CHEVROLET AVEO 2002 Service Repair Manual

Fig. 90: Electrical Connectors
Courtesy of GENERAL MOTORS CORP.
9. Connect the transaxle electrical connector.
10. Connect the PNP sensor electrical connector.
11. Connect the OSS sensor electrical connector.
12. Connect the ISS sensor electrical connector.

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Fig. 91: J 28467-B & Engine
Courtesy of GENERAL MOTORS CORP.
13. Remove the J 28467-B (1).
14. Connect the shift control cable into the transaxle. Refer to Shift Control Cable Replacement
- Floor
Shift.

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Fig. 92: Fluid Cooler Inlet/Outlet Hoses & Transaxle
Courtesy of GENERAL MOTORS CORP.
15. Connect the fluid cooler inlet and outlet hose into the transaxle.
16. Install the left and right drive axle assemblies. Refer to Inner Shaft and/or Housing Replacement
-
Front Drive Axle
.
17. Install the battery and battery tray.
18. Fill the transaxle with fluid. Refer to Draining Transmission Fluid
.
19. Measure the fluid level. Refer to Transmission Fluid Level Inspection
.
DRIVE PLATE DEFLECTION INSPECTION

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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.

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COOLER PIPE BENDING AND CHOKE INSPECTION
Fig. 94: Cooler Pipe Inlet Side

Courtesy of GENERAL MOTORS CORP.
1. Replace failured parts.
2. Apply compressed air of 2 kg/cm
2 from cooler pipe inlet side (1), inspect whether there is not cooler pipe
choke by confirming air flow smooth.
3. Remove foreign particles and clean inside of pipe line.
VEHICLE SPEED SENSOR INSPECTION
IMPORTANT: Inspect if there is abnormal pipe bending in the cooler pipe, pipe
deformation and small cross-section area of pipe line.

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Fig. 95: Vehicle Speed Sensor, 12 Volt Power Supply & Voltmeter
Courtesy of GENERAL MOTORS CORP.
1. Remove the connector of vehicle speed sensor, connect 12 volt power supply and voltmeter to the
terminal. Do not mistake polarit
y.

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Fig. 96: Pulses Per Revolution
Courtesy of GENERAL MOTORS CORP.
2. Rotate the driven gear.
3. Observe the voltage.
4. If the result of the inspection is bad, replace the vehicle speed sensor.
INPUT SPEED SENSOR INSPECTION
IMPORTANT: The voltage value will change from approximately 0 to 12 to 0 volts per
pulse (1). There will be 4 pulses per revolution (2).

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Fig. 97: Measuring The Resistance Of Each Input Speed Sensor Between Terminals
Courtesy of GENERAL MOTORS CORP.
1. Measure the resistance of each input speed sensor between terminals.

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Fig. 98: Sensor Resistance
Courtesy of GENERAL MOTORS CORP.
2. If the resistance value is not between the minimum and maximum resistance plot lines, then measure the
sensor resistance at 20°C (68°F).
3. If both resistance measurements are not between the minimum and maximum resistance plot lines, then
replace the input speed sensor.
PARK/NEUTRAL POSITION SWITCH INSPECTION
IMPORTANT: The resistance of the sensor can become infinity ohm when the
resistance measurement is made at high temperatures.

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Fig. 99: PNP Switch
Courtesy of GENERAL MOTORS CORP.
1. Disconnect the park/neutral position (PNP) switch.

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