I bought a 2005 aveo 1.6 automatic used. 109k on it. Was getting codes for cam sensor. Got crossthreaded when replacing. Had to take exhaust pulley off to get a tap in straight. So decided to replace timing belt as well. Old belt looked fine. Some fraying on the side starting to show up.

Everything at TDC before I took belt off. Also marked pulleys and old belt. Transferred marks to new belt. The exhaust pulley jumped forward when I took tension off the belt. The intake might have moved, I didn't think it had.

So before I line anything up, spark plugs are out. crank is at its mark, 6:00.
Intake cam is at 4:00. Exhaust cam is at 9:00. Dowel on exhaust cam at 11:00.
I get resistance when I move intake CCW to line up,
It wants to spring back down quickly. I used vice grips to hold it at 3:00. The marks on belt line up with pulleys.
I tension water pump, everything still good. Tighten it down . When I try to turn crank by hand I get to about 7:30 and feel a hard stop. I didn't try to force it past.
I could turn exhaust CCW to line up, but marks would be at 4:00 and 8:00. And the belt wouldn't line up. The marks are 16 teeth apart. Theyd have to be closer together,.

I did a compression test before all this. 170/175/170/180. Car was running ok.

The cams and/or crank have only moved like 29 degrees in either direction since I started.

Any help is much appreciated. This car hates me.

 

Hope this helps you.

 

Thx for replying. No I've watched them all. None of them tell you what to do when things aren't going to plan.

I managed to get it turned over by hand. Did all the steps made sure the tensioner was all lined up. I started the car for a minute. Wanted to make sure before I put everything back together.

It ran but all the tension came off the belt..it was about to jump off the pulleys. Wtf??
??????