and outlet hose (2).

2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2094860&pubCellSyskey=123739&pubO... 7/6/2010

Document ID: 2094860

Page 2 of 11

8. Remove the power steering hose from the power steering pump. Refer to Power Steering
Pump Replacement.
9. Remove the A/C compressor hose (2, 3) from the compressor.

10.
11.
12.
13.
14.

Disconnect
Disconnect
Disconnect
Disconnect
Disconnect

the
the
the
the
the

accelerator cable (1).


TPS connector.
IACV connector.
A/C pressure sensor connector.
power steering oil pressure switch cable.

http://localhost:9001/si/showDoc.do?docSyskey=2094860&pubCellSyskey=123739&pubO... 7/6/2010

Document ID: 2094860

15.
16.
17.
18.
19.
20.

Disconnect
Disconnect
Disconnect
Disconnect
Disconnect
Disconnect

the
the
the
the
the
the

coolant temperature sensor connector.


EGR valve connector.
camshaft sensor connector.
ignition coil connector.
oxygen sensor connector.
crank position sensor connector.

21.
22.
23.
24.
25.

Disconnect
Disconnect
Disconnect
Disconnect
Disconnect

the
the
the
the
the

injector main connector.


canister solenoid connector.
VGIS solenoid connector.
starter connector.
alternator connector.

Page 3 of 11

http://localhost:9001/si/showDoc.do?docSyskey=2094860&pubCellSyskey=123739&pubO... 7/6/2010

Document ID: 2094860

Page 4 of 11

26. Remove the clutch cable (3) and connectors on manual transmission vehicles.
27. Remove the shift control cable from the auto transaxle.

28. Support the engine assembly using the DW010-010 remover/installer (1).
29. Remove the engine mount bracket. Refer to Engine Mount Replacement.
30. Remove the transaxle mount bracket.

http://localhost:9001/si/showDoc.do?docSyskey=2094860&pubCellSyskey=123739&pubO... 7/6/2010

Document ID: 2094860

Page 5 of 11

31. Remove the transaxle rear mount bolts (1,2, 3) and the rear mount.

32. Remove the engine assembly.


33. Remove the transmission from the engine assembly.

http://localhost:9001/si/showDoc.do?docSyskey=2094860&pubCellSyskey=123739&pubO... 7/6/2010

Document ID: 2094860

Page 6 of 11

34. Remove the flywheel (2) (manual transmission) or flexible plate (1) (auto transmission).

Installation Procedure
Caution: Refer to Fastener Caution in the Preface section.

1. Install the flywheel (2) (manual transmission) or flexible plate (1) (auto transmission).
Tighten
Tighten the flywheel/flexible plate bolts to 45 Nm (33.2 lb ft).

http://localhost:9001/si/showDoc.do?docSyskey=2094860&pubCellSyskey=123739&pubO... 7/6/2010

Document ID: 2094860

Page 7 of 11

2. Install the transmission to the engine assembly.


Tighten
Tighten the transmission assembly bolts to 60 Nm (44.2 lb ft).

3. Support the engine assembly using the DW010-010 remover/installer (1).


4. Install the engine mount bracket. Refer to Engine Mount Replacement.
5. Install the transaxle mount bracket. Refer to Engine Mount Replacement.

http://localhost:9001/si/showDoc.do?docSyskey=2094860&pubCellSyskey=123739&pubO... 7/6/2010

Document ID: 2094860

Page 8 of 11

6. Install the transaxle rear mount secure with bolts (1, 2, 3).

7. Connect the clutch cable (3) and connectors on manual transmission vehicles.
8. Connect the shift control cable from the auto-transaxle.

http://localhost:9001/si/showDoc.do?docSyskey=2094860&pubCellSyskey=123739&pubO... 7/6/2010

Document ID: 2094860

9.
10.
11.
12.
13.

Connect
Connect
Connect
Connect
Connect

the
the
the
the
the

injector main connector.


canister solenoid connector.
VGIS solenoid connector.
starter connector.
alternator connector.

14.
15.
16.
17.
18.
19.

Connect
Connect
Connect
Connect
Connect
Connect

the
the
the
the
the
the

coolant temperature sensor connector.


EGR valve connector.
camshaft sensor connector.
ignition coil connector.
oxygen sensor connector.
crank position sensor connector.

Page 9 of 11

http://localhost:9001/si/showDoc.do?docSyskey=2094860&pubCellSyskey=123739&pubO... 7/6/2010

Document ID: 2094860

20.
21.
22.
23.
24.

Connect
Connect
Connect
Connect
Connect

the
the
the
the
the

Page 10 of 11

accelerator cable (1).


TPS connector.
IACV connector.
A/C pressure sensor connector.
power steering oil pressure switch cable.

25. Install the power steering hose from the power steering pump.
26. Install the A/C compressor hose (2, 3) from the compressor.

http://localhost:9001/si/showDoc.do?docSyskey=2094860&pubCellSyskey=123739&pubO... 7/6/2010

Document ID: 2094860

27.
28.
29.
30.
31.

Page 11 of 11

Connect the radiator inlet and outlet hose (1).


Connect the heater core inlet and outlet hose (2).
Refill the engine coolant system. Refer to Cooling System Draining and Filling.
Install the battery and battery tray. Refer to Battery Tray Replacement
Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.

http://localhost:9001/si/showDoc.do?docSyskey=2094860&pubCellSyskey=123739&pubO... 7/6/2010

Document ID: 2091133

2009 Chevrolet Aveo

Page 1 of 3

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - On Vehicle | Document ID: 2091133

Crankshaft Replacement
Removal Procedure
Special Tools
EN-49071 Crankshaft Rear Oil Seal Installer
Note: Take extreme care to prevent any scratches, nicks or damage to the inner side of the
cylinder and bearings.
Note: Check and confirm the sequence of the crankshaft caps and bearings.
1. Remove the pistons and connecting rods. Refer to Piston, Connecting Rod, and Bearing
Replacement.

2. Remove the crankshaft rear oil seal with housing (3).

2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2091133&pubCellSyskey=135384&pubO... 7/6/2010

Document ID: 2091133

Page 2 of 3

3. Remove the crankshaft cap bolts.


4. Remove the crankshaft caps with journal bearings.
5. Remove the crankshaft.

Installation Procedure
Note: Take extreme care to prevent any scratches, nicks or damage to the inner side of the
cylinder and bearings.
Note: Check and confirm the sequence of the crankshaft caps and bearings.
1. Coat and lubricate the crankshaft caps and bearings.
2. Install the crankshaft with bearings in sequence.
3. Install the crankshaft caps with bearings.
Tighten
Tighten the crankshaft cap bolts to 57.5 Nm (42.4 lb ft).
4. Install the crankshaft rear oil seal using the EN-49071 seal installer .

http://localhost:9001/si/showDoc.do?docSyskey=2091133&pubCellSyskey=135384&pubO... 7/6/2010

Document ID: 2091133

Page 3 of 3

5. Install the crankshaft rear oil seal housing.


Tighten
Tighten the crankshaft rear oil seal housing bolts to 10.5 Nm (7.7 lb ft).
6. Install the pistons and connecting rods. Refer to Piston, Connecting Rod, and Bearing
Replacement.

http://localhost:9001/si/showDoc.do?docSyskey=2091133&pubCellSyskey=135384&pubO... 7/6/2010

Document ID: 2091658

2009 Chevrolet Aveo

Page 1 of 3

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - On Vehicle | Document ID: 2091658

Piston, Connecting Rod, and Bearing Replacement


Special Tools
EN-49078 Piston Installer

Removal Procedure
1. Remove the cylinder head. Refer to Cylinder Head Replacement.
2. Remove the oil pan. Refer to Oil Pan Replacement.

Note: Check and confirm the piston assembly sequence and the connecting rod bearing
sequence.
3. Remove the connecting rod cap nuts (4) and rod cap (3).
4. Remove the piston and rod assembly (1).

2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2091658&pubCellSyskey=134201&pubO... 7/6/2010

Document ID: 2091658

Page 2 of 3

5. Separate the piston pin from the piston.


6. Separate the piston rings from the piston.

Installation Procedure

Note: Take extreme care to prevent any scratches or damage to the inner side of the
cylinder, piston, and connecting rod cap bearings.
1. Install the piston pin to the piston.
2. Install the piston rings to the piston.

http://localhost:9001/si/showDoc.do?docSyskey=2091658&pubCellSyskey=134201&pubO... 7/6/2010

Document ID: 2091658

Page 3 of 3

Note: Check and confirm the piston assembly sequence and the connecting rod bearing
sequence.
3. Install the piston assembly (1) using the EN-49078 installer .
4. Install the connecting rod cap (3) with bearings (2).
Caution: Refer to Fastener Caution in the Preface section.
5. Install the connecting rod cap nuts (4).
Tighten
Tighten the connecting rod caps nuts to 33 Nm(24.3 lb ft).
6. Install the oil pan. Refer to Oil Pan Replacement.
7. Install the cylinder head. Refer to Cylinder Head Replacement.

http://localhost:9001/si/showDoc.do?docSyskey=2091658&pubCellSyskey=134201&pubO... 7/6/2010

Document ID: 2094865

2009 Chevrolet Aveo

Page 1 of 2

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - On Vehicle | Document ID: 2094865

Camshaft Replacement
Removal Procedure
Note: Ensure that camshaft caps are set on the original position and direction.
1. Remove the timing chain. Refer to Camshaft Timing Chain, Sprocket, and Tensioner
Replacement.

2.
3.
4.
5.

Remove
Remove
Remove
Remove

the
the
the
the

camshaft
camshaft
camshaft
camshaft

sprocket bolts (6).


sprocket (4).
caps (1).
(2, 3).

Installation Procedure

2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2094865&pubCellSyskey=134203&pubO... 7/6/2010

Document ID: 2094865

Page 2 of 2

1. Lubricate the camshaft journals and the camshaft caps with engine oil.
2. Install the camshafts (1, 2).
Caution: Refer to Fastener Caution in the Preface section.
3. Install the camshaft caps (1) in their original positions.
Tighten
Tighten the camshaft cap bolts to 10 Nm (7.4 lb in).
4. Install the camshaft sprocket (4).
Tighten
Tighten the camshaft sprocket retaining bolts (1) to 60 Nm (44.2 lb ft).
5. Install the timing chain. Refer to Camshaft Timing Chain, Sprocket, and Tensioner
Replacement.

http://localhost:9001/si/showDoc.do?docSyskey=2094865&pubCellSyskey=134203&pubO... 7/6/2010

Document ID: 2044865

2009 Chevrolet Aveo

Page 1 of 3

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Repair Instructions - On Vehicle | Document ID: 2044865

Valve Stem Oil Seal and Valve Spring Replacement


Special Tools
EN-49074 Universal Valve Spring Compressor
EN-49075 Valve Spring Compressor Adapter
EN-49076 Cylinder Pressure Adapter

Removal Procedure
1. Remove the camshaft. Refer to Camshaft Replacement.

2. Remove the valve tappet (1).

2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2044865&pubCellSyskey=176753&pubO... 7/6/2010

Document ID: 2044865

Page 2 of 3

3. Install the EN-49074 compressor and EN-49075 adapter .


4. Remove the spark plug and install the EN-49076 adapter .
5. Install the compressed air hose to EN-49076 adapter . It keeps the valve not slip into the
cylinder by blowing compressed air into the cylinder.

6. Remove the valve spring (2), retainer (1), and seal (3).

Installation Procedure

http://localhost:9001/si/showDoc.do?docSyskey=2044865&pubCellSyskey=176753&pubO... 7/6/2010

Document ID: 2044865

Page 3 of 3

1. Install the EN-49074 compressor and EN-49075 adapter .


2. Remove the spark plug and install the EN-49076 adapter .
3. Install the EN-49076 adapter . It keeps the valve not slip into the cylinder by blowing
compressed air into the cylinder.
4. Install the valve spring (2), retainer (1), and seal (3).

5. Install the valve tappet. (1)


6. Install the camshaft. Refer to Camshaft Replacement.

http://localhost:9001/si/showDoc.do?docSyskey=2044865&pubCellSyskey=176753&pubO... 7/6/2010

Document ID: 2044874

2009 Chevrolet Aveo

Page 1 of 2

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Specifications | Document ID: 2044874

Fastener Tightening Specifications


Specification
Application

Metric

English

30 Nm

22.1 lb ft

Air Cleaner Assembly Bolts

6 Nm

4.4 lb ft

Air Filter Upper Housing Bolts

2 Nm

1.5 lb ft

Camshaft Cap Bolts

10 Nm

7.4 lb ft

Camshaft Sprocket Retaining Bolts

60 Nm

44.2 lb ft

Catalytic Converter Retaining Nuts

40 Nm

29.5 lb ft

Connecting Rod Bearing Cap Nuts

33 Nm

24.3 lb ft

57.5 Nm

42.4 lb ft

85 Nm

62.7 lb ft

10.5 Nm

7.7 lb ft

22 + 82 Nm

16.2 + 82 lb ft

Cylinder Head Cover Bolts

10 Nm

7.4 lb ft

Cylinder Head Cover Bracket Bolts

10 Nm

7.4 lb ft

Engine Mount Bracket Retaining Bolt/Nuts

65 Nm

47.9 lb ft

Engine Mount Retaining Bolts

55 Nm

40.5 lb ft

Exhaust Manifold Heat Shield Bolts

15 Nm

11 lb ft

Exhaust Manifold Retaining Bolts

25 Nm

18.4 lb ft

Exhaust Manifold Retaining Nuts

20 Nm

14.7 lb ft

Flywheel/Flexible Plate Bolts

45 Nm

33.2 lb ft

Front Exhaust Pipe-to-Front Muffler Nuts

40 Nm

29.5 lb ft

Front Exhaust Pipe-to-Main Catalytic Converter Nuts

40 Nm

29.5 lb ft

Generator Adjusting Bolt

20 Nm

14.7 lb ft

Generator Adjusting Bracket Retaining Bolt

33 Nm

24.3 lb ft

Intake Manifold Retaining Bolts

10 Nm

7.4 lb ft

2 Nm

1.5 lb ft

Oil Level Gage Tube Retaining Bolt

10.5 Nm

7.7 lb ft

Oil Pan Retaining Bolts

10.5 Nm

7.7 lb ft

Oil Pressure Switch Fitting

30 Nm

22.1 lb ft

Oil Pump Cover Bolts

10 Nm

7.4 lb ft

Power Steering Pump Bracket Mounting Bolts

20 Nm

14.7 lb ft

Power Steering Pump Mounting Bolts

20 Nm

14.7 lb ft

Spark Plugs Cable Cover Bolts

10 Nm

7.4 lb ft

10.5 Nm

7.7 lb ft

Timing Chain Cover Retaining Bolts (M8 x 1.25)

20 Nm

14.7 lb ft

Timing Chain Guide Retaining Bolts

10 Nm

7.4 lb ft

A/C Compressor Mounting Bracket Bolts

Crankshaft Bearing Cap Bolts


Crankshaft Pulley Bolt
Crankshaft Rear Oil Seal Cover Bolts (M6 x 1.0)
Cylinder Head Bolts

Intake Manifold Support Bracket Upper Bolts

Timing Chain Cover Retaining Bolts (M6 x 1.0)

2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2044874&pubCellSyskey=123714&pubO... 7/6/2010

Document ID: 2044874

Page 2 of 2

Timing Chain Lever Retaining Bolts

10 Nm

7.4 lb ft

Timing Chain Tensioner Retaining Bolts

12 Nm

8.8 lb ft

Transmission Assembly Blots (M/T and A/T)

60 Nm

44.2 lb ft

Water Pump Retaining Bolts

33 Nm

24.3 lb ft

http://localhost:9001/si/showDoc.do?docSyskey=2044874&pubCellSyskey=123714&pubO... 7/6/2010

Document ID: 2044873

2009 Chevrolet Aveo

Page 1 of 2

| Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.2L |
Specifications | Document ID: 2044873

Engine Mechanical Specifications


Specification
Application

Metric

English

General Data
l

Engine Type

Displacement

Bore Stroke

Compression Ratio

Firing Order

4 Cyclinder (In-Line)
1,206 cm
69.7-79 mm

2.7441- 3.1102 in
10.50.2:1
1-3-4-2

Cylinder Bore
l

Diameter

Out of Round (Maximum)

Taper (Maximum)

69.7 mm

2.7441 in

0.0065 mm

0.00025 in
0.07 x 30

Piston
l

Diameter

Clearance to Bore

69.7 mm

2.7441 in

0.0350.010 mm

(0.00130.0177 in)

Piston Rings
Piston Ring End Gap
l

Top Compression

0.15-0.30 mm

0.0059-0.0118 in

2nd Compression

0.3-0.4 mm

0.0118-0.0177 in

Groove Clearance
l

Top Impression

0.02-0.06 mm

0.00078-0.00236 in

2nd Impression

0.06-0.1 mm

0.00236-0.00393 in

16.995-17.000 mm

0.6691-0.6693 in

0.0060.019 mm

0.000780.00236 in

0.08-0.26 mm

0.0032-0.0102 in

Piston Pin
l

Diameter

Pin Off-Set

Camshaft
End Play
Journal OD
l

No. 1

23.939-23.96 mm

0.9425-0.9433 in

No. 2

23.939-23.96 mm

0.9425-0.9433 in

No. 3

23.939-23.96 mm

0.9425-0.9433 in

No. 4

23.939-23.96 mm

0.94250-0.9433 in

No. 5

23.939-23.96 mm

0.9425-0.9433 in

Journal ID
l

No. 1

23-23.021 mm

0.9055-0.9063 in

No. 2

23-23.021 mm

0.9055-0.9063 in

No. 3

23-23.021 mm

0.9055-0.9063 in

2010 General Motors Corporation. All rights reserved.

http://localhost:9001/si/showDoc.do?docSyskey=2044873&pubCellSyskey=123715&pubO... 7/6/2010

Document ID: 2044873

Page 2 of 2

No. 4

23-23.021 mm

0.9055-0.9063 in

No. 5

23-23.021 mm

0.9055-0.9063 in

48.982-49.000 mm

1.9284-1.9291 in

0.020-0.040 mm

0.00079-0.00158 in

0.08-0.26 mm

0.0032-0.0102 in

41.000-41.018 mm

1.6142-1.6149 in

0.02-0.04 mm

0.0008-0.0016 in

0.1-0.45 mm

0.0039-0.0177 in

Crankshaft
Main Journal
l

Diameter (All)

Main Bearing Clearance (All)

Crankshaft End Play

Connecting Rod Journal


l

Diameter (All)

Rod Bearing Clearance (All)

End Play

Valve System
Seat Inner Diameter
l

Intake

23.862 mm

0.9394 in

Exhaust

21.079 mm

0.8299 in

Valve Guide Inside Diameter (All)

5.0-5.012 mm

0.1968-0.1973 in

Valve Stem Diameter


l

Intake

4.9720.007 mm

0.9657-0.0002 in

Exhaust

4.963-0.007 mm

0.1954-0.0002 in

99.170.225 mm

3.9040.009 in

100.010.225 mm

3.9370.009 in

43.57 mm

1.715 in

Valve Length
l

Intake

Exhaust

Valve Spring
l

Free Length

Valve Closed

26013 N (1919.6 lbs) @ 32 mm (1.25 in)

http://localhost:9001/si/showDoc.do?docSyskey=2044873&pubCellSyskey=123715&pubO... 7/6/2010