engine CHEVROLET AVEO 2011 1.G Repair Manual

Black plate (17,1)Chevrolet Aveo Owner Manual - 2011
Vehicle Care 10-17
Cooling System
The cooling system allows the
engine to maintain the correct
working temperature.
A. Electric Engine Cooling Fan(Out of View)
B. Coolant Surge Tank with Pressure Cap
{WARNING
An electric engine cooling fan
under the hood can start up even
when the engine is not running
and can cause injury. Keep
hands, clothing, and tools away
from any underhood electric fan.
{WARNING
Heater and radiator hoses, and
other engine parts, can be very
hot. Do not touch them. If you do,
you can be burned.
Do not run the engine if there is a
leak. If you run the engine, it
could lose all coolant. That could
cause an engine fire, and you
could be burned. Get any leak
fixed before you drive the vehicle. Notice:
Using coolant other than
DEX‐COOL
®can cause premature
engine, heater core, or radiator
corrosion. In addition, the engine
coolant may require changing
sooner, at the first maintenance
service after each 30,000 miles
(50 000 km) or 24 months,
whichever occurs first. Any
repairs would not be covered by
the vehicle warranty. Always use
DEX‐COOL
®(silicate‐free) coolant
in the vehicle.

Black plate (18,1)Chevrolet Aveo Owner Manual - 2011
10-18 Vehicle Care
Engine Coolant
The cooling system in the vehicle
is filled with DEX-COOL®engine
coolant. This coolant is designed to
remain in the vehicle for 5 years or
240 000 km (150,000 mi), whichever
occurs first.
The following explains the cooling
system and how to check and add
coolant when it is low. If there is a
problem with engine overheating,
see Engine Overheating on
page 10‑21.
What to Use
{WARNING
Adding only plain water or some
other liquid to the cooling system
can be dangerous. Plain water
and other liquids, can boil before
the proper coolant mixture will.
The coolant warning system is
set for the proper coolant mixture.
With plain water or the wrong
mixture, the engine could get too
hot but you would not get the
overheat warning. The engine
could catch fire and you or
others could be burned. Use a
50/50 mixture of clean, drinkable
water and DEX-COOL coolant. Use a 50/50 mixture of clean,
drinkable water and DEX-COOL
coolant. If using this mixture,
nothing else needs to be added.
This mixture:.Gives freezing protection down
to
−37°C (−34°F), outside
temperature.
.Gives boiling protection up to
129°C (265°F), engine
temperature.
.Protects against rust and
corrosion.
.Will not damage aluminum parts.
.Helps keep the proper engine
temperature.
Notice: If an improper coolant
mixture is used, the engine could
overheat and be badly damaged.
The repair cost would not be
covered by the vehicle warranty.
Too much water in the mixture
can freeze and crack the engine,
radiator, heater core, and other
parts.

Black plate (19,1)Chevrolet Aveo Owner Manual - 2011
Vehicle Care 10-19
Notice:If extra inhibitors and/or
additives are used in the vehicle
cooling system, the vehicle
could be damaged. Use only the
proper mixture of the engine
coolant listed in this manual for
the cooling system. See
Recommended Fluids and
Lubricants on page 11‑6 for
more information.
Checking Coolant
The vehicle must be on a level
surface when checking the coolant
level.
Check to see if coolant is visible in
the coolant surge tank. If the coolant
inside the coolant surge tank is
boiling, do not do anything else until
it cools down. If coolant is visible
but the coolant level is not between
the Minimum and Maximum marks,
add a 50/50 mixture of clean,
drinkable water and DEX-COOL
coolant at the coolant surge tank, but be sure the cooling system is
cool before this is done. See
Engine
Coolant on page 10‑18 for more
information.
The engine coolant surge tank is
located in the rear of the engine
compartment on the driver side
of the vehicle. See Engine
Compartment Overview on
page 10‑8 for more information on
location.
{WARNING
Turning the surge tank pressure
cap when the engine and radiator
are hot can allow steam and
scalding liquids to blow out and
burn you badly. Never turn the
surge tank pressure cap —even a
little —when the engine and
radiator are hot.
When the engine is cold, the coolant
level should be between the
Maximum (A) and Minimum (B)
marks on the coolant surge tank.
The level rises at engine operation
temperature and drops again when
the engine cools down.
The coolant should be between the
Maximum (A) and Minimum (B)
marks, when the engine is cold. If it
is not, there could be a leak in the
cooling system.

Black plate (20,1)Chevrolet Aveo Owner Manual - 2011
10-20 Vehicle Care
How to Add Coolant to the
Coolant Surge Tank
{WARNING
You can be burned if you spill
coolant on hot engine parts.
Coolant contains ethylene glycol
and it will burn if the engine parts
are hot enough. Do not spill
coolant on a hot engine.
Notice: This vehicle has a
specific coolant fill procedure.
Failure to follow this procedure
could cause the engine to
overheat and be severely
damaged.
{WARNING
An electric engine cooling fan
under the hood can start up even
when the engine is not running
and can cause injury. Keep
hands, clothing, and tools away
from any underhood electric fan.
{WARNING
Steam and scalding liquids from a
hot cooling system can blow out
and burn you badly. They are
under pressure, and if you turn
the surge tank pressure
cap —even a little —they can
come out at high speed. Never
turn the cap when the cooling
system, including the surge tank
pressure cap, is hot. Wait for the
cooling system and surge tank
pressure cap to cool if you ever
have to turn the pressure cap.
If no coolant is visible in the surge
tank, add coolant as follows:
1. Remove the coolant surge tank pressure cap when the cooling
system, including the coolant
surge tank pressure cap and
upper radiator hose, is no longer
hot. Turn the pressure cap
slowly counterclockwise about
two or two and one-half turns. If a hiss is heard, wait for
that to stop. This will allow any
pressure still left to be vented
out the discharge hose.
2. Then keep turning the pressure
cap slowly and remove it.

Black plate (21,1)Chevrolet Aveo Owner Manual - 2011
Vehicle Care 10-21
3. Fill the coolant surge tankwith the proper mixture to the
Maximum mark on the coolant
surge tank. Wait about
5 minutes, then check to see if
the level is below the mark. If the
level is below the Maximum
mark, add additional coolant to
bring the level up to the mark.
Repeat this procedure until the
level remains constant at the
Maximum mark for at least
five minutes. 4. With the coolant surge tank
pressure cap off, start the
engine and let it run until the
upper radiator hose can be felt
getting hot. Watch out for the
engine cooling fan.
By this time, the coolant level
inside the coolant surge tank
may be lower. If the level is
lower than the Maximum mark,
add more of the proper mixture
to the coolant surge tank until
the level reaches the mark.
5. Replace the pressure cap. Be sure the pressure cap is
hand-tight and fully seated.
Notice: If the pressure cap is not
tightly installed, coolant loss and
possible engine damage may
occur. Be sure the cap is properly
and tightly secured.
Engine Overheating
The vehicle has an indicator to
warn of the engine overheating.
There is a coolant temperature
gauge on the instrument panel
cluster. See Engine Coolant
Temperature Gauge on page 5‑11.
If the decision is made not to lift the
hood when this warning appears,
get service help right away. See
Roadside Assistance Program on
page 13‑6.
If the decision is made to lift the
hood, make sure the vehicle is
parked on a level surface.

Black plate (22,1)Chevrolet Aveo Owner Manual - 2011
10-22 Vehicle Care
Then check to see if the engine
cooling fan is running. If the engine
is overheating, the fan should be
running. If it is not, do not continue
to run the engine. Have the vehicle
serviced.
Notice:Engine damage from
running the engine without
coolant is not covered by the
warranty.
Notice: If the engine catches fire
because of being driven with no
coolant, the vehicle can be badly
damaged. The costly repairs
would not be covered by the
vehicle warranty.If Steam is Coming from the
Engine Compartment
{WARNING
Steam from an overheated engine
can burn you badly, even if you
just open the hood. Stay away
from the engine if you see or hear
steam coming from it. Just turn it
off and get everyone away from
the vehicle until it cools down.
Wait until there is no sign of
steam or coolant before you open
the hood.
If you keep driving when the
engine is overheated, the liquids
in it can catch fire. You or others
could be badly burned. Stop the
engine if it overheats, and get out
of the vehicle until the engine
is cool.
If No Steam is Coming from
the Engine Compartment
If an engine overheat warning is
displayed but no steam can be seen
or heard, the problem may not be
too serious. Sometimes the engine
can get a little too hot when the
vehicle:
.Climbs a long hill on a hot day
.Stops after high-speed driving
.Idles for long periods in traffic
If the overheat warning is displayed
with no sign of steam:
1. Turn the air conditioning off, if equipped.
2. Turn the heater on to the highest temperature and to the highest
fan speed. Open the windows as
necessary.
3. If in a traffic jam, let the engine idle in N (Neutral) while stopped.
If it is safe to do so, pull off
the road, shift to P (Park) or
N (Neutral) and let the
engine idle.

Black plate (23,1)Chevrolet Aveo Owner Manual - 2011
Vehicle Care 10-23
If the temperature overheat gauge
is no longer in the overheat zone
or an overheat warning no longer
displays, the vehicle can be driven.
Continue to drive the vehicle slowly
for about 10 minutes. Keep a safe
vehicle distance from the vehicle in
front. If the warning does not come
back on, continue to drive normally.
If the warning continues, pull over,
stop, and park the vehicle
right away.
If there is no sign of steam, idle the
engine for three minutes while
parked. If the warning is still
displayed, turn off the engine
until it cools down.Power Steering Fluid
When to Check Power
Steering Fluid
The power steering fluid reservoir is
located toward the front of the
engine compartment on the driver
side of the vehicle. SeeEngine
Compartment Overview on
page 10‑8 for reservoir location.
It is not necessary to regularly
check power steering fluid unless
there is a leak suspected in the
system or an unusual noise is
heard. A fluid loss in this system
could indicate a problem. Have the
system inspected and repaired.
How to Check Power
Steering Fluid
Turn the key off and let the engine
compartment cool down.
The level should be above the MIN
mark on the reservoir. If the level
drops below the MIN mark, add
power steering fluid. Do not overfill
the reservoir and remember to
replace the cap tightly when finished
and clean up any spilled fluid.
What to Use
To determine what kind of fluid to
use, see Recommended Fluids and
Lubricants on page 11‑6. Always
use the proper fluid. Failure to use
the proper fluid can cause leaks and
damage hoses and seals.

Black plate (24,1)Chevrolet Aveo Owner Manual - 2011
10-24 Vehicle Care
Washer Fluid
What to Use
When the vehicle needs windshield
washer fluid, be sure to read the
manufacturer's instructions before
use. If operating the vehicle in an
area where the temperature may fall
below freezing, use a fluid that has
sufficient protection against
freezing.
Adding Washer Fluid
Open the cap with the washer
symbol on it. Add washer fluid until
the tank is full. SeeEngine
Compartment Overview on
page 10‑8 for reservoir location. Notice:
.When using concentrated
washer fluid, follow the
manufacturer's instructions
for adding water.
.Do not mix water with
ready-to-use washer fluid.
Water can cause the solution
to freeze and damage the
washer fluid tank and other
parts of the washer system.
Also, water does not clean as
well as washer fluid.
.Fill the washer fluid tank only
three-quarters full when it is
very cold. This allows for
fluid expansion if freezing
occurs, which could
damage the tank if it is
completely full.
.Do not use engine coolant
(antifreeze) in the windshield
washer. It can damage the
windshield washer system
and paint.
Brakes
This vehicle has front disc brakes
and could have rear drum brakes or
rear disc 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 can come and go or be
heard all the time the vehicle is
moving, except when applying the
brake pedal firmly.
{WARNING
The brake wear warning sound
means that soon the brakes will
not work well. That could lead to
a crash. When the brake wear
warning sound is heard, have the
vehicle serviced.
Notice: Continuing to drive with
worn-out brake pads could result
in costly brake repair.

Black plate (26,1)Chevrolet Aveo Owner Manual - 2011
10-26 Vehicle Care
Brake Fluid
The brake/clutch master cylinder
reservoir is filled with DOT 3 brake
fluid as indicated on the reservoir
cap. SeeEngine Compartment
Overview on page 10‑8 for the
location of the reservoir.
There are only two reasons why the
fluid level in the reservoir might
go down:
.The fluid level goes down
because of normal brake lining
wear. When new linings are
installed, the fluid level goes
back up.
.A fluid leak in the brake/clutch
hydraulic system can also cause
a low fluid level. Have the brake/
clutch hydraulic system fixed,
since a leak means that sooner
or later the brakes and/or clutch
will not work well.
Do not top off the brake/clutch fluid.
Adding fluid does not correct a leak.
If fluid is added when the linings are
worn, there will be too much fluid
when new brake linings are
installed. Add or remove brake fluid,
as necessary, only when work is
done on the brake/clutch hydraulic
system.
{WARNING
If too much brake fluid is added, it
can spill on the engine and burn,
if the engine is hot enough. You
or others could be burned, and
the vehicle could be damaged.
Add brake fluid only when work is
done on the brake/clutch
hydraulic system.
When the brake/clutch fluid falls to a
low level, the brake warning light
comes on. See Brake System
Warning Light on page 5‑16.
What to Add
Use only new DOT 3 brake fluid
from a sealed container. See
Recommended Fluids and
Lubricants on page 11‑6.
Always clean the brake/clutch fluid
reservoir cap and the area around
the cap before removing it. This
helps keep dirt from entering the
reservoir.

Black plate (27,1)Chevrolet Aveo Owner Manual - 2011
Vehicle Care 10-27
{WARNING
With the wrong kind of fluid in the
brake/clutch hydraulic system, the
brakes might not work well. This
could cause a crash. Always use
the proper brake/clutch fluid.
Notice:
.Using the wrong fluid can
badly damage brake/clutch
hydraulic system parts. For
example, just a few drops of
mineral-based oil, such as
engine oil, in the brake
hydraulic system can
damage brake hydraulic
system parts so badly that
they will have to be replaced.
Do not let someone put in
the wrong kind of fluid.
.If brake fluid is spilled
on the vehicle's painted
surfaces, the paint finish can
be damaged. Be careful not
to spill brake fluid on the
vehicle. If you do, wash it off
immediately.
Battery
Refer to the replacement number
shown on the original battery label
when a new battery is needed. See
Engine Compartment Overview on
page 10‑8 for battery location.
{DANGER
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
{WARNING
Batteries have acid that can burn
you and gas that can explode.
You can be badly hurt if you are
not careful. See Jump Starting on
page 10‑70 for tips on working
around a battery without
getting hurt.
Infrequent Usage: Remove the
black, negative (−) cable from the
battery to keep the battery from
running down.
Extended Storage: Remove the
black, negative (−) cable from the
battery or use a battery trickle
charger.