Repair Instructions - Off Vehicle PDF
Repair Instructions - Off Vehicle PDF
Repair Instructions - Off Vehicle PDF
2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (L95) |
Repair Instructions - Off Vehicle | Document ID: 2098003
Special Tools
Adjustment Procedure
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18. Rotate the crankshaft at least one full turn clockwise using the crankshaft pulley bolt.
19. Align the mark on the crankshaft gear to the notch at the bottom of the rear timing belt
cover.
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23. Rotate the coolant pump clockwise until the adjust arm pointer of the timing belt automatic
tensioner is aligned to the notch in the timing belt automatic tensioner bracket.
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27. Using the J 42492-A , rotate the coolant pump until the adjust arm pointer of the timing belt
automatic tensioner is aligned with the pointer on the timing belt automatic tensioner
bracket.
Tighten
Tighten the coolant pump retaining bolts to 10 N·m (89 lb in).
Tighten
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Tighten the upper and lower front timing belt cover bolts to 10 N·m (89 lb in).
Tighten
Tighten the crankshaft pulley bolt to 95 N·m (70 lb ft) using a torque wrench. Using the J
45059 or KM-470-B , tighten the crankshaft pulley bolt 30 degrees plus 15 degrees.
35. Install the right front wheel. Refer to Tire and Wheel Removal and Installation.
36. Install the air filter housing.
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Tighten
Tighten the air filter housing bolts to 8 N·m (71 lb in).
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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (L95) |
Repair Instructions - Off Vehicle | Document ID: 1398333
Valve Grind-In
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3. Check the contact pattern on the valve head and in the cylinder head.
4. Clean the valves, the valve guides, and the cylinder head.
Valve Grind
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1. Measure the diameter of the valve guide using the KM-571-B (1) and a commercially
available inside micrometer.
2. An oversize service code is on the valve guide and the valve stem end. The Valve Guide
Reaming Table give the correct size, reamer, and production codes for each service. 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 using the
KM-805 (1).
4. After reaming, cross out the code and emboss the valve guide with the new code.
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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (L95) |
Repair Instructions - Off Vehicle | Document ID: 2098034
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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (L95) |
Repair Instructions - Off Vehicle | Document ID: 2098038
1. Clean the oil pump and the engine block gasket mating surfaces.
2. Remove the safety relief valve bolt.
3. Remove the safety relief valve and the spring.
4. Remove the oil pump-to-crankshaft seal.
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Caution: 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.
11. Install the oil pump rear cover and the bolts and tighten to 6 N·m (53 lb in).
12. Install the safety relief valve, the spring, the washer, and the bolt and tighten to 30 N·m
(22 lb ft).
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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (L95) |
Repair Instructions - Off Vehicle | Document ID: 2098046
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7. 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.
Note: 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.
8. Measure all of the crankshaft bearing clearance using a commercially available plastic gaging,
ductile plastic threads.
9. Cut the plastic gaging threads to the length of the bearing width (1). Lay them axially
between the crankshaft journals and the crankshaft bearings.
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Tighten
Tighten the crankshaft bearing cap bolts to 50 N·m (37 lb ft). Using the J 45059 or the KM-
470-B (1), tighten the crankshaft bearing cap bolts another 45 degrees plus 15 degrees.
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printed on the plastic gaging package. Plastic gaging is available for different tolerance
ranges.
14. Inspect the bearing clearances for permissible tolerance ranges. Refer to Engine Mechanical
Specifications.
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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (L95) |
Repair Instructions - Off Vehicle | Document ID: 2098049
Special Tools
Piston Inspection
1. Inspect the connecting rod for bending or twisting. If the connecting rod is bent or twisted,
replace the connecting rod.
2. Inspect the connecting rod bearings.
3. Inspect the connecting rod lower end for wear.
4. Inspect the connecting rod upper end for scoring.
5. Inspect the crankshaft rod bearing journal for wear. Refer to Engine Mechanical
Specifications.
6. Inspect the piston for scoring, cracks, and wear.
7. Inspect the piston for taper using a micrometer.
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9. Inspect the engine block deck surface for flatness using a straight edge and a feeler gage.
Refer to Engine Mechanical Specifications.
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.
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Note: Grease the connecting rod journals and lubricate the connecting rod bearings slightly
so that the plastic gaging thread does not tear when the connecting rod bearing caps are
removed.
2. Install the upper connecting rod bearings into the connecting rod journals.
3. Install the lower connecting rod bearings into the connecting rod bearing caps.
4. Measure all of the connecting rod bearing clearances using a commercially available plastic
gaging, ductile plastic threads (1).
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.
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Tighten
Tighten the connecting rod bearing cap bolts to 25 N·m (18 lb ft).
8. Using the J 45059 or the KM-470-B (1), tighten the crankshaft cap bolts another 30 degrees
plus 15 degrees.
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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (L95) |
Repair Instructions - Off Vehicle | Document ID: 2098060
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7. Inspect the valve spring. If the valve spring ends are not parallel, replace the valve spring.
8. Measure the valve spring height. Refer to Engine Mechanical Specifications. If the valve
spring height does not match the specifications, replace the valve spring.
Cleaning Procedure
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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (L95) |
Repair Instructions - Off Vehicle | Document ID: 2098064
Special Tools
Disassembly Procedure
1. Remove the cylinder head with the intake manifold and the exhaust manifold attached. Refer
to Camshaft Replacement.
2. Remove the coolant temperature sensor (CTS).
3. Remove the exhaust manifold heat shield bolts.
4. Remove the exhaust manifold heat shield.
5. Remove the exhaust manifold retaining nuts in the sequence shown.
6. Remove the exhaust manifold.
7. Remove the exhaust manifold gasket.
8. Remove the exhaust manifold studs.
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12. Remove the intake manifold retaining nuts and retaining bolts in the sequence shown.
13. Remove the intake manifold.
14. Remove the intake manifold studs.
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15. Remove the direct ignition system (DIS) coil mounting bolts.
16. Remove the DIS coil with the ignition wires attached.
17. Remove the DIS coil mounting bracket bolts.
18. Remove the electrical exhaust gas recirculation (EEGR) valve adapter bolts.
19. Remove the EEGR valve adapter.
20. Remove the EEGR valve adapter gasket.
21. Remove the spark plugs.
22. Remove the camshaft cap bolts gradually and in the sequence shown for each camshaft cap.
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23. Remove the intake camshaft caps. Maintain the correct positions for installation.
24. Remove the intake camshaft.
25. Remove the intake valve tappet adjusters.
26. Remove the exhaust camshaft caps. Maintain the correct positions for installation.
27. Remove the exhaust camshaft.
28. Remove the exhaust valve tappet adjusters.
Warning: Valve springs can be tightly compressed. Use care when removing the retainers
and plugs. Personal injury could result.
29. Compress the valve springs with the J 8062 and the KM-653-A .
30. Remove the valve keys.
31. Remove the J 8062 and KM-653-A .
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34. Remove the valves. Maintain the original position of the valves for installation.
35. Remove the valve stem seals.
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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (L95) |
Repair Instructions - Off Vehicle | Document ID: 2098071
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6. Measure the height of the cylinder head from sealing surface to sealing surface. The cylinder
head height should be 138.13-138.18 mm (5.438-5.440 in). If the cylinder head height is
less than 138.13 mm (5.438 in), replace the cylinder head.
7. Inspect all threaded holes for damage.
8. Inspect all valve seats for excessive wear and burned spots.
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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (L95) |
Repair Instructions - Off Vehicle | Document ID: 2098072
Special Tools
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16. Tighten the camshaft cap bolts gradually and in the sequence shown for each camshaft cap
to 16 N·m (12 lb ft).
17. Install the spark plugs and tighten to 25 N·m (18 lb ft).
18. Install the exhaust gas recirculation (EGR) valve adapter gasket.
19. Install the EGR valve adapter.
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20. Install the EGR valve adapter bolts and tighten to 25 N·m (18 lb ft).
21. Install the direct ignition system (DIS) coil mounting bracket.
22. Install the DIS coil mounting bracket bolts and tighten to 10 N·m (89 lb in).
23. Install the DIS coil with the ignition wires attached.
24. Install the DIS coil mounting bolts and tighten to 10 N·m (89 lb in).
28. Install the fuel rail assembly with the bolts and tighten to 25 N·m (18 lb ft).
29. Install the thermostat housing assembly.
30. Install the thermostat housing mounting bolts and tighten to 20 N·m (15 lb ft).
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37. Install the coolant temperature sensor and tighten to 20 N·m (15 lb ft).
38. Install the cylinder head with the intake manifold and the exhaust manifold attached. Refer
to Cylinder Head Replacement.
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