2004 CHEVROLET AVEO brake fluid

Service............................................................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of Your
Vehicle......................................................5-4
Fuel................................................................5-5
Gasoline Octane............................................5-5
Gasoline Specifications....................................5-5
California Fuel...............................................5-6
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-7
Filling Your Tank............................................5-8
Filling a Portable Fuel Container.....................5-10
Checking Things Under the Hood....................5-11
Hood Release..............................................5-11
Engine Compartment Overview.......................5-14
Engine Oil...................................................5-15
Engine Air Cleaner/Filter................................5-20
Automatic Transaxle Fluid..............................5-21
Manual Transaxle Fluid..................................5-21
Hydraulic Clutch...........................................5-22
Engine Coolant.............................................5-23Coolant Surge Tank Pressure Cap..................5-25
Engine Overheating.......................................5-25
Cooling System............................................5-28
Power Steering Fluid.....................................5-34
Windshield Washer Fluid................................5-35
Brakes........................................................5-36
Battery........................................................5-39
Jump Starting...............................................5-40
Headlamp Aiming...........................................5-45
Bulb Replacement..........................................5-45
Halogen Bulbs..............................................5-45
Headlamps..................................................5-46
Front Turn Signal and Parking Lamps................5-46
Turn Signal Lamps (Side)..............................5-47
Fog Lamps..................................................5-48
Sidemarker Lamps (Front)..............................5-48
Sidemarker Lamps (Rear)..............................5-49
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps.........................................5-49
Windshield Wiper Blade Replacement..............5-50
Section 5 Service and Appearance Care
5-1

A. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-20.
B. Engine Oil Fill Cap. See “When to Add Engine Oil”
underEngine Oil on page 5-15.
C. Engine Oil Dipstick. See “Checking Engine Oil”
underEngine Oil on page 5-15.
D. Brake Fluid Reservoir. See “Brake Fluid” under
Brakes on page 5-36.
E. Automatic Transaxle Dipstick. SeeAutomatic
Transaxle Fluid on page 5-21.
F. Engine Coolant Surge Tank. SeeCooling System on
page 5-28.
G. Engine Compartment Fuse Block. See “Engine
Compartment Fuse Block” underFuses and Circuit
Breakers on page 5-85.
H. Battery. SeeBattery on page 5-39.
I. Power Steering Fluid Reservoir. SeePower Steering
Fluid on page 5-34.
J. Windshield Washer Fluid Reservoir. SeeWindshield
Washer Fluid on page 5-35.Engine Oil
If the oil pressure light
appears on the instrument
cluster, it means you
need to check your engine
oil level right away.
For more information, seeOil Pressure Light on
page 3-32.
You should check your engine oil level regularly; this is
an added reminder.
Checking Engine Oil
It is a good idea to check your engine oil every time you
get fuel. In order to get an accurate reading, the oil
must be warm and the vehicle must be on level ground.
The engine oil dipstick handle is a yellow loop.
SeeEngine Compartment Overview on page 5-14for
the location of the engine oil dipstick.
Turn off the engine and give the oil several minutes to
drain back into the oil pan. If you do not do this, the
oil dipstick might not show the actual level.
Pull the dipstick and clean it with a paper towel or cloth,
then push it back in all the way. Remove it again,
keeping the tip down and check the level.
5-15

Hydraulic Clutch
There is one reservoir for both the brake and the
hydraulic clutch fluid. SeeBrakes on page 5-36for
more information.
The hydraulic clutch linkage in your vehicle is
self-adjusting. The master cylinder reservoir is filled
with hydraulic fluid.
A fluid loss in this system could indicate a problem.
Have the system inspected and repaired.
When to Check and What to Use
Refer to the Maintenance Schedule to determine how
often you should check the fluid level in your master
cylinder reservoir and for the proper fluid. SeePart B:
Owner Checks and Services on page 6-19and
Part D: Recommended Fluids and Lubricants on
page 6-26.
How to Check and Add Fluid
To check the fluid level, look on the side of the reservoir.
If the fluid reaches the MAX (A) mark on the reservoir,
the fluid level is correct. The reservoir is located near
the back of the engine compartment on the driver’s side
of the vehicle. SeeEngine Compartment Overview
on page 5-14for more information on location.
5-22

Brakes
Brake Fluid
Your vehicle has one reservoir for both the brake and
clutch hydraulic systems. It is filled with DOT-3
brake fluid. SeeEngine Compartment Overview on
page 5-14for the location of the reservoir.
There are only two reasons why the brake fluid level
in the reservoir might go down. The first is that the brake
fluid goes down to an acceptable level during normal
brake lining wear. When new linings are put in, the fluid
level goes back up. The other reason is that fluid is
leaking out of the brake or clutch system. If it is,
you should have your brake/clutch system fixed, since a
leak means that sooner or later your brakes will not
work well, or will not work at all.
So, it is not a good idea to “top off” your brake fluid.
Adding brake fluid will not correct a leak. If you add fluid
when your linings are worn, then you will have too
much fluid when you get new brake linings. You should
add or remove brake fluid, as necessary, only when
work is done on the brake hydraulic system.
{CAUTION:
If you have too much brake uid, it can spill on
the engine. The uid will burn if the engine is
hot enough. You or others could be burned,
and your vehicle could be damaged. Add brake
uid only when work is done on the brake
hydraulic system.
When your brake fluid falls to a low level, your brake
warning light will come on. SeeBrake System Warning
Light on page 3-20.
What to Add
When you do need brake fluid, use only DOT-3 brake
fluid. Use new brake fluid from a sealed container only.
SeePart D: Recommended Fluids and Lubricants on
page 6-26.
Always clean the brake fluid reservoir cap and the area
around the cap before removing it. This will help keep
dirt from entering the reservoir.
5-36

Capacities and Specications
The following approximate capacities are given in English and metric conversions. Please refer toPart D:
Recommended Fluids and Lubricants on page 6-26for more information.
ApplicationCapacities
English Metric
Air Conditioning Refrigerant R134a 1.48 lbs 0.67 kg
Brake/Clutch Fluid 0.51 quarts 0.48 L
Cooling System 7.4 quarts 7.0 L
Engine Oil with Filter 3.96 quarts 3.75 L
Fuel Tank 11.9 gallons 45.0 L
Transaxle, Automatic
Complete Overhaul 6.2 quarts 5.87 L
Transaxle, Manual
Complete Drain and Refill 1.9 quarts 1.8 L
Wheel Nut Torque 81 lb ft 110Y
All capacities are approximate. When adding, be sure to fill to the appropriate level, as recommended in this
manual.
Engine Specications
Engine VIN Code Transaxle Spark Plug Gap
1.6L L4 (L91) 6 Automatic and Manual 0.039-0.043 inch (1.0-1.1 mm)
5-91

Maintenance Schedule......................................6-2
Introduction...................................................6-2
Maintenance Requirements..............................6-2
Your Vehicle and the Environment....................6-2
How This Section is Organized.........................6-3
Part A: Scheduled Maintenance Services...........6-4
Using Your Maintenance Schedule....................6-4
Selecting the Right Schedule...........................6-5
Short Trip/City Scheduled Maintenance..............6-7
Long Trip/Highway Scheduled Maintenance......6-14
Part B: Owner Checks and Services................6-19
At Each Fuel Fill..........................................6-19
At Least Once a Month.................................6-19At Least Twice a Year...................................6-20
At Least Once a Year...................................6-21
Part C: Periodic Maintenance Inspections.........6-24
Steering, Suspension and Front Drive Axle
Boot and Seal Inspection............................6-24
Exhaust System Inspection............................6-24
Fuel System Inspection..................................6-25
Engine Cooling System Inspection...................6-25
Throttle System Inspection.............................6-25
Brake System Inspection................................6-25
Part D: Recommended Fluids
and Lubricants..........................................6-26
Part E: Maintenance Record...........................6-28
Section 6 Maintenance Schedule
6-1

Selecting the Right Schedule
First you will need to decide which of the two schedules
is right for your vehicle. Here is how to decide which
schedule to follow:
Short Trip/City Denition
Follow the Short Trip/City Scheduled Maintenance if any
one of these conditions is true for your vehicle:
•Most trips are less than 5 miles (8 km). This is
particularly important when outside temperatures
are below freezing.
•Most trips include extensive idling, such as frequent
driving in stop-and-go traffic.
•If the vehicle is used for delivery service, police,
taxi or other commercial application.
One of the reasons you should follow this schedule if
you operate your vehicle under any of these conditions
is that these conditions cause engine oil to break
down sooner.
Short Trip/City Intervals
Every 3,000 Miles (5 000 km):Engine Oil and Filter
Change (or 3 months, whichever occurs first).
Every 6,000 Miles (10 000 km):Tire Rotation.
Every 15,000 Miles (25 000 km):Engine Air Cleaner
Filter Inspection. Passenger Compartment Air Filter
Replacement. Drive Belts Inspection.
Every 30,000 Miles (50 000 km):Engine Air Cleaner
Filter Replacement. Spark Plug Replacement. Cooling
System Service. EVAP System Service. PCV System
Service. Timing Belt Inspection. Brake/Clutch Fluid
Change (or 24 months, whichever occurs first).
Every 60,000 Miles (100 000 km):Spark Plug Wire
Replacement. Timing Belt Replacement.
Every 90,000 Miles (150 000 km):Fuel Filter
Replacement.
These intervals only summarize maintenance services.
Be sure to follow the complete scheduled maintenance
on the following pages.
6-5

Long Trip/Highway Denition
Follow this scheduled maintenanceonlyif none of
the conditions from the Short Trip/City Scheduled
Maintenance are true. Do not use this schedule if the
vehicle is used for trailer towing, driven in a dusty area
or used off paved roads. Use the Short Trip/City
schedule for these conditions.
Driving a vehicle with a fully warmed engine under
highway conditions will cause engine oil to break down
slower.
Long Trip/Highway Intervals
Every 7,500 Miles (12 500 km):Engine Oil and Filter
Change (or every 12 months, whichever occurs
first). Tire Rotation.
Every 15,000 Miles (25 000 km):Engine Air Cleaner
Filter Inspection. Passenger Compartment Air Filter
Replacement. Drive Belts Inspection.
Every 30,000 Miles (50 000 km):Engine Air Cleaner
Filter Replacement. Spark Plug Replacement. Cooling
System Service. EVAP System Service. PCV System
Service. Timing Belt Inspection. Brake/Clutch Fluid
Change (or 24 months, whichever occurs first).
Every 60,000 Miles (100 000 km):Spark Plug Wire
Replacement. Timing Belt Replacement.
Every 90,000 Miles (150 000 km):Fuel Filter
Replacement.
These intervals only summarize maintenance services.
Be sure to follow the complete scheduled maintenance
on the following pages.
6-6