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Chevy Chevrolet Aveo Workshop Service Repair Manual 2002-2006

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🏷️ Basic Information Identification Make: Chevrolet Model: Aveo Model Years Covered: 2002, 2003, 2004, 2005, 2006 Region Of Origin: South Korea (Daewoo Lanos platform) Codes Chassis Codes: T200/T250 (depending on market and minor revisions) 👋 Introduction Market Position Target Audience: DIY mechanics, independent repair shops, Chevrolet Aveo owners Value Proposition: Enables owners to perform dealership-level repairs and maintenance themselves, saving time and money. Competitive Analysis Manual Quality: Factory-level detail, comprehensive coverage surpassing generic repair guides. Key Features Completeness: Covers all engine types and all models within the specified production years. User Friendliness: Step-by-step instructions and clear illustrations make repairs accessible. Digital Accessibility: Instant download and broad device compatibility for immediate use. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English File Format: PDF Total Pages: >5000 Compatibility: Windows, Mac, iOS (iPhone, iPad), Android Distribution Method: Instant Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, rebuilding, performance tuning, troubleshooting Engine Performance: Diagnosis, tuning, emission controls Engine Management: ECU diagnostics, sensor functions, wiring schematics Fuel System: Fuel injection, fuel pump, injectors, fuel filter replacement Cooling System: Radiator, thermostat, water pump, hoses, fan assembly Ignition System: Spark plugs, ignition coils, wiring, timing Exhaust System: Catalytic converter, mufflers, pipes, oxygen sensors Transmission Manual: Removal, installation, internal components, clutch service Transmission Automatic: Removal, installation, internal components, fluid service Drivetrain: CV joints, drive axles, wheel bearings Brakes: Hydraulic system, ABS, disc/drum service, pad/rotor replacement Suspension: Shock absorbers, struts, control arms, bushings, ball joints Steering: Power steering system, steering rack, tie rods Electrical System: Battery, charging system, starter, lighting, accessories Wiring Diagrams: Comprehensive schematics for all electrical systems HVAC: Air conditioning service, refrigerant capacities, heater core Body And Chassis: Body panel repair, interior trim, glass replacement Sunroof: Service and repair procedures for sunroof operation Procedures Included Maintenance: Factory maintenance schedules, fluid changes, filter replacements Troubleshooting: Diagnostic trouble codes (DTCs), diagnostic trees, symptom-based troubleshooting Repair: Step-by-step repair instructions for all major systems Rebuild: Detailed engine and transmission overhaul procedures Timing Belt: Replacement procedures and service intervals Alignment: Front end alignment procedures and specifications Torque Specifications: Complete torque values for all fasteners Vacuum Diagrams: Vacuum routing diagrams for engine and accessories Serpentine Belt: Belt routing diagrams and replacement Technical Depth Diagnostic Capability: Advanced diagnostics including computer diagnostic codes and trouble trees Illustrative Content: Hundreds of detailed illustrations and diagrams Data Accuracy: Factory-level specifications and data Scope Of Repair: Covers simple to complicated repairs, maintenance, rebuilding, refurbishing, and restoration 📊 Manual Specifications File Format PDF Quality: Original Adobe document, perfect quality PDF Features: Fully indexed, bookmarked by topic, searchable text, zoomable images Printability: Printable in its entirety or select pages Required Software: Adobe PDF Reader, WinZip Binding Type Manual Delivery: Digital (Instant Download) Physical Format Equivalent: Printable PDF, equivalent to factory paperback or digital access Paper Type Digital Format: PDF (no physical paper type) ⚙️ Engine Specifications Primary Engine Engine Options Typical: 1.5L (4-cylinder) and 1.6L (4-cylinder) DOHC naturally aspirated engines Performance Horsepower Range Typical: Approximately 90-100 hp (1.5L) to 100-110 hp (1.6L) Torque Range Typical: Approximately 95-105 lb-ft (1.5L) to 105-115 lb-ft (1.6L) Fuel System Fuel Delivery: Electronic Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded gasoline Engine Management ECU Type: GM ECU (specific model designation not provided, but consistent with GM platforms) Timing Mechanism Timing Component: Timing Belt (critical for service) 🔧 Transmission Standard Manual Transmission: 5-speed manual transmission Optional Automatic Transmission: 4-speed automatic transmission Features Transmission Fluid Type Manual: GL-4 gear oil (specific viscosity to be detailed in manual) Transmission Fluid Type Automatic: Dexron III/VI compatible ATF (Automatic Transmission Fluid) 📐 Dimensions Exterior Body Styles: Hatchback (e.g., 5-door) and Sedan (e.g., 4-door) Wheelbase Typical: Approx. 2480 mm (97.6 inches) Weights Curb Weight Range: Approx. 1050-1150 kg (2315-2535 lbs) 🛡️ Safety Features Ratings Crash Test Information: Refer to manual for specific NHTSA/IIHS ratings if available; generally reflects subcompact safety standards of the era. Active Features ABS: Available anti-lock braking system (ABS) Passive Features Airbags: Driver and front passenger airbags standard, side airbags may be optional depending on trim. 💡 Technology Features Infotainment Audio System: Basic AM/FM/CD stereo system with optional premium speakers and auxiliary input. Driver Assistance Cruise Control: Available cruise control depending on trim level. Connectivity Power Accessories: Power windows and power door locks available on higher trims. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 5,000 miles (8,000 km) or 6 months, refer to manual for specific engine type. Timing Belt Replacement Interval: Recommended every 60,000 to 90,000 miles (96,000 to 144,000 km) or 5-7 years, crucial to follow. Coolant Flush Interval: Typically every 2-3 years or 30,000-50,000 miles. Fluid Specifications Engine Oil Specification: API Service SN/SP, ILSAC GF-6A, SAE 5W-30 or 5W-40 (check manual for specific viscosity based on climate). Coolant Specification: GM-spec silicate-free or hybrid organic acid technology (HOAT) coolant, typically orange or yellow. Known Issues Common Problems: Timing...
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Chevy Chevrolet Aveo Workshop Service Repair Manual 2002-2006
🏷️ Basic Information
Identification
Make:
Chevrolet
Model:
Aveo
Model Years Covered:
2002, 2003, 2004, 2005, 2006
Region Of Origin:
South Korea (Daewoo Lanos platform)
Codes
Chassis Codes:
T200/T250 (depending on market and minor revisions)
👋 Introduction
Market Position
Target Audience:
DIY mechanics, independent repair shops, Chevrolet Aveo owners
Value Proposition:
Enables owners to perform dealership-level repairs and maintenance themselves, saving time and money.
Competitive Analysis
Manual Quality:
Factory-level detail, comprehensive coverage surpassing generic repair guides.
Key Features
Completeness:
Covers all engine types and all models within the specified production years.
User Friendliness:
Step-by-step instructions and clear illustrations make repairs accessible.
Digital Accessibility:
Instant download and broad device compatibility for immediate use.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Language:
English
File Format:
PDF
Total Pages:
>5000
Compatibility:
Windows, Mac, iOS (iPhone, iPad), Android
Distribution Method:
Instant Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, rebuilding, performance tuning, troubleshooting
Engine Performance:
Diagnosis, tuning, emission controls
Engine Management:
ECU diagnostics, sensor functions, wiring schematics
Fuel System:
Fuel injection, fuel pump, injectors, fuel filter replacement
Cooling System:
Radiator, thermostat, water pump, hoses, fan assembly
Ignition System:
Spark plugs, ignition coils, wiring, timing
Exhaust System:
Catalytic converter, mufflers, pipes, oxygen sensors
Transmission Manual:
Removal, installation, internal components, clutch service
Transmission Automatic:
Removal, installation, internal components, fluid service
Drivetrain:
CV joints, drive axles, wheel bearings
Brakes:
Hydraulic system, ABS, disc/drum service, pad/rotor replacement
Suspension:
Shock absorbers, struts, control arms, bushings, ball joints
Steering:
Power steering system, steering rack, tie rods
Electrical System:
Battery, charging system, starter, lighting, accessories
Wiring Diagrams:
Comprehensive schematics for all electrical systems
HVAC:
Air conditioning service, refrigerant capacities, heater core
Body And Chassis:
Body panel repair, interior trim, glass replacement
Sunroof:
Service and repair procedures for sunroof operation
Procedures Included
Maintenance:
Factory maintenance schedules, fluid changes, filter replacements
Troubleshooting:
Diagnostic trouble codes (DTCs), diagnostic trees, symptom-based troubleshooting
Repair:
Step-by-step repair instructions for all major systems
Rebuild:
Detailed engine and transmission overhaul procedures
Timing Belt:
Replacement procedures and service intervals
Alignment:
Front end alignment procedures and specifications
Torque Specifications:
Complete torque values for all fasteners
Vacuum Diagrams:
Vacuum routing diagrams for engine and accessories
Serpentine Belt:
Belt routing diagrams and replacement
Technical Depth
Diagnostic Capability:
Advanced diagnostics including computer diagnostic codes and trouble trees
Illustrative Content:
Hundreds of detailed illustrations and diagrams
Data Accuracy:
Factory-level specifications and data
Scope Of Repair:
Covers simple to complicated repairs, maintenance, rebuilding, refurbishing, and restoration
📊 Manual Specifications
File Format
PDF Quality:
Original Adobe document, perfect quality
PDF Features:
Fully indexed, bookmarked by topic, searchable text, zoomable images
Printability:
Printable in its entirety or select pages
Required Software:
Adobe PDF Reader, WinZip
Binding Type
Manual Delivery:
Digital (Instant Download)
Physical Format Equivalent:
Printable PDF, equivalent to factory paperback or digital access
Paper Type
Digital Format:
PDF (no physical paper type)
⚙️ Engine Specifications
Primary Engine
Engine Options Typical:
1.5L (4-cylinder) and 1.6L (4-cylinder) DOHC naturally aspirated engines
Performance
Horsepower Range Typical:
Approximately 90-100 hp (1.5L) to 100-110 hp (1.6L)
Torque Range Typical:
Approximately 95-105 lb-ft (1.5L) to 105-115 lb-ft (1.6L)
Fuel System
Fuel Delivery:
Electronic Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline
Engine Management
ECU Type:
GM ECU (specific model designation not provided, but consistent with GM platforms)
Timing Mechanism
Timing Component:
Timing Belt (critical for service)
🔧 Transmission
Standard
Manual Transmission:
5-speed manual transmission
Optional
Automatic Transmission:
4-speed automatic transmission
Features
Transmission Fluid Type Manual:
GL-4 gear oil (specific viscosity to be detailed in manual)
Transmission Fluid Type Automatic:
Dexron III/VI compatible ATF (Automatic Transmission Fluid)
📐 Dimensions
Exterior
Body Styles:
Hatchback (e.g., 5-door) and Sedan (e.g., 4-door)
Wheelbase Typical:
Approx. 2480 mm (97.6 inches)
Weights
Curb Weight Range:
Approx. 1050-1150 kg (2315-2535 lbs)
🛡️ Safety Features
Ratings
Crash Test Information:
Refer to manual for specific NHTSA/IIHS ratings if available; generally reflects subcompact safety standards of the era.
Active Features
ABS:
Available anti-lock braking system (ABS)
Passive Features
Airbags:
Driver and front passenger airbags standard, side airbags may be optional depending on trim.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM/CD stereo system with optional premium speakers and auxiliary input.
Driver Assistance
Cruise Control:
Available cruise control depending on trim level.
Connectivity
Power Accessories:
Power windows and power door locks available on higher trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000 miles (8,000 km) or 6 months, refer to manual for specific engine type.
Timing Belt Replacement Interval:
Recommended every 60,000 to 90,000 miles (96,000 to 144,000 km) or 5-7 years, crucial to follow.
Coolant Flush Interval:
Typically every 2-3 years or 30,000-50,000 miles.
Fluid Specifications
Engine Oil Specification:
API Service SN/SP, ILSAC GF-6A, SAE 5W-30 or 5W-40 (check manual for specific viscosity based on climate).
Coolant Specification:
GM-spec silicate-free or hybrid organic acid technology (HOAT) coolant, typically orange or yellow.
Known Issues
Common Problems:
Timing belt failures (if not replaced on schedule), minor electrical gremlins, suspension wear, catalytic converter issues.
📚 Vehicle History
Brand Heritage
Chevrolet Positioning:
Entry-level, value-oriented subcompact offering from Chevrolet.
Model Evolution
Platform Origin:
Based on the Daewoo Lanos platform, which was originally developed by Daewoo Motors.
Market Introduction:
Introduced as a replacement for older Chevrolet models in various markets, focusing on affordability and practicality.
Production
Manufacturing Locations:
Primarily manufactured in South Korea by GM Daewoo (later GM Korea).
🏆 Awards & Recognition
Recognitions
Market Perception:
Positioned as an affordable and economical option in the subcompact segment.
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