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SECTION 1C

ENGINE (DOHC ENGINE MECHANICAL)

G141C01
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DOHC ENGINE MECH. - DOHC ENGINE UNIT (111)

NO.
OPERATION DESCRIPTION
OPERATION CODE
S
N
L
1.4D/1.6D
1.4D
1.6D/1.8D(Fam I)
1.8D/2.0D(Fam II)
2.0D
2.5X
1
. ENGINE ASSEMBLY (M/T) - OVERHAUL
1110100
6.3
6.7
6.7
6.7
6.9
—
INC : R & I Engine ass'y, Flywheel, Intake and exhaust manifold ass'y, Timing belt, Engine adjust.
.
.
.
.
.
.
.
. ENGINE ASSEMBLY (A/T) - OVERHAUL
1110300
6.3
6.7
6.7
6.7
6.9
16.4
INC : R & I Engine ass'y, Flywheel, Intake and exhaust manifold ass'y, Timing belt, Engine adjust.
.
.
.
.
.
.
.
2
. ENGINE ASSEMBLY (M/T) - REPLACE
1110800
4.4
4.6
4.6
4.6
4.8
—
INC : R & I Engine ass'y, Flywheel, Intake and exhaust manifold ass'y, Timing belt, Engine adjust.
.
.
.
.
.
.
.
. ENGINE ASSEMBLY (A/T) - REPLACE
1110900
4.4
4.6
4.6
4.6
4.8
7.5
INC : R & I Engine ass'y, Flywheel, Intake and exhaust manifold ass'y, Timing belt, Engine adjust.
.
.
.
.
.
.
.
S : AVEO/KALOS/BARINA, N : NUBIRA/LACETTI/FORENZA/OPTRA/VIVA, L : EVANDA/EPICA

G141C02
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DOHC ENGINE MECH. - BELT SYSTEM (113)

NO.
OPERATION DESCRIPTION
OPERATION CODE
S
N
L
1.4D/1.6D
1.4D
1.6D/1.8D(Fam I)
1.8D/2.0D(Fam II)
2.0D
2.5X
1
. BELT, ACCESSORY - REPLACE
1132200
0.2
0.2
0.2
0.2
0.2
0.3
2
. AUTO TENSIONER, ACCESSORY BELT - REPLACE
1132400
0.4
0.4
0.4
0.4
0.4
0.4
S : AVEO/KALOS/BARINA, N : NUBIRA/LACETTI/FORENZA/OPTRA/VIVA, L : EVANDA/EPICA

G141C03
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DOHC ENGINE MECH. - ENGINE BLOCK (121)

NO.
OPERATION DESCRIPTION
OPERATION CODE
S
N
L
1.4D/1.6D
1.4D
1.6D/1.8D(Fam I)
1.8D/2.0D(Fam II)
2.0D
2.5X
1
. OIL LEVEL INDICATOR - REPLACE
1210200
0.2
0.2
0.2
0.2
0.2
0.2
2
. TUBE, OIL LEVEL INDICATOR - REPLACE
1210300
0.3
0.3
0.3
0.3
1.5
0.2
3
. VALVE, OIL FILTER BY-PASS - REPLACE
1210500
0.5
0.5
0.5
0.5
0.5
—
4
. PLUG, EXPANSION - REPLACE
1210700
0.4
0.4
0.4
0.4
0.4
—
NOTE : Add appropriate labor MODEL(s) for removal if necessary components to gain access to plug to regular labor hours column
.
.
.
.
.
.
.
5
. PLUG, OIL GALLERY - REPLACE
1210900
3.6
4.0
4.0
4.0
4.2
9.6
INC : R & I Transaxle ass'y
.
.
.
.
.
.
.
6
. BLOCK, CYLINDER - REPLACE
1211100
9.0
7.6
7.6
7.6
7.6
10.9
7
. BRACKET, ENG BLOCK - REPLACE
1211300
—
—
—
—
—
0.3
S : AVEO/KALOS/BARINA, N : NUBIRA/LACETTI/FORENZA/OPTRA/VIVA, L : EVANDA/EPICA

G161B01
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DOHC ENGINE MECH. - CRANKSHAFT & PISTON (122)

NO.
OPERATION DESCRIPTION
OPERATION CODE
S
N
L
1.4D/1.6D
1.4D
1.6D/1.8D(Fam I)
1.8D/2.0D(Fam II)
2.0D
2.5X
1
. SEAL(S), CRANKSHAFT REAR MAIN (AUTO TRANSAXLE) - REPLACE
1220200
3.8
3.1
3.1
3.9
4.1
4.1
. SEAL(S), CRANKSHAFT REAR MAIN (MANUAL TRANSAXLE) - REPLACE
1220400
4.2
3.8
3.8
3.8
4.0
—
INC : R & I Transaxle ass'y
.
.
.
.
.
.
.
2
. BEARING, CRANKSHAFT MAIN (ONE) - REPLACE
1220600
1.6
1.5
1.5
1.1
1.7
8.1
INC : R & I Transaxle ass'y, Flywheel, Oil pan, Engine adjust.
.
.
.
.
.
.
.
A - Replace each additional
122060A
0.4
0.4
0.4
0.4
0.4
0.4
B - Replace rear main bearing (Auto transaxle)
122060B
2.8
2.6
2.6
2.6
2.6
2.7
C - Replace rear main bearing (Manual transaxle)
122060C
3.1
2.8
2.8
2.8
3.1
—
3
. BEARING, CONNECTING ROD (ONE) - REPLACE
1220800
1.3
1.4
1.4
2.3
2.6
10.1
INC : R & I Oil pan ass'y, Oil suction pipe
.
.
.
.
.
.
.
A - Replace each additional
122080A
0.3
0.3
0.3
0.3
0.3
0.3
B - Replace all
122080B
0.6
0.6
0.6
0.6
0.6
0.6
4
. CRANKSHAFT (M/T) - REPLACE
1221100
6.3
6.3
6.3
6.3
7.5
—
INC : R & I Engine ass'y, Cylinder head ass'y Flywheel, Piston ass'y, Engine adjust.
.
.
.
.
.
.
.
C - R&R cylinder head
122110C
1.0
1.0
1.0
1.0
1.0
—
D - Replace one piston rings
122110D
0.4
0.4
0.4
0.4
0.4
—
E - Replace all piston rings
122110E
1.2
1.2
1.2
1.2
1.2
—
F - Replace one connecting rod
122110F
0.4
0.4
0.4
0.4
0.4
—
G - Replace all connecting rods
122110G
1.1
1.1
1.1
1.1
1.1
—
H - Replace one piston
122110H
0.5
0.5
0.5
0.5
0.5
—
J - Replace all pistons
122110J
1.8
1.8
1.8
1.8
1.8
—
S : AVEO/KALOS/BARINA, N : NUBIRA/LACETTI/FORENZA/OPTRA/VIVA, L : EVANDA/EPICA

G161B01
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DOHC ENGINE MECH. - CRANKSHAFT & PISTON (122)

NO.
OPERATION DESCRIPTION
OPERATION CODE
S
N
L
1.4D/1.6D
1.4D
1.6D/1.8D(Fam I)
1.8D/2.0D(Fam II)
2.0D
2.5X
4
. CRANKSHAFT (A/T) - REPLACE
1221200
7.8
7.2
7.2
7.2
7.5
10.5
INC : R & I Engine ass'y, Cylinder head ass'y Flywheel, Piston ass'y, Engine adjust.
.
.
.
.
.
.
.
C - R&R cylinder head
122120C
1.0
1.0
1.0
1.0
1.0
1.0
D - Replace one piston rings
122120D
0.4
0.4
0.4
0.4
0.4
0.4
E - Replace all piston rings
122120E
1.2
1.2
1.2
1.2
1.2
1.2
F - Replace one connecting rod
122120F
0.4
0.4
0.4
0.4
0.4
0.4
G - Replace all connecting rods
122120G
1.1
1.1
1.1
1.1
1.1
1.1
H - Replace one piston
122120H
0.5
0.5
0.5
0.5
0.5
0.5
J - Replace all pistons
122120J
1.8
1.8
1.8
1.8
1.8
1.8
5
. CRANKSHAFT TARGET WHEEL - REPLACE
1221300
7.3
7.3
7.3
7.3
7.7
10.5
6
. PISTON, ROD AND/OR RINGS (ONE) - REPLACE
1221500
5.1
4.6
4.6
5.6
5.7
9.6
INC : R & I Cylinder head ass'y, Oil suction pipe, Engine adjust.
.
.
.
.
.
.
.
C - Replace each additional
122150C
0.8
0.8
0.8
0.8
0.8
0.8
D - Replace all
122150D
1.3
1.3
1.3
1.3
1.3
1.3
7
. FLYWHEEL (MANUAL T/M) - REPLACE
1221700
3.6
3.6
3.6
3.6
3.8
—
INC : R & I T/M ass'y, Clutch cover ass'y
.
.
.
.
.
.
.
8
. FLYWHEEL (AUTO T/M) - REPLACE
1221900
3.7
3.0
3.0
3.4
3.6
3.6
S : AVEO/KALOS/BARINA, N : NUBIRA/LACETTI/FORENZA/OPTRA/VIVA, L : EVANDA/EPICA

G141C05
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DOHC ENGINE MECH. - OIL PAN & PUMP (123)

NO.
OPERATION DESCRIPTION
OPERATION CODE
S
N
L
1.4D/1.6D
1.4D
1.6D/1.8D(Fam I)
1.8D/2.0D(Fam II)
2.0D
2.5X
1
. FILTER, OIL - REPLACE
1231100
0.4
0.4
0.4
0.4
0.4
0.5
2
. PLUG AND/OR GASKET, OIL PAN DRAIN - REPLACE
1231300
0.3
0.3
0.3
0.3
0.3
0.5
3
. PAN AND/OR GASKET, OIL - REPLACE
1231500
1.3
1.0
1.0
0.8
1.1
1.3
INC : Front exhaust pipe ass'y, Exhaust pipe bracket
.
.
.
.
.
.
.
4
. PUMP, ENGINE OIL - REPLACE
1231700
2.6
2.6
2.6
2.0
2.2
1.4
INC : R & I Timing belt, Oil pan, Engine adjust
.
.
.
.
.
.
.
5
. SENSOR, FUEL SWITCH & ENGINE OIL PRESSURE GAGE - REPLACE
1231900
0.3
0.3
0.3
0.3
0.3
0.3
6
. TUBE, OIL SUCTION - REPLACE
1232100
1.3
0.5
0.5
0.5
1.1
1.4
7
. OIL SEAL, CRANKSHAFT (FRONT) - REPLACE
1232300
1.8
1.8
1.8
1.8
1.8
8.1
8
. PIECE, CONNECTING - REPLACE
1232500
0.5
0.5
0.5
0.5
0.5
0.6
9
. VALVE, OIL PRESSURE RELIEF - REPLACE
1232700
0.3
0.3
0.3
0.3
0.3
—
10
. GASKET OIL PUMP - REPLACE
1232900
2.7
2.7
2.7
2.1
2.3
1.5
11
. PIPE AND/OR GASKET OIL VENTILATION - REPLACE
1233700
0.3
0.3
0.3
0.3
0.3
—
12
. HOSE, OIL VENTILATION - REPLACE
1233700
0.3
0.3
0.3
0.3
0.3
—
S : AVEO/KALOS/BARINA, N : NUBIRA/LACETTI/FORENZA/OPTRA/VIVA, L : EVANDA/EPICA

G141C06
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DOHC ENGINE MECH. - CYLINDER HEAD (131)

NO.
OPERATION DESCRIPTION
OPERATION CODE
S
N
L
1.4D/1.6D
1.4D
1.6D/1.8D(Fam I)
1.8D/2.0D(Fam II)
2.0D
2.5X
1
. GASKET, CYLINDER HEAD - REPLACE
1312300
3.4
3.2
3.2
3.9
3.9
9.5
INC : R & I Cylinder head ass'y, Intake & exhaust manifold, Engine adjust.
.
.
.
.
.
.
.
2
. HEAD, CYLINDER - REPLACE
1312500
3.4
3.2
3.2
3.9
3.9
9.5
INC : R & I Cylinder head ass'y, Intake & exhaust manifold, Valves, Engine adjust.
.
.
.
.
.
.
.
. HEAD, CYLINDER - OVERHAUL
1312600
5.9
5.8
5.8
6.9
6.9
12.7
INC : R & I Cylinder head ass'y, Intake & exhaust manifold, Valves, Engine adjust.
.
.
.
.
.
.
.
3
. VALVE (ONE CYLINDER) - REPLACE
1312700
4.6
4.1
4.1
5.4
5.4
10.1
INC : R & I Cylinder head ass'y, Intake & exhaust manifold, Camshaft, Valve Stem seals, Valves recondition, Engine adjust.
.
.
.
.
.
.
.
C - Valves (Each additional)
131270C
0.4
0.4
0.4
0.4
0.3
0.1
D - Valves (All)
131270D
1.5
1.5
1.5
1.5
1.5
1.8
4
. GUIDE, VALVE - REPLACE
1312800
4.9
4.4
4.4
5.5
5.5
10.1
INC : R & I Cylinder head ass'y, Intake & exhaust manifold, Camshaft, Valve, Stem seals, Valves recondition, Engine adjust.
.
.
.
.
.
.
.
C - Valves (Each additional)
131280C
0.3
0.3
0.3
0.3
0.3
0.1
D - Valves (All)
131280D
1.5
1.5
1.5
1.5
1.5
1.8
S : AVEO/KALOS/BARINA, N : NUBIRA/LACETTI/FORENZA/OPTRA/VIVA, L : EVANDA/EPICA

G141C06
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DOHC ENGINE MECH. - CYLINDER HEAD (131)

NO.
OPERATION DESCRIPTION
OPERATION CODE
S
N
L
1.4D/1.6D
1.4D
1.6D/1.8D(Fam I)
1.8D/2.0D(Fam II)
2.0D
2.5X
5
. SPRING CAP AND/OR SEAL, VALVE (ONE CYLINDER) - REPLACE
1312900
3.7
3.9
3.9
3.9
4.1
10.1
INC : R & I Cylinder head ass'y, Camshaft, Engine adjust.
.
.
.
.
.
.
.
C - Valves (Each additional)
131290C
0.4
0.4
0.4
0.4
0.4
0.1
D - Valves (All)
131290D
2.1
2.1
2.1
2.1
2.1
2.2
6
. LIFTER, VALVE - REPLACE
1313800
1.6
1.3
1.3
1.3
1.2
9.1
C - Valves (Each additional)
131380C
0.2
0.2
0.2
0.2
0.2
0.1
D - Valves (All)
131380D
0.5
0.5
0.5
0.5
0.5
0.2
7
. SENSOR, ENGINE COOLANT TEMP - REPLACE
1314100
0.4
0.4
0.4
0.2
0.2
0.2
S : AVEO/KALOS/BARINA, N : NUBIRA/LACETTI/FORENZA/OPTRA/VIVA, L : EVANDA/EPICA

G141C07
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DOHC ENGINE MECH. - CAM SUPPORT & SHAFT (132)

NO.
OPERATION DESCRIPTION
OPERATION CODE
S
N
L
1.4D/1.6D
1.4D
1.6D/1.8D(Fam I)
1.8D/2.0D(Fam II)
2.0D
2.5X
1
. COVER AND/OR GASKET, CAMSHAFT HOUSING (ONE PIECE) - REPLACE
1322100
0.5
0.5
0.5
0.5
0.5
1.1
2
. CAMSHAFT, EXHAUST/INTAKE - REPLACE
1322400
2.3
1.3
1.3
1.3
1.3
9.0
INC : R & I Dis coil, Camshaft gear, Ignition timing adjust.
.
.
.
.
.
.
.
C - Replace both
132240C
0.3
0.3
0.3
0.3
0.3
0.2
3
. CAP, OIL FILLER - REPLACE
1322700
0.2
0.2
0.2
0.2
0.2
0.2
4
. COVER, CAMSHAFT UPPER - REPLACE
1322800
0.2
0.2
0.2
0.2
0.2
0.2
5
. OIL SEAL, CAMSHAFT - REPLACE
1323000
2.1
1.8
1.8
1.2
1.2
—
S : AVEO/KALOS/BARINA, N : NUBIRA/LACETTI/FORENZA/OPTRA/VIVA, L : EVANDA/EPICA

G141C08
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DOHC ENGINE MECH. - TIMING COVER (133)

NO.
OPERATION DESCRIPTION
OPERATION CODE
S
N
L
1.4D/1.6D
1.4D
1.6D/1.8D(Fam I)
1.8D/2.0D(Fam II)
2.0D
2.5X
1
. PULLEY, CRANKSHAFT - REPLACE
1332100
0.6
0.4
0.4
0.4
0.4
8.1
2
. COVER, AND/OR GASKET, TIMING - REPLACE
1332200
—
—
—
—
1.0
6.7
3
. COVER, TIMING BELT REAR - REPLACE
1332300
1.4
1.6
1.6
1.6
1.6
—
4
. BELT, TIMING - REPLACE
1332500
1.1
1.1
1.1
1.3
1.3
—
. BELT, TIMING - ADJUST
1332700
1.7
1.1
1.1
1.3
1.3
—
5
. TENSIONER, TIMING BELT - REPLACE
1332900
1.3
1.1
1.1
1.3
1.3
—
INC : R & I Timing belt, Timing belt cover, Engine adjust.
.
.
.
.
.
.
.
6
. SPROCKET, CRANKSHAFT TIMING - REPLACE
1333100
1.3
0.9
0.9
1.3
1.3
8.8
INC : R & I Timing belt, Engine adjust.
.
.
.
.
.
.
.
7
. SPROCKET, CAMSHAFT TIMING - REPLACE
1333300
1.7
1.7
1.7
1.1
1.1
8.8
INC : R & I Timing belt, Engine adjust.
.
.
.
.
.
.
.
8
. PUMP AND/OR GASKET, COOLANT - REPLACE
1333500
2.0
1.8
1.8
1.3
1.3
2.3
9
. SENSOR, CRANKSHAFT POSITION - REPLACE
1333700
0.3
0.2
0.2
1.3
1.3
0.3
10
. SENSOR, CAMSHAFT POSITION - REPLACE
1333800
0.6
0.6
0.6
0.6
0.6
0.2
11
. PULLEY, IDLER - REPLACE
1333900
1.2
1.2
1.2
1.2
1.2
0.3
12
. COVER, CAMSHAFT DRIVE BELT (UPPER)
1334200
0.5
0.2
0.2
—
—
—
S : AVEO/KALOS/BARINA, N : NUBIRA/LACETTI/FORENZA/OPTRA/VIVA, L : EVANDA/EPICA

G141C08
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DOHC ENGINE MECH. - TIMING COVER (133)

NO.
OPERATION DESCRIPTION
OPERATION CODE
S
N
L
1.4D/1.6D
1.4D
1.6D/1.8D(Fam I)
1.8D/2.0D(Fam II)
2.0D
2.5X
13
. COVER, CAMSHAFT DRIVE BELT (LOWER)
1334300
0.9
0.7
0.7
—
—
—
14
. TENSIONER, TIMING CHAIN - REPLACE
1334500
—
—
—
—
—
8.8
15
. CHAIN, TIMING - REPLACE
1334600
—
—
—
—
—
8.9
16
. CHAIN, OIL PUMP - REPLACE
1334700
—
—
—
—
—
8.9
S : AVEO/KALOS/BARINA, N : NUBIRA/LACETTI/FORENZA/OPTRA/VIVA, L : EVANDA/EPICA

G141C09
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DOHC ENGINE MECH. - ENGINE & TRANSAXLE MOUNT (138)

NO.
OPERATION DESCRIPTION
OPERATION CODE
S
N
L
1.4D/1.6D
1.4D
1.6D/1.8D(Fam I)
1.8D/2.0D(Fam II)
2.0D
2.5X
1
. MOUNT, ENGINE (RH-FRONT) - REPLACE
1380100
0.9
0.8
0.8
0.8
0.8
0.8
2
. BRACKET, ENGINE MOUNT (RH-FRONT) - REPLACE
1380300
0.9
0.8
0.8
0.8
0.8
0.8
3
. MOUNT, TRANSAXLE (LH-FRONT) - REPLACE
1380500
0.9
0.9
0.9
0.9
0.9
0.9
4
. MOUNT, TRANSAXLE (CENTER-REAR) - REPLACE
1380700
0.9
0.9
0.9
0.8
0.8
0.8
A - Auto transaxle
138070A
0.4
—
—
—
—
—
5
. MOUNT, ENGINE (CENTER-FRONT) - REPLACE
1380800
—
—
—
—
0.8
0.8
6
. MEMBER, CENTER - REPLACE
1382500
—
—
—
—
0.7
0.7
7
. ROD, REACTION - REPLACE
1381300
0.5
0.5
0.5
0.5
—
—
8
. BRACKET, REACTION (LOWER) - REPLACE
1381500
0.9
0.9
—
0.9
—
—
9
. SHIELD, SPLASH - REPLACE
.
.
.
.
.
.
.
Right
1382100
0.3
0.3
0.3
0.3
0.3
0.3
Left
1382200
0.3
0.3
0.3
0.3
0.3
0.3
.
1382300
—
—
—
—
—
—
S : AVEO/KALOS/BARINA, N : NUBIRA/LACETTI/FORENZA/OPTRA/VIVA, L : EVANDA/EPICA
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