CHEVROLET AVEO 2002 Service Repair Manual

Shift Program Switch
Transmission Control Module (TCM) - A
7WH2377Signal
8GY2380Park/Neutral Position (PNP) Switch Low
Gear Signal
9BN323Park/Neutral Position (PNP) Switch Signal
Connector Part InformationKET MG 610366
4-Way F PCB 040 Series (WH)
PinWire ColorCircuit No.Function
1D-GN/WH1135Transmission Hold Signal
2BN/WH309Right Park Lamp Supply Voltage
3BK450Ground
4BK450Ground

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 32 © 2005 Mitchell Repair Information Company, LLC.

Transmission Control Module (TCM) B
Connector Part InformationAMP 1318756-1
24-Way F 025/090 SER 26POS PLUG ASSY (WH)
PinWire ColorCircuit No.Function
1BK/WH51Ground
2YE/BK1227Low Reference
3--Not Used
4RD1226Pressure Control Solenoid Control
5D-BU1225Torque Converter Clutch Solenoid Control
6PK839Ignition 1 Voltage
7YE710CAN Serial Data Low
8-10--Not Used
11PU898Transmission Fluid Temperature Sensor
Signal
12OG/BK586Transmission Fluid Temperature Sensor Low
Reference
13--Not Used
14PK1224Timing Valve Control
15YE/BK1223Shift Solenoid 2 Valve Control
16L-GN1222Shift Solenoid 1 Valve Control
17PU1807CAN Serial Data High
18-22--Not Used
23BK/WH51Ground
24OG440Battery Positive Voltage

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Thursday, July 16, 2009 1:17:17 PMPage 33 © 2005 Mitchell Repair Information Company, LLC.

Connector Part InformationAMP 1318757-1
26-Way F 025/090 SER 24POS PLUG ASSY (WH)
PinWire ColorCircuit No.Function
1D-GN/WH2383Park/Neutral Position (PNP) Switch Reverse
Signal
L-GN24Back-Up Lamps Supply Voltage
2--Not Used
3YE1481Hold Motor Indicator Control
4D-GN/WH1135Transmission Hold Signal
5--Not Used
6D-BU/WH1296Input Shaft Speed (ISS) Sensor High Signal
7WH2377Park/Neutral Position (PNP) Switch Drive
Signal
8YE2381Park/Neutral Position (PNP) Switch Neutral
Signal
9-15--Not Used
16YE/BK1297Input Shaft Speed (ISS) Sensor Low Signal
17--Not Used
18GY2380Park/Neutral Position (PNP) Switch Low
Gear Signal
19PK2384Park/Neutral Position (PNP) Switch 2nd
Gear Signal
20D-GN/YE2382Park/Neutral Position (PNP) Switch Park
Signal
21--Not Used
22L-BU20Stop Lamp Supply Voltage/Stop Lamp
Switch Signal
23D-BU2051Serial Data

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 34 © 2005 Mitchell Repair Information Company, LLC.

Vehicle Speed Sensor (VSS)
VISUAL IDENTIFICATION
AUTOMATIC TRANSMISSION COMPONENTS
During reassembly, please refer to the spring specifications below to help you to discriminate between the
different springs.
24--Not Used
25D-GN/WH817Vehicle Speed Signal
26--Not Used
Connector Part InformationYazaki 7283-1232
3-Way F (BK)
PinWire ColorCircuit No.Function
1PK839Ignition 1 Voltage
2BK/WH51Ground
3D-GN/WH817Vehicle Speed Signal

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 35 © 2005 Mitchell Repair Information Company, LLC.

Fig. 27: Upper Valve Body Spring Component View
Courtesy of GENERAL MOTORS CORP.
Automatic Transmission Components
MarkNameColorFree LengthOuter DiameterTotal
Number of
Coils
MetricEnglishMetricEnglish
13-4 Shift
ValveRed25.5 mm1.0039 in9.73 mm0.3831 in7.75
2
Lock Up
Control
Valve
Yellow20.87 mm0.8217 in5.55 mm0.2185 in11.15
3
Reverse
Control
Valve
-25.58 mm1.0071 in8.64 mm0.3402 in8.75
4
Secondary
Regulator
Valve
White34.56 mm1.3606 in8.8 mm0.346 in12.27
5
Reverse
Clutch
Accumulator
-65.4 mm2.5748 in17 mm0.669 in13.7

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 36 © 2005 Mitchell Repair Information Company, LLC.

Fig. 28: Upper Valve Body Key Component View
Courtesy of GENERAL MOTORS CORP.
Automatic Transmission Components
Piston
6
2nd Brake
Accumulator
Piston -
Outer
White69 mm2.7165 in16 mm0.63 in15.1
7
2nd Brake
Accumulator
Piston - Inner
-45.9 mm1.8071 in10.5 mm0.413 in16.9
8
3-4 Shift
Timing
Valve
Pink28.41 mm1.1185 in6.4 mm0.252 in10.49
MarkRetainerHeightWidthThickness
MetricEnglishMetricEnglishMetricEnglish

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 37 © 2005 Mitchell Repair Information Company, LLC.

Fig. 29: Upper Valve Body Check Ball Component View
Courtesy of GENERAL MOTORS CORP.
Automatic Transmission Components
1Check Valve11.5 mm0.453 in5 mm0.197 in3.2 mm0.126 in
2
Secondary
Regulator
Valve
16 mm0.63 in5 mm0.197 in3.2 mm0.126 in
3
Lock Up
Control
Valve
16 mm0.63 in5 mm0.197 in3.2 mm0.126 in
4
Reverse
Control
Valve
11.5 mm0.453 in5 mm0.197 in3.2 mm0.126 in
NameMetricEnglish
Check Ball5.535 mm0.21791 in

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 38 © 2005 Mitchell Repair Information Company, LLC.

Fig. 30: Lower Valve Body Key Component View
Courtesy of GENERAL MOTORS CORP.
Automatic Transmission Components
MarkRetainerHeightWidthThickness
MetricEnglishMetricEnglishMetricEnglish
1
4-3 Shift
Timing
Valve No. 1
36 mm1.417 in5 mm0.197 in3.2 mm0.126 in
22-3 Shift
Valve10 mm0.394 in5 mm0.197 in3.2 mm0.126 in
31-2 Shift
Valve10 mm0.394 in5 mm0.197 in3.2 mm0.126 in
4
Primary
Regulator
Valve
9.8 mm0.386 in5.2 mm0.205 in3.2 mm0.126 in
5Lock Up
Relay Valve16 mm0.63 in5 mm0.197 in3.2 mm0.126 in
Solenoid

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Thursday, July 16, 2009 1:17:17 PMPage 39 © 2005 Mitchell Repair Information Company, LLC.

Fig. 31: Differential Case Component View
Courtesy of GENERAL MOTORS CORP.
Callouts For Fig. 42
6Modulator
Valve24 mm0.945 in5 mm0.197 in3.2 mm0.126 in
7
Low
Modulator
Valve
24 mm0.945 in5 mm0.197 in3.2 mm0.126 in
CalloutComponent Name

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Thursday, July 16, 2009 1:17:17 PMPage 40 © 2005 Mitchell Repair Information Company, LLC.

DIAGNOSTIC INFORMATION AND PROCEDURES
DIAGNOSTIC CODE INDEX
DIAGNOSTIC CODE INDEX
1Differential Pinion Thrust Washer
2Differential Pinion Gear
3Differential Side Gear Thrust Washer
4Differential Side Gear
5Pin
6Differential Pinion Shaft
7Oil Seal
8Side Bearing Outer Race
9Tapered Roller Bearing
10Differential Case
11Differential Ring Gear
12Tapered Roller Bearing
13Side Bearing Outer Race
14Shim
15Oil Seal
DTCDescription
DTC P0562 (Non-Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0562 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0563 (Non-Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0563 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0601 or P1790 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0601 or P1790 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0604 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0604 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0705 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0705 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0706 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0706 (Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0711 DTC P0711Transmission Fluid
Temperature (TFT) Sensor Circuit
Performance
DTC P0712 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0712 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0713 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0713 (European and N. American Emissions) ** MULTIPLE VALUES **

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:18 PMPage 41 © 2005 Mitchell Repair Information Company, LLC.