2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo SPECIFICATIONS FAST! ER TIGHTENING SPECIFICA’ Fastener Tightening Specifica Specification Application Metric English AIC Compressor Hose Assembly Retaining Bolt |___33 Nm 24 Ib ft ‘AIC Compressor Mounting Bolts 27 Nm 20 1b ft ‘A/C Compressor Mounting Bracket Bolts 50.Nm 37 Ib ft Air Filter Housing Bolts 8Nm TL in Alternator Adjusting Bolt 25N.m 18 Ib ft ‘Alternator Adjusting Bracket Retaining Bolt 25Nm 18 Ib fe Auxiliary Catalytic Converter-to-Exhaust Manifold Nuts and Bracket Bolts 40.Nm 30 Tb ft Camshaft Gear Bolt Nm BIR Camshafi Pressure Plate Bolts 10Nm 89 Tb in Connecting Rod Bearing Cap Bolts 25Nm+30° | 18 Ib ft + 30° Coolant Pump Retaining Bolts 10 Nm 89 Ib in Coolant Temperature Sensor 20 Nm 15 Ib fe 5 5 5 Crankshaft Bearing Cap Bolts SO Nims aes | 37 Ib Re As + Crankshaft Position Sensor Retaining Bolt 10 Nm 89 Ibin SNw eos = Crankshaft Pulley Bolt 95. Num 530° + | 70 Tb As 309+ Cylinder Head Bolts (Camshaft Support Housing| 25Nm+70°+ | 18 Ib ft+70°+ & Cylinder Head Mounting Bolts) 70° + 30° 70° + 30° Electronic Ignition System Ignition Coil a a Mounting Bolts Electronic Ignition System Ignition Coil Ons Mounting Plate Bolts HOI sob an Engine Lift Bracket Bolt 25Nm 18 Ib ft Engine Mount Attaching Nuts 40.N.m 30 Ib ft Engine Mount Bracket Retaining Bolts 60 N.m 44 Ib ft Engine Mount Bracket-to-Engine Mount Prone ns Retaining Bolts Exhaust Manifold Heat Shield Bolts 15Nm IIb ft2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Exhaust Manifold Nuts 25. Nm 18 Ib ft Flexible Plate Bolts 60 Nm 44 Ib ft Flexible Plate Inspection Cover Bolts 10 Nm 89 Ib in Flywheel Bolts 35N ini 30°+ | 261d i 30°+ Flywheel Inspection Cover Bolts 12 Nm 106 Ib in Front Muffler-to-Main Catalytic Converter Nuts 30.N.m 2b ft Fuel Rail Retaining Bolts 25 Nm 18 Ib ft Intake Manifold Retaining Nuts 25m 18 Ib ft Intake Manifold Support Bracket Retaining Bolts|___25 N.m 18 1b ft Lower Timing Belt Cover Bolts 10. Nm 89 Ib in Oil Pan Drain Plug 35 Nm 25 Ib ft Oil Pan Retaining Bolts 10 Nm 89 Ib in Oil Pressure Switch 40 N.m 30 Ib ft Oil Pump/Pickup Tube and Support Bracket a 89 ib in Bolts Oil Pump Rear Cover Bolts 6Nm 331b in Oil Pump Retaining Bolts 10 N.m 89 Tb in Oil Pump Safety Relief Valve Bolt 30 Nm 22 Ib ft Power Steering Pump Mounting Bolts 25m 18 Ib ft Power Steering Pump Pulley Bolts 25 Nm 18 Ib ft Rear Timing Belt Cover Bolts 10 Nm 89 Ib in Right Transaxle Brace Bolts 60N.m 44 Ib ft Spark Plugs 25.N.m 18 1b ft Thermostat Housing Mounting Bolts 20N.m 15 Ib ft Throttle Cable Bracket Bolts 8Nm TL bin Timing Belt Automatic Tensioner Bolt 20N.m 15 Ib ft Transaxle Bell Housing Bolts 75N.m 35 Ib ft Upper Timing Belt Cover Bolts 10 Nm 89 Ib in Valve Cover Bolts 9Nm 80 Ib in ENGINE MECHANICAL SPECIFICATIONS Engine Mechanical Specifications Specification Application Metric English General Data « Engine Type 4 Cylinder - In-Line Displacement 1399 em? 85,37 in?2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo * Bore Stroke 77.9x73.4 mm | 3.07x2.89 in « Compression Ratio 951 « Firing Order 1-3-4-2 Maximum Power - At 5,600 RPM 61 kw (81.8 hp) Maximum Torque - At 3,000 RPM 123 Nm 90.7 Ib ft Cylinder Bore « Diameter 77.9 mm 3.07 in « Out of Round - Maximum 0.0065 mm. 0.00025 in « Taper - Maximum 0.0065 mm. 0.00025 in Piston « Diameter 77.87 mm 3.07 in # Clearance to Bore 0.03 mm 0.0012 in Piston Rings « Ring, End Gap - Top Compression 0.3 mm. 0.012 in Ring, End Gap - Second Compression. 0.3 mm 0.012 in * Groove Clearance - Top Impression 0.02 mm 0.0008 in « Groove Clearance - Second Compression 0.02 mm 0.0008 in Piston Pin « Diameter 18 mm 0.708 in « Pin Off-Set 0.5-0.7mm_ | 0.019-0.027 in Camshaft « Lifi Intake - 1.5 SOHC 4.773 mm 0.188 in « Lift Exhaust 5.267 mm 0.207 in « End Play 0,09-0.21 mm_| 0.0035-0.0082 in # Journal OD - No. | 39-435-39-455 | 559.1.553 in mm # Journal OD - No. 2 39.685-39.705 |). 569.1.563 in mm # Journal OD - No. 3 2 955-30.955 1,572-1.573 in Journal OD - No. 4 40.185-40.205 1,582 in mm * Journal OD - No. 5 a A35-40.455 1,591-1.592 in Bearing OD - No. 1 39.5-39.525 mm | 1.555-1.556 in2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo « Bearing OD - No. 2 39,75-39.775 mm|_1,564-1,565 in « Bearing OD - No. 3 40-40.025 mm | _1.574-1.575 in « Bearing OD - No. 4 40.25-40.275 mm| _1.584-1.585 in « Bearing OD - No. 5 40,5-40.525 mm | 1.594-1.595 in Crankshaft # Main Journal - Diameter - All S498 S494 | 9 164-2.165 in «Taper - Maximum 0.005 mm 0.0001 in + Out of Round - Maximum 0.004 mm 0.0001 in # Main Bearing Clearance - All 0,026-0,046 mm | 0,001-0,00181 in «Crankshaft End Play 0.1 mm 0.003 in 42.971-42.987 mm » Connecting Rod Journal - Diameter - All 1,691-1.692 in # Taper - Maximum 0,005 mm 0.0001 in # Out of Round - Maximum 0.004 mm 0.0001 in # Rod Bearing Clearance - All 0.019-0.07 mm_ | 0.0007-0.0027 in # Rod Side Clearance 0.07-0.242 mm_| 0.0027-0.009 in Valve Stem « Valve Lash Compensators Hydraulic « Face Angle - All 46°+/-730" # Seat Angle - All 45° « Seat Runout - Maximum, All 0.05 mm 0.0197 in « Face Runout - Maximum, All 6-6.015 mm _ | 0.2362-0.2368 in « Seat Width - Intake 1.3-15mm__ | 0.051-0.059 in # Seat Width - Exhaust 1.6-1.8mm | 0,063-0.071 in # Valve Guide Inside Diameter - All 7.03-7.050 mm | 0.276-0.277 in « Valve Stem Diameter - Intake 5.97-5.984 mm | 0,232-0.238 in # Valve Stem Diameter - Exhaust 5.96-5.974 mm | 0.231-0.237 in « Valve Diameter - All - Intake 37.9-38.1 mm_ | 1.486-1.494 in « Valve Diameter - Exhaust 30.9-31.1mm_ | 1.216-1.224 in « Valve Spring Free Length 40.9 mm 1.61 in « Valve Spring Loads - Valve Open@21.5 | 600.650 N 443-479 Ibs mm (0.846 in)2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo mm (1.24 in) + Valve Spring Loads - Valve Closed @31.5| 60.290 N 191-213 Ibs Lubricating Type Forced Feed Oil Filter Type Cartridge ( Full Flow) Oil Pan Capacity Including Oil Filter 3.75 liter 4 quarts Oil Pump + Gap Between Oil Pump Body and Out 0.4-0.484 mm 0.0157-0.0191 in Rotor + Out Rotor Side Clearance 0.045-0.1 mm_ | 0.0018-0.0039 in Inner Rotor Side Clearance 0.035-0.085 mm | 0.0014-0.0033 in « Relief Valve Spring Free Length 81mm 3.2in Oil Pump Type Rotary (Trochoid) Valve Guide Reaming Table Equipment Size Reamer Production Code | Service Code Normal = = K KM-253 . See 0.075 Special Tools and 1 Kl Equipment. KM-254 . See 0.150 Special Tools and 2 K2 Equipment. KM-255 . See 0.250 Special Tools and - A COMPONENT LOCATOR DISASSEMBLED VIEWS2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 1: Upper End Courtesy of GENERAL MOTORS CORP. Callouts For Fig. 1 Callout Component Name ol Bolt 02 Cap - Bayonet Joint 03 Valve Cover 04 Cylinder Head Bolt 05 Washer 06 Camshaft Support 07 Bolt 08 Camshaft Pressure Plate 09 Camshaft 10 Roller Follower u Roller Follower Lifter2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo 12 Cylinder Head Gasket 13 Bolt 14 Exhaust Manifold Heat Shield 15 Exhaust Manifold 16 Exhaust Oxygen Sensor 17 Nut 18 Exhaust Manifold Gasket 19 Coolant Temperature Sensor 20 Bolt-Stud. 21 ‘Adapter 22 Oil Duet Cap 23 Oil Duct Cap 24 Cylinder Head Oil Duct Sleeve 25 Intake Valve 26 Exhaust Valve 27 Screw Plug 28 Valve Guide 29 Intake Valve Spring Seat 30 Valve Key 31 Valve Spring Plate 32 Valve Spring 33 Valve Stem Seal 34 Exhaust Valve Spring Seat 35 Bolt-Stud 36 Valve Guide 37 Bolt-Stud 38 Thermostat 39 Thermostat Housing Seal Ring 40 Thermostat Housing 41 Bolt 42 Intake Manifold Gasket 43 Nut 44 Throttle Body 45. Bolt 46 Throttle Position Sensor 47 Idle Air Control Valve 48 Throttle Body Gasket 49 Intake Manifold2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo EGR Gasket 51 EGR Valve aoe Bolt 53 Shaft Seal Ring 54 Camshaft Position Sensor 55 Valve Cover Gasket 56 Tube 2: Lower End Courtesy of GENERAL MOTORS CORP. Callouts For Fig. 2 Callout Component Name 1 Connecting Rod Bearing Set2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo 2 Piston Pin 3 Piston Ring Set 4 Piston 5 Connecting Rod 6 Oil Level Gage Stick fl Gage Stick Tube 8 Oil Filter 9 Crankshaft Position Sensor 10 Connecting Piece u Flywheel - Manual Transaxle 2 Bolt - Manual Transaxle 13, Bolt 4 Shaft Seal Ring 15 Main Bearing 16 Main Bearing Cap Bolt 7 Oil Pan 18 Washer 19 Drain Plug 20 Bolt 21 Crankshaft Bearing - Lower 2 Crankshaft Bearing - Upper 23 Oil Pump Body Gasket 24 Gasket 25 Cover 26 Gear 27 Gear 28 Bolt Plug 29 Oil Pump Seal Ring 30 Spring 31 Pressure Relief Valve Plunger 32 Oil Pickup Tube 33 Bolt 34 Bracket 35 Seal 36 Timing Belt 37 Upper Timing Belt Front Cover 38 Bolt 39 Lower Timing Belt Front Cover2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Crankshaft Pulley 41 Washer 2 Bolt 4B Bolt 44 Crankshaft Gear 45 Auto Tensioner 46 Bolt 47 Camshaft Gear Bolt 48 Washer 49 Camshaft Gear 50 Rear Cover Bolt 51 Rear Timing Belt Cover 52 Bolt 33 Coolant Pump 34 Seal Ring 35 Oil Pump 56 Bolt 37 Engine Block 38 Bolt 59 Knock Sensor 60 Connecting Rod Bolt DIAGNOSTIC INFORMATION AND PROCEDURES DIAGNOSTIC STARTING POINT - ENG! MECHANICAL Begin the system diagnosis by reviewing Engine Component Description. Reviewing the description and operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the description and operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Engine Mechanical in order to identify the correct procedure for diagnosing the system and where the procedure is located SYMPTOMS INE MECHANICAL Strategy Based Diagnostics 1. Perform the Diagnostic System Check - Engine Controls in Engine Controls - 1.4L SOHC before using the symptom tables, if applicable. 2. Review the system operations in order to familiarize yourself with the system functions. Refer to Disassembled Views and Engine Component Description.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Alll diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform approach for repairing all systems. The diagnostic flow may always be used in order to resolve a system condition. The diagnostic flow is the place to start when repairs are necessary Visual/Physical Inspe 1. Inspect for aftermarket devices which could affect the operation of the engine. 2. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom 3. Inspect for the correct oil level, proper oil viscosity, and correct filter application 4. Verify the exact operating conditions under which the concern exists, Note factors such as engine RPM, ambient temperature, engine temperature, amount of engine warm-up time, and other specifics. 5. Compare the engine sounds, if applicable, to a known good engine and make sure you are not trying to correct a normal condition. Intermittent Test the vehicle under the same conditions that the customer reported in order to verify the system is operating properly Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: « Oil Leak Diagnosis « Engine Noise Diagnosis + Engine Knocks Cold and Continues for Two-Three Minutes and/or Knock Increases with Engine Torque « Engine Noise Under Load + Light Knock Hot « Engine Noise on Start-Up, but Only Lasting a Few Seconds « Knocks at Idle Hot « Main Bearing Noise « Connecting Rod Bearing Noise Symptom « Piston Noises « Base Engine Misfire with Abnormal Valve Train Noise « Engine Compression Test OIL PRESSURE DIAGNOSIS AND TESTI2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Tools Required « J 36648-A (KM 135) Adapter « J 21867 (KM 498-B) Pressure Gage 1. With the vehicle on a level surface, run the vehicle for a few minutes, allow adequate drain down time, 2-3 minutes, and measure for a low oil level 2. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. 3. Run the engine briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gage or light 4. Listen for a noisy valve train or a knocking noise. 5. Inspect for the following: * Foamy oil * Slow idle speed « Plugged oil filter « Oil diluted by the following: = Water = Engine coolant « Unburned fuel mixtures * Malfunctioning oil filter bypass valve « Incorrect or faulty oil pressure gage « Incorrect or faulty oil pressure gage sensor « Improper engine oil viscosity for the expected temperature2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 3: View Of Oil Pressure Gage Sensor Courtesy of GENERAL MOTORS CORP. 6. Remove the oil pressure gage sensor.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 4: Measuring Engine Oil Pressure Courtesy of GENERAL MOTORS CORP. 7. Install the J 36648-A (1) in place of the oil pressure sensor. 8. Connect the J 21867 (2) to the J 36648-A . 9. Start the engine and then allow the engine to reach normal operation temperature. IMPORTANT: The minimum oil pressure should be 30 kPa (8.88psi). The minimum oil pressure at idle should be 250 kPa (35psi). 10. Measure the engine oil pressure. 11. If the engine oil pressure is below specifications, inspect the engine for one or more of the following: * Loose oil filter adapter bolts Missing or damaged oil filter adapter O-ring seal or seals « Worn or dirty oil pump * Loose oil pump-to-engine block bolts « Loose, plugged or damaged oil pump screen e Missing or damaged oil pump screen O-ring seal2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Damage or leak in the oil pump screen suction tube . ure regulator valve * Malfunctioning oil pump pr Missing or incorrectly installed oil gallery plugs Loose camshaft intermediate drive shatt bolts Excessive bearing clearance for the following: = Connecting rod or rods = Crankshaft = Camshaft or camshafts = Camshaft intermediate drive shaft sprocket Cracked, porous or restricted oil galleries . Broken valve lifters 12. Repair or replace components as necessary. OIL LEAK DIAGNOSIS Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the necessary parts. On some occasions, a fluid leak may be difficult to locate or repair. The following procedures may help you in locating and repairing most leaks. Finding the Leak 1 Identify the fluid. Determine whether it is engine oil, automatic transi power steering fluid, ete. Identify where the fluid is leaking from. 1. After running the vehicle at normal operating temperature, park the vehicle over a large sheet of paper. 2. Wait a few minutes. Find the approximate location of the leak by the drippings on the paper. Visually check around the suspected component. Check around all the gasket mating surfaces for leaks. A mirror is useful for finding leaks in areas that are hard to reach If the leak still cannot be found, it may be necessary to clean the suspected area with a degreaser, steam, or spray solvent 1. Thoroughly clean the area. Dry the area, Operate the vehicle for several miles at normal operating temperature and varying speeds. 4. After operating the vehicle, visually check the suspected component 5. Ifyou still cannot locate the leak, try using the powder or black light and dye method, PR2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Powder Method Clean the suspected area. Apply an aerosol-type powder, such as foot powder, to the suspected area. Operate the vehicle under normal operating conditions. Visually inspect the suspected component. Trace the leak path over the white powder surface to the source. FONE Black Light and Dye Method A dye and light kit is available for finding leaks. Refer to the manufacturer's directions when using the kit. 1. Pour the specified amount of dye into the engine oil fill tube. 2. Operate the vehicle under normal operating conditions as directed in the kit. 3. Direct the light toward the suspected area, The dyed fluid will appear as a yellow path leading to the source. Repairing the Leak Once the origin of the leak has been pinpointed and traced back to its source, the cause of the leak must be determined in order for it to be repaired properly. If a gasket is replaced, but the sealing flange is bent, the new gasket will not repair the leak. The bent flange must be repaired also. Before attempting to repair a leak, check for the following conditions and correct them as they may cause a leak. Gaskets « The fluid level/pressure is too high. « The crankcase ventilation system is malfunctioning. ‘The fasteners are improperly tightened or the threads are dirty or damaged. The flanges or the sealing surface is warped. « There are scratches, burrs, or other damage to the sealing surface The gasket is damaged or worn There is cracking or porosity of the component. « An improper seal was used, where applicable. Seals « The fluid level/pressure is too high. The crankcase ventilation system is malfunctioning. « The seal bore is damaged, scratched, burred, or nicked. e The seal is damaged or worn.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Improper installation is evident. There are cracks in the component. The shaft surface is scratched, nicked, or damaged. « A loose or worn bearing is causing excess seal wear. ENGINE NOISE DIAGNOSIS Definition for Knock Engine knock refers to various types of engine noise. Heavy knock is usually very loud and the result of broken or excessively worn internal engine components. Light knock is a noticeable noise, but not as loud. Light knock can be caused by worn internal engine components. Loose or broken external engine components can also cause heavy or light knock. ENGINE KNOCKS COLD AND CONTINUES FOR TWO-THREE MINUTES AND/OR KNOCK INCREASES WITH ENGINE TORQUE Engine Knocks Cold and Continues for Two-Three Minutes and/or Knock Increases with Engine Torque Step Action Values Yes No Does the engine knock when it is cold 1 and continue for 2-3 minutes or does - Go to Step the knock increase with torque? 2 System OK Inspect the flywheel. 2 _|Is the flywheel contacting the splash - Go to Step shield? 3 Go to Step 4 3 _ [Reposition the splash shield Go to Step Did you complete the repair? 1 : Inspect the balancer and the drive 4 {pulleys . Is either the balancer or the drive Go to Step pulleys loose or broken? Go to Step 6 Tighten or replace the balancer or the 5 |drive pulleys. 5 Go to Step Did you find and correct the condition? 1 : Inspect the piston-to-bore clearance. 0.03 mm 6 [Is the clearance more than the specified | 4915 jy) | Go to Step value? 5 1 Go to Step 8 1. Bore the cylinder and hone to size. IMPORTANT: Cold engine piston knock usually2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo disappears when the cylinder is. grounded out. Cold engine piston knock, which disappears in about 1.5 minutes, is considered acceptable. necessary Go to Step 7 = 2. Replace the piston. Go to Step Did you find and correct the condition? 1 : 8 Inspect the connecting rod. . Go to Step Is the connecting rod bent? 9 System OK 9 Replace the connecting rod. . Go to Step Did you complete the replacement? 1 : ENGINE NOISE UNDER LOAD Engine Noise Under Load Step Action Values Yes No 1 Is there a heavy knock when the engine . Go to Step is hot and torque is applied? 2 System OK Inspect the balancer and the pulley hub. 2 [Is the balancer or the pulley hub = Go to Step broken? 3 Go to Step 4 Replace the broken balancer or the 3 |pulley hub. : Go to Step Did you complete the replacement? 1 3 4 Inspect the accessory belts. . Go to Step Are the belts too tight or nicked? 5 Go to Step 6 Replace and/or tension the belts to 5 | specifications, as necessary. : Go to Step Did you complete the replacement? 1 5 6 Inspect the exhaust system. . Go to Step Is the system grounded? 7 Go to Step 8 7 [Reposition the system, as necessary. . Go to Step Did you find and correct the condition? 1 - 8 Inspect the flywheel. . Go to Step | Go to Step Is the flywheel cracked? 9 10 9 [Replace the flywheel. : Go to Step Did you complete the replacement? 1 5 Inspect the main bearing clearance. __|0.026-0.046 10. |Is the clearance more than the specified | mm (0.001-| Go to Step | Go to Step range? 0.00181 in) iu 12 11 [Replace the main bearings, as .2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Did you complete the replacement? 1 5 Inspect the rod bearing clearance. 0019-007 12 ise eae more than the specified] (997. | Go to Step e 0.0027 in) 13 System OK B Replace the rod bearings, as necessary. . Go to Step ~ [Did you complete the replacement? 1 - LIGHT KNOCK HOT Light Knock Hot Step Action Values Yes No I Is there a light knock when the engine . Go to Step is hot? 2 System OK 5 [Is detonation or spark knock evident? - Go to Step - 3 Go to Step 4 Inspect the engine timing and the fuel 3 | quality. - Go to Step Did you find and correct the condition? 1 : Inspect the torque converter bolts. 45Nm (3 4 |Are the bolts tightened to the specified | “~ Ib fi) ~~ | Go to Step value? 5 Go to Step 6 5 Tighten the torque converter bolts. . Go to Step Did you find and correct the condition? 1 : Inspect the manifold. 6 _|Is there an exhaust leak at the 5 Go to Step manifold? 7 Go to Step 8 7 [Tighten the bolts or replace the gasket. z Go to Step Did you find and correct the condition? 1 : Inspect the rod bearing clearance. 0.019-0.07 g__[!sthe clearance within the specified mm range? (0,0007- | Go to Step 0.0027 in) 9 ¢g _ [Replace the rod bearings, as necessary. Go to Step Did you complete the replacement? 1 5 ENGINE NOISE ON START-UP, BUT ONLY LASTING A FEW SECONDS Engine Noise on Start-Up, but Only Lasting a Few Seconds Step Action Values Yes No IMPORTANT: ‘An engine that is only operated for short periods between start-ups may have lifter noise that2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo lasts for a few minutes. This is a normal condition. Does the engine knock during initial Go to Step start-up but last only a few seconds? 2 Inspect the engine oil 2 |Is the proper viscosity oil used in the - Go to Step crankcase? 4 Go to Step 3 Install oil of the proper viscosity for the 3 |expected seasonal temperatures. - Go to Step Did you find and correct the condition? 1 : Inspect the hydraulic lifters. 4 |Is there evidence of hydraulic lifter = Go to Step bleed-down? 5 Go to Step 6 IMPORTANT: When the engine is stopped, some vaives will be open. Spring pressure against the lifters will tend to bleed lifter down. ‘Attempts to repair this should be made only 5_| if the problem is consistent. - Clean, test, and replace the lifters, as necessary Did you find and correct the Go to Step condition? 1 : Inspect the crankshaft end clearance. . 0.1mm 6 JIsthe clearance more than specified | (9 4939 jn) | Go 10 Step value? “ 7 Go to Step 8 7 [Replace the crankshaft thrust bearing : Go to Step Did you complete the replacement? 1 e Inspect the front main bearing aerate g_ [clearance mam (0.001- Is the clearance more than the specified |" go 1g in) Go to Step range? 9 System OK Replace the worn parts of the front 9 |main bearing, : Go to Step Did you complete the replacement? 1 a KNOCKS AT IDLE HOT Knocks at Idle Hot Step ‘Action Values Yes No _ [Does the engine knock at idle when Go to Step hot? 2 Inspect the drive belts. Are the belts loose or worn? Go to Step 3 Goto Step 42004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Tension or replace the belts, as 3. |necessary. s Go to Step Did you find and correct the condition? 1 : Inspect the A/C compressor and the 4 _ {generator. . Is either the compressor or the Go to Step generator faulty? 5 Go to Step 6 Replace the faulty A/C compressor or 5 |the generator. - Go to Step Did you complete the replacement? 1 : 6 _ [Inspect the valve train. . Go to Step Are valve train components faulty? 1 Go to Step 8 Replace the faulty valve train 7 |components. - Go to Step Did you complete the replacement? 1 Q Inspect the engine oil 8 _|Is the proper viscosity oil used in the - Go to Step crankcase? 10 Go to Step 9 Install oil of the proper viscosity for the| 9 expected seasonal temperatures a Go to Step Did you find and correct the condition? 1 - Inspect the piston pin clearance. 0.02 mm 10 |Is the clearance more than the specified Oy Go to Step | Go to Step value? ooo) a 2 11 [Replace the piston and the pin. z Go to Step Did you complete the replacement? 1 5 2 Inspect the connecting rod alignment. . Go to Step | Go to Step Is the alignment faulty? 1B 14 13 Inspect and replace rods, as necessary. - Go to Step “ [Did you find and correct the condition? 1 2 Inspect the piston-to-bore clearance. 0.03 mm 14 |Is the clearance more than the specified 5 Go to Step | Go to Step value? Coos) 6 15 15. [Hone the bore and fit a new piston. z Go to Step Did you find and correct the condition? 1 - 16 Inspect the crankshaft balancer. . Go to Step | Go to Step Is the balancer loose? 17 18 17, | Torque or replace worn parts - Go to Step Did you find and correct the condition? 1 - Inspect the piston pin offset. 0.4-0.6 mm 18 |Is the offset toward the thrust side at | (0.02-0.003| Go to Step the specified range? Fil) 19 System OK2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Install the correct piston. '9 [Did you find and correct the condition? | Go to Step 1 MAIN BEARING NOISE Main Bearing Noise Step Action Values Yes No 1 Are dull thuds or knocks heard with . every engine revolution? Go to Step 2 | System OK Inspect the oil pump pressure. Go to Oil || the oil pump pressure low? Pressure Diagnosis and Testing |Go to Step 3 Inspect the crankshaft end play. 0.1mm Go to 3. [Does the crankshaft end play exceed | (9 993 jy) | Crankshaft the specified value? ? 7) | Replacement |Go to Step 4| Inspect the crankshaft journals 0.004mm | Goto 4 |Are the crankshaft journals out-of- (0.0002 in) | Crankshaft round? max __|Replacement|Go to Step 5 Inspect the belt tension. Go to Timing 5 |Is arepair necessary? e Belt Replacement |Go to Step 6 Inspect the crankshaft pulley Go to 6 Is the crankshaft pulley loose? : Crankshaft Replacement] System OK CONNECTING ROD BEAR! NOISE SYMPTOM Connecting Rod Bearing Noise Symptom Step ‘Action Yes No [IS aknock noise heard under all engine speeds? Goto Step 2 | System OK Inspect the crankshaft connecting rod {journal Goto Is the crankshaft connecting rod journal Crankshaft worn? Replacement | Go to Step 3 Cheek the oil pump pressure. Go to Oil 3__ |Is the oil pump pressure low? Pressure ° Diagnosis and Testing Go to Step 4 Inspect the crankshaft connecting rod 4 |journals. Goto Crankshaft2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Are the journals out-of-round? Replacement Go to Step 5 Inspect the connecting rods Go to Piston, Is there a misaligned connecting rod? Connecting 5 Rod, and Bearing Replacement | Go to Step 6 Inspect the connecting rod bolts. Go to Piston, Are the connecting rod bolts torqued Connecting 6 | properly? Rod, and Bearing System OK | Replacement PISTON NOISES Noises Step ‘Action Yes No ‘Are any of the following noises heard: a sharp double knock when the engine is 1 fidling, a light ticking with no load on the engine, or a slapping noise when the engine is cold? Go to Step 2 System OK Inspect the piston pin and the bushing. Go to Piston, Is the piston pin or the bushing worn or Connecting 2 |loose? Rod, and Bearing Replacement | Go to Step 3 Inspect the piston Go to Piston, Is the piston broken or cracked? Connecting 3 Rod, and Bearing Replacement | Go to Step 4 Inspect the connecting rods. Go to Piston, Is there a misaligned connecting rod? Connecting 4 Rod, and Bearing Replacement | Go to Step 5 Inspect the piston position Go to Piston, Is the piston 180 degrees out of position? Connecting I Rod, and Bearing Replacement | System OK MISFIRE WITH ABNORMAL VALVE TRAIN NOIS!2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Base Engine Misfire with Abnormal Valve Train Noise Step ‘Action Yes No 1 Is a light tapping sound heard from the engine? Goto Step2_| System OK Inspect the valve springs. Go to Cylinder 2. | Are the springs weak or broken? Head Disassemble Go to Step 3 Inspect the valves. Go to Cylinder 3. |Are the valves sticking or warped? Head Disassemble | Go to Step 4 Inspect the valve lifters. Go to Cylinder 4. | Are the valve lifters dirty, stuck, or worn? Head Disassemble Go to Step 5 Inspect the camshaft lobes. 5 |Are the camshaft lobes damaged or Go to Camshaft improperly machined? Replacement _| Go to Step 6 Inspect the oil supply to the valve train. Go to Cylinder 6 _|Is the oil supply insufficient or poor? Head Disassemble | Go to Step 7 Inspect the valve guides Go to Cylinder 7 |Are the valve guides worn? Head Disassemble Go to Step 8 Inspect the valve spring seat Go to Cylinder 8 _|Is the valve spring seat incorrect? Head Disassemble System OK ENGINE COMPRESSION TEST IMPORTANT: Disconnect the crankshaft position (CKP) sensor connector to disable the fuel and the ignition systems. Test the compression pressure for each cylinder, Low compression pressure may be the fault of the valves or the pistons. The following conditions should be considered when you check the cylinder compression: The engine should be at normal operating temperature. « The throttle must be wide open. « All the spark plugs should be removed. « The battery must be at or near full charge. 1. Place approximately 3 squirts of oil from a plunger-type oiler into each spark plug port 2. Insert the engine compression gage into each spark plug port.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo 3. Crank test each cylinder with 4-5 compression strokes using the starter motor. 4. The lowest reading should not be less than 70 percent of the highest reading. The compression gage reading should not be less than 689 kPa (100 psi) for any of the cylinders. 5, Examine the gage readings obtained after the 4 puffs per cylinder are obtained from cranking the starter motor. The readings are explained in the following descriptions: « Normal condition - Compression builds up quickly and evenly to the specified compression on each cylinder. « Piston rings faulty - Compression is low on the first stroke and tends to build up on following strokes, but the compression pressure does not reach normal, The compression pressure improves considerably with the addition of oil into the cylinder. « Valves faulty - Low compression pressure on the first stroke. The compression pressure does not tend to build up on the following strokes. The compression pressure does not improve much with the addition of oil into the cylinder. REPAIR INSTRUCTIONS L KE MANIFOLD REPLACEMENT Removal Procedure2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo w : View Of Pump Fuse Courtesy of GENERAL MOTORS CORP. Remove the fuel pump fuse. Start the engine. After it stalls, crank the engine 10 seconds to rid the fuel system of fuel pressure. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. Disconnect the negative battery cable. Disconnect the engine control module (ECM) ground terminal from the intake manifold2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 6: Locating Intake Ducting To Engine Courtesy of GENERAL MOTORS CORP. 5. Drain the engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling Disconnect the intake air temperature (IAT) sensor connector. 7. Disconnect the air intake tube from the throttle body,2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 7: View Of IAC Connector And TP Sensor Connector Courtesy of GENERAL MOTORS CORP. 8. Disconnect the idle air control valve (IAC) connector. 9. Disconnect the throttle position (TP) sensor connector.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 8: View Of Throttle Cable Courtesy of GENERAL MOTORS CORP. 10. Disconnect the heater inlet hose from the coolant distributor beneath the intake manifold 11. Disconnect the surge tank coolant hose at the throttle body. 12, Disconnect all of the necessary vacuum hoses, including the vacuum hose at the fuel pressure regulator and the brake booster vacuum hose at the intake manifold.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo / iS [Ai Vi Fig. 9: View Of Fuel Rail Fuel Feed Line Courtesy of GENERAL MOTORS CORP. 13. Disconnect the throttle cable from the throttle body and the intake manifold. 14, Remove the 2 throttle cable bracket bolts and the throttle cable bracket 15. Disconnect the fuel feed line from the fuel rail.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 10: View Of Fuel Injectors Courtesy of GENERAL MOTORS CORP. 16. Disconnect the fuel injector connectors from the fuel injectors. 17. Remove the 2 retaining bolts from the fuel injector rail 18. Remove the fuel injector rail and fuel injectors as an assembly. Refer to Fuel Rail Assembly Replacement in Engine Controls-1 4.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo 19. 20. 21 22. Fig. 11: View Of Serpentine Accessory Drive Belt Tensioner Courtesy of GENERAL MOTORS CORP. Remove the serpentine accessory drive belt. Remove the alternator bracket and the bolt. Remove the 3 intake manifold support bracket retaining bolts from the coolant distributor and the engine block. Remove the intake manifold support bracket.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 12: Removal Sequence Of Intake Manifold Retaining Nuts And Engine Lift Bracket Bolt Courtesy of GENERAL MOTORS CORP. Remove the intake manifold retaining nuts and the engine lift bracket bolt in the sequence shown N 82004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo 24. Remove the intake manifold. 25, Remove the intake manifold gasket. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. 26. Clean the sealing surfaces of the intake manifold and the cylinder head. Installation Procedure2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo one Fig. 14: Installing Sequence Of Intake Manifold Retaining Nuts And Engine Lift Bracket Bolt Courtesy of GENERAL MOTORS CORP. Install the intake manifold gasket. Install the intake manifold. NOTE: Refer to Fastener Notice in Cautions and Notices. Install the intake manifold retaining nuts and the engine lift bracket bolt in the sequence shown, Tighten: « Tighten the intake manifold retaining nuts in the sequence shown to 25 N.m (18 Ib ft) « Tighten the engine lift bracket bolt to 25 N.m (18 Ib fi).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 15: View Of Serpentine Accessory Drive Belt Tensioner Courtesy of GENERAL MOTORS CORP. Install the intake manifold support bracket. Install the intake manifold support bracket retaining bolts. Tighten: Tighten the intake manifold support bracket retaining bolts to 25 N.m (18 Ib fb). Install the alternator bracket and the bolts. Tighten: Tighten the alternator bracket retaining bolts to 25 N.m (18 Ib ft). NOTE: Refer to Belt Dressing Notice in Cautions and Notices. Install the serpentine accessory drive belt2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 16: View Of Fuel Injectors Courtesy of GENERAL MOTORS CORP. rs Install the fuel rail and the fuel injectors as an assembly. Refer to Fuel Rail Assembly Replacement in Engine Controls-14L ° Install the fuel rail retaining bolts. Tighten: Tighten the fuel rail retaining bolts to 25 N.m (18 lb ft). 10. Connect the fuel feed line to the fuel rail2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo 11 12, 13. 14, 15, 16, 17 Fig. 17: View Of Throttle Cable Courtesy of GENERAL MOTORS CORP. Connect the throttle cable to the intake manifold and the throttle body Connect the fuel injector connectors to the fuel injectors Connect all of the vacuum lines that were previously disconnected. Connect the heater inlet hose to the coolant distributor beneath the intake manifold. Connect the surge tank coolant hose to the throttle body. Connect the IAC valve connector. Connect the throttle position sensor connector.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo 18 19. 20. 21 22. 23. Fig. 18: Locating Intake Ducting To Engine Courtesy of GENERAL MOTORS CORP. Connect the air intake tube to the throttle body. Connect the IAT sensor connector. Connect the ECM ground terminal to the intake manifold, Connect the negative battery cable. Install the fuel pump fuse Refill the engine cooling system. Refer to Draining and Filling Cooling System in Engine Cooling TIMING BELT COVER REPLACEMENT. Removal Procedure2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 19: View Of Timing Belt Cover Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Remove the timing belt. Refer to Timing Belt Replacement. IMPORTANT: Take extreme care to prevent any scratches, nicks, or2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo damage to the camshaft. Such damage can impair vehicle operation. Remove the camshaft gear. Refer to Camshaft Gear Replacement. Remove the timing belt automatic tensioner bolt. Remove the timing belt automatic tensioner. Remove the rear timing belt cover bolts. NAWEY Remove the rear timing belt cover Installation Procedure Fig. 20: View Of Camshaft Gears And Timing Belt Courtesy of GENERAL MOTORS CORP. 1. Install the rear timing belt cover.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo 5. 6 7 NOTE: Refer to Fastener Notice in Cautions and Notices. Install the rear timing belt cover bolts. Tighten: Tighten the rear timing belt cover bolts to 10 N.m (89 Ib in). Install the timing belt automatic tensioner. Install the timing belt automatic tensioner bolt. Tighten: Tighten the timing belt automatic tensioner bolt to 20 N.m (15 Ib ft). IMPORTANT: Take extreme car to prevent any scratches, nicks, or damage to the camshaft. Such damage can impair vehicle operation. Install the camshaft gear. Refer to Camshaft Gear Replacement. Install the timing belt. Refer to Timing Belt Replacement. Connect the negative battery cable: TIMING BELT REPLACEMENT Tools Required « J 42492-A (KM 421-A) Timing Belt Adjuster J 45059 Angle Meter + KM-470-B Angular Torque Gage Removal Procedure2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo RYN Fig. 21: Locating Intake Ducting To Engine Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. Disconnect the negative battery cable. Disconnect the intake air temperature (IAT) sensor connector. Disconnect the air intake tube from the throttle body. Disconnect the breather tube from the valve cover.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 22: View Of Air Cleaner Housing Courtesy of GENERAL MOTORS CORP. Remove the air cleaner housing bolts. Remove the air cleaner housing. Remove the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels Remove the right front wheel well splash shield.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo g Belt Cover And Bolts Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Belt Dressing Notice in Cautions and Notices. 9. Remove the serpentine accessory drive bolt. Refer to Power Steering Pump Hoses and Pipes Replacement in Power Steering System, 10. Remove the upper timing belt cover bolts. 11. Remove the upper timing belt cover2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo 12. 13, 15, Fig. 24: View Of Lower Timing Belt Cover Courtesy of GENERAL MOTORS CORP. Remove the crankshaft pulley bolt. Remove the crankshaft pulley Remove the lower timing belt cover bolts Remove the lower timing belt cover2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 25: Aligning Crankshaft Gear To Rear Timing Belt Cover Bottom Notch Courtesy of GENERAL MOTORS CORP. 16. Install the crankshaft pulley bolt 17. Using the crankshaft pulley bolt, rotate the crankshaft clockwise until the mark on the crankshaft gear is aligned with the notch at the bottom of the rear timing belt cover.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo 18. 19, 20. 21 Fig. 26: Releasing/Adding Timing Belt Tension Using J 42492-A Courtesy of GENERAL MOTORS CORP. Slightly loosen the coolant pump retaining bolts. Using the J 42492-A (1), rotate the coolant pump counterclockwise to release the tension on the timing belt Remove the engine mount bracket. Refer to Engine Mount Replacement. Remove the timing belt. Installation Procedure2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo 3. Fig, 27: Installing Timing Belt Courtesy of GENERAL MOTORS CORP. Align the mark on the crankshaft gear to the notch on the bottom of the rear timing belt cover. Align the mark on the camshaft gear to the notch on the top of the rear timing belt cover. Install the timing belt.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 28: Releasing/Adding Timing Belt Tension Using J 42492-A “ourtesy of GENERAL MOTORS CORP. Using the J 42492-A (1), rotate the coolant pump clockwise to add the highest tension to the timing belt. Tighten the coolant pump retaining bolts loosely2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 29: Aligning Adjust Arm Hole Timing Belt Automatic Tensioner to Bracket Courtesy of GENERAL MOTORS CORP. Align the adjust arm hole of the timing belt automatic tensioner to the hole in the timing belt automatic tensioner bracket. Insert a 4.5 mm (0,177 in) driver through the adjust arm hole and the tensioner bracket hole.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 30: Aligning Crankshaft Gear To Rear Timing Belt Cover Bottom Notch Courtesy of GENERAL MOTORS CORP. 8. Rotate the crankshaft 2 full turns clockwise using the crankshaft pulley bolt. 9. Align the mark on the crankshaft gear to the notch at the bottom of the rear timing belt cover.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 31: Releasing/Adding Timing Belt Tension Using J 42492-A “ourtesy of GENERAL MOTORS CORP. 10. Remove the driver from the timing belt automatic tensioner 11. Slightly loosen the 3 coolant pump retaining bolts. 12. Using the J 42492-A (1), rotate the coolant pump.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 32: View Of Camshaft Gears And Timin; Courtesy of GENERAL MOTORS CORP. 13. Rotate the coolant pump until the adjust arm pointer of the timing belt automatic tensioner is aligned with the notch in the timing belt automatic tensioner bracket NOTE: Refer to Fastener Notice in Cautions and Notices. 14, Tighten the coolant pump retaining bolts. Tighten: Tighten the coolant pump retaining bolts to 10 N.m (89 Ib in).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 33: View Of Lower Timing Belt Cover Courtesy of GENERAL MOTORS CORP. 15, Remove the crankshaft pulley bolt. 16. Install the lower timing belt cover. 17. Install the lower timing belt cover bolts. Tighten: Tighten the lower timing belt cover bolts to 10 N.m (89 Ib in).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 34: View Of Crankshaft Pulley And Bolt Courtesy of GENERAL MOTORS CORP. 18. Install the crankshaft pulley. 19. Install the crankshaft pulley bolt Tighten: « Tighten the crankshaft pulley bolt to 95 N.m (70 Ib ft) using a torque wrench. « Using the KM-470-B or the J 45059 , tighten the crankshaft pulley bolt another 30 degrees plus 15 degrees.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 35: View Of Upper Timing Belt Cover And Bolts Courtesy of GENERAL MOTORS CORP. 20. Instal the upper timing belt cover. 21. Install the upper timing belt cover bolts. Tighten: Tighten the upper timing belt cover bolts to 10 N.m (89 Ib in)2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 36: View Of Serpentine Accessory Drive Belt Tensioner Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Belt Dressing Notice in Cautions and Notices. 22. Install the serpentine accessory drive belt2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 37: View Of Air Cleaner Housing Courtesy of GENERAL MOTORS CORP. eld. ‘e and Wheel Removal and Installation in Install the right front wheel well splas Install the right front wheel. Refer to Tires and Wheels. Install the air filter housing. Install the air filter housing bolts. Tighten: Tighten the air filter housing bolts to 8 N.m (71 Ib in).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 38: Locating Intake Ducting To Engine Courtesy of GENERAL MOTORS CORP. 27. Connect the air intake tube to the throttle body. 28. Connect the breather tube to the valve cover. 29. Connect the IAT sensor connector. 30. Connect the negative battery cable. TIMING BELT INSPECTION ‘Tools Required « J.42492-A (KM 421-A) Timing Belt Adjuster « J 45059 Angle Meter « KM-470-B Angular Torque Gage Adjustment Procedure2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo RYN Fig. 39: Locating Intake Ducting To Engine Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. Disconnect the negative battery cable. Disconnect the intake air temperature (IAT) sensor connector. Disconnect the air intake tube from the throttle body. Disconnect the breather tube from the valve cover.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 40: View Of Air Cleaner Housing Courtesy of GENERAL MOTORS CORP. Remove the air cleaner housing bolts. Remove the air cleaner housing. Remove the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels Remove the right front wheel well splash shield.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Courtesy of GENERAL MOTORS CORP. ° Remove the serpentine accessory drive belt. Refer to Power Steering Pump Hoses and Pipes Replacement in Power Steering System, 10, Remove the upper timing belt cover bolts. 11. Remove the upper timing belt cover.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 42: View Of Crankshaft Pulley And Bolt Courtesy of GENERAL MOTORS CORP. 12, Remove the crankshaft pulley bolt. 13, Remove the crankshaft pulley.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 43: View Of Lower Timing Belt Cover Courtesy of GENERAL MOTORS CORP. 14. Remove the lower timing belt cover bolts. 15. Remove the lower timing belt cover.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 44: Aligning Crankshaft Gear To Rear Timing Belt Cover Bottom Notch Courtesy of GENERAL MOTORS CORP. 16. Install the crankshaft pulley bolt 17. Rotate the crankshaft at least | full turn clockwise using the crankshaft pulley bolt. 18. Align the dot on the crankshaft gear to the notch at the bottom of the rear timing belt cover2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 45: Aligning Camshaft Gear Timing Mark To Rear Timing Belt Notch Courtesy of GENERAL MOTORS CORP. 19. Align the camshaft gear timing mark to the notch at the top of the rear timing belt cover.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 46: Releasing/Adding Timing Belt Tension Using J 42492-A Courtesy of GENERAL MOTORS CORP. Slightly loosen the 3 coolant pump retaining bolts. Using the J 42492-A , rotate the coolant pump clockwise to add the highest tension to the timing belt. Tighten the coolant pump retaining bolts loosely.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 47: Aligning Adjust Arm Hole Timing Belt Automatic Tensioner to Bracket Courtesy of GENERAL MOTORS CORP. Align the adjust arm hole of the timing belt automatic tensioner to the hole in the timing belt automatic tensioner bracket. Insert a 4.5 mm (0,177 in) driver through the adjust arm hole and the tensioner bracket hole. Rotate the crankshaft 2 full turns clockwise using the crankshaft pulley bolt Rotate the crankshaft at least 1 full turn clockwise using the crankshaft pulley bolt. Remove the driver from the timing belt automatic tensioner Loosen the coolant pump retaining bolts.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 48: View Of Camshaft Gears And Timin; Courtesy of GENERAL MOTORS CORP. 29. Rotate the coolant pump until the adjust arm pointer of the timing belt automatic tensioner is aligned with the notch in the timing belt automatic tensioner bracket NOTE: Refer to Fastener Notice in Cautions and Notices. 30. Tighten the coolant pump retaining bolts. Tighten: Tighten the coolant pump retaining bolts to 10 N.m (89 Ib in).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 49: View Of Lower Timing Belt Cover Courtesy of GENERAL MOTORS CORP. 31, Remove the crankshaft pulley bolt. 32. Install the lower timing belt cover. 33. Install the lower timing belt cover bolts. Tighten: Tighten the lower timing belt cover bolts to 10 N.m (89 Ib in).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 50: View Of Crankshaft Pulley And Bolt Courtesy of GENERAL MOTORS CORP. 34, Install the crankshaft pulley. 35. Install the crankshaft pulley bolt Tighten: « Tighten the crankshaft pulley bolt to 95 N.m (70 Ib ft) using a torque wrench « Use the KM-470-B or the J 45059 to tighten the crankshaft pulley bolt another 30 degrees plus 15 degrees.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo 36. 37. 38. Fig. 51: View Of Upper Timing Belt Cover And Bolts Courtesy of GENERAL MOTORS CORP. Install the upper timing belt cover. Install the upper timing belt cover bolts. Tighten: Tighten the upper timing belt cover bolts to 10 N.m (89 Ib in) NOTE: Refer to Belt Dressing Notice in Cautions and Notices. Install the serpentine accessory drive belt. Refer to Power Steering Pump Hoses and Pipes Replacement in Power Steering System2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo 39. 40. 41 42, Fig. 52: View Of Serpentine Accessory Drive Belt Tensioner Courtesy of GENERAL MOTORS CORP. Install the right front wheel well splash shield Install the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. Install the air cleaner housing. Install the air cleaner housing bolts. Tighten: Tighten the air filter housing bolts to 8 N.m (71 Ib in).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 53: Locating Intake Ducting To Engine Courtesy of GENERAL MOTORS CORP. 43. Connect the air intake tube to the throttle body. 44. Connect the breather tube to the valve cover. 45. Connect the IAT sensor connector. 46. Connect the negative battery cable. VALVE ROCKER ARM COVER REPLACEMENT. Removal Procedure2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 54: View Of Valve Cover Breather Hose Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Disconnect the breather hose from the valve cover2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 55: View Of Valve Cover, Gasket, And Bolts Courtesy of GENERAL MOTORS CORP. 3, Remove the eight bolts from the valve cover 4. Remove the valve cover. 5. Remove the valve cover gasket 6. Clean the sealing surfaces Installation Procedure2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 56: View Of Valve Cover, Gasket, And Bolts Courtesy of GENERAL MOTORS CORP. 1. Install the new valve cover gasket and the valve cover NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Install the eight bolts to the valve cover Tighten: Tighten the valve cover bolts to 9 N.m (80 Ib in).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 57: View Of Valve Cover Breather Hose Courtesy of GENERAL MOTORS CORP. 3. Connect the breather tube to the valve cover. 4. Connect the negative battery cable. VALVE GUIDE REAMING/VALVE AND SEAT GRINDING Tools Required « KM-419 Distance Gage. See Special Tools and Equipment. ¢ KM-571-B Gage or Equivalent * KM-340-1-C Cutter Set (Including tools KM 340-7, KM 340-13, and KM 340-26) « KM-253 Valve Guide Reamer. See Speci « KM-254 Valve Guide Reamer. See Sp « KM-255 Valve Guide Reamer. See Sp Tools and Equipment Tools and Equipment al Tools and Equipment.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. Lubricate the valve stem using a fine-grained paste. Lift the valve rhythmically from the seat with a commercially available valve grinding tool in order to distribute the paste.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 59: Cleaning Valves, Valve Guides And Cylinder Head Courtesy of GENERAL MOTORS CORP. 3. Check the contact pattern on the valve head and in the cylinder head. 4. Clean the valves, the valve guides, and the cylinder head. Valve Grind2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo wR Fig. 60: Refacing Valve Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. Ensure that there are no crater line burns on the valve cone. The valve may be reground only 2 times. Do not grind the valve stem end. The angle at the valve face angle is 46 degrees2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 61: Checking Valve Stem Projection Using KM-419 Courtesy of GENERAL MOTORS CORP. 4, Check the valve stem projection using the KM-419 (1). See Special Tools and Equipment Valve Guide Ream2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 62: Measuring Valve Guide Diameter Using KM-571-B Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. 1. Measure the diameter of the valve guide using the KM-571-B and a commercially available inside micrometer IMPORTANT: Valve oversizes may already have been fitted in production. 2. An oversize code is on the valve guide and the valve stem end. The Valve Guide Reaming Table gives the correct size, reamer, and production code for each service code. Refer to Engine Mechanical Specifications. 3. Ream the valve guide from the upper side of the cylinder head to the next oversize. After reaming, cross out the code and emboss the valve guide with the new code.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Valve Seat - Cut Fig. 63: View Of Valve Seat, Upper Correction Angle, And Lower Correction Angle Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. 1. Place the cylinder head on wooden blocks 2. Cut the intake and the exhaust valve seats using the KM 340-7 as follows « Valve seat-A 45 degree side (b) using the KM 340-13 Upper correction angle-A 30 degree side (a) using the KM 340-13 « Lower correction angle-A 60 degree side (c) using the KM 340-262004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 64: Checking Valve Stem Projection Using KM-419 Courtesy of GENERAL MOTORS CORP. Clean the chippings from the cylinder head. Inspect the dimension for the proper valve seat width. Specification: # Intake-1.3-1.5 mm (0.051-0.059 in) Exhaust-1.6-1.8 mm (0.063-0.071 in) Inspect the valve stem projection using the KM-419 (1). See Special Tools and Equipment.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo Fig. 65: View Of Cylinder Head And Valves Courtesy of GENERAL MOTORS CORP. 6. If the dimension is exceeded, install new valves and then check the valve stem projection again. Refer to Valve Guide Reaming/Valve and Seat Grinding 7. If the valve stem projection is still too large despite replacing the valves, replace the cylinder head. CYLINDER HEAD REPLACEMENT Removal Installation Tools Required « J.42492-A (KM 421-A) Timing Belt Adjuster 3.45059 Angular Meter « KM-470-B Angular Torque Gage2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.4L SOHC - Aveo NS Bw Fig. 66: View Of Pump Fuse Courtesy of GENERAL MOTORS CORP. CAUTION: Valve springs can be tightly compressed. Use care when removing the retainers and plugs. Personal injury could result. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. Remove the fuel pump fuse Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. Disconnect the negative battery cable Disconnect the engine control module (ECM) ground terminal from the intake