2002 CHEVROLET AVEO check engine

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
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Fig. 121: Transmission Fluid Level Graph
Courtesy of GENERAL MOTORS CORP.
1. Make sure the vehicle is level.
2. Shift into all range from P to 1 and return to P with engine idling.
3. Remove the transaxle fluid dipstick and check the transaxle fluid level.
IMPORTANT: When adding fluid or making a complet fluid change, always use T-IV
Automatic Transmission Fluid.
IMPORTANT: Measure the fluid level when the transaxle temperature is 70°C-80°C (158°
F-176°F).
IMPORTANT: During the fluid level check, the selector lever must be in position P.

2006 Chevrolet Aveo
2006 TRANSMISSION Automatic Transaxle - Aisin (81-40LE) - Introduction (2 Of 2) - Aveo
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2005 ACCESSORIES & EQUIPMENT
Instrument Panel, Gages, & Console - Aveo
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications
BULB USAGE SPECIFICATIONS
Bulb Usage Specifications
Application
Specification
MetricEnglish
Chime Module Screws3.5 N.m31 lb in
Clock Screws2.5 N.m22 lb in
Cupholder Screws2.5 N.m22 lb in
Floor Console Screws4 N.m35 lb in
HVAC Controls Screws4 N.m35 lb in
Instrument Cluster Screws4 N.m35 lb in
Instrument Cluster Trim Panel Screws4 N.m35 lb in
Instrument Panel Bolts Behind the HVAC Controls4 N.m35 lb in
Instrument Panel End Bolts4 N.m35 lb in
Instrument Panel Bolts20 N.m15 lb ft
Indicator LampColorBulb
ABS WiringAmber14 V 1.4 W
Air Bag WarningRed14 V 1.4 W
Battery Charge IndicatorRed14 V 1.4 W
Check EngineAmber14 V 1.4 W
Door Open WarningRed14 V 1.4 W
Engine OverheatRed14 V 1.4 W
Fasten Seat Belt WarningRed14 V 1.4 W
High Beam IndicatorBlue14 V 1.4 W
Low Fuel Level WarningAmber14 V 1.4 W
Oil Pressure WarningRed14 V 1.4 W
Parking Brake Indicator and Brake
Fluid WarningRed14 V 1.4 W
Service Engine Soon WarningAmber14 V 1.4 W
Transaxle Power Mode IndicatorAmber14 V 1.4 W
Turn Signal IndictorsGreen14 V 1.4 W

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
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Friday, July 31, 2009 1:07:02 PMPage 1 © 2005 Mitchell Repair Information Company, LLC.
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Friday, July 31, 2009 1:07:07 PMPage 1 © 2005 Mitchell Repair Information Company, LLC.

DIAGNOSTIC INFORMATION AND PROCEDURES
DIAGNOSTIC STARTING POINT - INSTRUMENT PANEL, GAGES AND CONSOLE
Begin the system diagnosis by reviewing the Symptoms
- Instrument Panel, Gages and Console . Reviewing
the symptom information will help you determine the correct symptom diagnostic procedure when a
malfunction exists.
DIAGNOSTIC SYSTEM CHECK - INSTRUMENT CLUSTER
Test Description
The numbers below refer to the step numbers on the diagnostic table.
1: Lack of communication may be due to a malfunction of the serial data circuits. The specified
procedure will determine the particular condition.
3: The presence of DTCs may be related to an engine electrical condition. The specified procedure will
compile all the available information before tests are performed.
Diagnostic System Check - Instrument Cluster
DIAGNOSTIC TROUBLE CODE (DTC) LIST
Diagnostic Trouble Code (DTC) List
Connector Part Information
AK 32104
1-Way F Metri-Pack 150 Series Sealed (BK)
PinWire ColorCircuit No.Function
1D-GN/WH31Oil Pressure Indicator Control
StepActionYesNo
1
Install a scan tool.
Does the scan tool power up?
Go to Step 2
Go to Scan Tool
Does Not Power Up
in Data Link
Communications
2
1. Turn ON the ignition, with the engine OFF.
2. Attempt to establish communication with the
engine control module (ECM).
Does the scan tool communicate with the ECM?
Go to Step 3
Go to Scan Tool
Does Not
Communicate with
Componentin Data
Link
Communications
3
Select the Display DTCs function for the ECM.
Does the scan tool display DTC P0461, P0462, P0463
or P0464?Go to Diagnostic
Trouble Code
(DTC) List
Go to Symptoms -
Instrument Panel,
Gages and Console
DTCDiagnostic ProcedureModules

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
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reports a failure on the second consecutive ignition cycle, the control module records the operating
conditions at the time of the failure. The control module writes the operating conditions to the Freeze
Frame and updates the Failure Records.
The fuel gage defaults to empty.
Conditions for Clearing the MIL/DTC
The control module turns OFF the MIL after 3 consecutive ignition cycles that the diagnostic runs and
does not fail.
A current DTC, Last Test Failed, clears when the diagnostic runs and passes.
A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other
emission related diagnostic.
Clear the MIL and the DTC with a scan tool.
Diagnostic Aids
Check for the following conditions:
A poor connection or damaged harness-Inspect ECM harness connectors for the following:
Backed out terminals
Improper mating
Broken locks
Poor wire to terminal connections
Intermittent test-Monitor a scan tool or digital voltmeter connected between the related circuits while
moving the connectors and harnesses. If the failure is induced, the voltage reading will change. This will
help locate a circuit condition. Refer to the following:
Intermittent Conditions
in Engine Controls - 1.6L (L91)
Test Description
The numbers below refer to the step numbers on the diagnostic table.
2: This step determines if the fault is present.
3: This step determines if the fuel level sensor signal and ground circuits are OK.
DTC P0461
StepActionValueYesNo
Schematic Reference: Instrument Cluster Schematics
Connector End View Reference: Instrument Panel, Gages, and Console Connector End Views

1
Did you perform the Diagnostic System Check -
Instrument Cluster?
-
Go to
Diagnostic
System Check
- Instrument

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
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The control module turns OFF the MIL after 3 consecutive ignition cycles that the diagnostic runs and
does not fail.
A current DTC, Last Test Failed, clears when the diagnostic runs and passes.
A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other
emission related diagnostic.
Clear the MIL and the DTC with a scan tool.
Diagnostic Aids
Use the Freeze Frame and/or Failure Records data in order to locate an intermittent condition. If you
cannot duplicate the DTC, the information included in the Freeze Frame and/or Failure Records data may
aid in determining the number of miles since the DTC set. The Fail Counter and Pass Counter can also aid
in determining the number of ignition cycles that the diagnostic reported a pass and/or fail. Operate the
vehicle within the same freeze frame conditions (RPM, engine load, vehicle speed, temperature, etc.).
This will isolate when the DTC failed.
Refer to the following:
Intermittent Conditions
in Engine Controls - 1.6L (L91)
Test Description
The number below refers to the step number on the diagnostic table.
2: This step determines if the fault is present.
DTC P0462
StepActionValueYesNo
Schematic Reference: Instrument Cluster Schematics
Connector End View Reference: Instrument Panel, Gages, and Console Connector End Views

1
Did you perform the Diagnostic System Check -
Instrument Cluster?
-
Go to Step 2
Go to
Diagnostic
System Check
- Instrument
Cluster
2
1. Turn ON the ignition, with the engine
OFF.
2. Observe the Fuel Level Sensor voltage
parameter with a scan tool.
Is the voltage more than the specified value?
4.25 V
Go to Step 4 Go to Step 3
1. Observe the Freeze Frame/Failure Records
for this DTC.
2. Turn OFF the ignition for 30 seconds.
3. Start the engine.

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Connector End View Reference: Instrument Panel, Gages, and Console Connector End Views
1
Did you perform the Diagnostic System Check -
Instrument Cluster?
-
Go to Step 2
Go to
Diagnostic
System Check
- Instrument
Cluster
2
1. Turn ON the ignition, with the engine
OFF.
2. Observe the Fuel Level Sensor voltage
parameter with a scan tool.
Is the voltage parameter less than the specified
value?
0.25 V
Go to Step 4 Go to Step 3
3
1. Observe the Freeze Frame/Failure
Records for this DTC.
2. Turn OFF the ignition for 30 seconds.
3. Start the engine.
4. Operate the vehicle within the Conditions
for Running the DTC. You may also
operate the vehicle within the conditions
that you observed from the Freeze
Frame/Failure Records.
Did the DTC fail this ignition?
-
Go to Step 4
Go to
Diagnostic Aids
4
1. Disconnect the fuel level sensor through
the access panel under the rear seat.
2. Connect a 3-amp fused jumper wire
between the signal circuit of the fuel level
sender and the low reference circuit of the
fuel level sender female terminal side.
3. Turn ON the ignition, with the engine
OFF.
4. Observe the Fuel Level Sensor voltage
parameter with a scan tool.
Is the voltage more than the specified value?
0.25 V
Go to Step 8 Go to Step 5
5
Jumper the fuel level sensor signal circuit to a
known good ground.
Is the voltage more than the specified value?
0.25 V
Go to Step 7 Go to Step 6
6
Test the signal circuit of the fuel level sensor for
an open, for a high resistance, or for a short to
voltage. Refer to Circuit Testing
and Wiring
Repairs in Wiring Systems.
-

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The control module stores the DTC information into memory when the diagnostic runs and fails.
The malfunction indicator lamp (MIL) will not illuminate.
The control module records the operating conditions at the time the diagnostic fails. The control module
stores this information in the Failure Records.
The driver information center, if equipped, may display a message.
Conditions for Clearing the DTC
A current DTC Last Test Failed clears when the diagnostic runs and passes.
A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other
non-emission related diagnostic.
Clear the DTC with a scan tool.
Test Description
The numbers below refer to the step numbers on the diagnostic table.
3: This step attempts to determine if the intermittent fault is a connector.
4: This step attempts to determine the location of the intermittent fault.
DTC P0464
StepActionYesNo
Schematic Reference: Instrument Cluster Schematics or
Connector End View Reference: Instrument Panel, Gages, and Console Connector End Views

1
Did you perform the Diagnostic System Check - Instrument
Cluster?
Go to Step
2
Go to Diagnostic
System Check -
Instrument Cluster

2
1. Start the engine.
2. Observe the DTC Information with a scan tool.
Are DTCs P0461, P0462, and P0463 also set?Go to
Dia
gnostic
Trouble
Code
(DTC)
List Go to Step 3
3
Observe the Fuel Level Sensor voltage parameter with a scan
tool while moving the fuel level sensor connector and the
engine control module (ECM) connector. Refer to Inducing
Intermittent Fault Conditions in Wiring Systems.
Does the scan tool indicate an abrupt change in value?Go to Step
5
Go to Step 4
4
Observe the fuel level sensor voltage with a scan tool while
moving the wiring harness between the fuel level sensor
connector and the ECM. Refer to Inducing Intermittent
Fault Conditions in Wiring Systems.
Does the scan tool indicate an abrupt change in value?Go to Step
6
Go to Intermittent
Conditionsin Engine
Controls
Repair the connector terminal as necessary. Refer to

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