Acura Integra Tips and DIY

I happened upon a friend's car that was having electrical problems, and I can't resist an opportunity to solder some wires.

This troubleshooting guide was written about a 2005 Chevrolet Aveo. The Chevy Aveo is also the Pontiac Wave, Suzuki Swift and Daewoo Kalos. This problem may also affect 2002, 2003, 2004, 2006, 2007 and 2008 models.

SYMPTOMS

• Speedometer/Instrument panel lights not working
• Interior lights not working
• Tail lights or brake lights not working

CAUSE

• S101 Splicer pack overheats and burns wiring under the hood

HOW TO CHECK

1. Open the hood and remove the fuse box cover
2. Look into the fuse box at the splicer (use diagram at right, click for full size)
3. Decide whether or not to take the fuse box apart, remove splicer and re-connect wires

There are no other steps. It is not possible to pull the wiring out and inspect the wires for signs of burning without removing and separating the whole fuse box. The top of the S101 may be burnt and discolored, and this would be 100% confirmation that you should follow the steps provided below.

HOW TO TAKE IT APART

1. Disconnect the battery (negative first), wrap the wire ends in rags, and cover the top of the battery terminals with a rag so none of your tools become conductors of its charge
2. Remove the engine compartment fuse box cover and the 10mm nut on the fusebox ground wire in the bottom right hand corner
3. Remove the two 10mm bolts that hold the fuse box in place in the engine bay
4. Remove white and grey harness connector on the left side of the fuse box
5. Break the splicer free from its perch in the fuse box (don't be shy, we're going to remove it completely)
6. Separate the upper and lower halves of the fuse box while minding the electrical tape on the right side
7. Remove the bottom of the fuse box and set it aside
8. Twist the fuse box upside down so you can pull the splicer out from underneath and assess the situation

HOW TO FIX IT

The concept here is to remove the splicer and join the wires together with a soldering iron instead. The splicer exists to connect the 14 wires in 3 groups. Unfortunately, its design is prone to failure. The following diagram shows which wires to solder together using three colors. Click for full size.

1. Cut 7 wires off the row of the splicer that contains
   1. Green with yellow stripe
   2. Brown
   3. Green
   4. Brown
   5. Green with yellow stripe
   6. Brown
   7. Green with yellow stripe
2. Solder all 7 of these wires together
3. Cut 4 wires off the other side
   1. Purple with white stripe
   2. Brown with white stripe
   3. Brown with white stripe
   4. Brown with white stripe
4. Solder all 4 of these wires together
5. Cut the last 3 wires from the splicer
   1. Purple
   2. Purple
   3. Purple with white stripe
6. Solder all 3 of these wires together
7. Cover everything in electrical tape
8. Put your car back together while connecting your battery last (positive first)

OPTIONAL STEPS

1. Destroy the splicer
2. Start car
3. Use lights

These Fram filters look like crap when you pull them out. Here is a picture comparing a brand new Fram CH-9018 with one that ran in my girlfriend's 2005 Cobalt for almost 5,000 miles. I did not distort the used filter--this is the shape it took on while inside the car.

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I found a few tools that are made specifically for this rubber Cobalt filter cap. Here are the part numbers:

1. Snap-on part number A106, a socket for oil filters on GM Ecotec Engines, 1 1/4" (32mm), 3/8" drive
2. Hazet part number 2169-32, oil filter wrench
3. Lisle part number 14700 Oil Filter Wrench for GM 2.2L, Filter Wrench for GM 2.2L
   

I just bought one on eBay that appears to be the Lisle.

The oil filter in a Chevy Cobalt sits at the front of the engine block under a rubber cap. A hex top measures 1 1/4 inches or 31.75 mm.

I used channel lock pliers to remove the filter the first few times I changed the oil on my girlfriend's car. The rubber top is starting to get chewed up despite my use of tape over the plier teeth.

Rest assured, a tool exists. Lisle part # 14700 Oil Filter Wrench for GM 2.2LThis 32mm, made in the USA, 3/8 inch drive socket fits the oil filter cap perfectly, and it won't bump into the intake like your wrench or my channel lock pliers.

I also found an ACDelco filter that comes with a new, replacment rubber cap and green gasket seal for about $10 here.