engine CHEVROLET AVEO 2002 Service Repair Manual

Replacing Brake System Parts
The braking system on a vehicle is complex. Its many
parts have to be of top quality and work well together if
the vehicle is to have really good braking. Your
vehicle was designed and tested with top-quality GM
brake parts. When you replace parts of your braking
system — for example, when your brake linings
wear down and you need new ones put in — be sure
you get new approved GM replacement parts. If you do
not, your brakes may no longer work properly. For
example, if someone puts in brake linings that are wrong
for your vehicle, the balance between your front and
rear brakes can change — for the worse. The braking
performance you have come to expect can change
in many other ways if someone puts in the wrong
replacement brake parts.
Battery
Your vehicle has a maintenance free battery. When it is
time for a new battery, get one that has the replacement
number shown on the original battery’s label. SeeEngine
Compartment Overview on page 5-12for battery location.
Warning:Battery posts, terminals, and related
accessories contain lead and lead compounds,
chemicals known to the State of California to cause
cancer and reproductive harm. Wash hands after
handling.
Vehicle Storage
If you are not going to drive your vehicle for 25 days
or more, remove the black, negative (−) cable from
the battery. This will help keep your battery from
running down.
{CAUTION:
Batteries have acid that can burn you and gas
that can explode. You can be badly hurt if you
are not careful. SeeJump Starting on
page 5-36for tips on working around a battery
without getting hurt.
5-35

4. Open the hoods and locate the batteries. Find the
positive (+) and negative (−) terminal locations on
each vehicle. Your vehicle’s positive (+) terminal is
located under a red tethered cap on the battery.
SeeEngine Compartment Overview on page 5-12
for more information on location.
Flip the cap up to access the positive (+) terminal.
{CAUTION:
An electric fan can start up even when the
engine is not running and can injure you. Keep
hands, clothing and tools away from any
underhood electric fan.
{CAUTION:
Using a match near a battery can cause battery
gas to explode. People have been hurt doing
this, and some have been blinded. Use a
ashlight if you need more light.
Be sure the battery has enough water. You do
not need to add water to the battery installed
in your new vehicle. But if a battery has ller
caps, be sure the right amount of uid is there.
If it is low, add water to take care of that rst.
If you don’t, explosive gas could be present.
Battery uid contains acid that can burn you.
Do not get it on you. If you accidentally get it
in your eyes or on your skin, ush the place
with water and get medical help immediately.
5-37

{CAUTION:
Fans or other moving engine parts can injure
you badly. Keep your hands away from moving
parts once the engine is running.
5. Check that the jumper cables do not have loose or
missing insulation. If they do, you could get a
shock. The vehicles could be damaged too.
Before you connect the cables, here are some
things you should know. Positive (+) will go
to positive (+) or to a remote positive (+) terminal if
the vehicle has one. Negative (−) will go to a
heavy, unpainted metal engine part or to a remote
negative (−) terminal if the vehicle has one.
Do not connect positive (+) to negative (−)oryou
will get a short that would damage the battery
and maybe other parts too. And do not connect the
negative (−) cable to the negative (−) terminal on
the dead battery because this can cause sparks.
6. Connect the red positive (+) cable to the positive (+)
terminal of the dead battery. Use a remote
positive (+) terminal if the vehicle has one.
7. Do not let the other end touch metal. Connect it to
the positive (+) terminal of the good battery. Use a
remote positive (+) terminal if the vehicle has one.8. Now connect the black negative (−) cable to the
negative (−) terminal of the good battery. Use a
remote negative (−) terminal if the vehicle has one.
Do not let the other end touch anything until the
next step. The other end of the negative (−) cable
does notgo to the dead battery. It goes to a
heavy, unpainted metal engine part or to a remote
negative (−) terminal on the vehicle with the
dead battery.
9. Connect the other end
of the negative (−)
cable at least 18 inches
(45 cm) away from the
dead battery, but not
near engine parts that
move. The electrical
connection is just as
good there, and the
chance of sparks
getting back to the
battery is much less.
10. Now start the vehicle with the good battery and run
the engine for a while.
11. Try to start the vehicle that had the dead battery. If
it will not start after a few tries, it probably needs
service.
5-38

Notice:If the jumper cables are connected or
removed in the wrong order, electrical shorting may
occur and damage the vehicle. The repairs would
not be covered by your warranty. Always connect
and remove the jumper cables in the correct
order, making sure that the cables do not touch
each other or other metal.
A. Heavy, Unpainted Metal Engine Part or Remote
Negative (–) Terminal
B. Good Battery or Remote Positive (+) and Remote
Negative (−) Terminals
C. Dead Battery or Remote Positive (+) TerminalTo disconnect the jumper cables from both vehicles, do
the following:
1. Disconnect the black negative (−) cable from the
vehicle that had the dead battery.
2. Disconnect the black negative (−) cable from the
vehicle with the good battery.
3. Disconnect the red positive (+) cable from the
vehicle with the good battery.
4. Disconnect the red positive (+) cable from the other
vehicle.
5. Return the positive (+) terminal cap to its original
position.
Headlamp Aiming
Headlamp aim has been preset at the factory and
should need no further adjustment.
However, if your vehicle is damaged in an accident, the
headlamp aim may be affected. Aim adjustment to
the low-beam headlamps may be necessary if it
is difficult to see the lane markers (for horizontal aim),
or if oncoming drivers flash their high-beam headlamps
at you (for vertical aim).
If you believe your headlamps need to be re-aimed, it is
recommend that you take the vehicle to your dealer
for service. Jumper Cable Removal
5-39

Tire Size
The following illustration shows an example of a typical
passenger car tire size.
(A) Passenger (P-Metric) Tire:The United States
version of a metric tire sizing system. The letter P as the
first character in the tire size means a passenger
vehicle tire engineered to standards set by the U. S.
Tire and Rim Association.
(B) Tire Width:The three-digit number indicates the
tire section width in millimeters from sidewall to sidewall.
(C) Aspect Ratio:A two-digit number that indicates
the tire height-to-width measurements. For example, if
the tire size aspect ratio is 70, as shown in item C of the
illustration, it would mean that the tire’s sidewall is
70% as high as it is wide.(D) Construction Code:A letter code is used to
indicate the type of ply construction in the tire. The
letter R means radial ply construction; the letter D
means diagonal or bias ply construction; and the letter B
means belted-bias ply construction.
(E) Rim Diameter:Diameter of the wheel in inches.
(F) Service Description:These characters represent
the load range and the speed rating of a tire. The
load range represents the load carry capacity a tire is
certified to carry. The speed rating is the maximum
speed a tire is certified to carry a load. Speed ratings
range from A to Z.
Tire Terminology and Denitions
Air Pressure:The amount of air inside the tire pressing
outward on each square inch of the tire. Air pressure
is expressed in pounds per square inch (psi) or
kilopascal (kPa).
Accessory Weight:This means the combined weight
of optional accessories. Some examples of optional
accessories are, automatic transmission, power steering,
power brakes, power windows, power seats, and air
conditioning.
Aspect Ratio:The relationship of a tire’s height to its
width.
5-48

{CAUTION:
Changing a tire can be dangerous. The vehicle
can slip off the jack and roll over or fall on you
or other people. You and they could be badly
injured or even killed. Find a level place to
change your tire. To help prevent the vehicle
from moving:
1. Set the parking brake rmly.
2. Put an automatic transaxle shift lever in
PARK (P), or shift a manual transaxle to
FIRST (1) or REVERSE (R).
3. Turn off the engine and do not restart
while the vehicle is raised.
4. Do not allow passengers to remain in the
vehicle.
To be even more certain the vehicle will not
move, you should put blocks at the front and
rear of the tire farthest away from the one
being changed. That would be the tire on the
other side, at the opposite end of the vehicle.When you have a flat tire, use the following example as
a guide to assist you in the placement of wheel
blocks.
The following information will tell you how to use the
jack and change a tire.
5-59

Vehicle Identication
Vehicle Identication Number (VIN)
This is the legal identifier for your vehicle. It appears on
a plate in the front corner of the instrument panel, on
the driver’s side. You can see it if you look through the
windshield from outside your vehicle. The VIN also
appears on the Vehicle Certification and Service Parts
labels and the certificates of title and registration.
Engine Identication
The eighth character in your VIN is the engine code.
This code will help you identify your engine,
specifications and replacement parts.
Service Parts Identication Label
You will find this label on the inside of the glove box. It
is very helpful if you ever need to order parts. On
this label, you will find the following:
•VIN
•Model designation
•Paint information
•Production options and special equipment
Do not remove this label from the vehicle.
Electrical System
Add-On Electrical Equipment
Notice:Don’t add anything electrical to your
vehicle unless you check with your dealer rst.
Some electrical equipment can damage your vehicle
and the damage wouldn’t be covered by your
warranty. Some add-on electrical equipment can
keep other components from working as they
should.
Your vehicle has an airbag system. Before attempting to
add anything electrical to your vehicle, seeServicing
Your Airbag-Equipped Vehicle on page 1-69.
5-74

Headlamp Wiring
The headlamp wiring is protected by fuses, one for each
headlamp, in the fuse block. An electrical overload
will cause the lamps to turn off. If this happens, have
your headlamp wiring checked right away.
Windshield Wiper Fuses
The windshield wiper motor is protected by an internal
circuit breaker and a fuse. If the motor overheats due to
heavy snow, etc., the wiper will stop until the motor
cools. If the overload is caused by some electrical
problem and not snow, etc., be sure to get it fixed.
Power Windows and Other Power
Options
Circuit breakers in the fuse block protect the power
windows and other power accessories. When the current
load is too heavy, the circuit breaker opens and
closes, protecting the circuit until the problem is fixed or
goes away.
Fuses and Circuit Breakers
The wiring circuits in your vehicle are protected from
short circuits by a combination of fuses, circuit breakers
and fusible thermal links in the wiring itself.
Look at the silver-colored band inside the fuse. If the
band is broken or melted, replace the fuse. Be sure you
replace a bad fuse with a new one of the identical
size and rating.
There are spare fuses provided in the engine
compartment fuse block. If you ever have a problem on
the road and do not have a spare fuse, you can borrow
one that has the same amperage. Just pick a feature of
your vehicle that you can get along without — like the
radio or cigarette lighter — and use its fuse, if it is the
correct amperage. Replace it as soon as you can.
There are two fuse blocks in your vehicle: the instrument
panel fuse block and the engine compartment fuse
block.
There is a fuse puller located on the engine
compartment fuse block. It can be used to easily
remove fuses from the fuse block.
5-75

Fuses Usage
LTR Cigar Lighter
HORN,
REAR/FOGHorn, Rear Fog Lamps
RADIO, CLK Audio, Clock
STOP Stop Lamp
TRN/SIG Turn Signal
CLSTR,
HAZRDInstrument Panel Cluster, Hazard
Flasher
CLSTR, CLK Instrument Panel Cluster, Clock
DR/LCK Door Lock, Remote Keyless Entry
BCK/UP Back-Up Lamp
ECM, TCMEngine Control Module,
Transmission Control Module
ECM, TCMEngine Control Module,
Transmission Control Module
WPR, WSWA Wiper, Washer
DIS,
INJECTORDirect Ignition System, Injector
ENG FUSE Engine Fuse
AIRBAG Airbag
HVAC HVAC Blower
ABS Anti-lock Brake System
BLANK Not Used
BLANK Not Used
DIODE (ABS) Anti-lock Brake System DiodeFuses Usage
BLANK Not Used
BLANK Not Used
CLK, RADIO Clock, Audio
Engine Compartment Fuse Block
The engine compartment fuse block is located on the
driver’s side of the vehicle, near the battery. SeeEngine
Compartment Overview on page 5-12for more
information on location. To access the fuses, pull out
the top and bottom flaps to release the cover. To
reinstall the cover, push the cover until it is secure.
5-77

Capacities and Specications
The following approximate capacities are given in English and metric conversions. SeePart D: Recommended Fluids
and Lubricants on page 6-25for more information.
ApplicationCapacities
English Metric
Air Conditioning Refrigerant R134a 1.48 lbs 0.67 kg
Cooling System 6.3 qt 6.0 L
Engine Oil with Filter 3.96 qt 3.75 L
Fuel Tank 11.9 gal 45.0 L
Transaxle, Automatic 6.2 qt 5.87 L
Transaxle, Manual 1.9 qt 1.8 L
Wheel Nut Torque 81 lb ft 110Y
All capacities are approximate. When adding, be sure to fill to the appropriate level, as recommended in this
manual. Recheck fluid level after filling.
Engine Specications
Engine VIN Code Transaxle Spark Plug Gap
1.6L L4 (L91) 6Automatic and
Manual0.039-0.043 inch (1.0-1.1 mm)
5-80