CHEVROLET AVEO 2002 Service Repair Manual

1
it is connected properly.
Is the connector disconnected or partially
disconnected?
-
Go to Step 2 Go to Step 3
2
Connect the electrical connector for the chime
module.
Is the repair complete?
-
System OK-
3Inspect fuse F4.
Is fuse F4 blown?-Go to Step 4 Go to Step 5
4
1. Inspect for a short circuit and repair it, if
necessary.
2. Replace the fuse.
Is the repair complete?
-
System OK-
5
1. Turn the ignition ON.
2. Inspect the voltage at fuse F4.
Is the specified voltage available at fuse F4?
11-14 V
Go to Step 7 Go to Step 6
6Repair the power supply circuit for fuse F4.
Is the repair complete?-System OK-
7
1. Disconnect the chime module.
2. Turn the ignition ON.
3. Inspect the voltage at terminal 8 of the
chime module connector.
Does the voltage equal the specified value?
11-14 V
Go to Step 9 Go to Step 8
8
Repair the open circuit between fuse F4 and the
chime module connector.
Is the repair complete?
-
System OK-
9
With the chime module disconnected, use an
ohmmeter to check the continuity between
terminal 5 of the chime module connector and
ground.
Does the ohmmeter indicate the specified value?
0 ohm
Go to Step 11 Go to Step 10
10
Repair the open circuit between terminal 5 of the
chime module connector and ground.
Is the repair complete?
-
System OK-
11
1. Disconnect the chime module connector.
2. Make sure the driver's side door is open.
3. Use an ohmmeter to check the continuity
between terminal 4 of the chime module
and ground.
Does the ohmmeter indicate the specified value?
0 ohm
Go to Step 12 Go to Step 13

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
Microsoft
Friday, July 31, 2009 1:07:02 PMPage 28 © 2005 Mitchell Repair Information Company, LLC.

KEY REMINDER CHIME INOPERATIVE
Key Reminder Chime Inoperative
12Replace the chime module.
Is the repair complete?-System OK-
13
1. Disconnect the front door contact switch.
2. Use an ohmmeter to check the continuity
between the door contact switch and
terminal 4 of the chime module.
Does the ohmmeter indicate the specified value?
0 ohm
Go to Step 15 Go to Step 14
14
Repair the open circuit between the door contact
switch and terminal 4 of the chime module.
Is the repair complete?
-
System OK-
15Replace the door contact switch.
Is the repair complete?-System OK-
StepActionValuesYesNo
1
Inspect the chime module connector to make sure
it is connected properly.
Is the connector disconnected or partially
disconnected?
-
Go to Step 2 Go to Step 3
2
Connect the electrical connector for the chime
module.
Is the repair complete?
-
System OK-
3Inspect fuse EF7 and F12.
Is fuse EF7 and F12 blown?-Go to Step 4 Go to Step 5
4
1. Inspect for a short circuit and repair it, if
necessary.
2. Replace the fuse.
Is the repair complete?
-
System OK-
5
1. Turn the ignition ON.
2. Inspect the voltage at fuse EF7 and F12.
Is the specified voltage available at fuse EF7 and
F12?
11-14 V
Go to Step 7 Go to Step 6
6
Repair the power supply circuit for fuse EF7 and
F12.
Is the repair complete?
-
System OK-
7
1. Disconnect the chime module.
2. Inspect the voltage at terminal 2 of the
chime module connector.
11-14 V

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
Microsoft
Friday, July 31, 2009 1:07:02 PMPage 29 © 2005 Mitchell Repair Information Company, LLC.

CLOCK MALFUNCTION
Clock Malfunction
Does the voltage equal the specified value?Go to Step 13 Go to Step 8
8
1. Disconnect the key reminder switch.
2. Use an ohmmeter to check the continuity
between the key reminder switch and fuse
EF7 and F12.
Does the ohmmeter indicate the specified value?
0 ohm
Go to Step 10 Go to Step 9
9
Repair the open circuit between the key reminder
switch and fuse EF7 and F12.
Is the repair complete?
-
System OK-
10
With the key reminder switch and the chime
module disconnected, check the continuity
between the key reminder switch and terminal 2
of the chime module connector.
Does the ohmmeter indicate the specified value?
0 ohm
Go to Step 12 Go to Step 11
11
Repair the open circuit between the key reminder
switch and terminal 2 of the chime module
connector.
Is the repair complete?
-
System OK-
12Replace the key reminder switch.
Is the repair complete?-System OK-
13
With the chime module disconnected, use an
ohmmeter to check continuity between terminal 5
of the chime module connector and ground.
Does the ohmmeter indicate the specified value?
0 ohm
Go to Step 15 Go to Step 14
14
Repair the open circuit between terminal 5 of the
chime module connector and ground.
Is the repair complete?
-
System OK-
15Replace the chime module.
Is the repair complete?-System OK-
StepActionValuesYesNo
1Inspect fuses F2, F23, and EF7.
Is either fuse F2, F23, and EF7 blown?-Go to Step 2 Go to Step 3
2
1. Check for a short circuit and repair it, if
necessary.
2. Replace the blown fuses.
Is the repair complete?
-
System OK-
1. Turn the ignition ON.

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
Microsoft
Friday, July 31, 2009 1:07:02 PMPage 30 © 2005 Mitchell Repair Information Company, LLC.

ENGINE COOLANT TEMPERATURE GAGE INACCURATE OR INOPERATIVE
Engine Coolant Temperature Gage Inaccurate or Inoperative
3
2. Use a voltmeter to check battery voltage
available at fuses F2, F23, and EF7.
Does the voltmeter indicate the value specified?
11-14 V
Go to Step 5 Go to Step 4
4Repair the open power supply circuit for the fuse.
Is the repair complete?-System OK-
5
Use a voltmeter to check the battery voltage
available at the clock connector terminal 5.
Does the voltmeter indicate the value specified?
11-14 V
Go to Step 7 Go to Step 6
6
Repair the open circuit between the clock
connector terminal 5 and the fuse F23.
Is the repair complete?
-
System OK-
7
Turn the ignition ON.
Is battery voltage available at the clock connector
terminal 15?
-
Go to Step 9 Go to Step 8
8
Repair the open circuit between terminal 15 of
the clock connector and fuse F2.
Is the repair complete?
-
System OK-
9
Inspect continuity between terminal 6 of the
clock connector and ground.
Does the multimeter indicate the value specified?
0 ohm
Go to Step 10 Go to Step 11
10Replace the clock.
Is the repair complete?-System OK-
11
Repair the open ground circuit between terminal
6, the clock connector, and ground G202.
Is the repair complete?
-
System OK-
StepActionValuesYesNo
1
Allow the engine to cool to room temperature.
With the ignition ON, does the temperature gage
always read at the high end of the scale?
-
Go to Step 7 Go to Step 2
2
Disconnect engine control module (ECM)
electrical connector.
Does the temperature gage indicator drop to the
low end of the scale?
-
-Go to Step 3
3
Inspect for a short to ground between the ECM
and the temperature gage.
Is there a short to ground?
-
Go to Step 4 Go to Step 5
4Repair the short to ground.
Is the repair complete?-System OK-
5Replace the temperature gage. -

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

FUEL GAGE INACCURATE OR INOPERATIVE
Fuel Gage Inaccurate or Inoperative
Is the repair complete?System OK-
6
1. Disconnect the ECM.
2. Turn the ignition ON.
3. Check the voltage at the ECM.
Does the voltage equal the value specified?
11-14 V
Go to Step 9 Go to Step 7
7
Inspect for an open circuit between the ECM and
the temperature gage.
Is there an open circuit?
-
Go to Step 8 Go to Step 5
8
Repair the open circuit between the ECM and the
temperature gage.
Is the repair complete?
-
System OK-
9
1. Disconnect the ECM.
2. Connect a jumper wire between the ECM
connector and ground.
3. Turn the ignition ON.
Does the temperature gage move to the high end
of the scale?
-
-Go to Step 5
StepActionValuesYesNo
1
1. Connect a scan tool.
2. Check for engine control diagnostic trouble
codes (DTCs).
Are any DTCs set?
-
-Go to Step 2
2
1. Turn the ignition OFF.
2. Disconnect engine control module (ECM)
connector.
3. Remove the instrument cluster.
4. Inspect continuity between ECM fuel gage
control circuit terminal and the instrument
cluster terminal 1.
Does the ohmmeter indicate the specified value?
0 ohm
Go to Step 4 Go to Step 3
3
Repair the open circuit between the instrument
cluster connector terminal 1 and the ECM fuel
gage control circuit terminal.
Is the repair complete?
-
System OK-

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
Microsoft
Friday, July 31, 2009 1:07:02 PMPage 32 © 2005 Mitchell Repair Information Company, LLC.

SPEEDOMETER AND/OR ODOMETER INACCURATE OR INOPERATIVE
Speedometer and/or Odometer Inaccurate or Inoperative
CHIME INOPERATIVE (SEAT BELT)
Chime Inoperative (Seat Belt)
4Replace the fuel gage.
Is the repair complete?-System OK-
StepActionValuesYesNo
1
1. Connect a scan tool.
2. Inspect for engine or automatic
transmission diagnostic trouble
codes (DTCs).
Are any DTCs set?
-
Go to DTC P0722 (Non
Europe or N. American
Emissions) or DTC P0722
(European and N. American
Emissions) in Automatic
Transmission Aisin - 81-40LE Go to Step
2
2
1. Turn the ignition OFF.
2. Disconnect the engine control
module (ECM) connector.
3. Remove the instrument cluster.
4. Inspect continuity between
terminal 3 of the vehicle speed
sensor connector and the
instrument cluster connector
terminal 2.
Does the ohmmeter indicate the
specified value?
0 ohm
Go to Step 4
Go to Step
3
3
Repair the open circuit between the
instrument cluster connector terminal 2
and terminal 3 of the vehicle speed
sensor connector.
Is the repair complete?
-
System OK-
4Replace the speedometer.
Is the repair complete?-System OK-
StepActionValuesYesNo
1
Inspect the chime module connector to make sure
it is connected properly.
Is the connector disconnected or partially
disconnected?
-
Go to Step 2 Go to Step 3
2
Connect the electrical connector for the chime
module.
Is the repair complete?
-
System OK-

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
Microsoft
Friday, July 31, 2009 1:07:02 PMPage 33 © 2005 Mitchell Repair Information Company, LLC.

3Inspect fuse F4.
Is fuse F4 blown?-Go to Step 4 Go to Step 5
4
1. Inspect for a short circuit and repair it, if
necessary.
2. Replace the fuse.
Is the repair complete?
-
System OK-
5
1. Turn the ignition ON.
2. Inspect the voltage at fuse F4.
Is the specified voltage available at fuse F4?
11-14 V
Go to Step 7 Go to Step 6
6Repair the power supply circuit for fuse F4.
Is the repair complete?-System OK-
7
1. Disconnect the chime module.
2. Turn the ignition ON.
3. Inspect the voltage at terminal 8 of the
chime module connector.
Does the voltage equal the specified value?
11-14 V
Go to Step 9 Go to Step 8
8
Repair the open circuit between fuse F4 and the
chime module connector.
Is the repair complete?
-
System OK-
9
With the chime module disconnected, use an
ohmmeter to check continuity between terminal 5
of the chime module connector and ground.
Does the ohmmeter indicate the specified value?
0 ohm
Go to Step 11 Go to Step 10
10
Repair the open circuit between terminal 5 of the
chime module connector and ground.
Is the repair complete?
-
System OK-
11
1. Disconnect the chime module connector.
2. Make sure the driver's side seat belt is
unfastened.
3. Use an ohmmeter to check the continuity
between terminal 1 of the chime module
and ground.
Does the ohmmeter indicate the specified value?
0 ohm
Go to Step 12 Go to Step 13
12Replace the chime module.
Is the repair complete?-System OK-
1. Disconnect the seat belt switch.
2. Make sure the driver's side seat belt is
unfastened.

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
Microsoft
Friday, July 31, 2009 1:07:02 PMPage 34 © 2005 Mitchell Repair Information Company, LLC.

REPAIR INSTRUCTIONS
CIGAR LIGHTER HOUSING REPLACEMENT
Removal Procedure
13
3. Use an ohmmeter to check the continuity
of the switch.
Does the ohmmeter indicate the specified value?
0 ohm
Go to Step 15 Go to Step 14
14Replace the seat belt switch.
Is the repair complete?-System OK-
15
Use an ohmmeter to check the continuity of the
wire between terminal 1 of the chime module and
the seat belt switch.
Does the ohmmeter indicate the specified value?
0 ohm
Go to Step 17 Go to Step 16
16
Repair the open circuit between terminal 1 of the
chime module and the seat belt switch.
Is the repair complete?
-
System OK-
17
Repair the open circuit between the seat belt
switch connector and ground.
Is the repair complete?
-
System OK-

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
Microsoft
Friday, July 31, 2009 1:07:02 PMPage 35 © 2005 Mitchell Repair Information Company, LLC.

Fig. 8: View of Cigar Lighter and Housing
Courtesy of GENERAL MOTORS CORP.
1. Disconnect the negative battery cable.
2. Remove the cigar lighter from the cigar lighter housing.
3. Remove the floor console. Refer to Console Replacement
- Front Floor in Instrument Panel, Gages and
Console.
4. Remove the cigar lighter housing from the instrument panel.
5. Disconnect the cigar lighter electrical connector.
Installation Procedure
CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
Microsoft
Friday, July 31, 2009 1:07:02 PMPage 36 © 2005 Mitchell Repair Information Company, LLC.

Fig. 9: View of Cigar Lighter and Housing
Courtesy of GENERAL MOTORS CORP.
1. Connect the cigar lighter electrical connector.
2. Install the cigar lighter housing in the instrument panel.
3. Install the floor console. Refer to Console Replacement
- Front Floor in Instrument Panel, Gages and
Console.
4. Install the cigar lighter in the cigar lighter housing.
5. Connect the negative battery cable.
AUDIO ALARM MODULE REPLACEMENT
Removal Procedure

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
Microsoft
Friday, July 31, 2009 1:07:02 PMPage 37 © 2005 Mitchell Repair Information Company, LLC.