Daewoo MATIZ Service Manual Download Page 100

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1F – 2 ENGINE CONTROLS

DAEWOO M-150 BL2

DTC P0122 Throttle Position Sensor Low

Voltage

1F-76

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0123 Throttle Position Sensor High

Voltage

1F-80

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0131 Oxygen Sensor Low Voltage

1F-84

. . . .

DTC P0132 Oxygen Sensor High Voltage

1F-88

. . . .

DTC P0133 Oxygen Sensor No Activity

1F-90

. . . . .

DTC P0137 Heated Oxygen Sensor Low

Voltage

1F-94

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0138 Heated Oxygen Sensor High

Voltage

1F-98

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0140 Heated Oxygen Sensor

No Activity

1F-100

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0141 Heated Oxygen Sensor

Heater Malfunction

1F-104

. . . . . . . . . . . . . . . . . . . .

DTC P0171 Fuel Trim System Too Lean

1F-106

. . . .

DTC P0172 Fuel Trim System Too Rich

1F-109

. . . .

DTC P1230 Fuel Pump Relay Low Voltage

1F-114

DTC P1231 Fuel Pump Relay High Voltage

1F-118

DTC P0261 Injector 1 Low Voltage

1F-122

. . . . . . . .

DTC P0262 Injector 1 High Voltage

1F-124

. . . . . . . .

DTC P0264 Injector 2 Low Voltage

1F-126

. . . . . . . .

DTC P0265 Injector 2 High Voltage

1F-128

. . . . . . . .

DTC P0267 Injector 3 Low Voltage

1F-130

. . . . . . . .

DTC P0268 Injector 3 High Voltage

1F-132

. . . . . . . .

DTC P0300 Multiple Cylinder Misfire

1F-135

. . . . . . .

DTC P0300 Multiple Cylinder Misfire

1F-139

. . . . . . .

DTC P1320 Crankshaft Segment Period

Segment adaptation At Limit

1F-142

. . . . . . . . . . . .

DTC P1321 Crankshaft Segment Period

Tooth Error

1F-144

. . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0327 Knock Sensor Circuit Fault

1F-146

. . . .

DTC P0335 Magnetic Crankshaft Position

Sensor Electrical Error

1F-150

. . . . . . . . . . . . . . . . .

DTC P0336 58X Crankshaft Position Sensor

No Plausible Signal

1F-152

. . . . . . . . . . . . . . . . . . . .

DTC P0337 58X Crankshaft Position Sensor

No Signal

1F-154

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0341 Camshaft Position Sensor

Rationality

1F-156

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0342 Camshaft Position Sensor

No Signal

1F-158

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0351 Ignition Signal Coil A Fault

1F-160

. . . . .

DTC P0352 Ignition Signal Coil B Fault

1F-162

. . . . .

DTC P0353 Ignition Signal Coil C Fault

1F-164

. . . . .

DTC P1382 Rough Road Data

Invalid (Non ABS)

1F-166

. . . . . . . . . . . . . . . . . . . . .

DTC P1382 Rough Road Data Invalid (ABS) 1F-170

DTC P1385 Rough Road Sensor Circuit Fault

(Non ABS)

1F-174

. . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P1385 Rough Road Sensor Circuit Fault

(ABS)

1F-178

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0400 Exhaust Gas Recirculation

Out Of Limit

1F-182

. . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P1402 Exhaust Gas Recirculation

Blocked

1F-186

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P1403 Exhaust Gas Recirculation

Valve Failure

1F-188

. . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0404 Exhaust Gas Recirculation

Opened

1F-192

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P1404 Exhaust Gas Recirculation

Closed

1F-196

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0405 EEGR Pintle Position Sensor

Low Voltage

1F-200

. . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0406 EEGR Pintle Position Sensor

High Voltage

1F-204

. . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0420 Catalyst Low Efficiency

1F-208

. . . . . . . .

DTC P0444 EVAP Purge Control Circuit

No Signal

1F-210

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0445 EVAP Purge Control Fault

1F-214

. . . . .

DTC P0462 Fuel Level Sensor Low Voltage

1F-218

DTC P0463 Fuel Level Sensor High Voltage 1F-222

DTC P0480 Low Speed Cooling Fan Relay

Circuit Fauit (Without A/C)

1F-226

. . . . . . . . . . . . . .

DTC P0480 Low Speed Cooling Fan Relay

Circuit Fauit (With A/C)

1F-230

. . . . . . . . . . . . . . . . .

DTC P0481 High Speed Cooling Fan Relay

Circuit Fauit (Without A/C)

1F-234

. . . . . . . . . . . . . .

DTC P0481 High Speed Cooling Fan Relay

Circuit Fauit (With A/C)

1F-238

. . . . . . . . . . . . . . . . .

DTC P0501 Vehicle Speed No Signal

(M/T Only)

1F-242

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P1505 Idle Air Control Valve (IACV)

Error

1F-246

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P1535 Evaporator Temperature Sensor

High Voltage

1F-250

. . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P1536 Evaporator Temperature Sensor

Low Voltage

1F-252

. . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P1537 A/C Compressor Relay High

Voltage

1F-254

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P1538 A/C Compressor Relay Low

Voltage

1F-256

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0562 System Voltage (Engine Side)

Too Low

1F-258

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0563 System Voltage (Engine Side)

Too High

1F-260

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0601 Engine Control Module Chechsum

Error

1F-262

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P0604 Engine Control Module Internal/

External RAM Error

1F-263

. . . . . . . . . . . . . . . . . . . .

DTC P0605 Engin Control Module NMVY

Write Error

1F-264

. . . . . . . . . . . . . . . . . . . . . . . . . . .

DTC P1610 Main Relay High Voltage

1F-266

. . . . . .

DTC P1611 Main Relay Low Voltage

1F-268

. . . . . . .

Summary of Contents for MATIZ

Page 1: ...ormation illustrations and specifications con tained in this manual are based on the latest prod uct information available at the time of manual ap proval The right is reserved to make changes at any time without notice DAEWOO MOTOR CO LTD INCHON KOREA MANUAL SUSPENSION 2 DRIVELINE AXLE 3 BRAKES 4 TRANSAXLE 5 STEERING 6 RESTRAINTS 8 BODY AND ACCESSORIES 9 7 HVAC HEATING VENTILATION AND AIR CONDITI...

Page 2: ...ENGINE CONTENTS SECTION 1A GENERAL ENGINE INFORMATION SECTION 1B SOHC ENGINE MECHANICAL SECTION 1D ENGINE COOLING SECTION 1E ENGINE ELECTRICAL SECTION 1F ENGINE CONTROLS SECTION 1G ENGINE EXHAUST ...

Page 3: ...SUSPENSION CONTENTS SECTION 2A SUSPENSION DIAGNOSIS SECTION 2B WHEEL ALIGNMENT SECTION 2C FRONT SUSPENSION SECTION 2D REAR SUSPENSION SECTION 2E TIRES AND WHEELS ...

Page 4: ...DRIVELINE AXLE CONTENTS SECTION 3B MANUAL TRANSAXLE DRIVE AXLE ...

Page 5: ...ES CONTENTS SECTION 4A HYDRAULIC BRAKES SECTION 4B MASTER CYLINDER SECTION 4C POWER BOOSTER SECTION 4D FRONT DISC BRAKES SECTION 4E REAR DRUM BRAKES SECTION 4F ANTILOCK BRAKE SYSTEM SECTION 4G PARKING BRAKE ...

Page 6: ...TRANSAXLE CONTENTS SECTION 5B FIVE SPEED MANUAL TRANSAXLE SECTION 5C CLUTCH ...

Page 7: ...STEERING CONTENTS SECTION 6A POWER STEERING SYSTEM SECTION 6B POWER STEERING PUMP SECTION 6C POWER STEERING GEAR SECTION 6D MANUAL STEERING GEAR SECTION 6E STEERING WHEEL AND COLUMN ...

Page 8: ...HVAC HEATING VENTILATION AND AIR CONDITIONING CONTENTS SECTION 7A HEATING AND VENTILATION SYSTEM SECTION 7B MANUAL CONTROL HEATING VENTILATION AND AIR CONDITIONING SYSTEM ...

Page 9: ...RESTRAINTS CONTENTS SECTION 8A SEAT BELTS SECTION 8B SUPPLEMENTAL INFLATABLE RESTRAINTS SIR ...

Page 10: ...N SECTION 9F AUDIO SYSTEMS SECTION 9G INTERIOR TRIM SECTION 9H SEATS SECTION 9I WATERLEAKS SECTION 9J WINDNOISE SECTION 9K SQUEAKS AND RATTLES SECTION 9L GLASS AND MIRRORS SECTION 9M EXTERIOR TRIM SECTION 9N FRAME AND UNDERBODY SECTION 9O BUMPERS AND FASCIAS SECTION 9P DOORS SECTION 9Q ROOF SECTION 9R BODY FRONT END SECTION 9S BODY REAR END SECTION 9T IMMOBILIZER ANTI THEFT SYSTEM ...

Page 11: ...III 1A 4 Diagnoctic Information and Procedure 1A 5 General Diagnosis 1A 5 Checking Engine Fluid Level 1A 11 Changing Engine Oil or Oil Filter 1A 11 Checking Engine Timing Belt 1A 12 Checking Accessory Belt 1A 12 Checking Spark Plug 1A 12 Checking Air Cleaner Element 1A 13 Checking Fuel Filter 1A 13 Checking Fuel System 1A 13 Checking Hose System 1A 13 Specifications 1A 14 General Specifications 1A...

Page 12: ... they should be kept in order They should be installed in the same locations and with the same mat ing surfaces as when they were removed Battery cables should be disconnected before any major work is performed on the engine Failure to disconnect cables may result in damage to wire harness or other electrical parts ON ENGINE SERVICE Caution Disconnect the negative battery cable be fore removing or...

Page 13: ...nister 4 Canister Solenoid 5 Manifold Absolute Pressure MAP Sensor 6 Intake Manifold 7 Ignition Coil 8 Idle Air Control IAC Valve 9 Throttle Position TP Sensor 10 Throttle Body 11 Brake Fluid Reservoir 12 Wiper Motor 13 Battery 14 Fuse Box 15 Air Cleaner Housing 16 Resonator 17 PCV Hose 18 Distributor 19 Exhaust Manifold 20 Snorkel 21 Engine 22 Washer Fluid Reservoir 23 Oil Level Gauge 24 Oil Fill...

Page 14: ...r Purge Solenoid 4 Manifold Absolute Pressure MAP Sensor 5 Intake Manifold 6 Throttle Position TP Sensor 7 Throttle Body 8 Idle Air Control IAC Valve 9 Brake Fluid Reservoir 10 Wiper Motor 11 Battery 12 Fuse Box 13 Air Cleaner Housing 14 Resonator 15 Electronic Ignition System Ignition Coil 16 Exhaust Manifold 17 Snorkel 18 Engine 20 Washer Fluid Reservoir 19 Oil Level Gauge 21 Oil Filler Cap ...

Page 15: ...iming D Faulty ignition coil D Replace the ignition coil Malfunction of Fuel D Lock of fuel in the fuel tank D Feed the fuel System D Dirty or clogged fuel filter D Replace the filter D Clogged fuel pipe D Clean the fuel pipe D Malfunction of the fuel pump D Replace the fuel pump D Malfunction of the fuel injector D Replace the injector D The foreign material in the fuel tank D Clean the fuel tank...

Page 16: ...f the high tension cable D Connect the cable correctly or replace it Malfunction of D Clogged fuel pipe D Clean the pipe Fuel System D Clogged or contaminated fuel filter D Replace the filter Others D Clogged exhaust system D Check and repair the system D Clogged or contaminated air cleaner element D Clean or replace the air cleaner element D Leak of the intake manifold gasket D Replace the gasket...

Page 17: ...sing or Ignition System D Poor spark plug or poor adjustment of the plug gap D Replace the plug or adjust the gap starting D Electric leakage or poor connection of the high tension cable D Connect the cable correctly or replace it Others D Malfunction of the air cleaner system D Clean or replace the air cleaner system D Leak of the intake manifold gasket D Replace the gasket Engine Surging Engine ...

Page 18: ...ace it Malfunction of Fuel System D Clogged or contaminated fuel filter and fuel pipe D Clean or replace the fuel filter and the fuel pipe Others D Leak of the intake manifold gasket D Replace the gasket D Excessive carbon deposit due to abnormal combustion D Remove the carbon Overheat Malfunction of D Lack of coolant D Refill coolant Cooling System D Malfunction of the thermostat D Replace the th...

Page 19: ...nsumption of Engine Oil Engine Oil D Loosened oil pan bolt D Tighten the bolt Engine Oil D Loosened oil filter D Tighten the filter D Loosened oil pressure switch D Tighten the switch D Leakage of camshaft front oil seal D Replace the seal D Leakage of crankshaft front oil seal D Replace the seal D Leakage at the cylinder head cover gasket D Replace the gasket D Damage of the cylinder head gasket ...

Page 20: ...m or the guide D Weak valve spring D Replace the spring Piston Ring Cylinder Noise D Abrasion of the piston the ring or the cylinder D Boring the cylinder or replace the piston the ring or the cylinder Connecting Rod Noise D Abrasion of the connecting rod bearing D Replace the bearing D Loosened the connecting rod nut D Tighten to the specified torque Crankshaft Noise D Abrasion of the crankshaft ...

Page 21: ...rrect level checking can not be performed Therefore wait until temperature reaches the normal operating condition and check the engine oil level D102A301 CHANGING ENGINE OIL OR OIL FILTER Tools Required 09915 47341 Oil Filter Wrench When checking engine oil level or condition if needed change engine oil including the filter as follows 1 After stopping the engine wait for a few minutes to accumulat...

Page 22: ...clearance exces sive carbon deposit worn electrode or damaged insula tor replace the new one if necessary Remove and check the spark plug as follows 1 Pull the high tension cable cap portion i and discon nect the high tension cable from the spark plug If pulling the high tension cable j circuit could be disconnected Therefore the cap portion should be used D102A305 2 Remove the spark plugs from cy...

Page 23: ...he specified period engine effi ciency is deteriorated by dust or foreign material Therefore replace a new one within the specified peri od CHECKING FUEL SYSTEM Check the fuel system as follows D Check the fuel line or line connection portion for dam age or leakage D Check the fuel hose surface for damage D Check the fuel cap for looseness CHECKING HOSE SYSTEM Check the engine vacuum hose PCV hose...

Page 25: ...GENERAL ENGINE INFORMATION 1A 15 DAEWOO M 150 BL2 ENGINE PERFORMANCE CURVE D Maximum Power 51 PS 37 5 KW at 6 000 rpm D Maximum Torque 7 KgSm 68 6 NSm at 4 600 rpm D12A101A ...

Page 26: ...1B 7 Timing Belt Engine Mount 1B 8 Diagnostic Information and Procedure 1B 9 Compression Pressure Check 1B 9 Oil Pressure Check 1B 9 Adjustment of Valve Clearance 1B 10 Ignition Timing Check and Adjustment Typical 1B 11 Valve Timing Check and Adjustment 1B 12 Repair Instructions 1B 14 On Vehicle Service 1B 14 Air Filter Assembly 1B 14 Air Filter Element 1B 15 Positive Crankcase Ventilation PCV Hos...

Page 27: ...two paths in engine block In one path e oil reaches crankshaft journal bearings Oil from crankshaft journal bearings is supplied to connect ing rod bearings by means of intersecting passages drilled in crankshaft and then injected from a small hole provided on big end of connecting rod to lubricate piston f rings and cylinder wall In another path g oil goes up to cylinder head and lubricates rocke...

Page 28: ...t bearings p are inserted in the journal bearing part No 3 D102B004 CONNECTING ROD The connecting rods n are made of forged steel and its section is typed I with its big end connected to crankshaft m and its small end to piston pin to transmit the power The big end is detachable and its upper and lower parts are fastened by bolting after the metal bearings q are inserted PISTON PISTON RING AND PIS...

Page 29: ...o that there is no slippage between them There is a tension pulley z that maintains the correct timing belt tension The timing belt is made of a tough reinforced rubber similar to that used on the serpentine drive belt The timing belt requires no lubrication D102B006 ENGINE MOUNT This is to absorb or reduce the engine vibration and im pact from the wheeled road Engine mount is attached to the engi...

Page 30: ...ONENT LOCATOR CYLINDER HEAD D12B4011 1 Oil Filler Cap 2 Cylinder Head Cover 3 Cylinder Head Cover Euro III 4 Distributor Case 5 Camshaft 6 Exhaust Rocker Arm 7 Cylinder Head Gasket 8 Cylinder Head 9 Intake Rocker Arm 10 Exhaust Valve 11 Intake Valve ...

Page 31: ...C ENGINE MECANICAL DAEWOO M 150 BL2 ENGINE BLOCK D21B0011 1 Oil Level Gauge Stick 2 Piston 3 Connecting Rod 4 Engine Block 5 Oil Filter 6 Flywheel 7 Crankshaft 8 Oil Pan 9 Oil Pump Strainer 10 Oil Pump Assembly ...

Page 32: ...d 2 Exhaust Gas Recirculation EGR Pipe 3 Exhaust Gas Recirculation EGR Valve and Solenoid 4 Throttle Body Assembly 5 Air Filter Assembly 6 Resonator 7 Snorkel 8 Oxygen Sensor 9 Exhaust Manifold 10 Exhaust Manifold Heat Shield 11 Exhaust Manifold Heat Shield Euro III 12 Exhaust Manifold Euro III ...

Page 33: ...gine Mount Brace Bracket 4 Transaxle Mount Bracket 5 Transaxle Mount Damping Block 6 Engine Mount Front Bracket 7 Engine Mount Front Damping Bush 8 Timing Belt 9 Timing Belt Tensioner 10 Crankshaft Gear 11 Timing Belt Upper Front Cover 12 Timing Belt Lower Front Cover 13 Crankshaft Pulley 14 Engine Mount Lower Bracket 15 Engine Mount Upper Bracket ...

Page 34: ...ure gauge ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ Unit ÁÁÁÁÁ ÁÁÁÁÁ Standard ÁÁÁÁÁ ÁÁÁÁÁ Limit ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ Compression Pressure 400 rpm kPa psi 1 225 75 177 73 1 176 72 1 274 78 170 62 184 84 7 After checking remove the gauge and install the re moved parts OIL PRESSURE CHECK Tools Required 09915 77310 Oil Pressure Gauge Prior to check oil pressure check the followings D Check oil level and add if r...

Page 35: ... ÁÁÁ ÁÁÁ 3 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Compression top Intake f f ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ dead center of No 1 cylinder Exhaust f f Q f marks indicates the place where the valve clear ance can be checked and adjusted 5 If the checking for the valve clearance of No 1 cylin der compression top dead center is over position No 1 cylinder on the exhaust top dead center as rotat ing the crankshaft in a 360 degree ar...

Page 36: ...just rod l properly D102B307 IGNITION TIMING CHECK AND ADJUSTMENT TYPICAL Note Ignition timing could not be adjusted for Direct Ignition System Euro Stage III Check and adjust the ignition timing in the following pro cedures 1 Warm up the engine to the normal operating tempera ture 2 Turn off the lamp and audio system and shift the shift gear lever in Neutral D12B3081 3 Connect terminal A and term...

Page 37: ... procedures 1 After removing the high headlamp loosen the bolts a and remove the timing belt front upper cover b D102B312 2 Turning the crankshaft clockwise twice align the notch d on the crankshaft pulley c with the mark 0 e for the timing check on the timing belt front lower cover D102B313 3 Check if the notch f on the camshaft sprocket is aligned with the triangle pointer g on the timing belt r...

Page 38: ... timing belt tensioner k and the timing belt l D102B317 4 Using the bolt turn the crankshaft clockwise to align the mark m on the crankshaft sprocket with the pointer n on the oil pump housing Then turn the camshaft to align the notch f with the pointer g D102B318 5 Install the timing belt l and the tensioner k Do not tighten the tensioner bolt completely Turning the crankshaft clockwise twice ali...

Page 39: ...D 3 Electric Cooling Fan 1D 3 Engine Coolant Temperature Sensor 1D 4 Coolant Temperature Sensor 1D 4 Component Locator 1D 5 Coolant Hose and Components 1D 5 Radiator Fan 1D 6 Diagnostic Information and Procedure 1D 7 Coolant Leaks Test 1D 7 Surge Tank Cap Test 1D 7 Thermostat Test 1D 7 Cooling System Diagnosis 1D 8 Repair Instructions 1D 9 On Vehicle Service 1D 9 Draining and Refilling the Cooling...

Page 40: ...g The surge tank h is connected to the radiator and throttle body to recover the coolant displaced by ex pansion from the high temperatures The surge tank maintains the correct coolant level The cooling system for this vehicle has no radiator cap and drain cock The coolant is added to the cooling sys tem through the surge tank To drain the cooling system disconnect the lower radiator hose and drai...

Page 41: ...in the thermostat is hermetically sealed in a metal case j The wax element of the thermostat ex pands when it is heated and contracts when it is cooled As the vehicle is driven and the engine warms the en gine coolant temperature increases When the engine coolant reaches a specified temperature the wax pellet element in the thermostat expands and exerts pressure against the metal case forcing the ...

Page 42: ...w speed when the coolant temperature reaches 93_C 199_F and high speed at 100_C 212_F D The ECM will change the cooling fan from high speed to low speed at 97_C 207_F and turn the cooling fans off at 90_C 194_F A C ON D The ECM will only turn the cooling fan on at high speed when the A C system is on regardless of any condition ENGINE COOLANT TEMPERATURE SENSOR The engine coolant temperature ECT s...

Page 43: ...Assembly 5 Lower Radiator Hose 6 Throttle Body Assembly 7 Surge Tank hose 8 Surge Tank 9 Coolant Temperature Sensor 10 Engine Coolant Temperature Sensor 11 Surge Tank Return Hose 12 Water Inlet Cap 13 Heater Outlet Hose 14 Heater Inlet Hose 15 Distributor Case 16 Thermostat 17 Thermostat Housing 18 Throttle Body Inlet Hose 19 Throttle Body Outlet Hose 20 Hose Bracket ...

Page 44: ...1D 6 ENGINE COOLING DAEWOO M 150 BL2 RADIATOR FAN D12D4021 1 Radiator Assembly 2 Electric Cooling Fan Assembly ...

Page 45: ...g the Adapter a 4 Pull the vacuum pressure valve to the open position If the surge tank cap does not seal properly replace the surge tank cap 5 Pressurize the cap to 90 to 120kPa 13 to 17psi 6 Wait 10 seconds and check the pressure held by the tank cap tester 7 If the pressure held by the cooling system pressure tester falls below 80kPa 11 6psi replace the surge tank cap D102D302 THERMOSTAT TEST 1...

Page 46: ...ap D Replace a faulty surge tank cap D A cracked or plugged cylinder head or engine block D Repair the damaged cylinder head or the damaged engine block D A faulty radiator D Replace a faulty radiator Loss of Coolant D A leak in the radiator D Replace a damaged radiator D A leak in the surge tank or the hose D Replace the surge tank or the hose D Looseness or damage of radiator hoses heater hoses ...

Page 47: ...he surge tank cap 1 D Disconnect the lower radiator hose 2 Caution Dispose of the used coolant to a used coolant holding tank to be picked up with the used oil for disposal Never pour the used coolant down the drain Ethylene glycol antifreeze is an extremely toxic chemical Disposing of it into the sewer sys tem or the ground water can contaminate the local environment D102D502 3 Connect the lower ...

Page 48: ... least 50 percent antifreeze but not more than 60 percent antifreeze for cold weather operation 9 Fill the surge tank to the specified MAX fill mark on the outside of the tank 10 Install the surge tank cap D102D504 SURGE TANK Removal Procedure Caution To prevent personal injury do not remove the surge tank cap while the engine and the radiator are hot because the heat causes the system to re main ...

Page 49: ...olts 2 D Remove the electric cooling fan assembly 3 3 5 4 5 NSm D12D507A Installation Procedure 1 Install the electric cooling fan assembly with the bolts Tighten Tighten the bolts to 3 5 4 5 NSm 31 40 lb in 2 Connect the cooling fan electrical connector 3 Connect the negative battery cable D12D5081 RADIATOR Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the lower radiator ...

Page 50: ...cooling fan Refer to Electric Cooling Fan in this section D12D5111 3 Connect the upper radiator hose to the radiator 1 4 Connect the surge tank hose to the radiator 2 5 Secure each hose with hose clamps 6 Refill the engine cooling system Refer to Draining and Refilling the Cooling System in this section 7 Connect the negative battery cable D102D512 THERMOSTAT TYPICAL Removal Procedure Caution To p...

Page 51: ...thermo stat housing Tighten Tighten the mounting bolts to 8 15 NSm 71 130 lb in 2 Secure the upper radiator hose to the thermostat housing with a hose clamp 3 Refill the engine cooling system Refer to Draining and Refilling the Cooling System in this section MAA1D010 THERMOSTAT EURO III Removal Procedure Caution To prevent personal injury do not remove the surge tank cap while the engine and the r...

Page 52: ...efilling the Cooling System in this section 4 Install the air filter assembly Refer to Section 1B SOHC Engine Mechanical D102D515 COOLANT TEMPERATURE SENSOR Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the lower radiator hose and drain the coolant Refer to Draining and Refilling the Cooling System in this section 3 Remove the coolant temperature sensor D Disconnect the el...

Page 53: ...or to the ECT sen sor 1 2 Connect the lower radiator hose and refill the coolant Refer to Draining and Refilling the Cooling System in this section 3 Connect the negative battery cable D102B533 COOLANT PUMP Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the lower radiator hose and drain the coolant Refer to Draining and Refilling the Cooling System in this section 3 Remove ...

Page 54: ...e bolts and the nuts to 9 12 NSm 80 106 lb in a 2 Install the rear timing belt cover Tighten Tighten the bolts to 9 12 NSm 80 106 lb in b 3 Install the timing belt Refer to Section 1B Engine Mechanical 4 Connect the lower radiator hose and drain the cool ant Refer to Draining and Refilling the Cooling Sys tem in this section 5 Connect the negative battery cable ...

Page 55: ... F 90 194 4 Temperature At High Speed ON C F 100 212 4 Temperature At High Speed OFF C F 97 207 Surge Tank Open Pressure of The Pressure Valve kPa psi 120 150 17 4 21 8 Surge Tank Open Pressure of The Vacuum Valve kPa psi 10 1 5 Water Pump Type Centrifugal Coolant Pump Impeller Diameter mm in 60 2 36 Impeller Blade Number EA 7 Radiator Type Cross Flow Core Width mm in 458 18 03 Radiator Core Heigh...

Page 56: ...re Sensor 20 15 Coolant Pipe Bolt 8 15 71 130 Electric Cooling Fan Motor Nut 3 0 3 2 27 28 Electric Cooling Fan Assembly Bolt 3 5 4 5 31 40 Distributor Case Bolt Nut 8 12 71 106 Radiator Mounting Bracket Bolt 3 5 4 5 31 40 Thermostat Housing Bolt 8 15 71 130 Water Inlet Cap Bolt 8 12 71 106 Coolant Pump Bolt Nut 9 12 80 106 Coolant Pump Stud Bolt 9 12 80 106 ...

Page 57: ...E 4 Distributor 1E 4 Ignition Coil 1E 5 Spark Plug 1E 5 Component Locator 1E 6 Starting System 1E 6 Charging System A type MANDO 1E 7 Charging System B type DAC 1E 8 Ignition System 1E 9 Diagnostic Information and Procedure 1E 10 Ignition System 1E 10 Battery Load Test 1E 12 Generator Output Test 1E 12 Generator System Check 1E 13 Repair Instructions 1E 14 On Vehicle Service 1E 14 Starter 1E 14 Ge...

Page 58: ... tery temperature of 18_C 0_F The current rating is the minimum amperage which must be maintained by the battery for 30 seconds at the specified temperature while meeting a minimum voltage requirement of 7 2 volts This rating is a measure of cold cranking ca pacity The battery is not designed to last indefinitely However with proper care the battery will provide many years of service If the batter...

Page 59: ... If the reading is below 10 volts the charge current will be very low and it could take some time before the battery accepts the current in excess of a few milliamperes Refer to Charging Time Required in this section which focuses on the factors affecting both the charging time required and the rough estimates in the table below Such low cur rent may not be detectable on ammeters available in the ...

Page 60: ...charge indi cator is on with the engine running a charging system defect is indicated The regulator voltage setting varies with temperature and limits the system voltage by controlling the rotor field current The regulator switches rotor field current on and off By varying the on off time correct average field current for proper system voltage control is ob tained At high speeds the on time may be...

Page 61: ...trols IGNITION COIL Ignition coil is a sort of transformer to generate high volt age 15 000 25 000V which can bring spark at the spark plugs and has an iron cored closed magnetic type The closed magnetic typed ignition coil is used for the High Energy Ignition H E I system Comparing with the iron cored open magnetic type the closed type almost has no loss of magnetic flux and smaller in size so it...

Page 62: ...NG SYSTEM D102E401 1 Starter Motor Assembly 2 Starter Solenoid Assembly 3 Starter Housing 4 Shift Lever 5 Armature Set 6 Armature 7 Pinion Gear Assembly 8 Ring Set 9 Field Frame Assembly 10 Brush Holder Assembly 11 Contact End Frame Assembly 12 Starter Through Bolts ...

Page 63: ...t 4 Generator Pully 5 Generator Collar Large 6 Generator Front Bracket 7 Front Bearing 8 Bearing Spot Plate 9 Generator Collar Small 10 Generator Rotor Assembly 11 Rear Bearing 12 Generator Stator Assembly 13 Rectifier Assembly 14 Voltage Regulator Brush Holder Assembly 15 Generator Rear Bracket 16 Battery Positive Terminal Nut 17 Through Bolt ...

Page 64: ...Nut 4 Generator Pully 5 Generator Collar 6 Generator Drive End Bracket 7 Generator Stator Assembly 8 Frame Bearing 9 Generator Fan 10 Generator Rotor Assembly 11 Frame Bearing 12 Generator Frame 13 Regulator Assembly 14 Brush Holder Assembly 15 Rectifier Assembly 16 Shield 17 Through Bolt 18 Generator Cover 19 Battery Positive Terminal Nut ...

Page 65: ... Ignition Wires 1 2 3 5 Support Clamp 6 Mounting Clamp 7 Distributor Assembly 8 Coupling 9 Distributor Oil Seal 10 Distributor Housing 11 Distributor Shaft 12 Plate 13 Optical Sensor Unit 14 Plate 15 Bushing 16 Disc Wheel 17 Inner Cover 18 Outer Cover 19 Distributor Rotor 20 Distributor Cap Seal 21 Distributor Cap ...

Page 66: ...Replace the starter motor D Broken the flywheel ring gear D Replace the flywheel D Connected circuit is open D Repair the open circuit Overcharging Battery D Faulty the IC regulator D Replace the IC regulator Battery Discharge D Loosen the generator drive belt D Adjust the belt tension or Replace the belt D The circuit is open or a short D Repair the open or a short circuit D Faulty IC regulator D...

Page 67: ...r D Replace the distributor or the optical sensor D Faulty spark plug D Replace the spark plug or Adjust the gap D Poor ignition timing D Reset the valve timing Engine Idling State is Unstable D Faulty spark plug D Replace the spark plug or Adjust the gap D Faulty ignition coil D Replace the ignition coil D Poor ignition timing D Reset the valve timing Poor Engine Accelerating D Poor ignition timi...

Page 68: ...L terminal circuit has damaged the regulator 3 Attach a digital multimeter a an ammeter b and a carbon pile load c to the battery d and the gen erator e of the rehicle D102E301 Important Be sure the vehicle battery is fully charged and the carbon pile load is turned off 4 With the ignition switch in the OFF position check and record the battery voltage 5 Remove the harness connector from the gener...

Page 69: ...amp should be on If not detach the harness at the generator and ground the L terminal in the harness with a fused 5 ampere jumper lead D If the lamp lights replace the generator Refer to Generator in the On Vehicle Service section D If the lamp does not light locate the open circuit between the ignition switch and the harness con nector The indicator lamp bulb may be burned out 3 With the ignition...

Page 70: ...emove the harness clip bolt to disconnect the harness clip 3 D Remove the ground bolt 4 D102E502 3 Remove the starter assembly D Remove the starter mounting bolts 1 D Remove the starter assembly 2 D12E5031 Installation procedure 1 Install in the reverse order of removal 2 Install the starter mounting bolts and starter solenoid nut Tighten D Tighten the starter mounting bolts to 55 65 NSm 41 48 lb ...

Page 71: ...the generator drive belt D Loosen the generator adjusting bolt 1 D Remove the lower bracket to generator bolt and nut 2 D Separate the generator drive belt from the genera tor D102E506 4 Remove the engine mounting lower bracket D Remove the engine mounting lower bracket at taching reaction rod bolt and nut 1 D Remove the engine mounting lower bracket bolts 2 D Remove the engine mounting lower brac...

Page 72: ...Sm 3 Install the bolts and nut Tighten D Tighten the generator adjusting bolt to 4 7 NSm 35 62 lb in a D Tighten the generator lower bracket bolt and nut to 18 28 NSm 13 21 lb ft b D Inspect the generator drive belt tension D12E511A BATTERY Removal Procedure 1 Disconnect the negative battery cable and then dis connect the positive battery cable D Remove the battery cable nut to disconnect the nega...

Page 73: ...orkel assem bly Refer to Section 1B SOHC Engine Mechanical 3 Disconnect the ignition wires and electrical connec tor D Disconnect the optical sensor connector 1 D Disconnect the ignition wires 2 D Remove the ignition wire clip 3 D102E515 4 Remove the distributor Important Mark on the distributor housing and case before remove distributor a D Remove the distributor bolts 1 D Carefully remove the di...

Page 74: ... tor D Disconnect the ignition wire 1 D Disconnect the ignition coil connector by pushing the connector s lock 2 D102E518 3 Remove the ignition coil D Remove the screws 1 D Remove the ignition coil 2 D12E519A 4 7 NSm Installation Procedure 1 Install in the reverse order of removal 2 Install the ignition coil screws Tighten Tighten the ignition coil screws to 4 7 NSm 35 62 lb in ...

Page 75: ... of time to prevent overheating and damaging the solenoid in 10 seconds D102E702 D Switch on to move the pinion gear 2 D Now check the clearance between the pinion and the stopper with the filler gauge 3 D If the clearance does not fall within the limits check for improper installation and replace all worn parts D102E703 3 Magnetic switch pull in test D Disconnect the starter motor terminal M 1 D ...

Page 76: ... and body Notice Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid D102E706 D Check the pinion gear s moving to the outside 2 D If the pinion gear move to the inside the circuit is open Replace the magnetic switch D102E707 5 Solenoid return test D Disconnect the starter motor terminal M 1 D Connect the 12 volt battery lead to the starter mo tor termi...

Page 77: ...Install the starter motor rpm gage 2 D Start the starter motor with the switch on 3 D Measure the speed of pinion gear and the current D If the measurement satisfy the limit the starter mo tor is normal D102E710 Desciption Limit The speed of pinion gear Minimum 2 000 rpm Condition Voltage Current Maximum 9V 150A D Replace the starter motor if necessary D102E711 Disassembly Procedure 1 Remove the s...

Page 78: ...ame assembly from the armature set 1 D102E714 4 Remove the solenoid assembly D Remove the solenoid screws 1 D Remove the magnetic switch 2 D Remove the spring 3 D102E715 5 Remove the armature set and solenoid from the start er housing D Remove the armature set 1 D Remove the rubber sealer 2 D Remove the shift lever plate 3 D Remove the shift lever 4 D Remove the solenoid 5 D Remove the gasket 6 ...

Page 79: ...cing it on a growler and hold ing back a saw blade over the armature core while the armature is rotated If the saw blade vibrates replace the armature D102E718 3 Open circuit test for armature coil D Check the continuity between the commutator bars using multimeter D Replace the armature assembly if necessary D102E719 4 Inspect the brushes wear D Inspect the brushes the pop out springs and the bru...

Page 80: ...1 GENERATOR A TYPE MANDO Disassembly Procedure 1 Remove the generator Refer to Generator in this section 2 Remove the front bracket and rear bracket D Remove the through bolts 1 D102E722 D Pry front bracket downwards using a screwdriver 2 D Separate the front bracket and rear bracket 3 D102E723 3 Remove the pulley and rotor assembly from the front bracket D Cover the rotor with the cloth 1 D Place...

Page 81: ...ve the support plate screws 1 D Remove the plate 2 D Remove the front bearing using the press 3 D102E726 6 Remove the battery positive terminal nut from the rear bracket D Remove the battery position terminal nut 1 D Remove the washer 2 D102E727 7 Remove the stator assembly from the rear bracket D Remove the rectifier screw 1 D Remove the brush holder and regulator assembly screws 2 D Remove the s...

Page 82: ... diodes D102E729 Inspection Measurement 1 Inspect the rotor assembly D Test the rotor for an open circuit by using the ohm meter 1 Replace the rotor if necessary D102E730 D Test the rotor for open or short circuit 2 Desciption Limit The measured resistance 2 9Ω D Replace the rotor if necessary D Test the rotor for open or ground circuit by using the ohmmeter 3 Replace the rotor if necessary D102E7...

Page 83: ...ier test Inspect the open circuit for stator coil lead termi nals using the ohmmeter 1 Replace the rectifier if necessary D102E734 D Negative rectifier test Inspect the open circuit for stator coil lead termi nals using the ohmmeter 2 Replace the rectifier if necessary D102E735 4 Inspect trio diodes D Inspect the open circuit for trio diodes using the ohmmeter 1 D Replace the heat sink if necessar...

Page 84: ...cedure 1 Install in the reverse order of removal D Assemble the stator assembly into the rear bracket and rotor assembly a Brushes b Hole D12E738A 2 Install the bolts nuts screws Tighten D Tighten the brush holder regulator rectifier screws to 9 12 NSm 80 106 lb in a D Tighten the battery positive terminal nut to 4 7 NSm 35 62 lb in b D102E739 6 8 NSm D Tighten the front bearing spot plate screws ...

Page 85: ...or in this section 2 Remove the cover from the generator D Remove the battery positive terminal nut 1 D Remove the cover 2 a Cover D102E742 3 Remove the regulator brush holder rectifier assem bly D Remove the stator coil lead and rectifier diode lead connections 1 D102E743 D Remove the rectifier bolts 2 D Remove the rectifier regulator screw 3 D Remove the brush holder regulator screw 4 D Remove t...

Page 86: ...racket and the frame D Remove the shield 1 D Remove the through bolts 2 D Remove the frame from the drive end bracket 3 D102E746 6 Remove the pulley and rotor assembly from the drive end bracket D Cover the rotor with the cloth 1 D Place the pulley upwards and vice the rotor 2 D Remove the pulley nut 3 D Remove the pulley 4 D102E747 7 Remove the drive end bracket rotor and space D Remove the colla...

Page 87: ... sufficiently low or the rotor must be replaced 1 D102E750 D Test the rotor for open or short circuits The read ing should be 2 6 to 2 8 ohms or the rotor should be replaced 2 D Test the rotor for open or ground circuits by using the ohmmeter The reading should be sufficiently high or the rotor must be replaced 3 D Inspect the fan blade for damage D102E751 2 Inspect the stator D Test the rotor for...

Page 88: ...ier D Positive rectifier test Inspect the open circuit for stator coil lead termi nals using the ohmmeter 1 Replace the rectifier if necessary D102E754 D Negative rectifier test Inspect the open circuit for stator coil lead termi nals using the ohmmeter 2 Replace the rectifier if necessary D102E755 4 Inspect trio diodes D Inspect the open circuit for trio diodes using the ohmmeter 1 Replace the he...

Page 89: ...embly Procedure 1 Install in the reverse order of removal 2 Install the screws nuts bolts Tighten D Tighten the regulator screw to 9 12 NSm 80 106 lb in a D Tighten the rectifier regulator screw to 9 12 NSm 80 106 lb in b D Tighten the brush holder regulator screw to 9 12 NSm 80 106 lb in c D12E758A 9 12 NSm D Tighten the rectifier bolts to 9 12 NSm 80 106 lb in d D12E759A 80 110 NSm D Tighten the...

Page 90: ...utor in this section 2 Remove the cap seal and rotor from the distributor housing D Remove the bolts 1 D Remove the distributor cap 2 D Remove the seal 3 D Remove the rotor 4 D102E762 D Inspect the cap for cracks or damage a D Inspect the cap electrode for damage wear or car bon traces b D Inspect the rotor for damage or carbon traces c D102E763 3 Remove the inner outer cover from the distributor ...

Page 91: ... unit from the distributor housing D Carefully remove the disc wheel 1 D Remove the bushing 2 D Remove the screws 3 D Remove the optical sensor unit plate 4 D Remove the optical sensor unit 5 D102E766 6 Remove the bearing plate from the distributor hous ing D Remove the screws 1 D Remove the bearing plate 2 D102E767 7 Remove the coupling shaft and bearing from the dis tributor housing D Remove the...

Page 92: ...1E 36 ENGINE ELECTRICAL DAEWOO M 150 BL2 D102E768 Assembly Procedure 1 Install in the reverse order of removal D Lubricate the shaft with clean engine oil ...

Page 93: ...ENGINE ELECTRICAL 1E 37 DAEWOO M 150 BL2 SCHEMATIC AND ROUTING DIAGRAMS STARTING SYSTEM D12E2011 ...

Page 94: ...1E 38 ENGINE ELECTRICAL DAEWOO M 150 BL2 CHARGING SYSTEM D12E2021 ...

Page 95: ...ENGINE ELECTRICAL 1E 39 DAEWOO M 150 BL2 IGNITION SYSTEM CIRCUIT TYPICAL D12E2031 ...

Page 96: ...1E 40 ENGINE ELECTRICAL DAEWOO M 150 BL2 IGNITION SYSTEM CIRCUIT EURO III MAA1E010 ...

Page 97: ...AC Regulator A Type V 14 4 15 0 Regulator Voltage A Type B Type V 14 4 15 0 14 3 4 9 Brushes Length A Type B Type mm in 18 5 0 728 20 0 0 787 13 5 0 531 14 0 551 Output A Type 12V 65A Output Capacity A Type B Type 12V 65A 12V 65A IGNITION SYSTEM SPECIFICATIONS Application Description Unit Standard Limit Ignition Coil Type Closed Magnetic Type First Coil Resistance Ω 1 2 10 Second Coil Resistance K...

Page 98: ...06 Starter Through Bolts 4 6 35 53 Starter Mounting Bolts 55 65 41 48 Starter Solenoid Assembly Screws 6 8 53 71 Starter Solenoid Nuts 9 12 80 106 Spark Plug 20 30 15 22 Generator Through Bolts 4 6 35 53 Generator Drive End Nut 80 110 59 81 Generator Battery Lead Connector Nut 4 7 35 62 Generator Bearing Plate Bolt 6 8 53 71 Generator Brush Holder Rectifier Screw 9 12 80 106 Generator Belt Tension...

Page 99: ...iagnostics 1F 9 EOBD Serviceability Issues 1F 9 Serial Data Communications 1F 10 Euro On Board Diagnostic EOBD 1F 10 Comprehensive Component Monitor Diagnostic Operation 1F 11 Common EOBD Terms 1F 11 DTC Types 1F 13 Reading Diagnostic Trouble Codes 1F 13 Primary System Based Diagnostics 1F 15 Diagnostic Information and Procedures 1F 17 System Diagnosis 1F 17 Diagnostic Aids 1F 17 Idle Learn Proced...

Page 100: ...t 1F 164 DTC P1382 Rough Road Data Invalid Non ABS 1F 166 DTC P1382 Rough Road Data Invalid ABS 1F 170 DTC P1385 Rough Road Sensor Circuit Fault Non ABS 1F 174 DTC P1385 Rough Road Sensor Circuit Fault ABS 1F 178 DTC P0400 Exhaust Gas Recirculation Out Of Limit 1F 182 DTC P1402 Exhaust Gas Recirculation Blocked 1F 186 DTC P1403 Exhaust Gas Recirculation Valve Failure 1F 188 DTC P0404 Exhaust Gas R...

Page 101: ...04 Fuel Pressure Regulator 1F 305 Fuel Filter 1F 306 Fuel Tank 1F 307 Fuel Rail and Injectors 1F 308 Evaporator Emission Canister 1F 309 Evaporator Emission Canister Purge Solenoid 1F 310 Manifold Absolute Pressure MAP Sensor 1F 310 Throttle Body 1F 311 Engine Coolant Temperature ECT Sensor 1F 312 Intake Air Temperature ECT Sensor 1F 313 Oxygen Sensor O2S 1 1F 314 Heated Oxygen Sensor HO2S 2 1F 31...

Page 102: ...sequential fuel in jection mode of operation If the ECM detects an incor rect CMP signal while the engine is running Diagnostic Trouble Code DTC P0341 will set If the CMP signal is lost while the engine is running the fuel injection system will shift to a calculated sequential fuel injection mode based on the last fuel injection pulse and the engine will continue to run As long as the fault is pre...

Page 103: ...llowing methods D Increasing the fuel injector pulse width D Increasing the idle speed rpm D Increasing the ignition dwell time Fuel Cut Off Mode No fuel is delivered by the fuel injectors when the ignition is off This prevents dieseling or engine run on Also the fuel is not delivered if there are no reference pulses re ceived from the CKP sensor This prevents flooding EVAPORATIVE EMISSION CONTROL...

Page 104: ...gle driver demand A broken or loose TP sen sor can cause intermittent bursts of fuel from the injector and an unstable idle because the ECM thinks the throttle is moving A problem in any of the TP sensor cir cuits should set a Diagnostic Trouble Code DTC P0122 or P0123 Once the DTC is set the ECM will sub stitute a default value for the TP sensor and some ve hicle performance will return CATALYST ...

Page 105: ... out a given distance a step or count for each pulse The pintle movement con trols the airflow around the throttle valves which in turn control the engine idle speed The desired idle speeds for all engine operating condi tions are programmed into the calibration of the ECM These programmed engine speeds are based on the coolant temperature the park neutral position switch status the vehicle speed ...

Page 106: ...ly atomized fuel at the injector tip Fuel from the tip is di rected at the intake valve causing it to become further atomized and vaporized before entering the combustion chamber A fuel injector which is stuck partially open would cause a loss of fuel pressure after the engine is shut down Also an extended crank time would be no ticed on some engines Dieseling could also occur be cause some fuel c...

Page 107: ...e for vehicles with Euro On Board Diagnostic EOBD system diagnostics Following a repair the technician should perform the following steps Important Follow the steps below when you verify re pairs on EOBD systems Failure to follow these steps could result in unnecessary repairs D Review and record the Failure Records and the Freeze Frame data for the DTC which has been diag nosed Freeze Fame data w...

Page 108: ...re may set DTC P0300 Related System Faults Many of the EOBD system diagnostics will not run if the Engine Control Module ECM detects a fault on a re lated system or component One example would be that if the ECM detected a Misfire fault the diagnostics on the catalytic converter would be suspended until the Misfire fault was repaired If the Misfire fault is severe enough the catalytic converter ca...

Page 109: ...sts A passive test is a diagnostic test which simply monitors a vehicle system or component Conversely an active test actually takes some sort of action when performing diagnostic functions often in response to a failed pas sive test For example the Electric Exhaust Gas Recir culation EEGR diagnostic active test will force the EEGR valve open during closed throttle deceleration and or force the EE...

Page 110: ...of diagnostic trouble codes When a malfunction is detected by the control module a DTC is set and the Malfunction Indicator Lamp MIL is illumi nated Malfunction Indicator Lamp MIL The Malfunction Indicator Lamp MIL is required by Euro On Board Diagnostics EOBD to illuminate under a strict set of guidelines Basically the MIL is turned on when the Engine Control Module ECM detects a DTC that will im...

Page 111: ...eze Frame on the third consecutive trip with a fail if empty Important For 0 8 SOHC engine eight fail records can be stored Each Fail Record is for a different DTC It is possible that there will not be Fail Records for every DTC if multiple DTCs are set Special Cases of Type B Diagnostic Tests Unique to the misfire diagnostic the Diagnostic Execu tive has the capability of alerting the vehicle ope...

Page 112: ...will cause that DTC num ber to be removed from the scan tool screen Fail This Ign Fail This Ignition This selection will display all DTCs that have failed dur ing the present ignition cycle History This selection will display only DTCs that are stored in the ECM s history memory It will not display Type B DTCs that have not requested the Malfunction Indicator Lamp MIL It will display all type A B ...

Page 113: ... indicates that the selected diag nostic test has not run during this ignition cycle Test Ran and Passed This message display indicates that the selected diag nostic test has done the following D Passed the last test D Run and passed during this ignition cycle D Run and passed since DTCs were last cleared If the indicated status of the vehicle is Test Ran and Passed after a repair verification the...

Page 114: ...ly identify which cylinder is misfiring Use diagnostic equipment to monitor misfire counter data on EOBD compliant vehicles Knowing which spe cific cylinder s misfired can lead to the root cause even when dealing with a multiple cylinder misfire Using the information in the misfire counters identify which cylin ders are misfiring If the counters indicate cylinders numbers 1 and 4 misfired look for...

Page 115: ... Improperly formed or damaged terminals All connec tor terminals in a problem circuit should be carefully inspected reformed or replaced to insure contact tension D Poor terminal to wire connection This requires re moving the terminal from the connector body Road Test If a visual inspection does not find the cause of the prob lem the vehicle can be driven with a voltmeter or a scan tool connected ...

Page 116: ...he engine grounds for cleanliness and tightness The EOBD system check is an organized approach to identifying a problem created by an electronic engine control system malfunction Diagnostic Aids An intermittent may be caused by a poor connection rubbed through wire insulation or a wire broken inside the insulation Check for poor connections or a dam aged harness Inspect the ECM harness and connec ...

Page 117: ...e display for DTCs P0107 P0108 P0113 P0118 P0122 P0123 P0172 P1392 Are two or more of the following DTCs stored Go to Multiple ECM Information Sensor DTCs Set Go to applicable DTC table 7 Compare the ECM data values displayed on the scan tool to the typical engine scan data values Are the displayed values normal or close to the typical values Go to ECM Output Diagnosis Go to indicated component sy...

Page 118: ...ted circuit An open or short to ground will appear in the open posi tions on the scan tool only when it is not commanded by the ECM or the scan tool while a short to voltage will appear in the short positions on the scan tool only while the component is being commanded by the ECM or scan tool ECM Output Diagnosis Step Action Value s Yes No 1 Perform an Euro On Board Diagnostic EOBD System Check Is...

Page 119: ... sensor circuits can cause one or more of the following DTCs to be set P0108 P0113 P0118 P0123 P1106 If a sensor input circuit has been shorted to voltage en sure that the sensor is not damaged A damaged sensor will continue to indicate a high or low voltage after the affected circuit has been repaired If the sensor has been damaged replace it An open in the sensor ground circuit between the ECM a...

Page 120: ... near the specified value 0 V Go to Step 5 Go to Step 9 5 Measure the voltage of the Manifold Absolute Pressure MAP sensor signal circuit between the ECM harness connector and ground Does the voltage measure near the specified value 0 V Go to Step 6 Go to Step 11 6 Measure the voltage of the Throttle Position TP sensor signal circuit between the ECM harness connector and ground Does the voltage me...

Page 121: ...he Fuel Tank Pressure sensor signal circuit between the ECM harness connector and ground Does the voltage measure near the specified value 0 V Go to Step 18 Go to Step 17 17 Locate and repair the short to voltage in the Fuel Tank Pressure sensor signal circuit Is the repair complete Go to Step 19 18 Replace the ECM Is the repair complete Go to Step 19 19 1 Using the scan tool clear the Diagnostic ...

Page 122: ...1F 24 ENGINE CONTROLS DAEWOO M 150 BL2 MAA1F020 ENGINE CRANKS BUT WILL NUT RUN ...

Page 123: ... Go to Step 5 5 Align or replace the timing belt as needed Is the repair complete Go to Step 2 6 Repair internal engine damage as needed Is the repair complete Go to Step 2 7 Inspect the fuel pump fuse Is the problem found Go to Step 8 Go to Step 9 8 Replace the fuse Is the repair complete Go to Step 2 9 Check for the presence of spark from all of the ignition wires while cranking the engine Is sp...

Page 124: ...6 Check for open in wire between the battery and EI system ignition coil connector terminal 1 and repair as needed Is the repair complete Go to Step 2 17 1 Turn the ignition OFF 2 Disconnect ECM connector and EI system ignition coil connector 3 Measure the resistance between following terminals D Terminal 2 of ignition coil and terminal 1 of ECM connector D Terminal 3 of ignition coil and terminal...

Page 125: ...repair complete Go to Step 2 26 Is the fuel pressure within the value specified 380 kPa 55 psi Go to Step 27 Go to Step 29 27 Check the fuel for contamination Is the fuel contaminated Go to Step 28 Go to Step 41 28 1 Remove the contaminated fuel from the fuel tank 2 Clean the fuel tank as needed Is the repair complete Go to Step 2 29 1 Check the fuel filter for restriction 2 Inspect the fuel lines...

Page 126: ... within the value specified 11 14 V Go to Step 38 Go to Step 37 37 Repair open or short circuit for power supply Is the repair complete Go to Step 2 38 1 Turn the ignition OFF 2 Disconnect ECM connector 3 Using an ohmmeter measure the resistance between following terminals D Terminal 10 of ECM and terminal 85 of fuel pump relay D Terminal 87 of fuel pump relay and terminal 3 of fuel pump Does the ...

Page 127: ...ecification Is the repair complete Go to Step 2 45 1 Inspect the fuse EF19 in engine fuse block 2 Check for an open between the circuit from terminal 2 of the three fuel injectors and terminal 87 of main relay Is the problem found Go to Step 48 Go to Main Relay Circuit Check 46 Measure the resistance between following terminals D Terminal 1 of injector 1 connector and terminal 30 of ECM connector ...

Page 128: ...e Control Module ECM controls the MIL by providing a ground path through the MIL control circuit to turn ON the MIL Diagnostic Aids An open ignition F16 fuse will cause the entire cluster to be inoperative Check the battery and ignition feed circuits for poor con nections if the MIL is intermittent Any circuitry that is suspected as causing an intermit tent complaint should be thoroughly checked f...

Page 129: ...ion Does any problem found Go to Step 5 Go to Step 4 4 Replace ECM Is the repair complete Go to On Board Diagnostic System Check 5 Repair any damaged terminals or poor connection Is the repair complete Go to On Board Diagnostic System Check 6 Check the fuse F1 Is the fuse blown Go to Step 7 Go to Step 8 7 1 Check for a short to ground in the circuit and repair as needed 2 Replace the blown fuse Is...

Page 130: ...function Indica tor Lamp MIL will be turned ON and remain ON until the engine is running if no Diagnostic Trouble Codes DTCs are stored Battery voltage is supplied through the ignition switch directly to the MIL telltale The Engine Control Module ECM controls the MIL by providing a ground path through the MIL control circuit to turn ON the MIL ...

Page 131: ...nition ON Is the MIL off Go to Step 6 Go to Step 4 4 Check the MIL control circuit for a short to ground and repair as needed Is a repair necessary Go to Step 7 Go to Step 5 5 Replace the instrument panel cluster Refer to Section 9E Instrumentation Driver Information Is the repair complete Go to Step 7 6 Replace the ECM Is the repair complete Go to Step 7 7 1 Using the scan tool clear the Diagnost...

Page 132: ...ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1 Relieve the fuel system pressure 2 Install a fuel pressure gauge 3 Turn the ignition ON Is the fuel pressure around the values specified but not holding steady ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ 380 kPa 55 psi ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Go to Step 13 ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ Go to Step 3 ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 3 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ...

Page 133: ... ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ 380 kPa 55 psi ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ System OK ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 11 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1 Remove the fuel rail and the fuel injectors as an assembly 2 With the fuel system under pressure inspect all of the fuel injectors for leaking Is the probl...

Page 134: ...off the fuel pump within 2 seconds after the ignition switch is turned ON Diagnostic Aids An intermittent problem may be caused by a poor con nection rubbed through wire insulation or a broken wire inside the insulation Fuel Pump Relay Circuit Check Step Action Value s Yes No 1 1 Turn the ignition OFF for 10 seconds 2 Turn the ignition ON 3 Listen for in tank fuel pump operation Does the fuel pump...

Page 135: ...ignition ON Is the test light on 2 sec Go to Step 8 Go to Step 7 7 Check for an open circuit between terminal 85 of fuel pump relay and terminal 10 of ECM and repair as needed Is the repair complete System OK 8 1 Turn the ignition OFF 2 Connect a test light between the fuel pump relay connector terminal 30 and ground Is the test light on Go to Step 10 Go to Step 9 9 1 Check the fuse EF19 if blown ...

Page 136: ...oil is sup plied voltage through the engine fuse block fuse EF26 The fuel injectors are supplied voltage through the en gine fuse block fuse EF25 Diagnostic Aids D An intermittent problem may be caused by a poor connection rubbed through wire insulation or a bro ken wire inside the insulation D A fault main relay will cause a no start condition There will be no voltage supplied to the EI system ig...

Page 137: ...ht connected to the ground probe the main relay terminals 85 and 30 Is the light on at both terminals Go to Step 8 Go to Step 5 5 1 Turn the ignition OFF 2 Check engine fuse block fuse EF19 Is one or both fuse blown Go to Step 6 Go to Step 7 6 1 Repair short circuit between terminal 87 of main relay and heated oxygen sensor 2 Replace fuse EF19 Is the repair complete System OK 7 Repair open circuit...

Page 138: ...o voltage output The Engine Control Module ECM send a 5 volt reference voltage to the MAP sensor As the in take manifold pressure changes the output voltage of MAP sensor also changes A low voltage high vacuum output of 1 to 1 5 volts is present at idle A high voltage low vacuum output of 4 5 to 5 0 volts is present at wide open throttle The MAP sensor is also used under cer tain conditions to mea...

Page 139: ...Step 5 2 1 Turn the ignition OFF 2 Connect a scan tool to the DLC 3 Disconnect the MAP sensor vacuum line 4 Connect a hand vacuum pump to the Map sensor 5 Turn the ignition ON 6 Note the MAP sensor voltage 7 Apply 34kPa 10 in Hg of vacuum to the Map sensor and note the voltage change Is the difference in voltage readings more than the value specified 1 5 V System OK Go to Step 3 3 Inspect the MAP ...

Page 140: ... above 950 rpm locate and repair the vacuum leak Also check for a binding throttle plate or throttle linkage or an incorrect base idle setting Idle Air Control Valve Reset Procedure Whenever the battery cable or the Engine Control Mod ule ECM connector or the ECM fuse EF6 is discon nected or replaced the following idle learn procedure must be performed 1 Turn the ignition ON for 5 seconds 2 Turn t...

Page 141: ...lve Is the repair complete System OK 6 1 Disconnect the Engine control Module ECM connector 2 Check for an open or short in the wires between following terminals D Terminal A of IAC valve connector and terminal 70 of ECM connector D Terminal B of IAC valve connector and terminal 71 of ECM connector D Terminal C of IAC valve connector and terminal 42 of ECM connector D Terminal D of IAC valve conne...

Page 142: ...1F 44 ENGINE CONTROLS DAEWOO M 150 BL2 MAA1F080 IGNITION SYSTEM CHECK ...

Page 143: ...res while cranking the engine Is spark present from all of the ignition wires System OK Go to Step 3 3 1 Measure the resistance of the ignition wires 2 Replace any ignition wire s with a resistance above the value specified 3 Check for the presence of spark from all of the ignition wires Is spark present from all of the ignition wires 30000 Ω System OK Go to Step 4 4 Is spark present from at least...

Page 144: ...tance within the value specified 400 600 Ω Go to Step 14 Go to Step 13 13 Replace the crankshaft position sensor Is the repair complete System OK 14 1 Turn the ignition ON 2 Measure the voltage between the CKP sensor connector terminals 1 and 3 Is the voltage within the value specified 0 95 1 10 V Go to Step 20 Go to Step 15 15 Measure the voltage between the CKP sensor connector terminal 1 and gr...

Page 145: ... Is the repair complete System OK 24 1 Turn the ignition OFF 2 Connect a test light between the EI system ignition coil connector terminal 2 and ground 3 Turn the ignition ON Is the test light on Go to Step 27 Go to Step 25 25 Check for an open in the wiring between the EI system ignition coil connector terminal 1 and the main relay connector terminal 87 Is the problem found Go to Step 26 Go to Ma...

Page 146: ...is results in high speed cooling fan operation Diagnostic Aids D If the owner complained of an overheating problem it must be determined if the complaint was due to an actual boil over or the engine coolant temperature gauge indicated overheating If the engine is over heating and the cooling fans are on the cooling sys tem should be checked D If the engine fuse block fuse EF15 become open blown im...

Page 147: ...gine 3 Turn the A C switch ON Does the cooling fan runs at low speed Go to Step 7 Go to Step 6 6 1 Diagnose the A C compressor clutch circuit 2 Repair the A C compressor clutch circuit as needed Is the repair complete System OK 7 1 Turn the ignition OFF 2 Start the engine 3 Turn the A C switch ON and raise the rpm 4 The cooling fan should run at high speed when the high side A C pressure reaches 2...

Page 148: ... Turn the ignition OFF 2 Disconnect Engine Control Module ECM connectors 3 Turn the ignition ON 4 Connect a jump wire between terminal 5 and ground Does the cooling fan run at low speed Go to Step 15 Go to Step 16 15 Replace the ECM Is the repair complete System OK 16 1 Turn the ignition OFF 2 Measure the resistance between following terminals D Terminal 85 of low speed cooling fan relay and termi...

Page 149: ...ENGINE CONTROLS 1F 51 DAEWOO M 150 BL2 BLANK ...

Page 150: ...e EBCM the Sup plemental Inflatable Restraint SIR system and the In strument Panel Cluster Diagnostic Aids Ensure that the correct application model line car year etc has been selected on the scan tool If communica tion still cannot be established try the scan tool on another vehicle to ensure that the scan tool or cables are not the cause of the condition An intermittent may be caused by a poor c...

Page 151: ...s the scan tool power up Go to Step 8 Go to Step 7 7 Check for damages in the terminal of DLC and scan tool and repair as needed Is the repair complete Go to Step 8 8 Using a scan tool request engine data of Engine Control Module ECM Does the scan tool display any data Go to Step 12 Go to Step 9 9 Install the scan tool on another vehicle and check for proper operation Does the scan tool work prope...

Page 152: ... 2 The fuel pump should run about 2 seconds after the ignition is turned to the ON position 3 Insert a clear tube attached to the vent valve of the fuel pressure gauge into a suitable container 4 Bleed the air from the fuel pressure gauge and hose until all of the air is bled from the fuel pressure gauge 5 The ignition switch must be in the OFF position at least 10 seconds in order to complete the...

Page 153: ...108 Manifold Absolute Pressure Sensor High voltage A YES P0112 Intake Air Temperature Sensor Low Voltage E YES P0113 Intake Air Temperature Sensor High voltage E YES P0117 Engine Coolant Temperature Sensor Low Voltage A YES P0118 Engine Coolant Temperature Sensor High voltage A YES P0122 Throttle Position Sensor Low Voltage A YES P0123 Throttle Position Sensor Hig voltage A YES P0131 Oxygen Sensor...

Page 154: ...ow Efficiency E YES P0444 EVAP Purge Control Circuit No Signal E YES P0445 EVAP Purge Control Circuit Fault E YES P0462 Fuel Level Sensor Low Voltage Cnl NO P0463 Fuel Level Sensor High voltage Cnl NO P0480 Low Speed Cooling Fan Relay Circuit Fault Without A C Cnl NO P0480 Low Speed Cooling Fan Relay Circuit Fault With A C Cnl NO P0481 High Speed Cooling Fan Relay High Voltage Without A C Cnl NO P...

Page 155: ...NTROLS 1F 57 DAEWOO M 150 BL2 Diagnostic Trouble Codes Cont d DTC Function Error Type Illuminate MIL P1660 Malfunction Indicator Lamp MIL High Voltage E YES P1661 Malfunction Indicator Lamp MIL Low Voltage E YES ...

Page 156: ...art load D The engine revolution speed is less than 4 000rpm D No Throttle Position TP Sensor fails conditions present D The Throttle Position TP angle greather than 20 0 D The MAP is less than 15 kPA An open or low voltage condition exists Action Taken when the DTC Sets D The Malfunction Indicator Lamp MIL will illuminate D The ECM will record operating conditions at the time the diagnostic fails...

Page 157: ... switch to LOCK 2 Disconnect the MAP sensor connector 3 Turn the ignition switch to ON 4 Measure the voltage between the MAP sensor connector terminals A and C Does the voltage measure within the value specified 4 5 5 0V Go to Step 5 Go to Step 6 5 Connect a fused jumper between the MAP sensor connector terminals B and C Does the scan tool show the MAP sensor voltage above the value specified 4V G...

Page 158: ...orm the diagnostic system check Is the repair complete System OK 11 1 Replace the manifold absolute pressure sensor 2 Clear any DTCs from the ECM 3 Perform the diagnostic system check Is the replacement complete System OK 12 Replace the ECM Is the replacement complete Go to Step 13 Go to Step 2 13 Check if any additional DTCs are set Are any DTCs displaced that have not been diagnosed Go to applic...

Page 159: ...ENGINE CONTROLS 1F 61 DAEWOO M 150 BL2 BLANK ...

Page 160: ...n the DTC Sets D The Malfunction Indicator Lamp MIL will illuminate D The ECM will record operating conditions at the time the diagnostic fails This information will be stored in the Freeze Frame and Failure Records buffers D A history DTC is stored D The ECM will substitutes a fixed MAP value and use TP to control the fuel delivery the scan tool will not show defaulted Conditions for Clearing the...

Page 161: ... Go to Step 5 Go to Step 6 5 Connect a fused jumper between the MAP sensor connector terminals B and C Does the scan tool show the MAP sensor voltage above the value specified 4V Go to Step 11 Go to Step 9 6 Measure the voltage between the MAP sensor connector terminal A and ground Does the voltage measure within the value specified 4 5 5 0V Go to Step 7 Go to Step 8 7 1 Turn the ignition switch t...

Page 162: ...he manifold absolute pressure sensor 2 Clear any DTCs from the ECM 3 Perform the diagnostic system check Is the replacement complete System OK 12 Replace the ECM Is the replacement complete Go to Step 13 Go to Step 2 13 Check if any additional DTCs are set Are any DTCs displaced that have not been diagnosed Go to applicable DTC table System OK ...

Page 163: ...ENGINE CONTROLS 1F 65 DAEWOO M 150 BL2 BLANK ...

Page 164: ...MIL on if failure is detected in three consecutive trips D Stores a History DTC on the third consecutive with a fail The DTC will be armed after the second fail D Stores a Freeze Frame on the third consecutive trip with a fail if empty D The ECM will default to 60 C 140 F for intake air temperature The scan tool will not show the de faulted value Conditions for Clearing the MIL DTC D The MIL will ...

Page 165: ...terminal 1 and the ECM connector terminal 79 Is the problem found Go to Step 7 Go to Step 6 6 Check for wire for a short to ECM reference voltage between the IAT sensor connector terminal 2 and the ECM connector terminal 47 Is the problem found 4 5 5 0V Go to Step 7 Go to Step 9 7 1 Turn the ignition switch to LOCK 2 Repair the wire or the connector terminal as needed 3 Clear any DTCs from the ECM...

Page 166: ...MIL on if failure is detected in three consecutive trips D Stores a History DTC on the third consecutive with a fail The DTC will be armed after the second fail D Stores a Freeze Frame on the third consecutive trip with a fail if empty D The ECM will default to last valid value for intake air temperature The scan tool will not show the de faulted value Conditions for Clearing the MIL DTC D The MIL...

Page 167: ...ls 1 and 2 of IAT sensor connector Does the voltage measure within the value specified 4 5 5 5V Go to Step 11 Go to Step 6 6 Measure the voltage between the IAT sensor connector terminal 2 and the battery ground negative post Does the voltage measure within the value specified 4 5 5 5V Go to Step 7 Go to Step 8 7 1 Turn the ignition switch to LOCK 2 Check for an open or short to battery voltage in...

Page 168: ...nsor High Voltage Cont d Step Action Value s Yes No 11 1 Replace the ECM 2 Perform the diagnostic system check Is the repair complete Go to Step 12 12 Check if any additional DTCs are set Are any DTCs displaced that have not been diagnosed Go to applicable DTC table System OK ...

Page 169: ...ENGINE CONTROLS 1F 71 DAEWOO M 150 BL2 BLANK ...

Page 170: ... greater than 3 seconds D A low voltage condition exits D ECT voltage is less than 0 03V Action Taken when the DTC Sets D The Malfunction Indicator Lamp MIL will illuminate D The ECM will record operating conditions at the time the diagnostic fails This information will be stored in the Freeze Frame and Failure Records buffers D A history DTC is stored D The coolant fan turns ON D The ECM will def...

Page 171: ...d 120 C Go to Step 5 Go to Step 6 5 1 Replace the ECT sensor 2 Clear any DTCs from the ECM 3 Perform the diagnostic system check Is the replacement complete System OK 6 Measure the voltage between ECT terminal A and ground Does the voltage measure within the value specified 4 5 5 0V Go to Step 7 Go to Step 8 7 1 Turn the ignition switch to LOCK 2 Disconnect the ECM wiring connector 3 Check for a f...

Page 172: ...seconds D The ECT sensor indicates that the engine coolant temperature is less than 40 C 40 F D ECT voltage is greater than 4 98V D A low voltage condition exits Action Taken when the DTC Sets D The Malfunction Indicator Lamp MIL will illuminate D The ECM will record operating conditions at the time the diagnostic fails This information will be stored in the Freeze Frame and Failure Records buffer...

Page 173: ...Step 5 Go to Step 6 5 1 Replace the ECT sensor 2 Clear any DTCs from the ECM 3 Perform the diagnostic system check Is the replacement complete System OK 6 Measure the voltage between ECT terminal B and ground Does the voltage measure within the value specified 4 5 5 0V Go to Step 7 Go to Step 8 7 1 Turn the ignition switch to LOCK 2 Disconnect the ECM wiring connector 3 Check for a faulty connecto...

Page 174: ...The Malfunction Indicator Lamp MIL will illuminate D The ECM will record operating conditions at the time the diagnostic fails This information will be stored in the Freeze Frame and Failure Records buffers D A history DTC is stored D The TP angle will default to 0 when the vehicle speed is less than 3 km h 2 mph and 10 when the vehicle speed is greater than 3 km h 2 mph The scan tool will not dis...

Page 175: ...TP sensor voltage over the specified value 4 0 V Go to Step 10 Go to Step 5 5 Connect a test light between B and the TP sensor signal circuit terminal C Is the TP sensor voltage greater than the specified value 4 0 V Go to Step 6 Go to Step 8 6 Check the TP sensor 5 volt reference circuit for an open or short to ground and repair as needed Is the repair complete Go to Step 12 Go to Step 7 7 Check ...

Page 176: ... 2 Start the engine and idle at normal operating temperature 3 Operate the vehicle within the Conditions for setting this DTC as specified in the supporting text Does the scan tool indicate that this diagnostic has run and passed Go to Step 13 Go to Step 2 13 Check if any additional DTCs are set Are any DTCs displayed that have not been diagnosed Go to Applicable DTC Table System OK ...

Page 177: ...ENGINE CONTROLS 1F 79 DAEWOO M 150 BL2 BLANK ...

Page 178: ...ails This information will be stored in the Freeze Frame and Failure Records buffers D A history DTC is stored D The TP angle will default to 0 when the vehicle speed is less than 3 km h 2 mph and 10 when the vehicle speed is greater than 3 km h 2 mph The scan tool will not display the default value Conditions for Clearing the MIL DTC D The MIL will turn off after four consecutive ignition cycles ...

Page 179: ...P sensor connector with a test light connected to B Does the test light illuminate Go to Step 7 Go to Step 9 6 Check the TP sensor signal circuit for an short to voltage and repair as needed Is the repair complete Go to Step 12 Go to Step 11 7 Check the 5 volt reference circuit for a short to B and repair as needed Is the repair complete Go to Step 12 Go to Step 8 8 Check the TP sensor electric co...

Page 180: ...EWOO M 150 BL2 DTC P0123 Throttle Position Sensor High Voltage Cont d Step Action Value s Yes No 13 Check if any additional DTCs are set Are any DTCs displayed that have not been diagnosed Go to Applicable DTC Table System OK ...

Page 181: ...ENGINE CONTROLS 1F 83 DAEWOO M 150 BL2 BLANK ...

Page 182: ...on Taken when the DTC Sets D The Malfunction Indicator Lamp MIL will illuminate D The ECM will record operating conditions at the time the diagnostic fails This information will be stored in the Freeze Frame and Failure Records buffers D A history DTC is stored Conditions for Clearing the MIL DTC D The MIL will turn off after four consecutive ignition cycles in which the diagnostic runs without a ...

Page 183: ... sensor signal voltage between the valve specified 0 15 0 7V Go To Diagnostic Aids Go to Step 6 6 1 Turn the ignition switch to LOCK 2 Check the Oxygen sensor wire between the Oxygen sensor and the ECM connector terminal 77 and 13 is open Is the problem found Go to Step 8 Go to Step 11 7 1 Turn the ignition switch to LOCK 2 Check the Oxygen sensor wire between the Oxygen sensor and the ECM connect...

Page 184: ...OLS DAEWOO M 150 BL2 DTC P0131 Oxygen Sensor Low Voltage Cont d Step Action Value s Yes No 12 Check if any additional DTCs are set Are any DTCs displaced that have not been diagnosed Go to applicable DTC table System OK ...

Page 185: ...ENGINE CONTROLS 1F 87 DAEWOO M 150 BL2 BLANK ...

Page 186: ...ls This information will be stored in the Freeze Frame and Records buffers D A history DTC is stored Conditions for Clearing the MIL DTC D The MIL will turn off after consecutive ignition cycles in which the diagnostic runs without a fault D A history DTC will clear after 40 consecutive warm up cycles without a fault D DTC s can be cleared by using the scan tool D Disconnecting the ECM battery fee...

Page 187: ...le ECM connector 3 Check the O2 sensor wire between the O2 sensor and ECM connector terminal 13 for short to battery voltage Is the problem found Go to Step 4 Go to Step 5 4 1 Repair the wire of the connector terminal as needed 2 Clear the DTCs from the ECM 3 Road tests the vehicle 4 Perform the diagnostic system check Is the repair complete System OK 5 1 Turn the ignition switch to LOCK 2 Replace...

Page 188: ...kPa D The ignition is at 10 volts D The upstream O2 sensor periods higher than 1 6 sec onds D A number of glitches higher than 5 during the test D DTCs P0107 P0108 P0112 P0113 P0117 P0118 P0122 P0123 P0131 P0132 P0131 P0132 P0137 P0138 P1671 P0300 P0335 P0336 P0341 P0400 P0404 P0405 P0444 P0445 are NOT SET Action Taken when the DTC Sets D Emission related D Armed after two trip with a fail D Disar...

Page 189: ...o Step 5 Go to Step 8 5 Check the oxygen sensorconnector for malfunction terminals or poor connection and repair as necessary Is repair necessary Go to Step 12 Go to Step 6 6 1 Run the engine at idle 2 Remove the jumper wire 3 Measure the voltage between the oxygen sensor connector terminal 2 and ground Does the oxygen sensor voltage measure above the specified value 0 6V Go to Step 7 Go to Step 1...

Page 190: ...es No 11 Replace the O2 sensor Is the repair complete Go to Step 12 12 1 Clear any DTCs from the ECM 2 Perform the diagnostic system check Is the repair complete Go to Step 13 13 Check if any additional DTCs are set Are any DTCs displaced that have not been diagnosed Go to applicable DTC table System OK ...

Page 191: ...ENGINE CONTROLS 1F 93 DAEWOO M 150 BL2 BLANK ...

Page 192: ... DTC Sets D Emission related D Armed after two trip with a fail D Disarmed after one trip with a pass D MIL on if failure is detected in three consecutive trips D Stores a History DTC on the third consecutive with a fail The DTC will be armed after the second fail D Stores a Freeze Frame on the third consecutive trip with a fail if empty Conditions for Clearing the MIL DTC D The MIL will turn off ...

Page 193: ...erminal 35 for short to ground Is the problem found Go to Step 5 Go to Step 6 5 1 Repair the wire of the connector terminal as needed 2 Clear the DTCs from the ECM 3 Road tests the vehicle 4 Perform the diagnostic system check Is the repair complete System OK 6 1 Turn the ignition switch to LOCK 2 Disconnect the Heated O2 sensor connector and engine control module ECM connector 3 Check the O2 sens...

Page 194: ... DAEWOO M 150 BL2 DTC P0137 Heated Oxygen Sensor Low Voltage Cont d Step Action Value s Yes No 10 Check if any additional DTCs are set Are any DTCs displaced that have not been diagnosed Go to applicable DTC table System OK ...

Page 195: ...ENGINE CONTROLS 1F 97 DAEWOO M 150 BL2 BLANK ...

Page 196: ...rips D Stores a History DTC on the third consecutive with a fail The DTC will be armed after the second fail D Stores a Freeze Frame on the third consecutive trip with a fail if empty Conditions for Clearing the MIL DTC D The MIL will turn off after four consecutive ignition cycles in which the diagnostic runs without a fault D A history DTC will clear after 40 consecutive warm up cycles without a...

Page 197: ...eck the Heated O2 sensor wire between the Heated O2 sensor connector terminal 4 and ECM connector terminal 35 for an open or short to battery voltage Is the problem found Go to Step 4 Go to Step 5 4 1 Repair the wire of the connector terminal as needed 2 Clear the DTCs from the ECM 3 Road tests the vehicle 4 Perform the diagnostic system check Is the repair complete System OK 5 1 Turn the ignition...

Page 198: ... transition from rich side to lean side or lean side to rich side during 7 8 seconds even with a forcing of O2 sensor controller D DTCs P0107 P0108 P0112 P0113 P0117 P0118 P0122 P0123 P0137 P0138 P0137 P0138 P0137 P0138 P1671 P0300 P0335 P0336 P0341 P0400 P0404 P0405 P0644 P0645 are NOT SET Action Taken when the DTC Sets D Emission related D Armed after two trip with a fail D Disarmed after one tr...

Page 199: ...tep 5 Go to Step 6 5 Check the Heated O2 sensor connector for malfunction terminals or poor connection and repair as necessary Is repair necessary Go to Step 12 Go to Step 9 6 1 Turn the ignition switch to On 2 Remove the jumper wire 3 Using a digital voltmeter DVM measure the voltage between the Heated O2 sensor signal circuit terminal 3 to ground Does the Heated O2 sensor voltage measure above t...

Page 200: ...oad tests the vehicle 4 Perform the diagnostic system check Is the replacement complete Go to Step 15 12 1 Turn the ignition switch to LOCK 2 Replace the ECM 3 Road tests the vehicle 4 Perform the diagnostic system check Is the replacement complete Go to Step 15 13 Check if any additional DTCs are set Are any DTCs displaced that have not been diagnosed Go to applicable DTC table System OK ...

Page 201: ...ENGINE CONTROLS 1F 103 DAEWOO M 150 BL2 BLANK ...

Page 202: ...consecutive trips D Stores a History DTC on the third consecutive with a fail The DTC will be armed after the second fail D Stores a Freeze Frame on the third consecutive trip with a fail if empty Conditions for Clearing the MIL DTC D The MIL will turn off after four consecutive ignition cycles in which the diagnostic runs without a fault D A history DTC will clear after 40 consecutive warm up cyc...

Page 203: ... Heated O2 sensor connector terminal 4 and ECM connector terminal 35 for an open or short to ground Is the problem found Go to Step 3 Go to Step 4 3 1 Repair the wire of the connector terminal as needed 2 Clear the DTCs from the ECM 3 Road tests the vehicle 4 Perform the diagnostic system check Is the repair complete System OK 4 1 Turn the ignition switch to LOCK 2 Replace the Heated O2 sensor 3 R...

Page 204: ...with a fail D Disarmed after one trip with a pass D MIL on if failure is detected in three consecutive trips D Stores a History DTC on the third consecutive with a fail The DTC will be armed after the second fail D Stores a Freeze Frame on the third consecutive trip with a fail if empty Conditions for Clearing the MIL DTC D The MIL will turn off after four consecutive ignition cycles in which the ...

Page 205: ... 5 5 Visually physically check the following items D Vacuum hoses for splits kinks and improper connections D Crankcase ventilation oil air separator for proper installation D Exhaust system for corrosion leaks loose or missing hardware D Oxygen sensor O2S is installed securely and the pigtail harness is not contacting exhaust manifold or engine D Fuel for excessive water alcohol or other contamin...

Page 206: ...pump will run for approximately 2 3 seconds It may be necessary to cycle the ignition switch ON more than once to obtain maximum fuel pressure 4 Note the fuel pressure with the fuel pump running The pressure should be within the specified value When the fuel pump stops the pressure may vary slightly then hold steady Is the fuel pressure steady and does the fuel pressure hold 380 KPa 55 psi Go to S...

Page 207: ...oolant temperature is between 80 C 176 F and 115 C 239 F D Manifold Absolute Pressure MAP is more than 70 kPa 10 2 psi D System is in closed loop D Adaptive index is ready Action Taken when the DTC Sets D Emission related D Armed after two trip with a fail D Disarmed after one trip with a pass D MIL on if failure is detected in three consecutive trips D Stores a History DTC on the third consecutiv...

Page 208: ...essive dirt or being plugged and repair as needed Is the repair complete Go to Step 21 Go to Step 6 6 Visually physically check the air intake system for collapsed or restricted and repair as needed Is the repair complete Go to Step 21 Go to Step 7 7 Inspect the throttle body inlet for damaged or foreign objects which may partially block the airflow and repair as needed Is the repair complete Go t...

Page 209: ...the Fuel System Diagnosis 2 If the table isolate a problem repair as needed Is the repair complete Go to Step 21 Go to Step 16 16 1 Perform the Evaporative Emission EVAP Control System Diagnosis 2 If the table isolate a problem repair as needed Is the repair complete Go to Step 21 Go to Step 17 17 1 Perform the Fuel Injector balance Test 2 If the table isolate a problem repair as needed Is the rep...

Page 210: ...art the engine and idle at normal operating temperature 3 Operate the vehicle within the Conditions for setting this DTC as specified in the supporting text Does the scan tool indicate that this diagnostic has run and passed Go to Step 21 Go to Step 2 22 Check if any additional DTCs are set Are any DTCs displayed that have not been diagnosed Go to applicable DTC table System OK ...

Page 211: ...ENGINE CONTROLS 1F 113 DAEWOO M 150 BL2 BLANK ...

Page 212: ...c fails This information will be stored in the Freeze Frame and Records buffers D A history DTC is stored D Coolant fan turns ON Conditions for Clearing the MIL DTC D The MIL will turn off after 4 consecutive ignition cycles in which the diagnostic runs without a fault D A history DTC will clear after 40 consecutive warm up cycles without a fault D DTC s can be cleared by using the scan tool Diagn...

Page 213: ...urn the ignition switch to LOCK 2 Connect a test light between the fuel pump relay connector terminal 30 and ground Is the test light ON Go to Step 6 Go to Step 8 6 Check for short to ground in the wire between the fuel pump relay connector terminal 87 and fuel pump connector Is the problem found Go to Step 7 Go to Step 8 7 1 Repair the wire between the fuel pump relay connector terminal 87 and fu...

Page 214: ...ition OFF for 10 seconds 4 Clear any DTCs from ECM 5 Turn the ignition switch to ON Does the fuel pump operate 2 55 seconds System OK Go to Step 13 13 1 Replace the ECM 2 Turn the ignition OFF for 10 seconds 3 Clear any DTCs from ECM 4 Turn the ignition switch to ON Does the fuel pump operate 2 55 seconds System OK Go to Step 14 14 1 Using the scan tool clear the DTCs 2 Start the engine and idle a...

Page 215: ...ENGINE CONTROLS 1F 117 DAEWOO M 150 BL2 BLANK ...

Page 216: ...be stored in the Freeze Frame and Records buffers D A history DTC is stored D Coolant fan turns ON Conditions for Clearing the MIL DTC D The MIL will turn off after 4 consecutive ignition cycles in which the diagnostic runs without a fault D A history DTC will clear after 40 consecutive warm up cycles without a fault D DTC s can be cleared by using the scan tool D Disconnecting the ECM battery fee...

Page 217: ...5 1 Replace the fuel pump relay 2 Turn the ignition OFF for 10 seconds 3 Clear any DTCs from ECM 4 Turn the Turn the ignition switch to ON Does the fuel pump operate 2 55 seconds Go to Step 11 Go to Step 6 6 Check for short to battery voltage wire between the fuel pump relay connector terminal 66 and the ignition after key ON 1 IGN 1 Is the problem found Go to Step 8 Go to Step 7 7 Check for an op...

Page 218: ...2 55 seconds System OK Go to Step 11 11 1 Using the scan tool clear the DTCs 2 Start the engine and idle at normal operating temperature 3 Operate the vehicle within the conditions for setting this DTC ad specified in the supporting text Does the scan tool indicate that this diagnostic has run and passed Go to Step 12 Go to Step 2 12 Check if any additional DTCs are set Are any DTCs displayed that...

Page 219: ...ENGINE CONTROLS 1F 121 DAEWOO M 150 BL2 BLANK ...

Page 220: ...bove conditions are met for 5seconds Action Taken when the DTC Sets D The Malfunction Indicator Lamp MIL will illuminate D The ECM will record operating conditions at the time the diagnostic fails This information will be stored in the Freeze Frame and Records buffers D A history DTC is stored Conditions for Clearing the MIL DTC D The MIL will turn off after 4 consecutive ignition cycles in which ...

Page 221: ...to LOCK 2 Check for short to ground in the wire between the injector 1 connector terminal 1 and ECM connector terminal 90 Is the problem found Go to Step 7 Go to Step 6 6 1 Turn the ignition switch to LOCK 2 Check for short to ground in the wire between the injector 1 connector terminal 2 and battery positive Is the problem found Go to Step 7 Go to Step 8 7 1 Repair the wire or the connector termi...

Page 222: ...above conditions are met for 5seconds Action Taken when the DTC Sets D The Malfunction Indicator Lamp MIL will illuminate D The ECM will record operating conditions at the time the diagnostic fails This information will be stored in the Freeze Frame and Records buffers D A history DTC is stored Conditions for Clearing the MIL DTC D The MIL will turn off after 4 consecutive ignition cycles in which...

Page 223: ...k for an open or short to battery voltage in the wire between the injector 1 connector terminal 1 and ECM connector terminal 90 Is the problem found Go to Step 7 Go to Step 6 6 1 Turn the ignition switch to Lock 2 Check for short to battery voltage in the wire between the injector 1 connector terminal 2 and battery positive Is the problem found Go to Step 7 Go to Step 8 7 1 Repair the wire or the ...

Page 224: ...bove conditions are met for 5 seconds Action Taken when the DTC Sets D The Malfunction Indicator Lamp MIL will illuminate D The ECM will record operating conditions at the time the diagnostic fails This information will be stored in the Freeze Frame and Records buffers D A history DTC is stored Conditions for Clearing the MIL DTC D The MIL will turn off after 4 consecutive ignition cycles in which...

Page 225: ...to LOCK 2 Check for short to ground in the wire between the injector 2 connector terminal 1 and ECM connector terminal 58 Is the problem found Go to Step 7 Go to Step 6 6 1 Turn the ignition switch to LOCK 2 Check for short to ground in the wire between the injector 2 connector terminal 2 and battery positive Is the problem found Go to Step 7 Go to Step 8 7 1 Repair the wire or the connector termi...

Page 226: ...bove conditions are met for 5 seconds Action Taken when the DTC Sets D The Malfunction Indicator Lamp MIL will illuminate D The ECM will record operating conditions at the time the diagnostic fails This information will be stored in the Freeze Frame and Records buffers D A history DTC is stored Conditions for Clearing the MIL DTC D The MIL will turn off after 4 consecutive ignition cycles in which...

Page 227: ...k for an open or short to battery voltage in the wire between the injector 2 connector terminal 2 and ECM connector terminal 58 Is the problem found Go to Step 7 Go to Step 6 6 1 Turn the ignition switch to Lock 2 Check for short to battery voltage in the wire between the injector 2 connector terminal 2 and battery positive Is the problem found Go to Step 7 Go to Step 8 7 1 Repair the wire or the ...

Page 228: ...ove conditions are met for 5 seconds Action Taken when the DTC Sets D The Malfunction Indicator Lamp MIL will illuminate D The ECM will record operating conditions at the time the diagnostic fails This information will be stored in the Freeze Frame and Records buffers D A history DTC is stored Conditions for Clearing the MIL DTC D The MIL will turn off after 4 consecutive ignition cycles in which ...

Page 229: ...to LOCK 2 Check for short to ground in the wire between the injector 3 connector terminal 1 and ECM connector terminal 89 Is the problem found Go to Step 7 Go to Step 6 6 1 Turn the ignition switch to LOCK 2 Check for short to ground in the wire between the injector 3 connector terminal 2 and battery positive Is the problem found Go to Step 7 Go to Step 8 7 1 Repair the wire or the connector termi...

Page 230: ...ector is commanded ON D The battery voltage is more than 16 volts D The above conditions are met for 5 seconds Action Taken when the DTC Sets D The Malfunction Indicator Lamp MIL will illuminate D The ECM will record operating conditions at the time the diagnostic fails This information will be stored in the Freeze Frame and Records buffers D A history DTC is stored Conditions for Clearing the MIL...

Page 231: ...es DTC P0268 reset Go to Step 5 Go to Diagnostic Aids 5 1 Turn the ignition switch to Lock 2 Check for an open or short to battery voltage in the wire between the injector 3 connector terminal 1 and ECM connector terminal 89 Is the problem found Go to Step 7 Go to Step 6 6 1 Turn the ignition switch to Lock 2 Check for short to battery voltage in the wire between the injector 3 connector terminal ...

Page 232: ...1F 134 ENGINE CONTROLS DAEWOO M 150 BL2 MAA1F160 ...

Page 233: ...lts D Engine Coolant Temperature ECT is between 7 C 20 F and 120 C 248 F D The engine speed is less than or equal to 1800 rpm or the crank angle sensing error has not been learned D There is the correct ratio between Crankshaft Posi tion CKP sensor pulses and CMP sensor pulses D DTCs P0106 P0107 P0108 P0117 P0118 P0122 P0123 P0320 P0337 P0341 P0342 and P0502 are not set Action Taken when the DTC S...

Page 234: ... 1 spark plug cable 4 Crank the engine and check for spark 5 Repeat the above procedure on cylinders 2 3 Is a spark observed on all four spark plug cables Go to Step 12 Go to Step 20 12 Replace any malfunctioning spark plugs if necessary Is the repair complete Go to Step 27 Go to Step 13 13 1 Turn the engine OFF 2 Disconnect the fuel injector connectors from the injectors 3 Install an injector tes...

Page 235: ...23 22 Check the affected cylinders ignition control circuit for an open or short and repair as necessary Is the repair complete Go to Step 27 Go to Step 26 23 Repair the connector or connections Is the repair complete Go to Step 27 24 1 Turn the ignition OFF 2 Replace the ECM Is the repair complete Go to Step 27 25 Replace the spark plug cable Is the repair complete Go to Step 27 26 Replace the fa...

Page 236: ...1F 138 ENGINE CONTROLS DAEWOO M 150 BL2 MAA1F160 ...

Page 237: ...eater than 10 km h 6 mph D Engine speed is between 600 and 4500 rpm D Vehicle voltage is between 11 and 16 volts D Engine Coolant Temperature ECT is between 7 C 20 F and 120 C 248 F D The engine speed is less than or equal to 1800 rpm or the crank angle sensing error has not been learned D There is the correct ratio between Crankshaft Posi tion CKP sensor pulses and CMP sensor pulses D DTCs P0106 ...

Page 238: ...tep 10 9 Check for a basic engine problem and repair as necessary Is the repair complete Go to Step 27 10 Replace the contaminated fuel Is the repair complete Go to Step 27 11 1 Turn the engine OFF 2 Disconnect the fuel injector harness connector 3 Install a spark tester on cylinder 1 spark plug cable 4 Crank the engine and check for spark 5 Repeat the above procedure on cylinders 2 3 Is a spark o...

Page 239: ...tep 25 21 Inspect the Engine Control Module ECM connector and connections Are the connections OK Go to Step 22 Go to Step 23 22 Check the affected cylinders ignition control circuit for an open or short and repair as necessary Is the repair complete Go to Step 27 Go to Step 26 23 Repair the connector or connections Is the repair complete Go to Step 27 24 1 Turn the ignition OFF 2 Replace the ECM I...

Page 240: ...mation will be stored in the Freeze Frame and Failure Records buffers D A history DTC is stored Conditions for Clearing the MIL DTC D The MIL will turn off after four consecutive ignition cycles in which the diagnostic runs without a fault D A history DTC will clear after 40 consecutive warm up cycles without a fault D DTC s can be cleared by using the scan tool Diagnostic Aids An intermittent may...

Page 241: ... Start the engine and idle for 1 minute Is DTC P1320 set Go to Step 4 Go to Diagnostic Aids 4 1 Remove the crankshaft 2 Check for a problem with the crahkshaft s visual defection and tooth Is a problem found Go to Step 5 Go to Step 6 5 Replace the crankshaft Is the replacement complete System OK 6 1 Turn the ignition OFF 2 Replace the ECM Is the repair complete Go to Step 7 7 1 Using the scan tool...

Page 242: ...me and Failure Records buffers D A history DTC is stored Conditions for Clearing the MIL DTC D The MIL will turn off after four consecutive ignition cycles in which the diagnostic runs without a fault D A history DTC will clear after 40 consecutive warm up cycles without a fault D DTC s can be cleared by using the scan tool D Disconnecting the ECM battery feed for more than 10 seconds Diagnostic A...

Page 243: ...he engine and idle for 1 minute Is DTC P1321 set Go to Step 4 Go to Diagnostic Aids 4 1 Remove the crankshaft 2 Check for a problem with the crahkshaft s visual defection and tooth Is a problem found Go to Step 5 Go to Step 6 5 Replace the crankshaft Is the replacement complete System OK 6 1 Turn the ignition OFF 2 Replace the ECM Is the repair complete Go to Step 7 7 1 Using the scan tool clear t...

Page 244: ...channel voltage level is being ex perienced a DTC P0327 will set Conditions for Setting the DTC D Knock sensor SPI bus in failure during 7 seconds D The knock sensor voltage is below 0 2V D Engine Coolant Temperature is higher than 80 C 176 F D Engine rpm is more than 2 500rpm D Mass air flow is higer than 180mg tdc Action Taken When The DTCs Sets D The Malfunction Indicator Lamp MIL will illumina...

Page 245: ...or audible noise present Go to Step 5 Go to Step 6 5 Repair the mechanical engine problem or a loose bracket or component Is the repair complete Go to Step 12 6 1 Turn the ignition switch to lock 2 Disconnect the engine control module ECM 3 With a digital voltmeter DVM connected to ground measure the resistance of the knock sensor through the knock sensor signal circuit terminal 50 Is the measured...

Page 246: ...and idle at normal operating temperature D Operate the vehicle within the conditions for setting this DTC as specified in the supporting text Does the scan tool indicate that this diagnostic has run and passed Go to Step 13 Go to Step 2 13 Check if any additional DTCs are set Are any DTCs displayed that have not been diagnosed Go to Applicable DTC table System OK ...

Page 247: ...ENGINE CONTROLS 1F 149 DAEWOO M 150 BL2 BLANK ...

Page 248: ...inate D The ECM will record operating conditions at the time the diagnostic fails This information will be stored in the Freeze Frame and Failure Records buffers D A history DTC is stored Conditions for Clearing the MIL DTC D The MIL will turn off after four consecutive ignition cycles in which the diagnostic runs without a fault D A history DTC will clear after 40 consecutive warm up cycles witho...

Page 249: ...ess connector Is the repair complete Go to Step 11 6 1 Reconnect the ECM and CKP sensor 2 Connect a digital voltmeter DVM to measure voltage on the 58X reference circuit terminal 54 at the ECM connector 3 Observe the voltage while cranking the engine Is the voltage near the specified value 2 5V Go to Step 9 Go to Step 7 7 Check the connection at the CKP sensor and replace the terminals if necessar...

Page 250: ...rs D A history DTC is stored Conditions for Clearing the MIL DTC D The MIL will turn off after four consecutive ignition cycles in which the diagnostic runs without a fault D A history DTC will clear after 40 consecutive warm up cycles without a fault D DTC s can be cleared by using the scan tool D Disconnecting the ECM battery feed for more than 10 seconds DIAGNOSTIC AIDS An intermittent may be c...

Page 251: ...s the repair complete Go to Step 11 6 1 Reconnect the ECM and CKP sensor 2 Connect a digital voltmeter DVM to measure voltage on the 58X reference circuit terminal 54 at the ECM connector 3 Observe the voltage while cranking the engine Is the voltage near the specified value 2 5V Go to Step 9 Go to Step 7 7 Check the connection at the CKP sensor and replace the terminals if necessary Do any termin...

Page 252: ...e Records buffers D A history DTC is stored Conditions for Clearing the MIL DTC D The MIL will turn off after four consecutive ignition cycles in which the diagnostic runs without a fault D A history DTC will clear after 40 consecutive warm up cycles without a fault D DTC s can be cleared by using the scan tool DIAGNOSTIC AIDS An intermittent may be caused by a poor connection rubbed through wire ...

Page 253: ... repair complete Go to Step 11 6 1 Reconnect the ECM and CKP sensor 2 Connect a digital voltmeter DVM to measure voltage on the 58X reference circuit terminal 54 at the ECM connector 3 Observe the voltage while cranking the engine Is the voltage near the specified value 2 5V Go to Step 9 Go to Step 7 7 Check the connection at the CKP sensor and replace the terminals if necessary Do any terminals r...

Page 254: ... The ECM will record operating conditions at the time the diagnostic fails This information will be stored in the Freeze Frame and Failure Records buffers D A history DTC is stored Conditions for Clearing the MIL DTC D The MIL will turn off after four consecutive ignition cycles in which the diagnostic runs without a fault D A history DTC will clear after 40 consecutive warm up cycles without a fa...

Page 255: ... while moving related connectors and wiring harness Is the problem found Go to Step 4 Go to Step 5 4 1 Turn the ignition switch to LOCK 2 Repair or replace the wire or the connector 3 Clear any DTCs from the ECM 4 Run the engine 5 Perform the diagnostic system check Is the repair complete System OK 5 1 Turn the ignition switch to LOCK 2 Replace the CMP sensor 3 Clear any DTCs from the ECM 4 Run th...

Page 256: ...The ECM will record operating conditions at the time the diagnostic fails This information will be stored in the Freeze Frame and Failure Records buffers D A history DTC is stored Conditions for Clearing the MIL DTC D The MIL will turn off after four consecutive ignition cycles in which the diagnostic runs without a fault D A history DTC will clear after 40 consecutive warm up cycles without a fau...

Page 257: ...open while moving related connectors and wiring harness Is the problem found Go to Step 4 Go to Step 5 4 1 Turn the ignition switch to LOCK 2 Repair or replace the wire or the connector 3 Clear any DTCs from the ECM 4 Run the engine 5 Perform the diagnostic system check Is the repair complete System OK 5 1 Turn the ignition switch to LOCK 2 Replace the CMP sensor 3 Clear any DTCs from the ECM 4 Ru...

Page 258: ...he ECM detects a problem in the spark timing 1 circuit it will set DTC P0351 Conditions for Setting the DTC D This DTC can be stored in key on status D Time of fault fall occurrence is greater than time of the DIS fall occurrence D Must receive more than 40 failure within 80 test cycles Action Taken When the DTC Sets D The Malfunction Indicator Lamp MIL will illuminate D The ECM will record operat...

Page 259: ...und Go to Step 8 Go to Step 3 3 Check for a faulty connection or a damaged terminal 31 at the engine control module ECM connector Is the problem found Go to Step 8 Go to Step 4 4 1 Turn the ignition switch to LOCK 2 Disconnect the ECM 3 Check the ignition control circuit for a short to ground Is the problem found Go to Step 8 Go to Step 5 5 Check the ignition control circuit for a short to battery...

Page 260: ...low voltage When the ECM detects a problem in the spark timing 3 circuit it will set DTC P0352 Conditions for Setting the DTC D This DTC can be stored in key on status D Time of fault fall occurrence is greater than time of the DIS fall occurrence D Must receive more than 40 failure within 80 test cycles Action Taken When The DTCs Sets D The Malfunction Indicator Lamp MIL will illuminate D The ECM...

Page 261: ...e ignition coil Is a problem found Go to Step 8 Go to Step 3 3 Check for a faulty connection or a damaged terminal 32 at the engine control module ECM connector Is the problem found Go to Step 8 Go to Step 4 4 1 Turn the ignition switch to LOCK 2 Disconnect the ECM 3 Check the ignition control circuit for a short to ground Is the problem found Go to Step 8 Go to Step 5 5 Check the ignition control...

Page 262: ...low voltage When the ECM detects a problem in the spark timing 3 circuit it will set DTC P0352 Conditions for Setting the DTC D This DTC can be stored in key on status D Time of fault fall occurrence is greater than time of the DIS fall occurrence D Must receive more than 40 failure within 80 test cycles Action Taken When The DTCs Sets D The Malfunction Indicator Lamp MIL will illuminate D The ECM...

Page 263: ...e ignition coil Is a problem found Go to Step 8 Go to Step 3 3 Check for a faulty connection or a damaged terminal 32 at the engine control module ECM connector Is the problem found Go to Step 8 Go to Step 4 4 1 Turn the ignition switch to LOCK 2 Disconnect the ECM 3 Check the ignition control circuit for a short to ground Is the problem found Go to Step 8 Go to Step 5 5 Check the ignition control...

Page 264: ...sor is located in front right wheel Conditions for Setting the DTC D Vehicle speed is higher than 10km h 6 21mph D No Vehicle Speed Sensor error not set D VR sensor output signal is higher than 0 26 D VR sensor output signal is not change for 30seconds Action Taken When The DTCs Sets D The Malfunction Indicator Lamp MIL will not illumi nate D The ECM will store conditions which were present when t...

Page 265: ...rve the VR sensor value displayed on the scan tool Is the VR sensor value near the specified value 0V Go to Step 5 Go to Step 12 5 1 Jumper the 5 volt reference circuit terminal 1 and the VR sensor signal circuit terminal 2 together at the VR sensor harness connector 2 Observe the VR sensor value displayed on the scan tool Is the VR sensor value near the specified value 4 95V Go to Step 6 Go to St...

Page 266: ...Turn the ignition ON 4 Check the VR sensor signal circuit for a short to battery voltage or a short to the 5 volt reference circuit and repair as needed Is the repair complete Go to Step 14 Go to Step 13 13 1 Turn the ignition OFF 2 Replace the ECM Is the repair complete Go to Step 14 14 1 Using the scan tool clear the DTCs 2 Start the engine and idle at normal operating temperature 3 Operate the ...

Page 267: ...ENGINE CONTROLS 1F 169 DAEWOO M 150 BL2 BLANK ...

Page 268: ...ition the ECM misfire detection diagnostic will be de activated Conditions for Setting the DTC D Vehicle speed is higher than 10km h 6 21mph D No Vehicle Speed Sensor error not set D VR sensor output signal is higher than 0 26 D VR sensor output signal is not change for 30seconds Action Taken When the DTC Sets D The Malfunction Indicator Lamp MIL will not illumi nate D The ECM will store condition...

Page 269: ...bserve the wheel speed sensor value displayed on the scan tool Is the Wheel speed sensor value near the specified value 0V Go to Step 5 Go to Step 12 5 1 Jumper the 5 volt reference circuit the Wheel speed sensor signal circuit together at the defected wheel speed sensor harness connector 2 Observe the defected Wheel speed sensor value displayed on the scan tool Is the wheel speed sensor value nea...

Page 270: ... the ECM 3 Turn the ignition ON 4 Check the wheel speed sensor signal circuit for a short to voltage or a short to the 5 volt reference circuit and repair as needed Is the repair complete Go to Step 14 Go to Step 13 13 1 Turn the ignition OFF 2 Replace the ECM Is the repair complete Go to Step 14 14 1 Using the scan tool clear the DTCs 2 Start the engine and idle at normal operating temperature 3 ...

Page 271: ...ENGINE CONTROLS 1F 173 DAEWOO M 150 BL2 BLANK ...

Page 272: ...e de acti vated Conditions for Setting the DTC D Vehicle speed is higher than 10km h 6 21mph D No Vehicle Speed Sensor error not set D VR sensor output signal is higher than 0 26 D VR sensor output signal is not change for 30 sec onds Action Taken When The DTCs Sets D The Malfunction Indicator Lamp MIL will not illumi nate D The ECM will store conditions which were present when the DTC was set as ...

Page 273: ...F 4 Observe the VR sensor value displayed on the scan tool Is the VR sensor value near the specified value 0V Go to Step 5 Go to Step 12 5 1 Jumper the 5 volt reference circuit terminal 1 and the VR sensor signal circuit terminal 2 together at the VR sensor harness connector 2 Observe the VR sensor value displayed on the scan tool Is the VR sensor value near the specified value 4 95V Go to Step 6 ...

Page 274: ...M 3 Turn the ignition ON 4 Check the VR sensor signal circuit for a short to battery voltage or a short to the 5 volt reference circuit and repair as needed Is the repair complete Go to Step 14 Go to Step 13 13 1 Turn the ignition OFF 2 Replace the ECM Is the repair complete Go to Step 14 14 1 Using the scan tool clear the DTCs 2 Start the engine and idle at normal operating temperature 3 Operate ...

Page 275: ...ENGINE CONTROLS 1F 177 DAEWOO M 150 BL2 BLANK ...

Page 276: ...ondition the ECM misfire detection diagnostic will be de activated Conditions for Setting the DTC D Vehicle speed is higher than 10km h 6 21mph D No Vehicle Speed Sensor error not set D VR sensor output signal is higher than 0 26 D VR sensor output signal is not change for 30seconds Action Taken When The DTCs Sets D The Malfunction Indicator Lamp MIL will not illumi nate D The ECM will store condi...

Page 277: ... OFF 4 Observe the Wheel speed sensor value displayed on the scan tool Is the Wheel speed sensor value near the specified value 0V Go to Step 5 Go to Step 12 5 1 Jumper the 5 volt reference circuit the Wheel speed sensor signal circuit together at the defected Wheel speed sensor harness connector 2 Observe the defected Wheel speed sensor value displayed on the scan tool Is the VR sensor value near...

Page 278: ...nect the ECM 3 Turn the ignition ON 4 Check the Wheel speed sensor signal circuit for a short to voltage or a short to the 5 volt reference circuit and repair as needed Is the repair complete Go to Step 14 Go to Step 13 13 1 Turn the ignition OFF 2 Replace the ECM Is the repair complete Go to Step 14 14 1 Using the scan tool clear the DTCs 2 Start the engine and idle at normal operating temperatur...

Page 279: ...ENGINE CONTROLS 1F 181 DAEWOO M 150 BL2 BLANK ...

Page 280: ...feedback signal By sending a 5 volt reference and a ground to the EEGR valve a voltage signal representing the EEGR valve pintle position is sent to the ECM This feedback signal can also be monitored on a scan tool and is the actual position of the EEGR pintle The actual EEGR position should always be near the commanded or Desired EEGR position ThisDiagnostic Trouble Code DTC will detect an open o...

Page 281: ...pair the open or poor connection in the EEGR ground circuit Is the repair complete Go to Step 19 6 With a test light still connected to ground probe the signal circuit at terminal 1 Does the test light illuminate Go to Step 8 Go to Step 9 7 With a test light still connected to ground again probe the signal circuit without commanding the EEGR valve with the scan tool Does the test light illuminate ...

Page 282: ...r as necessary Is a repair necessary Go to Step 19 Go to Step 18 17 Replace the EEGR valve Is the replacement complete Go to Step 19 18 Check the ECM electrical connector for a poor connection and repair as necessary Is a repair necessary Go to Step 19 Go to Step 12 19 1 Using the scan tool clear the Diagnostic Trouble Codes DTCs 2 Start the engine and idle at normal operating temperature 3 Operat...

Page 283: ...ENGINE CONTROLS 1F 185 DAEWOO M 150 BL2 BLANK ...

Page 284: ...e monitored on a scan tool and is the actual position of the EEGR pintle The actual EEGR position should always be near the commanded or Desired EEGR position ThisDiagnostic Trouble Code DTC will detect an open or short circuit Conditions for Setting the DTC D Engine Coolant Temperature ECT is greater than 80 C 176 F D Intake Air Temperature IAT is greater than 15 C 59 F D Manifold Absolute Pressu...

Page 285: ...move the EEGR valve assembly 3 Inspect the EEGR valve passages and pipe for a restriction or damage and repair as necessary Is a repair necessary Go to Step 5 Go to Step 4 4 Replace the EEGR valve Is the replacement complete Go to Step 5 5 1 Start the engine 2 Disconnect the battery for the specified time 3 Drive the vehicle to the specified value 4 Release the throttle and allow the vehicle to de...

Page 286: ... signal can also be monitored on a scan tool and is the actual position of the EEGR pintle The actual EEGR position should always be near the commanded or Desired EEGR position ThisDiagnostic Trouble Code DTC will detect an open or short circuit Conditions for Setting THE DTC D Engine Coolant Temperature ECT is greater than 80 C 176 F D Intake Air Temperature IAT is greater than 15 C 59 F D Manifo...

Page 287: ... at terminal 1 to the EEGR valve 3 Command the EEGR valve to the specified values using a scan tool After the command is raised does the test light glow brighter flash or maintain a steady glow 25 50 75 100 Go to Step 6 Go to Step 7 5 Repair the open or poor connection in the EEGR ground circuit Is the repair complete Go to Step 19 6 With a test light still connected to ground probe the signal cir...

Page 288: ...cuit for an open or poor connection at the EEGR valve electrical connector and repair as necessary Is a repair necessary Go to Step 19 Go to Step 18 17 Replace the EEGR valve Is the replacement complete Go to Step 19 18 Check the ECM electrical connector for a poor connection and repair as necessary Is a repair necessary Go to Step 19 Go to Step 12 19 1 Using the scan tool clear the Diagnostic Tro...

Page 289: ...ENGINE CONTROLS 1F 191 DAEWOO M 150 BL2 BLANK ...

Page 290: ... EEGR valve a voltage signal representing the EEGR valve pintle position is sent to the ECM This feedback signal can also be monitored on a scan tool and is the actual position of the EEGR pintle The actual EEGR position should always be near the commanded or Desired EEGR position ThisDiagnostic Trouble Code DTC will detect an open or short circuit Conditions for Setting THE DTC D EEGR circuit low...

Page 291: ...r the open or poor connection in the EEGR ground circuit Is the repair complete Go to Step 19 6 With a test light still connected to ground probe the signal circuit at terminal 1 Does the test light illuminate Go to Step 8 Go to Step 9 7 With a test light still connected to ground again probe the signal circuit without commanding the EEGR valve with the scan tool Does the test light illuminate Go ...

Page 292: ...s necessary Is a repair necessary Go to Step 19 Go to Step 18 17 Replace the EEGR valve Is the replacement complete Go to Step 19 18 Check the ECM electrical connector for a poor connection and repair as necessary Is a repair necessary Go to Step 19 Go to Step 12 19 1 Using the scan tool clear the Diagnostic Trouble Codes DTCs 2 Start the engine and idle at normal operating temperature 3 Operate t...

Page 293: ...ENGINE CONTROLS 1F 195 DAEWOO M 150 BL2 BLANK ...

Page 294: ...resenting the EEGR valve pintle position is sent to the ECM This feedback signal can also be monitored on a scan tool and is the actual position of the EEGR pintle The actual EEGR position should always be near the commanded or Desired EEGR position ThisDiagnostic Trouble Code DTC will detect an open or short circuit Conditions for Setting THE DTC D EEGR circuit high voltage Action Taken When The ...

Page 295: ...t the test light to B 2 Probe the 5 volt reference circuit to the EEGR valve Does the test light illuminate Go to Step 6 Go to Step 7 6 Check the 5 volt reference and signal circuit for a poor connection or proper terminal tension and repair as necessary Is a repair necessary Go to Step 12 Go to Step 7 7 1 Connect the test light to B 2 Probe the signal circuit at terminal 1 to the EEGR valve Does ...

Page 296: ...WOO M 150 BL2 DTC P1404 Electric Exhaust Gas Recirculation Opend Cont d Step Action Value s Yes No 13 Check if any additional DTCs are set Are any DTCs displayed that have not been diagnosed Go to Applicable DTC table System OK ...

Page 297: ...ENGINE CONTROLS 1F 199 DAEWOO M 150 BL2 BLANK ...

Page 298: ... pintle position is sent to the ECM This feedback signal can also be monitored on a scan tool and is the actual position of the EEGR pintle The actual EEGR position should always be near the commanded or Desired EEGR position ThisDiagnostic Trouble Code DTC will detect an open or short circuit Conditions for Setting THE DTC D EEGR voltage is less than 0 01V D EEGR potentiometer circuit low voltage...

Page 299: ...ect the test light to B 2 Probe the 5 volt reference circuit to the EEGR valve Does the test light illuminate Go to Step 6 Go to Step 7 6 Check the 5 volt reference and signal circuit for a poor connection or proper terminal tension and repair as necessary Is a repair necessary Go to Step 12 Go to Step 7 7 1 Connect the test light to B 2 Probe the signal circuit at terminal 2 to the EEGR valve Doe...

Page 300: ...EWOO M 150 BL2 DTC P0405 EEGR Pintle Position Sensor Low Voltage Cont d Step Action Value s Yes No 13 Check if any additional DTCs are set Are any DTCs displayed that have not been diagnosed Go to Applicable DTC table System OK ...

Page 301: ...ENGINE CONTROLS 1F 203 DAEWOO M 150 BL2 BLANK ...

Page 302: ...l representing the EEGR valve pintle position is sent to the ECM This feedback signal can also be monitored on a scan tool and is the actual position of the EEGR pintle The actual EEGR position should always be near the commanded or Desired EEGR position This Diagnostic Trouble Code DTC will detect an open or short circuit Conditions for Setting THE DTC D EEGR voltage is higher than 4 99V D EEGR p...

Page 303: ...onnect the test light to B 2 Probe the 5 volt reference circuit to the EEGR valve Does the test light illuminate Go to Step 6 Go to Step 7 6 Check the 5 volt reference and signal circuit for a poor connection or proper terminal tension and repair as necessary Is a repair necessary Go to Step 12 Go to Step 7 7 1 Connect the test light to B 2 Probe the signal circuit at terminal 2 to the EEGR valve ...

Page 304: ...WOO M 150 BL2 DTC P0406 EEGR Pintle Position Sensor High Voltage Cont d Step Action Value s Yes No 13 Check if any additional DTCs are set Are any DTCs displayed that have not been diagnosed Go to Applicable DTC table System OK ...

Page 305: ...ENGINE CONTROLS 1F 207 DAEWOO M 150 BL2 BLANK ...

Page 306: ...00 seconds D Airflow is between 25 50kg h D Engine Coolant Temperature ECT is more than 70 C 176 F D Engine speed between 2 400rpm and 3 000rpm D Vehicle speed is between 64km h 28 6mph and 80km h 49 7mph Note Test is aborted for this idle if D Change in engine speed is greater than 80 rpm D A C status changed D Cooling fan status changed D Insufficient air fuel shift D DTC s P0106 P0107 P0108 P01...

Page 307: ...3 Heated Oxygen Sensor HO2S Is a problem found Go to Step 4 Go to Step 5 4 Repair the exhaust system as needed Is the repair complete Go to Step 6 5 Replace the Three Way Catalytic Converter TWC Is the repair complete Go to Step 6 6 1 Using the scan tool clear the Diagnostic Trouble Codes DTCs 2 Start the engine and idle at normal operating temperature 3 Operate the vehicle within the Conditions f...

Page 308: ...ted or faulty fuel tank pressure sensor Disconnected damaged pinched or blocked EVAP purge line Disconnected or faulty EVAP canister purge valve Disconnected or faulty EVAP vent solenoid Open ignition feed circuit to the EVAP vent or purge so lenoid Damaged EVAP canister Leaking fuel sensor assembly O ring Leaking fuel tank or fuel filler beck Any of the above conditions can set DTC P0444 The test...

Page 309: ...tic reports the system has passed or if the battery is disconnected the diagnostic must fail twice before setting a DTC The initial failure is not reported to the diagnostic executive or displayed on a scan tool A passing system always reports to the diagnostic executive immediately Check for the following conditions D Missing or damaged fuel cap D Missing or damaged O rings at fuel vapor and EVAP...

Page 310: ...ector terminal 66 2 Clear any Diagnostic Trouble Codes DTCs from the ECM 3 Perform the diagnostic system check Is the repair complete System OK 5 1 Repair the line break in the wire between the EVAP canister purge valve connector 2 and the main relay connector terminal 87 2 Clear any Diagnostic Trouble Codes DTCs from the ECM 3 Perform the diagnostic system check Is the repair complete System OK 6...

Page 311: ...ENGINE CONTROLS 1F 213 DAEWOO M 150 BL2 BLANK ...

Page 312: ...ap Disconnected or faulty fuel tank pressure sensor Disconnected damaged pinched or blocked EVAP purge line Disconnected or faulty EVAP canister purge valve Disconnected or faulty EVAP vent solenoid Open ignition feed circuit to the EVAP vent or purge so lenoid Damaged EVAP canister Leaking fuel sensor assembly O ring Leaking fuel tank or fuel filler beck Any of the above conditions can set DTC P0...

Page 313: ...ssing or damaged O rings at fuel vapor and EVAP purge line canister fittings Cracked or punctured EVAP canister Damaged source vacuum line EVAP purge line EVAP vent hose or fuel tank vapor line Poor connection at the ECM Inspect the harness con nectors for the following conditions D Backed out terminals D Improper mating D Broken locks D Improperly formed D Damaged terminals D Poor terminal to wir...

Page 314: ... ON Go to Step 8 Go to Step 10 8 1 Repair the low voltage in the wire between the EVAP canister purge valve connector terminal 1 and the ECM connector terminal 66 2 Clear any Diagnostic Trouble Codes DTCs from the ECM 3 Perform the diagnostic system check Is the repair complete System OK 9 1 Replace the EVAP canister purge valve 2 Clear any Diagnostic Trouble Codes DTCs from the ECM 3 Perform the ...

Page 315: ...ENGINE CONTROLS 1F 217 DAEWOO M 150 BL2 BLANK ...

Page 316: ...Taken When The DTCs Sets D The Malfunction Indicator Lamp MIL will not illumi nate D The ECM will store conditions which were present when the DTC was set as Failure Records data only D This information will not be stored in the Freeze Frame data Conditions for Clearing the MIL DTC D A history DTC will clear after 40 consecutive warm up cycles without a fault D DTC s can be cleared by using the sc...

Page 317: ...he procedure several times Does the Fuel Level Sensor value on the scan tool increase and then decrease steadily when the float is moved Go to Diagnostic Aids Go to Step 8 6 Check for an open or short to ground in the Fuel Level Sensor circuit and repair as necessary Is the repair necessary Go to Step 11 Go to Step 9 7 Repair the open or short to ground in the Fuel Level Sensor circuit between the...

Page 318: ...LS DAEWOO M 150 BL2 DTC P0462 Fuel Level Sensor Low Voltage Cont d Step Action Value s Yes No 12 Check if any additional DTCs are set Are any DTCs displayed that have not been diagnosed Go to Applicable DTC table System OK ...

Page 319: ...ENGINE CONTROLS 1F 221 DAEWOO M 150 BL2 BLANK ...

Page 320: ...n Taken When the DTC Sets D The Malfunction Indicator Lamp MIL will not illumi nate D The ECM will store conditions which were present when the DTC was set as Failure Records data only D This information will not be stored in the Freeze Frame data Conditions for Clearing the MIL DTC D A history DTC will clear after 40 consecutive warm up cycles without a fault D DTC s can be cleared by using the s...

Page 321: ...ure several times Does the Fuel Level Sensor value on the scan tool increase and then decrease steadily when the float is moved Go to Diagnostic Aids Go to Step 8 6 Check for an open or short to battery voltage in the Fuel Level Sensor circuit and repair as necessary Is the repair necessary Go to Step 11 Go to Step 9 7 Repair the open or short to battery voltage in the Fuel Level Sensor circuit be...

Page 322: ...S DAEWOO M 150 BL2 DTC P0463 Fuel Level Sensor High Voltage Cont d Step Action Value s Yes No 12 Check if any additional DTCs are set Are any DTCs displayed that have not been diagnosed Go to Applicable DTC table System OK ...

Page 323: ...ENGINE CONTROLS 1F 225 DAEWOO M 150 BL2 BLANK ...

Page 324: ...nt flow to the cooling fan motors This allows the ECM driver to only have to handle the relatively low current used by the relay Conditions for Setting the DTC D Diagnostic Trouble Codes DTCs P0117 P0118 not set D Ignition ON D Ignition voltage is greater than 10 volts D Engine run time is greater than 5 seconds Action Taken When the DTC Sets D The Malfunction Indicator Lamp MIL will not illumi na...

Page 325: ...Disconnect the relay 3 Using a DVM measure the resistance between terminals 87 and 39 in the relay control circuit in the ECM harness connector to ground Does the DVM display infinite resistance Go to Step 12 Go to Step 10 5 1 Turn the ignition switch to LOCK 2 Disconnect the relay 3 Connect a test light between the relay coil terminals 30 and 87 in the relay harness connector 4 Turn the Turn the ...

Page 326: ...e Go to Step 14 12 Replace the relay Is the replacement complete Go to Step 14 13 Replace the ECM Is the replacement complete Go to Step 14 14 1 Using the scan tool clear the Diagnostic Trouble Codes DTCs 2 Start the engine and idle at normal operating temperature 3 Operate the vehicle within the conditions for setting the DTC as specifiec in the supporting text Does the scan tool indicate that th...

Page 327: ...ENGINE CONTROLS 1F 229 DAEWOO M 150 BL2 BLANK ...

Page 328: ... flow to the cooling fan motors This allows the ECM driver to only have to handle the relatively low current used by the relay Conditions for Setting the DTC D Diagnostic Trouble Codes DTCs P0117 P0118 not set D Ignition ON D Ignition voltage is greater than 10 volts D Engine run time is greater than 5 seconds Action Taken When The DTCs Sets D The Malfunction Indicator Lamp MIL will not illumi nat...

Page 329: ...isconnect the relay 3 Using a DVM measure the resistance between terminals 85 and 5 in the relay control circuit in the ECM harness connector to ground Does the DVM display infinite resistance Go to Step 12 Go to Step 10 5 1 Turn the ignition switch to LOCK 2 Disconnect the relay 3 Connect a test light between the relay coil terminals 86 and 85 in the relay harness connector 4 Turn the Turn the ig...

Page 330: ... Go to Step 14 12 Replace the relay Is the replacement complete Go to Step 14 13 Replace the ECM Is the replacement complete Go to Step 14 14 1 Using the scan tool clear the Diagnostic Trouble Codes DTCs 2 Start the engine and idle at normal operating temperature 3 Operate the vehicle within the conditions for setting the DTC as specifiec in the supporting text Does the scan tool indicate that thi...

Page 331: ...ENGINE CONTROLS 1F 233 DAEWOO M 150 BL2 BLANK ...

Page 332: ...nt flow to the cooling fan motors This allows the ECM driver to only have to handle the relatively low current used by the relay Conditions for Setting the DTC D Diagnostic Trouble Codes DTCs P0117 P0118 not set D Ignition ON D Ignition voltage is greater than 10 volts D Engine run time is greater than 5 seconds Action Taken When The DTCs Sets D The Malfunction Indicator Lamp MIL will not illumi n...

Page 333: ... Disconnect the relay 3 Using a DVM measure the resistance between terminals 85 and 5 in the relay control circuit in the ECM harness connector to ground Does the DVM display infinite resistance Go to Step 12 Go to Step 10 5 1 Turn the ignition switch to LOCK 2 Disconnect the relay 3 Connect a test light between the relay coil terminals 86 and 85 in the relay harness connector 4 Turn the Turn the ...

Page 334: ...te Go to Step 14 12 Replace the relay Is the replacement complete Go to Step 14 13 Replace the ECM Is the replacement complete Go to Step 14 14 1 Using the scan tool clear the Diagnostic Trouble Codes DTCs 2 Start the engine and idle at normal operating temperature 3 Operate the vehicle within the conditions for setting the DTC as specifiec in the supporting text Does the scan tool indicate that t...

Page 335: ...ENGINE CONTROLS 1F 237 DAEWOO M 150 BL2 BLANK ...

Page 336: ... flow to the cooling fan motors This allows the ECM driver to only have to handle the relatively low current used by the relay Conditions for Setting the DTC D Diagnostic Trouble Codes DTCs P0117 P0118 not set D Ignition ON D Ignition voltage is greater than 10 volts D Engine run time is greater than 5 seconds Action Taken When The DTCs Sets D The Malfunction Indicator Lamp MIL will not illumi nat...

Page 337: ...1 Turn the ignition switch to LOCK 2 Disconnect the relay 3 Using a DVM measure the resistance between terminals 85 and 39 in the high speed cooling fan relay control circuit in the ECM harness connector to ground Does the DVM display infinite resistance Go to Step 12 Go to Step 10 5 1 Turn the ignition switch to LOCK 2 Disconnect the relay 3 Connect a test light between the relay coil terminals 8...

Page 338: ...elay ignition feed circuit Is the repair complete Go to Step 14 12 Replace the relay Is the replacement complete Go to Step 14 13 Replace the ECM Is the replacement complete Go to Step 14 14 1 Using the scan tool clear the Diagnostic Trouble Codes DTCs 2 Start the engine and idle at normal operating temperature 3 Operate the vehicle within the conditions for setting the DTC as specifiec in the sup...

Page 339: ...ENGINE CONTROLS 1F 241 DAEWOO M 150 BL2 BLANK ...

Page 340: ...is greater than 2 100rpm D MAF is greater than 152mg tdc Action taken when The DTCs Sets D The Malfunction Indicator Lamp MIL will illuminate D The ECM will record operating conditions at the time the diagnostic fails This information will be stored in the Freeze Frame and failure records buffers D A history DTC is stored Conditions for Clearing the MIL DTC D The MIL will turn off after four conse...

Page 341: ...ep 12 Go to Step 4 4 1 Turn the ignition OFF 2 Disconnect the engine control module ECM connector 4 using a digital voltmeter DVM connected to ground measure the voltage in the Vehicle Speed Sensor VSS signal circuit at terminal 1 while rotating the wheels Is the voltage greater than or eqaul to specified value 0 5 v Go to Step 12 Go to Step 5 5 Measure the resistant in the VSS signal circuit whil...

Page 342: ... tool clear the Diagnostic Trouble Codes DTCs 2 Start the engine and idle at normal operating temperature 3 Operate the vehicle within the conditions for setting the DTC as specifiec in the supporting text Does the scan tool indicate that this diagnostic ran and passed Go to Step 15 Go to Step 2 13 Check if any additional DTCs are set Are any DTCs displayed that have not been diagnosed Go to Appli...

Page 343: ...ENGINE CONTROLS 1F 245 DAEWOO M 150 BL2 BLANK ...

Page 344: ...an 72 kPa 10 4 psi D Engine Coolant Temperature ECT is greater than 60_C 140_F D Ignition voltage is between 11 and 16 volts D The Intake Air Temperature IAT is greater than 20_C 4_F D Manifold Absolute Pressure is less than 60 kPa 8 7 psi D IAC valve is controlled fully opened D All of the above must be met for greater than 5 sec onds Action Taken When the DTC Sets D The Malfunction Indicator Lam...

Page 345: ...o Step 13 4 1 Measure the resistance between terminal D and B of the IAC valve 2 Measure the resistance between terminal C and A of the IAC valve Is the resistance equal to the specified value Go to Step 15 Go to Step 13 5 1 Turn the ignition OFF 2 Disconnect the IAC valve connector 3 Turn the ignition ON 4 With test light connected to ground probe the IAC connector terminals Does the test light i...

Page 346: ...Replace the IAC valve Is the repair complete Go to Step 15 14 1 Turn the ignition OFF 2 Replace the ECM Is the repair complete Go to Step 15 15 1 Using the scan tool clear the Diagnostic Trouble Codes DTCs 2 Start the engine and idle at normal operating temperature 3 Operate the vehicle within the Conditions for setting this DTC as specified in the supporting text Does the scan tool indicate that ...

Page 347: ...ENGINE CONTROLS 1F 249 DAEWOO M 150 BL2 BLANK ...

Page 348: ...tor Conditions for Setting the DTC D A short to battery voltage condition exists and is pres ent for more the 2 seconds Action Taken When the DTC Sets D The ECM will not illuminate the Malfunction Indicator Lamp MIL D A history DTCs is stored D The ECM will record operating conditions at the time the diagnostic fails This information will be stored Failure Records buffers D The A C compressor oper...

Page 349: ...o to Step 9 5 1 Turn the ignition switch to LOCK 2 Disconnect the ECM 3 With the test light connected to ground probe the ignition feed circuit at terminal 2 in the sensor harness connector Does the test light illuminate Go to Step 6 Go to Step 8 6 Repair a short to battery between the ECM wiring connector terminal 46 and evaporator temperature sensor terminal 2 Is the repair complete Go to Step 9...

Page 350: ...tor Conditions for Setting the DTC D A short to battery voltage condition exists and is pres ent for more the 2 seconds Action Taken When the DTC Sets D The ECM will not illuminate the Malfunction Indicator Lamp MIL D A history DTCs is stored D The ECM will record operating conditions at the time the diagnostic fails This information will be stored Failure Records buffers D The A C compressor oper...

Page 351: ...o to Step 9 5 1 Turn the ignition switch to LOCK 2 Disconnect the ECM 3 With the test light connected to ground probe the ignition feed circuit at terminal 2 in the sensor harness connector Does the test light illuminate Go to Step 6 Go to Step 8 6 Repair a short to battery between the ECM wiring connector terminal 46 and evaporator temperature sensor terminal 2 Is the repair complete Go to Step 9...

Page 352: ...was set as Failure Records data only D This information will not be stored in the Freeze Frame data Conditions for Clearing the MIL DTC D A history DTC will clear after 40 consecutive warm up cycles without a fault D DTC s can be cleared by using the scan tool Diagnostic Aids Inspect harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and...

Page 353: ...to Step 9 5 1 Turn the ignition switch to LOCK 2 Disconnect the ECM 3 With the test light connected to ground probe the ignition feed circuit at terminal 86 in the relay harness connector Does the test light illuminate Go to Step 8 Go to Step 6 6 Repair a short to battery voltage between the ECM wiring connector terminal 38 and A C compressor relay terminal 85 Is the repair complete Go to Step 9 7...

Page 354: ...TC was set as Failure Records data only D This information will not be stored in the Freeze Frame data Conditions for Clearing the MIL DTC D A history DTC will clear after 40 consecutive warm up cycles without a fault D DTC s can be cleared by using the scan tool Diagnostic Aids Inspect harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals ...

Page 355: ...to Step 9 5 1 1 Turn the ignition switch to LOCK 2 Disconnect the ECM 3 With the test light connected to ground probe the ignition feed circuit at terminal 86 in the relay harness connector Does the test light illuminate Go to Step 8 Go to Step 6 6 Repair a short to ground between the ECM wiring connector terminal 38 and A C compressor relay terminal 85 Is the repair complete Go to Step 9 7 Replac...

Page 356: ...cator Lamp MIL will not illumi nate D The ECM will store conditions which were present when the DTC was set as Failure Records data only D This information will not be stored in the Freeze Frame data Conditions for Clearing the MIL DTC D A history DTC will clear after 40 consecutive warm up cycles without a fault D DTC s can be cleared by using the scan tool Diagnostic Aids An Intermittent problem...

Page 357: ...2 Disconnect the engine control module ECM connector at the ECM 3 Turn the Turn the ignition switch to ON with the engine OFF 4 Using a DVM measure the ignition voltage at the ignition feed circuit terminal 29 Is the ignition voltage greater than the specified value 10V Go to Step 5 Go to Step 6 5 Check for a malfunctioning connection at the ECM harness terminals and repair as necessary Is a repai...

Page 358: ...resent when the DTC was set as Failure Records data only D This information will not be stored in the Freeze Frame data Conditions for Clearing the MIL DTC D A history DTC will clear after 40 consecutive warm up cycles without a fault D DTC s can be cleared by using the scan tool D Disconnecting the ECM battery feed for more than 10 seconds Diagnostic Aids An Intermittent problem may be caused by ...

Page 359: ... 2 Disconnect the engine control module ECM connector at the ECM 3 Turn the Turn the ignition switch to ON with the engine OFF 4 Using a DVM measure the ignition voltage at the ignition feed circuit terminal 29 Is the ignition voltage greater than the specified value 10V Go to Step 5 Go to Step 6 5 Check for a malfunctioning connection at the ECM harness terminals and repair as necessary Is a repa...

Page 360: ...ecksum value a checksum error is indi cated Conditions for Setting the DTC D The ECM detects more than 3 incorrect checksum Action Taken When the DTC Sets D The Malfunction Indicator Lamp MIL will not illumi nate D The ECM will store conditions which were present when the DTC was set as Failure Records data only D This information will not be stored in the Freeze Frame data Conditions for Clearing...

Page 361: ...ing the DTC D The ECM detects more than 3 incorrect checksum Action taken when The DTCs Sets D The Malfunction Indicator Lamp MIL will illuminate D The ECM will record operating conditions at the time the diagnostic fails This information will be stored in the Freeze Frame and Failure Records buffers D A history DTC is stored D Coolant fan turns on Conditions for Clearing the MIL DTC D The MIL wil...

Page 362: ...TC D The ECM detects more than 3 incorrect checksum Action taken when The DTCs Sets D The Malfunction Indicator Lamp MIL will illuminate D The ECM will record operating conditions at the time the diagnostic fails This information will be stored in the Freeze Frame and Failure Records buffers D A history DTC is stored D Coolant fan turns on Conditions for Clearing the MIL DTC D The MIL will turn of...

Page 363: ...ENGINE CONTROLS 1F 265 DAEWOO M 150 BL2 BLANK ...

Page 364: ...g the MIL DTC D The MIL will turn off after four consecutive ignition cycles in which the diagnostic runs without a fault D A history DTC will clear after 40 consecutive warm up cycles without a fault D Using the scan tool can clear DTC s Diagnostic Aids Inspect harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire...

Page 365: ... Disconnect the ECM wiring harness connector 3 With the test light connected to ground probe the ignition feed circuit at terminal 85 in the relay harness connector Does the test light illuminate Go to Step 5 Go to Step 7 5 Repair a high voltage between the ECM wiring connector terminal 7 and main relay terminal 85 Is the repair complete Go to Step 7 6 Replace the main relay Is the replacement com...

Page 366: ...L DTC D The MIL will turn off after four consecutive ignition cycles in which the diagnostic runs without a fault D A history DTC will clear after 40 consecutive warm up cycles without a fault D Using the scan tool can clear DTC s Diagnostic Aids Inspect harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connec ...

Page 367: ...Disconnect the ECM wiring harness connector 3 With the test light connected to ground probe the ignition feed circuit at terminal 85 in the relay harness connector Does the test light illuminate Go to Step 5 Go to Step 7 5 Repair a high voltage between the ECM wiring connector terminal 7 and main relay terminal 85 Is the repair complete Go to Step 7 6 Replace the main relay Is the replacement comp...

Page 368: ... have been substituted to defeat the system If the ECM receives an invalid release mes sage the ECM performs the following action D Disable the fuel injector circuit D Disable the fuel pump circuit D Disable the ignition coil D A Diagnostic Trouble Code DTC will stored if detect communication link failure between the ECM and im mobilizer control unit Conditions for Setting the DTC D Ignition switc...

Page 369: ...Is the resistance within the specified value 0 Ω Go to Step 5 Go to Step 4 4 Repair an open circuit between terminal 7 of immobilizer control unit and terminal 56 of the ECM Is the repair complete Go to Step 8 5 Check the terminals in immobilizer control unit and the ECM for damages and repair as needed Is the repair complete Go to Step 8 Go to Step 6 6 Replace the immobilizer control unit Is the ...

Page 370: ...e been substituted to defeat the system If the ECM receives an invalid release mes sage the ECM performs the following action D Disable the fuel injector circuit D Disable the fuel pump circuit D Disable the ignition coil A Diagnostic Trouble Code DTC will stored if detect communication link failure between the ECM and immo bilizer control unit Conditions for Setting the DTC D Ignition switch is t...

Page 371: ...e resistance within the specified value 0 Ω Go to Step 5 Go to Step 4 4 Repair an open circuit between terminal 7 of immobilizer control unit and terminal 56 of the ECM Is the repair complete Go to Step 8 5 Check the terminals in immobilizer control unit and the ECM for damages and repair as needed Is the repair complete Go to Step 8 Go to Step 6 6 Replace the immobilizer control unit Is the repai...

Page 372: ...aken When the DTC Sets D The Malfunction Indicator Lamp MIL will not illumi nate D The ECM will store conditions which were present when the DTC was set as Failure Records data only D This information will not be stored in the Freeze Frame data Conditions for Clearing the MIL DTC D A history DTC will clear after 40 consecutive warm up cycles without a fault D DTC s can be cleared by using the scan...

Page 373: ...o to Step 5 5 1 Turn the ignition switch to LOCK 2 Check for short to battery in the wire between the the cluster connector terminal C14 and ground Is the problem found Go to Step 6 Go to Step 7 6 1 Change the between cluster and ECM or repair the connector terminal as needed 2 Clear any DTCs from ECM 3 Perform the diagnostic system check Is the repair complete System OK 7 1 Replace the cluster 2 ...

Page 374: ...he diagnostic fails This information will be stored in the Freeze Frame and Failure Records buffers D A history DTC is stored Conditions for Clearing the MIL DTC D The MIL will turn off after four consecutive ignition cycles in which the diagnostic runs without a fault D A history DTC will clear after 40 consecutive warm up cycles without a fault D DTC s can be cleared by using the scan tool Diagn...

Page 375: ...gnition feed circuit at ECM wiring connector terminal 68 Does the test light illuminate Go to Step 4 Go to Step 5 4 1 Turn the ignition switch to LOCK 2 Replace the cluster Is the replacement complete Go to Step 6 5 Repair a short to battery between the ECM wiring connector terminal 68 and cluster wiring connector terminal B9 Is the repair complete Go to Step 6 6 1 Using the scan tool clear the Di...

Page 376: ... diagnostic fails This information will be stored in the Freeze Frame and Failure Records buffers D A history DTC is stored Conditions for Clearing the MIL DTC D The MIL will turn off after four consecutive ignition cycles in which the diagnostic runs without a fault D A history DTC will clear after 40 consecutive warm up cycles without a fault D DTC s can be cleared by using the scan tool Diagnos...

Page 377: ...n feed circuit at ECM wiring connector terminal 39 Does the test light illuminate Go to Step 4 Go to Step 5 4 1 Turn the ignition switch to LOCK 2 Replace the cluster Is the replacement complete Go to Step 6 5 Repair a short to ground or open between the ECM wiring connector terminal 39 and cluster wiring connector terminal A7 Is the repair complete Go to Step 6 6 1 Using the scan tool clear the D...

Page 378: ... Diagnostic EOBD System Check Are any Diagnostic Trouble Code s DTCs stored in the Engine Control Module ECM memory Go to Appropriate DTC Table Go to Step 2 2 1 Inspect all of the ECM ground connections 2 Inspect all of the vacuum hoses for splits kinks and proper connections 3 Check for air leaks at all of the mounting areas of the intake manifold sealing surfaces 4 Inspect the ignition wires for...

Page 379: ...4 Road test the vehicle with a voltmeter connected to a suspected circuit or a scan tool connected to the Data Link Connector DLC Did the voltmeter or the scan tool indicate an abnormal voltage or scan reading Go to Step 5 Go to Step 6 5 Replace the sensor in the affected circuit if a Diagnostic Trouble Code DTC was stored for this circuit except for the DTCs P0171 and P0172 Is the repair complete...

Page 380: ...nitor the oxygen sensor and the injector base pulse width with the scan tool Does the scan tool display a steady low voltage about 0 millivolts for the oxygen sensor with the control module commanding an injector base pulse width of the value specified 8 ms Go to Step 9 Go to Step 12 12 1 Check for an open diode across the A C clutch and for other open diodes 2 Repair or replace any components as ...

Page 381: ...the resistance value to specifications using the Temperature Vs Resistance tables for DTCs P0118 and P0113 3 If the resistance is not the same replace the faulty sensor Is the repair complete System OK 4 1 Check for a sticking throttle shaft or a binding linkage that may cause a high Throttle Position TP sensor voltage Repair or replace as needed 2 Check the TP sensor voltage reading with the thro...

Page 382: ...or with a resistance that is out of specifications Is the repair complete System OK 15 Perform an injector diagnosis Is the problem found Go to Step 16 Go to Step 17 16 Replace any restricted or leaking fuel injectors as needed Is the repair complete System OK 17 1 Check for the proper ignition voltage output for each cylinder with a spark tester 2 Inspect the spark plugs for cracks wear improper ...

Page 383: ...ash Is the problem found Go to Step 24 Go to Step 25 24 Repair or replace any components as needed Is the repair complete System OK 25 Check the idle air control valve operation Repair or replace components as needed Is the repair complete System OK 26 Check the throttle position sensor circuit for proper operation Repair or replace components as needed Is the repair complete System OK 27 Repair t...

Page 384: ...nitor the long term fuel trim reading using the scan tool Is the long term fuel trim reading within the value specified 20 25 Go to Step 7 Go to Step 5 5 Is the long term fuel trim reading below the value specified 20 Go to Diagnostic Aids for DTC P0172 Go to Step 6 6 Is the long term fuel trim reading above the value specified 25 Go to Diagnostic Aids for DTC P0171 7 Check the fuel system pressur...

Page 385: ...ecified 12 16 V Go to Step 16 Go to Step 15 15 Repair the generator Is the repair complete System OK 16 1 Check for intermittent Electric Exhaust Gas Recirculation EEGR valve operation 2 Repair or replace any components as needed Is the repair complete System OK 17 Repair the fuel system as needed Is the repair complete System OK 18 Replace the fuel filter Is the repair complete System OK 19 Repla...

Page 386: ...ck for a restricted fuel filter or contaminated fuel Is the problem found Go to Step 8 Go to Step 9 8 Repair or replace any components as needed Is the repair complete System OK 9 1 Check the ignition system output for all of the cylinders using a spark tester 2 Check for proper ignition control operation Is the ignition system operating properly Go to Step 10 Go to Step 11 10 1 With the engine at...

Page 387: ...ck the Engine Control Module ECM grounds for being clean tight and in their proper location 2 Check the exhaust recirculation valve for being open or partially open all the time 3 Check the torque converter clutch operation 4 Check the A C system operation 5 Check the generator output 6 Repair the generator if the output is not within the specified range Are all checks and repairs complete 12 16 V...

Page 388: ...istance is not within specifications as listed in the Diagnostic Aids for diagnostic trouble code P0118 Is the problem found Go to Step 6 Go to Step 7 6 Replace the ECT sensor or repair the circuit as needed Is the repair complete System OK 7 1 Check the ignition system output with a spark tester 2 Inspect the spark plugs for the proper heat range and gap 3 Check for the proper operation of the ig...

Page 389: ...r head the pistons etc for excessive wear 4 Replace any excessively worn parts Is the procedure complete Go to Step 13 13 1 Check the exhaust gas recirculation valve for proper operation 2 Check the air intake system for proper operation 3 Check the torque converter clutch operation and transaxle shift points 4 Check the service bulletins for Programmable Read Only Memory PROM updates 5 Check the ...

Page 390: ...VAP Canister Purge System for proper operation Is the problem found Go to Step 5 Go to Step 6 5 Repair or replace any components as needed Is the repair complete System OK 6 1 Disconnect all of the fuel injector harness connectors 2 Connect an injector test light between the harness terminals of each fuel injector 3 Note the test light while cranking the engine Does the test light blink on all con...

Page 391: ...rk plugs 3 Check the ignition system output on each cylinder with a spark tester Is the problem found Go to Step 15 Go to Step 16 15 Repair or replace any ignition components as needed Is the repair complete System OK 16 1 Check the generator output voltage 2 Repair or replace the generator if the generator output is less than the value specified 3 Check the Electric Exhaust Gas Recirculation EEGR...

Page 392: ...roblem found Go to Step 6 Go to Step 7 6 Replace the ignition wires Is the repair complete System OK 7 1 Perform a cylinder compression test 2 If the compression is low repair the engine as needed 3 Inspect for proper valve timing bent pushrods worn rocker arms broken or weak valve springs and worn camshaft lobes 4 Inspect the intake manifold and the exhaust manifold passages for casting flash Is ...

Page 393: ...o to Step 15 Go to Step 14 14 Replace any fuel injectors with a resistance that is out of specifications Is the repair complete System OK 15 Perform an injector diagnosis Is the problem found Go to Step 16 Go to Step 17 16 Replace any restricted or leaking fuel injectors Is the repair complete System OK 17 1 Check for electromagnetic interference 2 Monitor the engine rpm with a scan tool Does the ...

Page 394: ...Go to Step 2 Go to Important Preliminary Checks 2 1 Inspect the air filter for excessive contamination 2 Inspect for fuel system leaks Are all needed checks complete Go to Step 3 3 1 Inspect the spark plugs for excessive wear insulation cracks improper gap or heavy deposits 2 Replace any faulty spark plugs 3 Inspect the ignition wires for cracking hardness and proper connections Are all needed che...

Page 395: ...inding throttle linkage that may cause incorrect Throttle Position TP sensor voltage 2 Check the TP sensor voltage reading with the throttle closed Is the TP sensor voltage within the value specified 0 4 0 8 V Go to Step 6 Go to Diagnostic Aids for DTC P0123 6 1 Check the Engine Coolant Temperature ECT sensor voltage reading using the scan tool 2 Compare the ECT sensor reading with the ambient tem...

Page 396: ...resistance will increase slightly at higher temperatures 11 6 12 4 Ω Go to Step 18 Go to Step 17 17 Replace any fuel injectors with a resistance that is out of specifications Is the repair complete System OK 18 Perform an injector diagnosis Is the problem found Go to Step 19 Go to Step 20 19 Replace any leaking or restricted fuel injectors Is the repair complete System OK 20 1 With the engine OFF ...

Page 397: ...rculation EEGR valve for proper operation 2 Inspect the battery cables and the ground straps for proper connections 3 Check the generator voltage output Repair or replace the generator if the voltage output is not within the value specified Is the problem found 12 16 V Go to Step 27 Go to Step 28 27 Repair or replace any components as needed Is the repair complete System OK 28 1 Inspect for broken...

Page 398: ...ep 4 4 Is the long term fuel trim memory below the value specified 20 Go to Diagnostic Aids for DTC P0172 Go to Step 5 5 Is the long term fuel trim memory above the value specified 25 Go to Diagnostic Aids for DTC P0171 6 1 Check for a properly installed fuel cap 2 Check the fuel system pressure 3 Perform an injector diagnosis Is the problem found Go to Step 7 Go to Step 8 7 1 Repair or replace an...

Page 399: ...catalytic converter for contamination 3 Inspect for carbon buildup on the throttle body and the throttle plate and inside the engine Remove with a top engine cleaner 4 Check the Electric Exhaust Gas Recirculation EEGR valve for not opening 5 Check for proper Positive Crankcase Ventilation PCV operation Are all checks and needed repairs complete System OK ...

Page 400: ... the engine run smoothly after the ignition switch is turned OFF Go to Step 3 Go to Step 4 3 1 Check the ignition switch and the ignition switch adjustment 2 Replace the ignition switch if needed Is the repair complete System OK 4 1 Check the evaporative emission system 2 Check for leaking fuel injectors 3 Check the Idle Air Control IAC valve operation 4 Inspect for vacuum leaks 5 Check for the pr...

Page 401: ...pair complete System OK 4 1 Check the fuel system operation 2 Check the fuel injectors by performing an injector diagnosis Is the problem found Go to Step 5 Go to Step 6 5 Repair or replace any fuel system components as needed Is the repair complete System OK 6 1 Inspect the Electric Exhaust Gas Recirculation EEGR gasket for a leak or a loose fit 2 Check the EEGR valve for proper operation 3 Inspe...

Page 402: ...y to relieve the fuel system pres sure before disconnecting the fuel lines 1 Relieve the fuel system pressure D Start the engine and remove the rear seat cushon 1 D Remove the fuel pump access cover 2 D Disconnect the fuel pump assembly electrical con nector lock pin 3 D Disconnect the fuel pump assembly electrical con nector 4 D Crank the engine for an additional 10 seconds D102F503 2 Disconnect ...

Page 403: ...ll in the reverse order of removal 2 Perform an operational check of the fuel pump D Perform an operational check of the ignition switch ON the 2 seconds fuel pump operation D102F507 FUEL PRESSURE REGULATOR Removal Procedure Caution The fuel system is under pressure To avoid fuel spillage and the risk of personal injury or fire it is necessary to relieve the fuel system pres sure before disconnect...

Page 404: ...emoved O ring seals Replace the removed O ring seals with the new ones D102F511 D102F510 FUEL FILTER Removal Procedure Caution The fuel system is under pressure To avoid fuel spillage and the risk of personal injury or fire it is necessary to relieve the fuel system pres sure before disconnecting the fuel lines 1 Relieve the fuel system pressure Refer to Fuel Pump in this section 2 Remove the fuel...

Page 405: ...system pres sure before disconnecting the fuel lines 1 Relieve the fuel system pressure Refer to Fuel Pump in this section 2 Disconnect the fuel tank ventilation tube D Disconnect the clamp 1 D Disconnect the ventilation tube 2 3 Drain the fuel tank D Place a pan below the fuel tank to catch the drain ing fuel D Disconnect the fuel tank filter tube 1 D Drain the fuel from the fuel tank using the v...

Page 406: ...ne to prevent the vapor lock and check the hoses for leaks 2 Install the fuel tank strap bolts Tighten Tighten the fuel tank strap bolts to 18 22 NSm 13 16 lb ft D102F519 D102F518 FUEL RAIL AND INJECTORS Removal Procedure Caution The fuel system is under pressure To avoid fuel spillage and the risk of personal injury or fire it is necessary to relieve the fuel system pres sure before disconnecting...

Page 407: ...Important Different fuel injectors are calibrated for dif ferent flow rates When ordering new fuel injectors be certain to order the identical part number that is in scribed on the old fuel injector D12F522A 18 22 NSm Installation Procedure 1 Install in the reverse order of removal Important If a fuel injector becomes separated from the fuel rail and remains in the cylinder head replace the fuel i...

Page 408: ...ctthe evaporative EVAP emission canister purge solenoid connector 3 Disconnect the vacuum hoses from the EVAP canis ter purge solenoid 4 Unclip the EVAP emission canister purge solenoid from the mounting bracket 5 Installation should follow the removal procedure in the reverse order MAA1F440 MANIFOLD ABSOLUTE PRESSURE SENSOR Removal Procedure 1 Disconnect the manifold absolute pressure MAP sensor ...

Page 409: ...NSm 71 106 lb in Tighten the MAP sensor bracket bolt to 8 12 NSm 71 106 lb in D102F537 THROTTLE BODY Removal Procedure 1 Remove the air cleaner resonator assembly and air intake tube Refer to Section 1B SOHC Engine Me chanical 2 Drain the engine coolant Refer to Section 1D Engine Cooling D102F538 3 Disconnect the throttle cable the throttle position sensor and the idle air control valve connectors...

Page 410: ... the throttle body gasket 3 D Inspect the throttle body gasket for the deforma tion and the damages 9 12 NSm D12F542A Installation Procedure 1 Install in the reverse order of removal Important Make sure the throttle control cable do not hold the throttle open With the engine OFF check to see that the accelerator pedal is free 2 Install the throttle body with the bolts Tighten Tighten the throttle ...

Page 411: ...106 lb ft D102F544 INTAKE AIR TEMPERATURE IAT SENSOR Removal Procedure 1 Disconnect the negative battery cable 2 Remove the intake air temperature IAT sensor D Disconnect the IAT sensor connector 1 D Disconnect the IAT sensor 20 30 NSm D12F545A Installation Procedure 1 Install in the reverse order of removal 2 Install the IAT sensor Tighten Tighten the IAT sensor to 20 30 NSm 15 22 lb ft ...

Page 412: ...ze compound is used on the oxygen sensor threads This compound consists of a liquid graphite and glass beads The graphite will burn away but the glass beads will remain making the sen sor easier to remove New or service sensors will al ready have the compound applied to the threads If a sensor is removed from any engine and if for any reason it is to be reinstalled the threads must have anti seize...

Page 413: ...st have anti seize compound applied before reinstallation 2 Install the oxygen sensor Tighten Tighten the oxygen sensor to 35 44 NSm 26 33 lb ft MAA1F480 EXHAUST GAS RECIRCULATION VALVE Removal Procedure 1 Disconnect the negative battery cable 2 Remove the air cleaner assembly 3 Disconnect the electric exhaust gas recirculation EEGR valve connector D21F008 KNOCK SENSOR Removal Procedure 1 Disconne...

Page 414: ... negative battery cable 2 Note the ignition wire location and disconnect the ignition wires from the EI system ignition coil 3 Disconnect the EI system ignition coil connector 4 Remove the EI system ignition coil retaining bolts 5 Remove the EI system ignition coil MAA1F500 Installation Procedure 1 Install the EI system ignition coil 2 Tighten the EI system ignition coil to 8 12 NSm 71 106 lb in U...

Page 415: ... SENSOR Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the camshaft position CMP sensor con nector 3 Remove the CMP sensor retaining bolt 4 Remove the CMP sensor MAA1F540 Installation Procedure 1 Install the CMP sensor 2 Tighten the CMP sensor retaining bolt to 10 14 NSm 89 124 lb in MAA1F510 ENGINE CONTROL MODULE ECM Removal Procedure 1 Disconnect the ECM connector ...

Page 416: ...s D Remove the ECM MAA1F530 Installation Procedure 1 Install in the reverse order of removal Notice If disconnecting the battery cable to the ECM the IAC valve resetting should be proceeded 2 install the ECM with the bolts Tighten Tighten the ECM mounting bolts to 6 8 NSm 53 71 lb in ...

Page 417: ...nister Protective Cover 8 71 Electric Exhaust Gas Recirculation EEGR Valve Retaining Bolts 20 30 15 22 Fuel Rail Retaining Bolts 18 22 13 16 Fuel Tank Strap Retaining Nuts 18 22 13 16 Knock Sensor Bolt 15 25 11 18 Intake Air Temperature IAT Sensor 20 30 15 22 Manifold Absolute Pressure MAP Sensor Retaining Bolt 8 12 71 106 Oxygen Sensor 35 44 26 33 Heated Oxygen Sensor 35 44 26 33 Throttle Body Re...

Page 418: ...1F 320 ENGINE CONTROLS DAEWOO M 150 BL2 ECM WIRING DIAGRAM SIRIUS D3 1 OF 5 MAA1F610 ...

Page 419: ...ENGINE CONTROLS 1F 321 DAEWOO M 150 BL2 ECM WIRING DIAGRAM SIRIUS D3 2 OF 5 MAA1F620 ...

Page 420: ...1F 322 ENGINE CONTROLS DAEWOO M 150 BL2 ECM WIRING DIAGRAM SIRIUS D3 3 OF 5 MAAF630 ...

Page 421: ...ENGINE CONTROLS 1F 323 DAEWOO M 150 BL2 ECM WIRING DIAGRAM SIRIUS D3 4 OF 5 MAA1F640 ...

Page 422: ...1F 324 ENGINE CONTROLS DAEWOO M 150 BL2 ECM WIRING DIAGRAM SIRIUS D3 5 OF 5 MAA1F650 ...

Page 423: ...tem 1G 2 Muffler 1G 2 Catalytic Converter 1G 2 Component Locator 1G 3 Exhaust System 1G 3 Repair Instruction 1G 4 On Vehicle Service 1G 4 Exhaust Pipe Catalytic Converter 1G 4 Pup up Catalitic Converter 1G 5 Front Muffler 1G 7 Rear Muffler 1G 8 Specifications 1G 9 Fastener Tightening Specifications 1G 9 ...

Page 424: ...f holes open seams or any deterioration is discovered upon in spection of the front muffler and pipe assembly the complete assembly should be replaced The same pro cedure is applicable to the rear muffler assembly Heat shields in the front and rear muffler assembly posi tions as well as for the catalytic converter and front ex haust pipe protect the vehicle and the environment from high temperatur...

Page 425: ...ENGINE EXHAUST 1G 3 DAEWOO M 150 BL2 COMPONENT LOCATOR EXHAUST SYSTEM D12G4011 1 Pup up Catalytic Converter 2 Front Exhaust Pipe Catalytic Converter Assembly 3 Front Muffler Pipe 4 Rear Muffler Pipe ...

Page 426: ...edure 1 Remove the floor console Refer to Section 9G Inte rior Trim if equipped Heated Oxygen Sensor HO2S 2 Disconnect HO2S connector D102G501 3 Remove the front exhaust pipe from the exhaust manifold or pup up catalytic converter D Remove the nuts 1 D Remove the gasket 2 4 Check the gasket for damage or crack D102G502 5 Remove the front exhaust pipe from the front muffler pipe D Remove the nuts 1...

Page 427: ...verter assembly to the exhaust manifold Tighten Tighten the nuts to 25 35 NSm 18 25 lb ft a Front exhaust pipe nut 2 Install the front exhaust pipe and the catalytic con verter assembly to the front muffler pipe flange Use the nuts to secure the front exhaust pipe and the cat alytic converter assembly Tighten Tighten the nuts to 25 35 NSm 18 25 lb ft b Front muffler pipe nut Notice Make sure not t...

Page 428: ... Section 1B SOHC Engine Mechanical MAA1B040 7 Remove pup up catalytic convertor D Remove the bolts MAA1B041 Installation Procedure 1 Install pup up catalytic convertor to exhaust pipe Tighten Tighten the bolts to 25 35 NSm 18 25 lb ft MAA1B011 2 Install exhaust manifold Refer to Section 1B SOHC Engine Mechanical Tighten Tighten the bolts and nuts to 17 27 NSm 13 20 lb ft Tighten the exhaust manifo...

Page 429: ...nt muffler nuts D Remove the nuts 1 MAA1G030 2 Remove the front muffler to rear muffler nuts 3 Detach the front muffler from rubber hanger and re move the front muffler MAA1G031 Installation Procedure 1 Hang the front muffler to rubber hanger 2 Install the front muffler to rear muffler nuts Tighten Tighten the nuts to 25 35 NSm 18 25 lb ft 3 Install the exhaust pipe to front muffler nuts Tighten T...

Page 430: ...val Procedure 1 Remove the front muffler to rear muffler nuts Tighten Tighten the nuts to 25 35 NSm 18 25 lb ft 2 Detach the rear muffler from the rubber hangers MAA1G040 3 Remove the rear muffler 4 Installation should flow the removal procedure in re verse order ...

Page 431: ... Nuts 25 35 18 25 Front Exhaust Pipe to Exhaust Manifold Nuts 25 35 18 25 Front Exhaust Pipe to Pup up Catalytic Converter 25 35 18 25 Front Muffler to Rear Muffler nuts 25 35 18 25 Pup up Catalytic Convertor to Exhaust Manifold Bolt 25 35 18 25 Muffler Clamp Nut 24 28 18 21 Catalytic Converter Heat Shield 8 12 71 106 Rear Muffler Heat Shield 8 12 71 106 ...

Page 432: ... the steering column to the intermediate shaft for loose connections or wear D Inspect the joint from the intermediate shaft to the steering gear for loose connections or wear D Tighten the coupling flange pinch bolts D Replace the intermediate shaft as needed D Inspect the front and the rear suspension the steering gear and the linkage for loose or damaged parts D Tighten the front and the rear s...

Page 433: ...ners D Replace the strut dampeners D A failure to rotate tires D Rotate the tires D Replace the tires as needed D Overloaded vehicle D Maintain the proper load weight D Low tire inflation D Inflate the tires to the proper pressure Scuffed Tires D Incorrect toe D Adjust the toe D A twisted or a bent suspension arm D Replace the suspension arm Wheel Tramp D An out of balance tire or wheel D Balance ...

Page 434: ... D A loose steering gear mounting D Tighten the steering gear mounting bracket bolts D The steering preload adjustment is out of adjustment D Perform a rack bearing preload on vehicle adjustment D Loose connections or wear of the joint from the steering column to the intermediate shaft D Loose connections or wear of the joint from the intermediate shaft to the steering gear D Tighten the coupling ...

Page 435: ...g when D Worn or loose wheel bearings D Replace the wheel bearings Braking D A broken or a sagging coil spring D Replace the coil spring D A leaking caliper D Replace the caliper D Warped rotors D Replace the rotors D An incorrect or an uneven caster D If the caster is beyond specifications check the frame and repair it as needed Low or Uneven Trim D A broken or a sagging coil spring D Replace the...

Page 436: ...le nut D Replace the wheel bearing as needed Steering Wheel Surges or Jerks Power D Low pressure in the power steering system D Replace the seals and the hoses as needed D A sluggish steering gear valve D Clean the pinion valve assembly D Replace the pinion valve assembly as needed D A loose power steering pump drive belt D Adjust the power steering pump drive belt Cupped Tires D The front wheel a...

Page 437: ...e is moving It is constant and unwavering and increases with the speed of the vehicle If the wheel bearing noise cannot be positively diagnosed or if the origin of the noise cannot be determined perform the following test 1 Raise and suitably support the vehicle 2 Spin the wheels using your hand Check for out of round or out of balance tires bent rims or loose wheel bearings 3 Spin the rear wheels...

Page 438: ...ing Axis Inclination 2B 3 Included Angle 2B 3 Scrub Radius 2B 3 Setback 2B 3 Turning Angle 2B 3 Diagnostic Information and Procedures 2B 4 Tire Diagnosis 2B 4 Front Toe Adjustment 2B 5 Front Camber and Caster Check 2B 5 Rear Camber Check 2B 5 Rear Toe Check 2B 5 Specifications 2B 6 Wheel Alignment Specifications 2B 6 Fastener Tightening Specifications 2B 6 ...

Page 439: ...he setting which achieves degrees 0_ of toe when the vehicle is moving Incorrect toe in or toe out will cause tire wear and re duced fuel economy As the individual steering and sus pension components wear from vehicle mileage additional toe will be needed to compensate for the wear Always correct the toe dimension last CASTER D16A008A Caster is the tilting of the uppermost point of the steering ax...

Page 440: ...wed from the front of the ve hicle The included angle is calculated in degrees Most align ment racks will not measure the included angle directly To determine the included angle subtract the negative or add the positive camber readings to the Steering Axis Inclination SAI SCRUB RADIUS The scrub radius is the distance between true vertical and the line through the center of the strut and lower ball...

Page 441: ...pressure D Inflate the tires to the proper pressure D High speed driving with the low inflation pressure D Inflate the tires to the proper pressure Uneven Braking D Inbalanced inflation pressure D Inflate the tires to the proper pressure D Irregular tire wear D Replace the tires Noise and Vibration of The Body D Low inflation pressure D Inflate the tires to the proper pressure D Inbalanced wheel D...

Page 442: ...in this section Jounce the bumper three times before measuring the camber or the caster in order to prevent an incorrect reading If the front camber or caster measurements deviate from the specifications locate and replace or repair any dam aged loose bent dented or worn suspension part If the problem is body related repair the body REAR CAMBER CHECK The rear camber is not adjustable Refer to Whee...

Page 443: ...ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ Rear Camber 0_30 0_30 0_ 20 Caster Manual Steering 2_48 30 Caster Power Steering 2_48 30 Toe in 2 person load 10 10 20 20 FASTENER TIGHTENING SPECIFICATIONS ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Application ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ NSm ÁÁÁÁÁÁ ÁÁÁÁÁÁ Lb Ft ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Lb In ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Tie Rod End Lock Nut ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 45 ÁÁÁÁÁÁ ÁÁÁÁÁÁ 33 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ...

Page 444: ...kle 2C 5 Front Wheel Bearing 2C 6 Repair Instructions 2C 7 On Vehicle Service 2C 7 Strut Assembly 2C 7 Knuckle Assembly 2C 8 Front Longitudinal Frame and Stabilizer Shaft 2C 10 Control Arm 2C 12 Strut Bar 2C 12 Crossmember 2C 13 Unit Repair 2C 16 Hub Bearing and Knuckle 2C 16 Front Strut 2C 20 Specifications 2C 23 General Specifications 2C 23 Fastener Tightening Specifications 2C 23 Special Tools ...

Page 445: ... allow the wheel to turn The lower end of the steering knuckle pivots on a ball joint bolted to the control arm The ball joint is fastened to the steering knuckle with a bolt When servicing the control arm to body attachment and the stabilizer shaft to body insulators make sure the at taching bolts are loose until the control arms are moved to the trim height which is curb height Trim height is th...

Page 446: ...FRONT SUSPENSION 2C 3 DAEWOO M 150 BL2 COMPONENT LOCATOR FRONT SUSPENSION D16B401A ...

Page 447: ...earing Oil Seal 14 Inner Hub Bearing 15 Steering Knuckle 16 Dust Cover 17 Hub Bearing Spacer 18 Outer Hub Bearing 19 Outer Bearing Oil Seal 20 Rotor 21 Wheel Hub 22 Hub Bolt 23 Hub Assembly 24 Drive Axle to Hub Caulking Nut 25 Control Arm Ball Stud Bolt 26 Cotter Pin 27 Castellated Nut 28 Washer 29 Stabilizer Shaft Bushing 30 Control Arm Dust Seal 31 Clip 32 Control Arm Bushing 33 Control Arm Asse...

Page 448: ...est the strut dampener being tested D Compare the compression and re bound with those of a similar vehicle that has an acceptable ride quality D Replace the strut dampener if need ed Leaks D A slight trace of fluid D The strut dampener is OK D Leaks of the seal cover on the fully extended strut D Replace the strut dampener D Excessive leaks of fluid on the strut dampener D Replace the strut dampen...

Page 449: ...5 lb ft 5 Check the bearing end play according to the following method D Place a dial guage against the disc surface grasp the disc D Using a push pull movement note gage readings Specification 0 130mm or less 0 005 in Standard tighting torque of drive shaft nut 210 NSm 155 lb ft 6 If the axial end play of the front wheel bearing exceed 0 130mm torque the drive shaft nut successively Max allowance...

Page 450: ...ts 2 D16B502A 3 Remove the top of the strut assembly at driver side D Remove the bolt and the fuse box 1 2 D Remove the nuts 3 D106B503 4 Remove the lower of the strut assembly D Raise and suitably support the vehicle D Remove the wheel Refer to Section 2E Tires and Wheels D Remove the ABS front speed sensor electrical wire from the bracket if applicable 1 D Disconnect the brake hose from the brac...

Page 451: ...side 1 Tighten Tighten the nuts to 18 28 NSm 13 21 lb ft D Install the nuts at driver side 2 Tighten Tighten the nuts to 18 28 NSm 13 21 lb ft 7 Install the power steering fluid reservoir 8 Install the fuse box and bolt D106B506 KNUCKLE ASSEMBLY Tools Required KM 507 B Ball Joint Remover Removal Procedure 1 Remove the caulking nut D Straighten the bent flange caulking nut 1 D Remove the caulking n...

Page 452: ...steering knuckle assembly 2 D16B509A 70 90 NSm 50 70 NSm Installation Procedure 1 Install in the reverse order of removal 2 Install the steering knuckle assembly in the vehicle with strut bracket bolts 1 Tighten Tighten the strut bracket bolts to 70 90 NSm 52 66 lb ft 3 Install the brake caliper from the knuckle assembly 4 Install the control arm into the knuckle assembly with the stud bolt 2 Tigh...

Page 453: ...nual Transaxle D Remove the front under longitudinal frame bolt 1 D Remove the front under longitudinal frame nut 2 D16B512A D Remove the stabilizer shaft mounting bolts 3 D Remove the front under longitudinal frame D106B513 2 Remove the stabilizer shaft from the vehicle D Remove the cotter pin 1 D Remove the castellated nut 2 D Remove the washer 3 D Remove the rear bushing with separating the sta...

Page 454: ... Tighten the stabilizer shaft to body castellated nut to 40 50 NSm 30 36 lb ft D Install the cotter pin D16B517C 3 Install the front under longitudinal frame D Install the stabilizer shaft mounting bolts 1 Tighten Tighten the mounting bolts to 30 50 NSm 22 36 lb ft D16B518B 65 80 NSm 10 14 NSm D Install the front under longitudinal frame bolt 2 Tighten Tighten to bolt to 10 14 NSm 89 124 lb in D I...

Page 455: ...B Installation Procedure 1 Install the control arm onto the vehicle D Install the control arm bolt 1 Tighten Tighten the control arm bolt to 55 70 NSm 41 52 lb ft D Install the control arm to the knuckle assembly D Install the stud bolt 2 Tighten Tighten the stud bolt to 50 70 NSm 36 52 lb ft 2 Install the stabilizer shaft D10B522A STRUT BAR Removal Procedure 1 Open the hood 2 Remove the strut bar...

Page 456: ...re pipe bracket to strut bar nut Tighten Tighten the strut bar bolts to 35 55 NSm 25 41 lb ft D Install the purge control valve to the strut bar D106B525 CROSSMEMBER Removal Procedure 1 Remove the transaxle under cover Refer to Section 5B Five Speed Manual Transaxle 2 Remove the front under longitudinal frame Refer to Stabilizer Shaft in this section 3 Remove the damping bush bolt and nut D106B526...

Page 457: ...order of removal 2 Install the front damping bush to the crossmember Tighten D Tighten the bolts to 45 55 NSm 33 41 lb ft a Front damping bush bolt D Tighten the bolt to 35 41 NSm 25 30 lb ft b Front damping bush bolt D16B530A 17 27 NSm 17 27 NSm 3 Install the crossmember to the vehicle with the bolts Tighten Tighten the bolts to 17 27 NSm 13 20 lb ft a Crossmember right rear bolt b Crossmember ri...

Page 458: ...mber left rear bolt d Crossmember leftt side bolt D16B532A 68 83 NSm 4 Install the front damping bush to the vehicle Tighten Tighten the front damping bush bolt and nut to 68 83 NSm 51 61 lb ft 5 Install the front under longitudinal frame Refer to Stabilizer Shaft in this section ...

Page 459: ...ace Installer DW 340 030 Front Wheel Bearing Installer 09940 71430 Front Spring Compressor Disassembly Procedure 1 Remove the steering knuckle assembly Refer to Knuckle Assembly in this section 2 Remove the bolts from the wheel hub D106B702 3 Remove the wheel hub from the knuckle assembly using the front wheel hub remover DW 340 010 D Remove the wheel hub using the front wheel hub remover DW 340 0...

Page 460: ...220 020A 01 and differential bearing plate adapter DW 220 020A 04 4 D106B704 D Remove the oil seal from the wheel hub 5 Important Do not use removed oil seal D106B705 4 Remove the steering knuckle assembly D Remove the oil seal 1 Important Do not use removed oil seal D Remove the wheel bearing 2 D106B706 D Remove the outer bearing race 3 ...

Page 461: ...emble the inner bearing race using the front wheel hub remover DW 340 010 and the front bearing race installer DW 340 020 1 D106B709 D Assemble the outer bearing race using the front wheel hub remover DW 340 010 and the front wheel bearing race installer DW 340 020 2 D106B710 D Assemble the outer wheel bearing 3 D Assemble the outer wheel bearing oil seal 4 ...

Page 462: ...the outer wheel bearing into the wheel hub using the front wheel hub remover DW 340 010 and the front wheel bearing installer DW 340 030 3 D16B712A D Tighten the bolts 4 Tighten Tighten the bolt to 65 NSm 48 lb ft D106B713 D Install the bearing spacer 5 D106B714 D Press the inner wheel bearing into the wheel hub using the front wheel hub remover DW 340 010 and the front wheel bearing installer DW ...

Page 463: ... SPRING Tools Required 09940 71430 Front Spring Compressor Disassembly Procedure 1 Remove the strut assembly Refer to Strut Assem bly in this section 2 Compress the front spring with the front spring com pressor 09940 71430 Caution During compressing spring do not make spring end point to operator or dangerous direc tion D106B717 3 Fix the strut support using the bench vise and remove the strut nu...

Page 464: ...ve the coil spring upper seat 6 D Remove the coil spring seat 7 D Remove the bumper stopper 8 D16B719A 50 60 NSm Assembly Procedure 1 Install the coil spring front bumper stopper coil spring seat coil spring upper seat strut bearing bearing seat mounting seat mount assembly and in ner support to the strut 2 Tighten the strut nut D Fix the strut support using the bench vise D Tighten the nut Tighte...

Page 465: ...2C 22 FRONT SUSPENSION DAEWOO M 150 BL2 D106B720 3 Inspect the installation of coil spring 1 2 4 Install the strut assembly Refer to Strut Assembly in this section ...

Page 466: ...ÁÁÁÁÁÁÁ 50 60 ÁÁÁÁÁÁ ÁÁÁÁÁÁ 36 44 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Strut Assembly to Knuckle Bolts ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 70 90 ÁÁÁÁÁÁ ÁÁÁÁÁÁ 52 66 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Control Arm Mounting Bolt ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 55 70 ÁÁÁÁÁÁ ÁÁÁÁÁÁ 41 52 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Control Arm Ball Stud Bolt ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ...

Page 467: ...fferential Bearing Puller D13B113A DW 220 020A 04 Differential Bearing Plate Adapter D16B101A DW 340 010 Front Wheel Hub Remover D106B102 DW 340 020 Front Wheel Bearing Race Installer D106B103 DW 340 030 Front Wheel Bearing Installer D105B101 KM 507 B Ball Joint Remover D106B104 09940 71430 Front Spring Compressor ...

Page 468: ...on 2D 4 Checking the Rear Wheel Bearing End Play 2D 5 Rear Wheel Bearing Free Load 2D 5 Repair Instructions 2D 6 On Vehicle Service 2D 6 Shock Absorber 2D 6 Lateral Rod 2D 7 Trailing Arm 2D 8 Rear Axle Assembly 2D 9 Unit Repair 2D 12 Hub and Bearing Assembly 2D 12 Specifications 2D 15 General Specifications 2D 15 Fastener Tightening Specifications 2D 15 Special Tools and Equipment 2D 16 Special To...

Page 469: ...of an axle with trailing arms and a lateral rod two coil springs two shock ab sorbers two upper spring seats and two bump stop pers The axle structure maintains the relationship of the wheels to the body Each coil spring is retained between a seat in the under body and a seat welded to the top of the rear axle ...

Page 470: ... D106C401 1 Shock Absorber 2 Bumper Stopper 3 Coil Spring Upper Seat 4 Coil Spring 5 Washer 6 Bushing 7 Lateral Rod 8 Rear Axle 9 Oil Seal 10 Wheel Bearing Inner 11 ABS Wheel Speed Ring 12 Wheel Bearing Outer 13 Cotter Pin 14 Castellated Nut 15 Spindle Cap 16 Trailing Arm ...

Page 471: ...aulty shock absorber D Replace the shock absorber D Faulty coil spring D Replace the coil spring D Lateral rod bushing is worn or damaged D Replace the lateral rod bushing D Trailing arm bushing is worn or damaged D Replace the trailing arm bushing Vehicle Leans Toward D Rear axle deformation D Replace the rear axle the Side D Lateral rod deformation D Replace the lateral rod D Trailing arm deform...

Page 472: ...ighten the castellated nut 5 If the bearing play is high after tightening replace the wheel bearing REAR WHEEL BEARING FREE LOAD 1 Release the parking brake 2 Raise the vehicle and rotate the wheel 3 Remove the wheels 4 Check the torque when the hub moves by a spring scale ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ Standard No Load ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ 0 137 0 422 NSm 0 9 3 7 lb in D106C302 5 If the c...

Page 473: ...xle assem bly 1 2 D106C502 2 Remove the shock absorber D Remove the bolt 1 D Remove the nut 2 D16C503B Installation Procedure 1 Install the shock absorber D Install the shock absorber to rear axle bolt 1 Tighten Tighten the bolt to 45 70 NSm 33 52 lb ft D Install the shock absorber to body bracket nut 2 Tighten Tighten the shock absorber nut to 45 70 NSm 33 52 lb ft 2 Remove the jack stand and low...

Page 474: ...eral rod to body bracket bolt 1 D106C505 D Remove the lateral rod to rear axle nut 2 D106C506 2 Remove the lateral rod axle side bushing and washer from the lateral rod D16C507A Installation Procedure 1 Install in the reverse order of removal 2 Install the lateral rod to rear axle side nut Tighten Tighten the lateral rod axle side nut to 35 55 NSm 25 41 lb ft ...

Page 475: ...Procedure 1 Raise and suitably support the vehicle 2 Support the rear axle with adjustable jack stands 3 Separate the rear shock absorber from the rear axle assembly D Loosen the shock absorber to body bracket nut 1 D Remove the shock absorber to rear axle bolt 2 D106C510 4 Remove the trailing arm D Remove the trailing arm to rear axle bolts 1 D106C511 D Remove the trailing arm to body bracket bol...

Page 476: ...d brake plate Refer to Section 4E Rear Drum Brakes 2 Remove the lateral rod Refer to Lateral Rod in this section 3 Disconnect the rear axle and the trailing arm D Support the rear axle with adjustable jack stands 1 D Remove the shock absorber to rear axle bolt 2 D Loosen the shock absorber to body bracket nut 3 D Remove the trailing arm to rear axle bolt 4 Caution When disconnecting the rear axle ...

Page 477: ...0 Installation Procedure 1 Install in the reverse order of removal Important Make sure the spring diameter prior to installing the spring Upper spring diameter is smaller than lower spring diameter Caution Support the jack stand to the rear axle se curely until installing the trailing arm bolts D106C519 2 Install the rear bumper stopper and rear spring upper seat ...

Page 478: ... Tighten Tighten the trailing arm to rear axle bolt to 80 90 NSm 59 66 lb ft D16C516C D Install the shock absorber to rear axle bolt 2 Tighten Tighten the shock absorber to rear axle bolt to 45 70 NSm 33 52 lb ft 4 Install the lateral rod Refer to Lateral Rod in this section 5 Install the rear brake drum shoe and brake plate Re fer to Section 4E Rear Drum Brake ...

Page 479: ...el Bearing Race Installer Disassembly Procedure 1 Remove the rear brake drum Refer to Section 4E Rear Drum Brakes 2 Remove the rear wheel bearing D Remove the outer tapered roller bearing 1 D106C702 D Remove the oil seal 2 D Remove the inner tapered roller bearing 3 D106C703 3 Remove the bearing races from the brake drum D Remove the inner bearing race 1 ...

Page 480: ...heel hub remover DW 340 010 and the rear wheel bearing race installer DW 350 030 D Press the inner bearing race 1 D106C706 D Press the outer bearing race 2 D106C707 2 Install the wheel bearing and oil seal into the brake drum Important Coat or fill all the hollow spaces of both wheel bearing the ring seal lip and the brake drum with antifriction grease D Install the inner bearing 1 D Install the o...

Page 481: ...ION DAEWOO M 150 BL2 D106C708 D Install the outer bearing 3 3 Install the brake drum Refer to Section 4E Rear Drum Brakes 4 Adjust the end play and free load of the bearing Re fer to Check and Adjustments in this section ...

Page 482: ...IGHTENING SPECIFICATIONS ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Application ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ NSm ÁÁÁÁÁÁ ÁÁÁÁÁÁ Lb Ft ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Lb In ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Shock Absorber to Body Bracket Nut ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 45 70 ÁÁÁÁÁÁ ÁÁÁÁÁÁ 33 52 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Shock Absorber to Rear Axle Bolt ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 45 70 ÁÁÁÁÁÁ ÁÁÁÁÁÁ 33 52 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁ...

Page 483: ...2D 16 REAR SUSPENSION DAEWOO M 150 BL2 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE D16B101A DW 340 010 Front Wheel Hub Remover D106C101 DW 350 030 Rear Wheel Bearing Race Installer ...

Page 484: ...lance 2E 4 Diagnostic Information and Procedures 2E 5 Tire Wear 2E 5 Irregular or Excessive Tires Wear 2E 6 Repair Instructions 2E 7 On Vehicle Service 2E 7 Wheel 2E 7 On Vehicle Balancing 2E 8 Off Vehicle Balancing 2E 8 Correcting Non Uniform Tires 2E 8 Tire and Wheel Match Mounting 2E 9 Specifications 2E 10 Tire Size and Pressure Specifications 2E 10 Inflation Pressure Conversion Specifications ...

Page 485: ...e pressure and endures applied load and shock to tire it should have a high anti fatigue characteristic Bead A steel wire winding the ending part of carcass code coated with rubber film and wrapped with nylon cord pa pers It fixes tire to a rim Tube Tires used in mostly current vehicle are mostly tubeless tires Side Wall It is provided to improve the comfortable driving by pro tecting carcass and ...

Page 486: ...bly Use only replacement tires with the same size load range and construction as the original The use of any other tire size or construction type may seriously affect ride handling speedometer odometer calibration ve hicle ground clearance and tire clearance to the body and the chassis This does not apply to the spare tire fur nished with the vehicle It is recommended that new tires be installed i...

Page 487: ...ves to keep dust and water out Higher than recommended tire pressure can cause D Hard ride D Tire bruising or damage D Rapid tread wear at the center of the tire Lower than recommended pressure can cause D Tire squeal on turns D Hard steering D Rapid and uneven wear on the edges of the tread D Tire rim bruises and rupture D Tire cord breakage D High tire temperatures Unequal tire pressures on same...

Page 488: ...e the depth of the tire tread 2 If the depth of the tread is below the specified value replace the tire D106A302 ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ Limit of The Tread Wear ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 1 6mm 0 06 in 3 Indicators appear when the tire tread depth becomes shallow less than 1 6mm 0 06 in ...

Page 489: ...sive tire inflation pressures D Improper the tire rotation D Adjust tire inflation pressures D Rotate the tires D16A305C D Poor toe in D Adjust the toe in D16A305D D toe out D Adjust the toe in D16A305E D Poor camber or caster D Faulty suspensions D Poor wheel balancing D Improper the tire rotation D Check the steering knuckle control arm drive axle and suspensions Repair or replace them as needed...

Page 490: ...els from the vehicle can be due to foreign material or to a tight fit between the wheel centerhole and the hub or the rotor These wheels can be removed by 1 Retightening the wheel nuts on the affected wheel and then loosening the wheel nuts by two turns 2 Lowering the vehicle and rocking it from side to side as hard as possible using one or more person s body weight to loosen the wheel 3 Raising t...

Page 491: ...s 1 During on vehicle balancing do not remove the bal ance weights from the off vehicle dynamic balance 2 If more than 1 ounce of additional weight is required split the weight between the inner and the outer rim flanges 3 Spin the driven tire and wheel assemblies using the engine OFF VEHICLE BALANCING Perform wheel balancing with an electronic off vehicle balancer The balancer is easy to use and ...

Page 492: ... plant Match mounting aligns the radially stiffest part of the tire or high spot to the smallest radius or low spot of the wheel The high spot of the tire is originally marked by a red paint mark or an adhesive label on the outboard side wall The low spot of the wheel will be at the location of the valve stem Before dismounting a tire from its wheel scribe a line on the tire at the valve stem to a...

Page 494: ...e Axle Assembly 3B 3 Diagnostic Information and Procedures 3B 4 Diagnosis 3B 4 Repair Instructions 3B 5 On Vehicle Service 3B 5 Drive Axle Assembly 3B 5 Unit Repair 3B 9 Inner Joint 3B 9 Outer Joint 3B 10 Specifications 3B 12 General Specifications 3B 12 Fastener Tightening Specifications 3B 12 Special Tools and Equipment 3B 13 Special Tools Table 3B 13 ...

Page 495: ...nt wheel as semblies Each axle assembly consists of an inner constant velocity joint and an outer constant velocity joint connected to an axle shaft The inner joint is com pletely flexible and has the ability to move in and out The outer joint is also flexible but it cannot move in and out The drive axles use a Rzeppa style joint on the out board side and a Tripot style joint on the inboard side ...

Page 496: ...MPONENT LOCATOR DRIVE AXLE ASSEMBLY D104B401 1 Outer Joint Rzeppa 2 Outer Large Boot Clamp 3 Outer Boot 4 Outer Small Boot Clamp 5 Drive Axle Shaft 6 Inner Small Boot Clamp 7 Inner Boot 8 Inner Large Boot Clamp 9 Inner Joint Tripot 10 Inner Joint Housing ...

Page 498: ...ls 3 Remove the transaxle under cover D Remove the bolts 1 D Remove the under cover 2 D104B501 4 Drain the transaxle fluid through the drain plug 5 Remove the stabilizer bar Refer to Section 2C Front Suspension 6 Separate the control arm ball joint and the tie rod end from the knuckle Refer to Section 6D Manual Steer ing gear and Section 2C Front Suspension a Control arm ball joint bolt b Tie rod ...

Page 499: ...athead screwdriver between the trans axle case and the drive axle joint case 1 D Remove the drive axle 2 Important Cap the transaxle drive opening after the drive axle has been removed to keep any contamination out D104B504 Inspection Procedure 1 Inspect for worn or damaged spline of drive axle 1 2 Inspect for a leaking boot 2 3 Inspect for a bent shaft 3 D14B502A Installation Procedure 1 Clean th...

Page 500: ...izer bar castellated nut to 40 50 NSm 30 36 lb ft a Stabilizer bar mounting bolt b Stabilizer bar castellated nut D14B507A 8 Install the drive axle shaft nut Tighten Tighten the drive axle shaft nut to 210 NSm 155 lb ft Notice Always use a new nut Always peen the caulking nut with a punch and a hammer until the nut is locked into place on the wheel hub 9 Install the wheels Refer to Section 2E Tire...

Page 501: ...3B 8 MANUAL TRANSAXLE DRIVE AXLE DAEWOO M 150 BL2 35 55 NSm D13B521A 11 Install the transaxle under cover Tighten Tighten the transaxle under cover bolts to 35 55 NSm 25 41 lb ft ...

Page 502: ...ive axle Refer to Drive Axle Assem bly in this section 2 Remove the clamps on the joint boot D Remove the boot clamp large using the boot clamp pliers J 35566 1 D Remove the boot clamp small 2 D104B702 3 Remove the joint housing from boot a Boot b Joint housing D104B703 4 Degrease the joint assembly 5 Remove the tripot joint D Remove the circlip 1 D Remove the tripot joint 2 ...

Page 503: ...commended grease If not joint and boot can be damaged Important Always use new clamps Inspection Procedure 1 Inspect the operation of joint 2 Inspect for a leaking boot through the clamp side D104B706 OUTER JOINT WHEEL SIDE Disassembly Procedure 1 Remove the drive axle Refer to Drive Axle Assem bly in this section 2 Remove the clamps on the joint boot D Remove the boot clamps 1 2 D104B707 3 Degrea...

Page 504: ...haft 2 D104B709 3 Fill the joint housing with recommended grease when installing ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Capacity ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ 80 90 g 2 8 3 2 ounces Notice Always use the recommended grease If not joint and boot can be damaged Important Always use new clamps D104B710 Inspection Procedure 1 Inspect the operation of joint 2 Inspect for a leaking boot through the clamp side Important Do not disas...

Page 505: ...ÁÁÁÁÁ ÁÁÁÁÁÁÁÁ Grease Capacity ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Outer ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ g ounce 80 90 2 8 3 2 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ FASTENER TIGHTENING SPECIFICATIONS ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Application ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ NSm ÁÁÁÁÁÁ ÁÁÁÁÁÁ Lb Ft ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Lb In ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Control Arm Ball Joint Bolt ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 50 70 ÁÁÁÁÁÁ ÁÁÁÁÁÁ 36 52 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Á...

Page 506: ...MANUAL TRANSAXLE DRIVE AXLE 3B 13 DAEWOO M 150 BL2 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE D104B101 KM 507 B Tie Rod End Joint Remover D105B101 J 35566 Boot Clamp Pliers ...

Page 507: ...amp Operation 4A 2 Component Locator 4A 3 Brake System Non ABS 4A 3 Diagnostic Information and Procedures 4A 4 Brake System Testing 4A 4 Brake Hose Inspection 4A 4 Warning Lamp Operation 4A 5 Brake System Fault 4A 5 Manual Bleeding the Brakes 4A 6 Pedal Travel Check 4A 6 Brake Pedal Free Play Inspection 4A 7 Repair Instructions 4A 8 On Vehicle Service 4A 8 Brake Hose Front 4A 8 Brake Hose Rear 4A ...

Page 508: ... switch is in the III position the BRAKE warning lamp should il luminate It should go off when the ignition switch return to II position The following conditions will activate the BRAKE warning lamp D The lamp should be on whenever the parking brake applied and the ignition switch is in the II position D A low fluid level in the master cylinder will turn the BRAKE warning lamp on D17A007A ...

Page 509: ...sembly 10 Reservoir Cap 11 Reservoir 12 Grommet Seal 13 Master Cylinder 14 Proportioning Valve 15 Stoplamp Switch 16 Brake Pedal Assembly 17 Clutch Pedal Spring 18 Pedal Bracket Assembly 19 Clutch Pedal Pad 20 Clutch Pedal 21 Cushion 22 Bushing 23 Retaining Ring 24 Spring 25 Brake Pedal Pad 26 Brake Pedal 27 Brake Pedal Spring 28 Accelator Pedal Pad 29 Accelator Pedal 30 Rear Drum Brake Hose 31 E ...

Page 510: ...ght leak If the fluid level is nor mal check the vacuum booster pushrod length If an in correct pushrod length is found adjust or replace the rod Check the master cylinder using the following proce dure D Check for a cracked master cylinder casting or brake fluid leaking around the master cylinder Leaks are in dicated only if there is at least one drop of fluid A damp condition is not abnormal D C...

Page 511: ...ground D Faulty the fluid level sensor D Replace the sensor Stoplamp ON D Faulty the stoplamp switch D Replace the stoplamp switch D Push rod length is short D Adjust the push rod length of the power booster D Stoplamp switch circuit shorted to battery D Repair or Replace the wiring harness Poor Braking D Brake fluid lacks or leaks D Repair the leaks or add the fluid D Brake fluid contamination D ...

Page 512: ... air is removed 7 Check the leaks for the bleeder screw PEDAL TRAVEL CHECK 1 Start the engine 2 Push the pedal three times 3 With brake pedal depressed with a about 30Kg 66 15 lb load measure the clearance between the pedal pad and the lower dash panel Unit mm in ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ Specification ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ 60 2 36 D107A304 4 If clearance is less than 60mm 2 36 in the ...

Page 513: ...ral times to discharge the vacuum of the power booster 2 Measure the pedal movement until the hardness is felt when pushing the brake pedal by hand Unit mm in ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ Specification ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ 6 10 0 24 0 31 3 Brake pedal free play can not be adjusted D107A305 ...

Page 514: ... D Plug the opening in the brake pipe and caliper to prevent fluid loss or contamination D17A529B Installation Procedure 1 Connect the brake lines to the brake hose 1 Tighten Tighten the brake pipe to hose fitting to 16 NSm 12 lb ft 2 Install the brake hose coupling bolt 2 Tighten Tighten the bolt to 25 5 NSm 19 1 lb ft Important Use only Daewoo recommended brake fluid 3 Bleed the brake system Ref...

Page 515: ... Important Use only Daewoo recommended brake fluid 3 Bleed the brake system Refer to Manual Bleeding the Brakes in this section 4 Check the brake system for leaks 5 Install the wheels Refer to Section 2E Tires and Wheels D107A523 STOPLAMP SWITCH Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Disconnect the negative battery cable 2 Remove the stoplamp switch D Disconnect the con...

Page 516: ... D Remove the brake pedal pad 5 D17A527A Installation Procedure 1 Install the pad to the brake pedal 2 Install the brake pedal with spring bushing and cush ion 3 Connect the brake pedal to the power booster Tighten Tighten the brake pedal to pedal bracket bolt to 18 NSm 13 lb ft 4 Install the stoplamp switch Refer to Stoplamp Switch in this section D24C001A BRAKE PEDAL RIGHT HAND DRIVE Removal Pro...

Page 517: ...ts mounting brake pedal bracket 1 5 Remove the nuts mounting brake pedal bracket 2 D24D003 6 Remove the canister Refer to Section 1F Engine Controls 7 Remove the bolt mounting brake pedal bracket in the engine compartment 1 D24D004 8 Remove the brake pedal D Remove the snap rings 1 D Remove the bushings 2 D Remove the brake pedal spring 3 D Remove the cushion 4 D Remove the brake pedal pad 5 ...

Page 518: ...e pedal with the snap rings 5 Install the bolts and nuts mounting brake pedal brack et Tighten D Tighten the bolts mounting brake pedal bracket to 18 26 NSm 13 20 lb ft D Tighten the nuts mounting brake pedal bracket to 18 26 NSm 13 20 lb ft D24D007 6 Install the stoplamp switch with the bracket and the bolts Tighten Tighten the mounting bolts to 9 12 NSm 80 106 lb in 7 Connect the brake pedal rod...

Page 520: ...4A 14 HYDRAULIC BRAKES DAEWOO M 150 BL2 SCHEMATIC AND ROUTING DIAGRAMS BRAKE LAMP WARNING CIRCUIT D17A201B STOPLAMP SWITCH CIRCUIT D17A202B ...

Page 521: ...ic Information and Procedures 4B 3 Checking the Brake Fluid Level 4B 3 Repair Instructions 4B 4 On Vehicle Service 4B 4 Master Cylinder Assembly 4B 4 Brake Fluid Reservoir 4B 5 Proportioning Valve For Vehicle With the Non ABS Braking System 4B 5 Brake Fluid Level Switch 4B 6 Unit Repair 4B 8 Master Cylinder 4B 8 Specifications 4B 9 Fastener Tightening Specifications 4B 9 ...

Page 522: ...ssembly D Do not use lubricated shop air on brake parts as this may damage rubber components D If any hydraulic component is removed or discon nected it may be necessary to bleed all or part of the brake system D The torque values specified are for dry unlubricated fasteners D Perform all service operations on a clean bench free from all traces of mineral oil PROPORTIONING VALVE The proportioning ...

Page 523: ...MASTER CYLINDER 4B 3 DAEWOO M 150 BL2 DIAGNOSTIC INFORMATION AND PROCEDURES CHECKING THE BRAKE FLUID LEVEL 1 Check the fluid level 2 If the fluid level is below MAX refill the fluid to MAX D107A302 ...

Page 524: ...section 3 Remove the master cylinder D Disconnect the electrical connector D Loosen the brake pipe fittings D Plug the opening in the master cylinder to prevent fluid loss or contamination Notice Brake fluid may damage paintwork if spillage onto paintwork wash with cold water immediately D Remove the nuts mounting the master cylinder 3 D17A515A Installation Procedure Important Use only Daewoo reco...

Page 525: ...luid D Remove the screw 1 D Remove the fluid reservoir using a flathead screw driver 2 Notice Do not force one side strongly to prevent dam age of reservoir when removing the reservoir D17A518A Installation Procedure Important Use only Daewoo recommended brake fluid 1 Install the reservoir with the screw Tighten Tighten the screw to 4 NSm 35 lb ft 2 Install the fluid level switch connector Refer t...

Page 526: ...l the brake pipe fitting 2 Tighten Tighten the brake pipe fitting to proportioning valve to 16 NSm 12 lb ft 3 Bleed the brake system Refer to Section 4A Hy draulic Brakes D107A504 BRAKE FLUID LEVEL SWITCH Removal procedure 1 Remove the vacuum hose from the power booster Refer to Section 4C Power Booster 2 Remove the brake fluid level switch D Remove the brake fluid level switch locking system by t...

Page 527: ...NDER 4B 7 DAEWOO M 150 BL2 D107A506 Installation procedure 1 Install the brake fluid level switch 2 Connect the electrical connector 3 Install the vacuum hose to the power booster Refer to Section 4C Power Booster ...

Page 528: ...taining ring avoid dam aging the piston or the cylinder wall 8 Remove the primary piston 3 9 Carefully remove the secondary piston assembly and the spring from the master cylinder bore 4 D24B003 Assembly Procedure 1 Install the secondary piston assembly 2 Install the stop pin 3 Install the primary piston 4 Install the retaining ring 5 Install the boot 6 Install the washer 7 Install the reservoir s...

Page 529: ...lication ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ NSm ÁÁÁÁÁÁ ÁÁÁÁÁÁ Lb Ft ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Lb In ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Fluid Reservoir Screw ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 4 ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 35 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Master Cylinder Attaching Nuts ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 16 ÁÁÁÁÁÁ ÁÁÁÁÁÁ 12 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Brake Pipe Fittings to Master Cylinder Á...

Page 530: ... Diagnostic Information and Procedures 4C 3 Power Booster Functional Check 4C 3 Check Valve Functional Check 4C 3 Repair Instructions 4C 4 On Vehicle Service 4C 4 Vacuum Hose and Check Valve 4C 4 Power Booster Assembly 4C 5 Specifications 4C 8 General Specifications 4C 8 Fastener Tightening Specifications 4C 8 ...

Page 531: ... both sides of its diaphragm When the brakes are applied air at atmospheric pres sure is admitted to one side of the diaphragm to pro vide the power assist When the brakes are released at mospheric air is shut off from that side of the diaphragm The air is then drawn from the booster through the vacu um check valve by the vacuum source Important If any hydraulic component is removed or disconnecte...

Page 532: ...ecause of extra force produced If the brake pedal does not drop the vacuum system vacuum hoses check valve etc is probably defective and should be checked If no defect is revealed by checking the vacuum system the defect is in the booster itself CHECK VALVE FUNCTIONAL CHECK 1 Remove the vacuum hose 2 Suck the vacuum hose to power booster And also suck the vacuum hose to engine 3 If the air pass th...

Page 533: ...CHECK VALVE Removal Procedure 1 Remove the vacuum hose D Disconnect the vacuum hose from the intake man ifold 1 D17A502A D Disconnect the vacuum hose from the power booster 2 D107A503 Installation Procedure 1 Connect the vacuum hose to the power booster 2 Connect the vacuum hose to the intake manifold ...

Page 534: ...vis pin 2 D107A520 D Remove the nuts 3 D107A521 D Remove the power booster 4 D17A522A Installation Procedure 1 Install the power booster with the new cotter pin cle vis pin and nuts Tighten Tighten the nuts to 16 NSm 12 lb ft Important Make sure the distance from the booster to the center of the clevis bore should be 100mm 3 94 in 2 Install the master cylinder assembly Refer to Section 4B Master C...

Page 535: ...ter 3 Remove the instrument panel assembly Refer to Section 9E Instrument Driver Information 4 Remove the evaporator unit mounting screws and take off the evaporator unit a little Refer to Section 7B Manual Control Heating Ventilation and Air Con ditioning System 5 Remove the power booster D Straighten the cotter pin and remove it 1 D Remove the clevis pin 2 D24C002 D Remove the nuts 3 D107A521 D ...

Page 536: ...e from the booster to the center of the clevis bore should be 100mm 3 94 in 2 Install the evaporator unit with the screws Refer to Section 7B Manual Control Heating Ventilation and Air Conditioning System 3 Install the instrument panel assembly Refer to Sec tion 9E Instrument Driver Information 4 Connect the vacuum hose to the power booster 5 Install the master cylinder assembly Refer to Section 4...

Page 537: ...ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ Servo Force Ratio ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ 3 7 1 ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ Distance from the booster to the center of the clevis bore mm inch 96 3 78 FASTENER TIGHTENING SPECIFICATIONS ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Application ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ NSm ÁÁÁÁÁÁ ÁÁÁÁÁÁ Lb Ft ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Lb In ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Booster to Dash P...

Page 538: ...r 4D 3 Front Disc Brakes 4D 3 Diagnostic Information and Procedures 4D 4 Front Disc Brake 4D 4 Lining Inspection 4D 5 Rotor Inspection 4D 5 Repair Instructions 4D 6 On Vehicle Service 4D 6 Shoe and Lining 4D 6 Caliper Assembly 4D 7 Rotor 4D 7 Unit Repair 4D 8 Caliper Overhaul 4D 8 Specifications 4D 11 General Specifications 4D 11 Fastener Tightening Specifications 4D 11 ...

Page 539: ...d fasteners D Perform the service operations on a clean bench free from all mineral oil materials CLEARANCE CALIBRATION When the hydraulic pressure is applied to the piston the piston moves leftward The piston seal which extent considerable pressure against the piston moves with cylinder However as a part of the piston seal is fixed into a grove in the cylinder shape of the seal is as shown in bel...

Page 540: ...ENT LOCATOR FRONT DISC BRAKES D17B401A 1 Front Brake Caliper Assembly 2 Front Brake Boot Assemblies 3 Pins 4 Pin Boots 5 Front Brake Pads 6 Carrier 7 Pad Spring 8 Piston Boot 9 Piston 10 Piston Seal 11 Cylinder 12 Bleeder Screw Cap 13 Bleeder Screw ...

Page 541: ... Braking D Inoperative carrier D Replace the carrier D Sticked caliper piston D Repair the caliper piston or replace the caliper assembly if needed Dragging Brake D Sticked caliper piston D Repair the caliper piston or replace the caliper assembly if needed Noise and Vibration D Excessive rotor run out D Replace the rotor When Brake Applied D Interference of the dust cover D Repair the dust cover ...

Page 542: ...nt brake roughness D107B302 In addition to these tolerances the surface finish must be held to a specified range The control of the braking surface finish is necessary to avoid pulls and erratic per formance and to extend lining life Using a commercially available dial indicator check lat eral runout as follows Notice Permissible lateral runout is a maximum 0 05 mm 0 002 in If lateral runout excee...

Page 543: ...eels Refer to Section 2E Tires and Wheels 2 Remove the brake pads D Remove the pin bolt 1 D107B502 D Lift up the cylinder assembly 2 D17B503A Installation Procedure 1 Install the brake pads and the cylinder assembly with the pin bolt Tighten Tighten the pin bolt to 26 NSm 19 lb ft 2 Install the front wheels Refer to Section 2E Tires and Wheels ...

Page 544: ...nect the brake hose 2 Tighten Tighten the brake hose inlet fitting to coupling bolt to 25 5 NSm 19 1 lb ft 3 Install the front wheels Refer to Section 2E Tires and Wheels 4 Bleed the brake system Refer to Section 4A Hy draulic Brakes D117B506 ROTOR Removal Procedure 1 Remove the steering knuckle Refer to Section 2C Front Suspension 2 Remove the rotor bolts from the front wheel hub 3 Remove the rot...

Page 545: ...ction 2 Separate the cylinder assembly and the carrier D Remove the pin bolts 1 D Separate the cylinder assembly and the carrier 2 D107B702 3 Disassemble the carrier D Remove the front brake pad set 1 D Remove the springs 2 D Remove the guide pins and boots 3 Refer to Shoe and Lining in this section D17B703C D Remove the bleeder plug 1 D Remove the bleeder plug cap 2 ...

Page 546: ...WOO M 150 BL2 D107B704 D Remove the piston boot 3 Caution Do not face in the direction of removing D107B705 D Using compressed air blow out the piston from the cylinder 4 D Remove the piston 5 D107B706 D Remove the piston seal 6 ...

Page 547: ...seal D Push the piston inward until it is properly seated D Install the piston boot D Install the bleeder plug Tighten Tighten the bleeder plug to 6 NSm 53 lb in D Install the bleeder plug cap 2 Assemble the carrier D Install the guide pin and boot D Install the spring D Install the pads 3 Install the pin bolt connecting the cylinder assembly and carrier Tighten Tighten the pin bolt to 26 NSm 19 l...

Page 549: ...E 3 Diagnostic Information and Procedures 4E 4 Rear Drum Brake 4E 4 Drums 4E 5 Lining 4E 5 Repair Instructions 4E 6 On Vehicle Service 4E 6 Rear Brake Drum 4E 6 Brake Shoe 4E 7 Wheel Cylinder Assembly 4E 8 Backing Plate 4E 9 Unit Repair 4E 10 Wheel Cylinder 4E 10 Specifications 4E 11 General Specifications 4E 11 Fastener Tightening Specifications 4E 11 ...

Page 550: ...s transferred to the anchor plate through the backing plate to the axle flange Adjustment is automatic and occurs on any service brake applica tion Do not switch the position of shoes that have been in service as this may render the self adjustment fea ture inoperative and result in increased pedal travel Notice D Replace all the components included in the repair kits used to service this drum bra...

Page 551: ... Screw 3 Rear Brake Assembly 4 Rear Brake Plate 5 Wheel Cylinder 6 Strut Assembly 7 Brake Leading Shoe 8 Middle Return Spring 9 Upper Return Spring 10 Brake Shoe Retain Spring Pin 11 Trailing Shoe 12 Brake Shoe Retain Spring 13 Brake Shoe Retain Spring Cap 14 Lower Return Spring 15 Hub Bolt 16 Rear Brake Drum ...

Page 552: ...nder condition faulty D Replace the wheel cylinder D Malfunctioning self adjustment feature D Repair the self adjustment feature Dragging Brakes After Pedal is Released D Weakened brake shoe return spring D Replace the brake shoe return spring D Wheel cylinder condition faulty D Replace the wheel cylinder Excessive Pedal Travel D Excessively worn lining D Replace the lining D Malfunctioning self a...

Page 553: ...ÁÁÁÁ ÁÁÁÁÁÁ 182 7 165 D107C301 3 If the measured value is over the limit value or if the defect is found replace the drum LINING Inspect the brake drum as follows 1 Inspect the lining for wear or stain with oil 2 Measure the thickness Unit mm in ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ Lining Wear Limit Value ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ 1 0 039 D107C302 3 If the measured value is within the limit value or ...

Page 554: ... Remove the spindle cap 1 D Remove the cotter pin and do not reuse it 2 D Remove the castellated nut 3 D Remove the rear axle washer 4 D Remove the bearing race and oil seal Refer to Section 2D Rear Suspension D Remove the hub bolts using a hammer 5 Important Do not reuse removed hub bolts D107C503 Installation Procedure 1 Install the brake drum D Insert the new hub bolts using a hammer D Install ...

Page 555: ...dure 1 Remove the brake drum Refer to Brake Drum in this section 2 Remove the return spring D Remove the upper return spring 1 D Remove the upper return spring bracket 2 D Remove the lower return spring 3 D107C506 D Remove the adjust lever 4 D Remove the middle return spring 5 D107C507 3 Remove the brake shoe D Remove the readjusting unit 1 D Turn the brake shoe retaining spring pin rectangu larly...

Page 556: ...ing and adjust lever D Install the lower return spring D Install the upper return spring bracket D Install the upper return spring 6 Install the brake drum Refer to Brake Drum in this section D107C510 WHEEL CYLINDER ASSEMBLY Removal Procedure 1 Remove the brake drum Refer to Rear Brake Drum in this section 2 Remove the wheel cylinder D Remove the brake shoe upper spring 1 D Widen the leading shoe ...

Page 557: ...section D107C513 BACKING PLATE Removal Procedure 1 Remove the brake drum Refer to Rear Brake Drum in this section 2 Remove the brake shoe components Refer to Brake Shoe in this section 3 Remove the wheel cylinder assembly Refer to Wheel Cylinder Assembly in this section 4 Remove the bolts and the backing plate D17C514A Installation Procedure 1 Install the bolts and the backing plate Tighten Tighte...

Page 558: ... bleeder screw 5 3 Clean all parts with denatured alcohol Dry the parts with unlubricated compressed air D17C702A Assembly Procedure Important Lubricate the new seals the piston the pis ton cup and the wheel cylinder bore with clean brake fluid before assembly 1 Assemble wheel cylinder assembly D Insert the bleeder screw Tighten Tighten the bleeder screw to 6 NSm 53 lb in D Install the spring and ...

Page 560: ...termittent Shorted 4F 22 DTC 0404 Right Front Wheel Speed Sensor Circuit Open or Shorted 4F 24 DTC 0405 Right Front Wheel Speed Sensor Poor Air Gap or Missing Tooth Ring 4F 28 DTC 0406 Right Front Wheel Speed Sensor Circuit Intermittent Shorted 4F 30 DTC 0454 Left Rear Wheel Speed Sensor Circuit Open or Shorted 4F 32 DTC 0455 Left Rear Wheel Speed Sensor Poor Air Gap or Missing Tooth Ring 4F 36 DT...

Page 561: ...alve Time Out 4F 114 DTC 5503 CPU Loop Time Error 4F 115 DTC 5504 Excessive Dump Valve Time 4F 116 DTC 5560 Inoperative External Watch Dog 4F 117 DTC 5610 RAM ROM Error 8 Bit 4F 118 DTC 5630 ROM Error 16 Bit 4F 119 DTC 5640 RAM Error 16 Bit 4F 120 DTC 8001 Battery High Voltage Fault More Than 16V 4F 122 DTC 8002 Battery Low Voltage Fault Less Than 9V 4F 124 DTC 8003 Battery Low Voltage Fault Less ...

Page 562: ...m the master cylinder to the relevant brake caliper and al lows free flow as commanded by the driver during nor mal braking and reapply phases In the isolation phase the coil moves the armature down which closes the normally open isolation orifice and pre vents any further increase of pressure in the brake The valve also remains closed during the dump phase The lip seal provides a one way return p...

Page 563: ...accumulator The pressure will continue until a stall point is reached and compression of the piston cannot generate enough differential pressure anymore to open the outlet ball seat D17E006A Return Pump Return Pump Motor 0 12 0 16 in EBCM ELECTRONIC BRAKE CONTROL MODULE Notice There is no serviceable The EBCM must be re placed as an assembly The EBCM is attached to the hydraulic unit in the engine...

Page 564: ...parable to the conventional system but for a fully loaden vehicle the ef ficiency of the Dynamic Rear Proportioning System is higher due to the better use of rear axle braking capabili ty No indication is given to the driver when Dynamic Rear Proportioning is activated Also DRP remains active even in such cases where the anti lock function of the ABS is disabled D17E009A Critical Brake Points Idea...

Page 565: ...A Connector has 31 pins which are shown below figure And a connector includes a warning switch which grounds and lights the ABS warning lamp if there is No EBCM unit plugged in so that an indication is given that ABS is not available D17E011A Mechanical Switch ...

Page 566: ...alve FR Isolation Valve Low Pressure Accumulator FR Dump Valve RL Dump Valve RL Isolation Valve RR FL FR RL D17E205A NORMAL BRAKE MODE During non antilock braking pressure is applied through the brake pedal and fluid comes from the master cylinder into the hydraulic unit The normally open isolation cartridge and normally closed dump cartridge would remain in these positions to allow fluid pressure...

Page 567: ...cate excessive wheel deceleration imminent lockup the first step in the antilock sequence is to isolate the brake pressure being applied by the driver The EBCM sends a voltage to the coil to energize and close the isolation valves by pulling down on the armature This prevents any additional fluid pres sure applied by the driver from reaching the wheel Though each channel of the 4 channel system ca...

Page 568: ...eels rolling once again This is accomplished by dump ing a portion of the brake fluid pressure into a low pressure accumulator LPA The EBCM energizes the dump cartage coil s to open the dump cartridge allowing fluid from the wheels to be dumped into the LPA This done with very short activation pulses opening and closing the dump cartridge passageway Brake pressure is lowered at the wheel and allow...

Page 569: ...nder and pump pressure to reach the brakes This controlled pressure rise continues unitl the wheel is at optimum brake output or until the brake pressure is brough up to the master cylinder output pressure If more pressure is required more fluid is drawn from the master cylinder and applied to the brakes The driver may feel slight pedal pulsations or pedal drop this is normal and expected As fluid...

Page 570: ...ve RR Dump Valve FL Dump Valve FR Isolation Valve FR Dump Valve RL Dump Valve RL Isolation Valve PROPORTIONING FUNCTION If the rear wheels lock formerly during braking the vehicle may lose the stability Therefore to prevent this the ECM processes the speed sensor signal and brake signal to determine when the rear wheels are tending to lock up The EBCM then actuates the rear wheel isolation valves ...

Page 571: ... Front Wheel Speed Low ÑÑÑÑÑÑ ÑÑÑÑÑÑ 14 ÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑ LFWSHI ÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑ DK BLU ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Left Front Wheel Speed High ÑÑÑÑÑÑ ÑÑÑÑÑÑ 15 ÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑ IGN ÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑ RED YEL ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Switched Ignition ÑÑÑÑÑÑ ÑÑÑÑÑÑ 16 ÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑ GND ÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑ BLK ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Negative Battery Terminal ÑÑÑÑÑÑ ÑÑÑ...

Page 572: ...0 BL2 COMPONENT LOCATOR ABS D17E401A 1 Hydraulic Modulator Unit 2 Electronic Brake Control Module EBCM 3 Bolt 4 Upper Mounting Bracket 5 Grommet 6 Lower Mounting Bracket 7 Bracket Grommet 8 Rear Wheel Speed Sensor 9 Front Wheel Speed Sensor ...

Page 573: ...4F 14 ANTILOCK BRAKE SYSTEM DAEWOO M 150 BL2 ABS Cont d D17E402A ...

Page 574: ...ANTILOCK BRAKE SYSTEM 4F 15 DAEWOO M 150 BL2 BLANK ...

Page 575: ...t tery or ground D There is a loose connection in the wheel speed cir cuit D The wheel speed sensor resistance is very high D The EBCM is malfunctioning Fail Action This is a critical operational fault The ABS is disabled and the ABS warning lamp is turned on The proportion ing is operation Diagnostic Aids An intermittent malfunction may be caused by a poor connection rubbed through wire insulatio...

Page 576: ...speed sensor Is the repair complete ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ System OK ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 4 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Use a DVM to measure the resistance between ter minal 14 of the EBCM harness connector and termi nal 1 of the left front wheel speed sensor harness connector Is the resistanc...

Page 578: ...ANTILOCK BRAKE SYSTEM 4F 19 DAEWOO M 150 BL2 BLANK ...

Page 579: ...ical operational fault The ABS is disabled and the ABS warning lamp is turned on The proportion ing is operation Diagnostic Aids An intermittent malfunction may be caused by a poor connection rubbed through wire insulation or a wire that is broken inside the insulation Thoroughly check any circuitry suspected of causing the intermittent complaint Look for backed out terminals improper mating broke...

Page 581: ...ion in the wheel speed sen sor circuit D There is a loose connection in the EBCM D The EBCM is malfunctioning Fail Action This is a critical operational fault The ABS is disabled and the ABS warning lamp repeat intermittent turned on and off The proportioning is operation Diagnostic Aids An intermittent malfunction may be caused by a poor connection rubbed through wire insulation or a wire that is...

Page 582: ...ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 4 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Use a DVM to measure the resistance between ground and terminal 14 of the EBCM connector Does the DVM show the specified value ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ 1 ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ Go to Step 6 ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ Go to Step 5 ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 5 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑ...

Page 583: ... There is a loose connection in the wheel speed cir cuit D The wheel speed sensor resistance is very high D The EBCM is malfunctioning Fail Action This is a critical operational fault The ABS is disabled and the ABS warning lamp is turned on The proportion ing is operation Diagnostic Aids An intermittent malfunction may be caused by a poor connection rubbed through wire insulation or a wire that i...

Page 584: ...ÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ System OK ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 4 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Use a DVM to measure the resistance between ter minal 12 of the EBCM harness connector and termi nal 1 of the right front wheel speed sensor harness connector Is the resistance within the specified value ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑ...

Page 586: ...ANTILOCK BRAKE SYSTEM 4F 27 DAEWOO M 150 BL2 BLANK ...

Page 587: ...tical operational fault The ABS is disabled and the ABS warning lamp is turned on The proportion ing is operation Diagnostic Aids An intermittent malfunction may be caused by a poor connection rubbed through wire insulation or a wire that is broken inside the insulation Thoroughly check any circuitry suspected of causing the intermittent complaint Look for backed out terminals improper mating brok...

Page 589: ...tion in the wheel speed sen sor circuit D There is a loose connection in the EBCM D The EBCM is malfunctioning Fail Action This is a critical operational fault The ABS is disabled and the ABS warning lamp repeat intermittent turned on and off The proportioning is operation Diagnostic Aids An intermittent malfunction may be caused by a poor connection rubbed through wire insulation or a wire that i...

Page 590: ...ÑÑÑÑ ÑÑÑÑ 4 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Use a DVM to measure the resistance between ground and terminal 12 of the EBCM connector Does the DVM show the specified value ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ 1 ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ Go to Step 6 ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ Go to Step 5 ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 5 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Repair...

Page 591: ...here is a loose connection in the wheel speed cir cuit D The wheel speed sensor resistance is very high D The EBCM is malfunctioning Fail Action This is a critical operational fault The ABS is disabled and the ABS warning lamp is turned on The proportion ing is operation Diagnostic Aids An intermittent malfunction may be caused by a poor connection rubbed through wire insulation or a wire that is ...

Page 592: ...ystem OK ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 4 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ 1 Disconnect the connector C202 2 Use a DVM to measure the resistance between terminal 7 of the connector C202 and terminal 22 of the EBCM connector Does the DVM show the specified value ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ less th...

Page 593: ...ÑÑÑÑÑÑ ÑÑÑÑÑÑÑ System OK ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 16 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Use a DVM to measure the resistance between ground and terminal 23 of the EBCM connector Does the DVM show the specified value ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ 1 ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ Go to Step 18 ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ Go to Step 17 ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 17 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑ...

Page 594: ...ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Repair the short to voltage between terminal 14 of the connector C202 and terminal 23 of the EBCM connector Is the repair complete ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ System OK ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 26 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑ...

Page 595: ...cal operational fault The ABS is disabled and the ABS warning lamp is turned on The proportion ing is operation Diagnostic Aids An intermittent malfunction may be caused by a poor connection rubbed through wire insulation or a wire that is broken inside the insulation Thoroughly check any circuitry suspected of causing the intermittent complaint Look for backed out terminals improper mating broken...

Page 597: ...on in the wheel speed sen sor circuit D There is a loose connection in the EBCM D The EBCM is malfunctioning Fail Action This is a critical operational fault The ABS is disabled and the ABS warning lamp repeat intermittent turned on and off The proportioning is operation Diagnostic Aids An intermittent malfunction may be caused by a poor connection rubbed through wire insulation or a wire that is ...

Page 598: ...K ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 4 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Use a DVM to measure the resistance between ground and terminal 22 of the EBCM connector Does the DVM show the specified value ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ 1 ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ Go to Step 6 ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ Go to Step 5 ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 5 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑ...

Page 599: ...ÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Repair the short to voltage between terminal 7 of the connector C202 and terminal 2 of the left rear wheel speed sensor harness connector Is the repair complete ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ System OK ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 16 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑ...

Page 600: ...ANTILOCK BRAKE SYSTEM 4F 41 DAEWOO M 150 BL2 BLANK ...

Page 601: ...There is a loose connection in the wheel speed cir cuit D The wheel speed sensor resistance is very high D The EBCM is malfunctioning Fail Action This is a critical operational fault The ABS is disabled and the ABS warning lamp is turned on The proportion ing is operation Diagnostic Aids An intermittent malfunction may be caused by a poor connection rubbed through wire insulation or a wire that is...

Page 602: ...Ñ ÑÑÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 4 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ 1 Disconnect the connector C202 2 Use a DVM to measure the resistance between terminal 2 of the connector C202 and terminal 9 of the EBCM connector Does the DVM show the specified value ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ less than 1 ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ Ñ...

Page 603: ... ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ System OK ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 16 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Use a DVM to measure the resistance between ground and terminal 10 of the EBCM connector Does the DVM show the specified value ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ 1 ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ Go to Step 18 ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ Go to Step 17 ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 17 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ...

Page 604: ...ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Repair the short to voltage between terminal 2 of the connector C202 and terminal 9 of the EBCM con nector Is the repair complete ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ System OK ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 26 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑ...

Page 605: ...ical operational fault The ABS is disabled and the ABS warning lamp is turned on The proportion ing is operation Diagnostic Aids An intermittent malfunction may be caused by a poor connection rubbed through wire insulation or a wire that is broken inside the insulation Thoroughly check any circuitry suspected of causing the intermittent complaint Look for backed out terminals improper mating broke...

Page 607: ...ion in the wheel speed sen sor circuit D There is a loose connection in the EBCM D The EBCM is malfunctioning Fail Action This is a critical operational fault The ABS is disabled and the ABS warning lamp repeat intermittent turned on and off The proportioning is operation Diagnostic Aids An intermittent malfunction may be caused by a poor connection rubbed through wire insulation or a wire that is...

Page 608: ...OK ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 4 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Use a DVM to measure the resistance between ground and terminal 9 of the EBCM connector Does the DVM show the specified value ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ 1 ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ Go to Step 6 ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ Go to Step 5 ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 5 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑ...

Page 609: ...ÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Repair the short to voltage between terminal 2 of the connector C202 and terminal 2 of the right rear wheel speed sensor harness connector Is the repair complete ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ System OK ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 16 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑ...

Page 610: ...ANTILOCK BRAKE SYSTEM 4F 51 DAEWOO M 150 BL2 BLANK ...

Page 611: ...Diagnosis If the EBCM proceeds the self test about the dump valve or the motor driver and senses the fault the EBCM may make the fault code Cause s D EBCM internal fault Left front dump voltage shorted or ground open Warning Lamp Operation D ABS warning lamp ON D ABS warning lamp OFF if the ignition switch ON OFF Fail Action This is a critical operational fault The ABS is disabled and the ABS warn...

Page 612: ...ÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ 10 5 v to 13 5 v ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ Go to Step 5 ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ Go to Step 4 ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 4 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Repair the short to voltage between terminal 18 of the EBCM connector and engine fuse block Ef1 out ...

Page 613: ...Diagnosis If the EBCM proceeds the self test about the dump valve or the motor driver and senses the fault the EBCM may make the fault code Cause s D EBCM internal fault Left front dump voltage open or ground shorted Warning Lamp Operation D ABS warning lamp ON D ABS warning lamp OFF if the ignition switch ON OFF Fail Action This is a critical operational fault The ABS is disabled and the ABS warn...

Page 614: ...ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ 10 5 v to 13 5 v ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ Go to Step 5 ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ Go to Step 4 ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 4 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Repair the short to voltage between terminal 18 of the EBCM connector and engine fuse block Ef1 out...

Page 615: ...Diagnosis If the EBCM proceeds the self test about the dump valve or the motor driver and senses the fault the EBCM may make the fault code Cause s D EBCM internal fault Left front isolation voltage shorted or ground open Warning Lamp Operation D ABS warning lamp ON D ABS warning lamp OFF if the ignition switch ON OFF Fail Action This is a critical operational fault The ABS is disabled and the ABS...

Page 616: ...Ñ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ ÑÑÑÑÑ 10 5 v to 13 5 v ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ Go to Step 5 ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ Go to Step 4 ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 4 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Repair the short to voltage between terminal 18 of the EBCM connector and engine fuse block Ef1 o...

Page 617: ... Locator 4G 3 Parking Brake 4G 3 Repair Instructions 4G 4 On Vehicle Service 4G 4 Parking Brake Lever 4G 4 Parking Brake Warning Lamp Switch 4G 5 Parking Brake Cable 4G 6 Specifications 4G 8 General Specifications 4G 8 Fastener Tightening Specifications 4G 8 Schematic and Routing Diagrams 4G 9 Parking Brake System 4G 9 ...

Page 618: ...g light should glow and go OFF when the parking brake lever is released Whenever the parking brake is applied and the ignition switch is II the BRAKE warning light should glow When the brake is firmly applied the parking brake should securely hold the vehicle with ample pedal travel remaining Check for frayed cables rust etc or any condition that may inhibit present or future free move ment of the...

Page 619: ...150 BL2 COMPONENT LOCATOR PARKING BRAKE D107D401 1 Parking Brake Cable Clip 2 Parking Brake Cable 3 Strengthener 4 Cable Grommet 5 Parking Brake Lever Assembly 6 Parking Brake Warning Lamp Switch 7 Cotter Pin 8 Cable Pulley 9 Pin ...

Page 620: ... Trim 2 Remove the parking brake cable cover Refer to Sec tion 9G Interior Trim 3 Remove the parking brake lever D Disconnect the brake warning lamp switch 1 D Remove the brake warning switch lamp screw 2 Important The brake warning lamp switch screw should be removed with the lever fixed D107D502 D Remove the bolts 3 D Remove the nut 4 D107D503 D Remove the cotter pin 5 D Remove the pin 6 ...

Page 621: ...ng brake lever cover Refer to Section 9G Interior Trim D107D505 PARKING BRAKE WARNING LAMP SWITCH Removal Procedure 1 Remove the gear shift lever cover Refer to Section 5B Five Speed Manual Transaxle 2 Remove the parking brake warning lamp switch D Disconnect the parking brake warning lamp switch 1 D107D506 D Apply the parking brake 2 D Remove the parking brake warning lamp switch carefully 3 D107...

Page 622: ...D Remove the grommet 4 D107D510 3 Remove the rear brake drum assembly Refer to Sec tion 2D Rear Suspension 4 Disconnect the parking brake cable from the rear brake drum assembly D Remove the clip from the brake plate 1 D Disconnect the parking brake cable from the trailing shoe 2 Refer to Section 4E Rear Drum Brake D107D511 5 Remove the parking brake cable D Remove the clamp bolts fastening the br...

Page 623: ...g brake cable clamp bolts to 10 NSm 89 lb in 1 2 D17D515A 3 Connect the parking brake cable to the rear brake drum assembly Refer to Section 4E Rear Drum Brake 4 Install the rear brake drum assembly Refer to Sec tion 2D Rear Suspension 5 Install the grommet and the strengthener 6 Install the cable pulley with the adjustment nuts Tighten Tighten the adjustment nuts to 10 NSm 89 lb in 3 7 Install th...

Page 624: ...ÁÁÁÁÁÁÁÁÁÁÁÁ Application ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ NSm ÁÁÁÁÁÁ ÁÁÁÁÁÁ Lb Ft ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Lb In ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Parking Brake Cable Clamp Bolts ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 10 ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 89 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Parking Brake Lever Bolts ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 10 ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 89 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Parking Brake Lever Nut ÁÁÁÁÁÁÁ ÁÁÁÁÁ...

Page 625: ...PARKING BRAKE 4G 9 DAEWOO M 150 BL2 SCHEMATIC AND ROUTING DIAGRAMS PARKING BRAKE SYSTEM D17A201B ...

Page 626: ... Gear Shift Control 5B 3 Input Shaft and Counter Shaft Gear 5B 4 Gear Shift Fork 5B 6 Differential and Case 5B 7 Diagnostic Information and Procedure 5B 8 General Diagnosis 5B 8 Checking Fluid Level 5B 9 Changing Fluid 5B 9 Checking Transaxle Noise 5B 9 Checking Bearing Noise 5B 9 Repair Instruction 5B 10 On Vehicle Service 5B 10 Manual Transaxle Assembly 5B 10 Gear Shift Control Case Assembly 5B ...

Page 627: ...3B001 In case of shifting to 5th gear shift and select shaft ro tates to right that shift cam aparts from guide bolt and moves upwards by returning spring Therefore shifting to reverse in this condition is impossible because of in terference of guide bolt D103B002 When shifting to reverse from neutral position between 5th and reverse shift cam rotates to left and shifting is possible D103B003 DIFF...

Page 628: ...5B 3 DAEWOO M 150 BL2 COMPONENT LOCATORS GEAR SHIFT CONTROL D13B4011 1 Gear Shift Control Lever Knob 2 Gear Shift Cable Bracket 3 Select Cable 4 Shift Cable 5 Select Arm 6 Gear Shift Control Lever 7 Gear Shift Control Lever Guide ...

Page 629: ...5B 4 FIVE SPEED MANUAL TRANSAXLE DAEWOO M 150 BL2 INPUT SHAFT AND COUNTER SHAFT GEAR D13B4031 ...

Page 630: ...9 3rd Gear Synchronizer Ring 20 Input Shaft 3rd Gear 21 Input Shaft 3rd Gear Bearing 22 Input Shaft 23 Input Shaft Bearing Right 24 Input Shaft Oil Seal 25 Reverse Gear Shaft Bolt 26 Reverse Gear Shaft 27 Reverse Idle Gear 28 Counter Shaft Nut 29 Counter Shaft 5th Gear 30 Counter Shaft Bearing Shim 31 Counter Shaft Bearing Left 32 Counter Shaft 4th Gear 33 Counter Shaft 3rd 4th Gear Spacer 34 Coun...

Page 631: ...ol Case Gasket 10 Low Speed Shift Fork 11 Low Speed Shift Shaft 12 Low Speed Shift Shaft Spring Ball 13 Low Speed Shift York 14 High Speed Shift York 15 High Speed Shaft Spring Ball 16 High Speed Shift Shaft 17 High Speed Shift Fork 18 Reverse Shift Arm 19 5th Reverse Shift Ball 20 5th Reverse Shift Shaft Spring Ball 21 Reverse Shift Shaft Guide Spring Ball 22 5th Reverse Shift Shaft 23 5th Revers...

Page 632: ...Drain Plug 10 Oil Gutter 11 Side Cover Plate 12 Side Cover 13 Differential Ring Gear 14 Differential Oil Seal Left 15 Differential Bearing Left 16 Differential Case 17 Speedometer Drive Gear 18 Differential Bearing Right 19 Differential Oil Seal Right 20 Differential Pinion Gear Shaft Pin 21 Differential Side Gear Adjust Shim 22 Differential Side Gear 23 Differential Pinion Gear Shaft 24 Different...

Page 633: ...ut shaft or counter shaft D Replace bearing D Poor adjustment of clutch cable D Adjust clutch cable D Distorted or broken clutch disc D Replace clutch disc D Damaged pressure plate D Replace pressure plate Noise in the Neutral Gear D Insufficient lubricant D Supply lubricant D Worn input shaft gear D Replace gear D Worn bearings on the input shaft gears D Replace bearing D Worn clutch release bear...

Page 634: ... TRANSAXLE NOISE Many noises that appear to come from the transaxle may actually originate with other sources such as tires road surfaces wheel bearings or engine and exhaust system Identify the cause of any noise before attempting to re pair the clutch the transaxle or their related linkages To verify suspected transaxle noises 1 Select a smooth level asphalt road to reduce tyre and resonant body...

Page 635: ...e the battery and battery tray Refer to Section 1E Engine Electrical 3 Disconnect the select and the shift cable D Remove the cable pins 1 D Remove the washers 2 D Disconnect the select and the shift cable 3 D Remove the cable E rings 4 D Disconnect the cables from the cable bracket D103B502 4 Remove the engine wiring harness bending strap 5 Disconnect the ground wire and the backup lamp switch co...

Page 636: ...dometer cable D Loosen the nut 1 D Disconnect the cable 2 9 Remove the vehicle speed sensor VSS if equipped D Disconnect VSS connector D Remove the VSS D102E502 10 Remove the starter motor D Remove upper two bolts that securing starter mo tor to transaxle D13B5041 11 Fix the engine assembly D Remove the cowl panel weatherstrip D Position the engine support fixture DW110 021 on the cowl panel and t...

Page 637: ...the transaxle fluid D Remove the drain plug and drain the fluid 16 Disconnect the clutch cable D Remove the cable adjust nut 1 D Disconnect the cable from the wire clip 2 D Disconnect the cable from the transaxle mount hole 3 D103B509 17 Remove the front under longitudinal frames and sta bilizer Refer to Section 2C Front Suspension 18 Remove the drive axle only transaxle side Refer to Section 3B M...

Page 638: ...st man ifold pipe 2 D Make free the front exhaust pipe D13B5111 21 Support the transaxle with the transaxle remove install support DW220 030N D Position the support on the jack a D Support the transaxle case and mount using a jack and the transaxle remove install support D103B512 22 Remove the transaxle lower bolt and nut a Lower bolt b Lower nut D13B5131 23 Remove the transaxle mount bolts ...

Page 639: ... transaxle assembly by adjusting jack D Remove the transaxle assembly by pulling and lowering it slowly D103B516 26 Support the engine to normal position using the en gine support fixture DW110 021 Notice The abnormal position of the engine may dam age to the related parts or interfere with them You have to support the engine to normal position when removing the transaxle Important If it is imposs...

Page 640: ...ront exhaust pipe nuts Tighten D Tighten the front exhaust pipe nuts exhaust man ifold side to 25 35 NSm 18 25 lb ft D13B519A 5 Install the transaxle upper bolts Tighten Tighten the bolts to 55 65 NSm 41 48 lb ft a Exhaust manifold side bolt b Thermostat housing side bolt D13B548A 6 Install the starter motor Tighten Tighten the starter motor bolts to 18 28 NSm 13 21 lb ft 7 Connect all electric co...

Page 641: ...ty 2 1L 2 21 qt D Tighten the oil level plug to 36 54 NSm 26 40 lb ft b D13B521A 10 Adjust the clutch cable Refer to Section 5C Clutch D Adjust the clutch cable by the clutch cable adjust nut 11 Install the transaxle under cover Tighten Tighten the transaxle under cover bolts to 35 55 NSm 25 41 lb ft D103B501 GEAR SHIFT CONTROL CASE ASSEMBLY Removal Procedure 1 Remove the air hose air cleaner to t...

Page 642: ...ift control case can not be re moved D103B524 6 Remove the gear shift control case assembly D Remove the bolts 1 Important Make sure the gear shift lever is in NEU TRAL D Remove the gear shift control case assembly 2 D Remove the gasket 3 D103B525 7 Remove the shift lever D Position the gear shift control case assembly to the vice with a protector D Remove the lever pin with a pin punch and a ham ...

Page 643: ...e the Plate from the case 2 D103B528 Inspection Procedure 1 Inspect for worn or damaged the fifth reverse shift cam 1 2 Inspect for worn or damaged shift interlock plate 2 3 Inspect for worn or damaged select shift lever 3 4 Inspect for bent or damaged select shift shaft 4 D13B529A Installation Procedure 1 Install in the reverse order of removal 2 Install the shift guide bolt Tighten Tighten the s...

Page 644: ...4 Install the shift interlock bolt Tighten Tighten the shift interlock bolt to 18 28 NSm 13 21 lb ft D103B532 SPEEDOMETER DRIVEN GEAR AND CABLE Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Remove the speedometer driven gear assembly D Loosen the nut 1 D Disconnect the cable 2 D Remove the bolt 3 D Remove the speedometer driven gear assembly 4 D103B533 D Disconnect the vehicle...

Page 645: ...edometer driven gear housing 2 Remove the driven gear pin and disconnect the driv en gear D Check for a damaged or torn O ring D Check for a worn or damaged tooth of driven gear a O ring b Driven gear pin c Driven gear D103B536 Installation Procedure 1 Install in the reverse order of removal Important Install the speedometer driven gear assem bly after connecting the speedometer cable with the spe...

Page 646: ...les from the cable bracket D19E573A 4 Remove the floor console Refer to Section 9G Inte rior Trim D Put aside the floor carpet in order to get the gear shift cable shown D13B5381 5 Disconnect the gear shift lever side select and shift control cable D Remove the select control cable clip 1 D Ply off the eye ring 2 D Remove the select control cable E ring 3 D Disconnect the select control cable 4 D ...

Page 647: ...he selector lever control cable clip 2 D Install the select control cable to gear shift lever bracket with E ring 3 D Insert a driver to the select arm adjustment hole to prevent the movement of gear shift lever in NEU TRAL 4 7 Tighten the adjust nuts Tighten Tighten the select cable adjust nut to 8 12 NSm 71 106 lb in D103B543 GEAR SHIFT CONTROL LEVER Removal Procedure 1 Remove the floor console ...

Page 648: ...L2 D13B544A Installation Procedure 1 Install in the reverse order of removal 2 Install the gear shift control lever assembly Tighten Tighten the bolts to 4 7 NSm 35 62 lb in 3 Adjust the select cables Refer to Gear Shift Control Cable in this section ...

Page 649: ...fer to Manual Transaxle Assembly in this section 2 Position the manual transaxle to a transaxle stand us ing the transaxle fixture DW220 010 D13B7021 3 Remove the related clutch parts Refer to Section 5C Clutch 4 Remove the manual transaxle mounting bracket D Remove the bolts 1 D Remove the nut 2 D Remove the mounting bracket 3 D103B703 5 Disconnect the backup light switch and speedometer driven g...

Page 650: ... D Remove the gear shift control case assembly 3 D Remove the gasket 4 D103B706 8 Remove the side cover D Remove the bolts 1 D Remove the side cover using a rubber hammer 2 D Remove the sealant on the side cover and the transaxle case D103B707 9 Remove the fifth gear shift fork guide ball the snap ring and the input shaft fifth gear snap ring D Remove the fifth gear shift fork plug 1 D Remove the ...

Page 651: ...the hub assembly together 1 D Remove the sleeve key and spring from the syn chronizer hub assembly D103B710 12 Remove the input shaft fifth gear the synchronizer ring and the fifth gear bearing D Pull and remove the fifth gear wave spring and synchronizer ring together 1 D Remove the fifth gear bearing D103B711 13 Remove the countershaft fifth gear D Shift the shift yoke using a driver to engage t...

Page 652: ...move the bolt and remove the fifth reverse gear shift shaft spring and ball 1 D Remove the bolt and remove the third fourth gear shift shaft spring and ball 2 D Remove the bolt and remove the first second gear shift shaft spring and ball 3 Important There is difference between the fifth re verse gear shift shaft spring and the others Mark it to distinguish easily when installing D103B715 16 Remove...

Page 653: ...y hitting with a rubber hammer lightly D Remove the sealant on the case D103B717 18 Remove the reverse gear shift lever D Remove the bolts 1 D Remove the reverse gear shift lever 2 D103B718 19 Remove the reverse idle gear shaft assembly D Push the reverse idle gear toward inner case D Pulling shaft and remove the reverse idle gear and shaft 1 D Remove the reverse idle gear from the shaft D103B719 ...

Page 654: ...ower side of differ ential 1 D Remove the differential assembly by moving it right and left 2 D103B722 23 Remove the related parts of the transaxle case Left Side D Remove the bolt 1 D Remove the oil gutter 2 D Remove the bolts 3 D Remove the oil plate 4 D Remove the differential left side oil seal using a hammer and a copper chisel 5 D103B723 D Remove the bolts 6 D Remove the case cap Left Side 7...

Page 655: ...ween Sleeve and Shift Fork 0 2 0 6 0 008 0 024 1 0 0 039 D103B726 Assembly Procedure 1 Install the related parts of the transaxle case Right Side D Install the input shaft oil seal using the bushing seal installer DW09943 78210 D Install the differential right side oil seal using the bushing seal installer 09913 76010 Important Use only a new oil seal Important Coat the transaxle inner parts with ...

Page 656: ... the low and the high speed shift shaft assem bly to the gear unit 5 Install the gear unit D Push the gear unit by matching it with the input and the counter shaft hole 1 Notice Be careful not to damage teeth of the counter shaft pinion and the differential ring gear D13B730A 6 Install the fifth reverse gear shift shaft 7 Install the reverse idle gear shaft assembly and the reverse gear shift leve...

Page 657: ...ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ THREE BOND 1215 D Install the transaxle left side case to the transaxle right side case Tighten Tighten the bolts to 15 22 NSm 11 16 lb ft a D Tighten the bolts 8 stud bolts 3 if equipped with auto clutch Tighten the bolts to 15 22 NSm 11 16 lb ft b D13B733A 10 Install the first second gear shift shaft ball and spring Tighten Tighten the bolt to10 16 NSm 7 12 lb ft a 11 Install th...

Page 659: ...matching synchronizer s oil groove and in put shaft punched mark 1 D103B738 17 Install the fifth gear synchronizer hub assembly D Install the synchronizer springs to hub 1 D Install the synchronizer key 2 Important In case of assembling synchronizer sleeve and hub let A B D Position the longer boss side of hub toward inner side 3 D Position the chamfered spline of sleeve toward inner side and inst...

Page 660: ...nap ring 2 Important Use only new snap ring D Tighten the fork plug after inserting the guide ball into the fork hole D13B742A 22 Install the side cover 1 D Coat the side cover with recommended sealant ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ Side Cover Sealant ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ THREE BOND 1215 Tighten Tighten the side cover bolts to 8 12 NSm 71 106 lb in D13B743A 23 Install the gear shift control case assembly D In...

Page 661: ... 65 NSm 41 48 lb ft a D Tighten the nut to 55 65 NSm 41 48 lb ft b D13B701A 26 Install the related clutch parts Refer to Section 5C Clutch 27 Remove the transaxle assembly from transaxle stand D Remove the transaxle assembly using the trans axle fixture DW220 010A 28 Install the transaxle assembly Refer to Manual Transaxle Assembly in this section D103B746 INPUT SHAFT Tools Required DW09921 57810 ...

Page 662: ...er b Left side bearing c Fourth gear D103B748 4 Remove the fourth gear bearing 5 Remove the fourth gear synchronizer ring and wave spring D103B749 6 Remove the third fourth synchronizer circlip D103B750 7 Remove the third fourth synchronizer hub assembly the third gear 1 synchronizer ring D Position the third gear to the gear bearing remover DW09921 57810 D Remove the following parts a Third fourt...

Page 663: ...limit Unit mm in ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Clearance Between ÁÁÁÁÁÁ ÁÁÁÁÁÁ Standard ÁÁÁÁÁÁ ÁÁÁÁÁÁ Limit ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Clearance Between Gear and Ring 1 0 0 039 0 5 0 020 D103B754 2 Inspecting cone contact condition D When synchronizer mechanism is abnormal in op eration connection between ring inner surface and gear cone area is considered to be partially defec tive in spite of correct clearance between g...

Page 664: ... 3rd 4th gear 9 6 0 378 10 0 0 394 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 5th gear 9 4 0 370 9 8 0 386 D103B756 4 Inspecting wear of synchronizer ring D Check for worn or damaged synchronizer ring teeth Replace it if necessary D103B757 5 Inspecting synchronizer key and spring D Check for worn synchronizer key 1 D Check for weak damaged or broken spring 2 D103B758 Assembly Procedure 1 Install the third gear bearing the t...

Page 665: ...D Insert the hub assembly into the input shaft 1 Important Position the longer flange of hub toward the third gear and match the key and the ring groove D Install the hub assembly using a hammer and the gear bearing installer DW09940 53111 D13B761A Notice When installing gear bearing and hub assem bly install them slowly using the gear bearing installer DW09940 53111 and a hammer If overpressed th...

Page 666: ...stall the input shaft right side bearing D Install the bearing to the input shaft using the gear bearing installer DW09925 98221 and a hammer 1 9 Install the gear unit Refer to Gear Unit in this sec tion D103B765 COUNTER SHAFT Tools Required 09913 76010 Bushing Seal Installer DW09913 80112 Gear Bearing Installer DW09921 57810 Gear Bearing Remover DW09925 98221 Gear Bearing Installer DW09940 53111 ...

Page 667: ... DW09921 57810 D Remove the following parts by pressing a Counter shaft left side bearing b Fourth gear D103B767 4 Remove the counter shaft third fourth gear spacer 5 Remove the counter shaft third gear and second gear D Position the second gear to the gear bearing re mover DW09921 57810 D Remove the following parts by pressing a Third gear b Second gear D103B768 6 Remove the counter shaft second ...

Page 668: ...hronizer ring D Remove the first gear synchronizer ring from the first gear D103B770 10 Disassemble the first second gear synchronizer hub assembly D Push the hub from the hub assembly 1 D Disassemble the synchronizer sleeve and key 2 D Disassemble the synchronizer springs 3 D103B771 11 Remove the counter shaft first gear bearing D103B772 Synchronizer Hub and Sleeve Inspection D Check the sleeve f...

Page 669: ... ÁÁÁÁÁÁÁÁÁ First synchronizer ring A 8 2 0 323 ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ Key Groove Width ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ Second synchronizer ring B 9 6 0 378 D103B775 2 Assemble the first second synchronizer hub assem bly D Install the synchronizer springs to hub D Install the synchronizer keys to hub Important Let A B when installing the keys D Install the hub to the sleeve a Sleeve b Hub D103...

Page 670: ... the second gear bearing 1 D Install the second gear 2 D103B778 7 Install the counter shaft third gear and the third fourth gear spacer D Insert the third gear and the third fourth gear spacer into the counter shaft D Install the following parts using the gear bearing installer DW09913 80112 and a hammer a Third fourth gear spacer b Third gear D103B779 8 Install the counter shaft fourth gear D Ins...

Page 671: ...ocedure 1 Remove the gear unit Refer to Gear Unit in this section 2 Remove the each shift shaft assembly from the gear unit 3 Remove the first second gear shift shaft assembly D Fix the shift shaft assembly to a vise with protector D Remove the first second gear fork pin using a pin punch and a hammer 1 D Remove the first second gear shift fork 2 D103B783 D Remove the first second gear shift yoke ...

Page 672: ...semble the fifth reverse gear shift shaft assem bly D Remove the shift shaft not installed with yoke by pushing 1 D Remove the following parts from the reverse shift arm a Fifth reverse gear ball b Reverse shift guide ball and spring D Fix the shift shaft assembly to a vise with protector D Remove the reverse gear shift arm pin using a pin punch and a hammer 2 D Remove the reverse gear shift arm 3...

Page 673: ...2 0 283 ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ Fifth Gear Shift Fork 7 8 0 307 7 2 0 283 D103B788 Low Speed Shift Shaft High Speed Shift Shaft 5th Reverse Shift Shaft Assembly Procedure 1 Install in the reverse order of removal Important Use only new fork fin and yoke pin D103B789 DIFFERENTIAL Disassembly Procedure 1 Remove the differential assembly Refer to Gear Unit in this section 2 Remove the differential ring gea...

Page 674: ...ide gears 2 D Remove the adjust shims from the side gears 3 D13B793A 6 Remove the differential right side bearing and speedometer drive gear D Remove the right side bearing using the differential bearing puller DW220 020A 01 and the differen tial bearing plate adapter DW220 020A 02 D Remove the speedometer drive gear 1 D13B794A 7 Remove the differential left side bearing D Remove the left side bea...

Page 675: ...ÁÁÁÁÁÁÁÁ 1 10 0 0433 1 15 0 0453 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ 1 20 0 0472 D103B796 2 After checking for worn or scratched thrust adjusting shim replace it if necessary a Side gear b Driver D103B797 Assembly Procedure 1 Install the differential left side bearing D Insert the left side bearing 1 D Install the left side bearing using the bushing seal installer 09913 76010 and a hammer Import...

Page 676: ...s and washers simul taneously D103B800 4 Install the pinion gear shaft and pin D Insert the shaft into the gear pin hole by rotating 1 D Press the pin using a pin punch and a hammer 2 Important Use only new pin D13B801A 5 Install the differential ring gear D Fix the differential assembly to a vise D Install the ring gear with the bolts 1 Tighten Tighten the bolts to 80 100 NSm 59 74 lb ft 6 Instal...

Page 677: ...ve width of 1st gear mm in 8 2 0 323 8 6 0 339 synchronizer ring 2nd 3rd 4th gear mm in 9 6 0 378 10 0 0 394 5th gear mm in 9 4 0 370 9 8 0 386 Shift fork end thickness Low speed shift fork 1st 2nd mm in 8 7 0 343 8 1 0 319 High speed shift fork 3rd 4th mm in 7 8 0 307 7 2 0 283 5th gear shift fork mm in 7 8 0 307 7 2 0 283 Clearance between gear and synchronizer ring mm in 1 0 0 039 0 5 0 020 Cle...

Page 678: ... Bolt 18 28 13 21 Gear Shift Lever Bolt 4 7 35 62 High Speed Shift Shaft Bolt 10 16 7 12 Low Speed Shift Shaft Bolt 10 16 7 12 Oil Drain Plug 25 30 18 22 Oil Level Plug 36 54 26 40 Radiator Lower Hose Bracket Bolts 8 15 70 132 Reverse Idle Gear Shaft Bolt 18 28 13 21 Reverse Shift Lever Bolt 18 28 13 21 Select Cable Nut Shift Lever Side 8 12 71 106 Select Lever Bolt 18 28 13 21 Side Cover Plate Sc...

Page 679: ...taller D103B106 DW09913 80112 Gear Bearing Installer D103B104 DW09921 57810 Gear Bearing Remover D103B107 DW09925 98221 Gear Bearing Installer D103B105 DW09940 53111 Gear Bearing Installer D103B109 DW09943 78210 Bushing Seal Installer D103B103 DW110 021 Engine Assembly Support Fixture D13B101A DW220 010A Transaxle Fixture ...

Page 680: ...W220 020A 01 Differential Bearing Puller D13B113A DW220 020A 02 Differential Bearing Plate Adapter D13B114A DW220 020A 03 Differential Bearing Plate Adapter D103B102 DW220 031 Transaxle Remove Install Support D103B108 KM466 A Gear Bearing Remover Installer D103B111 KM519 Oil Seal Installer ...

Page 681: ...Operation 5C 2 Driving Members 5C 2 Driven Members 5C 2 Operating Members 5C 2 Component Locator 5C 3 Clutch Components 5C 3 Diagnostic Information and Procedures 5C 4 General Diagnosis 5C 4 Clutch Pedal Operation 5C 5 Clutch Cable Adjustment 5C 5 Repair Instruction 5C 6 On Vehicle Service 5C 6 Pressure Plate Clutch Disc and Input Shaft Bearing 5C 6 Clutch Release Bearing Shaft and Bushing 5C 8 Cl...

Page 682: ...ng the splines of the input shaft but which drives the input shaft through these same splines The driving and driven members are held in contact by spring pressure This pressure is exerted by a dia phragm spring in the pressure plate assembly OPERATING MEMBERS The clutch release system consists of the clutch pedal the clutch release shaft the clutch cable the release arm and the release bearing Wh...

Page 683: ...R CLUTCH COMPONENTS D13C4011 1 Clutch Disc 2 Pressure Plate 3 Release Bearing 4 Release Shaft 5 Release Shaft Bushing No 1 6 Release Shaft Bushing No 2 7 Release Shaft Seal 8 Release Arm 9 Clutch Cable Adjusting Nut 10 Clutch Cable 11 Clutch Pedal ...

Page 684: ...loor When Disengaged D Interfered clutch release bearing D Lubricate and adjust clutch release bearing D Weakened diaphragm spring D Replace pressure plate Clutch Vibration D Clutch facing with oily contamination D Replace clutch disc D Release bearing slides unsmoothly on input shaft bearing retainer D Lubricate retainer release bearing D Wobbly clutch disc or poor facing contact D Replace clutch...

Page 685: ... After starting the engine check if the clearance between pedal and floor is within specified range in condition of idling lifting parking brake and drawing out clutch ped al ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Clearance Between Pedal and Floor just Before Clutch Connection ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ 30 40 mm 1 2 1 6 in Caution During inspection take care on sudden departure CLUTCH CABLE ADJUSTMENT D...

Page 686: ...e 1 Remove the transaxle from the vehicle Refer to Sec tion 5B Manual Transaxle 2 Support the engine to normal position using the en gine fixture DW110 021 Notice The abnormal position of the engine may dam age to the related parts and interfere with them You must support the engine to normal position after remov ing the transaxle D13C5021 3 Remove the pressure plate and the clutch disc D Fix the ...

Page 687: ... inspection D Measure rivet head depth from clutch disc surface and replace if below limit Unit mm in ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ Standard ÁÁÁÁÁÁ ÁÁÁÁÁÁ Limit ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Rivet Head Depth 1 2 0 047 0 5 0 02 D Replace the clutch disc if clutch disc surface is contaminated or clutch disc rivets are loosen D103C506 3 Clutch disc runout in rotational direction inspection D Measure runout in rota...

Page 688: ...eel holder 09924 17810 D Install the pressure plate bolts Tighten Tighten the bolts to 18 28 NSm 13 21 lb ft D103C510 D103C509 CLUTCH RELEASE BEARING SHAFT AND BUSHING Tools Required 09923 46040 Bushing Joint Pipe 09925 48220 Bushing Remover Installer 09930 30102 Sliding Shaft 09943 88211 Bushing Bearing Installer Removal Procedure 1 Remove the transaxle from the vehicle Refer to Sec tion 5B Manua...

Page 689: ... joint pipe 09923 46040 D Remove the bushing No 1 by pulling D103C513 Inspection Procedure Release Bearing and Shaft 1 Release bearing inspection D Check for noisy worn and damaged release bear ing D Check for a grabbing rotation of release bearing D Replace the release bearing if necessary D103C514 2 Release shaft inspection D Check for a warped shaft 1 D Check for a worn fork 2 D Replace the sha...

Page 690: ...release shaft bushing No 2 and seal using the bushing remover installer 09925 48220 and a hammer D103C517 4 Install the release bearing D Coat the spline of transaxle input shaft with multi purpose grease 1 D Coat the release bearing bore and the connecting of release shaft with multi purpose grease 2 D Install the release bearing D103C518 CLUTCH RELEASE ARM Removal Procedure 1 Disconnect the clut...

Page 691: ...ten Tighten the bolt and nut to 10 16 NSm 7 5 12 lb ft 3 Adjust the clutch cable Refer to Diagnosis in this section D103B506 CLUTCH CABLE Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Disconnect the clutch cable from the transaxle D Remove the adjusting nut 1 D Disconnect the cable from the wire clip 2 D Pull and remove the cable from the transaxle mount hole 3 D13C5211 2 Disc...

Page 692: ...fer to Diagnosis in this section D103C524 CLUTCH PEDAL Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Disconnect the clutch cable Refer to Clutch Cable in this section 2 Remove the clutch pedal D Release the pedal return spring D Remove the nut 1 D Remove the clutch pedal 2 D Remove the bushing 3 D Remove the pedal return spring 4 D103C302 Installation Procedure 1 Install the p...

Page 693: ...ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Disc Runout Limit in Rotational Direction ÁÁÁÁÁ ÁÁÁÁÁ mm in ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 0 7 0 028 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Pedal Free Travel ÁÁÁÁÁ ÁÁÁÁÁ mm in ÁÁÁÁÁÁ ÁÁÁÁÁÁ 0 0 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Clutch Pedal ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Pedal Travel ÁÁÁÁÁ ÁÁÁÁÁ mm in ÁÁÁÁÁÁ ÁÁÁÁÁÁ 100 110 3 9 4 3 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Clutch Pedal ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ...

Page 694: ...6040 Bushing Joint Pipe D102B116 09924 17810 Fly Wheel Holder D103C104 09925 48220 Bushing Remover Installer D103C102 09925 98210 Input Shaft Bearing Installer D103C106 09930 30102 Sliding Shaft D103C107 09943 88211 Bushing Bearing Installer D103B103 DW110 021 Engine Assembly Support Fixture D103C103 DW210 010 Clutch Center Guide ...

Page 695: ...ormation and Procedures 6B 3 Power Steering Pump 6B 3 Repair Instructions 6B 4 On Vehicle Service 6B 4 Pump Drive Belt 6B 4 Pump Drive Pulley 6B 5 Pump Assembly 6B 5 Unit Repair 6B 7 Pump 6B 7 Specifications 6B 8 General Specifications 6B 8 Fastener Tightening Specifications 6B 8 Special Tools and Equipment 6B 9 Special Tools Table 6B 9 ...

Page 696: ...6B 2 POWER STEERING PUMP DAEWOO M 150 BL2 DESCRIPTION AND OPERATION POWER STEERING PUMP The pump has a remote fluid reservoir A pressure relief valve inside the flow control valve limits pump pressure ...

Page 697: ...p D Replace the power steering pump Growling Noise in Steering Pump D Restricted flow of the pump hoses and the steering gear pipes D Clean out the pipes and the hoses D Replace the pipes and the hoses as needed D Scores cracks or breaks of the pressure plate the pump ring the thrust plate and the rotor D Replace the power steering pump D Improperly contacted power steering hose with the body D Se...

Page 698: ...e bolt 2 D105C525 D Loosen the front bracket adjusting bolts 3 D Push the pump forward 4 18 22 NSm 20 24 NSm 20 24 NSm D15C526A Installation Procedure 1 Install the pump drive belt with the bolts Tighten D Tighten the front bracket adjusting bolt to 18 22 NSm 13 16 lb ft 1 D Tighten the rear bracket adjusting bolt to 20 24 NSm 15 18 lb ft 2 D Tighten the power steering pump bolt to 20 24 NSm 15 18...

Page 699: ...Install the pump drive belt 3 Tighten the steering pump pulley nut using the power steering pulley remove holder DW310 020 Tighten Tighten the steering pump pulley nuts to 55 69 NSm 41 51 lb ft 4 Install the front passenger side headlamp Refer to Section 9B Lighting Systems D105C529 PUMP ASSEMBLY Removal Procedure 1 Remove the front passenger side headlamp Refer to Section 9B Lighting Systems 2 Di...

Page 700: ... ft 1 D Tighten the power steering bolt to 20 24 NSm 15 18 lb ft 2 5 Connect the pressure line pipe to the outlet connec tion on the steering pump Tighten Tighten the pressure line pipe fitting to 21 35 NSm 16 26 lb ft 3 6 Install the front passenger side headlamp Refer to Section 9B Lighting Systems Notice When adding fluid or making a complete fluid change always use DEXRONr II or DEXRONr III po...

Page 701: ...POWER STEERING PUMP 6B 7 DAEWOO M 150 BL2 UNIT REPAIR PUMP The power steering pump in this vehicle is not service able A faulty pump must be replaced ...

Page 702: ...Lb In ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Power Steering Pump Bolt ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 20 24 ÁÁÁÁÁÁ ÁÁÁÁÁÁ 15 18 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Power Steering Pump Front Bracket Bolt ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 20 24 ÁÁÁÁÁÁ ÁÁÁÁÁÁ 15 18 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Power Steering Pump Front Bracket Adjusting Bolt ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 18 22 ÁÁÁÁÁÁ ÁÁÁÁÁÁ 13 16 ÁÁÁÁÁÁÁ Á...

Page 703: ...POWER STEERING PUMP 6B 9 DAEWOO M 150 BL2 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE D105C101 DW310 020 Power Steering Pulley Remove Holder ...

Page 704: ...ess otherwise noted TABLE OF CONTENTS Description and Operation 6C 2 Power Rack and Pinion 6C 2 Diagnostic Information and Procedures 6C 3 Power Rack and Pinion Steering Gear 6C 3 Adjust the Free Load of the Steering Gear 6C 5 Repair Instructions 6C 6 On Vehicle Service 6C 6 Rack and Pinion Assembly 6C 6 Power Steering Gear Rack and Pinion Boot 6C 7 Unit Repair 6C 8 Tie Rod End Boot 6C 8 Hydraulic...

Page 705: ...ston converts hydraulic pressure to a linear force which moves the rack left or right The force is then transmitted through the tie rods and the tie rod ends to the steering knuckles which turn the wheels If hydraulic assist is not available manual control is maintained However under these conditions more steering effort is required The movement of the steering wheel is transferred to the pinion T...

Page 706: ...diate shaft D Stuck and improperly aligned power steering pump flow control valve D Replace the power steering pump D Improper binding or looseness of tie rods and ball joints D Tighten the tie rods and the ball joints Replace the tie rods and the ball joints as needed D Poor adjustments of the steering gear D Perform a straight ahead check Momentary Increase in Effect When Turning the Wheel D Int...

Page 707: ...stalled steering gear to intermediate shaft joints D Tighten the joint bolt D Loose tie rods and ball joints D Tighten the tie rods and the ball joints D Replace the tie rods and the ball joints as needed Hard Steering or Lack of Assist Especially During Parking D Stuck and improperly installed power steering pump flow control valve D Replace the power steering pump D Insufficient pressure of the ...

Page 708: ...ification value or the measured torque is over the specification value adjust the tightening torque D Place the rack gear in the straight ahead position D Tighten the adjust plug to 10 NSm 89 lb in D Turn the steering wheel all the way to the right and the left about 5 times repeatedly D Place the rack gear in the straight ahead position D Loosen the adjust plug D105C302 D Tighten the adjust plug ...

Page 709: ...he front exhaust pipe nuts Refer to Section 1G Engine Exhaust D105C534 5 Remove the rack and pinion assembly D Disconnect the return line pipe from the steering gear 1 D Disconnect the pressure inlet line pipe from the steering gear 2 D Plug the opening in the power steering pipe line to prevent fluid loss and contamination D105C535 D Remove the power steering gear retaining bracket tighten bolts ...

Page 710: ...power steering pressure line fitting 1 to 21 35 NSm 16 25 lb ft 1 Tighten the return line fitting to 21 35 NSm 16 25 lb ft 2 Important When adding fluid or making a complete fluid change always use DEXRONR II or III power steering fluid Failure to use the proper fluid will cause hose and seal change and fluid leaks 4 Fill the fluid reservoir with power steering fluid 5 Inspect for leaks If there a...

Page 711: ... from the rack and pinion housing D Remove the fitting 1 D Remove the fitting 2 D15C715A Assembly Procedure 1 Connect the cylinder lines to the rack and pinion housing 2 Install the power steering line fittings at the pinion valve end Tighten Tighten the power steering line fittings to 25 35 NSm 18 25 lb ft 1 3 Install the power steering line fittings at the cylinder end Tighten Tighten the power ...

Page 712: ...ter plug locknut 1 D Remove the adjuster plug 2 D Remove the adjuster spring 3 D105C703 3 Remove the steering pinion D Remove the dust cap 1 D Remove the retaining ring 2 D105C704 D Remove the steering pinion dust cap 3 D Remove the steering pinion locknut 4 Notice If the stub shaft is not held damage to the pin ion teeth will occur While holding the stub shaft remove the locknut from the pinion D...

Page 713: ...housing and the rack gear in this vehicle is not serviceable as unit The faulty parts must be replaced as whole units D105C708 Inspection Procedure 1 Inspect the tie rod ends and the ball joints for dam age Refer to Section 6D Manual Steering Gear 2 Inspect the tie rod ends and the rack pinion boot for cracks or abnormal wear Refer to Section 6D Manu al Steering Gear 3 Inspect the metal part for d...

Page 714: ...eplaced D105C711 Assembly Procedrue 1 Install the steering pinion gear D Install the retaining ring 1 D Install the needle bearing 2 D Install the pinion shaft seal using a drift 3 D105C712 40 50 NSm 2 Install the steering pinion locknut 4 Tighten Tighten the pinion locknut to 40 50 NSm 30 36 lb ft D15C713A 45 55 NSm 3 Install the dust cap 5 Tighten Tighten the dust cap to 45 55 NSm 33 41 lb ft 4 ...

Page 715: ...L2 D105C714 6 Install the rack bearing D Install the adjuster spring 1 D Tighten the adjuster plug 2 D Tighten the plug locknut 3 7 Install the rack and pinion steering assembly to the vehicle Refer to Rack and Pinion Assembly in this section ...

Page 716: ...side 33 5_ 2_ 175 Tire Inside 34 9_ 2_ Outside 30 5_ 2_ Grease Rack POLYUREAS Ball Joint SYNTHETICS OILS LI SOAPS FASTENER TIGHTENING SPECIFICATIONS Application NSm Lb Ft Lb In Power Steering Gear Bracket Bolt 50 55 36 41 Power Steering Gear Pinion Nut 40 50 30 36 Power Steering Gear Pinion Dust Cover 45 55 33 41 Power Steering Gear Pressure Line Fitting 25 35 18 25 Power Steering Oil Pressure Pip...

Page 717: ...nt Locator 6D 3 Manual Rack and Pinion Steering Gear 6D 3 Diagnostic Information and Procedures 6D 4 Manual Rack and Pinion Steering Gear 6D 4 Straight Ahead Check 6D 5 Steering Wheel Restoration 6D 6 Check The Turning Resistance of the Tie Rod End or Tie Rod 6D 6 Adjust the Free Load of the Steering Gear 6D 6 Repair Instructions 6D 7 On Vehicle Service 6D 7 Tie Rod End 6D 7 Rack and Pinion Boot 6...

Page 718: ...nual rack and pinion steering system consists of two main components the rack and the pinion The mo tion of the pinion is transferred through the pinion teeth that mesh with the teeth on the rack which moves the rack The force is then transmitted through the arms on the struts which turn the wheels ...

Page 719: ...ellated Nut 5 Tie Rod End 6 Tie Rod End Lock Nut 7 Rack and Pinion Boot Clamp 8 Rack and Pinion Boot 9 Rack and Pinion Boot Wire Clamp 10 Tie Rod 11 Shock Damper Ring 12 Steering Rack Gear 13 Bulkhead Retainer 14 Bulkhead Bushing 15 Steering Gear Housing 16 Steering Gear Bracket Bushing 17 Packing 18 Dust Cover 19 Pinion Plug 20 Steering Pinion Gear 21 Roller Bearing 22 Rack Bearing 23 Adjuster Sp...

Page 720: ... steering gear D Perform straight ahead check Looseness in the Steering System D Improperly installed tie rods D Tighten the tie rods D Improper and insufficient lubrication D Lubricate the rack and pinion assembly Rattling Noise in the Steering Gear D Improperly installed steering gear mounting D Tighten the steering gear mounting bolts D Improperly installed tie rods D Tighten the tie rods ...

Page 721: ...ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Is the steering wheel off center by more than 5 de grees ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Go to Step 4 ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ Go to Step 5 ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 3 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ The pinion is displaced on the rack The steering pinion position must be corrected Is the repair complete ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ...

Page 722: ...ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ Tie Rod End Ball Joint 0 49 3 43 NSm 4 5 30 lb in ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ Tie Rod Ball Joint 0 49 3 43 NSm 4 5 30 lb in 3 If the values exceed the specified values replace the tie rod end or the tie rod 4 But If the ball joint of the tie rod end or the tie rod falls down of itself replace it ADJUST THE FREE LOAD OF THE STEERING GEAR 1 Place the steering whee...

Page 723: ...fer to Section 2E Tires and wheels 2 Disconnect the tie rod and from the steering knuckle D Remove the cotter pin 1 D Remove the castellated nut 2 D Use a ball joint remover KM 507 B separate the tie rod end 3 D105B502 3 Remove the tie rod end D Mark the tie rod tie rod end lock nut and tie rod end 1 D Loosen the tie rod end lock nut anticlockwise 2 D Loosen the tie rod end 3 D105B503 ...

Page 724: ...2 Tighten Tighten the castellated nut to 30 55 NSm 21 41 lb ft 5 Install the split pin 6 Install the wheel Refer to Section 2E Tires and Wheels 7 Make the toe in adjustment by turning the tie rod ad juster Refer to Section 2B Wheel Alignment D105B505 RACK AND PINON BOOT Removal Procedure 1 Remove the tie rod end Refer to Tie Rod End in this section 2 Remove the tie rod end lock nut D105B506 3 Remo...

Page 725: ...Y Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Remove the intermediate shaft lower pinch bolt Re fer to Section 6E Steering Wheel and Column 2 Remove the wheels Refer to Section 2E Tires and Wheels 3 Disconnect the tie rod end from the steering knuckle Refer to Tie Rod End in this section 4 Remove the front exhaust pipe nuts Refer to Section 1G Engine Exhaust 5 Remove the ste...

Page 726: ... with the bolts Tighten Tighten the steering gear bracket bolts to 50 55 NSm 36 41 lb ft 4 Install the front exhaust pipe nuts Refer to Section 1G Engine Exhaust 5 Connect the tie rod end to the steering knuckle Refer to Tie Rod End in this section 6 Install the wheels Refer to Section 2E Tires and Wheels 7 Install the intermediate shaft lower pinch bolt Refer to Section 6E Steering Wheel and Colu...

Page 727: ...nd 2 Install the tie rod end wire clamp 3 Install the tie rod end Refer to Tie Rod End in this section D105B703 RACK AND PINION Left Hand Drive Shown Right Hand Drive Similar Disassembly Procedure 1 Remove the rack and pinion steering assembly from the vehicle Refer to Rock and Pinion Assembly in this section 2 Remove the rack and pinion boot D Remove the tie rod end Refer to Tie Rod End in this s...

Page 728: ...rack gear perfectly from the steering gear housing by turning the pinion gear 1 D Disconnect the shock damper ring from the tie rod ball joint 2 D15B706A D Vise the rack gear 3 Important Clothe the rack gear with a cloth before vis ing the rack gear Notice Do not vise the rack gear over two teeth face D105B707 D Remove the tie rod 4 D Remove the shock damper ring 5 ...

Page 729: ...st cover 1 D Remove the pinion plug 2 Important Do not reuse the removed pinion plug D105B710 D Remove the pinion and bearing assembly 3 D105B711 6 Remove the rack gear toward the driver side of the steering gear a Rack gear Notice Remove the rack gear toward the driver side of the steering gear to prevent the bulk head in the steering gear housing from damaging in installing and removing the rack...

Page 730: ... gear for wear and damage 4 D105B713 2 Inspect the pinion and bearing assembly damage D Inspect the pinion gear for wear and damage 1 D Inspect the bearing for loose and operation 2 D105B714 3 Inspect the tie rod end boot and the rack and pinion boot for damage D Inspect the tie rod end boot for crack and wear 1 D Inspect the rack and pinion boot for crack and wear 2 D105B715 4 Inspect the steerin...

Page 731: ...oved 2 Install the rack gear D Coat the rack gear with grease 1 D Insert the rack gear carefully 2 D15B718A 3 Install the pinion and bearing assembly D Set the rack in balance 1 D Coat the pinion and bearing assembly and steering gear housing surface with grease D Install the pinion and bearing assembly 2 D Coat the pinion plug with Loctitte D Install the pinion plug 3 Tighten Tighten the pinion p...

Page 732: ...Sm 59 89 lb ft D105B721 6 Install the shock damper ring to the tie rod ball joint a Tie rod ball joint D Coat the tie rod ball joint with grease D105B722 7 Install the rack and pinion boot D Install the rack and pinion boot 1 D Install the rack and pinion boot wire clamp 2 D Install the rack and pinion boot clamp 3 8 Install the tie rod end Refer to Tie Rod End in this sections 9 Install the rack ...

Page 734: ...6D 18 MANUAL STEERING GEAR DAEWOO M 150 BL2 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE D105B101 KM 507 B Ball Joint Remover ...

Page 735: ...E 2 Component Locator 6E 3 Steering Wheel and Column 6E 3 Diagnostic Information and Procedures 6E 4 Steering Column Diagnosis 6E 4 Repair Instructions 6E 7 On Vehicle Service 6E 7 Steering Wheel 6E 7 Steering Column Cover 6E 8 Turn Signal Switch and Lever Wiper Switch and Lever 6E 8 Ignition Switch 6E 9 Ignition Lock Cylinder and Switch with Immobilizer 6E 9 Switch Housing 6E 10 Steering Column 6...

Page 736: ...ess in a front end collision to lessen the chance of driver in jury The ignition switch and the lock are mounted on the col umn allowing the ignition and steering operations to be locked to inhibit theft of the car The column levers trigger the turn signals the headlight beams and the windshield washer and wipers Notice Apply a thin coat of lithium grease to all friction points when reassembling t...

Page 737: ...mn Lower Cover 7 Turn Signal Switch 8 Windshield Wiper Switch 9 Steering Column Assembly 10 Retaining Ring 11 Washer 12 Spring 13 Switch Housing 14 Bolt 15 Support Bolt 16 Steering Column Housing 17 Steering Column Jacket 18 Ignition Switch Retaining Screw 19 Ignition Switch 20 Steering Lock Housing Assembly 21 Steering Column Shaft 22 Pinch Bolt 23 Intermediate Shaft 24 Steering Column Upper Nut ...

Page 738: ... Extreme misalignment of the housing to the cover D Realign the cover on the housing D Replace the cover as needed Key Cannot Be D The ignition switch to be set incorrectly D Reset the ignition switch Removed in the B Position D Damaged lock cylinder D Replace the lock cylinder Column Condition Probable Cause Correction Noise in the Column D Improperly installed intermediate shaft to column joints...

Page 739: ...ncelling mechanism D Replace the turn signal switch Turn Signal Dimmer Switch Difficult to Operate D Improperly installed turn signal dimmer switch and turn signal dimmer switch lever D Remove and inspect the turn signal dimmer switch and signal dimmer switch lever D Reinstall the signal dimmer switch and signal dimmer switch lever D Foreign material in the signal dimmer switch housing D Remove an...

Page 740: ...ector D Reconnect the ignition switch electrical connector D Replace the ignition switch electrical connector Ignition Switch Will D Damaged ignition switch D Replace the ignition switch Not Turn D Improperly installed ignition switch D Remove and inspect the ignition switch D Reinstall the ignition switch Wiper Switch Lever Condition Probable Cause Correction Switch Inoperative D Damaged wiper sw...

Page 741: ...In order to install the steering wheel correctly match mark the steering column shaft to the steering wheel 5 D Remove the steering wheel using the steering wheel puller DW310 010 6 Important Be careful not to hit the top of steering col umn shaft with hammer during repair work D15A503A Installation Procedure 1 Install the SIR module Refer to Section 8B Supple mental Inflatable Restraints For vehi...

Page 742: ...URN SIGNAL SWITCH AND LEVER WIPER SWITCH AND LEVER Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Disconnect the negative battery cable 2 Remove the steering column cover Refer to Steer ing Column Cover in this section 3 Remove the turn signal switch D Disconnect the turn signal switch by pushing the locking from the switch housing 1 D Disconnect the connector 2 D105A507 4 Remo...

Page 743: ...witch D Disconnect the electrical connector 1 D Remove the screw 2 D105A510 Installation Procedure 1 Connect the electrical connector 2 Install the ignition switch with the screw 3 Install the steering wheel Refer to Steering Wheel in this section 4 Connect the negative battery cable D105A511 IGNITION LOCK CYLINDER WITH IMMOBILIZER Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1...

Page 744: ...105A513 SWITCH HOUSING Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Remove the steering wheel Refer to Steering Wheel in this section 2 Remove the turn signal switch and windshield wiper switch Refer to Turn Signal Switch and Lever Wiper Switch and Lever in this section 3 Remove the switch housing D Disconnect the horn electrical connector 1 D Remove the screws retaining the ...

Page 745: ...ove the intermediate shaft upper pinch bolt 2 D Remove the steering column lower nuts 3 D Remove the steering column upper nuts 4 D15A517B D15A518B Installation Procedure Important Align the match mark on the intermediate shaft and the steering column shaft 1 Install the steering column D Install the intermediate shaft upper pinch bolt 1 Tighten Tighten the pinch bolt to 21 29 NSm 16 22 lb ft D In...

Page 746: ...y match mark the intermediate shaft to the steering column 1 D Remove the intermediate shaft upper pinch bolt 2 D Remove the intermediate shaft lower pinch bolt 3 D15A521A Installation Procedure 1 Install the intermediate shaft with the bolts Tighten D Tighten the intermediate shaft lower pinch bolt to 21 29 NSm 16 22 lb ft 1 D Tighten the intermediate shaft upper pinch bolt to 21 29 NSm 16 22 lb ...

Page 747: ...is section Caution Be careful not to impact on the steering column shaft Plastic sleeve may be broken that is installed to secure the driver at the accident 2 Remove the steering column shaft from the steering column D Remove the retaining ring 1 D Remove the washer 2 D Remove the spring 3 D Remove the washer 4 D Remove the locking of the alignment spacer 5 D Push strongly the steering column shaf...

Page 748: ...acer in the steering column jacket easily 1 Install the steering column shaft to the steering col umn D Position the locking of the alignment spacer on the groove of the steering column D Install the washer D Install the spring D Install the washer D Install the retaining ring 2 Install the steering column to the vehicle Refer to Steering Wheel in this section ...

Page 750: ...6E 16 STEERING WHEEL AND COLUMN DAEWOO M 150 BL2 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE D105A101 DW310 010 Steering Wheel Puller ...

Page 751: ...agnostic Informatin and Procedures 7A 6 Heater System 7A 6 Insufficient Heating or Defrosting 7A 6 Blower Electrical 7A 10 Improper Air Delivery or No Mode Shift 7A 11 Too Much Heat 7A 13 Controls 7A 15 Blower Noise 7A 16 Repair Instructions 7A 18 On Vehicle Service 7A 18 Control Assembly and Control Cables 7A 18 Blower Motor and Cooling Hose 7A 20 Blower Resistor 7A 20 Blower Motor Switch 7A 21 H...

Page 752: ... red portion of the knob 2 The Rotary Blower Control Knob D Turns on to operate the blower motor at four speeds D Turns to stop the blower D Operates completely independently both from the mode control that regulates the defroster door and from the temperature control knob D Changes the fan speed in any mode and at any temperature setting 3 The Rotary Mode Control Knob D Actuates by cable D Regula...

Page 753: ...mbly 2 Temperature Control Cable 3 Mode Select Cable 4 Rack 5 Bracket 6 Cable Clamp 7 Bulb Socket Assembly 8 Pinion Assembly 9 A C Switch 10 Housing 11 Detent Cap 12 Detent Spring 13 Blower Switch 14 Rear Defogger Switch 15 Recirculating Fresh Air Door Cable 16 Panel 17 A C Push Knob 18 Rotary Knob 19 Recirculating Knob 20 Rear Defogger Push Knob 21 Recirculation ...

Page 754: ... Right Hand Drive Similar D18A402A 1 Blower Module Assembly 2 Plastic Washer 3 Blower Link 4 Blower Lever 5 Air Intake Case 6 Valve Retainer 7 Heater Duct Assembly 8 Blower Connector Duct 9 Orifice Case 10 Cable Clamp 11 Blower Valve 12 Blower Resistor 13 Lower Case 14 Cooling Hose 15 Blower Motor ...

Page 755: ...er Module Assembly 5 Plastic Washer 6 Temperature Control Lever 7 Temperature Control Lever Bearing 8 Defroster Link 9 Defroster Lever 10 Spring 11 Ventilation Link 12 Ventilation Lever 13 Temperature Control Link 14 Heater Link 15 Heater Lever 16 Cable Link 17 Left Heater Case 18 Defroster Valve 19 Ventilation Valve 20 Temperature Control Valve 21 Right Heater Case 22 Case Seal 23 Heater Core Cov...

Page 756: ...ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Check the surge tank cap Refer to Section 1D Engine Cooling Is the surge tank cap OK ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Go to Step 10 ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ Go to Step 9 ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 9 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Repair or replace the surge tank cap as needed Is the repair complete ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ...

Page 757: ...ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1 Check the temperature door D Travel D Cables D Linkage 2 Verify the accuracy of the temperature controls at full hot 3 Verify the accuracy of the temperature controls at full cold Is the repair complete ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ System OK ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁ...

Page 760: ...on ON 2 Use a short detector to locate a possible short D From the fuse Ef6 to the blower switch D From the blower swtich to the blower resistor D From the blower resistor to the blower motor 3 Repair any short 4 Replace any blown fuse Is the repair complete ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ System OK ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁ...

Page 761: ...ÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Go to Step 2 ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ System OK ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 2 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Examine the affected door in the unit for proper cable attachment D Check the cable connection to the door D Check that the cable sheath is properly re tained Is the cable con...

Page 763: ...w change as the setting for the blower speed switch is changed ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ System OK ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ Go to Blower Electrical ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 7 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1 Check the temperature door travel the cables and the linkage 2 Adjust to full c...

Page 764: ...t the temperature door goes to full cold 3 Check the temperature door for full hot Is the temperature door travel correct ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ System OK ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 15 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1 Check for hot air leaks from the engine com...

Page 766: ...Á ÁÁÁÁÁÁ ÁÁÁÁÁÁ Go to Step 6 ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 6 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1 Examine the blower fan for wear spots cracked blades a cracked hub a loose fan retaining nut or bad alignment 2 Examine the blower case for wear spots Did you find any problem ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Go to ...

Page 767: ...Á System OK ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 16 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Is the noise present in all modes but not all temper ature positions ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Go to Step 17 ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ Go to Step 18 ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 17 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1 Check the temperature door seals 2 Repai...

Page 768: ...umentation Driver informa tion 3 Remove the control assembly D Remove the control assembly retaining screws 1 D Separate the control assembly from the instrument panel 2 D Disconnect the electrical connectors 3 D Disconnect the mode control cable from the heater module 4 D Disconnect the temperature control cable from the heater module 5 D Remove the glove box from the instrument panel Refer to Se...

Page 769: ...l cables to the control assembly 2 Connect the recirculating fresh air door cable to the blower module 3 Install the glove box to the instrument panel Refer to Section 9E Instrumentation Driver Information 4 Connect the temperature control cable and the mode control cable to the heater module 5 Connect the electrical connectors 6 Install the control assembly with the screws 7 Install the instrumen...

Page 770: ...r D Disconnect the motor electrical connector 1 D Turn the blower motor 2 D108A509 Installation Procedure 1 Install the blower motor by turning the motor clock wise 2 Connect the motor electrical connector 3 Install the blower motor cooling hose D108A510 BLOWER RESISTOR Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Remove the blower resistor D Disconnect the blower resistor co...

Page 771: ...Procedure 1 Remove the control assembly Refer to Control As sembly and Control Cables in this section 2 Remove the blower motor switch D Remove the switch knob 1 D108A513 D Remove the blower motor switch retaining screw 2 D Turn the blower motor switch anticlockwise 3 D108A514 Installation Procedure 1 Install the blower motor switch with the screw 2 Install the switch knob 3 Install the control as...

Page 772: ...ner housing D Raise and suitably support the vehicle D Disconnect the hose from the heater module using a hose remover DW100 020 1 D108A516 D Lower the vehicle D Disconnect the hose from the thermostat 2 D18A517A 4 Remove the heater outlet hoses D Raise and suitably support the vehicle D Disconnect the hose from the heater module using a hose remover DW100 020 1 D Disconnect the B terminal from th...

Page 773: ...nnect the hose to the heater module using a hose installer DW100 020 2 D Lower the vehicle D108A519 2 Install the heater inlet hoses D Connect the hose to the thermostat 1 D Raise and suitably support the vehicle DW100 020 D18A520A D Connect the hose to the heater module using a hose installer DW100 020 2 D Lower the vehicle D Install the air cleaner housing 3 Refill the coolant Refer to Section 1...

Page 774: ...r center Refer to Section 9E Instrumentation Driver Information 3 Remove the heater module to blower module con nection tube on the vehicle not equipped with A C a Heater module to blower module connection tube D108A524 4 Remove the evaporator on the vehicle equipped with A C Refer to Section 7B Manual Control Heating Ventilation and Air Conditioning System D108A525 5 Remove the heater module D Re...

Page 775: ...nformation 5 Connect the heater hoses to the heater module Re fer to Heater Hoses in this section D108A529 D108A530 BLOWER MODULE Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Remove the glove box from the instrument panel Re fer to Section 9E Instrumentation Driver Information 2 Remove the heater module to blower module con nection tube on the vehicle not equipped with A C Re...

Page 776: ...6 Install the heater module to blower module connec tion tube on the vehicle not equipped with A C Refer to Heater Module in this section 7 Install the glove box to the instrument panel Refer to Section 9E Instrumentation Driver Information D108A532 DEFROSTER DUCT AND HOSES Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Remove the instrument panel Refer to Section 9E Instrument...

Page 777: ...the instrument panel Refer to Section 9E Instrumentation Driver Information 2 Remove the ventilation duct retaining screws a Retaining screw 3 Remove the ventilation duct b Ventilation duct D108A535 Installation Procedure 1 Install the ventilation duct with the screws 2 Install the instrument panel Refer to Section 9E In strumentation Driver Information ...

Page 778: ...e the heater module Refer to Heater Module in this section 2 Remove the heater core D Remove the heater core cover 1 D Remove the heater core 2 D108A702 Assembly Procedure 1 Install the heater core to the heater module 2 Install the heater core cover 3 Install the heater module Refer to Heater Module in this section ...

Page 780: ...7A 30 HEATING AND VENTILATION SYSTEM DAEWOO M 150 BL2 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE D102B119 DW 100 020 Spring Clamp Remover Installer ...

Page 781: ...HEATING AND VENTILATION SYSTEM 7A 31 DAEWOO M 150 BL2 SCHEMATIC AND ROUTING DIAGRAMS NON A C DIAGRAMS D18A201B ...

Page 782: ...7A 32 HEATING AND VENTILATION SYSTEM DAEWOO M 150 BL2 AIR FLOW THROUGH DUCTS NON A C Left Hand Drive Shown Right Hand Drive Similar D108A202 ...

Page 783: ... Chart R 134a System 7B 11 Repair Instructions 7B 13 On Vehicle Service 7B 13 General A C System Service Procedures 7B 13 O Ring Replacement 7B 13 Handling Refrigerant 7B 13 Handling of Refrigerant Lines and Fittings 7B 13 Maintaining Chemical Stability in the Refrigeration System 7B 14 Discharging Adding Oil Evacuating and Charging Procedures for A C System 7B 14 Serviceable Components 7B 17 Cont...

Page 784: ...ve replace the expansion valve If excessive moisture is found in the A C system recycle the refrigerant A restricted expansion valve will result in low suction pressure and no cooling This may be caused by debris in the refrigerant system If debris is believed to be cause recycle the refrigerant replace the expansion valve and replace the receiver dryer Evaporator Core The evaporator is device whi...

Page 785: ...MANUAL CONTROL HEATING VENTILATION AND AIR CONDITIONING SYSTEM 7B 3 DAEWOO M 150 BL2 COMPONENT LOCATOR A C SYSTEM Left Hand Drive Shown Right Hand Drive Similar D18B401B ...

Page 786: ...Evaporator Core 8 Expansion Valve 9 Evaporator Inlet Pipe 10 Plate 11 Evaporator Lower Case 12 O ring 13 High Pressure Pipe Compressor Condenser 14 Compressor 15 Compressor Magnetic Clutch 16 Compressor Pulley 17 Compressor Clutch Drive 18 Shaft Bolt 19 High Pressure Pipe Condenser Receiver Dryer 20 Condenser 21 Receiver Dryer 22 Dual Cut Switch 23 Receiver Dryer Bracket 24 Compressor Bracket 25 C...

Page 787: ...5 Check for slippage of the compressor clutch 6 Check the drive belt tension INSUFFICIENT COOLING QUICK CHECK PROCEDURE Perform the following hand feel procedure to get a quick idea of whether the air conditioning A C system has the proper charge of Refrigerant 134a 1 Warm up the engine Run the engine at idle 2 Open the hood and all the doors 3 Turn the A C switch ON 4 Set the temperature control ...

Page 789: ... Testing Instructions D Follow the entire path of the refrigerant system D Completely circle each joint at 25 to 50 mm 1 to 2 inches per second D Hold the probe tip within 6 mm 1 4 inch of the sur face D Do not block the air intake The audible tone changes from 1 to 2 clicks per second into a solid alarm if there is a leak Adjust the balance control to maintain 1 to 2 clicks per second Test all of...

Page 790: ...ep 7 Go to Step 4 7 1 Add the refrigerant R 134a 2 Check the A C system for leaks 3 Repair any refrigerant leaks as needed 4 Recover evacuate and recharge the A C system Are both pressure within the specified value High Side Pressure 1 500 kPa 217 5 Psi Go to Step 8 8 1 Start the engine and allow it to run at idle 2 Set the A C controls to following positions D The A C switch to the ON position D ...

Page 791: ...and outlet pipes Go to Step 16 Go to Step 15 15 1 Recover the A C system refrigerant 2 Replace the expansion valve as needed 3 Evacuate and recharge the A C system 4 Check the A C system for leaks 5 Note the discharge air temperature with the A C ON Is the discharge temperature normal Go to Step16 Go to Step 18 16 Feel the liquid pipe between the condenser and the expansion valve Is the pipe cold ...

Page 792: ...mpt to turn the clutch driver not the pulley Can you turn the clutch driver freely by hand Go to Step 23 Go to Step 21 21 1 Recover the A C system refrigerant 2 Replace the A C compressor 3 Evacuate and recharge the A C system Is the repair complete System OK 22 1 Add the refrigerant R 134a Does the cooling performance improve System OK Go to Step 23 23 1 Recover the A C system refrigerant 2 Repla...

Page 795: ... good practice to replace the cap after each use of the drum If it is necessary to transport or carry any container of refrigerant in a vehicle do not carry it in the passenger compartment HANDLING OF REFRIGERANT LINES AND FITTINGS Notice Using too low or too high torque when tightening a fitting can result in loose joints or deformed joint parts Both conditions can result in refrigerant leakage D...

Page 796: ...only refillable refrigerant tanks that are authorized for the charging station being used The use of other tanks may cause personal injury or void the warranty Refer to the manufacturer s in structions for the charging station Caution To avoid personal injury always wear goggles and gloves when performing work that in volves opening the refrigeration system A charging station discharges evacuates ...

Page 797: ...rol indicator shows that the refrig erant tank is full during the recovery process and the unit shuts off install an empty unit tank to store the refriger ant needed for steps later in the procedure Do not use any other type of tank Evacuation The unit tank must contain a sufficient amount of R 134a refrigerant for charging Check the amount of refrigerant in the tank If there is less than 3 6 kg 8...

Page 798: ...nning 7 Close the high side coupler valve 8 Disconnect the high side hose from the vehicle 9 Open the high side and low side valves on the con trol panel 10 The system will quickly draw in refrigerant from both hoses through the low side hose 11 Close the low side coupler valve 12 Disconnect the low side hose from the vehicle Unsuccessful Transfer Sometimes the total charge does not transfer into ...

Page 799: ...A Heating and Ventilation System With out Air Conditioning BLOWER MOTOR AND COOLING HOSE To remove the blower motor and cooling hose refer to Section 7A Heating and Ventilation System Without Air Conditioning BLOWER RESISTOR To remove the blower resistor refer to Section 7A Heat ing and Ventilation System Without Air Conditioning BLOWER MOTOR SWITCH To remove the blower motor switch refer to Secti...

Page 800: ... 5 D108A506 Installation Procedure 1 Install the A C push knob to the control assembly 2 Connect the A C push knob electrical connector 3 Install the control assembly with the screws 4 Connect the mode control cable to the heater mod ule 5 Connect the temperature control cable to the heater module 6 Install the instrument cluster housing trim panel Re fer to Section 9E Instrumentation Driver Infor...

Page 801: ...dual cut switch to 13 NSm 115 lb in D18B506B 3 Install the receiver dryer D Install the new O rings D Install the bracket bolt 1 Tighten Tighten the bracket bolt to 5 NSm 44 lb in D Install the receiver dryer flange nuts 2 Tighten Tighten the receiver dryer flange nut to 14 NSm 10 5 lb ft D Connect the dual cut switch connector 4 Install the front bumper fascia Refer to Section 9O Bumpers and Fasc...

Page 802: ... lb in 2 2 Install the front bumper fascia Refer to Section 9O Bumpers and Fascias D108B509 D18B510A COMPRESSOR Removal Procedure 1 Remove the receiver dryer Refer to Receiver Dryer and Dual Cut Switch in this section 2 Remove the A C belt Refer to Section 6B Power Steering Pump 3 Remove the compressor D Discharge and recover the refrigerant Refer to Discharging Adding Oil Evacuating and Charg ing...

Page 803: ... bolt Tighten Tighten the A C low pressure pipe line bolt to 23 NSm 17 lb ft 4 5 Evacuate and charge the system Refer to Discharg ing Adding Oil Evacuating and Charging Procedure for A C System in this section 6 Install the A C belt Refer to Section 6B Power Steer ing Pump 7 Install the receiver dryer Refer to Receiver Dryer and Dual Cut Switch in this section D18B513A CONDENSER 1 Disconnect the n...

Page 804: ...eiver dryer pipe fitting to 14 NSm 10 5 lb ft 2 3 Evacuate and recharge the system Refer to Dis charging Adding Oil Evacuating and Charging Pro cedures for A C System in this section 4 Install the front bumper fascia Refer to Section 9O Bumpers and Fascias 5 Connect the negative battery cable D108B517 A C HIGH PRESSURE PIPE LINE Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Di...

Page 805: ... Remove the A C high pressure pipe line between the condenser and the receiver dryer D Loosen the fitting securing the receiver dryer to the condenser 1 D108B520 D Remove the receiver dryer flange nuts 2 D18B521A 6 Remove the A C high pressure pipe line between the receiver dryer and the evaporator D Remove the purge control valve Refer to Section 1F Engine Controls D Remove the bracket nut 1 D Lo...

Page 806: ...n the fitting securing the high pressure pipe line to the receiver dryer to 14 NSm 10 5 lb ft 3 D Tighten the bracket nut to 5 NSm 44 lb in 4 D Tighten the receiver dryer flange nuts to 14 NSm 10 5 lb ft 5 D Tighten the nut securing the high pressure pipe line to the evaporator to 14 NSm 10 5 lb ft 6 D Tighten the bracket nut to 5 NSm 44 lb in 7 2 Install the purge control valve Refer to Section 1...

Page 807: ... this section 3 Remove the A C low pressure pipe line D Remove the bolt securing the A C low pressure pipe line at the compressor 1 D18B527A D Remove the bracket nut from shut bar 2 D18B528A D Remove the purge control valve Refer to Section 1F Engine Controls D Loosen the nut securing the A C low pressure pipe line at the evaporator 3 D18B529B Installation Procedure Important Discard the removed O...

Page 808: ...EVAPORATOR UNIT AND DRAIN HOSE Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Disconnect the negative battery cable 2 Discharge and recover the refrigerant Refer to Dis charging Adding Oil Evacuating and Charging Pro cedures for A C System in this section 3 Loosen the high pressure pipe line receiver dry er evaporator nut and the low pressure pipe line evaporator compressor nut...

Page 809: ...l the drain hose 4 Install the glove box Refer to Section 9E Instrumen tation Driver Information 5 Tighten the high pressure pipe line receiver dry er evaporator nut and the low pressure pipe line evaporator compressor nut to 14 NSm 10 5 lb ft 6 Evacuate and recharge the system Refer to Dis charging Adding Oil Evacuating and Charging Pro cedures for A C System in this section 7 Connect the negativ...

Page 810: ...tor 6 D Loosen the fitting and remove the high pressure pipe line 7 D Remove the tape 8 D Remove the evaporator plate seal 9 D Loosen the fitting and remove the expansion valve 10 D18B702A Assembly Procedure 1 Install the exponsion valve with the fitting Tighten Tighten the high pressure pipe line coupling to 17 NSm 13 lb ft 1 2 Install the evaporator plate seal 3 Install the tape 4 Install the hi...

Page 811: ...aft bolt 2 D18B704A 3 Remove the compressor pulley D Remove the snap ring using a ring pryer 1 D Remove the pulley 2 D18B705A 4 Disconnect the wiring harness holder and remove the electromagnetic clutch a Electromagnetic clutch D18B706B Assembly Procedure 1 Connect the wiring harness holder and install the clutch coil 2 Install the snap ring and compressor pulley 3 Use the clutch hub holding tool ...

Page 812: ... Dual Cut Switch Pressure kPa 205 245 180 220 ON OFF 300 400 240 280 FASTENER TIGHTENING SPECIFICATIONS Application NSm Lb Ft Lb In Compressor Upper Bracket Bolts 20 15 Compressor Front Head to Rear Head Through Bolt 22 16 High Pressure Pipe Line Compressor Condenser Bolt 23 17 High Pressure Pipe Line Compressor Condenser Fitting 23 17 High Pressure Pipe Line Compressor Condenser Clamp Nut 5 44 Re...

Page 813: ...MANUAL CONTROL HEATING VENTILATION AND AIR CONDITIONING SYSTEM 7B 31 DAEWOO M 150 BL2 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE D108B101 DW 610 010 Clutch Hub Holding Tool ...

Page 814: ...7B 32 MANUAL CONTROL HEATING VENTILATION AND AIR CONDITIONING SYSTEM DAEWOO M 150 BL2 SCHEMATIC AND ROUTING DIAGRAMS A C DIAGRAMS D18B201B ...

Page 815: ...NTROL HEATING VENTILATION AND AIR CONDITIONING SYSTEM 7B 33 DAEWOO M 150 BL2 A C AIRFLOW Left Hand Drive Shown Right Hand Drive Similar D108B202 A C SYSTEM Left Hand Drive Shown Right Hand Drive Similar D18B203A ...

Page 816: ...LR Front Seat Belt 8A 2 Three Point ELR Front Seat Belt 8A 2 Three Point ELR Rear Outboard Seat Belt 8A 2 Two Point Lap Rear Center Seat Belt 8A 2 Operational and Functional Checks 8A 2 Component Locator 8A 3 Front and Rear Seat Belt 8A 3 Diagnostic Information and Procedures 8A 4 Seat Belt Warning Lamp is Inoperative 8A 4 Repair Instructions 8A 5 On Vehicle Service 8A 5 Three Point WLR ELR Front ...

Page 817: ...r ELR seat belt is always unlocked allowing the passenger freedom of movement except in emergencies rapid deceleration rapid acceleration or hard cornering maneuvers TWO POINT LAP REAR CENTER SEAT BELT The two point lap rear center seat belt is a single contin uous length of webbing The webbing is routed from the anchor through a latch plate and into a single retractor OPERATIONAL AND FUNCTIONAL C...

Page 818: ...M 150 BL2 COMPONENT LOCATOR FRONT AND REAR SEAT BELT D1AA401B 1 Front Seat Belt 2 Front Seat Belt Buckle 3 Rear Seat Belt Three Point 4 Rear Seat Belt Two Point Buckle Three Point 5 Rear Seat Belt Buckle Three Point Two Point ...

Page 819: ...erative D Seat belt warning lamp wiring harness is open circuit or a short circuit D Repair the wiring harness D The continuity between the two terminals at the switch side of the connector is fail D Replace the seat belt switch D The continuity between the terminal for the BLK wire and ground is fail D Repair the open ground D The warning lamp bulb in the instrument cluster is blown D Replace the...

Page 820: ...r washer 2 D Remove the plastic protector on the seat belt an chor D11A502A 3 Remove the lower B pillar trim panel Refer to Sec tion 9G Interior Trim 4 Remove the bolt on the upper B pillar D Using a flathead screwdriver open the bolt cap 1 D Remove the bolt 2 D Remove the spacer and the fiber washer 3 D110A503 5 Remove the seat belt retractor bolt D Remove the floor carpet to be seen the retracto...

Page 821: ...n Tighten the seat belt retractor bolt to 30 45 NSm 22 33 lb ft b Seat belt retractor bolt D1AA505B 4 Install the bolt on the lower B pillar D Install the bolt Tighten Tighten the lower B pillar bolt to 30 45 NSm 22 33 lb ft D Install the spacers and the spring washer D Install the plastic protector on the seat belt anchor 5 Relocate the seatback D110A501 THREE POINT PRETENSIONER FRONT SEAT BELT W...

Page 822: ...e lower retractor bolt 2 D Remove the fiber washer 3 D Remove the seat belt retractor D1AA504C Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasteners to prevent premature corrosion 1 Install in the reverse order of removal 2 Install the bolt on the upper B pillar Tighten Tighten the seat belt upper bolt to 30 45 ...

Page 823: ...emove the patch 3 D Before removing the driver seat belt buckle dis connect the reminder light connector D1AA507B Installation Procedure 1 Install the front seat belt buckle D Connect the reminder light connector D Install the patch D Install the buckle D Install the bolt Tighten Tighten the seat belt buckle bolt to 30 45 NSm 22 33 lb ft D109E566 THREE POINT ELR REAR OUTBOARD SEAT BELT Removal Pro...

Page 824: ... cap using a flathead screw driver D Remove the bolt 2 D Remove the plastic washers the spacers and the fiber washer 3 D110A510 6 Remove the seat belt retractor bolt D Remove the bolt 1 D Remove the fiber washer 2 D Remove the rear seat belt D1AA511B Installation Procedure 1 Install in the reverse order of removal 2 Install the seat belt retractor bolt and the upper bolt Tighten D Tighten the seat...

Page 825: ...t and the fiber washer 3 D Remove the buckle two point and three point 4 D1AA514B Installation Procedure 1 Install in the reverse order of removal 2 Install the three point rear seat belt buckle with the bolt Tighten Tighten the three point rear seat belt buckle bolt and the two point rear seat belt bolt to 30 45 NSm 22 33 lb ft a Two point rear seat belt and three point rear seat belt buckle bolt...

Page 826: ...Á ÁÁÁÁÁÁ 22 33 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Seat Belt Lower Bolt ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 30 45 ÁÁÁÁÁÁ ÁÁÁÁÁÁ 22 33 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Seat Belt Retractor Bolt ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 30 45 ÁÁÁÁÁÁ ÁÁÁÁÁÁ 22 33 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Seat Belt Buckle Bolt ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 30 45 ÁÁÁÁÁÁ ÁÁÁÁÁÁ 22 33 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁ...

Page 827: ...8A 12 SEAT BELTS DAEWOO M 150 BL2 SCHEMATIC AND ROUTING DIAGRAMS DRIVER SEAT BELT WARNING D1AA201A ...

Page 828: ... Circuit Short To Ground 8B 26 DTC 08 Passenger Firing Circuit Short To Battery Voltage 8B 28 DTC 09 Driver Pretensioner Circuit Resistance Too High 8B 30 DTC 10 Driver Pretensioner Circuit Resistance Too Low 8B 32 DTC 11 Driver Pretensioner Circuit Short to Ground 8B 34 DTC 12 Driver Pretensioner Circuit Short to Battery Voltage 8B 36 DTC 13 Passenger Pretensioner Circuit Resistance Too High 8B 3...

Page 829: ...gnostic Illustration 19 8B 68 Diagnostic Illustration 20 8B 68 Diagnostic Illustration 21 8B 68 Repair Instructions 8B 69 On Vehicle Service 8B 69 Driver Airbag Module 8B 69 Clock Spring 8B 70 Passenger Airbag Module 8B 71 Sensing and Diagnostic Module SDM 8B 72 Airbag Module Deployment In Vehicle 8B 74 Airbag Module Deployment Outside of Vehicle 8B 76 Deployed Airbag Module Disposal Procedure 8B ...

Page 830: ...SDM The SDM D Has no user serviceable parts D Is under the front console assembly D Continuously monitors the system components D Records any faults which are discovered D Illuminates a warning lamp that alerts the driver to any faults D Allows the fault codes to be retrieved with a scan tool The SDM controls the deployment of the airbag system through the use of the D Arming sensor D Capacitor D ...

Page 831: ... the clock spring Caution Disassembling the clock spring can cause injury and vehicle damage The clock spring should never be disassembled The clock spring must be replaced if the airbags have been deployed D110B008A WIRING HARNESS CONNECTORS The connector for the sensing and diagnostic module SDM has a built in shorting bar that will turn ON the warning lamp if there is a poor connection at the S...

Page 832: ...ocedures in the correct sequence can cause the airbag system to deploy unexpectedly and possibly cause a serious injury Only trained personnel at franchised Daewoo dealers and authorized Daewoo service dealerships may service the airbag system Never attempt to disassemble repair or reuse the D Airbag modules D Clock spring D Sensing and diagnostic module D Wiring harness When making SIR repairs D ...

Page 833: ... Compressed Ar gas D110B003 2 When crashing firing current flows from the SDM to the initiator 3 Initiator is burning and the inside pressure is increas ing and the piston hits the safety disc D110B004 4 Safety disc is broken and the compressed Ar gas is spouted out D110B005 5 Compressed Ar gas and the burned initiator are car bureted And the airbag is deployed ...

Page 834: ...TS SIR 8B 7 DAEWOO M 150 BL2 COMPONENT LOCATOR SIR COMPONENT Left Hand Drive Shown Right Hand Drive Similar D110B401 1 Driver Airbag Module 2 Passenger Airbag Module 3 Clock Spring 4 Sensing and Diagnostic Module SDM 5 Wiring Harness ...

Page 835: ...nnector DLC D Reveals the fault codes D Receives serial data transmission through the termi nal J 13 of the DLC D Receives ground through the terminal A 4 of the DLC CLEARING FAULT CODES When the sensing and diagnostic module SDM re ceives the CODE ERASE command from the scan tool the SDM D Clears the entire fault memory D Turns OFF the warning lamp D Resets for fault detection External Fault Serv...

Page 836: ...SUPPLEMENTAL INFLATABLE RESTRAINTS SIR 8B 9 DAEWOO M 150 BL2 BLANK ...

Page 837: ...nal 9 of the SDM to the terminal J 13 of the assembly line diagnostic link Diagnostic System Check ÁÁÁÁ ÁÁÁÁ Step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Action ÁÁÁÁÁ ÁÁÁÁÁ Value s ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ No ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1 Turn the ignition ON 2 Check the warning lamp Does the warning lamp turn off after 4 seconds ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁ...

Page 838: ...ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Repair the open DLC ground circuit Is the repair complete ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ System OK ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 10 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1 Turn the ignition ON 2 Check the voltage at the cigar lighter positive terminal Does the voltmeter show the specified value ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁ...

Page 840: ...SUPPLEMENTAL INFLATABLE RESTRAINTS SIR 8B 13 DAEWOO M 150 BL2 BLANK ...

Page 841: ...n D The combined resistance of the driver airbag module the harness wiring and the connector contacts is above a specified value as with an open circuit Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge The capacitor supplies reserve power to deploy the airbags even if the battery is discon nected Unintentional deployment...

Page 842: ...ÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ Go to Step 6 ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 4 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1 Replace the SDM 2 Reconnect the negative battery cable 3 Set the scan tool for CODE ERASE 4 Do the diagnostic system check Does the code 01 still show as a current fault ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ...

Page 843: ...t The SDM monitors the circuit re sistance during this check DTC 02 Will Set When D The combined resistance of the driver airbag module the harness wiring and the connector contacts is be low a specified value as with a short circuit between the wires to the driver airbag module Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to dis...

Page 845: ... check the driver airbag module firing circuit The SDM allows a very small amount of current to flow through the driver airbag module firing circuit The SDM monitors the voltage during this check DTC 03 Will Set When D The firing circuit is shorted to ground Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge The capacitor ...

Page 846: ...ÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Go to Step 6 ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ Go to Step 4 ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 4 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1 Replace the SDM 2 Reconnect the negative battery cable 3 Set the sc...

Page 847: ...e tests the SDM will check the driver airbag module firing circuit The SDM allows a very small amount of current to flow through the circuit The SDM monitors voltage during this check DTC 04 Will Set When D The firing circuit is shorted to voltage Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge The capacitor supplies re...

Page 848: ...ÁÁ ÁÁÁÁÁÁÁ Go to Step 6 ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ Go to Step 4 ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 4 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1 Replace the SDM 2 Reconnect the negative battery cable 3 Set the scan tool for CODE ERASE 4 Do the diagnostic system check Does the code 04 still show as...

Page 849: ...uit resistance during this check DTC 05 Will Set When D The combined resistance of the passenger airbag module the harness wiring and the connector con tacts is above a specified value as in an open circuit Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge The capacitor supplies reserve power to deploy the airbags even if...

Page 850: ... will create a complete circuit be tween the wires from the passenger airbag module 3 Connect an ohmmeter to the terminals on the SDM side of the wiring harness connector for the passenger side airbag module D Refer to Diagnostic Illustration 8 in this section Does the ohmmeter show the specified value ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ 0 W ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁ...

Page 851: ...s check DTC 06 Will Set When D The combined resistance of the passenger airbag module the harness wiring and the connector con tacts is below a specified value as in a short circuit between the wires to the passenger airbag module Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge The capacitor supplies reserve power to de...

Page 852: ...ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1 Replace the SDM 2 Reconnect the negative battery cable 3 Set the scan tool to CODE ERASE 4 Do the diagnostic system check Does the code 06 still show as a current fault ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Go to Step 3 ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ System...

Page 853: ... SDM will check the passenger airbag firing circuit The SDM allows a very small amount of current to flow through the circuit The SDM monitors the voltage during this check DTC 07 Will Set When D The firing circuit is shorted to ground Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge The capacitor supplies reserve power ...

Page 854: ...t the electrical connector from the passenger airbag module 2 Disconnect the electrical connector at the SDM D The shorting bar at the disconnected SDM connector will create a complete circuit be tween the wires from the passenger side air bag module 3 Use an ohmmeter to check the continuity between ground and one of the terminals at the SDM side of the wiring harness connector for the passenger s...

Page 855: ...ests the SDM will check the passenger airbag firing circuit The SDM allows a very small amount of current to flow through the circuit The SDM monitors the voltage during this check DTC 08 Will Set When D The firing circuit is shorted to the voltage Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge The capacitor supplies t...

Page 856: ...Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1 Disconnect the electrical connector for the passenger airbag module 2 Disconnect the electrical connector at the SDM D The shorting bar at the disconnected SDM connector will create a complete circuit be tween the wires from the passenger airbag module 3 Use a multimeter to check the vol...

Page 857: ...t resistance during this check DTC 09 Will Set When D The combined resistance of the driver pretensioner module the harness wiring and the connector con tacts is above a specified value as in an open circuit Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge The capacitor supplies reserve power to deploy the airbags even i...

Page 858: ...ill create a complete circuit be tween the wires from the driver seat belt pre tensioner module 3 Connect an ohmmeter to the terminals on the SDM side of the wiring harness connector for the driver seat belt pretensioner module D Refer to Diagnostic Illustration 16 in this section Does the ohmmeter show the specified value ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ 0 W...

Page 859: ...he SDM monitors the circuit resistance during this check DTC 10 Will Set When D The combined resistance of the driver pretensioner the harness wiring and the connector contacts is be low a specified value as with a short circuit between the wires to the driver airbag module Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharg...

Page 860: ...o to Step 4 ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 2 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1 Replace the SDM 2 Reconnect the negative battery cable 3 Set the scan tool to CODE ERASE 4 Do the diagnostic system check Does the code 10 still show as a current fault ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Go to Step 3 ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁ...

Page 861: ...he SDM will check the driver pretensioner circuit The SDM allows a very small amount of current to flow through the driver pretensioner circuit The SDM monitors the voltage during this check DTC 11 Will Set When D The firing circuit is shorted to ground Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge The capacitor suppl...

Page 862: ...connector from the driver seat belt pretensioner module 2 Disconnect the electrical connector at the SDM D The shorting bar at the disconnected SDM connector will create a complete circuit be tween the wires from the driver seat belt pre tensioner module 3 Use an ohmmeter to check the continuity between ground and one of the terminals at the SDM side of the wiring harness connector for the driver ...

Page 863: ...ng these tests the SDM will check the driver pretensioner circuit The SDM allows a very small amount of current to flow through the circuit The SDM monitors voltage during this check DTC 12 Will Set When D The firing circuit is shorted to voltage Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge The capacitor supplies res...

Page 864: ...Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1 Disconnect the electrical connector for the driver seat belt pretensioner module 2 Disconnect the electrical connector at the SDM D The shorting bar at the disconnected SDM connector will create a complete circuit be tween the wires from the driver seat belt pre tensioner module 3 Use a multimeter to chec...

Page 865: ...it resistance during this check DTC 13 Will Set When D The combined resistance of the passenger preten sioner module the harness wiring and the connector contacts is above a specified value as in an open cir cuit Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge The capacitor supplies reserve power to deploy the airbags e...

Page 866: ...e circuit be tween the wires from the passenger seat belt pretensioner module 3 Connect an ohmmeter to the terminals on the SDM side of the wiring harness connector for the passenger seat belt pretensioner module D Refer to Diagnostic Illustration 19 in this section Does the ohmmeter show the specified value ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ 0 W ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ...

Page 867: ...check DTC 14 Will Set When D The combined resistance of the passenger preten sioner module the harness wiring and the connector contacts is below a specified value as in a short cir cuit between the wires to the passenger airbag mod ule Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge The capacitor supplies reserve power...

Page 868: ...Á ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 2 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1 Replace the SDM 2 Reconnect the negative battery cable 3 Set the scan tool to CODE ERASE 4 Do the diagnostic system check Does the code 14 still show as a current fault ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Go to Step 3 ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ Sy...

Page 869: ... the SDM will check the passenger pretensioner circuit The SDM allows a very small amount of current to flow through the circuit The SDM monitors the voltage during this check DTC 15 Will Set When D The firing circuit is shorted to ground Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge The capacitor supplies reserve pow...

Page 870: ...er seat belt pretensioner module 2 Disconnect the electrical connector at the SDM D The shorting bar at the disconnected SDM connector will create a complete circuit be tween the wires from the passenger seat belt pretensioner module 3 Use an ohmmeter to check the continuity between ground and one of the terminals at the SDM side of the wiring harness connector for the passenger seat belt pretensi...

Page 871: ...se tests the SDM will check the passenger pretensioner circuit The SDM allows a very small amount of current to flow through the circuit The SDM monitors the voltage during this check DTC 16 Will Set When D The firing circuit is shorted to the voltage Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge The capacitor supplie...

Page 872: ...ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1 Disconnect the electrical connector for the passenger seat belt pretensioner module 2 Disconnect the electrical connector at the SDM D The shorting bar at the disconnected SDM connector will create a complete circuit be tween the wires from the passenger seat belt pretensioner module 3 Use a multimeter to ch...

Page 873: ... circuit The SDM monitors the circuit resistance during this check DTC 18 Will Set When D Connection between the driver firing circuit and the driver pretensioner circuit or the SDM internal con nection problem may exist Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge The capacitor supplies reserve power to deploy the a...

Page 874: ...r at the SDM D The shorting bar at the disconnected SDM connector will create a complete circuit be tween the wires from the driver airbag module and the driver pretensioner module 3 Connect an ohmmeter to the terminals on the SDM side of the wiring harness connector for the driver pretensioner module D Refer to Diagnostic Illustration 16 in this section Does the ohmmeter show the specified value ...

Page 875: ...the circuit The SDM monitors the circuit resistance during this check DTC 19 Will Set When D Connection between the drive firing circuit and the passenger pretensioner circuit or SDM internal con nection problem may exist Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge The capacitor supplies reserve power to deploy the ...

Page 876: ...nnector at the SDM D The shorting bar at the disconnected SDM connector will create a complete circuit be tween the wires from the driver airbag module and the passenger pretensioner module 3 Connect an ohmmeter to the terminals on the SDM side of the wiring harness connector for the passenger pretensioner module D Refer to Diagnostic Illustration 19 in this section Does the ohmmeter show the spec...

Page 877: ...he circuit The SDM monitors the circuit resist ance during this check DTC 20 Will Set When D Connection between the passenger firing circuit and the driver pretensioner circuit or SDM internal con nection problem may exist Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge The capacitor supplies reserve power to deploy the...

Page 878: ... connector at the SDM D The shorting bar at the disconnected SDM connector will create a complete circuit be tween the wires from the passenger airbag module and the driver pretensioner module 3 Connect an ohmmeter to the terminals on the SDM side of the wiring harness connector for the driver pretensioner module D Refer to Diagnostic Illustration 16 in this section Does the ohmmeter show the spec...

Page 879: ...ircuit The SDM monitors the circuit resistance during this check DTC 21 Will Set When D Connection between the passenger firing circuit and the passenger pretensioner circuit or SDM internal connection problem may exist Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge The capacitor supplies reserve power to deploy the ai...

Page 880: ...al connector at the SDM D The shorting bar at the disconnected SDM connector will create a complete circuit be tween the wires from the passenger airbag module and the passenger pretensioner mod ule 3 Connect an ohmmeter to the terminals on the SDM side of the wiring harness connector for the passenger pretensioner module D Refer to Diagnostic Illustration 19 in this section Does the ohmmeter show...

Page 881: ...h the circuit The SDM monitors the circuit resist ance during this check DTC 22 Will Set When D Connection between the driver pretensioner circuit and the passenger pretensioner circuit or SDM inter nal connection problem may exist Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge The capacitor supplies reserve power to d...

Page 883: ... check its voltage supply If the voltage supply is too high or too low the SDM may not receive the proper information when it attempts to use a known current to test the airbag module circuits DTC 23 Will Set When D The SDM receives voltage higher than a specified value Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge Th...

Page 884: ...OK ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Go to Step 3 ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ Go to Step 2 ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 2 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Repair the charging system Is the repair complete ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Go to Diagnostic System Check ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 3 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ...

Page 885: ...DM may not receive the proper information when it attempts to use a known current to test the airbag module circuits DTC 24 Will Set When D The SDM receives the voltage lower than a specified value Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge The capacitor supplies reserve power to deploy the airbags even if the batt...

Page 887: ...ng lamp turns ON for approximately four seconds after the ignition is first switched ON and then The warning lamp turns OFF When the warning lamp operates incorrectly the warn ing lamp continues to blink four times per second demonstrating that the SDM is faulty and must be re placed Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor t...

Page 888: ...ÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ Go to Step 5 ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 5 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Repair the short to ground in the instrument harness Is the repair complete ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Go to Diagnostic System Check ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 6 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ...

Page 890: ...he sensing and diagnostic module SDM will perform tests to diagnose any malfunctions within itself DTC 32 Will Set When D The SDM has previously detected a crash Test Description Caution Before testing disconnect the negative battery cable Wait 1 minute for the SDM capacitor to discharge The capacitor supplies reserve power to deploy the airbags even if the battery is discon nected Unintentional d...

Page 891: ...onnector C208 D110B305 DIAGNOSTIC ILLUSTRATION 3 Measuring the wiring harness for the continuity of the driver side airbag module circuit D110B306 DIAGNOSTIC ILLUSTRATION 4 Checking the continuity of the driver airbag circuit on the sensing and diagnostic module SDM side of the clock spring connector D110B307 DIAGNOSTIC ILLUSTRATION 5 Checking the driver airbag circuit for a short to ground with t...

Page 892: ...DIAGNOSTIC ILLUSTRATION 7 Checking the clock spring connector for a short to volt age on the sensing and diagnostic module side D110B310 DIAGNOSTIC ILLUSTRATION 8 Checking the passenger airbag circuit continuity on the sensing and diagnostic module side of the connector D110B311 DIAGNOSTIC ILLUSTRATION 9 Checking the passenger airbag circuit for a short to ground ...

Page 893: ...g the sensing and diagnostic module voltage supply at the terminal 5 D110B313 DIAGNOSTIC ILLUSTRATION 12 Checking the voltage supply on the instrument harness side at the terminal 2 of the connector C208 D110B314 DIAGNOSTIC ILLUSTRATION 13 Checking for a short to ground on the sensing and diag nostic module side of the supplemental inflatable re straints harness at the terminal 3 of the connector ...

Page 894: ...8 D110B316 DIAGNOSTIC ILLUSTRATION 15 Checking the voltage of the warning lamp circuit on the instrument harness side at the terminal 3 of the connec tor C208 D110B310 DIAGNOSTIC ILLUSTRATION 16 Checking the driver seat belt pretensioner circuit conti nuity on the sensing and driagnostic module side of the connector D110B311 DIAGNOSTIC ILLUSTRATION 17 Checking the driver seat belt pretensioner cir...

Page 895: ...10 DIAGNOSTIC ILLUSTRATION 19 Checking the passenger seat belt pretensioner circuit continuity on the sensing and driagnostic module side of the connector D110B311 DIAGNOSTIC ILLUSTRATION 20 Checking the passenger seat belt pretensioner circuit for a short to ground D110B311 DIAGNOSTIC ILLUSTRATION 21 Checking the passenger seat belt pretensioner circuit for a short to voltage ...

Page 896: ...or expansion a module suddenly propelled toward a person or ob ject can cause injury or vehicle damage 4 Remove the driver airbag module D Disconnect the driver airbag module connector 1 D Disconnect the horn terminal connector 2 D Remove the driver airbag module 3 15 NSm D1AB503A Installation Procedure Caution When removing an airbag module or han dling a new airbag module always keep the top of ...

Page 897: ... Caution If the clock spring is not properly aligned the steering wheel may not be able to rotate com pletely during a turn Restricted turning ability can cause the vehicle to crash Improper alignment of the clock spring also may make the supplemental inflatable restraints SIR system inoperative pre venting the airbags from deploying during a crash Both of these outcomes can result in injury Notic...

Page 898: ...1 Disconnect the negative battery cable 2 Remove the glove box Refer to Section 9E Instru ment Driver Information 3 Disconnect the passenger airbag module connector D110B509 4 Remove the passenger airbag module D Remove the nuts 1 D Remove the airbag module torx bolts using a torx bolt wrench DS 401 a Passenger airbag module torx bolt D Remove the passenger airbag module 2 15 NSm 10 NSm D1AB510A I...

Page 899: ...110B511 3 Remove the SDM D Disconnect the SDM electrical connector 1 D Remove the torx bolts using a torx bolt wrench DS 401 2 D Remove the SDM 3 D1AB512A Installation Procedure Notice Do not install an SDM that has been dropped or has water damage dents cracks or other visible de fects Attempted use of a defective SDM can result in vehicle damage 1 Install the SDM with the mounting torx bolts so ...

Page 900: ...oor console Refer to Section 9G Interior Trim 4 Connect the negative battery cable 5 Check for proper operation of the system D Turn the ignition ON while watching the supple mental inflatable restraints warning lamp D The warning lamp should turn ON for about 4 sec onds and then turn OFF ...

Page 901: ...efore handling Caution Wear the gloves and the eye protectors during the disposal process Caution If the deployment fails disconnect the volt age source and wait 5 minutes before approaching the vehicle Deployment Procedure 1 Disconnect both battery cables and place the battery at least 10 meters 32 8 feet from the vehicle Caution Wait 1 minute after disconnecting both battery cables to allow the ...

Page 902: ...ends of the wires leading to the passenger airbag module 16 Use two additional wires each at least 10 meters 33 feet long to reach from the deployment battery to the passenger airbag module 17 Strip 13 mm 0 5 inch of insulation from the ends of these two additional wires 18 Twist the two wires together at one end 19 Place the twisted ends of the two wires near the de ployment battery Do not connec...

Page 903: ...flat ground outdoors at least 10 meters 33 feet from any ob stacles or people 2 Place a vehicle battery at least 10 meters 33 feet away from the airbag module 3 Deploy the airbag module using the deployment tool 4 Using the proper precautions dispose of the deployed airbag Refer to Deployed Airbag Module Disposal Procedure in this section DEPLOYED AIRBAG MODULE DISPOSAL PROCEDURE Caution After an ...

Page 904: ...er for approval or special instructions before deploying an airbag module Deployed airbag modules should be disposed of in the same manner as any other scrap parts with the addition of the following steps 1 Place the deployed airbag in a sturdy plastic bag 2 Seal the plastic bag securely 3 Wash your hands and rinse them with water after handling a deployed airbag ...

Page 905: ... Mounting Bolts ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 15 ÁÁÁÁÁÁ ÁÁÁÁÁÁ 11 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Passenger Airbag Module Mounting Nuts ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 10 ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 89 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Passenger Airbag Module Mounting Bolts ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 15 ÁÁÁÁÁÁ ÁÁÁÁÁÁ 11 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ...

Page 906: ...SUPPLEMENTAL INFLATABLE RESTRAINTS SIR 8B 79 DAEWOO M 150 BL2 SCHEMATIC AND ROUTING DIAGRAMS SUPPLEMENTAL INFLATABLE RESTRAINTS SIR ELECTRICAL SCHEMATIC D1AB201B ...

Page 907: ...n and Operation 9A 2 How to Read Electrical Wiring Diagram 9A 2 How to Check Terminal Number of Connector 9A 4 Special Tools and Equipment 9A 5 Special Tools Table 9A 5 Schematic and Routing Diagrams 9A 6 Wire Color Chart 9A 6 Power Distribution Schematic 9A 7 Relay Fuse Box Locator Engine Room 9A 8 Fuse Box Locator Passenger Compartment 9A 9 Fuse Chart 9A 10 Front Harness Routing 9A 11 Engine Har...

Page 908: ...9A 2 BODY WIRING SYSTEM DAEWOO M 150 BL2 DESCRIPTION AND OPERATION HOW TO READ ELECTRICAL WIRING DIAGRAM D111001A ...

Page 909: ... Relay Box Locator and Fuse Box Locator in this section C Connector Connector No C202 terminal No 10 Refer to How to Check Terminal Number of Connect in this section D Internal circuit of component Relay Component Name Terminal Number E Internal circuit of component Switch Terminal Number F Wiring Harness Color Refer to Wire Color Chart in this section G Ground line G402 Ground Position In case of...

Page 910: ...9A 4 BODY WIRING SYSTEM DAEWOO M 150 BL2 HOW TO CHECK TERMINAL NUMBER OF CONNECTOR Terminal number is given based on female terminal connector Example Terminal number 4 of 6 pin connection D111002A ...

Page 911: ...BODY WIRING SYSTEM 9A 5 DAEWOO M 150 BL2 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE D1011101 DW 540 010 Relay Remover ...

Page 912: ...UTING DIAGRAMS WIRE COLOR CHART Wire Color Abbreviation On Schematic Green DK GRN Blue DK BLU Brown BRN Orange ORN Yellow YEL Grey GRY Red RED Black BLK White WHT Purple PPL Wires With Tracers Wire Color Abbreviation On Schematic Red with White Tracer RED WHT ...

Page 913: ...BODY WIRING SYSTEM 9A 7 DAEWOO M 150 BL2 POWER DISRIBUTION SCHEMATIC D111005B ...

Page 914: ...9A 8 BODY WIRING SYSTEM DAEWOO M 150 BL2 RELAY FUSE BOX LOCATOR ENGINE ROOM SIRIUS D3 D111003B RELAY FUSE BOX LOCATOR ENGINE ROOM FENIX 5MR D111003C ...

Page 915: ...BODY WIRING SYSTEM 9A 9 DAEWOO M 150 BL2 FUSE BOX LOCATOR PASSENGER COMPARTMENT LHD D111004A FUSE BOX LOCATOR PASSENGER COMPARTMENT RHD D111004B ...

Page 916: ...nd Illumination Lamps Right Side Ef13 10A 58 Tail and Illumination Lamps Left Side Ef14 10A BAT A C Compressor Ef15 30A BAT Radiator Fan Ef16 10A Spare Ef17 10A BAT Horn Ef18 20A BAT Headlamp Relay Hi Beam Passing DRL Module Ef19 15A BAT ECM Main Relay Ef20 15A BAT Front Fog Lamp Ef21 15A Spare F1 Fuse 10A IGN 1 Cluster Clock IMMO Anti Theft Control Unit DRL Relay F2 10A IGN 1 SDM F3 25A IGN 1 Haz...

Page 917: ...BODY WIRING SYSTEM 9A 11 DAEWOO M 150 BL2 FRONT HARNESS ROUTING Left Hand Drive Shown Right Hand Drive Similar D111401D ...

Page 918: ...9A 12 BODY WIRING SYSTEM DAEWOO M 150 BL2 ENGINE HARNESS ROUTING SIRIUS D3 Left Hand Drive Shown Right Hand Drive Similar D111402D ...

Page 919: ...BODY WIRING SYSTEM 9A 13 DAEWOO M 150 BL2 ENGINE HARNESS ROUTING FENIX 5NR Left Hand Drive Shown Right Hand Drive Similar D111411A ...

Page 920: ...9A 14 BODY WIRING SYSTEM DAEWOO M 150 BL2 INSTRUMENT HARNESS ROUTING Left Hand Drive D111403E ...

Page 921: ...BODY WIRING SYSTEM 9A 15 DAEWOO M 150 BL2 INSTRUMENT HARNESS ROUTING Right Hand Drive D111403F ...

Page 922: ...9A 16 BODY WIRING SYSTEM DAEWOO M 150 BL2 AIRBAG HARNESS ROUTING Left Hand Drive Shown Right Hand Drive Similar D111404D ...

Page 923: ...BODY WIRING SYSTEM 9A 17 DAEWOO M 150 BL2 BODY HARNESS ROUTING D111405D ...

Page 924: ...9A 18 BODY WIRING SYSTEM DAEWOO M 150 BL2 BODY HARNESS ROUTING Cont d D111406D ...

Page 925: ...BODY WIRING SYSTEM 9A 19 DAEWOO M 150 BL2 FRONT DOOR HARNESS ROUTING D111407D ...

Page 926: ...9A 20 BODY WIRING SYSTEM DAEWOO M 150 BL2 REAR DOOR HARNESS ROUTING D111408D ...

Page 927: ...BODY WIRING SYSTEM 9A 21 DAEWOO M 150 BL2 TAILGATE HARNESS ROUTING D111409D ...

Page 928: ...mps 9B 4 Stoplamps and Interior Courtesy Lamp 9B 5 Rear Fog Lamp 9B 6 Repair Instructions 9B 7 Headlamps 9B 7 Turn Signal Lamps 9B 8 Side Turn Signal Lamps 9B 8 Taillamps Assembly 9B 9 Front Fog Lamp 9B 9 Rear Fog Backup Lamp s 9B 10 Center High Mounted Stoplamp 9B 11 CHMSL Mounting Bracket 9B 12 License Plate Lamps 9B 12 Door Jamb Switch 9B 13 Interior Courtesy Lamp 9B 13 Daytime Running Lamp Mod...

Page 929: ...e signal only to the first detent and hold it there When the lever is released it will return to horizontal and the turn signal will cancel REAR FOG LAMP The rear fog lamp is incorporated in the drive side tail lamp assembly and are controlled by the rear fog lamp switch on the instrument panel The rear fog lamp can be turned on only when headlamps are on TAILLAMPS The taillamps stoplamps backup l...

Page 930: ...of the headlamp combination switch D Repair or Replace the wiring harness D Fuse Ef8 or Ef9 is blown D Replace the fuse Ef10 or Ef11 D The open circuit or a short circuit between the fuse Ef8 or Ef9 and the terminal 1 of the headlamp connector D Repair or Replace the wiring harness D Headlamp bulb is blown D Replace the headlamp bulb D The open grounds G101 G102 circuit D Repair or Replace the ope...

Page 931: ...lay and the terminal 9 of the hazard lamp switch connector D Repair or Replace the wiring harness D Faulty turn signal lamp relay D Replace the turn signal lamp relay D The open circuit or a short circuit between the terminal 49a of the turn signal lamp relay and the terminal 2 of the turn signal lamp switch connector D Faulty turn signal lamp switch D Replace the turn signal lamp switch D The ope...

Page 932: ...ce the wiring harness D Stoplamp bulb is blown D Replace the stoplamp bulb D The open ground G401 G402 circuits D Repair or Replace the open ground circuit Interior Courtesy Lamp Does Not Work D The open circuit or a short circuit in the power supply circuit to the fuse Ef2 D Repair or Replace the wring harness D Fuse Ef2 is blown D Replace the fuse Ef2 D The open circuit or a short circuit betwee...

Page 933: ...Replace the wiring harness D Faulty rear fog lamp relay D Replace the rear fog lamp relay D The open circuit or a short circuit between the terminal 87 of the rear fog lamp relay and terminal 6 of the rear fog lamp connector D Repair or Replace the wiring harness D The open circuit or a short circuit between the terminal E of the rear fog lamp relay and terminal 6 of the rear fog lamp switch D Rep...

Page 934: ... Remove the bolts 1 D Remove the front bumper spacer from the bumper fasia 2 D19D502A 4 Remove the headlamp D Remove the bolts and washer 1 D Disconnect the electrical connectors D Remove the headlamp 2 D19D503A Installation Procedure 1 Install the headlamp with the bolts 2 Connect the headlamp connector and parking lamp connector 3 Install the front bumper spacer with the bolts 4 Connect the nega...

Page 935: ... D19D506A Installation Procedure 1 Connect the electrical connector 2 Install the turn signal lamp assembly with the screw 3 Install the front bumper spacer Refer to Section 9M Exterior Trim 4 Connect the negative battery cable D29B001 SIDE TURN SIGNAL LAMPS Removal Procedure 1 Disconnect the negative battery cable 2 Slide the side turn signal lamp rearward 3 Remove the lamp 4 Disconnect the elect...

Page 936: ... taillamp 2 D19D509A Installation Procedure 1 Install the taillamp assembly with the screws 2 Connect the electrical connector 3 Install the luggage compartment wheelhouse trim Refer to Section 9G Interior Trim 4 Connect the negative battery cable D19C501A FRONT FOG LAMP Removal Procedure 1 Disconnect the negative battery cable 2 Raise and suitably support the vehicle 3 Remove the front wheels 4 R...

Page 937: ...e front wheelhouse splash shields with the clips and the bolts 4 Install the front wheels 5 Lower the vehicle 6 Connect the negative battery cable D19D508C REAR FOG BACKUP LAMP S Removal Procedure 1 Disconnect the negative battery cable 2 Remove the taillamp assembly Refer to Taillamps Assembly in this section 3 Remove the bulb s D19D509A Installation Procedure 1 Install the bulb s 2 Install the t...

Page 938: ...HMSL cover D Remove the screws 1 D Remove the CHMSL cover 2 D29B004A 5 Remove the CHMSL and bulb D Remove the screws 1 D29B005B D Remove the screw from bulb socket 2 D Remove the CHMSL 3 D Remove the bulb 4 D19E554A Installation Procedure 1 Install the CHMSL bulb 2 Install the CHMSL with the screws 3 Install the CHMSL cover with the screws 4 Install the tailgate trim panel Refer to Section 9G In t...

Page 939: ...l the rear window wiper motor assembly Refer to Section 9D Wipers Washer Systems 3 Install the CHMSL Refer to Center High Mounted Stoplamp in this section 4 Connect the negative battery cable D19D510A LICENSE PLATE LAMPS Removal Procedure 1 Disconnect the negative battery cable 2 Remove the license plate lamp from the tailgate han dle D Remove the screws 1 D Draw out the license plate lamp 2 D Rem...

Page 940: ...D109D513 DOOR JAMB SWITCH Removal Procedure 1 Disconnect the negative battery cable 2 Remove the door jamb switch D Remove the screw 1 D Disconnect the electrical connector 2 D Remove the door jamb switch 3 D109D514 Installation Procedure 1 Install the door jamb switch with the screw 2 Connect the electrical connector 3 Connect the negative battery cable D19D515A INTERIOR COURTESY LAMP Removal Pro...

Page 941: ... 4 Connect the negative battery cable D29B007 DAYTIME RUNNING LAMP MODULE W Europe Only Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the electrical connector 1 3 Remove the screws 2 and the daytime running lamp module D29B008 Installation Procedure 1 Install the daytime running lamp module with the bolts 2 Connect the electrical connector 3 Connect the negative battery ca...

Page 942: ...onnect the negative battery cable 2 Open the tailgate 3 Remove the luggage room lamp D Remove the luggage room lamp 1 D Disconnect the electrical connector 2 D209B105 Installation Procedure 1 Connect the electrical connector 2 Install the luggage room lamp 3 Connect the negative battery cable ...

Page 943: ...Bulb Number Backup Lamp s 21W Center High Mounted Stoplamp 21W Headlamps Double 60 55W Interior Courtesy Lamp 10W License Plate Lamp 5W Front Turn Signal Lamps 21W Rear Fog Lamp 21W Rear Turn Signal Lamps 21W Side Marker Turn Signal Lamps 5W Tail and Stoplamp Double 5 21W 5W Parking Lamp 5W ...

Page 944: ...LIGHTING SYSTEMS 9B 17 DAEWOO M 150 BL2 SCHEMATIC AND ROUTING DIAGRAMS BACKUP LAMP S CIRCUIT D19D201B ...

Page 945: ...9B 18 LIGHTING SYSTEMS DAEWOO M 150 BL2 HEADLAMPS CIRCUIT D19D202B ...

Page 946: ...LIGHTING SYSTEMS 9B 19 DAEWOO M 150 BL2 HEADLAMP LEVELING CIRCUIT D19B723B ...

Page 947: ...9B 20 LIGHTING SYSTEMS DAEWOO M 150 BL2 TAIL AND LICENSE PLATE LAMPS CIRCUIT D19D203B ...

Page 948: ...LIGHTING SYSTEMS 9B 21 DAEWOO M 150 BL2 STOPLAMPS CIRCUIT D19D204B ...

Page 949: ...9B 22 LIGHTING SYSTEMS DAEWOO M 150 BL2 TURN AND HAZARD LAMPS CIRCUIT D19D205B ...

Page 950: ...LIGHTING SYSTEMS 9B 23 DAEWOO M 150 BL2 INTERIOR COURTESY LAMP CIRCUIT D19D206B ...

Page 951: ...9B 24 LIGHTING SYSTEMS DAEWOO M 150 BL2 FRONT FOG LAMP CIRCUIT D19B724A1 ...

Page 952: ...LIGHTING SYSTEMS 9B 25 DAEWOO M 150 BL2 REAR FOG LAMP CIRCUIT D19B724B ...

Page 953: ...9B 26 LIGHTING SYSTEMS DAEWOO M 150 BL2 DIMMER CONTROL CIRCUIT EXCEPT W EUROPE D29B009A ...

Page 954: ...LIGHTING SYSTEMS 9B 27 DAEWOO M 150 BL2 DAYTIME RUNNING LAMPS CIRCUIT W EUROPE ONLY D29B010A ...

Page 955: ...ly come in contact with exposed electrical terminals Disconnecting this cable will help prevent personal injury and damage to the vehicle The ignition must also be in B unless otherwise noted TABLE OF CONTENTS Description and Operation 9C 2 Horn 9C 2 Repair Instructions 9C 3 On Vehicle Service 9C 3 Horn 9C 3 Schematic and Routing Diagrams 9C 4 Horn Wiring System 9C 4 ...

Page 956: ... DESCRIPTION AND OPERATION HORN The horn is located under the hood It is attached near the radiator at the front of the vehicle The horn is actu ated by pressing the steering wheel pad which grounds the horn s electrical circuit ...

Page 957: ...ld D Remove the clip and bolts a Bolts and clips D Remove the wheel house splash shield b Splash shield D19D517A 5 Remove the horn D Remove the bolt 1 D Disconnect the electrical connector 2 D19D518A Installation Procedure 1 Install the horn with the bolt 2 Connect the electrical connector 3 Install the front wheel house splash shield with the clips and the bolts 4 Install the front wheels 5 Lower...

Page 958: ...9C 4 HORN DAEWOO M 150 BL2 SCHEMATIC AND ROUTING DIAGRAMS HORN WIRING SYSTEM D19D207B ...

Page 959: ... 2 Windshield Washer System 9D 2 Rear Window Wiper Washer System 9D 2 Diagnostic Information and Procedures 9D 3 Windshield Rear Window Wiper and Washer System 9D 3 Repair Instructions 9D 6 On Vehicle Service 9D 6 Windshield Wiper Arm 9D 6 Rear Window Wiper Arm 9D 6 Windshield Wiper Motor 9D 7 Rear Window Wiper Motor 9D 8 Windshield Wiper Linkage 9D 9 Windshield Wiper Blade 9D 10 Washer Reservoir ...

Page 960: ...lever on the right side of the steering column WINDSHIELD WASHER SYSTEM The windshield washer system is equipped with a wash er fluid reservoir a washer fluid pump hoses nozzles and a wiper washer switch The windshield washer res ervoir is mounted inner the front right wheel well splash shield Attached to the reservoir is a washer pump which pumps fluid through the hoses to the two nozzles mounted...

Page 961: ... the wiper motor is the open circuit or a short circuit D Repair or Replace the wiring harness D The circuit between the fuse F8 and the wiper motor is the open circuit or a short circuit D Repair or Replace the wiring harness D The circuit between the wiper relay and the wiper motor is the open circuit or a short circuit D Repair or Replace the wiring harness D Faulty wiper motor D Replace the wi...

Page 962: ... D Faulty wiper motor D Replace the wiper motor Windshield Washer Does Not Work Windshield Wipers OK D The open or a short in the power supply circuit to the fuse F9 D Repair or Replace the open or a short in the power supply circuit to the fuse F9 D Fuse F9 is blown D Replace the fuse D The circuit between the fuse F9 and the wiper washer switch is the open circuit or a short circuit D Repair or ...

Page 963: ...ar window wiper motor is the open circuit or a short circuit D Repair or Replace the wiring harness D Faulty rear window wiper motor D Replace the rear window wiper motor D Poor ground G403 D Repair or Replace the wiring harness Rear Window Washer Does Not Work Rear Window Wiper OK D The open or a short in the power supply circuit to the fuse F9 D Repair or Replace the open or a short in the power...

Page 964: ...emove the nut 2 D Remove the wiper arm 3 D109D520 Installation Procedure 1 Install the wiper arm with the nut 2 Install the cap D109D521 REAR WINDOW WIPER ARM Removal Procedure 1 Remove the washer nozzle from the wiper arm Refer to Rear Washer Nozzle in this section 2 Remove the wiper blade Refer to Windshield Wiper Blade in this section 3 Remove the wiper arm D Remove the cap 1 D Remove the nut 2...

Page 965: ...ar Removal Procedure 1 Disconnect the negative battery cable 2 Remove the windshield wiper arm Refer to Wind shield Wiper Arm in this section 3 Remove the cowl vent grille Refer to Section 9R Body Front End 4 Separate the wiper motor from the wiper linkage D Remove the wiper linkage ball from the wiper linka ge 1 D109D524 5 Remove the wiper motor from the engine room D Disconnect the electrical co...

Page 966: ... to Section 9R Body Front End 5 Install the windshield wiper arm Refer to Windshield Wiper Arm in this section 6 Connect the negative battery cable D19D529A REAR WINDOW WIPER MOTOR Removal Procedure 1 Disconnect the negative battery cable 2 Remove the wiper arm from the tailgate Refer to Windshield Wiper Arm in this section 3 Remove the tailgate inside trim Refer to Section 9G Interior Trim 4 Remo...

Page 967: ...nstall the wiper arm Refer to Windshield Wiper Arm in this section 5 Connect the negative battery cable D109D523 WINDSHIELD WIPER LINKAGE Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Remove the windshield wiper arms Refer to Wind shield Wiper Arm in this section 2 Remove the cowl vent grille Refer to Section 9R Body Front End 3 Separate the wiper linkage from the wiper motor ...

Page 968: ...ille Refer to Section 9R Body Front End 4 Install the windshield wiper arms Refer to Wind shield Wiper Arm in this section D109D534 WINDSHIELD WIPER BLADE Removal Procedure 1 Pull the wiper blade off the arm by pushing the wiper blade retaining clip 1 D109D535 Installation Procedure 1 Install the wiper blade to the arm D109D536 WASHER RESERVOIR Removal Procedure 1 Disconnect the negative battery c...

Page 969: ...r reservoir assembly 4 D109D539 Installation Procedure 1 Install the washer reservoir assembly with the bolts 2 Connect the washer pump electrical connector 3 Connect the washer hose connector 4 Install the front RH wheelhouse splash shield with the screws and the clips 5 Lower the vehicle 6 Install the washer reservoir with the bolt 7 Connect the negative battery cable D109D540 WASHER PUMP Remova...

Page 970: ...the cowl vent grille Refer to Section 9R Body Front End 2 Remove the washer nozzle from the cowl vent grille D Disconnect the washer nozzle hose 1 D Remove the washer nozzle 2 D109D542 Installation Procedure 1 Install the washer nozzle to the cowl vent grille 2 Install the washer nozzle hose to the washer nozzle 3 Install the cowl vent grille Refer to Sec tion 9R Body Front End D109D543 REAR WINDO...

Page 971: ...t cap con nector D109C522 WASHER HOSE Removal Procedure 1 Remove the cowl vent grille Refer to Section 9R Body Front End a Cowl vent grille 2 Disconnect the washer hose connector b Washer hose connector D19D537A 3 Raise and suitably support the vehicle 4 Remove the front RH wheel 5 Remove the front RH wheel house splash shield D Remove the screws 1 D Remove the clips 2 D Remove the wheel house spl...

Page 972: ...6A Installation Procedure 1 Connect the washer hose to the washer pump 2 Install the front RH wheel house splash shield with the screws and the clips 3 Install the front RH wheel 4 Lower the vehicle 5 Connect the washer hose connector 6 Install the cowl vent grille Refer to Section 9R Body Front End ...

Page 973: ...WIPERS WASHER SYSTEMS 9D 15 DAEWOO M 150 BL2 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application NSm Lb Ft Lb In Wiper Linkage Conclusion Nut 1 5 2 0 13 18 ...

Page 974: ...9D 16 WIPERS WASHER SYSTEMS DAEWOO M 150 BL2 SCHEMATIC AND ROUTING DIAGRAMS WINDSHIELD REAR WINDOW WIPER AND WASHER SYSTEM D19D208B ...

Page 975: ... Indicator Lamps 9E 2 Component Locator 9E 3 Instrument Panel Assembly 9E 3 Instrument Cluster 9E 4 Diagnostic Information and Procedures 9E 5 Cigar Lighter 9E 5 HVAC Panel Illumination 9E 6 Digital Clock 9E 7 Repair Instructions 9E 8 On Vehicle Service 9E 8 Cigar Lighter 9E 8 Ashtray 9E 9 Instrument Cluster Trim Panel Vents 9E 9 Digital Clock 9E 10 Glove Box 9E 11 Instrument Cluster 9E 11 Instrum...

Page 976: ...nstrument Cluster Indicator Lamps Specifications in this section SPEEDOMETER ODOMETER TRIP ODOMETER The speedometer measures the speed of the vehicle It consists of an instrument cluster gauge connected to the vehicle speed sensor on the transaxle output shaft The odometer measures the total distance the vehicle has traveled since it was manufactured It consists of an instrument cluster gauge conn...

Page 977: ...e 5 Instrument Panel Upper Cap 6 Passenger s Airbag Blank Cover 7 Demister Grille 8 Side Ventilation Grille 9 Glove Box Bracket 10 Glove Box 11 Instrument Cluster Housing Molding 12 Center Ventilation Grille 13 Switch Blank Cover Fog Lamp Switch 14 Hazard Warning Switch 15 Immobilizer LED Indicator Switch 16 Ashtray Bracket 17 Ashtray 18 Ashtray Lamp 19 Cigar Lighter Housing 20 Instrument Cluster ...

Page 978: ...ION DAEWOO M 150 BL2 INSTRUMENT CLUSTER D109B404 1 Instrument Cluster Lens 2 Instrument Cluster Window Plate 3 Speedometer Gauge 4 Fuel Gauge 5 Temperature Gauge 6 Instrument Cluster Case 7 Fronted Circuit Plate 8 Instrument Cluster Bulb ...

Page 982: ... the cigar lighter from the cigar lighter socket D19B502A 4 Remove the cigar lighter socket from the cigar lighter housing Caution Ashtray housing edge could cause seri ous injury D Push out the socket D Disconnect the electrical connector 1 D Remove the socket 2 D109B503 Installation Procedure 1 Connect the electrical connector 2 Install the cigar lighter socket 3 Install the cigar lighter in the...

Page 983: ... pan el D Remove the screws 1 D Remove the ashtray bracket 3 D109B506 Installation Procedure 1 Install the ashtray bracket with the screws 2 Install the ashtray D109B507 INSTRUMENT CLUSTER TRIM PANEL VENTS Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Remove the instrument cluster trim panel from the in strument panel Refer to Instrument Cluster Trim Panel in this section 2 Re...

Page 984: ... Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Disconnect the negative battery cable 2 Pry off the defroster grille 3 Unlock the locking of the digital clock a Digital clock D109B512 4 Remove the digital clock from the instrument panel D Disconnect the electrical connector 1 D Remove the digital clock 2 D109B513 Installation Procedure 1 Connect the electrical connector 2 Install th...

Page 985: ...rocedure 1 Install the glove box to the instrument panel with the hinge pins D19B514A INSTRUMENT CLUSTER Removal Procedure 1 Disconnect the negative battery cable 2 Remove the instrument cluster trim panel from the in strument panel Refer to Instrument Cluster Trim Panel in this section 3 Remove the instrument cluster assembly from the in strument panel D Remove the screws 1 D Disconnect the elect...

Page 986: ...ing Wheel and Col umn 4 Remove the steering column trim cover Refer to Section 6E Steering Wheel and Column 5 Remove the signal lamp switch and the wiper switch Refer to Section 6E Steering Wheel and Column 6 Pry off the A pillar trim panels Refer to Section 9G Interior Trim 7 Remove the instrument cluster trim panel from the instrument panel D Remove the screws 1 D Using a flathead screwdriver re...

Page 987: ...Disconnect the ALDL connector 2 D109B520 18 Remove the instrument trim panel assembly D Remove the bolts after removing the caps 1 D Remove the screws on the side plate 2 D Remove the tie bar retaining bolts on the lower panel 3 D Remove the instrument trim panel assembly 4 D109B521 Installation Procedure 1 Install the instrument trim panel assembly with the bolts and screws 2 Connect the ALDL con...

Page 988: ...on 6E Steering Wheel and Column 16 Install the steering wheel to the steering column 17 Install the driver s airbag module to the steering wheel Refer to Section 8B Supplemental Inflatable Restraints SIR For vehicle equipped with the air bag 18 Connect the negative battery cable D109B522 TIE BAR Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Disconnect the negative battery cabl...

Page 989: ...s 1 D Remove the defroster duct 2 D109B524 7 Remove the bolts and the tie bar a Tie bar D109B525 8 Remove the bolts and the tie bar center b Tie bar center D109B526 Installation Procedure 1 Install the tie bar with the bolts 2 Install the tie bar center with the bolts 3 Install the defroster duct to the cowl upper panel with the screws ...

Page 990: ...Drive Shown Right Hand Drive Similar Removal Procedure 1 Remove the instrument cluster trim panel from the in strument panel D Remove the screws 1 D Using a flathead screwdriver remove the central console cover 2 Notice To prevent the instrument panel damage cover the flathead screwdriver with a soft cloth D109B527 Installation Procedure 1 Install the instrument cluster trim panel with the screws ...

Page 991: ...g module blank cov er 1 D109B703 5 Remove the ventilation duct from the instrument pan el D Remove the screws D Remove the ventilation duct 1 D109B704 6 Remove the ventilation grilles from the instrument panel D Remove the screws D Remove the ventilation grilles 1 D109B705 7 Remove the cigar lighter housing from the instrument panel D Remove the screws D Remove the cigar lighter housing 1 ...

Page 992: ...he demister grilles from the instrument panel a Defroster grille b Demister grille D109B521 Installation Procedure 1 Install the defroster grilles and the demister grilles to the instrument 2 Install the instrument panel guide to the instrument panel with the screws 3 Install the glove box striker and the bracket to the in strument panel with the screws 4 Install the cigar lighter housing to the i...

Page 993: ...AMPS Removal Procedure 1 Disconnect the negative battery cable 2 Remove the instrument cluster from the instrument panel Refer to Instrument Cluster in this section 3 Remove the indicator bulbs from the rear of the clus ter D109B712 Installation Procedure 1 Install the indicator bulb 2 Install the instrument cluster to the instrument panel Refer to Instrument Cluster in this section 3 Connect the ...

Page 994: ... face plate 3 Install the instrument cluster Refer to Instrument Cluster in this section 4 Connect the negative battery cable D109B713 FUEL GAUGE TEMPERATURE GAUGE Removal Procedure 1 Disconnect the negative battery cable 2 Remove the instrument cluster Refer to Instrument Cluster in this section 3 Remove the instrument cluster lens and the face plate a Window plate D109B716 4 Remove the fuel gaug...

Page 995: ...ation Procedure 1 Install the fuel gauge temperature gauge to the clus ter assembly with the screws 2 Install the instrument cluster lens and the face plate 3 Install the instrument cluster Refer to Instrument Cluster in this section 4 Connect the negative battery cable ...

Page 997: ...INSTRUMENT DRIVER INFORMATION 9E 23 DAEWOO M 150 BL2 SCHEMATIC AND ROUTING DIAGRAMS INSTRUMENT CLUSTER SIRIUS D3 D19B201B ...

Page 998: ...9E 24 INSTRUMENT DRIVER INFORMATION DAEWOO M 150 BL2 INSTRUMENT CLUSTER FENIX 5MR D19B201S ...

Page 999: ...INSTRUMENT DRIVER INFORMATION 9E 25 DAEWOO M 150 BL2 INSTRUMENT PANEL ILLUMINATION D19B202B ...

Page 1000: ...9E 26 INSTRUMENT DRIVER INFORMATION DAEWOO M 150 BL2 DIGITAL CLOCK D19B203B ...

Page 1001: ... and Operation 9F 2 Stereo Cassette AM FM Radio with CD Changer and RDS Audio Security System 9F 2 Front and Rear Speakers 9F 2 Roof Antenna 9F 2 Tape Player and Cassette Care 9F 2 Compact Disc Care 9F 2 Component Locator 9F 3 Audio Systems 9F 3 Diagnostic Information and Procedures 9F 4 Audio System 9F 4 Repair Instructions 9F 6 On Vehicle Service 9F 6 Audio System 9F 6 CD Changer 9F 6 Front Spea...

Page 1002: ...ode is entered ERROR 1 will appear on the display After this CODE will appear once again and the correct security code can be entered The time between each new coding attempt is doubled a total of ten coding attempts can be made FRONT AND REAR SPEAKERS All audio systems use four speakers two speakers mounted in the front doors and two speakers mounted in the rear parcel side shelf ROOF ANTENNA Roo...

Page 1003: ...ATOR AUDIO SYSTEMS D19D401B 1 Roof Antenna Assembly 2 Roof Antenna Pole 3 Roof Antenna Base 4 Roof Antenna Frame 5 Roof Antenna Cable 6 Front Speaker 7 Rear Speaker 8 Audio 9 CD Changer Cable 10 CD Changer Bracket 11 CD Changer Magazine 12 CD Changer ...

Page 1004: ...ystem FM Does Not Work AM and Cassette OK D Audio system is out of order D Replace the audio system AM Radio Does Not Work FM and Cassette OK D AM radio reception is poor Using a test antenna test the AM radio reception D Replace the audio system D AM radio reception is good Using a test antenna test the AM radio reception D Replace the antenna cable between the audio system and the antenna Front ...

Page 1005: ... Cause Correction Rear Speakers Distorted or Inoperative D The connection of the rear speaker connector and the audio connector is poor D Confirm the connection D Rear speaker is out of order D Replace the rear speaker D Audio system is out of order D Replace the audio system ...

Page 1006: ...ve the audio system 3 D109D548 Installation Procedure 1 Connect the electrical connector and the antenna cable 2 Install the audio system with the screws 3 Install the instrument cluster trim panel Refer to Sec tion 9E Instrument Driver Information 4 Connect the negative battery cable D19D549A CD CHANGER Removal Procedure 1 Disconnect the negative battery cable 2 Remove the audio system from the i...

Page 1007: ...pads retaining the CD chang er cable 1 D Remove the clip retaining tie bar 2 D Remove the clip retaining instrument panel wiring harness 3 D19D550A 7 Remove the CD changer cable D Remove the CD changer cable 1 D19D552A 8 Remove the CD changer assembly D Remove the CD changer bracket mounting bolts 1 D Remove the CD changer bracket mounting screws 2 D Remove the CD changer assembly 3 ...

Page 1008: ...ct the CD changer electrical connectors 5 Install the floor console Refer to Section 9G Interior Trim 6 Install the Audio System to the instrument panel Re fer to Audio System in this section 7 Connect the negative battery cable D109D555 FRONT SPEAKERS Removal Procedure 1 Disconnect the negative battery cable 2 Remove the door seal trim Refer to Section 9P Doors 3 Remove the speaker D Remove the s...

Page 1009: ...oor trim panel with the screws 2 Install the door trim panel Refer to Section 9G Interi or Trim D109D559 REAR SPEAKERS Removal Procedure 1 Disconnect the negative battery cable 2 Open the tailgate 3 Remove the rear speaker from the rear parcel side shelf D Disconnect the electrical connector 1 D Remove the screws 2 D Remove the rear speaker 3 D109D560 Installation Procedure 1 Install the rear spea...

Page 1010: ...s 3 Remove the roof antenna D Remove the screw from the vehicle inside 1 D Remove the roof antenna 2 D19D562A 3 NSm Installation Procedure 1 Install the roof antenna with the screw Tighten Tighten the roof antenna retaining screw to 3 NSm 27 lb in a Roof antenna retaining screw 2 Install the interior courtesy lamp Refer to Section 9B Lighting Systems 3 Connect the negative battery cable ...

Page 1011: ...AUDIO SYSTEMS 9F 11 DAEWOO M 150 BL2 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application NSm Lb Ft Lb In Roof Antenna Retaining Screw 3 27 ...

Page 1012: ...9F 12 AUDIO SYSTEMS DAEWOO M 150 BL2 SCHEMATIC AND ROUTING DIAGRAMS AUDIO SYSTEM CIRCUIT Left Hand Drive Shown Right Hand Drive Similar D19D209B ...

Page 1013: ...omponent Locator 9G 3 Interior Trim 9G 3 Repair Instructions 9G 4 On Vehicle Service 9G 4 Front Door Trim Panel Standard 9G 4 Front Door Trim Panel Deluxe 9G 5 Rear Door Trim Panel Standard 9G 6 Rear Door Trim Panel Deluxe 9G 7 Rear Door Interior Garnish Molding 9G 8 Rear Door Exterior Garnish Molding 9G 9 Tailgate Trim Panel 9G 9 A Pillar Trim Panel 9G 10 Upper B Piller Trim Panel 9G 10 Lower B P...

Page 1014: ...ents The pressure relief vent is located in the luggage compartment behind the spare wheel FLOOR CONSOLE The floor console fits over the tunnel in the floor of the vehicle and extends from under the center of the instru ment panel to the front seat area The floor console con tains the transaxle shift lever and a cupholder The sensing and diagnosis module SDM for the airbag system is located under ...

Page 1015: ...Panel 2 B Pillar Upper Trim Panel 3 C Pillar Trim Panel 4 Front Rocker Trim Panel 5 B Pillar Lower Trim Panel 6 Rear Rocker Trim Panel 7 Rear Parcel Side Shelf 8 Wheel House Trim Panel 9 Floor Console 10 Parking Brake Cable Cover 11 Console Cover Assembly 12 Deposit Box 13 Console Boot Assembly ...

Page 1016: ...ure 1 Remove the door pull from the front door D Remove the screws 1 D Remove the door pull 2 D109E533 2 Remove the inside door handle D Remove the screw 1 D Disconnect the inside door handle rod 2 D Pry off the inside door handle 3 D109E534 3 Remove the window regulator handle from the front door D Using a cloth pull out the clip 1 D Remove the regulator handle 2 ...

Page 1017: ...the clip 3 Install the inside door handle and the door pull with the screws D19E537A FRONT DOOR TRIM PANEL DELUXE Removal Procedure 1 Remove the inside door handle Refer to Section 9P Doors 2 Remove the power window mirror control switch as sembly from the front door D Remove the screws 1 D Remove the power window mirror control switch assembly 2 D Disconnect the electrical connectors 3 D19E538A 3...

Page 1018: ...erstrip Refer to Sec tion 9P Doors 3 Install the door trim panel with the screws and the clips 4 Install the power window mirror control switch assem bly with the screw 5 Install the inside door handle Refer to Section 9P Doors D109E541 2 REAR DOOR TRIM PANEL STANDARD Tool Required KM 475 B Trim Remover Removal Procedure 1 Remove the inside door handle D Remove the screw 1 D Disconnect the inside ...

Page 1019: ...h to prevent the paint damage of the door D109E545 Installation Procedure 1 Install the trim panel 2 Install the window regulator handle with the clip 3 Install the inside door handle and the door pull with the screws D109E546 REAR DOOR TRIM PANEL DELUXE Removal Procedure 1 Remove the inside door handle Refer to Section 9P Doors 2 Remove the window regulator handle from the rear door Refer to Sect...

Page 1020: ...el weatherstrip Refer to Sec tion 9P Doors 2 Install the trim panel with the screws and the clips 3 Install the door pull with the screw 4 Install the window regulator handle Refer to Section 9P Doors 5 Install the inside door handle Refer to Section 9P Doors D109E549 REAR DOOR INTERIOR GARNISH MOLDING Removal Procedure 1 Pry off interior garnish molding D Pry off the garnish molding caps 1 D109E5...

Page 1021: ...09E552 Installation Procedure 1 Install the exterior garnish molding with the screw 2 Install the interior garnish molding Refer to Rear Door Interior Garnish Molding in this section D19E553A TAILGATE TRIM PANEL Removal Procedure 1 Open the tailgate 2 Remove the trim from the tailgate D Remove the clips by pushing the center of the clip 1 D Remove the trim 2 D19E554A Installation Procedure 1 Insta...

Page 1022: ...el D109E557 UPPER B PILLAR TRIM PANEL Removal Procedure 1 Remove the bolt on the upper B pillar trim panel Re fer to Section 8A Seat Belts 2 Pry off the upper B pillar trim panel D Pry off the upper B pillar trim panel by hands 1 D109E558 Installation Procedure 1 Install the upper B pillar trim panel 2 Install the bolt on the upper B pillar trim panel Refer to Section 8A Seat Belts ...

Page 1023: ...ve the plastic protector from the seat belt an chor D109E559 2 Pry off the lower B pillar trim panel D109E560 Installation Procedure 1 Install the lower B pillar trim panel 2 Install the bolt on the lower B piller trim panel Refer to Section 8A Seat Belts D109E561 C PILLAR TRIM PANEL Removal Procedure 1 Disconnect the negative battery cable 2 Open the tailgate 3 Disconnect the rear speaker electri...

Page 1024: ...by hands 1 D109E563 Installation Procedure 1 Install the C pillar trim panel 2 Install the rear seat belt bolt on the C pillar trim panel Refer to Section 8A Seat Belts 3 Install the rear seatback 4 Install the rear parcel side shelf Refer to Rear Parcel Side Shelf in this section 5 Connect the rear speaker connector 6 Connect the negative battery cable D109E564 REAR PARCEL SHELF Removal Procedure...

Page 1025: ... D Remove the rear parcel side shelf 2 D109E567 Installation Procedure 1 Install the rear parcel side shelf with the screw 2 Install the rear speaker to the rear parcel shelf Refer to Section 9F Audio Systems 3 Install the rear parcel shelf Refer to Rear Parcel Shelf in this section 4 Install the seatback 5 Connect the negative battery cable D109E568 FRONT ROCKER TRIM PANEL Removal Procedure 1 Pry...

Page 1026: ... the spring washer 2 D Remove the plastic protector from the seat belt an chor D109E571 3 Pry off the rear rocker trim panel D Remove the screws securing the rear rocker trim panel 1 D Remove the clip 2 D Pry off the rear rocker trim panel 3 D109E572 Installation Procedure 1 Install the rear rocker trim panel with the screws and the clip 2 Install the rear seat belt bolt on the floor 3 Install the...

Page 1027: ...emove the gear shift lever boot cover 1 D Remove the screws 2 D Remove the floor console 3 D19E576A Installation Procedure 1 Install the floor console 2 Install the gear shift lever boot cover to the floor con sole 3 Tighten the floor console screws D109E577 PARKING BRAKE CABLE COVER Removal Procedure 1 Remove the parking brake cable cover D Remove the screw 1 D Remove the cable cover 2 ...

Page 1028: ...efer to Section 9H Seats 4 Remove the floor console Refer to Floor Console in this section 5 Pry off the front rocker trim panel Refer to Front Rocker Trim Panel in this section 6 Pry off the rear rocker trim panel Refer to Rear Rocker Trim Panel in this section 7 Pry off the lower B pillar trim panel Refer to Lower B pillar Trim Panel in this section 8 Remove the parking brake cable cover Refer t...

Page 1029: ... Install the front rocker trim panel Refer to Front Rocker Trim Panel in this section 7 Install the floor console Refer to Floor Console in this section 8 Install the rear seat cushion Refer to Section 9H Seats 9 Install the front seats Refer to Section 9H Seats 10 Connect the negative battery cable D109E584 LUGGAGE COMPARTMENT WHEELHOUSE TRIM PANEL Removal Procedure 1 Pry off the luggage compartm...

Page 1030: ...9G 18 INTERIOR TRIM DAEWOO M 150 BL2 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE D109E101 KM 475 B Trim Remover ...

Page 1031: ... ignition must also be in B unless otherwise noted TABLE OF CONTENTS Description and Operation 9H 2 Seats 9H 2 Component Locator 9H 3 Front Seat 9H 3 Rear Seat 9H 4 Repair Instructions 9H 5 On Vehicle Service 9H 5 Front Seats 9H 5 Head Restraint 9H 5 Front Seatback 9H 6 Front Seat Cushion 9H 7 Front Seats Guide Rail 9H 9 Front Seat Cushion Frame 9H 9 Rear Seatback 9H 10 Rear Seat Cushion 9H 11 Rea...

Page 1032: ... seat system This vehicle is equipped with low backed front seats with separate head restraints and a three passenger folding rear seat Split folding rear seat is optional Seats cushions and seatbacks have formed foam pads which fit the contours of the full panel seatback frame assem bly and the designed contour of the seat cushion frame There are no front seat forward or rearward relocation provi...

Page 1033: ...3 DAEWOO M 150 BL2 COMPONENT LOCATOR FRONT SEAT D109B402 1 Head Restraint 2 Guide Sleeve 3 Seatback 4 Seatback Frame 5 Seat Cushion 6 Seat Cushion Frame 7 Recliner 8 Recliner Knob 9 Seat Side Cover 10 Guide Rail ...

Page 1034: ...S DAEWOO M 150 BL2 REAR SEAT D19B403A 1 Rear Seatback Cushion 2 Rear Seatback Frame 3 Rear Seat Hinge 4 Rear Seat Lock 5 Rear Seat Cushion 6 Seat Release Knob 7 Eyelet 8 Seat Back Hinge 9 Rear Cushion Pull Loop ...

Page 1035: ...3 28 NSm D19B529A Installation Procedure 1 Connect the seat belt warning lamp connector 2 Install the front seat with the bolts Tighten Tighten the seat bolt to 23 28 NSm 17 21 lb ft a Seat bolt 3 Connect the negative battery cable D109B530 HEAD RESTRAINT Removal Procedure 1 Pull the head restraint up to the stop position 2 Insert a small flathead screwdriver in the notch in the left guide sleeve ...

Page 1036: ...eat assembly Refer to Front Seats in this section 3 Remove the recliner knob from the front seat D Remove the screw 1 D Remove the recliner knob 2 D109B533 4 Remove the recliner cover from the front seat D Remove the screws 1 D Remove the recliner cover 2 D109B534 5 Remove the recliner from the front seat D Remove the bolts on the seat cushion 1 D Remove the seatback cover hog rings D Remove the s...

Page 1037: ...e hog rings D109B537 4 Install the recliner knob and the cover with the screws 5 Install the front seat assembly Refer to Front Seat in this section 6 Connect the negative battery cable D109B532 FRONT SEAT CUSHION Removal Procedure 1 Disconnect the negative battery cable 2 Remove the front seat assembly Refer to Front Seat in this section 3 Remove the seat belt buckle Refer to Section 8A Seat Belt...

Page 1038: ...Remove the seatback bolt 2 D Remove the seat cushion 3 D109B536 Installation Procedure 1 Install the seat cushion with the seatback bolt and the recliner bolts D109B537 2 Install the recliner cover and the recliner knob with the screws 3 Install the seat belt buckle Refer to Section 8A Seat Belts 4 Install the front seat assembly Refer to Front Seats in this section 5 Connect the negative battery ...

Page 1039: ...cedure 1 Install the guide rail to the seat with the bolts 2 Install the front seat assembly Refer to Front Seat in this section 3 Connect the negative battery cable D109B539 FRONT SEAT CUSHION FRAME Removal Procedure 1 Disconnect the negative battery cable 2 Remove the front seat cushion Refer to Front Seat Cushion in this section 3 Remove the guide rail D Remove the bolts 1 D Remove the guide ra...

Page 1040: ...ion 4 Connect the negative battery cable D109B542 REAR SEATBACK Removal Procedure 1 Remove the rear seatback D Remove the rear seatback lock by pulling the lock knob upward 1 D Remove the seatback hinge bolts 2 D Remove the rear seatback 3 D19B543A 23 28 NSm Installation Procedure 1 Install the rear seatback with the hinge bolts Tighten Tighten the hinge bolts to 23 28 N m 17 21 lb ft a Rear seatb...

Page 1041: ... bolts Tighten Tighten the rear seat cushion bolt to 23 28 N m 17 21 lb ft a Rear seat cushion bolt D109B718 REAR SEATBACK LATCH Removal Procedure 1 Remove the rear seatback assembly Refer to Rear Seatback in this section 2 Remove the lock knob from the seatback D Remove the lock knob by twisting it 1 D109B719 3 Remove the rear seatback cover from the seatback frame 4 Remove the lock from the seat...

Page 1042: ...Install the rear seatback assembly Refer to Rear Seatback in this section D109B721 REAR SEATBACK HINGE Removal Procedure 1 Remove the rear seatback assembly Refer to Rear Seatback in this section 2 Remove the hinge from the seatback D Remove the nut D Remove the hinge D109B722 Installation Procedure 1 Install the hinge to the seatback with the nut 2 Install the rear seatback assembly Refer to Rear...

Page 1043: ...ÁÁÁÁÁ ÁÁÁÁÁÁÁ Lb In ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Front Seat Bolts Both ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 23 28 ÁÁÁÁÁÁ ÁÁÁÁÁÁ 17 21 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Rear Seat Cushion Bolts ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 23 28 ÁÁÁÁÁÁ ÁÁÁÁÁÁ 17 21 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Rear Seatback Bolts ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 23 28 ÁÁÁÁÁÁ ÁÁÁÁÁÁ 17 21 ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ...

Page 1044: ...ONTENTS Diagnostic Information and Procedures 9I 2 Waterleak Diagnosis 9I 2 Repair Instructions 9I 5 On Vehicle Service 9I 5 Waterleak Repair 9I 5 Specifications 9I 7 Recommended Materials for Waterleak Repairs 9I 7 Watertest Stand Specifications 9I 7 ...

Page 1045: ... the origin of all the leaks before making any repairs Random repairs may stop the leak only temporarily and may make future re pairs more difficult Continue localized testing in the gen eral area in order to ensure that all leaks are found Generalized Testing 1 Set up the watertest stands D109A301 1 1 2 inch by 36 inch Pipe 2 Full jet Spray Nozzle 1 2 GG 25 or Equivalent Nozzle Height at 1 600 mm...

Page 1046: ...d Testing Spot Test 1 Do localized testing with a water hose or an air hose 2 Begin testing by spraying the air or the water at the base of the suspected leak area Continue spraying the air or the water upward until the leak is found Water Hose Test 1 Place another person inside the vehicle in order to detect the location of the leak 2 Use a water hose without a nozzle D109A304 3 Begin spraying th...

Page 1047: ...Apply soapy water to the outside of the vehicle in the suspected leak area 2 Blow air from inside the vehicle The air pressure should not exceed 205 kPa 29 7 psi 3 Determine the location of the leaks from the bubbles formed in the soapy water D109A306 ...

Page 1048: ...he leak It may be necessary to remove the garnish molding or the trim strip lace in order to locate the leak 2 While spraying water over leak area carefully push the glass outward in order to determine the size of the leak 3 Mark the location of the leak 4 Use water to clean any dirt frame the area Dry the area with an air hose D109A503 5 Using a sharp knife trim off the uneven edges of the adhesi...

Page 1049: ... the adhesive into the leak area and into the joint between the original ma terial and the vehicle body in order to ensure a wa tertight seal 11 Spray warm or hot water over the repaired area in order to determine if the leak was repaired Do not run a heavy stream of water directly on the freshly applied adhesive 12 Install the trim strip lace if it was removed 13 Install the garnish molding if it...

Page 1051: ...ts that run in all four directions north south east and west 2 Choose streets with little traffic or noise that would in terfere with the test 3 Drive the vehicle at the speeds at which the noise was noticed by the customer or until the noise is pro duced Do not exceed legal speed limits 4 The windnoise is external if any of the following condi tions occur D The windnoise is caused by the wind D T...

Page 1052: ...e very similar to waterleak re pairs Refer to Section 9I Waterleaks The actual proce dure depends on the type of seal being repaired Leaks around the door opening weatherstrips do not always in dicate a faulty weatherstrip A door or window adjust ment may resolve the condition Refer to Section 9L Glass and Mirrors ...

Page 1053: ...Reinstall the insulators over the tape Thump From Rear of Vehicle on Bumps D Improperly secured spare tire in the rear compartment D Open the rear compartment and perform a visual inspection of the spare tire and the tools D Tightly secure the spare tire and all tools D Perform a road test to verify that the noise is eliminated Glass Knock Coming From the Rear of the Vehicle When Driving Over Bump...

Page 1054: ...ansaxle control lever lower boot D Move the control lever between gears and listen for squeaks D Remove the floor console and replace the lower shift boot or apply talcum powder to the lower shift boot Squeak Coming From Instrument Cluster Trim Plate D Rubbing of the cluster trim plate on the instrument panel D Test drive the vehicle in order to verify this condition D Remove the instrument cluste...

Page 1055: ...icle There are three means to prevent squeaks or rattles D Attach the parts securely so that there is no rela tive motion during the operation of the vehicle D Separate the parts so that there is no contact dur ing operation D Insulate the parts so that no squeaks or rattles oc cur with the movement of the parts Low uniform friction surfaces can be used to eliminate stick slip motion ...

Page 1056: ...side Rearview Mirrors 9L 2 Components Locator 9L 3 Glass and Mirror 9L 3 Diagnostic Information and Procedures 9L 4 Testing Rear Window Defogger Grid Line 9L 4 Repair Instructions 9L 5 On Vehicle Service 9L 5 Windshield 9L 5 Rear Window Glass 9L 7 Rear Window Defogger Grid Line Repair 9L 9 Rear Window Defogger Braided Lead Wire Repair 9L 10 Front Door Glass 9L 10 Front Door Quarter Glass 9L 12 Rea...

Page 1057: ...ide rearview mirror can be manually adjusted up down fore aft and left right The rearview mirror pivots in two places the ball and socket mirror pivot and the up down hinge lever at the mirror support OUTSIDE REARVIEW MIRRORS Three types of outside rearview mirrors are available The outside rearview mirrors are adjusted by hand which is standard The remote control and the electric outside rearview...

Page 1058: ...ng 2 Windshield 3 Inside Rearview Mirror 4 Rear Window Glass 5 Rear Window Glass Damping 6 Outside Rearview Mirror Manual 7 Outside Rearview Mirror Cover 8 Outside Rearview Mirror Trim Cover 9 Outside Rearview Mirror Cable 10 Nuts 11 Front Door Glass 12 Rear Door Glass 13 Outside Rearview Mirror Electric ...

Page 1059: ...d line The voltmeter will indicate bat tery voltage if the grid line is open 4 If a grid line is found to be open move a voltmeter ter minal from one side of the grid line and retest at a point nearer to the other side of the window Continue to retest each time bringing one of the voltmeter ter minals closer to the opposite side of the window from where it was originally connected The break in the...

Page 1060: ...wl vent grille Refer to Section 9R Body Front End 2 Remove the inside rearview mirror Refer to Inside Rearview Mirror in this section 3 Remove the weatherstrip around the windshield D19E502 4 Using the glass sealant remover J 24402 cut the adhesive around the windshield D19E503 5 Remove the windshield from the vehicle 6 Using a knife remove the adhesive from the wind shield ...

Page 1061: ...he weatherstrip in place 3 Apply adhesive primer to the windshield frame and the perimeter of the windshield D19E506 4 Apply glass adhesive to the windshield frame D19E507A 5 Install the windshield into the windshield frame 6 Reposition the tape over the weatherstrip the wind shield and the windshield frame to hold the wind shield in place 7 Let the adhesive dry for 24 hours 8 Remove the tape ...

Page 1062: ...earview Mirror in this section 11 Install the cowl vent grille Refer to Section 9R Body Front End D19E509 REAR WINDOW GLASS Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the rear window defogger electrical con nectors D19E510 3 Using the glass sealant remover J 24402 cut the adhesive around the rear window glass D19E503 4 Remove the rear window glass from the vehicle 5 Usi...

Page 1063: ...e rear window into the rear window frame 5 Reposition the tape over the weatherstrip the rear window and the rear window frame to hold the rear window in place 6 Let the adhesive dry for 24 hours 7 Remove the tape D19E514A 8 Check for waterleaks by pouring water on the rear window If a leak is found dry the window and fill the area that leaks with adhesive If the leak persists remove the rear wind...

Page 1064: ...d below the repair areas D A repair decal or tape must be used in order to control the width of the repair areas D If a decal is used the die cut metered slot must be the same width as the grid line 6 Apply the grid repair material to the repair area using a small wooden stick or a spatula The grid repair material should be at room temperature 7 Carefully remove the decal or the tape D19E517 Notic...

Page 1065: ...be reattached by resoldering Use a solder contain ing 3 percent silver and a rosin flux paste 1 Disconnect the negative battery cable 2 The repair area should be buffed with fine steel wool before soldering the bus lead wire 3 Apply the paste type rosin flux in small quantities to the wire lead and the bus lead wire repair area using a brush D109E520 4 Coat the soldering iron tip with solder use o...

Page 1066: ... 5 Remove the glass from the front door D Remove the glass retaining bolts 1 D Remove the glass 2 Notice Make sure not to contact the glass with the body to prevent the paint damage D19E524 Installation Procedure 1 Install the front door glass with the bolts D19E522 2 Install the front door glass run ...

Page 1067: ...OR QUARTER GLASS Removal Procedure 1 Remove the front door seal trim Refer to Section 9P Doors 2 Remove the outside rearview mirror Refer to Out side Rearview Mirror in this section 3 Remove the guide rail D Remove the screw 1 D Remove the inside bolt 2 D Remove the outside bolt 3 D Remove the division bar 4 D109E525 4 Remove the quarter glass from the front door D Remove the quarter glass assembl...

Page 1068: ...P Doors D19E523 REAR DOOR GLASS Removal Procedure 1 Remove the glass run Refer to Section 9P Doors 2 Remove the glass D Remove the bolts 1 D Remove the glass 2 Notice Make sure not to contact the glass with the body to prevent the paint damage D19E524 Installation Procedure 1 Install the glass with the bolts 2 Install the glass run Refer to Section 9P Doors D19E527 INSIDE REARVIEW MIRROR Removal P...

Page 1069: ...IEW MIRROR MANUAL Removal Procedure 1 Remove the outside rearview mirror cover from the outside rearview mirror D19E530 2 Remove the outside rearview mirror D Remove the screws 1 D Remove the outside rearview mirror 2 D19E531 Installation Procedure 1 Install the outside rearview mirror with the screws 2 Install the outside rearview mirror cover ...

Page 1070: ...29 3 Remove the outside rearview mirror cover from the outside rearview mirror D109E530 4 Remove the outside rearview mirror D Remove the screws 1 D Remove the outside rearview mirror 2 D109E531 Installation Procedure 1 Install the outside rearview mirror with the screws 2 Install the outside rearview mirror cover 3 Install the mirror adjusting lever with the nuts 4 Install the outside rearview in...

Page 1071: ... from the outside rearview mirror D209B108 3 Remove the outside rearview mirror D Remove the screws 1 D Disconnect the electrical connector 2 D Remove the outside rearview mirror 3 D109E531 Installation Procedure 1 Connect the outside rearview mirror 2 Install the outside rearview mirror with the screws 3 Install the outside rearview mirror cover 4 Connect the negative battery cable ...

Page 1072: ...GLASS AND MIRRORS 9L 17 DAEWOO M 150 BL2 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE D109E102 J 24402 Glass Sealant Remover ...

Page 1073: ...9L 18 GLASS AND MIRRORS DAEWOO M 150 BL2 SCHEMATIC AND ROUTING DIAGRAMS REAR WINDOW DEFOGGER D19E201B ...

Page 1074: ...ERIOR TRIM TABLE OF CONTENTS Description and Operation 9M 2 Emblems and Lettering 9M 2 Mud Guards 9M 2 Repair Instructions 9M 3 On Vehicle Service 9M 3 Roof Molding 9M 3 Rear Spoiler 9M 3 Front Bumper Spacer 9M 4 Tailgate Handle 9M 5 ...

Page 1075: ...re attached by adhesive The company emblem appears on the hood The lettering which appears in several places on the body of the vehicle features the model the grade and the company name MUD GUARDS Front and rear mud guards are optional equipment on all models Mud guards will help prevent an excessive buildup of mud on the body ...

Page 1076: ...E SERVICE D109E586 ROOF MOLDING Removal Procedure 1 Remove the roof molding from the plastic clips 1 D109E587 Installation Procedure 1 Press the roof molding onto the plastic clips D19E588A REAR SPOILER Removal Procedure 1 Open the tailgate 2 Remove the spoiler seals ...

Page 1077: ...T BUMPER SPACER Removal Procedure 1 Support the hood suitably 2 Disconnect the negative battery cable 3 Remove the front bumper spacer D Remove the bolts 1 D Remove the front bumper spacer from the bumper fascia 2 4 Remove the turn signal lamps Refer to Section 9B Lighting Systems D209B110 Installation Procedure 1 Install the turn signal lamps Refer to Section 9B Lighting Systems 2 Install the fro...

Page 1078: ...s 4 Remove the license plate lamps Refer to Section 9B Lighting Systems 5 Remove the tailgate handle D Remove the screws 1 D Remove the tailgate handle 2 D209B112 Installation Procedure 1 Install the tailgate handle with the screws 2 Install the license plate lamps Refer to Section 9B Lighting Systems 3 Remove the tailgate lock cylinder Refer to Section 9P Doors 4 Connect the negative battery cabl...

Page 1079: ...ABLE OF CONTENTS Description and Operation 9N 2 General Body Construction 9N 2 Transaxle Under Covers 9N 2 Repair Instructions 9N 3 On Vehicle Service 9N 3 Alignment Checking 9N 3 Floor Pan Insulators 9N 3 Specifications 9N 4 Underbody Dimensions 9N 4 ...

Page 1080: ...er camber angles Since the individual underbody parts contribute directly to the overall strength of the body it is essential to ob serve proper welding techniques during service repair operations The underbody parts should be properly sealed and rustproofed whenever body repair operations destroy or damage the original sealing and rustproof ing When rustproofing critical underbody parts use a goo...

Page 1081: ...ures that result from the use of the catalytic converter in the exhaust system There fore when servicing a vehicle it is essential that any in sulators that may have been disturbed or removed be reinstalled in the original sequence and location Also if an insulator needs to be replaced use only the insula tion specified for that location on the floor pan When servicing or replacing interior insula...

Page 1082: ...9N 4 FRAME AND UNDERBODY DAEWOO M 150 BL2 SPECIFICATIONS UNDERBODY DIMENSIONS Unit mm in DBDM118A ...

Page 1083: ...FRAME AND UNDERBODY 9N 5 DAEWOO M 150 BL2 Unit mm in DBDM119A Unit mm in DBDM120 ...

Page 1084: ...9N 6 FRAME AND UNDERBODY DAEWOO M 150 BL2 Unit mm in DBDM117A ...

Page 1085: ...OF CONTENTS Description and Operation 9O 2 Bumpers 9O 2 Component Locator 9O 3 Bumpers and Fascias 9O 3 Repair Instructions 9O 4 On Vehicle Service 9O 4 Front Bumper Fascia 9O 4 Front Bumper Impact Bar 9O 5 Rear Bumper Fascia 9O 6 Rear Bumper Bracket 9O 8 ...

Page 1086: ...ithout damage After absorbing the energy of a collision these bumper systems restore themselves to their original position Both the front and the rear bumpers feature an internal foam energy absorber and a polymer fascia cover The front bumper consists of the bumper fascia and the im pact bar Remove the fascia before removing the impact bar The rear bumper consists of the bumper fascia and the bra...

Page 1087: ... M 150 BL2 COMPONENT LOCATOR BUMPERS AND FASCIAS D19C401A 1 Front Towing Cover 2 Front Bumper 3 Front Bumper Impact Beam 4 Front Bumper Reinforcement 5 Rear Bumper Reinforcement 6 Rear Bumper 7 Rear Bumper Bracket 8 Rear Towing Cover ...

Page 1088: ...ative battery cable 2 Raise and suitably support the vehicle 3 Remove the front wheels 4 Remove the front wheel house splash shields D Remove the clip and bolts a Bolt and clip D Remove the wheel house splash shield b Splash shield D109C502 5 Remove the bolts on the both side of the fascia a Bolt D109C503 6 Remove the clips under the fascia a Clip ...

Page 1089: ... Install the bumper fascia 3 Install the clips on the top of the fascia a Fascia upper clip 4 Install the bolts on the top of the fascia b Fascia upper bolt 5 Install the front bumper spacer Refer to Section 9M Exterior Trim D109C506 6 Raise and suitably support the vehicle 7 Install the clips under the fascia c Fascia lower clip 8 Install the bolts on the both side of the fascia 9 Install the fro...

Page 1090: ... to use the correct fasteners to prevent premature corrosion 1 Install the impact bar with the nuts C19C507A 2 Install the front wiring harness retaining clip to the im pact bar 3 Install the front bumper fascia Refer to Front Bump er Fascia in this section 4 Connect the negative battery cable D19C510A REAR BUMPER FASCIA Removal Procedure 1 Raise and suitably support the vehicle 2 Remove the bolts...

Page 1091: ... 3 D19C513A Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasteners to prevent premature corrosion 1 Install the fascia 2 Install the fascia upper nut a The fascia upper nut 3 Install the fascia upper screws b The fascia upper screws D19C514A 4 Raise and suitably support the vehicle 5 Install the fascia lower bolt...

Page 1092: ...AR BUMPER BRACKET Removal Procedure 1 Raise and suitably support the vehicle 2 Remove the rear bumper bracket D Remove the bolts 1 D Remove the bracket 2 D19C516A Installation Procedure 1 Install the rear bumper bracket with the bolts 2 Lower the vehicle ...

Page 1093: ...k Striker 9P 9 Tailgate Lock Striker 9P 9 Door Lock Striker Adjustment 9P 10 Tailgate Lock Striker Adjustment 9P 11 Front Door Lock 9P 13 Childproof Rear Door Lock 9P 14 Central Door Lock Actuator 9P 16 Tailgate Lock 9P 16 Inside Door Handle 9P 17 Outside Front Door Handle 9P 17 Outside Rear Door Handle 9P 18 Door Lock Cylinder 9P 18 Manual Window Regulator 9P 19 Power Front Window Regulator 9P 19...

Page 1094: ...the lever to the unlock posi tion The rear door will now work normally POWER DOOR LOCKS The power door locks use a solenoid that is contained in each door lock assembly The door locks are activated by the actuator on the inside door handle or by the lock cylinder on the driver door only When the driver door is locked or unlocked by the actuator or lock cylinder all doors are locked or unlocked acc...

Page 1095: ...DOORS 9P 3 DAEWOO M 150 BL2 COMPONENT LOCATOR FRONT DOOR D19C403A ...

Page 1096: ...trip 14 Door Weatherstrip 15 Glass Run 16 Front Door 17 Inside Channel Weatherstrip 18 Inside Handle Rod 19 Door Lock 20 Door Lock Cylinder Rod 21 Lock Rod 22 Actuator Rod 23 Actuator 24 Window Regulator 25 Outside Channel Weatherstrip 26 Outside Handle Rod 27 Outside Handle 28 Division Bar 29 Quarter Glass 30 Quarter Glass Run 31 Door Hinge 32 Door Hold Open Link 33 Power Window Switch Cover 34 M...

Page 1097: ...DOORS 9P 5 DAEWOO M 150 BL2 REAR DOOR D19C404A ...

Page 1098: ...Opening Weatherstrip 11 Door Weatherstrip 12 Glass Run 13 Interior Garnish Molding 14 Rear Door 15 Inside Channel Weatherstrip 16 Upper Guide Rail 17 Exterior Garnish Molding 18 Lower Guide Rail 19 Lock Rod 20 Door Lock 21 Inside Handle Rod 22 Actuator Rod 23 Actuator 24 Outside Handle Rod 25 Outside Handle 26 Window Regulator 27 Outside Channel Weatherstrip 28 Door Hinge 29 Door Hold Open Link 30...

Page 1099: ...ction 9L Glass and Mirrors 3 Remove the guide rail from the door D Remove the screws 1 D Remove the inside bolts 2 D Remove the outside bolts 3 D Remove the division bar 4 D109E522 4 Remove the glass run a Glass run D109E526 Installation Procedure 1 Install the glass run 2 Install the division bar with the bolts and the screws 3 Install the outside rearview mirror Refer to Section 9L Glass and Mir...

Page 1100: ...he door pocket handle bracket D109C567 5 Remove the guide piece D Remove the screw 1 D Remove the guide piece 2 D109C568 6 Remove the upper guide rail and the glass run D Remove the bolts 1 D Lift up and remove the upper guide rail and the glass run simultaneously 2 D109C569 Installation Procedure 1 Install the upper guide rail and the rear door glass run 2 Install the guide piece with the screw 3...

Page 1101: ... premature corrosion 1 Install the door lock striker with the screws D109C572 TAILGATE LOCK STRIKER Removal Procedure 1 Open the tailgate and suitably support it 2 Remove the tailgate lock striker D Remove the screws 1 D Disconnect the cable 2 D Remove the striker 3 D109C573 Installation Procedure Notice Dissimilar metal in direct contact with each oth er may corrode rapidly Make sure to use the c...

Page 1102: ...ts of a striker with two screws that are threaded into a tapped floating cage plate located in the appropriate body pillar This floating cage plate allows the striker to be easily adjusted in or out and up or down The door is secured in the closed position when the door lock fork snaps over and en gages the striker D19C575A Fore Aft Adjustment 1 The door must be properly aligned 2 Close the door u...

Page 1103: ...ly using the ends of the striker screws Move the floating cage plate to the desired position Notice It is important to use a flat end rotary file in or der not to damage the tapped floating cage plate The striker screws and the tapped floating cage plate are im portant attaching parts that could affect the performance of vital components and systems 4 If proper adjustment requires that the floatin...

Page 1104: ...to adjust the tailgate striker in an fore and aft or in and out direction perform the follow ing procedure 1 The tailgate must be properly aligned 2 Loosen the striker screws 3 The floating cage plate can be moved slightly using the ends of the striker screws Move the floating cage plate to the desired position Notice It is important to use a flat end rotary file in or der not to damage the tapped...

Page 1105: ... middle of the striker between the rear body pillar and the end of the striker D109C582 5 If a up and down adjustment is required use the fol lowing steps D Remove the striker screws 1 D Remove the spacer in order to move the striker to ward the down of the vehicle 2 D Add a 2 mm 0 08 inch spacer in order to move the striker toward the up of the vehicle D Install the striker screws D19C583A FRONT ...

Page 1106: ... 2 Connect the outside door handle rod and the key rod to the door lock 3 Install the seal trim Refer to Door Seal Trim in this section 4 Connect the negative battery cable if equipped with the central door lock system D109C566 CHILDPROOF REAR DOOR LOCK Removal Procedure 1 Disconnect the negative battery cable if equipped with the central door lock system 2 Remove the door trim panel Refer to Sect...

Page 1107: ...tals in direct contact with each other may corrode rapidly Make sure to use the correct fasteners to prevent premature corrosion 1 Install the rear door lock with the screws Important Connect the actuator connector if equipped with the central door lock system 2 Connect the outside door handle rod to the door lock 3 Install the guide rail with the screw 4 Install the seal trim Refer to Door Seal T...

Page 1108: ...D109C589 Installation Procedure 1 Install the door lock actuator to the door lock assem bly with the screws 2 Install the door lock assembly to the vehicle Refer to Door Lock in this section 3 Install the door seal trim Refer to Door Seal Trim in this section 4 Connect the negative battery cable D109C590 TAILGATE LOCK Removal Procedure 1 Remove the tailgate trim panel Refer to Section 9G Interior ...

Page 1109: ...93 INSIDE DOOR HANDLE Removal Procedure 1 Removal the inside door handle D Remove the screw 1 D Remove the inside door handle 2 D109C594 Installation Procedure 1 Install the inside door handle with the screw D109C595 OUTSIDE FRONT DOOR HANDLE Removal Procedure 1 Disconnect the negative battery cable 2 Remove the front door lock rods 3 Remove the outside front door handle D Remove the bolts 1 D Rem...

Page 1110: ...he outside rear door handle D Remove the bolts 1 D Remove the outside rear door handle 2 D109C598 Installation Procedure 1 Install the outside rear door handle with the bolts 2 Install the rear door lock Refer to Childproof Rear door Lock in this section 3 Connect the negative battery cable D109C599 DOOR LOCK CYLINDER Removal Procedure 1 Disconnect the negative battery cable 2 Remove the outside d...

Page 1111: ...and Mirrors 2 Remove the window regulator D Remove the screws 1 D Remove the regulator 2 D109C602 Installation Procedure 1 Install the regulator with the screws 2 Install the glass Refer to Section 9L Glass and Mir rors D109C603 POWER FRONT WINDOW REGULATOR Removal Procedure 1 Disconnect the negative battery cable 2 Remove the glass Refer to Section 9L Glass and Mirrors 3 Remove the window regulat...

Page 1112: ...onnect the window motor electrical connector 4 Install the glass Refer to Section 9L Glass and Mir rors 5 Connect the negative battery cable D109C606 FRONT DOOR ASSEMBLY Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the electrical connector under the instru ment panel Important In case of the front passenger door remove the glove box in advance D109C607 3 Remove the fender...

Page 1113: ... fender Refer to Section 9R Body Front End 7 Connect the electrical connector 8 Connect the negative battery cable 9 Perform the waterleak test Refer to Section 9I Wa terleak 10 Check for windnoise Refer to Section 9J Wind noise D109C609 REAR DOOR ASSEMBLY Removal Procedure 1 Disconnect the negative battery cable 2 Pry off the lower B pillar trim panel Refer to Section 9G Interior Trim 3 Disconnec...

Page 1114: ...rear door electrical connector 6 Connect the negative battery cable 7 Perform the waterleak test Refer to Section 9I Wa terleaks 8 Check for windnoise Refer to Section 9J Windnoise D109C612 TAILGATE Removal Procedure 1 Disconnect the negative battery cable 2 Remove the luggage compartment wheelhouse trim panel Refer to Section 9G Interior Trim 3 Disconnect the tailgate electrical connector a Tailg...

Page 1115: ...nnect the negative battery cable D209B113 TAILGATE LOCK CYLINDER Removal Procedure 1 Disconnect the negative battery cable 2 Open the tailgate 3 Remove the rear window wiper motor assembly Re fer to Section 9D Wipers Washer Systems 4 Remove the tailgate lock cylinder D Disconnect the tailgate lock rod 1 D Remove the nuts from the tailgate lock cylinder 2 D Remove the tailgate lock cylinder 3 D209B...

Page 1116: ...eal Trim in this section 2 Remove the door hold open link D Remove the hinge to body bolt 1 D Remove the hinge to door bolts 2 D Remove the door hold open link 3 D109C618 Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fastener to prevent premature corrosion 1 Install the door hold open link to the door and the body...

Page 1117: ...Straighten the retaining tabs 1 D Remove the channel weatherstrip 2 D109C622 Installation Procedure 1 Install the channel weatherstrip onto the door trim panel 2 Bend the retaining tabs to secure the channel weath erstrip to the door trim panel 3 Install the door trim panel Refer to Section 9G Interi or Trim D109C623 DOOR OUTSIDE CHANNEL WEATHERSTRIP Removal Procedure 1 Remove the channel weathers...

Page 1118: ...the weatherstrip screw D109C625 DOOR WEATHERSTRIP Removal Procedure 1 Remove the door hold open link bolt D109C626 2 Remove the door weatherstrip D Remove the clip 1 D Remove the weatherstrip pins 2 D109C627 Installation Procedure 1 Install the door weatherstrip with the clip and the pins 2 Install the door hold open link bolt ...

Page 1119: ...vance D109C628 Installation Procedure 1 Install the door seal trim 2 Install the door pocket handle bracket for the deluxe trim 3 Install the door trim panel Refer to Section 9G Interi or Trim D109C629 DOOR OPENING WEATHERSTRIP Removal Procedure 1 Mark the door opening weatherstrip edge by a soluble pen D109C630 2 Remove the door opening weatherstrip D Take off the rocker trim panel partially 1 D ...

Page 1120: ...ure 1 Remove the window regulator handle D Using a cloth pull out the clip 1 D Remove the window regulator handle 2 D109C632 Installation Procedure 1 Install the window regulator handle with the clip D19C634A TAILGATE STRUT Removal Procedure 1 Open the tailgate and suitably support it 2 Remove the tailgate strut assembly D Remove the end fitting nut from the ball studs rear body 1 D Removethe end ...

Page 1121: ...DOORS 9P 29 DAEWOO M 150 BL2 D19C635A Installation Procedure 1 Install the tailgate strut with the ball studs ...

Page 1122: ...9P 30 DOORS DAEWOO M 150 BL2 SCHEMATIC AND ROUTING DIAGRAMS POWER DOOR LOCKS LEFT HAND DRIVE D19C201B ...

Page 1123: ...DOORS 9P 31 DAEWOO M 150 BL2 POWER DOOR LOCKS RIGHT HAND DRIVE D19C201S ...

Page 1124: ...9P 32 DOORS DAEWOO M 150 BL2 POWER DOOR LOCKS W ANTI THEFT CONTROL LHD D19C201S ...

Page 1125: ...DOORS 9P 33 DAEWOO M 150 BL2 POWER DOOR LOCKS W ANTI THEFT CONTROL RHD D19C202S ...

Page 1126: ...9P 34 DOORS DAEWOO M 150 BL2 POWER WINDOWS FRONT ONLY D19C202B ...

Page 1127: ... 2 Sun Visors 9Q 2 Passenger Assist Handles 9Q 2 Coat Hook 9Q 2 Component Locator 9Q 3 Roof 9Q 3 Repair Instructions 9Q 4 On Vehicle Service 9Q 4 Formed Headliner 9Q 4 Manual SunRoof 9Q 5 Sun Visors 9Q 6 Passenger Assist Handle and the Coat Hook 9Q 6 Specifications 9Q 8 Fastener Tightening Specifications 9Q 8 ...

Page 1128: ...NUAL SUNROOF The sunroof is D Intended to provide light and air through the roof of the vehicle during the driving D Built into the roof D Made of glass SUN VISORS The sun visors swing down or side in order to block out glare They also swing to the side when they are re leased from the support PASSENGER ASSIST HANDLE There is a passenger assist handle for the front passen ger seat Passengers can u...

Page 1129: ...R ROOF D19C402B 1 Sunroof Handle 2 Sunroof Screen 3 Sunroof Screen Seal 4 Sunroof Upper Frame 5 Roof Seal 6 Sunroof Lower Frame 7 Sunroof Cover 8 Roof Rail 9 Rear Spoiler 10 Roof Molding 11 Roof Rack Bracket 12 Roof Rack Pad 13 Cap 14 Roof Rack ...

Page 1130: ...ff the upper B pillar trim panel Refer to Sec tion 9G Interior Trim 6 Pry off the C pillar trim panel Refer to Section 9G Interior Trim 7 Remove the passenger assist handle and the coat hook Refer to Passenger Assist Handle and The Coat Hook in this section 8 Remove the sunroof molding if equipped with Re fer to Manual Sunroof in this section 9 Take off the tailgate opening weatherstrip Refer to S...

Page 1131: ...clips 1 D Remove the lock 2 D Remove the screen 3 D109C558 2 Remove the inside sunroof molding in the passenger compartment a Inside sunroof molding D109C559 3 Remove the lower sunroof frame D Remove the screws 1 D Remove the lower sunroof frame 2 D109C560 4 Remove the upper sunroof frame a Upper sunroof frame ...

Page 1132: ... lower sunroof frame make sure to tighten the screws previously as shown the fig ure and tighten all the screws D109C562 SUN VISORS Removal Procedure 1 Remove the sun visors D Remove the screws 1 D Remove the sun visors 2 D109C563 Installation Procedure 1 Install the sun visors with the screws D109C564 PASSENGER ASSIST HANDLE OR THE COAT HOOK Removal Procedure 1 Remove the passenger assist handle ...

Page 1133: ...ROOF 9Q 7 DAEWOO M 150 BL2 D109C565 Installation Procedure 1 Install the passenger assist handle or the coat hook to the headliner with the screws ...

Page 1134: ...CATIONS ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Application ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ NSm ÁÁÁÁÁÁ ÁÁÁÁÁÁ Lb Ft ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ Lb In ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Sunroof Frame Screws ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 3 ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 27 ...

Page 1135: ...ont End 9R 2 Repair Instructions 9R 3 On Vehicle Service 9R 3 Lubrication 9R 3 Fasteners 9R 3 Anticorrosion Materials 9R 3 Front End Sealing 9R 4 Cowl Vent Grille 9R 4 Hood 9R 5 Hood Hinge 9R 5 Hood Prop Rod 9R 6 Hood Latch 9R 7 Hood Latch Release Lever 9R 8 Hood Latch Release Cable 9R 9 Fender 9R 9 ...

Page 1136: ...O M 150 BL2 DESCRIPTION AND OPERATION BODY FRONT END This vehicle has a unitized body with a frame assembly supporting the engine and the transaxle The fender panels and the radiator support are also integral parts of the body ...

Page 1137: ... with steel may corrode rapidly if it is not protected by special finishes or isolators The fasteners used have a special finish which provides adequate protection from corrosion These special fas teners differ in color in order to easily identify them from the standard metric fasteners which are medium blue in color When replacing fasteners avoid substituting otherwise similar fasteners in the sa...

Page 1138: ...cessary D109C521 COWL VENT GRILLE Removal Procedure 1 Remove the wiper arm assembly Refer to Section 9D Wiper Washer Systems 2 Remove the cowl vent grille screws and the clips D Remove the screws after removing the upper cap 1 D Remove the lower retaining plastic clips 2 D Close the hood D Lift up the cowl vent grille 3 D19C522A 3 Remove the cowl vent grille D Disconnect the front washer hose conn...

Page 1139: ...od 1 Raise and support the hood 2 Remove the hood D Remove the bolts 1 D Remove the hood 2 D109C525 Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasteners to prevent premature corrosion 1 Install the hood with the bolts 2 Inspect the hood for proper alignment D109C526 HOOD HINGE Removal Procedure 1 Remove the hoo...

Page 1140: ...each other may corrode rapidly Make sure to use the correct fasteners to prevent premature corrosion 1 Install the hood hinge with the bolts 2 Install the bolts along the top of the fender 3 Install the cowl vent grille with the screws and the caps 4 Install the hood Refer to Hood in this section D109C530 HOOD PROP ROD Removal Procedure 1 Support the hood in the open position 2 Remove the hood pro...

Page 1141: ...9C533 HOOD LATCH Removal Procedure 1 Open the hood 2 Remove the hood latch D Remove the screws 1 D Disconnect the hood latch release cable 2 D Remove the hood latch 3 D109C534 Installation Procedure 1 Connect the hood latch release cable to the latch Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasteners to prevent premature corrosion ...

Page 1142: ... hood latch release lever D Disconnect the cable 1 D Remove the hood latch release lever 2 D19C536A Installation Procedure 1 Connect the hood latch release cable to the hood latch lever D109C537 Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasteners to prevent premature corrosion 2 Install the hood latch lever release to the instrument...

Page 1143: ...e the hood latch release cable after removing the plastic strip a Hood latch release cable D19C539C Installation Procedure 1 Connect the hood latch release cable to the hood latch Refer to Hood Latch in this section 2 Arrange the hood latch release cable with the plastic strip 3 Push the cable toward the passenger compartment through the body hole 4 Connect the hood latch release cable to the hood...

Page 1144: ...C541A 5 Remove the screws on the side of the front bumper fascia a Bumper fascia side bolts 6 Remove the bolt under the fender b Fender mounting bolt D19C542A 7 Lower the vehicle 8 Take off the cowl vent grille Remove the bolt on the top of the fender a Fender mounting bolt D19C543A 9 Remove the front bumper spacer Refer to Section 9M Exterior Trim 10 Remove the fender front bolt a Fender front bo...

Page 1145: ... correct fasteners to prevent premature corrosion 2 Install the bolts along the top of the fender D19C545A 3 Install the front bumper spacer 4 Install the cowl vent grille 5 Raise and suitably support the vehicle 6 Install the bolts under the fender 7 Install the screws on the side of the front bumper fascia 8 Open the front door Install the bolt on the A pillar 9 Install the bolt at the base of t...

Page 1146: ...REAR END TABLE OF CONTENTS Description and Operation 9S 2 Fuel Filler Door 9S 2 Repair Instructions 9S 3 On Vehicle Service 9S 3 Fuel Filler Door 9S 3 Fuel Filler Door Remote Cable and Handle 9S 3 Tailgate Remote Cable and Handle 9S 5 ...

Page 1147: ...9S 2 BODY REAR END DAEWOO M 150 BL2 DESCRIPTION AND OPERATION FUEL FILLER DOOR The fuel filler door attaches to the fuel tank pocket on the right side of the vehicle ...

Page 1148: ...ts 1 D Remove the fuel filler door 2 D109C547 Installation Procedure 1 Install the fuel filler door with the bolts D109C548 FUEL FILLER DOOR REMOTE CABLE AND HANDLE Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Pry off the front rocker trim panel Refer to Section 9G Interior Trim 2 Remove the fuel filler door remote handle D Remove the screws 1 D Disconnect the cable 2 D Remov...

Page 1149: ...larly a Lock striker D19C550B 7 Remove the fuel filler door remote cable D Remove the cable retaining strip D Disconnect the fuel filler door remote cable 1 D19C550C Installation Procedure 1 Connect the fuel filler door remote cable to the fuel filler door 2 Retain the cable with the strip D19C549A 3 Install the lock striker of the fuel filler 4 Install the luggage compartment wheelhouse trim pane...

Page 1150: ...l Refer to Section 9G Interior Trim 5 Pry off the luggage compartment wheelhouse trim panel Refer to Section 9G Interior Trim 6 Disconnect the cable from the tailgate lock striker Refer to Section 9P Doors 7 Remove the tailgate remote cable D Remove the cable retaining strip D Disconnect the tailgate remote cable 1 D109C551 Installation Procedure 1 Connect the tailgate remote cable to the tailgate...

Page 1151: ...t 9T 10 Serial Data Link 9T 11 Electronic Control Module ECM 9T 11 Security Indicator 9T 12 Diagnostic Information and Procedures 9T 13 Immobilizer System FENIX 5MR 9T 13 Immobilizer System SIRIUS D3 9T 13 DTC 1600 ECM Immobilizer Error No Answer 9T 14 DTC 1601 ECM Immobilizer Error Incorrect Answer 9T 16 DTC 1602 ECM Immobilizer Error ECM Locked 9T 18 P1628 ECM Immobilizer Error 9T 20 P1629 ECM I...

Page 1152: ...9T ii REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM DAEWOO M 150 BL2 BLANK ...

Page 1153: ...age to the vehicle The ignition must also be in LOCK unless otherwise noted TABLE OF CONTENTS Description and Operation 9T 2 Remote Keyless Entry and Anti Theft System 9T 2 Remote Locking and Unlocking 9T 2 Security Indicator 9T 2 Intrusion Sensing 9T 2 Siren 9T 2 Vehicle Locator 9T 2 Autolocking Safety Lock 9T 3 Control Module Receiver 9T 3 Repair Instructions 9T 4 On Vehicle Service 9T 4 Siren 9...

Page 1154: ...at least two years before replacement is necessary SECURITY INDICATOR There is a security indicator on the instrument panel Af ter the LOCK button of the transmitter is pressed the module is placed in the armed mode and the security indicator flashes The security indicator turns ON for 1 8 second and OFF for 7 8 second It then flashes at that frequency until the control module receiver is disarmed...

Page 1155: ...s turned ON D The tailgate is opened D The hood is opened CONTROL MODULE RECEIVER The remote keyless entry control module receiver is contained in the tie bar center The module receiver pro cesses signals from the remote transmitter and the in trusion sensors and it activates the alarm if an intrusion is detected The control module receiver will not communicate with transmitters from other vehicle...

Page 1156: ...ouse splash shield D Remove the clip and bolts a Bolts and clips D Remove the wheel house splash shield b Splash shield D209B106 5 Remove the siren D Remove the screws 1 D Disconnect the electrical connector 2 D209B107 Installation Procedure 1 Install the siren with the screws 2 Connect the electrical connector 3 Install the front wheel house splash shield with the clips and the bolts 4 Install th...

Page 1157: ...amming mode message to the control module receiver 3 Press any button of the transmitter to generate a data code including a password which will be recorded by the control module receiver The control module re ceiver sends a response message to the scan tool to indicate that the first password has been recorded 4 Press any button of the transmitter three more times until the control module receive...

Page 1158: ... ENTRY AND ANTI THEFT SYSTEM DAEWOO M 150 BL2 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application NSm Lb Ft Lb In Hood Open Switch Mounting Screw 8 71 Siren Bracket Mounting Bolt 22 16 Siren Mounting Screws 8 71 ...

Page 1159: ...REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM 9T 7 DAEWOO M 150 BL2 SCHEMATIC AND ROUTING DIAGRAMS D209T000 REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM ...

Page 1160: ...9T 8 REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM DAEWOO M 150 BL2 BLANK ...

Page 1161: ...n and Procedures 9T 13 Immobilizer System FENIX 5MR 9T 13 Immobilizer System SIRIUS D3 9T 13 DTC 1600 ECM Immobilizer Error No Answer 9T 14 DTC 1601 ECM Immobilizer Error Incorrect Answer 9T 16 DTC 1602 ECM Immobilizer Error ECM Locked 9T 18 P1628 ECM Immobilizer Error 9T 20 P1629 ECM Immobilizer Error 9T 22 Key Status Errors FENIX 5MR 9T 24 Key Status Errors SIRIUS D3 9T 24 Communication Between ...

Page 1162: ...s with integrated trans ponder D the toroidal coil Detection coil for energizing and reading the transponder mounted at the ignition lock D the Immobilizer control unit ICU with power supply ignition input circuit transponder modulation and demodulation unit EEPROM driver electronic for the external status LED serial data link hardware D the external status LED for displaying the Immobilizer statu...

Page 1163: ...e ECM VIN code should be reset to get identical with the immobilizer control unit s During diagnostic procedures the VIN code can be read for comparison with the ECM VIN code by using the scan tool s Read immobilizer control unit VIN code command SERIAL DATA LINK Serial data can be exchanged between a scan tool and the ECM and the Immobilizer control unit The scan tool connection is the data link ...

Page 1164: ...ignition SECURITY INDICATOR There is a security indicator on the instrument panel Status LED An external LED displays the immobilizer system status The immobilizer contains the LED driver hardware for di rect connection of one LED Status LED Modes Status LED Immobilizer System Status Note Blinking Active Ignition OFF Blinking Active Invalid key detected Ignition ON OFF Inactive Valid key detected ...

Page 1165: ...nctions do not require a password D Reading an ignition key to determine if the transpond er is working or if a key is authorized D Reading the immobilizer ID code to verify that it matches the ECM ID code IMMOBILIZER SYSTEM SIRIUS D3 The immobilizer anti theft system requires diagnosis when it is not possible to start the engine If the no start condition occurs because of the immobilizer system a...

Page 1166: ...nit sends a serial data release message to the elec tronic control module ECM Included in the release message is an identification ID code which assures that neither the immobilizer control unit nor the ECM has been substituted to defeat the system If the ECM re ceives an invalid release message the ECM performs the following actions D Disables the fuel injector circuit D Disables the fuel pump ci...

Page 1167: ...Select CURRENT KEY STATUS from the scan tool menu Did the STATUS OF CURRENT KEY message indicate KEY IS WRONG Go to Key Status Errors Go to Step 3 3 Read the IMMO ECM ID CODE message that was displayed after requesting DIAGNOSIS Did the message differ from normal message Normal Message ECM MODE LEARNT IMMO MODE LEARNT VIN CODE SAME Go to Identification ID Code Repro gramming Go to Step 4 4 Check f...

Page 1168: ...y is detected the immobilizer control unit sends a serial data release message to the elec tronic control module ECM Included in the release message is an identification ID code which assures that neither the immobilizer control unit nor the ECM has been substituted to defeat the system If the ECM re ceives an invalid release message the ECM performs the following actions D Disables the fuel injec...

Page 1169: ...TUS from the scan tool menu 2 Read the STATUS OF CURRENT KEY message Does the KEY STATUS message indicate KEY IS WRONG Go to Key Status Errors Go to Step 3 3 1 Select DIAGNOSIS from the scan tool menu 2 Read the IMMO ECM ID CODE immobilization and electronic control module identification code message Did the message differ from normal message Normal Message ECM MODE LEARNT IMMO MODE LEARNT VIN COD...

Page 1170: ...valid key is detected the immobilizer control unit sends a serial data release message to the elec tronic control module ECM Included in the release message is an identification ID code which assures that neither the immobilizer control unit nor the ECM has been substituted to defeat the system If the ECM re ceives an invalid release message the ECM performs the following actions D Disables the fu...

Page 1171: ... from the scan tool menu 2 Read the STATUS OF CURRENT KEY message Does the KEY STATUS message indicate KEY IS WRONG Go to Key Status Errors Go to Step 3 3 1 Select DIAGNOSIS from the scan tool menu 2 Read the IMMO ECM ID CODE immobilization and electronic control module identification code message Did the message differ from normal message Normal Message ECM MODE LEARNT IMMO MODE LEARNT VIN CODE S...

Page 1172: ...tected the immobilizer control unit sends a serial data release message to the elec tronic control module ECM Included in the release message is an identification ID code which assures that neither the immobilizer control unit nor the ECM has been substituted to defeat the system If the ECM re ceives an invalid release message the ECM performs the following actions D Disables the fuel injector cir...

Page 1173: ...obilizer and Test Equipment 2 Read the IMMO ECM ID CODE message that was displayed after requesting DIAGNOSIS Did the message differ from normal message Normal Message ECM MODE LEARNT IMMO MODE LEARNT VIN CODE SAME Go to Identification ID Code Repro gramming Go to Step 3 3 Check for an open serial data wire between the immobilizer control unit and the ECM Was the circuit open Go to Step 4 Go to St...

Page 1174: ...mobilizer con trol unit If a valid key is detected the immobilizer control unit sends a serial data release message to the elec tronic control module ECM Included in the release message is an identification ID code which assures that neither the immobilizer control unit nor the ECM has been substituted to defeat the system If the ECM re ceives an invalid release message the ECM performs the follow...

Page 1175: ...hed between the scan tool and the immobilizer control unit Go to Step 2 Go to Communi cation Between Immobilizer and Test Equipment 2 1 Select DIAGNOSIS from the scan tool menu 2 Read the IMMO ECM ID CODE immobilization and electronic control module identification code message Did the message differ from normal message Normal Message ECM MODE LEARNT IMMO MODE LEARNT VIN CODE SAME Go to Identificat...

Page 1176: ...il 4 If the detection coil is not open replace the immobilizer control unit Refer to Immobilizer Control Unit in this section KEY STATUS ERRORS SIRIUS D3 The following KEY STATUS messages may be shown on the scan tool after commanding FIRST KEY COD ING and KEY ADD D IGNITION OFF STATUS This message informs the technician that the ignition is off during the key coding process Turn the ignition ON d...

Page 1177: ...ontrol unit Refer to Immobilizer Control Unit in this section Notice Install the resistor cover in the DLC connec tor after remove the scan tool Because ECM Immo bilizer Error Problem may exist COMMUNICATION BETWEEN IMMOBILIZER CONTROL UNIT AND TEST EQUIPMENT SIRIUS D3 1 Connect the test equipment as described in the Scan Tool Equipment Manual 2 If communication between the scan tool and the test ...

Page 1178: ...er con trol unit has recorded all of the new keys or after a deletion has reauthorized all of the remaining keys The immobilizer control unit can record a maximum of five keys 10 Return the system to the normal mode 11 Turn OFF the ignition 12 Turn ON the ignition 13 Crank to start the engine ID CODE REPROGRAMMING Reprogram the identification ID code in the following situations D An immobilizer co...

Page 1179: ...ilizer control unit and the ECM TRANSPONDER Each valid ignition key has an internal transponder which is a read write transponder The transponder contains an implementation of a cryp to algorithm with 96 bits of user configurable secret key contained in EEPROM and transmits data to the ICU by modulating the amplitude of the electromagnetic field and receives data and commands in a similar way D105...

Page 1180: ...ers with the screws Refer to Section 6E Steering Wheel and Column D105A504 IMMOBILIZER CONTROL UNIT Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Disconnect the negative battery cable 2 Remove the steering column covers Refer to Section 6E Steering Wheel and Column D29T003 3 Slide the immobilizer control unit toward steering wheel until it slides off its mounting bracket 4 Dis...

Page 1181: ...dure in this section Also the electronic control module ECM identification ID code must be reset Refer to Identification ID Code Reprogramming in this section 1 Connect the electrical connectors to the immobilizer control unit 2 Slide the immobilizer control unit onto its mounting bracket D105A505 3 Install the steering column covers Refer to Section 6E Steering Wheel and Column 4 Connect the nega...

Page 1182: ...SYSTEM DAEWOO M 150 BL2 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Application ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ NSm ÑÑÑÑÑÑ ÑÑÑÑÑÑ Lb Ft ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ Lb In Immobilizer Control Unit Mounting Bolts 4 35 ...

Page 1183: ...IMMOBILIZER ANTI THEFT SYSTEM 9T 31 DAEWOO M 150 BL2 SCHEMATIC AND ROUTING DIAGRAMS D19T001B IMMOBILIZER ANTI THEFT SYSTEM ...

Page 1184: ...9T 32 IMMOBILIZER ANTI THEFT SYSTEM DAEWOO M 150 BL2 SCHEMATIC AND ROUTING DIAGRAMS D209T001 REMOTE KEYLESS ENTRY AND IMMOBILIZER ANTI THEFT SYSTEM ...

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