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Chevrolet AVEO 2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Chevrolet Model: Aveo Year: 2004 Generation Generation Designation: T200 Codes Chassis Code: T200 👋 Introduction Market Position Vehicle Segment: Subcompact car, known for affordability and fuel efficiency. Competitive Analysis Key Competitors 2004: Hyundai Accent, Kia Rio, Ford Fiesta, Toyota Yaris (Vitz). Key Features Manual Advantage: Empowers owners and technicians with comprehensive repair and maintenance knowledge, reducing reliance on specialized shops. User Accessibility: User-friendly PDF format, accessible on Windows OS, smartphones, and tablets without installation. Manual Benefit For Owners: Enables owners to perform routine maintenance and repairs, saving money and extending the vehicle's lifespan. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service and repair for all major systems. Page Count Estimated Page Count: Refer to actual PDF for precise count, typically 500+ pages for such comprehensive coverage. Manual Type Manual Type: Service and Repair Manual Language Language: English Format Digital Format: PDF Device Compatibility: Compatible with all Windows operating systems, smartphones, and tablets that support PDF viewing. 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, lubrication, cooling, fuel, ignition, emissions, starting, charging. Drivetrain Systems: Clutch, manual gearbox, propeller shafts, rear axle, front axle. Suspension Steering Brakes: Front suspension, rear suspension, steering system, brake system (hydraulic, mechanical, parking). Wheels Tires: Wheel and tire specifications, mounting, balancing, alignment. Body Chassis: Bodywork construction, chassis frame, doors, windows, interior trim, exterior trim. HVAC System: Heating, ventilation, and air conditioning (HVAC) system components and service. Electrical Electronic: Electrical system overview, battery, charging system, starting system, lighting, instrumentation, wiring diagrams, fuses, relays. Cruise Control System: If equipped, includes service and troubleshooting for the cruise control system. Safety Restraints: Information on airbags, seatbelts, and related components. Procedures Included Maintenance Procedures: Routine maintenance, fluid changes, filter replacements, inspections. Repair Procedures: Component removal, installation, adjustment, and overhaul for all covered systems. Diagnostic Procedures: Troubleshooting guides, symptom-based diagnostics, common fault identification. Schematics Diagrams: Electrical wiring diagrams, vacuum diagrams, hydraulic schematics. Bodywork Procedures: Detailed procedures for body panel repairs, adjustments, and interior trim removal/installation. Electrical Procedures: Comprehensive coverage including component testing, wiring harness repair, fuse/relay identification, and troubleshooting of various electrical circuits. Technical Depth Depth Of Coverage: Dealer-level instructional guides covering basic repairs to complex overhauls. Repair Complexity: Suitable for all levels of repair, from basic fluid checks to engine rebuilds and complex electrical troubleshooting. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Print Quality Printability: High-quality, printable pages for all sections. Binding Type Binding: N/A (Digital PDF - printable) Paper Type Paper Quality: N/A (Digital PDF - printable on user's choice of paper) ⚙️ Engine Specifications Primary Engine Engine Code 1: F14D3 (1.4L DOHC I4) Performance Horsepower 1 Approx: 94 hp @ 6000 rpm Torque 1 Approx: 130 Nm (96 lb-ft) @ 3200 rpm Horsepower 2 Approx: 103 hp @ 6000 rpm Torque 2 Approx: 145 Nm (107 lb-ft) @ 3200 rpm Fuel System Fuel Delivery System: Electronic Fuel Injection (EFI) / Multi-point Fuel Injection (MPI) Emission Control Systems: Includes information on catalytic converters, oxygen sensors, and emission control modules relevant to the 2004 model year. Engine Code 2 Engine Code 2: F16D3 (1.6L DOHC I4) 🔧 Transmission Standard Standard Transmission Type: 5-speed Manual Transmission Optional Optional Transmission Type: 4-speed Automatic Transmission Features Transmission Fluid Type: Refer to specific manual chapter for fluid type (e.g., Dexron III/VI for automatic, manual gear oil). 📐 Dimensions Exterior Body Styles: Hatchback (3-door and 5-door), Sedan (4-door) Wheelbase Approx: 2480 mm (97.6 in) Weights Curb Weight Approx: 1050 - 1150 kg (2315 - 2535 lbs) depending on body style and equipment. 🛡️ Safety Features Ratings NHTSA Crash Test Results: Refer to specific NHTSA data for 2004 models; generally mixed to adequate for the era. Active Features Available Active Safety: Anti-lock Braking System (ABS) (often optional), Electronic Brakeforce Distribution (EBD). Passive Features Available Passive Safety: Front airbags, Seatbelt pretensioners, potentially side airbags on higher trims. 💡 Technology Features Infotainment Infotainment Features: Basic AM/FM/CD player, optional auxiliary input, limited display information. Driver Assistance Available Driver Assistance: Limited; primarily ABS if equipped. No advanced driver-assistance systems (ADAS). Connectivity Connectivity Options: Minimal; typically power windows, power locks on higher trims. No Bluetooth or USB connectivity as standard. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, refer to manual for specific engine oil type. Spark Plug Replacement Interval: Approximately 60,000 - 100,000 miles (96,000 - 160,000 km) depending on spark plug type (e.g., platinum or iridium). Timing Belt Replacement Interval: For engines with a timing belt, typically 60,000 - 100,000 miles (96,000 - 160,000 km). The F14D3 and F16D3 engines use a timing belt. Fluid Specifications Engine Oil Viscosity: Commonly 5W-30 or 10W-30 API SJ or higher, check manual for precise OEM recommendation. Coolant Type: Ethylene glycol-based coolant, typically orange or green color (GMC/ACDelco coolant is recommended). Brake...
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Chevrolet AVEO 2004 Service Repair ManualChevrolet AVEO 2004 Service Repair ManualChevrolet AVEO 2004 Service Repair ManualChevrolet AVEO 2004 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Chevrolet
Model:
Aveo
Year:
2004
Generation
Generation Designation:
T200
Codes
Chassis Code:
T200
👋 Introduction
Market Position
Vehicle Segment:
Subcompact car, known for affordability and fuel efficiency.
Competitive Analysis
Key Competitors 2004:
Hyundai Accent, Kia Rio, Ford Fiesta, Toyota Yaris (Vitz).
Key Features
Manual Advantage:
Empowers owners and technicians with comprehensive repair and maintenance knowledge, reducing reliance on specialized shops.
User Accessibility:
User-friendly PDF format, accessible on Windows OS, smartphones, and tablets without installation.
Manual Benefit For Owners:
Enables owners to perform routine maintenance and repairs, saving money and extending the vehicle's lifespan.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive service and repair for all major systems.
Page Count
Estimated Page Count:
Refer to actual PDF for precise count, typically 500+ pages for such comprehensive coverage.
Manual Type
Manual Type:
Service and Repair Manual
Language
Language:
English
Format
Digital Format:
PDF
Device Compatibility:
Compatible with all Windows operating systems, smartphones, and tablets that support PDF viewing.
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, lubrication, cooling, fuel, ignition, emissions, starting, charging.
Drivetrain Systems:
Clutch, manual gearbox, propeller shafts, rear axle, front axle.
Suspension Steering Brakes:
Front suspension, rear suspension, steering system, brake system (hydraulic, mechanical, parking).
Wheels Tires:
Wheel and tire specifications, mounting, balancing, alignment.
Body Chassis:
Bodywork construction, chassis frame, doors, windows, interior trim, exterior trim.
HVAC System:
Heating, ventilation, and air conditioning (HVAC) system components and service.
Electrical Electronic:
Electrical system overview, battery, charging system, starting system, lighting, instrumentation, wiring diagrams, fuses, relays.
Cruise Control System:
If equipped, includes service and troubleshooting for the cruise control system.
Safety Restraints:
Information on airbags, seatbelts, and related components.
Procedures Included
Maintenance Procedures:
Routine maintenance, fluid changes, filter replacements, inspections.
Repair Procedures:
Component removal, installation, adjustment, and overhaul for all covered systems.
Diagnostic Procedures:
Troubleshooting guides, symptom-based diagnostics, common fault identification.
Schematics Diagrams:
Electrical wiring diagrams, vacuum diagrams, hydraulic schematics.
Bodywork Procedures:
Detailed procedures for body panel repairs, adjustments, and interior trim removal/installation.
Electrical Procedures:
Comprehensive coverage including component testing, wiring harness repair, fuse/relay identification, and troubleshooting of various electrical circuits.
Technical Depth
Depth Of Coverage:
Dealer-level instructional guides covering basic repairs to complex overhauls.
Repair Complexity:
Suitable for all levels of repair, from basic fluid checks to engine rebuilds and complex electrical troubleshooting.
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Print Quality
Printability:
High-quality, printable pages for all sections.
Binding Type
Binding:
N/A (Digital PDF - printable)
Paper Type
Paper Quality:
N/A (Digital PDF - printable on user's choice of paper)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
F14D3 (1.4L DOHC I4)
Performance
Horsepower 1 Approx:
94 hp @ 6000 rpm
Torque 1 Approx:
130 Nm (96 lb-ft) @ 3200 rpm
Horsepower 2 Approx:
103 hp @ 6000 rpm
Torque 2 Approx:
145 Nm (107 lb-ft) @ 3200 rpm
Fuel System
Fuel Delivery System:
Electronic Fuel Injection (EFI) / Multi-point Fuel Injection (MPI)
Emission Control Systems:
Includes information on catalytic converters, oxygen sensors, and emission control modules relevant to the 2004 model year.
Engine Code 2
Engine Code 2:
F16D3 (1.6L DOHC I4)
🔧 Transmission
Standard
Standard Transmission Type:
5-speed Manual Transmission
Optional
Optional Transmission Type:
4-speed Automatic Transmission
Features
Transmission Fluid Type:
Refer to specific manual chapter for fluid type (e.g., Dexron III/VI for automatic, manual gear oil).
📐 Dimensions
Exterior
Body Styles:
Hatchback (3-door and 5-door), Sedan (4-door)
Wheelbase Approx:
2480 mm (97.6 in)
Weights
Curb Weight Approx:
1050 - 1150 kg (2315 - 2535 lbs) depending on body style and equipment.
🛡️ Safety Features
Ratings
NHTSA Crash Test Results:
Refer to specific NHTSA data for 2004 models; generally mixed to adequate for the era.
Active Features
Available Active Safety:
Anti-lock Braking System (ABS) (often optional), Electronic Brakeforce Distribution (EBD).
Passive Features
Available Passive Safety:
Front airbags, Seatbelt pretensioners, potentially side airbags on higher trims.
💡 Technology Features
Infotainment
Infotainment Features:
Basic AM/FM/CD player, optional auxiliary input, limited display information.
Driver Assistance
Available Driver Assistance:
Limited; primarily ABS if equipped. No advanced driver-assistance systems (ADAS).
Connectivity
Connectivity Options:
Minimal; typically power windows, power locks on higher trims. No Bluetooth or USB connectivity as standard.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, refer to manual for specific engine oil type.
Spark Plug Replacement Interval:
Approximately 60,000 - 100,000 miles (96,000 - 160,000 km) depending on spark plug type (e.g., platinum or iridium).
Timing Belt Replacement Interval:
For engines with a timing belt, typically 60,000 - 100,000 miles (96,000 - 160,000 km). The F14D3 and F16D3 engines use a timing belt.
Fluid Specifications
Engine Oil Viscosity:
Commonly 5W-30 or 10W-30 API SJ or higher, check manual for precise OEM recommendation.
Coolant Type:
Ethylene glycol-based coolant, typically orange or green color (GMC/ACDelco coolant is recommended).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid, refer to manual for specific recommendation.
Power Steering Fluid:
Refer to manual; often a specific ATF or power steering fluid type.
Known Issues
Common Aveo T200 Issues:
Minor oil leaks, clutch wear, HVAC blower motor resistor issues, early electrical gremlins, potential rust on older models.
📚 Vehicle History
Brand Heritage
Chevrolet History Context:
Chevrolet, a division of General Motors, has a long history of producing a wide range of vehicles, often emphasizing value and accessibility.
Model Evolution
Aveo T200 Introduction:
The T200 generation of the Aveo was introduced globally, serving as an entry-level model for Chevrolet in many markets, often replacing the Daewoo Kalos.
Production
Manufacturing Locations:
Primarily manufactured in South Korea (as Daewoo) and later assembled in other GM facilities globally.
🏆 Awards & Recognition
Recognitions
Historical Awards:
Specific awards for the 2004 Aveo are not widely documented; it was positioned as a value-oriented vehicle.
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