Battery, Charging System and Starting System Chevrolet Aveo I

Fastener Tightening Specifications

Fastener Tightening Specifications

Battery Usage

Battery Usage

Battery Voltage Specifications

Starter Motor Usage

Starter Motor Usage

Generator Usage

Generator Usage

General Specifications

General Specifications

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Engine Electrical Connector End Views

Clutch Start Switch Connector Part Information KET MG 630676 2-Way F 250 Series Pin Wire Color Circuit No. Function 1 YE 5 Crank Voltage 2 PU 2 Clutch Start Switch Signal

Generator Connector Part Information PED 12186568 4-Way F Metri-Pack 150 Series (BK) Pin Wire Color Circuit No. Function A - - Not Used B D-BU 25 Charge Indicator Signal C PK 39 Ignition 1 Voltage D - - Not Used

Ignition Switch Connector Part Information KET MG 650887 6-Way F 250 III Series (WH) Pin Wire Color Circuit No. Function 1 RD/BK 341 Ignition 3 Voltage 2 RD/BK 141 Ignition 3 Voltage 3 YE 5 Crank Voltage 4 PK 3 Ignition 1 Voltage 5 OG 142 Battery Positive Voltage 6 YE 4 Accessory Voltage

Park/Neutral Position (PNP) Relay Connector Part Information AK 36905 6-Way Pin Wire Color Circuit No. Function 30 YE 5 Crank Voltage 30 YE 5 Crank Voltage 85 YE 5 Crank Voltage 86 BN 323 Park/Neutral Position (PNP) Signal 86 PU 434 Automatic Transmission Shift Lock Control 87 PU 6 Starter Solenoid Crank Voltage

Diagnostic Starting Point - Engine Electrical

Begin the system diagnosis by reviewing the following Description and Operations

1. «Battery Description and Operation»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__battery-description-and-operation)
2. «Starting System Description and Operation»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__starting-system-description-and-operation)
3. «Charging System Description and Operation»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__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.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

1. 2: Lack of communication may be due to a malfunction of the serial data circuits. The specified procedure will determine the particular condition.
2. 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

Diagnostic Trouble Code (DTC) List

Diagnostic Trouble Code (DTC) List

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

1. The ignition is ON with the engine OFF.
2. 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

1. The control module stores the DTC information into memory when the diagnostic runs and fails.
2. The malfunction indicator lamp (MIL) will not illuminate.
3. The control module records the operating conditions at the time the diagnostic fails. The control module stores this information in the Failure Records.
4. The driver information center, if equipped, may display a message.

Conditions for Clearing the DTC

1. A current DTC Last Test Failed clears when the diagnostic runs and passes.
2. A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other non-emission related diagnostic.
3. Clear the DTC with a scan tool.

DTC P0562

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.

This diagnostic procedure supports the following DTC

DTC P0563 System Voltage High

1. The ignition is ON with the engine OFF.
2. DTC P0563 runs continuously once the above condition is met.

The ECM detects a system voltage above 16 volts for more than 5 minutes.

1. The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition cycle that the diagnostic runs and fails.
2. 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 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

1. The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail.
2. A current DTC, Last Test Failed, clears when the diagnostic runs and passes.
3. A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic.
4. Clear the MIL and the DTC with a scan tool.

DTC P0563

Symptoms - Engine Electrical

1. «Battery Description and Operation»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__battery-description-and-operation)
2. «Starting System Description and Operation»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__starting-system-description-and-operation)
3. «Charging System Description and Operation»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__charging-system-description-and-operation)

Visual/Physical Inspection

1. Inspect for aftermarket devices which could affect the operation of the starting, charging or ignition systems. Refer to «Checking Aftermarket Accessories»(/chevrolet/aveo/i-2003-2008/remont/electrical-component-locations/#wiring-systems-electrical-power-management__checking-aftermarket-accessories) in Wiring Systems.
2. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.
3. Inspect the battery for correct installation and physical damage.
4. Test the condition of the battery. Terminal voltage should be 11.5-13.5 volts.
5. 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.
6. If the battery, wiring and switches are in satisfactory condition and the engine is known to be functioning properly, remove and test the starter motor.
7. 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.
8. Inspect the generator for loose or improper mounting and the generator drive belt for correct installation.
9. Inspect the drive belt for correct installation. Refer to «Power Steering Pump Drive Belt Replacement»(/chevrolet/aveo/i-2003-2008/remont/manual-power-steering/#power-steering-system) 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

1. «Starter Solenoid Does Not Click»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__starter-solenoid-does-not-click)
2. «Starter Solenoid Clicks, Engine Does Not Crank»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__starter-solenoid-clicks-engine-does-not)
3. «Engine Cranks Slowly»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__engine-cranks-slowly)
4. «Charge Indicator Always On»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__charge-indicator-always-on)
5. «Charge Indicator Inoperative»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__charge-indicator-inoperative)
6. «Battery Inspection/Test»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system)
7. «Battery Charging»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system)
8. «Battery Electrical Drain/Parasitic Load Test»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__battery-electrical-drainparasitic-load-test)
9. «Battery Common Causes of Failure»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__battery-common-causes-of-failure)
10. «Jump Starting in Case of Emergency»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__jump-starting-in-case-of-emergency)
11. «Starter Motor Noise Diagnosis»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system)
12. «Charging System Test»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__charging-system-test)
13. «Generator Noise Diagnosis»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system)

Diagnostic Aids

Tools Required

J 42000 Digital Battery Tester. See Special Tools .

Follow these instructions in order to avoid an incorrect diagnosis because of connections

1. If testing the vehicle with the battery cables still connected, wiggle the J 42000 clips on the terminal bolt. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__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.
2. If correct connections to the battery terminal bolts in the vehicle are in doubt, perform the following steps: Disconnect the negative battery cable. Disconnect the positive battery cable. Install the test adapters on the terminals. Follow the instructions for testing a removed battery.
3. If the tester displays a REPLACE BATTERY result for a battery tested in the vehicle with the battery cables connected, perform the following steps: Disconnect the negative battery cable. Disconnect the positive battery cable. Install the test adapters. Follow the instructions for testing a removed battery. Replace the battery only if the second test shows a REPLACE BATTERY result. Use the test code from the second test for any warranty purposes.
4. 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

1. For best results, use an automatic taper-rate battery charger with a voltage capability of 16 volts.
2. 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»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__special-tools) .
3. 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»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__special-tools) .
4. 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.
5. The charging area should be well ventilated.
6. 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.
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. 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. Tap the hydrometer lightly in order to dislodge any air bubbles. The bubbles may cause a false indication. 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»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system) .

Battery Electrical Drain/Parasitic Load Test

Tools Required

1. J 36169-A Fused Jumper Wire
2. J 38758 Parasitic Draw Test Switch. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__special-tools) .
3. J 39200 Digital Multimeter

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.
3. Install the J 38758 between the negative battery cable and the negative battery terminal. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__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.
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.
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. Set the Ammeter J 39200 to the 10 A scale. Connect the ammeter to the test switch terminals. Turn OFF the test switch. This allows the current to flow through the ammeter. 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. Open the test switch. Take the reading in milliamps. Note the battery reserve capacity. Refer to «Battery Usage»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__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. 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. 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. 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. Repeat the parasitic current drain test procedure after any repair has been completed. 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. 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

1. A vehicle accessory was left on overnight.
2. 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.
3. The electrical load has exceeded the generator output, (particularly with the addition of aftermarket equipment).
4. Existing conditions in the charging system, including the following possibilities: A slipping belt A Bad generator
5. The battery has not been properly maintained, including a loose battery hold down or missing battery insulator if used.
6. 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»(/chevrolet/aveo/i-2003-2008/remont/electrical-component-locations/#wiring-systems-electrical-power-management) 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.
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

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. Do not let the vehicles touch. Make sure that the jumper cables do not have loose clamps or missing insulation.
2. Perform the following steps on both vehicles: Place the automatic transmission in park, or the manual transmission in neutral. Block the wheels. Set the parking brake. Turn OFF all electrical loads that are not needed, (leave the hazard flashers ON). Turn OFF the ignition.
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.
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.
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: Turn the ignition OFF. Allow the booster vehicle engine to run at approximately 1,500 RPM for 5 minutes. Attempt to start the engine of the vehicle with the discharged battery.
9. Disconnect the black negative (-) cable (1) from the vehicle with the discharged battery.
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

Charge Indicator Always On

Charge Indicator Always On

Charge Indicator Inoperative

Charge Indicator Inoperative

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

Starter Solenoid Does Not Click

Starter Solenoid Does Not Click

Starter Solenoid Clicks, Engine Does Not Crank

Starter Solenoid Clicks, Engine Does Not Crank

Engine Cranks Slowly

Perform the inspections on the following items

1. Battery-Perform the Battery Inspection/Test Refer to «Battery Inspection/Test»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
2. 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»(/chevrolet/aveo/i-2003-2008/remont/electrical-component-locations/#wiring-systems-electrical-power-management__circuit-testing) , «Wiring Repairs»(/chevrolet/aveo/i-2003-2008/remont/electrical-component-locations/#wiring-systems-electrical-power-management__wiring-repairs) , «Testing for Intermittent Conditions and Poor Connections»(/chevrolet/aveo/i-2003-2008/remont/electrical-component-locations/#wiring-systems-electrical-power-management__testing-for-intermittent-conditions-and-poor) and «Connector Repairs»(/chevrolet/aveo/i-2003-2008/remont/electrical-component-locations/#wiring-systems-electrical-power-management__connector-repairs) in Wiring Systems.
3. 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 .

Inspect the flywheel ring gear for damage or unusual wear.

Starter Motor Noise Diagnosis

Removal Procedure

1. Disconnect the negative battery cable and then disconnect the positive battery cable.
2. Remove the nuts from the battery rods that fasten the battery hold-down bar clamp.
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

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).
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).

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.

1. Disconnect the negative battery cable.
2. Remove the upper and the lower starter mounting bolts.
3. Remove the starter solenoid nuts to disconnect the electrical cable.
4. Remove the starter assembly.

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).
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»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system) .

1. Disconnect the negative battery cable.
2. Disconnect the intake air temperature (IAT) sensor electrical connector from the air intake tube.
3. Remove the breather tube clamp and all other clamps to remove the air intake tube.
4. Remove the battery harness connector nut from the generator.
5. Remove the generator shackle bracket bolt.
6. Remove the serpentine accessory drive belt. For vehicles equipped with power steering and air conditioning. Refer to «Power Steering Pump Drive Belt Replacement»(/chevrolet/aveo/i-2003-2008/remont/manual-power-steering/#power-steering-system) in Power Steering.
7. Remove the nuts which hold the generator lower bracket-to-generator bolts.
8. Carefully remove the generator.

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).
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).
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).
7. Install the air intake tube and the connector.
8. Install the IAT electrical connector to the air intake tube.
9. Connect the negative battery cable.

Disassembly Procedure

1. Remove the starter. Refer to «Starter Motor Replacement»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Remove the starter through-bolts.
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.
6. To begin the no-load test, close the switch (3) and compare the RPM (4), the current, and the voltage readings (2) with the specifications. Refer to «Starter Motor Usage»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system__starter-motor-usage) . Make disconnections only with the switch open. Use the test results as follows: Rated current draw and no-load speed indicate a normal condition for the starter motor. 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. Failure to operate with high current draw indicates a direct ground in the terminal or fields, or frozen bearings. 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. Low, no-load speed and low current indicate high internal resistance and high current draw, which usually mean shorted fields.
7. Remove the solenoid assembly screws.
8. Remove the field connector nut. Disconnect the field connector.
9. Remove the plunger return spring.
10. Test the solenoid windings by checking the current draw. Check the hold-in windings by connecting an ammeter (3) in series with a 12-volt battery, the switch terminal (2), and to ground. Connect the carbon pile (4) across the battery. 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.
11. Check both windings, connecting them according to the preceding test. Ground the solenoid motor terminal. Adjust the voltage to 10 volts. The ammeter reading should be 59-79 amperes. Check the connections and replace the solenoid, if necessary.
12. Slide the field frame with enclosed armature assembly away from the starter assembly.
13. Remove the shield.
14. Separate the field frame from the 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.
20. Remove the locking ring from the groove in the driveshaft.
21. Remove the pinion stop and the drive from the driveshaft.
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.
23. Rotate the solenoid 90 degrees and remove it along with the return spring.
24. Remove the plunger with the boot and the shift lever assembly. Test the solenoid windings, if not done in Step 11.
25. When the starter motor is disassembled and the solenoid is replaced, it is necessary to check the pinion clearance.
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.
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

1. Install the drive and the pinion stop on the driveshaft.
2. Install the lock ring to the groove on the driveshaft and insert the collar.
3. Install the shift lever, washer and the cushion.
4. Lubricate the drive end of the armature shaft with lubricant.
5. Position the solenoid assembly.
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).
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.
11. Position the commutator end frame/brush holder assembly, lining up the end frame holes with the through-bolt holes in the housing.
12. Install the starter through-bolts.
13. Install the starter. Refer to «Starter Motor Replacement»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system) . Tighten: Tighten the starter through-bolts to 6 N.m (53 lb in).

1. Remove the generator. Refer to «Generator Replacement»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
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.
4. Remove the stator connections from the rectifier bridge terminals by cutting the wires.
5. Pry off the baffle.
6. Remove the rectifier/regulator/brush hold assembly screws.
7. Remove the brush holder assembly and the regulator.
8. Test the rectifier bridge by connecting the ohmmeter terminals to the bridge and the heat sink.
9. Retest by connecting the ohmmeter terminals in reverse.
10. Replace the rectifier bridge, if each reading is the same.
11. Test the remaining two diodes after the above procedure.
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.
13. Remove the generator through-bolts.
14. Move to the drive end of the generator and remove the drive end bearing nut.
15. Remove the pulley and the collars.
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.
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.
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.
20. Remove the rotor assembly.
21. Remove the stator.
22. Test the stator for an open circuit using the ohmmeter.
23. Remove the ring in the slip ring end frame.

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).
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»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
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.
12. Weld the connectors of the rectifier bridge.

Battery Description and Operation

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

1. No water need be added for the life of the battery.
2. 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.
3. 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.
4. 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.

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

1. Vehicle accessories are left on overnight.
2. Slow average driving speeds are used for short periods.
3. The vehicle's electrical load is more than the generator output, particularly with the addition of aftermarket equipment.
4. There are defects in the charging system, such as electrical shorts, a slipping generator belt, a faulty generator, or a faulty voltage regulator.
5. There has been battery abuse, including failure to keep the battery cable terminals clean and tight, or a loose battery hold-down.
6. 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: GREEN DOT VISIBLE - Any green appearance is interpreted as a green dot, meaning the battery is ready for testing. 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»(/chevrolet/aveo/i-2003-2008/remont/charging-system/#battery-charging-system-and-starting-system) .

The time required to charge a battery will vary depending upon the following factors

1. Size of Battery - A completely discharged large heavy-duty battery requires more than twice the recharging as a completely discharged small passenger car battery.
2. 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.
3. 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.
4. 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.
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

1. If the charge current is not measurable at the end of the above charging times, the battery should be replaced.
2. If the charge current is measurable during the charging time, the battery is good, and charging should be completed in the normal manner.
3. If the charge current is still not measurable after using the charging time calculated by the above method, the battery should be replaced.
4. 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

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.
4. Shift an automatic transaxle to PARK, or a manual transaxle to NEUTRAL.
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.
6. Clamp one end of the second cable to the negative terminal of the booster battery. Make the final 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.

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.

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.

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

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

Scheme 7

Scheme 8

See also:
• Scan Tool Does Not Power Up
• Engine Controls Schematics
• Master Electrical Component List
• Testing for Intermittent Conditions and Poor Connections
• Circuit Testing
• Wiring Repairs
• Connector Repairs
• Diagnostic Trouble Code (DTC) List
• Checking Aftermarket Accessories
• Power Steering Pump Drive Belt Replacement
• Battery Disconnect Caution
• Fastener Notice
• General Electrical Diagnosis Procedures
• Instrument Panel Cluster (IPC) Replacement
• Ignition Lock Cylinder and Switch Replacement
• Safety Glasses Caution
• Batteries Produce Explosive Gases Caution
• Ignition OFF When Disconnecting Battery Notice
• Battery Description and Operation
• Starting System Description and Operation
• Charging System Description and Operation
• Symptoms - Engine Electrical
• Battery Inspection/Test
• Diagnostic Trouble Code (DTC) List
• Charging System Test
• Starter Solenoid Does Not Click
• Starter Solenoid Clicks, Engine Does Not Crank
• Engine Cranks Slowly
• Charge Indicator Always On
• Charge Indicator Inoperative
• Battery Electrical Drain/Parasitic Load Test
• Battery Common Causes of Failure
• Jump Starting in Case of Emergency
• Special Tools
• Battery Usage
• Starter Motor Usage