removal and installation - justanswer · 2017-04-04 · model applications model coverage model...

MODEL APPLICATIONS

Model Coverage

Model Years

Cruze 2011-14

Sonic 2012-14

REMOVAL AND INSTALLATION

NOTE:

If the timing belt is being replaced due to the maintenance schedule interval, then the

timing belt tensioner and idler pulley must also be replaced.

REMOVAL AND INSTALLATION > REMOVAL

1. Remove the air cleaner assembly.

1. LWE Engine

a. Disconnect the mass airflow sensor / intake air temperature sensor wiring

harness plug (2). See Fig 1.

b. Unclip the engine control module (ECM) wiring harness (3) from the air

cleaner housing.

c. Remove the air cleaner outlet duct.

d. Remove the secondary air injection pump inlet hose (4) from the air cleaner

upper housing.

e. Unclip the water drain hose (2) from the air cleaner lower housing (1). See Fig

2.

f. Remove the air cleaner assembly (1).

1. LUW Engine

Service Manual: TIMING BELT REPLACEMENT - 1.8L

LUW & LWE

Print Date: 4/4/2017

2013 Chevrolet Sonic 1.8L Eng LS

of 27Printer Friendly View

4/4/2017http://www2.prodemand.com/Print/Index?content=tabs&module=true&tab=true&terms=tru...

a. Disconnect the intake air temperature sensor wiring harness plug (1). See Fig

3.

b. Remove the air cleaner outlet duct.

c. Remove the air cleaner assembly (1). See Fig 4.

a. Unclip the air cleaner inlet duct

b. Unclip the drain hose, if equipped

Fig 1: Air Cleaner Outlet Duct (LWE)

Courtesy of GENERAL MOTORS COMPANY



Fig 2: Water Drain Hose (LWE)




Fig 3: Intake Air Sensor Wiring Harness Plug (LUW)




Fig 4: Air Cleaner Assembly (LUW)


2. Remove the timing belt upper front cover.

a. Remove the 2 timing belt upper front cover bolts (2). See Fig 5.

b. Remove the timing belt upper front cover (1).



Fig 5: Timing Belt Upper Front Cover


3. Raise and support the vehicle.

4. Remove the tire and wheel assembly.

5. Remove the right front wheelhouse liner.

6. Remove the drive belt tensioner.

a. Remove the generator and air conditioning compressor belt.

a. Release tension to the drive belt tensioner by rotating counterclockwise

(1) and lock with EN 6349 pin (2). See Fig 6.

b. Remove the drive belt (1). See Fig 7.

b. Remove the drive belt tensioner bolt (1). See Fig 8.

c. Remove the drive belt tensioner (2).



Fig 6: Drive Belt Tensioner And Special Tool




Fig 7: Drive Belt Routing




Fig 8: Drive Belt Tensioner Bolt


7. Remove the front under-car noise insulation shield.

8. Set the engine to top dead center (TDC).

9. For vehicle with manual transmission: Remove the transmission front mount.

a. Raise vehicle.

b. Remove transmission front mount bolts (1). See Fig 9.

c. Remove transmission front mount (2).



Fig 9: Transmission Front Mount Bolts


10. For vehicle with manual transmission: Remove the bolted connection (1). See Fig 10.



Fig 10: Connection Bolt


11. For vehicle with automatic transmission: Remove the bolt (1). See Fig 11.



Fig 11: Automatic Transmission Bracket Bolt


12. Install EN-6625 locking device (2) to block the crankshaft. See Fig 12.



Fig 12: Locking Device And Bolt


13. Install the bolt or bolted connection (1). See Fig 12.

14. Remove and DISCARD the crankshaft balancer bolt (1). See Fig 13.



Fig 13: Crankshaft Balancer And Bolt


15. Remove the 4 lower timing belt cover bolts (2). See Fig 14.



Fig 14: Timing Belt Lower Front Cover


16. Remove the lower timing belt cover (1). See Fig 14.

17. Lower the vehicle.

18. Prepare the left half of the EN-6340 locking tool. See Fig 15.

NOTE:

The left half of the EN-6340 locking tool can be recognized by the lettering

"left", arrow, on the tool.

a. Remove the 2 bolts (2). See Fig 15.

b. Remove the front panel (1) from the EN-6340 locking tool - left.



Fig 15: Identifying Camshaft Adjuster Locking Tool (EN-6340)


19. Install the EN-6340 locking tool into the camshaft adjusters.

NOTE:

The spot type marking (4) on the intake camshaft adjuster does not

correspond to the groove of EN-6340 locking tool - left during this

process but must be somewhat above as shown. See Fig 16.

a. Install the EN-6340 locking tool - left (1) in the camshaft adjusters as shown.

See Fig 16.

NOTE:



The spot type marking (3) on the exhaust camshaft adjuster must

correspond to the groove on EN-6340 locking tool - right. See Fig 16.

b. Install EN-6340 locking tool - right (2) in the camshaft adjusters as shown.

See Fig 16.

Fig 16: Installing Camshaft Adjuster Locking Tool (EN-6340)



21. Apply tension to the drive belt tensioner (2) in the direction of the arrow, using an Allen

key (1). See Fig 17.

22. Install the EN-6333 locking pin (3).

23. Remove the timing belt idler pulley.

a. Remove and DISCARD the timing belt idler pulley bolt (2). See Fig 18.



b. Remove the timing belt idler pulley (1).

Fig 17: View Of Timing Belt Tensioner, Allen Key And KM-6333




Fig 18: Timing Belt Idler Pulley Bolt


24. Remove the timing belt (1). See Fig 19.



Fig 19: Timing Belt Routing


REMOVAL AND INSTALLATION > INSTALLATION

1. Install the timing belt (1) in the enclosed assembly tool (2). See Fig 1.

NOTE:

Threading the timing belt through the engine mount bracket is only permissible

in conjunction with the assembly tool supplied with NEW timing belts or

otherwise it is possible to damage the toothed belt at this stage by kinking it.



NOTE:

If the toothed belt has been used, observe the direction of rotation.

Fig 1: Timing Belt And Assembly Tool


2. Guide the timing belt through the engine mount bracket with the assembly tool.

3. Remove the assembly tool.

4. Install the timing belt (1). See Figure.

5. Guide the timing belt past the tensioner and place it on the crankshaft sprocket wheel.

6. Place the timing belt on the exhaust and intake camshaft position actuator adjusters.




8. Install the timing belt idler pulley. See Figure.

a. Install the timing belt idler pulley (2) and tighten the NEW bolt (1) in three

passes using the EN-45059 meter:

a. First pass tighten to 20 N.m (15 lb ft).

b. Second pass to 120 degrees.

c. Final pass to 15 degrees.

b. Install the timing belt.

9. Apply tension to the drive belt tensioner (2) in the direction of the arrow, using an Allen

key (1). See Figure.

10. Remove the EN-6333 locking pin (3). See Figure.

11. Release tension on timing belt tensioner.

NOTE:

The timing belt tensioner moves automatically to the correct position.

12. Remove bolt or bolted connection (1). See Figure.

13. Remove EN-6625 locking device (2). See Figure.


15. Remove the EN-6340 locking tool. See Figure.

16. Check the timing

a. Turn the crankshaft 720 degrees in the direction of engine rotation by the

crankshaft balancer bolt.

NOTE:

Note the marking at the camshaft sprockets.

b. Install EN-6340 locking tool - left (1) into the camshaft adjusters as shown.

See Figure.

NOTE:



The spot type marking (4) on the intake camshaft adjuster does not

correspond to the groove of EN-6340 locking tool - left during this

process but must be somewhat above as shown. See Figure.

c. Install EN-6340 locking tool - right (2) into the camshaft adjusters as shown.

See Figure.

NOTE:

The spot type marking (3) on the exhaust camshaft adjuster must

correspond to the groove on EN-6340 locking tool - right.

17. Remove the EN-6340 locking tool.


19. Control the crankshaft balancer position.

NOTE:

The timing belt drive gear and oil pump housing must align. See Fig 2.



Fig 2: Aligning Timing Belt Drive Gear And Oil Pump Housing

Courtesy of GENERAL MOTORS CORP.

20. Install EN-6625 locking device (2) to block the crankshaft. See Figure.

21. Install the bolt or bolted connection (1). See Figure.

22. Install the lower timing belt cover (1). See Figure.

23. Install the 4 lower timing belt cover bolts (2) and tighten to 6 N.m (53 lb in). See Figure.

24. Install the crankshaft balancer (2). See Figure.

25. Install a NEW crankshaft balancer bolt (1) and tighten a first pass to 95 N.m (70 lb ft).

See Figure.

26. Tighten the NEW crankshaft balancer bolt a second pass to an additional 45 degrees.

using the EN-45059 meter.

27. Tighten the NEW crankshaft balancer bolt a final pass to an additional 15 degrees.

using the EN-45059 meter.



28. Remove bolt or bolted connection (1). See Figure.

29. Remove EN-6625 locking device (2). See Figure.

30. For vehicle with automatic transmission: Install the bolt (1) and tighten to 45 N.m

(33 lb ft). See Figure.

31. For vehicle with manual transmission: Install the bolt (1) and tighten to 40 N.m (32 lb

ft). See Figure.

32. Clean the drive belt tensioner thread.

33. Install drive belt tensioner (2). See Figure.

34. Install the drive belt tensioner bolt (1) and tighten to 55 N.m (41 lb ft).

35. Install the generator and air conditioning compressor drive belt (1). See Figure.

NOTE:

Ensure that the drive belt is aligned on the generator pulley (4), crankshaft

balancer (5), drive belt tensioner (6) water pump pulley (7) and A/C

compressor. The drive belt must lie on the water pump pulley between the

flange (1) and (2). See Fig 3.

36. Check the position of the drive belt (3).

37. Release tension to the tensioner by rotating counterclockwise (1). See Figure.

NOTE:

Allow tensioner to slide back slowly.

38. Remove EN 6349 pin (2). See Figure.

39. Apply tension to the tensioner clockwise (1). See Figure.



Fig 3: Checking Drive Belt Position


40. Install the right front wheelhouse liner.


42. Remove the EN-6340 locking tool.

43. Install the timing belt upper front cover (1). See Figure.

44. Install the 2 timing belt upper front cover bolts (2) and tighten to 6 N.m (53 lb in).

45. Install the air cleaner assembly.

1. LWE Engine

a. Install the air cleaner assembly (1). See Figure.

b. Clip in the water drain hose (2) to the air cleaner lower housing (1). See

Figure.



c. Install the air cleaner outlet duct (1). See Figure.

d. Install the secondary air injection pump inlet hose (4) to the air cleaner upper

housing.

e. Connect the mass airflow sensor / intake air temperature sensor wiring

harness plug (2).

f. Clip in the ECM wiring harness (3) the air cleaner housing.

1. LUW Engine

a. Install the air cleaner assembly (1). See Figure.

a. Clip in the drain hose, if equipped

b. Clip in the air cleaner inlet duct

b. Install the air cleaner outlet duct.

c. Connect the intake air temperature sensor wiring harness plug (1). See Figure.

46. Reset the CHANGE TIMING BELT message. After the engine timing belt has been

replaced, reset the CHANGE TIMING BELT message by locating and removing the

fuses that supply power to the Instrument Cluster for two minutes.



removal and installation - justanswer · 2017-04-04 · model applications model coverage model...

Documents