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SECTION 1C2

DIESEL DOHC ENGINE MECHANICAL

DIESEL DOHC ENGINE MECH. — DOHC ENGINE UNIT

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
2.0 LNP
2.0 LNP
1
. ENGINE ASSEMBLY OVERHAUL D33
1110100
10.8
.
Measure Cylinder Head
111010D
0.8
.
Overhaul Cylinder Head (Cylinder Head Detached)
111010E
3.2
.
Overhaul oil pump (oil pump detached)
111010F
0.2
.
Replace camshaft
111010G
.
.
Replace Cylinder Head (Cylinder Head Detached)
111010H
.
.
2
. ENGINE ASSEMBLY OVERHAUL 6T45
1110300
10.3
.
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
. REPLACE ENGINE WITH EXCHANGE ENGINE — DIESEL ENGINE MT
1110200
.
.
4
. REPLACE ENGINE WITH EXCHANGE ENGINE — DIESEL ENGINE AT
1110400
.
.
5
. ENGINE REMOVAL AND INSTALLATION (D16-5)
1110600
4.0
4.1
Remove and inst manual gearbox from/on engine
111060A
1.3
1.3
6
. ENGINE REMOVAL AND INSTALLATION (6T40)
1110700
3.7
3.8
Remove and inst manual gearbox from/on engine
111070A
.
.
Remove and inst automatic transmission with torque converter from/on engine
111070B
.
1.5
7
. ENGINE REPLACEMENT (D16)
1110800
4.1
4.1
Remove And Inst Manual Gearbox From/On Engine
111080D
.
.
Replace one piston and/or con-rod
111080F
.
.
Replace piston rings
111080G
.
.
J300 : CRUZE

DIESEL DOHC ENGINE MECH. — DOHC ENGINE UNIT

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
2.0 LNP
2.0 LNP
8
. ENGINE REPLACEMENT (6T30/6T40)
1110900
3.7
3.8
Remove And Inst Manual Gearbox From/On Engine
111090D
1.3
.
Remove And Inst Automatic Transmission From/On Engine
111090E
1.5
.
Replace one piston and/or con-rod
111090F
.
.
Replace piston rings
111090G
.
.
9
. ENGINE OIL AND OIL FILTER REPLACEMENT
1112200
0.4
0.3
J300 : CRUZE

DIESEL DOHC ENGINE MECH. — BELT SYSTEM

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
2.0 LNP
2.0 LNP
1
. GENERATOR AND AIR CONDITIONING COMPRESSOR AND POWER STEERING PUMP BELT REPLACEMENT
1132200
0.6
0.6
2
. DRIVE BELT IDLER PULLEY REPLACEMENT
1132300
0.7
0.6
3
. DRIVE BELT TENSIONER REPLACEMENT
1132400
0.6
0.7
4
. POWER STEERING PUMP BELT REPLACEMENT
1132700
.
.
J300 : CRUZE

DIESEL DOHC ENGINE MECH. — ENGINE BLOCK

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
2.0 LNP
2.0 LNP
1
. WATER-IN-FUEL DRAINING
1210100
.
.
2
. OIL LEVEL INDICATOR REPLACEMENT
1210200
0.2
0.2
3
. OIL LEVEL INDICATOR TUBE REPLACEMENT
1210300
1.2
1.2
4
. ENGINE — REPAIR USING SHORT BLOCK — PETROL ENGINE
1211200
.
.
Measure cylinder head
121120A
.
.
Overhaul oil pump (oil pump detached)
121120B
.
.
Remove And Inst Attaching Parts (cylinder head)
121120C
.
.
5
. ENGINE OIL PRESSURE INDICATOR SWITCH REPLACEMENT
1211500
0.5
0.3
J300 : CRUZE

DIESEL DOHC ENGINE MECH. — CRANKSHAFT & PISTON

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
2.0 LNP
2.0 LNP
1
. CRANKSHAFT REAR OIL SEAL REPLACEMENT (6T30/6T40)
1220200
8.0
8.0
2
. CRANKSHAFT REAR OIL SEAL REPLACEMENT (D16-5)
1220400
7.3
7.3
3
. PISTON, CONNECTING ROD, AND BEARING REMOVAL AND INST
1220800
10.5
10.9
Replace One Piston And/Or Con-Rod
122080A
0.3
.
Replace An Additional Piston And/Or Con-Rod
122080C
0.3
.
Replace Piston Rings
122080D
0.8
.
4
. CRANKSHAFT REMOVAL AND INST (D16)
1221100
9.6
9.3
Measure Crankshaft
122110L
1.3
1.1
5
. CRANKSHAFT REMOVAL AND INST (6T30/6T40)
1221200
9.2
8.9
Measure Crankshaft
122120L
1.1
1.1
6
. ENGINE FLYWHEEL REPLACEMENT
1221700
7.2
7.2
Rear Crankshaft Seal Ring Replacement
122170A
0.3
.
Replace Rear Crankshaft Seal Ring
122170B
0.3
0.3
7
. PISTONS AND CONNECTING RODS, — REMOVE AND REINST — DIESEL ENGINE
1221800
10.5
10.9
Replace one additional piston and/or connecting rod
122180A
.
.
Replace one piston and/or connecting rod
122180B
.
.
Replace piston rings
122180C
.
.
8
. AUTOMATIC TRANSMISSION FLEX PLATE REPLACEMENT
1221900
8.0
8.0
Replace Rear Crankshaft Seal Ring
122190A
.
.
Rear Crankshaft Seal Ring Replacement
122190D
.
.
J300 : CRUZE

DIESEL DOHC ENGINE MECH. — OIL SUMP & PUMP

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
2.0 LNP
2.0 LNP
1
. OIL FILTER ELEMENT — REPLACE — DIESEL ENGINE
1231100
.
.
2
. OIL FILTER ADAPTER AND OIL COOLER ASSEMBLY REPLACEMENT
1231200
2.2
1.9
3
. HOUSING, OIL FILTER AND COOLER REPLACEMENT
1231400
.
.
4
. SUMP REPLACEMENT
1231500
0.7
0.7
Oil Pan Replacement
123150A
0.2
.
5
. ENGINE OIL COOLER REPLACEMENT
1231600
1.7
1.7
6
. OIL PUMP COVER WITH OIL PUMP REPLACEMENT
1231700
5.3
.
Overhaul Oil Pump
123170A
0.2
.
7
. OIL PUMP — OVERHAUL
1231800
6.2
.
8
. OIL PUMP SUCTION PIPE REPLACEMENT
1232100
3.0
.
9
. ENGINE OIL LEVEL SENSOR REPLACEMENT
1232200
.
.
10
. CRANKSHAFT FRONT OIL SEAL REPLACEMENT
1232300
1.3
1.2
11
. ENGINE OIL PRESSURE CHECK
1232400
.
.
12
. OIL FLOW CHECK VALVE REPLACEMENT
1232600
.
.
13
. OIL PRESSURE RELIEF VALVE REPLACEMENT
1232700
0.4
0.4
14
. SEAL RING — OIL PUMP REPLACEMENT
1232900
6.1
.
15
. POSITIVE CRANKCASE VENTILATION VALVE HOSE REPLACEMENT
1233700
0.2
0.2
16
. ENGINE OIL FILLER CAP — REPLACE — DIESEL ENGINE
1233800
.
.
17
. ENGINE OIL COOLER INLET PIPE REPLACEMENT
1234000
0.5
.
18
. ENGINE OIL COOLER OUTLET PIPE REPLACEMENT
1234100
1.0
1.0
J300 : CRUZE

DIESEL DOHC ENGINE MECH. — CYLINDER HEAD

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
2.0 LNP
2.0 LNP
1
. COMPRESSION CHECK
1311100
.
.
2
. VALVE ROCKER ARMS — REPLACE — DIESEL ENGINE
1312100
6.5
6.5
3
. CYLINDER HEAD GASKET REPLACEMENT
.
.
.
Cylinder Head Removal and Installation
1312300
9.2
9.2
Adjust valve clearance
131230A
.
.
4
. CYLINDER HEAD REMOVAL AND INSTALLATION
1312400
9.2
9.2
Adjust Valve Clearance
131240A
.
.
Measure Cylinder Head
131240B
0.8
.
Remove and Inst Attaching Parts
131240C
.
.
Cylinder Head Replacement
131240D
2.2
.
Replace or repair one valve
131240E
0.5
.
Replace or repair one additional valve
131240F
.
.
5
. CYLINDER HEAD — REMOVE AND REINST — DIESEL ENGINE
1312500
9.2
9.2
Cylinder Head Replacement
131250C
.
.
Measure cylinder head
131250D
.
.
Overhaul cylinder head
131250E
.
.
Replace or repair one additional valve
131250F
.
.
Replace or repair one valve
131250G
.
.
6
. REMOVE AND REINST VALVE SPRING
1312900
6.7
.
Adjust valve clearance (hydraulic tappet)
131290E
.
.
Remove and reinst valve springs
131290F
0.3
.
7
. VALVE CLEARANCE ADJUSTMENT
1313000
.
.
8
. VALVE STEM OIL SEAL AND VALVE SPRING REPLACEMENT
1313400
7.4
7.4
9
. VALVE BRIDGES, REPLACE — DIESEL ENGINE
1313600
.
.
10
. HYDRAULIC VALVE LASH ADJUSTER REPLACEMENT
1313800
6.7
6.7
Adjust valve clearance
131380A
.
.
J300 : CRUZE

DIESEL DOHC ENGINE MECH. — CYLINDER HEAD

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
2.0 LNP
2.0 LNP
11
. ENGINE COOLANT TEMPERATURE SENSOR REPLACEMENT (ENGINE BLOCK) (THERMOSTAT HOUSING)
1314100
1.2
.
12
. VALVE STEM SEALS — REPLACE — DIESEL ENGINE
1314200
7.4
7.4
13
. ENGINE COOLANT TEMPERATURE SENSOR REPLACEMENT (RADIATOR) (1.6L LXV, 1.6 LXT AND 1.8L 2H0)
1314400
.
.
J300 : CRUZE

DIESEL DOHC ENGINE MECH. — CAM SUPPORT & SHAFT

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
2.0 LNP
2.0 LNP
1
. CAMSHAFT COVER REPLACEMENT
1322100
0.8
0.8
2
. CAMSHAFT REPLACEMENT
1322300
0.5
.
Adjust valve clearance (hydraulic tappet)
132230D
.
0.1
Replace one other, or tappets/hydraulic tappets
132230E
.
0.1
Replace one tappet/hydraulic tappet
132230F
.
.
3
. INTAKE CAMSHAFT REPLACEMENT
1322400
6.6
6.4
Replace one tappet/hydraulic tappet
132240D
.
0.1
Replace one other, or tappets/hydraulic tappets
132240E
.
0.1
Adjust Valve Clearance
132240F
.
.
4
. EXHAUST CAMSHAFT REPLACEMENT
1322600
6.5
6.2
Replace One Tappet/hydraulic Tappet
132260D
.
0.1
Replace One Additional or Valve Tappets
132260E
.
0.1
Adjust Valve Clearance
132260F
.
.
5
. ENGINE (IGNITION COIL) COVER REPLACEMENT
1322800
0.3
0.3
6
. CAMSHAFT SEAL REPLACEMENT
1322900
.
.
Replace one further seal ring
132290A
.
.
7
. CAMSHAFT FRONT OIL SEAL — REPLACEMENT
1323000
1.3
1.3
8
. CRANKSHAFT PULLEY REPLACEMENT
1332100
1.2
1.2
9
. TIMING BELT CENTER FRONT COVER REPLACEMENT
1332200
.
.
10
. TIMING BELT REAR COVER REPLACEMENT
1332300
2.7
.
11
. TIMING BELT REPLACEMENT
1332500
.
.
crankshaft sprocket replacement
133250D
.
.
Timing Belt Tensioner Replacement
133250E
.
.
J300 : CRUZE

DIESEL DOHC ENGINE MECH. — CAM SUPPORT & SHAFT

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
2.0 LNP
2.0 LNP
12
. EXHAUST CAMSHAFT REPLACEMENT
1322600
.
.
Replace one additional or valve tappets (hydrotappet)
132260A
.
.
Replace one tappet/hydraulic tappet
132260B
.
.
Adjust valve clearance (hydraulic tappet)
132260C
.
.
13
. ENGINE FRONT COVER REPLACEMENT
1332200
5.4
5.4
14
. TIMING BELT ADJUSTMENT
1332700
.
.
15
. TIMING BELT TENSIONER REPLACEMENT
1332900
.
.
J300 : CRUZE

DIESEL DOHC ENGINE MECH. — TIMING COVER

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
2.0 LNP
2.0 LNP
1
. CRANKSHAFT SPROCKET REPLACEMENT
1333100
6.5
6.5
2
. CAMSHAFT GEAR REPLACEMENT
1333300
2.4
.
Replace one further camshaft gear
133330A
.
.
3
. WATER PUMP REPLACEMENT
1333500
3.0
3.0
4
. WATER PUMP PULLEY REPLACEMENT
1333600
0.6
0.6
5
. CRANKSHAFT POSITION SENSOR
1333700
0.3
.
6
. CAMSHAFT POSITION SENSOR REPLACEMENT
1333800
0.2
.
7
. TIMING BELT IDLER PULLEY REPLACEMENT
1333900
2.4
.
8
. TIMING BELT UPPER FRONT COVER REPLACEMENT
1334200
0.8
.
9
. TIMING BELT LOWER FRONT COVER REPLACEMENT
1334300
0.9
.
10
. TIMING CHAIN TENSIONER REPLACEMENT
1334500
5.7
5.6
11
. TIMING CHAIN REPLACEMENT
1334600
6.4
6.4
12
. ACTUATOR EXHAUST CAMSHAFT REPLACEMENT
1336400
.
.
13
. ACTUATOR INLET CAMSHAFT REPLACEMENT
1336500
.
.
14
. CAMSHAFT POSITION ACTUATOR ADJUSTER REPLACEMENT
1336800
.
.
15
. EXHAUST CAMSHAFT POSITION ACTUATOR ADJUSTER REPLACEMENT
1336900
.
.
J300 : CRUZE

DIESEL DOHC ENGINE MECH. — ENGINE & TRANSAXLE MOUNT

NO.
OPERATION DESCRIPTION
OPERATION CODE
MODEL
J300
J309
2.0 LNP
2.0 LNP
1
. ENGINE MOUNT REPLACEMENT — RIGHT SIDE
1380100
0.3
0.3
2
. ENGINE MOUNT BRACKET REPLACEMENT — RIGHT SIDE
1380300
0.4
0.4
3
. TRANSMISSION MOUNT REPLACEMENT
1380500
1.1
1.0
4
. TRANSMISSION REAR MOUNT REPLACEMENT
1380700
0.5
0.5
5
. TRANSMISSION FRONT MOUNT REPLACEMENT
1381200
0.4
0.4
6
. TRANSMISSION MOUNT BRACKET REPLACEMENT - REAR
1381300
0.5
0.5
7
. ENGINE SIGHT SHIELD REPLACEMENT
1382100
0.1
0.1
8
. ENGINE LEAK TEST (CO CONCENTRATION IN COOLANT)
1410100
0.1
0.1
J300 : CRUZE


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