Service Manual2011 Aveo DIAGNOSIS

Aveo

DIAGNOSIS

Electric Connector View

X-1 : TCM Vehicle Side Wiring Connector
A1	Ground	B1	R
A2	Pressure Control Solenoid Ground	B3	Clock
A4	Pressure Control Solenoid	B4	Hold
A5	Lock-Up Solenoid	B6	Input Speed Sensor
A6	Ignition (+)	B7	D
A7	CAN (Low)	B8	N
A11	Transmission Fluid Temperature Sensor	B16	Input Speed Sensor Ground
A12	Transmission Fluid Temperature Sensor Ground	B18	L
A14	Timing Solenoid	B19	2
A15	Shift Solenoid No.2	B20	P
A16	Shift Solenoid No.1	B22	Stop Lamp Switch
A17	CAN (High)	B23	DLC
A23	Ground	B25	Output Speed Sensor
A24	B+	-	-

X-2 : TR Switch Connector
1	P
2	R
3	Ground
4	2
5	N
6	ST(-)
7	D
8	1
9	ST(+)

X-4 : Output Speed Sensor Connector
1	Ignition
2	Ground
3	Output Speed Sensor

X-3 : Transaxle Wiring Connector
1	Transmission Fluid Temperature Sensor
2	Timing Solenoid
3	Pressure Control Solenoid
4	Lock-Up Solenoid
5	Shift Solenoid No.1
6	Transmission Fluid Temperature Sensor Ground
8	Pressure Control Solenoid Ground
10	Shift Solenoid No.2

X-5 : Input Speed Sensor
1	Input Speed Sensor Ground
2	Input Speed Sensor

Wiring Harness and Connector Inspection

Reproducing test

Perform symptom simulation test on the basis of user's condition. Refer to the below factors.

Occuring-road condition, speed, accelerate, reduce speed, straight, curve, air temperature, weather, etc.

Inspect the connection condition of between connectors.

Inspect the failure between connectors by visual check and contact pressure check.

Connector disconnected
Terminals rusted
Terminals deformation or loose fit

Inspect the Continuity of the wiring harness.

Disconnect both ends connector of wiring harness, measure resistance between one connector terminal and other.

Normal : 1Ω or less (No open circuit)
Abnormal : ∞ Ω (Open circuit)

Notice : Measure the resistance while slightly shaking wire harness vertically and horizontally.

It is rare case wiring harness is broken at the middle of it, and most cases occur at the connector.

Inspect the short circuit of the wiring harness.

Disconnect the connectors of the wiring harness at both ends, measure resistance between the applicable terminals of the connector and body earth.

Normal : 1M Ω or higher (No short circuit)
Abnormal : Low resistance (Short circuit)

Measure the resistance between one terminal an another terminal in the same connector.(Except between power supply or between earth).

Normal : 1M Ω or higher (No short circuit)
Abnormal : Low resistance (Short circuit)

Notice : Measure the wiring harness while slightly shaking vertically and horzontally.

It is usual case of the short circuit that wiring harness is crowded body and clamping failure.

Temporary connection failure of the connector.

It is thought that temporally the connection failure of the connector is cause when you can not decide cause of DTC detection.

Therfore make sure to inspect and clean the connector and delete the memorized DTC.

Road Test

Road test is to diagnosis failure symptom accurately and check the failure symptom after procedure.

Confirm whether below condition before road test. Oil temperature is hot condition (50~80°C).

D range test

Check for up-shift, down-shift, kick-down and lock-up operation at the shift point shown in the shift schedule.
Check for engine brake operation.
Check for Check abnormal shock, noise and harshness.

"P" range test

Park vehicle on a gradient (more than 5°), shift into the "P" range and release parking brake.

Then, check to see no moving vehicle by operation of parking lock pawl.

Function Check

Confirm whether below condition before function check.

Oil temperature is hot condition (50~80°C).
Switch of A/C and light etc are off.

Stall Test

Stall test' purpose is to inspect overall performance of A/T and engine by measuring the stall speed in "D" and "R" range.

Chock 4 Wheels and apply parking brake fully, lock vehicle perfectly.
Fully pressed on foot brake pedal with left foot.
Shift into "D" and "R" range, fully press on accelerator pedal with right foot.

Quickly read stall speed at this time.

Standards

2390 ± 150 rpm

Notice : Do not continuously run longer than 5 sec because of extreme increasing oil temp.

Make sure to keep interval for more than 1 min between stall tests.

Result of Stall Test	Cause of Failure
Lower than standards both "D" and "R"	Less engine power Torque converter one way clutch failure
Higher than standards only "D"	Lower line pressure Pressure control solenoid (PCS) failure Primary regulator valve failure Forward clutch (C1) failure (Slipping) No.2 One-way clutch (F2) failure
Higher than standards only "R"	Lower line pressure Pressure control solenoid (PCS) failure Primary regulator valve failure Reverse clutch (C3) failure (Slipping) 1st & reverse brake (B3) failure (Slipping)
Higher than standards both "D" and "R"	Lower line pressure Pressure control solenoid (PCS) failure Primary regulator valve failure Oil pump failure Oil strainer failure (clogging) Oil leak for each range circuit

Time Lag Test

Time lag is time till slightly shock can be felt when shift lever is shifted "N" → "D" and "N" → "R" while engine idling.

Time lag test can inspect hydraulic condition and clutch/brake condition.

Chock 4 Wheels and apply parking brake fully, lock vehicle perfectly.
Measure time lag by using stop watch from moment when shift lever is shifted in "N" → "D" and "N" → "R" until moment slightly shock can be felt.

"N → D"	less than 0.7 sec
"N" → "R"	less than 1.2 sec

Notice : Make sure to take 3 measurement and take the average value.

Make sure to keep interval for more than 1 min between time lag tests. (That purpose is to remove clutch/brake pressure was left unfinished.)

Result of Time Lag Test	Cause of Failure
Longer than standards "N" → "D"	Lower line pressure Pressure control solenoid (PCS) failure Primary regulator valve failure Forward Clutch (C1) failure (Slipping) Timing solenoid failure Oil leak for "D" range circuit
Longer than standards "N" → "R"	Lower line pressure Pressure control solenoid (PCS) failure Primary regulator valve failure Reverse clutch (C3) failure (slipping) 1st & reverse brake (B3) failure (slipping) Oil leak for "R" range circuit

Hydraulic Test

Hydraulic test can inspect working condition inside A/T by measuring line pressure in "D" / "R" range and "idle" / "stall" condition.

Chock 4 Wheels and apply parking brake fully, lock vehicle perfectly.
Install oil pressure gage adapter DW240-010-02 to test hole for line pressure.
Fully pressed on foot brake pedal with left foot, shift into "D" and "R" range and measure line pressure "idle" / "stall" condition.

Line pressure Mpa (kgf/cm²)	D	R
Engine idle	0.37 (3.9) -0.41 (4.2)	0.59 (6.0) -0.68 (6.9)
Engine stall	1.10 (11.3) -1.23 (12.5)	1.58 (16.2) -1.83 (18.6)

Notice : Do not continuously run longer than 5 sec because of extreme increasing oil temp.

Make sure to keep interval for more than 1 min between stall tests.

Make sure to check no oil leak after installing oil pressure gage adapter.

Result of Hydraulic Test	Cause of Failure
Higher than standards both "D and "R"	Pressure control solenoid (PCS) failure Primary regulator valve failure
Lower than standards both "D and "R"	Pressure control solenoid (PCS) failure Primary regulator valve failure Oil pump failure Oil strainer failure (clogging) Oil leak for each range circuit
Lower than standards only "D	"D" hydraulic circuit failure Forward clutch (C1) failure
Lower than standards only "R"	"R" hydraulic circuit failure Reverse clutch (C3) failure 1st and reverse brake (B3) failure

Manual Shifting Test

Manual shifting test is to determine whether failure symptom is within electrical failure or mechanical failure.

Disconnect wire harness of shift solenoid, check the range and gear positions correspond with below table when driving by manual shifting.

Range	Gear
D	3rd gear
R	Reverse

Notice : Make sure to disconnect only wire harness of shift solenoid.

Unit Inspection

Drive Plate Deflection

Inspect drive plate deflection if within standard value.

Standard Value

within 0.2mm (0.008 in)

Action :

Standard value is not within the specified value, replace drive plate.

When "abnormal wear" or "stick" on torque converter sleeve or oil pump is found, replace torque converter and A/T.

Notice :

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 cause major failure "No move".
Do not tighten the bolts by using impact wrench.

Cooler Pipe Bending and Choke

Inspect it whether there is abnormal pipe bending in the cooler pipe, pipe deformation and small cross-section area of pipe line.

Action : Replace failure parts.

Apply compressed air of 2kg/cm² from cooler pipe inlet side, inspect whether there is not cooler pipe choke by confirming air flow smooth.

Action : Remove foreign particles and clean inside of pipe line.

Vehicle Speed Sensor

Remove the connector of vehicle speed sensor, connect 12V power supply and voltmeter to the terminal.(Do not mistake polarity)
Check voltage change from approx. 0V to 12V with vehicle speed sensor driven gear rotated.

Notice : The voltage change should be 4 times for 1 revolution of the vehicle speed sensor driven gear.

Action : If the result of inspection is bad, replace the vehicle speed sensor.

Input Speed Sensor

Inspect resistance of each input speed senor between terminals.

Notice :

Make sure to inspect resistance again at 20 degree C when resistance differ from standards except 20°C.
It might become infinity ohm when inspect resistance at higher temperature.

Action : If the result of inspection is bad, replace ISS.

Transmission Range (TR) Switch

Remove TR switch connector and inspect continuty each range according to the conection chart.

Action : If the result of inspection is bad, replace the TR switch.

Transmission Fluid Temperature Sensor

Inspect the resistance between the terminals of TFT sensor at 10° and 110°C.

Standard Value	10°C	110°C
Standard Value	5.80~7.09 kΩ	0.23~0.263 kΩ

Action : If the result of inspection is bad, replace the TFT sensor.

Shift Solenoid (NO.1,2), Timing Solenoid, Lock-Up Solenoid

Inspect the resistance of each shift solenoid between the terminal and the body earth.

Action : If the result of inspection is bad, replace each solenoid.

Notice :

Make sure to inspect resistance again at 20°C when resistance differ from standards except 20°C.
It might become infinity ohm when inspecting resistance at higher temperature.

Inspect the operation of each shift solenoid.

Solenoid (No.1,2), Lock-up solenoid (Normal open type)

No battery connection	Leak air
Battery connection	No leak air

Timing solenoid (Normal close type)

No battery connection	No leak air
Battery connection	Leak air

Action : If the result of inspection is bad, replace the each solenoid.

Notice : Do not damage the strainer on the tip of solenoid while inspecting operation.

Pressure Control Solenoid

Inspect the resistance of each pressure control solenoid between terminals.

Action : Repalce the valve body assembly. (No replacement of solenoid by itself)

Notice :

Make sure to inspect resistance again at 20°C when resistance differ from standards except 20°C.
It might become infinity ohm when inspecting resistance at higher temperature.

On-Vehicle Repair (Matrix Chart)

Shift Lever Diagnosis

Shift Lever Does Not Move With Brake Pedal Depressed

Step	Action	Yes	No
1	Turn the ignition ON, with the engine OFF. Press and hold the brake pedal. Attempt to move the shift lever out of the PARK position. Does the shift lever move out of the PARK position?	Check for the intermittent and poor connections.	Go to Step 2
2	Turn the ignition OFF. Disconnect the brake switch. Turn the ignition ON, with the engine OFF. Press and hold the brake pedal. Attempt to move the shift lever out of the PARK position. Does the shift lever move out of the PARK position?	Go to Step 4	Go to Step 3
3	Turn the ignition OFF. Disconnect the BTSI (Brake Transfer Shift Interlock) solenoid. Turn the ignition ON, with the engine OFF. Press and hold the brake pedal. Attempt to move the shift lever out of the PARK position. Does the shift lever move out of the PARK position?	Go to Step 6	Go to Step 5
4	Inspect for poor connections at the brake switch. Check for the short to battery in the brake switch supply voltage circuit. Do you find and correct the condition?	Go to Step 10	Go to Step 7
5	Inspect for poor connections at the BTSI solenoid. Do you find and correct the condition?	Go to Step 10	Go to Step 8
6	Repair the short to battery in the BTSI solenoid supply circuit. Is the repair complete?	Go to Step 10	-
7	Replace the brake switch. Refer to Section 4A, Hydraulic Brakes. Is the replacement complete?	Go to Step 10	-
8	Replace the BTSI solenoid. Is the problem found?	Go to Step 9	Go to Step 10
9	Replace the IP fuse or relay. Is the replacement complete?	Go to Step 10	-
10	Operate the system in order to verify the repair. Do you find and correct the condition?	System OK	Go to Step 1

Shift Lever Can Be Moved Without Brake Pedal Depressed

Step	Action	Yes	No
1	Turn the ignition ON, with the engine OFF. Apply the parking brake and block the wheels. Attempt to move the shift lever out of the PARK position without pressing the brake pedal. Does the shift lever move out of the PARK position without pressing the brake?	Go to Step 2	Check for the intermittent and poor connections.
2	Turn the ignition OFF. Connect a test lamp between the battery positive voltage supply circuit at the brake switch and a good ground. Turn the ignition ON, with the engine OFF. Does the test lamp illuminate?	Go to Step 3	Go to Step 7
3	Check for the wiring harness circuit between the brake switch terminal 1 and a good ground with a test lamp. Does the test lamp illuminate?	Go to Step 8	Go to Step 4
4	Connect a test lamp between the ignition 1 voltage supply circuit at the BTSI solenoid and a good ground. Does the test lamp illuminate?	Go to Step 5	Go to Step 9
5	Check for the wiring harness circuit between the BTSI solenoid terminal 3 and a good ground with a test lamp. Does the test lamp illuminate?	Go to Step 6	Go to Step 10
6	Check for the wiring harness circuit between the P position switch terminal 1 and a good ground with a test lamp. Does the test lamp illuminate?	Go to Step 15	Go to Step 11
7	Repair the open in the battery positive voltage supply circuit of the brake switch. Is the repair complete?	Go to Step 16	-
8	Check for poor connections at the brake switch. Do you find and correct the condition?	Go to Step 16	Go to Step 12
9	Repair the open in the ignition 1 voltage supply circuit of the BTSI solenoid. Is the repair complete?	Go to Step 16	-
10	Check for poor connections at the BTSI solenoid. Do you find and correct the condition?	Go to Step 16	Go to Step 13
11	Check for poor connections at the P position switch. Do you find and correct the condition?	Go to Step 16	Go to Step 14
12	Replace the brake switch. Is the repair complete?	Go to Step 16	-
13	Replace the BTSI solenoid. Is the repair complete?	Go to Step 16	-
14	Replace the P position switch. Is the repair complete?	Go to Step 16	-
15	Replace the IP fuse or relay. Is the replacement complete?	Go to Step 16	-
16	Operate the system in order to verify the repair. Do you find and correct the condition?	System OK	Go to Step 1

Transmission Adaptive Learn Procedure

Perform the transmission adaptive learn procedure after any of the following service procedures:

Transmission Control Module (TCM) replacement
TCM calibration change
Control valve body replacement
Transmission overhaul
Transmission replacement

Drive the vehicle to warm the transmission fluid until 50°C-110 °C (122-230°F). The adaptive learn procedure will not work unless the transmission fluid is the correct temperature.

Note : Do not make the stall test to rise up the transmission fluid temperature.

Perform the following steps for the adaptation of the upshifting.

Perform the 1-2, 2-3, and 3-4 gear upshift in DRIVE(D) with each throttle opening.

Note : Throttle opening learning condition is 20%, 40%, 60%, 80% and 100%.

Repeat the above step five times.

Perform the following steps for the adaptation of the 3-4 shifting.

Perform the 3-4 gear upshift in DRIVE(D) with each throttle opening.

Note : Throttle opening learning condition is 20%, 40%, 60%, 80% and 100%.

Repeat the above step five times.

Perform the following steps for the adaptation of the 4-3 shifting.

Accelerate in DRIVE(D) until 4th gear.
Perform the 4-3 kick down with each vehicle speed.

Note : Vehicle speed learning condition is 20-55 km/h (12-34 mph), 55-70 km/h (34-43 mph), 70-90km/h (43-56 mph), 90-125 km/h (56-78 mph) and more than 125km/h (78 mph).

Repeat the above steps five times.

Note : Do not hit the accelerator.

Confirm that the shift quality has been improved.