CHEVROLET AVEO 2002 Service Repair Manual

Fig. 438: Spring, Check Valve & Check Ball
Courtesy of GENERAL MOTORS CORP.
5. Install the check valve, spring, and check ball.
6. Install the ball, spring, spring seat, and bolt.
Tighten: Ti
ghten the bolts to 6.5 N.m (57 lb in).

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Fig. 439: Control Valve Body, Cover, Gaskets & Plate
Courtesy of GENERAL MOTORS CORP.
7. Install the 2
gaskets, the plate, and the lower valve body cover.

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Fig. 440: Control Valve Body & Bolts
Courtesy of GENERAL MOTORS CORP.
8. Tighten the bolts temporarily.
9. Tighten the bolts completely. The bolt lengths are 49 mm (1.93 in), 20 mm (0.79 in), and 60 mm (2.36
in).
Tighten: Ti
ghten the bolts to 11 N.m (97 lb in).

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Fig. 441: Shift Solenoid Valves & Bolts
Courtesy of GENERAL MOTORS CORP.
10. Install the 5 shift solenoid valves with the 5 bolts (1). The bolt lengths are 49 mm (1.93 in) and 20 mm
(0.79 in).
Tighten: Tighten the bolts to 11 N.m (97 lb in).
11. Install the manual valve.

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Fig. 442: Primary Regulator Valve Sleeve, Plug & Pin
Courtesy of GENERAL MOTORS CORP.
12. Make sure that the primary regulator valve is positioned in the same place where it was removed.
DESCRIPTION AND OPERATION
MANUAL FOURTH GEAR

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Manual Fourth Gear
Fig. 443: Manual Fourth Gear Schematics

Courtesy of GENERAL MOTORS CORP.
PositionSolenoidClutchBrake1-Way Clutch
Shift 1Shift 2TimingC1C2C3B1B2B3F1F2
D4thOFFONOFFOFFONOFFONONOFFOFFOFF

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A. Front Planetary Gear
B. Rear Planetary Gear
D - 4th Gear
1. The input shaft rotates clockwise.
The direct clutch (C2) operates. Connect the input shaft to the planetary carrier.
2. The planetary carrier revolves clockwise.
3. The planetary long pinion rotates itself clockwise.
4. The rear planetary sun gear is going to rotate counterclockwise.
The O/D and 2nd brake (B1) operates. Lock rotates the planetary sun gear.
5. The planetary long pinion revolves clockwise while rotating itself clockwise.
6. The ring gear rotates clockwise.
7. The counter drive gear rotates clockwise for the ring gear and one.
8. The counter driven gear rotates counterclockwise.
9. The differential gear drive pinion rotates counterclockwise for the counter driven gear and one.
10. The differential gear rotates clockwise.
Engine Brake
The driving force is connected to the input shaft directory without the 1-way clutch. Therefore the engine brake
operates.
MANUAL THIRD GEAR
Manual Third Gear
Position
SolenoidClutchBrake1-Way Clutch
Shift 1Shift 2TimingC1C2C3B1B2B3F1F2
D3rdOFFOFFOFFONONOFFOFFONOFFOFFOFF

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Fig. 444: Manual Third Gear Schematics
Courtesy of GENERAL MOTORS CORP.
A. Front Planetary Gear
B. Rear Planetary Gear
D - 3rd Gear

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1. The input shaft rotates clockwise.
The forward clutch (C1) operates. Connect the input shaft to the front sun gear.
The direct clutch (C2) operates. Connect the input shaft to the planetary carrier.
2. The planetary short pinion and the planetary long pinion can not rotate itself, and the planetary gear unit
rotates clockwise as one.
3. The counter drive gear rotates clockwise for the ring gear and one.
4. The counter drive gear rotates counterclockwise.
5. The differential drive pinion rotates counterclockwise for the counter driven gear and one.
6. The differential rotates clockwise.
Engine Brake
The driving force is connected to the input shaft directory without the 1-way clutch. Therefore the engine brake
operates.
MANUAL SECOND GEAR
Manual Second Gear
Position
SolenoidClutchBrake1-Way Clutch
Shift 1Shift 2TimingC1C2C3B1B2B3F1F2
D2ndONOFFOFFONOFFOFFOFFONOFFONOFF
22ndONOFFOFFONOFFOFFONONOFFONOFF

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Fig. 445: Manual Second Gear Schematics
Courtesy of GENERAL MOTORS CORP.
A. Front Planetary Gear
B. Rear Planetar
y Gear

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