CHEVROLET AVEO 2002 Service Repair Manual

Fig. 60: OSS Sensor, Retaining Bolt & O-Ring
Courtesy of GENERAL MOTORS CORP.
1. Install a new O-ring on the OSS sensor.
2. Install the OSS sensor and retaining bolt into the transaxle.
Tighten: Ti
ghten the OSS sensor retaining bolt to 7.4 N.m (65 lb in).
IMPORTANT: Lubricate the O-ring with T-IV Automatic Transmission Fluid GM P/N
88900925 (Canadian P/N 22689186).
NOTE: Refer to Fastener Notice
in Cautions and Notices.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 61: OSS Sensor Electrical Connector
Courtesy of GENERAL MOTORS CORP.
3. Connect the OSS sensor electrical connector.
4. Connect the negative battery cable.
TRANSMISSION CONTROL MODULE (TCM) REPLACEMENT
Removal Procedure
1. Disconnect the negative battery cable.
CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 62: TCM Electrical Connector
Courtesy of GENERAL MOTORS CORP.
2. Locate the transmission control module (TCM) electrical connector next to the brake pedal assembly.
3. Disconnect the transmission control module (TCM) electrical connector.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Fig. 63: TCM Retaining Bolts
Courtesy of GENERAL MOTORS CORP.
4. Remove the TCM retaining bolts.
5. Remove the TCM.
Installation Procedure

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Thursday, July 16, 2009 1:17:19 PMPage 75 © 2005 Mitchell Repair Information Company, LLC.

Fig. 64: TCM Retaining Bolts
Courtesy of GENERAL MOTORS CORP.
1. Connect the negative battery cable.
2. Install the TCM and retaining bolts.
Tighten: Tighten the TCM retaining bolts to 5 N.m (44 lb in).
NOTE: Refer to Fastener Notice in Cautions and Notices.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Thursday, July 16, 2009 1:17:19 PMPage 76 © 2005 Mitchell Repair Information Company, LLC.

Fig. 65: TCM Electrical Connector
Courtesy of GENERAL MOTORS CORP.
3. Connect the TCM electrical connector.
4. Connect the negative battery cable.
TRANSMISSION COOLER PIPES AND HOSES REPLACEMENT (INLET)
Removal Procedure

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Thursday, July 16, 2009 1:17:20 PMPage 77 © 2005 Mitchell Repair Information Company, LLC.

Fig. 66: Radiator Threaded Connector & Fluid Cooler Hoses
Courtesy of GENERAL MOTORS CORP.
1. Raise and support the vehicle.
2. Drain the transaxle fluid.
3. Remove the clip from the radiator threaded connector, then disconnect the fluid cooler hoses.
NOTE: Refer to Vehicle Lifting and Jacking Notice in Cautions and Notices.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Thursday, July 16, 2009 1:17:20 PMPage 78 © 2005 Mitchell Repair Information Company, LLC.

Fig. 67: Removing Fluid Cooler Inlet Pipe, Bolt & Transaxle
Courtesy of GENERAL MOTORS CORP.
4. Remove the fluid cooler inlet pipe bolt from the transaxle.
5. Remove the inlet pipe fitting nut from the transaxle.
6. Remove the fluid cooler inlet pipe and hoses.
Installation Procedure

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Thursday, July 16, 2009 1:17:20 PMPage 79 © 2005 Mitchell Repair Information Company, LLC.

Fig. 68: Installing Fluid Cooler Inlet Pipe, Bolt & Transaxle
Courtesy of GENERAL MOTORS CORP.
1. Install the fluid cooler inlet pipe fitting nut into the transaxle.
Tighten: Tighten the fluid cooler inlet pipe fitting nut to 35 N.m (26 Ib ft).
2. Install the fluid cooler inlet pipe bolt into the transaxle.
Tighten: Ti
ghten the fluid cooler inlet pipe bolt to 9 N.m (80 Ib in).
NOTE: Refer to Fastener Notice in Cautions and Notices.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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Thursday, July 16, 2009 1:17:20 PMPage 80 © 2005 Mitchell Repair Information Company, LLC.

Fig. 69: Radiator Threaded Connector & Fluid Cooler Hoses
Courtesy of GENERAL MOTORS CORP.
3. Connect the fluid cooler hoses and install the clip into the radiator threaded connector.
4. Lower the vehicle.
5. Fill the transaxle with fluid. Refer to Draining Transmission Fluid
.
TRANSMISSION COOLER PIPES AND HOSES REPLACEMENT (OUTLET)
Removal Procedure

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