Frame and Underbody Chevrolet Aveo I

Fastener Tightening Specifications

Fastener Tightening Specifications

Scheme 1

Dimensions - Frame

Scheme 2

Dimensions - Frame

Scheme 3

Dimensions - Frame

Scheme 4

Dimensions - Body

Scheme 5

Dimensions - Body

Scheme 6

Dimensions - Body

Scheme 7

Dimensions - Body

Scheme 8

Dimensions - Body

Scheme 9

Dimensions - Body

Scheme 10

Dimensions - Body

Frame Door Opening - Rear (Notch Back)

Dimensions - Body

Scheme 11

Dimensions - Body

Hatch Back - Rear Door Opening

Dimensions - Body

Scheme 12

Dimensions - Body

Scheme 13

Dimensions - Body

Gap Chart - Hatch Back

Scheme 14

Dimensions - Body

Gap Chart - Notch Back

Scheme 15

Dimensions - Body

Gap Chart - Doors

Scheme 16

Dimensions - Body

Scheme 17

Dimensions - Body

Scheme 18

Measurements - Underbody (Hatchback)

Scheme 19

Measurements - Underbody (Hatchback)

Scheme 20

Measurements - Underbody (Hatchback)

Scheme 21

Measurements - Underbody (Hatchback)

Scheme 22

Measurements - Underbody (Hatchback)

Scheme 23

Measurements - Underbody (Notchback)

Scheme 24

Measurements - Underbody (Notchback)

Scheme 25

Measurements - Underbody (Notchback)

Scheme 26

Measurements - Underbody (Notchback)

Dimensions - Body Specifications

Dimensions - Body Specifications

Vehicle Weights-Four Door

Vehicle Weights-Five Door

Underbody Inspection

An accurate method of determining the alignment of the underbody uses a measuring tram gage. The tram gage set used to perform the recommended measuring checks must include a vertical pointer able to reach 457 mm (18 in).

Two types of measurements can be made with a tram gage: direct point-to-point measurements and measurements calculated on a horizontal plane, datum line, parallel to the underbody. Point-to-point measurements are generally taken on steering and suspension engine compartment parts and simply require the vertical pointers to be set equally.

For horizontal plane measurements, the vertical pointers must be set as specified for each point to be measured.

Dimensions-to-gage holes are measured to the center of the holes and flush to the adjacent surface metal unless otherwise specified. It is recommended that the diagonal dimensions to the cross-body be checked on both sides in order to verify the dimensional accuracy of the vehicle underbody.

Floor Pan Insulators

The floor pan insulators have been designed for the higher floor pan temperatures that result from the use of the catalytic converter in the exhaust system. Therefore, when servicing a vehicle, it is essential that any insulators that may have been disturbed or removed be reinstalled in the original sequence and location. Also, an insulator needs to be replaced. Use only the insulation specified for that location on the floor pan.

When servicing or replacing interior insulators, observe the following instructions

1. Install the insulators in the original position and sequence. Butt the pieces together in order to avoid gapping or overlapping.
2. If it is necessary to replace an insulator, use only the specified insulation.
3. Use the original part to determine the amount of replacement material required and as a template for cutting and fitting the new piece to the floor pan.
4. When installing the insulator, do not enlarge any cutouts or holes that are used for the attachment of interior parts such as the instrument panel or the floor console.
5. Route the cross-body harness for interior parts over the floor pan insulators. Clip it in the original location.
6. Do not apply spray-on deadeners or trim adhesives to the top of the floor pan at the area directly over the catalytic converter or the muffler.

Removal Procedure

1. Raise and suitably support the vehicle.
2. Remove the front wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/aveo/i-2003-2008/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
3. Remove the nuts, the bolts, and the engine under cover.

Installation Procedure

1. Install the engine under cover with the bolts and nuts. Tighten: Tighten the engine under cover nuts and bolts to 3.5 N.m (31 lb in).
2. Install the front wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/aveo/i-2003-2008/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
3. Lower the vehicle.

Frame Reference Point Description

Whenever possible, make judgements and conclusions based on measurement. Measure the wheel alignments so as to prevent any future trouble like unsymmetrical wear of the tires or catching of the steering wheel.

1. If there are any deviations, use a tram tracking gage and measure parts of the body (A).
2. If there is any twisting to the body, measure using a frame centering gage (B). Specifications Pointer B - Short pointer height adjustment 15-290 mm (0.59-11.42 in) Pointer B - Long pointer height adjustment 185-450 mm (7.28-17.72 in)
3. When measuring body dimensions, use a universal tram gage (C).

Scheme 27

Welding Description

Spot welding is also known as resistance spot welding and it is the most suitable method of welding for automobiles. It has 3 main features

1. The welding can be performed instantaneously
2. It exercises very little effect on the original material
3. It reduces the generation of distortion to the absolute minimum

Scheme 28

When performing spot welding (3), make absolutely sure that you conform to the conditions governed by the current (2), conductivity time (1), welding pressure, holding time, and shutdown time recommended for the spot welder.

Scheme 29

When the welding intervals (1) are too small, this leads to branching, making it impossible to maintain the desired soldering state.

Welding Description

Scheme 30

Welding Description

Scheme 31

Even if you perform the welding in accordance with the conditions, the strength of the welded sections may fluctuate widely with drops in the voltage and other factors. The quality of the welding cannot be evaluated unless the welded sections are destroyed.

Provide yourself with a steel plate of the same thickness and conduct a destruction test.

1. If holes appear in the steel plates (1, 4), this means that the welding is standard strength.
2. Drive a wedge (2) between 2 panels near the nugget. If the welded parts do not come apart and the diameter of the nugget (3) appears more than 3 mm, the welding should be satisfactory.

In all these cases, it is recommended that the gas welding method be employed. However, if it is not possible to perform spot welding because of space restrictions, plug welding based on the arc welding method may be performed instead. Here the welding sections must be close together.

Gas Welding

Gas welding is indispensable for body repair because of the broad range of its applications from joining the body panels, cutting the materials that construct the body and applying heat to reform panels and also because it is easy to get hold of the tools. However, this method requires experience.

Scheme 32

Scheme 33

The illustration is an example of how not to perform gas welding, avoid operations like the following

1. Welding the bending angle of a flange (1)
2. Melting the finger end of a flange (2)

Carbon Dioxide Arc Welder (MIG ARC Welding)

This welding process uses inexpensive carbon dioxide instead of expensive inert gases as a shielding means. Consumable metal electrodes are employed. It has a wide range of applications, including butt welding of thin plate, fillet welding, plug welding, and MIG spot welding. In terms of the weld strength, it is also highly stable.

Scheme 34

This vehicle is constructed with a unitized body which incorporates integral front and rear frame side rails.

The front suspension lower control arms are bolted to and retained by supports, one each on the right and left sides. The front suspension lower control arm supports are attached to the underbody with 3 bolts at 2 locations. The engine is bolted to the integral front side rails. The suspension strut towers must be dimensionally correct in relation to the remainder of the underbody in order to maintain specified suspension strut and caster/camber angles.

Since the individual underbody parts contribute directly to the overall strength of the body, it is essential to observe proper welding techniques during service repair operations. The underbody parts should be properly sealed and rustproofed whenever body repair operations destroy or damage the original sealing and rustproofing. When rustproofing critical underbody parts, use a good-quality type of air-dry primer, such as a corrosion resistant chromate or an equivalent material. Combination-type primer/surfacers are not recommended.

Engine Under Covers

The engine under covers are molded pieces of plastic that serve as shields for the underside of the engine. The covers help protect the engine from small rocks, gravel and other objects that would otherwise come into contact with the engine during normal driving conditions.

See also:
• Vehicle Lifting and Jacking Notice
• Tire and Wheel Removal and Installation
• Fastener Notice