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 ft2004 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 in2004 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 in2004 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 VIEWS2004 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 Bolt2004 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 Bolt2004 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 Set2004 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 Washer2004 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 order2004 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 Test2004 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 temperature2004 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 seal2004 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, PR2004 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 usually2004 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 Step2004 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 SECONDS2004 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 a2004 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 and2004 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, and2004 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 Procedure2004 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 manifold2004 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 rail2004 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 82004 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 belt2004 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 Assembly2004 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 Procedure2004 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 cover2004 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 cover2004 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 loosely2004 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 hole2004 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 cover2004 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 System2004 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 cover2004 Chevrolet Aveo 2004 ENGINE Engine Mechanical - 1.5L - Aveo Courtesy of GENERAL MOTORS CORP. Fig. 54: View Of Breather Hose2004 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 Procedure2004 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 fuse2004 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 manifold2004 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.