maintenance CHEVROLET AVEO 2002 Service Repair Manual

Seats and Restraint Systems........................... 1-1
Front Seats
............................................... 1-2
Rear Seats
............................................... 1-6
Safety Belts
.............................................1-10
Child Restraints
.......................................1-28
Air Bag Systems
......................................1-50
Restraint System Check
............................1-58
Features and Controls..................................... 2-1
Keys
........................................................ 2-2
Doors and Locks
....................................... 2-7
Windows
.................................................2-13
Theft-Deterrent Systems
............................2-15
Starting and Operating Your Vehicle
...........2-18
Mirrors
....................................................2-34
Storage Areas
.........................................2-36
Sunroof
..................................................2-37
Instrument Panel............................................. 3-1
Instrument Panel Overview
.......................... 3-2
Climate Controls
......................................3-12
Warning Lights, Gages, and Indicators
........3-17
Secondary Information Center (SIC)
............3-24
Audio System(s)
.......................................3-34Driving Your Vehicle....................................... 4-1
Your Driving, the Road, and Your Vehicle
..... 4-2
Towing
...................................................4-29
Service and Appearance Care.......................... 5-1
Service
..................................................... 5-3
Fuel
......................................................... 5-5
Checking Things Under the Hood
...............5-11
Headlamp Aiming
.....................................5-45
Bulb Replacement
....................................5-45
Windshield Wiper Blade Replacement
.........5-50
Tires
......................................................5-51
Appearance Care
.....................................5-76
Vehicle Identification
.................................5-83
Electrical System
......................................5-84
Capacities and Specifications
.....................5-91
Maintenance Schedule..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance and Information.............. 7-1
Customer Assistance and Information
........... 7-2
Reporting Safety Defects
...........................7-10
Index.................................................................1
2004 Chevrolet Aveo Owner ManualM

Servicing Your Air Bag-Equipped
Vehicle
Air bags affect how your vehicle should be serviced.
There are parts of the air bag systems in several places
around your vehicle. Your dealer and the service manual
have information about servicing your vehicle and the air
bag systems. To purchase a service manual, seeService
Publications Ordering Information on page 7-11.
{CAUTION:
For up to 10 seconds after the ignition key is
turned off and the battery is disconnected,
an air bag can still inate during improper
service. You can be injured if you are close
to an air bag when it inates. Avoid yellow
connectors. They are probably part of the air
bag system. Be sure to follow proper service
procedures, and make sure the person
performing work for you is qualied to do so.
The air bag systems do not need regular maintenance.
Restraint System Check
Checking Your Restraint Systems
Now and then, make sure the safety belt reminder light
and all your belts, buckles, latch plates, retractors
and anchorages are working properly. Look for any other
loose or damaged safety belt system parts. If you see
anything that might keep a safety belt system from doing
its job, have it repaired.
Torn or frayed safety belts may not protect you in a
crash. They can rip apart under impact forces. If a belt
is torn or frayed, get a new one right away.
Also look for any opened or broken air bag covers, and
have them repaired or replaced. (The air bag system
does not need regular maintenance.)
1-58

Notice:If you keep driving your vehicle with this
light on, after a while, your emission controls
may not work as well, your fuel economy may not
be as good and your engine may not run as
smoothly. This could lead to costly repairs that
may not be covered by your warranty.
Notice:Modications made to the engine,
transaxle, exhaust, intake or fuel system of your
vehicle or replacement tires that do not match your
vehicle’s original tires can affect your vehicle’s
emission controls and may cause this light to come
on. Modications to these systems could lead to
costly repairs not covered by your warranty.
This may also result in a failure to pass a required
Emission Inspection/Maintenance test.
When the ignition is on, this light should come on and
should go out after a few seconds as a check to
show you it is working. If the light does not come on,
have it repaired.This light will also come on during a malfunction in one
of two ways:
•Light Flashing— A misfire condition has been
detected. A misfire increases vehicle emissions
and may damage the emission control system on
your vehicle. Diagnosis and service may be
required.
•Light On Steady— An emission control system
malfunction has been detected on your vehicle.
Diagnosis and service may be required.
3-29

Have you recently changed brands of fuel?
If so, be sure to fuel your vehicle with quality fuel.
SeeGasoline Octane on page 5-5. Poor fuel quality will
cause your engine not to run as efficiently as designed.
You may notice this as stalling after start-up, stalling
when you put the vehicle into gear, misfiring, hesitation
on acceleration or stumbling on acceleration.
(These conditions may go away once the engine is
warmed up.) This will be detected by the system and
cause the light to turn on.
If you experience one or more of these conditions,
change the fuel brand you use. It will require at least
one full tank of the proper fuel to turn the light off.
If none of the above steps have made the light turn off,
your dealer can check the vehicle. Your dealer has
the proper test equipment and diagnostic tools to fix
any mechanical or electrical problems that may
have developed.Emissions Inspection and
Maintenance Programs
Some state/provincial and local governments have or
may begin programs to inspect the emission control
equipment on your vehicle. Failure to pass this
inspection could prevent you from getting a vehicle
registration.
Here are some things you need to know to help your
vehicle pass an inspection:
Your vehicle will not pass this inspection if the
Check Engine light is on or not working properly.
Your vehicle will not pass this inspection if the OBD
(on-board diagnostic) system determines that critical
emission control systems have not been completely
diagnosed by the system. The vehicle would be
considered not ready for inspection. This can happen
if you have recently replaced your battery or if your
battery has run down. The diagnostic system is
designed to evaluate critical emission control systems
during normal driving. This may take several days
of routine driving. If you have done this and your vehicle
still does not pass the inspection for lack of OBD
system readiness, your GM dealer can prepare the
vehicle for inspection.
3-31

Oil Pressure Light
If you have a low engine
oil pressure problem, this
light will stay on after
you start your engine, or
come on when you
are driving. This indicates
that your engine is not
receiving enough oil.
The engine could be low on oil, or could have some
other oil problem. Have it fixed immediately.
The oil light could also come on in three other situations:
•When the ignition is on but the engine is not
running, the light will come on as a test to show you
it is working. The light will go out when you turn
the ignition on. If it does not come on with the
ignition on, you may have a problem with the fuse
or bulb. Have it fixed right away.
•If you are idling at a stop sign, the light may blink
on and then off.
•If you make a hard stop, the light may come on for
a moment. This is normal.
{CAUTION:
Do not keep driving if the oil pressure is low.
If you do, your engine can become so hot that
it catches re. You or others could be burned.
Check your oil as soon as possible and have
your vehicle serviced.
Notice:Lack of proper engine oil maintenance
may damage the engine. The repairs would not be
covered by your warranty. Always follow the
maintenance schedule in this manual for changing
engine oil.
Fog Lamp Light
If your vehicle has this
feature, the fog lamps light
will come on when the
fog lamps are in use.
The light will go out when the fog lamps are turned off.
See “Fog Lamps” underExterior Lamps on page 3-8
for more information.
3-32

Tires..............................................................5-51
Inflation - Tire Pressure.................................5-59
Tire Inspection and Rotation...........................5-60
When It Is Time for New Tires.......................5-61
Buying New Tires.........................................5-62
Uniform Tire Quality Grading..........................5-63
Wheel Alignment and Tire Balance..................5-64
Wheel Replacement......................................5-64
Tire Chains..................................................5-66
If a Tire Goes Flat........................................5-66
Changing a Flat Tire.....................................5-67
Compact Spare Tire......................................5-75
Appearance Care............................................5-76
Cleaning the Inside of Your Vehicle.................5-76
Care of Safety Belts......................................5-79
Weatherstrips...............................................5-79
Cleaning the Outside of Your Vehicle..............5-79Sheet Metal Damage.....................................5-81
Finish Damage.............................................5-81
Underbody Maintenance................................5-82
Chemical Paint Spotting.................................5-82
Vehicle Care/Appearance Materials..................5-82
Vehicle Identication......................................5-83
Vehicle Identification Number (VIN).................5-83
Service Parts Identification Label.....................5-84
Electrical System............................................5-84
Add-On Electrical Equipment..........................5-84
Headlamp Wiring..........................................5-84
Windshield Wiper Fuses................................5-84
Power Windows and Other Power Options.......5-84
Fuses and Circuit Breakers............................5-85
Capacities and Specications..........................5-91
Section 5 Service and Appearance Care
5-2

Doing Your Own Service Work
If you want to do some of your own service work, you
will want to use the proper service manual. It tells
you much more about how to service your vehicle than
this manual can. To order the proper service manual,
seeService Publications Ordering Information on
page 7-11.
Your vehicle has an air bag system. Before attempting
to do your own service work, seeServicing Your Air
Bag-Equipped Vehicle on page 1-58.
You should keep a record with all parts receipts and list
the mileage and the date of any service work you
perform. SeePart E: Maintenance Record on page 6-28.
{CAUTION:
You can be injured and your vehicle could be
damaged if you try to do service work on a
vehicle without knowing enough about it.
CAUTION: (Continued)
CAUTION: (Continued)

Be sure you have sufficient knowledge,
experience, the proper replacement parts
and tools before you attempt any vehicle
maintenance task.
Be sure to use the proper nuts, bolts and
other fasteners. “English” and “metric”
fasteners can be easily confused. If you
use the wrong fasteners, parts can later
break or fall off. You could be hurt.
Adding Equipment to the Outside of
Your Vehicle
Things you might add to the outside of your vehicle
can affect the airflow around it. This may cause
wind noise and affect windshield washer performance.
Check with your dealer before adding equipment to
the outside of your vehicle.
5-4

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
of 87 or higher. If the octane is less than 87, you may
get a heavy knocking noise when you drive. If this
occurs, use a gasoline rated at 87 octane or higher as
soon as possible. Otherwise, you might damage
your engine. A little pinging noise when you accelerate
or drive uphill is considered normal. This does not
indicate a problem exists or that a higher-octane fuel is
necessary. If you are using 87 octane or higher-octane
fuel and hear heavy knocking, your engine needs
service.
Gasoline Specications
It is recommended that gasoline meet specifications
which were developed by automobile manufacturers
around the world and contained in the World-Wide
Fuel Charter which is available from the Alliance
of Automobile Manufacturers at www.autoalliance.org.
Gasoline meeting these specifications could provide
improved driveability and emission control system
performance compared to other gasoline.
In Canada, look for the
“Auto Makers’ Choice”
label on the pump.
Canada Only
5-5

Notice:Use only engine oil identied as meeting
GM Standard GM6094M and showing the American
Petroleum Institute Certied For Gasoline Engines
starburst symbol. Failure to use the recommended
oil can result in engine damage not covered by
your warranty.
GM Goodwrench
®oil meets all the requirements for
your vehicle.
If you are in an area of extreme cold, where the
temperature falls below−20°F (−29°C), it is
recommended that you use either an SAE 5W-30
synthetic oil or an SAE 0W-30 oil. Both will provide
easier cold starting and better protection for your engine
at extremely low temperatures.
Engine Oil Additives
Do not add anything to your oil. The recommended oils
with the starburst symbol that meet GM Standard
GM6094M are all you will need for good performance
and engine protection.
When to Change Engine Oil
If any one of these is true for you, use the short trip/city
maintenance schedule:
•Most trips are less than 5 miles (8 km). This is
particularly important when outside temperatures
are below freezing.
•Most trips include extensive idling (such as frequent
driving in stop-and-go traffic).
•You frequently tow a trailer or use a carrier on top
of your vehicle.
•The vehicle is used for delivery service, police, taxi
or other commercial application.
5-18

Driving under these conditions causes engine oil to
break down sooner. If any one of these is true for your
vehicle, then you need to change your oil and filter
every 3,000 miles (5 000 km) or 3 months — whichever
occurs first.
If none of them is true, use the long trip/highway
maintenance schedule. Change oil and filter every
7,500 miles (12 500 km) or 12 months — whichever
occurs first. Driving a vehicle with a fully warmed engine
under highway conditions will cause engine oil to
break down slower.What to Do with Used Oil
Used engine oil contains certain elements that may be
unhealthy for your skin and could even cause cancer.
Do not let used oil stay on your skin for very long.
Clean your skin and nails with soap and water, or a
good hand cleaner. Wash or properly dispose of
clothing or rags containing used engine oil. See the
manufacturer’s warnings about the use and disposal of
oil products.
Used oil can be a threat to the environment. If you
change your own oil, be sure to drain all the oil from the
filter before disposal. Never dispose of oil by putting it
in the trash, pouring it on the ground, into sewers,
or into streams or bodies of water. Instead, recycle it by
taking it to a place that collects used oil. If you have
a problem properly disposing of your used oil, ask your
dealer, a service station or a local recycling center
for help.
5-19