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Kalos-Aveo
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GMDE Start PageLoad static TOCLoad dynamic TOCHelp?

SECTION 1C

DOHC ENGINE MECHANICAL

Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical erminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

SPECIFICATIONS

Engine Specifications

Application
Description
General Data:
.
Engine Type
4 Cylinder (In-Line)
Displacement
1399 cm³
Bore Stroke
77.9 x 73.4 mm (3.0669 in. x 2.8897 in.)
Compression Ratio
9.5 ± 0.2 : 1
Firing Order
1-3-4-2
Cylinder Bore:
.
Diameter
77.9 mm (3.0669 in.)
Out of Round (Maximum)
0.0065 mm (0.00025 in.)
Taper (Maximum)
0.07 x 30°
Piston :
.
Diameter
77.87 mm (3.0657 in.)
Clearance to Bore
0.030 ± 0.010 mm (0.0012 ± 0.0004 in.)
Piston Rings:
.
Ring, End Gap:
.
Top Compression
0.15 ~ 0.30 mm (0.0059 ~ 0.0118 in.)
2nd Compression
0.3 ~ 0.5 mm (0.0118 ~ 0.0197 in.)
Groove Clearance:
.
Top Impression
0.05 ~ 0.09 mm (0.00197 ~ 0.00354 in)
2nd Impression
0.06 ~ 0.1 mm (0.00236 ~ 0.00393 in.)
Piston Pin :
.
Diameter
17.990 ~ 17.995 mm (0.7082 ~ 0.7085 in.)
Pin Off-Set
0.8 ± 0.1 mm (0.0315 ± 0.0039 in.)
Camshaft:
.
Lift Intake:
8.5 mm (0.335 in)
Lift Exhaust
8.5 mm (0.335 in.)
End Play
0.1 ~ 0.25 mm (0.00394 ~ 0.00984 in.)
Journal OD:
.
No. 1
29.935 ~ 29.95 mm (1.1785 ~ 1.1793 in.)
No. 2
26.935 ~ 26.95 mm (1.0604 ~ 1.0610 in.)
No. 3
26.935 ~ 26.95 mm (1.0604 ~ 1.0610 in.)
No. 4
26.935 ~ 26.95 mm (1.0604 ~ 1.0610 in.)
No. 5
26.935 ~ 26.95 mm (1.0604 ~ 1.0610 in.)
Bearing OD:
.
No. 1
30.01 mm (1.181 in.)
No. 2
27.01 mm (1.063 in.)
No. 3
27.01 mm (1.063 in.)
No. 4
27.01 mm (1.063 in.)
No. 5
27.01 mm (1.063 in.)
Crankshaft :
.
Main Journal
.
Diameter (All)
54.982 ~ 54.994 mm (2.164 ~ 2.165 in.)
Taper (Maximum)
0.005 mm (0.000197 in.)
Out of Round (Maximum)
0.004 mm (0.000157 in.)
Main Bearing Clearance (All)
0.026 ~ 0.042 mm (0.00102 ~ 0.00165 in.)
Crankshaft End Play
0.05 ~ 0.28 mm (0.002 ~0.011 in.)
Connecting Rod Journal:
.
Diameter (All)
42.971 ~ 42.981 mm (1.691 ~ 1.692 in.)
Taper (Maximum)
0.005 mm (0.000197 in.)
Out of Round (Maximum)
0.004 mm (0.000157 in.)
Rod Bearing Clearance (All)
0.019 ~ 0.071 mm (0.0007 ~ 0.0028 in.)
Rod Side Clearance
0.070 ~ 0.242 mm (0.0027 ~ 0.009 in.)
Valve System:
.
Valve Lash Compensators
HLA
Face Angle (All)
45.125 ~ 45.375°
Seat Angle (All)
44.5 ~ 45°
Seat Runout (Maximum, All)
0.05 mm (0.00197 in.)
Face Runout (Maximum, All)
0.03 mm (0.00118 in.)
Seat Width:
.
Intake
1.17 ~ 1.57 mm (0.0461 ~ 0.0618 in.)
Exhaust
1.4 ~ 1.8 mm (0.0551 ~ 0.0709 in. )
Valve Guide Inside Diameter (All)
6.0 ~ 6.02 mm (0.236 ~ 0.237 in.)
Valve Stem Diameter
.
Intake
5.955 ~ 5.970 mm (0.234 ~ 0.235 in.)
Exhaust
5.935 ~ 5.950 mm (0.234 ~ 0.234 in.)
Valve Diameter (All):
.
Intake
28.57 ± 0.12 mm (1.125 ± 0.0047 in.)
Exhaust
27.24 ± 0.14 mm (1.074 ± 0.0055 in.)
Valve Spring Loads:
.
Valve Open
580 ± 26 N (426 ± 19 lbs) @ 23 mm (0.90 in.)
Valve Closed
260 ± 13 N (191 ± 9.6 lbs) @ 32 mm (1.25 in.)
Oil Pump :
.
Gap Between Oil Pump Body and Out Rotor
0.400 ~ 0.484 mm (0.0157 ~ 0.0191 in.)
Out Rotor Side Clearance
0.045 ~ 0.100 mm (0.0018 ~ 0.0039 in.)
Inner Rotor Side Clearance
0.035 ~ 0.085 mm (0.0014 ~ 0.0033 in.)
Relief Valve Spring Free Length
81 mm (3.2 in.)

Fastener Tightening Specifcations

Application
N•m
Lb-Ft
Lb-In
Accessory Belt Tension Retaining Bolt
45
33.2
-
A/C Compressor Hose Assembly Retaining Bolt
33
24
-
A/C Compressor Mounting Bolts
27
20
-
A/C Compressor Mounting Bracket Bolts
50
37
-
Air Filter Housing Bolts
12
-
106
Generator Adjusting Bolt
20
15
-
Generator Adjusting Bracket Retaining Bolt
20
15
-
Auxiliary Catalytic Converter-to-Exhaust Manifold Nust
40
30
-
Camshaft Cap Bolts
16
12
-
Connecting Rod Bearing Cap Bolts
25 + 30° + 15°
18 + 30° + 15°
-
Water Pump Retaining Bolts
10
-
89
Coolant Temperature Sensor
20
15
-
Crankshaft Bearing Cap Bolts
50 + 45° + 15°
37 + 45° + 15°
-
Crankshaft Pulley Bolt
95 + 30° + 15°
70 + 30° + 15°
-
Crankshaft Position Sensor Retaining Bolt
10
-
89
Cylinder Head Bolts(Camshaft Support Housing & Cylinder Head Mounting Bolts)
25 + 60° + 60° +60° + 10°
18 + 60° + 60° + 60° + 10°
-
Electronic Ignition System Ignition Coil Mounting Bracket Bolts
10
-
89
Electronic Ignition System Ignition Coil Mounting Bolts
10
-
89
Engine Mount Bracket Retaining Bolt
65
48
-
Engine Mount Retaining Nuts
40
30
-
Engine Mount-to-Engine Mount Bracket Retaining Bolts
60
44
-
Exhaust Camshaft Gear Bolt
67.5
49
-
Exhaust Flexible Pipe Bracket Bolts
40
30
-
Exhaust Gas Recirculation Valve Adapter Bolts
25
18
-
Exhaust Manifold Heat Shield Bolts
15
11
-
Exhaust Manifold Retaining Nuts
25
18
-
Flexible Plate Bolts
60
44
-
Flexible Plate Inspection Cover Bolts
10
-
89
Flywheel Bolts
35 + 30° + 15°
25 + 30° + 15°
-
Flywheel Inspection Cover Bolts
12
-
106
Front Muffler-to-Main Catalytic Converter Nuts
30
22
-
Fuel Rail Retaining Bolts
25
18
-
Intake Camshaft Gear Bolt
67.5
49
-
Intake Manifold Retaining Nuts/Bolts
25
18
-
Intake Manifold Support Bracket Upper Bolts
25
18
-
Intake Manifold Support Bracket Lower Bolt-to-Engine Block
40
30
-
Lower Front Timing Belt Cover Bolts
10
-
89
Oil Pan Retaining Bolts
10
-
89
Oil Pressure Switch
40
30
-
Oil Pump Rear Cover Bolts
6
-
53
Oil Pump Retaining Bolts
10
-
89
Oil Pump Pickup Tube and Support Bracket Bolts
10
-
89
Oil Pump Safety Relief Valve Bolts
30
22
-
Power Steering Pump Mounting Bolts
25
18
-
Power Steering Pump Pulley Bolts
25
18
-
Rear Timing Belt Cover Bolts
10
-
89
Engine Beautification Cover Bolts
3
-
27
Spark Plugs
25
18
-
Thermostat Housing Mounting Bolts
20
15
-
Throttle Cable Bracket Bolts
8
-
71
Timing Belt Automatic Tensioner Bolts
25
18
-
Timing Belt Idler Pulley Bolt
40
30
-
Transaxle Bell Housing Bolts
75
55
-
Transaxle Brace Bolts
40
30
-
Transaxle Torque Converter Bolts
65
48
-
Upper Front Timing Belt Cover Bolts
10
-
89
Cylinder Head Cover Nuts
10
-
89

SPECIAL TOOLS

Special Tools Table


J42492
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J-42492
Timing Belt Adjuster

DW110060
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DW110-060
Engine Assembly Lift Support

KM427
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KM-427
Piston Pin Service Set

MKM571B
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MKM-571-B
Gauge

KM253
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KM-253
Valve Guide Reamer

KM254
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KM-254
Valve Guide Reamer

KM255
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KM-255
Valve Guide Reamer

KM3400
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KM-340-0
Cutter Set Includes:
KM-340-7
KM-340-13
KM-340-26

KM348
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KM-348
Valve Spring Compressor

KM419
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KM-419
Distance Gauge

KM635
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KM-635
Crankshaft Rear Oil Seal Installer

MKM412
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MKM-412
Engine Overhaul Stand

T7B11C04
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EN-48803
Camshaft Seal Installer

KM498B
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KM-498-B
Pressure Gauge

KM470B
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KM-470-B
Angular Torque Gauge

J36972
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J-36972
Crankshaft Rear Oil Seal Installer

KM135
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KM-135
Adapter

COMPONENT LOCATOR

Upper End


T6B31C12
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  1. Engine Beautification Cover
  2. Oil Cap
  3. Cylinder Head Cover
  4. Cylinder Head Cover Bolt
  5. Cylinder Head Washer
  6. Cylinder Head Cover Gasket
  7. Hydraulic Valve Lash Adjuster
  8. Valve Key
  9. Valve Spring Retainer
  10. Valve Spring
  11. Valve Stem Oil Seal
  12. Freeze Plug
  13. Exhaust Manifold
  14. Nut
  15. Exhaust Manifold Heat Shield
  16. Oxygen Sensor
  17. Bolt
  18. Bolt
  19. Thermostat Housing Assembly
  20. Thermostat Housing Seal
  21. Cylinder Head Gasket
  22. Exhaust Valve
  23. Intake Valve
  24. Camshaft Seal
  25. Camshaft Position Sensor
  26. Washer
  27. Camshaft Gear Bolt
  28. Camshaft
  29. Plug
  30. Stud
  31. Engine Coolant Temperature Sensor
  32. Bolt
  33. Front Camshaft Cap
  34. Plug
  35. Valve Guide
  36. Intermediate Camshaft Cap
  37. Washer
  38. Head Bolt
  39. Exhaust Gas Recirculation Pipe
  40. Intake Manifold
  41. Throttle Body
  42. Intake Manifold Gasket
  43. Exhaust Manifold Gasket
  44. Cylinder Head

Lower End


T6B31C13
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  1. Piston Ring Set
  2. Piston
  3. Piston Pin
  4. Connecting Rod
  5. Connecting Rod Bearing Set
  6. Connecting Rod Bolt
  7. Oil Level Gauge Stick
  8. Gauge Stick Tube
  9. Connecting Piece
  10. Oil Filter
  11. Crankshaft Pulley Bolt
  12. Washer
  13. Crankshaft Pulley
  14. Crankshaft Gear
  15. Rear Timing Belt Cover
  16. Bolt
  17. Water Pump
  18. Oil Pump
  19. Engine Block Seal Ring
  20. Oil Pump Body Gasket
  21. Engine Block
  22. Pressure Relief Valve Plunger
  23. Spring
  24. Oil Pump Seal Ring
  25. Bolt Plug
  26. Crankshaft Bearing Set
  27. Crankshaft
  28. Shaft Seal Ring
  29. Flywheel (Manual Transaxle)
  30. Bolt (Manual Transaxle)
  31. Bolt
  32. Crankshaft Position Sensor
  33. Flexible Plate (Automatic Transaxle)
  34. Bolt (Automatic Transaxle)
  35. Crankshaft Main Bearing Cap
  36. Bolt
  37. Bolt
  38. Knock Sensor
  39. Oil Pan
  40. Threaded Ring
  41. Bolt
  42. Bolt
  43. Oil Pickup Tube
  44. Bolt
  45. Seal
  46. Timing Belt
  47. Cover Seal
  48. Cover
  49. Bolt
  50. Idler Pulley
  51. Rear Cover Bolt
  52. Bolt
  53. Auto Tensioner
  54. Seal
  55. Bolt
  56. Gear
  57. Gear
  58. Cover
  59. Bolt
  60. Intake Manifold Support Bracket


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