check engine CHEVROLET AVEO 2002 Service Manual PDF

{CAUTION:
Snow can trap exhaust gases under your
vehicle. This can cause deadly CO (carbon
monoxide) gas to get inside. CO could
overcome you and kill you. You cannot see it
or smell it, so you might not know it is in your
vehicle. Clear away snow from around the
base of your vehicle, especially any that is
blocking your exhaust pipe. And check around
again from time to time to be sure snow does
not collect there.
Open a window just a little on the side of the
vehicle that is away from the wind. This will
help keep CO out.Run your engine only as long as you must. This saves
fuel. When you run the engine, make it go a little
faster than just idle. That is, push the accelerator
slightly. This uses less fuel for the heat that you get and
it keeps the battery charged. You will need a
well-charged battery to restart the vehicle, and possibly
for signaling later on with your headlamps. Let the
heater run for a while.
Then, shut the engine off and close the window almost
all the way to preserve the heat. Start the engine
again and repeat this only when you feel really
uncomfortable from the cold. But do it as little as
possible. Preserve the fuel as long as you can. To help
keep warm, you can get out of the vehicle and do
some fairly vigorous exercises every half hour or so until
help comes.
4-25

Service............................................................5-3
Accessories and Modifications..........................5-3
California Proposition 65 Warning.....................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of Your
Vehicle......................................................5-4
Fuel................................................................5-5
Gasoline Octane............................................5-5
Gasoline Specifications....................................5-5
California Fuel...............................................5-5
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-6
Filling the Tank..............................................5-7
Filling a Portable Fuel Container.......................5-9
Checking Things Under the Hood....................5-10
Hood Release..............................................5-10
Engine Compartment Overview.......................5-12
Engine Oil...................................................5-13
Engine Air Cleaner/Filter................................5-17
Automatic Transaxle Fluid..............................5-19
Manual Transaxle Fluid..................................5-21
Hydraulic Clutch...........................................5-21
Engine Coolant.............................................5-22
Coolant Surge Tank Pressure Cap..................5-24
Engine Overheating.......................................5-24
Cooling System............................................5-26Power Steering Fluid.....................................5-30
Windshield Washer Fluid................................5-31
Brakes........................................................5-32
Battery........................................................5-35
Jump Starting...............................................5-36
Headlamp Aiming...........................................5-39
Bulb Replacement..........................................5-40
Halogen Bulbs..............................................5-40
Headlamps..................................................5-40
Front Turn Signal and Parking Lamps..............5-42
Turn Signal Lamps (Side)..............................5-42
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps.........................................5-43
Replacement Bulbs.......................................5-44
Windshield Wiper Blade Replacement..............5-44
Tires..............................................................5-45
Tire Sidewall Labeling...................................5-46
Tire Terminology and Definitions.....................5-48
Inflation - Tire Pressure.................................5-51
Tire Inspection and Rotation...........................5-52
When It Is Time for New Tires.......................5-53
Buying New Tires.........................................5-54
Different Size Tires and Wheels......................5-54
Uniform Tire Quality Grading..........................5-55
Wheel Alignment and Tire Balance..................5-56
Wheel Replacement......................................5-56
Section 5 Service and Appearance Care
5-1

Fuel
Use of the recommended fuel is an important part of the
proper maintenance of your vehicle.
Gasoline Octane
Use regular unleaded gasoline with a posted octane
rating of 87 or higher. If the octane rating is less than 87,
you may 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, your
engine needs service.
Gasoline Specications
At a minimum, gasoline should meet ASTM specification
D 4814 in the United States or CAN/CGSB-3.5 in
Canada. Some gasolines may contain an
octane-enhancing additive called methylcyclopentadienyl
manganese tricarbonyl (MMT). General Motors
recommends against the use of gasolines containing
MMT. SeeAdditives on page 5-6for additional
information.
California Fuel
If your vehicle is certified to meet California Emissions
Standards, it is designed to operate on fuels that
meet California specifications. See the underhood
emission control label. If this fuel is not available
in states adopting California emissions standards, your
vehicle will operate satisfactorily on fuels meeting
federal specifications, but emission control system
performance may be affected. The malfunction indicator
lamp may turn on and your vehicle may fail a
smog-check test. SeeMalfunction Indicator Lamp on
page 3-34. If this occurs, return to your authorized GM
dealer for diagnosis. If it is determined that the
condition is caused by the type of fuel used, repairs
may not be covered by your warranty.
5-5

Additives
To provide cleaner air, all gasolines in the United States
are now required to contain additives that will help
prevent engine and fuel system deposits from forming,
allowing your emission control system to work
properly. In most cases, you should not have to add
anything to your 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 your vehicle experiences problems due to
dirty injectors or valves, look for gasoline that is
advertised as TOP TIER Detergent Gasoline. Also, your
GM dealer has additives that will help correct and
prevent most deposit-related problems.
Gasolines containing oxygenates, such as ethers and
ethanol, and reformulated gasolines may be available in
your area. General Motors recommends that you use
these gasolines if they comply with the specifications
described earlier. However, E85 (85% ethanol) and other
fuels containing more than 10% ethanol must not be used
in vehicles that were not designed for those fuels.
Notice:Your vehicle was not designed for fuel that
contains methanol. Do not use fuel containing
methanol. It can corrode metal parts in your fuel
system and also damage the plastic and rubber
parts. That damage would not be covered under
your warranty.Some gasolines that are not reformulated for low
emissions may contain an octane-enhancing additive
called methylcyclopentadienyl manganese tricarbonyl
(MMT); ask the attendant where you buy gasoline
whether the fuel contains MMT. General Motors
recommends against the use of such gasolines. Fuels
containing MMT can reduce the life of spark plugs
and the performance of the emission control system may
be affected. The malfunction indicator lamp may turn
on. If this occurs, return to your authorized GM dealer for
service.
Fuels in Foreign Countries
If you plan on driving in another country outside the
United States or Canada, the proper fuel may be hard
to find. Never use leaded gasoline or any other fuel
not recommended in the previous text on fuel. Costly
repairs caused by use of improper fuel would not
be covered by your warranty.
To check the fuel availability, ask an auto club, or
contact a major oil company that does business in the
country where you will be driving.
5-6

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.
Hood Release
To open the hood, do the following:
1. Pull the hood release
handle inside the
vehicle. It is located on
the lower left side of
the instrument panel.
2. Then go to the front of the vehicle and lift up on the
secondary hood release lever, located under the
front center of the hood.
5-10

A. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-17.
B. Engine Oil Fill Cap. See “When to Add Engine Oil”
underEngine Oil on page 5-13.
C. Engine Oil Dipstick. See “Checking Engine Oil”
underEngine Oil on page 5-13.
D. Brake Fluid Reservoir. See “Brake Fluid” under
Brakes on page 5-32.
E. Automatic Transaxle Dipstick. SeeAutomatic
Transaxle Fluid on page 5-19.
F. Engine Coolant Surge Tank. SeeCooling System on
page 5-26.
G. Engine Compartment Fuse Block. SeeEngine
Compartment Fuse Block on page 5-77.
H. Power Steering Fluid Reservoir. SeePower Steering
Fluid on page 5-30.
I. Battery. SeeBattery on page 5-35.
J. Windshield Washer Fluid Reservoir. See “Adding
Washer Fluid” underWindshield Washer Fluid
on page 5-31.Engine Oil
If the oil pressure light
appears on the instrument
cluster, it means you
need to check your engine
oil level right away.
For more information, seeOil Pressure Light on
page 3-37.
You should check your engine oil level regularly; this is
an added reminder.
5-13

Checking Engine Oil
It is a good idea to check your engine oil every time you
get fuel. In order to get an accurate reading, the oil
must be warm and the vehicle must be on level ground.
The engine oil dipstick handle is a yellow loop. See
Engine Compartment Overview on page 5-12for
the location of the engine oil dipstick.
1. Turn off the engine and give the oil several minutes
to drain back into the oil pan. If you do not do this,
the oil dipstick might not show the actual level.
2. Pull the dipstick and clean it with a paper towel or
cloth, then push it back in all the way. Remove it
again, keeping the tip down and check the level.
When to Add Engine Oil
If the oil is below the lower hole at the tip of the
dipstick (B), you will need to add at least one quart/liter
of oil. But you must use the right kind. This section
explains what kind of oil to use. For engine oil crankcase
capacity, seeCapacities and Specifications on
page 5-80.
Notice:Do not add too much oil. If your engine has
so much oil that the oil level gets above the upper
hole (A) that shows the proper operating range, your
engine could be damaged.
SeeEngine Compartment Overview on page 5-12for
the location of the engine oil fill cap.
Be sure to add enough oil to put the level somewhere in
the proper operating range, between the holes on the
dipstick. Push the dipstick all the way back in when you
are through.
5-14

Automatic Transaxle Fluid
When to Check Automatic Transaxle
Fluid
Check your automatic transaxle fluid level at least twice
a year. Add fluid if needed. SeeAt Least Twice a
Year on page 6-19.
How to Check Automatic Transaxle
Fluid
Because this operation can be a little difficult, you may
choose to have this done at the dealership service
department.
If you do it yourself, be sure to follow all the instructions
here, or you could get a false reading on the dipstick.
Notice:Too much or too little uid can damage the
transaxle. Too much can mean that some of the uid
could come out and fall on hot engine or exhaust
system parts, starting a re. Too little uid could
cause the transaxle to overheat. Be sure to get an
accurate reading if you check the transaxle uid.Wait at least 30 minutes before checking the transaxle
fluid level if you have been driving:
•When outside temperatures are above 90°F (32°C).
•At high speed for quite a while.
•In heavy traffic — especially in hot weather.
To get the right reading, the fluid should be at normal
operating temperature, which is 158°F to 176°F
(70°C to 80°C).
Get the vehicle warmed up by driving about
15 miles (24 km) when outside temperatures are
above 50°F (10°C). If it is colder than 50°F (10°C),
you may have to drive longer.
Checking the Fluid Level
Prepare your vehicle as follows:
1. Park your vehicle on a level place. Keep the engine
running.
2. With the parking brake applied, place the shift lever
in PARK (P).
3. With your foot on the brake pedal, move the shift
lever through each gear range, pausing for about
three seconds in each range. Then, position
the shift lever in PARK (P).
4. Let the engine run at idle for three to five minutes.
5-19

Then, without shutting off the engine, follow these steps:
The automatic transaxle dipstick is located toward the
front of the engine compartment, near the power
steering fluid reservoir. SeeEngine Compartment
Overview on page 5-12for more information on location.
1. Pull out the dipstick and wipe it with a clean rag
or paper towel.
2. Push the dipstick back in all the way, wait three
seconds and then pull it back out again.
3. Check both sides of the dipstick, and read the lower
level. The fluid level must be between the two
dimples in the hot range.
4. If the fluid level is in the acceptable range, push the
dipstick back in all the way.How to Add Automatic Transaxle Fluid
Refer to the Maintenance Schedule to determine
what kind of transaxle fluid to use. SeePart D:
Recommended Fluids and Lubricants on page 6-25.
If the fluid level is low, add only enough of the proper
fluid to bring the level into the area between the
two dimples in the hot range on the dipstick.
1. Pull out the dipstick.
2. Using a long-neck funnel, add enough fluid at the
dipstick hole to bring it to the proper level.
It does not take much fluid, generally less than
one pint (0.5 L). Do not overfill.
Notice:Use of the incorrect automatic transaxle
uid may damage your vehicle, and the damages
may not be covered by your warranty. Always
use the automatic transaxle uid listed inPart D:
Recommended Fluids and Lubricants on page 6-25.
3. After adding fluid, recheck the fluid level as
described under “How to Check Automatic
Transaxle Fluid,” earlier in this section.
4. When the correct fluid level is obtained, push the
dipstick back in all the way.
5-20

Manual Transaxle Fluid
It is not necessary to check the transaxle fluid level.
A transaxle fluid leak is the only reason for fluid loss.
If a leak occurs, take the vehicle to the dealership
service department and have it repaired as soon as
possible. SeePart D: Recommended Fluids and
Lubricants on page 6-25for the proper fluid to use.
Hydraulic Clutch
There is one reservoir for both the brake and the
hydraulic clutch fluid. SeeBrakes on page 5-32for more
information.
The hydraulic clutch linkage in your vehicle is
self-adjusting. The master cylinder reservoir is filled with
hydraulic fluid.
A fluid loss in this system could indicate a problem.
Have the system inspected and repaired.
When to Check and What to Use
Refer to the Maintenance Schedule to determine how
often you should check the fluid level in your master
cylinder reservoir and for the proper fluid. SeePart B:
Owner Checks and Services on page 6-18andPart D:
Recommended Fluids and Lubricants on page 6-25.
How to Check and Add Fluid
To check the fluid level, look on the side of the reservoir.
If the fluid reaches the MAX (A) mark on the reservoir,
the fluid level is correct. The reservoir is located
near the back of the engine compartment on the driver’s
side of the vehicle. SeeEngine Compartment Overview
on page 5-12for more information on location.
5-21