brake CHEVROLET AVEO 2004 1.G Service Manual

{CAUTION:
With the wrong kind of uid in your brake
system, your brakes may not work well, or they
may not even work at all. This could cause a
crash. Always use the proper brake uid.
Notice:
Using the wrong uid can badly damage brake
system parts. For example, just a few drops of
mineral-based oil, such as engine oil, in your
brake system can damage brake system parts so
badly that they will have to be replaced. Do not
let someone put in the wrong kind of uid.
If you spill brake uid on your vehicle’s painted
surfaces, the paint nish can be damaged.
Be careful not to spill brake uid on your vehicle.
If you do, wash it off immediately. See
Appearance Care on page 5-76.
Brake Wear
Your vehicle has front disc brakes and rear drum brakes.
Disc brake pads have built-in wear indicators that make
a high-pitched warning sound when the brake pads
are worn and new pads are needed. The sound
may come and go or be heard all the time your vehicle
is moving, except when you are pushing on the
brake pedal firmly.
{CAUTION:
The brake wear warning sound means that soon
your brakes will not work well. That could lead
to an accident. When you hear the brake wear
warning sound, have your vehicle serviced.
Notice:Continuing to drive with worn-out brake
pads could result in costly brake repair.
Some driving conditions or climates may cause a brake
squeal when the brakes are first applied or lightly
applied. This does not mean something is wrong with
your brakes.
5-37

Properly torqued wheel nuts are necessary to help
prevent brake pulsation. When tires are rotated, inspect
brake pads for wear and evenly tighten wheel nuts in
the proper sequence to GM torque specifications.
Your rear drum brakes do not have wear indicators, but
if you ever hear a rear brake rubbing noise, have the
rear brake linings inspected immediately. Also, the rear
brake drums should be removed and inspected each
time the tires are removed for rotation or changing.
When you have the front brake pads replaced, have the
rear brakes inspected, too.
Brake linings should always be replaced as complete
axle sets.
SeeBrake System Inspection on page 6-25.
Brake Pedal Travel
See your dealer if the brake pedal does not return to
normal height, or if there is a rapid increase in
pedal travel. This could be a sign of brake trouble.
Brake Adjustment
Every time you make a moderate brake stop, your disc
brakes adjust for wear. If you rarely make a moderate or
heavier stop, then your brakes might not adjust correctly.If you drive in that way, then – very carefully – make a
few moderate brake stops about every 1,000 miles
(1 600 km), so your brakes will adjust properly.
If your brake pedal goes down farther than normal, your
rear drum brakes may need adjustment. Adjust them by
backing up and firmly applying the brakes a few times.
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.
5-38

Jump Starting
If your battery has run down, you may want to use
another vehicle and some jumper cables to start your
vehicle. Be sure to follow the steps below to do it safely.
{CAUTION:
Batteries can hurt you. They can be dangerous
because:
They contain acid that can burn you.
They contain gas that can explode or ignite.
They contain enough electricity to burn you.
If you do not follow these steps exactly, some or
all of these things can hurt you.
Notice:Ignoring these steps could result in costly
damage to your vehicle that would not be covered
by your warranty.
Trying to start your vehicle by pushing or pulling it
will not work, and it could damage your vehicle.1. Check the other vehicle. It must have a 12-volt
battery with a negative ground system.
Notice:If the other vehicle’s system is not a 12-volt
system with a negative ground, both vehicles can
be damaged. Only use vehicles with 12-volt systems
with negative grounds to jump start your vehicle.
2. Get the vehicles close enough so the jumper cables
can reach, but be sure the vehicles are not touching
each other. If they are, it could cause a ground
connection you do not want. You would not be able
to start your vehicle, and the bad grounding
could damage the electrical systems.
To avoid the possibility of the vehicles rolling, set
the parking brake firmly on both vehicles involved in
the jump start procedure. Put an automatic
transaxle in PARK (P) or a manual transaxle in
NEUTRAL before setting the parking brake.
Notice:If you leave your radio or other accessories
on during the jump starting procedure, they could
be damaged. The repairs would not be covered
by your warranty. Always turn off your radio and
other accessories when jump starting your vehicle.
5-40

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.
Belt:A rubber coated layer of cords that is located
between the plies and the tread. Cords may be made
from steel or other reinforcing materials.
Bead:The tire bead contains steel wires that hold the
tire onto the rim.
Bias Ply Tire:A pneumatic tire in which the plies are
laid at alternate angles, less than 90 degrees to the
centerline of the tread.Cold Ination Pressure:The amount of air pressure
in a tire, measured in pounds per square inch (psi)
or kilopascal (kPa), before a tire has built up heat from
driving. SeeInflation - Tire Pressure on page 5-59.
Curb Weight:This means the weight of a motor vehicle
with standard and optional equipment including the
maximum capacity of fuel, oil and coolant, but without
passengers and cargo.
DOT Markings:A code molded into the sidewall of a
tire signifying that the tire is in compliance with the
U.S. Department of Transportation motor vehicle safety
standards. The DOT code includes the Tire Identification
Number (TIN), an alphanumeric designator which can
also identify the tire manufacturer, production plant,
brand and date of production.
GVWR:Gross Vehicle Weight Rating, seeLoading
Your Vehicle on page 4-32.
GAWR FRT:Gross Axle Weight Rating for the front
axle, seeLoading Your Vehicle on page 4-32.
GAWR RR:Gross Axle Weight Rating for the rear axle,
seeLoading Your Vehicle on page 4-32.
5-56

If you need to replace any of your wheels, wheel bolts
or wheel nuts, replace them only with new GM
original equipment parts. This way, you will be sure to
have the right wheel, wheel bolts and wheel nuts
for your vehicle.
{CAUTION:
Using the wrong replacement wheels, wheel
bolts or wheel nuts on your vehicle can be
dangerous. It could affect the braking and
handling of your vehicle, make your tires lose
air and make you lose control. You could have
a collision in which you or others could be
injured. Always use the correct wheel, wheel
bolts and wheel nuts for replacement.Notice:The wrong wheel can also cause problems
with bearing life, brake cooling, speedometer or
odometer calibration, headlamp aim, bumper height,
vehicle ground clearance and tire or tire chain
clearance to the body and chassis.
SeeChanging a Flat Tire on page 5-67for more
information.
Used Replacement Wheels
{CAUTION:
Putting a used wheel on your vehicle is
dangerous. You can’t know how it’s been used
or how far it’s been driven. It could fail
suddenly and cause a crash. If you have to
replace a wheel, use a new GM original
equipment wheel.
5-65

Tire Chains
Notice:Use tire chains only where legal and only
when you must. Use only SAE Class “S” type chains
that are the proper size for your tires. Install them on
the front tires and tighten them as tightly as possible
with the ends securely fastened. Drive slowly and
follow the chain manufacturer’s instructions. If you
can hear the chains contacting your vehicle, stop and
retighten them. If the contact continues, slow down
until it stops. Driving too fast or spinning the wheels
with chains on will damage your vehicle.
If a Tire Goes Flat
It’s unusual for a tire to “blowout” while you’re driving,
especially if you maintain your tires properly. If air goes
out of a tire, it’s much more likely to leak out slowly.
But if you should ever have a “blowout,” here are a few
tips about what to expect and what to do:
If a front tire fails, the flat tire will create a drag that
pulls the vehicle toward that side. Take your foot off the
accelerator pedal and grip the steering wheel firmly.
Steer to maintain lane position, and then gently brake to
a stop well out of the traffic lane.A rear blowout, particularly on a curve, acts much like a
skid and may require the same correction you’d use
in a skid. In any rear blowout, remove your foot from the
accelerator pedal. Get the vehicle under control by
steering the way you want the vehicle to go. It may be
very bumpy and noisy, but you can still steer. Gently
brake to a stop, well off the road if possible.
{CAUTION:
Lifting a vehicle and getting under it to do
maintenance or repairs is dangerous without
the appropriate safety equipment and training.
The jack provided with your vehicle is
designed only for changing a at tire. If it is
used for anything else, you or others could be
badly injured or killed if the vehicle slips off
the jack. Use the jack provided with your
vehicle only for changing a at tire.
If a tire goes flat, the next part shows how to use your
jacking equipment to change a flat tire safely.
5-66

Changing a Flat Tire
If a tire goes flat, avoid further tire and wheel damage
by driving slowly to a level place. Turn on your
hazard warning flashers.
{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.
CAUTION: (Continued)
CAUTION: (Continued)
To be even more certain the vehicle won’t
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.
The following steps will tell you how to use the jack and
change a tire.
5-67

12. Tighten the wheel nuts
firmly in a crisscross
sequence, as shown.
{CAUTION:
Incorrect wheel nuts or improperly tightened
wheel nuts can cause the wheel to come loose
and even come off. This could lead to an
accident. Be sure to use the correct wheel
nuts. If you have to replace them, be sure to
get new GM original equipment wheel nuts.
Stop somewhere as soon as you can and have
the nuts tightened with a torque wrench to the
proper torque specication. See “Capacities
and Specications” in the Index for wheel nut
torque specication.Notice:Improperly tightened wheel nuts can lead
to brake pulsation and rotor damage. To avoid
expensive brake repairs, evenly tighten the wheel
nuts in the proper sequence and to the proper
torque specication. See “Capacities and
Specications” in the Index for the wheel nut
torque specication.
Do not try to put a wheel cover on your compact spare
tire. It will not fit. Store the wheel cover in the cargo
area until you have the flat tire repaired or replaced.
Notice:Wheel covers will not t on your compact
spare. If you try to put a wheel cover on the
compact spare, you could damage the cover or
the spare.
5-73

Fuses Usage
DIS,
INJECTORDirect Ignition System, Injector
ABS, ENG
FUSEAntilock Brake System, Engine Fuse
AIRBAG Air Bag
HVAC
BLOWERHVAC Blower
BLANK Not Used
BLANK Not Used
BLANK Not Used
BLANK Not Used
BLANK Not Used
BLANK Not Used
CLOCK, AUDIO Clock, AudioEngine 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 5-14for 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.
5-87

Fuses Usage
H/L HI RH Head Lamp High Right Side
BLANK Not Used
H/L HI LH Head Lamp High Left Side
BLANK Not Used
H/L LOW RH Head Lamp Low Right Side
ILL RHParking Lamp Right Side,
Illumination Circuit
H/L LOW LH Head Lamp Low Left Side
ILL LHParking Lamp Left Side, License
Plate Lamp
ROOM LAMP Room Lamp
BLANK Not Used
DEFOG Defogger
SUN ROOF Sunroof
ILL LAMP Illumination RelayFuses Usage
HORN Horn
HEAD LAMP Headlamp
FUEL PUMP Fuel Pump
A/C COMP Air Conditioning Compressor
FRT FOG Front Fog Lamp
BLOWER Blower
ABS Antilock Brake System
IP F/BOX Instrument Panel Fuse Box
RAD’ FAN Radiator Fan
IGN 2 Ignition 2
IGN 1 Ignition 1
POWER
WINDOWPower Windows
FUSE SPARE Spare Fuse
5-89