Service Manual2009 Cruze SOHC ENGINE MECHANICAL

SECTION 1B

SOHC ENGINE MECHANICAL

SOHC ENGINE MECH. — SOHC ENGINE UNIT

NO.	OPERATION DESCRIPTION	OPERATION CODE	MODEL
			J300
			2.0 DSL
1	. ENGINE ASSEMBLY OVERHAUL D33	1110100	10.7
	Measure Cylinder Head	111010D	0.8
	Overhaul Cylinder Head (Cylinder Head Detached)	111010E	3.1
	Overhaul oil pump (oil pump detached)	111010F	0.2
	Replace camshaft	111010G	0.4
	Replace Cylinder Head (Cylinder Head Detached)	111010H	2.1
2	. ENGINE ASSEMBLY OVERHAUL 6T45	1110300	10.2
	Measure Cylinder Head	111030D	0.8
	Overhaul Cylinder Head (Cylinder Head Detached)	111030E	3.1
	Overhaul oil pump (oil pump detached)	111030F	0.2
	Replace camshaft	111030G	0.4
	Replace Cylinder Head (Cylinder Head Detached)	111030H	2.1
3	. REPLACE ENGINE WITH EXCHANGE ENGINE — DIESEL ENGINE MT	1110200	10.7
4	. REPLACE ENGINE WITH EXCHANGE ENGINE — DIESEL ENGINE AT	1110400	10.2
5	. ENGINE REMOVAL AND INSTALLATION (D16-5)	1110600	.
	Remove and inst manual gearbox from/on engine	111060A	.
	Remove and inst automatic transmission with torque converter from/on engine	111060B	.
6	. ENGINE REMOVAL AND INSTALLATION (D16-5)	1110700	.
	Remove and inst manual gearbox from/on engine	111070A	.
	Remove and inst automatic transmission with torque converter from/on engine	111070B	.
7	. ENGINE REPLACEMENT (D33)	1110800	4.0
	Remove And Inst Manual Gearbox From/On Engine	111080D	1.3
	Replace one piston and/or con-rod	111080F	.
	Replace piston rings	111080G	.

J300 : CRUZE

SOHC ENGINE MECH. — SOHC ENGINE UNIT

NO.	OPERATION DESCRIPTION	OPERATION CODE	MODEL
			J300
			2.0 DSL
8	. ENGINE REPLACEMENT (6T45)	1110900	3.5
	Remove And Inst Automatic Transmission From/On Engine	111090E	1.4
	Replace one piston and/or con-rod	111090F	.
	Replace piston rings	111090G	.
9	. ENGINE OIL AND OIL FILTER REPLACEMENT	1112200	0.3
10	. GENERATOR AND AIR CONDITIONING COMPRESSOR AND POWER STEERING PUMP BELT REPLACEMENT	1132200	0.3
11	. DRIVE BELT IDLER PULLEY REPLACEMENT	1132300	0.6
12	. DRIVE BELT TENSIONER REPLACEMENT	1132400	0.4
13	. POWER STEERING PUMP BELT REPLACEMENT	1132700	.
14	. WATER-IN-FUEL DRAINING	1210100	0.2
15	. OIL LEVEL INDICATOR REPLACEMENT	1210200	0.1
16	. OIL LEVEL INDICATOR TUBE REPLACEMENT	1210300	0.3
17	. ENGINE OIL PRESSURE INDICATOR SWITCH REPLACEMENT	1211500	.
18	. CRANKSHAFT REAR OIL SEAL REPLACEMENT (6T45)	1220200	6.1
19	. CRANKSHAFT REAR OIL SEAL REPLACEMENT (D33)	1220400	4.5
20	. PISTON, CONNECTING ROD, AND BEARING REMOVAL AND INST	1220800	.
	Replace One Piston And/Or Con-Rod	122080A	.
	Replace An Additional Piston And/Or Con-Rod	122080C	.
	Replace Piston Rings	122080D	.

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SOHC ENGINE MECH. — SOHC ENGINE UNIT

NO.	OPERATION DESCRIPTION	OPERATION CODE	MODEL
			J300
			2.0 DSL
21	. CRANKSHAFT REMOVAL AND INST (D33)	1221100	9.5
21	Measure Crankshaft	122110L	1.3
22	. CRANKSHAFT REMOVAL AND INST (6T45)	1221200	.
22	Measure Crankshaft	122120L	.
23	. ENGINE FLYWHEEL REPLACEMENT	1221700	5.2
	Rear Crankshaft Seal Ring Replacement	122170A	0.2
	Replace Rear Crankshaft Seal Ring	122170B	.
24	. PISTONS AND CONNECTING RODS, — REMOVE AND REINST — DIESEL ENGINE	1221800	10.3
	Replace one additional piston and/or connecting rod	122180A	0.3
	Replace one piston and/or connecting rod	122180B	0.3
	Replace piston rings	122180C	0.7
25	. AUTOMATIC TRANSMISSION FLEX PLATE REPLACEMENT	1221900	5.7
25	Rear Crankshaft Seal Ring Replacement	122190D	0.2
26	. OIL FILTER ELEMENT — REPLACE — DIESEL ENGINE	1231100	0.2
27	. OIL FILTER ADAPTER AND OIL COOLER ASSEMBLY REPLACEMENT	1231200	0.5
28	. HOUSING, OIL FILTER AND COOLER REPLACEMENT	1231400	6.0
29	. OIL PAN REPLACEMENT	1231500	2.9
29	Oil Pan Replacement	123150A	0.2
30	. ENGINE OIL COOLER REPLACEMENT	1231600	0.5
31	. OIL PUMP COVER WITH OIL PUMP REPLACEMENT	1231700	6.0
31	Overhaul Oil Pump	123170A	0.2
32	. OIL PUMP — OVERHAUL	1231800	6.1
33	. OIL PUMP SUCTION PIPE REPLACEMENT	1232100	2.9
34	. ENGINE OIL LEVEL SENSOR REPLACEMENT	1232200	.

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SOHC ENGINE MECH. — SOHC ENGINE UNIT

NO.	OPERATION DESCRIPTION	OPERATION CODE	MODEL
			J300
			2.0 DSL
35	. CRANKSHAFT FRONT OIL SEAL REPLACEMENT	1232300	.
36	. ENGINE OIL PRESSURE CHECK	1232400	2.4
37	. OIL FLOW CHECK VALVE REPLACEMENT	1232600	.
38	. OIL PRESSURE RELIEF VALVE REPLACEMENT	1232700	0.3
39	. SEAL RING — OIL PUMP REPLACEMENT	1232900	6.0
40	. POSITIVE CRANKCASE VENTILATION VALVE HOSE REPLACEMENT	1233700	.
41	. ENGINE OIL FILLER CAP — REPLACE — DIESEL ENGINE	1233800	0.1
42	. ENGINE OIL COOLER INLET PIPE REPLACEMENT	1234000	0.4
43	. ENGINE OIL COOLER OUTLET PIPE REPLACEMENT	1234100	0.4
44	. COMPRESSION CHECK	1311100	.
45	. VALVE ROCKER ARMS — REPLACE — DIESEL ENGINE	1312100	3.8
46	. CYLINDER HEAD GASKET REPLACEMENT	.	.
	Cylinder Head Removal and Installation	1312300	5.0
	Adjust valve clearance	131230A	.
47	. CYLINDER HEAD REMOVAL AND INSTALLATION	1312400	.
	Adjust Valve Clearance	131240A	.
	Measure Cylinder Head	131240B	.
	Remove and Inst Attaching Parts	131240C	.
	Cylinder Head Replacement	131240D	.
	Replace or repair one valve	131240E	.
	Replace or repair one additional valve	131240F	.

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SOHC ENGINE MECH. — SOHC ENGINE UNIT

NO.	OPERATION DESCRIPTION	OPERATION CODE	MODEL
			J300
			2.0 DSL
48	. CYLINDER HEAD — REMOVE AND REINST — DIESEL ENGINE	1312500	5.0
	Cylinder Head Replacement	131250C	2.1
	Measure cylinder head	131250D	0.8
	Overhaul cylinder head	131250E	3.1
	Replace or repair one additional valve	131250F	0.4
	Replace or repair one valve	131250G	0.4
49	. REMOVE AND REINST VALVE SPRING	1312900	4.1
	Adjust valve clearance (hydraulic tappet)	131290E	0.2
	Remove and reinst valve springs	131290F	0.7
50	. VALVE CLEARANCE ADJUSTMENT	1313000	.
51	. VALVE STEM OIL SEAL AND VALVE SPRING REPLACEMENT	1313400	.
52	. VALVE BRIDGES, REPLACE — DIESEL ENGINE	1313600	3.8
53	. HYDRAULIC VALVE LASH ADJUSTER REPLACEMENT	1313800	3.9
53	Adjust valve clearance	131380A	.
54	. ENGINE COOLANT TEMPERATURE SENSOR REPLACEMENT (ENGINE BLOCK) (THERMOSTAT HOUSING)	1314100	0.3
55	. VALVE STEM SEALS — REPLACE — DIESEL ENGINE	1314200	4.5
56	. ENGINE COOLANT TEMPERATURE SENSOR REPLACEMENT (RADIATOR) (1.6L LXV, 1.6 LXT AND 1.8L 2H0)	1314400	.
57	. CAMSHAFT COVER REPLACEMENT	1322100	1.8
58	. CAMSHAFT REPLACEMENT	1322300	3.8
	Adjust valve clearance (hydraulic tappet)	132230D	0.2
	Replace one other, or tappets/hydraulic tappets	132230E	.
	Replace one tappet/hydraulic tappet	132230F	.
59	. INTAKE CAMSHAFT REPLACEMENT	1322400	.
	Replace one tappet/hydraulic tappet	132240D	.
	Replace one other, or tappets/hydraulic tappets	132240E	.
	Adjust Valve Clearance	132240F	.

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SOHC ENGINE MECH. — SOHC ENGINE UNIT

NO.	OPERATION DESCRIPTION	OPERATION CODE	MODEL
			J300
			2.0 DSL
60	. EXHAUST CAMSHAFT REPLACEMENT	1322600	.
	Replace One Tappet/hydraulic Tappet	132260D	.
	Replace One Additional or Valve Tappets	132260E	.
	Adjust Valve Clearance	132260F	.
61	. ENGINE (IGNITION COIL) COVER REPLACEMENT	1322800	0.2
62	. CAMSHAFT SEAL REPLACEMENT	1322900	.
62	Replace one further seal ring	132290A	.
63	. CAMSHAFT FRONT OIL SEAL — REPLACEMENT	1323000	2.4
64	. CRANKSHAFT PULLEY REPLACEMENT	1332100	0.4
65	. TIMING BELT CENTER FRONT COVER REPLACEMENT	1332200	.
66	. TIMING BELT REAR COVER REPLACEMENT	1332300	2.6
67	. TIMING BELT REPLACEMENT	1332500	2.3
	Timing Belt Idler Pulley Replacement	133250C	0.2
	crankshaft sprocket replacement	133250D	0.2
	Timing Belt Tensioner Replacement	133250E	0.2
	Water Pump Replacement	133250F	0.2
68	. EXHAUST CAMSHAFT REPLACEMENT	1322600	.
	Replace one additional or valve tappets (hydrotappet)	132260A	.
	Replace one tappet/hydraulic tappet	132260B	.
	Adjust valve clearance (hydraulic tappet)	132260C	.
69	. TIMING BELT ADJUSTMENT	1332700	2.3
70	. TIMING BELT TENSIONER REPLACEMENT	1332900	2.3
71	. CRANKSHAFT SPROCKET REPLACEMENT	1333100	2.4
72	. CAMSHAFT GEAR REPLACEMENT	1333300	2.3
72	Replace one further camshaft gear	133330A	.

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SOHC ENGINE MECH. — SOHC ENGINE UNIT

NO.	OPERATION DESCRIPTION	OPERATION CODE	MODEL
			J300
			2.0 DSL
73	. WATER PUMP REPLACEMENT	1333500	2.5
74	. WATER PUMP PULLEY REPLACEMENT	1333600	.
75	. CRANKSHAFT POSITION SENSOR	1333700	0.4
76	. CAMSHAFT POSITION SENSOR REPLACEMENT	1333800	0.3
77	. TIMING BELT IDLER PULLEY REPLACEMENT	1333900	2.3
78	. TIMING BELT UPPER FRONT COVER REPLACEMENT	1334200	0.7
79	. TIMING BELT LOWER FRONT COVER REPLACEMENT	1334300	0.8
80	. ACTUATOR EXHAUST CAMSHAFT REPLACEMENT	1336400	.
81	. ACTUATOR INLET CAMSHAFT REPLACEMENT	1336500	.
82	. CAMSHAFT POSITION ACTUATOR ADJUSTER REPLACEMENT	1336800	.
83	. EXHAUST CAMSHAFT POSITION ACTUATOR ADJUSTER REPLACEMENT	1336900	.
84	. ENGINE MOUNT REPLACEMENT — RIGHT SIDE	1380100	.
85	. ENGINE MOUNT BRACKET REPLACEMENT — RIGHT SIDE	1380300	1.0
86	. ENGINE SIGHT SHIELD REPLACEMENT	1382100	.
87	. ENGINE LEAK TEST (CO CONCENTRATION IN COOLANT)	1410100	.
88	. RADIATOR REPLACEMENT	1410500	1.5
88	Additional work for vehicles with automatic transmission	141050A	0.1
89	. CHARGE AIR COOLER REPLACEMENT	1411800	0.7
90	. COOLING SYSTEM LEAK TESTING	1411900	0.2
91	. RADIATOR AND AIR CHARGE COOLER BRACKET REPAIR	1412100	0.5

J300 : CRUZE

SOHC ENGINE MECH. — SOHC ENGINE UNIT

NO.	OPERATION DESCRIPTION	OPERATION CODE	MODEL
			J300
			2.0 DSL
92	. ENGINE COOLANT FAN RESISTOR MOUNT REPAIR	1412200	0.5
93	. LOWER AND UPPER RADIATOR MOUNTING PIN REPAIR	1412300	0.5
94	. RADIATOR SUPPORT REPLACEMENT	1430300	0.8
95	. ENGINE COOLANT FAN REPLACEMENT	1430900	1.6
96	. ENGINE COOLANT FAN ENGINE REPLACEMENT	1431100	.
96	Additional Engine Coolant Fan Engine Replacement	143110A	0.2
97	. RADIATOR SURGE TANK REPLACEMENT	1450400	0.2
98	. RADIATOR INLET HOSE REPLACEMENT	1450700	0.4
99	. RADIATOR OUTLET HOSE REPLACEMENT	1450800	0.4
100	. RADIATOR SURGE TANK OUTLET HOSE REPLACEMENT	1451100	.
101	. ENGINE COOLANT INLET PIPE REPLACEMENT	1451200	0.3
102	. ENGINE COOLANT OUTLET PIPE REPLACEMENT	1451300	0.3
103	. HOSE, INLET HEATER	1453100	0.4
104	. HOSE, OUTLET HEATER	1453200	0.4
105	. HOSE, ALL HEATER	1453300	0.6
106	. THROTTLE BODY HEATER INLET HOSE REPLACEMENT	1454600	.
107	. RADIATOR SURGE TANK INLET HOSE/PIPE REPLACEMENT	1454700	.
108	. ENGINE COOLANT AIR BLEED HOSE REPLACEMENT	1454800	0.3
109	. ENGINE COOLANT THERMOSTAT REPLACEMENT	1480500	0.4
109	Check thermostat	148050A	.
110	. ENGINE COOLANT THERMOSTAT HOUSING REPLACEMENT	1480900	0.4

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SOHC ENGINE MECH. — SOHC ENGINE UNIT

NO.	OPERATION DESCRIPTION	OPERATION CODE	MODEL
			J300
			2.0 DSL
111	. GLOW PLUG REPLACEMENT	1510600	1.3
111	One additional Glow Plug Replacement	151060A	0.3
112	. SPARK PLUG REPLACEMENT	1510800	.
113	. IGNITION COIL REPLACEMENT	1511900	.
114	. ALTERNATOR REPLACEMENT	1541700	1.7
114	Auxiliary Alternator Bracket Replacement	154170A	.
115	. GENERATOR AND AIR CONDITIONING COMPRESSOR BRACKET REPLACEMENT	1544100	5.2
116	. STARTER REPLACEMENT	1560800	0.5
117	. BATTERY REPLACEMENT	1570300	0.3
118	. BATTERY POSITIVE CABLE REPLACEMENT	1570800	0.2
119	. BATTERY TRAY REPLACEMENT	1571200	0.4
120	. ENGINE COOLANT FAN RESISTOR REPLACEMENT	1585300	1.6
121	. FUEL TANK FUEL PUMP MODULE REPLACEMENT (1.6L LXV, 1.6 LXT AND 1.8L 2H0)	1710300	0.8
122	. FUEL TANK FILLER PIPE REPLACEMENT	1710500	0.5
123	. FUEL TANK VENT PIPE REPLACEMENT (1.6L LXV, 1.6 LXT AND 1.8L 2H0)	1710700	.
124	. FUEL TANK REPLACEMENT (1.6L LXV, 1.6 LXT AND 1.8L 2H0)	1710900	0.8
125	. FUEL PRESSURE CHECK (FEED)	1711300	.
126	. FUEL SENDER ASSEMBLY REPLACEMENT	1711700	0.8
127	. FUEL FILTER REPLACEMENT	1720300	0.3

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SOHC ENGINE MECH. — SOHC ENGINE UNIT

NO.	OPERATION DESCRIPTION	OPERATION CODE	MODEL
			J300
			2.0 DSL
128	. FUEL FEED PIPE REPLACEMENT (1.6L LXV, 1.6 LXT AND 1.8L 2H0)	1720500	0.6
129	. EVAPORATIVE EMISSION CANISTER REPLACEMENT	1731500	.
130	. THROTTLE BODY ASSEMBLY REPLACEMENT	1810100	0.3
131	. FUEL INJECTOR REPLACEMENT	1811100	0.4
131	Additional Fuel Injector Replacement	181100B	0.3
132	. FUEL RAIL REPLACEMENT	1811300	0.7
133	. FUEL INJECTION PUMP REPLACEMENT	1811500	3.9
134	. FUEL INJECTOR FUEL FEED PIPE REPLACEMENT	1812000	0.6
134	. FUEL INJECTOR FUEL FEED PIPES REPLACEMENT	181200A	0.3
135	. FUEL HOSE REPLACEMENT — FUEL INJECTION PUMP TO FUEL FEED BLOCK	1812300	0.3
136	. FUEL INJECTION PUMP DRIVE PULLEY — REPLACEMENT	1812400	2.4
137	. FUEL RETURN HOSE REPLACEMENT — FUEL RETURN PIPE TO FUEL INJECTION PUMP	1812500	0.4
138	. ACCELERATOR PEDAL POSITION SENSOR REPLACEMENT	1820500	.
139	. ACCELERATOR PEDAL POSITION SENSOR REPLACEMENT (1.6L LXV, 1.6 LXT AND 1.8L 2H0)	1821800	0.3
140	. ENGINE CONTROL MODULE REPLACEMENT	1860100	0.5
141	. CONTROLLER, ECM/PCM — REPROGRAM	1860300	0.8
142	. CONTROLLER, ECM/TCM — DIAGNOSIS	1860400	0.3
143	. CONTROLLER, TCM — REPLACE	1860500	0.6
144	. CONTROLLER, TCM — REPROGRAM	1860600	0.5
145	. BRACKET, CONTROLLER — REPLACE	1860700	0.5
146	. SENSOR, MAP SOHC — REPLACE	1860800	0.3

J300 : CRUZE

SOHC ENGINE MECH. — SOHC ENGINE UNIT

NO.	OPERATION DESCRIPTION	OPERATION CODE	MODEL
			J300
			2.0 DSL
147	. MANIFOLD ABSOLUTE PRESSURE SENSOR REPLACEMENT	1860900	.
148	. KNOCK SENSOR REPLACEMENT	1861300	.
149	. DIAGNOSTIC TIME — DTC RELATED DIAGNOSIS FOR ALL DIAGNOSIS ECUS	1869900	0.3
150	. AIR CLEANER ASSEMBLY REPLACEMENT	1910300	0.3
151	. AIR CLEANER ELEMENT REPLACEMENT	1910500	0.2
152	. AIR CLEANER OUTLET DUCT REPLACEMENT	1910700	.
153	. INTAKE AIR TEMPERATURE SENSOR REPLACEMENT	1910900	0.3
154	. AIR CLEANER INLET DUCT REPLACEMENT	1913000	0.5
155	. MASS AIRFLOW SENSOR/INTAKE AIR TEMPERATURE SENSOR REPLACEMENT	1913100	0.2
156	. REAR INTAKE AIR DUCT RESONATOR INSULATOR REPLACEMENT	1913200	0.7
157	. CHARGE AIR COOLER INLET HOSE REPLACEMENT	1913500	0.3
158	. CHARGE AIR COOLER OUTLET HOSE REPLACEMENT	1913600	0.2
159	. AIR CLEANER OUTLET FRONT DUCT REPLACEMENT	1913800	0.2
159	Additional Air Cleaner Outlet Front Duct Replacement	191380A	0.3
160	. INTAKE MANIFOLD REPLACEMENT	1930100	.
161	. INTAKE MANIFOLD REPLACEMENT	1930200	1.7
162	. EXHAUST GAS RECIRCULATION VALVE REPLACEMENT	1930700	0.6
163	. INTAKE MANIFOLD GASKET REPLACEMENT	1931600	.
164	. INTAKE MANIFOLD GASKET — REPLACE — DIESEL ENGINE	1931700	1.5
165	. PCV ASSEMBLY REPLACEMENT	1932600	0.5

J300 : CRUZE

SOHC ENGINE MECH. — SOHC ENGINE UNIT

NO.	OPERATION DESCRIPTION	OPERATION CODE	MODEL
			J300
			2.0 DSL
166	. EXHAUST GAS RECIRCULATION VALVE ADAPTER REPLACEMENT	1932800	.
167	. PCV PIPE — REPLACEMENT	1932900	0.2
168	. EXHAUST GAS RECIRCULATION PIPE REPLACEMENT	1933100	0.4
169	. EXHAUST GAS RECIRCULATION COOLING PIPE REPLACEMENT — UPPER	1933200	0.4
170	. EXHAUST GAS RECIRCULATION COOLING PIPE REPLACEMENT	1933300	1.7
171	. EXHAUST MANIFOLD REPLACEMENT	1940300	1.7
172	. EXHAUST MANIFOLD HEAT SHIELD REPLACEMENT	1940800	1.3
173	. TURBOCHARGER REPLACEMENT	1941600	1.2
174	. TURBOCHARGER OIL FEED PIPE REPLACEMENT	1941700	0.8
175	. TURBOCHARGER OIL RETURN PIPE REPLACEMENT	1941800	0.4
176	. HEATED OXYGEN SENSOR 1 REPLACEMENT (1.6L LXV, 1.6 LXT AND 1.8L 2H0)	1942100	.
177	. HEATED OXYGEN SENSOR 2 REPLACEMENT (1.6L LXV, 1.6 LXT AND 1.8L 2H0)	1942200	.
178	. TURBOCHARGER HEAT SHIELD REPLACEMENT (CATALYTIC CONVERTER HEAT SHIELD)	1942300	0.5
179	. VACUUM PIPE REPLACEMENT	1950800	0.3
180	. EXHAUST GAS RECIRCULATION VALVE VACUUM TANK REPLACEMENT	1951300	0.3
181	. VACUUM PUMP ASSEMBLY REPLACEMENT	1951400	0.6
182	. EXHAUST FLEXIBLE PIPE REPLACEMENT	1960900	0.5
183	. EXHAUST PARTICULATE FILTER REPLACEMENT	1961400	0.8

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SOHC ENGINE MECH. — SOHC ENGINE UNIT

NO.	OPERATION DESCRIPTION	OPERATION CODE	MODEL
			J300
			2.0 DSL
184	. CATALYTIC CONVERTER REPLACEMENT	1961500	0.8
185	. EXHAUST HEAT SHIELD REPLACEMENT	1961700	0.8
186	. EXHAUST REAR MUFFLER HEAT SHIELD REPLACEMENT	1961900	0.4
187	. MIDDLE SILENCER WITH CENTRE EXHAUST PIPE REPLACEMENT	1962100	.
188	. REAR SILENCER REPLACEMENT	1962200	0.3
189	. EXHAUST SYSTEM REPLACEMENT	1962500	1.0
190	. FUEL TANK HEAT SHIELD REPLACEMENT	1962600	0.7
191	. EXHAUST PRESSURE SENSOR REPLACEMENT	1963200	0.3
192	. EXHAUST TEMPERATURE SENSOR REPLACEMENT — POSITION 1	1963500	0.4
193	. EXHAUST TEMPERATURE SENSOR REPLACEMENT — POSITION 2	1963700	0.6

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