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Chevrolet Aveo 2004-2010 Service Repair Manual

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🏷️ Basic Information Identification Make: Chevrolet Model: Aveo Generation: T200 / T250 Model Years: 2004-2010 Codes Chassis Codes: T200, T250 👋 Introduction Market Position Segment: Subcompact Car Competitive Analysis Competitors...
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SKU: 65036
Chevrolet Aveo 2004-2010 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Chevrolet
Model:
Aveo
Generation:
T200 / T250
Model Years:
2004-2010
Codes
Chassis Codes:
T200, T250
👋 Introduction
Market Position
Segment:
Subcompact Car
Competitive Analysis
Competitors 2000S:
Honda Fit, Toyota Yaris, Ford Fiesta, Nissan Versa, Hyundai Accent, Kia Rio
Key Features
Value Proposition:
Affordable transportation, fuel efficiency, practical interior space for its class.
📋 Manual Details
Coverage Areas
Primary Focus:
Comprehensive Service and Repair
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Manual (FSM) / Workshop Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed rebuild procedures, component identification, diagnostics, timing belt/chain service, piston/ring inspection, valve train service, cylinder head overhaul.
Fuel System:
Fuel pump testing, injector diagnostics, throttle body cleaning and calibration, fuel pressure regulation, evaporative emission control system (EVAP) service.
Cooling System:
Radiator and fan diagnostics, thermostat replacement, water pump service, coolant capacity and specifications, leak testing.
Lubrication System:
Oil pump inspection, oil pan removal and gasket replacement, oil pressure testing, oil filter specifications and replacement intervals.
Chassis:
Suspension component inspection and replacement (struts, shocks, control arms, ball joints, tie rods), steering system diagnostics, wheel bearing service, brake system overhaul (pads, rotors, calipers, lines).
Electrical System:
Battery diagnostics, charging system testing (alternator, regulator), starter motor troubleshooting, lighting system repair, horn and wiper system service, power windows and locks.
Powertrain Control Module:
PCM location, basic diagnostic trouble code (DTC) retrieval and interpretation (where applicable without specialized scanners).
Emission Control:
Catalytic converter function, oxygen sensor diagnostics, EGR system service, PCV system operation, emission testing procedures.
Body And Interior:
Door panel removal, seat adjustment mechanisms, interior trim component replacement, basic body panel alignment.
HVAC System:
Heater core replacement, blower motor diagnostics, AC system refrigerant handling (basic information), temperature control unit operation.
Procedures Included
Scheduled Maintenance:
Oil change intervals, filter replacement procedures, fluid level checks, spark plug replacement, belt inspection and replacement.
Troubleshooting:
Systematic diagnostic flowcharts, symptom-based troubleshooting guides, common problem identification.
Disassembly Assembly:
Step-by-step instructions for component removal and installation with detailed diagrams.
Wiring Diagrams:
Complete electrical schematics for all major vehicle systems.
Technical Depth
Depth Level:
Intermediate to Advanced
📊 Manual Specifications
File Format
Quality:
High-resolution, clear text and diagrams.
Print Quality
Printability:
Printable without restriction.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
Z16SE, L14 (1.4L), L16 (1.6L), F14D3, F16D3
Performance
1.4L Hp Approx:
94 hp @ 6000 rpm
1.6L Hp Approx:
103-107 hp @ 6000 rpm
Torque Specs:
Varies by engine, typically around 90-100 lb-ft for 1.4L and 105-110 lb-ft for 1.6L.
Fuel System
Injection Type:
Multi-port Fuel Injection (MPI)
Engine Type
Configuration:
Inline 4-cylinder, DOHC
Engine Maintenance
Timing Belt Replacement Interval:
Refer to manual for specific mileage/time, typically around 60,000-100,000 miles or 4-5 years.
🔧 Transmission
Standard
Type Common:
5-speed Manual Transmission
Optional
Type Optional:
4-speed Automatic Transmission
Features
Automatic Features:
Lock-up torque converter for improved fuel economy.
Fluid Specifications
Manual Transmission Fluid:
GL-4 gear oil, SAE 75W-90 or 80W-90 (refer to manual for precise spec).
Automatic Transmission Fluid:
Dexron III or equivalent (refer to manual for precise spec).
📐 Dimensions
Exterior
Wheelbase Approx:
97.6 inches (2480 mm) (T250)
Length Approx:
161.4 inches (4100 mm) (T250 Hatchback)
Width Approx:
67.3 inches (1710 mm)
Height Approx:
59.3 inches (1505 mm)
Weights
Curb Weight Approx:
2300-2500 lbs (1043-1134 kg), depending on trim and engine
Cargo
Cargo Volume Hatchback:
Approximately 10.1 cu ft with rear seats up (varies slightly by generation).
🛡️ Safety Features
Ratings
NHTSA Front Driver Side Impact:
4 Stars (for some models/years, check specific test data)
NHTSA Front Passenger Side Impact:
4 Stars (for some models/years, check specific test data)
IIHS Side Impact:
Acceptable to Good (varies by year and testing methodology)
Active Features
ABS:
Available on higher trims or as an option.
Passive Features
Airbags:
Front airbags standard, side-impact airbags available on some models.
💡 Technology Features
Infotainment
Audio System:
Base models feature AM/FM radio with CD player; higher trims may offer auxiliary input and improved speaker systems.
Driver Assistance
Cruise Control:
Available on higher trim levels.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first (typical for synthetic blend).
Engine Oil Filter Change:
Replace with every oil change.
Engine Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed based on driving conditions.
Cabin Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km) or annually.
Spark Plug Replacement:
Recommended around 60,000 - 100,000 miles depending on plug type (standard vs. iridium).
Fluid Specifications
Engine Oil Type:
API SM or SN, ILSAC GF-4 or GF-5; SAE 5W-30 recommended (refer to manual for precise specification).
Coolant Type:
Dex-Cool (orange) or equivalent G-48/G-11 (green) antifreeze/coolant, a 50/50 mixture with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Engine Performance:
Occasional rough idle, potential for oil leaks from valve cover gasket or oil pan gasket.
Transmission Issues:
Automatic transmission can sometimes exhibit hesitant shifting or delayed engagement; manual clutch wear.
Suspension Components:
Premature wear of front struts and bushings, tie rod ends, and ball joints.
Electrical Gremlins:
Reports of power window motor failures, occasional issues with instrument cluster illumination.
Exhaust System:
Corrosion on exhaust pipes and mufflers can occur in certain climates.
📚 Vehicle History
Brand Heritage
Parent Company:
General Motors (GM)
Model Evolution
First Generation T200:
Introduced globally as Daewoo Kalos, later rebadged as Chevrolet Aveo. Known for its distinctive styling.
Second Generation T250:
Launched around 2006-2007, featuring updated styling, interior, and revised powertrains. Offered in sedan and hatchback body styles.
Production
Global Production:
Produced in various GM factories worldwide, including South Korea (GM Daewoo) and Thailand.
🏆 Awards & Recognition
Recognitions
Awards None Significant:
While not a recipient of major accolades, the Aveo was recognized for its affordability and practicality in its segment.
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