1.5L Engine PDF

2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical- 1.5L - Aveo 2004 ENGINE Engine Mechanical - 1.5L - 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 35.Nm 26 1b ft ‘A/C Compressor Mounting Bracket Bolts 50 Nm 37 Ib ft Air Filter Housing Bolts 12Nm 106 Ib in Alternator Adjusting Bolt 25N.m 18 Ib ft ‘Alternator Adjusting Bracket Retaining Bolt 25.Nm 18 Ib ft Auxiliary Catalytic Converter-to-Exh . Manifold Nato and Bracket Bolle 40 Nim 30 Ib ft Camshaft Gear Bolt Nm Sib Camshafi Pressure Plate Bolts 10Nm 89 1b in Connecting Rod Bearing Cap Bolts 25 N.m+30°+15° | 18 Ib f+30°+15° Coolant Pump Retaining Bolts 10Nm 89 Ib in Coolant Temperature Sensor 20 Nm 15 Ib ft Crankshaft Bearing Cap Bolts 30 N.m-+45°415° | 37 Ib ftr45°+15° Crankshaft Position Sensor Retaining Bolt 10Nm 89 Ib in Crankshaft Pulley Bolt 95 Nm+30°415°| 70 1b +304 15° Cylinder Head Bolts - Camshaft Support ZN Gs stone Housing and Cylinder Head Mounting Bolts eect eta Electronic Ignition System Ignition Coil a a Mounting Bolts Electronic Ignition System Ignition Coil RamTTe PLAS Bon ae Ki eo iv in Engine Lift Bracket Bolt 25Nm T8Ib ft Engine Mount Attaching Nuts 40Nm 30 Ib ft Engine Mount Bracket Retaining Bolts 60. Nm 44 Ib ft Engine Mount Bracket-to-Engine Mount 60 Nim 44 Ib ft Retaining Bolts Exhaust Manifold Heat Shield Bolts Nm iibh Exhaust Manifold Nuts 2N.m 16 Ib ft2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical- 1.5L - Aveo Flexible Plate Bolts 60 Nm 44 Ib ft Flexible Plate Inspection Cover Bolts 10 Nm 89 Ib in Flywheel Bolts 35. N.m+30°+15° [ 26 Ib f+30°415° Flywheel Inspection Cover Bolts 12N.m 106 Ib in Front Muffler-to-Main Catalytic Converter Nuts 30 Nm 22 Ib ft Fuel Rail Retaining Bolts 25Nm 18 Ib ft Intake Manifold Retaining Nuts 22N.m 16 Ib ft Intake Manifold Support Bracket Retaining 25.Nm Isto ft Bolts Lower Timing Belt Cover Bolts 10 Nm 89 Ib in Oil Pan Drain Plug 35 N.m 25 Ib ft Oil Pan Retaining Bolts 10 Nm 89 Ib in Oil Pressure Switch 40 Nm 30 Ib ft Oil Pump Retaining Bolts 10 Nm 89 Ib in Oil Pump/Pickup Tube and Support Bracket —s as Bolts Oil Pump Safety Relief Valve Bolt 40 Nm 30 Ib ft Oil Pump Rear Cover Bolts 8Nm 71 Ib in Power Steering Pump Mounting Bolts 25 Nm 18 Ib ft Power Steering Pump Pulley Bolts 25 N.m 18 Ib ft Rear Timing Belt Cover Bolts 10 N.m 89 Ib in Right Transaxle Brace Bolts 60 Nm 44 Ib ft Spark Plugs 25 Nm 18 Ib ft Thermostat Housing Mounting Bolts 20 Nm IIb it Throttle Cable Bracket Bolts 8Nm 71 Ib in Timing Belt Automatic Tensioner Bolt 20 Nm 15 Ib ft Transaxle Bell Housing Bolts 75.N.m 55 Ib ft Transaxle Torque Converter Bolts 65 Nm 48 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 1.498 com> 91.44 in?2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Bore Stroke 76.5x81.5 mm. 3.01x3.21 in « Compression Ratio 9.31-9.7:1 « Firing Order 1-3-4-2 © Maximum Power - At 5,600 RPM 62 kw (83.1 hp) * Maximum Torque - At 3,000 RPM 128 N.m 94.4 Ib ft Cylinder Bore ¢ Diameter 76.5 mm 3.01 in ¢ Out of Round - Maximum 0.0065 mm 0.00025 in Taper - Maximum 0.0065 mm 0.00025 in Piston ¢ Diameter 76.47 mm 3.01 in « Clearance to Bore 0.03 mm 0.0012 in Piston Rings » Ring, End Gap - Top 0.3 mm 0.012 in Compression + Ring, End Gap - Second noe 0.012 in Compression Groove Clearance - Top 0.02 mm 0.0008 in Impression « Groove Clearance - Second 0.02 mm 0.0008 in Compression Piston Pin « Diameter 18 mm. 0.708 in Pin Off-Set 0.5-0.7 mm 0.019-0.027 in Camshaft « Lift Intake 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 mm 1.552-1.553 in e Journal OD - No. 2 39.685-39.705 mm. 1.562-1,553 in ¢ Journal OD - No. 3 39.935-39.955 mm 1.572-1.573 in Journal OD - No. 4 40.185-40.205 mm 1,582 in2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical- 1.5L - Aveo « Journal OD - No. 5 40.435-40.455 mm 1.591-1,592 in « Bearing OD - No. 1 39,5-39.525 mm 1555-1556 in « 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~ | 54.982-54.994 mm 2.164-2.165 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 * Connecting Rod Journal - Diameter - All 42.971-42.987 mm 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 45° # Seat Angle - All 45° + Seat Runout - Maximum, ae ss Sea 6-6.015 mm 0.2362-0.2368 in « Seat Width - Intake 131.5 mm 0.051-0.059 in « Seat Width - Exhaust .6-1.8 mm 0.063-0.071 in * Valve Guide Inside 6-6.015 mm 0.236-0.237 in Diameter - All e Valve Stem Diameter - 5.97-5.984 mm 0.232-0,238 in2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical- 1.5L - Aveo Intake Intake + Valve Stem Diameter - 5,96-5.974 mm 0.231-0.237 in Exhaust « Valve Diameter - All - 37.9-38.1 mm 1.486-1.494 in Valve Diameter - Exhaust 30.9-31.1 mm 1.216-1,224 in Valve Spring Free Length - Filter . : Nae 40.9 mm 1.61 in * Valve Spring Loads - Valve Open @ 21.5 mm (0.846 600-650 N 443-479 Ibs in) * Valve Spring Loads - Valve Closed @ 31.5 mm (1.24 260-290 N 191-213 Ibs in) Lubricating Type Forced Feed Oil Filter Type Cartridge (Full Flow) Oil Pan Capacity Including OT 5 75 jor ae Oil Pump + Gap Between Oil Pump Body and Out Rotor 0.4-0.484 mm 0.0157-0.0191 in e 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 8lmm 3.2in Oil Pump Type Rotary (Trochoid) Valve Guide Reaming Table Size Reamer Production Code Service Code Normal - - K 0.075 KM-253 1 Kl 0.150 KM-254 2 K2 0.250 KM. - A COMPONENT LOCATOR DISASSEMBLED VIEWS2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 1: Cylinder Head & Manifolds Disassembled View Courtesy of GENERAL MOTORS CORP. Callouts For Fig. 1 26 Callout Component Name 1 Camshaft Position Sensor 2 Tube 3 Valve Cover Gasket 4 Bolt 5 Cap, Bayonet Joint 6 Valve Cover 7 Cylinder Head Bolt 8 Washer 9 Camshaft Support 10 Bolt2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Camshaft Pressure Plate 12 Camshaft 13 Roller Follower 14 Roller Follower Lifter 15 Intake Valve Spring Seat 16 Intake Valve Guide 7 Oil Duct Cap 18 Oil Duct Cap 19 Cylinder Head Gasket 20 Coolant Temperature Sensor 21 ‘Adapter 22 Bolt-Stud 23 Cylinder Head Oil Duct Sleeve 24 Exhaust Manifold Gasket 25 Exhaust Manifold 26 Exhaust Manifold Heat Shield 27 Bolt 28 Exhaust Oxygen Sensor 29 Nut 30 Intake Valve 31 Exhaust Valve 32 Screw Plug 33 Bolt 34 Thermostat Housing 35 Thermostat Housing Seal Ring 36 Thermostat 37 Bolt-Stud 38 Bolt-Stud 39 Exhaust Valve Guide 40 Exhaust Valve Spring Seat 41 Valve Stem Seal a2 Valve Spring B Valve Spring Plate 44 Valve Key 45 Intake Manifold Gasket 46 Nut a7 Throttle Body 48 Bolt2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Throttle Position Sensor 50 Idle Air Control Valve 51 Throttle Body Gasket 52 Intake Manifold 53 Shaft Seal Ring 19, 2: Engine Block Disassembled View Courtesy of GENERAL MOTORS CORP. Callouts For Fig. 2 Callout ‘Component Name I Connecting Rod Bearing Set 2 Piston Pin 3 Piston Ring Set2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 4 Piston 5 Connecting Rod 6 Oil Level Gage Stick 7 Gage Stick Tube 8 Oil Filter 9 Crankshaft Position Sensor 10 Connecting Piece Ul Flywheel - Manual Transaxle 12 Bolt - Manual Transaxle B 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 22 Crankshaft Bearing - Upper 2B 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 40 Crankshaft Pulley 41 Washer2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Bolt B Bolt 4 Crankshaft Gear 45 Auto Tensioner 46 Bolt 47 Camshaft Gear Bolt 48 Washer 49 Camshaft Gear 50 Rear Cover Bolt 31 Rear Timing Belt Cover 52 Bolt 33 Coolant Pump 34 Seal Ring 35 Oil Pump 56 Bolt 37 Engine Block 58 Bolt 59 Knock Sensor 60 Connecting Rod Bolt DIAGNOSTIC INFORMATION AND PROCEDURES DIAGNOSTIC STARTING POINT - ENGINE 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 - ENGINE 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. 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 order2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo to resolve a system condition. The diagnostic flow is the place to start when repairs are necessary. ‘Visual/Physical Inspection 16: Inspect for aftermarket devices which could affect the operation of the engine 17: Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. 18: Check for the correct oil level, proper oil viscosity, and correct filter application. 19: 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. 20: 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 PRESSURE DIAGNOSIS AND TESTI 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 Test2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Tools Required « J 36648-A (KM 135) Adapter Oil Pressure Diagnosis an 1 N J 21867 (KM 498-B) Pressure Gage ting 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. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. Run the engine briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gage or light. Listen for a noisy valve train or a knocking noise. Inspect for the following: Foamy oil « Slow idle speed « Plugged oil filter « Oil diluted by the following: = Water = Engine coolant = Unbured 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 temperature2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - 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 - 1.5L - Aveo Fig. 4: Installing J 36648-A And Connecting J 21867 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 (8.88 psi). The minimum oil pressure at idle should be 250 kPa (35 psi). 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 seal2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - 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, PR2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - 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 - 1.5L - 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 the} - 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 4 (pulleys. . 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. S Go to Step Did you complete the repair? 1 : Inspect the piston-to-bore clearance. 6 | Is the clearance more than the specified value? 0.03 mm (0.001 in) | 6° Step 7 |Goto Step 8 1. Bore the cylinder and hone to size. IMPORTANT: Cold engine piston knock usually2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical- 1.5L - Aveo disappears when the cylinder is. grounded out. Cold engine piston knock, which disappears in about 1.5 minutes, is considered acceptable. Did you complete the replacement? 1 7 = 2. Replace the piston. Go to Step Did you complete the replacement? 1 : 3g _ | 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 Inspect the torque converter bolts. 4 |Are the bolts tightened to specified {45 ane Go to Step value? 5 Go to Step 6 5 _ | Tighten the torque converter bolts Go to Step > _|Did you complete the repair? 1 - 6 Inspect the accessory belts. . 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 repair? 1 - 8 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 - 10 Inspect the flywheel. . Go to Step | Go to Step Is the flywheel cracked? iu 12 Replace the flywheel. Go to Step2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Inspect the main bearing clearance. _|0.026-0.046 12 [Is the clearance more than the specified | mm (0.001-| Go to Step | Go to Step value? 0.0018 in) 13 14 Replace the main bearings, as 13. |necessary - Go to Step Did you complete the replacement? 1 : 3 Inspect the rod bearing clearance 0019-007 14 sti cesenea more than the specified] (9 4997. | Go to Step c 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 | _ Is there a light knock when the engine . Go to Step is hot? 2 System OK [Is detonation or spark knock evident? Go to Step 3 |Goto Step 4 Inspect the engine timing and the fuel 3 | quality. - Go to Step Is a repair necessary? 1 E Inspect the torque converter bolts. 4 | Are the bolts tightened to the specified | “> ca Go to Step value? 5 Goto Step 6 5 Tighten the torque converter bolts. . Go to Step Did you complete the repair? 1 E Inspect the manifold. 6 [Is there an exhaust leak at the - Go to Step manifold? 7___|GotoStep 8 7 Tighten the bolts or replace the gasket. . Go to Step 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 : ENGINE NOISE ON START-UP, B UT ONLY LASTING A FEW SECONDS2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical- 1.5L - Aveo 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 condit 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 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. 2 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 z if the problem is consistent. Clean, test, and replace the lifters, as Go to Step necessary Did you complete the repair? 1 5 Inspect the crankshaft end clearance. O.1mm 6 [sthe clearance more than specified | (9 4939 jn) | G0 % Step value? ? 1 Go to Step 8 7 Replace the crankshaft thrust bearing, . Go to Step Did you complete the replacement? 1 5 Inspect the front main bearing 0.026-0.046 g_ [slearanee: mm (0.001. Is the clearance more than the specified |"); jn) | G0 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 - KNOCKS AT IDLE HOT Knocks at Idle Hot Step Action Values Yes No 1 Does the engine knock at idle when hot? Go to Step 2 Svstem OK.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 2 Inspect the drive belts. . Go to Step Are the belts loose or worn? 3 Go to Step 4 Tension or replace the bel 3 |necessary. a 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. a Go to Step Did you complete the replacement? 1 5 6 Inspect the valve train. . Go to Step Are valve train components faulty? 7 Go to Step 8 Replace the faulty valve train 7 |components. a Go to Step Did you complete the replacement? 1 - Inspect the engine oil 8 _|Is the proper viscosity oil used in the a Go to Step crankcase? 10 Go to Step 9 Install oil of the proper viscosity for the| 9 |expected seasonal temperatures. - Go to Step Did you complete the repair? 1 5 Inspect the piston pin clearance. Oem 10 Is the clearance more than the specified] Go to Step | Go to Step (0.0008 in) value? ll 12 ml Replace the piston and the pin. . Go to Step Did you complete the replacement? 1 Q 12_|Inspect the connecting rod alignment. z Go to Step | Go to Step Is the alignment faulty? 13 14 B Inspect and replace rods, as necessary. . Go to Step Did you find and correct the condition? 1 : Inspeet the piston-to-bore clearance. | 4 93 mum 14 |Is the clearance within the specified on Go to Step | Go to Step (0.0012 in) value? 16 15 15 Hone the bore and fit a new piston, . Go to Step Did you complete the repair? 1 3 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 complete the repair? 1 a2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 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 System OK 19 Install the correct piston. . Go to Step Did you complete the repair? 1 s 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? 7 Pressure o Diagnosi and Testing |Go to Step 3 Inspect the crankshaft end play em Goto 3 |Does the crankshaft end play exceed (0.0039 in) Crankshaft the specified value? Ss Replacement | o 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? = Crankshaft Replacement] System OK Connecting Rod Bearing Noise Symptom CONNECTING ROD BEARING NOISE SYMPTOM Step Action Yes No 1 Is a knock noise heard under all engine speeds? Goto Step 2 _| System OK Inspect the crankshaft connecting rod acnos 5 {journal Go to * Is the crankshaft connecting rod journal Crankshaft worn? Replacement | Go to Step3 Check the oil pump pressure 3 |Is the oil pump pressure low? Go to Oil 2 Pressure and2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Testing Go to 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 Inspect the piston pin and the bushing. Go to Piston, Bearing 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, 5 Is the piston 180 degrees out of position? Connecting Rod, and2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo | Replacement | System OK BASE ENGI MISFIRE WITH ABNORMAL VALVE TRAIN NOISE. Base Engine Misfire with Abnormal Valve Train Noise Step ‘Action Yes No | |Isalight 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 Di emble 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.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo « 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. BONS 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 INT KE MANIFOLD REPLACEMENT Removal Procedure2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo w : View Of 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. Disconnect the engine control module (ECM) ground terminal from the intake manifold2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - 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 - 1.5L - 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 - 1.5L - Aveo 13. 14. 15. Fig. 8: View Of Throttle Cable Courtesy of GENERAL MOTORS CORP. Disconnect the heater inlet hose from the coolant distributor beneath the intake manifold Disconnect the surge tank coolant hose at the throttle body. 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. Disconnect the throttle cable from the throttle body and the intake manifold. Remove the 2 throttle cable bracket bolts and the throttle cable bracket. Disconnect the fuel feed line from the fuel rail2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 9: View Of Fuel Feed Line And Fuel Rail Courtesy of GENERAL MOTORS CORP.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 16. 17 18. Fig. 10: View Of Fuel Injector Courtesy of GENERAL MOTORS CORP. Disconnect the fuel injector connectors from the fuel injectors. Remove the 2 retaining bolts from the fuel injector rail Remove the fuel injector rail and fuel injectors as an assembly. Refer to Fuel Rail Assembly Replacement in Engine Controls - 1.5L.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - 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 - 1.5L - Aveo Fig. 12: Removal Sequence Of Intake Manifold Retaining Nuts And Engine Life Bracket Bolt Courtesy of GENERAL MOTORS CORP. Remove the intake manifold retaining nuts and the engine lift bracket bolt in the sequence shown N 82004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 13: View Of Intake Manifold And Cylinder Head sy of GENERAL MOTORS CORP. 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 1. Install the intake manifold gasket. 2. Install the intake manifold. NOTE: Refer to Fastener Notice in Cautions and Notices.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 14: Intake Manifold Retaining Nuts And Engine Lift Bracket Bolt Tightening Sequence Courtesy of GENERAL MOTORS CORP. 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 22 N.m (16 Ib fb). « Tighten the engine lift bracket bolt to 25 N.m (18 Ib fi).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - 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 belt2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 741 TV WX 16: View Of Fuel Injector sy of GENERAL MOTORS CORP. Replacement in Engine Controls - 1.5L. Install the fuel rail retaining bolts. Tighten: Tighten the fuel rail retaining bolts to 25 N.m (18 Ib ft) Connect the fuel feed line to the fuel rail Install the fuel rail and the fuel injectors as an assembly, Refer to Fuel Rail Assembly2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - 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 - 1.5L - Aveo Fig. 18: Locating Intake Ducting To Engine Courtesy of GENERAL MOTORS CORP. 18, Connect the air intake tube to the throttle body. 19. Connect the IAT sensor connector. 20. Connect the ECM ground terminal to the intake manifold. 21. Connect the negative battery cable. 22. Install the fuel pump fuse. 23. Refill the engine cooling system, Refer to Draining and Filling Cooling System in Engine Cooling TIMING BELT REPLACEMENT Tools Required « J.42492-A (KM 421-A) Timing Belt Adjuster « KM-470-B Angular Torque Gage + J.45059 Angle Meter Removal Procedure2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. Disconnect the negative battery cable Disconnect the intake air temperature (LAT) sensor connector. Disconnect the air intake tube from the throttle body Locating Intake Ducting To Engine sy of GENERAL MOTORS CORP. 4. Disconnect the breather tube from the valve cover.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 20: 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 - 1.5L - Aveo 10. 1 12, 13, Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Belt Dressing Notice in Cautions and Notices. Remove the serpentine accessory drive bolt. Refer to Power Steering Pump Hoses and Pipes Replacement in Power Steering System Remove the upper timing belt cover bolts. Remove the upper timing belt cover. Remove the crankshaft pulley bolt. Remove the crankshaft pulley. Remove the lower timing belt cover bolts.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 22: View Of Lower Timing Belt Cover Courtesy of GENERAL MOTORS CORP. 15. Remove the lower timing belt cover2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 23: Aligning Crankshaft Gear With Bottom Rear Timing Belt Cover 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 - 1.5L - Aveo 18. 19, 20. 21 Fig. 24: 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 1 N 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 cover2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Aligning The Mark On Camshaft Gear To Notch On Top Of Rear Timing er Courtesy of GENERAL MOTORS CORP. 3. Install the timing belt.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 26: 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 loosely2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 7 Fig. 27: Aligning Timing Belt Automatic Tensioner Adjust Arm Hole In 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 driver through the adjust arm hole and the tensioner bracket hole2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 28: Aligning Crankshaft Gear With Bottom Rear Timing Belt Cover 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 - 1.5L - Aveo Fig. 29: 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 - 1.5L - Aveo Fig. 30: Aligning Timing Belt Automatic Tensioner Adjust Arm Pointer With Bracket Notch 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). 15, Remove the crankshaft pulley bolt.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 16, Install the lower timing belt cover. Fig. 31: View Of Lower Timing Belt Cover Cou of GENERAL MOTORS CORP. 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 - 1.5L - Aveo Fig. 32: 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 J 45059 or the KM-470-B , tighten the crankshaft pulley bolt another 30 degrees plus 15 degrees.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Courtesy of GENERAL MOTORS CORP. 20. Install 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 - 1.5L - Aveo Fig. 34: View Of Serpentine Accessory Drive Belt Tensioner Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Belt Dressing Notice in Cautions and Notices. Install the serpentine accessory drive belt 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 filter housing.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 35: View Of Air Filter Housing Courtesy of GENERAL MOTORS CORP. 26. Install the air filter housing bolts. Tighten: Tighten the air filter housing bolts to 12 N.m (106 Ib in).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 36: 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 Timing Belt Adjuster « KM-470-B Angular Torque Gage « J. 45059 Angle Meter Adjustment Procedure CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo L. Disconnect the negative battery cable. 2. Disconnect the intake air temperature (IAT) sensor connector. 3. Disconnect the air intake tube from the throttle body Fig. 37: Locating Intake Ducting To Engine Courtesy of GENERAL MOTORS CORP. 4. Disconnect the breather tube from the valve cover.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 6 Fig. 38: 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. NOTE: Refer to Belt Dressing Notice in Cautions and Notices. Remove the serpentine accessory drive belt. Refer to Power Steering Pump Hoses and Pipes Replacement in Power Steering System Remove the upper timing belt cover bolts.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 39: View Of Upper Timing Belt Cover And Bolts Courtesy of GENERAL MOTORS CORP. 11, Remove the upper timing belt cover.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 40: 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 - 1.5L - Aveo Fig. 41: 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 - 1.5L - Aveo Fig. 42: Aligning Crankshaft Gear With Bottom Rear Timing Belt Cover 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 cover2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 19. ing Belt Cover Fig. 43: Aligning Camshaft Gear Timing Mark To Top Rear Ti Notch Courtesy of GENERAL MOTORS CORP. 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 - 1.5L - Aveo Fig. 44: 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 (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 - 1.5L - Aveo Fig. 45: Aligning Timing Belt Automatic Tensioner Adjust Arm Hole In 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 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 - 1.5L - Aveo 29. 30. Fig. 46: Aligning Timing Belt Automatic Tensioner Adjust Arm Pointer With Bracket Notch Courtesy of GENERAL MOTORS CORP. 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. Tighten the coolant pump retaining bolts. Tighten: Tighten the coolant pump retaining bolts to 10 N.m (89 Ib in). Remove the crankshaft pulley bolt.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 32. Install the lower timing belt cover. Fig. 47: View Of Lower Timing Belt Cover Cou of GENERAL MOTORS CORP. 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 - 1.5L - Aveo Fig. 48: 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. ‘« Using the J 45059 or the KM-470-B , tighten the crankshaft pulley bolt another 30 degrees plus 15 degrees.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Courtesy of GENERAL MOTORS CORP. 36. Install the upper timing belt cover. 37. 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. 38. Install the serpentine accessory drive belt. Refer to Power Steering Pump Hoses and Pipes Replacement in Power Steering System2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 39. 40. 41 42, Fig. 50: 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 12 N.m (106 lb in),2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 1: 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. TIMING BELT COVER REPLACEMENT Removal Procedure 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.w 2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo View Of Timing Belt Cover And Bolts sy of GENERAL MOTORS CORP. IMPORTANT: Take extreme care to prevent any scratches, nicks, or damage to the camshaft. Such damage can impair vehicle operation. Remove the camshaft gear. Refer to Camshaft Replacement. Remove the timing belt automatic tensioner bolt. Remove the timing belt automatic tensioner.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 6. Remove the rear timing belt cover bolts. 7. Remove the rear timing belt cover. Installation Procedure 1. Install the rear timing belt cover. NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Install the rear timing belt cover bolts. Tighten: Tighten the rear timing belt cover bolts to 10 N.m (89 Ib in). 3. Install the timing belt automatic tensioner.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical- 1.5L - Aveo Fig. 53: Aligning Timing Belt Automatic Tensioner Adjust Arm Pointer With Bracket Notch Courtesy of GENERAL MOTORS CORP. 4. 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 care to prevent any scratches, nicks, or damage to the camshaft. Such damage can impair vehicle operation. 5. Install the camshaft gear. Refer to Camshaft Replacement. 6. Install the timing belt. Refer to Timing Belt Replacement. 7. Connect the negative battery cable. VALVE ROCKER ARM COVER REPLACEMENT. Removal Procedure CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable. 2. Disconnect the breather hose from the valve cover2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Courtesy of GENERAL MOTORS CORP. Fig. 54: View Of Breather Hose2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 55: View Of Valve Cover And Camshaft Housing Courtesy of GENERAL MOTORS CORP. we Remove the 8 bolts from the valve cover, Remove the valve cover. we Remove the valve cover gasket. Clean the sealing surfaces of the valve cover and the camshaft housing a Installation Procedure2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 56: View Of Valve Cover And Camshaft Housing 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 8 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 - 1.5L - Aveo Fig. 57: View Of Breather Hose Courtesy of GENERAL MOTORS CORP. 3. Connect the breather tube to the valve cover. 4. Connect the negative battery cable. CYLINDER HEAD REPLACEMENT Tools Required « J.42492-A (KM 421-A) Timing Belt Adjuster « KM-470-B Angular Torque Gage « 3.45059 Angle Meter Removal Procedure 1. Remove the fuel pump fuse2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo N Be 8: View Of Fuel 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. 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 manifold2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 5. 6 Drain the engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling. Disconnect the intake air temperature (IAT) sensor connector. Disconnect the breather tube from the valve cover. Disconnect the air intake tube from the throttle body. Fig. 59: Locating Intake Ducting To Engine Courtesy of GENERAL MOTORS CORP.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 60: View Of EI System Ignition Coil Connector Courtesy of GENERAL MOTORS CORP. Disconnect the electronic ignition (EI) system ignition coil connector. Disconnect the engine coolant temperature (ECT) sensor connector. Refer to Engine Coolant Temperature (ECT) Sensor Replacement in Engine Controls - 1.5L.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 61: View Of IAC Connector And TP Sensor Connector Courtesy of GENERAL MOTORS CORP. 11. Disconnect the idle air control (AC) valve connector. 12. Disconnect the throttle position (TP) sensor connector.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo gl OM Fig. 62: View Of Camshaft Position Sensor Courtesy of GENERAL MOTORS CORP. 13, Remove the camshaft position (CMP) sensor.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 63: View Of Air Cleaner Housing Courtesy of GENERAL MOTORS CORP. 14, Remove the air cleaner housing bolts 15, Remove the air cleaner housing,2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Courtesy of GENERAL MOTORS CORP. 16. Remove the upper timing belt cover bolts. 17. Remove the upper timing belt cover.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 65: Aligning Camshaft Gear Timing Mark To Top Rear Timing Belt Cover Notch Courtesy of GENERAL MOTORS CORP. 18. Align the camshaft gear timing mark to the notch in the rear timing belt cover. 19. Remove the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 20. Remove the right front wheel well splash shield NOTE: Refer to Belt Dressing Notice in Cautions and Notices.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 66: View Of Serpentine Accessory Drive Belt Tensioner Courtesy of GENERAL MOTORS CORP. 21. Remove the serpentine accessory drive belt.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo / iS [Ai Vi Fig. 67: View Of Fuel Feed Line And Fuel Rail Courtesy of GENERAL MOTORS CORP. 22. Disconnect the fuel feed line at the fuel rail.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 68: View Of Alternator Bracket And Nut Courtesy of GENERAL MOTORS CORP. Remove the power steering pipe bracket mounting nut. Refer to Power Steering Pump Hoses and Pipes Replacement in Power Steering System Remove the alternator nut. Remove the alternator bracket retaining nut. Remove the alternator bracket.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 69: View Of Throttle Cable Courtesy of GENERAL MOTORS CORP. Disconnect the brake booster vacuum hose at the intake manifold. Disconnect all of the necessary vacuum hoses and electrical connector Disconnect the MAP sensor from the intake manifold. Remove the crankshaft pulley bolt Remove the crankshaft pulley Remove the lower timing belt cover bolts.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 70: View Of Lower Timing Belt Cover Courtesy of GENERAL MOTORS CORP. 33, Remove the lower timing belt cover2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 71: Releasing/Adding Timing Belt Tension Using J 42492-A Courtesy of GENERAL MOTORS CORP. 34, Slightly loosen the coolant pump retaining bolts. 35. Remove the coolant pump counterclockwise using the J 42492-A (1) to relieve the timing belt tension. 36. Remove the timing belt. Refer to Timing Belt Replacement.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 72: View Of Crankcase Ventilation Tube And Camshaft Housing Courtesy of GENERAL MOTORS CORP. 37. Disconnect the crankcase ventilation tube at the camshaft housing.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo ew Se 40, Fig. 73: Holding Camshaft While Loosening/Tightening Sprocket Bolt Courtesy of GENERAL MOTORS CORP. Remove the valve cover bolts. Remove the valve cover and the valve cover gasket IMPORTANT: Take care to prevent any scratches, nicks, or damage to the camshaft. While holding the camshaft firmly in place, remove the camshaft gear bolt Remove the camshaft gear2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 43. 44. 45. Fig. 74: View Of Rear Timing Belt Cover Upper Bolts Courtesy of GENERAL MOTORS CORP. Remove the rear timing belt cover upper bolts. Disconnect the ignition wires at the spark plugs Remove the retaining nuts from the catalytic converter at the exhaust manifold flange Disconnect the front heated oxygen sensor electrical connector.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 75: Identifying Front Heated Oxygen Sensor Connector Courtesy of GENERAL MOTORS CORP.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 76: View Of Heater Inlet Hose And Surge Tank Coolant Hose Courtesy of GENERAL MOTORS CORP. 46, Disconnect the heater inlet hose at the coolant distributor. 47. Disconnect the surge tank coolant hose at the throttle body2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Tt RX OE.) ni? << \\ ara CTT aN Fig. 77: View Of Intake Manifold Support Bracket And Retaining Bolts Courtesy of GENERAL MOTORS CORP. 48. Remove the intake manifold support bracket retaining bolts.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 78: View Of Throttle Cable Courtesy of GENERAL MOTORS CORP. 49. Disconnect the throttle cable at the throttle body and the intake manifold.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 50. 51 52. Fig. 79: Loosening Sequence Of Cylinder Head Bolts Courtesy of GENERAL MOTORS CORP. Gradually loosen all of the cylinder head bolts in the sequence shown. Remove the cylinder head bolts, Remove the camshaft carrier assembly. NOTE: Use extreme care when removing the cylinder head to prevent any engine oil, dirt, or coolant from entering the engine. Damage to the engine could result. Remove the cylinder head with the intake manifold and the exhaust manifold attached. Remove the cylinder head gasket Installation Procedure CAUTION: Valve springs can be tightly compressed. Use care when removing the retainers and plugs. Personal injury could result.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 80: Applying Gasket Maker To Sealing Surface Of Camshaft Carrier Courtesy of GENERAL MOTORS CORP. Apply a continuous 3 mm (0.12 in) bead of gasket maker to the sealing surface of the camshaft carrier. Install the cylinder head gasket Install the cylinder head with the intake manifold and the exhaust manifold attached. Install the camshaft carrier assembly2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 81: Cylinder Head Bolt Tightening Sequence Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 5. Install the cylinder head bolts in the sequence shown. Tighten: Tighten the cylinder head bolts to 25 N.m (18 lb ft).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 82: Tightening Cylinder Head Bolts Using J 45059 Or KM-470-B Courtesy of GENERAL MOTORS CORP. 6. Using the J 45059 or the KM-470-B (1), tighten the cylinder head bolts another 70 degrees plus 70 degrees plus 30 degrees.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo AO Fig. 83: View Of Throttle Cable Courtesy of GENERAL MOTORS CORP. 7. Connect the throttle cable at the throttle body and at the intake manifold.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo oo Tt ; RX Ek) TN a << \ LP BQH Y Fig. 84: View Of Intake Manifold Support Bracket And Retaining Bolt Courtesy of GENERAL MOTORS CORP. Install the intake manifold support bracket retaining bolt. Tighten: Tighten the intake manifold support bracket retaining bolts to 25 N.m (18 Ib ft),2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 85: View Of Heater Inlet Hose And Surge Tank Coolant Hose Courtesy of GENERAL MOTORS CORP. 9. Connect the surge tank coolant hose at the throttle body. 10. Connect the heater inlet hose to the coolant distributor. 11. Install the catalytic converter nuts at the exhaust manifold flange. Tighten: Tighten the auxiliary catalytic converter-to-exhaust manifold nuts to 40 N.m (30 Ib ft) 12. Connect the front heated oxygen sensor electrical connector2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 86: Identifying Front Heated Oxygen Sensor Connector Courtesy of GENERAL MOTORS CORP.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 87: View Of Rear Timing Belt Cover Upper Bolts Courtesy of GENERAL MOTORS CORP. 13. Install the rear timing belt cover upper bolts. Tighten: Tighten the rear timing belt cover upper bolts to 10 N.m (89 Ib in).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 88: Holding Camshaft While Loosening/Tightening Sprocket Bolt Courtesy of GENERAL MOTORS CORP. IMPORTANT: Take extreme care to prevent any scratches, nicks, or damage to the camshaft. Such damage can impair vehicle operation. 14. Install the camshaft gear 5. While holding the crankshaft pulley bolt, install the camshaft gear bolt. Tighten: Tighten the camshaft gear bolt to 45 N.m (33 Ib fi)2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 89: View Of Crankcase Ventilation Tube And Camshaft Housing Courtesy of GENERAL MOTORS CORP. 16. Connect the crankcase ventilation tube to the camshaft housing.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo ing Belt Cover Fig. 90: Aligning Camshaft Gear Timing Mark To Top Rear Ti Notch Courtesy of GENERAL MOTORS CORP. Align the mark on the camshaft gear to the notch at the top of the rear timing belt cover.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 91: Aligning Crankshaft Gear Mark To Bottom Rear Timing Belt Cover Notch Courtesy of GENERAL MOTORS CORP. Align the mark on the crankshaft gear to the notch at the bottom of the rear timing belt cover. Install the timing belt. Refer to Timing Belt Replacement. Inspect the timing belt tension. Refer to Timing Belt Inspection. 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 - 1.5L - Aveo Fig. 92: View Of Throttle Cable Courtesy of GENERAL MOTORS CORP. Install the crankshaft pulley. Install the crankshaft pulley bolt. Tighten: « Tighten the crankshaft pulley bolts to 95 N.m (70 Ib ft) « Using the J 45059 or the KM-470-B , tighten the crankshaft pulley bolt another 30 degrees plus 15 degrees Connect all of the vacuum hoses and electrical connectors. Connect the brake booster hose at the intake manifold. Connect the upper radiator hose at the thermostat housing.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo mR as Fig. 93: View Of Alternator Bracket And Nut Courtesy of GENERAL MOTORS CORP. Install the alternator bracket Install the alternator bracket retaining nut Tighten: Tighten the alternator bracket retaining nut to 25 N.m (18 Ib ft) Install the alternator nut. Do not tighten.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo / iS [Ai Vi Fig. 94: View Of Fuel Feed Line And Fuel Rail Courtesy of GENERAL MOTORS CORP. 30. Connect the fuel feed line at the fuel rail. NOTE: Refer to Belt Dressing Notice in Cautions and Notices. 31. Install the serpentine accessory drive belt. Refer to Power Steering Pump Hoses and Pipes Replacement in Power Steering System. 32. Install the upper timing belt cover.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 33. 34. 35. 36 Fig. 95: View Of Upper Timing Belt Cover And Bolts Courtesy of GENERAL MOTORS CORP. Install the upper timing belt cover bolts. Tighten: Tighten the upper timing belt cover bolts to 10 N.m (89 Ib in). Install the A/C compressor drive belt, as nec 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. ry.2004 ENGINE Engine Mechanical - 1.5L - Aveo 2004 Chevrolet Aveo Fig. 96: View Of Air Cleaner Housing Courtesy of GENERAL MOTORS CORP. Install the air filter housing. Install the air filter housing bolts. Tighten: Tighten the air filter housing bolts to 12 N.m (106 Ib in). Connect the air intake tube to the throttle body. Connect the breather tube to the valve cover. Connect the IAT sensor connector. Install the CMP sensor2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 4B 44 45 46 47 48 49 50 sl 32 Fig. 97: View Of IAC Connector And TP Sensor Connector Courtesy of GENERAL MOTORS CORP. Connect the ECT sensor connector. Connect the IAC valve connector Connect the TP sensor connector. Connect the EI system ignition coil connector. Connect the fuel injector harness connectors. Connect the O2 sensor connector. Connect the PCM/ECM ground terminal at 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.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo OIL PAN REPLACEMENT Removal Procedure CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable 2. Drain the engine oil from the engine crankcase. 3. Disconnect the rear heated oxygen (HO2S) sensor. Fig. 98: Ider g Front Heated Oxygen Sensor Connector Courtesy of GENERAL MOTORS CORP. 4, Remove the catalytic converter upper flange nuts from the exhaust manifold and the bolts from the bracket.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 99: View Of Muffler And Pipe Courtesy of GENERAL MOTORS CORP. 5. Remove the nuts from the front muffler pipe to the connecting pipe.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo @ Qo eo — | he === SS SS view Of Oil Pan sy of GENERAL MOTORS CORP. 6. Remove the oil pan retaining bolts. 7. Remove the oil pan from the engine block. Installation Procedure 1. Make sure that the oil pan and mounting surface on the engine block are free of all oil and debris 2. Install the oil pan gasket to the oil pan.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 9 Qe eo cle i V7 | g onl | = = SS ~.. = = = 101: View Of Oil Pan sy of GENERAL MOTORS CORP. IMPORTANT: Install the oil pan within 5 minutes after applying liquid gasket to the oil pan. Install the oil pan to the engine block. NOTE: Refer to Fastener Notice in Cautions and Notices. Install the oil pan retaining bolts. Tighten: Tighten the oil pan retaining bolts to 10 N.m (89 Ib in). Install the catalytic converters-to-exhaust manifold nuts Tighten: Tighten the catalytic converter-to-exhaust manifold nuts and bracket bolts to 40 N.m (30 Ib ft)2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 102: Identifying Front Heated Oxygen Sensor Connector Courtesy of GENERAL MOTORS CORP.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 103: View Of Muffler And Pipe Courtesy of GENERAL MOTORS CORP. Install the nuts from the front muffler pipe to the connecting pipe and catalytic converter. Tighten: Tighten the front muffler-to-connecting pipe nuts to 30 N.m (22 Ib fi) Connect the rear heated oxygen sensor connector. Connect the negative battery cable. Install the oil pan drain plug. ‘Tighten: Tighten the oil pan drain plug to 35 N.m (25 Ib ft)2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 9 Qe eo —] he | = = SS ~.. = = = 104: View Of Oil Pan sy of GENERAL MOTORS CORP. 10. Refill the engine crankcase with engine oil OIL PAN CI NING AND INSPECTION CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 105: Cleaning Oil Pan Courtesy of GENERAL MOTORS CORP. Clean the oil pan sealing surface Clean the engine block sealing surface. Clean the oil pan retaining bolts Clean the oil pan retaining bolt holes in the engine block FONE OIL PUMP REPLACEMENT Removal Procedure 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.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 3. Remove the rear timing belt cover. Refer to Timing Belt Cover Replacement. 4. Disconnect the oil pressure switch connector. : View Of Oil Pressure Gage Sensor Courtesy of GENERAL MOTORS CORP. Remove the crankshaft position (CKP) sensor bolt. Remove the CKP sensor. Remove the oil pan. Refer to Oil Pan Replacement. Remove the oil pump pickup tube and the support bracket bolts. wera2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 107: View Of Oil Pump/Pickup Tube And Bolts Courtesy of GENERAL MOTORS CORP. 9, Remove the oil pump pickup tube.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo ig. 108: Identifying Oil Pump Retaining Bolts Courtesy of GENERAL MOTORS CORP. 10. Remove the oil pump retaining bolts. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. 11. Carefully separate the oil pump and the gasket from the engine block and the oil pan. 12. Remove the oil pump. Installation Procedure 1. Apply a bead of room temperature vulcanizing (RTV) sealer to the oil pump gasket t to the oil pump. Di inerall anemic2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo ig. 109: Identifying Oil Pump Retaining Bolts Courtesy of GENERAL MOTORS CORP. 3. Coat the threads of the oil pump bolts with LOCTITE® 242 NOTE: Refer to Fastener Notice in Cautions and Notices. 4. Install the oil pump to the engine block with the bolts (1). Tighten: Tighten the oil pump retaining bolts to 10 N.m (89 Ib in).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 110: View Of Oil Pump And Crankshaft Seal Courtesy of GENERAL MOTORS CORP. 5. Install a new oil pump to the crankshaft seal 6. Coat the lip of the seal with a thin coat of grease.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 111: View Of Oil Pump/Pickup Tube And Bolts Courtesy of GENERAL MOTORS CORP. 7. Coat the threads of the oil pump pickup tube and the support bracket bolts with LOCTITE® 242, 8. Install the oil pump pickup tube and the bolts. Tighten: Tighten the oil pump pickup tube and the support bracket bolts to 10 N.m (89 Ib in). 9. Install the oil pan. Refer to Oil Pan Replacement. 10. Install the CKP sensor and the bolt Tighten: Tighten the crankshaft position sensor retaining bolt to 10 N.m (89 Ib in). Connect the oil pressure switch connector2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 112: View Of Oil Pressure Gage Sensor Courtesy of GENERAL MOTORS CORP. 12. Install the rear timing belt cover. Refer to Timing Belt Cover Replacement. 13. Install the timing belt. Refer to Timing Belt Replacement. 14, Connect the negative battery cable OIL PUMP CLEANING AND INSPECTION Inspection Procedure 1. Clean the oil pump and the engine block gasket mating surfaces.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 113: View Of Oil Pump And Crankshaft Seal Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. 2. Remove the safety relief valve bolt. Remove the safety relief valve and the spring 4. Remove the oil pump-to-crankshaft seal2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 114: View Of Oil Pump Courtesy of GENERAL MOTORS CORP. Remove the oil pump rear cover bolts. Remove the rear cover. Clean the oil pump housing and all of the parts. Inspect all of the parts for signs of wear. Refer to Engine Mechanical Specifications. Coat all of the oil pump parts with clean engine oil Reinstall all of the oil pump parts. NOTE: Fill oil pump cavities with petroleum jelly prior to installation. This will ensure that there is oil pressure immediately on start-up and will prevent engine damage. Install the oil pump rear cover and the bolts. Tighten: Tighten the oil pump rear cover bolts to 8 N.m (71 Ib in) Install the safety relief valve, the spring, the washer, and the bolt.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Tighten: Tighten the oil pump safety relief valve bolt to 40 N.m (30 Ib fi). ENGINE MOUNT REPLACEMENT Tools Required J 28467-B (DW 117) Universal Engine Assembly Support Fixture Removal Procedure 1. Disconnect the negative battery cable CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. NOTE: Refer to Engine Mounting Notice in Cautions and Notices. 2, Remove the air cleaner housing bolts and the air filter housing assembly NOTE: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or crankshaft balancer. Jacking against the oil pan may cause it to crack or break.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 115: Supporting Engine Assembly Using J 28467-B Courtesy of GENERAL MOTORS CORP. 3. Support the engine assembly using the J 28467-B2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 116: View Of Engine Mount Bracket Retaining Bolts Courtesy of GENERAL MOTORS CORP. 4, Remove the engine mount bracket retaining bolts (1).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 117: View Of Engine Mount Attaching Nuts Courtesy of GENERAL MOTORS CORP. 5. Remove the engine mount attaching nuts (1). 6. Remove the engine mount. Installation Procedure 1. Install the engine mount2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 118: View Of Engine Mount Attaching Nuts Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 2. Install the engine mount attaching nuts (1). Tighten: Tighten the engine mount attaching nuts to 40 N.m (30 Ib ft).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 119: View Of Engine Mount Bracket Retaining Bolts Courtesy of GENERAL MOTORS CORP. 3. Install the engine mount bracket retaining bolts (1). Tighten: Tighten the engine mount bracket retaining bolts to 60 N.m (44 Ib ft),2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 120: Supporting Engine Assembly Using J 28467-B Courtesy of GENERAL MOTORS CORP. 4. Remove the J 28467-B 5. Connect the negative battery cable. ENGINE REPLACEMENT Tools Required « KM-470-B Angular Torque Gage « J 45059 Angle Meter Removal Procedure 1, Remove the fuel pump fuse, Drain the engine oil. NOTE: If the engine is damaged internally and a new engine assembly is installed in the vehicle, ensure that all foreign material is flushed out of the cooling system. You must also flush out the oil cooler system. Failure to rid the oil cooler system of debris can result in engine damage.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo IMPORTANT: On vehicles equipped with a manual transaxle, the manual transaxle must be removed before engine removal. Refer to Transmission Replacement in Manual Transaxle - D16. Fig. 121: View Of Fuel Pump Fuse Courtesy of GENERAL MOTORS CORP. 2. Start the engine. After it stalls, crank the engine. 3. Remove the hood. Refer to Hood Replacement in Body Front End. 4, Drain the engine oil2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo eI AH ° Fig. 122: View Of Battery Cable Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. Disconnect the negative battery cable. Disconnect and separate the battery positive cable. Disconnect the negative battery cable from the vehicle frame Discharge the air conditioning (A/C) system, if equipped. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning, Disconnect the intake air temperature (IAT) sensor connector. Remove the air intake tube from the throttle body and the air filter housing2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 123: Locating Intake Ducting To Engine Courtesy of GENERAL MOTORS CORP. 11. Disconnect the breather tube from the valve cover.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 124: View Of Serpentine Accessory Drive Belt Tensioner Courtesy of GENERAL MOTORS CORP. 12. Remove the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 13. Remove the right front wheel well splash shield. 14. Remove the serpentine accessory drive belt.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 17. 18 19. 20. 21 22. Kon a Oe le { pie Fig. 125: View Of HO2 Sensor Harness Courtesy of GENERAL MOTORS CORP. Drain the engine coolant. Refer to Draining and Filling Cooling System in Engine Cooling, Remove the coolin; -m radiator and the engine cooling fans. Refer to Radiator Replacement and Cooling Fan Replacement - Electric in Engine Cooling Disconnect the upper radiator hose from the thermostat housing. Disconnect the coolant surge tank hose from the radiator Disconnect the power steering return hose from the power steering pump, if equipped Drain the power steering system, if equipped. Disconnect the power steering pressure hose from the power steering pump, if equipped. Disconnect the electrical connector at the electronic ignition (El) system ignition coil, and the engine control module (ECM) ground terminal at the intake manifold and at the starter motor. Disconnect the pre-converter oxygen (O2) sensor connector.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 126: Pre-Converter HO2 Sensor Connector View Courtesy of GENERAL MOTORS CORP. Disconnect the electrical connectors at the fuel injectors. Disconnect the idle air control (IAC) valve connector. Disconnect the throttle position (TP) sensor connector. Disconnect the engine coolant temperature (ECT) sensor connector and the knock sensor, if equipped. Disconnect the alternator voltage regulator connector. Disconnect all of the necessary vacuum lines, including the brake booster vacuum hose. Disconnect the fuel feed line at the fuel rail Disconnect the throttle cable from the throttle body and the intake manifold bracket. Disconnect the camshaft position (CMP) sensor connector.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 127: View Of Camshaft Position Sensor Courtesy of GENERAL MOTORS CORP. 33. Disconnect the surge tank coolant hose at the throttle body. 34, Disconnect the heater inlet hose from the coolant distributor.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 128: View Of Heater Inlet And Outlet Hoses Courtesy of GENERAL MOTORS CORP. Disconnect the heater outlet hose at the coolant pipe. Disconnect the surge tank coolant hose from the coolant pipe. Disconnect the lower radiator hose at the coolant pipe. Disconnect the starter solenoid $ terminal wire. Remove the A/C compressor hose assembly retaining bolt.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 40. 4 42. 43. 4: 45 = Fig. 129: View Of A/C Compressor Courtesy of GENERAL MOTORS CORP. Disconnect the A/C compressor hose assembly from the compressor. Disconnect the A/C compressor coil connector Remove the A/C compressor mounting bolts. Remove the A/C compressor. Remove the A/C compressor mounting bracket bolts. Remove the A/C compressor mounting bracket from the engine block.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 130: Identifying Front Heated Oxygen Sensor Connector Courtesy of GENERAL MOTORS CORP. 46. Remove the catalytic converter nuts from the exhaust manifold.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 131: View Of Muffler And Pipe Courtesy of GENERAL MOTORS CORP. 47, Remove the nuts from the front muffler pipe to the connecting pipe.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 132: View Of Crankshaft Pulley And Bolt Courtesy of GENERAL MOTORS CORP. Remove the engine crankshaft pulley bolt. Remove the engine crankshaft pulley. Disconnect the vacuum lines at the evaporative (EVAP) emission canister purge. Disconnect the electrical connector at the EVAP emission canister purge solenoid and the knock sensor Disconnect the electrical connector at the oil pressure switch.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 133: View Of Oil Pressure Gage Sensor Courtesy of GENERAL MOTORS CORP. Disconnect the crankshaft position (CKP) sensor connector and the CMP sensor connector. Remove the CKP sensor retaining bolt Remove the CKP sensor2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 62. 63. 64, Fig. 134: View Of Battery Tray Courtesy of GENERAL MOTORS CORP. Remove the battery Remove the battery tray. Remove the right transaxle brace bolts from the transaxle. Disconnect the back up switch connector. Remove the hydraulic clutch pipe Remove the transaxle bell housing bolts. NOTE: Refer to Engine Lifting Notice in Cautions and Notices. Support the transaxle with a floor jack Install the engine lifting device. Disconnect the right engine mount bracket from the rubber engine mount by removing the retaining bolts (1)2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 135: View Of Engine Mount Bracket Retaining Bolts Courtesy of GENERAL MOTORS CORP. 65. Remove the right engine mount bracket from the engine block. 66. Separate the engine block from the transaxle. 67. Remove the engine. 68. Transfer any nec: parts Installation Procedure 1. Install the engine into the engine compartment. 2. Align the trans: alignment pins (1) to the transaxle,2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 136: View Of Transaxle Alignment Pins Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 3. Install the transaxle bell housing bolts. Tighten: Tighten the transaxle bell housing bolts to 75 N.m (55 Ib ft).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 137: View Of Engine Mount Bracket Retaining Bolts Courtesy of GENERAL MOTORS CORP. Install the right engine mount bracket to the engine block Install the right engine mount bracket retaining bolts (1) to the engine block Tighten: Tighten the engine mount bracket retaining bolts to 60 N.m (44 Ib ft), Install the engine mount-to-bracket retaining bolts. Tighten: Tighten the engine mount bracket-to-engine mount retaining bolts to 60 N.m (44 Ib ft), Remove the floor jack used for support of the transaxle. Remove the engine lifting device. Install the right transaxle brace bolts to the transaxle. Tighten: Tighten the right transaxle brace bolts to 60 N.m (44 Ib ft).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 13. 15. 16 17. Connect the back up switch electrical connector. Install the hydraulic clutch pipe. Install the battery tray. Fig. 138: View Of Battery Tray Courtesy of GENERAL MOTORS CORP. Install the battery with the nut. Connect the vacuum lines at the EVAP emission canister purge solenoid. Connect the electrical connectors at the EVAP emission canister purge solenoid. Connect the oil pressure switch connector Install the crankshaft pulley.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 139: View Of Crankshaft Pulley And Bolt Courtesy of GENERAL MOTORS CORP. Install the crankshaft pulley bolt. Tighten: « Tighten the crankshaft pulley bolt to 95 N.m (70 Ib ft) using a torque wrench, « Using the J 45059 or the KM-470-B , tighten the crankshaft pulley bolt another 30 degrees plus 15 degrees Install the CKP sensor and the CKP sensor retaining bolt. Tighten: Tighten the crankshaft position sensor retaining bolt to 10 N.m (89 Ib in). Connect the CKP sensor connector, Install the nuts from the front muffler pipe to the connecting pipe. ‘Tighten: Tighten the front muffler pipe to the connecting pipe to 30 N.m (22 Ib ft),2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 140: View Of Muffler And Pipe Courtesy of GENERAL MOTORS CORP.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo ig. 141: Identifying Front Heated Oxygen Sensor Connector tesy of GENERAL MOTORS CORP. Cc 22. Install the nuts from the front muffler pipe to the catalytic converter. ‘Tighten: Tighten the catalytic converter-to-exhaust manifold nuts to 40 N.m (30 Ib ft)2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 142: View Of O2 Sensor Harness Courtesy of GENERAL MOTORS CORP. 23. Connect the power steering pressure hose from the power steering pump.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 24. 25. Fig. 143: View Of Crankshaft Pulley And Bolt Courtesy of GENERAL MOTORS CORP. Install the A/C compressor mounting bracket, if equipped. Install the A/C compressor mounting bracket bolts, if equipped Tighten: Tighten the A/C compressor mounting bracket bolts to 50 N.m (37 Ib ft). Install the A/C compressor, if equipped Install the A/C compressor mounting bolts, if equipped Tighten: Tighten the A/C compressor mounting bolts to 35 N.m (26 Ib ft). Connect the A/C compressor coil connector. Install the serpentine accessory drive belt. Connect the A/C compressor hose assembly and the A/C compressor hose assembly retaining bolt, if equipped. Tighten: Tighten the A/C compressor hose assembly retaining bolt to 33 N.m (24 Ib fi)2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 31. Install the right front wheel well splash shield. 32. Install the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 33. Connect the fuel feed line to the fuel rail. Fig. 144: View Of Fuel Feed Line And Fuel Rail Courtesy of GENERAL MOTORS CORP. 34, Connect all of the necessary vacuum lines, including the brake booster vacuum hose.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 35, 36. 37, 38. 39. 40. 41 Fig. 145: View Of Fuel Pump Fuse Courtesy of GENERAL MOTORS CORP. Connect the pre-converter 02 sensor connector. Connect the starter solenoid S terminal wire, Connect the alternator voltage regulator connector. Connect the ECT sensor connector. Connect the TP sensor connector. Connect the IAC valve connector, Connect the CMP sensor connector.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 42, 4B 44. 45. 46 47. 48 49. 50. Fig. 146: Locating Intake Ducting To Engine Courtesy of GENERAL MOTORS CORP. Connect the electrical connectors at the fuel injectors. Connect the electrical connector at the EI system ignition coil and the PCM/ECM ground terminal at the intake manifold, Install the air intake tube between the throttle body and the air filter housing. Connect the breather tube to the valve cover, Connect the IAT sensor connector. Install the cooling system radiator and the engine cooling fans. Refer to Radiator Replacement in Engine Cooling Connect the lower radiator hose to the coolant pipe. Connect the upper radiator hose to the thermostat housing. Connect the coolant surge tank hose to the radiator.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo ei ars 53. 54, Fig. 147: View Of Coolant Hoses Courtesy of GENERAL MOTORS CORP. Connect the heater outlet hose to the coolant pipe. Connect the heater inlet hose to the coolant distributor Connect the coolant surge tank hose to the coolant pipe. Connect the surge tank coolant hose to the throttle body.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo EF 56 57. 58. 59 60. 6l 62. 64, Fig. 148: View Of Battery Cable Courtesy of GENERAL MOTORS CORP. Connect the throttle cable to the throttle body and the intake manifold bracket. Install the fuel pump fuse Connect the negative battery cable to the vehicle frame. Connect the negative battery cable to the battery. Connect and assemble the battery positive cable. Refill the engine crankcase with engine oil Refill the engine coolant system. Refer to Draining and Filling Cooling System in Engine Cooling Refill the engine coolant system. Refer to Checking and Adding Power Steering Fluid in Power Steering System Bleed the power steering system as necessary. Refer to Bleeding the Power Steering System in Power Steering System. Refill the A/C refrigerant system as necessary. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning. Install the hood. Refer to Hood Replacement in Body Front End.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo EXHAUST MANIFOLD REMOVAL. Removal Procedure CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. 1. Disconnect the negative battery cable 2. Disconnect the ignition wires from the spark plugs. 3. Disconnect the oxygen (02) sensor. Fig. 149: Identifying Front Heated Oxygen Sensor Connector Courtesy of GENERAL MOTORS CORP. Remove the exhaust manifold heat shield bolts. we Remove the exhaust manifold heat shield, a Remove the auxiliary catalytic converter upper flange nuts.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 150; Removal Sequence Of 8 Exhaust Manifold Nuts Courtesy of GENERAL MOTORS CORP. 7. Remove the 8 exhaust manifold nuts in the sequence shown. 8. Remove the exhaust manifold. 9. Remove the exhaust manifold gasket. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. 10. Clean the sealing surfaces of the exhaust manifold and the cylinder head CRANKSHAFT AND BEARINGS CLEANING AND INSPECTION Tools Required « KM-470-B Angular Torque Gage « J 45059 Angle Meter Inspection Procedure2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. Coat the crankshaft bearings with engine oil Install the upper crankshaft bearings into the engine block crankshaft journals Install the lower crankshaft bearings into the crankshaft bearing caps. Install the crankshaft. Inspect the crankshaft end play with the crankshaft bearings installed WwW Fig. 151: Inspecting Crankshaft End Play Courtesy of GENERAL MOTORS CORP. 6. Check for permissible crankshaft end play. Refer to Engine Mechanical Specifications2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 152: Checking Crankshaft Journal For Out-Of-Round Runout Courtesy of GENERAL MOTORS CORP. With the crankshaft mounted on the front and the rear crankshaft bearings, check the middle crankshaft journal for permissible out-of-round, runout. Refer to Engine Mechanical Specifi2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 153: Placement Of Plastigage On Journal Courtesy of GENERAL MOTORS CORP. IMPORTANT: Grease the crankshaft journals and lubricate the crankshaft bearings slightly so that the plastic gaging thread does not tear when the crankshaft bearing caps are removed. Measure all of the crankshaft bearing clearances using a commercially available plastic gaging, ductile plastic threads. Cut the plastic gaging threads to the length of the bearing width. Lay them axially (1) between the crankshaft journals and the crankshaft bearings (1)2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 154: Using J 45059 To Tighten Bearing Caps Courtesy of GENERAL MOTORS CORP. 10. Install the crankshaft bearing caps NOTE: Refer to Fastener Notice in Cautions and Notices. 11. Install the crankshaft bearing cap bolts. Tighten: « Tighten the crankshaft bearing cap bolts to 50 N.m (37 Ib ft). « Using the J 45059 or the KM-470-B (1), tighten the crankshaft bearing cap bolts another 45 degrees plus 15 degrees. 12. Remove the crankshaft bearing caps. Measure the width of the flattened plastic thread (1) of the plastic gaging using the scale printed on the plastic gaging package. Plastic gaging is available for different tolerance range:2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 155: Measuring Plastigage Courtesy of GENERAL MOTORS CORP. 14. Inspect the bearing clearances for permissible tolerance ranges. Refer to Engine Mechanical Specifications. PISTON, CONNECTING ROD, AND BEARING REPLACEMENT. Tools Required « KM-470-B Angular Torque Gage « J 24086-B (KM-427) Piston Pin Remover/Installer « 3.45059 Angle Meter Removal Procedure2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. Remove the cylinder head with the intake manifold and exhaust manifold attached Refer to Cylinder Head Replacement Remove the oil pan. Refer to Oil Pan Replacement. Remove the oil pump/pickup tube bolts. Fig. 156: View Of Oil Pump/Pickup Tube Courtesy of GENERAL MOTORS CORP. Remove the oil pump/pickup tube. Move the piston to the bottom of the piston stroke. Mark the connecting rod cap Remove the connecting rod cap bolts.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 8. Remove the connecting rod cap and lower connecting rod bearing 9. Remove the upper piston connecting rod bearing. 10. Ridge ream the cylinder wall. } i) al? \ Fig. 157: Removing Cylinder Ridge Courtesy of GENERAL MOTORS CORP. CAUTION: Handle the piston carefully. Worn piston rings are sharp and may cause bodily injury. 11. Remove the piston 12, Use a piston ring expander tool to expand the piston rings2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 158: Expanding Piston Rings Courtesy of GENERAL MOTORS CORP. 13. Remove the piston rings.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 159: Pressing Out Piston Pin Courtesy of GENERAL MOTORS CORP. 14. Remove the piston pin from the piston and connecting rod assembly using theJ 24086- B(1) 15. Separate the piston from the connecting rod. Installation Procedure CAUTION: Avoid contact with moving parts and hot surfaces while working around a running engine in order to prevent physical injury.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 1. Align the notch on the piston and connecting rod so that the proper sides will be facing the front of the engine. 2. Install the piston pin guide through the piston and the connecting rod. Fig. 160: Pressing In Piston Pin Courtesy of GENERAL MOTORS CORP. 3. Coat the piston pin with clean oil 4. Install the piston pin into the opposite side of the piston. 5. Install the piston pin into the piston and connecting rod assembly using the J 24086-B (1).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 6. Select a set of new piston rings. 7. Measure the piston ring gap using a feeler gage. Refer to Engine Mechanical Specifications SEES Measuring Piston Ring Gap Using Feeler Gage Courtesy of GENERAL MOTORS CORP. 8. Increase the piston ring gap by carefully filing off excess material if the piston ring gap is below specifications2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 10. 11 Fig. 162: Measuring Piston Ring Side Using Feeler Gage Courtesy of GENERAL MOTORS CORP. Measure the piston ring side clearance using a feeler gage. Refer to Engine Mechanical Specifications. If the piston ring is too thick, try another piston ring. If no piston ring can be found that fits to specifications, the piston ring may be ground to size with emery paper placed on a sheet of glass.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 163: Ring Courtesy of GENERAL MOTORS CORP. /iew Of Piston Rings, Second Compression Ring, And Top Compression Install a piston oil ring, the expander, then the second piston oil ring to the bottom ring groove of the piston Install the second compression ring to the middle ring groove of the piston Install the top compression ring to the top ring groove of the piston.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical- 1.5L - Aveo NOTE: Use a piston ring expander to install the piston rings. The rings may be damaged if expanded more than necessary. 15. Use a piston ring expander to install the piston rings. Do not expand the piston rings beyond the expansion necessary for installation. 16. Stagger the piston oil rings (2), the oil ring rail gaps (3), the second compression ring (4), and the top compression ring in relation to the notch on the top of the piston (1) Fig. 164: View Of Piston Ring Installed Positions Courtesy of GENERAL MOTORS CORP. 17. Lubricate the cylinder wall and the piston rings with clean engine oil. 18. Install the piston using a ring compressor and a wood handle. Guide the lower connecting rod end to prevent damaging the crankshaft journal2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 165: Installing Piston Courtesy of GENERAL MOTORS CORP. 19. Install the connecting rod cap and the bearings. Refer to Crankshaft and Bearings Cleaning and Inspection 20. Install the connecting rod cap bearing bolts Tighten: « Tighten the connecting rod bearing cap bolts to 25 N.m (18 Ib ft) « Using the J 45059 or the KM-470-B (1), tighten | turn of 30 degrees plus 15 degrees,2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 166: Using J 45059 Or KM-470-B To Torque Rod Bolts Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. 21. Install the oil pump/pickup tube2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 167: View Of Oil Pump/Pickup Tube Courtesy of GENERAL MOTORS CORP. 22. Install the oil pump/pickup tube bolts Tighten: Tighten the oil pump/pickup tube and support bracket bolts to 10 N.m (89 Ib in). 23. Install the oil pan. Refer to Oil Pan Replacement. 24. Install the cylinder head with the intake manifold and the exhaust manifold attached. Refer to Cylinder Head Replacement. PISTON, CONNECTING ROD, AND BEARINGS CLEANING AND INSPECTION ‘Tools Required e KM-470-B Aneular Torque Gage2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo « J 45059 Angle Meter Piston Inspection 1 ween a 7 CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. Inspect the connecting rod for bending or twisting. If the connecting rod is bent or twisted, replace the connecting rod. Inspect the connecting rod bearings. Inspect the connecting rod lower end for wear. Inspect the connecting rod upper end for scoring. Inspect the crankshaft rod bearing journal for wear. Refer to Engine Mechanical Specifications Inspect the piston for scoring, cracks, and wear. Inspect the piston for taper using a micrometer Fig. 168: Inspecting Piston For Taper Courtesy of GENERAL MOTORS CORP.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 169: Inspecting Piston Fit To Connecting Rod Courtesy of GENERAL MOTORS CORP. 8. Inspect the piston for fit to the connecting rod.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 170: Inspecting Engine Block Cylinder Bore Courtesy of GENERAL MOTORS CORP. 9. Inspect the engine block deck surface for flatness using a straight edge and a feeler gage. Refer to Engine Mechanical Specific: 10. Inspect the bearing bore for concentricity and alignment using a bore gage. Refer to Engine Mechanical Specifications. If beyond specifications, replace the engine block 11, Inspect the engine block cylinder bore for wear, runout, ridging, and taper using a bore gage. Refer to Engine Mechanical Specifications. 12, Inspect the engine block cylinder bore for glazing. Connecting Rod Inspection 1. Coat the connecting rod bearings with engine oil CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. 2. Install the upper connecting rod bearings into the connecting rod journals. IMPORTANT: Grease the connecting rod journals and lubricate the connecting rod bearings slightly so that the plastic gaging2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo thread does not tear when the connecting rod bearing caps are removed. 3. Install the lower connecting rod bearings into the connecting rod bearing caps. 4. Measure all of the connecting rod bearing clearances using a commercial available plastic gaging, ductile plastic threads Fig. 171: Placement Of Plastigage On Journal Courtesy of GENERAL MOTORS CORP. 5. Cut the plastic gaging threads to the length of the bearing width. Lay them axially between the connecting rod journals and the connecting rod bearings. 6. Install the connecting rod bearing caps. NOTE: Refer to Fastener Notice in Cautions and Notices.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 7. Install the connecting rod bearing cap bolts. Tighten: « Tighten the connecting rod bearing cap bolts to 25 N.m (18 Ib fi) « Using the KM-470-B (1), tighten the connecting rod bearing cap bolts another 30 degrees plus 15 degrees 8. Remove the connecting rod bearing caps. 9. Measure the width of the flattened plastic thread of the plastic gaging (1) using the scale printed on the plastic gaging package. Plastic gaging is available for different tolerance ranges 10. Inspect the bearing clearance for permissible tolerance ranges. Refer to Engine Mechanical Specifications. CAMSHAFT GEAR REPLACEMENT. Removal Procedure 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. 3. Remove the valve cover bolts2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 172: View Of Valve Cover And Camshaft Housing Courtesy of GENERAL MOTORS CORP. Remove the valve cover. While holding the camshaft firmly in place, remove the camshaft gear bolt.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 173: Holding Camshaft While Loosening/Tightening Sprocket Bolt Courtesy of GENERAL MOTORS CORP. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. IMPORTANT: Take extreme care to prevent any scratches, nicks, or damage to the camshaft. Such damage can impair vehicle operation. 6. Remove the camshaft gear. Installation Procedure 1. Install the camshaft gear.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 174: Holding Camshaft While Loosening/Tightening Sprocket Bolt Courtesy of GENERAL MOTORS CORP. IMPORTANT: Take extreme care to prevent any scratches, nicks, or damage to the camshaft. Such damage can impair vehicle operation. NOTE: Refer to Fastener Notice in Cautions and Notices. 2. While holding the camshaft firmly in place, install the camshaft gear bolt. Tighten: Tighten the camshaft gear bolt to 45 N.m (33 Ib ft).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 175: View Of Valve Cover And Camshaft Housing Courtesy of GENERAL MOTORS CORP. 3. Install the valve cover. 4. Install the valve cover bolts. Tighten: Tighten the valve cover bolts to 9 N.m (80 Ib in). 5. Install the timing belt. Refer to Timing Belt Replacement. 6. Connect the negative battery cable. CAMSHAFT REPLACEMENT Tools Required KM-S65-A Valve Spring Compressor Removal Procedure 1. Remove the timing belt. Refer to Timing Belt Replacement. 2. Disconnect the air breather tube at the valve cover.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 3. Remove the valve cover bolts. 4. Remove the valve cover. Fig. 176: View Of Valve Cover And Camshaft Housing Courtesy of GENERAL MOTORS CORP. 5. Remove the valve cover gasket. 6. Install the KM-565-A IMPORTANT: Take extreme care to prevent any scratches, nicks, or damage to the camshaft. Such damage can impair vehicle operation.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 177: Removal Of Roller Followers Using KM-565-A Courtesy of GENERAL MOTORS CORP. 7. Remove the roller followers using the KM-565-A (1)2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 178: Holding Camshaft While Loosening/Tightening Sprocket Bolt Courtesy of GENERAL MOTORS CORP. 8. While holding the camshaft firmly in place, remove the camshaft gear bolt. 9. Remove the camshaft gear.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 179: View Of Battery Courtesy of GENERAL MOTORS CORP. 10. Disconnect the positive battery cable from the battery IL. Remove the battery and the battery tray. Refer to Battery and Battery Tray Replacement in Engine Electrical2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 180: Courtesy of GENERAL MOTORS view Of EI System Ignition Coil Connector CORP. 12. Disconnect the electronic ignition (EI) system ignition coil connector. 13. Disconnect the EI system ignition wires at the ignition coil. 14. Remove the El system ignition coil mounting nuts 15. Remove the El system ignition coil.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 181: View Of EI System Ignition Coil Mounting Plate Courtesy of GENERAL MOTORS CORP. 16. Remove the El system ignition coil mounting plate bolts. 17. Remove the EI system ignition coil mounting plate2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 182: View Of Camshaft Pressure Plate Courtesy of GENERAL MOTORS CORP. 18. Remove the camshaft pressure plate bolts 19. Remove the camshaft pressure plate.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 183: Removal Of Camshaft Courtesy of GENERAL MOTORS CORP. 20. Remove the camshaft. Installation Procedure 1. Install the camshaft 2. Install the camshaft pressure plate,2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 184: View Of Camshaft Pressure Plate Courtesy of GENERAL MOTORS CORP. NOTE: Refer to Fastener Notice in Cautions and Notices. Install the camshaft pressure plate bolts. Tighten: Tighten the camshaft pressure plate bolts to 10 N.m (89 Ib in) Measure camshaft end play. Camshaft end play should be 0.09-0.21 mm (0.0035- 0.0083 in)2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 185: View Of EI System Ignition Coil Mounting Plate Courtesy of GENERAL MOTORS CORP. 5. Install the EI system ignition coil mounting plate 6. Install the EI system ignition coil mounting plate bolts. Tighten: Tighten the El system ignition coil mounting plate bolts to 10 N.m (89 Ib in).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 186: Courtesy of GENERAL MOTORS view Of EI System Ignition Coil Connector CORP. Install the EI system ignition coil. Install the EI system ignition coil mounting bolts. Tighten: Tighten the El system ignition coil mounting bolts to 10 N.m (89 Ib in). Connect the ignition wires at the El system ignition coil. Connect the EI system ignition coil connector.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 187: View Of Battery Courtesy of GENERAL MOTORS CORP. 11. Install the battery and the battery tray. Refer to Battery and Battery Tray Replacement in Engine Electrical 12. Connect the positive battery cable to the battery.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 188: Holding Camshaft While Loosening/Tightening Sprocket Bolt Courtesy of GENERAL MOTORS CORP. NOTE: Take extreme care to prevent any scratches, nicks, or damage to the camshaft. Such damage can impair vehicle operation. 13. Install the camshaft gear 14. While holding the camshaft firmly in place, install the camshaft gear bolt. Tighten: Tighten the camshaft gear bolt to 45 N.m (33 Ib fi)2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 189: Removal Of Roller Followers Using KM-565-A Courtesy of GENERAL MOTORS CORP. 15. Install the camshaft followers using the KM-565-A. 16, Remove the KM-565-A (1).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 190: View Of Valve Cover And Camshaft Housing Courtesy of GENERAL MOTORS CORP. 17. Install the valve cover gasket. 18. Install the valve cover. 19. Install the valve cover bolts. Tighten: Tighten the valve cover bolts to 9 N.m (80 Ib in), 20. Connect the air breather tube to the valve cover. 21. Install the timing belt. Refer to Timing Belt Replacement. VALVE ROCKER ARMS CLEANING AND INSPECTION Inspection Procedure 1. Inspect valve stem tip wear. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical- 1.5L - Aveo wn aus Fig. 191: Inspecting Valve Stem Courtesy of GENERAL MOTORS CORP. Inspect the valve keeper grooves and oil seal grooves for chips and wear. Inspect the valves for burns or cracks. Inspect the valve stem for burrs and scratches. Inspect the valve stem. The valve stem must be straight. Inspect the valve face for grooving. If the groove is so deep the refacing would result in a sharp edge, replace the valve. Inspect the valve spring. If the valve spring ends are not parallel, replace the valve spring. Measure the valve spring height, Refer to Engine Mechanical Specifications. If the2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo valve spring height does not match the specifications, replace the valve spring Fig. 192: Measuring Valve Spring Height Courtesy of GENERAL MOTORS CORP. Cleaning Procedure CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo inder Head Fig. 193: View Of C. Courtesy of GENERAL MOTORS CORP. Clean the cylinder head. Clean the valve guides, Clean all of the threaded holes. RONS Clean the valves of carbon, oil, and varnish: VALVE GUIDE REAMING/VALVE AND SEAT GRINDING Tools Required « KM-253 Valve Guide Reamer « KM-254 Valve Guide Reamer « KM-255 Valve Guide Reamer « KM-340-1-C Cutter Set (KM-340-7, KM-340-13 and KM-340-26 all part of this kit) « KM-419 Distance Gage « KM-571-B Gage or Equivalent Valve Grin CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. 1. Lubricate the valve stem using a fine-grained paste. 2. 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 - 1.5L - Aveo sy of GENERAL MOTORS CORP. 3. Check the contact pattern on the valve head and in the cylinder head.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 195: Checking Contact Pattern On The Valve Head And In The Cylinder Head Courtesy of GENERAL MOTORS CORP. 4, Clean the valves, the valve guides, and the cylinder head. Valve Grind CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. 1. Ensure that there are no crater line burns on the valve cone, 2. The valve may be reground only 2 times. Do not grind the valve stem end.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 196: Refacing Valve Courtesy of GENERAL MOTORS CORP. 3. The angle at the valve face angle is 46 degrees2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Checking Valve Stem Projection Using KM-419 of GENERAL MOTORS CORP. 4, Check the valve stem projection using the KM-419 (1). Valve Guide Ream CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. 1. Measure the diameter of the valve guide using the KM-571-B (1) and a commercially available inside micrometer IMPORTANT: Valve oversizes may already have been fitted in production. IMPORTANT: An oversize code is on the valve guide and the valve stem2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo end. 2. An oversize code is on the valve guide and the valve stem end. The valve guide reaming table gives the correct size, reamer (1), and production code for each service code. Refer to the Valve Guide Reaming Table in 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 Fig. 198: Measuring Valve Guide Diameter Using KM-571-B Courtesy of GENERAL MOTORS CORP. Valve Seat - Cut 1. Place the cylinder head on wooden blocks. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 2. Cut the intake and the exhaust valve seats using the KM-340-7 as follows: « The valve seat is a 45-degree (b) side using the KM-340-13 « The upper correction angle is a 30-degree (a) side using the KM-340-13, « The lower correction angle is a 60-degree (c) side using the KM-340-26 Fig. 199: View Of Valve Seat, Upper Correction Angel And Lower Correction Angle Courtesy of GENERAL MOTORS CORP. 3. Clean the chippings from the cylinder head. 4, Inspect the dimension for the proper valve seat width Specification: « The intake equals 1.3-1.5 mm (0.051-0.059 in). # The exhaust equals 1.6-1.8 mm (0.063-0.071 in). 5. Inspect the valve stem projection using the KM-419 (1)2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 200: C Checking Valve Stem Projection Using KM-419 of GENERAL MOTORS CORP.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 201: Rechecking Valve Stem Projection 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 Grind and Valve Grind-In in the previous supporting text. 7. If the valve stem projection is still too large despite replacing the valves, replace the cylinder head CYLINDER HEAD DISASSEMBLE Tools Required J 8062, (KM-348) Valve Spring Compressor - Head Off Disassembly Procedure CAUTION: Valve springs can be tightly compressed. Use care when removing the retainers and plugs. Personal injury could result.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. Fig. 202: View Of Rocker Arms Courtesy of GENERAL MOTORS CORP. 1, Remove the cylinder head with the intake manifold and the exhaust manifold attached. Refer to Cylinder Head Replacement. 2. Remove the coolant temperature sensor2004 ENGINE Engine Mechanical - 1.5L - Aveo 2004 Chevrolet Aveo Fig. 203: view Of Exhaust Manifold Courtesy of GENERAL MOTORS CORP. Remove the exhaust manifold heat shield bolts. Remove the exhaust manifold heat shield. Remove the exhaust manifold nuts. Remove the exhaust manifold. Remove the exhaust manifold gasket. Remove the exhaust manifold studs. Remove the spark plugs.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 10. Il 12. 13, Fig. 204: View Of Intake Manifold Courtesy of GENERAL MOTORS CORP. Remove the intake manifold retaining nuts Remove the intake manifold. Remove the intake manifold gasket. Remove the intake manifold studs.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo View Of Thermostat And Gasket Courtesy of GENERAL MOTORS CORP. 14. Remove the thermostat housing mounting bolts. 15. Remove the thermostat housing 16, Remove the thermostat and thermostat gasket.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 206: Compressing Valve Springs Using J 8062 Courtesy of GENERAL MOTORS CORP. 17. Using the J 8062 (1), compress the valve springs 18. Remove the valve keys. 19. Remove the valve spring plates. 20. Remove the valve springs. 21. Remove the valves 22, Remove the valve stem oil seals. 23. Remove camshaft carrier alignment pins CYLINDER HEAD CLEANING AND INSPECTION CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. Clean the sealing surfaces. Inspect the cylinder head gasket and the mating surfaces for leaks, corrosion, and blowby N2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 207: Inspecting Cylinder Head Courtesy of GENERAL MOTORS CORP. Inspect the cylinder head for cracks. Inspect the length and the width of the cylinder head using a feeler gage and a straight edge. Check the sealing surfaces for damage. Specification: The cylinder head sealing surfaces must be flat within 0.15 mm (0.0059 in) maximum.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 6. Measure the height of the cylinder head from sealing surface to sealing surface. The cylinder head height should be 95.9-96.1 mm (3.775-3.783 in) (A). If the cylinder head height is less than 95.9 mm (3.775 in), replace the cylinder head. 7. Inspect all threaded holes for damage 8, Inspect the valve seats for excessive wear and burned spots CYLINDER HEAD ASSEMBLE Tools Required J 8062 (KM-348) Valve Spring Compressor - Head Off Assembly Procedure CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. 1. Install the camshaft carrier alignment pins. 2. Install the valve stem oil seals.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 3. Coat the valves with engine oil 4. Install the valves, 5. Install the valve springs. CAUTION: Valve springs can be tightly compressed. Use care when removing the retainers and plugs. Personal injury could result. 6. Using the J 8062 (1), compress the valve springs. 7. Install the valve keys. 8. Install the valve spring plate2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 210: View Of Thermostat And Gasket Courtesy of GENERAL MOTORS CORP. Install the thermostat and the gasket. Install the thermostat housing. NOTE: Refer to Fastener Notice in Cautions and Notices. Install the thermostat housing mounting bolts. Tighten: Tighten the thermostat housing mounting bolts to 20 N.m (15 Ib ft)2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 12, 13, 15. 7 Fig. 211: View Of Intake Manifold Courtesy of GENERAL MOTORS CORP. Install the intake manifold studs. Install the intake manifold gasket. Install the intake manifold. Install the intake manifold retaining nuts. Tighten: Tighten the intake manifold retaining nuts to 22 N.m (16 lb ft). Install the spark plugs. Tighten: Tighten the spark plugs to 25 N.m (18 Ib ft). Install the exhaust manifold studs2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 18. 19, 20. Fig. 212: View Of Exhaust Manifold Courtesy of GENERAL MOTORS CORP. Install the exhaust manifold gasket. Install the exhaust manifold. Install the exhaust manifold nuts. Tighten: Tighten the exhaust manifold nuts to 25 N.m (18 Ib ft).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 213: View Of Rocker Arms Courtesy of GENERAL MOTORS CORP. 21. Install the exhaust manifold heat shield, 22. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 15 N.m (11 Ib ft) 23. Install the coolant temperature sensor Tighten: Tighten the coolant temperature sensor to 20 N.m (15 Ib ft). 24. Install the cylinder head with the intake manifold and the exhaust manifold attached. Refer to Cylinder Head Replacement. CRANKSHAFT REPLACEMENT2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Tools Required J. 36972 or KM-635 Crankshaft Rear Oil Seal Installer J.42492-A Timing Belt Adjuster « KM-470-B Angular Torque Gage OTC 1726 (KM-412) Engine Overhaul Stand or Equivalent « J 45059 Angle Meter Disassembly Procedure CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. IMPORTANT: Take extreme care to prevent any scratches, nicks, or damage to the camshaft. Such damage can impair vehicle operation. 1. Remove the engine. Refer to Engine Replacement. 2. Remove the flywheel bolts.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo a) Fig. 214: View Of Flywheel Courtesy of GENERAL MOTORS CORP. Remove the flywheel Remove the crankshaft rear oil seal Mount the engine assembly on the OTC 1726. Fig. 215: Removal Of Upper And Lower Timing Belt Cover And Bolts Courtesy of GENERAL MOTORS CORP. Remove the upper timing belt cover bolts. Remove the upper timing belt cover. Remove the lower timing belt cover bolts. Remove the lower timing belt cover.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 10. 11 12, 13, Fig. 216: Releasing/Adding Timing Belt Tension Using J 42492-A Courtesy of GENERAL MOTORS CORP. Slightly loosen the 3 coolant pump retaining bolts. Rotate the coolant pump using the J 42492-A (1) to remove the tension from the timing belt. Remove the timing belt. Remove the valve cover bolts. Remove the valve cover and the valve cover gasket: IMPORTANT: Take extreme care to prevent any scratches, nicks, or damage to the camshaft. Such damage can impair vehicle operation.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 217: Holding Camshaft While Loosening/Tightening Sprocket Bolt Courtesy of GENERAL MOTORS CORP. 15, While holding the camshaft firmly in place, remove the camshaft gear bolt. 16. Remove the camshaft gear.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 17, 18. 19, 20. 21 Fig. 218: View Of Timing Belt Automatic Tensioner Bolt Courtesy of GENERAL MOTORS CORP. Remove the timing belt automatic tensioner bolt (1). Remove the timing belt automatic tensioner. Remove the rear timing belt cover bolts, Remove the rear timing belt cover. Remove the crankshaft timing belt gear.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 219: View Of Oil Pump/Pickup Tube And Bolts Courtesy of GENERAL MOTORS CORP. Rotate the engine on the OTC 1726 . Remove the oil pan retaining bolts. Remove the oil pan Remove the oil pickup tube bolts. Remove the oil pump pickup tube.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 220: Identifying Oil Pump Retaining Bolts Courtesy of GENERAL MOTORS CORP. 27. Remove the oil pump retaining bolts (1). 28. Remove the oil pump.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 29, 30. 31 32. Fig. 221: View Of Connecting Rod Bearing Caps Courtesy of GENERAL MOTORS CORP. Mark the order of the rod bearing caps. Remove the connecting rod cap bolts for all of the pistons. Remove the connecting rod bearing caps and the lower connecting rod bearings. Remove the upper connecting rod bearings.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 39, . 222: View Of Crankshaft Bearing Caps sy of GENERAL MOTORS. RP. C Mark the order of the crankshaft bearing caps. Remove the crankshaft bearing cap bolls. Remove the crankshaft bearing caps. Remove the crankshaft bearings from the crankshaft bearing caps. Remove the crankshaft. Remove the crankshaft bearings from the engine block. CAUTION: Refer to Safety Glasses Caution in Cautions and Notices. Clean the parts, as necessary Assembly Procedure 1 With crankshaft and bearings in place. plastic gage all bearing clearances. Refer to2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Crankshaft and Bearings Cleaning and Inspection. 2. Inspect the crankshaft end play with the crankshaft bearings installed. Fig. 223: Inspecting Crankshaft End Play Courtesy of GENERAL MOTORS CORP. 3. Inspect for permissible crankshaft end play, Refer to Engine Mechanical Specifications2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 224: Checking Crankshaft Journal For Out-Of-Round Runout Courtesy of GENERAL MOTORS CORP. With the crankshaft mounted on the front and the rear crankshaft bearings, check the middle crankshaft journal for permissible out-of-round, runout. Refer to Engine Mechanical Specifications. Coat the crankshaft bearings with engine oil Apply a bead of adhesive sealing compound to the grooves of the rear crankshaft bearing cap Install the crankshaft bearings in the engine block2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 10. Fig. 225: Installing The Crankshaft Bearings In The Engine Block Courtesy of GENERAL MOTORS CORP. Install the crankshaft Install the crankshaft bearings to the crankshaft bearing caps Install the crankshaft bearing caps. NOTE: Do not reuse crankshaft bearing cap bolts. Failure to replace the crankshaft bearing cap bolts can lead to crankshaft bearing cap bolt breakage or crankshaft bearing failure. A broken crankshaft bearing bolt can lead to extensive engine damage. NOTE: Refer to Fastener Notice in Cautions and Notices.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 226: Using J 45059 To Tighten Bearing Caps Courtesy of GENERAL MOTORS CORP. 11. Install new crankshaft bearing cap bolts. Tighten: « Tighten the crankshaft bearing cap bolts to 50 N.m (37 Ib ft). # Using the J 45059 or the KM-470-B (1), tighten the crankshaft bearing cap bolts another 45 degrees plus 15 degrees. 12. Install the upper connecting rod bearings to the connecting rods. 13. Install the lower connecting rod bearings to the connecting rod bearing caps.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 227: View Of Connecting Rod Bearings Courtesy of GENERAL MOTORS CORP. Install the connecting rod bearing caps to the connecting rods. IMPORTANT: Do not reuse the old connecting rod bearing cap bolts. Damage to the engine could result. Install new connecting rod bearing cap bolts. Tighten: « Tighten the connecting rod bearing cap bolts to 25 N.m (18 Ib ft) « Using the J 45059 or the KM-470-B (1), tighten the connecting rod bearing cap bolts another 30 degrees plus 15 degrees.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 228: Identifying Oil Pump Retaining Bolts Courtesy of GENERAL MOTORS CORP. 16. Install the oil pump. 17. Install the oil pump retaining bolts (1). Tighten: Tighten the oil pump retaining bolts to 10 N.m (89 lb in),2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 229: View Of Oil Pump/Pickup Tube And Bolts Courtesy of GENERAL MOTORS CORP. 18. Install the oil pump/pickup tube 19. Install the oil pump/pickup tube bolts. Tighten: Tighten the oil pump/pickup tube and support bracket bolts to 10 N.m (89 Ib in).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 9 Qe eo —] he | = = SS ~.. = = = 230: View Of Oil Pan sy of GENERAL MOTORS CORP. Install the oil pan gasket to the oil pan. Install the oil pan IMPORTANT: Install the oil pan within 5 minutes after applying the liquid gasket to the oil pan. Install the oil pan retaining bolts. Tighten: Tighten the oil pan retaining bolts to 10 N.m (89 Ib in).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo ing Belt Automatic Tensioner Bolt Courtesy of GENERAL MOTORS CORP. Install the crankshaft timing belt gear. Install the rear timing belt cover. 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 (1). Tighten: Tighten the timing belt automatic tensioner bolt to 20 N.m (15 Ib ft).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 232: Holding Camshaft While Loosening/Tightening Sprocket Bolt Courtesy of GENERAL MOTORS CORP. IMPORTANT: Take extreme care to prevent any scratches, nicks, or damage to the camshaft. Such damage can impair vehicle operation. 28. Install the camshaft gear 29. Install the camshaft gear bolt while holding the camshaft firmly in place Tighten: Tighten the camshaft gear bolt to 45 N.m (33 Ib fi)2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 233: View Of Lower Timing Belt Cover Courtesy of GENERAL MOTORS CORP. Install the timing belt. Adjust the timing belt tension. Refer to Timing Belt Inspection. Install the valve cover gasket and the valve cover. Install the valve cover bolts. Tighten: Tighten the valve cover bolts to 9 N.m (80 Ib in), Install the lower timing belt cover. 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 - 1.5L - Aveo 36 37. on 40. 4 42. Install the power steering pump. Install the power steering pump mounting bolts. Tighten: Tighten the power steering pump mounting bolts to 25 N.m (18 lb ft). 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). Install the engine lifting device Dismount the engine from the OTC 1726 Install the crankshaft rear oil seal using the J 36972 (1) or KM-6352004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Fig. 234: Installing Crankshaft Rear Oil Seal Using J 36972 KM-635 Courtesy of GENERAL MOTORS CORP. Fig. 235: View Of Flywheel Courtesy of GENERAL MOTORS CORP. 43, Install the flywheel 44. Install the flywheel bolts. Tighten: « Tighten the flywheel bolts to 35 N.m (26 Ib ft) using a torque wrench « Using the J 45059 or the KM-470-B , tighten the flywheel bolts another 30 degrees plus 15 degrees. 45. Install the engine. Refer to Engine Replacement. EXHAUST MANIFOLD INSTALLATION Installation Procedure 1, Install the exhaust manifold gasket.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 2 Install the exhaust manifold. NOTE: Refer to Fastener Notice in Cautions and Notices. Fig. 236: Tightening Sequence Of 8 Exhaust Manifold Nuts Courtesy of GENERAL MOTORS CORP. Install the 8 exhaust manifold nuts and torque in the sequence shown. Tighten: Tighten the exhaust manifold nuts 22 N.m (16 Ib fi). Install the catalytic converter-to-exhaust manifold nuts. Tighten: Tighten the catalytic converter-to-exhaust manifold nuts to 40 N.m (30 Ib ft). Install the exhaust manifold heat shield. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 15 N.m (11 Ib ft).2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo 7. Connect the O2 sensor Fig. 237: Identifying Front Heated Oxygen Sensor Connector Courtesy of GENERAL MOTORS CORP. 8. Connect the ignition wires to the spark plugs. 9. Connect the negative battery cable, DESCRIPTION AND OPERATION ENGINE COMPONENT DESCRIPTION cy der Head and Gasket The cylinder head is made of an aluminum alloy. The cylinder head uses crossflow intake and exhaust ports. A spark plug is located on the exhaust side of each combustion chamber. Crankshaft The crankshaft is supported by the 5 main bearings. The number 3 bearing is the end thrust bearing. The main bearings are lubricated from the oil holes which intersect the main oil gallery on the exhaust side of the engine block.2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Timing Belt The timing belt coordinates the crankshaft and the camshaft and keeps them synchronized The timing belt also turns the coolant pump. The timing belt and the pulleys are toothed so that there is no slippage between them. There is a tension pulley that maintains the correct timing belt tension. The timing belt is made of a tough reinforced rubber similar to that used on the serpentine accessory drive belt. The timing belt requires no lubrication. Oil Pump The oil pump draws engine oil from the oil pan and feeds it under pressure to the various parts of the engine. An oil strainer is mounted before the inlet of the oil pump to remove impurities which could clog or damage the oil pump or the other engine components, When the drive gear rotates, the driven gear rotates. This causes the space between the gears to open and narrow constantly, pulling oil in from the oil pan when the space opens and pumping the oil out to the engine as it narrows. At high engine speeds, the oil pump supplies a much higher amount of oil than required for lubrication of the engine. The oil pressure regulator prevents too much oil from entering the engine lubrication passages. During normal oil supply, a coil spring and a valve keep the bypass closed, directing all of the oil pumped to the engine. When the amount of oil being pumped increases, the pressure becomes high enough to overcome the force of the spring. This opens the valve of the oil pressure regulator, allowing the excess oil to flow through the valve and drain back to the oil pan. Oil Pan The oil pan is mounted to the bottom of the cylinder block. The oil pan houses the crankcase and is made of aluminum Engine oil is pumped from the oil pan by the oil pump. After the oil passes through the oil filter, the oil is fed through 2 paths to lubricate the cylinder block and the cylinder head. In one path, the oil is pumped through the oil passages in the crankshaft to the connecting rods, then to the pistons and the cylinders in the cylinder block. The oil then drains back into the oil pan. In the second path, the oil is pumped through the oil passages to the camshaft. The oil passes through the internal passageways in the camshafts to lubricate the valve assemblies in the cylinder head before draining back into the oil pan. Exhaust Manifold A single 4-port, rear-takedown exhaust manifold is used with this engine. The exhaust manifold is designed to direct the escaping exhaust gases out of the combustion chambers with a minimum of back pressure. Intake Manifold2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo The intake manifold is made of aluminum. The intake manifold is heated by the engine coolant. An air/fuel mixture is transferred through the intake manifold to the engine cylinders for combustion. Camshaft The cast-iron camshaft is supported by the 5 bearing surfaces in an aluminum camshaft carrier located on the top of the cylinder head. The camshaft gear is power driven by the crankshaft, using the timing belt. CLEANLINESS AND. RE An automobile engine is a combination of many machined, honed, polished, and lapped surfaces with tolerances that are measured in the ten-thousandths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the surfaces on initial operation. Proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever valve train components are removed for service, they should be kept in order. They should be installed in the same locations, and with the same mating surfaces, as when they were removed. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices. NOTE: Any time service is being performed which requires removal of the air cleaner assembly, always cover the throttle body opening. This will prevent any foreign material from entering the engine. SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS Special Tools Illustration Tool Number/ Description J-28467-B Engine Assembly Support Fixture2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo J-36972 Crankshaft Rear Oil Seal Installer a J-42492-A Timing Belt Adjuster J-36648-A (KM-135) Adapter =—=c—s KM-253 Valve Guide Reamer oe) Noa Valve Guide Reamer === RM 259 Valve Guide Reamer2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo KM-340-0 Cutter Set 45-8062 (KM-348) Valve Spring Compressor - Head Off KM-419 Distance Gage ce wy J-24086-B (KM-427) 7 Piston Pin Remover/Installer Set N 5 KM-470-B2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Angular Torque Gage KM-S65-A LL, Valve Spring Compressor KM-635 Crankshaft Rear Oil Seal Installer J-21867 (KM-498-B) Pressure Gage OTC-1726 (KM-412) Engine Overhaul Stand2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo M-571-B Gage J-45049 Angle Meter

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