Chevrolet 2009 Aveo Service Manual Download Page 36

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2009 Chevrolet Aveo

Aveo, Wave, G3, Barina (VIN S/T) Service Manual

Engine

Engine Controls and Fuel - 1.6L (LXT)

Repair Instructions

Document ID: 2098074

Fuel Tank Replacement

Removal Procedure

Warning:

Refer to

Relieving Fuel Pressure Warning

in the Preface section.

1. Relieve the fuel pressure. Refer to

Fuel Pressure Relief

Warning:

Refer to

Battery Disconnect Warning

in the Preface section.

2. Disconnect the negative battery cable.
3. Drain the fuel tank.
4. Disconnect the parking brake cable retainer clamps and the support along the fuel tank to

provide clearance for the tank.

Page 1 of 5

Document ID: 2098074

7/5/2010

http://localhost:9001/si/showDoc.do?docSyskey=2098074&pubCellSyskey=124959&pubO...

Summary of Contents for 2009 Aveo

Page 1: ...27 70 158 467 441 60 140 667 603 50 122 973 837 45 113 1188 991 40 104 1459 1180 35 95 1802 1412 30 86 2238 1700 25 77 2796 2055 20 68 3520 2500 15 59 4450 3055 10 50 5670 3760 5 41 7280 4651 0 32 9420 5800 5 23 12300 7273 10 14 16180 9200 15 5 21450 9200 20 4 28680 15080 30 22 52700 25600 40 40 100700 45300 2010 General Motors Corporation All rights reserved Page 1 of 1 Document ID 1591851 7 5 20...

Page 2: ... local weather station or by using another reference source 4 267 14 000 56 64 3 962 13 000 58 66 3 658 12 000 61 69 3 353 11 000 64 72 3 048 10 000 66 74 2 743 9 000 69 77 2 438 8 000 71 79 2 134 7 000 74 82 1 829 6 000 77 85 1 524 5 000 80 88 1 219 4 000 83 91 914 3 000 87 95 610 2 000 90 98 305 1 000 94 102 0 0 Sea Level 96 104 305 1 000 101 105 2010 General Motors Corporation All rights reserv...

Page 3: ...ation Specification Metric English Firing Order 1 3 4 2 Spark Plug Wire Resistance 2 000 12 000 ohms Spark Plug Gap 1 0 1 1 mm 0 039 0 043 in Spark Plug Torque 25 N m 18 lb ft Spark Plug Type Woojin BKR6E 11 2010 General Motors Corporation All rights reserved Page 1 of 1 Document ID 1640706 7 5 2010 http localhost 9001 si showDoc do docSyskey 1640706 pubCellSyskey 124797 pubO ...

Page 4: ...8 5 N m 75 lb in Exhaust Gas Recirculation Valve Retaining Bolts 30 N m 22 lb ft Fuel Filter Mounting Bracket Assembly Bolt 4 N m 35 lb in Fuel Pressure Regulator Retaining Screw 12 N m 106 lb in Fuel Rail Retaining Bolts 25 N m 18 lb ft Fuel Tank Retaining Bolts 20 N m 15 lb ft Idle Air Control Valve Retaining Bolts 3 N m 27 lb in Knock Sensor Bolt 20 N m 15 lb ft Manifold Absolute Pressure Senso...

Page 5: ...ter 4 EVAP Vent Solenoid 5 Fuel Tank 6 Intake Manifold Tuning Valve IMTV Vacuum Actuator Variable Geometry Induction System VGIS Vacuum Actuator 7 IMTV Solenoid VGIS Solenoid 8 IMTV Vacuum Reservoir VGIS Vacuum Reservoir 9 EVAP Purge Solenoid 10 Manifold Absolute Pressure MAP Sensor 2010 General Motors Corporation All rights reserved Page 1 of 1 Document ID 1497903 7 5 2010 http localhost 9001 si ...

Page 6: ... 4 Evaporative Emissions EVAP Canister 5 Evaporative Emissions EVAP Canister Vent Solenoid Valve 6 Air Filter 7 Fresh Air Intake 8 Fuel Filler Cap 9 Fuel Filler Tube 10 Check Valve 11 Fuel Tank 12 Fuel Fill Vent Valve 13 Fuel Level at Shut Off 14 Fuel Pressure Relief Valve 15 Fuel Tank Pressure Sensor 16 Rollover Valve 2010 General Motors Corporation All rights reserved Page 1 of 1 Document ID 142...

Page 7: ... 3 EVAP Canister Purge Vacuum Line to Intake Manifold 4 EVAP Canister Purge Solenoid Valve 5 EVAP Service Port 6 EVAP Canister Vent Solenoid Valve 7 EVAP Canister 8 Fuel Fill Tube 9 Fuel Filler Cap 10 Fuel Tank Pressure Sensor FTP 11 Fuel Sender Assembly 2010 General Motors Corporation All rights reserved Page 1 of 1 Document ID 1461363 7 5 2010 http localhost 9001 si showDoc do docSyskey 1461363 ...

Page 8: ...emoval Procedure Warning Refer to Battery Disconnect Warning in the Preface section 1 Disconnect the negative battery cable 2 Disconnect the engine control module ECM connectors 3 Remove the ECM retaining nuts 2010 General Motors Corporation All rights reserved Page 1 of 3 Document ID 2098050 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098050 pubCellSyskey 124938 pubO ...

Page 9: ...n Refer to Fastener Caution in the Preface section 2 Install the ECM to the ECM mount and install the retaining bolts Tighten Tighten the ECM retaining bolts to 4 N m 35 lb in Page 2 of 3 Document ID 2098050 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098050 pubCellSyskey 124938 pubO ...

Page 10: ...ollowing procedures 6 Refer to Control Module References for programming and setup information Program the ECM Crankshaft Position System Variation Learn Idle Learn Page 3 of 3 Document ID 2098050 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098050 pubCellSyskey 124938 pubO ...

Page 11: ...rocedure with the scan tool and perform the following 3 1 Accelerate to wide open throttle WOT 3 2 Release throttle when fuel cut off occurs 3 3 Observe fuel cut off for applicable engine 3 4 Engine should not accelerate beyond calibrated RPM value 3 5 Release throttle immediately if value is exceeded 3 6 Block drive wheels 3 7 Set parking brake 3 8 DO NOT apply brake pedal 3 9 Cycle ignition from...

Page 12: ...ds after the learn procedure is completed successfully The CKP system variation learn procedure is also required when the following service procedures have been performed regardless of whether or not DTC P0315 is set Hold throttle while fuel cut off occurs An engine replacement An ECM replacement A harmonic balancer replacement A crankshaft replacement A CKP sensor replacement Any engine repairs w...

Page 13: ...cle is equipped with an automatic transaxle apply the parking brake While pressing the brake pedal place the transaxle in drive D for 10 seconds 9 Turn the A C OFF for 10 seconds if equipped 10 If the vehicle is equipped with an automatic transaxle while pressing the brake pedal place the transaxle in park neutral 11 Turn the ignition OFF The idle learn procedure is complete The throttle body asse...

Page 14: ...ive battery cable 3 Drain the coolant below the engine coolant temperature ECT sensor level 4 Disconnect the ECT sensor connector Caution Use care when handling the coolant sensor Damage to the coolant sensor will affect the operation of the fuel control system 5 Remove the ECT sensor Installation Procedure Caution Refer to Fastener Caution in the Preface section 2010 General Motors Corporation Al...

Page 15: ...5 lb ft 2 Connect the ECT sensor connector 3 Fill the cooling system Refer to Cooling System Draining and Filling 4 Connect the negative battery cable Page 2 of 2 Document ID 2098051 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098051 pubCellSyskey 124939 pubO ...

Page 16: ...Preface section 1 Disconnect the negative battery cable 2 Remove the manifold absolute pressure MAP sensor electrical connector 3 Disconnect the vacuum hose 4 Remove the MAP sensor bolt 5 Remove the MAP sensor Installation Procedure Caution Refer to Fastener Caution in the Preface section 2010 General Motors Corporation All rights reserved Page 1 of 2 Document ID 2098052 7 5 2010 http localhost 90...

Page 17: ...AP sensor bolt to 10 N m 89 lb in 2 Connect the vacuum hose 3 Connect the MAP sensor electrical connector 4 Connect the negative battery cable Page 2 of 2 Document ID 2098052 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098052 pubCellSyskey 124942 pubO ...

Page 18: ...ve battery cable Caution Refer to Heated Oxygen and Oxygen Sensor Caution in the Preface section 2 Disconnect the front heated oxygen sensor HO2S1 connector Caution Remove oxygen sensors with the engine temperature above 48 C 120 F Otherwise the oxygen sensors may be difficult to remove 3 Carefully remove the HO2S1 from the exhaust manifold using EN 46577 Installation Procedure 2010 General Motors...

Page 19: ... and if for any reason it is to be reinstalled the threads must have anti seize compound applied before reinstallation 1 Coat the threads of the HO2S1 will an anti seize compound if needed Caution Refer to Fastener Caution in the Preface section 2 Install the HO2S1 to the exhaust manifold using EN 46577 Tighten Tighten the oxygen sensor to 42 N m 31 lb ft 3 Connect the HO2S1 connector 4 Connect th...

Page 20: ...d Oxygen and Oxygen Sensor Caution in the Preface section Caution Do not solder heated oxygen sensor wires Soldering the wires will result in the loss of the air reference to the sensor Refer to Engine Electrical for proper wire and connection repair techniques 2 Disconnect the electrical connector 3 Remove the heated oxygen sensor 2 HO2S2 Installation Procedure 2010 General Motors Corporation All...

Page 21: ...rom any engine and if for any reason it is to be reinstalled the threads must have anti seize compound applied before reinstallation 1 Coat the threads of the HO2S2 with an anti seize compound if needed Caution Refer to Fastener Caution in the Preface section 2 Install the HO2S2 Tighten Tighten the heated oxygen sensor to 42 N m 31 lb ft 3 Connect the electrical connector 4 Connect the negative ba...

Page 22: ...4 Remove the IAC valve 5 Clean the IAC valve O ring seal area the pintle valve seat and the air passage with a suitable fuel system cleaner Do not use methyl ethyl ketone Installation Procedure Do Not push or pull on the IAC valve pintle on IAC valves that have been in service The force required to move the pintle may damage the threads on the worm drive Do Not soak the IAC valve in any liquid cle...

Page 23: ...quired to retract the pintle will not damage the IAC valve The purpose of the 28 mm 1 1 in setting is to prevent the IAC pintle from bottoming out on the pintle seat This 28 mm 1 1 in setting is also an adequate setting for controlled idle on a restart 1 Lubricate a new O ring with engine oil Install the new O ring onto the valve 2 Install the IAC valve into the throttle body Caution Refer to Fast...

Page 24: ...ve retaining bolts to 3 N m 27 lb in 4 Connect the IAC valve connector 5 Connect the negative battery cable 6 Perform the idle learn procedure Refer to Idle Learn Page 3 of 3 Document ID 2098055 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098055 pubCellSyskey 124947 pubO ...

Page 25: ...connect Warning in the Preface section 1 Disconnect the negative battery cable 2 Disconnect the electronic throttle control ETC connector from the accelerator pedal 3 Remove the 3 accelerator pedal retaining nuts 4 Remove the accelerator pedal Installation Procedure 2010 General Motors Corporation All rights reserved Page 1 of 2 Document ID 2098056 7 5 2010 http localhost 9001 si showDoc do docSys...

Page 26: ...elerator pedal retaining nuts Tighten Tighten the accelerator pedal retaining nuts to 19 N m 14 lb ft 3 Connect the ETC connector to the accelerator pedal 4 Connect the negative battery cable Page 2 of 2 Document ID 2098056 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098056 pubCellSyskey 145217 pubO ...

Page 27: ...re Warning Refer to Battery Disconnect Warning in the Preface section 1 Disconnect the negative battery cable 2 Disconnect the intake air temperature sensor connector 3 Remove the air cleaner inlet duct from the throttle body 2010 General Motors Corporation All rights reserved Page 1 of 4 Document ID 2098058 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098058 pubCellSyskey 124952 pubO ...

Page 28: ...ove the throttle body and discard the gasket Installation Procedure Caution Use care when cleaning the old gasket from the aluminum surfaces in order to prevent damage to the sealing surfaces 1 Clean the gasket mating surface on the intake manifold Page 2 of 4 Document ID 2098058 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098058 pubCellSyskey 124952 pubO ...

Page 29: ...e electronic throttle body assembly with a new gasket Caution Refer to Fastener Caution in the Preface section 4 Install the electronic throttle body retaining nuts and bolts Tighten Tighten the throttle body retaining bolts and nuts to 15 N m 11 lb ft 5 Connect the electronic throttle body electrical connector 6 Install the throttle body coolant hoses Page 3 of 4 Document ID 2098058 7 5 2010 http...

Page 30: ...leaner inlet duct to the throttle body 8 Connect the negative battery cable 9 Fill the cooling system Page 4 of 4 Document ID 2098058 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098058 pubCellSyskey 124952 pubO ...

Page 31: ...nt 2 Open the throttle valve of the throttle body 3 Use a solvent soaked cloth to remove dirt or carbon deposits buildup from the throttle valve and the throttle bore 4 Ensure that the throttle valve and throttle bore are clean and dry 5 Inspect that the throttle valve operates smoothly and freely Install the throttle body to the vehicle Refer to Throttle Body Assembly Replacement 2010 General Mot...

Page 32: ...es the fuel injection pump or the connections In order to reduce the risk of personal injury cover the fuel system components with a shop towel before disconnection This will catch any fuel that may leak out Place the towel in an approved container when the disconnection is complete 1 Remove the fuel cap 2 Remove the fuel pump fuse from the engine fuse box 3 Start the engine and allow the engine t...

Page 33: ... personal injury The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage Place the towel in an approved container when the connection of the fuel pressure gage is complete Caution Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system 1 Install the J 34730 1A to the fuel pressure connec...

Page 34: ... Inspect for fuel leaks Removal Procedure 1 Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure 2 Place a shop towel under the fuel pressure gage to catch any remaining fuel spillage 3 Remove the J 34730 1A from fuel pressure connection 4 Drain any fuel remaining in the fuel pressure gage into an approved container 5 Install the...

Page 35: ...e service procedures Failure to follow these precautions may result in personal injury 1 Remove the fuel filler cap 2 Install the J 42960 2 into the fuel fill pipe in order to hold the door open 3 Insert the J 42960 1 into the fuel tank until the hose reaches the bottom of the fuel tank 4 Use an air operated pump device in order to drain as much fuel through the fuel fill pipe as possible J 42960 ...

Page 36: ...he fuel pressure Refer to Fuel Pressure Relief Warning Refer to Battery Disconnect Warning in the Preface section 2 Disconnect the negative battery cable 3 Drain the fuel tank 4 Disconnect the parking brake cable retainer clamps and the support along the fuel tank to provide clearance for the tank 2010 General Motors Corporation All rights reserved Page 1 of 5 Document ID 2098074 7 5 2010 http loc...

Page 37: ... the fuel tank 8 Disconnect the canister vapor tube at the control valve vapor tube 9 Disconnect the fuel line near the right front of the fuel tank 10 Disconnect the wiring harness clips and the fuel line clips as needed Page 2 of 5 Document ID 2098074 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098074 pubCellSyskey 124959 pubO ...

Page 38: ... fuel tank 13 Remove the fuel tank retaining nuts 14 Carefully lower the fuel tank 15 Remove the fuel tank 16 Transfer any parts as needed Installation Procedure Page 3 of 5 Document ID 2098074 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098074 pubCellSyskey 124959 pubO ...

Page 39: ... lb ft 3 Connect the fuel line 4 Connect the wiring harness clips and the fuel line clips as needed 5 Connect the fuel pump electrical connector 6 Connect the fuel vapor line 7 Connect the fuel tank filler tube and the fuel tank vent tube 8 Install the fuel tank filler tube clamp at the fuel tank 9 Install the front exhaust pipe Refer to Front Pipe Replacement Page 4 of 5 Document ID 2098074 7 5 2...

Page 40: ...brake cable retainer clamps to 10 N m 89 lb in 11 Connect the negative battery cable 12 Fill the fuel tank 13 Perform a leak check of the fuel tank and the fuel line connections Page 5 of 5 Document ID 2098074 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098074 pubCellSyskey 124959 pubO ...

Page 41: ...ve the fuel fill cap Warning Refer to Battery Disconnect Warning in the Preface section 2 Disconnect the negative battery cable 3 Remove the rear seat Refer to Rear Seat Cushion Replacement 4 Remove the fuel sender assembly access cover 2010 General Motors Corporation All rights reserved Page 1 of 3 Document ID 2098075 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098075 pubCellSyskey 1249...

Page 42: ...the FTP from the fuel sender assembly Installation Procedure 1 Install the FTP sensor to the fuel sender assembly 2 Connect the FTP sensor electrical connector Page 2 of 3 Document ID 2098075 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098075 pubCellSyskey 124961 pubO ...

Page 43: ...stall the rear seat Refer to Rear Seat Cushion Replacement 5 Connect the negative battery cable 6 Install the fuel fill cap Page 3 of 3 Document ID 2098075 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098075 pubCellSyskey 124961 pubO ...

Page 44: ...al Procedure Warning Refer to Relieving Fuel Pressure Warning in the Preface section 1 Relieve the fuel system pressure Refer to Fuel Pressure Relief 2 Remove the fuel pump assembly Refer to Fuel Pump Replacement 2010 General Motors Corporation All rights reserved Page 1 of 4 Document ID 2098076 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098076 pubCellSyskey 124963 pubO ...

Page 45: ...rce but can be reconnected 4 Push the terminal wedge 1 in the insulator connector 5 Remove the fuel level sensor 1 from the sender housing 2 6 Remove the sender housing Page 2 of 4 Document ID 2098076 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098076 pubCellSyskey 124963 pubO ...

Page 46: ... fuel sender assembly 3 Installation Procedure 1 Install the wires 1 into the sender assembly 2 Page 3 of 4 Document ID 2098076 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098076 pubCellSyskey 124963 pubO ...

Page 47: ...der assembly onto the fuel pump assembly 1 3 Install the fuel level sensor onto the sender housing 4 Connect the wire into the insulator connector 5 Connect the insulator connector 6 Install the fuel pump assembly into the fuel tank Refer to Fuel Pump Replacement Page 4 of 4 Document ID 2098076 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098076 pubCellSyskey 124963 pubO ...

Page 48: ...edure Warning Refer to Relieving Fuel Pressure Warning in the Preface section 1 Relieve the fuel system pressure Refer to Fuel Pressure Relief Warning Refer to Battery Disconnect Warning in the Preface section 2010 General Motors Corporation All rights reserved Page 1 of 3 Document ID 2098078 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098078 pubCellSyskey 124964 pubO ...

Page 49: ...sconnect the electrical connector at the fuel pump assembly 6 Disconnect the fuel line 7 Remove the fuel pump assembly clip 8 Remove the fuel pump assembly from the tank 9 Remove and discard the gasket Installation Procedure Page 2 of 3 Document ID 2098078 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098078 pubCellSyskey 124964 pubO ...

Page 50: ...el pump assembly clip 5 Connect the fuel pump assembly connector 6 Install the fuel pump line 7 Install the fuel pump access cover 8 Install the EF10 fuse 9 Connect the negative battery cable 10 Perform an operational check of the fuel pump 11 Install the rear seat Refer to Rear Seat Cushion Replacement Page 3 of 3 Document ID 2098078 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098078 pu...

Page 51: ...e work on the fuel or EVAP system is taking place Anytime work is being done on the fuel system disconnect the negative battery cable except for those tests where battery voltage is required 1 Relieve the fuel pressure Refer to Fuel Pressure Relief 2 Disconnect the front fuel hose from the fuel rail 2010 General Motors Corporation All rights reserved Page 1 of 8 Document ID 2098079 7 5 2010 http l...

Page 52: ...ifting and Jacking the Vehicle 4 Disconnect the front fuel hose from the fuel pipe 5 Disconnect the rear fuel hose from the fuel pipe Page 2 of 8 Document ID 2098079 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098079 pubCellSyskey 124965 pubO ...

Page 53: ... pipe mounting plastic bolt 7 Remove the fuel pipe mounting screws and cover 8 Remove the fuel pipe Page 3 of 8 Document ID 2098079 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098079 pubCellSyskey 124965 pubO ...

Page 54: ...p access cover Refer to Fuel Sender Assembly Replacement 10 Disconnect the fuel hose from the fuel pump Page 4 of 8 Document ID 2098079 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098079 pubCellSyskey 124965 pubO ...

Page 55: ...nt 12 Remove rear fuel hose Installation Procedure 1 Connect the rear fuel hose 2 Install the fuel tank Refer to Fuel Tank Replacement Page 5 of 8 Document ID 2098079 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098079 pubCellSyskey 124965 pubO ...

Page 56: ...r Refer to Fuel Sender Assembly Replacement 4 Install the fuel pipe 5 Install the fuel pipe mounting screws and cover Page 6 of 8 Document ID 2098079 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098079 pubCellSyskey 124965 pubO ...

Page 57: ...stall the fuel pipe mounting plastic bolt 7 Connect the rear fuel hose to the fuel pipe Page 7 of 8 Document ID 2098079 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098079 pubCellSyskey 124965 pubO ...

Page 58: ...l pipe 9 Lower the vehicle 10 Connect the fuel hose to the fuel rail 11 Connect the negative battery cable if disconnected Page 8 of 8 Document ID 2098079 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098079 pubCellSyskey 124965 pubO ...

Page 59: ...ing Fuel Pressure Warning in the Preface section 1 Relieve the fuel system pressure Refer to Fuel Pressure Relief Warning Refer to Battery Disconnect Warning in the Preface section 2 Disconnect the negative battery cable 3 Remove the engine cover bolts and cover 2010 General Motors Corporation All rights reserved Page 1 of 7 Document ID 2098080 7 5 2010 http localhost 9001 si showDoc do docSyskey ...

Page 60: ...ute pressure sensor 8 Disconnect the fuel injector harness connectors 9 Remove the purge solenoid valve to intake manifold hose 10 Remove the MAP sensor vacuum hose 11 Remove the upper intake manifold bracket bolts 12 Remove the upper intake manifold bracket Page 2 of 7 Document ID 2098080 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098080 pubCellSyskey 124968 pubO ...

Page 61: ...ector O rings Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail components Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly Page 3 of 7 Document ID 2098080 7 5 2010 http localhost 9001 si showDoc do docSyskey 209...

Page 62: ...allation Procedure Use care when servicing the fuel system components especially the fuel injector electrical connectors the fuel injector tips and the injector O rings Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail components Do not immerse the fuel rail assembly in a...

Page 63: ...l the fuel injectors into the fuel rail sockets with the fuel injector terminals facing outward 3 Install the fuel injector retainer clips onto the fuel injectors and the fuel rail ledge 4 Make sure that the clip is parallel to the fuel injector harness connector 5 Install the fuel rail assembly into the cylinder head Caution Refer to Fastener Caution in the Preface section Page 5 of 7 Document ID...

Page 64: ...ottle body coolant hose 8 Connect the fuel feed hose 9 Install the intake manifold upper bracket with the bolts 10 Install the MAP sensor vacuum hose 11 Install the purge solenoid to intake manifold hose Page 6 of 7 Document ID 2098080 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098080 pubCellSyskey 124968 pubO ...

Page 65: ...Camshaft position sensor 15 Connect the intake air temperature sensor 16 Connect the electronic throttle control connector 17 Install the engine cover with bolts 18 Connect the negative battery cable 19 Perform a leak check of the fuel rail and fuel injectors Page 7 of 7 Document ID 2098080 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098080 pubCellSyskey 124968 pubO ...

Page 66: ... in the Preface section 1 Disconnect the negative battery cable 2 Disconnect the evaporative emission EVAP canister purge solenoid connector 3 Disconnect the vacuum hoses from the EVAP canister purge solenoid 4 Remove the EVAP canister purge solenoid from the intake manifold Installation Procedure 2010 General Motors Corporation All rights reserved Page 1 of 2 Document ID 2098082 7 5 2010 http loc...

Page 67: ...Connect the vacuum hoses to the EVAP canister purge solenoid 3 Connect the EVAP canister purge solenoid connector 4 Connect the negative battery cable Page 2 of 2 Document ID 2098082 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098082 pubCellSyskey 124971 pubO ...

Page 68: ... the area where work on the fuel or EVAP system is taking place Anytime work is being done on the fuel system disconnect the negative battery cable except for those tests where battery voltage is required 1 Disconnect the evaporative emission EVAP canister purge solenoid valve to intake manifold hose 2010 General Motors Corporation All rights reserved Page 1 of 8 Document ID 2098085 7 5 2010 http ...

Page 69: ...anister purge solenoid valve and the EVAP canister vapor pipe 3 Disconnect the EVAP canister pipe from the EVAP canister vapor rear tube Page 2 of 8 Document ID 2098085 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098085 pubCellSyskey 124973 pubO ...

Page 70: ...5 Remove the EVAP canister vapor pipe plastic bolt and cover 6 Remove the EVAP canister vapor pipe 4 mounting screws and cover 7 Remove the EVAP canister vapor pipe Page 3 of 8 Document ID 2098085 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098085 pubCellSyskey 124973 pubO ...

Page 71: ...anister purge tube clip 11 Disconnect the EVAP canister purge tube 12 Remove the fuel tank Refer to Fuel Tank Replacement 13 Remove the rollover valve tube from the fuel tank Installation Procedure Page 4 of 8 Document ID 2098085 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098085 pubCellSyskey 124973 pubO ...

Page 72: ...ent 3 Connect the EVAP canister purge tube 4 Install the EVAP canister purge tube clip 5 Connect the EVAP canister vapor rear tube 6 Install the EVAP canister vapor rear tube clip Page 5 of 8 Document ID 2098085 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098085 pubCellSyskey 124973 pubO ...

Page 73: ... EVAP canister vapor pipe mounting screws and cover 9 Install the EVAP canister vapor pipe plastic bolt and cover 10 Lower the vehicle Page 6 of 8 Document ID 2098085 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098085 pubCellSyskey 124973 pubO ...

Page 74: ...nister vapor rear tube 12 Connect the EVAP canister front tube from the EVAP canister purge solenoid valve and the EVAP canister vapor pipe Page 7 of 8 Document ID 2098085 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098085 pubCellSyskey 124973 pubO ...

Page 75: ...13 Connect the EVAP canister purge solenoid valve to intake manifold hose Page 8 of 8 Document ID 2098085 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098085 pubCellSyskey 124973 pubO ...

Page 76: ...fuel or EVAP system is taking place Anytime work is being done on the fuel system disconnect the negative battery cable except for those tests where battery voltage is required 1 Raise and suitably support the vehicle Refer to Lifting and Jacking the Vehicle 2 Remove the evaporative emission EVAP canister vent solenoid valve bracket bolt 2010 General Motors Corporation All rights reserved Page 1 o...

Page 77: ...al connector 5 Remove the EVAP canister vent solenoid valve hose clip 6 Disconnect the EVAP canister vent solenoid valve hoses 7 Remove the EVAP canister vent solenoid valve Installation Procedure Page 2 of 4 Document ID 2098084 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098084 pubCellSyskey 124972 pubO ...

Page 78: ...EVAP canister vent solenoid valve electrical connector 4 Install the EVAP canister vent solenoid valve bracket to the EVAP canister vent solenoid valve Caution Refer to Fastener Caution in the Preface section Page 3 of 4 Document ID 2098084 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098084 pubCellSyskey 124972 pubO ...

Page 79: ...hten Tighten the EVAP canister vent solenoid valve bracket bolt to 4 N m 35 lb in 6 Lower the vehicle 7 Connect the negative battery cable if disconnected Page 4 of 4 Document ID 2098084 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098084 pubCellSyskey 124972 pubO ...

Page 80: ...g place Anytime work is being done on the fuel system disconnect the negative battery cable except for those tests where battery voltage is required 1 Disconnect the canister fuel vapor hoses 2 Remove the bolt that secures the canister flange to the vehicle 3 Slide the canister out of the track holder 4 Remove the canister Installation Procedure 2010 General Motors Corporation All rights reserved ...

Page 81: ...n the Preface section 2 Install the canister flange bolt Tighten Tighten the evaporative emission EVAP canister flange bolt to 4 N m 35 lb in 3 Connect the canister fuel vapor hoses Page 2 of 2 Document ID 2098086 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098086 pubCellSyskey 124974 pubO ...

Page 82: ...ttery cable 2 Disconnect the electronic ignition EI system ignition coil connector 3 Note the ignition wire location and remove the ignition wire 4 Remove the EI system ignition coil retaining nuts 5 Remove the EI system ignition coil Installation Procedure Caution Refer to Fastener Caution in the Preface section 2010 General Motors Corporation All rights reserved Page 1 of 2 Document ID 2097901 7...

Page 83: ...ng nuts Tighten Tighten the EI system ignition coil retaining nuts to 10 N m 89 lb in 2 Connect the EI system ignition coil connector 3 Connect the negative battery cable Page 2 of 2 Document ID 2097901 7 5 2010 http localhost 9001 si showDoc do docSyskey 2097901 pubCellSyskey 124981 pubO ...

Page 84: ...onditions 1 Correct routing of the spark plug wires Incorrect routing may cause cross firing 2 Any signs of cracks or splits in the wires 3 Inspect each boot for the following conditions If corrosion carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal replace the wire and the component connected to the wire Tearing Piercing Arcing Carbon tracking Corroded terminal 20...

Page 85: ...ion 2 Remove the engine cover from the engine 3 Disconnect the spark plug wire 1 at each spark plug Twist each spark plug boot 1 2 turn before removing Pull only on the boot or use a tool designed for this purpose in order to remove the wire 2010 General Motors Corporation All rights reserved Page 1 of 3 Document ID 2098087 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098087 pubCellSyskey...

Page 86: ...astener Caution in the Preface section from each spark plug Twist each spark plug boot 1 2 turn before removing Pull only on the boot or use a tool designed for this purpose in order to remove the wires from the coil Push down on each boot in order to inspect the seating Reinstall any loose boot Wire routing must be kept intact during service and followed exactly when wires have been disconnected ...

Page 87: ...ll the engine cover on the engine Tighten Tighten the engine cover bolts to 3 N m 31 lb in Page 3 of 3 Document ID 2098087 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098087 pubCellSyskey 124983 pubO ...

Page 88: ...ty conditions Ensure that the spark plug has the correct heat range An incorrect heat range causes the following conditions Spark plug fouling Colder plug Pre ignition causing spark plug and or engine damage Hotter plug Inspect for a bent or broken terminal post 1 Test for a loose terminal post 1 by twisting and pulling the post The terminal post 1 should NOT move 2010 General Motors Corporation A...

Page 89: ...nsulator 2 for cracks All or part of the electrical charge may arc through the crack instead of the electrodes 3 4 Inspect the spark plug boot for damage Inspect the spark plug recess area of the cylinder head for moisture such as oil coolant or water A spark plug boot that is saturated causes arcing to ground Page 2 of 4 Document ID 1456106 7 5 2010 http localhost 9001 si showDoc do docSyskey 145...

Page 90: ...broken or worn side electrode 3 Inspect for a broken worn or loose center electrode 4 by shaking the spark plug A rattling sound indicates internal damage A loose center electrode 4 reduces the spark intensity Inspect for bridged electrodes 3 4 Deposits on the electrodes 3 4 reduce or eliminates the gap Inspect for worn or missing platinum pads on the electrodes 3 4 if equipped Inspect for excessi...

Page 91: ...rmal combustion deposits may not burn off Deposit fouling Oil coolant or additives that include substances such as silicone very white coating reduces the spark intensity Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode Page 4 of 4 Document ID 1456106 7 5 2010 http localhost 9001 si showDoc do docSyskey 1456106 pubCellSyskey 124984 pubO ...

Page 92: ...reads Clean the spark plug recess area before removing the spark plug Failure to do so can result in engine damage due to dirt or foreign material entering the cylinder head or in contamination of the cylinder head threads Contaminated threads may prevent proper seating of the new spark plug Use only the spark plugs specified for use in the vehicle Do not install spark plugs that are either hotter...

Page 93: ...e changed during handling Use a round wire feeler gauge to be sure of an accurate check particularly on used plugs Installing plugs with the wrong gap can cause poor engine performance and may even damage the engine 1 Gap the spark plugs to the specifications Refer to Ignition System Specifications Caution Refer to Fastener Caution in the Preface section Page 2 of 3 Document ID 2098089 7 5 2010 ht...

Page 94: ...ations carefully Over or under tightening can also cause severe damage to engine or spark plug 2 Install the spark plugs to the engine Tighten Tighten the spark plugs to 25 N m 18 lb ft 3 Install the spark plug wires to the spark plugs Refer to Spark Plug Wire Replacement 4 Install the engine cover and tighten the 4 bolts Tighten Tighten the engine cover bolts to 3 N m 31 lb in Page 3 of 3 Documen...

Page 95: ...val Procedure Warning Refer to Battery Disconnect Warning in the Preface section 1 Disconnect the negative battery cable 2 Disconnect the crankshaft position CKP sensor electrical connector 3 Remove the CKP sensor bolt 2010 General Motors Corporation All rights reserved Page 1 of 3 Document ID 2098090 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098090 pubCellSyskey 124986 pubO ...

Page 96: ...er to Fastener Caution in the Preface section 1 Install the CKP sensor with the bolt Tighten Tighten the CKP sensor bolt to 6 5 N m 58 lb in Page 2 of 3 Document ID 2098090 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098090 pubCellSyskey 124986 pubO ...

Page 97: ...2 Connect the CKP sensor electrical connector 3 Connect the negative battery cable Page 3 of 3 Document ID 2098090 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098090 pubCellSyskey 124986 pubO ...

Page 98: ...acement Removal Procedure Warning Refer to Battery Disconnect Warning in the Preface section 1 Disconnect the negative battery cable 2 Remove the engine cover bolts and the nuts 3 Remove the engine cover 2010 General Motors Corporation All rights reserved Page 1 of 3 Document ID 2098091 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098091 pubCellSyskey 124987 pubO ...

Page 99: ...o Timing Belt Replacement Installation Procedure Caution Refer to Fastener Caution in the Preface section 1 Install the CMP sensor and bolt Tighten Tighten the CMP sensor bolts to 7 N m 62 lb in Page 2 of 3 Document ID 2098091 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098091 pubCellSyskey 124987 pubO ...

Page 100: ...ming Belt Replacement 3 Connect the CMP sensor electrical connector 4 Install the engine cover 5 Connect the negative battery cable Page 3 of 3 Document ID 2098091 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098091 pubCellSyskey 124987 pubO ...

Page 101: ...e Warning Refer to Battery Disconnect Warning in the Preface section 1 Disconnect the negative battery cable 2 Disconnect the rough road sensor electrical connector and remove the rough road sensor Installation Procedure 2010 General Motors Corporation All rights reserved Page 1 of 2 Document ID 2097936 7 5 2010 http localhost 9001 si showDoc do docSyskey 2097936 pubCellSyskey 139027 pubO ...

Page 102: ...he rough road sensor and connect the electrical connector 2 Connect the negative battery cable Page 2 of 2 Document ID 2097936 7 5 2010 http localhost 9001 si showDoc do docSyskey 2097936 pubCellSyskey 139027 pubO ...

Page 103: ... Warning Refer to Battery Disconnect Warning in the Preface section 1 Disconnect the negative battery cable 2 Remove the intake manifold bracket bolts and bracket 3 Disconnect the knock sensor KS electrical connector 2010 General Motors Corporation All rights reserved Page 1 of 3 Document ID 2098092 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098092 pubCellSyskey 124945 pubO ...

Page 104: ...on Refer to Fastener Caution in the Preface section 1 Install the KS with the bolt Tighten Tighten the KS bolt to 20 N m 15 lb ft 2 Connect the KS electrical connector Page 2 of 3 Document ID 2098092 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098092 pubCellSyskey 124945 pubO ...

Page 105: ... 4 Connect the negative battery cable Tighten the bracket upper bolt to 25 N m 18 lb ft Tighten the bracket lower bolt to 45 N m 33 lb ft Page 3 of 3 Document ID 2098092 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098092 pubCellSyskey 124945 pubO ...

Page 106: ...he Preface section 1 Disconnect the negative battery cable 2 Disconnect the electrical exhaust gas recirculation EGR valve electrical connector 3 Remove the EGR valve retaining bolts 4 Remove the EGR valve Installation Procedure Caution Refer to Fastener Caution in the Preface section 2010 General Motors Corporation All rights reserved Page 1 of 2 Document ID 2098093 7 5 2010 http localhost 9001 s...

Page 107: ...e electrical EGR valve retaining bolts to 30 N m 22 lb ft 2 Connect the EGR valve electrical connector 3 Connect the negative battery cable Page 2 of 2 Document ID 2098093 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098093 pubCellSyskey 124988 pubO ...

Page 108: ...ocedure 1 Remove the exhaust gas recirculation EGR pipe mounting bolts from the intake manifold 2 Remove the EGR pipe mounting bolts from the EGR valve 3 Raise and suitable support the vehicle Refer to Lifting and Jacking the Vehicle 2010 General Motors Corporation All rights reserved Page 1 of 3 Document ID 2097945 7 5 2010 http localhost 9001 si showDoc do docSyskey 2097945 pubCellSyskey 124989 ...

Page 109: ...Caution Refer to Fastener Caution in the Preface section 1 Install the EGR pipe and the lower bolt attaching the EGR pipe to the intake manifold Tighten Tighten the EGR pipe mounting bolt to 12 N m 106 lb in Page 2 of 3 Document ID 2097945 7 5 2010 http localhost 9001 si showDoc do docSyskey 2097945 pubCellSyskey 124989 pubO ...

Page 110: ...bolts to 10 N m 89 lb in 3 Lower the vehicle 4 Install the EGR pipe mounting bolts to the intake manifold Tighten Tighten the EGR pipe to intake manifold mounting bolts to 12 N m 106 lb in Page 3 of 3 Document ID 2097945 7 5 2010 http localhost 9001 si showDoc do docSyskey 2097945 pubCellSyskey 124989 pubO ...

Page 111: ...ery Disconnect Warning in the Preface section 1 Disconnect the negative battery cable 2 Disconnect the intake manifold tuning IMT valve solenoid 2 connector 3 Disconnect the vacuum hoses from the IMT valve solenoid 2 4 Remove the IMT valve solenoid 2 Installation Procedure 2010 General Motors Corporation All rights reserved Page 1 of 2 Document ID 2097940 7 5 2010 http localhost 9001 si showDoc do...

Page 112: ...the vacuum hoses to the IMT valve solenoid 2 3 Connect the IMT valve solenoid 2 connector 4 Connect the negative battery cable Page 2 of 2 Document ID 2097940 7 5 2010 http localhost 9001 si showDoc do docSyskey 2097940 pubCellSyskey 138498 pubO ...

Page 113: ...the intake manifold tuning IMT valve actuator valve Note Ensure the IMT valve is closed before removing the IMT valve actuator retaining bolts and valve 2 Remove the IMT valve actuator valve bolts 3 Remove the IMT valve actuator valve from the IMT valve Installation Procedure 2010 General Motors Corporation All rights reserved Page 1 of 2 Document ID 2097942 7 5 2010 http localhost 9001 si showDoc...

Page 114: ...ction 2 Install the IMT valve actuator valve bolts Tighten Tighten the IMT valve actuator valve retaining bolts to 12 N m 106 lb ft 3 Connect the vacuum hose to the IMT valve actuator valve Page 2 of 2 Document ID 2097942 7 5 2010 http localhost 9001 si showDoc do docSyskey 2097942 pubCellSyskey 138499 pubO ...

Page 115: ...ing Valve Vacuum Reservoir Replacement Removal Procedure 1 Remove the vacuum hoses from the intake manifold IMT vacuum reservoir 1 2 Remove the IMT valve reservoir 1 Installation Procedure 2010 General Motors Corporation All rights reserved Page 1 of 2 Document ID 1480007 7 5 2010 http localhost 9001 si showDoc do docSyskey 1480007 pubCellSyskey 139185 pubO ...

Page 116: ...stall the IMT valve reservoir 1 2 Install the vacuum hoses to the IMT valve reservoir 1 Page 2 of 2 Document ID 1480007 7 5 2010 http localhost 9001 si showDoc do docSyskey 1480007 pubCellSyskey 139185 pubO ...

Page 117: ...faulty replacement of the entire air cleaner inlet duct will be necessary 1 Turn OFF the ignition 2 Disconnect the electrical connector from the intake air temperature IAT sensor 3 Disconnect the breather tube from the air cleaner intake duct 4 Loosen the clamps securing the air cleaner intake duct 5 Remove air cleaner intake duct Installation Procedure 2010 General Motors Corporation All rights r...

Page 118: ... duct Caution Refer to Fastener Caution in the Preface section 2 Tighten the clamps securing the air cleaner intake duct Tighten Tighten the clamp to 3 N m 27 lb in 3 Connect the breather tube to the air cleaner intake duct 4 Connect the electrical connector to the IAT sensor Page 2 of 2 Document ID 2098094 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098094 pubCellSyskey 139186 pubO ...

Page 119: ...e air cleaner filter from lower air cleaner housing Installation Procedure 1 Install the air cleaner filter into the lower air cleaner housing 2 Install the upper air cleaner cover to lower air cleaner housing Caution Refer to Fastener Caution in the Preface section 3 Install the upper air cleaner screws Tighten Tighten the upper air cleaner cover screws to 3 N m 27 lb in 4 Install the intake duct...

Page 120: ...eaner assembly 2 Remove the air cleaner intake duct from the air cleaner assembly 3 Remove the air cleaner assembly attachment bolts 4 Remove the air cleaner assembly Installation Procedure 1 Install the air cleaner assembly Caution Refer to Fastener Caution in the Preface section 2010 General Motors Corporation All rights reserved Page 1 of 2 Document ID 2098096 7 5 2010 http localhost 9001 si sh...

Page 121: ...ut to 10 N m 89 lb in 3 Install the air cleaner intake duct to the air cleaner assembly Tighten Tighten the air cleaner intake duct clamp to 3 N m 27 lb in Page 2 of 2 Document ID 2098096 7 5 2010 http localhost 9001 si showDoc do docSyskey 2098096 pubCellSyskey 124991 pubO ...

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Chevrolet 2009 Aveo, Service Manual

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