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SECTION 1C1

PETROL DOHC ENGINE MECHANICAL

PETROL DOHC ENGINE MECH. — DOHC ENGINE UNIT

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
1.6 LXT
1.6 LXV
1.8X
1.8L
1
. ENGINE ASSEMBLY OVERHAUL D33
1110100
.
.
.
.
Measure Cylinder Head
111010D
.
.
.
.
Overhaul Cylinder Head (Cylinder Head Detached)
111010E
.
.
.
.
Overhaul oil pump (oil pump detached)
111010F
.
.
.
.
Replace camshaft
111010G
.
.
.
.
Replace Cylinder Head (Cylinder Head Detached)
111010H
.
.
.
.
2
. ENGINE ASSEMBLY OVERHAUL 6T45
1110300
.
.
.
.
Measure Cylinder Head
111030D
.
.
.
.
Overhaul Cylinder Head (Cylinder Head Detached)
111030E
.
.
.
.
Overhaul oil pump (oil pump detached)
111030F
.
.
.
.
Replace camshaft
111030G
.
.
.
.
Replace Cylinder Head (Cylinder Head Detached)
111030H
.
.
.
.
3
. ENGINE REMOVAL AND INSTALLATION (D16-5)
1110600
.
4.0
4.0
4.8
Remove and inst manual gearbox from/on engine
111060A
.
1.3
1.3
1.0
4
. ENGINE REMOVAL AND INSTALLATION (6T40)
1110700
.
3.6
3.6
4.5
Remove and inst manual gearbox from/on engine
111070A
.
1.3
1.3
.
Remove and inst automatic transmission with torque converter from/on engine
111070B
.
1.8
1.8
1.5
5
. ENGINE REPLACEMENT (D16)
1110800
4.1
8.7
7.7
8.7
Remove And Inst Manual Gearbox From/On Engine
111080D
1.3
.
.
.
Replace one piston and/or con-rod
111080F
0.4
.
.
.
Replace piston rings
111080G
0.8
.
.
.
6
. ENGINE REPLACEMENT (6T30/6T40)
1110900
3.7
9.7
7.6
8.3
Remove And Inst Manual Gearbox From/On Engine
111090D
1.4
1.4
.
.
Remove And Inst Automatic Transmission From/On Engine
111090E
1.9
2.1
.
.
Replace one piston and/or con-rod
111090F
0.5
.
.
.
Replace piston rings
111090G
0.9
.
.
.
7
. ENGINE OIL AND OIL FILTER REPLACEMENT
1112200
0.5
0.4
0.2
0.3
J300 : CRUZE / J309 : ORLANDO

PETROL DOHC ENGINE MECH. — BELT SYSTEM

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
1.6 LXT
1.6 LXV
1.8X
1.8L
1
. GENERATOR AND AIR CONDITIONING COMPRESSOR AND POWER STEERING PUMP BELT REPLACEMENT
1132200
0.3
0.3
0.2
0.2
2
. DRIVE BELT IDLER PULLEY REPLACEMENT
1132300
0.3
1.4
1.4
1.4
3
. DRIVE BELT TENSIONER REPLACEMENT
1132400
0.4
0.4
0.3
0.3
4
. POWER STEERING PUMP BELT REPLACEMENT
1132700
.
0.2
0.2
0.2
J300 : CRUZE / J309 : ORLANDO

PETROL DOHC ENGINE MECH. — ENGINE BLOCK

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
1.6 LXT
1.6 LXV
1.8X
1.8L
1
. WATER-IN-FUEL DRAINING
1210100
.
.
.
.
2
. OIL LEVEL INDICATOR REPLACEMENT
1210200
.
.
0.1
0.1
3
. OIL LEVEL INDICATOR TUBE REPLACEMENT
1210300
.
0.3
0.2
0.3
4
. ENGINE — REPAIR USING SHORT BLOCK — PETROL ENGINE
1211200
.
10.1
10.0
9.7
Measure cylinder head
121120A
.
1.0
0.8
0.7
Overhaul oil pump (oil pump detached)
121120B
.
0.4
0.3
0.2
Remove And Inst Attaching Parts (cylinder head)
121120C
.
1.2
1.1
0.7
5
. ENGINE OIL PRESSURE INDICATOR SWITCH REPLACEMENT
1211500
0.4
1.5
1.5
1.5
J300 : CRUZE / J309 : ORLANDO

PETROL DOHC ENGINE MECH. — CRANKSHAFT & PISTON

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
1.6 LXT
1.6 LXV
1.8X
1.8L
1
. CRANKSHAFT REAR OIL SEAL REPLACEMENT (6T30/6T40)
1220200
5.5
5.0
5.8
8.1
2
. CRANKSHAFT REAR OIL SEAL REPLACEMENT (D16-5)
1220400
4.9
4.9
4.5
6.7
3
. PISTON, CONNECTING ROD, AND BEARING REMOVAL AND INST
1220800
6.1
9.1
8.5
8.5
Replace One Piston And/Or Con-Rod
122080A
.
0.4
0.2
0.2
Replace An Additional Piston And/Or Con-Rod
122080C
.
0.4
0.2
0.2
Replace Piston Rings
122080D
.
0.8
0.6
0.6
4
. CRANKSHAFT REMOVAL AND INST (D16)
1221100
8.5
9.3
9.1
8.6
Measure Crankshaft
122110L
.
1.1
1.1
.
5
. CRANKSHAFT REMOVAL AND INST (6T30/6T40)
1221200
8.4
9.1
9.0
8.8
Measure Crankshaft
122120L
.
1.2
1.1
.
6
. ENGINE FLYWHEEL REPLACEMENT
1221700
4.8
4.8
5.8
6.4
Rear Crankshaft Seal Ring Replacement
122170A
.
.
.
.
Replace Rear Crankshaft Seal Ring
122170B
0.3
0.4
0.3
.
7
. AUTOMATIC TRANSMISSION FLEX PLATE REPLACEMENT
1221900
5.4
5.4
5.3
8.0
Replace Rear Crankshaft Seal Ring
122190A
0.3
.
.
.
Rear Crankshaft Seal Ring Replacement
122190D
.
.
.
.
J300 : CRUZE / J309 : ORLANDO

PETROL DOHC ENGINE MECH. — OIL SUMP & PUMP

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
1.6 LXT
1.6 LXV
1.8X
1.8L
1
. OIL FILTER ADAPTER AND OIL COOLER ASSEMBLY REPLACEMENT
1231200
.
.
.
1.5
2
. HOUSING, OIL FILTER AND COOLER REPLACEMENT
1231400
.
1.6
.
1.6
3
. SUMP REPLACEMENT
1231500
1.4
1.6
1.5
1.3
Oil Pan Replacement
123150A
.
.
.
.
4
. ENGINE OIL COOLER REPLACEMENT
1231600
.
1.6
1.5
1.5
5
. OIL PUMP COVER WITH OIL PUMP REPLACEMENT
1231700
4.2
4.7
4.2
4.2
Overhaul Oil Pump
123170A
0.5
.
0.2
.
6
. OIL PUMP — OVERHAUL
1231800
.
4.9
4.8
4.2
7
. OIL PUMP SUCTION PIPE REPLACEMENT
1232100
.
.
.
.
8
. ENGINE OIL LEVEL SENSOR REPLACEMENT
1232200
.
1.5
1.5
.
9
. CRANKSHAFT FRONT OIL SEAL REPLACEMENT
1232300
1.2
1.0
1.0
0.9
10
. ENGINE OIL PRESSURE CHECK
1232400
.
0.5
0.5
0.5
11
. OIL FLOW CHECK VALVE REPLACEMENT
1232600
.
0.7
0.7
0.7
12
. OIL PRESSURE RELIEF VALVE REPLACEMENT
1232700
0.7
1.5
1.5
1.5
13
. SEAL RING — OIL PUMP REPLACEMENT
1232900
.
.
.
.
14
. POSITIVE CRANKCASE VENTILATION VALVE HOSE REPLACEMENT
1233700
0.3
0.3
0.2
0.2
15
. ENGINE OIL COOLER INLET PIPE REPLACEMENT
1234000
1.4
1.4
1.4
1.4
16
. ENGINE OIL COOLER OUTLET PIPE REPLACEMENT
1234100
1.4
1.4
1.4
0.7
J300 : CRUZE / J309 : ORLANDO

PETROL DOHC ENGINE MECH. — CYLINDER HEAD

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
1.6 LXT
1.6 LXV
1.8X
1.8L
1
. COMPRESSION CHECK
1311100
0.7
0.5
0.7
0.5
2
. CYLINDER HEAD GASKET REPLACEMENT
.
.
.
.
.
Cylinder Head Removal and Installation
1312300
4.1
4.2
4.1
4.3
Adjust valve clearance
131230A
.
0.7
0.3
0.5
3
. CYLINDER HEAD REMOVAL AND INSTALLATION
1312400
4.1
4.2
4.1
4.3
Adjust Valve Clearance
131240A
.
0.7
0.3
.
Measure Cylinder Head
131240B
.
1.0
0.9
.
Remove and Inst Attaching Parts
131240C
1.0
1.2
1.1
.
Cylinder Head Replacement
131240D
2.9
1.5
.
.
Replace or repair one valve
131240E
0.4
.
0.2
.
Replace or repair one additional valve
131240F
0.4
.
0.1
.
4
. REMOVE AND REINST VALVE SPRING
1312900
2.2
2.8
3.0
2.8
Adjust valve clearance (hydraulic tappet)
131290E
.
0.7
0.6
0.4
Remove and reinst valve springs
131290F
2.3
2.3
2.2
.
5
. VALVE CLEARANCE ADJUSTMENT
1313000
.
2.7
3.1
2.7
6
. VALVE STEM OIL SEAL AND VALVE SPRING REPLACEMENT
1313400
4.4
4.2
4.4
4.2
7
. HYDRAULIC VALVE LASH ADJUSTER REPLACEMENT
1313800
2.2
2.9
3.0
6.7
Adjust valve clearance
131380A
.
0.7
0.6
0.4
8
. ENGINE COOLANT TEMPERATURE SENSOR REPLACEMENT (ENGINE BLOCK) (THERMOSTAT HOUSING)
1314100
0.3
0.3
0.2
0.2
9
. ENGINE COOLANT TEMPERATURE SENSOR REPLACEMENT (RADIATOR) (1.6L LXV, 1.6 LXT AND 1.8L 2H0)
1314400
0.2
0.3
0.2
0.2
J300 : CRUZE / J309 : ORLANDO

PETROL DOHC ENGINE MECH. — CAM SUPPORT & SHAFT

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
1.6 LXT
1.6 LXV
1.8X
1.8L
1
. CAMSHAFT COVER REPLACEMENT
1322100
0.8
0.5
0.4
0.3
2
. CAMSHAFT REPLACEMENT
1322300
2.2
2.9
2.9
2.9
Adjust valve clearance (hydraulic tappet)
132230D
0.2
0.5
0.6
0.4
Replace one other, or tappets/hydraulic tappets
132230E
0.3
0.3
0.2
.
Replace one tappet/hydraulic tappet
132230F
0.1
0.1
0.1
.
3
. INTAKE CAMSHAFT REPLACEMENT
1322400
1.9
2.7
2.7
2.7
Replace one tappet/hydraulic tappet
132240D
0.2
0.2
0.1
.
Replace one other, or tappets/hydraulic tappets
132240E
0.3
0.3
0.2
.
Adjust Valve Clearance
132240F
.
0.5
0.5
.
4
. EXHAUST CAMSHAFT REPLACEMENT
1322600
1.9
2.7
2.7
2.7
Replace One Tappet/hydraulic Tappet
132260D
0.2
0.2
0.1
.
Replace One Additional or Valve Tappets
132260E
0.3
0.3
0.2
.
Adjust Valve Clearance
132260F
.
0.7
0.5
.
5
. ENGINE (IGNITION COIL) COVER REPLACEMENT
1322800
.
0.3
0.2
0.2
6
. CAMSHAFT SEAL REPLACEMENT
1322900
1.3
2.0
1.9
2.0
Replace one further seal ring
132290A
0.4
0.4
0.3
0.2
7
. CAMSHAFT FRONT OIL SEAL — REPLACEMENT
1323000
.
1.1
.
.
8
. CRANKSHAFT PULLEY REPLACEMENT
1332100
0.4
0.5
0.4
1.2
9
. TIMING BELT CENTER FRONT COVER REPLACEMENT
1332200
.
0.4
0.6
0.4
10
. TIMING BELT REAR COVER REPLACEMENT
1332300
2.2
2.2
2.0
2.2
11
. TIMING BELT REPLACEMENT
1332500
1.7
0.9
0.8
0.8
crankshaft sprocket replacement
133250D
0.2
0.3
0.2
.
Timing Belt Tensioner Replacement
133250E
0.3
0.5
0.6
0.3
J300 : CRUZE / J309 : ORLANDO

PETROL DOHC ENGINE MECH. — CAM SUPPORT & SHAFT

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
1.6 LXT
1.6 LXV
1.8X
1.8L
12
. EXHAUST CAMSHAFT REPLACEMENT
1322600
1.9
2.7
2.7
2.7
Replace one additional or valve tappets (hydrotappet)
132260A
0.2
0.1
0.5
.
Replace one tappet/hydraulic tappet
132260B
0.1
0.2
0.2
.
Adjust valve clearance (hydraulic tappet)
132260C
.
0.5
0.1
.
13
. TIMING BELT ADJUSTMENT
1332700
.
.
.
.
14
. TIMING BELT TENSIONER REPLACEMENT
1332900
1.8
1.4
1.3
1.1
J300 : CRUZE / J309 : ORLANDO

PETROL DOHC ENGINE MECH. — TIMING COVER

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
1.6 LXT
1.6 LXV
1.8X
1.8L
1
. CRANKSHAFT SPROCKET REPLACEMENT
1333100
.
1.0
0.9
0.8
2
. CAMSHAFT GEAR REPLACEMENT
1333300
1.3
1.9
.
.
Replace one further camshaft gear
133330A
0.3
.
.
.
3
. WATER PUMP REPLACEMENT
1333500
2.3
0.9
0.8
0.9
4
. WATER PUMP PULLEY REPLACEMENT
1333600
.
0.5
0.4
0.6
5
. CRANKSHAFT POSITION SENSOR
1333700
0.6
0.8
0.6
0.8
6
. CAMSHAFT POSITION SENSOR REPLACEMENT
1333800
0.4
0.3
0.2
0.2
7
. TIMING BELT IDLER PULLEY REPLACEMENT
1333900
1.2
1.0
0.9
0.9
8
. TIMING BELT UPPER FRONT COVER REPLACEMENT
1334200
0.3
0.3
0.2
0.2
9
. TIMING BELT LOWER FRONT COVER REPLACEMENT
1334300
0.5
0.5
0.4
0.4
10
. ACTUATOR EXHAUST CAMSHAFT REPLACEMENT
1336400
.
0.2
0.2
0.2
11
. ACTUATOR INLET CAMSHAFT REPLACEMENT
1336500
.
0.2
0.2
0.2
12
. CAMSHAFT POSITION ACTUATOR ADJUSTER REPLACEMENT
1336800
.
2.0
1.8
2.0
13
. EXHAUST CAMSHAFT POSITION ACTUATOR ADJUSTER REPLACEMENT
1336900
.
1.9
1.8
1.9
J300 : CRUZE / J309 : ORLANDO

PETROL DOHC ENGINE MECH. — ENGINE & TRANSAXLE MOUNT

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
1.6 LXT
1.6 LXV
1.8X
1.8L
1
. ENGINE MOUNT REPLACEMENT — RIGHT SIDE
1380100
1.0
0.7
0.6
0.3
2
. ENGINE MOUNT BRACKET REPLACEMENT — RIGHT SIDE
1380300
1.1
0.7
0.6
0.4
3
. TRANSMISSION MOUNT REPLACEMENT — LIFT SIDE
1380500
1.0
1.0
1.0
1.0
4
. TRANSMISSION REAR MOUNT REPLACEMENT
1380700
0.5
0.5
0.5
0.5
5
. TRANSMISSION FRONT MOUNT REPLACEMENT
1381200
0.3
0.3
0.3
0.3
6
. TRANSMISSION MOUNT BRACKET REPLACEMENT - REAR
1381300
0.5
0.5
0.5
0.4
7
. ENGINE SIGHT SHIELD REPLACEMENT
1382100
0.3
.
.
.
8
. ENGINE LEAK TEST (CO CONCENTRATION IN COOLANT)
1410100
0.3
0.3
0.3
0.2
J300 : CRUZE / J309 : ORLANDO


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