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

[petrified.rabbit]

http://cgi.ebay.com/ebaymotors/06-07-08 ... 2c53bff817

http://cgi.ebay.com/ebaymotors/06-07-08 ... 3236wt_689

http://cgi.ebay.com/ebaymotors/06-07-08 ... 2eac4756b1


not sure which part of the state you are in, but there is also a few in kalamazoo

http://cgi.ebay.com/ebaymotors/06-07-08 ... 3236wt_689

http://cgi.ebay.com/ebaymotors/2006-200 ... 2eabaabbd4

[petrified.rabbit]

one of the kalamazoo links is messed up because its not easy to cross post links on an iphone.

[Daox]

I didn't have much time to work on the car last night as I had diner plans, but I got some pics worth sharing.

First thing I did was move the car out of the garage so I could lower the engine down to remove the tranny. Before doing that though, I snapped a few pics. This is the back side of the block.





And the front side.





I then dropped it down to the floor.





Snapped a pic of the end of it. Looks like my timing belt cover is busted. Oddly enough the timing belt itself doesn't seem to have snapped, and I don't see any missing teeth either... I'll have to inspect it more when I get to that point.





Last, but probably the only real work that was done was that I unbolted the tranny and pulled it off.

[Daox]

there is a junkyard in wi on ebay with that engine..

Doh, I meant there were no 2.0Ls near me. I'll take a look at the 1.6Ls though and see if there are any cheap low mile ones available. I'm a bit partial to rebuilding just because I know I have a fresh engine, but it will cost a bit more.

[MetroMPG]

That's strange - the timing belt not being broken. Maybe there are teeth missing from one spot

[petrified.rabbit]

its not uncommon for one of the pulleys to freeze up stopping the belt from spinning which damages the engine, but the belt just pops off so it looks ok. not sure if that is common on aveos, as the stories i always get online is that the belt breaks..

http://appleton.craigslist.org/pts/1660382734.html would need to verify on daewootech that it still "fits".

i am sure it will bolt up the the tranny, but it might need harness swapped too. but it seems the same amount of work (to me) as the 2.0 because a few wires come up short on the 2.0 swap, and you need the manifolds and everything its not just a direct long block swap..

even putting the matching tranny in is a good idea. the d20 manual drops in place of the d16 manual. i would assume a similar occurrence with automatics, but you can never be sure.

[petrified.rabbit]

whoa dude where did you get that how much did it cost and how hard was it to put in?

Theres many things to get if your gonna tackle a project like this, the engine itself just slips in place of the 1.6 without any moditications, you can use the same tranny/clutch and the same engine mounts as the 1.6

What you need:
- 2.0 Engine (Duh )
- 2.0 Flywheel (the 1.6's flywheel bolt holes are ever so slightly off)
- 2.0 Alternator with brackets if the engine you get hasnt got any
- 2.0 Power steering pump
- 2.0 A/C compressor if you want it (I didnt get it so i lost my A/C)
- 2.0 Serpentine belt tensionner
- The bracket that holds the front accessories (PS Pump, A/C, Belt tensionner), again if the engine you get doesnt have it
- 2.0 Starter motor (the 1.6's is totally different, won't work)
- 2.0 Engine computer (it runs on the 1.6's ECU but the engine pings when you give it gas, better get the 2.0 ECU)
- 2.0 Wiring harness (you can use the 1.6's harness no problem, but you need to modify it which mainly consists of lengthening some wires to acomodate the bigger motor) > this is the hardest part of the swap and the most time consuming.
- Any missing original 2.0 sensors (if you are missing any, i got the engine with all the sensors in it)
- A new serpentine belt (if your going without A/C you will need a custom length belt unless you get the dummy pully that goes in place of the A/C compressor)
- A new timing belt (I recommend changing it while you have the engine outside the car)

Note that >>NONE<< of the 1.6 accessories (including the flywheel) work with the 2.0. You need to get ALL the 2.0 accesories for it to run properly. You also need to fabricate an intake system and modify the exhaust system a little but you can keep the 1.6's cat.

The ONLY things you can keep from your 1.6 stuff are:
- Transmission
- Clutch assembly
- Wiring harness (needs to be modified, i kept the 1.6 harness)
- Engine mounts
- Exhaust system (needs to be modified a little to fit right)

You dont need to touch any other things, like radiator, cooling system etc, they all connect to the 2.0

Total cost for me was around $2000 CAD in parts and $2100 CAD in labour (it took my mechanic 36 hours) It could have probly taken less time, I have ALOT of wasted time because of taking the car inside, taking stuff appart then opps something is missing, putting it back together and sending it back outside to wait for the needed part.

If your gonna do a project like this, expect some problems from the engine since its most likely a salvaged motor. Mine has both crankcase oil seals shot. They have been changed under warranty tho (most engines come with a 1 year warranty or whatever). Also id highly recommend replacing the timing belt, regardless of the mileage of the engine, you dont know how long its been sitting, a good tune up (injector cleaner blah blah that kinda stuff) and get your 1st oil change sooner then normal.

Always be prepared for unexpected costs but its fairly straightforward if you have all the needed stuff.

this is an old post on here...

[Daox]

Thats very tempting... Has anyone done the swap to ensure there is clearance? I'd imagine its starting to get a bit tight in there.

[petrified.rabbit]

there was a build thread but nemasys has it in there..

[Daox]

Yeah, but isn't it a 2.2L in the Leganza?