2005 Aveo 5-spd sedan - timing belt broke - being repaired

[Daox]

Well, I didn't get as much as I wanted done today (had to fix my tiller), but the engine is almost ready to be dropped into the car. Since the engine is from a 2007 Aveo, I had to do some part swapping.

I started with the flywheel. The engine I got was an automatic, so I needed to put the manual trans flywheel on it.






And then the starter.




The timing belt cover was pretty cracked up, so I swapped it for the original engine's cover.






When removing the cover, I noticed this, and that just wont do.




So, I swapped the engine mount from the original engine as well.




And, it was a good thing I did. I found fragments of the cracked timing belt cover in the bottom. They could have easily been tossed around and caused problems.




While reassembling, I also reinstalled the alternator.




Here is the difference between the 07 DBW throttle body and the 05 cabled throttle body. A few of the vacuum lines are different as well.




But, the differences don't stop there. This is a comparison of the valve covers. The 07 is the dull one. The PCV valve is a bit different as well as the 05 having a large port on the bottom left (in the pic).




Moving on to the intake manifold, it looks like they also installed a position sensor on the actuator for the secondary runners. It doesn't get in the way of anything, so I am going to use the 07 manifold. However, I did notice that one plugged vacuum nipple on the 04 manifold is smaller than the one on the 07.




Next, I found a difference between the two oxygen sensors. The connectors are different. So, I had to swap those as well.




So, thats about as far as I have gotten. I could use a little help though. I don't know where the hoses that attach to these places go. There is one on the bottom of the throttle body. Its a coolant line.




There is also the large port on the end of the valve cover (that isn't on the 07 valve cover). This appears to be just some form of breather. Some help identifying where these go would be great.

[thehunterooo]

very good pics

[MetroMPG]

Looks like you're going to need a new oil filter too. The guys at the yard weren't too careful!

[petrified.rabbit]

would you be willing to send me your old exhaust and intake gaskets? the ones that bolt to the head, if you still have them of course.

[serega12]

Looks like you're going to need a new oil filter too. The guys at the yard weren't too careful!

LOL... I don't think Daox would reuse the same oil filter anyways. I don't think I would. You don't know how long it's been on there...

[reddemonx92]

Hey the yellow numbers above the spark plugs, what does it label?

[thehunterooo]

cylinder numbers im guessing

[Daox]

Looks like you're going to need a new oil filter too. The guys at the yard weren't too careful!

Haha, yeah a few things were cracked and broken, but not a ton. I have a new oil filter sitting on the shelf in the garage ready to go. I'll do that once the engine is in the car. No need for the new one to possibly get beat up during the reinstall.

[Daox]

would you be willing to send me your old exhaust and intake gaskets? the ones that bolt to the head, if you still have them of course.

Yeah, send me a PM and we can figure something out.

The only thing about the intake is that there are 4 separate gaskets. If you look at the pic below, each orange/red piece is a gasket. Its not one solid gasket.

[Daox]

Hey the yellow numbers above the spark plugs, what does it label?

Yeah, its just cylinder numbers. Not sure why the previous owner did it. IMO its not real hard to keep track of four individual cylinders haha.