Aveo 2004-2005

Timing Belt & Sprockets

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Removal & Installation



  1. Drain the engine coolant and engine oil.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Intake Air Temperature (IAT) sensor
     
    Radiator hoses
     
    Air cleaner assembly and air intake duct
     
    Valve cover breather tube
     
    Right front wheel and splash shield
     
    Accessory drive belt
     
    Crankshaft pulley
     
    Upper front timing belt cover
     
    Power steering pump and position aside
     
    Lower front timing belt cover
     
    Reinstall the crankshaft pulley bolt
     

  4.  
  5. Rotate the engine clockwise one full turn until the mark on the crankshaft gear aligns with the notch at the bottom of the rear timing cover.
  6.  
  7. Align the camshaft gear timing marks.

    Click image to see an enlarged view

    Fig. Aligning the crankshaft and camshaft gear timing marks-1.6L engine

  8.  
  9. Slightly loosen the water pump bolts.
  10.  
  11. Using tool J-42492-A, turn the water pump clockwise until the adjuster arm pointer of the timing belt tensioner is aligned with the notch in the tensioner bracket.

    Click image to see an enlarged view

    Fig. Aligning the timing belt tensioner pointer with the notch in the bracket-1.6L engine

  12.  
  13. Tighten the water pump bolts.
  14.  
  15. Remove the timing belt.
  16.  
  17. Remove the crankshaft and camshaft gears.
  18.  
  19. Remove the timing belt tensioner.
  20.  
  21. Remove the idler pulley.
  22.  
  23. Remove the rear timing belt cover.
  24.  

To install:

  1. Install the rear timing belt cover. Tighten the bolts to 89 inch lbs. (10 Nm).
  2.  
  3. Install the idler pulley. Tighten the bolt to 30 ft. lbs. (40 Nm).
  4.  
  5. Install the timing belt tensioner. Tighten the bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the crankshaft gear.
  8.  
  9. Install the camshaft gears.
  10.  
  11. While firmly holding the camshafts in place, tighten the camshaft gear bolts to 49 ft. lbs. (68 Nm).
  12.  
  13. Install the timing belt.
  14.  
  15. Rotate the crankshaft 2 full turns clockwise using the pulley bolt.
  16.  
  17. Slightly loosen the water pump bolts.
  18.  
  19. Using tool J-42492-A, turn the water pump until the adjuster arm pointer of the timing belt tensioner is aligned with the pointer on the tensioner bracket.

    Click image to see an enlarged view

    Fig. Aligning the timing belt tensioner pointer with the pointer on the bracket-1.6L engine

  20.  
  21. Tighten the water pump bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
  22.  
  23. Remove the crankshaft pulley bolt.
  24.  
  25. Install the upper and lower timing belt covers. Tighten the bolts to 89 inch lbs. (10 Nm).
  26.  
  27. Install the crankshaft pulley bolt. Tighten the bolt to 70 ft. lbs. (95 Nm) plus an additional 15°.
  28.  
  29. Install or connect the following:

    Accessory drive belt
     
    Right front wheel and splash shield
     
    Valve cover breather tube
     
    Air cleaner assembly and air intake duct
     
    Intake Air Temperature (IAT) sensor
     
    Radiator hoses
     
    Engine oil
     
    Coolant
     
    Negative battery cable
     

  30.  

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the timing belt front cover.
  4.  
  5. Remove the power steering pump mounting bolts, if equipped with power steering.
  6.  
  7. Reinstall the crankshaft pulley bolt.
  8.  
  9. Using the crankshaft pulley bolt, rotate the crankshaft clockwise until the timing mark on the crankshaft gear aligns with the notch at the bottom of the rear timing cover.

    Click image to see an enlarged view

    Fig. Turn the crankshaft to align the timing mark on the crankshaft gear with the rear timing cover mark.

  10.  
  11. Slightly loosen the water pump retaining bolts.
  12.  
  13. Using Special Tool J-42492-A, rotate the water pump counterclockwise to release the tension on the timing belt.

    Click image to see an enlarged view

    Fig. Use Special Tool J-42492-A (1) to release the tension on the timing belt.

  14.  
  15. Removing the timing belt.
  16.  
  17. Remove the engine cover.
  18.  
  19. Disconnect the spark plug wires from the spark plugs.
  20.  
  21. Dsconnect the crankcase ventilation tubes from the valve cover.
  22.  
  23. Disconnect the Camshaft Position (CMP) sensor.
  24.  
  25. Remove the valve cover and the valve cover gasket.
    CAUTION
    Take extreme care to prevent any scratches, nicks or damage to the camshafts.

  26.  
  27. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
  28.  
  29. Remove the intake camshaft gear.
  30.  
  31. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
  32.  
  33. Remove the exhaust camshaft gear.

    Click image to see an enlarged view

    Fig. Hold the camshaft firmly in place with a wrench to remove the camshaft gear bolt.

  34.  

To install:

  1. While holding the intake camshaft firmly in place, install the intake camshaft gear bolt. Tighten the bolt to 49 ft. lbs.
  2.  
  3. While holding the exhaust camshaft firmly in place, install the intake camshaft gear bolt. Tighten the bolt to 49 ft. lbs.
  4.  
  5. Install the valve cover and gasket.
  6.  
  7. Connect the CMP sensor.
  8.  
  9. Connect the crankshaft ventilation tubs to the valve cover.
  10.  
  11. Connect the spark plug wires.
  12.  
  13. Install the engine cover.

    Click image to see an enlarged view

    Fig. Timing belt routing-1.6L engine

  14.  
  15. Ensure the timing mark on the crankshaft gear aligns with the notch at the bottom of the rear timing cover is aligned.
  16.  
  17. Align the timing marks on the camshaft gears.

    Click image to see an enlarged view

    Fig. Aligning the crankshaft and camshaft gear timing marks-1.6L engine

  18.  
  19. Rotate the water pump clockwise using Special Tool J-42492-A until the adjusting arm pointer of the timing belt automatic tensioner is aligned with the notch in the timing belt automatic tensioner bracket.
  20.  
  21. Tighten the water pump retaining bolts.
  22.  
  23. Rotate the crankshaft 2 full turns clockwise using the crankshaft pulley bolt.
  24.  
  25. Loosen the water pump retaining bolts.
  26.  
  27. Rotate the water pump until the adjust arm pointer of the timing belt automatic tensioner is aligned with the pointer on the timing belt automatic tensioner bracket and second time.
  28.  
  29. Tighten the water pump retaining pump to 89 inch lbs. (10 Nm).
  30.  
  31. Remove the crankshaft pulley bolt.
  32.  
  33. Replace the power steering pump mounting bolts.
  34.  
  35. Install the timing belt front cover. For additional information, refer to the following section, -Timing Belt Front Cover, Removal & Installation.-
  36.  
  37. Connect the negative battery cable.
  38.  

 
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