GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Aveo 🢒 Engine 🢒 Engine Mechanical - 1.6L (LXV) 🢒 Piston, Connecting Rod, and Bearing Replacement

Removal Procedure

    Object Number: 2049696 Size: SH
  1. Remove the engine assembly. Refer to Engine Replacement.
  2. Install the engine assembly to the stand.
  3. Remove the ignition coil. Refer to Ignition Coil Replacement.

    4. Object Number: 2049365 Size: SH
  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. Object Number: 2049375 Size: SH
  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 intake and exhaust sprockets. Refer to Camshaft Intake Sprocket with Actuator Replacement and Camshaft Exhaust Sprocket with Actuator Replacement.

    12. Object Number: 2049388 Size: SH
  12. Remove the camshaft rear cover (1).

    13. Object Number: 2049036 Size: SH
  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.

    16. Object Number: 2049555 Size: SH
  16. Remove the engine coolant distributor (1).

    17. Object Number: 2049556 Size: SH
  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 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.

    26. Object Number: 2049768 Size: SH

    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. Object Number: 2049769 Size: SH
  28. Separate the piston pin (5) from the piston.
  29. Separate the piston ring (1) from the piston (3) using the expansion tool.

Installation Procedure

    Object Number: 2049769 Size: SH

    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 (1) from the piston (3) using the expansion tool.

    3. 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 (1.6L only - EN-49153).

    4. Caution: Refer to Fastener Caution in the Preface section.

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

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

    12. Object Number: 2049556 Size: SH

    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).

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


    Object Number: 2049555 Size: SH
  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. Object Number: 2049388 Size: SH
  18. Install the camshaft rear cover (1).
  19. Install the camshaft intake and exhaust sprockets. Refer to Camshaft Intake Sprocket with Actuator Replacement and Camshaft Exhaust Sprocket with Actuator Replacement.
  20. Install timing belt system and adjust the timing. Refer to Timing Belt Replacement.
  21. Install the accessory belt. Refer to Drive Belt Replacement.
  22. Install the power steering pump and bracket. Refer to Power Steering Pump Replacement.

    23. Object Number: 2049365 Size: SH
  23. Install the cylinder head cover (1).
  24. Install the cylinder head cover bolts.
  25. Install the PCV hose from the cylinder head cover.
  26. Attach the PCV clips from the PCV hose.
  27. Install the ignition coil. Refer to Ignition Coil Replacement.