Service Manual2009 Aveo Flywheel

Aveo

Flywheel - M/T Only -

Tools Required

Engine Fixture EN–48356

Flywheel Locking Device KM-652

Removal Procedure

Install the engine fixture EN-48356.
Remove the manual transmission. Refer to Section 5B, Manual Transaxle.

Install the flywheel locking device(KM-652) to block the crankshaft.
Install the transmission tightening bolt with KM-652.

Remove the flywheel bolts.
Remove the flywheel.

Installation Procedure

Remove the flywheel.
Remove the flywheel bolts.

Tighten

Tighten the flywheel bolts to 35+30°+15° N•m (25.8+30°+15° lb-ft).

Remove the flywheel locking device(KM-652) to block the crankshaft.

Flexible Plate - A/T Only -

Tools Required

Engine Fixture EN–48356

Flywheel Locking Device KM-652

Removal Procedure

Install the engine fixture EN-48356.
Remove the auto transmission. Refer to Section 5A, Automatic Transaxle.

Install the flywheel locking device(KM-652) to block the crankshaft.
Install the transmission tightening bolt with KM-652.

Remove the flexible plate bolts.
Remove the flexible plate.

Installation Procedure

Remove the flexible plate.
Remove the flexible plate bolts.

Tighten

Tighten the flexible plate bolts to 35+30°+15° N•m (25.8+30°+15° lb-ft).

Remove the flywheel locking device(KM-652) to block the crankshaft.

Crankshaft Front Oil Seal Ring

Tools Required

Assembly Sleeves KM-6351

Removal Procedure

Remove the timing belt. Refer to “Timing System” in this section.
Remove the crankshaft sprocket.

Remove the crankshaft front oil seal ring.

Installation Procedure

Attach the installer inside sleeve(a).
Attach the crankshaft front oil seal ring to the inside sleeve(a).
Attach the installer outside sleeve(b).
Install the crankshaft bolt(d) and washer(c).

Install the crankshaft sprocket.
Install the timing belt. Refer to “Timing System” in this section.

Crankshaft Rear Oil Seal Ring

Tools Required

Crankshaft Rear Oil Seal Installer(-) EN-49204

Removal Procedure

Remove the flywheel or flexible plate. Refer to “Flywheel (M/T ONLY)” or “Flexible Plate (A/T ONLY)” in this section.
Remove the crankshaft position(CKP) sensor. Refer to Section 1F2, Engine Controls - 1.4 DOHC - G14D.

Remove the crankshaft rear oil seal with housing.

Installation Procedure

Install the new crankshaft rear oil seal.
Install the installer EN-49204 and then tighten the bolts to press seal ring all the way in.
Remove the installer EN-49204.

Engine Mount

Tools Required

Engine Fixture EN–48356

Removal Procedure

Remove the air cleaner assembly. Refer to “Air Cleaner Assembly" in this section.

Install the engine fixture EN-48356.

Remove the engine mount bolts and nuts.

Installation Procedure

Install the engine mount bolts and nuts.

Tighten

Tighten the engine mount bolts and nuts to 55 N•m (40.5 lb-ft).

Remove the engine fixture EN-48356.
Install the air cleaner assembly. Refer to “Air Cleaner Assembly" in this section.

Reaction Rod

Remove and Installation Procedure

Remove the reaction rod-to-bracket bolt and nut.

Tighten

Tighten reaction rod-to-bracket bolt and nut to 80 N•m (59 lb-ft).

Remove the reaction rod-to-crossmember bolts.

Tighten

Tighten reaction rod-to-crossmember bolts to 55 N•m (40.5 lb-ft).

Engine Assembly

Tools Required

Engine Assembly Remove/Install Pallet Supporter EN-48244

Engine Assembly Remove/Install Pallet EN-49156

Removal Procedure

Caution : Do not accomplish this procedure when the engine is hot. It may cause damage and can be injured.

Release the fuel pressure. Refer to Section 1F2, Engine Controls - 1.4 DOHC - G14D.
Disconnect the fuel pipe from the fuel rail.

Disconnect the EVAP hose from the EVAP canister solenoid valve.
Drain the engine coolant. Refer to Section 1D, Engine Cooling.
Remove the air cleaner assembly. Refer to “Air Cleaner Assembly" in this section.

Remove the battery and tray. Refer to Section 1E, Engine Electrical.
Remove the fuse box tightening bolts.

Discharge the A/C gas system, if equipped. Refer to Section 7B, HVAC System.
Remove the A/C inlet/outlet pipe tightening bolt from the A/C compressor.

Drain the power steering oil if equipped. Refer to Section 6A, Power Steering Pump.
Remove the power steering pump pressure line union nut. Refer to Section 6A, Power Steering Pump.
Remove the power steering pressure pipe retaining clamp bolt from the intake manifold. Refer to Section 6A, Power Steering Pump.
Disconnect the power steering hose from the power steering pump. Refer to Section 6A, Power Steering Pump.

Disconnect the related sensor and actuator connectors and the pull engine wiring harness aside.

Oil Switch Wiring Connector
A/C Compressor Connector

Intake Air Temperature Sensor Connector
A/C Pressure Sensor(ACP) Connector
Cam Position Solenoid Valve Connector
Electric Throttle Controller(ETC) Connector
Manifold Air Pressure(MAP) Sensor Connector
EVAP Solenoid Valve Connector
Injector Connectors

Ignition Coil Connector
Camshaft Position Sensor(CPS) Connectors(Right/Left)
Coolant Temperature Sensor Connector
Oxygen Sensor Connector
Ground Tightening Bolt
Thermostat Heater Connector

Crankshaft Position(CKP) Sensor Connector
Knock Sensor Connector
Alternator Connector
Alternator B+ Tightening Nut
Oil Level Switch Connector(If equipped)
Starter Solenoid B+ Tightening Nut
Ground Tightening Nut
Starter Solenoid Ground Tightening Nut

Disconnect the coolant hose(1) from water pump.
Disconnect the coolant hose(2) from the thermostat housing.
Disconnect the heater core coolant inlet/outlet hoses(3) from the coolant distributor.
Disconnect the ETC-to-coolant tank hose(4).
Disconnect the brake boost hose(5) from the intake manifold.

Remove and disconnect the cables and wiring harness related to the automatic transaxle. Refer to Section 5A, AISIN Automatic Transaxle(A/T ONLY).
Disconnect the auto transaxle fluid cooler inlet/outlet hoses. Refer to Section 5A, AISIN Automatic Transaxle(A/T ONLY).

Remove and disconnect the cables and wiring harness related to the manual transaxle. Refer to Section 5B1, Five-Speed Manual Transaxle(D16)(M/T ONLY).

Remove the reaction rod. Refer to “Reaction Rod” in this section.

Remove the exhaust front pipe. Refer to Section 1G, Engine Exhaust.
Remove the drive axle shafts. Refer to Section 3A, Drive Axle.

Install the pallet EN-49156 on the supporter EN-48244.
Lift the vehicle up using by lifter.
Locate the pallet and supporter under the vehicle engine and transaxle.
Lift the vehicle down until engine assembly fixing on the pallet EN-49156.

Remove the engine mount. Refer to “Engine Mount” in this section.
Remove the transaxle mount. Refer to Section 5A, AISIN Automatic Transaxle(A/T ONLY). Refer to Section 5B, Five-Speed Manual Transaxle(D16)(M/T ONLY).

Separate the engine and the transaxle. Refer to Section 5A, AISIN Automatic Transaxle(A/T ONLY). Refer to Section 5B, Five-Speed Manual Transaxle(D16)(M/T ONLY).

Installation Procedure

Assemble the engine and the transaxle. Refer to Section 5A, AISIN Automatic Transaxle(A/T ONLY). Refer to Section 5B, Five-Speed Manual Transaxle(D16)(M/T ONLY).

Place the engine assembly on the pallet EN-49156 on the supporter EN-48244.
Lift the vehicle up using by lifter.
Locate the engine assembly with the pallet and supporter.
Lift the vehicle down.

Install the engine mount. Refer to “Engine Mount” in this section.
Install the transaxle mount. Refer to Section 5A, AISIN Automatic Transaxle(A/T ONLY). Refer to Section 5B, Five-Speed Manual Transaxle(D16)(M/T ONLY).

Install the drive axle shafts. Refer to Section 3A, Drive Axle.
Install the exhaust front pipe. Refer to Section Section 1G, Engine Exhaust.

Install the reaction rod. Refer to “Reaction Rod” in this section.

Install and connect the cables and wiring harness related to the automatic transaxle. Refer to Section 5A, AISIN Automatic Transaxle(A/T ONLY).
Connect the auto transaxle fluid cooler inlet/outlet hoses. Refer to Section 5A, AISIN Automatic Transaxle(A/T ONLY).

Install and connect the cables and wiring harness related to the manual transaxle. Refer to Section 5B1, Five-Speed Manual Transaxle(D16)(M/T ONLY).

Connect the coolant hose(1) to the water pump.
Connect the coolant hose(2) to the thermostat housing.
Connect the heater core coolant inlet/outlet hoses(3) to the coolant distributor.
Connect the ETC-to-coolant tank hose(4).
Connect the brake boost hose(5) to the intake manifold.

Connect the related sensor and actuator connectors.

Crankshaft Position(CKP) Sensor Connector
Knock Sensor Connector
Alternator Connector
Alternator B+ Tightening Nut
Oil Level Switch Connector(If equipped)
Starter Solenoid B+ Tightening Nut
Ground Tightening Nut
Starter Solenoid Ground Tightening Nut

Tighten

Tighten the alternator B+ tightening nut to 15 N•m (11 lb-ft).
Tighten the starter solenoid B+ tightening nut to 10.5 N•m (7.7 lb-ft).
Tighten the ground tightening nut to 12 N•m (8.8 lb-ft).
Tighten the starter solenoid ground tightening nut to 38 N•m (28 lb-ft).

Ignition Coil Connector
Camshaft Position Sensor(CPS) Connectors(Right/Left)
Coolant Temperature Sensor Connector
Oxygen Sensor Connector
Ground Tightening Bolt

Tighten

Tighten the ground tightening bolt to 12 N•m (8.8 lb-ft).

Thermostat Heater Connector

Oil Switch Wiring Connector
A/C Compressor Connector

Install the power steering pump pressure line union nut. Refer to Section 6A, Power Steering Pump.
Install the power steering pressure pipe retaining clamp bolt to the intake manifold. Refer to Section 6A, Power Steering Pump.
Connect the power steering hose to the power steering pump. Refer to Section 6A, Power Steering Pump.

Install the A/C inlet/outlet pipe tightening bolt from the A/C compressor if equipped.
Charge the A/C gas system. Refer to Section 7B, HVAC System.

Install the fuse box tightening bolts.
Install the battery and tray. Refer to Section 1E, Engine Electrical.

Install the air cleaner assembly. Refer to “Air Cleaner Assembly" in this section.
Connect the fuel pipe to the fuel rail.
Connect the EVAP hose to the EVAP canister solenoid valve.