Top 10 2004 Chevrolet Aveo Questions & Answers

A couple of days ago my brake lights on my 2004 Chevy Aveo wouldn't work, so I attempted to remove the lamp covers to check the bulbs. Also, before this my shifter would get stuck in park and could only be released by pressing the unlock gadget next to the shifter. Back to the brakes...Well, you open the trunk and remove the two screws just like the manual said, but it was very hard to pull off. There's 2 prongs holding the other half of the light on. The lamp will come loose by prying it (very hard). You think the cover will break, but it'll come loose. The bulbs were all OK.

After much frustration and internet info, the STOP LAMP SWITCH, GM#96436331 ($9.30 at Chevy dealer), which is located under the dash and has contact with the brake pedal, was defective. Once replaced, both my brake lights AND SHIFTING problems were cured. So if the brake lights suddenly don't work or you have problems getting the vehicle out of park, check the switch by pushing the prong (end that has contact with brake) of the switch in and out. If it doesn't retract smoothly...that's the PROBLEM. Good Luck.

Try these...the same thing happened to me last year and I found these. Mine was 3346; good luck.
1156, 1165, 1325, 2145, 2151, 2152,
2253, 2346, 2453, 2654, 3116, 3221,
3241, 3251, 3265, 3346, 3451, 3462,
4136, 4314, 4316, 4362, 4513, 4524,
4853, 5241, 5253, 5312, 5436, 5445,
5624, 5813, 6361, 6451, 6645, 8253

2004 ENGINE
Engine Mechanical - 1.6L (L91) - Aveo
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications
Application
Specification
Metric English
A/C Compressor Mounting Bolts 27 N.m 20 lb ft
A/C Compressor Mounting Bracket Bolts 50 N.m 37 lb ft
Air Filter Housing Bolts 12 N.m 106 lb in
Alternator Adjusting Bolt 20 N.m 15 lb ft
Alternator Adjusting Bracket Retaining Bolt 20 N.m 15 lb ft
Auxiliary Catalytic Converter-to-Exhaust Manifold
Nuts and Bracket Bolts
40 N.m 30 lb ft
Camshaft Cap Bolts 16 N.m 12 lb ft
Camshaft Gear Bolt 67.5 N.m 49 lb ft
Camshaft Pressure Plate Bolts 10 N.m 89 lb in
Connecting Rod Bearing Cap Bolts 25 N.m+30°+15° 18 lb ft+30°+15°
Coolant Pump Retaining Bolts 10 N.m 89 lb in
Coolant Temperature Sensor 20 N.m 15 lb ft
Crankshaft Bearing Cap Bolts 50 N.m+45°+15° 37 lb ft+45°+15°
Crankshaft Position Sensor Retaining Bolt 10 N.m 89 lb in
Crankshaft Pulley Bolt 95 N.m+30°+15° 70 lb ft+30°+15°
Cylinder Head Bolts - Camshaft Support Housing
and Cylinder Head Mounting Bolts
25 N.m+60°+60°
+60°+15°
18 lb ft+60°+60°
+60°+10°
Electronic Ignition System Ignition Coil Mounting
Bolts
10 N.m 89 lb in
Electronic Ignition System Ignition Coil Mounting
Plate Bolts 10 N.m 89 lb in
Engine Mount Bracket Retaining Bolt 65 N.m 48 lb ft
Engine Mount Bracket-to-Engine Mount Retaining
Bolts
60 N.m 44 lb ft
Engine Mount Retaining Nuts 40 N.m 30 lb ft
Exhaust Flexible Pipe Bracket Bolts 40 N.m 30 lb ft
Exhaust Gas Recirculation Valve Adapter Bolts 25 N.m 18 lb ft
Exhaust Manifold Heat Shield Bolts 15 N.m 11 lb ft
Exhaust Manifold Nuts 25 N.m 18 lb ft
Flexible Plate Bolts 60 N.m 44 lb ft
Flexible Plate Inspection Cover Bolts 10 N.m 89 lb in
Flywheel Bolts 35 N.m+30°+15° 26 lb ft+30°+15°
Flywheel Inspection Cover Bolts 12 N.m 106 lb in
Front Muffler-to-Main Catalytic Converter Nuts 30 N.m 22 lb ft
Fuel Rail Retaining Bolts 25 N.m 18 lb ft
MITCHELL 1 ARTICLE - 2004 ENGINE Engine Mechanical - 1.6L (L91) - Aveo Page 1 of 330
http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7BEEDCF... 3/30/2009
ENGINE MECHANICAL SPECIFICATIONS
Engine Mechanical Specifications
Intake Manifold Retaining Nuts 25 N.m 18 lb ft
Intake Manifold Support Bracket Lower Bolt-to-
Engine Block 40 N.m 30 lb ft
Intake Manifold Support Bracket Upper Bolts 25 N.m 18 lb ft
Lower Timing Belt Cover Bolts 10 N.m 89 lb in
Oil Pan Retaining Bolts 10 N.m 89 lb in
Oil Pressure Switch 40 N.m 30 lb ft
Oil Pump Retaining Bolts 10 N.m 89 lb in
Oil Pump/Pickup Tube and Support Bracket Bolts 10 N.m 89 lb in
Oil Pump Safety Relief Valve Bolt 36 N.m 22 lb ft
Oil Pump Rear Cover Bolts 6 N.m 53 lb in
Power Steering Pump Mounting Bolts 25 N.m 18 lb ft
Power Steering Pump Pulley Bolts 25 N.m 18 lb ft
Rear Timing Belt Cover Bolts 10 N.m 89 lb in
Spark Plug Cover Bolts 3 N.m 27 lb in
Spark Plugs 25 N.m 18 lb ft
Thermostat Housing Mounting Bolts 20 N.m 15 lb ft
Throttle Cable Bracket Bolts 8 N.m 71 lb in
Timing Belt Automatic Tensioner Bolt 25 N.m 18 lb ft
Timing Belt Idler Pulley Bolt 40 N.m 30 lb in
Transaxle Bell Housing Bolts 75 N.m 55 lb ft
Transaxle Brace Bolts 40 N.m 30 lb ft
Transaxle Torque Converter Bolts 65 N.m 48 lb ft
Upper Timing Belt Cover Bolts 10 N.m 89 lb in
Valve Cover Bolts 10 N.m 89 lb in
Application
Specification
Metric English
General Data

Engine Type 4 Cylinder - In-Line

Displacement 1598 cm3 97.51 in3

Bore Stroke 79.0x81.5 mm 3.1x3.21 in

Compression Ratio 9.5:1

Firing Order 1-3-4-2

Maximum Power - At 6200 RPM 77 kw/103.3 hp

Maximum Torque - At 3400 RPM 145 N.m 106.9 lb ft
Cylinder Bore

Diameter 79 mm 3.1 in

Out of Round - Maximum 0.0065 mm 0.00025 in

Taper - Maximum 0.0065 mm 0.00025 in
Piston
MITCHELL 1 ARTICLE - 2004 ENGINE Engine Mechanical - 1.6L (L91) - Aveo Page 2 of 330

There are 16 possible codes: 1156, 1165, 1251. 2145, 2152, 3241, 3346, 3351, 3451, 4316, 4362, 4313, 4524, 5241, 5624, 6361

1.Release parking brake.
2. Apply the brake pedal at least 10 times.
3. Raise and support vehicle with jack stands, etc.
4. Remove the tire and wheel assembly.
5. Remove the lock ring and the caulking nut from the spindle.
6. Remove the drum from the spindle.
Note: Pull the drum straight off the spindle.

There is an opening on the inside for adjusting the tension,It's under a rubber cap.You can use a screw driver to make the adjustment

Hello Joe...The Aveo has had it shares of problems, and this is one of them....NHTSA issued several bulletins on the 04 Aveo...this following is the one pertaining to the shift interlock.....

Make : CHEVROLET Model : AVEO Year : 2004
Manufacturer : GENERAL MOTORS CORP.
Service Bulletin Num : 070730007 Date of Bulletin: APR 01, 2007
NHTSA Item Number: 10022265
Component: POWER TRAIN:AUTOMATIC TRANSMISSION
Summary:
AUTOMATIC TRANSAXLE/TRANSMISSION SHIFT LEVER MAY NOT SHIFT OUT OF PARK (REPLACE BRAKE TRANSAXLE SHIFT INTERLOCK (BTSI) SOLENOID). *KB

Take that bulletin number to your dealer and see if they can help.

Untill you can get it repaired heres a little tip for getting it out of park....There is a a little hole in front of their gearshift lever that can correct the problem, temporarily. It should say "brake interlock release" or something like that. With car running, put a key-size object into it and push down while moving the lever. It does not damage the transmission, it just releases the lock. (make sure your foot is on the brake)

Now for the brake light issue...do you have power at the switch you replaced? If so go to the relay and check there...if no power there it's probably a bad ground.

Also...you may or may not know, but the timing belts on these Aveos are prone to failure at aprox 50k ...these failures have caused severe engine damage.
Good luck...i hope the information i've provided you find useful.
Please time to rate me.

check tps sensor (throttle position sensor in backside of the throttle cable) and map sensor (manifold absolute pressure on front little 1 inch sensor with vacuum line) make sure there plugged in. the ecm (engine control module driver side inner fender) and tcm (transmission control module under dash) both need the data to know when to upshift and increase fuel/air. Otherwise the computer runs default values and guesses off of other sensors giving poor performance. also disconnect battery for 15 min. usually resets aveo service lights if you dont have a scanner.

This also happened to my 2004 Chevy Aveo. The drivers side rear wheel locked up when it first got extremely cold in December 2009. I had to change the rear wheel cylinder because it broke. They also found the rear wheel bearing also had to be changed. GM charges $180 for 1 rear wheel bearing. To make matters worse I had to order the whole backing plate which came with the rear wheel cylinder and a whole bunch of hardware.
If you look in the GM manual it says that you should flush and change your brake fluid every 24 months. My mechanic told me that moisture normal wrecks the brake cylinder. I'm not sure what happened to the wheel bearing but from now on I'll make sure to flush my brake fluid every 24 months.

For the 2004 Chevrolet Aveo 1.6L DOHC In-Line 4-Cylinder:

Firing Order:
1-3-2-4

Cylinders:
.........(back)..........
|....1....2....3....4....|
.........(front)

Let me know if this helped, or if you have additional information or questions. Feel free to contact me at FixYa.com!

P2135 Throttle Position Sensor (TPS) Property Malfunction, remember this is not a car that is built by GM it is a Korean import.