Positioning:
Subcompact car positioned as an affordable and practical option in its segment.
Competitors:
Dominated by vehicles like the Hyundai Accent, Kia Rio, Toyota Yaris, Honda Fit, and Ford Fiesta during its production run.
Selling Points:
Affordability, fuel efficiency, maneuverability in urban environments, surprisingly spacious interior for its class.
Primary Coverage:
Service and Repair
Estimated Page Count:
Thousands (typical for a comprehensive service manual)
Type:
Factory-level Service Repair Manual (likely a compilation of OEM documentation)
Usefulness For Diy:
Specifically written for the do-it-yourselfer and experienced mechanic, providing the same level of detail as dealer technicians.
Instruction Style:
Numbered instructions and detailed substeps provide a clear, sequential approach to repairs.
Format:
Digital Download (PDF)
Powertrain:
Engine, Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Emission Control, Automatic Transmission, Manual Transmission, Clutch, Drivetrain (Drive Shaft, Differential, Axles)
Chassis:
Suspension (Front and Rear), Steering System (Power Steering), Brakes (Front and Rear, Parking Brake), Wheels and Tires
Body & Electrical:
Body Exterior and Interior (Doors, Hood, Glass, Mirrors, Seats), HVAC System (Air Conditioning), Electrical System (Starting, Charging, Lighting, Instruments, Gauges, Audio/Visual), Restraint Systems (Airbags, Seatbelts), Cruise Control, Wiper and Washer System, Door Locks, Engine Immobilizer, Multiplex/CAN Communication
Comfort Systems:
Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair.
General Repair:
Step-by-step repair procedures based on complete disassembly and reassembly.
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, tune-ups.
Diagnostics:
Troubleshooting guides, symptom analysis, diagnostic trouble codes (DTCs) interpretation, electrical system diagnosis.
Component Replacement:
Detailed instructions for replacing individual components and sub-assemblies.
Body Repair:
Body panel alignment, door and latch adjustment, glass replacement, interior trim removal and installation.
Troubleshooting Guides:
Structured troubleshooting procedures for diagnosing common problems based on symptoms.
Depth:
Comprehensive from basic maintenance to complex engine and transmission overhauls, including electrical system diagnostics and wiring diagrams.
Electrical Diagrams:
Detailed wiring diagrams for all electrical systems, including lighting, ignition, starting, charging, and accessories.
Compatibility:
All PC-based Windows operating systems, Mac, and Linux.
Printability:
Fully printable, allowing users to print specific sections or the entire manual.
Binding:
N/A (Digital Download)
Paper Quality:
N/A (Digital Download)
Text Search:
Likely searchable text within the PDF for quick information retrieval.
Illustrations:
Hundreds of photos, drawings, and illustrations to guide through procedures, with enlarged insets for detailed part examination.
Engine Type Usdm 2002-2004:
1.6L DOHC I4 (G16DOHC)
Engine Type Usdm 2005-2008:
1.6L DOHC I4 (engine codes may vary, often updated for emissions and performance)
Horsepower 1.6L:
Approximately 103-106 hp @ 6000 rpm (varies slightly by year and market)
Torque 1.6L:
Approximately 105-107 lb-ft @ 3200-3400 rpm (varies slightly by year and market)
Fuel Delivery:
Electronic Fuel Injection (EFI), Sequential Multi-port Fuel Injection (SFI)
ECU:
Engine Control Unit (ECU) with diagnostic capabilities.
Timing System:
Belt-driven or chain-driven timing system depending on the specific engine variant. Manual will detail replacement procedures and specifications.
Emission Systems:
Catalytic Converter, Oxygen Sensors, EGR (Exhaust Gas Recirculation) if applicable.
Transmission Type Standard:
5-speed Manual Transmission
Transmission Type Optional:
4-speed Automatic Transmission
Transmission Fluid Spec Manual:
GL-4 gear oil (specific viscosity, e.g., 75W-90, to be confirmed in manual).
Transmission Fluid Spec Automatic:
Dexron III or equivalent (specific Dexron type to be confirmed in manual).
NHTSA Frontal Impact Driver:
4-star (typical for the era and segment).
NHTSA Frontal Impact Passenger:
4-star (typical for the era and segment).
ABS:
Anti-lock Braking System (ABS) often optional or standard on higher trims.
Traction Control:
Traction Control System (TCS) may be available on certain models.
Airbags:
Frontal airbags (driver and passenger), optional side airbags on some models.
Seatbelts:
3-point seatbelts with pretensioners for front occupants.
Audio System:
Basic AM/FM/CD player, often with auxiliary input on later models. Optional premium audio system might be available.
Navigation:
Not typically available on factory models of this generation.
Cruise Control:
Available on higher trim levels or as an option.
Bluetooth:
Rarely factory-equipped; typically an aftermarket addition.
Dashboard Layout:
Simple and functional dashboard with analog gauges for speed, tachometer (optional), fuel, and temperature. Central digital display for odometer and trip meter.
Oil Change Interval:
Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, whichever comes first (refer to manual for exact specification).
Air Filter Replacement Interval:
Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed based on driving conditions.
Spark Plug Replacement Interval:
Every 60,000 - 100,000 miles (96,000 - 160,000 km) for iridium or platinum plugs, sooner for standard plugs.
Engine Oil Type:
SAE 5W-30 synthetic or synthetic blend meeting API SN/SP or ILSAC GF-6 specifications (confirm in manual).
Coolant Type:
GM-specific Dex-Cool (orange) or a compatible Asian long-life coolant (pink or red).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (check manual for specific recommendation).
Common Complaints Engine:
Occasional oil leaks, potential for timing chain wear on higher mileage engines, sometimes ignition coil failures.
Common Complaints Suspension:
Worn strut mounts, control arm bushings, and sway bar links are common due to age and road conditions.
Common Complaints Electrical:
Window regulator failures, issues with dashboard illumination, and occasional starter motor problems.
Common Complaints Transmission:
Rough shifting in automatics, clutch wear in manuals (especially if driven hard).
Common Complaints HVAC:
A/C compressor clutch issues, evaporator leaks, or blower motor resistor failures can occur.
Manufacturer:
Chevrolet, a division of General Motors (GM).
Platform Origin:
The Aveo (T200) was originally developed by Daewoo (a GM subsidiary) and introduced globally as a replacement for the Daewoo Kalos.
Generation Change 2005:
A significant facelift and platform update (T250) occurred around the 2005 model year, offering updated styling and some mechanical improvements.
Manufacturing Locations:
Primarily South Korea (Daewoo) and also produced in other GM facilities globally.
