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Home >> Pontiac >> 2009 >> G3 Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 67 (Engine Mechanical - 1.6L (LDE, LLU, And LXV) Or 1.8L (2H0) - Repair Instructions - On Vehicle) >> Piston, Connecting Rod, and Bearing Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2010 Chevrolet Aveo. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Piston, Pin, Connecting Rod & Rings
    GM2049769Courtesy of GENERAL MOTORS CORP.
    NOTE: Take extreme care to prevent any scratches or damage to the inner side of the cylinder, piston, and connecting rod cap bearings.
  1. Install the piston pin (5) to the piston.
  2. Install the piston ring (1) from the piston (3) using the expansion tool.
    3. NOTE: Check and confirm the piston assembly sequence and the connecting rod bearing sequence, to not confuse.
  3. Install the piston assembly using the piston installer (1.6L only - EN-49153).
    4. CAUTION: Refer to Fastener Caution .
  4. Install the connecting rod cap and bolts with bearings.

    Tighten:  Tighten the connecting rod caps bolts to 35+45° +15° N.m (25.8+45° +15° lb ft).

  5. Install the flexible plate or flywheel. Refer to Automatic Transmission Flex Plate Replacement  and Engine Flywheel Replacement .
  6. Install the oil pump assembly. Refer to Oil Pump Replacement .
  7. Install the engine oil cooler. Refer to Engine Oil Cooler Replacement .
  8. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement .
  9. Install the alternator. Refer to Generator Replacement (1.4L LDT, 1.6L LXV) .
  10. Install the starter. Refer to Starter Replacement (1.4L LDT, 1.6 LXV) .
  11. Install the oil pan. Refer to Oil Pan Replacement .
    12. Fig 2: Cylinder Head & Bolts
    GM2049556Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not reuse the cylinder head gasket.
  12. Install the cylinder head assembly (2) with the new cylinder head gasket.
  13. Install the cylinder head bolts (1).

    Tighten:  Tighten the cylinder head bolts to 25+90° +90° +90° +45° N.m (18.4+90° +90° +90° +45° lb ft).

    14. Fig 3: Coolant Distributor
    GM2049555Courtesy of GENERAL MOTORS CORP.
  14. Install the engine coolant distributor (1).
  15. Install the intake manifold. Refer to Intake Manifold Replacement .
  16. Install the throttle body. Refer to THROTTLE BODY ASSEMBLY REPLACEMENT ..
  17. Install the exhaust manifold. Refer to Catalytic Converter Replacement (1.4L LDT/1.6L LXV) .
    18. Fig 4: Timing Belt Rear Cover & Bolts
    GM2049388Courtesy of GENERAL MOTORS CORP.
  18. Install the camshaft rear cover (1).
  19. Install the camshaft intake and exhaust sprockets. Refer to Camshaft Intake Sprocket with Actuator Replacement  and Camshaft Exhaust Sprocket with Actuator Replacement .
  20. Install timing belt system and adjust the timing. Refer to Timing Belt Replacement .
  21. Install the accessory belt. Refer to Drive Belt Replacement .
  22. Install the power steering pump and bracket. Refer to Power Steering Pump Replacement (1.4L LDT and 1.6L LXV Engines) .
    23. Fig 5: Cylinder Head Cover
    GM2049365Courtesy of GENERAL MOTORS CORP.
  23. Install the cylinder head cover (1).
  24. Install the cylinder head cover bolts.
  25. Install the PCV hose from the cylinder head cover.
  26. Attach the PCV clips from the PCV hose.
  27. Install the ignition coil. Refer to IGNITION COIL REPLACEMENT .
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