CHEVROLET AVEO 2002 Service Repair Manual

Vehicle Data Collection and Event
Data Recorders
Your vehicle, like other modern motor vehicles, has a
number of sophisticated computer systems that monitor
and control several aspects of the vehicle’s performance.
Your vehicle uses on-board vehicle computers to monitor
emission control components to optimize fuel economy,
to monitor conditions for airbag deployment and, if so
equipped, to provide anti-lock braking and to help the
driver control the vehicle in difficult driving situations.
Some information may be stored during regular
operations to facilitate repair of detected malfunctions;
other information is stored only in a crash event by
computer systems, such as those commonly called event
data recorders (EDR).
In a crash event, computer systems, such as the Airbag
Sensing and Diagnostic Module (SDM) in your vehicle
may record information about the condition of the vehicle
and how it was operated, such as data related to
engine speed, brake application, throttle position, vehicle
speed, safety belt usage, airbag readiness, airbag
performance, and the severity of a collision. This
information has been used to improve vehicle crash
performance and may be used to improve crash
performance of future vehicles and driving safety. Unlike
the data recorders on many airplanes, these on-board
systems do not record sounds, such as conversation of
vehicle occupants.To read this information, special equipment is needed
and access to the vehicle or the device that stores
the data is required. GM will not access information
about a crash event or share it with others other than:•with the consent of the vehicle owner or, if the
vehicle is leased, with the consent of the lessee,
•in response to an official request of police or similar
government office,
•as part of GM’s defense of litigation through the
discovery process, or
•as required by law.
In addition, once GM collects or receives data, GM may:
•use the data for GM research needs,
•make it available for research where appropriate
confidentiality is to be maintained and need is
shown, or
•share summary data which is not tied to a specific
vehicle with non-GM organizations for research
purposes.
Others, such as law enforcement, may have access to
the special equipment that can read the information
if they have access to the vehicle or the device
that stores the data.
If your vehicle is equipped with OnStar
®, please check
the OnStar®subscription service agreement or manual
for information on its operations and data collection.
7-10

Collision Damage Repair
If your vehicle is involved in a collision and it is damaged,
have the damage repaired by a qualified technician using
the proper equipment and quality replacement parts.
Poorly performed collision repairs will diminish your
vehicle’s resale value, and safety performance can be
compromised in subsequent collisions.
Collision Parts
Genuine GM Collision parts are new parts made with the
same materials and construction methods as the parts
with which your vehicle was originally built. Genuine GM
Collision parts are your best choice to assure that your
vehicle’s designed appearance, durability and safety are
preserved. The use of Genuine GM parts can help
maintain your GM New Vehicle Warranty.
Recycled original equipment parts may also be used for
repair. These parts are typically removed from vehicles
that were total losses in prior accidents. In most
cases, the parts being recycled are from undamaged
sections of the vehicle. A recycled original equipment
GM part, may be an acceptable choice to maintain your
vehicle’s originally designed appearance and safety
performance, however, the history of these parts is not
known. Such parts are not covered by your GM New
Vehicle Limited Warranty, and any related failures
are not covered by that warranty.Aftermarket collision parts are also available. These are
made by companies other than GM and may not have
been tested for your vehicle. As a result, these parts may
fit poorly, exhibit premature durability/corrosion problems,
and may not perform properly in subsequent collisions.
Aftermarket parts are not covered by your GM New
Vehicle Limited Warranty, and any vehicle failure related
to such parts are not covered by that warranty.
Repair Facility
GM also recommends that you choose a collision repair
facility that meets your needs before you ever need
collision repairs. Your GM dealer may have a collision
repair center with GM-trained technicians and state
of the art equipment, or be able to recommend a
collision repair center that has GM-trained technicians
and comparable equipment.
7-11

Insuring Your Vehicle
Protect your investment in your GM vehicle with
comprehensive and collision insurance coverage. There
are significant differences in the quality of coverage
afforded by various insurance policy terms. Many
insurance policies provide reduced protection to your
GM vehicle by limiting compensation for damage repairs
by using aftermarket collision parts. Some insurance
companies will not specify aftermarket collision
parts. When purchasing insurance, we recommend that
you assure your vehicle will be repaired with GM
original equipment collision parts. If such insurance
coverage is not available from your current insurance
carrier, consider switching to another insurance carrier.
If your vehicle is leased, the leasing company may
require you to have insurance that assures repairs with
Genuine GM Original Equipment Manufacturer (OEM)
parts or Genuine Manufacturer replacement parts. Read
your lease carefully, as you may be charged at the
end of your lease for poor quality repairs.
If an Accident Occurs
Here is what to do if you are involved in an accident.
•Try to relax and then check to make sure you are all
right. If you are uninjured, make sure that no one else
in your vehicle, or the other vehicle, is injured.
•If there has been an injury, call 911 for help. Do not
leave the scene of an accident until all matters have
been taken care of. Move your vehicle only if its
position puts you in danger or you are instructed to
move it by a police officer.
•Give only the necessary and requested information
to police and other parties involved in the accident.
Do not discuss your personal condition, mental frame
of mind, or anything unrelated to the accident. This
will help guard against post-accident legal action.
•If you need roadside assistance, call GM Roadside
Assistance. SeeRoadside Assistance Program on
page 7-6for more information.
•If your vehicle cannot be driven, know where the
towing service will be taking it. Get a card from the
tow truck operator or write down the driver’s name,
the service’s name, and the phone number.
•Remove any valuables from your vehicle before it is
towed away. Make sure this includes your insurance
information and registration if you keep these items
in your vehicle.
7-12

•Gather the important information you will need from
the other driver. Things like name, address, phone
number, driver’s license number, vehicle license
plate, vehicle make, model and model year, Vehicle
Identification Number (VIN), insurance company and
policy number, and a general description of the
damage to the other vehicle.
•If possible, call your insurance company from the
scene of the accident. They will walk you through the
information they will need. If they ask for a police
report, phone or go to the police department
headquarters the next day and you can get a copy of
the report for a nominal fee. In some states with “no
fault” insurance laws, a report may not be necessary.
This is especially true if there are no injuries and both
vehicles are driveable.
•Choose a reputable collision repair facility for your
vehicle. Whether you select a GM dealer or a private
collision repair facility to fix the damage, make sure
you are comfortable with them. Remember, you will
have to feel comfortable with their work for a
long time.
•Once you have an estimate, read it carefully and
make sure you understand what work will be
performed on your vehicle. If you have a question,
ask for an explanation. Reputable shops welcome
this opportunity.
Managing the Vehicle Damage Repair
Process
In the event that your vehicle requires damage repairs,
GM recommends that you take an active role in its
repair. If you have a pre-determined repair facility of
choice, take your vehicle there, or have it towed there.
Specify to the facility that any required replacement
collision parts be original equipment parts, either new
Genuine GM parts or recycled original GM parts.
Remember, recycled parts will not be covered by your
GM vehicle warranty.
Insurance pays the bill for the repair, but you must live
with the repair. Depending on your policy limits, your
insurance company may initially value the repair using
aftermarket parts. Discuss this with your repair
professional, and insist on Genuine GM parts.
Remember if your vehicle is leased you may be
obligated to have the vehicle repaired with Genuine GM
parts, even if your insurance coverage does not pay
the full cost.
If another party’s insurance company is paying for the
repairs, you are not obligated to accept a repair
valuation based on that insurance company’s collision
policy repair limits, as you have no contractual limits with
that company. In such cases, you can have control of
the repair and parts choices as long as cost stays within
reasonable limits.
7-13

Reporting Safety Defects
Reporting Safety Defects to the
United States Government
If you believe that your vehicle has a defect which could
cause a crash or could cause injury or death, you
should immediately inform the National Highway Traffic
Safety Administration (NHTSA), in addition to notifying
General Motors.
If NHTSA receives similar complaints, it may open an
investigation, and if it finds that a safety defect exists in
a group of vehicles, it may order a recall and remedy
campaign. However, NHTSA cannot become involved in
individual problems between you, your dealer, or
General Motors.To contact NHTSA, you may call the Vehicle
Safety Hotline toll-free at 1-888-327-4236
(TTY: 1-800-424-9153); go to http://www.safercar.gov;
or write to:
Administrator, NHTSA
400 Seventh Street, SW.
Washington, D.C. 20590
You can also obtain other information about motor
vehicle safety from http://www.safercar.gov.
Reporting Safety Defects to the
Canadian Government
If you live in Canada, and you believe that your vehicle
has a safety defect, you should immediately notify
Transport Canada, in addition to notifying General
Motors of Canada Limited. You may call them at
1-800-333-0510 or write to:
Transport Canada
Place de Ville Tower C
330 Sparks Street
Ottawa, Ontario K1A 0N5
7-14

Reporting Safety Defects to
General Motors
In addition to notifying NHTSA (or Transport Canada) in
a situation like this, we certainly hope you will notify
General Motors. Please call the Chevrolet Customer
Assistance Center at 1-800-222-1020, or write:
Chevrolet Motor Division
Chevrolet Customer Assistance Center
P.O. Box 33170
Detroit, MI 48232-5170
In Canada, please call us at 1-800-263-3777 (English)
or 1-800-263-7854 (French). Or, write:
General Motors of Canada Limited
Customer Communication Centre, 163-005
1908 Colonel Sam Drive
Oshawa, Ontario L1H 8P7
Service Publications Ordering
Information
Service Manuals
Service Manuals have the diagnosis and repair
information on engines, transmission, axle suspension,
brakes, electrical, steering, body, etc.
Transmission, Transaxle, Transfer
Case Unit Repair Manual
This manual provides information on unit repair service
procedures, adjustments, and specifications for GM
transmissions, transaxles, and transfer cases.
Service Bulletins
Service Bulletins give technical service information
needed to knowledgeably service General Motors cars
and trucks. Each bulletin contains instructions to
assist in the diagnosis and service of your vehicle.
In Canada, information pertaining to Product Service
Bulletins can be obtained by contacting your General
Motors dealer or by calling 1-800-GM-DRIVE
(1-800-463-7483).
7-15

Owner’s Information
Owner publications are written specifically for owners
and intended to provide basic operational information
about the vehicle. The owner’s manual will include
the Maintenance Schedule for all models.
In-Portfolio: Includes a Portfolio, Owner’s Manual, and
Warranty Booklet.
RETAIL SELL PRICE: $35.00
Without Portfolio: Owner’s Manual only.
RETAIL SELL PRICE: $25.00
Current and Past Model Order Forms
Service Publications are available for current and
past model GM vehicles. To request an order form,
please specify year and model name of the vehicle.
ORDER TOLL FREE: 1-800-551-4123
Monday-Friday 8:00 AM - 6:00 PM
Eastern Time
For Credit Card Orders Only
(VISA-MasterCard-Discover), visit Helm, Inc. on the
World Wide Web at: www.helminc.com
Or you can write to:
Helm, Incorporated
P.O. Box 07130
Detroit, MI 48207
Prices are subject to change without notice and without
incurring obligation. Allow ample time for delivery.
Note to Canadian Customers: All listed prices are
quoted in U.S. funds. Canadian residents are to make
checks payable in U.S. funds.
7-16

A
Accessories and Modifications............................ 5-3
Accessory Power Outlet(s)...............................3-16
Adding Equipment to Your Airbag-Equipped
Vehicle.......................................................1-70
Additives, Fuel................................................. 5-6
Add-On Electrical Equipment............................5-74
Air Cleaner/Filter, Engine.................................5-17
Air Conditioning..............................................3-18
Airbag
Passenger Status Indicator...........................3-26
Readiness Light..........................................3-32
Airbag Sensing and Diagnostic Module (SDM)....7-10
Airbag System................................................1-56
Adding Equipment to Your Airbag-Equipped
Vehicle...................................................1-70
How Does an Airbag Restrain?......................1-63
Passenger Sensing System...........................1-65
Servicing Your Airbag-Equipped Vehicle..........1-69
What Makes an Airbag Inflate?......................1-63
What Will You See After an Airbag Inflates?....1-64
When Should an Airbag Inflate?....................1-61
Where Are the Airbags?...............................1-59
AM-FM Radio.................................................3-39
Antenna, Fixed Mast.......................................3-71
Anti-Lock Brake System (ABS)........................... 4-7
Anti-Lock Brake, System Warning Light..............3-34Appearance Care
Aluminum Wheels........................................5-71
Care of Safety Belts....................................5-69
Chemical Paint Spotting...............................5-72
Cleaning Exterior Lamps/Lenses....................5-69
Cleaning the Inside of Your Vehicle................5-66
Fabric/Carpet..............................................5-67
Finish Care.................................................5-70
Finish Damage............................................5-72
Instrument Panel, Vinyl, and Other Plastic
Surfaces.................................................5-68
Sheet Metal Damage...................................5-72
Tires..........................................................5-71
Underbody Maintenance...............................5-72
Vehicle Care/Appearance Materials................5-73
Washing Your Vehicle...................................5-69
Weatherstrips..............................................5-69
Windshield and Wiper Blades........................5-70
Ashtray(s)......................................................3-17
Audio System(s).............................................3-38
AM-FM Radio.............................................3-39
Care of Your CD Player...............................3-71
Care of Your CDs ........................................3-71
Fixed Mast Antenna.....................................3-71
Radio with CD............................3-41, 3-45, 3-52
Radio with Six-Disc CD................................3-61
Understanding Radio Reception.....................3-70
1

Automatic Transaxle
Fluid..........................................................5-19
Operation...................................................2-21
B
Battery..........................................................5-35
Before Leaving on a Long Trip.........................4-19
Brake
Anti-Lock Brake System (ABS)........................ 4-7
Emergencies................................................ 4-8
Parking......................................................2-26
System Inspection.......................................6-24
System Warning Light..................................3-27
Brakes..........................................................5-32
Braking........................................................... 4-6
Braking in Emergencies..................................... 4-8
Break-In, New Vehicle.....................................2-17
Bulb Replacement...........................................5-40
Front Turn Signal and Parking Lamps.............5-42
Halogen Bulbs............................................5-40
Headlamp Aiming........................................5-39
Headlamps.................................................5-40
Replacement Bulbs......................................5-44
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps........................................5-43
Turn Signal Lamps......................................5-42
Buying New Tires...........................................5-54
C
California Fuel.................................................. 5-5
California Proposition 65 Warning....................... 5-3
Canadian Owners................................................ ii
Capacities and Specifications............................5-80
Carbon Monoxide.............2-9, 2-11, 2-30, 4-22, 4-35
Care of
Safety Belts................................................5-69
Your CD Player...........................................3-71
Your CDs ...................................................3-71
Center Rear Passenger Position, Safety Belts.....1-28
Chains, Tire...................................................5-57
Charging System Light....................................3-33
Check
Engine Light...............................................3-34
Checking Things Under the Hood......................5-10
Chemical Paint Spotting...................................5-72
Child Restraints
Child Restraint Systems...............................1-36
Infants and Young Children...........................1-32
Lower Anchors and Tethers for Children..........1-42
Older Children.............................................1-30
Securing a Child Restraint in a
Rear Seat Position...................................1-49
Securing a Child Restraint in the
Right Front Seat Position..........................1-51
Where to Put the Restraint...........................1-40
Cigarette Lighter.............................................3-17
2

Cleaning
Aluminum Wheels........................................5-71
Exterior Lamps/Lenses.................................5-69
Fabric/Carpet..............................................5-67
Finish Care.................................................5-70
Inside of Your Vehicle..................................5-66
Instrument Panel, Vinyl, and Other Plastic
Surfaces.................................................5-68
Tires..........................................................5-71
Underbody Maintenance...............................5-72
Washing Your Vehicle...................................5-69
Weatherstrips..............................................5-69
Windshield and Wiper Blades........................5-70
Climate Control System...................................3-18
Air Filter, Passenger Compartment.................3-21
Outlet Adjustment........................................3-21
Clock............................................................3-32
Clutch, Hydraulic.............................................5-21
Collision Damage Repair..................................7-11
Compact Spare Tire........................................5-66
Control of a Vehicle.......................................... 4-6
Coolant
Engine Temperature Gage............................3-28
Heater, Engine............................................2-20
Surge Tank Pressure Cap.............................5-24
Cooling System..............................................5-26
Cruise Control................................................3-10
Cruise Control Light........................................3-29
Cupholder(s)..................................................2-34Customer Assistance Information
Courtesy Transportation.................................. 7-8
Customer Assistance for Text
Telephone (TTY) Users............................... 7-4
Customer Assistance Offices........................... 7-4
Customer Satisfaction Procedure..................... 7-2
GM Mobility Reimbursement Program............... 7-6
Reporting Safety Defects to General Motors....7-15
Reporting Safety Defects to the
Canadian Government..............................7-14
Reporting Safety Defects to the
United States Government.........................7-14
Roadside Assistance Program......................... 7-6
Service Publications Ordering Information........7-15
D
Daytime Running Lamps..................................3-14
Daytime Running Lamps Indicator Light.............3-29
Defensive Driving............................................. 4-2
Doing Your Own Service Work........................... 5-4
Dome Lamp ...................................................3-16
Door
Ajar Light...................................................3-38
Central Door Unlocking System....................... 2-7
Door Ajar Reminder....................................... 2-8
Locks.......................................................... 2-7
Rear Door Security Locks............................... 2-8
3