Aveo 2004-2005

Cylinder Head

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Removal & Installation



  1. Relieve the fuel system pressure.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    Engine oil
     
    Electronic Control Module (ECM) ground terminal from intake manifold
     
    Air cleaner housing
     
    Throttle cable
     
    Radiator hoses
     
    Intake manifold pressure sensor
     
    Intake Air Temperature (IAT) sensor
     
    Coolant temperature sensor
     
    Fuel feed line from fuel rail
     
    Intake manifold support bracket
     
    Intake manifold vacuum hoses
     
    Spark plug wires
     
    Direct Ignition Coil (DIS) and bracket
     
    Accessory drive belt
     
    Right front tire
     
    Right wheelwell splash shield
     
    Upper front timing cover
     
    Align the camshaft gear timing marks
     
    Crankshaft pulley
     
    Lower front timing belt cover
     
    Slightly loosen the water pump bolts
     
    Rotate the water pump counterclockwise to relieve the timing belt tension
     
    Remove the timing belt
     

  4.  
  5. Support the engine with a lifting device, then remove the engine mounting bracket
  6.  
  7. Remove the valve cover.
  8.  
  9. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt and gear.
  10.  
  11. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt and gear.
  12.  
  13. Remove or disconnect the following:

    Timing belt tensioner
     
    Idler pulley
     
    Right engine mount
     
    Rear timing belt cover
     
    Intake manifold
     
    Exhaust pipe
     
    Exhaust manifold
     

  14.  
  15. Remove the cylinder head bolts gradually in the sequence shown and remove the cylinder head. See Figure 3.

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-1.6L engine

  16.  

To install:

  1. The cylinder head should be cleaned and inspected prior to installation.
  2.  
  3. Lightly oil all bolt and stud bolt threads before installation.
  4.  
  5. Clean all gasket mating surfaces thoroughly.
  6.  
  7. Install a new head gasket on the cylinder block.
    WARNING
    Always use new cylinder head bolts when installing the cylinder head or damage to the engine may occur.

  8.  
  9. Install the cylinder head on the cylinder block.
  10.  
  11. Tighten the cylinder head bolts in reverse of the removal sequence. Tighten the 2004 cylinder head bolts to 18 ft. lbs. (25 Nm). Tighten an additional 70°, plus 70°, plus another 50°. Tighten 2005 bolts to 18 ft. lbs. (25 Nm). Tighten an additional 60°, plus 60°, plus another 10°.
  12.  
  13. Install the right engine mount. Tighten the engine mount attaching bolts to 22 ft. lbs. (30 Nm).
  14.  
  15. Install or connect the following:

    Intake manifold
     
    Intake manifold support bracket. Tighten the bolts to 18 ft. lbs. (25 Nm).
     
    Throttle cable
     
    Surge tank coolant hose
     
    Heater hose to cylinder head
     
    Fuel feed line at the fuel rail
     
    All vacuum hoses
     
    Exhaust manifold
     
    Rear timing belt cover
     
    Timing belt tensioner. Tighten the bolts to 18 ft. lbs. (25 Nm).
     
    Idler pulley. Tighten the bolts to 18 ft. lbs. (25 Nm).
     
    Intake and exhaust camshaft gears. Tighten the bolts to 49 ft. lbs. (68 Nm).
     

  16.  
  17. Apply a small amount of gasket sealant to the corners of the front camshaft caps and the top of the rear camshaft cover-to-cylinder head seal.
  18.  
  19. Install the valve cover using a new gasket
  20.  
  21. Align the timing marks on the camshaft gears.
  22.  
  23. Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover.
  24.  
  25. Install the timing belt and rotate the water pump clockwise to apply tension to the timing belt.
  26.  
  27. Tighten the water pump bolts to 89 inch lbs. (10 Nm).
  28.  
  29. Adjust the timing belt tension.
  30.  
  31. Install or connect the following:

    Spark plug wires
     
    Upper and lower timing belt covers Crankshaft pulley. Tighten the bolt to 70 ft. lbs. (95 Nm), plus an additional 30°, then another 15°.
     
    Accessory drive belt
     
    Air cleaner housing
     
    Radiator hoses
     
    Front splash shield
     
    Right front wheel
     
    Coolant temperature sensor
     
    Fuel feed line from fuel rail
     
    IAT sensor
     
    Intake manifold pressure sensor
     
    DIS coil connector
     
    Fuel injector connectors
     
    ECM ground terminal
     
    Negative battery cable
     

  32.  
  33. Fill the engine with oil and coolant.
  34.  
  35. Start the engine and check for leaks.
  36.  

  1. Properly relieve the fuel system pressure.
  2.  
  3. Drain the cooling system.
  4.  
  5. Disconnect the breather tube from the valve cover.
  6.  
  7. Disconnect the intake air temperature (IAT) sensor connector.
  8.  
  9. Disconnect the air intake assembly from the throttle body.
  10.  
  11. Remove the air filter housing.
  12.  
  13. Disconnect the A/C pressure (ACP) transducer connector.
  14.  
  15. Disconnect the idle air control (IAC) valve connector and throttle position (TP) sensor connector.
  16.  
  17. Disconnect the throttle cable from the throttle body and the intake manifold.
  18.  
  19. Disconnect the engine coolant hose at the throttle body.
  20.  
  21. Disconnect the manifold absolute pressure (MAP) sensor connector.
  22.  
  23. Disconnect the brake booster vacuum hose.
  24.  
  25. Disconnect the variable geometry induction solenoid (VGIS) connector.
  26.  
  27. Disconnect the VGIS vacuum tank hose.
  28.  
  29. Remove the engine appearance cover bolts and the cover.
  30.  
  31. Disconnect the breather tube from the valve cover.
  32.  
  33. Disconnect the crankcase ventilation tube from the valve cover.
  34.  
  35. Disconnect the camshaft position (CMP) sensor connector.
  36.  
  37. Disconnect the ignition wires from the spark plugs.
  38.  
  39. Disconnect the fuel injector harness connectors.
  40.  
  41. Disconnect the fuel line.
  42.  
  43. Remove the bracket nut from the power steering pressure pipe and remove the power steering pressure pipe.
  44.  
  45. Remove the accessory drive bolt.
  46.  
  47. Disconnect the exhaust gas recirculation (EGR) valve connector.
  48.  
  49. Disconnect the ignition coil connector from the electronic ignition (EI) system.
  50.  
  51. Disconnect the front heated oxygen sensor (HO2S) connector.
  52.  
  53. Raise and safely support the vehicle.
  54.  
  55. Remove the right front wheel.
  56.  
  57. Remove the engine under-cover.
  58.  
  59. Remove the canister purge solenoid valve at the intake manifold support bracket.
  60.  
  61. Remove the bracket bolts from the upper and lower intake manifold support.
  62.  
  63. Disconnect the connector from the engine coolant temperature (ECT) sensor.
  64.  
  65. Remove the exhaust manifold heat shield.
  66.  
  67. Remove the catalytic converter.
  68.  
  69. Loosen the hose clamp on the upper radiator hose at the thermostat housing and disconnect the upper radiator hose.
  70.  
  71. Remove the cover from the upper front timing belt.
  72.  
  73. Remove the crankshaft damper.
  74.  
  75. Remove the cover from the lower front timing belt.
  76.  
  77. Align the camshaft gear timing marks.
  78.  
  79. Slightly loosen the water pump retaining bolts.
  80.  
  81. Rotate the coolant pump counterclockwise using Special Tool J 42492-A to relieve the timing belt tension.
  82.  
  83. Remove the timing belt. For additional information, refer to the following section, -Timing Belt & Sprockets, Removal & Installation.-
  84.  
  85. Remove the valve cover.
    WARNING
    Use extreme care when installing the camshaft not to nick, scratch, or damage the camshaft lobes or bearing surfaces.

  86.  
  87. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt and remove the intake camshaft gear.
  88.  
  89. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt and remove the exhaust camshaft gear.
  90.  
  91. Remove the bolts from the timing belt automatic tensioner and remove the timing belt automatic tensioner.
  92.  
  93. Remove the camshaft position (CMP) sensor.
  94.  
  95. Remove the timing belt idler pulley.
  96.  
  97. Remove the rear timing belt cover.
  98.  
  99. Disconnect the heater outlet hose from the coolant pipe.
  100.  
  101. Loosen all of the cylinder head bolts in several steps using the sequence shown.

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-1.6L engine

  102.  
  103. Remove and discard the cylinder head bolts.
  104.  
  105. Remove the cylinder head with the intake manifold and the exhaust manifold attached.
    WARNING
    Use extreme care when removing the cylinder head to prevent any engine oil , dirt, or coolant from entering the engine. Damage to the engine could result.

  106.  
  107. Remove the cylinder head gasket.
  108.  
  109. Remove the intake and exhaust manifold if necessary.
  110.  

To install:

  1. Clean the sealing surfaces of the cylinder head and inspect for cracks and warpage. Inspect the gasket and mating surfaces for leaks, corrosion and blow-by.
  2.  
  3. Assembly the intake and exhaust manifold to the cylinder head, if removed.
  4.  
  5. Install the cylinder head gasket.
  6.  
  7. Install the cylinder head with the intake manifold and the exhaust manifold attached.
  8.  
  9. Install new cylinder head bolts, and tighten the bolts as follows:
    1. Tighten the bolts in the sequence shown to 18 ft. lbs. (25 Nm).
    2.  
    3. Tighten the bolts in the sequence shown an additional 60 degrees.
    4.  
    5. Tighten the bolts in the sequence shown an additional 60 degrees for a second time.
    6.  
    7. Tighten the bolts in the sequence shown an additional 60 degrees a third time.
    8.  
    9. Tighten the bolts in the sequence shown an additional 10 degrees.

      Click image to see an enlarged view

      Fig. Cylinder head bolt torque sequence-1.6L engine

    10.  

  10.  
  11. Connect the heater outlet hose to the coolant pipe.
  12.  
  13. Install the rear timing belt cover and tighten the bolts to 89 inch lbs. (10 Nm).
  14.  
  15. Install the CMP sensor. Tighten the bolts to 106 inch lbs. (12 Nm).
  16.  
  17. Install the timing belt idler pulley and tighten the bolt to 30 ft. lbs. (40 Nm).
  18.  
  19. Install the timing belt automatic tensioner. Tighten the bolts to 18 ft. lbs. (25 Nm).
  20.  
  21. Install the intake camshaft gear. While holding the intake camshaft firmly in place, tighten the intake camshaft gear bolt to 49 ft. lbs. (67.5 Nm).
  22.  
  23. Install the exhaust camshaft gear. While holding the exhaust camshaft firmly in place, tighten the exhaust camshaft gear bolt to 49 ft. lbs. (67.5 Nm).
  24.  
  25. Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the seal between the rear valve cover and the cylinder head.
  26.  
  27. Install the valve cover and the valve cover gasket. Tighten the bolts to 89 inch lbs. (10 Nm).
    NOTE
    Ensure that the exhaust camshaft gear dowel pin is approximately in the 11 o'clock position.

  28.  
  29. Align the timing marks on the camshaft gear.
  30.  
  31. Align the mark on the crankshaft gear to the notch at the bottom of the rear timing belt cover.
    WARNING
    Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt.

  32.  
  33. Install the timing belt.
  34.  
  35. Rotate the water pump clockwise using Special Tool J 42492-A to apply tension to the timing belt. Tighten the retaining bolt to 89 inch lbs. (10 Nm).
  36.  
  37. Install the retaining bolts that secure the engine mount to the engine mount bracket. Tighten to 44 ft. lbs. (60 Nm).
  38.  
  39. Install the lower front timing belt cover and tighten the bolts to 89 inch lbs. (10 Nm).
  40.  
  41. Install the crankshaft pulley. For additional information, refer to the following section, -Crankshaft Damper, Removal & Installation.-
  42.  
  43. Install the upper front timing belt cover and tighten the bolts to 89 inch lbs. (10 Nm).
  44.  
  45. Connect the coolant hoses to the thermostat housing.
  46.  
  47. Install the catalytic converter.
  48.  
  49. Install the exhaust manifold heat shield.
  50.  
  51. Connect the ECT sensor connector.
  52.  
  53. Install the upper bolts to the intake manifold support bracket and tighten to 18 ft. lbs. (25 Nm).
  54.  
  55. Install the canister purge solenoid valve at the intake manifold support bracket.
  56.  
  57. Install the engine under-cover.
  58.  
  59. Connect the front HO 2 S connector.
  60.  
  61. Connect the EI system ignition coil connector.
  62.  
  63. Connect the EGR valve connector.
    WARNING
    Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt.

  64.  
  65. Install the accessory drive belt. Tighten the alternator bracket retaining nut to 18 ft. lbs. (25 Nm).
  66.  
  67. Reconnect the following:

    The fuel line at the fuel rail
     
    Fuel injector harness connectors
     
    Ignition wires to the spark plugs
     
    CMP sensor connector
     
    Crankcase ventilation tube to the valve cover
     
    Breather tube to the valve cover
     

  68.  
  69. Install the engine cover.
  70.  
  71. Reconnect the following:

    VGIS vacuum tank hose
     
    VGIS connector
     
    Brake booster vacuum hose
     
    MAP sensor connector
     
    Coolant hoses to the throttle body
     
    Throttle cable to the throttle body and the intake manifold
     
    TP sensor connector
     
    IAC valve connector
     
    A/C pressure transducer connector
     

  72.  
  73. Install the air intake assembly.
  74.  
  75. Connect the IAT sensor connector.
  76.  
  77. Connect the breather tube to the valve cover.
  78.  
  79. Connect the negative battery cable.
  80.  
  81. Refill the engine cooling system to the correct level.
  82.  
  83. Start the engine and check for leaks.
  84.  

 
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