2002 CHEVROLET AVEO sensor

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

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
Microsoft
Friday, July 31, 2009 1:07:02 PMPage 23 © 2005 Mitchell Repair Information Company, LLC.

Did you find and correct the condition?Go to Step 12 Go to Step 8
7
Test the low reference circuit of the fuel level
sensor for an open, or for a high resistance.
Refer to Circuit Testing
and Wiring Repairs
in Wiring Systems.
Did you find and correct the condition?-
Go to Step 12 Go to Step 9
8
Test for shorted terminals and poor connections
at the fuel level sensor. Refer to Testing for
Intermittent Conditions and Poor
Connections and Connector Repairsin Wiring
Systems.
Did you find and correct the condition?-
Go to Step 12 Go to Step 10
9
Test for shorted terminals and poor connections
at the engine control module (ECM). Refer to
Testin
g for Intermittent Conditions and Poor
Connections and Connector Repairsin Wiring
Systems.
Did you find and correct the condition?-
Go to Step 12 Go to Step 11
10
Replace the fuel sender assembly. Refer to the
following:
Fuel Sender Assembly Replacement
in Engine
Controls - 1.6L (L91)

Did you complete the replacement?-
Go to Step 12
-
11
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 12
-
12
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 2 Go to Step 13
Go to

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
Microsoft
Friday, July 31, 2009 1:07:02 PMPage 24 © 2005 Mitchell Repair Information Company, LLC.

DTC P0464
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).
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
This diagnostic procedure supports the following DTC:
DTC P0464 Fuel Level Circuit Intermittent
Conditions for Running the DTC
DTCs P0107, P0108, P0112, P0113, P0122, P0123, and P0502 are not set.
The engine is running.
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).
Conditions for Setting the DTC
The ECM detects that the fuel level changes more than 3.9 percent for 7.5 seconds.
Action Taken When the DTC Sets
13
Observe the Capture Info with a scan tool.
Are there any DTCs that have not been
diagnosed?
-
Diagnostic
Trouble Code
(DTC) List in
Engine
Controls - 1.6L
System OK

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
Microsoft
Friday, July 31, 2009 1:07:02 PMPage 25 © 2005 Mitchell Repair Information Company, LLC.

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

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

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

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
Microsoft
Friday, July 31, 2009 1:07:02 PMPage 26 © 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.

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

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
Microsoft
Friday, July 31, 2009 1:07:03 PMPage 83 © 2005 Mitchell Repair Information Company, LLC.

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.

2005 Chevrolet Aveo
2005 ACCESSORIES & EQUIPMENT Instrument Panel, Gages, & Console - Aveo
Microsoft
Friday, July 31, 2009 1:07:03 PMPage 84 © 2005 Mitchell Repair Information Company, LLC.