Quote Originally Posted by joeblow55 View Post
I just did this job last weekend. Thought I would add a few comments to let others know what they are in for. First off, the write up here is an excellent guide. Gave me the confidence that I could do this myself. Things I found out along the way while doing the job...
1) Cam lock tool isn't a must, but it would sure make life easier. I noticed one of the cams rotate when tension on the old belt was relieved. Since I marked the belts and pulleys/gears as mentioned in this write-up, I didn't worry about it too much. My guess is that valve spring pressure on at least a couple of the valves wants to cause the cam to move unless you hold it still with a lock tool. Not having one made it very difficult, (but not impossible) to put the new belt on. This is where having the belt and pulleys marked with the white paint was absolutely a fabulous idea.
2) Others have said removing the water pump can be done without taking off the inner cover, and instead, just prying it out of the way. I tried this for about 90 minutes and was not able to get it off. Finally I said "screw it" and pulled off the inner cover to get the water pump out. This requires removing the cam gears, no way around it. The cams and the gears have dowel pins, so they go right back on without a problem. here again, the cam lock tool would be useful, to hold everything still while re-tightening the bolts that hold the gears on. My advice here is not to waste your time trying to remove the water pump with that cover in place. Maybe others have done it, but I don't think it's worth the extra headache.
3) DEFINITELY get the water pump tool and a 5mm allen socket.
All told, it took me 9 hours start to finish. A few distractions and 90 minutes lost to the water pump / shield issue mentioned above, and this could have been done in about 5-6 hours. Possibly less if I had a cam lock tool. Car started right up and runs perfect. No leaks. For what it's worth, my ORIGINAL belt (2008 Aveo sedan) had 107,500 miles on it and still looked pretty good.
Reading all this stuff about timing belts needing to be changed at 60,000 made me nervous, but after seeing the condition of the original belt I have to wonder about that a little. I don't know anything about "1st Gen vs. 2nd Gen" and just how many miles
these things are rated for, but mine looked good. Still, glad to have replaced it, and now won't worry about it for another 70,000 miles or so.
100,000 on original belt, you are a very lucky man, go buy a lotto ticket. Yea, removing the water pump with the rear cover installed takes some jimmying but once you get the angle right it comes out easily. I just zip tied the pullies together. It works great. Get some real big ones and go between the spokes and they will not move. Took me 11 hrs but I took the time to clean out the water pump housing and thermostat and flush the motor which is not necessary but I did it anywho. Happy Driving! Good to hear others are doing it themselves. It isn't that bad as long as you take your time. I think next time it will take me around 4 hrs now that I know what I am doing.

Jon