Question about Chevrolet Aveo

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Can someone supply me with the procedures for replacing the timing belt and diagram on gear location for a 2004 chevy avero 1.6 DOHC. It broke the belt,so everything is out of time.Thank you

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  • jeffmiller90 May 03, 2010

    can some one else help me out with this?

  • jeffmiller90 May 03, 2010

    That is what I was looking for. Thank you very much for taking the time to get that info for me.I really appreciate when one of you put some effort out to help.

×

2 Answers

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  • Chevrolet Master
  • 17,970 Answers

2004 CHEVROLET AVEO - L4 1.6L 1598cc 98ci GAS FI N 6
Belts / Tensioners / Pulleys

Part Number 5060740
Belt Routing Diagram Multiple Accessory, w/A.C.

Can someone supply me with - a59aef9.jpg




Aveo 2004-2005 Repair guide

Timing Belt & Sprockets - Removal & Installation

  1. Drain the engine coolant and engine oil.
  2. 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
  3. 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.
  4. Align the camshaft gear timing marks.

    86ebae8.jpg
    Fig. Aligning the crankshaft and camshaft gear timing marks-1.6L engine
  5. Slightly loosen the water pump bolts.
  6. 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.


    Fig. Aligning the timing belt tensioner pointer with the notch in the bracket-1.6L engine
  7. Tighten the water pump bolts.
  8. Remove the timing belt.
  9. Remove the crankshaft and camshaft gears.
  10. Remove the timing belt tensioner.
  11. Remove the idler pulley.
  12. Remove the rear timing belt cover.
To install:
  1. Install the rear timing belt cover. Tighten the bolts to 89 inch lbs. (10 Nm).
  2. Install the idler pulley. Tighten the bolt to 30 ft. lbs. (40 Nm).
  3. Install the timing belt tensioner. Tighten the bolts to 18 ft. lbs. (25 Nm).
  4. Install the crankshaft gear.
  5. Install the camshaft gears.
  6. While firmly holding the camshafts in place, tighten the camshaft gear bolts to 49 ft. lbs. (68 Nm).
  7. Install the timing belt.
  8. Rotate the crankshaft 2 full turns clockwise using the pulley bolt.
  9. Slightly loosen the water pump bolts.
  10. 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.

    129dbc2.jpg
    Fig. Aligning the timing belt tensioner pointer with the pointer on the bracket-1.6L engine
  11. Tighten the water pump bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
  12. Remove the crankshaft pulley bolt.
  13. Install the upper and lower timing belt covers. Tighten the bolts to 89 inch lbs. (10 Nm).
  14. Install the crankshaft pulley bolt. Tighten the bolt to 70 ft. lbs. (95 Nm) plus an additional 15°.
  15. 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

continue...

Posted on May 03, 2010

  • ZJ Limited
    ZJ Limited May 03, 2010

    continue...






    1. Disconnect the negative battery cable.


    2. Remove the timing belt front cover.


    3. Remove the power steering pump mounting bolts, if equipped with
      power steering.



    4. Reinstall the crankshaft pulley bolt.


    5. 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.











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






    6. Slightly loosen the water pump retaining bolts.


    7. Using Special Tool J-42492-A, rotate the water pump
      counterclockwise to release the tension on the timing belt.











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






    8. Removing the timing belt.


    9. Remove the engine cover.


    10. Disconnect the spark plug wires from the spark plugs.


    11. Dsconnect the crankcase ventilation tubes from the valve cover.


    12. Disconnect the Camshaft Position (CMP) sensor.


    13. Remove the valve cover and the valve cover gasket.



      CAUTION

      Take extreme care to prevent any scratches, nicks or damage to the
      camshafts.






    14. While holding the intake camshaft firmly in place, remove the
      intake camshaft gear bolt.



    15. Remove the intake camshaft gear.


    16. While holding the exhaust camshaft firmly in place, remove the
      exhaust camshaft gear bolt.



    17. Remove the exhaust camshaft gear.










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







    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. While holding the exhaust camshaft firmly in place, install the
      intake camshaft gear bolt. Tighten the bolt to 49 ft. lbs.



    3. Install the valve cover and gasket.


    4. Connect the CMP sensor.


    5. Connect the crankshaft ventilation tubs to the valve cover.


    6. Connect the spark plug wires.


    7. Install the engine cover.










      Fig. Timing belt routing-1.6L engine





    8. Ensure the timing mark on the crankshaft gear aligns with the
      notch at the bottom of the rear timing cover is aligned.



    9. Align the timing marks on the camshaft gears



    10. 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.



    11. Tighten the water pump retaining bolts.


    12. Rotate the crankshaft 2 full turns clockwise using the crankshaft
      pulley bolt.



    13. Loosen the water pump retaining bolts.


    14. 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.



    15. Tighten the water pump retaining pump to 89 inch lbs. (10 Nm).


    16. Remove the crankshaft pulley bolt.


    17. Replace the power steering pump mounting bolts.


    18. Install the timing belt front cover. For additional information,
      refer to the following section, -Timing Belt Front Cover, Removal &
      Installation.-



    19. Connect the negative battery cable.

    Hope thats help.



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  • Chevrolet Master
  • 1,851 Answers

Hi,
Your 2004 chevy avero 1.6 DOHC engine head is what is very difficult and very expensive to do properly. Please go HERE and read the entire page before making your final decision. This article is made just for this purpose.
Also - for exact pictures - and diagrams for your specific car is best. To obtain these FREE - simply call or go to your local dealer with the VIN number in hand and ask for the print outs and specs you want. Also - check for RECALLS - this alone can save you many thousands of dollars over the life time of cars.
Best of luck with your project.

Posted on May 03, 2010

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