engine CHEVROLET AVEO 2002 Service Repair Manual

I
Ignition Positions.............................................2-18
Immobilizer....................................................2-16
Immobilizer Operation......................................2-16
Infants and Young Children, Restraints...............1-32
Inflation - Tire Pressure...................................5-51
Inspection
Brake System.............................................6-24
Engine Cooling System................................6-24
Exhaust System..........................................6-23
Fuel System...............................................6-23
Part C - Periodic Maintenance.......................6-23
Steering, Suspension and Front Drive Axle
Boot and Seal.........................................6-23
Instrument Panel
Overview..................................................... 3-4
Instrument Panel (I/P)
Brightness..................................................3-15
Cluster.......................................................3-24
J
Jump Starting.................................................5-36
K
Keyless Entry System....................................... 2-4
Keys............................................................... 2-2
L
Labeling, Tire Sidewall.....................................5-46
Lamps
Dome ........................................................3-16
Exterior......................................................3-13
Fog ...........................................................3-15
LATCH System
Child Restraints...........................................1-42
Liftgate..........................................................2-11
Light
Airbag Readiness........................................3-32
Anti-Lock Brake System Warning...................3-34
Brake System Warning.................................3-27
Charging System.........................................3-33
Cruise Control.............................................3-29
Daytime Running Lamps Indicator..................3-29
Door Ajar...................................................3-38
Fog Lamp ..................................................3-38
Highbeam On.............................................3-29
Hold Mode .................................................3-34
Low Fuel Warning.......................................3-30
6

Light (cont.)
Malfunction Indicator....................................3-34
Oil Pressure...............................................3-37
Passenger Airbag Status Indicator..................3-26
Safety Belt Reminder...................................3-32
Safety Belt Reminder Tone...........................3-25
Loading Your Vehicle.......................................4-27
Lockout Protection............................................ 2-9
Locks
Central Door Unlocking System....................... 2-7
Door ........................................................... 2-7
Lockout Protection......................................... 2-9
Rear Door Security Locks............................... 2-8
Long Trip/Highway Scheduled Maintenance........6-13
Loss of Control...............................................4-13
Low Fuel Warning Light...................................3-30
M
Maintenance, Normal Replacement Parts............5-81
Maintenance Schedule
At Each Fuel Fill.........................................6-18
At Least Once a Month................................6-18
At Least Once a Year..................................6-20
At Least Twice a Year..................................6-19
Brake System Inspection..............................6-24
Engine Cooling System Inspection.................6-24
Exhaust System Inspection...........................6-23
Fuel System Inspection................................6-23Maintenance Schedule (cont.)
How This Section is Organized....................... 6-3
Introduction.................................................. 6-2
Long Trip/Highway Scheduled Maintenance.....6-13
Maintenance Requirements............................. 6-2
Part A - Scheduled Maintenance Services......... 6-4
Part B - Owner Checks and Services.............6-18
Part C - Periodic Maintenance Inspections......6-23
PartD-Recommended Fluids and Lubricants....6-25
PartE-Maintenance Record........................6-27
Selecting the Right Schedule.......................... 6-5
Short Trip/City Scheduled Maintenance............. 6-6
Steering, Suspension and Front Drive Axle
Boot and Seal Inspection..........................6-23
Using.......................................................... 6-4
Your Vehicle and the Environment................... 6-2
Malfunction Indicator Light................................3-34
Manual Seats................................................... 1-2
Manual Transaxle
Fluid..........................................................5-21
Operation...................................................2-25
Manual Windows............................................2-12
Mirrors
Manual Rearview Mirror................................2-32
Outside Convex Mirror.................................2-33
Outside Heated Mirrors................................2-33
Outside Manual Mirrors................................2-32
Outside Power Mirror...................................2-33
MyGMLink.com................................................ 7-4
7

N
New Vehicle Break-In......................................2-17
Normal Maintenance Replacement Parts............5-81
O
Odometer......................................................3-25
Odometer, Trip...............................................3-25
Off-Road Recovery..........................................4-11
Oil
Engine.......................................................5-13
Pressure Light.............................................3-37
Older Children, Restraints................................1-30
Online Owner Center........................................ 7-4
Other Warning Devices...................................... 3-6
Outlet Adjustment............................................3-21
Outlet(s), Accessory Power...............................3-16
Outside
Convex Mirror.............................................2-33
Heated Mirrors............................................2-33
Manual Mirrors............................................2-32
Power Mirror...............................................2-33
Owners, Canadian............................................... ii
P
Paint, Damage...............................................5-72
Park (P)
Shifting Into................................................2-27
Shifting Out of............................................2-28
Parking
Brake........................................................2-26
Over Things That Burn.................................2-30
Parking Your Vehicle.......................................2-29
Part A - Scheduled Maintenance Services............ 6-4
Part B - Owner Checks and Services................6-18
Part C - Periodic Maintenance Inspections..........6-23
Part D - Recommended Fluids and Lubricants....6-25
PartE-Maintenance Record...........................6-27
Passenger Airbag Status Indicator.....................3-26
Passenger Compartment Air Filter.....................3-21
Passenger Sensing System..............................1-65
Passing.........................................................4-11
Power
Accessory Outlet(s)......................................3-16
Electrical System.........................................5-75
Steering Fluid.............................................5-30
Windows....................................................2-13
Pretensioners, Safety Belt................................1-29
8

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

Safety Belts (cont.)
Questions and Answers About Safety Belts.....1-17
Rear Seat Passengers.................................1-25
Right Front Passenger Position......................1-25
Safety Belt Extender....................................1-29
Safety Belt Use During Pregnancy.................1-25
Safety Belts Are for Everyone.......................1-12
Shoulder Belt Height Adjuster........................1-24
Safety Warnings and Symbols.............................. iii
Seats
Driver Seat Height Adjuster............................. 1-3
Head Restraints............................................ 1-5
Manual........................................................ 1-2
Rear Seat Operation...............................1-6, 1-9
Reclining Seatbacks...................................... 1-3
Secondary Information Center (SIC)...................3-31
Securing a Child Restraint
Rear Seat Position......................................1-49
Right Front Seat Position..............................1-51
Selecting the Right Schedule, Maintenance.......... 6-5
Service........................................................... 5-3
Accessories and Modifications......................... 5-3
Adding Equipment to the Outside of Your
Vehicle..................................................... 5-4
California Proposition 65 Warning.................... 5-3
Doing Your Own Work................................... 5-4
Engine Soon Light.......................................3-34
Publications Ordering Information...................7-15Servicing Your Airbag-Equipped Vehicle..............1-69
Sheet Metal Damage.......................................5-72
Shifting Into Park (P).......................................2-27
Shifting Out of Park (P)...................................2-28
Short Trip/City Scheduled Maintenance................ 6-6
Shoulder Belt Height Adjuster...........................1-24
Signals, Turn and Lane-Change.......................... 3-7
Spare Tire
Compact....................................................5-66
Installing....................................................5-61
Removing...................................................5-60
Storing.......................................................5-65
Specifications, Capacities.................................5-80
Speedometer..................................................3-25
Starting Your Engine.......................................2-19
Steering.......................................................... 4-9
Steering, Suspension and Front Drive
Axle Boot and Seal Inspection.......................6-23
Steering Wheel, Tilt Wheel................................. 3-6
Storage Areas................................................2-34
Cupholder(s)...............................................2-34
Glove Box..................................................2-34
Sunglasses Storage Compartment..................2-35
Stuck in Sand, Mud, Ice, or Snow.....................4-26
Sun Visors.....................................................2-13
Sunroof.........................................................2-35
10

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.
Microsoft
Thursday, July 16, 2009 1:17:42 PMPage 1 © 2005 Mitchell Repair Information Company, LLC.

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.

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.

J 28467-B (DW 110-060) Engine Support Fixture
DW 260-120 (DW 260-012) Transaxle Support Fixture. See Special Tools.
Removal Procedure
Fig. 74: Fluid Cooler Inlet/Outlet Hoses & Transaxle
Courtesy of GENERAL MOTORS CORP.
1. Remove the battery and battery tray.
2. Drain the transaxle fluid. Refer to Draining Transmission Fluid
.
3. Remove the left and right drive axle assemblies. Refer to Inner Shaft and/or Housing Replacement
-
Front Drive Axle
.
4. Disconnect the fluid cooler inlet and outlet hoses from the transaxle.
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 1:17:20 PMPage 86 © 2005 Mitchell Repair Information Company, LLC.

Fig. 75: J 28467-B & Engine
Courtesy of GENERAL MOTORS CORP.
5. Disconnect the shift control cable from the transaxle. Refer to Shift Control Cable Replacement
-Floor
Shift.
6. Install the J 28467-B (1) to support the engine.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
Microsoft
Thursday, July 16, 2009 1:17:20 PMPage 87 © 2005 Mitchell Repair Information Company, LLC.