Service Manual2009 Aveo GENERAL ENGINE INFORMATION

SECTION 1A

GENERAL ENGINE INFORMATION

Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help to prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

COMPONENT LOCATOR

Engine Compartment - 1.2 DOHC - B12D -

Air Cleaner Filter
Throttle Body
Intake Manifold
Accelerator Cable
Brake Oil Reservoir
Engine Coolant Reservoir
Washer Fluid Reservoir
ECM
Fuse Box
Battery
Power Steering Oil Reservoir
Transmission
DIS Ignition Coil
Exhaust Manifold
Engine Oil Cap
Oil Level Gauge

Engine Compartment - 1.4 DOHC - G14D -

Air Cleaner Filter
Engine Oil Cap
Brake Oil Reservoir
Engine Coolant Reservoir
Fuse Box
Battery
Washer Fluid Reservoir
Power Steering Oil Reservoir
Engine Oil Level Gauge
Tranmsission Oil Level Gauge

DIAGNOSIS

General Diagnosis

Condition	Probable Cause	Correction
Hard Starting (With normal cranking)	Malfunction of the Fuel System	.
	Improper or impure fuel.	Clean the fuel and fuel line.
	Lack of a fuel in the fuel tank.	Fill a fuel in the fuel tank.
	Clogged or contaminated the fuel filter.	Replace the fuel filter.
	Clogged the fuel line.	Clean the fuel line.
	Malfunction of the fuel pump.	Replace the fuel pump.
	Malfunction of the injectors.	Replace the injectors.
	Mixed up a water or impurity in the fuel tank.	Clean the fuel tank.
	Decline of Compression Pressure	.
	Poor tightening the injector.	Tighten to the specified torque.
	Poor tightening the glow plug.	Tighten to the specified torque.
	Cracked the cylinder head gasket.	Tighten to the specified torque.
	Leakage of the valve seat.	Replace the cylinder head.
	Interference of the valve stem.	Replace the valve.
	Low elasticity or damage of the valve spring.	Replace the valve spring.
	Abnormal interference of pistons and cylinders.	Replace the piston rings.
	Excessive wear of pistons, rings or cylinders.	Replace the cylinder block.
	Others	.
	Broken the timing belt.	Replace the timing belt.
	Malfunction of PCV(Positive Crankcase Ventilation) valve.	Check and replace the PCV valve.
	Loosening, damage or leakage of the vacuum hose.	Connect the hose correctly or replace it
	Leakage of intake system gasket.	Replace the intake system gasket.
Lack of Engine Power	Decline of Compression Pressure	Refer to the above page.
	Malfunction of the Fuel System	.
	Clogged the fuel line.	Clean the fuel line.
	Clogged or contaminated the fuel filter	Replace the fuel filter
	Improper or impure fuel.	Clean the fuel and fuel line.
	Others	.
	Clogged or contaminated the air cleaner element.	Clean or replace the air cleaner element.
	Leakage of intake system gasket.	Replace the intake system gasket.
	Dragging brakes.	Repair or replace the brakes
	Slipping clutch.	Adjust or replace the clutch.
Rough Engine Idling	Decline of Compression Pressure	Refer to the above page.
	Malfunction of the Fuel System	.
	Clogged the fuel line.	Clean the fuel line.
	Clogged or contaminated the fuel filter	Replace the fuel filter
	Improper or impure fuel.	Clean the fuel and fuel line.
	Malfunction of the fuel pump.	Replace the fuel pump.
	Malfunction of the injectors.	Replace the injectors.
	Others	.
	Clogged or contaminated the air cleaner element.	Clean or replace the air cleaner element.
	Malfunction of PCV(Positive Crankcase Ventilation) valve.	Check and replace the PCV valve.
	Loosening, damage or leakage of the vacuum hose.	Connect the hose correctly or replace it
	Leakage of intake system gasket.	Replace the intake system gasket.
Engine Hesitate (Upon pressing accelerating pedal, the engine makes delayed response. This situation is remarkable when cruising or starting.)	Decline of Compression Pressure	Refer to the above page.
	Malfunction of the Fuel System	.
	Clogged the fuel line.	Clean the fuel line.
	Clogged or contaminated the fuel filter	Replace the fuel filter
	Improper or impure fuel.	Clean the fuel and fuel line.
	Malfunction of the fuel pump.	Replace the fuel pump.
	Malfunction of the injectors.	Replace the injectors.
	Others	.
	Clogged or contaminated the air cleaner element.	Clean or replace the air cleaner element.
	Leakage of intake system gasket.	Replace the intake system gasket.
Engine Surging (Engine power makes fluctuation in a fixed speed and speed changes without operating the accelerating pedal)	Decline of Compression Pressure	Refer to the above page.
	Malfunction of the Fuel System	.
	Clogged the fuel line.	Clean the fuel line.
	Clogged or contaminated the fuel filter.	Replace the fuel filter.
	Improper or impure fuel.	Clean the fuel and fuel line.
	Malfunction of the fuel pump.	Replace the fuel pump.
	Malfunction of the injectors.	Replace the injectors.
	Others	.
	Clogged or contaminated the air cleaner element.	Clean or replace the air cleaner element.
	Leakage of intake system gasket.	Replace the intake system gasket.
Excessive Detonation (According to the opening range of throttle valve, knocking sound of metallic is made with abnormal explosion.)	Overheated Engine	Refer to the “Overheat” in this section.
	Malfunction of the Fuel System	.
	Clogged or contaminated the fuel filter.	Replace the fuel filter.
	Leakage of intake system gasket.	Replace the intake system gasket.
	Excessive carbon deposit due to abnormal combustion.	Remove the carbon.
Overheat	Malfunction of Cooling System	.
	Lack of the coolant.	Refill the coolant.
	Malfunction of the thermostat.	Replace the thermostat.
	Malfunction of the cooling fan.	Replace the cooling fan.
	Poor performance of the water pump.	Replace the water pump.
	Clogged or leaky radiator.	Clean and repair or replace the radiator.
	Malfunction of Lubrication System	.
	Poor the engine oil	Replace the engine oil with the specified one.
	Blocking the oil filter or strainer.	Clean or replace the oil filter or the strainer.
	Lack of the engine oil.	Refill the engine oil.
	Poor oil pump performance.	Replace or repair the oil pump.
	Leakage of the engine oil.	Repair the related one.
	Others	.
	Dragging brakes.	Repair or replace the brakes
	Slipping the clutch.	Adjust or replace the clutch.
	Leakage of intake system gasket.	Replace the intake system gasket.
Poor Fuel Consumption	Decline of Compression Pressure	Refer to the above page.
	Malfunction of the Fuel System	.
	Clogged the fuel line.	Clean the fuel line.
	Clogged or contaminated the fuel filter	Replace the fuel filter
	Improper or impure fuel.	Clean the fuel and fuel line.
	Malfunction of the injectors.	Replace the injectors.
	Malfunction of Cooling System	.
	Malfunction of the thermostat.	Replace the thermostat.
	Others	.
	Improperly installed valves.	Repair or replace valves.
	Slipping the clutch.	Repair or replace the clutch.
	Low pressure of tires.	Adjust the pressure of tires.
Excessive Consumption of Engine Oil	Leakage of the Engine Oil	.
	Loosened the drain plug.	Tightening the drain plug.
	Loosened the oil pan bolt.	Tightening the oil pan bolt.
	Poor the condition of the liquid gasket.	Clean and Coat the liquid gasket.
	Loosened the oil filter cap.	Tightening the oil filter cap.
	Loosened the oil pressure switch.	Tightening the oil pressure switch.
	Leakage of the camshaft front oil seal.	Replace the camshaft front oil seal.
	Leakage of the crankshaft front oil seal.	Replace the crankshaft front oil seal.
	Leakage of the crankshaft rear oil seal.	Replace the crankshaft rear oil seal.
	Leakage of the cylinder head cover gasket.	Replace the cylinder head cover gasket.
	Leakage of the cylinder head gasket.	Replace the cylinder head gasket.
	Oil Mixing in Combustion Chamber	.
	Stuck the piston ring.	Remove carbon and replace the ring.
	Worn the piston or the cylinder.	Replace the piston or the cylinder block.
	Worn the piston ring or ring groove.	Replace the piston or rings.
	Inadequate position of the piston ring cutting part.	Adjust the position.
	Abrasion or damage of the valve system.	Replace the valve system.
Low oil Pressure	Malfunction of Lubrication System	.
	Inadequate oil viscosity.	Replace the engine oil with the specified one.
	Loosening of the oil pressure switch.	Tighten the switch.
	Lack of the engine oil.	Refill the engine oil.
	Blocking the oil strainer.	Clean the strainer.
	Poor the oil pump performance.	Replace the oil pump.
Engine Noise	Valve Noise	.
	Abrasion of valve stem or guide.	Replace the valve or the cylinder head.
	Weak valve spring.	Replace the valve spring.
	Abrasion of the finger-follower and valve bridge.	Replace the finger-follower or valve bridge.
	Piston, Ring, Cylinder Noise	.
	Abrasion of the piston, the ring or the cylinder.	Replace the piston, the ring or the cylinder block.
	Connecting Rod Noise	.
	Abrasion of the connecting rod bearing.	Replace the connecting rod bearing.
	Loosened the connecting rod nut.	Tighten the connecting rod nut to the specified torque.
	Crankshaft Noise	.
	Abrasion of the crankshaft bearing.	Replace the crankshaft bearing
	Abrasion of the crankshaft journal.	Replace the crankshaft journal.
	Loosened bearing cap bolts.	Tighten the bearing cap bolts to the specified torque.
	Excessive clearance of the crankshaft thrust bearing.	Adjust or replace.
	Lowered the oil pressure	Refer to the “Low Oil Pressure” in this section.

GENERAL INFORMATION

Cleanliness and Care

An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten–thousandths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly, to protect and lubricate the surfaces on initial operation. Proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever valve train components are removed for service, they should be kept in order. They should be installed in the same locations, and with the same mating surfaces, as when they were removed. Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts.

On-Engine Service

Caution : Disconnect the negative battery cable before removing or installing any electrical unit, or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted.

Notice : Any time the air cleaner is removed, the intake opening should be covered. This will protect against accidental entrance of foreign material, which could follow the intake passage into the cylinder and cause extensive damage when the engine is started.