Removal of cylinder head

06-21-2009, 08:38 AM
Does anyone have a good resource online on how to remove the cylinder head of a 2004 Chevy Aveo? The timing belt stripped out taking out 1 or more valves (can't tell how many until I get the stupid head off). I can get a rebuilt head from the local napa for not too much (way less than a new engine) and if I can take it apart I can put it back together.

My big problem here is that I have a lot of experience with chevy 350s but have never worked with or around anything this . . . small.

The real question that I am having at this point is if I remove the head with the intake manifold still on, and if so how to remove the EFI from on top of it, because I can not for the life of me figure out how to remove the lower intake manifold bolts.

Any help would be great thank you (and yes I know the car isn't worth it, but I am currently driving an 1984 GMC Sierra . . . with a 350 in it . . . 8 miles a gallon X 20 gallon gas tank, so seems to be worth it to me just as a commuter car)

06-22-2009, 02:19 AM
Welcome to AF!

If you go to they have repair information for the Aveo. It tells what to do to remove the head and the intake and the EFI. btw, how many miles were on the engine when this happened? I have an 05 pushing 70,000 miles and have never changed the belt. ~Dave~

06-22-2009, 07:59 PM
Had 72k miles on it when the teeth stripped out of the timing belt. Autozone is decent for general info, but I happen to be a very visual person (think pictures)

Anyways, I am slowly figuring it out, and am taking pictures of eveything . . . so when I finally figure it out I will most likely be posting a nice guide with pictures of every nut bolt and connector.

06-23-2009, 08:03 AM
Thanks for the mileage info. I'd best change my belt ASAP. Autozone lists mostly what to do rather than how to do it and yes, the pictures would help a lot. A picture's worth a thousand...... If you keep in touch and let us know how it goes with pic's you'll be helping a whole lot of people that have the same problem. So, thanks in advance for that. We appreciate it.

06-24-2009, 07:26 PM
It's too bad, my All Data for this car just ran out June 21st. I picked it up so I could change the timing belt, which by the way Dave is "supposed" to be done every 60K, so I would definitely get it done soon as this is an interference engine.

You could get your own subscription. I think it's $29.95 for the first vehicle, then they lower it to $16.95 for any others and also for a renew. The only thing I have against it is, it doesn't have ALL of the information. Although it does a pretty good job. I don't think the car company(GM), gives it all away, or whatever kind of a deal they make with them.

Anyway, I hope this helps some, Toni.

06-27-2009, 06:49 AM
Hehe, well I think I am almost there, and I took a ton of pictures so I could get the stupid thing back together . . . and just for general info, if you wanna take off the head you are going to be disassembling half the engine from the top down . . . super fun

06-27-2009, 02:03 PM
Thanks for the update. Hope everything goes well. You'll have no trouble with it.

06-27-2009, 02:59 PM
Hehe, no trouble my . . . the stupid thing is now diconnected from the block, yet still won't come out . . . taking out the AC system now . . . sigh . . .

06-27-2009, 08:10 PM
Hang in there. When you get time could you run through all that you had to do to pull the head. Sounds like it's being a real PITA. Think of all the labor you are saving if you took it to the dealer. Hope you don't have a hole in a piston. That would be the berries.

12-30-2010, 04:49 PM

A friend of mine just had the same problem, timing belt went, and presumably there is internal damage to valves and possibly cylinders. I'm hoping to help her out a little and figure I can at least remove the head and survey the damage. Of course the shop wants way more than the job is worth (I think.....). Came across this thread, and hoped that maybe some of those photos might still be around, or at least advice on whether or not this is a worthwhile undertaking. I'm loath to let the shop do, and especially on an engine this size, I figure its a one man job...

Any advice? I realize this is an older thread, but I hope the bump might be worth it.
Thanks in advance.


12-31-2010, 09:21 AM
Hey Jonny, there is a website that I found that was quite helpful. I'm not sure that I can post it on here though.

This motor is actually a Daewoo {Korean} and not manufactured by GM. Turns out that the Daewoo had or has a car with the same engine, I think it was a Lanos or maybe a Kalos.

Anyways, if you want the name of the site, let me know and I'll either post it here or send it to the email address of your choice.


01-01-2011, 10:56 AM
Hey thanks!

Yeah, that website might be really useful. I don't know entirely what she intends to do with the car, but again, if I can help save a couple hundred dollars, then great.

Send the link to

I appreciate it. Didn't know if such an old thread would get resurrected with any success.


05-11-2011, 10:03 AM
My Aveo's timing belt idler pulley broke while driving 55 MPH. I replaced the tensioner , water pump, idler pulley, serpentine belt , and timing belt. Tried to start the car and have no compression. I see that there isn't any updates to this thread :disappoin so, I'm going to create a guide with video and pics on how to remove the head and fix the bent valves. If your interested send me an email. BTW.. so far this is what I've spent on this repair.

$65 towing car to my driveway
$132.95 (timing belt, serpentine belt, water pump) at autozone
$93 (tension pulley and idler pulley) Chevy dealer
$25 new spark plugs and hose clamp
$50 for a Husky socket set metric / standard

05-15-2011, 06:31 PM
I have a PDF file of the whole engine and it will walk you through the steps. I was able to take the head out in just about three hours. All 16 valves were shot. I am sending the head to the machine shop and I should be able to have the whole thing reinstalled with a new timing belt, water pump, tensioner and idler in about another 3 to 4 hours. Aprox total costs of $700. Unfortunately the file is too big to upload. It is 2.8 MG. How can I upload this file or pass it on if somebody is interested.

07-27-2011, 09:55 AM
laflega- Can you send me the PDF file to remove the head on an Aveo?
I need to replace mine. Dealer just quoted me $1600 P&L!!!!
I saw a rebuilt one online for $575

07-28-2011, 08:59 PM
Just send you the file through adobe online. You will need a crow wrench 41mm, an angle torque meter and a torque wrench. Be sure to replace the idler, the tensioner and the water pump. Ensure that all your timing marks are in line where they are suppose to be. The camshaft tends to move because of the pressure on the valves. You do not have to buy a camshaft holder tool. I just used zip ties and tied the camshafts together with the timing marks properly aligned. It just worked find. take your time and you should be OK. MAKE SURE ALL YOUR TIMING MARKS ARE IN ALLIGNED PROPERLY. Once you have everything in line, rotate by hand the crankshaft with a ratchet to ensure after a few rotations your marks are in line. Good luck.

09-01-2011, 04:46 PM
Laflega; Can yoo send methat file too. I have an 04 and mechanic is quoting me $2300 for head, timing belt, surpintine, thermostat and housing, water pump, tensioner, plugs. I figured $900 in parts. Hope someone can help with instructions.

09-08-2011, 08:32 PM
I just sent you an EMAIL address where you can get an electronic copy of the service manual for the 2004 AVEO. It is less than $20.00

11-29-2011, 08:44 PM
I'm in the middle of removing the head on my 04 aveo. I'm wondering. Do I have to remove the intake manifold in order to get the head off. Thanks for any info.

01-04-2012, 06:40 PM
can you please send me a copy as well. I have an 05 with 50K on the clock that broke the timing belt.....

01-26-2012, 02:10 PM
I could sure use a copy of the pdf file for the head removal on the 2004 aveo.

11-12-2012, 09:45 AM
please send the pdf file on removing the aveo cylinder head to Just destroyed my second aveo engine with another bleeping timing belt failure. Decided to rebuild the head myself now that junker engines are over a grand a piece

thanks Rocky

11-23-2012, 10:02 AM
can i get a copy of the head removal link on a 2005 aveo.

01-20-2014, 04:24 PM
Me too (


05-14-2014, 06:29 PM
I would like that info as well! I will be doing the head rebuild next week Thursday. Thanks!

09-22-2015, 06:23 PM
Hey I have a 2005 Chevy Aveo which had the timing belt go. There is internal damage but i will not know how much until I get inside. I would love to have any help with diagrams on how to remove the head and fix damage. My E-Mail is Thanks

Add your comment to this topic!