Chevrolet Aveo (2002-2011): How to Remove the Bumpers

Production Years and Model Codes

The first generation of the Chevrolet Aveo was produced from 2002 to 2011 and was available under two factory designations:

• T200 – The initial version (2002–2008), developed by GM Daewoo (later GM Korea).
• T250 – The facelifted version (2008–2011) with updated design and technical improvements.

The model was also sold under other names:

• Daewoo Kalos (Europe, Asia until 2005)
• Holden Barina (Australia and New Zealand)
• Suzuki Swift+ (Canada, 2004–2009)
• Pontiac G3/Wave (USA, Canada, Mexico)

 

Model Overview

The Chevrolet Aveo I was designed as a global compact car for emerging markets and Europe. It replaced the Daewoo Lanos and became one of the first GM projects after acquiring the Korean brand.

Body Styles:

• 5-door hatchback (most popular version)
• 4-door sedan (from 2003, called Aveo Sedan in some markets)
• 3-door hatchback (rare version for Europe)

Engines:

• 1.2L (E-TEC II) – 80 hp (rare in Russia, more common in Europe)
• 1.4L (E-TEC II) – 94 hp (base engine for Russia)
• 1.5L (E-TEC II) – 100 hp (post-facelift)
• 1.6L (E-TEC II) – 106 hp (top version)

Transmissions:

• 5-speed manual (primary)
• 4-speed automatic (optional, considered unreliable)

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Note: Mounting points may vary depending on the production year and body type.

Front Bumper Removal

1. Open the hood.
2. Remove the clips and unscrew the bolts securing the upper part under the hood.
3. Turn the wheels to access the side being worked on.
4. Unscrew the bolts holding the wheel arch liners in place.
5. Remove the bolts (fastened upward from below) securing the bumper corners to the fenders.
6. Unscrew the bolts (fastened upward from below) securing the lower sides.
7. From the engine side, unscrew two nuts on each side that attach the reinforcement bar to the chassis.
   • Alternative: The bumper can be removed without the reinforcement bar by detaching the clips (marked with blue arrows). This requires removing the headlights and fog light covers. However, removing the bumper with the reinforcement bar is easier.
8. With an assistant, carefully pull the bumper forward (ensure no wires are snagged).
9. Disconnect any electrical connectors (if present).

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Rear Bumper Removal

1. Open the trunk lid and unscrew the bolts securing the top part in the opening.
2. Remove the trunk interior trim panels.
3. (T200 only) Unscrew the nuts inside the trunk on the rear panel.
4. Behind the trim panels, unscrew the bolts and nuts in the wheel wells.
5. Remove the side bolts (fastened upward from below).
6. Unscrew the bolts securing the wheel arch liners.
7. Behind the liners, remove the bolts (fastened upward from below) that attach the corners to the fenders.
8. Under the car, unscrew two nuts on each side securing the bumper reinforcement to the rear panel.
   • Alternative: The bumper can be removed without the reinforcement by taking out the rear lights and removing the clips around the perimeter. However, removing it with the reinforcement is the correct method.
9. With an assistant, carefully pull the bumper backward (check for any wiring).
10. Disconnect any electrical connectors (if present).

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Suspension:

• Front: McPherson strut
• Rear: Semi-independent torsion beam (simple but durable)

2008 Facelift (T250)

In 2008, the Aveo received noticeable updates:

• New front bumper with a larger Chevrolet-style grille.
• Redesigned headlights and taillights.
• Updated dashboard with improved materials.
• New 1.5L engine (replacing the 1.4L, power increased to 100 hp).

Despite the updates, the Aveo remained a budget model with basic features. Competitors like the Hyundai Accent and Kia Rio offered more advanced technology.

 

Interesting Facts

Daewoo Development, Chevrolet Branding

Originally developed as the Daewoo Kalos, the Aveo was rebranded under Chevrolet after Daewoo's bankruptcy.

Global Production

The Aveo was assembled not only in Korea but also in:

• Russia (Avtotor plant in Kaliningrad)
• Ukraine (ZAZ, for the local market)
• China (as the Buick Sail)
• Ecuador and Uzbekistan (for local markets)

Racing Involvement

In the 2000s, the Aveo was used in touring car races (e.g., Russia’s LADA Granta Cup), where its simple design made it easy to modify.

Rust Issues

Owners in cold climates reported corrosion on the sills and wheel arches, especially in early models (2002–2006).

Model Successor

In 2011, the Aveo T250 was replaced by the second generation (T300), fully developed in Korea under GM’s control.

 

Conclusion

The Chevrolet Aveo I (T200/T250) is a typical budget car of the 2000s. Its simple design, low cost, and reliability made it popular in Russia and Eastern Europe. However, by the end of its production (2011), it lagged behind competitors in comfort and durability.

Today, the first-gen Aveo is an affordable used car in the secondary market. Its main advantages are cheap parts and easy repairs, but buyers should carefully check for rust on the body.