Frame and Underbody: Other Chevrolet Aveo I facelift

Frame Door Opening - Rear (Notch Back)

Frame Door Opening - Rear (Notch Back) Dimensions

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Windshield and Rear Glass (Notch Back) Dimensions

Gap Chart - Notch Back

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Gap Chart - Notch Back Measurements

Gap Chart - Doors

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Gap Chart - Doors Measurements

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Floor Pan Dimensions

Dimensions - Body Specifications

Vehicle Weights - Four Door

Vehicle Weights - Five Door

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Body Side View Dimensions(Notchback)

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Underbody Reference Points Measurements (Notchback)

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Underbody Frame Dimensions (Notchback)

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Rear Underbody Dimensions (Notchback)

Rear Frame (Notchback)

Rear Frame Dimensions (Notchback)

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.

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.

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.

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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.

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