Chevrolet Aveo 2012 User Manual

Name: Chevrolet Aveo 2012
Brand: Chevrolet
SKU: 3868831
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CHEVROLET SONIC 2012 BODY REPAIR MANUAL

CHEVROLET SONIC 2012

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FOREWORD

2012 Chevrolet Aveo Service Manual

Volume 1

This manual provides information on the diagnosis, the service procedures, the adjustments, and the specifications for the 2012 Chevrolet Aveo.

The technicians who understandmaterialthin this manu	al and in the appropriate Dealer Service Bulletins better serve the vehicle
owners.

When this manual refers to a brand name, a part number, or a specific tool, you may use an equivalent product in place of the recommended item. All information, illustrations, and specifications in this manual are based on the latest product information available at the time of publication approval. General Motors reserves the right to make changes attimeanywithout notice.

Published by

North American Operations

General Motors LLC

Warren, Michigan 48090

The information cutoff date is 09/28/09.

LITHO IN U.S.A.

No part of this manual may be reproduced, stored in any retrieval system, or transmitted in any form or by any means including but not limited to electronic, mechanical, photocopying, and recording without the prior written permission of General Motors LLC. This applies to all text, illustrations, and tables.

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CHEVROLET

SONIC

BODY REPAIR MANUAL 2012

HATCHBACK

SEDAN

Title	Section

PREFACE	00
	01
GENERAL INFORMATION	01
	02
BODY HARDWARE AND TRIM	02
	03
BODY REPAIR	03
BODY SYSTEMS	04
ROOF	05
SEATBELTS	06
SEATS	07
RESTRAINTS	08
STEERING	09
	10
SUSPENSION	10
	11
HVAC SYSTEM	11

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	Index	PREFACE	0-0

Definition of Danger, Warning, Caution, and Note Approved Equipment for Collision Repair Warning Batteries Produce Explosive Gases Warning Battery Disconnect Warning

Brake Fluid Irritant Warning Brake Fluid Warning Collision Sectioning Warning Cracked Window Warning Defroster Outlet Warning Electric Coolant Fan Warning Exhaust Service Warning Eye Protection Warning

Gasoline/Gasoline Vapors Warning Glass and Sheet Metal Handling Warning Halogen Bulb Warning

Hood Hold-Open Device Warning Parking Brake and Drive Wheels Warning Protective Goggles and Glove Warning Radiator Cap Removal Warning Relieving Fuel Pressure Warning

Repair Material Curing Warning

Safety Glasses and Compressed Air Warning

Sensing and Diagnostic Module Voltage after Ignition is Turned Off Warning Servicing the SIR System Warning

SIR Inflator Module Handling and Storage Warning

Safety Glasses Warning

Safety Goggles and Fuel Warning

Sensing and Diagnostic Module Handling Warning SIR Seatbelt Pretensioner Handling Warning

SIR Warning

Torque-to-Yield Fastener Warning

Brake Fluid Damage to Electrical Connections Caution

Brake Fluid Effects on Paint and Electrical Components Caution Catalytic Converter Movement Caution

Clearcoat/Ultraviolet Screeners Caution

Component Fastener Tightening Caution

Exterior Trim Emblem Removal Caution Fastener Caution

Fuel Tank Strap Fastener Caution

Ignition OFF When Disconnecting Battery Caution Installing Hoses without Twists or Bends Caution Liftgate Assist Rod Caution

Steering Column in Lock Position Caution

Steering Wheel in the Full Turn Position Caution Steering Wheel Straight and Column Locked Caution Tape Corners of Panel Caution

Torque-to-Yield Fastener Caution

Vehicle Lifting and Jacking Caution Windshield Installation Caution

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Caution Notices	PREFACE	0-0

Definition of Danger, Warning, Caution, and Note

The diagnosis and repair procedures in a GM Service Manual contain both general and specific Dangers, Warnings, Cautions, Notes or Importants. GM is dedicated to the presentation of service information that helps the technician to diagnose and repair the systems necessary for the proper operation of the vehicle, however, certain procedures may present a hazard to the technician if they are not followed in the recommended manner . Dangers, Warnings, Cautions and Notes or Importants are elements designed to prevent these hazards, however, not all hazards can be foreseen. This information is placed at strategic locations within the service manual. This information is designed to prevent the following from occurring:

•Serious bodily injury or death to the technician

•Damage to the vehicle

•Unnecessary vehicle repairs

•Unnecessary component replacement

•Improper repair or replacement of vehicle components.

•Any warning or caution that appears in this service category is referenced from the individual service categories.

DANGER Defined

When encountering a DANGER, you will be asked to take a necessary action or not to take a prohibited action. If a DANGER is not heeded, the following consequences may occur:

•Serious bodily injury or death to the technician

•Serious bodily injury or death to other technicians in the workplace area

WARNING Defined

When encountering a WARNING, you will be asked to take a necessary action or not to take a prohibited action. If a WARNING is not heeded, the following consequences may occur:

•Serious bodily injury to the technician

•Serious bodily injury to other technicians in the workplace area

•Serious bodily injury to the driver and/or passenger(s) of the vehicle, if the vehicle has been improperly repaired

CAUTION Defined

CAUTIONS call special attention to a necessary action or to a prohibited action. If a CAUTION is not heeded, the following consequences may occur:

•Damage to the vehicle

•Unnecessary vehicle repairs

•Unnecessary component replacement

•Improper operation or performance of the system or component under repair

•Damage to any systems or components which are dependent upon the proper operation of the system or component under repair

•Improper operation or performance of any systems or components which are dependent upon the proper operation or performance of the system or component under repair

•Damage to fasteners, basic tools, or special tools

•The leakage of coolant, lubricant, or other vital fluids

NOTE or IMPORTANT Defined

NOTE and IMPORTANT statements emphasize a necessary characteristic of a diagnostic or repair procedure. NOTE or IMPORTANT statements are designed to do the following:

•Clarify a procedure

•Present additional information for accomplishing a procedure

•Give insight into the reason or reasons for performing a procedure in the manner recommended

•Present information that will help to accomplish a procedure in a more effective manner

•Present information that gives the technician the benefit of past experience in accomplishing a procedure with greater ease

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Caution Notices	PREFACE	0-0

Approved Equipment for Collision Repair Warning

Warning: To avoid personal injury when exposed to welding flashes or to galvanized (Zinc Oxide) metal toxic fumes while grinding/cutting on any type of metal or sheet molded compound, you must work in a properly ventilated area, wearing an approved respirator, eye protection , earplugs, welding gloves, and protective clothing.

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Caution Notices	PREFACE	0-0

Batteries Produce Explosive Gases Warning

Warning: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines:

•Always shield your eyes.

•Avoid leaning over the battery whenever possible.

•Do not expose the battery to open flames or sparks.

•Do not allow battery acid to contact the eyes or the skin.

•Flush any contacted areas with water immediately and thoroughly.

•Get medical help.

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Caution Notices	PREFACE	0-0

Battery Disconnect Warning

Warning: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. For Vehicles equipped with OnStar® (UE1) with Back Up Battery: The Back Up Battery is a redundant power supply to allow limited OnStar® functionality in the event of a main vehicle battery power disruption to the VCIM (OnStar®module). Do not disconnect the main vehicle battery or remove the OnStar® fuse with the ignition key in any position other than OFF. Retained accessory power (RAP) should be allowed to time out or be disabled (simply opening the driver door should disable RAP) before disconnecting power. Disconnecting power to the OnStar® module in any way while the ignition is On or with RAP activated may cause activation of the OnStar® Back-Up Battery (BUB) system and will discharge and permanently damage the back-up battery. Once the Back-Up Battery is activated it will stay on until it has completely discharged. The BUB is not rechargeable and once activated the BUB must be replaced.

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Caution Notices	PREFACE	0-0

Brake Fluid Irritant Warning

Warning: Brake fluid may irritate eyes and skin. In case of contact, take the following actions:

•Eye contact—rinse thoroughly with water.

•Skin contact—wash with soap and water.

•If ingested—consult a physician immediately.

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Caution Notices	PREFACE	0-0

Brake Fluid Warning

Warning: Use only Delco Supreme 11, GMP/N12377967 (CanadianP/N992667), or equivalent DOT3 brake fluid from a clean, sealed container. Do not use fluid from an open container that may be contaminated with water. Improper or contaminated fluid could result in damage to components, or loss of braking, with possible injury.

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Caution Notices	PREFACE	0-0

Collision Sectioning Warning

Warning: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle and cause personal injury if the vehicle is in a collision.

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Caution Notices	PREFACE	0-0

Cracked Window Warning

Warning: If a window is cracked but still intact, crisscross the window with masking tape in order to reduce the risk of damage or personal injury.

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Caution Notices	PREFACE		0-0
Defroster Outlet Warning
Warning: If broken glass fallse intodefrosterth	outlets, it can be	blown into the passenger compartment and cause personal
injury.

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Caution Notices	PREFACE	0-0

Electric Coolant Fan Warning

Warning: An electric fan under the hood can start up even when the engine is not running and can injure you. Keep hands, clothing and tools away from any underhood electric fan.

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Caution Notices	PREFACE	0-0

Exhaust Service Warning

Warning: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

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Caution Notices	PREFACE	0-0

Eye Protection Warning

Warning: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury.

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Caution Notices	PREFACE	0-0

Gasoline/Gasoline Vapors Warning

Warning: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

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Caution Notices	PREFACE	0-0

Glass and Sheet Metal Handling Warning

Warning: When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and gloves in order to reduce the chance of personal injury.

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Caution Notices	PREFACE	0-0

Halogen Bulb Warning

Warning: Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury:

•Turn off the lamp switch and allow the bulb to cool before changing the bulb.

•Leave the lamp switch OFF until the bulb change is complete.

•Always wear eye protection when changing a halogen bulb.

•Handle the bulb only by its base. Avoid touching the glass.

•Keep dirt and moisture off the bulb.

•Properly dispose of the used bulb.

•Keep halogen bulbs out of the reach of children.

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Caution Notices	PREFACE	0-0

Hood Hold-Open Device Warning

Warning: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury.

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Caution Notices	PREFACE	0-0

Parking Brake and Drive Wheels Warning

Warning: Apply the parking brake and block the drive wheels before performing this procedure in order to prevent bodily injury.

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Caution Notices	PREFACE	0-0

Protective Goggles and Glove Warning

Warning: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.

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Caution Notices	PREFACE	0-0

Radiator Cap Removal Warning

Warning: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.

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Caution Notices	PREFACE	0-0

Relieving Fuel Pressure Warning

Warning: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, covertemthe fuel sys components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

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Caution Notices	PREFACE	0-0

Repair Material Curing Warning

Warning: At least 24hours are required for complete curing of repair material. The repair area should not be physically disturbed until after that time. Insufficient curing of urethane adhesive may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.

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Caution Notices	PREFACE	0-0

Safety Glasses and Compressed Air Warning

Warning: Wear safety glasses when using compressed air in order to prevent eye injury.

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Caution Notices	PREFACE	0-0

Safety Glasses Warning

Warning: Wear safety glasses in order to avoid eye damage.

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Caution Notices	PREFACE	0-0

Safety Goggles and Fuel Warning

Warning: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.

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Caution Notices	PREFACE	0-0

Sensing and Diagnostic Module Handling Warning

Warning: Be careful when you handle a sensing and diagnostic module (SDM). Do not strike or jolt the SDM. Before applying power to the SDM:

•Remove any dirt, grease, etc. from the mounting surface

•Position the SDM horizontally on the mounting surface

•Point the arrow on the SDM toward the front of the vehicle

•Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque value

Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs.

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Caution Notices	PREFACE	0-0

Sensing and Diagnostic Module Voltage after Ignition is Turned Off Warning

Warning: The sensing and the diagnosis module (SDM) can maintain sufficient voltage to deploy the airbags and pretensioners for up to 1 minute after the ignition has been turned OFF and the fuse has been removed. If the airbags and pretensioners are not disconnected, do not begin service until one minute has been passed after disconnecting power to the SDM. Failure to do so may cause personal injury.

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