Tablero Aveo 2005....

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
2005 ACCESSORIES & EQUIPMENT
Instrument Panel, Gages, & Console - Aveo
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications

Specification
Application Metric English
Chime Module Screws 3.5 N.m 31 lb in
Clock Screws 2.5 N.m 22 lb in
Cupholder Screws 2.5 N.m 22 lb in
Floor Console Screws 4 N.m 35 lb in
HVAC Controls Screws 4 N.m 35 lb in
Instrument Cluster Screws 4 N.m 35 lb in
Instrument Cluster Trim Panel Screws 4 N.m 35 lb in
Instrument Panel Bolts Behind the HVAC Controls 4 N.m 35 lb in
Instrument Panel End Bolts 4 N.m 35 lb in
Instrument Panel Bolts 20 N.m 15 lb ft
BULB USAGE SPECIFICATIONS
Bulb Usage Specifications

Indicator Lamp Color Bulb
ABS Wiring Amber 14 V 1.4 W
Air Bag Warning Red 14 V 1.4 W
Battery Charge Indicator Red 14 V 1.4 W
Check Engine Amber 14 V 1.4 W
Door Open Warning Red 14 V 1.4 W
Engine Overheat Red 14 V 1.4 W
Fasten Seat Belt Warning Red 14 V 1.4 W
High Beam Indicator Blue 14 V 1.4 W
Low Fuel Level Warning Amber 14 V 1.4 W
Oil Pressure Warning Red 14 V 1.4 W
Parking Brake Indicator and Brake
Red 14 V 1.4 W
Fluid Warning
Service Engine Soon Warning Amber 14 V 1.4 W
Transaxle Power Mode Indicator Amber 14 V 1.4 W
Turn Signal Indictors Green 14 V 1.4 W
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Friday, July 31, 2009 1:07:07
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2005 Chevrolet Aveo
SCHEMATIC AND ROUTING DIAGRAMS

INSTRUMENT CLUSTER SCHEMATICS
Fig. 1: Instrument Panel Gages Schematic

Courtesy of GENERAL MOTORS CORP.
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2005 Chevrolet Aveo
Fig. 2: Indicator Lamps and Illumination Schematic

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2005 Chevrolet Aveo
Fig. 3: Warning Indicators W/O Tachometer Schematic

DRIVER INFORMATION SYSTEM SCHEMATICS
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2005 Chevrolet Aveo
Fig. 4: Power, Grounds and Indicators Schematic

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2005 Chevrolet Aveo
Fig. 5: Warning Indicators with Tachometer Schematic

AUDIBLE WARNINGS SCHEMATICS
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2005 Chevrolet Aveo
Fig. 6: Multifunction Alarm Module Schematic

COMPONENT LOCATOR
INSTRUMENT PANEL, GAGES, AND CONSOLE COMPONENT VIEWS
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2005 Chevrolet Aveo
Fig. 7: I/P Components Component Views

Callouts For Fig. 9

Callout Component Name
1 Multifunction Alarm Module
2 Ignition Key Alarm Switch
3 Defogger Switch
4 Clock/Tele Tail
5 Cluster
6 Radio
7 Tweeter Right/Left Similar
8 Cigar Lighter
9 Wiper Switch
10 Blower Switch
11 Horn Switch
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2005 Chevrolet Aveo
12 Headlamp Switch
INSTRUMENT PANEL, GAGES, AND CONSOLE CONNECTOR END VIEWS
Clock
 KM 01-20DS-HU
Connector Part Information
 20-Way M (BK)
Pin Wire Color Circuit No. Function

Daytime Running Lamp (DRL) On Indicator
1 WH 629
Control (w/Tach)
Rear Fog Lamp Supply Voltage (Rear Fog
2 L-BU 122
Lamps)
3 D-GN/WH 157 Courtesy Lamp Control
4 D-GN 867 ABS Warning Indicator Control (w/ABS)
5 OG 540 Battery Positive Voltage
6 BK 450 Ground
7 D-GN/YE 358 Air Bag Indicator Control (w/Tach)
Front Fog Lamp Supply Voltage (w/Front
8 L-BU 318
Fog Lamps)
9 BK/WH 238 Seat Belt Switch - Driver (w/Tach)
10 YE 749 Security Indicator Control
Malfunction Indicator Lamp (MIL) Control
11 BN/BK 419
(w/Tach)
12 - - Not Used
13 D-GN 31 Oil Pressure Indicator Control (w/Tach)
14 YE 1481 Hold Mode Indicator Control
15 YE 43 Accessory Voltage
16 BN/WH 309 Right Park Lamp Supply Voltage
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2005 Chevrolet Aveo
17 PK 239 Ignition 1 Voltage

18 - - Not Used
Charge Indicator Control/Charge Indicator
19 D-BU 25
Signal (w/Tach)
20 YE 18 Hazard Indicator Control
Ignition Key Alarm Switch
 KET MG 610070
Connector Part Information  2-Way F 090 (2.3 mm) Series (WH)

Key In Ignition Switch Signal (w/Remote
L-GN 80
Keyless Entry)
2
Key In Ignition Switch Signal (w/Lamp
L-GN 80
Driver Module)
Instrument Cluster
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2005 Chevrolet Aveo
 KET MG 611336
Connector Part Information
 26-Way F PCB Connector (WH)

1 WH 30 Fuel Level Sensor Signal
2 D-GN/WH 817 Vehicle Speed Signal
3 WH 121 Engine Speed Signal
Engine Coolant Temperature (ECT) Sensor
4 WH 135
Gauge Signal
5 PU 172 Low Fuel Indicator Control
6 BN 33 Brake Warning Indicator Control
7 WH 15 Right Turn Signal Lamps Supply Voltage
8 GY/D-GN 11 Headlamp High Beam Supply Voltage
9 D-BU 14 Left Turn Signal Lamps Supply Voltage
BK 450 Ground (w/o Dimming)
13 Instrument Panel Lamps Dimming Control
L-GN/RD 230
(w/Dimming)
14 BK 450 Ground
15-16 - - Not Used
Charge Indicator Control/Charge Indicator
17 D-BU 25
Signal (w/o Tach)
Malfunction Indicator Lamp (MIL) Control
18 BN/BK 419
(w/o Tach)
19 D-G 31 Oil Pressure Indicator Control (w/o Tach)
20 BK/WH 238 Seat Belt Switch - Driver (w/o Tach)
Daytime Running Lamp (DRL) On Indicator
21 WH 629
Control (w/o Tach)
22 L-BU 122 Rear Fog Lamp Supply Voltage (w/o Tach)
23 D-GN/WH 358 Air Bag Indicator Control (w/o Tach)
24 OG 640 Battery Positive Voltage (w/o Tach)
25 D-GN/WH 157 Courtesy Lamp Control (w/o Tach)
26 BK 450 Ground
Multifunction Alarm Module
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2005 Chevrolet Aveo
 KET MG 610896
Connector Part Information  8-Way F PCB Connector SDL-II PCB Hsg (WH)

1 BK/WH 238 Seat Belt Switch - Driver
2 L-GN 80 Key In Ignition Switch Signal
3 PU/WH 821 Engine Overspeed Indicator Control
4 PU 126 Left Front Door Open Switch Signal
5 BK 450 Ground
7 - - Not Used
Oil Pressure Switch
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 AK 32104
Connector Part Information  1-Way F Metri-Pack 150 Series Sealed (BK)

1 D-GN/WH 31 Oil Pressure Indicator Control
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

Step Action Yes No
Install a scan tool. Go to Scan Tool
Does the scan tool power up? Does Not Power Up
1
in Data Link
Go to Step 2 Communications
1. Turn ON the ignition, with the engine OFF. Go to Scan Tool
Does Not
2. Attempt to establish communication with the Communicate with
2 engine control module (ECM). Component in Data
Link
Does the scan tool communicate with the ECM? Go to Step 3 Communications
Select the Display DTCs function for the ECM. Go to Diagnostic Go to Symptoms -
3 Does the scan tool display DTC P0461, P0462, P0463 Trouble Code Instrument Panel,
or P0464? (DTC) List Gages and Console
DIAGNOSTIC TROUBLE CODE (DTC) LIST
Diagnostic Trouble Code (DTC) List

DTC Diagnostic Procedure Modules
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2005 Chevrolet Aveo
P0461 DTC P0461 ECM

P0462 DTC P0462 ECM
P0463 DTC P0463 ECM
P0464 DTC P0464 ECM
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
diagnostic fails, the control module stores this information in the Failure Records. If the diagnostic
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2005 Chevrolet Aveo
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
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
Step Action Value Yes No
Schematic Reference: Instrument Cluster Schematics
Connector End View Reference: Instrument Panel, Gages, and Console Connector End Views
Did you perform the Diagnostic System Check -
Instrument Cluster? Go to
1 - Diagnostic
System Check
- Instrument
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Go to Step 2 Cluster
IMPORTANT:
If DTCs P0462 or P0463 are also set, diagnose
those DTCs first.
Refer to DTC P0462 or DTC P0463 .
1. Turn OFF the ignition.

2. Disconnect the fuel level sender through
2 the access panel under the rear seat. 5V
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? Go to Step 3 Go to Step 5

1. Jumper the fuel level sensor signal circuit
and low reference circuits together.
3 parameter with a scan tool. 5V
Is the fuel level sensor voltage at the specified

value? Go to Step 4 Go to Step 6
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
4 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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2005 Chevrolet Aveo
Test the fuel level signal sensor circuit for an

open or high resistance. Refer to Testing for
5 Continuity and Wiring Repairs in Wiring -
Systems.
Test the low reference circuit and the fuel level
signal circuit for an open or high resistance.
6 Refer to Testing for Continuity and Wiring -
Repairs in Wiring Systems.
Replace the fuel level sender assembly. Refer to
the following:
Fuel Sender Assembly Replacement in Engine

7 -
Controls - 1.6L (L91)
Did you complete the replacement? Go to Step 10 -

Test for an intermittent and for a poor connection
at the control module. Refer to Testing for
Intermittent Conditions and Poor
8 -
Connections and Connector Repairs in Wiring
Systems.
Replace the control module. Refer to the
following:
Engine Control Module (ECM) Replacement

9 -
in Engine Controls - 1.6L (L91)
Did you complete the replacement? Go to Step 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
10 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

Go to
Diagnostic
Observe the Capture Info with a scan tool. Trouble Code
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Are there any DTCs that have not been (DTC) List in
11 diagnosed? - Engine Controls
- 1.6L System OK
DTC P0462
Circuit Description
level.
If the ECM detects a signal voltage lower than the operating range of the sensor, this DTC sets.
DTC Descriptor
DTC P0462 Fuel Level Sensor Circuit Low Voltage

 The ECM detects that fuel level signal voltage is less than 0.25 volts.
 The above condition is present for more than 10 seconds.
 The control module illuminates the malfunction indicator lamp (MIL) when the diagnostic runs and fails.
 The control module records the operating conditions at the time the diagnostic fails. The control module
stores this information in the Freeze Frame/Failure Records.
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does not fail.
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:
Test Description
The number below refers to the step number on the diagnostic table.
DTC P0462
Did you perform the Diagnostic System Check - Go to
Instrument Cluster? Diagnostic
1 - System Check
- Instrument
OFF.
2 2. Observe the Fuel Level Sensor voltage 4.25 V
Is the voltage more than the specified value? Go to Step 4 Go to Step 3

1. Observe the Freeze Frame/Failure Records
for this DTC.
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2005 Chevrolet Aveo

for Running the DTC. You may also
3 that you observed from the Freeze -
Go to
Did the DTC fail this ignition? Go to Step 4 Diagnostic Aids
1. Turn OFF the ignition.
2. Disconnect the fuel level sensor through
the access panel under the rear seat.
4 OFF. 4.25 V
Is the voltage less than the specified value? Go to Step 6 Go to Step 5

Test the signal circuit of the fuel level sensor for
a short to ground. Refer to Circuit Testing and
5 -
Wiring Repairs in Wiring Systems.
Test for shorted terminals and poor connections
at the fuel level sensor. Refer to Testing for
6 -
Systems.
at the engine control module (ECM). Refer to
Testing for Intermittent Conditions and Poor
7 -
Systems.
Replace the fuel sender assembly. Refer to the
following:

8 - -
Did you complete the replacement? Go to Step 10

following:
9 - -
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2005 Chevrolet Aveo
Did you complete the replacement?

Go to Step 10

Go to
Diagnostic
Observe the Capture Info with a scan tool.
Trouble Code
11 Are there any DTCs that have not been -
(DTC) List in
diagnosed?
Engine Controls
- 1.6L System OK
DTC P0463
Circuit Description
level.
If the ECM detects a signal voltage higher than the operating range of the sensor, this DTC sets.
DTC Descriptor
DTC P0463 Fuel Level Sensor Circuit High Voltage
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2005 Chevrolet Aveo

 The fuel level signal voltage is more than 4.25 volts.

 The above condition is present for more than 10 seconds.
 The control module illuminates the malfunction indicator lamp (MIL) when the diagnostic runs and fails.
stores this information in the Freeze Frame/Failure Records.
does not fail.
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, load, vehicle speed, temperature, etc.). This will
isolate when the DTC failed.
 Refer to the following:
Test Description
The number below refers to the step number on the diagnostic table.
DTC P0463
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2005 Chevrolet Aveo
Did you perform the Diagnostic System Check - Go to
Instrument Cluster? Diagnostic
1 - System Check
- Instrument
OFF.
2 parameter with a scan tool. 0.25 V
Is the voltage parameter less than the specified

value? Go to Step 4 Go to Step 3
1. Observe the Freeze Frame/Failure
Records for this DTC.
3 -
for Running the DTC. You may also
Go to
Did the DTC fail this ignition? Go to Step 4 Diagnostic Aids
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.
4 0.25 V
OFF.

Jumper the fuel level sensor signal circuit to a
5 known good ground. 0.25 V
Test the signal circuit of the fuel level sensor for
an open, for a high resistance, or for a short to
6 voltage. Refer to Circuit Testing and Wiring -
Repairs in Wiring Systems.
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2005 Chevrolet Aveo

Test the low reference circuit of the fuel level
sensor for an open, or for a high resistance.
7 Refer to Circuit Testing and Wiring Repairs -
in Wiring Systems.
at the fuel level sensor. Refer to Testing for
8 -
Systems.
at the engine control module (ECM). Refer to
Testing for Intermittent Conditions and Poor
9 -
Systems.
Replace the fuel sender assembly. Refer to the
following:

10 - -

following:

11 - -


Go to
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2005 Chevrolet Aveo
Diagnostic
Observe the Capture Info with a scan tool. Trouble Code
13 Are there any DTCs that have not been - (DTC) List in
diagnosed? Engine
Controls - 1.6L System OK
DTC P0464
Circuit Description
level.
If the ECM detects that the fuel level sensor signal changes more than a calibrated amount within a certain time,
this DTC sets.
DTC Descriptor
DTC P0464 Fuel Level Circuit Intermittent
 DTCs P0107, P0108, P0112, P0113, P0122, P0123, and P0502 are not set.
 This diagnostic will be delayed for 5 seconds if one or more of the following occurs:
 The change in manifold absolute pressure (MAP) sensor is more than 10 kPa.
 The change in engine speed is more than 50 RPM.
 The change in throttle position (TP) sensor is less than 2 percent.
 The intake air temperature (IAT) sensor is more than -10°C (50°F).
The ECM detects that the fuel level changes more than 3.9 percent for 7.5 seconds.

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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.
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.
non-emission related diagnostic.
 Clear the DTC with a scan tool.
Test Description
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
Step Action Yes No
Schematic Reference: Instrument Cluster Schematics or
Did you perform the Diagnostic System Check - Instrument Go to Diagnostic
1 Cluster? Go to Step System Check -
2 Instrument Cluster
1. Start the engine. Go to
Diagnostic
2. Observe the DTC Information with a scan tool. Trouble
2
Code
Are DTCs P0461, P0462, and P0463 also set? (DTC)
List Go to Step 3
Observe the Fuel Level Sensor voltage parameter with a scan
tool while moving the fuel level sensor connector and the
3 engine control module (ECM) connector. Refer to Inducing
Intermittent Fault Conditions in Wiring Systems. Go to Step
Does the scan tool indicate an abrupt change in value? 5 Go to Step 4
Observe the fuel level sensor voltage with a scan tool while
moving the wiring harness between the fuel level sensor
4 connector and the ECM. Refer to Inducing Intermittent Go to Intermittent
Fault Conditions in Wiring Systems. Go to Step Conditions in Engine
Does the scan tool indicate an abrupt change in value? 6 Controls
Repair the connector terminal as necessary. Refer to
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2005 Chevrolet Aveo
Connector Repairs in Wiring Systems. Go to Step

5
Did you complete the repair? 7 -
Repair the harness/wiring as necessary. Refer to Wiring
6 Repairs in Wiring Systems. Go to Step
Did you complete the repair? 7 -
4. Operate the vehicle within the Conditions for Running
7
the DTC. You may also operate the vehicle within the
conditions that you observed from the Freeze
Go to Step
Did the DTC fail this ignition? 2 Go to Step 8
Go to
Diagnostic
Trouble
Code
Observe the Capture Info with a scan tool.
8 (DTC)
Are there any DTCs that have not been diagnosed?
List in
Engine
Controls -
1.6L System OK
SYMPTOMS - INSTRUMENT PANEL, GAGES AND CONSOLE
Symptom List
Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom:
 Clock Malfunction
 Engine Coolant Temperature Gage Inaccurate or Inoperative
 Fuel Gage Inaccurate or Inoperative
 Speedometer and/or Odometer Inaccurate or Inoperative
 Chime Inoperative (Seat Belt) Seat belt
 Door Open Warning Chime Inoperative
 Key Reminder Chime Inoperative
DOOR OPEN WARNING CHIME INOPERATIVE
Door Open Warning Chime Inoperative

Step Action Values Yes No
Inspect the chime module connector to make sure
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2005 Chevrolet Aveo
it is connected properly.
1 Is the connector disconnected or partially -
disconnected? Go to Step 2 Go to Step 3
Connect the electrical connector for the chime
2 module. -
Is the repair complete? System OK -
Inspect fuse F4.
3 -
Is fuse F4 blown? Go to Step 4 Go to Step 5
1. Inspect for a short circuit and repair it, if
necessary.
4 2. Replace the fuse. -

1. Turn the ignition ON.
5 2. Inspect the voltage at fuse F4. 11-14 V
Is the specified voltage available at fuse F4? Go to Step 7 Go to Step 6

Repair the power supply circuit for fuse F4.
6 -
1. Disconnect the chime module.
7 3. Inspect the voltage at terminal 8 of the 11-14 V
chime module connector.
Does the voltage equal the specified value? Go to Step 9 Go to Step 8

Repair the open circuit between fuse F4 and the
8 chime module connector. -
With the chime module disconnected, use an
ohmmeter to check the continuity between
9 terminal 5 of the chime module connector and 0 ohm
ground.
Does the ohmmeter indicate the specified value? Go to Step 11 Go to Step 10
Repair the open circuit between terminal 5 of the
10 chime module connector and ground. -
1. Disconnect the chime module connector.
2. Make sure the driver's side door is open.
3. Use an ohmmeter to check the continuity
11 between terminal 4 of the chime module 0 ohm
and ground.

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2005 Chevrolet Aveo
Replace the chime module.

12 -
1. Disconnect the front door contact switch.
13 between the door contact switch and 0 ohm
terminal 4 of the chime module.

Repair the open circuit between the door contact
14 switch and terminal 4 of the chime module. -
Replace the door contact switch.
15 -
KEY REMINDER CHIME INOPERATIVE
Key Reminder Chime Inoperative

1 -
Is the connector disconnected or partially
2 module. -
Inspect fuse EF7 and F12.
3 -
Is fuse EF7 and F12 blown? Go to Step 4 Go to Step 5
necessary.

2. Inspect the voltage at fuse EF7 and F12.
5 11-14 V
Is the specified voltage available at fuse EF7 and
F12? Go to Step 7 Go to Step 6
Repair the power supply circuit for fuse EF7 and
6 F12. -
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2005 Chevrolet Aveo
Does the voltage equal the specified value?

Go to Step 13 Go to Step 8
1. Disconnect the key reminder switch.
8 between the key reminder switch and fuse 0 ohm
EF7 and F12.

Repair the open circuit between the key reminder
9 switch and fuse EF7 and F12. -
With the key reminder switch and the chime
module disconnected, check the continuity
10 between the key reminder switch and terminal 2 0 ohm
of the chime module connector.
Repair the open circuit between the key reminder
switch and terminal 2 of the chime module
11 -
connector.
Replace the key reminder switch.
12 -
ohmmeter to check continuity between terminal 5
13 0 ohm
of the chime module connector and ground.
15 -
CLOCK MALFUNCTION
Clock Malfunction
Inspect fuses F2, F23, and EF7.
1 -
Is either fuse F2, F23, and EF7 blown? Go to Step 2 Go to Step 3
1. Check for a short circuit and repair it, if
necessary.
2 2. Replace the blown fuses. -

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2005 Chevrolet Aveo
2. Use a voltmeter to check battery voltage

3 available at fuses F2, F23, and EF7. 11-14 V
Does the voltmeter indicate the value specified? Go to Step 5 Go to Step 4
Repair the open power supply circuit for the fuse.
4 -
Use a voltmeter to check the battery voltage
5 available at the clock connector terminal 5. 11-14 V
Does the voltmeter indicate the value specified? Go to Step 7 Go to Step 6
Repair the open circuit between the clock
6 connector terminal 5 and the fuse F23. -
Turn the ignition ON.
7 Is battery voltage available at the clock connector -
terminal 15? Go to Step 9 Go to Step 8
Repair the open circuit between terminal 15 of
8 the clock connector and fuse F2. -
Inspect continuity between terminal 6 of the
9 clock connector and ground. 0 ohm
Does the multimeter indicate the value specified? Go to Step 10 Go to Step 11
Replace the clock.
10 -
Repair the open ground circuit between terminal
11 6, the clock connector, and ground G202. -
ENGINE COOLANT TEMPERATURE GAGE INACCURATE OR INOPERATIVE
Engine Coolant Temperature Gage Inaccurate or Inoperative

Allow the engine to cool to room temperature.
1 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
Disconnect engine control module (ECM)
electrical connector.
2 -
Does the temperature gage indicator drop to the
low end of the scale? - Go to Step 3
Inspect for a short to ground between the ECM
3 and the temperature gage. -
Is there a short to ground? Go to Step 4 Go to Step 5
Repair the short to ground.
4 -
Replace the temperature gage.
5 -
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2005 Chevrolet Aveo

1. Disconnect the ECM.
6 3. Check the voltage at the ECM. 11-14 V
Does the voltage equal the value specified? Go to Step 9 Go to Step 7

Inspect for an open circuit between the ECM and
7 the temperature gage. -
Is there an open circuit? Go to Step 8 Go to Step 5
Repair the open circuit between the ECM and the
8 temperature gage. -
1. Disconnect the ECM.
2. Connect a jumper wire between the ECM
connector and ground.
9 3. Turn the ignition ON. -
Does the temperature gage move to the high end

of the scale? - Go to Step 5
FUEL GAGE INACCURATE OR INOPERATIVE
Fuel Gage Inaccurate or Inoperative

1. Connect a scan tool.
2. Check for engine control diagnostic trouble
1 codes (DTCs). -
Are any DTCs set? - Go to Step 2

1. Turn the ignition OFF.
2. Disconnect engine control module (ECM)
connector.
3. Remove the instrument cluster.
2 0 ohm
4. Inspect continuity between ECM fuel gage
control circuit terminal and the instrument
cluster terminal 1.

Repair the open circuit between the instrument
cluster connector terminal 1 and the ECM fuel
3 -
gage control circuit terminal.
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2005 Chevrolet Aveo
Replace the fuel gage.

4 -
SPEEDOMETER AND/OR ODOMETER INACCURATE OR INOPERATIVE
Speedometer and/or Odometer Inaccurate or Inoperative

1. Connect a scan tool. Go to DTC P0722 (Non
2. Inspect for engine or automatic Europe or N. American
1 transmission diagnostic trouble - Emissions) or DTC P0722
codes (DTCs). (European and N. American
Emissions) in Automatic Go to Step
Are any DTCs set? Transmission Aisin - 81-40LE 2
1. Turn the ignition OFF.
2. Disconnect the engine control
module (ECM) connector.
3. Remove the instrument cluster.
4. Inspect continuity between
2 terminal 3 of the vehicle speed 0 ohm
sensor connector and the
instrument cluster connector
terminal 2.
Does the ohmmeter indicate the Go to Step

specified value? Go to Step 4 3
Repair the open circuit between the
instrument cluster connector terminal 2
3 and terminal 3 of the vehicle speed -
sensor connector.
Replace the speedometer.
4 -
CHIME INOPERATIVE (SEAT BELT)
Chime Inoperative (Seat Belt)

1 -
Is the connector disconnected or partially
2 module. -
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2005 Chevrolet Aveo
Inspect fuse F4.

3 -
Is fuse F4 blown? Go to Step 4 Go to Step 5
necessary.

5 2. Inspect the voltage at fuse F4. 11-14 V
Is the specified voltage available at fuse F4? Go to Step 7 Go to Step 6

Repair the power supply circuit for fuse F4.
6 -
Does the voltage equal the specified value? Go to Step 9 Go to Step 8

Repair the open circuit between fuse F4 and the
8 chime module connector. -
ohmmeter to check continuity between terminal 5
9 0 ohm
of the chime module connector and ground.
1. Disconnect the chime module connector.
2. Make sure the driver's side seat belt is
unfastened.
11 3. Use an ohmmeter to check the continuity 0 ohm
between terminal 1 of the chime module
and ground.

12 -
1. Disconnect the seat belt switch.

2. Make sure the driver's side seat belt is
unfastened.
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2005 Chevrolet Aveo

13 of the switch. 0 ohm
Replace the seat belt switch.
14 -
Use an ohmmeter to check the continuity of the
wire between terminal 1 of the chime module and
15 0 ohm
the seat belt switch.
16 chime module and the seat belt switch. -
Repair the open circuit between the seat belt
17 switch connector and ground. -
REPAIR INSTRUCTIONS
CIGAR LIGHTER HOUSING REPLACEMENT
Removal Procedure
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2005 Chevrolet Aveo
Fig. 8: View of Cigar Lighter and Housing

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
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
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2005 Chevrolet Aveo
Fig. 9: View of Cigar Lighter and Housing

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
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2005 Chevrolet Aveo
Fig. 10: View of Chime Module and Screws


2. Remove the screws and the chime module.
3. Disconnect the electrical connector.
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2005 Chevrolet Aveo
Fig. 11: View of Chime Module and Screws

1. Connect the electrical connector.
NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Install the chime module with the screws.
Tighten: Tighten the chime module screws to 3.5 N.m (31 lb in).
TRIM PANEL REPLACEMENT - INSTRUMENT PANEL (I/P) CENTER
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2005 Chevrolet Aveo
Removal Procedure
Fig. 12: View of Instrument Panel Center Cover

1. Remove the instrument panel center lower cover. Refer to Instrument Panel (I/P) Trim Panel
Replacement - Lower .
2. Remove the screws and the instrument panel center upper cover.
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2005 Chevrolet Aveo
Fig. 13: View of Instrument Panel Center Cover

1. Instal the instrument panel center upper cover.
Tighten: Tighten the instrument panel center upper cover screws to 4 N.m (35 lb in).
2. Install the instrument panel center lower cover.
STORAGE COMPARTMENT REPLACEMENT - INSTRUMENT PANEL (I/P)
Removal Procedure
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2005 Chevrolet Aveo
Fig. 14: View of Glove Box

Open and remove the glove box.
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2005 Chevrolet Aveo
Fig. 15: View of Glove Box

1. Position the glove box in the instrument panel.

2. Install the glove box.
INSTRUMENT PANEL CLUSTER (IPC) REPLACEMENT
Removal Procedure
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2005 Chevrolet Aveo
Fig. 16: View of Instrument Cluster Trim Panel


2. Remove the instrument cluster trim panel.
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2005 Chevrolet Aveo
Fig. 17: View of Instrument Cluster, Screws, and Electrical Connectors

3. Remove the screws and the instrument cluster.

4. Disconnect the electrical connectors.
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2005 Chevrolet Aveo
Fig. 18: View of Instrument Cluster, Screws, and Electrical Connectors

1. Connect the electrical connectors.

2. Install the instrument cluster with the screws.
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2005 Chevrolet Aveo
Fig. 19: View of Instrument Cluster Trim Panel

3. Install the instrument cluster trim panel.

SPEEDOMETER REPLACEMENT
Removal Procedure
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2005 Chevrolet Aveo
Fig. 20: View of Screws and Speedometer From Instrument Cluster


2. Remove the instrument cluster. Refer to Instrument Panel Cluster (IPC) Replacement .
3. Remove the instrument cluster lens and the face plate.
4. Remove the screws and the speedometer from the instrument cluster.
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2005 Chevrolet Aveo
Fig. 21: View of Screws and Speedometer From Instrument Cluster

1. Install the speedometer to the instrument cluster with the screws.

2. Install the instrument cluster lens and the face plate.
3. Install the instrument cluster. Refer to Instrument Panel Cluster (IPC) Replacement .
FUEL GAGE REPLACEMENT
Removal Procedure
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2005 Chevrolet Aveo
Fig. 22: View of Screws and Fuel Gage From Cluster Assembly

4. Remove the screws and the fuel gage from the cluster assembly.
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2005 Chevrolet Aveo
Fig. 23: View of Screws and Fuel Gage From Cluster Assembly
1. Install the fuel gage to the cluster assembly with the screws.
TEMPERATURE GAGE REPLACEMENT
Removal Procedure
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2005 Chevrolet Aveo
Fig. 24: View of Screws and Temperature Gage From Cluster Assembly

4. Remove the screws and the temperature gage from the cluster assembly.
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2005 Chevrolet Aveo
Fig. 25: View of Screws and Temperature Gage From Cluster Assembly
1. Install the temperature gage to the cluster assembly with the screws.
INSTRUMENT CLUSTER LAMP REPLACEMENT
Removal Procedure
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2005 Chevrolet Aveo
Fig. 26: View of Bulb From Rear of Cluster


3. Remove the bulb from the rear of the cluster.
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2005 Chevrolet Aveo
Fig. 27: View of Bulb From Rear of Cluster

1. Install the new bulb.

ASHTRAY REPLACEMENT
Removal Procedure
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2005 Chevrolet Aveo
Fig. 28: View of Ashtray

Remove the ashtray.
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2005 Chevrolet Aveo
Fig. 29: View of Ashtray

Install the ashtray.
CUPHOLDER REPLACEMENT
Removal Procedure
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2005 Chevrolet Aveo
Fig. 30: View of Screws and Cupholder From Instrument Panel

1. Remove the instrument panel. Refer to Instrument Cluster Lamp Replacement .

2. Remove the screws and the cupholder from the instrument panel.
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2005 Chevrolet Aveo
Fig. 31: View of Screws and Cupholder From Instrument Panel

1. Install the cupholder with the screws.
Tighten: Tighten the cupholder screws to 2.5 N.m (22 lb in).
2. Install the instrument panel. Refer to Instrument Cluster Lamp Replacement .
INSTRUMENT PANEL (I/P) TRIM PANEL REPLACEMENT - LOWER
Removal Procedure
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2005 Chevrolet Aveo
Fig. 32: View of Instrument Panel Center Lower with Flathead Screwdriver
Remove the instrument panel center lower cover using a flathead screwdriver.
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2005 Chevrolet Aveo
Fig. 33: View of Instrument Panel Center Lower with Flathead Screwdriver
Install the instrument panel center lower cover.
INSTRUMENT PANEL (I/P) ASSEMBLY REPLACEMENT (NORTH AMERICA)
Removal Procedure
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2005 Chevrolet Aveo
Fig. 34: View Of Steering Wheel Column (North America)


2. Remove the driver's air bag module from the steering wheel, if equipped. Refer to Inflatable Restraint
Steering Wheel Module Replacement in SIR.
3. Remove the steering wheel from the steering column. Refer to Steering Wheel Replacement in Steering
Wheel and Column.
4. Remove the steering column trim cover. Refer to Steering Column Replacement in Steering Wheel and
Column.
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2005 Chevrolet Aveo
Fig. 35: View of Instrumental Panel Cluster Assembly

5. Remove the signal lamp switch and the wiper switch. Refer to Multifunction, Turn Signal Switch
Replacement in Steering Wheel and Column and Wipers/Washer Switch Replacement in
Wiper/Washers.
6. Remove the windshield pillar garnish moldings. Refer to Garnish Molding Replacement - Windshield
Pillar in Interior Trim.
7. Remove the instrument cluster assembly. Refer to Instrument Panel Cluster (IPC) Replacement .
8. Remove the side cover.
9. Remove the instrument panel lower cover.
10. Remove the instrument panel center upper, lower cover.
11. Remove the cigar lighter and ashtray.
12. Remove the cupholder.
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2005 Chevrolet Aveo
Fig. 36: View of Instrument Panel For Audio System and A/C Controller
13. Remove the A/C controller from the instrument. Refer to HVAC Control Assembly Replacement in
HVAC Systems - Manual.
14. Remove the audio system from the instrument panel. Refer to Radio Replacement in Entertainment.
15. Remove the digital clock.
16. Remove the glove box assembly from the instrument panel. Refer to Storage Compartment
Replacement - Instrument Panel (I/P) .
17. Remove the passenger's air bag module from the instrument panel, if equipped. Refer to Inflatable
Restraint Instrument Panel Module Replacement in SIR.
18. Disconnect the ALDL connector.
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2005 Chevrolet Aveo
Fig. 37: View of Instrument Panel and End Bolts

19. Remove the instrument panel bolts behind the heating, ventilation, and air conditioning (HVAC) controls.
20. Remove the instrument panel bolts above the steering column.
21. Remove the instrument panel bolts from the ends of the instrument panel.
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2005 Chevrolet Aveo
Fig. 38: View of Instrumental Panel and End Screws

22. Remove the instrument panel end screws.

23. Remove the tie-bar retaining bolts.
24. Remove the instrument panel from the vehicle.
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2005 Chevrolet Aveo

1. Install the instrument panel assembly with the bolts and screws.
Tighten: Tighten the instrument panel bolts to 20 N.m (15 lb ft).
2. Connect ALDL connector with the screws.

3. Install the passenger's air bag module to the instrument panel. Refer to Inflatable Restraint Instrument
Panel Module Replacement in SIR.
4. Install glove box assembly from the instrument panel. Refer to Storage Compartment Replacement -
Instrument Panel (I/P) .
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2005 Chevrolet Aveo
5. Install the digital clock.

6. Install the audio system from the instrument panel. Refer to Radio Replacement in Entertainment.
7. Install the A/C controller from the instrument. Refer to HVAC Control Assembly Replacement in
Tighten: Tighten the instrument panel bolts behind the HVAC controls to 4 N.m (35 lb in).
8. Install the cupholder.

9. Install the cigar lighter and ashtray.
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2005 Chevrolet Aveo
Fig. 41: View Of Steering Wheel Column (North America)

10. Install the instrument panel center upper, lower cover.

11. Install the instrument panel lower cover.
12. Install the side cover.
13. Install the instrument cluster assembly. Refer to Instrument Panel Cluster (IPC) Replacement .
14. Install the windshield pillar garnish molding. Refer to Garnish Molding Replacement - Windshield
15. Install the signal lamp switch and the wiper switch. Refer to Multifunction, Turn Signal Switch
Replacement in Steering Wheel and Column for signal, and refer to Wipers/Washer Switch
Replacement in Wiper/Washer.
16. Install the steering column trim cover. Refer to Steering Column Replacement in Steering Wheel and
Column.
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2005 Chevrolet Aveo
17. Install the steering wheel to the steering column. Refer to Steering Wheel Replacement in Steering
Wheel and Column.
18. Install the driver's air bag module from the steering wheel, if equipped. Refer to Inflatable Restraint
INSTRUMENT PANEL (I/P) ASSEMBLY REPLACEMENT (EUROPEAN AND NON-EUROPEAN)
Removal Procedure
Fig. 42: View Of Steering Wheel Column (European and Non-European)

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2005 Chevrolet Aveo

2. Remove the driver's air bag module from the steering wheel, if equipped. Refer to Inflatable Restraint
3. Remove the steering wheel from the steering column. Refer to Steering Wheel Replacement in Steering
Wheel and Column.
4. Remove the steering column trim cover. Refer to Steering Column Replacement in Steering Wheel and
Column.
Fig. 43: View of Instrumental Panel Cluster Assembly

5. Remove the signal lamp switch and the wiper switch. Refer to Multifunction, Turn Signal Switch
Replacement in Steering Wheel and Column and Wipers/Washer Switch Replacement in
Wiper/Washers.
6. Remove the windshield pillar garnish moldings. Refer to Garnish Molding Replacement - Windshield
7. Remove the instrument cluster assembly. Refer to Instrument Panel Cluster (IPC) Replacement .
8. Remove the side cover.
9. Remove the instrument panel lower cover.
10. Remove the instrument panel center upper, lower cover.
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2005 Chevrolet Aveo
11. Remove the cigar lighter and ashtray.

12. Remove the cupholder.
13. Remove the A/C controller from the instrument. Refer to HVAC Control Assembly Replacement in
14. Remove the audio system from the instrument panel. Refer to Radio Replacement in Entertainment.
15. Remove the digital clock.
16. Remove the glove box assembly from the instrument panel. Refer to Storage Compartment
Replacement - Instrument Panel (I/P) .
17. Remove the passenger's air bag module from the instrument panel, if equipped. Refer to Inflatable
Restraint Instrument Panel Module Replacement in SIR.
18. Disconnect the ALDL connector.
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2005 Chevrolet Aveo
Fig. 45: View of Instrument Panel and End Bolts

19. Remove the instrument panel bolts behind the heating, ventilation, and air conditioning (HVAC) controls.
20. Remove the instrument panel bolts above the steering column.
21. Remove the instrument panel bolts from the ends of the instrument panel.
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2005 Chevrolet Aveo

22. Remove the instrument panel end screws.

23. Remove the tie-bar retaining bolts.
24. Remove the instrument panel from the vehicle.
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2005 Chevrolet Aveo

1. Install the instrument panel assembly with the bolts and screws.
Tighten: Tighten the instrument panel bolts to 20 N.m (15 lb ft).
2. Connect ALDL connector with the screws.

3. Install the passenger's air bag module to the instrument panel. Refer to Inflatable Restraint Instrument
Panel Module Replacement in SIR.
4. Install glove box assembly from the instrument panel. Refer to Storage Compartment Replacement -
Instrument Panel (I/P) .
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2005 Chevrolet Aveo
5. Install the digital clock.

6. Install the audio system from the instrument panel. Refer to Radio Replacement in Entertainment.
7. Install the A/C controller from the instrument. Refer to HVAC Control Assembly Replacement in
Tighten: Tighten the instrument panel bolts behind the HVAC controls to 4 N.m (35 lb in).
8. Install the cupholder.

9. Install the cigar lighter and ashtray.
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2005 Chevrolet Aveo
Fig. 49: View Of Steering Wheel Column (European and Non-European)

10. Install the instrument panel center upper, lower cover.

11. Install the instrument panel lower cover.
12. Install the side cover.
13. Install the instrument cluster assembly. Refer to Instrument Panel Cluster (IPC) Replacement .
14. Install the windshield pillar garnish molding. Refer to Garnish Molding Replacement - Windshield
15. Install the signal lamp switch and the wiper switch. Refer to Multifunction, Turn Signal Switch
Replacement in Steering Wheel and Column for signal, and refer to Wipers/Washer Switch
Replacement in Wiper/Washer.
16. Install the steering column trim cover. Refer to Steering Column Replacement in Steering Wheel and
Column.
17. Install the steering wheel to the steering column. Refer to Steering Wheel Replacement in Steering
Wheel and Column.
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2005 Chevrolet Aveo
18. Install the driver's air bag module from the steering wheel, if equipped. Refer to Inflatable Restraint
CLOCK REPLACEMENT - CONSOLE
Removal Procedure
Fig. 50: View of Screws and Clock


2. Remove the instrument panel center upper cover. Refer to Trim Panel Replacement - Instrument Panel
(I/P) Center .
3. Remove the screws and the clock.
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2005 Chevrolet Aveo
Fig. 51: View of Screws and Clock

1. Install the clock with the screws.
Tighten: Tighten the clock screws to 2.5 N.m (23 lb in).
2. Install the instrument panel center upper cover. Refer to Trim Panel Replacement - Instrument Panel
(I/P) Center .
CONSOLE REPLACEMENT - FRONT FLOOR
Removal Procedure
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2005 Chevrolet Aveo
Fig. 52: View of Gearshift and Boot

NOTE: Fastener Notice in Cautions and Notices.

2. Remove the gearshift lever boot.
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2005 Chevrolet Aveo
Fig. 53: View of Screws and Floor Console

3. Remove the screws from the floor console.

5. Remove the floor console.
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2005 Chevrolet Aveo
Fig. 54: View of Gearshift and Boot

1. Connect the electrical connector.
2. Install the floor console with the screws.
Tighten: Tighten the floor console screws to 4 N.m (35 lb in).
3. Install the gearshift lever boot.

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2005 Chevrolet Aveo
DESCRIPTION AND OPERATION

INSTRUMENT PANEL DESCRIPTION
Cigar Lighter
The cigar lighter is located in the front portion of the floor console. To use the lighter, push it in completely.
When the lighter is hot, it will release itself from contact with the heating element. The lighter and the heating
element can be damaged if the lighter is not allowed to release itself fully from the heating element.
Ashtray
The ashtray is located below the audio system. To access the ashtray, pull it out from the center console. The
ashtray lamp will go ON when the parking lamps or the headlamps are turned ON.
Instrument Panel Vents
The center and the side vents in the instrument panel can be adjusted up and down and from side to side. The
side vents can also be aimed toward the side windows in order to defog them.
Glove Box
The glove box can be opened by pulling up on the latch handle. The glove box must be removed in order to gain
access to the passenger's side air bag module.
Digital Clock
The digital clock is located in the instrument panel, above the audio system. The clock is capable of a 12-hour
or a 24-hour display.
Instrument Cluster
The instrument cluster is located above the steering column and in the instrument cluster trim panel. The
instrument cluster contains the instruments that provide the driver with vehicle performance information. The
instrument cluster contains a speedometer, an odometer, a trip odometer, a temperature gage, a fuel gage, and
several indicator lamps. For replacement of the indicator lamp bulbs contained in the instrument cluster, refer to
Bulb Usage Specifications and Instrument Cluster Lamp Replacement .
Speedometer/Odometer/Trip Odometer
The speedometer measures the speed of the vehicle in km/h (mph). It consists of an instrument cluster gage
connected to the vehicle speed sensor (VSS) on the transaxle output shaft.
The odometer measures in kilometers (miles) the total distance the vehicle has traveled since it was
manufactured. It consists of an instrument cluster gage connected to the VSS on the transaxle output shaft.
The trip odometer measures the distance the vehicle has traveled since the odometer was last reset. It consists of
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2005 Chevrolet Aveo
an instrument cluster gage connected to the VSS on the transaxle output shaft. The trip odometer can be reset to
zero at any time so that the driver can record the distance traveled from any starting point.
Fuel Gage
The fuel gage consists of an instrument cluster gage connected to a sending unit in the fuel tank.
The fuel gage indicates the quantity of fuel in the tank only when the ignition switch is turned to ON or ACC.
When the ignition is turned to LOCK or START, the pointer may come to rest at any position.
Temperature Gage
The temperature gage consists of an instrument cluster gage connected to a temperature sensor that is in contact
with the circulating engine coolant.
The temperature gage indicates the temperature of the coolant. Prolonged driving or idling in very hot weather
may cause the pointer to move beyond the center of the gage. The engine is overheating if the pointer moves
into the red zone at the upper limit of the gage.
Instrument Cluster Indicator Lamps
The instrument cluster contains indicator lamps that indicate the function of certain systems or the existence of
potential problems with the operation of the vehicle. The indicator lamps are replaceable. For replacement of
the indicator lamps contained in the instrument cluster, refer to Bulb Usage Specifications and Instrument
Cluster Lamp Replacement .
Chime Module
The chime module is located above the instrument panel fuse block and will sound in order to bring attention to
one or more of the following conditions:
 The lamps are ON, the door is ajar, and the ignition switch is not in ACC, ON, or START.
 The seat belt is unbuckled when the ignition switch is in ON or START.
 The door is open when the ignition switch is in ON or START.
 The key is left in the ignition switch when the ignition is in LOCK and the door is open.
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2005 Chevrolet Aveo

2005 ACCESSORIES & EQUIPMENT

Instrument Panel, Gages, & Console - Aveo

Fastener Tightening Specifications

BULB USAGE SPECIFICATIONS

Bulb Usage Specifications

SCHEMATIC AND ROUTING DIAGRAMS

Fig. 1: Instrument Panel Gages Schematic

Fig. 2: Indicator Lamps and Illumination Schematic

Fig. 3: Warning Indicators W/O Tachometer Schematic

DRIVER INFORMATION SYSTEM SCHEMATICS

Fig. 4: Power, Grounds and Indicators Schematic

Fig. 5: Warning Indicators with Tachometer Schematic

AUDIBLE WARNINGS SCHEMATICS

Fig. 6: Multifunction Alarm Module Schematic

Fig. 7: I/P Components Component Views

Callouts For Fig. 9

INSTRUMENT PANEL, GAGES, AND CONSOLE CONNECTOR END VIEWS

Pin Wire Color Circuit No. Function

17 PK 239 Ignition 1 Voltage

Ignition Key Alarm Switch

Pin Wire Color Circuit No. Function

Pin Wire Color Circuit No. Function

Multifunction Alarm Module

Pin Wire Color Circuit No. Function

Oil Pressure Switch

Pin Wire Color Circuit No. Function

DIAGNOSTIC INFORMATION AND PROCEDURES

DIAGNOSTIC SYSTEM CHECK - INSTRUMENT CLUSTER

Diagnostic System Check - Instrument Cluster

DIAGNOSTIC TROUBLE CODE (DTC) LIST

Diagnostic Trouble Code (DTC) List

P0461 DTC P0461 ECM

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.

Conditions for Setting the DTC

Action Taken When the DTC Sets

Conditions for Clearing the MIL/DTC

Check for the following conditions:

 Poor wire to terminal connections

Intermittent Conditions in Engine Controls - 1.6L (L91)

2: This step determines if the fault is present.

Refer to DTC P0462 or DTC P0463 .

1. Turn OFF the ignition.

Is the fuel level voltage at the specified value? Go to Step 3 Go to Step 5

Is the fuel level sensor voltage at the specified

Refer to the following:

Fuel Sender Assembly Replacement in

2. Inspect for the following:

3. If you find a condition, repair the

Did you find and correct the condition? Go to Step 10 Go to Step 7

Test the fuel level signal sensor circuit for an

Fuel Sender Assembly Replacement in Engine

Did you complete the replacement? Go to Step 10 -

Engine Control Module (ECM) Replacement

Did you complete the replacement? Go to Step 10 -

Did the DTC fail this ignition? Go to Step 11 Go to Step 2

This diagnostic procedure supports the following DTC:

DTC P0462 Fuel Level Sensor Circuit Low Voltage

Conditions for Running the DTC

 The engine is running.