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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 >> Removal Procedure

Removal 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: Engine Assembly On Stand
    GM2049696Courtesy of GENERAL MOTORS CORP.
  1. Remove the engine assembly. Refer to Engine Replacement .
  2. Install the engine assembly to the stand.
  3. Remove the ignition coil. Refer to IGNITION COIL REPLACEMENT .
    4. Fig 2: Cylinder Head Cover
    GM2049365Courtesy of GENERAL MOTORS CORP.
  4. Detach the PCV clips from the PCV hose.
  5. Remove the PCV hose from the cylinder head cover.
  6. Remove the cylinder head cover bolts.
  7. Remove the cylinder head cover (1).
  8. Remove the power steering pump and bracket. Refer to Power Steering Pump Replacement (1.4L LDT and 1.6L LXV Engines) .
    9. Fig 3: Timing Belt
    GM2049375Courtesy of GENERAL MOTORS CORP.
  9. Remove the timing belt. Refer to Timing Belt Replacement .
  10. Remove the timing belt tensioner. Refer to Timing Belt Replacement .
  11. Remove the camshaft intake and exhaust sprockets. Refer to Camshaft Intake Sprocket with Actuator Replacement  and Camshaft Exhaust Sprocket with Actuator Replacement .
    12. Fig 4: Timing Belt Rear Cover & Bolts
    GM2049388Courtesy of GENERAL MOTORS CORP.
  12. Remove the camshaft rear cover (1).
    13. Fig 5: Exhaust Manifold & Catalytic Converter
    GM2049036Courtesy of GENERAL MOTORS CORP.
  13. Remove the exhaust manifold. Refer to Catalytic Converter Replacement (1.4L LDT/1.6L LXV) .
  14. Remove the throttle body. Refer to THROTTLE BODY ASSEMBLY REPLACEMENT .
  15. Remove the intake manifold. Refer to Intake Manifold Replacement .
    16. Fig 6: Coolant Distributor
    GM2049555Courtesy of GENERAL MOTORS CORP.
  16. Remove the engine coolant distributor (1).
    17. Fig 7: Cylinder Head & Bolts
    GM2049556Courtesy of GENERAL MOTORS CORP.
  17. Remove the cylinder head bolts (1).
  18. Remove the cylinder head assembly (2) with the cylinder head gasket.
  19. Remove the engine oil cooler. Refer to Engine Oil Cooler Replacement .
  20. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement .
  21. Remove the alternator. Refer to Generator Replacement (1.4L LDT, 1.6L LXV) .
  22. Remove the starter. Refer to Starter Replacement (1.4L LDT, 1.6 LXV) .
  23. Remove the oil pan. Refer to Oil Pan Replacement .
  24. Remove the oil pump assembly. Refer to Oil Pump Replacement .
  25. Remove the flexible plate or flywheel. Refer to Automatic Transmission Flex Plate Replacement  and Engine Flywheel Replacement .
    26. Fig 8: Piston, Connecting Rod, Cap & Bolts
    GM2049768Courtesy of GENERAL MOTORS CORP.
    NOTE: Check and confirm the piston assembly sequence and the connecting rod bearing sequence, to not confuse.
  26. Remove the connecting rod cap (2) and bolts (3).
  27. Remove the piston assembly (1).
    28. Fig 9: Piston, Pin, Connecting Rod & Rings
    GM2049769Courtesy of GENERAL MOTORS CORP.
  28. Separate the piston pin (5) from the piston.
  29. Separate the piston ring (1) from the piston (3) using the expansion tool.
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