2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical- 1.2L - Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo SPECIFICATIONS FAST! ER TIGHTENING SPECIFICA’ Fastener Tightening Specifica Specification Application Metric English AIC Compressor Mounting Bracket Bolts 38Nm 28 Ib ft Adjusting Bolt 22Nm 16 Ib ft Air Cleaner Housing Nuts 12Nm 106 Ib in Camshaft Gear Bolt 35N.m 41 Ib ft Camshaft Thrust Plate Screws 10Nm 89 Ib in Catalytic Converter Lower Flange Nuts 40 Nm 30 Ib ft Catalytic Converter to Exhaust Manifold Nuts 25-35 Nm 18-25 Ib ft Connecting Rod Bearing Cap Nuts 33Nm 24 Ib ft Crankshaft Main Bearing Cap Bolts 57 Nm 42 Ib ft Crankshaft Pulley Bolt 70 Nm 52 Ib ft Cylinder Head Bolts 65-70 Nm 48-52 Ib ft Cylinder Head Cover Hexagon Bolts 9-12 Nn 80-106 Ib in Engine Mount Brace Bracket Nuts 20N.m 15 Ib ft Engine Mount Damping Block Bolts 50N.m 37 Ib ft Engine Mount Intermediate Bracket Bolts 55 Nm 41 ib ft Engine Mount Intermediate Bracket Upper Nuts 65 N.m 44 Tb ft Engine Mount Lower Bracket Bolts 38 Nm 28 Ib ft Engine Mount Upper Bracket Bolts 38N.m 28 Ib ft Exhaust Manifold Bolts/Nuts 22N.m 16 Ib ft Exhaust Manifold Heat Shield Bolts 10 Nm 89 Ib in Flywheel Inspection Lower Bolts 3.5Nm 49 Ib in Front Exhaust Pipe Bracket Bolts 40 Nm 30 Ib ft Front Exhaust Pipe Nuts 30 N.m 2Ibh Generator Belt Tension Adjusting Bolt 23N.m 17 Ib ft Generator Lower Bolts/Nut 23 N.m I7 Ib tt Generator Shackle Bolts 30N.m 2Ibht Intake Manifold Main Bracket Bolts - [0M 10 Nm 89 1b in Intake Manifold Main Bracket Nuts 10Nm 89 Ib in Intake Manifold Nuts 17N.m 13 Ib ft2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical- 1.2L - Aveo Intake Manifold Subsidiary Bracket Bolt 10 N.m 89 Ib in Intake Manifold Subsidiary Bracket Nut 17Nm 13 Ib ft Intermediate Bracket Bolt 55. N.m 37 Ib ft Oil Level Gage Guide Tube Bolt 10.5 N.m 93 Ib in Oil Pan Bolts/Nuts 10 N.m 89 Ib in Oil Pump Cover Bolts 10.5 Nm 93 Ib in Oil Pump Pickup Tube Bolts 10 N.m 89 Ib in Oil Pump Strainer Bolt 10.5 Nm 93 1b in Power Steering Rear Bracket Nut 22Nm 16 Ib ft Rocker Arm Shaft Bolts 10 N.m 89 Ib in Timing Belt Front Lower Cover Bolts 10.5 Nm 93 Ib in Timing Belt Front Upper Cover Bolts 10.5 Nm 93 1b in Timing Belt Rear Cover Bolts 10.5 Nm 93 Tb in Timing Belt Tensioner Bolt 19 Nm 14 Ib tt Valve Adjusting Lock Nuts 17Nm 13 Ib ft Valve Cover Bolts 10.5 Nm 93 Ib in Water Outlet Case Nuts/Bolt 10.5 Nm 93 Ib in ENG MECHANICAL SPECIFICATIONS General Specifications Specification Application Metric English Engine Information « Engine Type Overhead Cam L-4 « Bore 68.5 mm 2.70 in ¢ Compression Ratio 9.3:1 Firing Order 13-42 # Lubricating Type Forced Feed ¢ Maximum Power at 5,400 RPM 52.2 kW 7LHP « Maximum Torque at 4,200 RPM 104 Nm 76.7 Ib ft Oil Pump Type Trocboid Rotor # Oil Filter Type Cartridge (Full Flow) Oil Pan Capacity Including Oil Filter 3.2 liter 3.4 quarts « Stroke 78.0 mm 3.07 in « Total Displacement 1150 om?2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical- 1.2L - Aveo Cylinder Compression Check Specifications Cylinder Number Condition 1 2 3 4 Compression top dead center of No. I cylinder « Intake oO oO : - Exhaust 0 a Oo a Exhaust top dead center of No. | cylinder « Intake S S oO oO Exhaust > oO - Oo * O marks indicate the place where the valve clearance can be checked and adjusted. Valve Clearance Specifications Specification Application Metric English Cold * Intake 0.15 +0002 mm 0.0059 + 0.0008 0.00787 +/- « Exhaust 0.2 +/-0.02mm | 9 0098 in Hot * Intake 0.25 +/- 0.02 mm |°-0098 = 0.0008 Exhaust 0.3 +/- 0.02 mm 0.0118 +/- 0.0008 in Engine Mechanical Specifications Specification Application Metric English Camshaft « Bearing Outside Diameter, Head Journal 1 | 43.5000-43.516 | 1 543.1 7139 in D,No. 1 mm + Bearing Outside Diameter, Head Journal I | 43.700-43.716 | 1 459.4 7911 in D. No. 2 mm « Bearing Outside Diameter, Head Journal |_| 43.900-43.916 |) a5 1 7990 in D, No. 3 mm « Bearing Outside Diameter, Head Journal | | 44.100-44.116 | | 736 17369 in D,No. 4 mm e Bearing Outside Diameter. Head Journal I 44 300-44.316 1.744-1.745 in2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical- 1.2L - Aveo D, No. 5 End Play e Journal Outside Diameter No. 43.425-43.450 1.710-1.711 in mm « Journal Outside Diameter No. 2 ie cecoal IETS 10719 i « Journal Outside Diameter No. 3 ere een |I72Se1°726 ia « Journal Outside Diameter No. 4 14.025-44.050 1.733 1.734 in 5. « Journal Outside Diameter No. 5 14225-44250) a41-1.742 in Lift Exhaust 5.38 mm 0.212 in «Lift Intake 5.42 mm 0.213 in Crankshaft 37,982-38 | . + Connecting Rod Journal Diameter, All 57,982-38.000 | 495-1 496 in mm ¢ Main Journal Crankshaft End Play 0.11-0.31 mm | 0,004-0.012 in ¢ Main Journal Diameter, All $53.982-44-000 |) 7316-1.7323 in ¢ Main Journal Main Bearing Clearance, All | 9.020-0.040 mm | 0.0008-0.0016 in ¢ Main Journal Out of Round, Maximum 0.005 mm 0.0002 in ¢ Main Journal Taper, Maximum 0.005 mm 0.0002 in ¢ Out of Round, Maximum 0.005 mm 0.0002 in « Rod Bearing Clearance, All 0,020-0,040 mm | 0,0008-0.0016 in « Rod Side Clearance 0.10-0.25 mm | 0.004-0.010 in + Taper, Maximum 0.005 mm 0.0002 in Cylinder Bore « Diameter 68.5 mm 2.70 in « Out of Round, Maximum 0.005 mm 0.00020 in «Taper, Maximum 0.005 mm 0.00020 in Oil Pump + Gap Between Oi Pump Body and Outer] 9 10.0.17 mm | 0.0039.0.067 in Inner Rotor Side Clearance 0.065-0.115 mm 0.0026-0.0045 in Outer Rotor Side Clearance 0.065-0.115 mm 0.0026-0.0045 in2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical- 1.2L - Aveo « Relief Valve Spring Free Length 52.4 mm 2.06 in Piston # Clearance to Bore 0.025-0.045 mm | 0.0010-0.0018 in Diameter 68.465-68.485 | 5 695.2.696 in mm Piston Pin « Diameter 16.995-17.000 | 9 6691-0,6693 in mm « Pin Off-Set 0.4-0.9mm | 0.016-0.035 in Piston Rings, End Gap « Top Compression 0.15-0.30 mm | 0.006-0.012 in « 2nd Compression 0,30-0.45 mm_| 0.012-0.0.18 in Piston Rings, Groove Clearance «Top Impression 0.02-0.06 mm | 0,0008-0,002 in «2nd Impression 0.02-0.06 mm | 0.0008-0.002 in Valve System + Face Angle, All 45 degrees « Face Runout, Maximum, All 0.045 mm 0.0018 in + Seat Angle, All 45 degrees @ Seat Runout, Maximum, All 0.05 mm 0.0019 in « Seat Width, Exhaust 156 mm 0.061 in « Seat Width, Intake 156 mm 0.061 in « Valve Diameter, All, Exhaust 317-319 mm | _1.248-1.256 in « Valve Diameter, All, Intake 35.5-35.7 mm | 1398-1406 in « Valve Guide Inside Diameter 5.500-5.512 mm | 0.2165-0.2170 in « Valve Lash Compensators Mechanical # Valve Spring Loads, Valve Closed . a aioe atta + Valve Spring Loads, Valve Open Rae eee eaten « Valve Stem Diameter, Exhaust 5.440-5.455 mm | _0.214-0.215 in « Valve Stem Diameter, Intake $.465-5.480 mm | 0.215-0.216 in COMPONENT LOCATOR DISASSEMRI ED VIFWS2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 1: Cylinder Head Disassembled View Courtesy of GENERAL MOTORS CORP. Callouts For Fig. 1 Callout ‘Component Name 1 Oil Filter Cap 2 Cylinder Head Cover 3 Valve Spring 4 Intake Rocker Arm Shaft 5 Exhaust Rocker Arm Shaft 6 Water Outlet Case 7 Camshaft 8 Rocker Arm 9 Cylinder Head Gasket 10 Cylinder Head u Rocker Arm 12 Intake Valve2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo 13 [Exhaust Valve Fig. 2: Engine Block Disassembled View Courtesy of GENERAL MOTORS CORP. Callouts For Fig. 2 Callout Component Name 1 Oil Level Gage Stick 2 Piston 3 Connecting Rod 4 Engine Block 5 Oil Filter i Flywheel2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo 1 Crankshaft 8 Oil Pan 9 Oil Pump Strainer 10 Oil Pump Assembly Fig. 3: Intake Manifold and Air Flow System Disassembled View Courtesy of GENERAL MOTORS CORP. Callouts For Fig. 3 Callout Component Name 1 Air Filter Assembly Exhaust Gas Recirculation (EGR) Pipe Exhaust Gas Recirculation (EGR) Valve and Solenoid Intake Manifold Throttle Body Assembly Oxygen Sensor Exhaust Manifold cofalal}ur}a}os|re Exhaust Manifold Heat Shield2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo 9 [Resonator Fig, 4: Timing Belt Components Disassembled View Courtesy of GENERAL MOTORS CORP. Callouts For Fig. 4 Callout Component Name 1 Timing Belt Upper Front Cover 2 Timing Belt Tensioner 3 Timing Belt Rear Cover Timing Belt Crankshaft Gear Crankshaft Pulley alalula Timing Belt Lower Front Cover DIAGNOSTIC INFORMATION AND PROCEDURES2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo DIAGNOSTIC STARTING POINT - EN MECHANICAL Begin the system diagnosis by reviewing the Symptoms-Engine Mechanical Symptoms - Engine Mechanical , 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 Engine Component Description in order to identify the correct procedure for diagnosing the system and where the procedure is located SYMPTOMS - ENGINE MECHANICAL Strategy Based Diagnostics 1. Perform the Diagnostic System Check - Engine Controls in Engine Controls - 1.2L 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 and Lubrication Description. 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 Inspecti « Inspect for aftermarket devices which could affect the operation of the engine Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Check for the correct oil level, proper oil viscosity, and correct filter application 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. 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2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo symptom: « Oil Pressure Diagnosis and Testing * 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 + Valve Timing Inspection and Adjustment OIL PRESSURE DIAGNO! ‘Tools Required J 21867 (KM 498-B) Pressure Gage. See Special Tools and Equipment 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. N 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 = Unbured fuel mixtures2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo * 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 6. Remove the oil pressure gage sensor. 7. Install the J 21867 (1) in place of the oil pressure sensor. See Special Tools and Equipment : View Of J21867 And Oil Pressure Sensor Courtesy of GENERAL MOTORS CORP. 8. Start the engine and then allow the engine to reach normal operation temperature. 9. Measure the engine oil pressure. IMPORTANT: The minimum oil pressure at idle should be 30 kPa (8.882004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo psi). The minimum oil pressure at 2000 RPM should be 250 kPa (35 p: 10. 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 « Missing or damaged oil pump screen O-ring seal Damage or leak in the oil pump screen suction tube * Malfunctioning oil pump pressure regulator valve * Missing or incorrectly installed oil gallery plugs « Loose camshaft intermediate drive shaft bolts « Excessive bearing clearance for the following = Connecting rod or rods = Crankshaft = Camshaft or camshafts = Camshatt intermediate drive shaft sprocket « Cracked, porous or restricted oil galleries « Broken valve lifters 11. 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 transmission fluid, power steering fluid, ete. 2. 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. 3. Find the approximate location of the leak by the drippings on the paper.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo 3. 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 4, 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. After operating the vehicle, visually check the suspected component 5. If you still cannot locate the leak, try using the powder or black light and dye method. wn s 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. RYN Visually inspect the suspected component. Trace the leak path over the white powder surface to the source. 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. te The fasteners are impronerly tightened or the threads are dirty or damavced2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo The flanges or the sealing surface is warped. , burrs, or other damage to the sealing surface. There are scratch: ‘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. The seal is damaged or worn. Improper installation is evident. There are cracks in the component. « The shaft surface is scratched, nicked, or damaged. seal wear. A loose or worn bearing is causing excess 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 the| 5 Go to Step 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2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical- 1.2L - Aveo pulleys. 4 |Is either the balancer or the drive - Go to Step pulleys loose or broken? 5 Go to Step 6 Tighten or replace the balancer or the 5 |drive pulleys. a Go to Step Did you complete the repair? 1 : Inspect the piston-to-bore clearance. 0.03 mm 6 |Is the clearance greater than the ©. 001 in) Go to Step specified value? 7 Go to Step 8 1. Bore the cylinder and hone to size. IMPORTANT: Cold engine piston knock usually disappears when the cylinder is 7 grounded out. Cold engine piston knock, which disappears in about 1.5 - minutes, is considered acceptable. 2. Replace the piston. Go to Step Did you complete the replacement? 1 : g _| Inspect the connecting rod. . Go to Step Is the connecting rod bent? 9 System OK [Replace the connecting rod Go to Step Did you complete the replacement? 1 : OISE 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 repair? 1 - Inspect the torque converter bolts. 45Nm(33 4 |Are the bolts tightened to specified Ib ft) “| Go to Step value? 5 Go to Step 6 5 Tighten the torque converter bolts. . Go to Step Did you complete the repair? 1 a2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo 6 [Inspect the accessory belts. 7 Go to Step Are the belts too tight or nicked? 7 Go to Step 8 Replace and/or tension the belts to 7 _ | specifications, as necessary. : Go to Step Did you complete the replacement? 1 : g_ | Inspect the exhaust system . Go to Step | Go to Step Is the system grounded? 9 10 [Reposition the system, as necessary : Go to Step Did you complete the repair? 1 a 10 _ [Inspect the flywheel. Go to Step | Go to Step Is the flywheel cracked? i 12 11 [Replace the flywheel . Go to Step Did you complete the replacement? 1 S Inspect the main bearing clearance. _|0.026-0.046 12. JIs the clearance more than the specified| mm (0.001-| Go to Step | Go to Step range? 0.0018 in) 13 14 Replace the main bearings, as 13. |necessary : Go to Step Did you complete the replacement? 1 5 Inspect the rod bearing clearance. 0019-007 14 ise eae more than the specified] (997. | Go to Step i 0.0028 in) 15 System OK 15 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 i 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 Is a repair necessary? 1 a 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 complete the repair? 1 a2004 Chevri ‘olet Aveo: 2004 ENGINE Engine Mechanical- 1.2L - Aveo Inspect the manifold. 6 [Is there an exhaust leak at the 5 Go to Step manifold? 7 Go to Step 8 Tighten the bolts or replace the gasket. Go to Step a 2 . - Did you complete the repair? 1 : Inspect the rod bearing clearance. 0.019-0.07 8 Is the clearance within the specified mm range? (0,0007- | Go to Step 0.0028 in) 9 System OK 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 lasts for a few minutes. This is a normal condition. Does the engine knock during initial start-up but last only a few seconds? Go to Step 2 System OK Inspect the engine oil 2 {Is the proper vi ry 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 complete the repair? 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 valves will be open. Spring pressure against the lifters will tend to bleed lifter down. 5_| Attempts to repair this should be made only . if the problem is consistent. Clean, test, and replace the lifters, as Go to Step necessary Did you complete the repair? 1 e Inspect the crankshaft end clearance. f 0.1mm 6 Is the clearance more than specified | (9 4939 jn) | G0 t0 Step value? = a Go to Step 8 7 [Replace the crankshaft thrust bearing, : Go to Step Did vou complete the replacement? 1 a2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Inspect the front main bearing clearance }0.026-0.046 8 [isthe clearance more than the specified" (0.00'"] Go to Step range? in) 9 System OK Replace the worn parts of the front 9 |main bearing. - Go to Step Did you complete the replacement? 1 5 KNOCKS AT IDLE HOT Knocks at Idle Hot Step ‘Action Values Yes No 1 _ [Does the engine knock at idle when . Go to Step hot? 2 System OK 2 Inspect the drive belts. . Go to Step Are the belts loose or worn? 3 Go to Step 4 Tension or replace the belts, as 3 |necessary. - Go to Step Did you complete the repair? 1 a 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 repair? 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 - Inspect the engine oil 8 |Is the proper viscosity oil used in the 5 Go to Step crankcase? 10 |Goto Step 9 Install oil of the proper viscosity for the| 9 Jexpected seasonal temperatures. - Go to Step Did you complete the repair? 1 5 Inspect the piston pin clearance. SS 10 Is the clearance more than the specified| 0 Jp.) | Go to Step | Go to Step (0.0008 in) value? W 2 11 [Replace the piston and the pin. . Go to Step Did you complete the replacement? 1 52004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo 12_ | Inspect the connecting rod alignment. . Go to Step | Go to Step *_|Is the alignment faulty? 13 14 B Inspect and replace rods, as n Iry. . Go to Step Did you find and correct the condition? 1 : Inspeet the piston-to-bore clearance. | 9 93 mum 14 JIs the clearance within the specified 4 Go to Step | Go to Step 9 (0.0012 in) value? 16 15 15 [Hone the bore and fit a new piston 7 Go to Step Did you complete the repair? 1 a 16 Inspect the crankshaft balancer. . Go to Step | Go to Step Is the balancer loose? 17 18 17_ | Toraue or replace worn parts . Go to Step Did you complete the repair? 1 S 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? in) 19 19_ |!nstall the correct piston a Go to Step Did you complete the repair? I e 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 Check the oil pump pressure. Go to Oil 5 _|Is the oil pump pressure low? : Pressure 2 Diagnosis and Testing |Go to Step 3 Inspect the crankshaft end play Oem Goto 3 |Does the crankshaft end play exceed. 0 0039 in) Crankshaft the specified value? ee Replacement | Go to Step 4 Inspect the crankshaft journals. 0.004 mm 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 a repair necessary? : Belt Replacement |Go to Step 6 Inspect the crankshaft pulley Goto 6 _|Is the crankshaft pulley loose? e Crankshaft Replacement] System OK2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo CONNECTING ROD BEARING NOISE SYMPTOM Connecting Rod Bearing Noise Symptom Step Action Yes No | |!Saknock noise heard under all engine speeds? Goto Step2 | System OK Inspect the crankshaft connecting rod y {joumal Goto Is the crankshaft connecting rod journal Crankshaft worn? Replacement | Go to Step 3 Check the oil pump pressure. Go to Oil 3__ [Is the oil pump pressure low? Pressure ° Diagnosis and Testing Goto Step 4 Inspect the crankshaft connecting rod Go to 4 |journals. Crankshaft 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 Piston Noises Step ‘Action Yes No Are any of the following noises heard: a sharp double knock when the engine is idling, 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. Is the piston pin or the bushing worn or loose? Go to Piston, Connecting Rod, and Bearing Replacement Go to Step 3 Inspect the piston. Go to Piston,2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Is the piston broken or cracked? Connecting 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 5 Rod, and Bearing Replacement | System OK BASE ENGINE MISFIRE WITH ABNORMAL VALVE TRAIN NOISE Base Engine Misfire with Abnormal Valve Train Noise Step ‘Action Yes No 1 Is a light tapping sound heard from the engine? Go to 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. 4) |Are the valve lifters dirt Go to Cylinder 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2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo 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. Place approximately 3 squirts of oil from a plunger-type oiler into each spark plug port Insert the engine compression gage into each spark plug port. Crank test each cylinder with 4-5 compression strokes using the starter motor. 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: BONS « 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 VALVE TIMING INSPECTION AND ADJUSTMENT ‘Adjust the valve clearance in the following procedures 1, Remove the air filter/resonator assembly and the relevant parts installed on the cylinder head cover. 2, Remove the cylinder head cover hexagon bolts and remove the cover. 3. Turn over the crankshaft to make No. 1 cylinder match with the compression top dead2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo center (TDC). When the camshaft sprocket notch (2) is aligned with the timing belt rear cover triangle pointer (1), and the crankshaft sprocket point (3) is aligned with the oil pump housing point (4), the TDC is on the ignition sequence for No. I cylinder. Fig. 6: View of Camshaft, Sprocket Notch, Timing Belt Rear Cover Triangle Pointer And Oil Pump Housing Point Courtesy of GENERAL MOTORS CORP. Cheek the valve clearance for No. | cylinder compression TDC. For Cylinder Compression Check Specifications, refer to Engine Mechanical Specifications2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo a Fig. 7: View Of Timing Belt Rear Cover Triangle Pointer And Camshaft Sprocket Point Courtesy of GENERAL MOTORS CORP. When the valve clearance check of No. | cylinder compression TDC is complete, position No. | cylinder on the exhaust, TDC, while rotating the crankshaft in a 360- degree are. When the camshaft sprocket point (2) is aligned with the timing belt rear cover triangle pointer (1), the exhaust TDC is on the ignition sequence for No. 1 cylinder. Check the valve clearance for the No. 1 cylinder exhaust TDC. For Cylinder Compression Check Specifications, refer to Engine Mechanical Specifications .2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 8: Measuring Valve Clearance Courtesy of GENERAL MOTORS CORP. 7. Check and adjust the valve clearance (a) using thickness gage. The measured value of valve clearance should meet the specified value. If not, adjust the valve clearance. IMPORTANT: In case of a hot engine, warm up the engine until the electric cooling fan begins to work and stop the engine to adjust the clearance within 20-30 minutes from there.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 9: View Of Valve Clearance Adjust Nut And Adjust Rod Courtesy of GENERAL MOTORS CORP. 8, When adjusting the valve clearance, loosen the adjust nut (2) and tighten or loosen the adjust rod (1) properly. For Valve Clearance Specifications, refer to Engine Mechanical Specifications Valve Timing Procedure 1. Check the valve timing. 2. After removing the air filter housing, loosen the bolts (1) and remove the timing belt front upper cover (2).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 10: View Of Timing Belt Front Upper Cover And Bolts Courtesy of GENERAL MOTORS CORP.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 11: View Of Notch And Crankshaft Pulley Courtesy of GENERAL MOTORS CORP. 3. Turning the crankshaft clockwise twice, align the notch (2) on the crankshaft pulley (1), marked 0, for the timing check on the timing belt front lower cover.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 12: View Of Notch And Triangle Pointer Courtesy of GENERAL MOTORS CORP. IMPORTANT: Notch (2) should be aligned with pointer (1) to set the valve timing normally. 4. Check if the notch (2) on the camshaft sprocket is aligned with the triangle pointer (1) on the timing belt rear cover. Valve Timing Adjustment Procedure 1. Adjust the valve timing. 2. Loosen the bolt and remove the timing belt pulley (1). In loosening the bolt, use the driver (2) in the picture as shown.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 13: Loosening Timing Belt Pulley Bolt Courtesy of GENERAL MOTORS CORP.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 14: View Of Guide Tube And Timing Belt Front Lower Cover Courtesy of GENERAL MOTORS CORP. 3. Remove the oil level gage guide tube (2) and the timing belt front lower cover (1).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 15: View Of Timing Belt Tensioner And Timing Belt Courtesy of GENERAL MOTORS CORP. Remove the timing belt tensioner (2) and the timing belt (1) Using the bolt, turn the crankshaft clockwise to align the mark (4) on the crankshaft sprocket with the pointer (3) on the oil pump housing. Then, turn the camshaft to align the notch (1) with the pointer (2)2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 16: Aligning Crankshaft And Camshaft Sprocket Timing Marks Courtesy of GENERAL MOTORS CORP.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 17: View Of Timing Belt, Tensioner, Mark And Pointer Courtesy of GENERAL MOTORS CORP. IMPORTANT: Do not tighten the tensioner bolt completely. 6. Install the timing belt (1) and the tensioner (2). NOTE: Refer to Fastener Notice in Cautions and Notices. 7. Tum the crankshaft twice clockwise. Align the mark (3) with the pointer (4) and tighten the tensioner bolt. Tighten: Tighten the tensioner bolt to 19 N.m (14 Ib ft). 8. Install all removed parts.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo INTAKE MANIFOLD REPLACEMENT, Removal Procedure CAUTION: Wear safety glasses in order to avoid eye damage. Fig. 18: Locating Fuel Pump Fuse Courtesy of GENERAL MOTORS CORP. 1. Remove the fuel pump fuse. 2. 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. 3. Disconnect the negative battery cable 4, Remove the air filter housing Remove the fuel rail. Refer to Fuel Rail Assembly Replacement in Engine Controls - 1.2L.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo 6. Disconnect the A/C pressure sensor connector Fig. 19: View Of A/C Pressure Sensor Courtesy of GENERAL MOTORS CORP. 7. Disconnect the power steering pump pressure sensor connector.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 20: Disconnecting Power Steering Pump Pressure Sensor Connector Courtesy of GENERAL MOTORS CORP. 8. Disconnect the throttle cable bracket with the bolt.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo 10. 11 12. 13, Fig. 21: View Of Throttle Cable Bracket Courtesy of GENERAL MOTORS CORP. Disconnect the manifold absolute pressure (MAP) sensor connector. Remove the brake booster vacuum hose at the intake manifold. Remove the exhaust gas recirculation (EGR) pipe and valve Remove the engine wiring harness from the intake manifold Remove the intake manifold retaining bolts and the nuts in the sequence shown.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 22: View Of Intake Manifold Retaining Bolts And Nuts Courtesy of GENERAL MOTORS CORP.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 23: Removal Of Intake Manifold Courtesy of GENERAL MOTORS CORP. 14. Remove the intake manifold.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 24: Removal Of Intake Manifold Subsidiary Bracket, Bolts And Gasket Courtesy of GENERAL MOTORS CORP. 15, Remove the intake manifold gasket. 16. Remove the intake manifold subsidiary bracket bolts. 17. Remove the intake manifold subsidiary bracket. Installation Procedure2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo ene Fig. 25: Installing Intake Manifold Subsidiary Bracket, Bolts, And Gasket Courtesy of GENERAL MOTORS CORP. Install the intake manifold gasket. Install the intake manifold subsidiary bolts. Install the intake manifold subsidiary bracket.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 26: Installing Intake Manifold Retaining Nuts And Bolts Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 4. Install the intake manifold retaining nuts and the bolts in the sequence shown. Tighten: Tighten the intake manifold retaining nuts and bolts to 17 N.m (13 Ib ft). TIMING BELT COVER REPLACEMENT Removal Procedure CAUTION: Refer to Battery Disconnect Caution in Cautions and2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Notices. Disconnect the negative battery cable. Remove the timing belt. Refer to Timing Belt Replacement N IMPORTANT: Take extreme care to prevent any scratches, nicks, or damage to the camshaft. Such damage can impair vehicle operation. Remove the camshaft gears. Refer to Camshaft Gear Replacement . Remove the timing belt automatic tensioner bolts. Remove the timing belt automatic tensioner. Remove the rear timing belt cover bolts (1). auEw Fig. 27: View Of Rear Timing Belt Cover And Bolts Courtesy of GENERAL MOTORS CORP. 7. Remove the rear timing belt cover (2).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Installation Procedure 1 2 3. 4 Install the rear timing belt cover (2) Fig. 28: View Of Rear Timing Belt Cover And Bolts Courtesy of GENERAL MOTORS CORP. 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 10.5 N.m (93 Ib in). Install the timing belt automatic tensioner. Install the timing belt automatic tensioner bolts. Tighten: Tighten the timing belt automatic tensioner bolts to 19 N.m (14 Ib ft).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo 5. Install the camshaft gears. Refer to Camshaft Gear Replacement 6. Install the timing belt. Refer to Timing Belt Replacement 7. Connect the negative battery cable. TIMING BELT REPLACEMENT CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. Removal Procedure Disconnect the negati Disconnect the intake air temperature (LAT) sensor connector. Disconnect the air intake tube from the throttle body. Disconnect the breather tube from the valve. Remove the air cleaner housing bolts. e battery cable. WEYNS2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo 10. I 12. Fig. 29: View Of Air Cleaner Housing Bolts Courtesy of GENERAL MOTORS CORP. 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. Remove the A/C compressor drive belt. Fi . 30: View Of Timing Belt Front Upper Cover and Bolts Courtesy of GENERAL MOTORS CORP. NOTE: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Remove the alternator drive belt. Remove the upper timing belt cover bolts. Remove the upper timing belt cover.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 31: Aligning Mark On Camshaft Gear Courtesy of GENERAL MOTORS CORP. 13. Align the mark on the crankshaft gear 14, Remove the crankshaft pulley bolt. 15. Remove the crankshaft pulley 16, Remove the lower timing belt cover bolts.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 32: View Of Lower Timing Belt Cover And Bolts Courtesy of GENERAL MOTORS CORP. 17, Remove the lower timing belt cover.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo ing Belt And Timing Belt Tensioner Bolt Courtesy of GENERAL MOTORS CORP. 18. Loosen the timing belt tensioner bolt, 19, Remove the timing belt. Installation Procedure2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo 1 Fig. 34: View Of Timing Belt And Timing Belt Tensioner Bolt Courtesy of GENERAL MOTORS CORP. IMPORTANT: If the camshaft or crankshaft rotates in the process of installing the timing belt, perform the valve timing setting necessary. Refer to Valve Timing Inspection and Adjustment . NOTE: Refer to Fastener Notice in Cautions and Notices. Install the timing belt tensioner bolt Tighten: Tighten the timing belt tensioner bolt to 19 N.m (14 Ib ft).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo a 3. Fig. 35: View Of Lower Timing Belt Cover And Bolts Courtesy of GENERAL MOTORS CORP. IMPORTANT: Turn the crankshaft twice to align the notch on the camshaft with the pointer on the rear cover and tighten the tensioner bolt. Install the timing belt front lower cover bolts. Tighten: Tighten the timing belt front lower cover bolts to 10.5 N.m (93 Ib in), Install the oil level gage guide tube bolt Tighten: Tighten the oil level gage guide tube bolt to 10.5 N.m (93 Ib in)2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 36: View Of Timing Belt Front Upper Cover and Bolts Courtesy of GENERAL MOTORS CORP. 4, Install the timing belt front upper cover bolts Tighten: Tighten the timing belt front upper cover bolts to 10.5 N.m (93 Ib in), 5. Install the crankshaft pulley bolt. ‘Tighten: Tighten the crankshaft pulley bolts to 70 N.m (52 Ib ft).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 37: View Of Air Cleaner Housing Bolts Courtesy of GENERAL MOTORS CORP. 6. Install the alternator drive belt 7. Install the compressor drive belt. 8. Install the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. Install the air cleaner housing, 10. Install the air cleaner housing bolts. Tighten: Tighten the air cleaner housing bolts to 12 N.m (106 Ib in) VALVE ROCKER ARM COVER REPLACEMENT. Removal Procedure CAUTION: Refer to Battery Disconnect Caution in Cautions and2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Notices. Disconnect the negative battery cable. Disconnect the positive crankcase ventilation (PCV) hose from the valve cover. Disconnect the ignition wires at the spark plug and the ignition coil. Fig. 38: View Of Ignition Coil Courtesy of GENERAL MOTORS CORP. 4, Remove the ignition coil2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 39: View Of Valve Cover, Hexagon Bolts And Gasket Courtesy of GENERAL MOTORS CORP. 5. Remove the valve cover hexagon bolts 6. Remove the valve cover with gasket. 7. Clean the sealing surfaces of the valve cover and the cylinder head. Installation Procedure 1. Install the new valve cover gasket and the valve cover2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 40: View Of Valve Cover, Hexagon Bolts And Gasket Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Install the bolts to the valve cover. Tighten: Tighten the valve cover hexagon bolts to 10.5 N.m (93 Ib in).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 41: View Of Ignition Coil Courtesy of GENERAL MOTORS CORP. Connect the PCV hose to the valve cover. 4, Install the ignition coil 5. Connect the negative battery cable, CYLINDER HEAD REPLACEMENT Removal Procedure CAUTION: Wear safety glasses in order to avoid eye damage.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo we Fig. 42: Locating Fuel Pump Fuse Courtesy of GENERAL MOTORS CORP. 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.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 43: View Of Ignition Coil Cc sy of GENERAL MOTORS CORP. Drain the engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling. Disconnect the positive crankcase ventilation (PCV) hose from the valve cover Remove the ignition coil.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 44: View Of Air Cleaner Housing Bolts Courtesy of GENERAL MOTORS CORP. Remove the air cleaner housing bolts. Remove the air cleaner housing. on2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 45: View Of A/C Pressure Transducer Connector And MTIA Connector Courtesy of GENERAL MOTORS CORP. 9. Disconnect the main throttle idle actuator (MTIA) connector. 10. Disconnect the A/C pressure transducer connector.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 46: View Of Brake Booster Vacuum Hose, Intake Manifold, Throttle Cable, Throttle Body And IAT Sensor Connector Courtesy of GENERAL MOTORS CORP. 11. Disconnect the intake air temperature (LAT) sensor connector 12. Disconnect the throttle cable from the throttle body 13. Disconnect the brake booster vacuum hose at the intake manifold.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 47: View Of Fuel Injector Harness Connectors And Fuel Line Courtesy of GENERAL MOTORS C' Disconnect the fuel injector hamess connectors. aE Disconnect the fuel line at the fuel rail.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Ly tr Lehi yi 12 Fig. 48: View Of Coolant Temperature Sensor Connector Courtesy of GENERAL MOTORS CORP. 16. Disconnect the camshaft position sensor connector 17. Disconnect the coolant temperature sensor connector.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 49: Slightly Loosening Of Power Steering Lower Adjusting Bolt Courtesy of GENERAL MOTORS CORP. 18. Slightly loosen the power steering lower adjusting bolt.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 50: Removal Of A/C With Power Steering Drive Belt Courtesy of GENERAL MOTORS CORP. 19. Slightly loosen the power steering upper adjusting bolt. NOTE: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. 20. Remove the A/C with power steering drive belt2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 51: View Of Timing Belt Front Upper Cover and Bolts Courtesy of GENERAL MOTORS CORP. Nv Remove the upper timing belt cover bolts. 22. Remove the upper timing belt cover,2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 52: Aligning Mark On Camshaft Gear Courtesy of GENERAL MOTORS CORP. 23. Align the camshaft gear timing mark to the notch in the rear timing belt cover.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 53: Alternator Drive Belt Courtesy of GENERAL MOTORS CORP. 24. Slightly loosen the alternator retaining bolts. 25, Remove the alternator drive belt,2004 ENGINE Engine Mechanical - 1.2L - Aveo 2004 Chevrolet Aveo Fig. 54: View Of Crankshaft Pulley Cour sy of GENERAL MOTORS CORP. Remove the engine under cover. Remove the crankshaft pulley Remove the crankshaft pulley. bolt.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 55: View Of Lower Timing Belt Cover And Bolts Courtesy of GENERAL MOTORS CORP. 29. Remove the lower timing belt cover bolts. 30. Remove the lower timing belt cover2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo 31 32, 33. Fig. 56: View Of Timing Belt And Timing Belt Tensioner Bolt Courtesy of GENERAL MOTORS CORP. Remove the timing belt automatic tensioner bolt. Remove the timing belt automatic tensioner Remove the timing belt. Refer to Timing Belt Replacement2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo OY \7- Fig. 57: Removal Of Camshaft Gear Bolt And Camshaft Courtesy of GENERAL MOTORS CORP. 34, Remove the camshaft gear bolt from the camshaft.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 58: View Of Timing Belt Rear Cover And Bolts Courtesy of GENERAL MOTORS CORP. 35, Remove the timing belt rear cover bolts. 36. Remove the timing belt rear cover from the cylinder head and cylinder block.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 59: View Of Heat Shield And Bolts Courtesy of GENERAL MOTORS CORP. 37. Remove the heat shield mounting bolts. 2 Remove the heat shield.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 60: Removal Of Retaining Nuts From Catalytic C. Courtesy of GENERAL MOTORS CORP. 39. Remove the retaining nuts from the catalytic converter at the exhaust manifold flange.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 61: View Of Valve Cover, Hexagon Bolts, And Gasket Courtesy of GENERAL MOTORS CORP. 40. Remove the valve cover with the hexagon bolts. 41. Remove the valve cover gasket.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo a iyo ap Fig. 62: Cylinder Head Bolt Loosening Sequence Courtesy of GENERAL MOTORS CORP. 42. Gradually loosen all of the cylinder head bolts in the sequence shown 43. Remove the cylinder head bolts. 44, Remove the cylinder head assembly from the engine block, with the intake/exhaust manifold, throttle body, water outlet case and cylinder head gasket ing Procedure CAUTION: Wear safety glasses in order to avoid eye damage.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 63: w Of Cylinder Head Courtesy of GENERAL MOTORS CORP. Clean the gasket surfaces of the cylinder head and the engine block Make sure the gasket surfaces of the cylinder head and the engine block are free of nicks and heavy scratches. Clean the cylinder head bolts. NOTE: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components. Inspect the cylinder head for warpage. Refer to Cylinder Head Cleaning and Inspection .2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Installation Procedure 1. Install the cylinder head gasket. 2. Install the cylinder head with the intake manifold and the exhaust manifold attached. NOTE: Refer to Fastener Notice in Cautions and Notices. Fig. 64: Cylinder Head Bolt Tightening Sequence Courtesy of GENERAL MOTORS CORP. 3. Install the cylinder head bolts in the sequence shown. Tighten: Tighten the cylinder head bolts in the sequence previously shown to 65-70 N.m (48-52 Ib ft). 4, Install the cylinder head cover hexagon bolts. Tighten: Tighten the cylinder head cover hexagon bolts to 9-12 N.m (80-106 Ib in).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 65: View Of Valve Cover, Hexagon Bolts And Gasket Courtesy of GENERAL MOTORS CORP. Install the catalytic converter nuts at the exhaust manifold flange Tighten: Tighten the catalytic converter to exhaust manifold nuts to 25-35 N.m (18-25 Ib ft)2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 66: View Of Heat Shield And Bolts Courtesy of GENERAL MOTORS CORP. 6. Install the heat shield. 7. Install the heat shield mounting bolts. Tighten: Tighten the heat shield mounting bolts to 10 N.m (89 Ib in),2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 67: View Of Timing Belt Rear Cover And Bolts Courtesy of GENERAL MOTORS CORP. Install the timing belt rear cover from the cylinder head and cylinder block. Install the timing belt rear cover bolts. Tighten: Tighten the timing belt rear cover bolts to 10.5 N.m (93 Ib in)2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 68: View Of Lower Timing Belt Cover And Bolts Courtesy of GENERAL MOTORS CORP. 10. Install the timing belt. Refer to Timing Belt Replacement 11. Install the lower timing belt cover. 12. Install the lower timing belt cover bolts. Tighten: Tighten the lower timing belt cover bolts to 10.5 N.m (93 Ib in),2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 69: View Of Timing Belt Front Upper Cover and Bolts Courtesy of GENERAL MOTORS CORP. 13. Install the upper timing belt cover. 14. Install the upper timing belt cover bolts. Tighten: Tighten the upper timing belt cover bolts to 10.5 N.m (95 Ib in).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo 15. 16, Fig. 70: View Of Crankshaft Pulley Courtesy of GENERAL MOTORS CORP. Install the crankshaft pulley. Install the crankshaft pulley bolts. Tighten: Tighten the crankshaft pulley bolts to 70 N.m (52 Ib ft) Install the A/C with power steering drive belt. Refer to Power Steering Pump Drive Belt Replacement Install the alternator drive belt.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 71: Alternator Drive Belt Courtesy of GENERAL MOTORS CORP.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo 19. 20. 21 22. 7} )\ a MS EAE Fig. 72: View Of Coolant Temperature Sensor Connector Courtesy of GENERAL MOTORS CORP. Connect the coolant temperature sensor connector. Connect the camshaft position sensor connector. Connect the fuel line at the fuel rail. Connect the fuel injector harness connectors2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 73: View Of Fuel Injector Harness Connectors And Fuel Line Courtesy of GENERAL MOTORS CORP.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 74: View Of Brake Booster Vacuum Hose, Intake Manifold, Throttle Cable, Throttle Body And IAT Sensor Connector Courtesy of GENERAL MOTORS CORP. 23. Connect the brake booster vacuum hose at the intake manifold. 24, Connect the throttle cable from the throttle body. 25. Connect the IAT sensor connector2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo 8 Fig. 75: View Of A/C Pressure Transducer Connector And MTIA Connector Courtesy of GENERAL MOTORS CORP. Connect the A/C Pressure transducer connector Connect the MTIA connector.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo yy Fig. 76: View Of Air Cleaner Housing Bolts Courtesy of GENERAL MOTORS CORP. Install the air cleaner housing, Install the air cleaner housing bolts Tighten: Tighten the air cleaner housing bolts to 12 N.m 106 Ib in).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 77: View Of Ignition Coil Courtesy of GENERAL MOTORS CORP. Connect the PCV hose from the valve cover. Install the ignition coil Connect the negative battery cable. Install the fuel pump fuse. Refill the engine cooling system. Refer to Draining and Fil Engine Cooling. ing Cooling System in OIL PAN REPLACEMENT Removal Procedure CAUTION: Wear safety glasses in order to avoid eye damage. Drain the engine oil from the engine crankcase. Remove the front exhaust pipe. Refer to Front Pipe Replacement in Engine Exhaust. Remove the flywheel or flexible plate inspection cover bolts.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.2L - Aveo Fig. 78: Flywheel Or Flexible Plate Inspection Cover Courtesy of GENERAL MOTORS CORP. 4. Remove the flywheel or flexible plate inspection cover. 5. Remove the oil pan retaining bolts and the nuts.