lock CHEVROLET AVEO 2002 Service Repair Manual

Q
Questions and Answers About Safety Belts.........1-17
R
Radios..........................................................3-38
AM-FM Radio.............................................3-39
Care of Your CD Player...............................3-71
Care of Your CDs ........................................3-71
Radio with CD............................3-41, 3-45, 3-52
Radio with Six-Disc CD................................3-61
Understanding Reception..............................3-70
Rear Door Security Locks.................................. 2-8
Rear Seat Operation...................................1-6, 1-9
Rear Seat Passengers, Safety Belts..................1-25
Rear Windshield Washer/Wiper.........................3-10
Rearview Mirrors.............................................2-32
Reclining Seatbacks.......................................... 1-3
Recreational Vehicle Towing.............................4-34
Remote Keyless Entry System............................ 2-4
Remote Keyless Entry System, Operation............ 2-5
Removing the Flat Tire and Installing the
Spare Tire..................................................5-61
Removing the Spare Tire and Tools...................5-60
Replacement Bulbs.........................................5-44Reporting Safety Defects
Canadian Government..................................7-14
General Motors...........................................7-15
United States Government............................7-14
Restraint System Check
Checking the Restraint Systems....................1-71
Replacing Restraint System Parts
After a Crash..........................................1-72
Right Front Passenger Position, Safety Belts......1-25
Roadside
Assistance Program....................................... 7-6
Rocking Your Vehicle to Get it Out....................4-26
Running the Engine While Parked.....................2-31
S
Safety Belt
Pretensioners..............................................1-29
Reminder Light............................................3-32
Reminder Tone............................................3-25
Safety Belts
Care of ......................................................5-69
Center Rear Passenger Position....................1-28
Driver Position............................................1-18
How to Wear Safety Belts Properly................1-17
9

2006 TRANSMISSION
Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications
Application
Specification
MetricEnglish
Check Valve Spring Bolts6.5 N.m57 lb in
Control Cable Adjusting Nut8 N.m71 lb in
Damping Block Connection Nut and Bolt80 N.m59 lb ft
Differential Case-to-Differential Ring Gear Bolt102 N.m75 lb ft
Drain Plug17 N.m13 lb ft
Fluid Cooler Inlet Pipe Bolt9 N.m80 lb in
Fluid Cooler Inlet Pipe Fitting Nut35 N.m26 lb ft
Fluid Cooler Rear Outlet Pipe Clip Bolt9 N.m80 lb in
Fluid Cooler Rear Outlet Pipe Fitting Nut35 N.m26 lb ft
Front Outlet Pipe Clip Bolt9 N.m80 lb in
Front Outlet Pipe Union Bolt35 N.m26 lb ft
Input Speed Sensor Retaining Bolt5.4 N.m48 lb in
Manual Detent Spring Bolt9.8 N.m87 lb in
Manual Valve Lever Shaft Nut12 N.m106 lb in
Lower Transaxle-to-Engine Retaining Bolts73 N.m54 lb ft
Lower Transaxle-to-Engine Retaining Bolts31 N.m23 lb ft
Lower Transaxle-to-Engine Retaining Bolts21 N.m15 lb ft
Oil Pan Bolts7 N.m62 lb in
Oil Pump Bolts25 N.m18 lb ft
Oil Reservoir Lock Plate Bolts5.4 N.m48 lb in
Oil Strainer Bolts9.8 N.m87 lb in
Output Speed Sensor Retaining Bolt7.4 N.m65 lb in
Park/Neutral Position Switch Bolts5.4 N.m48 lb in
Parking Lock Pawl Bracket Bolts7.4 N.m65 lb in
Planetary Ring Gear Nut-Maximum29 N.m22 lb ft
Planetary Ring Gear Nut-Standard9.8 N.m87 lb in
Rear Mounting Bracket Bolts60 N.m44 lb ft
Screw Plugs7.4 N.m65 lb in
Shift Control Lever Assembly Mounting Bolts8 N.m71 lb in
Shift Solenoid Valve Bolts11 N.m97 lb in

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo

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

10O-Ring
11Transaxle Wire
12Torsion Spring
13Transaxle Oil Apply Pipe Clamp
14Parking Lock Pawl
15Manual Valve Lever
16Spacer
17Oil Seal
18Park/Neutral Position Switch
19Lock Washer
20Control Lever
21Washer
22Spring
23O-Ring
24Overdrive Brake Accumulator Piston
25O-Ring
26Spring
27O-Ring
28Forward Clutch Accumulator Piston
29O-Ring
30O-Ring
31Direct Clutch Accumulator Piston
32O-Ring
33Spring
34Manual Detent Spring
35Pin
36Parking Lock Rod
37Parking Lock Pawl Shaft
38Manual Valve Lever Shaft
39Parking Lock Pawl Bracket
40Oil Pan
41Gasket
42Magnet
43Oil Strainer
44Gasket
45Valve Body

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 23 © 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. 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
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 39 © 2005 Mitchell Repair Information Company, LLC.

Fig. 78: Removal Of Rear Mounting Bracket Bolts And Bracket
Courtesy of GENERAL MOTORS CORP.
13. Remove the damping block connection nut and bolt.
14. Remove the rear mountin
g bracket bolts and rear mounting bracket.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:20 PMPage 90 © 2005 Mitchell Repair Information Company, LLC.

Fig. 88: Installing Damping Block Connection Nut And Bolt
Courtesy of GENERAL MOTORS CORP.
5. Install the rear mounting bracket bolts and the bracket.
Tighten: Tighten the rear mounting bracket bolts to 60 N.m (44 lb ft).
6. Install the damping block connection nut and bolt.
Tighten: Tighten the damping block connection nut and bolt to 80 N.m (59 lb ft).

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:20 PMPage 100 © 2005 Mitchell Repair Information Company, LLC.

Fig. 93: Inspecting Drive Plate Deflection
Courtesy of GENERAL MOTORS CORP.
1. Inspect if the drive plate deflection is within standard value.
Specifications: The drive plate deflection standard value is 0.2 mm (0.008 in).
2. If the standard value is not within the specified value, replace the drive plate.
3. When abnormal wear or stick on torque converter sleeve or oil pump is found, replace torque converter
and automatic transmission.
IMPORTANT: When assembling torque converter and drive plate. Be sure to use correct
bolt with correct length. The bolt pushes up torque converter front cover,
and it damages lock-up clutch lining. As a result, it causes major failure -
No move.
IMPORTANT: Do not tighten the bolts by using an impact wrench.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:20 PMPage 105 © 2005 Mitchell Repair Information Company, LLC.

Fig. 101: TFT Sensor
Courtesy of GENERAL MOTORS CORP.
1. Measure the resistance of the transmission fluid temperature (TFT) sensor between terminals 1 and 6 (1,
2) of the TFT connector at 10°C (50°F) and 110°C (230°F).
2. If the resistance measurement of 10°C (50°F) is not between 5.8-7.09 k ohms, replace the TFT sensor.
3. If the resistance measurement of 110°C (230°F) is not between 0.23-0.263 k ohms, replace the TFT
sensor.
SHIFT SOLENOID (1, 2), TIMING SOLENOID, LOCK-UP SOLENOID INSPECTION

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:20 PMPage 113 © 2005 Mitchell Repair Information Company, LLC.