Chevrolet Aver 2005 Sistema de Arranque y Carga

2005 Chevrolet Aveo
2005 ENGINE Engine Electrical - Aveo, (Swift+ & Wave Canadian)
2005 ENGINE
Engine Electrical - Aveo, (Swift+ & Wave Canadian)
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications

Specification
Application Metric English
Battery Cable Nuts 4.5 N.m 40 lb in
Battery Carrier Tray Lower Bolts 20 N.m 15 lb ft
Battery Carrier Tray Upper Bolts 20 N.m 15 lb in
Battery Retainer Clamp-to-Battery Rod Nuts 4 N.m 35 lb in
Front Bearing Plate Screws 8 N.m 71 lb in
Fuel Rail Retaining Bolts 20 N.m 15 lb in
Generator Battery Lead Nut 15 N.m 11 lb ft
Generator Brush Holder Screws 12 N.m 106 lb in
Generator Drive and End Bearing Nut 81 N.m 60 lb ft
Generator Drive End Bearing Nut 81 N.m 60 lb ft
Generator Lower Bracket-to-Generator Nuts 25 N.m 18 lb ft
Generator Shackle Bracket Bolt 25 N.m 18 lb ft
Generator Through-Bolts 10 N.m 89 lb in
Harness Ground Bolt 41 N.m 30 lb ft
Starter Field Coil Connector Nut 8 N.m 71 lb in
Starter Mounting Bolts 43 N.m 32 lb ft
Starter Solenoid Assembly Screws 8 N.m 71 lb in
Starter Solenoid Nuts 15 N.m 11 lb ft
Starter Through-Bolts 6 N.m 53 lb in
BATTERY USAGE
Battery Usage
Application Description
L4 Engine
Cold Cranking Amps 550 amps
Load Test 270 amps
RC - Minimum 90 minutes
Replacement 85B-60
Battery Voltage Specifications
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15:36:58 Page 1 © 2011 Mitchell Repair Information Company, LLC.
2005 Chevrolet Aveo
Specification
Minimum Voltage:
l 9.6 V 21°C 70°F
l 9.4 V 20°C 68°F
l 9.1 V 0°C 32°F
l 8.8 V -10°C 14°F
l 8.5 V -18°C 0°F
l 8.0 V Below -18°C Below 0°F
STARTER MOTOR USAGE
Starter Motor Usage

Starter
l No Load Test @ 12 volts Maximum 90 amps
l Drive Pinion Speed Minimum 2,600 RPM
Solenoid
l Hold-in Windings @ 12 volts 12-20 amps
l Pull-in Windings @ 12 volts 60-90 amps
GENERATOR USAGE
Generator Usage
Generator Types CS-121D
GENERAL SPECIFICATIONS
General Specifications
Specification
Battery
l Manual
410 Cold Cranking Amps
¡ 1.2L SOHC
¡ 1.5L SOHC
l Automatic
550 Cold Cranking Amps
¡ 1.4L SOHC/DOHC
martes, 9 de junio de 2020 15:36:58 Page 2 © 2011 Mitchell Repair Information Company, LLC.
2005 Chevrolet Aveo
¡ 1.5L SOHC
Alternator
¡ 1.4L SOHC/DOHC 85 A
¡ 1.5L SOHC, A/T
Alternator
¡ 1.2L SOHC 75 A
¡ 1.5L SOHC, M/T
Starter-Manual (No-Load Test Current Draw)

0.8 kW
¡ 1.2L SOHC Maximum 53 A (Drive Pinion Speed at
Minimum 5,000 RPM, 11.5 V
¡ 1.5L SOHC
Starter-Automatic (No-Load Test Current Draw)

1.2 kW
¡ 1.4L SOHC/DOHC Maximum 90 A (Drive Pinion Speed at
Minimum 2,600 RPM, 11.5 V
¡ 1.5L SOHC
SCHEMATIC AND ROUTING DIAGRAMS

STARTING AND CHARGING SCHEMATICS
2005 Chevrolet Aveo
Fig. 1: Starting Systems Schematics

Courtesy of GENERAL MOTORS CORP.
2005 Chevrolet Aveo
Fig. 2: Charging Systems Schematics

COMPONENT LOCATOR
ENGINE ELECTRICAL COMPONENT VIEWS
2005 Chevrolet Aveo
Fig. 3: Generator and Starter Component Views

Callouts For Fig. 3

Callout Component Name
1 Generator
2 Starter
2005 Chevrolet Aveo
Fig. 4: Ignition Switch Component Views

Callouts For Fig. 4

1 Ignition Switch
2005 Chevrolet Aveo
Fig. 5: I/P Fuse Block Component Views

Callouts For Fig. 5

1 Ignition Lock Module (North America)
1 Rear Fog Relay (LHD - w/Rear Fog)
2 Defog Relay (RHD)
2 Turn Signal/Hazard Flasher (LHD)
3 Wiper Relay
4 Park/Neutral Position (PNP) Relay (RHD)
4 Daytime Relay Lamp (DRL) Relay (Scandinavian)
5 Blink Relay
6 Blower Relay
7 Turn Signal/Hazard Flasher (RHD)
7 Park/Neutral Position (PNP) Relay (LHD)
8 Defog Relay (LHD)
2005 Chevrolet Aveo
8 Rear Fog Relay (RHD)

9 Fuse Block - I/P
Fig. 6: Generator Assembly DOHC Component Views

Callouts For Fig. 6

1 Generator Assembly
2 Generator Drive End Nut
3 Generator Pulley
4 Generator Collar
5 Generator Front Bracket
6 Front Bearing
7 Generator Stator Assembly
8 Fan
9 Generator Rotor Assembly
10 Generator Rear Bracket
11 Rectifier Assembly
12 Cover
13 Voltage Regulator/Brush Holder Assembly
2005 Chevrolet Aveo
ENGINE ELECTRICAL CONNECTOR END VIEWS
Clutch Start Switch
l KET MG 630676
Connector Part Information
l 2-Way F 250 Series
Pin Wire Color Circuit No. Function

1 YE 5 Crank Voltage
2 PU 2 Clutch Start Switch Signal
Generator
2005 Chevrolet Aveo
l PED 12186568
Connector Part Information
l 4-Way F Metri-Pack 150 Series (BK)

A - - Not Used
B D-BU 25 Charge Indicator Signal
C PK 39 Ignition 1 Voltage
D - - Not Used
Ignition Switch
l KET MG 650887
Connector Part Information l 6-Way F 250 III Series (WH)
2005 Chevrolet Aveo
1 RD/BK 341 Ignition 3 Voltage

2 RD/BK 141 Ignition 3 Voltage
4 PK 3 Ignition 1 Voltage
5 OG 142 Battery Positive Voltage
6 YE 4 Accessory Voltage
Park/Neutral Position (PNP) Relay
l AK 36905
Connector Part Information l 6-Way

86 BN 323 Park/Neutral Position (PNP) Signal
86 PU 434 Automatic Transmission Shift Lock Control
87 PU 6 Starter Solenoid Crank Voltage
DIAGNOSTIC INFORMATION AND PROCEDURES

DIAGNOSTIC STARTING POINT - ENGINE ELECTRICAL
Begin the system diagnosis by reviewing the following Description and Operations:
l Battery Description and Operation

l Starting System Description and Operation
2005 Chevrolet Aveo
l Charging System Description and Operation
Reviewing the Description and Operation information will help you determine the correct symptom diagnostic
procedure when a malfunction exists. Reviewing the Description and Operation information will also help you
determine if the condition described by the customer is normal operation. Refer to Symptoms - Engine
Electrical in order to identify the correct procedure for diagnosing the system and where the procedure is
located.
DIAGNOSTIC SYSTEM CHECK - ENGINE ELECTRICAL
Test Description
The numbers below refer to the step numbers on the diagnostic table.
2: Lack of communication may be due to a malfunction of the serial data circuits. The specified
procedure will determine the particular condition.
3: The presence of DTCs may be related to an engine electrical condition. The specified procedure will
compile all the available information before tests are performed.
Diagnostic System Check - Engine Electrical

Step Action Yes No
Perform the Battery Inspection/Test. Refer to Battery
1 Inspection/Test.
Does the battery pass the test? Go to Step 2 -
Install a scan tool. Go to Scan Tool
Does the scan tool power up? Does Not Power Up
2
in Data Link
Go to Step 3 Communications
1. Turn ON the ignition, with the engine OFF. Go to Scan Tool
Does Not
2. Attempt to establish communication with the Communicate with
3 engine control module (ECM). Component in Data
Link
Does the scan tool communicate with the ECM? Go to Step 4 Communications
Select the Display DTCs function for the ECM. Go to Diagnostic
Does the scan tool display DTC P0562 or P0563? Trouble Code
4
(DTC) List in Go to Symptoms -
Engine Controls Engine Electrical
DIAGNOSTIC TROUBLE CODE (DTC) LIST
Diagnostic Trouble Code (DTC) List

DTC Diagnostic Procedure Modules
P0562 DTC P0562 ECM
P0563 DTC P0563 ECM
2005 Chevrolet Aveo
DTC P0562
Circuit Description
The engine control module (ECM) uses the ignition 1 voltage circuit to monitor system voltage. Voltage that is
out of range will cause damage to components and incorrect input readings. If the ECM detects an excessively
low system voltage, DTC P0562 will set.
DTC Descriptor
This diagnostic procedure supports the following DTC:
DTC P0562 System Voltage Low
Conditions for Running the DTC
l The ignition is ON with the engine OFF.

l DTC P0562 runs continuously once the above condition is met.
Conditions for Setting the DTC
The ECM detects a system voltage below 11 volts for more than 5 minutes.
Action Taken When the DTC Sets
l The control module stores the DTC information into memory when the diagnostic runs and fails.
l The malfunction indicator lamp (MIL) will not illuminate.
l The control module records the operating conditions at the time the diagnostic fails. The control module
stores this information in the Failure Records.
l The driver information center, if equipped, may display a message.
Conditions for Clearing the DTC
l A current DTC Last Test Failed clears when the diagnostic runs and passes.
l A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other
non-emission related diagnostic.
l Clear the DTC with a scan tool.
DTC P0562
Step Action Values Yes No
Schematic References: Engine Controls Schematics in Engine Controls - 1.6L (L91)
Connector End View References: Master Electrical Component List
Go to
Did you perform the Diagnostic System Check - Diagnostic
1 -
Engine Electrical? System Check -
Engine
2005 Chevrolet Aveo
Go to Step 2 Electrical
1. Start the engine.
2. Raise the engine speed above 1,500 RPM.
3. With a scan tool, observe the Ignition 1
2 voltage parameter in the engine control 10.5 V
module (ECM) data list.
Is the voltage more than the specified value? Go to Step 3 Go to Step 4

1. Observe the Freeze Frame/Failure Records
data for this DTC.
2. Turn OFF the ignition for 30 seconds.
3. Operate the vehicle within the Conditions Go to Testing
3 for Running the DTC. You may also - for
operate the vehicle within the conditions Intermittent
that you observed from the Freeze Conditions and
Frame/Failure Records. Poor
Connections in
Did the DTC fail this ignition? Go to Step 4 Wiring Systems
1. Measure the voltage at the battery with a
DMM.
3. Compare the voltage at the battery to the
4 Ignition 1 voltage parameter in the ECM 0.5 V
data list.
Is the battery voltage and Ignition 1 parameter

readings different by more than the specified Go to Charging
value? Go to Step 5 System Test
Test the ignition 1 voltage circuit of the ECM for
high resistance. Refer to Circuit Testing and
5 -
Wiring Repairs in Wiring Systems.
Did you find and correct the condition? Go to Step 8 Go to Step 6
Test for an intermittent or poor connection at the
harness connector of the ECM. Refer to Testing
for Intermittent Conditions and Poor
6 -
Connections and Connector Repairs in Wiring
Systems.
Replace the ECM. Refer to Engine Control
Module (ECM) Replacement in Engine
7 - -
Controls - 1.6L (L91)
Did you complete the replacement? Go to Step 8
1. Clear the DTCs with a scan tool.
2005 Chevrolet Aveo

4. Operate the vehicle within the Conditions
for Running the DTC. You may also
8 operate the vehicle within the conditions -
that you observed from the Freeze
Frame/Failure Records.
Did the DTC fail this ignition? Go to Step 2 Go to Step 9

Go to
Diagnostic
Observe the Capture Info with a scan tool.
Trouble Code
9 Are there any DTCs that have not been -
(DTC) List in
diagnosed?
Engine Controls
- 1.6L (L91) System OK
DTC P0563
Circuit Description
The engine control module (ECM) uses the ignition 1 voltage circuit to monitor system voltage. Voltage that is
out of range will cause damage to components and incorrect input readings. If the ECM detects an excessively
high system voltage, DTC P0563 will set.
DTC Descriptor
This diagnostic procedure supports the following DTC:
DTC P0563 System Voltage High
Conditions for Running the DTC
l The ignition is ON with the engine OFF.

l DTC P0563 runs continuously once the above condition is met.
Conditions for Setting the DTC
The ECM detects a system voltage above 16 volts for more than 5 minutes.
Action Taken When the DTC Sets
l The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition
cycle that the diagnostic runs and fails.
l The control module records the operating conditions at the time the diagnostic fails. The first time the
diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic
reports a failure on the second consecutive ignition cycle, the control module records the operating
2005 Chevrolet Aveo
conditions at the time of the failure. The control module writes the operating conditions to the Freeze
Frame and updates the Failure Records.
Conditions for Clearing the MIL/DTC
l The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles
that the diagnostic runs and does not fail.
l A current DTC, Last Test Failed, clears when the diagnostic runs and passes.
l A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other
emission related diagnostic.
l Clear the MIL and the DTC with a scan tool.
DTC P0563
Schematic References: Engine Controls Schematics in Engine Controls - 1.6L (L91)
Connector End View References: Master Electrical Component List
Go to
Diagnostic
Did you perform the Diagnostic System Check -
1 - System Check -
Engine Electrical?
Engine
Go to Step 2 Electrical
3. With a scan tool, observe the Ignition 1
2 voltage parameter in the Engine Control 16 V
Module (ECM) data list.
Is the voltage less than the specified value? Go to Step 3 Go to Step 4

1. Observe the Freeze Frame/Failure Records
data for this DTC.
3. Operate the vehicle within the Conditions Go to Testing
3 for Running the DTC. You may also - for
operate the vehicle within the conditions Intermittent
that you observed from the Freeze Conditions and
Frame/Failure Records. Poor
Connections in
Did the DTC fail this ignition? Go to Step 4 Wiring Systems
1. Measure the voltage at the battery with a
DMM.
4 2. Raise the engine speed above 1,500 RPM. 0.5 V
3. Compare the voltage at the battery to the
Ignition 1 parameter in the ECM data list.
2005 Chevrolet Aveo
Is the battery voltage and Ignition 1 parameter

readings different by more than the specified Go to Charging
value? Go to Step 5 System Test
Replace the ECM. Refer to Engine Control
Module (ECM) Replacement in Engine
5 - -
Controls - 1.6L (L91)
Did you complete the replacement? Go to Step 6
1. Clear the DTCs with a scan tool.
4. Operate the vehicle within the Conditions
6 for Running the DTC. You may also -
operate the vehicle within the conditions
that you observed from the Freeze
Frame/Failure Records.
Did the DTC fail this ignition? Go to Step 2 Go to Step 7

Go to
Diagnostic
Observe the Capture Info with a scan tool.
Trouble Code
7 Are there any DTCs that have not been -
(DTC) List in
diagnosed?
Engine Controls
- 1.6L (L91) System OK
SYMPTOMS - ENGINE ELECTRICAL
IMPORTANT: Review the system operation in order to familiarize yourself with the system
functions. Refer to the following:

l Charging System Description and Operation
Visual/Physical Inspection
l Inspect for aftermarket devices which could affect the operation of the starting, charging or ignition
systems. Refer to Checking Aftermarket Accessories in Wiring Systems.
l Inspect the easily accessible or visible system components for obvious damage or conditions which could
cause the symptom.
l Inspect the battery for correct installation and physical damage.
l Test the condition of the battery. Terminal voltage should be 11.5-13.5 volts.
l Inspect the wiring for damage. Inspect the connections to the starter motor, the starter solenoid, the
ignition switch, the battery and all related ground points.
l If the battery, wiring and switches are in satisfactory condition and the engine is known to be functioning
2005 Chevrolet Aveo
properly, remove and test the starter motor.

l When the charging system is operating normally, the charge indicator lamp will come ON when the
ignition switch is turned ON and will go out when the engine starts.
l Inspect the generator for loose or improper mounting and the generator drive belt for correct installation.
l Inspect the drive belt for correct installation. Refer to Power Steering Pump Drive Belt Replacement in
Power Steering Systems.
Intermittent
Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for
Intermittent Conditions and Poor Connections in Wiring Systems.
Symptom List
Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom:
l Starter Solenoid Does Not Click

l Starter Solenoid Clicks, Engine Does Not Crank
l Engine Cranks Slowly
l Charge Indicator Always On
l Charge Indicator Inoperative
l Battery Inspection/Test
l Battery Charging
l Battery Electrical Drain/Parasitic Load Test
l Battery Common Causes of Failure
l Jump Starting in Case of Emergency
l Starter Motor Noise Diagnosis
l Charging System Test
l Generator Noise Diagnosis
BATTERY INSPECTION/TEST
Diagnostic Aids
Tools Required
J 42000 Digital Battery Tester. See Special Tools.
CAUTION: Before servicing any electrical component, the ignition key must be in the
OFF or LOCK position and all electrical loads must be OFF, unless
instructed otherwise in these procedures. If a tool or equipment could
easily come in contact with a live exposed electrical terminal, also
disconnect the negative battery cable. Failure to follow these precautions
2005 Chevrolet Aveo
may cause personal injury and/or damage to the vehicle or its

components.
IMPORTANT: The battery test using the J 42000 requires correct connections to the battery
terminals. See Special Tools. A failure to obtain the correct connections during
the test may result in a failed test on a good battery.
Follow these instructions in order to avoid an incorrect diagnosis because of connections:
l If testing the vehicle with the battery cables still connected, wiggle the J 42000 clips on the terminal bolt.
See Special Tools. This may cut through any coating or through any oxidation that may be present on the
bolt. Even new bolts contain a protective coating that may insulate or cause a resistance in the test circuit.
l If correct connections to the battery terminal bolts in the vehicle are in doubt, perform the following
steps:
1. Disconnect the negative battery cable.
2. Disconnect the positive battery cable.
3. Install the test adapters on the terminals.
4. Follow the instructions for testing a removed battery.
l If the tester displays a REPLACE BATTERY result for a battery tested in the vehicle with the battery
cables connected, perform the following steps:
2. Disconnect the positive battery cable.
3. Install the test adapters.
4. Follow the instructions for testing a removed battery.
5. Replace the battery only if the second test shows a REPLACE BATTERY result.
6. Use the test code from the second test for any warranty purposes.
l Use the correct terminal adapters. Do not use any common bolts or a combination of bolts, of nuts, and of
washers as adapters when testing the battery.
Battery Inspection/Test
Inspect the battery for a cracked, broken, or
damaged case, which may be indicated by battery
1 -
acid leakage.
Is the battery OK? Go to Step 2 Go to Step 19
Compare the Cold Cranking Amperage (CCA)
and Reserve Capacity (RC) of the battery to the
original battery or Original Equipment (OE)
2 -
specification. Refer to Battery Usage.
Does the battery meet or exceed the
specification? Go to Step 3 Go to Step 19
3 Does the hydrometer display a yellow dot? - Go to Step 4 Go to Step 5
Tap the hydrometer lightly on top with the handle
2005 Chevrolet Aveo
of a small screwdriver in order to dislodge any air

4 bubbles inside the battery. -
Does the hydrometer display a yellow dot? Go to Step 19 Go to Step 5
1. Turn OFF the ignition.
2. Attempt to rotate the negative battery cable
5 connector clockwise with light finger -
pressure.
Does the negative connector rotate? Go to Step 6 Go to Step 7

Use a torque wrench in order to verify the torque
4.5 N.m (40
6 of the negative battery terminal bolt.
lb in)
Is the torque at the specified value? Go to Step 8 Go to Step 7
CAUTION:
Refer to Battery Disconnect Caution in
Cautions and Notices.
7 -
Disconnect the negative battery cable.Is the cable
disconnected? Go to Step 9 -
CAUTION:
Refer to Battery Disconnect Caution in
Cautions and Notices.

2. Inspect for the following conditions and
repair as needed:
8 l The cable bolt is too long or -
deformed at the end.
l There is foreign material present
inside the nut in the battery terminal.
l Damage to the battery terminal face
or cable connector ring.
Is the repair complete? Go to Step 9 -

Rotate the positive battery cable connector
9 clockwise with light finger pressure. -
Does the positive connector rotate? Go to Step 10 Go to Step 11
Use a torque wrench in order to verify the torque
4.5 N.m (40
10 of the positive battery terminal bolt.
lb in)
Is the torque at the specified value? Go to Step 12 Go to Step 11
CAUTION:
Before servicing any electrical component, the
ignition key must be in the OFF or LOCK
position and all electrical loads must be OFF,
unless instructed otherwise in these
procedures. If a tool or equipment could easily
2005 Chevrolet Aveo
come in contact with a live exposed electrical

terminal, also disconnect the negative battery
cable. Failure to follow these precautions may
cause personal injury and/or damage to the
11 vehicle or its components. -
Disconnect the positive battery cable.Is the cable

disconnected? Go to Step 13 -
CAUTION:
Before servicing any electrical component, the
ignition key must be in the OFF or LOCK
position and all electrical loads must be OFF,
unless instructed otherwise in these
procedures. If a tool or equipment could easily
come in contact with a live exposed electrical
terminal, also disconnect the negative battery
cable. Failure to follow these precautions may
cause personal injury and/or damage to the
vehicle or its components.
12 1. Disconnect the positive battery cable. -

2. Inspect for the following conditions and
repair as needed:
l The cable bolt is too long or
deformed at the end.
l There is foreign material present
inside the nut in the battery terminal.
l Damage to the battery terminal face
or cable connector ring.
Is the repair complete? Go to Step 13 -

1. Clean and wire brush the lead face of both
battery terminals and the metal contact
rings in both cable connectors.
2. Remove the bolts from the cable
connectors in order to provide access to the
13 connector rings as needed. -
3. If either of the battery terminals or the
cable rings are excessively damaged or
corroded, replace as needed.
Are any metal connecting parts clean and in good

condition? Go to Step 14 -
1. Connect the positive battery cable to the
battery positive terminal.
2. Tighten the cable bolt to the specified 4.5 N.m (40
2005 Chevrolet Aveo
value. lb in)
14
Is the cable bolt properly tightened? Go to Step 15 -
1. Connect the negative battery cable to the
battery negative terminal.
2. Tighten the cable bolt to the specified 4.5 N.m (40
15
value. lb in)
Is the cable bolt properly tightened? Go to Step 16 -

IMPORTANT:
Ensure that all of the electrical loads are
turned OFF.
1. Install the J 42000 Digital Battery Tester.

See Special Tools.
16 -
2. Follow the directions supplied with the
tester.
3. Follow any direction displayed on the
tester.
Did the tester pass the battery? Go to Step 17 Go to Step 18

IMPORTANT:
Always write the test code displayed by the
tester on the repair order for any warranty
purposes. The number is a unique code that
describes the test data for a particular battery
at a particular time. The test code may
occasionally repeat when you retest the same
battery. More often, each test will result in a
17 different code. -
1. Press the CODE button on the J 42000 .

See Special Tools.
2. Write the displayed code on the repair
order.
Did you complete this action? Battery OK -
IMPORTANT:
Always write the test code displayed by the
tester on the repair order for any warranty
purposes. The number is a unique code that
describes the test data for a particular battery
at a particular time. The test code may
occasionally repeat when you retest the same
battery. More often, each test will result in a
different code.
2005 Chevrolet Aveo
1. Press the CODE button on the J 42000 .

See Special Tools.
2. Write the displayed code on the repair
18 order. -
3. Replace the battery. Refer to Battery and
Battery Tray Replacement.
Did you complete the replacement? Battery OK -

Replace the battery. Refer to Battery and
19 Battery Tray Replacement. -
Did you complete the replacement? Battery OK -
BATTERY CHARGING
l For best results, use an automatic taper-rate battery charger with a voltage capability of 16 volts.
2005 Chevrolet Aveo
Fig. 7: Determining If Battery Should Be Charged

l A battery showing a green dot in the hydrometer (1) does not need to be charged unless the J 42000
Battery Tester has shown that the battery needs to be charged. See Special Tools.
l A battery showing a dark green dot in the hydrometer (2) should be charged unless J 42000 has indicated
no charge is needed. See Special Tools.
l Do not charge a battery when the built in hydrometer is clear or yellow in the center (3). Tap the
hydrometer lightly in order to dislodge any air bubbles. The bubbles may cause a false indication. If the
hydrometer is still clear or yellow, replace the battery.
2005 Chevrolet Aveo
l The charging area should be well ventilated.

l Do not charge a battery that appears to be frozen. Allow the battery to warm to room temperature and test
it before charging.
Charging Time Required
The time required to charge a battery will vary depending upon the following factors:
1. The battery charger capacity. The higher the chargers amperage, the less time it will take to charge the
battery.
2. The state-of-charge of the battery. A completely discharged battery requires more than twice as much
charging time as a half charged battery. In a discharged battery with a voltage below 11 volts, the battery
has a very high internal resistance and may only accept a very low current at first. Later, as the charging
current causes the acid content to increase in the electrolyte, the charging current will increase. Extremely
discharged batteries may not activate the reversed voltage protection in some chargers. Refer to the
manufacturer's instructions for operating this circuitry.
3. The temperature of the battery. The colder the battery is, the more time it takes to recharge the battery.
The charging current accepted by a cold battery is very low at first: then, as the battery warms, the
charging current will increase.
Charging Procedure
NOTE: Turn off the ignition key when disconnecting or reconnecting battery power in
order to prevent system damage.
NOTE: Refer to Fastener Notice in Cautions and Notices.
NOTE: Use the correct fastener in the correct location. Replacement fasteners must be
the correct part number for that application. Fasteners requiring replacement or
fasteners requiring the use of thread locking compound or sealant are identified
in the service procedure. Do not use paints, lubricants, or corrosion inhibitors
on fasteners or fastener joint surfaces unless specified. These coatings affect
fastener torque and joint clamping force and may damage the fastener. Use the
correct tightening sequence and specifications when installing fasteners in
order to avoid damage to parts and systems.
Use the following procedure to charge the battery:
1. Turn OFF the charger.

2. Ensure that all of the battery terminal connections are clean and tight.
3. Connect the charger positive lead to the battery positive terminal.
NOTE: Do not connect the negative charger lead to the housings of other vehicle
electrical accessories or equipment. The action of the battery charger may
damage such equipment.
2005 Chevrolet Aveo
4. Connect the negative charger lead to a solid engine ground or to a ground stud in the engine compartment
that is connected directly to the battery negative terminal, but away from the battery. If the negative
battery cable is disconnected and a terminal adapter is being used, connect directly to the adapter.
5. Turn ON the charger and set to the highest setting for normal charging.
6. Inspect the battery every half hour after starting the battery charger.
l Charge the battery until the hydrometer has a green dot or until the taper-rate charger indicates that
the battery is fully charged, whichever occurs first.
l Tap the hydrometer lightly in order to dislodge any air bubbles. The bubbles may cause a false
indication.
l Estimate the battery temperature by feeling the side of the battery. If it feel hot to the touch or its
temperature is over 45°C (125°F), discontinue charging and allow the battery to cool before
resuming charging.
7. After charging, test the battery. Refer to Battery Inspection/Test.
BATTERY ELECTRICAL DRAIN/PARASITIC LOAD TEST
Tools Required
l J 36169-A Fused Jumper Wire

l J 38758 Parasitic Draw Test Switch. See Special Tools.
l J 39200 Digital Multimeter
CAUTION: 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:
l Always shield your eyes.

l Avoid leaning over the battery whenever possible.
l Do not expose the battery to open flames or sparks.
l Do not allow battery acid to contact the eyes or the skin.
¡ Flush any contacted areas with water immediately and
thoroughly.
¡ Get medical help.
CAUTION: Before servicing any electrical component, the ignition key must be in the
OFF or LOCK position and all electrical loads must be OFF, unless
instructed otherwise in these procedures. If a tool or equipment could
easily come in contact with a live exposed electrical terminal, also
disconnect the negative battery cable. Failure to follow these precautions
may cause personal injury and/or damage to the vehicle or its
components.
2005 Chevrolet Aveo
NOTE: Do not turn the parasitic draw test switch to the OFF position with the engine
running. Damage will occur to the vehicle's electrical system.
NOTE: The test switch must be in the ON position when removing the fuses in order to
maintain continuity in the electrical system. This avoids damaging the digital
multimeter due to accidental overloading, such as a door being opened to
change a fuse.
1. Disconnect the battery negative cable.

2. Turn OFF the test switch.
2005 Chevrolet Aveo
Fig. 8: View Of J 38758

3. Install the J 38758 between the negative battery cable and the negative battery terminal. See Special
Tools.
4. Wait 20 minutes. Components such as ECM and EBCM have timers that draw several amps of current
while they cycle down. This can give a false parasitic drain reading. Wait for these components to power
down before continuing this test.
2005 Chevrolet Aveo
5. Turn ON the test switch.

6. Road test the vehicle while activating all accessories, including the radio and the air conditioning.
7. Lower the door glass, then exit the vehicle. Do not move the door handle after closing the door.
8. Open the hood.
9. Turn OFF the ignition switch. Remove the key.
IMPORTANT: From this point on, electrical continuity must be maintained in the ground
circuit of the battery through the Test Switch J 38758 in the ON position or
through the ammeter J 39200 . See Special Tools.
10. Wait 20 minutes for the ECM and EBCM to power down.
11. Connect a jumper wire with a 10 A fuse J 36169-A to the terminals of the test switch.
12. Turn the test switch to the OFF position.
13. Wait 10 seconds. If the fuse does not blow, the current is less than 10 A. The ammeter can be used safely.
14. Before the fused jumper wire is removed, turn the test switch to the ON position.
15. Perform the following procedure in order to detect a high current drain:
IMPORTANT: If an ammeter other than J 39200 is used, ensure that the vehicle
does not have a high current drain that would damage the ammeter
when connected to the circuit.
1. Set the Ammeter J 39200 to the 10 A scale.

2. Connect the ammeter to the test switch terminals.
3. Turn OFF the test switch. This allows the current to flow through the ammeter.
4. Wait one minute, then inspect the current reading.
¡ When there is a current reading of 2 A or less, turn ON the test switch, this maintains
continuity in the electrical system.
¡ Then, switch the meter down to the 2 A scale, for a more accurate reading, when the test
switch is reopened.
5. Open the test switch.
6. Take the reading in milliamps.
7. Note the battery reserve capacity. Refer to Battery Usage .
¡ Divide the number by 4. Example: 90/4=22.5
¡ Compare this to the ammeter reading.
¡ The current drain in milliamps should not exceed this number.
¡ Example: if a battery has a reserve capacity of 90 minutes, the current drain should not
exceed 22 milliamps.
8. When the current draw is too high, remove the electrical system fuses one at a time until the draw
returns to a value less than or equal to specifications.
¡ Start with the fuses that are hot all the time. Check the circuits and the components that are
hot all the time.
2005 Chevrolet Aveo
¡To remove the fuse, you must first open the door, which causes a high enough current flow to
damage the ammeter.
¡ Protect the ammeter, without disturbing the electrical continuity, by turning ON the test tool
before opening the door.
¡ Remove the courtesy lamp fuse.
¡ Note the ammeter reading.
¡ If the parasitic load is still excessive, start removing the remaining fuses one at a time.
¡ Keep the courtesy lamp fuse out during diagnosis, so the door can remain open.
¡ Perform steps 11 through 13 each time a fuse is removed.
9. Removing the ECM fuse should cause a drop of less than 10 milliamps. A drop greater than 10
milliamps indicates a possible short to ground. No drop in the milliampere reading indicates the
ECM is not drawing current.
10. Repeat the parasitic current drain test procedure after any repair has been completed.
11. When the cause of the excessive current draw has been located and repaired, remove the ammeter
and the parasitic draw test switch.
NOTE: Use the correct fastener in the correct location. Replacement

fasteners must be the correct part number for that application.
Fasteners requiring replacement or fasteners requiring the use of
thread locking compound or sealant are identified in the service
procedure. Do not use paints, lubricants, or corrosion inhibitors on
fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the
fastener. Use the correct tightening sequence and specifications
when installing fasteners in order to avoid damage to parts and
systems.
12. Connect the battery negative cable to the negative battery terminal.
Tighten: Tighten the battery negative cable to 4.5 N.m (40 lb in).
BATTERY COMMON CAUSES OF FAILURE
A battery is not designed to last forever. With proper care, however, the battery will provide years of good
service. If the battery tests good but still fails to perform well, the following are some of the more common
causes:
l A vehicle accessory was left on overnight.

l The driving speeds have been slow with frequent stops, (stop-and-go driving), with many electrical
accessories in use, particularly air conditioning, headlights, wipers, heated rear window, cellular
telephone, etc.
l The electrical load has exceeded the generator output, (particularly with the addition of aftermarket
equipment).
l Existing conditions in the charging system, including the following possibilities:
2005 Chevrolet Aveo
l A slipping belt
l A Bad generator
l The battery has not been properly maintained, including a loose battery hold down or missing battery
insulator if used.
l There are mechanical conditions in the electrical system, such as a short or a pinched wire, attributing to
power failure. Refer to General Electrical Diagnosis Procedures in Wiring Systems.
Electrolyte Freezing
The freezing point of electrolyte depends on its specific gravity. A fully charged battery will not freeze until the
ambient temperature gets below -54°C (-65°F). However, a battery with a low state of charge may freeze at
temperatures as high as -7°C (20°F). Since freezing may ruin a battery, the battery should be protected against
freezing by keeping it properly charged. As long as the green eye is visible in the hydrometer, the freezing point
of the battery will be somewhere below -32°C (-25°F).
Battery Protection During Vehicle Storage
Certain devices on the vehicle maintain a small continuous current drain, (parasitic load), on the battery. A
battery that is not used for an extended period of time will discharge. Eventually permanent damage will result.
Discharged batteries will also freeze in cold weather. Refer to Battery Inspection/Test.
In order to maintain the battery state of charge while storing the vehicle for more than 30 days:
1. Make sure that the green dot is visible in the hydrometer.
CAUTION: Before servicing any electrical component, the ignition key must be
in the OFF or LOCK position and all electrical loads must be OFF,
unless instructed otherwise in these procedures. If a tool or
equipment could easily come in contact with a live exposed electrical
terminal, also disconnect the negative battery cable. Failure to follow
these precautions may cause personal injury and/or damage to the
2. Disconnect the battery ground cable to protect the battery from discharge by parasitic current drains.
When the battery cannot be disconnected:
1. Maintain a high state of charge.

2. Establish a regular schedule for recharging the battery every 20-45 days.
A battery that has remained in a discharged state for a long period of time is difficult to recharge or may be
permanently damaged.
JUMP STARTING IN CASE OF EMERGENCY
CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid.
2005 Chevrolet Aveo
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:
l Always shield your eyes.

l Avoid leaning over the battery whenever possible.
l Do not expose the battery to open flames or sparks.
l Do not allow battery acid to contact the eyes or the skin.
¡ Flush any contacted areas with water immediately and
thoroughly.
¡ Get medical help.
NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the
vehicle or equipment being used to jump start the engine is also 12 volt,
negative ground. Use of any other type of system will damage the vehicle's
electrical components.
This vehicle has a 12 volt positive, negative ground electrical system. Do not try to jump start a vehicle if you
are unsure of the other vehicles positive voltage or ground position. The booster, (charged), battery and the
discharged battery should be treated carefully when using jumper cables.
1. Position the vehicle with the booster, (charged), battery so that the jumper cables will comfortably reach
the battery of the other vehicle.
l Do not let the vehicles touch.
l Make sure that the jumper cables do not have loose clamps or missing insulation.
2. Perform the following steps on both vehicles:

1. Place the automatic transmission in park, or the manual transmission in neutral.
2. Block the wheels.
3. Set the parking brake.
4. Turn OFF all electrical loads that are not needed, (leave the hazard flashers ON).
2005 Chevrolet Aveo
Fig. 9: Identifying Proper Jumper Cable Connection

IMPORTANT: Some vehicles have a battery remote positive stud. ALWAYS use the
2005 Chevrolet Aveo
battery remote positive stud in order to give or to receive a jump-start.
3. Connect the red positive (+) cable to the positive (+) terminal (1) of the booster, (charged), battery. Use a
remote positive (+) terminal if the vehicle has one.
4. Connect the red positive (+) cable to the positive (+) terminal of the discharged battery. Use a remote
positive (+) terminal if the vehicle has one.
5. Connect the black negative (-) cable to the negative (-) terminal (3) of the booster, (charged), battery.
CAUTION: Do not connect a jumper cable directly to the negative terminal of a

discharged battery to prevent sparking and possible explosion of
battery gases.
6. The final connection is made to a heavy, unpainted metal engine part (4) of the vehicle with the
discharged battery. This final attachment must be at least 46 cm (18 in) away from the dead battery.
7. Start the engine of the vehicle that is providing the jump start and turn OFF all electrical accessories.
Raise the engine RPM to approximately 1,500 RPM.
NOTE: Never operate the starter motor more than 15 seconds at a time without
pausing in order to allow it to cool for at least 2 minutes. Overheating will
damage the starter motor.
8. Crank the engine of the vehicle with the discharged battery. If the engine does not crank or cranks too
slowly, perform the following steps:
1. Turn the ignition OFF.
2. Allow the booster vehicle engine to run at approximately 1,500 RPM for 5 minutes.
3. Attempt to start the engine of the vehicle with the discharged battery.
2005 Chevrolet Aveo
Fig. 10: View Of Black Negative Cable & Terminals

9. Disconnect the black negative (-) cable (1) from the vehicle with the discharged battery.
2005 Chevrolet Aveo
10. Disconnect the black negative (-) cable from the negative (-) terminal (2) of the booster, (charged),
battery.
11. Disconnect the red positive (+) cable from the positive terminal (3) of the booster, (charged), battery.
12. Disconnect the red positive (+) cable from the positive terminal (4) of the vehicle with the discharged
battery.
CHARGING SYSTEM TEST
Charging System Test

Did you review the Battery Description and
Operation, the Starting System Description Go to
1 and Operation and the Charging System - Symptoms -
Description and Operation and perform the Engine
necessary inspections? Go to Step 2 Electrical
1. Turn OFF all electrical loads.
Go to Testing
3. Install a scan tool. for
2 4. With the scan tool view the Battery 11-15.5 V Intermittent
Voltage parameter in the engine data list. Conditions and
Poor
Does the scan tool indicate the voltage is within Connections in
the specified value? Go to Step 3 Wiring Systems
2. Connect a charging system tester to the
battery, follow the manufacturer's
instructions.
3. Operate the engine at 2,500 RPM.
3 85 A
4. Adjust the carbon pile as necessary in
order to obtain the maximum current
output.
Is the generator output within 10 A of the

specified value? Go to Step 9 Go to Step 4
1. Maintain the engine speed at 2,500 RPM
and continue to operate the generator at the
load test value.
4 2. Measure the voltage drop between the 0.5 V
generator output terminal and the battery
positive terminal.
Is the voltage above the specified value? Go to Step 6 Go to Step 5

1. Maintain the engine speed at 2,500 RPM
2005 Chevrolet Aveo
and continue to operate the generator at the

load test value.
2. Measure the voltage drop between the
5 battery negative terminal and the generator 0.5 V
metal housing.
Is the voltage above the specified value? Go to Step 7 Go to Step 8

Test the battery positive circuit between the
generator output terminal and the battery positive
6 terminal for a high resistance. Refer to Circuit -
Testing and Wiring Repairs in Wiring Systems.
Repair the high resistance in the ground circuit
between the generator housing and the battery
7 negative terminal. Refer to Circuit Testing and -
Did you complete the repair? Go to Step 9 -
Replace the generator. Refer to Generator
8 Replacement. -
Operate the system in order to verify the repair.
9 -
Did you correct the condition? System OK Go to Step 3
CHARGE INDICATOR ALWAYS ON
Charge Indicator Always On

Did you review the following and perform the
necessary inspections?

1 -
l Starting System Description and
Go to
Operation Symptoms -
l Charging System Description and Engine
Operation Go to Step 2 Electrical
Start the engine. Go to Testing
Does the battery charge indicator remain for
illuminated after the engine is started? Intermittent
2 -
Conditions and
Poor
Go to Step 3 Connections
1. Install a scan tool.
3 2. With a scan tool, observe the Battery 10-15 V
Voltage parameter in the engine data list.
2005 Chevrolet Aveo
Does the voltage measure within the normal Go to Charging

operating range? Go to Step 4 System Test
Test the charge indicator control circuit for a
short to ground. Refer to Circuit Testing or
4 -
Did you find and correct the condition? Go to Step 5 -
5 -
CHARGE INDICATOR INOPERATIVE
Charge Indicator Inoperative

Step Action Yes No
Did you review the following description and
operations and perform the necessary inspections?
1 l Battery Description and Operation

Go to Symptoms -
l Charging System Description and Operation Go to Step 2 Engine Electrical
Turn ON the ignition, with the engine OFF. Go to Testing for
Does the battery charge indicator illuminate? Intermittent
2 Conditions and
Poor Connections
in Wiring Systems Go to Step 3
1. Disconnect the generator connector.
2. Connect a 20 amp fused jumper to the charge
3 indicator control circuit.
3. Turn the ignition switch to the ON position.
Does the battery charge indicator illuminate? Go to Step 4 Go to Step 6

Test the generator supply voltage circuit for an open.
Refer to Circuit Testing or Wiring Repairs in Wiring
4
Systems.
5 Replacement.
Did you complete the replacement? Go to Step 9 -
1. Inspect the charge indicator bulb and replace as
necessary.
2. Test the charge indicator supply voltage circuit
6 for an open. Refer to Circuit Testing or Wiring
Repairs in Wiring Systems.
2005 Chevrolet Aveo
Test the charge indicator control circuit for an open.

Refer to Circuit Testing or Wiring Repairs in Wiring
7
Systems.
Did you complete the replacement? Go to Step 9 Go to Step 8
Repair or replace the instrument panel cluster (IPC).
Refer to Instrument Panel Cluster (IPC)
8
Replacement in Instrument Panel, Gages and Console.
9
GENERATOR NOISE DIAGNOSIS
Diagnostic Aids
Noise from a generator may be due to electrical or mechanical noise. Electrical noise (magnetic whine) usually
varies with the electrical load placed on the generator and is a normal operating characteristic of all generators.
When diagnosing a noisy generator, it is important to remember that loose or misaligned components around
the generator may transmit the noise into the passenger compartment and that replacing the generator may not
solve the problem.
Generator Noise Diagnosis

Step Action Yes No
Test the generator for proper operation using the
1 Generator Tester. Refer to Charging System Test.
Is the generator operating properly? Go to Step 2 Go to Step 11
1. Start the engine. Verify that the noise can be
heard.
2. Turn OFF the engine.
2 3. Disconnect the connector from the generator.
5. Listen for the noise.
Has the noise stopped? Go to Step 11 Go to Step 3

1. Turn OFF the engine.
2. Remove the drive belt.
3 3. Spin the generator pulley by hand.
Does the generator shaft spin smoothly and without any

roughness or grinding noise? Go to Step 4 Go to Step 11
Inspect the generator for a loose pulley and/or pulley
4 nut.
Is the generator pulley or pulley nut loose? Go to Step 11 Go to Step 5
1. Loosen all of the generator mounting bolts.
2005 Chevrolet Aveo
2. Tighten the generator mounting bolts to

specifications. Refer to Generator Replacement.
5 3. Install the drive belt.
Has the noise decreased or stopped? System OK Go to Step 6

Inspect the generator for the following conditions:
l Stained or stretched electrical connections.

l Hoses or other vehicle equipment resting on the
6 generator, (which may cause the noise to be
transmitted into the passenger compartment).
Are any electrical connections pulling on the generator

or are any hoses, etc. resting on the generator? Go to Step 7 Go to Step 8
1. Reroute the electrical connections to relieve the
tension.
7 2. Reroute the hoses, etc. away from the generator.

Inspect the drive belt for proper tension.
8
Is the drive belt loose? Go to Step 9 Go to Step 10
1. Replace the drive belt tensioner.
9 2. Start the vehicle.

Compare the vehicle with a known good vehicle.
10
Do both vehicles make the same noise? System OK Go to Step 11
IMPORTANT:
If no definite generator problems were found, be
sure that all other possible sources of objectionable
noise are eliminated before replacing the generator.
Replacing the generator may not change the noise
11 level if the noise is a normal characteristic of the
generator or the generator mounting.

Replacement.Has the noise decreased or stopped? Go to Step 12 -
12
STARTER SOLENOID DOES NOT CLICK
2005 Chevrolet Aveo
Starter Solenoid Does Not Click

Step Action Yes No
Did you review the following and perform the
necessary inspections?
Go to Charging
1 l Battery Description and Operation System Description
and Operation
Symptoms - Engine
l Charging System Description and Operation Go to Step 2 Electrical
Turn the ignition to the START position. Go to Testing for
Does the starter solenoid click? Intermittent
2
Conditions and
Poor Connections Go to Step 3
2. Disconnect the starter solenoid crank voltage
circuit from the starter solenoid.
3. Connect a test lamp between the starter solenoid
3 crank voltage circuit of the starter and a good
ground.
4. Turn the ignition to the START position.
Does the test lamp illuminate? Go to Step 7 Go to Step 4

2. Disconnect the Park/Neutral Position (PNP)
switch or the Clutch Pedal Position (CPP)
switch.
4 3. Connect a 10-amp fused jumper between the
crank voltage circuit of the appropriate switch
and the starter solenoid crank voltage circuit.

1. Connect a test lamp between the crank voltage
circuit and the PNP switch or the CPP switch
and a good ground.
5

Test the crank voltage circuit of the PNP switch or the
CPP switch for a high resistance or an open. Refer to
6
Circuit Testing or Wiring Repairs in Wiring Systems
Inspect for a poor connection at starter solenoid. Refer
to Testing for Intermittent Conditions and Poor
2005 Chevrolet Aveo
Connections and Connector Repairs in Wiring

7 Systems.
Inspect the PNP switch or the CPP switch for proper
8 operation.
Inspect for a poor connection at the PNP switch or the
CPP switch. Refer to Testing for Intermittent
9 Conditions and Poor Connections or Connector
Inspect for a poor connection at the ignition switch.
Refer to Testing for Intermittent Conditions and
10 Poor Connections or Connector Repairs in Wiring
Systems.
Repair the high resistance or open in the starter
solenoid crank voltage circuit. Refer to Wiring
11
Replace the starter. Refer to Starter Motor
12 Replacement.
Replace the PNP switch or the CPP switch.
13
Replace the ignition switch. Refer to Ignition Lock
Cylinder and Switch Replacement in Steering Wheel
14
and Column.
Operate the system for which the symptom occurred.
15
STARTER SOLENOID CLICKS, ENGINE DOES NOT CRANK
Starter Solenoid Clicks, Engine Does Not Crank

Step Action Yes No
Did you review the following description and
operations and perform the necessary inspections?
1 l Battery Description and Operation

Go to Symptoms -
l Charging System Description and Operation Go to Step 2 Engine Electrical
Turn the ignition to the START position. Go to Starter
2 Did the starter solenoid click? Solenoid Does Not
Go to Step 3 Click
2005 Chevrolet Aveo
Inspect the engine and belt drive system for mechanical Go to Symptoms -
binding-(seized engine, seized generator). Engine Mechanical
3
Does the engine move freely? in Engine
Go to Step 4 Mechanical 1.6L.
Test the battery positive cable between the battery and
the starter solenoid for high resistance. Refer to Circuit
4
Testing or Wiring Repairs in Wiring Systems.
Test the ground circuit between the battery and the
starter motor for a high resistance. Refer to Circuit
5
Testing or Wiring Repairs in Wiring Systems.
Inspect for poor connections at the starter. Refer to
Testing for Intermittent Conditions and Poor
6 Connections or Connector Repairs in Wiring
Systems.
Replace the starter. Refer to Starter Motor
7 Replacement or .
Operate the system for which the symptom occurred.
8
ENGINE CRANKS SLOWLY
Perform the inspections on the following items:
l Battery-Perform the Battery Inspection/Test Refer to Battery Inspection/Test.

l Wiring-Inspect the wiring for damage. Inspect all connections to the starter motor, the solenoid, the
battery, and all ground connections. Refer to Circuit Testing , Wiring Repairs ,Testing for
Intermittent Conditions and Poor Connections andConnector Repairs in Wiring Systems.
l Engine-Verify that the engine is not seized.
If the battery, the wiring, and the engine are functioning properly, and the engine continues to crank slowly,
replace the starter motor. Refer to Starter Motor Replacement.
STARTER MOTOR NOISE DIAGNOSIS
Diagnostic Aids
Inspect the flywheel ring gear for damage or unusual wear.
Starter Motor Noise Diagnosis

Step Action Yes No
Did you review the Battery Description and
Operation, the Starting System Description and
2005 Chevrolet Aveo
Operation and the Charging System Description and Go to Symptoms -

1
Operation and perform the necessary inspections? Go to Step 2 Engine Electrical
Start the engine. Go to Testing for
Does the starter operate normally? Intermittent
2 Conditions and
Poor Connections
in Wiring Systems Go to Step 3
Start the engine while listening to the starter motor
turn. Is there a loud whoop, (it may sound like a siren
3 if the engine is revved while the starter is engaged),
after the engine starts, but while the starter is still held
in the engaged position? Go to Step 6 Go to Step 4
Do you hear a rumble, a growl, or, in some cases, a
4 knock as the starter is coasting down to a stop after
starting the engine? Go to Step 7 Go to Step 5
When the engine is cranked, do you hear a high-
pitched whine after the engine cranks and starts
5
normally? (This is often diagnosed as a starter drive
gear hang-in or a weak solenoid). Go to Step 9 Go to Step 7
Inspect the flywheel ring gear for the following:
l Chipped gear teeth

l Missing gear teeth
6
l Milled teeth
Is the flywheel bent, or does it have damaged teeth? Go to Step 8 Go to Step 9

1. Remove the starter motor. Refer to Starter
Motor Replacement.
2. Inspect the starter motor bushings and clutch
7 gear.
Does the clutch gear have chipped or milled teeth or

worn bushings? Go to Step 9 Go to Step 8
Replace the flywheel.
8
Replace the starter motor. Refer to Starter Motor
9 Replacement.
10
REPAIR INSTRUCTIONS
BATTERY AND BATTERY TRAY REPLACEMENT
2005 Chevrolet Aveo
Removal Procedure
Fig. 11: View Of Battery

1. Disconnect the negative battery cable and then disconnect the positive battery cable.
CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
2. Remove the nuts from the battery rods that fasten the battery hold-down bar clamp.
2005 Chevrolet Aveo
Fig. 12: View Of Battery Tray

3. Check the battery carrier tray for obvious cracks or damage. Detach the carrier tray if necessary by
removing the upper and the lower bolts.
Installation Procedure
2005 Chevrolet Aveo
Fig. 13: View Of Battery Tray

1. Install the battery carrier by fastening the carrier tray upper and lower bolts.
Tighten: Tighten the battery carrier tray upper and the lower bolts to 20 N.m (15 lb ft).
2005 Chevrolet Aveo
Fig. 14: View Of Battery

2. Install the battery into the tray.

3. Fasten the bar clamp to the battery by loosely attaching the battery rods from the batter tray cutouts
through the bar clamp holes, and loosely tightening the nuts.
Tighten: Tighten the battery retainer clamp-to-battery rod nuts to 4 N.m (35 lb in).
4. Connect the negative battery cables.
Tighten: Tighten the battery cable nuts to 4.5 N.m (40 lb in).
BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE
Removal Procedure
CAUTION: Before servicing any electrical component, the ignition key must be
2005 Chevrolet Aveo
in the OFF or LOCK position and all electrical loads must be OFF,
unless instructed otherwise in these procedures. If a tool or
equipment could easily come in contact with a live exposed electrical
terminal, also disconnect the negative battery cable. Failure to follow
these precautions may cause personal injury and/or damage to the
1. Record all preset and theft codes, (if equipped), from the radio.
2. Turn the ignition switch to the OFF position.
3. Verify that all the electrical components are OFF such as interior lights, all doors are closed, the
underhood lamp, etc.
4. Loosen the clamping bolt from the battery negative cable.
5. Remove the battery negative cable from the battery.
6. Position the battery negative cable away from any body ground.
1. Verify that all the electrical components are OFF such as interior lights, all doors are closed, the
underhood lamp, etc.
2. Clean corrosion from the negative battery cable using a metal brush.
3. Install the battery negative cable to the battery.
4. Install the clamping bolt to the negative cable.
Tighten: Tighten the battery negative cable to 4.5 N.m (40 lb in).
5. Reset the radio stations and the clock.
STARTER MOTOR REPLACEMENT
Removal Procedure
2005 Chevrolet Aveo
Fig. 15: View Of Starter


2. Remove the upper and the lower starter mounting bolts.
2005 Chevrolet Aveo
Fig. 16: View Of Starter Assembly

3. Remove the starter solenoid nuts to disconnect the electrical cable.

4. Remove the starter assembly.
2005 Chevrolet Aveo
Fig. 17: View Of Starter

1. Place the starter assembly in position.
2. Install the upper and the lower starter mounting bolts.
Tighten: Tighten the starter mounting bolts to 43 N.m (32 lb ft).
2005 Chevrolet Aveo
Fig. 18: View Of Starter Assembly

3. Position the starter electrical wire on the solenoid terminal.

4. Install the starter solenoid nuts.
Tighten: Tighten the starter solenoid nuts to 15 N.m (11 lb ft).
5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure.
GENERATOR REPLACEMENT
Removal Procedure
2005 Chevrolet Aveo
Fig. 19: View Of Valve Cover Breather Hose


2. Disconnect the intake air temperature (IAT) sensor electrical connector from the air intake tube.
2005 Chevrolet Aveo
Fig. 20: Locating Intake Ducting To Engine

3. Remove the breather tube clamp and all other clamps to remove the air intake tube.
2005 Chevrolet Aveo
Fig. 21: View Of Generator Voltage Regulator

4. Remove the battery harness connector nut from the generator.
2005 Chevrolet Aveo
Fig. 22: View Of Alternator Bracket And Retaining Nut

5. Remove the generator shackle bracket bolt.
2005 Chevrolet Aveo
Fig. 23: View Of Serpentine Accessory Drive Belt Tensioner

6. Remove the serpentine accessory drive belt. For vehicles equipped with power steering and air
conditioning. Refer to Power Steering Pump Drive Belt Replacement in Power Steering.
2005 Chevrolet Aveo
Fig. 24: Removing And Installing Generator, Nuts And Bracket-To-Generator Bolts
7. Remove the nuts which hold the generator lower bracket-to-generator bolts.
8. Carefully remove the generator.
2005 Chevrolet Aveo
Fig. 25: Removing And Installing Generator, Nuts And Bracket-To-Generator Bolts
1. Install the generator at the generator lower bracket and insert the generator bolts.
2. Install the nut and the washers on the generator lower bracket-to-generator bolts.
Tighten: Tighten the generator lower bracket-to-generator nuts to 25 N.m (18 lb ft).
2005 Chevrolet Aveo
Fig. 26: Installing Generator, Lower Support Bracket Assembly, And Bolts
3. Install the generator and the lower support bracket assembly to the engine block with the bolts.
4. Secure the generator to the shackle bracket with the bolt.
Tighten: Tighten the generator shackle bracket bolt to 25 N.m (18 lb ft).
2005 Chevrolet Aveo
Fig. 27: View Of Generator Voltage Regulator

5. Connect the harness connector to the back of the generator.

6. Install the generator lead to the battery and fasten the lead with the nut.
Tighten: Tighten the generator battery lead nut to 15 N.m (11 lb ft).
2005 Chevrolet Aveo
Fig. 28: Locating Intake Ducting To Engine

7. Install the air intake tube and the connector.
2005 Chevrolet Aveo
Fig. 29: View Of Valve Cover Breather Hose

8. Install the IAT electrical connector to the air intake tube.

9. Connect the negative battery cable.
STARTER MOTOR OVERHAUL
Disassembly Procedure
2005 Chevrolet Aveo
Fig. 30: Removing Starter And Through-Bolts

NOTE: Never operate the starter motor more than 15 seconds at a time without
pausing in order to allow it to cool for at least 2 minutes. Overheating will
damage the starter motor.
1. Remove the starter. Refer to Starter Motor Replacement.

2. Remove the starter through-bolts.
2005 Chevrolet Aveo
Fig. 31: View Of Commutator End Frame And Brush Holder Assembly
3. Remove the commutator end frame and brush holder assembly.

4. Inspect the brushes, the pop-out springs, and the brush holders for wear and damage. Replace the
assembly, if needed.
5. Check the armature to see if it turns freely. If the armature does not turn freely, break down the assembly
immediately, starting with Step 14. Otherwise, give the armature a no-load test.
2005 Chevrolet Aveo
Fig. 32: View Of Voltage Readings, Switch and RPM

NOTE: Complete the testing as quickly as possible in order to prevent

overheating and damaging the solenoid.
IMPORTANT: If the specified current draw does not include the solenoid, deduct from
the armature reading (1) the specified current draw of the solenoid hold-in
winding.
6. To begin the no-load test, close the switch (3) and compare the RPM (4), the current, and the voltage
2005 Chevrolet Aveo
readings (2) with the specifications. Refer to Starter Motor Usage. Make disconnections only with the
switch open. Use the test results as follows:
1. Rated current draw and no-load speed indicate a normal condition for the starter motor.
2. Low RPM combined with high current draw is an indication of excessive friction caused by tight,
dirty, or worn bearings; a bent armature shaft; a shorted armature; or shorted field coils.
3. Failure to operate with high current draw indicates a direct ground in the terminal or fields, or
frozen bearings.
4. Failure to operate with no current draw indicates an open field circuit, open armature coils, broken
brush springs, worn brushes, high insulation between the commutator bars, or other causes which
would prevent good contact between the brushes and the commutator.
5. Low, no-load speed and low current indicate high internal resistance and high current draw, which
usually mean shorted fields.
Fig. 33: View Of Solenoid Assembly And Screws

7. Remove the solenoid assembly screws.
2005 Chevrolet Aveo
Fig. 34: View Of Field Connector

8. Remove the field connector nut. Disconnect the field connector.
2005 Chevrolet Aveo
Fig. 35: View Of Solenoid Assembly

9. Remove the plunger return spring.
2005 Chevrolet Aveo
2005 Chevrolet Aveo
Fig. 36: View Of Ammeter And Carbon Pile

IMPORTANT: If the solenoids is not removed from the starting motor, the connector
strap terminals must be removed from the terminal on the solenoid before
making these tests.
10. Test the solenoid windings by checking the current draw.

1. Check the hold-in windings by connecting an ammeter (3) in series with a 12-volt battery, the
switch terminal (2), and to ground.
2. Connect the carbon pile (4) across the battery.
3. Adjust the voltage to 10 bolts. The ammeter reading should be 13 to 19 amperes. Current will
decrease as the windings heat up. Current draw readings that are over specifications indicate
shorted turns or a ground in the windings of the solenoid. Both conditions require replacement of
the solenoid. Current draw readings that are under specifications indicate excessive resistance. No
reading indicates an open circuit.
2005 Chevrolet Aveo
Fig. 37: View Of Shield, Armature And Field Frame Assembly

IMPORTANT: Current will decrease as the windings heat up. Current draw readings that
are over specifications indicate shorted turns or a ground in the windings
of the solenoid. Both conditions require replacement of the solenoid.
Current draw readings that are under specifications indicate excessive
resistance. No reading indicates an open circuit.
11. Check both windings, connecting them according to the preceding test.
1. Ground the solenoid motor terminal.
2. Adjust the voltage to 10 volts. The ammeter reading should be 59-79 amperes.
3. Check the connections and replace the solenoid, if necessary.
12. Slide the field frame with enclosed armature assembly away from the starter assembly.
2005 Chevrolet Aveo
13. Remove the shield.
Fig. 38: Separating Field Frame And Armature

14. Separate the field frame from the armature.
2005 Chevrolet Aveo
Fig. 39: View Of Armature

15. Inspect the shaft and the pinion for discoloration, damage, or wear. Replace, if necessary.
16. Inspect the armature commutator. If the commutator is rough, it should be turned down. The outside
diameter of the commutator must measure at least 26.9-27.1 mm (1.059-1.067 in) after it is undercut or
turned. Do not turn out-of-round commutators.
17. Inspect the points where the armature conductors join the commutator bars. Make sure they have a good
connection. A burned commutator bar is usually evidence of a poor connection.
18. If the test equipment is available, check the armature for short circuits by placing it on a growler, and
holding back a saw blade over the armature core while the armature is rotated. If the saw blade vibrates,
replace the armature.
19. Recheck the armature after cleaning between the commutator bars. If the saw blade vibrates, replace the
armature.
2005 Chevrolet Aveo
Fig. 40: View Of Locking Ring And Drive Shaft

20. Remove the locking ring from the groove in the driveshaft.
2005 Chevrolet Aveo
Fig. 41: View Of Pinion Stop, Drive, And Driveshaft

21. Remove the pinion stop and the drive from the driveshaft.
2005 Chevrolet Aveo

22. If not done in the previous steps, remove the screws that hold the solenoid assembly into the housing, and
remove the nut from the field coil connector.
2005 Chevrolet Aveo

23. Rotate the solenoid 90 degrees and remove it along with the return spring.
2005 Chevrolet Aveo
Fig. 44: View Of Shift Lever, Washer And Cushion

24. Remove the plunger with the boot and the shift lever assembly. Test the solenoid windings, if not done in
Step 11.
2005 Chevrolet Aveo
Fig. 45: View Of Pinion Clearance

IMPORTANT: The pinion clearance must be correct to prevent the buttons on the shift
2005 Chevrolet Aveo
lever yoke from rubbing on the clutch collar during the cranking.
25. When the starter motor is disassembled and the solenoid is replaced, it is necessary to check the pinion
clearance.
Fig. 46: View Of Pinion

26. Disconnect the motor field coil connector from the solenoid motor terminal and carefully insulate the
connector.
27. Connect one 12-volt battery lead to the solenoid switch terminal and the other to the starter frame.
28. Flash a jumper lead momentarily from the solenoid motor terminal to the starter frame, allowing shifting
of the pinion in the cranking position, where it will remain until the battery is disconnected.
2005 Chevrolet Aveo
IMPORTANT: A means for adjusting the pinion clearance is not provided on the starter
motor. If the clearance does not fall within the limits, check for improper
installation and replace all worn parts.
29. Push the pinion back as far as possible to take up any movement, and check the clearance with a feeler
gage. The clearance should be 0.25 to 3.56 mm (0.01 to 0.14 in).
Assembly Procedure
Fig. 47: View Of Pinion Stop, Drive, And Driveshaft

CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.
1. Install the drive and the pinion stop on the driveshaft.
2005 Chevrolet Aveo
Fig. 48: View Of Locking Ring And Drive Shaft

2. Install the lock ring to the groove on the driveshaft and insert the collar.
2005 Chevrolet Aveo

3. Install the shift lever, washer and the cushion.
2005 Chevrolet Aveo
Fig. 50: View Of Armature

4. Lubricate the drive end of the armature shaft with lubricant.
2005 Chevrolet Aveo

5. Position the solenoid assembly.
2005 Chevrolet Aveo

6. Fasten the solenoid assembly with the screws.
Tighten: Tighten the starter solenoid assembly screws to 8 N.m (71 lb in).
7. Install the field coil connection to the starter terminal. Install the nut.
Tighten: Tighten the starter field coil connector nut to 8 N.m (71 lb in).
2005 Chevrolet Aveo
Fig. 53: View Of Shield, Armature And Field Frame Assembly

8. Position the armature assembly into the field frame.

9. Place the shield on the armature and field frame assembly.
10. Install the armature and field frame assembly with the shield into the starter housing.
2005 Chevrolet Aveo

11. Position the commutator end frame/brush holder assembly, lining up the end frame holes with the
through-bolt holes in the housing.
2005 Chevrolet Aveo
Fig. 55: Removing Starter And Through-Bolts

12. Install the starter through-bolts.

13. Install the starter. Refer to Starter Motor Replacement.
Tighten: Tighten the starter through-bolts to 6 N.m (53 lb in).
GENERATOR OVERHAUL
Disassembly Procedure
2005 Chevrolet Aveo
Fig. 56: Removing Generator

1. Remove the generator. Refer to Generator Replacement.

2. Mark a match line that cannot easily be removed on the end frame to make assembly easier.
3. Pry off the plastic cover to expose the stator connections.
2005 Chevrolet Aveo
Fig. 57: View Of Stator Connections And Rectifier Bridge Terminals

NOTE: If the stator connections are welded in, use just enough heat to melt the
lead. Avoid using to much heat as it can damage the diodes.
4. Remove the stator connections from the rectifier bridge terminals by cutting the wires.
2005 Chevrolet Aveo
Fig. 58: Removing Rectifier, Regulator, And Brush Hold Assembly Screws
5. Pry off the baffle.

6. Remove the rectifier/regulator/brush hold assembly screws.
IMPORTANT: If the brush can be reused, reassemble the brush to the holder with the
retaining pin, after cleaning the brush with a soft, clean cloth.
7. Remove the brush holder assembly and the regulator.
2005 Chevrolet Aveo
Fig. 59: Testing Rectifier Bridge Using Ohmmeter Terminals

8. Test the rectifier bridge by connecting the ohmmeter terminals to the bridge and the heat sink.
2005 Chevrolet Aveo
Fig. 60: Retesting Using Ohmmeter Terminals In Reverse

9. Retest by connecting the ohmmeter terminals in reverse.
2005 Chevrolet Aveo
Fig. 61: Testing Rectifier Bridge Using Ohmmeter Terminals

10. Replace the rectifier bridge, if each reading is the same.

11. Test the remaining two diodes after the above procedure.
IMPORTANT: Some kinds of digital ohmmeters are not suited for the test of the bridge
diode. In this case, consult the manufacturer regarding the test capacity.
12. Test the diodes by connecting the ohmmeter terminals to the bridge terminal and the base plate. If the
reading is the same, the rectifier bridge should be replaced.
2005 Chevrolet Aveo
Fig. 62: View Of Generator Through-Bolts

13. Remove the generator through-bolts.
2005 Chevrolet Aveo
Fig. 63: View Of Generator Drive End And Drive End Bearing Nut
IMPORTANT: The fastening torque of this nut is 81 N.m (60 lb ft) and may not normally
be unfastened using hand strength.
14. Move to the drive end of the generator and remove the drive end bearing nut.
15. Remove the pulley and the collars.
2005 Chevrolet Aveo
Fig. 64: Testing Rotor For Open Circuit Using Ohmmeter

16. Test the rotor for an open circuit using the ohmmeter with the drive end frame assembled. The reading
should be sufficiently high, or the rotor must be replaced.
2005 Chevrolet Aveo
Fig. 65: Testing Rotor For Open And Short Circuits Using Ohmmeter
17. Test the rotor for open and short circuits. The reading should be 1.7 to 2.3 ohms, or the rotor should be
replaced.
2005 Chevrolet Aveo
Fig. 66: Removing Drive End Frame

18. Remove the drive end frame from the shaft.

19. For vehicles with an internal generator fan, remove the drive end frame and the fan.
2005 Chevrolet Aveo
Fig. 67: Removing Rotor Assembly

20. Remove the rotor assembly.
2005 Chevrolet Aveo
Fig. 68: Removing Stator

21. Remove the stator.
2005 Chevrolet Aveo
Fig. 69: Testing Stator For Open Circuit Using Ohmmeter

22. Test the stator for an open circuit using the ohmmeter.
2005 Chevrolet Aveo
Fig. 70: Removing Slip Ring End Frame Ring

23. Remove the ring in the slip ring end frame.
Assembly Procedure
2005 Chevrolet Aveo
Fig. 71: View Of Generator Through-Bolts

CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.
1. Install the new ring in the slip ring end frame.

2. Install the stator.
3. Position the rotor assembly shaft with the drive end frame in the slip ring end assembly until the gap
between the outer lace and the end frame casting is 1.9 mm (0.075 in).
4. Install the generator through-bolts.
Tighten: Tighten the generator through-bolts to 10 N.m (89 lb in).
2005 Chevrolet Aveo
Fig. 72: View Of Generator Drive End And Drive End Bearing Nut
5. Position the fan, the collars, and the pulley on the rotor shaft and secure with the nut.
Tighten: Tighten the generator drive and end bearing nut to 81 N.m (60 lb ft).
6. Install the generator. Refer to Generator Replacement.
2005 Chevrolet Aveo
Fig. 73: Removing Rectifier, Regulator, And Brush Hold Assembly Screws
7. Wield the brush holder terminal to the regulator terminal, if removed.

8. Fix the brush holder with the retainer pin, and weld the regulator/brush holder assembled terminal to the
rectifier terminal.
9. Apply silicone grease between the bridge and the end frame for radiation purposes.
10. Fasten the screws holding the rectifier regulator/brush holder assembly to the end frame.
11. Punch the new baffle with the pin into the brush.
2005 Chevrolet Aveo
Fig. 74: View Of Stator Connections And Rectifier Bridge Terminals

NOTE: Protect the diode in the rectifier bridge from excessive heat while welding.
Overheating the diode will cause damage to the rectifier bridge.
12. Weld the connectors of the rectifier bridge.
DESCRIPTION AND OPERATION

BATTERY DESCRIPTION AND OPERATION
2005 Chevrolet Aveo
CAUTION: Refer to Batteries Produce Explosive Gases Caution in Cautions and

Notices.
The battery has three major functions in the electrical system. First, the battery provides a source of energy for
cranking the engine. Second, the battery acts as a voltage stabilizer for the electrical system. Finally, the battery
can, for a limited time, provide energy when the electrical demand exceeds the output of the generator.
The sealed battery is standard on all cars. There are no vent plugs in the cover. The battery is completely sealed,
except for 2 small vent holes in the sides. These vent holes allow the small amount of gas produced in the
battery to escape.
The sealed battery has the following advantages over conventional batteries:
l No water need be added for the life of the battery.

l It is protected against overcharge. If too much voltage is applied to the battery, it will not accept as much
current as a conventional battery. In a conventional battery, the excess voltage will still try to charge the
battery, leading to gassing, which causes liquid loss.
l It is not as liable to self-discharge as a conventional battery. This is particularly important when a battery
is left standing for long periods of time.
l It has more power available in a lighter and a smaller case.
Ratings
A battery has two ratings:
1. a reserve capacity rating designated at 27°C (80°F), which is the time a fully charged battery will provide
25 amperes current flow at or above 10.5 volts;
2. A cold cranking amp rating determined under testing at -18°C (0°F), which indicates the cranking load
capacity.
Reserve Capacity
The reserve capacity is the maximum length of time it is possible to travel at night with the minimum electrical
load and no generator output. Expressed in minutes, Reserve Capacity (or RC rating) is the time required for a
fully charged battery, at a temperature of 27°C (81°F) and being discharged at a current of 25 amperes, to reach
a terminal voltage of 10.5 volts.
Cold Cranking Amperage
The cold cranking amperage test is expressed at a battery temperature of -18°C (0°F). The current rating is the
minimum amperage, which must be maintained by the battery for 30 seconds at the specified temperature, while
meeting a minimum voltage requirement of 7.2 volts. This rating is a measure of cold cranking capacity.
The battery is not designed to last indefinitely. However, with proper care, the battery will provide many years
of service.
2005 Chevrolet Aveo
If the battery tests well, but fails to perform satisfactorily in service for no apparent reason, the following factors
may point to the cause of the trouble:
l Vehicle accessories are left on overnight.

l Slow average driving speeds are used for short periods.
l The vehicle's electrical load is more than the generator output, particularly with the addition of
aftermarket equipment.
l There are defects in the charging system, such as electrical shorts, a slipping generator belt, a faulty
generator, or a faulty voltage regulator.
l There has been battery abuse, including failure to keep the battery cable terminals clean and tight, or a
loose battery hold-down.
l There are mechanical problems in the electrical system, such as shorted or pinched wires.
Built-In Hydrometer
The sealed battery has a built-in, temperature-compensated hydrometer in the top of the battery. This
hydrometer is to be used with the following diagnostic procedure:
1. When observing the hydrometer, make sure that the battery has a clean top.
2. Under normal operation, two indications can be observed:
l GREEN DOT VISIBLE - Any green appearance is interpreted as a green dot, meaning the battery
is ready for testing.
l DARK GREEN DOT IS NOT VISIBLE - If there is a cranking complaint, the battery should be
tested. The charging and electrical systems should also be checked at this time.
3. Occasionally, a third condition may appear:
CLEAR OR BRIGHT YELLOW - This means the fluid level is below the bottom of the hydrometer. This
may have been caused by excessive or prolonged charging, a broken case, excessive tipping, or normal
battery wear. Finding a battery in this condition may indicate high charging by a faulty charging system.
Therefore, the charging and the electrical systems may need to be checked if a cranking complaint exists.
If the cranking complaint is caused by the battery, replace the battery.
CHARGING SYSTEM DESCRIPTION AND OPERATION
1. Batteries with the green dot showing do not require charging unless they have just been discharged, such
as in cranking a vehicle.
2. When charging sealed-terminal batteries out of the vehicle, install the adapter kit. Make sure all the
charger connections are clean and tight. For best results, batteries should be charged while the electrolyte
and the plates are at room temperature. A battery that is extremely cold may not accept current for several
hours after starting the charger.
3. Charge the battery until the green dot appears. The battery should be checked every half-hour while
charging. Tipping or shaking the battery may be necessary to make the green dot appear.
4. After charging, the battery should be load tested. Refer to Battery Inspection/Test.
Charging Time Required
2005 Chevrolet Aveo
The time required to charge a battery will vary depending upon the following factors:
l Size of Battery - A completely discharged large heavy-duty battery requires more than twice the
recharging as a completely discharged small passenger car battery.
l Temperature - A longer time will be needed to charge any battery at -18°C (0°F) than at 27°C (81°F).
When a fast charger is connected to a cold battery, the current accepted by the battery will be very low at
first. The battery will accept a higher current rate as the battery warms.
l Charger Capacity - A charger which can supply only 5 amperes will require a much longer charging
period than a charger that can supply 30 amperes or more.
l State-of-Charge - A completely discharged battery requires more than twice as much charge as a one half
charged battery. Because the electrolyte is nearly pure water and a poor conductor in completely
discharged battery, the current accepted by the battery is very low at first. Later, as the charging current
causes the electrolyte acid content to increase, the charging current will likewise increase.
Charging a Completely Discharged Battery (Off The Vehicle)
Unless this procedure is properly followed, a perfectly good battery may be needlessly replaced.
The following procedure should be used to recharge a completely discharged battery:
1. Measure the voltage at the battery terminals with an accurate voltmeter. If the reading is below 10 volts,
the charge current will be very low, and it could take some time before the battery accepts the current in
excess of a few milliamperes. Refer to the paragraph above to Charging Time Required which focuses on
the factors affecting both the charging time required and the rough estimates in the table below. Such low
current may not be detectable on ammeters available in the field.
2. Set the battery charger on the high setting.
IMPORTANT: Some charges feature polarity protection circuitry, which prevents

charging unless the charger leads are correctly connected to the battery
terminals. A completely discharged battery may not have enough voltage
to activate this circuitry, even though the leads are connected properly,
making it appear that the battery will not accept charging current.
Therefore, follow the specific charger manufacturer's instruction for
bypassing or overriding the circuitry so that the charger will turn on and
charge a low-voltage battery.
3. Battery chargers vary in the amount of voltage and current provided. The time required for the battery to
accept a measurable charger current at various voltages may be a follows:
Charging System Description and Operation

Voltage Hours
16.0 or more Up to 4 hours
14.0-15.9 Up to 8 hours
13.9 or less Up to 16 hours
l If the charge current is not measurable at the end of the above charging times, the battery should be
2005 Chevrolet Aveo
replaced.
l If the charge current is measurable during the charging time, the battery is good, and charging should be
completed in the normal manner.
IMPORTANT: It is important to remember that a completely discharged battery must be

recharged for a sufficient number of ampere hours (AH) to restore the
battery to a usable state. As a general rule, using the reserve capacity
(RC) rating as the number of ampere hours of charge usually brings the
green dot into view.
l If the charge current is still not measurable after using the charging time calculated by the above method,
the battery should be replaced.
l If the charge current is measurable during the charging time, the battery is good, and charging should be
completed in the normal manner.
Jump Starting Procedure
NOTE: Refer to Ignition OFF When Disconnecting Battery Notice in Cautions and
Notices.
1. Position the vehicle with the good (charged) battery so that the jumper cables will reach from the one
battery to the other.
2. Turn off the ignition, all the lights, and all the electrical loads in both vehicles. Turn on the hazard
flashers if jump starting where there is traffic. In addition, turn on any other lights needed for the work
area.
3. In both vehicles, apply the parking brake firmly.
NOTE: Route the accelerator cable through the groove in throttle body lever.
Securely seat the accelerator cable.
4. Shift an automatic transaxle to PARK, or a manual transaxle to NEUTRAL.
CAUTION: Cables that have missing or loose insulation should be replaced.

Failure to properly maintain cables could result in personal injury or
vehicle damage.
5. Clamp one end of the first jumper cable to the positive terminal on the battery. Make sure it does not
touch any other metal parts. Clamp the other end of the same cable to the positive terminal on the other
battery. Never connect the other end to the negative terminal of the discharged battery.
CAUTION: Do not connect a jumper cable directly to the negative terminal of a

discharged battery to prevent sparking and possible explosion of
battery gases.
6. Clamp one end of the second cable to the negative terminal of the booster battery. Make the final
2005 Chevrolet Aveo
connection to a solid engine ground, such as the engine lift bracket, at least 450 mm (18 in) from the
discharged battery.
7. Start the engine of the vehicle with the good battery. Run the engine at a moderate speed for several
minutes. Then start the engine of the vehicle which has the discharged battery.
8. Remove the jumper cables by reversing the above sequence exactly. Remove the negative cable from the
vehicle with the discharged battery first. While removing each clamp, take care that it does not touch any
other metal while the other end remains attached.
Generator
The charging system has several models available, including the 0114D (ValeoMando) or the CS-121D
(Delphi). The number denotes the outer diameter, in millimeters of the stator lamination.
CS generators are equipped with internal regulators. The Y connection (ValeoMando) or Delta (Delphi) stator, a
rectifier bridge, and a rotor with slip rings and brushes are electrically similar to earlier generators. A
conventional pulley and fan are used. There is no test hole.
Unlike three-wire generators, the 0114D (ValeoMando) or CS-121D (Delphi) may be used with only two
connections; battery positive and an L terminal to the charge indicator lamp. Use of the "P", "I", and "S"
terminals is optional. The "P" terminal is connected to the stator and may be connected externally to a
tachometer or other device.
As with other charging systems, the charge indicator lamp lights when the ignition switch is turned to ON, and
goes out when the engine is running. If the charge indicator is on with the engine running, a charging system
defect is indicated. This indicator light will glow at full brilliance for several kinds of defects, as well as when
the system voltage is too low.
The regulator voltage setting varies with temperature and limits the system voltage by controlling the rotor field
current. The mono regulator having 2-3 pins in the terminal can be applied for generator. The regulator
maintains the system voltage by controlling field current on-off without typically fixed frequency.
Charging System
The generator provides DC voltage to operate the vehicle's electrical systems and to recharge the battery. Built-
in regulators control the voltage output of the generator. When the ignition switch is turned to the ON position,
battery voltage is applied through the F4 fuse, and the charge indicator to the regulator in the generator. When
the generator is not rotating, the regulator provides a good ground and causes the charge indicator to light.
Voltage from the F7 fuse also generates a magnetic field around the field coil. As the engine starts and the
generator begins to rotate, a voltage is also generated in the stator. The voltage regulator senses this voltage and
takes control of the field current. AC voltage is generated in 3 stator coils. This AC voltage is converted to DC
voltage in the rectifier bridge. The DC output, after being regulated by the voltage regulator, is applied to the
vehicle's battery and electrical supply circuits at the BAT terminal of the generator. A separate output voltage is
provided to the charge indicator. Since equal voltage is now being provided to both sides of the charge
indicator, the lamp loses its ground and goes out. The voltage regulator is also connected to battery voltage
through the generator BAT terminal. When the battery is fully charged, the voltage regulator decreases field
excitation. This reduces the output of the generator to prevent overcharging. When the battery has been
discharged or is heavily loaded, the voltage regulator increases the field excitation and voltage output of the
generator.
2005 Chevrolet Aveo
STARTING SYSTEM DESCRIPTION AND OPERATION
Wound field starter motors have pole pieces, arranged around the armature, which are energized by wound field
coils.
Enclosed shift lever cranking motors have the shift lever mechanism and the solenoid plunger enclosed in the
drive housing, protecting them from exposure to dirt, icy conditions, and splashes.
In the basic circuit, solenoid windings are energized when the switch is closed. The resulting plunger and shift
lever movement causes the pinion to engage the engine flywheel ring gear. The solenoid main contacts close.
Cranking then takes place.
When the engine starts, pinion overrun protects the armature from excessive speed until the switch is opened, at
which time the return spring causes the pinion to disengage. To prevent excessive overrun, the switch should be
released immediately after the engine starts.
Starting System
The engine electrical system includes the battery, the ignition, the starter, the generator, and all the related
wiring. Diagnostic tables will aid in troubleshooting system faults. When a fault is traced to a particular
component, refer to that component section of the service manual.
The starting system circuit consists of the battery, the starter motor, the ignition switch, and all the related
electrical wiring. All of these components are connected electrically.
SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS
Special Tools
Illustration Tool Number/ Description
J 36169-A
Fused Jumper Wire
J 38758
Parasitic Draw Test Tool
2005 Chevrolet Aveo
J 39200
Digital Multimeter
J 42000
Digital Battery Tester

Chevrolet Aver 2005 Sistema de Arranque y Carga

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2005 Chevrolet Aveo

2005 ENGINE Engine Electrical - Aveo, (Swift+ & Wave Canadian)

Engine Electrical - Aveo, (Swift+ & Wave Canadian)

Fastener Tightening Specifications

Battery Voltage Specifications

martes, 9 de junio de 2020 15:37:59

STARTER MOTOR USAGE

Starter Motor Usage

Starter-Manual (No-Load Test Current Draw)

Starter-Automatic (No-Load Test Current Draw)

SCHEMATIC AND ROUTING DIAGRAMS

Fig. 1: Starting Systems Schematics

Fig. 2: Charging Systems Schematics

Fig. 3: Generator and Starter Component Views

Callouts For Fig. 3

Fig. 4: Ignition Switch Component Views

Callouts For Fig. 4

Fig. 5: I/P Fuse Block Component Views

Callouts For Fig. 5

8 Rear Fog Relay (RHD)

Fig. 6: Generator Assembly DOHC Component Views

Callouts For Fig. 6

ENGINE ELECTRICAL CONNECTOR END VIEWS

Clutch Start Switch

Pin Wire Color Circuit No. Function

Pin Wire Color Circuit No. Function

Pin Wire Color Circuit No. Function

1 RD/BK 341 Ignition 3 Voltage

Park/Neutral Position (PNP) Relay

Pin Wire Color Circuit No. Function

DIAGNOSTIC INFORMATION AND PROCEDURES

l Battery Description and Operation

l Charging System Description and Operation

DIAGNOSTIC SYSTEM CHECK - ENGINE ELECTRICAL

Diagnostic System Check - Engine Electrical

DIAGNOSTIC TROUBLE CODE (DTC) LIST

Diagnostic Trouble Code (DTC) List

This diagnostic procedure supports the following DTC:

DTC P0562 System Voltage Low

Conditions for Running the DTC

l The ignition is ON with the engine OFF.

Conditions for Setting the DTC

Action Taken When the DTC Sets

Conditions for Clearing the DTC

Is the voltage more than the specified value? Go to Step 3 Go to Step 4

Is the battery voltage and Ignition 1 parameter

1. Clear the DTCs with a scan tool.

2. Turn OFF the ignition for 30 seconds.

Did the DTC fail this ignition? Go to Step 2 Go to Step 9

This diagnostic procedure supports the following DTC:

DTC P0563 System Voltage High

Conditions for Running the DTC

l The ignition is ON with the engine OFF.

Conditions for Setting the DTC

Action Taken When the DTC Sets

Conditions for Clearing the MIL/DTC

Is the voltage less than the specified value? Go to Step 3 Go to Step 4

Is the battery voltage and Ignition 1 parameter

Did the DTC fail this ignition? Go to Step 2 Go to Step 7

SYMPTOMS - ENGINE ELECTRICAL

l Battery Description and Operation

properly, remove and test the starter motor.

l Starter Solenoid Does Not Click