Chevrolet Aveo T200 factory workshop and repair manual

- Safety first
- Wear safety glasses, nitrile or mechanic’s gloves, and work in a well‑ventilated area because cleaners are toxic and flammable.
- Disconnect the negative battery terminal before starting to avoid electrical shorting or accidental cranking.
- Keep a fire extinguisher nearby when using spray cleaners.

- Quick overview of two cleaning options (choose one)
- Cleaning with the intake manifold in place (less invasive, good for light carbon): remove air intake and throttle body, spray cleaner into throttle/runner ports, brush, and wipe.
- Cleaning with intake manifold removed (deep clean, needed for heavy carbon or if gasket replacement is necessary): remove manifold, clean thoroughly on a bench, inspect and replace gaskets/PCV parts as needed.

- Basic tools you already should have (descriptions + how to use)
- Metric socket set (8 mm–19 mm common sizes), ratchet, and 6" extension
- Description: sockets fit over bolt heads; ratchet turns sockets quickly; extension reaches recessed bolts.
- How to use: pick the correct socket that fits snugly on the bolt, attach to ratchet, use the extension if bolt is recessed. Pull the ratchet handle toward you to loosen; push away to tighten (ratchet direction switch).
- Combination wrenches (metric set)
- Description: open end and boxed end on each wrench for different access.
- How to use: use boxed end for best grip; open end for quick fit in tight spaces; pull toward you on the handle for controlled torque.
- Phillips and flathead screwdrivers (various sizes)
- Description: used for hose clamps, electrical connectors, small screws.
- How to use: use the appropriately sized tip to avoid stripping heads; apply steady pressure.
- Pliers: needle‑nose and slip‑joint
- Description: needle‑nose for reaching small clips; slip‑joint for gripping larger items.
- How to use: needle‑nose to remove small clamps and pull vacuum lines; slip‑joint to hold or turn parts carefully.
- Hose clamp pliers or long‑nose pliers
- Description: specialized for spring‑type clamps on coolant or vacuum hoses.
- How to use: compress clamp, slide off hose, hold clamp with pliers while removing.
- Torx/Allen key set (if applicable)
- Description: some throttle bodies or sensors use Torx/Allen fasteners.
- How to use: match head shape and use appropriate torque to avoid rounding heads.
- Shop rags and disposable towels
- Description: absorb cleaners, catch drips, keep openings clean.
- How to use: stuff rags into openings when removing parts to prevent debris entering.
- Plastic scraper or gasket scraper (plastic preferred)
- Description: removes gasket material without damaging aluminum/plastic surfaces.
- How to use: gently scrape at a low angle to remove residue; avoid gouging surfaces.
- Nylon or brass brushes (small)
- Description: removes carbon without scratching metal.
- How to use: use a brush to agitate deposits and wipe away loosened carbon.
- Throttle body/intake cleaner (spray can labeled for throttle or intake use)
- Description: solvent designed to dissolve carbon deposits on throttle plates, ports and intake runners.
- How to use: spray short bursts, let dissolve, agitate with nylon brush, wipe away with rag. Do not spray large amounts into a running engine.
- Small vacuum or compressed air (optional but helpful)
- Description: clears debris and dries parts quickly.
- How to use: use low pressure to blow out loose residue; keep a rag under openings to catch debris.
- Magnetic pickup/flashlight
- Description: pick up dropped bolts and inspect hard‑to‑see areas.
- How to use: use flashlight to inspect; magnetic pickup to retrieve bolts.

- Extra tools you should obtain (why required, how to use)
- Torque wrench (metric, click‑type)
- Why required: properly torquing throttle body and intake manifold bolts prevents leaks and warped parts.
- How to use: set desired torque on wrench, snug bolts in a cross pattern, final torque to spec (consult repair manual for values).
- Service manual or reliable repair guide for Chevy Aveo T200
- Why required: provides exact bolt torque specs, hose routing, vacuum line diagrams, sensor locations and safe disassembly order.
- How to use: follow step sequences and torque values for reassembly and troubleshooting.
- Replacement gaskets and seals kit (throttle body gasket, intake manifold gasket, O‑rings)
- Why required: gaskets are often compressed or damaged during removal and must be replaced to prevent vacuum or coolant leaks.
- How to use: remove old gasket material, clean mating surfaces, fit new gasket(s) and torque bolts to spec.
- New PCV valve (if applicable) and vacuum hoses
- Why required: PCV valve or brittle vacuum hoses commonly fail and cause carbon buildup or vacuum leaks.
- How to use: remove old valve, push new one into place; replace hoses and clamp as needed.

- Preparatory steps (tools used: battery wrench, rags, marker/tape)
- Park on a flat surface, let engine cool for at least 30–60 minutes.
- Disconnect negative battery terminal with a 10 mm socket or wrench.
- Label and photograph vacuum lines, electrical connectors and hose routing with tape/marker or phone photos to aid reassembly.
- Remove engine cover (if fitted) using basic sockets or screwdrivers.

- Cleaning intake with manifold in place (beginner method — tools used: screwdrivers, ratchet/sockets, throttle cleaner, nylon brush, rags)
- Remove air intake hose and airbox: loosen worm‑drive clamp with a flathead screwdriver or 8 mm socket; pull hose off.
- Disconnect electrical connectors and vacuum lines from the throttle body (use needle‑nose pliers for clips); mark each connection.
- Loosen and remove throttle body bolts (likely 8–10 mm); remove throttle body by lifting straight out; keep bolts organized.
- Inspect throttle body gasket; if old/flat, replace with new gasket.
- Spray throttle body cleaner onto throttle plate and bore; use a nylon brush to remove carbon; wipe clean with rags.
- With throttle body removed, spray short bursts of intake cleaner into the intake runner openings while gently rotating the engine by hand (crank is not recommended) or use a brush to clean accessible carbon; avoid letting large amounts of solvent run into the intake.
- Reinstall throttle body with new gasket if needed; torque bolts to manual spec using torque wrench.
- Reconnect hoses, sensors, battery; start engine and let idle—if necessary, follow a recommended idle relearn procedure from manual.

- Cleaning by removing intake manifold (deep clean — tools used: sockets, extensions, pliers, torque wrench, drain pan)
- Drain coolant if manifold carries coolant passages (put a drain pan under radiator petcock); cap removed passages with rags to prevent spills.
- Remove components blocking manifold removal: intake hose, throttle body, sensors, fuel rails/injectors or connector harnesses as required. Use the socket set and pliers; label everything.
- Remove all manifold bolts in the reverse torque sequence and pattern recommended in the service manual; lift manifold carefully to avoid damaging attached sensors or broken bolts.
- Inspect manifold, ports, and mating surface. Use plastic scraper and nylon/brass brushes with intake/throttle cleaner to remove carbon deposits. For stubborn carbon, soak parts briefly and brush; do not use harsh wire brushes on soft aluminum/plastic.
- Clean mating surfaces thoroughly — remove all old gasket material. Use a plastic scraper and solvent, then wipe dry.
- Inspect for cracks, broken mounts, or coolant passage corrosion. If cracked, manifold replacement is required.
- Replace intake manifold gasket (and throttle gasket, PCV parts, O‑rings) with new parts. Clean torque‑to‑spec and tighten bolts in the correct sequence with a torque wrench.
- Refill coolant if drained, bleed cooling system per service manual.
- Reconnect all sensors, vacuum lines, fuel lines (if removed), and battery. Start engine and check for leaks (vacuum, coolant, fuel) and for smooth idle.

- How to use spray cleaners safely and effectively
- Use short bursts—do not soak the sensor openings or inside the engine.
- Let solvent evaporate and wipe thoroughly; use compressed air at low pressure to dry passages if available.
- Dispose of rags and used solvent per local hazardous waste rules.

- Common replacement parts and when they’re needed (why + what to buy)
- Intake manifold gasket
- Why: compressed/damaged when removed; prevents vacuum and/or coolant leaks.
- What to buy: OEM or quality aftermarket gasket kit specific to Aveo T200 engine code.
- Throttle body gasket
- Why: brittle or flattened gaskets cause intake leaks.
- What to buy: matched throttle gasket.
- PCV valve
- Why: a clogged or stuck PCV causes excessive crankcase pressure and carbon buildup.
- What to buy: OE or equivalent PCV valve for Aveo T200 engine year.
- Vacuum hoses
- Why: old hoses crack and leak, causing poor idle and vacuum loss.
- What to buy: high‑temp vacuum hose of correct inner diameter or a hose kit.
- Intake manifold (replacement condition)
- Why: cracked manifold, warped mating surface, or damaged coolant passage.
- What to buy: replacement manifold specific to Aveo T200 engine variant; consider used OEM only if verified undamaged.
- Sensors/O‑rings (MAP/IAT/Maf if attached)
- Why: sensors can fail or their O‑rings can leak when disturbed.
- What to buy: OEM sensor or O‑ring kit per sensor type.

- Inspection checklist after cleaning and reassembly
- Check for vacuum leaks (listen for hissing, use soapy water on coolant joints if applicable).
- Verify coolant level and absence of leaks if coolant was drained.
- Confirm no diagnostic trouble codes; clear codes with an OBD‑II reader if necessary and re‑scan.
- Drive and verify improved idle and throttle response.

- Troubleshooting common issues post‑clean
- Rough idle or check engine light: ensure all vacuum hoses and electrical connectors were reconnected and that throttle body is clean and reassembled correctly.
- Leaks: re‑torque bolts to spec and inspect gaskets and hoses.
- Persistent carbon: consider full manifold removal or professional carbon cleaning service (walnut blasting often used by shops).

- Final notes (brief)
- If you are not comfortable removing the manifold or handling fuel/coolant lines, stop and have a shop do the job. Proper torque values and tightening sequence from the factory manual are essential to avoid leaks and damage.
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