Aveo 2008
Body Repair Manual
0. SERVICE NOTICE
1. GENERAL INFORMATION
2. PREPARATIONS OF BODYWORK
3. WELDING AND TOOLS
4. FRONT
5. ROOF, BACK PANEL AND REAR FLOOR PANEL
6. FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER
7. FENDER, HOOD, TAILGATE AND TRUNK LID
8. BODY DIMENSION
9. SEALING, CAULKING AND DEADNER
10. RUST PREVENTION
Electrical Wiring Diagrams
LHD
1. HOW TO READ ELECTRICAL WIRING DIAGRAM
2. POSITION OF CONNECTORS AND GROUNDS
3. WIRING DIAGRAM FOR POWER SUPPLIES
4. USAGE AND CAPACITY OF FUSES IN FUSE BLOCK
5. ELECTRICAL WIRING DIAGRAMS
1. STARTING & CHARGING SYSTEM
2. ECM (ENGINE CONTROL MODULE) : MR - 140
3. ECM (ENGINE CONTROL MODULE) : HV - 240
4. ECM (ENGINE CONTROL MODULE) : SIRIUS D42
5. TCM (TRANSMISSION CONTROL MODULE)
6. AIR CONDITIONER
7. FATC (FULL AUTOMATIC TEMPERATURE CONTROL CIRCUIT)
8. RADIATOR COOLING FAN CIRCUIT
9. HEAD LAMP & HEAD LAMP LEVELING DEVICE (HLLD) CIRCUIT
10. DRL (DAY TIME RUNNING LIGHT) CIRCUIT
11. ILLUMINATION CIRCUIT
12. FRONT & REAR FOG LAMP CIRCUIT
13. HAZARD & TURN SIGNAL LAMP CIRCUIT
14. STOP LAMP, CENTER HIGH MOUNT STOP LAMP (CHMSL) & REVERSE LAMP CIRCUIT
15. HORN, POWER JACK, ASHTRAY LAMP & CIGAR LIGHTER CIRCUIT
16. LAMPS (ROOM, DOOR OPENING WARNING) CIRCUIT
17. CHIME BELL, SEAT BELT & KEY REMIND SWITCH CIRCUIT
18. WIPER CIRCUIT
19. REAR WINDOW DEFROSTER & OSRV MIRROR HEATING SYSTEM CIRCUIT
20. ELECTRIC OSRV MIRROR CIRCUIT
21. POWER WINDOW CIRCUIT
22. CENTRAL DOOR LOCKING SYSTEM CIRCUIT
23. CLUSTER
24. CLOCK
25. AUDIO CIRCUIT
26. ANTI LOCK BRAKE SYSTEM (ABS)
27. AIR BAG (SDM : SENSING & DIAGNOSTIC MODULE)
28. SUN ROOF CIRCUIT
29. IMMOBILIZER SYSTEM CIRCUIT
30. ANTI-THEFT CONTROL SYSTEM CIRCUIT
31. BATTERY SAVER CIRCUIT
RHD
1. HOW TO READ ELECTRICAL WIRING DIAGRAM
2. POSITION OF CONNECTORS AND GROUNDS
3. WIRING DIAGRAM FOR POWER SUPPLIES
4. USAGE AND CAPACITY OF FUSES IN FUSE BLOCK
5. ELECTRICAL WIRING DIAGRAMS
1. STARTING & CHARGING SYSTEM
2. ECM (ENGINE CONTROL MODULE) : MR - 140
3. ECM (ENGINE CONTROL MODULE) : HV - 240
4. ECM (ENGINE CONTROL MODULE) : SIRIUS D42
5. TCM (TRANSMISSION CONTROL MODULE)
6. AIR CONDITIONER
7. FATC (FULL AUTOMATIC TEMPERATURE CONTROL CIRCUIT)
8. RADIATOR COOLING FAN CIRCUIT
9. HEAD LAMP & HEAD LAMP LEVELING DEVICE (HLLD) CIRCUIT
10. ILLUMINATION CIRCUIT
11. FRONT & REAR FOG LAMP CIRCUIT
12. HAZARD & TURN SIGNAL LAMP CIRCUIT
13. STOP LAMP, CENTER HIGH MOUNT STOP LAMP (CHMSL) & REVERSE LAMP CIRCUIT
14. HORN, POWER JACK, ASHTRAY LAMP & CIGAR LIGHTER CIRCUIT
15. LAMPS (ROOM, DOOR OPENING WARNING) CIRCUIT
16. CHIME BELL, SEAT BELT & KEY REMIND SWITCH CIRCUIT
17. WIPER CIRCUIT
18. REAR WINDOW DEFROSTER & OSRV MIRROR HEATING SYSTEM CIRCUIT
19. ELECTRIC OSRV MIRROR CIRCUIT
20. POWER WINDOW CIRCUIT
21. CENTRAL DOOR LOCKING SYSTEM CIRCUIT
22. CLUSTER
23. CLOCK
24. AUDIO CIRCUIT
25. ANTI LOCK BRAKE SYSTEM (ABS)
26. AIR BAG (SDM : SENSING & DIAGNOSTIC MODULE)
27. SUN ROOF CIRCUIT
28. IMMOBILIZER SYSTEM CIRCUIT
29. ANTI-THEFT CONTROL SYSTEM CIRCUIT
30. BATTERY SAVER CIRCUIT
Labour Time Guide
0. General Information
1. Engine
SOHC ENGINE MECHANICAL
DOHC ENGINE MECHANICAL
ENGINE COOLING
ENGINE ELECTRICAL
ENGINE CONTROLS
ENGINE INTAKE & EXHAUST
2. Suspension
FRONT SUSPENSION
REAR SUSPENSION
TIRES & WHEEL
3. Driveline Axle
4. Brakes
HYDRAULIC BRAKE
MASTER CYLINDER & POWER BOOSTER
FRONT BRAKES
REAR BRAKES
ANTI-LOCK BRAKES SYSTEM
PARKING BRAKES
5. Transmissions/Transaxle
ZF 16HP AUTO TRANSAXLE
AISIN AUTO TRANSAXLE
FIVE-SPEED MANUAL TRANSAXLE: D16, D20
FIVE-SPEED MANUAL TRANSAXLE: Y4M
CLUTCH
6. Steering
POWER STEERING SYSTEM
MANUAL STEERING GEAR
STEERING WHEEL & COLUMN
7. (HVAC) Heating, Ventilation, and Air Conditioning
HEATING & VENTILATION
HVAC CONTROL
8. Restraints
SEAT BELTS
SUPPLEMENTAL INFLATABLE RESTRAINTS
9. Body and Accessories
BODY WIRING SYSTEM
LIGHTING SYSTEM
WIPER/WASHER SYSTEM
INSTRUMENT DRIVER SYSTEM
AUDIO & ANTI-THEFT SYSTEM
INTERIOR TRIM
SEATS
GLASS & MIRRORS
EXTERIOR PARTS
BUMPERS & FASCIAS
BODY &ACCESSORIES (DOORS)
ROOF
BODY FRONT END
BODY REAR END
10. Paint
Paint
Paint Exterior
Pre-Delivery Inspection
FOREWORD
GENERAL INTRODUCTION
ENGINE COMPARTMENT
BODY - ACCESSORIES
UNDER VEHICLE
ROAD TEST
APPEARANCE
ANNEX
Service Manual
0. General Information
1. Engine
GENERAL ENGINE INFORMATION
1.2 SOHC ENGINE MECHANICAL
SPECIFICATIONS
SPECIAL TOOLS
COMPONENT LOCATOR
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Oil Pump
Oil Pan
Engine Mount
Intake Manifold
Exhaust Manifold
Engine
UNIT REPAIR
GENERAL DESCRIPTION AND SYSTEM OPERATION
DOHC ENGINE MECHANICAL
SPECIFICATIONS
SPECIAL TOOLS
COMPONENT LOCATOR
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Oil Pump
Oil Pan
Engine Mount
Intake Manifold
Exhaust Manifold
Camshaft Gears
Rear Timing Belt Cover
Engine
Pistons and Rods
UNIT REPAIR
GENERAL DESCRIPTION AND SYSTEM OPERATION
ENGINE COOLING
ENGINE ELECTRICAL
SPECIFICATIONS
SCHEMATIC AND ROUTING DIAGRAMS
COMPONENT LOCATOR
DIAGNOSIS
MAINTENANCE AND REPAIR
GENERAL DESCRIPTION AND SYSTEM OPERATION
ENGINE CONTROLS
SPECIFICATIONS
SCHEMATIC AND ROUTING DIAGRAMS
COMPONENT LOCATOR
DIAGNOSIS
SYSTEM DIAGNOSIS
Diagnostic Aids
Idle Learn Procedure
TEC (TOOTH ERROR CORRECTION) Learn Procedure
ON-Board Diagnostic (EOBD) System Check (1.2L SOHC)
ON-Board Diagnostic (EOBD) System Check (1.4L DOHC)
Multiple ECM Information Sensor DTCs Set
Engine Cranks But Will Not Run (1.2L SOHC)
Engine Cranks But Will Not Run (1.4L DOHC)
No Malfunction Indicator Lamp (1.2L SOHC)
No Malfunction Indicator Lamp (1.4L DOHC)
Malfunction Indicator Lamp On Steady (1.2L SOHC)
Malfunction Indicator Lamp on Steady (1.4L DOHC)
Fuel System Diagnosis
Fuel Pump Relay Circuit Check (1.2L SOHC)
Fuel Pump Relay Circuit Check (1.4L DOHC)
Main Relay Circuit Check (1.2L SOHC)
Manifold Absolute Pressure Check (1.2L SOHC)
Manifold Absolute Pressure Check (1.4L DOHC)
Idle Air Control System Check (1.2L SOHC)
Idle Air Control System Check (1.4L DOHC)
Ignition System Check (1.2L SOHC)
Ignition System Check (1.4L DOHC)
Engine Cooling Fan Circuit Check - Single Fan (1.2L SOHC)
Engine Cooling Fan Circuit Check - Single Fan (1.4L DOHC)
Data Link Connector Diagnosis (1.2L SOHC)
Data Link Connector Diagnosis (1.4L DOHC)
Fuel Injector Coil Test
Fuel Injector Balance Test
TROUBLE CODE DIAGNOSIS (1.2L SOHC)
Clearing Trouble Codes
Diagnostic Trouble Codes (1.2L SOHC)
Diagnostic Trouble Code (DTC)
P0030 H02S (Sensor 1) Heater Circuit Not Functioning
P0036 H02S (Sensor 2) Heater Circuit Not Functioning
P0107 Manifold Absolute Pressure Sensor Low Voltage
P0108 Manifold Absolute Pressure Sensor High Voltage
P0131 HO2S (Sensor 1) Low Voltage
P0137 HO2S (Sensor 2) Low Voltage
P0132 HO2S (Sensor 1) High Voltage
P0138 HO2S (Sensor 2) High Voltage
P0261 Injector 1 Low Voltage
P0264 Injector 2 Low Voltage
P0267 Injector 3 Low Voltage
P0270 Injector 4 Low Voltage
P0262 Injector 1 High Voltage
P0265 Injector 2 High Voltage
P0268 Injector 3 High Voltage
P0271 Injector 4 High Voltage
P0351 Ignition Control Circuit 1 and 4 Fault
P0352 Ignition Control Circuit 2 and 3 Fault
P0400 Exhaust Gas Recirculation Flow Out of Limit
P0401 Exhaust Gas Recirculation Blocked
P0444 EVAP Purge Control Circuit No Signal
P0445 EVAP Purge Control Circuit Fault
P0480 - Low Speed Cooling Fan Relay Circuit Fault
P0481 - High Speed Cooling Fan Relay Circuit Fault
P0601 - Engine Control Module Checksum Error
P0604 - Engine Control Module RAM Error
P0605 - Engine Control Module Write Error
P1535 - Evaporator Temperature Sensor High Voltage
P1536 - Evaporator Temperature Sensor Low Voltage
DTC P0112
DTC P0113
DTC P0117
DTC P0118
DTC P0122
DTC P0123
DTC P0133
DTC P0140
DTC P0171
DTC P0172
DTC P0222
DTC P0223
DTC P0300
DTC P0327
DTC P0335
DTC P0336
DTC P0337
DTC P0341
DTC P0342
DTC P0403
DTC P0404
DTC P0405
DTC P0406
DTC P0420
DTC P0462
DTC P0463
DTC P0501
DTC P0510
DTC P0562
DTC P0563
DTC P0628
DTC P0629
DTC P0650
DTC P0656
DTC P1390
DTC P1396
DTC P1610
DTC P1611
DTC P1628
DTC P1629
DTC P1650
DTC P2101
DTC P2118
DTC P2119
TROUBLE CODE DIAGNOSIS (1.4 DOHC)
Clearing Trouble Codes
Diagnostic Trouble Codes (1.4 DOHC)
DTC P0016
DTC P0106
DTC P0107
DTC P0108
DTC P0112
DTC P0113
DTC P0117
DTC P0118
DTC P0122
DTC P0123
DTC P0131
DTC P0132
DTC P0133
DTC P0134
DTC P0135
DTC P0137
DTC P0138
DTC P0140
DTC P0141
DTC P0171
DTC P0172
DTC P0201
DTC P0202
DTC P0203
DTC P0204
DTC P0300
DTC P0315
DTC P0317
DTC P0324
DTC P0325
DTC P0335
DTC P0336
DTC P0340
DTC P0351
DTC P0352
DTC P0401
DTC P0402
DTC P0404
DTC P0405
DTC P0406
DTC P0420
DTC P042E
DTC P0443
DTC P0461
DTC P0462
DTC P0463
DTC P0502
DTC P0506
DTC P0507
DTC P0532
DTC P0533
DTC P0562
DTC P0563
DTC P0601
DTC P0602
DTC P0606
DTC P0660
DTC P0700
DTC P1133
DTC P1134
DTC P1166
DTC P1391
DTC P1392
DTC P1393
DTC P1396
DTC P1397
DTC P1631
DTC P2297
DTC P2610
DTC U0101
DTC U0167
SYMPTOM DIAGNOSIS
MAINTENANCE AND REPAIR
GENERAL DESCRIPTION AND SYSTEM OPERATION
ENGINE EXHAUST
2. Suspension
SUSPENSION DIAGNOSIS
WHEEL ALIGNMENT
FRONT SUSPENSION
REAR SUSPENSION
TIRES AND WHEELS
3. Driveline Axle
AUTOMATIC TRANSAXLE DRIVE AXLE
MANUAL TRANSAXLE DRIVE AXLE
4. Brakes
HYDRAULIC BRAKES
MASTER CYLINDER
POWER BOOSTER
FRONT DISC BRAKES
REAR DRUM BRAKES
ANTILOCK BRAKE SYSTEM
SPECIFICATIONS
SCHEMATIC AND ROUTING DIAGRAMS
COMPONENT LOCATOR
DIAGNOSIS
Diagnostic Trouble Code AND Description
Diagnostic Circuit Check
No Communication with HECU
ABS Warning Lamp Inoperative/No DTC Set
ABS Warning Lamp On/No DTC Set
Brake Warning Lamp On
Brake Warning Lamp Inoperative/No DTC Set
C1101 Battery Voltage Too High
C1102 Battery Voltage Too Low
C1200 Left Front Wheel Speed Sensor Circuit Open or Shorted
C1201 Left Front Wheel Speed Excessive Variation
C1202 Left Front Wheel Speed Sensor No Signal
C1203 Right Front Wheel Speed Sensor Circuit Open or Shorted
C1204 Right Front Wheel Speed Excessive Variation
C1205 Right Front Wheel Speed Sensor No Signal
C1206 Left Rear Wheel Speed Sensor Circuit Open or Shorted
C1207 Left Rear Wheel Speed Excessive Variation
C1208 Left Rear Wheel Speed Sensor No Signal
C1209 Right Rear Wheel Speed Sensor Circuit Open or Shorted
C1210 Right Rear Wheel Speed Excessive Variation
C1211 Right Rear Wheel Speed Sensor No Signal
C1604 HECU Internal Fault
C2112 Valve Relay or Fuse Failure
C2402 Pump Motor Failure
MAINTENANCE AND REPAIR
GENERAL DESCRIPTION AND SYSTEM OPERATION
PARKING BRAKE
5. Transmissions/Transaxle
AISIN AUTOMATIC TRANSAXLE
SPECIFICATIONS
SPECIAL TOOLS
SCHEMATIC DIAGRAMS
COMPONENT LOCATOR
DIAGNOSIS
DIAGNOSTIC TROUBLE CODE DIAGNOSIS
Diagnostic Trouble Code Chart
DTC P0562
DTC P0563
DTC P0601
DTC P0604
DTC P0705
DTC P0706
DTC P0711
DTC P0712
DTC P0713
DTC P0717
DTC P0722
DTC P0741
DTC P0742
DTC P0751
DTC P0752
DTC P0756
DTC P0757
DTC P0787
DTC P0788
DTC P0962
DTC P0963
DTC P0973
DTC P0974
DTC P0976
DTC P0977
DTC P2769
DTC P2770
DTC U0001
DTC U0100
DTC U0401
MAINTENANCE AND REPAIR
UNIT REPAIR
Major Component Disassembly
Major Component Assembly
Oil Pump
Direct Clutch
Planetary Ring Gear
One-Way Clutch
Forward and Reverse Clutch
Counter Driven Gear
Valve Body
Differential Case
GENERAL DESCRIPTION AND SYSTEM OPERATION
FIVE-SPEED MANUAL TRANSAXLE
SPECIFICATIONS
SPECIAL TOOLS
DIAGNOSIS
COMPONENT LOCATORS
MAINTENANCE AND REPAIR
UNIT REPAIR
Major Component Disassembly
Input Shaft and Cluster Gear
Mainshaft
Housing Case
Differential
Major Component Assembly
GENERAL DESCRIPTION AND SYSTEM OPERATION
FIVE-SPEED MANUAL TRANSAXLE (Y4M)
SPECIFICATIONS
SPECIAL TOOLS
DIAGNOSIS
COMPONENT LOCATORS
MAINTENANCE AND REPAIR
GENERAL DESCRIPTION AND SYSTEM OPERATION
CLUTCH (HYDRAULIC TYPE)
CLUTCH (CABLE TYPE)
6. Steering
POWER STEERING SYSTEM
POWER STEERING PUMP
POWER STEERING GEAR
MANUAL STEERING GEAR
STEERING WHEEL AND COLUMN
7. (HVAC) Heating, Ventilation, and Air Conditioning
HEATING AND VENTILATION SYSTEM
MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
SPECIFICATIONS
SPECIAL TOOLS
SCHEMATIC AND ROUTING DIAGRAMS
DIAGNOSIS
COMPONENT LOCATOR
MAINTENANCE AND REPAIR
UNIT REPAIR
GENERAL DESCRIPTION AND SYSTEM OPERATION
AUTOMATIC TEMPERATURE CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
SPECIFICATIONS
SCHEMATIC AND ROUTING DIAGRAMS
DIAGNOSIS
MAINTENANCE AND REPAIR
GENERAL DESCRIPTION AND SYSTEM OPERATION
8. Restraints
SEAT BELTS
SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
SPECIFICATIONS
SPECIAL TOOLS
SCHEMATIC AND ROUTING DIAGRAMS
DIAGNOSIS
Diagnostic Trouble Code (DTC)
Scan Tool Diagnostics
SIR Diagnostic System Check
Sensing and Diagnostic Module (SDM) Integrity Check
DTC B1101
DTC B1102
DTC B1103
Diagnostic TIC Trouble Code (DTC) B1346
DTC B1347
DTC B1348
DTC B1349
DTC B1352
DTC B1353
DTC B1354
DTC B1355
DTC B1361
DTC B1362
DTC B1363
DTC B1364
DTC B1367
DTC B1368
DTC B1369
DTC B1370
DTC B1378
DTC B1379
DTC B1380
DTC B1381
DTC B1382
DTC B1383
DTC B1384
DTC B1385
DTC B1395
DTC B1400
DTC B1401
DTC B1402
DTC B1403
DTC B1404
DTC B1405
DTC B1409
DTC B1410
DTC B1414
DTC B1415
DTC B1451
DTC B1453
DTC B1620
DTC B1650
DTC B1651
DTC B1652
DTC B1657
DTC B2500
DTC B2502
MAINTENANCE AND REPAIR
GENERAL DESCRIPTION AND SYSTEM OPERATION
9. Body and Accessories
BODY WIRING SYSTEM
LIGHTING SYSTEMS
SPECIFICATIONS
SCHEMATIC AND ROUTING DIAGRAMS
DIAGNOSIS
MAINTENANCE AND REPAIR
GENERAL DESCRIPTION AND SYSTEM OPERATION
HORN
WIPERS/WASHER SYSTEMS
INSTRUMENTATION/DRIVER INFORMATION
SPECIFICATIONS
SCHEMATIC AND ROUTING DIAGRAMS
DIAGNOSIS
MAINTENANCE AND REPAIR
GENERAL DESCRIPTION AND SYSTEM OPERATION
AUDIO SYSTEMS
INTERIOR TRIM
SEATS
WATERLEAKS
WINDNOISE
SQUEAKS AND RATTLES
GLASS AND MIRRORS
EXTERIOR TRIM
FRAME AND UNDERBODY
BUMPERS AND FASCIAS
DOORS
ROOF
BODY FRONT END
BODY REAR END
REMOTE KEYLESS ENTRY AND ANTI-THEFT SYSTEM
IMMOBILIZER ANTI-THEFT SYSTEM