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Home >> Chevrolet >> 2005 >> Aveo Base, 4D Hatchback >> Repair and Diagnosis >> External Pages >> Different car >> Section 46 (Engine Mechanical - 1.6L (L91)) >> Repair Instructions >> Cylinder Head Disassemble >> Disassembly Procedure

Disassembly Procedure

WARNING: This page is about a different car, the 2004 Suzuki Swift + and 2004 Chevrolet Aveo. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Removal Sequence Of Exhaust Manifold Retaining Nuts
    GM1291215Courtesy of GENERAL MOTORS CORP.
  1. Remove the cylinder head with the intake manifold and the exhaust manifold attached. Refer to Camshaft Replacement .
  2. Remove the coolant temperature sensor (CTS).
  3. Remove the exhaust manifold heat shield bolts.
  4. Remove the exhaust manifold heat shield.
  5. Remove the exhaust manifold retaining nuts in the sequence shown.
  6. Remove the exhaust manifold.
  7. Remove the exhaust manifold gasket.
  8. Remove the exhaust manifold studs.
    9. Fig 2: Identifying Fuel Injector Harness
    GM1289655Courtesy of GENERAL MOTORS CORP.
  9. Remove the thermostat housing mounting bolts.
  10. Remove the thermostat housing assembly.
  11. Remove the fuel rail retaining bolts and the fuel rail assembly.
    12. Fig 3: Removal Sequence Of Intake Manifold Retaining Nuts And Retaining Bolts
    GM1291157Courtesy of GENERAL MOTORS CORP.
  12. Remove the intake manifold retaining nuts and retaining bolts in the sequence shown.
  13. Remove the intake manifold.
  14. Remove the intake manifold studs.
    15. Fig 4: Removing DIS Coil Mounting Bracket
    GM1291244Courtesy of GENERAL MOTORS CORP.
  15. Remove the direct ignition system (DIS) coil mounting bolts.
  16. Remove the DIS coil with the ignition wires attached.
  17. Remove the DIS coil mounting bracket bolts.
  18. Remove the electrical exhaust gas recirculation (EEGR) valve adapter bolts.
  19. Remove the EEGR valve adapter bolts.
  20. Remove the EEGR valve adapter.
  21. Remove the EEGR valve adapter gasket.
  22. Remove the spark plugs.
    23. Fig 5: Removal Sequence Of Camshaft Cap Bolts
    GM1291253Courtesy of GENERAL MOTORS CORP.
  23. Remove the camshaft cap bolts gradually and in the sequence shown for each camshaft cap.
    24. Fig 6: View Of Intake Valve Tapper Adjusters
    GM1289656Courtesy of GENERAL MOTORS CORP.
  24. Remove the intake camshaft caps. Maintain the correct positions for installation.
  25. Remove the intake camshaft.
  26. Remove the intake valve tappet adjusters.
  27. Remove the exhaust camshaft caps. Maintain the correct positions for installation.
  28. Remove the exhaust camshaft.
  29. Remove the exhaust valve tappet adjusters.
    30. Fig 7: Compressing Valve Springs
    GM1289657Courtesy of GENERAL MOTORS CORP.
    CAUTION: Valve springs can be tightly compressed. Use care when removing the retainers and plugs. Personal injury could result.
  30. Compress the valve springs with J 8062  and KM-653-A  .
  31. Remove the valve keys.
  32. Remove the J 8062  and KM-653-A  .
  33. Remove the valve spring caps.
  34. Remove the valve springs. Maintain the original position of the valve springs for installation.
    35. Fig 8: Removal Of Valve Stem Seals
    GM1289658Courtesy of GENERAL MOTORS CORP.
  35. Remove the valves. Maintain the original position of the valves for installation.
  36. Remove the valve stem seals.
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