Chevrolet Aveo 2009 Service Manual
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Chevrolet Aveo 2009 Service Manual

Engine controls and fuel - 1.6l (lxt)
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See also: Owner's Manual
Document ID: 1591851
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2009 Chevrolet Aveo
Aveo, Wave, G3, Barina (VIN S/T) Service Manual

Temperature Versus Resistance

°C
°F
Temperature vs Resistance Values (Approximate)
100
212
90
194
80
176
70
158
60
140
50
122
45
113
40
104
35
95
30
86
25
77
20
68
15
59
10
50
5
41
0
32
-5
23
-10
14
-15
5
-20
-4
-30
-22
-40
-40
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| Document ID: 1591851
Specifications
ECT Ohms
177
241
332
467
667
973
1188
1459
1802
2238
2796
3520
4450
5670
7280
9420
12300
16180
21450
28680
52700
100700
© 2010 General Motors Corporation. All rights reserved.
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Engine
Engine Controls and Fuel - 1.6L (LXT)
IAT Ohms
187
246
327
441
603
837
991
1180
1412
1700
2055
2500
3055
3760
4651
5800
7273
9200
9200
15080
25600
45300
Page 1 of 1
7/5/2010

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  • Page 1 Document ID: 1591851 Page 1 of 1 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 1591851 Specifications Temperature Versus Resistance °C °F ECT Ohms IAT Ohms...
  • Page 2 Document ID: 839729 Page 1 of 1 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 839729 Specifications Altitude Versus Barometric Pressure Altitude Measured in Altitude Measured in...
  • Page 3 Document ID: 1640706 Page 1 of 1 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 1640706 Specifications Ignition System Specifications Specification Application Metric English Firing Order...

  • Page 4: Fastener Tightening Specifications

    Document ID: 1735697 Page 1 of 1 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 1735697 Specifications Fastener Tightening Specifications Specification Application Metric English Accessory Mounting Bracket Bolts 37 N·m...
  • Page 5 Document ID: 1497903 Page 1 of 1 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 1497903 Schematic and Routing Diagrams Emission Hose Routing Diagram (1) To HVAC...
  • Page 6 Document ID: 1420658 Page 1 of 1 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 1420658 Schematic and Routing Diagrams Evaporative Emissions Hose Routing Diagram (1) Intake Manifold...
  • Page 7 Document ID: 1461363 Page 1 of 1 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 1461363 Schematic and Routing Diagrams Fuel Hose/Pipes Routing Diagram (1) Fuel Tank...
  • Page 8 Document ID: 2098050 Page 1 of 3 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098050 Repair Instructions Engine Control Module Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning in the Preface section.
  • Page 9 Document ID: 2098050 Page 2 of 3 4. Remove the ECM from the ECM mount. Installation Procedure 1. Position the ECM in place. Caution: 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 10 Document ID: 2098050 Page 3 of 3 3. Connect the ECM connectors. 4. Connect the negative battery cable. 5. Perform the following procedures: • Program the ECM • Crankshaft Position System Variation Learn • Idle Learn 6. Refer to Control Module References for programming and setup information.
  • Page 11 Document ID: 1629748 Page 1 of 2 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 1629748 Repair Instructions Crankshaft Position System Variation Learn Important: If the crankshaft position variation learn procedure has not learned, a false misfire could be detected and DTC P0300 may set.
  • Page 12 Document ID: 1629748 Page 2 of 2 • Hold throttle while fuel cut-off occurs. 5. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to P0315.
  • Page 13 Document ID: 1685961 Page 1 of 1 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 1685961 Repair Instructions Idle Learn The Idle Learn Procedure listed below must be performed whenever the following occurs: •...
  • Page 14 Document ID: 2098051 Page 1 of 2 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098051 Repair Instructions Engine Coolant Temperature Sensor Replacement Removal Procedure 1. Relieve the coolant system pressure.
  • Page 15 Document ID: 2098051 Page 2 of 2 1. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N·m (15 lb ft). 2. Connect the ECT sensor connector. 3. Fill the cooling system. Refer to Cooling System Draining and Filling.
  • Page 16 Document ID: 2098052 Page 1 of 2 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098052 Repair Instructions Manifold Absolute Pressure Sensor Replacement Removal Procedure Warning:...
  • Page 17 Document ID: 2098052 Page 2 of 2 1. Install the MAP sensor with the bolt. Tighten Tighten the MAP 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. http://localhost:9001/si/showDoc.do?docSyskey=2098052&pubCellSyskey=124942&pubO...
  • Page 18 Document ID: 2098053 Page 1 of 2 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098053 Repair Instructions Heated Oxygen Sensor Replacement - Sensor 1 Special Tools...
  • Page 19 Document ID: 2098053 Page 2 of 2 Note: A special anti-seize compound is used on the oxygen sensor threads. This compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads.
  • Page 20 Document ID: 2098054 Page 1 of 2 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098054 Repair Instructions Heated Oxygen Sensor Replacement - Sensor 2 Removal Procedure...
  • Page 21 Document ID: 2098054 Page 2 of 2 Note: A special anti-seize compound is used on the oxygen sensor threads. This compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads.
  • Page 22 Document ID: 2098055 Page 1 of 3 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098055 Repair Instructions Idle Air Control Valve Replacement Removal Procedure Warning:...
  • Page 23 Document ID: 2098055 Page 2 of 3 Note: If installing a new IAC valve, be sure to replace it with an identical part. The IAC valve pintle shape and diameter are designed for the specific application. Measure the distance between the tip of the IAC valve pintle and the mounting flange. If the distance is greater than 28 mm (1.1 in), use finger pressure to slowly retract the pintle.
  • Page 24 Document ID: 2098055 Page 3 of 3 3. Install the IAC valve retaining bolts. Tighten Tighten the idle air control valve retaining bolts to 3 N·m (27 lb in). 4. Connect the IAC valve connector. 5. Connect the negative battery cable. 6.
  • Page 25 Document ID: 2098056 Page 1 of 2 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098056 Repair Instructions Accelerator Pedal Position Sensor Replacement Removal Procedure Warning:...
  • Page 26 Document ID: 2098056 Page 2 of 2 1. Position the accelerator pedal. Caution: Refer to Fastener Caution in the Preface section. 2. Install the 3 accelerator pedal retaining nuts. Tighten Tighten the accelerator pedal retaining nuts to 19 N·m (14 lb ft). 3.
  • Page 27 Document ID: 2098058 Page 1 of 4 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098058 Repair Instructions Throttle Body Assembly Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning in the Preface section.
  • Page 28 Document ID: 2098058 Page 2 of 4 4. Disconnect the electronic throttle body connector. 5. Disconnect the coolant hoses from the electronic throttle body. 6. Remove the throttle body retaining bolts. 7. Remove 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.
  • Page 29 Document ID: 2098058 Page 3 of 4 Note: If the electronic throttle control valve is removed from the throttle body, the throttle body may be cleaned in a cold immersion type cleaner. Do not clean the electronic throttle control valve with any type of solvent or cleaner. 2.
  • Page 30 Document ID: 2098058 Page 4 of 4 7. Install the air cleaner inlet duct to the throttle body. 8. Connect the negative battery cable. 9. Fill the cooling system. http://localhost:9001/si/showDoc.do?docSyskey=2098058&pubCellSyskey=124952&pubO... 7/5/2010...
  • Page 31 Document ID: 2098059 Page 1 of 1 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098059 Repair Instructions Throttle Body Inspection and Cleaning Warning: Wear safety glasses when using compressed air in order to prevent eye injury.
  • Page 32 Document ID: 2098061 Page 1 of 1 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098061 Repair Instructions Fuel Pressure Relief Warning: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury.
  • Page 33 Document ID: 2098062 Page 1 of 2 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098062 Repair Instructions Fuel Pressure Gage Installation and Removal Special Tools...
  • Page 34 Document ID: 2098062 Page 2 of 2 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the gage. 4.
  • Page 35 Document ID: 2097105 Page 1 of 1 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2097105 Repair Instructions Fuel Tank Draining Special Tools • J 42960-2 Fuel Flapper Door Holder •...

  • Page 36: Fuel Tank Replacement

    Document ID: 2098074 Page 1 of 5 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098074 Repair Instructions Fuel Tank Replacement Removal Procedure Warning: Refer to Relieving Fuel Pressure Warning in the Preface section.
  • Page 37 Document ID: 2098074 Page 2 of 5 5. Remove the fuel tank filler tube clamp at the fuel tank. 6. Disconnect the fuel tank filler tube. 7. Disconnect the fuel tank filler tube at the fuel tank. 8. Disconnect the canister vapor tube at the control valve vapor tube. 9.
  • Page 38 Document ID: 2098074 Page 3 of 5 11. Remove the front exhaust pipe. Refer to Front Pipe Replacement. 12. Support the fuel tank. 13. Remove the fuel tank retaining nuts. 14. Carefully lower the fuel tank. 15. Remove the fuel tank. 16.
  • Page 39 Document ID: 2098074 Page 4 of 5 1. Raise the fuel tank into position. Caution: Refer to Fastener Caution in the Preface section. Caution: Refer to Fuel Tank Strap Fastener Caution in the Preface section. 2. Install the fuel tank mounting straps and bolts. Tighten Tighten the fuel tank strap retaining bolts to 20 N·m (15 lb ft).
  • Page 40 Document ID: 2098074 Page 5 of 5 10. Install the parking brake cable retainer clamps and the support. Tighten Tighten the parking brake cable retainer clamps to 10 N·m (89 lb in). 11. Connect the negative battery cable. 12. Fill the fuel tank. 13.
  • Page 41 Document ID: 2098075 Page 1 of 3 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098075 Repair Instructions Fuel Tank Pressure Sensor Replacement Removal Procedure 1. Remove the fuel fill cap.
  • Page 42 Document ID: 2098075 Page 2 of 3 5. Disconnect the fuel tank pressure (FTP) sensor electrical connector. 6. Remove 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. http://localhost:9001/si/showDoc.do?docSyskey=2098075&pubCellSyskey=124961&pubO...
  • Page 43 Document ID: 2098075 Page 3 of 3 3. Install the fuel pump access cover. 4. Install the rear seat. Refer to Rear Seat Cushion Replacement. 5. Connect the negative battery cable. 6. Install the fuel fill cap. http://localhost:9001/si/showDoc.do?docSyskey=2098075&pubCellSyskey=124961&pubO... 7/5/2010...
  • Page 44 Document ID: 2098076 Page 1 of 4 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098076 Repair Instructions Fuel Sender Assembly Replacement Removal Procedure Warning: Refer to Relieving Fuel Pressure Warning in the Preface section.
  • Page 45 Document ID: 2098076 Page 2 of 4 3. Disconnect the insulator connector. Note: The wedge may be disconnected with severe force 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.
  • Page 46 Document ID: 2098076 Page 3 of 4 7. Remove the fuel sender assembly (3). Installation Procedure 1. Install the wires (1) into the sender assembly (2). http://localhost:9001/si/showDoc.do?docSyskey=2098076&pubCellSyskey=124963&pubO... 7/5/2010...
  • Page 47 Document ID: 2098076 Page 4 of 4 Note: Ensure the sender assembly and the fuel level sensor are installed properly. If not the fuel gauge and fuel level warning indicator will not function properly. 2. Install the sender assembly onto the fuel pump assembly (1). 3.

  • Page 48: Fuel Pump Replacement

    Document ID: 2098078 Page 1 of 3 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098078 Repair Instructions Fuel Pump Replacement Removal Procedure Warning: Refer to Relieving Fuel Pressure Warning in the Preface section.
  • Page 49 Document ID: 2098078 Page 2 of 3 2. Disconnect the negative battery cable. 3. Remove the rear seat. Refer to Rear Seat Cushion Replacement. 4. Remove the fuel pump access cover. 5. Disconnect the electrical connector at the fuel pump assembly. 6.
  • Page 50 Document ID: 2098078 Page 3 of 3 1. Clean the gasket mating surface on the fuel tank. 2. Position the new gasket in place. 3. Install the fuel pump into the fuel tank in the same location as removed for ease of line and connector installation.
  • Page 51 Document ID: 2098079 Page 1 of 8 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098079 Repair Instructions Fuel Hose/Pipes Assembly Replacement Removal Procedure Warning: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place.
  • Page 52 Document ID: 2098079 Page 2 of 8 3. Lift and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Disconnect the front fuel hose from the fuel pipe. 5. Disconnect the rear fuel hose from the fuel pipe. http://localhost:9001/si/showDoc.do?docSyskey=2098079&pubCellSyskey=124965&pubO...
  • Page 53 Document ID: 2098079 Page 3 of 8 6. Remove the fuel pipe mounting plastic bolt. 7. Remove the fuel pipe mounting screws and cover. 8. Remove the fuel pipe. http://localhost:9001/si/showDoc.do?docSyskey=2098079&pubCellSyskey=124965&pubO... 7/5/2010...
  • Page 54 Document ID: 2098079 Page 4 of 8 9. Remove the fuel pump access cover. Refer to Fuel Sender Assembly Replacement. 10. Disconnect the fuel hose from the fuel pump. http://localhost:9001/si/showDoc.do?docSyskey=2098079&pubCellSyskey=124965&pubO... 7/5/2010...
  • Page 55 Document ID: 2098079 Page 5 of 8 11. Remove the fuel tank. Refer to Fuel Tank Replacement. 12. Remove rear fuel hose. Installation Procedure 1. Connect the rear fuel hose. 2. Install the fuel tank. Refer to Fuel Tank Replacement. http://localhost:9001/si/showDoc.do?docSyskey=2098079&pubCellSyskey=124965&pubO...
  • Page 56 Document ID: 2098079 Page 6 of 8 3. Install the fuel pump access cover. Refer to Fuel Sender Assembly Replacement. 4. Install the fuel pipe. 5. Install the fuel pipe mounting screws and cover. http://localhost:9001/si/showDoc.do?docSyskey=2098079&pubCellSyskey=124965&pubO... 7/5/2010...
  • Page 57 Document ID: 2098079 Page 7 of 8 6. Install the fuel pipe mounting plastic bolt. 7. Connect the rear fuel hose to the fuel pipe. http://localhost:9001/si/showDoc.do?docSyskey=2098079&pubCellSyskey=124965&pubO... 7/5/2010...
  • Page 58 Document ID: 2098079 Page 8 of 8 8. Connect the front fuel hose to the fuel pipe. 9. Lower the vehicle. 10. Connect the fuel hose to the fuel rail. 11. Connect the negative battery cable, if disconnected. http://localhost:9001/si/showDoc.do?docSyskey=2098079&pubCellSyskey=124965&pubO... 7/5/2010...
  • Page 59 Document ID: 2098080 Page 1 of 7 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098080 Repair Instructions Fuel Injection Fuel Rail Assembly Replacement Removal Procedure...
  • Page 60 Document ID: 2098080 Page 2 of 7 4. Disconnect the electronic throttle control connector. 5. Disconnect the intake air temperature sensor. 6. Disconnect the camshaft position sensor. 7. Disconnect the manifold absolute pressure sensor. 8. Disconnect the fuel injector harness connectors. 9.
  • Page 61 Document ID: 2098080 Page 3 of 7 13. Disconnect the fuel feed line. 14. Disconnect the throttle body outlet coolant hose. Caution: • 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.
  • Page 62 Document ID: 2098080 Page 4 of 7 15. Remove the fuel rail mounting bolts. Caution: • 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.
  • Page 63 Document ID: 2098080 Page 5 of 7 Note: Different injectors are calibrated for different flow rates. When ordering new fuel injectors, be certain to order the identical part number that is inscribed on the old injector. 1. Lubricate the new fuel injector O-rings with engine oil. Install the new O-rings on the fuel injectors.
  • Page 64 Document ID: 2098080 Page 6 of 7 6. Install the fuel rail mounting bolts. Tighten Tighten the fuel rail mounting bolts to 25 N·m (18 lb ft). 7. Connect the throttle body coolant hose. 8. Connect the fuel feed hose. 9.
  • Page 65 Document ID: 2098080 Page 7 of 7 12. Connect the fuel injector harness connectors. Rotate each fuel injector as required to avoid stretching the wiring harness. 13. Connect the MAP sensor connector. 14. Connect the Camshaft position sensor. 15. Connect the intake air temperature sensor. 16.
  • Page 66 Document ID: 2098082 Page 1 of 2 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098082 Repair Instructions Evaporative Emission Canister Purge Solenoid Valve Replacement Removal Procedure...
  • Page 67 Document ID: 2098082 Page 2 of 2 1. Attach the EVAP canister purge solenoid to the intake manifold. 2. Connect the vacuum hoses to the EVAP canister purge solenoid. 3. Connect the EVAP canister purge solenoid connector. 4. Connect the negative battery cable. http://localhost:9001/si/showDoc.do?docSyskey=2098082&pubCellSyskey=124971&pubO...
  • Page 68 Document ID: 2098085 Page 1 of 8 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098085 Repair Instructions Evaporative Emission System Hoses/Pipes Replacement Removal Procedure Warning: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place.
  • Page 69 Document ID: 2098085 Page 2 of 8 2. Remove the EVAP canister front tube from the EVAP canister purge solenoid valve and the EVAP canister vapor pipe. 3. Disconnect the EVAP canister pipe from the EVAP canister vapor rear tube. http://localhost:9001/si/showDoc.do?docSyskey=2098085&pubCellSyskey=124973&pubO...
  • Page 70 Document ID: 2098085 Page 3 of 8 4. Lift and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 5. Remove the EVAP canister vapor pipe plastic bolt and cover. 6. Remove the EVAP canister vapor pipe 4 mounting screws and cover. 7.
  • Page 71 Document ID: 2098085 Page 4 of 8 8. Remove the EVAP canister vapor rear tube clip. 9. Disconnect the EVAP canister vapor rear tube. 10. Remove the EVAP canister purge tube clip. 11. Disconnect the EVAP canister purge tube. 12. Remove the fuel tank. Refer to Fuel Tank Replacement.
  • Page 72 Document ID: 2098085 Page 5 of 8 1. Install the rollover valve to the fuel tank. 2. Install the fuel tank. Refer to Fuel Tank Replacement. 3. Connect the EVAP canister purge tube. 4. Install the EVAP canister purge tube clip. 5.
  • Page 73 Document ID: 2098085 Page 6 of 8 7. Install the EVAP canister vapor pipe. 8. Install the EVAP canister vapor pipe mounting screws and cover. 9. Install the EVAP canister vapor pipe plastic bolt and cover. 10. Lower the vehicle. http://localhost:9001/si/showDoc.do?docSyskey=2098085&pubCellSyskey=124973&pubO...
  • Page 74 Document ID: 2098085 Page 7 of 8 11. Connect the EVAP canister vapor pipe from the EVAP canister vapor rear tube. 12. Connect the EVAP canister front tube from the EVAP canister purge solenoid valve and the EVAP canister vapor pipe. http://localhost:9001/si/showDoc.do?docSyskey=2098085&pubCellSyskey=124973&pubO...
  • Page 75 Document ID: 2098085 Page 8 of 8 13. Connect the EVAP canister purge solenoid valve to intake manifold hose. http://localhost:9001/si/showDoc.do?docSyskey=2098085&pubCellSyskey=124973&pubO... 7/5/2010...
  • Page 76 Document ID: 2098084 Page 1 of 4 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098084 Repair Instructions Evaporative Emission Canister Vent Solenoid Valve Replacement Removal Procedure Warning: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place.
  • Page 77 Document ID: 2098084 Page 2 of 4 3. Remove the EVAP canister vent solenoid valve bracket. 4. Disconnect the EVAP canister vent solenoid valve electrical connector. 5. Remove the EVAP canister vent solenoid valve hose clip. 6. Disconnect the EVAP canister vent solenoid valve hoses. 7.
  • Page 78 Document ID: 2098084 Page 3 of 4 1. Connect the EVAP canister vent solenoid valve hoses. 2. Install the EVAP canister vent solenoid valve hose clip. 3. Connect the EVAP canister vent solenoid valve electrical connector. 4. Install the EVAP canister vent solenoid valve bracket to the EVAP canister vent solenoid valve.
  • Page 79 Document ID: 2098084 Page 4 of 4 5. Install the bolt to the EVAP canister vent solenoid valve bracket. Tighten 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. http://localhost:9001/si/showDoc.do?docSyskey=2098084&pubCellSyskey=124972&pubO...
  • Page 80 Document ID: 2098086 Page 1 of 2 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098086 Repair Instructions Evaporative Emission Canister Replacement Removal Procedure Warning: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place.
  • Page 81 Document ID: 2098086 Page 2 of 2 1. Insert the canister into the track and slide it into position. Caution: Refer to Fastener Caution in 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.
  • Page 82 Document ID: 2097901 Page 1 of 2 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2097901 Repair Instructions Ignition Coil Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning in the Preface section.
  • Page 83 Document ID: 2097901 Page 2 of 2 1. Install the EI system ignition coil into the mounting location and install the retaining 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.
  • Page 84 Document ID: 959727 Page 1 of 1 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 959727 Repair Instructions Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation.
  • Page 85 Document ID: 2098087 Page 1 of 3 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098087 Repair Instructions Spark Plug Wire Replacement Removal Procedure 1. Turn OFF the ignition.
  • Page 86 Document ID: 2098087 Page 2 of 3 from each spark plug. 4. Disconnect the spark plug wire from the coil (2). • 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.
  • Page 87 Document ID: 2098087 Page 3 of 3 4. Install the engine cover on the engine. Tighten Tighten the engine cover bolts to 3 N·m (31 lb in). http://localhost:9001/si/showDoc.do?docSyskey=2098087&pubCellSyskey=124983&pubO... 7/5/2010...
  • Page 88 Document ID: 1456106 Page 1 of 4 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 1456106 Repair Instructions Spark Plug Inspection Spark Plug Usage • Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions.
  • Page 89 Document ID: 1456106 Page 2 of 4 2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: •...
  • Page 90 Document ID: 1456106 Page 3 of 4 4. Inspect (3) for evidence of improper arcing. • Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. •...
  • Page 91 Document ID: 1456106 Page 4 of 4 - Reduced ignition system voltage output • Weak coils • Worn ignition wires • Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off.

  • Page 92: Spark Plug Replacement

    Document ID: 2098089 Page 1 of 3 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098089 Repair Instructions Spark Plug Replacement Removal Procedure Caution: Observe the following service precautions: •...
  • Page 93 Document ID: 2098089 Page 2 of 3 3. Remove the spark plug wires from the spark plugs. Refer to Spark Plug Wire Replacement. 4. Remove the spark plugs from the engine. Installation Procedure Caution: It is important to check the gap of all new and reconditioned spark plugs before installation.
  • Page 94 Document ID: 2098089 Page 3 of 3 Caution: Be sure plug threads smoothly into cylinder head and is fully seated. Use a thread chaser if necessary to clean threads in cylinder head. Cross-threading or failing to fully seat spark plug can cause overheating of plug, exhaust blow-by, or thread damage. Follow the recommended torque specifications carefully.
  • Page 95 Document ID: 2098090 Page 1 of 3 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098090 Repair Instructions Crankshaft Position Sensor Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning in the Preface section.
  • Page 96 Document ID: 2098090 Page 2 of 3 4. Remove the CKP sensor. Installation Procedure Caution: Refer 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). http://localhost:9001/si/showDoc.do?docSyskey=2098090&pubCellSyskey=124986&pubO...
  • Page 97 Document ID: 2098090 Page 3 of 3 2. Connect the CKP sensor electrical connector. 3. Connect the negative battery cable. http://localhost:9001/si/showDoc.do?docSyskey=2098090&pubCellSyskey=124986&pubO... 7/5/2010...
  • Page 98 Document ID: 2098091 Page 1 of 3 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098091 Repair Instructions Camshaft Position Sensor Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning in the Preface section.
  • Page 99 Document ID: 2098091 Page 2 of 3 4. Disconnect the camshaft position (CMP) sensor electrical connector. 5. Remove the timing belt front cover. Refer to 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 100 Document ID: 2098091 Page 3 of 3 2. Install the timing bolt front cover. Refer to Timing Belt Replacement. 3. Connect the CMP sensor electrical connector. 4. Install the engine cover. 5. Connect the negative battery cable. http://localhost:9001/si/showDoc.do?docSyskey=2098091&pubCellSyskey=124987&pubO... 7/5/2010...
  • Page 101 Document ID: 2097936 Page 1 of 2 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2097936 Repair Instructions Rough Road Sensor Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning in the Preface section.
  • Page 102 Document ID: 2097936 Page 2 of 2 1. Install the rough road sensor and connect the electrical connector. 2. Connect the negative battery cable. http://localhost:9001/si/showDoc.do?docSyskey=2097936&pubCellSyskey=139027&pubO... 7/5/2010...
  • Page 103 Document ID: 2098092 Page 1 of 3 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098092 Repair Instructions Knock Sensor Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning in the Preface section.
  • Page 104 Document ID: 2098092 Page 2 of 3 4. Remove the Knock sensor bolt. 5. Remove the knock sensor. Installation Procedure Caution: 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.
  • Page 105 Document ID: 2098092 Page 3 of 3 3. Install the intake manifold bracket and bolts. Tighten • Tighten the bracket upper bolt to 25 N·m (18 lb ft). • Tighten the bracket lower bolt to 45 N·m (33 lb ft). 4.
  • Page 106 Document ID: 2098093 Page 1 of 2 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098093 Repair Instructions Exhaust Gas Recirculation Valve Replacement Removal Procedure Warning:...
  • Page 107 Document ID: 2098093 Page 2 of 2 1. Install the EGR valve with the bolts. Tighten Tighten the 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. http://localhost:9001/si/showDoc.do?docSyskey=2098093&pubCellSyskey=124988&pubO...
  • Page 108 Document ID: 2097945 Page 1 of 3 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2097945 Repair Instructions Exhaust Gas Recirculation Valve Pipe Replacement Removal Procedure 1.
  • Page 109 Document ID: 2097945 Page 2 of 3 4. Remove the lower mounting bolt attaching the EGR pipe to the intake manifold. 5. Remove the EGR pipe. Installation Procedure 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 110 Document ID: 2097945 Page 3 of 3 2. Install the EGR pipe mounting bolts to the EGR valve. Tighten Tighten the EGR pipe to EGR valve mounting 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 111 Document ID: 2097940 Page 1 of 2 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2097940 Repair Instructions Intake Manifold Tuning Valve Actuator Solenoid Replacement Removal Procedure...
  • Page 112 Document ID: 2097940 Page 2 of 2 1. Install the IMT valve solenoid. 2. Connect the vacuum hoses to the IMT valve solenoid (2). 3. Connect the IMT valve solenoid (2) connector. 4. Connect the negative battery cable. http://localhost:9001/si/showDoc.do?docSyskey=2097940&pubCellSyskey=138498&pubO... 7/5/2010...
  • Page 113 Document ID: 2097942 Page 1 of 2 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2097942 Repair Instructions Intake Manifold Tuning Valve Actuator Replacement Removal Procedure 1.
  • Page 114 Document ID: 2097942 Page 2 of 2 1. Install the IMT valve actuator valve to the IMT valve. Caution: Refer to Fastener Caution in the Preface section. 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.
  • Page 115 Document ID: 1480007 Page 1 of 2 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 1480007 Repair Instructions Intake Air Tuning Valve Vacuum Reservoir Replacement Removal Procedure 1.
  • Page 116 Document ID: 1480007 Page 2 of 2 1. Install the IMT valve reservoir (1). 2. Install the vacuum hoses to the IMT valve reservoir (1). http://localhost:9001/si/showDoc.do?docSyskey=1480007&pubCellSyskey=139185&pubO... 7/5/2010...
  • Page 117 Document ID: 2098094 Page 1 of 2 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098094 Repair Instructions Air Cleaner Inlet Duct Replacement Removal Procedure Note: The intake air temperature sensor is no longer replaced as a separate service item. If the intake air temperature sensor is faulty, replacement of the entire air cleaner inlet duct will be necessary.
  • Page 118 Document ID: 2098094 Page 2 of 2 Note: An improperly installed air cleaner intake duct or breather tube will cause incorrect sensor readings resulting in MIL illumination or a drivability concern. 1. Install the air cleaner intake duct. Caution: Refer to Fastener Caution in the Preface section.
  • Page 119 Document ID: 2097989 Page 1 of 1 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2097989 Repair Instructions Air Cleaner Element Replacement Removal Procedure 1. Loosen the air cleaner intake duct clamp at the air cleaner assembly.
  • Page 120 Document ID: 2098096 Page 1 of 2 2009 Chevrolet Aveo Aveo, Wave, G3, Barina (VIN S/T) Service Manual Engine Engine Controls and Fuel - 1.6L (LXT) | Document ID: 2098096 Repair Instructions Air Cleaner Assembly Replacement Removal Procedure 1. Loosen the air cleaner intake duct clamp at the air cleaner assembly.
  • Page 121 Document ID: 2098096 Page 2 of 2 2. Install the air cleaner assembly attachment bolts. Tighten Tighten the nut 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). http://localhost:9001/si/showDoc.do?docSyskey=2098096&pubCellSyskey=124991&pubO...

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