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

yes, but from what i have seen, you can swap a 2.0 to a 2.2 in the daewoo.

http://daewootech.com/forum/viewtopic.php?f=1&t=10133

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the 2.2 would be a good build for an NA build, the only major difference between the 2.0 and 2.2 is the connecting rod are longer and the block is taller in the 2.2, otherwise you can use all the parts from the more popular 2.0.

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so assuming that is correct (the guys there know there stuff), then the 2.2 has a higher deck height but otherwise has the same dimension for the most part..

there is also a list of other engines you could chose from..

Thanks rabbit. I'll do some reading on that site.

Another quick update of mostly pictures. I got the clutch & flywheel removed tonight to get it on the engine stand. Of course the bolts were too short to get it on the stand so I'll have to go get some tomorrow. In the mean time I started removing other things...

Pressure plate, clutch & flywheel.

http://aveoforum.com/pictures/aveo016.JPG



All taken apart.

http://aveoforum.com/pictures/aveo017.JPG



Flywheel removed.

http://aveoforum.com/pictures/aveo018.JPG



This is the passenger side motor mount. Apparently the previous owner, in an attempt to fix the car decided it was wise to only put 2 of the 4 or 5 bolts back in to hold the engine up. Well, they both bent. I unbent the one still in the mount and pulled it out...

http://aveoforum.com/pictures/aveo019.JPG



The other didn't fare so well. The other end of it is still in the block.

http://aveoforum.com/pictures/aveo020.JPG



Removed the motor mount.

http://aveoforum.com/pictures/aveo021.JPG



Removed the crankshaft & timing pulley.

http://aveoforum.com/pictures/aveo022.JPG



Interesting note, the crankshaft and timing pulley are one piece... kind of. It seems the bore and keyway are pressed in. Odd design I've never seen before (not that I've seen a ton). EDIT: The smaller timing pulley actually pulls out of the larger pulley. Mine was just gooed together.

http://aveoforum.com/pictures/aveo023.JPG

http://aveoforum.com/pictures/aveo024.JPG



And the timing belt cover all removed.

http://aveoforum.com/pictures/aveo025.JPG

So I'm guessing you didn't find any hidden missing teeth on the belt when you took it off?

Ah yes, I forgot about that. Aside from being beaten up around the outer edges (opposite the toothed side), the belt looks good and the teeth all seemed to be quite intact. There was no cracking or anything that I could see.

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Originally Posted by Daox

Ah yes, I forgot about that. Aside from being beaten up around the outer edges (opposite the toothed side), the belt looks good and the teeth all seemed to be quite intact. There was no cracking or anything that I could see.

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So then the "snapped timing belt - being repaired" is not quite correct then? :) Or was it ultimately the reason for the engine failure?

Well, at this point I have no idea why the engine failed. But, the valves definitely smashed into the pistons somehow. There are score marks on every piston (in addition to the shallow stock cuts).

without seeing the car or knowing what the mileage and such are i would be willing to bet the tensioner failed. thats probably at least as common as a belt actually breaking, and probably even more common since that is typically what beaks belts.

hows the build coming along?

There are no updates since the last post. I have a small crew of in-laws & friends staying over at the house this weekend to do some work on my house. I'll get back to the car during the week.

Wow - lucky you.

You should invite the small crew to come back next week and help with the engine rebuild too :D

Haha, while I greatly appreciate the help with the house, the engine work is a different story. It is my territory, and I don't need or want help. :)

i feel the same way. my buddies will just reccomend and talk, talk, talk. lol very distracting
this is me while working on cars :evil: <-- dont bother me lol or else

LOL... and the thing is - if there will be 20 friends helping - there probably will be 25 different opinions... all very different from each other... :D

Another small update. (Sensing a pattern yet?) I don't get much time to work on stuff, so I just gotta try to do a little each night.

I got the engine up on the stand last night.

http://aveoforum.com/pictures/aveo026.JPG



Then flipped it over and removed the oil pan. And yes, there were bits of piston chunks here and there.

http://aveoforum.com/pictures/aveo027.JPG


Again, if anyone one wants pics of engine components let me know. I'll be posting lots of pics along the way.

the water pump is part of the block itself?

It looks like the pump assembly slides into a pocket in the block. I'll get more pics when I replace it.

http://aveoforum.com/pictures/aveo025.JPG

So I take it you decided on rebuild over swap?

Did you ever figure out what caused the piston and housing to break?

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Originally Posted by serega12

So I take it you decided on rebuild over swap?

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Yeah, I think I have my mind made up on the rebuild. Still gotta get things totally apart and checked out to make sure there isn't more damage I don't know about to the block or something critical.

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Originally Posted by reddemonx92

Did you ever figure out what caused the piston and housing to break?

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I'm guessing its what rabbit said, the tensioner failed. This caused the timing belt to slip/jump and the valves ended up smashing into the piston.

Oh ok...
so how much does it cost to fix the valve and pistons?

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Originally Posted by reddemonx92

Oh ok...
so how much does it cost to fix the valve and pistons?

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Well, a new set of pistons runs just over $100, new rings are $35, and a rebuilt head goes for around $400. Then I need the gaskets, etc. It'll be $700 all said and done depending on what I all want to replace while I'm in there.

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Originally Posted by trempus

the water pump is part of the block itself?

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I got more pictures for ya. Here is the whole deal. Kind of a neat little setup. Very simple.

http://aveoforum.com/pictures/aveo028.JPG



http://aveoforum.com/pictures/aveo029.JPG



http://aveoforum.com/pictures/aveo030.JPG



http://aveoforum.com/pictures/aveo031.JPG

And here are pics of the oil pan. I forgot to snap a few of them before. Good news for the autocrossers, the pan in the pan is there to stop oil from sloshing away from the oil pickup helping to ensure your engine will never be starved for oil while cornering/braking hard.

http://aveoforum.com/pictures/aveo032.JPG


http://aveoforum.com/pictures/aveo033.JPG

Here is the rest of the work that was done over the weekend. I got the entire engine disassembled.


Alright, got the engine upside down again.
http://aveoforum.com/pictures/aveo034.JPG



Removed the oil pump.
http://aveoforum.com/pictures/aveo035.JPG



Took the rod ends and bearing halves for the crankshaft.
http://aveoforum.com/pictures/aveo036.JPG



Here are the components removed from the block.
http://aveoforum.com/pictures/aveo037.JPG

http://aveoforum.com/pictures/aveo038.JPG



Still got the pistons in the block.
http://aveoforum.com/pictures/aveo039.JPG



If your pistons ever look like this you have problems! :lol:
http://aveoforum.com/pictures/aveo040.JPG



All empty!
http://aveoforum.com/pictures/aveo041.JPG

I added up all the parts I'd need to rebuild and it all came to $650 at the least. Then, I found an automatic engine locally for $450. So, now I'm leaning heavily toward the salvage engine. It only has 33k miles on it, so its still pretty new. I was leaning away from the salvage yard engine before because I couldn't find any engines locally with less than 100k miles on them and they were asking quite a bit more for them ($800+).

I'd go the used engine route.

Saves more money for turbo tinkering. :)

what was the condition of the block and crank? any scoring or other damage ?

I would have gone with a used engine in the first place, when staying stock its not worth my time to rebuild..

I haven't done a through inspection of every bearing surface, but the ones I have seen look pretty good.

I didn't like the salvage yard engine option until I found one with less than 100k on it.

I'd put a new timing belt and tensioner on just for the added protection. At the next change, I'd replace the water pump too.

You have my respect for the amount of work you're doing on it in such a short time.

This may be a stupid question - I am not a mechanic - but given that the bearings are worn in to each other, shouldn't you keep track of which one goes where? Or do you? Or doesn't it matter? (Just curious, as I said I'm not a mechanic).

Yup, you're right. You need to keep the bearing caps and rod ends in order and matched to where they came off.

Well, I just purchased a new/used engine for the Aveo. It only took me this long because I needed to arrange transportation to get it home. I'll hopefully be picking it up sometime this week.

Did you go for a straight replacement, or a swap?

Think he's going with a replacement.

It will be a replacement, but it is an engine from an 07 Aveo. So, I will need to swap some parts around (the throttle body at the very least).

I have the same gen 1 aveo but 06 and had my timing belt changed at 57,000mi. called the dealers around and they said it won't go much past 60,000. A young lady had her car in getting the same treatment as yours there. Hers had only 61,500 on it and poof! I think it sucks that you have to have this done every 60k but at least you can stay on top of other things too like your water pump,ect... Which I forgot to have them change when it was in. [-X

Didnt 07s start using ecotec motors?

09 is ecotec, 07 is just the first facelift cars of the sedan..

I wonder? I have only really paid attention to the gen 1... They were going to add hp and mileage with the 07 is that the case?