engine CHEVROLET AVEO 2009 1.G Service Manual

Run the engine for short periods only as needed to
keep warm, but be careful.
To save fuel, run the engine for only short periods as
needed to warm the vehicle and then shut the engine off
and close the window most of the way to save heat.
Repeat this until help arrives but only when you feel
really uncomfortable from the cold. Moving about
to keep warm also helps.
If it takes some time for help to arrive, now and then
when you run the engine, push the accelerator
pedal slightly so the engine runs faster than the idle
speed. This keeps the battery charged to restart
the vehicle and to signal for help with the headlamps.
Do this as little as possible to save fuel.If Your Vehicle is Stuck in Sand,
Mud, Ice, or Snow
Slowly and cautiously spin the wheels to free the
vehicle when stuck in sand, mud, ice, or snow.
SeeRocking Your Vehicle to Get It Out on page 4-16.
{CAUTION:
If you let your vehicle’s tires spin at high speed,
they can explode, and you or others could be
injured. The vehicle can overheat, causing an
engine compartment re or other damage.
Spin the wheels as little as possible and avoid
going above 35 mph (55 km/h) as shown on the
speedometer.
For information about using tire chains on the vehicle,
seeTire Chains on page 5-68.
4-15

Service............................................................5-3
Accessories and Modications..........................5-3
California Proposition 65 Warning.....................5-4
California Perchlorate Materials Requirements.....5-4
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of
the Vehicle.................................................5-5
Fuel................................................................5-5
Gasoline Octane............................................5-5
Gasoline Specications....................................5-5
California Fuel...............................................5-6
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-7
Filling the Tank..............................................5-8
Filling a Portable Fuel Container.....................5-11
Checking Things Under the Hood....................5-11
Hood Release..............................................5-12
Engine Compartment Overview.......................5-14
Engine Oil...................................................5-16
Engine Oil Life System..................................5-18
Engine Air Cleaner/Filter................................5-19
Automatic Transmission Fluid.........................5-21
Manual Transmission Fluid.............................5-23
Hydraulic Clutch...........................................5-23
Cooling System............................................5-24
Engine Coolant.............................................5-25Engine Overheating.......................................5-30
Power Steering Fluid.....................................5-32
Windshield Washer Fluid................................5-33
Brakes........................................................5-34
Battery........................................................5-37
Jump Starting...............................................5-38
Headlamp Aiming...........................................5-43
Bulb Replacement..........................................5-43
Halogen Bulbs
..............................................5-43
Headlamps..................................................5-44
Front Turn Signal, Sidemarker and
Parking Lamps..........................................5-45
Center High-Mounted Stoplamp (CHMSL)
(Hatchback)..............................................5-47
Center High-Mounted Stoplamp (CHMSL)
(Sedan)...................................................5-47
Taillamps, Turn Signal, Sidemarker,
Stoplamps and Back-up Lamps...................5-48
License Plate Lamp......................................5-49
Replacement Bulbs.......................................5-49
Windshield Wiper Blade Replacement..............5-50
Tires..............................................................5-51
Tire Sidewall Labeling...................................5-52
Tire Terminology and Denitions.....................5-54
Ination - Tire Pressure.................................5-57
Tire Pressure Monitor System.........................5-59
Section 5 Service and Appearance Care
5-1

Tire Pressure Monitor Operation.....................5-60
Tire Inspection and Rotation...........................5-62
When It Is Time for New Tires.......................5-63
Buying New Tires.........................................5-64
Different Size Tires and Wheels......................5-65
Uniform Tire Quality Grading..........................5-66
Wheel Alignment and Tire Balance..................5-67
Wheel Replacement......................................5-67
Tire Chains..................................................5-68
If a Tire Goes Flat........................................5-69
Changing a Flat Tire.....................................5-70
Removing the Spare Tire and Tools................5-71
Removing the Flat Tire and Installing the
Spare Tire................................................5-73
Storing a Flat or Spare Tire and Tools............5-78
Compact Spare Tire......................................5-78
Appearance Care............................................5-79
Interior Cleaning...........................................5-79
Fabric/Carpet...............................................5-80
Leather.......................................................5-81
Instrument Panel, Vinyl, and Other Plastic
Surfaces..................................................5-81
Care of Safety Belts......................................5-82
Weatherstrips...............................................5-82Washing Your Vehicle...................................5-82
Cleaning Exterior Lamps/Lenses.....................5-83
Finish Care..................................................5-83
Windshield and Wiper Blades.........................5-84
Aluminum Wheels.........................................5-84
Tires...........................................................5-85
Sheet Metal Damage.....................................5-85
Finish Damage.............................................5-85
Underbody Maintenance................................5-85
Chemical Paint Spotting.................................5-85
Vehicle Identication......................................5-86
Vehicle Identication Number (VIN).................5-86
Service Parts Identication Label.....................5-86
Electrical System............................................5-86
Add-On Electrical Equipment..........................5-86
Headlamp Wiring..........................................5-87
Windshield Wiper Fuses................................5-87
Power Windows and Other Power Options.......5-87
Fuses and Circuit Breakers............................5-87
Instrument Panel Fuse Block..........................5-88
Engine Compartment Fuse Block....................5-89
Capacities and Specications..........................5-93
Section 5 Service and Appearance Care
5-2

California Proposition 65 Warning
Most motor vehicles, including this one, contain and/or
emit chemicals known to the State of California to
cause cancer and birth defects or other reproductive
harm. Engine exhaust, many parts and systems
(including some inside the vehicle), many uids, and
some component wear by-products contain and/or emit
these chemicals.
California Perchlorate Materials
Requirements
Certain types of automotive applications, such as airbag
initiators, seat belt pretensioners, and lithium batteries
contained in remote keyless transmitters, may contain
perchlorate materials. Special handling may be
necessary. For additional information, see
www.dtsc.ca.gov/hazardouswaste/perchlorate.
Doing Your Own Service Work
{CAUTION:
You can be injured and the vehicle could be
damaged if you try to do service work on a vehicle
without knowing enough about it.
Be sure you have sufficient knowledge,
experience, the proper replacement parts,
and tools before attempting any vehicle
maintenance task.
Be sure to use the proper nuts, bolts, and
other fasteners. English and metric fasteners
can be easily confused. If the wrong fasteners
are used, parts can later break or fall off. You
could be hurt.
If doing some of your own service work, use the proper
service manual. It tells you much more about how to
service the vehicle than this manual can. To order
the proper service manual, seeService Publications
Ordering Information on page 7-17.
5-4

This vehicle has an airbag system. Before attempting to
do your own service work, seeServicing Your
Airbag-Equipped Vehicle on page 1-73.
Keep a record with all parts receipts and list the mileage
and the date of any service work performed. See
Maintenance Record on page 6-17.
Adding Equipment to the Outside of
the Vehicle
Things added to the outside of the vehicle can affect the
airow around it. This can cause wind noise and can
affect fuel economy and windshield washer performance.
Check with your dealer/retailer before adding equipment
to the outside of the vehicle.
Fuel
Use of the recommended fuel is an important part of the
proper maintenance of this vehicle. To help keep the
engine clean and maintain optimum vehicle performance,
we recommend the use of gasoline advertised as TOP
TIER Detergent Gasoline.
Gasoline Octane
Use regular unleaded gasoline with a posted octane
rating of 87 or higher. If the octane rating is less than 87,
you might notice an audible knocking noise when you
drive, commonly referred to as spark knock. If this
occurs, use a gasoline rated at 87 octane or higher as
soon as possible. If you are using gasoline rated at
87 octane or higher and you hear heavy knocking, the
engine needs service.
Gasoline Specications
At a minimum, gasoline should meet ASTM specication
D 4814 in the United States or CAN/CGSB-3.5 or
3.511 in Canada. Some gasolines contain an
octane-enhancing additive called methylcyclopentadienyl
manganese tricarbonyl (MMT). We recommend
against the use of gasolines containing MMT. See
Additives on page 5-6for additional information.
5-5

California Fuel
If the vehicle is certied to meet California Emissions
Standards, it is designed to operate on fuels that
meet California specications. See the underhood
emission control label. If this fuel is not available
in states adopting California emissions standards, the
vehicle will operate satisfactorily on fuels meeting federal
specications, but emission control system performance
might be affected. The malfunction indicator lamp
could turn on and the vehicle might fail a smog-check
test. SeeMalfunction Indicator Lamp on page 3-32.
If this occurs, return to your authorized dealer/retailer for
diagnosis. If it is determined that the condition is
caused by the type of fuel used, repairs might not be
covered by the vehicle warranty.
Additives
To provide cleaner air, all gasolines in the United States
are now required to contain additives that help prevent
engine and fuel system deposits from forming, allowing
the emission control system to work properly. In
most cases, you should not have to add anything to the
fuel. However, some gasolines contain only the
minimum amount of additive required to meet U.S.
Environmental Protection Agency regulations. To help
keep fuel injectors and intake valves clean, or if the
vehicle experiences problems due to dirty injectors or
valves, look for gasoline that is advertised as TOP TIER
Detergent Gasoline.
For customers who do not use TOP TIER Detergent
Gasoline regularly, one bottle of GM Fuel System
Treatment PLUS, added to the fuel tank at every
engine oil change, can help clean deposits from fuel
injectors and intake valves. GM Fuel System Treatment
PLUS is the only gasoline additive recommended by
General Motors.
5-6

Filling the Tank
{CAUTION:
Fuel vapor burns violently and a fuel re can
cause bad injuries. To help avoid injuries to you
and others, read and follow all the instructions on
the pump island. Turn off the engine when you are
refueling. Do not smoke if you are near fuel or
refueling the vehicle. Do not use cellular phones.
Keep sparks, ames, and smoking materials away
from fuel. Do not leave the fuel pump unattended
when refueling the vehicle. This is against the law
in some places. Do not re-enter the vehicle while
pumping fuel. Keep children away from the fuel
pump; never let children pump fuel.To open the fuel ller door,
pull up on the release
lever with this symbol on it.
It is located on the oor
on the outboard side of the
driver seat.
5-8

Filling a Portable Fuel Container
{CAUTION:
Never ll a portable fuel container while it is in the
vehicle. Static electricity discharge from the
container can ignite the fuel vapor. You can be
badly burned and the vehicle damaged if this
occurs. To help avoid injury to you and others:
Dispense fuel only into approved containers.
Do not ll a container while it is inside a
vehicle, in a vehicle’s trunk, pickup bed, or on
any surface other than the ground.
Bring the ll nozzle in contact with the inside
of the ll opening before operating the nozzle.
Contact should be maintained until the lling
is complete.
Do not smoke while pumping fuel.
Do not use a cellular phone while
pumping fuel.
Checking Things Under
the Hood
{CAUTION:
An electric fan under the hood can start up and
injure you even when the engine is not running.
Keep hands, clothing, and tools away from any
underhood electric fan.
{CAUTION:
Things that burn can get on hot engine parts and
start a re. These include liquids like fuel, oil,
coolant, brake uid, windshield washer and other
uids, and plastic or rubber. You or others could
be burned. Be careful not to drop or spill things
that will burn onto a hot engine.
5-11

Engine Compartment Overview
Automatic Transmission shown, Manual Transmission similar
5-14

A.Engine Air Cleaner/Filter on page 5-19.
B. Engine Oil Fill Cap. See “When to Add Engine Oil”
underEngine Oil on page 5-16.
C. Brake/Clutch Fluid Reservoir. See “Brake Fluid”
underBrakes on page 5-34andHydraulic Clutch on
page 5-23.
D. Engine Coolant Surge Tank. SeeCooling System on
page 5-24.
E.Engine Compartment Fuse Block on page 5-89.
F.Battery on page 5-37.G. Windshield Washer Fluid Reservoir. See “Adding
Washer Fluid” underWindshield Washer Fluid
on page 5-33.
H. Engine Oil Dipstick. See “Checking Engine Oil”
underEngine Oil on page 5-16.
I. Automatic Transmission Dipstick. SeeAutomatic
Transmission Fluid on page 5-21.
J. Power Steering Fluid Reservoir. SeePower Steering
Fluid on page 5-32.
5-15