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