CHEVROLET AVEO 2002 Service Repair Manual

Fig. 7: I/P Components Component Views
Courtesy of GENERAL MOTORS CORP.
Callouts For Fig. 9
CalloutComponent Name
1Multifunction Alarm Module
2Ignition Key Alarm Switch
3Defogger Switch
4Clock/Tele Tail
5Cluster
6Radio
7Tweeter Right/Left Similar
8Cigar Lighter
9Wiper Switch
10Blower Switch
11Horn Switch

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2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
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INSTRUMENT PANEL, GAGES, AND CONSOLE CONNECTOR END VIEWS
Clock
12Headlamp Switch
Connector Part InformationKM 01-20DS-HU
20-Way M (BK)
PinWire ColorCircuit No.Function
1WH629Daytime Running Lamp (DRL) On Indicator
Control (w/Tach)
2L-BU122Rear Fog Lamp Supply Voltage (Rear Fog
Lamps)
3D-GN/WH157Courtesy Lamp Control
4D-GN867ABS Warning Indicator Control (w/ABS)
5OG540Battery Positive Voltage
6BK450Ground
7D-GN/YE358Air Bag Indicator Control (w/Tach)
8L-BU318Front Fog Lamp Supply Voltage (w/Front
Fog Lamps)
9BK/WH238Seat Belt Switch - Driver (w/Tach)
10YE749Security Indicator Control
11BN/BK419Malfunction Indicator Lamp (MIL) Control
(w/Tach)
12--Not Used
13D-GN31Oil Pressure Indicator Control (w/Tach)
14YE1481Hold Mode Indicator Control
15YE43Accessory Voltage
16BN/WH309Right Park Lamp Supply Voltage

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Ignition Key Alarm Switch
Instrument Cluster
17PK239Ignition 1 Voltage
18--Not Used
19D-BU25Charge Indicator Control/Charge Indicator
Signal (w/Tach)
20YE18Hazard Indicator Control
Connector Part Information
KET MG 610070
2-Way F 090 (2.3 mm) Series (WH)
PinWire ColorCircuit No.Function
1OG340Battery Positive Voltage
2
L-GN80Key In Ignition Switch Signal (w/Remote
Keyless Entry)
L-GN80Key In Ignition Switch Signal (w/Lamp
Driver Module)

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Multifunction Alarm Module
Connector Part InformationKET MG 611336
26-Way F PCB Connector (WH)
PinWire ColorCircuit No.Function
1WH30Fuel Level Sensor Signal
2D-GN/WH817Vehicle Speed Signal
3WH121Engine Speed Signal
4WH135Engine Coolant Temperature (ECT) Sensor
Gauge Signal
5PU172Low Fuel Indicator Control
6BN33Brake Warning Indicator Control
7WH15Right Turn Signal Lamps Supply Voltage
8GY/D-GN11Headlamp High Beam Supply Voltage
9D-BU14Left Turn Signal Lamps Supply Voltage
10OG640Battery Positive Voltage
11PK239Ignition 1 Voltage
12BN/WH309Right Park Lamp Supply Voltage
13
BK450Ground (w/o Dimming)
L-GN/RD230Instrument Panel Lamps Dimming Control
(w/Dimming)
14BK450Ground
15-16--Not Used
17D-BU25Charge Indicator Control/Charge Indicator
Signal (w/o Tach)
18BN/BK419Malfunction Indicator Lamp (MIL) Control
(w/o Tach)
19D-G31Oil Pressure Indicator Control (w/o Tach)
20BK/WH238Seat Belt Switch - Driver (w/o Tach)
21WH629Daytime Running Lamp (DRL) On Indicator
Control (w/o Tach)
22L-BU122Rear Fog Lamp Supply Voltage (w/o Tach)
23D-GN/WH358Air Bag Indicator Control (w/o Tach)
24OG640Battery Positive Voltage (w/o Tach)
25D-GN/WH157Courtesy Lamp Control (w/o Tach)
26BK450Ground

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Oil Pressure Switch
Connector Part Information
KET MG 610896
8-Way F PCB Connector SDL-II PCB Hsg (WH)
PinWire ColorCircuit No.Function
1BK/WH238Seat Belt Switch - Driver
2L-GN80Key In Ignition Switch Signal
3PU/WH821Engine Overspeed Indicator Control
4PU126Left Front Door Open Switch Signal
5BK450Ground
6BN/WH309Right Park Lamp Supply Voltage
7--Not Used
8PK239Ignition 1 Voltage

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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

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DTC P0461
Circuit Description
The fuel level sensor changes resistance based on fuel level. The fuel level sensor has a signal circuit and a
ground circuit. The engine control module (ECM) applies 5 volts on the signal circuit to the sensor. The ECM
monitors the changes in this voltage caused by changes in the resistance of the sensor in order to determine fuel
level.
When the fuel tank is full, the sensor resistance is low, and the ECM signal voltage is high. When the fuel tank
is empty, the sensor resistance is high, and the signal voltage is low.
The ECM uses inputs from the fuel level sensor in order to calculate the total fuel percentage remaining in the
fuel tank. The ECM uses the fuel level information for the evaporative emission (EVAP) and misfire
diagnostics. The fuel level information is sent to the instrument panel cluster (IPC).
This diagnostic tests for a stuck fuel level sensor signal. If the fuel level signal appears to be stuck, based on a
lack of signal variation expected during normal operation, this DTC sets.
DTC Descriptor
This diagnostic procedure supports the following DTC:
DTC P0461 Fuel Level Sensor Circuit Performance
Conditions for Running the DTC
DTCs P0462, P0463, and P0502 are not set.
The engine is running.
DTC P0461 runs continuously once the above conditions are met.
Conditions for Setting the DTC
The ECM does not detect a decrease in fuel level over a distance of 250 Km (155 miles).
Action Taken When the DTC Sets
The control module illuminates the malfunction indicator lamp (MIL) on the second consecutive ignition
cycle that the diagnostic runs and fails.
The control module records the operating conditions at the time the diagnostic fails. The first time the
dia
gnostic fails, the control module stores this information in the Failure Records. If the diagnostic
P0461DTC P0461 ECM
P0462DTC P0462 ECM
P0463DTC P0463 ECM
P0464DTC P0464 ECM

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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

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Go to Step 2 Cluster
2
Refer to DTC P0462 or DTC P0463 .
1. Turn OFF the ignition.
2. Disconnect the fuel level sender through
the access panel under the rear seat.
3. Jumper the fuel level sensor signal circuit
to a known good ground.
4. Turn ON the ignition, with the engine
OFF.
5. Observe the Fuel Level Sensor voltage
parameter with a scan tool.
Is the fuel level voltage at the specified value?
IMPORTANT:
If DTCs P0462 or P0463 are also set, diagnose
those DTCs first.
5 V
Go to Step 3 Go to Step 5
3
1. Jumper the fuel level sensor signal circuit
and low reference circuits together.
2. Observe the Fuel Level Sensor voltage
parameter with a scan tool.
Is the fuel level sensor voltage at the specified
value?
5 V
Go to Step 4 Go to Step 6
4
1. Remove the fuel sender assembly.
Refer to the following:
Fuel Sender Assembly Replacement
in
Engine Controls - 1.6L (L91)
2. Inspect for the following:
A stuck fuel level sensor (i.e. the
fuel strainer interfering with the
sender float arm.)
Foreign material in the fuel tank,
(i.e. Ice).
A fuel tank that is deformed
3. If you find a condition, repair the
condition as necessary.
Did you find and correct the condition?

Go to Step 10 Go to Step 7

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5
Test the fuel level signal sensor circuit for an
open or high resistance. Refer to Testing for
Continuity and Wiring Repairs in Wiring
Systems.
Did you find and correct the condition?-
Go to Step 10 Go to Step 8
6
Test the low reference circuit and the fuel level
signal circuit for an open or high resistance.
Refer to Testing for Continuity
and Wiring
Repairs in Wiring Systems.
Did you find and correct the condition?
-
Go to Step 10 Go to Step 8
7
Replace the fuel level sender assembly. Refer to
the following:
Fuel Sender Assembly Replacement
in Engine
Controls - 1.6L (L91)

Did you complete the replacement?-
Go to Step 10 -
8
Test for an intermittent and for a poor connection
at the control module. Refer to Testing for
Intermittent Conditions and Poor
Connections and Connector Repairs in Wiring
Systems.
Did you find and correct the condition?-
Go to Step 10 Go to Step 9
9
Replace the control module. Refer to the
following:
Engine Control Module (ECM) Replacement

in Engine Controls - 1.6L (L91)

Did you complete the replacement?-
Go to Step 10 -
10
1. Clear the DTCs with a scan tool.
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 11 Go to Step 2
Observe the Capture Info with a scan tool.
Go to
Diagnostic
Trouble Code

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