Service Manual2007 Aveo, Epica, Nubira/Lacetti DIESEL ENGINE (SOHC ENGINE MECHANICAL)

SECTION 1B2

DIESEL ENGINE (SOHC ENGINE MECHANICAL)

SOHC ENGINE MECH. - SOHC ENGINE UNIT (111)

NO.	OPERATION DESCRIPTION	OPERATION CODE	N	L2
NO.	OPERATION DESCRIPTION	OPERATION CODE	2.0 DSL	2.0 DSL
1	. ENGINE ASSEMBLY (M/T) - OVERHAUL	1110100	13.0	13.0
	INC : R & I Engine ass'y, Flywheel, Intake and exhaust manifold ass'y, Timing belt, Engine adjust.	.	.	.
	. ENGINE ASSEMBLY (A/T) - OVERHAUL	1110300	12.8	12.8
	INC : R & I Engine ass'y, Flywheel, Intake and exhaust manifold ass'y, Timing belt, Engine adjust.	.	.	.
2	. ENGINE ASSEMBLY (M/T) - REPLACE	1110800	9.3	9.3
	INC : R & I Engine ass'y, Intake and exhaust manifold ass'y, Engine adjust.	.	.	.
	. ENGINE ASSEMBLY (A/T) - REPLACE	1110900	9.2	9.2
	INC : R & I Engine ass'y, Intake and exhaust manifold ass'y, Engine adjust.	.	.	.
.	. ENGINE OIL - REPLACE	1112200	0.5	0.5

S1 : T200 (AVEO / Aveo, Epica, Nubira/Lacetti / BARINA / SWIFT+ / WAVE), S2 : T250(AVEO / BARINA / G3 / WAVE) N : NUBIRA / LACETTI / FORENZA / OPTRA / VIVA, L1 : EVANDA / EPICA / VERONA, L2 : EPICA / TOSCA

SOHC ENGINE MECH. - BELT SYSTEM (113)

NO.	OPERATION DESCRIPTION	OPERATION CODE	N	L2
NO.	OPERATION DESCRIPTION	OPERATION CODE	2.0 DSL	2.0 DSL
1	. BELT, ACCESSORY - REPLACE	1132200	0.5	0.5
2	. IDLE, ACCESSORY BELT - REPLACE	1132300	0.6	0.6
3	. AUTO TENSIONER, ACCESSORY BELT - REPLACE	1132400	0.6	0.6

SOHC ENGINE MECH. - ENGINE BLOCK (121)

NO.	OPERATION DESCRIPTION	OPERATION CODE	N	L2
NO.	OPERATION DESCRIPTION	OPERATION CODE	2.0 DSL	2.0 DSL
1	. OIL LEVEL INDICATOR - REPLACE	1210200	0.2	0.2
2	. TUBE, OIL LEVEL INDICATOR - REPLACE	1210300	0.3	0.3
3	. PLUG, EXPANSION - REPLACE	1210700	0.4	0.4
3	NOTE : Add appropriate labor MODEL(s) for removal if necessary components to gain access to plug to regular labor hours column	.	.	.
4	. PLUG, OIL GALLERY - REPLACE	1210900	4.0	4.0
4	INC : R & I Flywheel	.	.	.
5	. BLOCK, CYLINDER - REPLACE	1211100	13.7	13.7
5	INC : Overhaul Engine ass'y, R & I Crankshaft, Piston	.	.	.

SOHC ENGINE MECH. - CRANKSHAFT & PISTON (122)

NO.	OPERATION DESCRIPTION	OPERATION CODE	N	L2
NO.	OPERATION DESCRIPTION	OPERATION CODE	2.0 DSL	2.0 DSL
1	. SEAL(S), CRANKSHAFT REAR MAIN (AUTO TRANSAXLE) - REPLACE	1220200	4.4	4.4
	. SEAL(S), CRANKSHAFT REAR MAIN (MANUAL TRANSAXLE) - REPLACE	1220400	4.0	4.0
	INC : R & I Flywheel	.	.	.
2	. BEARING, CRANKSHAFT MAIN (ONE) - REPLACE	1220600	13.1	13.1
	INC : R & I Engine ass'y, Flywheel, Crankshaft balance unit, Engine adjust.	.	.	.
	A - Replace each additional	122060A	0.1	0.1
3	. BEARING, CONNECTING ROD (ONE) - REPLACE	1220800	6.0	6.0
	INC : R & I Cylinder head, Crankshaft balance unit	.	.	.
	A - Replace each additional	122080A	0.2	0.2
	B - Replace all	122080B	0.4	0.4
4	. CRANKSHAFT (M/T) - REPLACE	1221100	13.1	13.1
	INC : R & I Engine ass'y, Cylinder head ass'y, Flywheel, Crankshaft balance unit, Engine adjust.	.	.	.
	D - Replace one piston rings	122110D	0.1	0.1
	E - Replace all piston rings	122110E	0.4	0.4
	F - Replace one connecting rod	122110F	0.1	0.1
	G - Replace all connecting rods	122110G	0.4	0.4
	H - Replace one piston	122110H	0.1	0.1
	J - Replace all pistons	122110J	0.4	0.4
	. CRANKSHAFT (A/T) - REPLACE	1221200	12.9	12.9
	INC : R & I Engine ass'y, Cylinder head ass'y, Flywheel, Crankshaft balance unit, Engine adjust.	.	.	.
	D - Replace one piston rings	122120D	0.1	0.1
	E - Replace all piston rings	122120E	0.4	0.4
	F - Replace one connecting rod	122120F	0.1	0.1
	G - Replace all connecting rods	122120G	0.4	0.4
	H - Replace one piston	122120H	0.1	0.1
	J - Replace all pistons	122120J	0.4	0.4

SOHC ENGINE MECH. - CRANKSHAFT & PISTON (122)

NO.	OPERATION DESCRIPTION	OPERATION CODE	N	L2
NO.	OPERATION DESCRIPTION	OPERATION CODE	2.0 DSL	2.0 DSL
5	. CRANKSHAFT TARGET WHEEL - REPLACE	1221300	13.0	13.0
5	A - With manual transaxle	122130A	0.3	0.3
6	. UNIT, CRANKSHAFT BALANCE - REPLACE	1221400	1.3	1.3
7	. PISTON, ROD AND/OR RINGS (ONE) - REPLACE	1221500	6.1	6.1
	INC : R & I Cylinder head, Crankshaft balance unit, Engine adjust.	.	.	.
	C - Replace each additional	122150C	0.2	0.2
	D - Replace all	122150D	0.5	0.5
8	. FLYWHEEL (MANUAL T/M) - REPLACE	1221700	3.9	3.9
8	INC : R & I Transaxle ass'y, Clutch cover ass'y	.	.	.
9	. FLYWHEEL (AUTO T/M) - REPLACE	1221900	4.4	4.4
10	. CASE, CRANK LOWER - REPLACE	1222900	1.9	1.9

SOHC ENGINE MECH. - OIL PAN & PUMP (123)

NO.	OPERATION DESCRIPTION	OPERATION CODE	N	L2
NO.	OPERATION DESCRIPTION	OPERATION CODE	2.0 DSL	2.0 DSL
1	. FILTER, OIL - REPLACE	1231100	0.4	0.4
2	. CAP AND/OR SEAL, OIL FILTER HOUSING - REPLACE	1231210	0.4	0.4
3	. PLUG AND/OR GASKET, OIL PAN DRAIN - REPLACE	1231300	0.3	0.3
4	. HOUSING AND/OR SEAL, OIL FILTER - REPLACE	1231400	0.4	0.4
5	. PAN AND/OR GASKET, OIL - REPLACE	1231500	1.2	1.2
5	INC : Front exhaust pipe ass'y, Drive axle intermshaft	.	.	.
6	. COOLER AND/OR SEAL, ENGINE OIL - REPLACE	1231600	0.5	0.5
7	. PUMP, ENGINE OIL - REPLACE	1231700	2.7	2.7
7	INC : R & I Timing belt, Oil pan, Engine adjust	.	.	.
8	. SENSOR, FUEL SWITCH & ENGINE OIL PRESSURE GAGE - REPLACE	1231900	0.4	0.4
9	. TUBE, OIL SUCTION - REPLACE	1232100	1.2	1.2
10	. OIL SEAL, CRANKSHAFT (FRONT) - REPLACE	1232300	1.2	1.2
11	. VALVE, OIL PRESSURE RELIEF - REPLACE	1232700	0.4	0.4
12	. GASKET, OIL PUMP - REPLACE	1232900	2.6	2.6
13	. PIPE AND/OR GASKET, INTERNAL PCV - REPLACE	1233100	0.7	0.7
14	. VALVE, PCV - REPLACE	1233200	0.3	0.3
15	. HOSE, OIL VENTILATION - REPLACE	1233700	0.4	0.4

SOHC ENGINE MECH. - CYLINDER HEAD (131)

NO.	OPERATION DESCRIPTION	OPERATION CODE	N	L2
NO.	OPERATION DESCRIPTION	OPERATION CODE	2.0 DSL	2.0 DSL
1	. FOLLOWER, CAM (ONE CYLINDER) - REPLACE	1312100	5.2	5.2
	A - Cam follower (Each additional)	131210A	0.1	0.1
	B - Cam followers (All)	131210B	0.2	0.2
2	. GASKET, CYLINDER HEAD - REPLACE	1312300	3.8	3.8
2	INC : R & I Cylinder head ass'y, Engine adjust.	.	.	.
3	. HEAD, CYLINDER - REPLACE	1312500	4.8	4.8
	INC : R & I Intake & exhaust manifold, Engine adjust.	.	.	.
	. HEAD, CYLINDER - OVERHAUL	1312600	6.7	6.7
	INC : R & I Cylinder head ass'y, Intake & exhaust manifold, Valves, Engine adjust.	.	.	.
4	. VALVE (ONE CYLINDER) - REPLACE	1312700	5.5	5.5
	INC : R & I Cylinder head ass'y, Intake & exhaust manifold, Camshaft, Valves recondition, Engine adjust.	.	.	.
	C - One cylinder valve (Each additional)	131270C	0.4	0.4
	D - Valves (All)	131270D	1.2	1.2
5	. SPRING CAP AND/OR SEAL, VALVE (ONE CYLINDER) - REPLACE	1312900	5.5	5.5
	INC : R & I Camshaft, Engine adjust.	.	.	.
	C - One cylinder valve spring (Each additional)	131290C	0.4	0.4
	D - Springs (All)	131290D	1.2	1.2
6	. LIFTER, CAM FOLLOWER (ONE CYLINDER) - REPLACE	1313500	5.2	5.2
	INC : R & I Cylinder head ass'y, camshaft, Engine adjust.	.	.	.
	C - One cylinder follower lifter (Each additional)	131350C	0.1	0.1
	D - Lifters (All)	131350D	0.2	0.2
7	. BRIDGE AND/OR CAP, CAM FOLLOWER LIFTER (ONE CYLINDER) - REPLACE	1313600	5.2	5.2
	INC : R & I Cylinder head ass'y, camshaft, Engine adjust.	.	.	.
	C - One cylinder cam follower bridge (Each additional)	131360C	0.1	0.1
	D - Bridges (All)	131360D	0.2	0.2
8	. SENSOR, ENGINE COOLANT TEMP - REPLACE	1314100	0.3	0.3

SOHC ENGINE MECH. - CAM SUPPORT & SHAFT (132)

NO.	OPERATION DESCRIPTION	OPERATION CODE	N	L2
NO.	OPERATION DESCRIPTION	OPERATION CODE	2.0 DSL	2.0 DSL
1	. COVER AND/OR GASKET, CAMSHAFT HOUSING (ONE PIECE) - REPLACE	1322100	1.5	1.5
2	. CAMSHAFT, EXHAUST/INTAKE - REPLACE	1322400	2.9	2.9
2	INC : R & I Camshaft gear, Ignition timing adjust.	.	.	.
3	. CAP, OIL FILLER - REPLACE	1322700	0.2	0.2
4	. COVER, CAMSHAFT UPPER - REPLACE	1322800	0.2	0.2
5	. OIL SEAL, CAMSHAFT - REPLACE	1323000	1.4	1.4
6	. PLUG, CAMSHAFT COVER OPENING - REPLACE	1323100	0.2	0.2
	A - Replace each additional	132310A	0.1	0.1
	B - Replace All	132310B	0.1	0.1
7	. OIL SEAL, CAMSHAFT COVER - REPLACE	1323200	0.4	0.4
	A - Replace each additional	132320A	0.2	0.2
	B - Replace All	132320B	0.4	0.4

SOHC ENGINE MECH. - TIMING COVER (133)

NO.	OPERATION DESCRIPTION	OPERATION CODE	N	L2
NO.	OPERATION DESCRIPTION	OPERATION CODE	2.0 DSL	2.0 DSL
1	. PULLEY, CRANKSHAFT - REPLACE	1332100	0.5	0.5
2	. COVER TIMING BELT REAR - REPLACE	1332300	2.0	2.0
3	. BELT, TIMING - REPLACE	1332500	1.8	1.8
3	. BELT, TIMING - ADJUST	1332700	1.8	1.8
4	. TENSIONER, TIMING BELT - REPLACE	1332900	1.9	1.9
4	INC : R & I Timing belt, Engine adjust.	.	.	.
5	. SPROCKET, CRANKSHAFT TIMING - REPLACE	1333100	1.9	1.9
5	INC : R & I Timing belt, Engine adjust.	.	.	.
6	. SPROCKET, CAMSHAFT TIMING - REPLACE	1333300	1.9	1.9
6	INC : R & I Timing belt, Engine adjust.	.	.	.
7	. PUMP AND/OR GASKET, COOLANT - REPLACE	1333500	2.2	2.2
8	. SENSOR, CRANKSHAFT POSITION - REPLACE	1333700	0.3	0.3
9	. SENSOR, CAMSHAFT POSITION - REPLACE	1333800	0.3	0.3
10	. PULLEY, IDLER - REPLACE	1333900	1.9	1.9
11	. COVER, CAMSHAFT DRIVE BELT (UPPER) - REPLACE	1334100	0.3	0.3
12	. COVER, CAMSHAFT DRIVE BELT (LOWER) - REPLACE	1334200	0.7	0.7

SOHC ENGINE MECH. - ENGINE & TRANSAXLE MOUNT (138)

NO.	OPERATION DESCRIPTION	OPERATION CODE	N	L2
NO.	OPERATION DESCRIPTION	OPERATION CODE	2.0 DSL	2.0 DSL
1	. MOUNT, ENGINE (RH-FRONT) - REPLACE	1380100	0.8	0.8
2	. BRACKET, ENGINE MOUNT (RH-FRONT) - REPLACE	1380300	0.8	0.8
3	. MOUNT, TRANSAXLE (LH-FRONT) - REPLACE	1380500	0.9	0.9
4	. MOUNT, TRANSAXLE (CENTER-REAR) - REPLACE	1380700	0.8	0.8
4	A - Auto transaxle	138070A	—	—
5	. MOUNT, ENGINE (CENTER-FRONT) - REPLACE	1380800	0.8	0.8
6	. MEMBER, CENTER - REPLACE	1382500	0.7	0.7
7	. SHIELD, SPLASH - REPLACE	.	.	.
	Right	1382100	0.3	0.3
	Left	1382200	0.3	0.3
	.	1382300	—	—