Document ID: 2096108 Page 1 of 2

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - Off Vehicle | Document ID: 2096108

Crankshaft and Bearing Cleaning and Inspection

Inspection Procedure

1. Measure the block flatness. If it is out of specification, replace it. Refer to Engine Mechanical
Specifications.

2. Measure the crankshaft bending (1) (out-of-round). If it is out of specification, replace it.
Refer to Engine Mechanical Specifications.
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3. Measure the crankshaft end play. If it is out of specification, replace it. Refer to Engine
Mechanical Specifications.

4. Cut the plastic gauge (1) the same length of the bearing width and put it on the crankshaft
bearing. It should be parallel with the crankshaft.
5. Install the crankshaft journal bearing and cap.
6. Remove the connecting rod bearing and cap again.
7. Measure the clearance of the connecting rod bearing oil. If it is out of specification, replace it.
Refer to Engine Mechanical Specifications.

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Document ID: 2052652 Page 1 of 4

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - Off Vehicle | Document ID: 2052652

Piston, Connecting Rod, and Bearing Cleaning and

Inspection
Inspection Procedure

1. Clean the inner of the cylinder with a clean cloth.

2. Inspect the inner of the cylinder if it is damaged.
3. Measure the inner diameter of the cylinder (1). If it is out of specification, replace it. Refer to
Engine Mechanical Specifications.

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4. Clean the piston with a clean cloth.

5. Measure the outer diameter of the piston (1), 15 mm up from the bottom. If it is out of
specification, replace it. Refer to Engine Mechanical Specifications.

6. Measure the inner diameter of the cylinder, 50 mm below from the surface of the cylinder
head, and the clearance of the piston (1), 15 mm up from the end of the piston skirt. If it is
out of specification, replace it. Refer to Engine Mechanical Specifications.

7. Measure the piston ring groove clearance (1). If the piston ring groove clearance is out of
specification, replace the piston and rings. Refer to Engine Mechanical Specifications.

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8. Measure the piston ring gap (1). If the piston ring gap is out of specification, replace the
piston ring. Refer to Engine Mechanical Specifications.

9. Measure the piston pin (1). If it is out of specification, replace it. Refer to Engine Mechanical
Specifications.

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10. Cut the plastic gauge (1) the same length as the bearing width and put it on the crankshaft
bearing. It should be parallel with the crankshaft.
11. Install the connecting rod bearing and caps.

Tighten
Tighten the connecting rod caps bolts to 35+45°+15° N·m (25.8+45°+15° lb ft)

12. Remove the connecting rod bearing and caps again.

13. Measure the clearance of the connecting rod bearing oil. If it is out of specification, replace it.
Refer to Engine Mechanical Specifications.

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Document ID: 2096114 Page 1 of 3

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - Off Vehicle | Document ID: 2096114

Valve Rocker Arm Cleaning and Inspection

Valve Inspection Procedure

1. Inspect the valve for damage from the head to tip for the following conditions:
• Pitting in the valve seat area (1)
• Lack of valve margin (2)
• Bending in the valve stem (3)
• Pitting or excessive wear in the stem (4)
• Worn valve key grooves (5)
• Worn valve tip (6)
2. Replace the valve if any of these conditions exist.
3. Inspect the valve springs. If the valve spring ends are not parallel, replace the valve spring.
4. Inspect the valve spring seating surface of the valve rotators for wear or gouges. Replace as
required.

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Note: Valve guide is not movable. Replace the cylinder head if it is out of specification.

5. Measure the valve stem diameter (1) and valve guide inside diameter (2). If it is out of
specification, replace it. Refer to Engine Mechanical Specifications.

6. Measure the valve spring free length. If it is out of specification, replace it. Refer to Engine
Mechanical Specifications.

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7. Measure the valve spring right angles. If it is out of specification, replace it. Refer to Engine
Mechanical Specifications.

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Document ID: 2052590 Page 1 of 3

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - Off Vehicle | Document ID: 2052590

Cylinder Head Disassemble

Disassemble Procedure

Special Tools

• EN-49074 Universal Valve Spring Compressor

• EN-49155 Valve Spring Compressing Adapter
• KM-845 Suction Device

Note: Take extreme care to prevent any scratches, nicks or damage to the camshaft
surfaces.

1. Remove the camshaft position solenoid valve housing.

2. Remove the camshaft cap bolts in this sequence (1)-(4)-(2)-(3).
3. Remove the camshaft caps.

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4. Remove the camshafts (1, 2) and oil seal rings (3).

5. Remove the valve tappet using the KM-845 suction device .

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6. Install the EN-49074 compressor and EN-49155 adapter .

7. Remove the valve key.

8. Remove the valves (5), springs (3), retainers (2), and seals (4).

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Document ID: 2052585 Page 1 of 2

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - Off Vehicle | Document ID: 2052585

Cylinder Head Cleaning and Inspection

Inspection Procedure

Note: Take extreme care to prevent any scratches, nicks or damage to the cylinder head
surface.

1. Clean the sealing surfaces.

2. Inspect the cylinder head for the following:
• Cracks, damage or pitting in the combustion chambers.
• Debris in the oil galleries. Continue to clean the galleries until all debris is removed.
• Coolant leaks or damage to the deck face sealing surface.
• Damage to any gasket surfaces.
• Damage to any threaded bolt holes.
• Burnt or eroded areas in the combustion chamber.
• Cracks in the exhaust ports and combustion chambers.
• External cracks in the water passages.
• Restrictions in the intake or exhaust passages.
• Restrictions in the cooling system passages.
• Rusted, damaged or leaking core plugs.
3. If the cylinder head is cracked or damaged, it must be replaced. No welding or patching of
the cylinder head is recommended.
4. Measure the clearance between the straight-edge and the cylinder head deck face using a
feeler gauge at four points along the straight-edge.
5. Check the sealing surfaces
© 2010for deformation
General and warping.
Motors Corporation. The
All rights cylinder head sealing surfaces
reserved.

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(include the intake and exhaust sealing surfaces) must be flat within the specification. Refer
to Engine Mechanical Specifications.
6. Remove the intake and exhaust camshafts. Refer to Camshaft Replacement.

7. Measure the height of the cylinder head from sealing surface to sealing surface. The cylinder
head height should be within specifications. Replace the cylinder head. If the cylinder head
height is out of specifications, replace the cylinder head. Refer to Engine Mechanical
Specifications.

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Document ID: 2096126 Page 1 of 4

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - Off Vehicle | Document ID: 2096126

Cylinder Head Assemble

Special Tools

• EN-49074 Universal Valve Spring Compressor

• EN-49155 Valve Spring Compressing Adapter
• KM-422 Installer

Assemble Procedure

1. Install the valve spring (3), retainer (2), and seal (4).

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2. Install the EN-49074 compressor and EN-49155 adapter .

3. Install the valve key.

Note: Do not scratch the valve tappet. Do not use gloves or tools, except special service
tools.

4. Install the valve tappet.

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5. Coat and lubricate the camshaft bearing and cam surfaces with clean engine oil.
6. Install the camshafts (1, 2) on the cylinder head.

Note:
• The grooves (1) adjacent to the sealing surfaces must remain free from sealant.
• It is essential to ensure that no sealant is applied outside the marked sealing areas.

7. Apply surface sealant LOCTITE 574 to sealing surfaces (1) of the 1st camshaft bearing cap
thinly and evenly.

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8. Install the camshaft bearing caps in this sequence (2)-(3)-(1)-(4).

9. Install the camshaft position solenoid valve housing.

Tighten
Tighten the camshaft bearing cap bolts to 8 N·m (70.8 lb in).

10. Install the new camshaft oil seal rings using KM-422 installer. Refer to Camshaft Front Oil
Seal Replacement.

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2053120

Drive Belt Replacement

Removal Procedure

Note: To remove the power steering pump belt, do remove the accessory belt in advance.

1. Rotate the tensioner star-nut (1) and remove the accessory belt.
2. Remove the power steering belt. Refer to Refer to Power Steering Pump Replacement.

Installation Procedure

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1. Install the power steering belt. Refer to Power Steering Pump Replacement.
2. Rotate the tensioner star-nut (1) and install the accessory belt.
3. Install the engine front shield at the position of right front wheel.

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2053121

Drive Belt Tensioner Replacement

Removal Procedure

Note: To remove the power steering pump belt, do remove the accessory belt in advance.

1. Rotate the tensioner star-nut (1 and remove the accessory belt.

2. Remove the power steering belt. Refer to Power Steering Pump Replacement.

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3. Remove the accessory belt tensioner (1.

Installation Procedure

Caution: Refer to Fastener Caution in the Preface section.

1. Install the accessory belt tensioner (1) and tighten to 50 N·m (36.8 lb ft).

2. Install the power steering belt. Refer to Power Steering Pump Replacement.
3. Rotate the tensioner star-nut (1) and install the accessory belt.
4. Install the engine front shield at the position of right front wheel.

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2053121

Drive Belt Tensioner Replacement

Removal Procedure

Note: To remove the power steering pump belt, do remove the accessory belt in advance.

1. Rotate the tensioner star-nut (1 and remove the accessory belt.

2. Remove the power steering belt. Refer to Power Steering Pump Replacement.

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3. Remove the accessory belt tensioner (1.

Installation Procedure

Caution: Refer to Fastener Caution in the Preface section.

1. Install the accessory belt tensioner (1) and tighten to 50 N·m (36.8 lb ft).

2. Install the power steering belt. Refer to Power Steering Pump Replacement.
3. Rotate the tensioner star-nut (1) and install the accessory belt.
4. Install the engine front shield at the position of right front wheel.

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Document ID: 2050710 Page 1 of 2

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2050710

Intake Manifold Replacement

Removal Procedure

Warning: Refer to Battery Disconnect Warning in the Preface section.

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection.
2. Release the fuel pressure. Refer to Fuel Pressure Relief.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
4. Remove the power steering pressure pipe clamp from the intake manifold.
5. Disconnect the related sensor and actuator connectors and the pull engine wiring harness
aside.
• A/C pressure sensor (ACP) connector
• CAM position solenoid valve connector
• Electric throttle controller (ETC) connector
• Manifold air pressure (MAP) sensor connector
• EVAP solenoid valve connector
• Injector connectors
6. Disconnect the fuel line from the fuel rail.
7. Disconnect the ETC coolant inlet/outlet hoses and then pull it aside.
8. Remove the PCV hose from the ETC.
9. Remove the cylinder head cover. Refer to Valve Rocker Arm Cover Replacement.

10. Remove the electric throttle controller (ETC). Refer to Throttle Body Assembly Replacement.
11. Remove the intake manifold (2) with the gasket.

Installation Procedure
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Caution: Refer to Fastener Caution in the Preface section.

Note: Do not reuse the intake manifold gasket.

1. Install the intake manifold (2) with the new gasket and tighten.
• The intake manifold bolts (1) to 20 N·m (14.7 lb ft).
• The intake manifold lower bracket bolt to 8 N·m (70.8 lb in).
2. Install the electric throttle controller (ETC). Refer to Throttle Body Assembly Replacement.
3. Install the cylinder head cover. Refer to Valve Rocker Arm Cover Replacement.
4. Install the PCV hose to the ETC.
5. Connect the ETC coolant inlet/outlet hoses.
6. Connect the fuel line to the fuel rail.
7. Connect the related sensor and actuator connectors.
• A/C pressure sensor (ACP) connector
• CAM position solenoid valve connector
• Electric throttle controller (ETC) connector
• Manifold air pressure (MAP) sensor connector
• EVAP solenoid valve connector
• Injector connectors
8. Install the power steering pressure pipe clamp to the intake manifold.
9. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
10. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection.

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Document ID: 2049866 Page 1 of 8

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2049866

Timing Belt Replacement

Special Tools

• EN-48356 Engine Fixture

• KM-6625 Flywheel Locking Device
• KM-6333 Fixing Rod
• MK-6340 Locking Tool
• MK-6628 Locking Tool

Removal Procedure

Warning: Refer to Battery Disconnect Warning in the Preface section.

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection.
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
3. Install EN-48356 fixture .
4. Remove the accessory belt. Refer to Drive Belt Replacement.
5. Remove the accessory belt tensioner. Refer to Drive Belt Tensioner Replacement.

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6. Rotate the crankshaft pulley clockwise.

7. Align the notches (1) between the pulley and the cover.

8. Remove the transmission bolt (1).

9. Install KM-6625 locking device to block the crankshaft.
10. Install the transmission bolt (1).
11. Remove the cylinder head cover. Refer to Valve Rocker Arm Cover Replacement.
12. Remove the engine mount. Refer to Engine Mount Replacement.

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13. Remove the crankshaft pulley (2).

14. Remove the timing belt upper cover (1).
15. Remove the engine mount bracket.
16. Remove the timing belt lower cover (3).
17. Remove the timing belt center cover.

18. Install KM-6333 rod during rotating the timing belt tensioner.
19. Remove the timing belt.

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20. Remove the timing belt tensioner (1).

21. Remove the timing belt idler (2).

Adjustment Procedure

1. Align the both camshaft horizontally to install the MK-6628 locking tool .
2. Confirm the both camshaft sprocket spot aligned.

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3. Prepare the right half of MK-6340 locking tool .

Note: Recognizable from the lettering "Right"

4. Unscrew the bolts (1) and detach the front panel (2) from MK-6340 locking tool .

Note: The spot-type marking (4) on the intake camshaft sprocket does not correspond to the
groove of MK-6340 locking tool during this process.

5. Confirm aligning between the intake side spot (3) and the exhaust side spot (4) on the
camshaft sprockets.
6. If not aligned as shown, remove and install the camshaft sprocket to align. Refer to Camshaft
Gear Replacement.

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7. Insert the left of MK-6340 locking tool (1) into the intake camshaft sprocket side.
8. Insert the right of MK-6340 locking tool (2) into the exhaust camshaft sprocket side.

Note: If not aligned the notches, rotate the crankshaft until aligning after remove KM-6625
locking device .

9. Confirm alignment of the notches between the crankshaft sprocket and the cover.

Caution: Refer to Fastener Caution in the Preface section.

10. Install the timing belt idler (2) and tighten to 50 N·m (36.8 lb ft).
11. Install the timing belt tensioner (1) and tighten to 55 N·m (40.6 lb ft).

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12. Install the timing belt and adjust.

13. Pull out KM-6333 rod .

Installation Procedure

1. Install the timing belt center cover.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the timing belt lower cover (3) and tighten the bolts to 6 N·m (53.1 lb in).
3. Install the engine mount bracket and tighten the bolt to 65 N·m (47.9 lb ft).
4. Install the timing belt upper cover (1) and tighten the bolts to 4 N·m (35.4 lb ft).

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5. Install the crankshaft pulley (2) with aligning crankshaft pulley notches and tighten to
25 N·m (18.4 lb ft).
6. Install the engine mount. Refer to Engine Mount Replacement
7. Install the cylinder head cover. Refer to Valve Rocker Arm Cover Replacement.
8. Install the accessory belt. Refer to Drive Belt Tensioner Replacement.
9. Install the accessory belt tensioner. Refer to Drive Belt Replacement.

10. Remove the transmission bolt (1).

11. Remove KM-6625 locking device to block the crankshaft.
12. Install the transmission bolt (1) and tighten to 60 N·m (44.2 lb ft).

13. Remove EN-48356 fixture .

14. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
15. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection.

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Document ID: 2050729 Page 1 of 3

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2050729

Valve Rocker Arm Cover Replacement

Removal Procedure

Warning: Refer to Battery Disconnect Warning in the Preface section.

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection.
2. Disconnect the related sensor and actuator connector and pull engine wiring harness aside.
3. Disconnect the oil switch wiring connector.
4. Disconnect the A/C compressor connector.
5. Disconnect the manifold air temperature (MAT) sensor connector.
6. Disconnect the A/C pressure (ACP) sensor connector.
7. Disconnect the CAM position solenoid valve connectors (right/left).
8. Disconnect the manifold air pressure (MAP) sensor connector.
9. Disconnect the EVAP canister purge solenoid valve connector.
10. Disconnect the injectors connectors.
11. Disconnect the ignition coil connector.
12. Disconnect the camshaft position sensor (CPS) connectors (right/left).

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13. Remove the ignition coil. Refer to Ignition Coil Replacement.

14. Detach the PCV clips from the PCV hose.
15. Remove the PCV hose from the cylinder head cover.
16. Unscrew the cylinder head cover bolts.
17. Remove the cylinder head cover (1).

Installation Procedure

Note: Check and Confirm the damage or crack of the cylinder head gasket. If damaged or
cracked, replace the new one.

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1. Install the cylinder head (1) with the gasket.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the cylinder head cover bolts and tighten to 8 N·m (70.8 lb in).
3. Install the PCV hose to the cylinder head cover.
4. Attach the PCV clips to the PCV hose.
5. Install the ignition coil. Refer to Ignition Coil Replacement
6. Install the engine wiring harness and connect the related sensor and actuator connector.
7. Connect the oil switch wiring connector.
8. Connect the A/C compressor connector.
9. Connect the manifold air temperature (MAT) sensor connector.
10. Connect the A/C pressure (ACP) sensor connector.
11. Connect the CAM position solenoid valve connectors (right/left).
12. Connect the manifold air pressure (MAP) sensor connector.
13. Connect the EVAP canister purge solenoid valve connector.
14. Connect the injector connectors
15. Connect the ignition coil connector.
16. Connect the camshaft position sensor (CPS) connectors (right/left).
17. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and
Connection.

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2053122

Camshaft Position Intake Actuator Replacement

Removal Procedure

1. Remove the camshaft adjuster bolts (3).

Note: Ensure the location and direction of the intake/exhaust adjusters when removed.

2. Remove the camshaft©adjusters (1,Motors

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Installation Procedure

Note: Ensure the location and direction of the intake/exhaust adjusters when removed.

1. Install the camshaft adjusters (1, 2).

Caution: Refer to Fastener Caution in the Preface section.

2. Install the camshaft adjuster bolts (3) and tighten to 65 N·m +120° +15° (47.9 lb ft

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+120° +15° ).

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2053124

Camshaft Position Exhaust Actuator Replacement

Removal Procedure

1. Remove the camshaft adjuster bolts (3).

Note: Ensure the location and direction of the intake/exhaust adjusters when removed.

2. Remove the camshaft©adjusters (1,Motors

2010 General 2). Corporation. All rights reserved.

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Installation Procedure

Note: Ensure the location and direction of the intake/exhaust adjusters when removed.

1. Install the camshaft adjusters (1, 2).

Caution: Refer to Fastener Caution in the Preface section.

2. Install the camshaft adjuster bolts (3) and tighten to 65 N·m +120° +15° (47.9 lb ft

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+120° +15° ).

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2050739

Cylinder Head Replacement

Removal Procedure

1. Drain the engine coolant. Refer to Cooling System Draining and Filling.
2. Release the fuel pressure. Refer to Fuel Pressure Relief.
3. Remove the timing belt. Refer to Timing Belt Replacement.
4. Remove the timing belt tensioner. Refer to Timing Belt Replacement.

5. Remove the camshaft. Refer to Camshaft Gear Replacement.

6. Remove the timing belt rear cover (1).
7. Remove the intake manifold. Refer to Intake Manifold Replacement.

© 2010 General Motors Corporation. All rights reserved.

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8. Remove the exhaust manifold. Refer to Catalytic Converter Replacement.

9. Remove the coolant distributor (1).

10. Remove the cylinder head bolts (1).

11. Remove the cylinder head (2) with the gasket.

Installation Procedure

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1. Install the cylinder head (2) with the new gasket.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the cylinder head bolts (1) and tighten to 25 N·m +90° +90° +90° +45°
(18.4 lb ft +90° +90° +90° +45° ).

3. Install the coolant distributor (1).

4. Install the exhaust manifold. Refer to Catalytic Converter Replacement.
5. Install the intake manifold. Refer to Intake Manifold Replacement.

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6. Install the timing belt rear cover (1) and tighten to 6 N·m (53.1 lb in).
7. Install the camshaft. Refer to Camshaft Replacement.
8. Adjust the belt timing. Refer to Timing Belt Replacement.

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2050919

Oil Pan Replacement

Special Tools

EN-49152 Oil Pan Bolt Remover/Installer

Removal Procedure
1. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement.
2. Remove the front exhaust pipe. Refer to Front Pipe Replacement.

3. Remove the transmission rear mounting bracket (2), for automatic transmission only.

© 2010 General Motors Corporation. All rights reserved.

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4. Remove the oil pan-to-transmission bolts (1).

5. Remove the oil pan bolts (1) using EN-49152 remover/installer .

6. Remove the oil pan baffle (2).

7. Remove the oil suction filter (3).

Installation Procedure

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1. Install the oil suction filter to the oil pan.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the oil pan baffle.

Tighten
Tighten the oil pan baffle bolts (1) to 10 N·m (7.3 lb ft).

3. Clean the oil pan sealing surface.

4. Apply the oil pan sealant LOCTITE 5900 on the sealing surface.

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5. Install the oil pan bolts (1) using EN-49152 remover/installer .

Tighten
Tighten the oil pan bolts (1) to 14 N·m (10.3 lb ft).

6. Install the oil pan-to-transmission bolts (1).

Tighten
Tighten the oil pan-to-transmission bolts to 40 N·m (29.5 lb ft).

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7. Install the transmission rear mounting bracket (2), for automatic transmission only.

Tighten
Tighten the transmission rear mounting bracket bolts and nut to 80 N·m (59 lb ft).

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2050921

Oil Pump Replacement

Removal Procedure

1. Drain the engine coolant. Refer to Cooling System Draining and Filling.
2. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement.
3. Remove the exhaust manifold. Refer to Catalytic Converter Replacement.
4. Remove the timing belt. Refer to Timing Belt Replacement.
5. Remove the oil pan. Refer to Oil Pan Replacement.
6. Remove the power steering pump and bracket. Refer to Power Steering Pump Replacement.
7. Remove the alternator. Refer to Generator Replacement.
8. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement.

9. Remove the engine coolant pipe (1) bolts.

10. Remove the engine coolant pipe (2) bracket bolt and then push the pipe into the oil cooler
housing.

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11. Remove the crankshaft sprocket (2).

12. Remove the engine front cover assembly (3) with the gasket.

Inspection Procedure

1. Clean the measuring surface.

2. Measure the axial clearance of rotors.

If out-of-specifications, replace with a new one. Refer to Engine Mechanical Specifications.

Installation Procedure

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Caution: Refer to Fastener Caution in the Preface section.

Note: Do not reuse the engine front cover gasket.

1. Install the engine front cover assembly (3) with the new gasket.

Tighten
Tighten the engine front cover assembly bolts to 20 N·m (14.7 lb ft).

2. Install the crankshaft sprocket (2).

3. Install the engine coolant pipe (1) bolts.

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4. Install the engine coolant pipe (2) bracket bolt and then push the pipe into the oil cooler
housing.

5. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement.

6. Install the alternator. Refer to Generator Replacement.
7. Install the power steering pump and bracket. Refer to Power Steering Pump Replacement.
8. Install the oil pan. Refer to Oil Pan Replacement.
9. Install the timing belt. Refer to Timing Belt Replacement.

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2050922

Engine Mount Replacement

Special Tools

EN-48356 Engine Fixture

Removal Procedure
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.

2. Install EN-48356 fixture .

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3. Remove the engine mount bolts (2) and nuts (1).

Installation Procedure

Caution: Refer to Fastener Caution in the Preface section.

1. Install the engine mount bolts (2) and nuts (1) and tighten to 55 N·m (40.5 lb ft).
2. Remove EN-48356.
3. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2050924

Engine Replacement

Special Tools

• EN-48244 Engine Assembly Remove/Install Pallet Supporter

• EN-49156 Engine Assembly Remove/Install Pallet

Removal Procedure

1. Release the fuel pressure. Refer to Fuel Pressure Relief.

2. Disconnect the fuel pipe from the fuel rail.
3. Disconnect the EVAP hose from the EVAP canister solenoid valve.
4. Drain the engine coolant. Refer to Cooling System Draining and Filling.
5. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.

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6. Remove the battery and tray. Refer to Battery Tray Replacement.

7. Remove the fuse box bolts.

8. Discharge the A/C gas system, if equipped. Refer to Refrigerant Recovery and Recharging.
9. Remove the A/C inlet/outlet pipe bolt (1) from the A/C compressor.

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10. Drain the power steering oil if equipped. Refer to Power Steering Pump Replacement.
11. Remove the power steering pump pressure line union nut. Refer to Power Steering Pump
Replacement.
12. Remove the power steering pressure pipe retaining clamp bolt (1) from the intake manifold.
13. Disconnect the power steering hose from the power steering pump.
14. Disconnect the following:
• Oil switch wiring connector
• A/C compressor connector
15. Disconnect the following:
• Intake air temperature sensor connector
• A/C pressure sensor (ACP) connector
• Cam position solenoid valve connector
• Electric throttle controller (ETC) connector
• Manifold air pressure (MAP) sensor connector
• EVAP solenoid valve connector
• Injector connectors
16. Disconnect the following
• Ignition coil connector
• Camshaft position sensor (CPS) connectors (right/left)
• Coolant temperature sensor connector
• Oxygen sensor connector
• Ground bolt
• Thermostat heater connector

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17. Disconnect the following and pull the engine harness aside.
• Crankshaft position (CKP) sensor connector
• Knock sensor connector
• Alternator connector
• Alternator B+ g nut
• Oil level switch connector, if equipped
• Starter solenoid B+ tightening nut
• Ground nut
• Starter solenoid ground nut

18. Disconnect the coolant hose (1) from water pump.

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19. Disconnect the coolant hose (2) from the thermostat housing.
20. Disconnect the heater core coolant inlet/outlet hoses (3) from the coolant distributor.
21. Disconnect the ETC-to-coolant tank hose (4).
22. Disconnect the brake boost hose (5) from the intake manifold.

23. Remove and disconnect the cables and wiring harness related to the automatic transaxle.
24. Disconnect the auto transaxle fluid cooler inlet/outlet hoses.

25. Remove and disconnect the cables and wiring harness related to the manual transaxle.

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26. Remove the reaction rod (1).

27. Remove the exhaust front pipe. Refer to Front Pipe Replacement.
28. Remove the drive axle shafts. Refer to Front Drive Axle Inner Shaft Replacement

29. Install EN-49156 remove/install pallet on to EN-48244 pallet supporter .

30. Lift the vehicle up using by lifter.
31. Locate the pallet and supporter under the vehicle engine and transaxle.
32. Lift the vehicle down until engine assembly fixing on the EN-49156 remove/install pallet .
33. Remove the engine mount. Refer to Engine Mount Replacement.
34. Remove the transaxle mount.

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35. Separate the engine and the transaxle.

Installation Procedure

1. Assemble the engine to the transaxle.

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2. Place the engine assembly on the pallet EN-49156 remove/install pallet on the EN-48244
pallet supporter
3. Lift the vehicle up using by lifter.
4. Locate the engine assembly with the pallet and supporter.
5. Lift the vehicle down.
6. Install the engine mount. Refer to Engine Mount Replacement.
7. Install the transaxle mount.

8. Install the drive axle shafts. Refer to Front Drive Axle Inner Shaft Replacement.
9. Install the exhaust front pipe. Refer to Front Pipe Replacement.

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10. Install the reaction rod (1).

11. Install and connect the cables and wiring harness related to the automatic transaxle.
12. Connect the auto transaxle fluid cooler inlet/outlet hoses.

13. Install and connect the cables and wiring harness related to the manual transaxle.

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14. Connect the coolant hose (1) to the water pump.

15. Connect the coolant hose (2) to the thermostat housing.
16. Connect the heater core coolant inlet/outlet hoses (3) to the coolant distributor.
17. Connect the ETC-to-coolant tank hose (4).
18. Connect the brake boost hose (5) to the intake manifold.

Caution: Refer to Fastener Caution in the Preface section.

19. Position the engine harness and connect the following connectors.
• Crankshaft position (CKP) sensor connector
• Knock sensor connector
• Alternator connector
• Alternator B+ nut
• Oil level switch connector, if equipped
• Starter solenoid B+ nut
• Ground tightening nut
• Starter solenoid ground nut

Tighten
• Tighten the alternator B+ nut to 15 N·m (11 lb ft).
• Tighten the starter solenoid B+ nut to 10.5 N·m (7.7 lb ft).
• Tighten the ground nut to 12 N·m (8.8 lb ft).
• Tighten the starter solenoid ground nut to 38 N·m (28 lb ft).
20. Connect the following:
• Ignition coil connector
• Camshaft position sensor (CPS) connectors (right/left)
• Coolant temperature sensor connector
• Oxygen sensor connector

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• Ground bolt

Tighten
Tighten the ground bolt to 12 N·m (8.8 lb ft).

• Thermostat heater connector

21. Connect the following:
• Oil switch wiring connector
• A/C compressor connector

22. Install the power steering pump pressure line union nut.
23. Install the power steering pressure pipe retaining clamp bolt (1) to the intake manifold.
24. Connect the power steering hose to the power steering pump.

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25. Install the A/C inlet/outlet pipe bolt (1) from the A/C compressor if equipped.
26. Charge the A/C gas system. Refer to Refrigerant Recovery and Recharging.
27. Install the fuse box tightening bolts.
28. Install the battery and tray. Refer to Battery Tray Replacement.

29. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
30. Connect the fuel pipe to the fuel rail.
31. Connect the EVAP hose to the EVAP canister solenoid valve.

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2095948

Engine Oil and Oil Filter Replacement

Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.

2. Locate the vessel for containing engine oil beneath drain plug of the vehicle.
3. Remove the oil drain (2) carefully.
4. Drain the engine oil.

5. Remove the oil filter cap (1).

© 2010 General Motors Corporation. All rights reserved.

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6. Remove the oil filter.

Installation Procedure

Note: Do not re-use the engine oil filter.

1. Install the new oil filter.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the oil filter cap (1) and tighten to 25 N·m (18.4 lb ft).

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Note: Refer to engine oil specifications in the owners manual and refill with the
recommended engine oil and quantity.

3. Install the drain plug (2) and tighten to 9 N·m (79.7 lb in).
4. Open the oil filling cap.
5. Refill the new engine oil.

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2053132

Oil Pressure Relief Valve Replacement (Primary)

Removal Procedure

1. Remove the oil pan. Refer to Oil Pan Replacement.

2. Remove the oil pressure relief valve plug (3).

3. Remove the valve spring (2).
4. Remove the valve piston (1).

Installation Procedure

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1. Clean the plug thread, spring and piston (1).

2. Install the valve piston (2).
3. Install the valve spring (3).

Caution: Refer to Fastener Caution in the Preface section.

4. Install the oil pressure relief valve plug.

Tighten
Tighten the oil pressure relief valve plug to 21 N·m (15.5 lb ft).

5. Install the oil pan. Refer to Oil Pan Replacement.

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2053134

Oil Pressure Relief Valve Replacement (Secondary)

Removal Procedure

1. Remove the oil pan. Refer to Oil Pan Replacement.

2. Remove the oil overpressure relief valve plug (3).

3. Remove the valve spring (2).
4. Remove the valve piston (1).

Installation Procedure

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1. Clean the plug thread, spring and piston (1).

2. Install the valve piston (2).
3. Install the valve spring (3).

Caution: Refer to Fastener Caution in the Preface section.

4. Install the oil overpressure relief valve plug.

Tighten
Tighten the oil pressure relief valve plug to 10 N·m (88.5 lb in).

5. Install the oil pan. Refer to Oil Pan Replacement.

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2096040

Oil Level Indicator and Tube Removal

Removal Procedure

1. Remove the oil indicator tube tightening bolt.

2. Remove the oil indicator and tube.

Installation Procedure

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1. Install the oil indicator and tube.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the oil indicator tube tightening bolt and tighten to 10 N·m (7.3 lb ft).

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2096051

Crankshaft Replacement
Special Tools

EN-49204 Crankshaft Rear Oil Seal Installer

Removal Procedure

Note:
• Take extreme care to prevent any scratches, nicks or damage to the inner side of the
cylinder and bearings.
• Check and confirm the sequence of the crankshaft caps and bearings.

1. Remove the pistons and connecting rods. Refer to Piston, Connecting Rod, and Bearing
Replacement.
2. Remove the crankshaft cap bolts.
3. Remove the crankshaft caps with journal bearings (1).
4. Remove the crankshaft (2).
5. Remove the crankshaft rear oil seal (3) with housing (4).
6. Detach the crankshaft rear oil seal from the housing.

Installation Procedure

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Note:
• Take extreme care to prevent any scratches, nicks or damage to the inner side of the
cylinder and bearings.
• Check and confirm the sequence of the crankshaft caps and bearings.

1. Coat and lubricate the crankshaft caps and bearings (1).

2. Install the crankshaft (2) with bearings in sequences.

Caution: Refer to Fastener Caution in the Preface section.

3. Install the crankshaft caps with journal bearings (1) and tighten the crankshaft bolts to
50+50° N·m (36.8+50° lb ft).

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4. Attach the crankshaft rear oil seal to the housing.

5. Install the crankshaft rear oil seal with housing using the EN-49204 seal installer .
6. Install the pistons and connecting rods. Refer to Piston, Connecting Rod, and Bearing
Replacement.

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2050733

Camshaft Gear Replacement

Removal Procedure

1. Remove the timing belt. Refer to Timing Belt Replacement.

2. Remove the camshaft sprocket bolt cap (4).
3. Remove the camshaft sprocket bolts (3).
4. Remove the camshaft sprockets (1, 2).

Installation Procedure

© 2010 General Motors Corporation. All rights reserved.

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Note: When installing the camshaft sprockets, the timing adjustment procedure must be
accomplished. Refer to Timing Belt Replacement.

1. Install the camshaft sprockets (1, 2).

Caution: Refer to Fastener Caution in the Preface section.

2. Install the camshaft sprocket bolts (3).

Tighten
Tighten the camshaft sprocket bolts to 65 N·m (47.9 lb ft).

3. Install the camshaft sprocket bolt caps (4).

Tighten
Tighten the camshaft sprocket bolt cap to 50 N·m (36.8 lb ft).

4. Install the timing belt. Refer to Timing Belt Replacement.

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2053125

Camshaft Front Oil Seal Replacement

Special Tools

KM-422 Installer

Removal Procedure
1. Remove the camshaft sprocket. Refer to Camshaft Gear Replacement.

Note: Extremely take care of contacting of camshaft surface. If damaged on the camshaft
surface, engine oil could be leaked.

2. Remove the camshaft seal ring (1).

Installation Procedure

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Note: Do not reuse the camshaft seal ring.

1. Install the camshaft seal ring (1) with new one.

2. Install the KM-422 installer (3) with shims (2), with a total thickness of approximately
10 mm and tighten the camshaft bolt (1) manually.
3. Remove the KM-422 installer .
4. Install the camshaft sprocket. Refer to Camshaft Gear Replacement

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Document ID: 2096097 Page 1 of 5

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2096097

Camshaft Replacement
Special Tools

KM-422 Installer

Removal Procedure
Note: Take extreme care to prevent any scratches, nicks or damage to the camshafts and
caps bearing surfaces.

1. Remove the camshaft sprocket. Refer to Camshaft Gear Replacement.

2. Remove the timing belt tensioner. Refer to Timing Belt Replacement.

3. Remove the timing belt rear cover (1).

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4. Remove the camshaft position solenoid valve housing.

5. Remove the camshaft cap bolts in sequence (1, 4, 2, 3).
6. Remove the camshaft caps.

7. Remove the intake (2)/exhaust (1) camshafts with the seal rings (3).

Installation Procedure

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1. Coat/Lubricate the camshaft bearing and cam surfaces with clean engine oil.

Note: It is essential to ensure that no sealant is applied outside the marked sealing areas.

2. Install the camshafts (1, 2) on the cylinder head.

Note: The grooves (1) adjacent to the sealing surfaces must remain free from sealant

3. Apply surface sealant LOCTITE 574 to sealing surfaces (1) of the 1st camshaft bearing cap
thinly and evenly.

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4. Install the camshaft bearing caps in sequence (2, 3, 1, 4).

Caution: Refer to Fastener Caution in the Preface section.

5. Install the camshaft position solenoid valve housing.

Tighten
Tighten the camshaft bearing cap bolts to 8 N·m (70.8 lb in).

6. Install the new camshaft oil seal rings using KM-422 . Refer to Camshaft Front Oil Seal
Replacement.

7. Install the timing belt rear cover (1).

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Tighten
Tighten the timing belt rear cover bolts (2) to 6 N·m (53.1 lb in).

8. Install the timing belt tensioner. Refer to Timing Belt Replacement.

9. Install the camshaft sprocket. Refer to Camshaft Gear Replacement.

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Document ID: 2087660 Page 1 of 3

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2087660

Camshaft Cleaning and Inspection

1. Measure the camshaft lift.

2. Replace the camshaft if the measured value is not as specified.

Specification
The specification is 46.3 mm (1.8228 in).

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3. Measure the outer diameter of each journal (1) at the 4 different places.
4. Replace the camshaft if the measured value is not as specified.

Specification
The specification is 27.939-27.960 mm (1.1000-1.1008 in).

5. Measure the straightness of the camshaft using a dial gage.

6. Replace the camshaft if the measured value is over the specified limit.

Specification
The specification limit is 0.04 mm (0.0016 in).

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7. Measure the camshaft endplay using a dial gage.

8. Replace the camshaft if the measured value is over the specified limit.

Specification
The specification limit is 0.130-.215 mm (0.0051-.0085 in).

9. Measure the inner diameter of the cylinder head journal at the 2 places.

Specification
The specification limit is 28.000-28.021 mm (1.1024-1.1032 in).

10. If necessary, replace cylinder head.

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Document ID: 2053141 Page 1 of 3

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2053141

Valve Clearance Adjustment

Measurement

1. Remove the cylinder head cover. Refer to Valve Rocker Arm Cover Replacement.

2. Rotate the crankshaft pulley clockwise.

3. Align the notches (1) between the pulley and the cover.

4. Measure the valve clearance (2) and (6). Rotate the crankshaft pulley clockwise through
180 degrees.
5. Measure the valve clearance (3) and (7). Rotate the crankshaft pulley clockwise through
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180 degrees.
6. Measure the valve clearance (4) and (8). Rotate the crankshaft pulley clockwise through
180 degrees.
7. Measure the valve clearance (1) and (5). Rotate the crankshaft pulley clockwise through
180 degrees.
8. If the measured values are out-of-specifications, replace the new valve tappets.

Specifications
• Intake Side: 0.21-0.29 mm (Nominal Value: 0.25 mm)
• Exhaust Side: 0.27-0.35 mm (Nominal Value: 0.30 mm)
9. Determine the tappet size. Refer to Valve Clearance Determine Tappet Size.
10. Replace the valve tappets if necessary.

Determine Replacement Size Tappet

1. Remove the old tappet.

2. Locate the ID number inside old tappet.
3. Locate the ID number in the following table and record the value.
4. Perform the following calculation to determine the replacement tappet size.

Value (old tappet) + Measured Clearance - Nominal Value = X (new tappet)

Example:

• ID of old tappet = 20 = 3.20 mm and clearance was 0.31 mm

• 3.20 mm + 0.31 mm - 0.25 mm = 3.265 mm
• 3.265 mm (value) = 27X (ID number) = 55353766 (part number)

Tappet Selection
Part Number ID Number Value (mm)

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24465260 04 3.060-3.050
24465261 06 3.050-3.070
24438041 08 3.070-3.090
24438145 10 3.090-3.110
24438146 12 3.110-3.130
24438147 14 3.130-3.150
24438148 16 3.150-3.170
24438149 18 3.170-3.190
24438150 20 3.190-3.210
24438151 22 3.210-3.230
55353764 24X 3.230-3.244
55353765 25X 3.244-3.258
55353766 27X 3.258-3.272
55353767 28X 3.272-3.286
55353768 30X 3.286-3.300
55353769 31X 3.300-3.314
55353770 32X 3.314-3.328
55353771 34X 3.328-3.342
55353772 35X 3.342-3.356
55353773 36X 3.356-3.370
55353774 38X 3.370-3.384
55353775 39X 3.384-3.398
55353776 41X 3.398-3.412
55353777 42X 3.412-3.426
55353778 43X 3.426-3.440
55353779 45 3.440-3.460
55353780 47 3.460-3.480
55353781 49 3.480-3.500
55353782 51 3.500-3.520
55353783 53 3.520-3.540
55353784 55 3.540-3.560
55353785 57 3.560-3.580
55353786 59 3.580-3.600

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2053126

Valve Stem Oil Seal and Valve Spring Replacement

Special Tools

• EN-49074 Universal Valve Spring Compressor

• EN-49155 Valve Spring Compressing Adapter
• EN-49154 Adapter-Cylinder Pressure
• KM-845 Suction Device

Removal Procedure

1. Remove the camshaft. Refer to Camshaft Replacement.

2. Remove the valve tappet using KM-845 suction device .

3. Remove the spark plugs and then install the EN-49154 pressure .
4. Apply the compressed air to the adapter to avoid dropping of valves in the cylinders inside.
5. Install EN-49074 compressor and EN-49155 adapter .

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6. Remove the valve key (1).

7. Remove the valve springs (3), retainers (2), and seals (4).
8. Remove the EN-49074 compressor and EN-49155 adapter .

Installation Procedure

1. Install the seals (4), retainers (2), and valve spring (3).
2. Install EN-49074 compressor and EN-49155 adapter .
3. Install the valve key (1).

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4. Install the valve tappet using KM-845 .

5. Install the camshaft. Refer to Camshaft Replacement.

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Document ID: 2087659 Page 1 of 1

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2087659

Valve Spring Inspection and Measurement

1. Measure the valve spring height. Refer to Engine Mechanical Specifications. If the valve
spring height does not match the specifications, replace the valve spring.

2. Measure the valve spring squareness. Refer to Engine Mechanical Specifications. If the valve
spring squareness does not match the specifications, replace the valve spring.
3. Inspect the valve spring seating surface of the valve rotators for wear or gouges. Replace as
required.

© 2010 General Motors Corporation. All rights reserved.

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2053137

Automatic Transmission Flex Plate Replacement

Special Tools

• EN-48356 Engine Fixture

• KM-652 Flywheel Locking Device

Removal Procedure

1. Install EN-48356 engine fixture .

2. Remove the automatic transmission. Refer to Transmission Replacement.

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3. Install KM-652 locking device (1) to block the crankshaft.

4. Install the transmission bolt with KM-652 locking device .

5. Remove the flexible plate bolts (2).

6. Remove the flexible plate (1).

Installation Procedure

1. Install the flexible plate (1).

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Caution: Refer to Fastener Caution in the Preface section.

2. Install the flexible plate bolts (2).

Tighten
Tighten the flexible plate bolts (2) to 35 N·m +30° +15° (25.8 lb ft +30° +15°).

3. Remove KM-652 locking device to block the crankshaft.

4. Install the automatic transmission. Refer to Transmission Replacement

5. Remove EN-48356 engine fixture

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2053135

Engine Flywheel Replacement

Special Tools

• EN-48356 Engine Fixture

• KM-652 Flywheel Locking Device

Removal Procedure

1. Install EN-48356 fixture .

2. Remove the manual transmission. Refer to Transmission Replacement and Transmission
Replacement.
3. Install KM-652 locking device (1) to block the crankshaft
4. Install the transmission bolt with KM-652 Flywheel Locking Device .

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5. Remove the flywheel bolts.

6. Remove the flywheel (1).

Installation Procedure

1. Install the flywheel (1).

Caution: Refer to Fastener Caution in the Preface section.

2. Install the flywheel bolts.

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Tighten
Tighten the flywheel bolts to 35 N·m +30° +15° (25.8 lb ft +30° +15°).

3. Remove KM-652 locking device (1)

4. Install the manual transaxle. Refer to Transmission Replacement and Transmission
Replacement

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2053138

Crankshaft Front Oil Seal Replacement

Special Tools

KM-6351 Assembly Sleeves

Removal Procedure
1. Remove the timing belt. Refer to Timing Belt Replacement.
2. Remove the crankshaft sprocket.

3. Remove the crankshaft front oil seal ring (1).

Installation Procedure

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1. Attach the installer inside sleeve (1).

2. Attach the crankshaft front oil seal ring to the inside sleeve (1).
3. Attach the installer outside sleeve (2).
4. Install the crankshaft bolt (4) and washer (3).

5. Install the crankshaft sprocket.

6. Install the timing belt. Refer to Timing Belt Replacement.

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2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2053139

Crankshaft Rear Oil Seal Replacement

Special Tools

EN-49204 Crankshaft Rear Oil Seal Installer

Removal Procedure
1. Remove the flywheel or flexible plate. Refer to Automatic Transmission Flex Plate
Replacement and Engine Flywheel Replacement.
2. Remove the crankshaft position (CKP) sensor. Refer to Crankshaft Position Sensor
Replacement.

3. Remove the crankshaft rear oil seal with housing.

Installation Procedure

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1. Install the new crankshaft rear oil seal (1).

2. Install EN-49204 installer and then tighten the bolts to press seal ring all the way in.
3. Remove EN-49204 installer .
4. Install the crankshaft position sensor. Refer to Crankshaft Position Sensor Replacement
5. Install the flywheel or flexible plate. Refer to Automatic Transmission Flex Plate Replacement
and Engine Flywheel Replacement

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Document ID: 2052509 Page 1 of 8

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Repair Instructions - On Vehicle | Document ID: 2052509

Piston, Connecting Rod, and Bearing Replacement

Special Tools

DW110-030 Engine Overhaul Stand

Removal Procedure

1. Remove the engine assembly. Refer to Engine Replacement.

2. Install the engine assembly to the DW110-030 stand .
3. Remove the ignition coil. Refer to Ignition Coil Replacement.

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4. Detach the PCV clips from the PCV hose.

5. Remove the PCV hose from the cylinder head cover.
6. Remove the cylinder head cover bolts.
7. Remove the cylinder head cover (1).
8. Remove the power steering pump and bracket. Refer to Power Steering Pump Replacement.
9. Remove the timing belt. Refer to Timing Belt Replacement.
10. Remove the timing belt tensioner. Refer to Timing Belt Replacement.
11. Remove the camshaft sprocket. Refer to Camshaft Gear Replacement.

12. Remove the camshaft rear cover (1).

13. Remove the exhaust manifold. Refer to Catalytic Converter Replacement.
14. Remove the throttle body. Refer to Throttle Body Assembly Replacement.
15. Remove the intake manifold. Refer to Intake Manifold Replacement.

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16. Remove the engine coolant distributor (1).

17. Remove the cylinder head bolts (1).

18. Remove the cylinder head assembly (2) with the cylinder head gasket.
19. Remove the engine oil cooler. Refer to Engine Oil Cooler Replacement.
20. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement.
21. Remove the alternator. Refer to Generator Replacement.
22. Remove the starter. Refer to Starter Motor Replacement.
23. Remove the oil pan. Refer to Oil Pan Replacement.
24. Remove the oil pump assembly. Refer to Oil Pump Replacement.
25. Remove the flexible plate or flywheel. Refer to Automatic Transmission Flex Plate
Replacement and Engine Flywheel Replacement.

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Note: Check and confirm the piston assembly sequence and the connecting rod bearing
sequence, to not confuse.

26. Remove the connecting rod cap (2) and bolts (3).
27. Remove the piston assembly. (1)

28. Separate the piston pin (5) from the piston (3).
29. Separate the piston ring (1) from the piston using the expansion tool.

Installation Procedure

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Note: Take extreme care to prevent any scratches or damage to the inner side of the
cylinder, piston, and connecting rod cap bearings.

1. Install the piston pin (5) to the piston.

2. Install the piston ring from the piston using the expansion tool.

Note: Check and confirm the piston assembly sequence and the connecting rod bearing
sequence, to not confuse.

3. Install the piston assembly using the piston installer.

Caution: Refer to Fastener Caution in the Preface section.

4. Install the connecting rod cap and bolts with bearings.

Tighten
Tighten the connecting rod caps bolts to 35+45° +15° N·m (25.8+45° +15° lb ft).

5. Install the flexible plate or flywheel. Refer to Automatic Transmission Flex Plate Replacement
and Engine Flywheel Replacement.

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6. Install the oil pump assembly. Refer to Oil Pump Replacement.

7. Install the engine oil cooler. Refer to Engine Oil Cooler Replacement.
8. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement.
9. Install the alternator. Refer to Generator Replacement.
10. Install the starter. Refer to Starter Motor Replacement.
11. Install the oil pan. Refer to Oil Pan Replacement.

Note: Do not reuse the cylinder head gasket.

12. Install the cylinder head assembly (2) with the new cylinder head gasket.
13. Install the cylinder head bolts (1).

Tighten

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Tighten the cylinder head bolts to 25+90° +90° +90° +45° N·m (18.4+90° +90° +90°
+45° lb ft).

14. Install the engine coolant distributor (1).

15. Install the intake manifold. Refer to Intake Manifold Replacement.
16. Install the throttle body. Refer to Throttle Body Assembly Replacement.
17. Install the exhaust manifold. Refer to Catalytic Converter Replacement.

18. Install the camshaft rear cover (1).

19. Install timing belt system and adjust the timing. Refer to Timing Belt Replacement.
20. Install the timing system. Refer to Timing Belt Replacement.
21. Install the power steering pump and bracket. Refer to Power Steering Pump Replacement.

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22. Install the cylinder head cover (1).

23. Install the cylinder head cover bolts.
24. Install the PCV hose from the cylinder head cover.
25. Attach the PCV clips from the PCV hose.
26. Install the ignition coil. Refer to Ignition Coil Replacement.
27. Install the engine assembly. Refer to Engine Replacement.

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Document ID: 2051334 Page 1 of 2

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Component Locator | Document ID: 2051334

Cylinder Block

(1) Cylinder Block

(2) Engine Oil Level Indicator
(3) Oil Level Indicator Tube
(4) Oil Switch
(5) Oil Pan
(6) Oil Pump Filter
(7) Crankshaft Balancer (Pulley)
(8) Water Pump
(9) Water Pump Gasket
(10) Oil Pump Plug
(11) Check Valve
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(12) Crankshaft Front Seal

(13) Engine Front Cover
(14) Engine Oil Pump Cover
(15) Engine Front Cover Gasket
(16) Retainer
(17) Engine Oil Level Switch Connector
(18) Engine Oil Level Switch
(19) Oil Plug
(20) Oil Plug Washer
(21) Oil Pressure Relief Valve
(22) Oil Pressure Relief Valve Spring
(23) Oil Pressure Relief Valve Spring Plug
(24) Oil Pressure Relief Valve
(25) Oil Overpressure Relief Valve Spring
(26) Oil Overpressure Relief Valve Spring Plug
(27) Oil Filter Cap
(28) Oil Filter Cap Seal
(29) Oil Filter
(30) Oil Filter Housing Assembly
(31) Oil Cooler Pipe Seal
(32) Oil Cooler Pipe
(33) Oil Filter Housing Gasket
(34) Oil Cooler Gasket
(35) Oil Cooler Seal
(36) Engine Oil Cooler
(37) Engine Oil Cooler Outlet Pipe
(38) Engine Oil Cooler Outlet Pipe Seal
(39) Crankshaft
(40) Crankshaft Journal Bearings
(41) Crankshaft Flywheel Retainer
(42) Crankshaft Rear Oil Seal Housing and Seal Ring
(43) Crankshaft Position Sensor Bracket
(44) Crankshaft Position Sensor
(45) Flexible Plate (A/T only)
(46) Flexible Plate Retainer (A/T only)
(47) Flywheel
(48) Piston
(49) Piston Rings
(50) Piston Pin Retainer
(51) Piston Pin
(52) Connecting Rod
(53) Connection Rod Bearing
(54) Crankshaft Journal Bearing Cap
(55) Crankshaft Journal Bearing Cap Bolt
(56) Knock Sensor

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Document ID: 2051331 Page 1 of 2

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Component Locator | Document ID: 2051331

Cylinder Head

(1) Cylinder Head

(2) Cylinder Head Gasket
(3) Intake Valve
(4) Intake Valve Seat Ring
(5) Exhaust Valve
(6) Exhaust Valve Seat Ring
(7) Closure Plug
(8) Exhaust Camshaft Seal Ring
(9) Intake Camshaft Seal Ring
(10) Dowel Pin
(11) Valve Guide
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(12) Valve Spring Seat

(13) Valve Spring
(14) Valve Spring Retainer
(15) Valve Key
(16) Valve Tappet
(17) Cylinder Head Bolt
(18) Intake Camshaft Position Sensor
(19) Exhaust Camshaft Position Sensor
(20) Exhaust Camshaft
(21) Intake Camshaft
(22) Exhaust Camshaft Sensor Target Wheel
(23) Intake Camshaft Sensor Target Wheel
(24) Camshaft Cap
(25) Camshaft Front Cap
(26) Cylinder Head Cover Gasket
(27) PCV Pipe
(28) Cylinder Head Cover
(29) Cylinder Head Cover Bolt
(30) Engine Oil Cap
(31) Ignition Coil Cover
(32) Ignition Coil
(33) Ignition Coil Bolt
(34) Spark Plug
(35) Thermostat Housing
(36) Thermostat
(37) Thermostat Housing Gasket
(38) Plug
(39) Seal
(40) Retainer
(41) Engine Coolant Distributor
(42) Engine Coolant Temperature Sensor
(43) Retainer
(44) Engine Coolant Distributor Gasket

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Document ID: 2051337 Page 1 of 2

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Component Locator | Document ID: 2051337

Intake/Exhaust/Timing System

(1) Intake Manifold Assembly

(2) Intake Manifold Gasket
(3) Throttle Body Seal
(4) MAP Sensor
(5) EVAP Canister Purge Solenoid Valve
(6) EVAP Pipe
(7) Intake Manifold Mount
(8) Intake Manifold Mount Bracket
(9) Oxygen Sensor
(10) Exhaust Manifold
(11) Exhaust Manifold Gasket
© 2010 General Motors Corporation. All rights reserved.

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Document ID: 2051337 Page 2 of 2

(12) Exhaust Manifold Shield

(13) Throttle Body
(14) Throttle Body Heater Coolant Inlet Pipe
(15) Throttle Body Heater Coolant Outlet Hose
(16) Fuel Rail Retaining Bolt
(17) Throttle Body Heater Coolant Outlet Pipe
(18) Fuel Injector
(19) Injector Retainer
(20) Fuel Rail
(21) Intake Camshaft Position Actuator Solenoid Valve
(22) Exhaust Camshaft Position Actuator Solenoid Valve
(23) Timing Belt Rear Cover
(24) Intake Camshaft Sprocket
(25) Timing Belt Rear Cover Bolt
(26) Exhaust Camshaft Sprocket
(27) Timing Belt Idler
(28) Timing Belt Tensioner
(29) Crankshaft Sprocket
(30) Timing Belt
(31) Timing Belt Front Upper Cover
(32) Timing Belt Front Center Cover
(33) Timing Belt Sheet Part
(34) Timing Belt Front Lower Cover
(35) Crankshaft Balancer (Pulley)
(36) Washer
(37) Crankshaft Balancer Bolt

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Document ID: 2051129 Page 1 of 2

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Specifications | Document ID: 2051129

Fastener Tightening Specifications

Specification
Application Metric English
Accessory Belt Tensioner Bolt 50 N·m 36.8 lb ft
Alternator B+ Tightening Nut 15 N·m 11 lb ft
Camshaft Adjuster Bolts 65 N·m + 120° + 15° 47.9 lb ft + 120° + 15°
Camshaft Bearing Cap Bolts 8 N·m 70.8 lb in
Camshaft Sprocket Bolt Cap 50 N·m 36.8 lb ft
Camshaft Sprocket Bolts 65 N·m 47.9 lb ft
Closure Bolt 15 N·m 11 lb ft
Connecting-rod Caps Bolts 35 N·m + 45° +15° 25.8 lb ft +45° +15°
Coolant Pipe To Coolant Distributor Case
8 N·m 70.8 lb in
Bolts
Crankshaft Cap Bolts 50 N·m + 50° 36.8 lb ft + 50°
Crankshaft Pulley Bolt 25 N·m 18.4 lb ft
25 N·m + 90° + 90° + 18.4 lb ft + 90° + 90° +
Cylinder Head Bolts
45° 45°
Cylinder Head Cover Bolts 8 N·m 70.8 lb in
Engine Front Cover Assembly Bolts 20 N·m 14.7 lb ft
Engine Mount Bolts and Nuts 55 N·m 40.5 lb ft
Engine Mount Bracket Bolt 65 N·m 47.9 lb ft
Exhaust Manifold Lower Bracket Bolts 20 N·m 14.7 lb ft
Exhaust Manifold Nuts 20 N·m 14.7 lb ft
Flywheel Flexible Plate Bolts 35 N·m+ 30° + 15° 25.8 lb ft + 30° + 15°
Ground Tightening Nut 12 N·m 8.8 lb ft
Heat Exchanger Bolts 8 N·m 70.8 lb in
Heat Shields Bolts 8 N·m 70.8 lb in
Ignition Coil Bolt 8 N·m 70.8 lb in
Indicator Tube Tightening Bolt 10 N·m 7.3 lb ft
Intake Manifold Bolts 20 N·m 14.7 lb ft
Intake Manifold Lower Bracket Bolt 8 N·m 70.8 lb in
Oil Cooler Tightening Bolts 25 N·m 18.4 lb ft
Oil Pan Baffle Bolts 10 N·m 7.3 lb ft
Oil Pan Bolts 14 N·m 10.3 lb ft
Oil Pan-to-Transmission Bolts 40 N·m 29.5 lb ft
Reaction Rod-to-Bracket Bolt and Nut 80 N·m 59 lb ft
Reaction Rod-to-Crossmember Bolts 55 N·m 40.5 lb ft
Spark Plug 25 N·m 18.4 lb ft
© 2010 General Motors Corporation. All rights reserved.

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Document ID: 2051129 Page 2 of 2

Starter Solenoid B+ Tightening Nut 10.5 N·m 7.7 lb ft

Starter Solenoid Ground Tightening Nut 38 N·m 28 lb ft
Timing Belt Idler Bolt 50 N·m 36.8 lb ft
Timing Belt Lower Cover Bolts 6 N·m 53.1 lb in
Timing Belt Rear Cover Bolts 6 N·m 53.1 lb in
Timing Belt Tensioner Bolt 55 N·m 40.6 lb ft
Timing Belt Upper Cover Bolts 4 N·m 35.4 lb in
Transmission Tightening Bolt 60 N·m 44.2 lb ft

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Document ID: 2054190 Page 1 of 3

2009 Chevrolet Aveo | Aveo, Wave, G3, Barina (VIN S/T) Service Manual | Engine | Engine Mechanical - 1.4L (LDT) |
Specifications | Document ID: 2054190

Engine Mechanical Specifications

Specification
Application Metric English
Camshaft
l Lift - Intake 46.3 mm 1.8228 in
l Lift - Exhaust 45.3 mm 1.7835 in
l Bending 0.04 mm 0.0016 in
l Journal Outer Diameter : No. 1 27.939-27.960 mm 1.1000-1.1008 in
l Journal Outer Diameter : No. 2 27.939-27.960 mm 1.1000-1.1008 in
l Journal Outer Diameter : No. 3 27.939-27.960 mm 1.1000-1.1008 in
l Journal Outer Diameter : No. 4 27.939-27.960 mm 1.1000-1.1008 in
l Journal Outer Diameter : No. 5 27.939-27.960 mm 1.1000-1.1008 in
l Trust Clearance (End Play) 0.13-0.215 mm 0.0051-0.0085 in
Connecting Rod
l Thrust Clearance - End Play 0.07-0.242 mm 0.0028-0.0095 in
l Width 21.839-21.890 mm 0.8598-0.8618 in
l Diameter - Piston Pin 19.012-19.020 mm 0.7485-0.7488 in
l Diameter - Crankshaft 46.000-46.012 mm 1.8110-1.8115 in
l Bending 0.04 mm 0.0016 in
l Twist 0.016 mm 0.0006 in
l Journal Bearing Oil Clearance 0.019-0.063 mm 0.0007-0.0025 in
Crankshaft
l Thrust Clearance - End Play 0.1-0.202 mm 0.0039-0.0080 in
Main: 54.980-54.997 mm Main: 2.1646-2.1652 in
l Journal Outer Diameter
Pin: 42.971-42.987 mm Pin: 1.6918-1.6924 in
Main: 0.0155-0.047 mm Main: 0.0006-0.0019 in
l Journal Bearing Oil Clearance
Pin: 0.019-0.067 mm Pin: 0.0007-0.0026 in
l Bending 0.03 mm 0.0012 in
Cylinder Block
l Diameter 77.9 mm 3.067 in
l Deck Surface Flatness 0.025/65 mm 0.0010/2.5591 in
l Cylindricity 0.0065 mm 0.0003 in
Cylinder Head
l Journal Inner Diameter: No. 1 28.000-28.021 mm 1.1024-1.1032 in
l Journal Inner Diameter: No. 2 28.000-28.021 mm 1.1024-1.1032 in
l Journal Inner Diameter: No. 3 28.000-28.021 mm 1.1024-1.1032 in
l Journal Inner Diameter: No.General
© 2010 4 28.000-28.021
Motors mm
Corporation. All 1.1024-1.1032 in
rights reserved.

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Document ID: 2054190 Page 2 of 3

l Journal Inner Diameter: No. 5 28.000-28.021 mm 1.1024-1.1032 in

l Journal Clearance 0.04-0.082 mm 0.0016-0.0032 in
l Height 135.55 mm 5.3366 in
l Surface Flatness Deformation 0.0008/1.9685-
0.02/50-0.025/150 mm
Cover/Block 0.0010/5.9055 in
l Manifolds Surface Deformation 0.05 mm 0.002 in
Valve
l Deviation 0.3 mm 0.0118 in
l Seat Inner Diameter - Intake 30.7 mm 1.2087 in
l Seat Inner Diameter - Exhaust 27.2 mm 1.0709 in
l Face Diameter - Intake 31.02 ±0.1 mm 1.2173-1.2252 in
l Face Diameter - Exhaust 27.5 ±0.1 mm 1.0787-1.0866 in
l Guide Inner Diameter - Intake 5.0-5.016 mm 0.1969-0.1975 in
l Guide Inner Diameter -
5.0-5.016 mm 0.1969-0.1975 in
Exhaust
l Valve Stem Outer Diameter -
4.965-4.980 mm 0.1955-0.1961 in
Intake
l Valve Stem Outer Diameter -
4.950-4.965 mm 0.1945-0.1955 in
Exhaust
l Valve Length - Intake 117.10-117.30 mm 4.6102-4.6181 in
l Valve Length - Exhaust 116.16-116.36 4.5732-4.5811 in
l Valve Spring - Free Length 41.6 mm 1.6378 in
0.0083-0.0114 in
0.21-0.29 mm (Nominal
l Clearance - Intake
0.25 mm)
Nominal 0.0098 in)
0.0106-0.0138 in
0.27-0.35 mm (Nominal
l Clearance - Exhaust
0.25 mm)
Nominal 0.0098 in)
Oil Pump Axial Clearance 0.02-0.058 mm 0.0008-0.0023 in
Piston
l Piston 77.9 mm 3.1102 in
l Diameter 0.030-0.060 mm 0.0012-0.0024 in
Piston Ring
l Groove Clearance - Top Ring 0.04-0.08 mm 0.0016-0.0031 in
l Groove Clearance - 2nd Ring 0.03-0.07 mm 0.0012-0.0028 in
l Groove Clearance - Oil Ring 0.06-0.15 mm 0.0024-0.0059 in
l End Gap - Top Ring 0.15-0.30 mm 0.0059-0.0118 in
l End Gap - 2nd Ring 0.30-0.50 mm 0.0118-0.0197 in
l End Gap - Oil Ring 0.20-0.70 mm 0.0079-0.0276 in
Piston Pin
l Diameter 19.000-19.005 mm 0.7480-0.7482 in
l Length 49.84 mm 1.9268 in

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Document ID: 2054190 Page 3 of 3

l Clearance 0.007-0.020 mm 0.0003-0.0008 in

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