Timing belt replacement instructions

Tiny
JONSOLOW13
  • MEMBER
  • 2007 CHEVROLET AVEO
  • 1.6L
  • 4 CYL
  • 2WD
  • MANUAL
  • 107,000 MILES
We are pretty sure something went wrong with the upper half of the engine; valves probably. 2 questions.
(1) If it is just valves would you recommend a head job (mill, valves, cams, etc.) Or switch out the entire engine? FYI, we are in FL and the car was a NY car. Has some rust obviously.

(2) If we go with switching out the motor, could you confirm the compatible years (we think 2007-2009)?

Thanks,

Jon
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Tuesday, January 26th, 2021 AT 1:49 PM

7 Replies

Tiny
JACOBANDNICKOLAS
  • EXPERT
Hi,

As far as the replacement engine, I would only use the same year, make, and model. They are changing things so often, you may run into trouble.

As far as the cylinder head, it really needs to be removed and inspected to see what happened. Can you tell me if there is noise or another issue that leads you to believe there is a problem with the valves?

If you decide to remove the head, here are the directions. They are a bit extensive but can be done. The attached pics correlate with the directions.

_______________________________________

2007 Chevrolet Aveo L4-1.6L
Cylinder Head Replacement
Vehicle Engine, Cooling and Exhaust Engine Cylinder Head Assembly Service and Repair Removal and Replacement Cylinder Head Replacement
CYLINDER HEAD REPLACEMENT
Cylinder Head Replacement

Tools Required
* J 45059 Angle Meter
* KM-470-B Angular Torque Gage
* J 42492-A (KM-421-A) Timing Belt Adjuster

Removal Procedure

pic 1

Caution: Refer to Safety Glasses Caution.

1. Remove the fuel pump fuse.
2. Start the engine. Crank the engine after the engine stalls for 10 seconds to rid the fuel system of fuel pressure.
3. Drain the engine coolant.

Pic 2

4. Disconnect the breather tube from the valve cover.
5. Disconnect the intake air temperature (IAT) sensor connector.
6. Disconnect the air intake tube from the throttle body.

Pic 3

7. Remove the air filter housing bolts.
8. Remove the air filter housing.

Pic 4

9. Disconnect the A/C pressure (ACP) transducer connector.

Pic 5

10. Disconnect the idle air control (IAC) valve connector.
11. Disconnect the throttle position (TP) sensor connector.
12. Disconnect the throttle cable from the throttle body and the intake manifold.
13. Disconnect the engine coolant inlet/outlet hose at the throttle body.

Pic 6

14. Disconnect the manifold absolute pressure (MAP) sensor connector.
15. Disconnect the brake booster vacuum hose.
16. Disconnect the variable geometry induction solenoid (VGIS) connector.
17. Disconnect the VGIS vacuum tank hose.

Pic 7

18. Remove the engine cover bolts and the cover.
19. Disconnect the breather tube from the valve cover.
20. Disconnect the crankcase ventilation tube from the valve cover.

Pic 8

21. Disconnect the camshaft position (CMP) sensor connector.
22. Disconnect the ignition wires from the spark plugs.
23. Disconnect the fuel injector harness connectors.

Pic 9

24. Disconnect the fuel line.

Pic 10

25. Remove the bracket nut from the power steering pressure pipe.
26. Remove the power steering pressure pipe.
27. Remove the alternator adjusting nut.

Pic 11

28. Remove the accessory drive bolt.
29. Disconnect the exhaust gas recirculation (EGR) valve connector.
30. Disconnect the ignition coil connector from the electronic ignition (EI) system.
31. Disconnect the front heated oxygen sensor (HO2S) connector.

Pic 12

32. Remove the right front wheel.
33. Remove the engine under-cover bolt and the nuts.
34. Remove the engine under-cover.
35. Remove the canister purge solenoid valve at the intake manifold support bracket.

Pic 13

36. Remove the bracket bolts from the upper intake manifold support.
37. Remove the bracket bolts from the lower intake manifold support.
38. Disconnect the connector from the engine coolant temperature (ECT) sensor.

Pic 14

39. Remove the exhaust manifold heat shield bolts.
40. Remove the exhaust manifold heat shield.
41. Remove the catalytic converter.

Pic 15

42. Loosen the hose clamp on the upper radiator hose at the thermostat housing.
43. Disconnect the upper radiator hose from the thermostat housing.

Pic 16

44. Remove the cover bolts from the upper front timing belt.
45. Remove the cover from the upper front timing belt.

Pic 17

46. Remove the crankshaft pulley bolt.
47. Remove the crankshaft pulley.

Pic 18

48. Remove the cover bolts from the lower front timing belt.
49. Remove the cover from the lower front timing belt.

Pic 19

50. Align the camshaft gear timing marks.

Pic 20

51. Slightly loosen the coolant pump retaining bolts.
52. Rotate the coolant pump counterclockwise using J 42492-A (1) to relieve the timing belt tension.
53. Remove the timing belt.

Pic 21

54. Remove the valve cover.

Notice: Use extreme care when installing the camshaft not to nick, scratch, or damage the camshaft lobes or bearing surfaces.

55. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
56. Remove the intake camshaft gear.
57. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
58. Remove the exhaust camshaft gear.

Pic 22

59. Remove the bolts from the timing belt automatic tensioner.
60. Remove the timing belt automatic tensioner.

Pic 23

61. Remove the camshaft position (CMP) sensor bolts.
62. Remove the CMP sensor.

Pic 24

63. Remove the bolt from the timing belt idler pulley.
64. Remove the timing belt idler pulley.

Pic 25

65. Remove the bolts from the rear timing belt cover.
66. Remove the rear timing belt cover.

Pic 26

67. Disconnect the heater outlet hose from the coolant pipe.

Pic 27

68. Loosen all of the cylinder head bolts gradually and in the sequence shown.
69. Remove the cylinder head bolts.
70. Remove the cylinder head with the intake manifold and the exhaust manifold attached.

Notice: Use extreme care when removing the cylinder head to prevent any engine oil, dirt, or coolant from entering the engine. Damage to the engine could result.

71. Remove the cylinder head gasket.
72. Disassembly the cylinder head, if applicable.
73. Clean and inspect the cylinder head as necessary.

Installation Procedure

1. Assemble the cylinder head, if applicable.

Pic 28

2. Install the cylinder head gasket.
3. Install the cylinder head with the intake manifold and the exhaust manifold attached.
4. Install the cylinder head bolts.

Notice: Refer to Fastener Notice.

5. Tighten the cylinder head bolts gradually and in the sequence shown.

Tighten the bolts to 25 N.M (18 lb ft). Adjust the bolts to 60 degrees plus 60 degrees plus 60 degrees plus 10 degrees using J 45059 or KM-470-B.

Pic 29

6. Connect the heater outlet hose to the coolant pipe.

Pic 30

7. Install the rear timing belt cover.
8. Install the bolts to the rear timing belt cover.

Tighten the bolts to 10 N.M (89 lb in).

Pic 31

9. Install the CMP sensor. Install the CMP sensor bolts.

Tighten the bolts to 12 N.M (106 lb in).

Pic 32

10. Install the timing belt idler pulley. Install the bolt. To the timing belt idler pulley

Tighten the bolt to 40 N.M (30 lb ft).

Pic 33

11. Install the timing belt automatic tensioner. Install the bolts to the timing belt automatic tensioner.

Tighten the bolts to 25 N.M (18 lb ft).

Pic 34

Notice: Use extreme care when installing the camshaft not to nick, scratch, or damage the camshaft lobes or bearing surfaces.

12. Install the intake camshaft gear.
13. While holding the intake camshaft firmly in place, install the intake camshaft gear bolt.

Tighten the bolt to 67.5 N.M (49 lb ft).

14. Install the exhaust camshaft gear.
15. While holding the exhaust camshaft firmly in place, install the exhaust camshaft gear bolt.

Tighten the bolt to 67.5 N.M (49 lb ft).

Pic 35

16. Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the seal between the rear valve cover and the cylinder head.
17. Install the valve cover and the valve cover gasket.
18. Install the valve cover bolts.

Tighten the bolts to 10 N.M (89 lb in).

Pic 36

Important: Ensure that the exhaust camshaft gear dowel pin is approximately in the 11 o'clock position.

19. Align the timing marks on the camshaft gear.

Pic 37

20. Align the mark on the crankshaft gear to the notch at the bottom of the rear timing belt cover.

Pic 38

Notice: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt.

21. Install the timing belt.
22. Rotate the coolant pump clockwise using J 42492-A (1), to apply tension to the timing belt.

Tighten the retaining bolt to 10 N.M (89 lb in).

23. Inspect and adjust the timing belt tension.

Pic 39

24. Install the retaining bolts that secure the engine mount to the engine mount bracket.

Tighten the retaining bolts to 60 N.M (44 lb ft).

25. Install the lower front timing belt cover.
26. Install the bolts to the lower front timing belt cover.

Tighten the bolts to 10 N.M (89 lb in).

Pic 40

27. Install the crankshaft pulley.
28. Install the crankshaft pulley bolt.

Tighten the bolt to 95 N.M (70 lb ft) using a torque wrench. Using J 45059 or KM-470-B, tighten the crankshaft pulley bolt to 30 degrees plus 15 degrees.

Pic 41

29. Install the upper front timing belt cover.
30. Install the bolts to the upper front timing belt cover.

Tighten the bolts to 10 N.M (89 lb in).

Pic 42

31. Connect the upper radiator hose to the thermostat housing.
32. Connect the throttle body coolant hose to the thermostat housing.
33. Install the catalytic converter.

Pic 43

34. Install the exhaust manifold heat shield. Install the bolts to the exhaust manifold heat shield.

Tighten the bolts to 15 N.M (11 lb ft).

Pic 44

35. Connect the ECT sensor connector.
36. Install the upper bolts to the intake manifold support bracket.

Tighten the bolts to 25 N.M (18 lb ft).

Pic 45

37. Install the canister purge solenoid valve at the intake manifold support bracket.
38. Install the engine under-cover.

Pic 46

39. Connect the front HO2S connector.
40. Connect the EI system ignition coil connector.
41. Connect the EGR valve connector.

Notice: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt.

42. Install the accessory drive belt.

Pic 47

43. Install the alternator bracket retaining nut.

Tighten the nut to 25 N.M (18 lb ft).

44. Install the alternator nut. Do NOT tighten.

Pic 48

45. Connect the fuel line at the fuel rail.

Pic 49

46. Connect the fuel injector harness connectors.
47. Connect the ignition wires from the spark plugs.
48. Connect the CMP sensor connector.

Pic 50

49. Connect the crankcase ventilation tube to the valve cover.
50. Connect the breather tube to the valve cover.
51. Install the engine cover.
52. Install the engine cover bolts.

Pic 51

53. Connect the VGIS vacuum tank hose.
54. Connect the VGIS connector.
55. Connect the brake booster vacuum hose.
56. Connect the MAP sensor connector.

Pic 52

57. Connect the engine coolant inlet/outlet hose to the throttle body.
58. Connect the throttle cable to the throttle body and the intake manifold.
59. Connect the TP sensor connector.
60. Connect the IAC valve connector.

Pic 53

61. Connect the A/C pressure transducer connector.

Pic 54

62. Install the air filter housing. Install the air filter housing bolts.

Tighten the bolts to 8 N.M (71 lb in).

Pic 55

63. Connect the air intake tube to the throttle body.
64. Connect the IAT sensor connector.
65. Connect the breather tube to the valve cover.
66. Install the fuel pump fuse.
67. Connect the negative battery cable.
68. Fill the engine cooling system.

______________________________________

Let me know if this helps or if you have other questions.

Take care,
Joe
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Tuesday, January 26th, 2021 AT 2:42 PM
Tiny
DEMETRICAR
  • MEMBER
  • 2008 CHEVROLET AVEO
  • 1.6L
  • 173,000 MILES
My timing belt broke in August and a couple hours after it my car battery died. I paid a mechanic to fix my car he told me that I had damaged valves on my engine from my timing belt breaking. Unfortunately he never fixed it after me paying him but I sued to get the money back and I just want to know what is really wrong with my car. If what he told me was true and what is my next step fixing my car?
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Wednesday, March 10th, 2021 AT 1:49 PM (Merged)
Tiny
JACOBANDNICKOLAS
  • EXPERT
Hi and thanks for using 2CarPros.

I am sorry to say, but he is most likely correct. The engine in this vehicle is known as an interference engine. Basically what that means is this. There is not enough clearance between the top of the pistons and the valves in the cylinder head and if the belt breaks and allows the engine to turn with the engine timing compromised, the two will hit each other and cause internal damage. Usually, it will bend valves in the head.

To fix the engine, the head needs removed first and the components inspected. If damage has only occurred to the valves, then it should be repairable. However, when this happens, often times other things are damaged or broken such as valve guides, the cylinder head itself, even the pistons.

Most times it ends up cheaper to find a good used engine from a salvage yard and replace the one in the vehicle. Once you add parts and labor to repair the old one, it can be very expensive.

I hope this helps or at least helps you better understand what happened. Feel free to ask other questions if you have them

Take care,
Joe
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Wednesday, March 10th, 2021 AT 1:49 PM (Merged)
Tiny
DT8020
  • MEMBER
  • 2005 CHEVROLET AVEO
My timing belt broke and oil is on my spark plugs car made a horrible noise and then shut down does this mean major trouble
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Wednesday, March 10th, 2021 AT 1:49 PM (Merged)
Tiny
MHPAUTOS
  • EXPERT
Hi there,

This is an interference type engine and with a failed timing belt engine damage will result, you will have to remove the head to do a full inspection first.

Mark (mhpautos)
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Wednesday, March 10th, 2021 AT 1:49 PM (Merged)
Tiny
AVEO54
  • MEMBER
  • 2004 CHEVROLET AVEO
  • 4 CYL
  • FWD
  • MANUAL
  • 36,600 MILES
I have a 2004 aveo and I know about the timing belt issues. I bought my aveo in 2008 used and it had 19900 miles on it, it now has 36600 miles on it since the car was not used hard by previous owner and I have taken good care of the car, will the timing belt
last till about 60000 miles or should I get it replaced at 40000 since I heard some of them have broken at that mileage.
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Wednesday, March 10th, 2021 AT 1:50 PM (Merged)
Tiny
DOCFIXIT
  • EXPERT
GM says replace at 60K miles the engine is an interference engine and damage to valves will occur if T belt breaks. So maybe replacing a little sooner is a good idea.
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Wednesday, March 10th, 2021 AT 1:50 PM (Merged)

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