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Dave Nova
Dave Nova, Chevrolet Technician
Category: Chevy
Satisfied Customers: 19452
Experience:  ASE Master Certification. GM World Class Certification
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2004 chevy aveo: timing marks..idler pulley..the belt to slip

Resolved Question:

The timing marks on my son's 2004 chevy aveo will not line up. The belt did not break, but the idler pulley borke in half and may have caused the belt to slip. How did I get the timing marks to line up? We have replaced the pulley and the timing belt, but we were not able to aline the timing marks due to the belt slipping, help, thanks in advance for your assistance and prompt response.
Submitted: 8 years ago.
Category: Chevy
Expert:  Dave Nova replied 8 years ago.

What engine size does the car have? 1.2 , 1.4 , 1.5 or 1.6 liter?

Customer: replied 8 years ago.

Engine size 1.6 Liter.

Expert:  Dave Nova replied 8 years ago.
Object Number:(NNN) NNN-NNNN Size: SH

  • Disconnect the negative battery cable.
  • Disconnect the intake air temperature (IAT) sensor connector.
  • Disconnect the air intake tube from the throttle body.
  • Disconnect the breather tube from the valve cover.
    Object Number:(NNN) NNN-NNNN Size: SH

  • Remove the air filter housing bolts.
  • Remove the air filter housing.
  • Remove the right front wheel. Refer to
  • Remove the right front splash shield.
    Object Number:(NNN) NNN-NNNN Size: SH

  • Remove the accessory drive belt.
  • Remove the crankshaft pulley bolt.
  • Remove the crankshaft pulley.
    Object Number:(NNN) NNN-NNNN Size: SH

  • Remove the upper front timing belt cover bolts.
  • Remove the upper front timing belt cover by prying on the two tabs located on each side of the cover.
  • Remove the lower front timing belt cover bolts.
  • Remove the lower front timing belt cover.
  • Remove the power steering pump mounting bolts, if equipped.
  • Install the crankshaft pulley bolt.
    Object Number:(NNN) NNN-NNNN Size: SH
  • Using the crankshaft pulley bolt, rotate the crankshaft clockwise until the timing mark on the crankshaft gear is aligned with the timing mark at the bottom of the rear timing belt cover.
    Object Number:(NNN) NNN-NNNN Size: SH

  • Slightly loosen the coolant pump retaining bolts.
  • Using the J 42492-A (1), rotate the coolant pump counterclockwise to release the tension on the timing belt.
    Object Number:(NNN) NNN-NNNN Size: SH

    Important: Remove the timing belt behind the power steering pump.

  • Remove the timing belt.
  • Installation Procedure


      Object Number:(NNN) NNN-NNNN Size: SH

    1. Align the timing mark on the crankshaft gear to the timing mark on the bottom of the rear timing belt cover.
      Object Number:(NNN) NNN-NNNN Size: SH

      Important: Ensure that the exhaust camshaft gear dowel pin (1) is approximately in the 11 o'clock position.

    2. Align the timing marks (2) on the camshaft gears.
    3. Install the timing belt.
      Object Number:(NNN) NNN-NNNN Size: SH

    4. Rotate the coolant pump clockwise using the J 42492-A (1).
      Object Number:(NNN) NNN-NNNN Size: SH

    5. Rotate the coolant pump clockwise until the adjust arm pointer of the timing belt automatic tensioner is aligned to the notch in the timing belt automatic tensioner bracket.

       


      Object Number:(NNN) NNN-NNNN Size: SH

    6. Tighten the coolant pump retaining bolts.
    7. Rotate the crankshaft 2 full turns clockwise using the crankshaft pulley bolt.
    8. Loosen the coolant pump retaining bolts.
    9. Rotate the coolant pump until the adjust arm pointer of the timing belt automatic tensioner is aligned with the pointer on the timing belt automatic tensioner bracket.
      Object Number:(NNN) NNN-NNNN Size: SH

    10. Tighten the coolant pump retaining bolts.

      Tighten
      Tighten the coolant pump retaining bolts to 10 N·m (89 lb in).


      Object Number:(NNN) NNN-NNNN Size: SH

    11. Remove the crankshaft pulley bolt.
    12. Install the upper and lower front timing belt cover.
    13. Install the upper and lower front timing belt cover bolts.

      Tighten
      Tighten the upper and lower front timing belt cover bolts to 10 N·m (89 lb in).


      Object Number:(NNN) NNN-NNNN Size: SH

    14. Install the crankshaft pulley.
    15. Install the crankshaft pulley bolt.

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

    16. Install the accessory drive belt, if equipped.
    17. Install the right front splash shield.
    18. Install the right front wheel.
    Dave Nova and 3 other Chevy Specialists are ready to help you
    Customer: replied 8 years ago.
    Thank you.

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