Chevrolet Aveo T200 factory workshop and repair manual

- Goal: remove and reinstall (or replace) the water-pump pulley on a Chevrolet Aveo T200. Short, clear steps and tool explanations for a beginner. Follow safety warnings exactly.

Safety first
- Wear safety glasses and gloves to protect from coolant and flying debris.
- Work on a cold engine; hot coolant can cause severe burns.
- Disconnect the negative battery terminal before starting to avoid accidental starts.
- Use a quality floor jack and two jack stands on solid ground; never rely on the jack alone.
- Place wheel chocks behind the rear wheels to prevent the car from rolling.

When a part replacement is required (what, why)
- Replace the water pump assembly when the pump leaks coolant, the pulley/bearing has radial play or noise, or the pump shaft is corroded.
- Replace the pulley if it’s bent, cracked, badly corroded, or the bearing inside the pulley (if the pulley contains one) is worn.
- Prefer replacing the whole water pump assembly if the pump bearing or seal is bad — bearings and seals are often not serviceable separately and a new pump prevents repeated labor.
- Replace associated items at the same time if worn: serpentine/drive belt, belt tensioner, idler pulley, and gasket(s). This saves time and avoids repeat failures.
- Replace coolant after disassembly that allows coolant loss; a proper fresh coolant fill and bleed is required.

Tools required (detailed descriptions and how to use them)
- Floor jack
- Description: hydraulic jack rated for cars.
- Use: position under manufacturer-specified lift point, pump handle to raise, then place jack stands. Never work under a car supported only by the jack.
- Jack stands (pair), rated for vehicle weight
- Description: adjustable metal stands to hold the car safely.
- Use: set at appropriate height, lower the car onto them; ensure both stands contact solid frame points.
- Wheel chocks
- Description: rubber or plastic wedges.
- Use: put behind rear wheels to prevent roll.
- Socket set (metric) with ratchet and extensions
- Description: includes common metric sockets (8, 10, 12, 13, 14 mm commonly useful), 3/8" drive ratchet and 6" extension.
- Use: choose the correct socket for bolt heads; use extension to reach recessed bolts; pull the ratchet handle smoothly to break bolt torque.
- Combination wrench set (metric)
- Description: open+box-end wrenches in common sizes.
- Use: use box end for final loosening/tightening where a socket cannot reach.
- Breaker bar
- Description: long non-ratcheting bar for extra leverage.
- Use: place a socket on the bolt and use the bar for stubborn bolts; apply steady pressure, not jerks.
- Torque wrench (click type)
- Description: calibrated wrench to tighten bolts to specific torque.
- Use: set required torque, tighten bolts until it clicks to avoid over/under tightening. Important for pulley and pump bolts.
- Pulley holding tool or strap wrench (or pry bar used carefully)
- Description: tool to prevent the pulley/water pump shaft from turning while loosening/tightening bolts.
- Use: hold the pulley from turning while you break bolt torque. If unavailable, a hand-held strap wrench can work. Do not jam screwdrivers into the pulley — that damages parts.
- Pulley puller (universal three-jaw or two-jaw) — recommended
- Description: threaded central forcing screw and legs that hook the pulley lip to pull the pulley off a shaft.
- Why required: some water pump pulleys are pressed-on and will not come off with bolts removed; a puller removes the pulley without damaging the shaft.
- Use: hook jaws behind pulley lip, thread forcing screw to press on shaft center, tighten evenly to pull the pulley straight off. Use penetrating oil if tight. Keep hands clear when under tension.
- Penetrating oil (WD-40, PB Blaster)
- Description: lubricant that helps free rusty or seized bolts.
- Use: spray on bolts, let soak a few minutes before attempting to turn.
- Screwdrivers (flat and Phillips)
- Description: standard hand screwdrivers.
- Use: remove plastic clips or hose clamps where applicable.
- Pliers (needle-nose and slip-joint)
- Description: gripping tools.
- Use: remove spring clamps, hold small parts.
- Drain pan
- Description: container to catch coolant.
- Use: catch coolant drained from radiator or pump.
- Funnel and coolant (correct type for Aveo) + measuring jug
- Description: for refilling and measuring coolant and water mix.
- Use: refill with correct coolant mixture, bleed the cooling system according to procedure.
- Shop rags and a small flat container for bolts
- Description: keeps workspace clean and bolts organized.
- Use: wipe spilled coolant, keep bolts in order.
- Optional: Impact wrench (air or battery)
- Description: power tool that removes bolts quickly.
- Why optional: useful for stubborn bolts but can over-torque; if used, verify final torque with torque wrench.
- Optional: Service manual or printed torque specs
- Description: vehicle-specific procedure and torque numbers.
- Why required: gives exact torque values and bolt sequences; recommended to avoid damage.

Preparation steps
- Disconnect the negative battery terminal and secure away from contact with the battery post.
- Raise the front of the car with the floor jack and place it securely on jack stands; chock rear wheels.
- Remove the engine cover or undertray if it blocks access to the belt and pump.
- Drain coolant to below the water pump level or remove lower splash shield to allow coolant to be caught; place drain pan under radiator drain or loosen lower radiator hose as appropriate to reduce spills.
- Inspect and note the routing of the serpentine/drive belt or take a photo for reassembly.

Remove the drive/serpentine belt
- Locate the belt tensioner; use the correct sized socket or wrench to rotate the tensioner and relieve tension on the belt.
- While holding the tensioner off, slip the belt off the water-pump pulley and other pulleys; release the tensioner carefully back to position.
- Remove the belt from the engine compartment and set aside (or discard if aged and plan to replace).

Remove the water-pump pulley
- Inspect the pulley for visible retaining bolts in its face; if bolts are present, use the appropriate socket to remove them while holding the pulley steady with a strap wrench or pulley holding tool.
- If the pulley is bolted on and comes off easily, set it aside for inspection.
- If the pulley is pressed-on (no visible bolts holding it to the pump) or will not budge after bolts are removed, use a pulley puller:
- Hook puller jaws behind the pulley lip evenly.
- Thread the forcing screw down until it contacts the pump shaft and tighten steadily; the pulley should come straight off the shaft.
- Apply penetrating oil around the hub if it’s stubborn, and work the puller slowly until it releases.
- Keep bolts in a container and note their orientation.

Inspect parts and decide on replacement
- Check the pulley for wobble, cracks, corrosion, or damaged blade lips. Replace if any damage or if bearing noise is present.
- Rotate the removed pulley by hand (if it contains a bearing) to feel for roughness or play; any roughness or play = replace.
- Inspect the water pump shaft for play: rock the pump pulley mounting area by hand; if the pump shaft has axial or radial play or makes noise, the entire water pump needs replacement.
- Inspect the pump housing for coolant residue or crusty corrosion indicating leaks; leaking = replace pump.
- Inspect belt, tensioner, and idler pulley; any glazing, cracks, or rough bearings = replace.

Reinstallation options
- If reusing the pulley (only if it’s perfect and bearing is good), slide the pulley back onto the pump shaft:
- If it’s a press-fit pulley, press it squarely onto the shaft. Use the puller tool in reverse (or a proper press) to press the pulley on evenly — do not hit the pulley with a hammer as this can damage the bearing.
- If it’s bolted on, align the pulley and tighten bolts finger-tight first, then torque to specification with a torque wrench.
- If replacing the pulley only, use the new pulley part designed for the Aveo T200 and follow the same installation method.
- If replacing the water pump, replace the pump and gasket/seal as a unit:
- Clean mating surfaces thoroughly to remove old gasket material.
- Install new gasket/seal with proper sealant if specified.
- Bolt the new pump in place finger-tight, then torque to factory specification in a cross pattern.
- Install the new pulley onto the new pump as above.

Reassemble belt and refill
- Reinstall the serpentine/drive belt following the routing picture; rotate the tensioner and slip the belt on, then release smoothly.
- Reconnect negative battery terminal.
- Refill cooling system with the correct type and concentration of coolant; top up to the proper level.
- Start the engine and check for leaks around the pump and pulley. Allow the engine to reach operating temperature, run the heater, and watch temperature gauge.
- Recheck belt alignment and tension and retorque bolts if required after initial run-in.
- Lower the car, remove jack stands, and do a final check for leaks and belt noise.

Signs you must replace the entire water pump rather than only the pulley
- Visible coolant leakage from the pump housing or weep hole.
- Bearing play or grinding noise when spinning the pulley by hand.
- Pulley wobble caused by shaft wear.
- Corrosion or pitting on pump shaft or housing.
- If any of the above are present, buy a complete OEM or high-quality aftermarket water pump kit (pump + gasket). Also buy a new serpentine belt and, ideally, a new tensioner and idler pulley if they show wear.

Parts to buy (typical list)
- Water pump assembly (OEM or reputable aftermarket) — required if pump faulty.
- Water pump gasket or seal — always replace when pump is removed.
- Water-pump pulley (if damaged and sold separately).
- Serpentine/drive belt — inspect and replace if aged.
- Belt tensioner and idler pulley — replace if noisy or worn.
- Coolant (correct type for Aveo; check label or manual) and distilled water for mixing if needed.
- New bolts/studs if old bolts are corroded or stretched.

Final checks and test drive
- Check coolant level after the engine has cooled and top up as needed.
- Inspect for leaks and listen for unusual noises for the first few miles of driving.
- Re-torque bolts after a short test drive if manufacturer recommends.

Quick troubleshooting tips (brief)
- If belt squeal after reassembly: check belt routing, alignment, and tensioner condition.
- If overheating: check coolant level, air trapped in the cooling system, and thermostat operation.
- If new pulley won’t press on: do not force with a hammer; use a press or the proper puller/installer tool to avoid bearing damage.

End note
- If you are uncomfortable with using a pulley puller, removing the belt tensioner, or working under the car, consider a professional technician. Replacing the whole water pump and related wear items is common practice to avoid repeat labor.
rteeqp73

Aveo T200 VS Civic EP3

Building a turbocharged Chevy Aveo!!!! We have no idea why but we got this 2004 Chevy Aveo to tear apart put a new engine in and add a turbo and many other ...

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