torque CHEVROLET AVEO 2002 Service User Guide

Capacities and Specications
The following approximate capacities are given in English and metric conversions. SeePart D: Recommended Fluids
and Lubricants on page 6-25for more information.
ApplicationCapacities
English Metric
Air Conditioning Refrigerant R134a 1.48 lbs 0.67 kg
Cooling System 6.3 qt 6.0 L
Engine Oil with Filter 3.96 qt 3.75 L
Fuel Tank 11.9 gal 45.0 L
Transaxle, Automatic 6.2 qt 5.87 L
Transaxle, Manual 1.9 qt 1.8 L
Wheel Nut Torque 81 lb ft 110Y
All capacities are approximate. When adding, be sure to fill to the appropriate level, as recommended in this
manual. Recheck fluid level after filling.
Engine Specications
Engine VIN Code Transaxle Spark Plug Gap
1.6L L4 (L91) 6Automatic and
Manual0.039-0.043 inch (1.0-1.1 mm)
5-80

TRANSMISSION GENERAL SPECIFICATIONS
Transmission General Specifications
Washer Thickness
Shim Thickness
Stator Shaft Bolts25 N.m18 lb ft
TCM Retaining Bolts5 N.m44 lb in
Torque Converter Bolts45 N.m43 lb ft
Transaxle Apply Clamp Bolt5.4 N.m48 lb in
Transaxle Case Plate Bolt9.8 N.m87 lb in
Transaxle Housing Bolts29 N.m22 lb ft
Transaxle Rear Cover Bolts25 N.m18 lb ft
Unions25 N.m18 lb ft
Upper Transaxle Mounting Bracket Bolts60 N.m44 lb ft
Upper Transaxle-to-Engine Mounting Bolts73 N.m54 lb ft
Valve Body Bolts11 N.m97 lb in
Application
Specification
MetricEnglish
MakerAISIN
Type or Model81-40LE
Gear Ratio - 1st2.875:1
Gear Ratio - 2nd1.568:1
Gear Ratio - 3rd1.000:1
Gear Ratio - 4th0.697:1
Reverse2.300:1
Final Drive Ratio3.750:1
Oil Capacity5.6L5.9 qt
Transmission Fluid Type
T-IV Automatic Transmission Fluid (GM
Part No. U.S. 88900925, in Canada
22689186)
MetricEnglish
0.95 mm0.0374 in
1 mm0.0394 in
1.05 mm0.0413 in
1.1 mm0.0433 in
1.15 mm0.0453 in
1.2 mm0.0472 in
Specification

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

CONNECTOR END VIEWS
Automatic Transmission Connector
2Select Control Lever Assembly
3Bolt
4Cable Fastener
5Clamp
6E-Ring
7Bolt
8Select Control Cable
9Shift Program Switch
10Shift Indicator Lamp
Connector Part InformationYazaki 7283-1407-40
10-Way (GY)
PinWire ColorCircuit No.Function
1PU898Transmission Fluid Temperature Sensor
Signal
2PK1224Timing Valve Control
3RD1226Pressure Control Solenoid Control
4D-BU1225Torque Converter Clutch Solenoid Control
5L-GN1222Shift Solenoid 1 Valve Control
6OG/BK586Transmission Fluid Temperature Sensor Low
Reference
7--Not Used
8YE/BK1227Low Reference
9--Not Used

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 29 © 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
Microsoft
Thursday, July 16, 2009 1:17:17 PMPage 33 © 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. 77: View Of Torque Converter Bolts
Courtesy of GENERAL MOTORS CORP.
11. Remove the service hall cover.
12. Remove the torque converter bolts.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:20 PMPage 89 © 2005 Mitchell Repair Information Company, LLC.

Fig. 89: View Of Torque Converter Bolts
Courtesy of GENERAL MOTORS CORP.
7. Install the torque converter bolts.
Tighten: Tighten the torque converter bolts to 45 N.m (33 lb ft).
8. Install the service hall cover.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:20 PMPage 101 © 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. 222: Measuring Preload Of Differential Gear Using A Small Torque Wrench & DT 46461
Courtesy of GENERAL MOTORS CORP.
24. Using DT 46461 and a small torque wrench, measure the preload of the differential gear. See Special
Tools.
IMPORTANT: Note the measured value.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:24 PMPage 235 © 2005 Mitchell Repair Information Company, LLC.

Fig. 226: Measuring Preload Of Differential Gear Using A Small Torque Wrench & DT 46461
Courtesy of GENERAL MOTORS CORP.
29. Using DT 46461 and a small torque wrench, measure the preload of the differential gear. See Special
Tools. From this value deduct the value measured previously. This new value is the preload of the
counter driven gear.
Specification:
The preload for a new bearing is 0.33-0.76 N.m (3.21-6.77 lb in).
The preload for a used bearing is 0.17-0.38 N.m (1.48-3.39 lb in).
30. If the preload of the counter driven gear does not satisfy the specification, select the adjuster shim from
the table below and re-measure the value. Until the value is within the specification, repeat the procedure.
IMPORTANT: When the preload is larger than the specification, select a thinner adjuster
shim. When the preload is smaller than specification, select a thicker
adjuster shim.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:24 PMPage 239 © 2005 Mitchell Repair Information Company, LLC.