CHEVROLET AVEO 2002 Service Repair Manual

DTC P0717 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0717 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0722 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0722 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0727 (Non European or N. American Emissions) ** MULTIPLE VALUES **
DTC P0727 (European or N. American Emissions) ** MULTIPLE VALUES **
DTC P0741 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0741 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0742 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0742 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0743 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0743 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0748 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0748 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0751 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0751 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0752 Shift Solenoid (SS1) Valve
Performance or Stuck On
DTC P0753 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0753 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0756 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0756 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0757 2-3 Shift Solenoid (SS) Valve
Performance or Stuck On
DTC P0758 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0758 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0785 or P1710 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P0785 or P1710 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P0787 Timing Solenoid (ST) Electrical
(Ground Short)
DTC P0788 Timing Solenoid (ST) Electrical
(Open or Short to Power)
DTC P0962 Pressure control solenoid (PCS)
Voltage Low
DTC P0963 Pressure control solenoid (PCS)
Voltage High
DTC P0973 Shift Solenoid 1 (SS1) Short to
Ground
DTC P0974 Shift Solenoid 1 (SS1) Open or Short
to Power
DTC P0976 Shift Solenoid 2 (SS2) Short to
Ground

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:18 PMPage 42 © 2005 Mitchell Repair Information Company, LLC.

REPAIR INSTRUCTIONS
TRANSMISSION FLUID TEMPERATURE SENSOR REPLACEMENT
Removal Procedure
1. Drain the transaxle fluid from the transaxle. Refer to Draining Transmission Fluid.
DTC P0977 Shift Solenoid 2 (SS2) Open or Short
to Power
DTC P1701 or P1792 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P1701 or P1792 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P1702 (Non European or N. American Emissions) ** MULTIPLE VALUES **
DTC P1702 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P1781 Malfunction of Engine Speed Signal
DTC P1791 (European and N. American Emissions) ** MULTIPLE VALUES **
DTC P1791 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC P2769 Torque Converter Clutch (TCC)
Electrical (Ground Short)
DTC P2770 Torque Converter Clutch (TCC)
Electrical (Open or Short to Power)
DTC U0401 TCM Received Invalid Data from
ECM
DTC U2105 (Non Europe or N. American Emissions) ** MULTIPLE VALUES **
DTC U2105 (Europe and N. American Emissions) ** MULTIPLE VALUES **
IMPORTANT: The Transmission Fluid Temperature (TFT) sensor is incorporated into the
wiring harness assembly. The harness and sensor have to be replaced as an
assembly

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:18 PMPage 43 © 2005 Mitchell Repair Information Company, LLC.

Fig. 32: Transmission Pan Bolts
Courtesy of GENERAL MOTORS CORP.
2. Remove the 18 oil pan retainin
g bolts, then remove the oil pan and gasket.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:18 PMPage 44 © 2005 Mitchell Repair Information Company, LLC.

Fig. 33: Solenoids & Wiring Harness Assembly
Courtesy of GENERAL MOTORS CORP.
3. Disconnect the wirin
g harness assembly from the five solenoids.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:18 PMPage 45 © 2005 Mitchell Repair Information Company, LLC.

Fig. 34: Locating Transmission Fluid Temperature Sensor
Courtesy of GENERAL MOTORS CORP.
4. Remove the wiring harness retaining bolt, then remove the wiring harness and TFT sensor from the
transaxle.
Installation Procedure

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:18 PMPage 46 © 2005 Mitchell Repair Information Company, LLC.

Fig. 35: Transmission Fluid Temperature Sensor
Courtesy of GENERAL MOTORS CORP.
1. Coat a new O-ring with ATF, then install it on the harness connector.
2. Install the TFT sensor and wiring harness into the transaxle case.
NOTE: Refer to Fastener Notice in Cautions and Notices.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:18 PMPage 47 © 2005 Mitchell Repair Information Company, LLC.

3. Install the wiring harness retaining bolt.
Tighten: Tighten the bolt to 5.5 Nm (48 lb-in).
Fig. 36: Solenoid Wiring Harness Assembly

Courtesy of GENERAL MOTORS CORP.
4. Connect the wirin
g harness to the five solenoids.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:18 PMPage 48 © 2005 Mitchell Repair Information Company, LLC.

Fig. 37: Transmission Pan Bolts
Courtesy of GENERAL MOTORS CORP.
5. Install a new gasket on the oil pan, then install the oil pan to the transaxle with the 18 retaining bolts.
Tighten: Tighten the bolts to 7.5 Nm (65 lb-in).
6. Fill the transaxle with fluid. Refer to Draining Transmission Fluid
.
GEARSHIFT CONTROL LEVER REPLACEMENT
Removal Procedure

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:18 PMPage 49 © 2005 Mitchell Repair Information Company, LLC.

Fig. 38: Wiring Harness Connectors & Shift Control Lever
Courtesy of GENERAL MOTORS CORP.
1. Disconnect the negative battery cable.
2. Remove the floor console. Refer to Console Replacement
- Front Floor .
3. Disconnect the wirin
g harness connectors from the shift control lever.
CAUTION: Refer to Battery Disconnect Caution .

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:18 PMPage 50 © 2005 Mitchell Repair Information Company, LLC.

Fig. 39: Control Cable Adjusting Nut
Courtesy of GENERAL MOTORS CORP.
4. Loosen the control cable adjusting nut.
5. Disconnect the control cable from the shift control lever assembl
y.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:18 PMPage 51 © 2005 Mitchell Repair Information Company, LLC.