Replace Timing Belt on 2004 Chevrolet Aveo
Timing belt replacement on 2004 Chevrolet Aveo, also replace water pump, idler pully and tensioner.
Removal & Installation
Drain the engine coolant and engine oil.
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
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.
Align the camshaft gear timing marks.
Aligning the crankshaft and camshaft gear timing marks—1.6L engine
Aligning the crankshaft and camshaft gear timing marks—1.6L engine
See Photo 1
Slightly loosen the water pump bolts.
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. (I bought this tool for $18.00, its a 17mm open end with a rachet hole on end)
Aligning the timing belt tensioner pointer with the notch in the bracket—1.6L engine
Aligning the timing belt tensioner pointer with the notch in the bracket—1.6L engine
See Photo 2
Tighten the water pump bolts.
Remove the timing belt.
Remove the crankshaft and camshaft gears. (not necessary)
Remove the timing belt tensioner.
Remove the idler pulley.
Remove the rear timing belt cover. (not necessary)
To install:
Install the rear timing belt cover. Tighten the bolts to 89 inch lbs. (10 Nm).
Install the idler pulley. Tighten the bolt to 30 ft. lbs. (40 Nm).
Install the timing belt tensioner. Tighten the bolts to 18 ft. lbs. (25 Nm).
Install the crankshaft gear.
Install the camshaft gears.
While firmly holding the camshafts in place, tighten the camshaft gear bolts to 49 ft. lbs. (68 Nm).
Install the timing belt.
Rotate the crankshaft 2 full turns clockwise using the pulley bolt.
Slightly loosen the water pump bolts.
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.
Aligning the timing belt tensioner pointer with the pointer on the bracket—1.6L engine
Aligning the timing belt tensioner pointer with the pointer on the bracket—1.6L engine
See Photo 2.
Tighten the water pump bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
Remove the crankshaft pulley bolt.
Install the upper and lower timing belt covers. Tighten the bolts to 89 inch lbs. (10 Nm).
Install the crankshaft pulley bolt. Tighten the bolt to 70 ft. lbs. (95 Nm) plus an additional 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