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I'm puzzled by what you wrote about tightening the bolts. You said 85 on the harmonic balancer (which should actually be 70 + torque-to-angles of 30 and 15). Did you pin the flywheel in order to...

Did you torque all (on both parts) of the motor mount bolts and nuts to spec? Also, on the same subject, how about the harmonic balancer bolt?

Did you check to make sure the pointer mechanism on the tensioner pulley moves all the way to the overlapped position if you push on it with your fingers?

First check to see that the 3 allen bolts of the WP are all torqued correctly (best done with an inch torque wrench), and that the tension is still corect (i.e. pointers align). If those are ok,...

IMO you have been getting some bad advice, along with much worse service from whatever shop you are taking your Aveo to.
First off, the water pump does not need to be replaced every time the belt...

Glad you found it! You are REALLY fortunate in 2 ways. First that you did the job before the whole thing blew up (which sounds like it was really close). And second, that the belt was walking off...

What you just wrote changes everything I had been previously thinking - my mistake in assuming you had replaced all 4 parts. And this new information makes your belt-walking problems very easy to...

I can't imagine how you could have bent a cam pulley, unless you used a pry bar on one for some reason. And the tensioner pointers being lined up should always give the correct tension. Don't like...

Are you using a torque wrench to tighten the 3 Allen WP bolts? If not, maybe you're not getting them tight enough. There's a side force from the tension of the belt pulling at the WP that's working...

Glad it went well for you - must have been the GF who did all the heavy thinking ;)
Just curious if that was the first belt change on your '04, and how many miles are on it.

If you're using a gear and the brakes, an extension bar supported by a jackstand will make life much easier, for removal but especially for torquing it back on. I wonder if the guy in the vid used...

With the manual tranny you can just put it in gear and apply the brake, which is the method I used for the first belt change on my '05. But as the second belt change was approaching, I had my...

Automatic or manual tranny?

I would also not pry it - the last thing you would want at this point is a nick or gouge in the block mating surface. Back-and-forth rotation using the tool should eventually bust up the crud. I'm...

I think Rabbit is right about the suction caused by not draining. I didn't think of that because I drained the system, and the old pump came off with hardly any effort. First try removing the...

I can't imagine anything other than one or more of the WP bolts being capable of holding the pump on through all the stuff you're doing. Did you remove all 3 of the 5MM allen bolts? If so, the...

This DIY was done for a 2006, and I know the job is essentially the same for 04-06. I also know there are significant changes to the timing belt setup on the newer Aveos, and the timing belt change...

You said you were just short of red line when the tensioner broke. If it were mine, I would skip the head and look for a new engine instead. But I'm just a DIY amature mechanic, and that's JMHO. Good...

If you had the cam/crank marks lined up correctly, and also got it to run (at all), then you most likely were ok with that part of it. If it had been a full rotation out of synch, you would have...