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Daewoo NUBIRA, User Manual

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4T40–E AUTOMATIC TRANSAXLE  5A – 3

DAEWOO V–121 BL4

DTC P0723 AUTOMATIC TRANSMISSION 

VEHICLE SPEED SENSOR (A/T VSS)
INTERMITTENT

5A–110

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

DTC P0724 BRAKE SWITCH 

CIRCUIT HIGH

5A–112

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

DTC P0730 INCORRECT GEAR RATIO

5A–114

. . . . 

DTC P0741 TCC CIRCUIT STUCK OFF

5A–116

. . . . 

DTC P0742 TCC CIRCUIT STUCK ON

5A–119

. . . . . 

DTC P0748 PC SOLENOID 

CIRCUIT ELECTRICAL

5A–123

. . . . . . . . . . . . . . . . . 

DTC P0751 1–2 SHIFT SOLENOID 

PERFORMANCE

5A–126

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

DTC P0753 1–2 SHIFT SOLENOID 

ELECTRICAL

5A–130

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

DTC P0756 2–3 SHIFT SOLENOID 

PERFORMANCE

5A–133

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

DTC P0758 2–3 SHIFT SOLENOID 

ELECTRICAL

5A–137

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

DTC P1790 ROM CHECKSUM ERROR

5A–140

. . . . 

DTC P1792 EEPROM 

CHECKSUM ERROR

5A–141

. . . . . . . . . . . . . . . . . . 

DTC P1810 AUTOMATIC TRANSMISSION 

FLUID PRESSURE MANUAL VALVE POSITION
SWITCH (TFP VAL. POSITION SW.)
MALFUNCTION

5A–142

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

DTC P1811 MAXIMUM ADAPT 

AND LONG SHIFT

5A–147

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

DTC P1887 TCC RELEASE SWITCH 

CIRCUIT MALFUNCTION

5A–151

. . . . . . . . . . . . . . . 

MAINTENANCE AND REPAIR

5A–154

. . . . . . . . . . . . . 

ON–VEHICLE SERVICE

5A–154

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

TRANSAXLE FLUID LEVEL CHECKING

PROCEDURE

5A–154

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

CHANGING THE FLUID

5A–155

. . . . . . . . . . . . . . . . . . 

REPAIRING FLUID LEAKS

5A–155

. . . . . . . . . . . . . . . 

CASE POROSITY REPAIR

5A–156

. . . . . . . . . . . . . . . 

FLUID LEVEL SET AFTER SERVICE

5A–157

. . . . . . 

OIL COOLER FLUSHING

5A–157

. . . . . . . . . . . . . . . . 

SHIFT CONTROL LEVER

5A–158

. . . . . . . . . . . . . . . . 

SHIFT CONTROL CABLE

5A–164

. . . . . . . . . . . . . . . . 

CONTROL CABLE ADJUSTMENT

5A–167

. . . . . . . . 

PARK/NEUTRAL POSITION SWITCH

5A–168

. . . . . . 

BRAKE TRANSAXLE SHIFT INTERLOCK

5A–169

. . 

KEY INTERLOCK

5A–170

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

AUTOMATIC TRANSMISSION VEHICLE 

SPEED SENSOR (A/T VSS)

5A–172

. . . . . . . . . . . . 

PAN, GASKET, AND FILTER

5A–173

. . . . . . . . . . . . . . 

REVERSE/LOW SERVO ASSEMBLY

5A–174

. . . . . . 

2ND/4TH SERVO ASSEMBLY

5A–175

. . . . . . . . . . . . 

CASE SIDE COVER PAN AND GASKETS

5A–176

. . 

1–2 SHIFT SOLENOID

5A–177

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

2–3 SHIFT SOLENOID

5A–178

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

PRESSURE CONTROL SOLENOID

5A–178

. . . . . . . 

TCC SOLENOID

5A–179

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

DRIVE AXLE OIL SEAL

5A–180

. . . . . . . . . . . . . . . . . . 

OIL COOLER PIPES

5A–180

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

OIL COOLER HOSES AND PIPE

5A–181

. . . . . . . . . . 

TRANSAXLE MOUNT

5A–183

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

TRANSAXLE BRACKET

5A–185

. . . . . . . . . . . . . . . . . 

TRANSAXLE ASSEMBLY

5A–187

. . . . . . . . . . . . . . . . 

TRANSAXLE BRACE

5A–193

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

UNIT REPAIR

5A–195

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

TORQUE CONVERTER REMOVAL

5A–195

. . . . . . . . 

TRANSAXLE HOLDING 

FIXTURE ASSEMBLY

5A–195

. . . . . . . . . . . . . . . . . . 

STUB SHAFT REMOVAL

5A–196

. . . . . . . . . . . . . . . . . 

AUTOMATIC TRANSMISSION VEHICLE 

SPEED SENSOR REMOVAL

5A–196

. . . . . . . . . . . . 

OIL PAN AND GASKET REMOVAL

5A–197

. . . . . . . . 

OIL FILTER/SEAL, OIL LEVEL CONTROL 

VALVE REMOVAL

5A–197

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

OIL FEED PIPES REMOVAL

5A–197

. . . . . . . . . . . . . . 

INTER 4TH SERVO REMOVAL

5A–198

. . . . . . . . . . . 

LOW/REVERSE SERVO REMOVAL

5A–198

. . . . . . . 

CASE SIDE COVER REMOVAL

5A–198

. . . . . . . . . . . 

OIL PUMP AND OIL PUMP SHAFT 

REMOVAL

5A–199

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

WIRE HARNESS DISCONNECT

5A–199

. . . . . . . . . . 

PRESSURE SWITCH ASSEMBLY 

REMOVAL

5A–199

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

CONTROL VALVE BODY ASSEMBLY 

AND GASKET REMOVAL

5A–200

. . . . . . . . . . . . . . . 

SPACER PLATE AND GASKET REMOVAL

5A–200

. 

CHECKBALL REMOVAL

5A–200

. . . . . . . . . . . . . . . . . 

MANUAL VALVE CLIP REMOVAL

5A–201

. . . . . . . . . 

CHANNEL PLATE AND GASKET 

REMOVAL

5A–201

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

ACCUMULATOR SPRING REMOVAL

5A–201

. . . . . . 

OUTPUT SHAFT SLEEVE REMOVAL

5A–202

. . . . . 

DRIVE, DRIVEN SPROCKETS, DRIVE LINK

REMOVAL

5A–202

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

INPUT SPEED SENSOR REMOVAL

5A–202

. . . . . . . 

WIRING HARNESS REMOVAL

5A–203

. . . . . . . . . . . 

DRIVEN SPROCKET SUPPORT 

ASSEMBLY REMOVAL

5A–203

. . . . . . . . . . . . . . . . . 

2ND CLUTCH PLATES REMOVAL

5A–203

. . . . . . . . 

REVERSE INPUT CLUTCH 

HOUSING REMOVAL

5A–204

. . . . . . . . . . . . . . . . . . 

INTERMEDIATE 4TH BAND REMOVAL

5A–204

. . . . 

DIRECT/COAST CLUTCH AND 

REACTION GEAR SET REMOVAL

5A–204

. . . . . . 

Summary of Contents for NUBIRA

Page 1: ......

Page 2: ...T 2 DTC 53 PCM ECM Immobilized Error 9T 2 KEY STATUS ERRORS 9T 2 COMMUNICATION BETWEEN IMMOBILIZER AND TEST EQUIPMENT 9T 3 MAINTENANCE AND REPAIR 9T 4 ON VEHICLE SERVICE 9T 4 KEY CODING PROCEDURE 9T 4...

Page 3: ...following procedure 1 Insert the immobilizer data cartridge into the scan tool 2 Turn the ignition OFF 3 Connect the scan tool to the data link connec tor DLC 4 Turn the ignition ON but do not start t...

Page 4: ...it in this section S NO TRANSPONDER DETECTED The fault may be in ignition key transponder the detection coil or the immobilizer Follow the steps below to diagnose the problem 1 Try a different key If...

Page 5: ...ilizer 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...

Page 6: ...Turn the ignition ON 10 Start the engine After reprogramming the ID code the scan tool SYSTEM DIAGNOSIS command can verify that the PCM ECM ID code matches the immobilizer control unit ID code If the...

Page 7: ...trim panel upward and pull it outward to remove it 3 Remove the instrument panel side cover 4 Remove the bolts and the knee bolster 5 Remove the steering column lower cover Refer toSection 6E Steerin...

Page 8: ...he new detection coil Installation Procedure 1 Install the detection coil by pressing it onto the lock cylinder until it snaps in place 2 Connect the two pin connector to the immobilizer 3 Install the...

Page 9: ...pull the knee bolster trim panel loose from its retaining clips 3 Slide the knee bolster trim panel upward and pull it outward to remove it 4 Remove the instrument panel side cover 5 Remove the bolts...

Page 10: ...knee bolster with the bolts Tighten Tighten the knee bolster mounting bolts to 22 NSm 16 lb in 4 Install the instrument panel side cover 5 Install the knee bolster trim panel 6 Connect the negative b...

Page 11: ...ucted from the detection coil to the im mobilizer control unit The immobilizer control unit reads the radio frequency signal A release message is sent to the powertrain control module PCM engine contr...

Page 12: ...train control module PCM engine con trol module ECM detects that the ignition is being turned ON the PCM ECM waits for a release message from the immobilizer control unit If a release message is not r...

Page 13: ...ENTRY AND ANTI THEFT SYSTEM 2 OF 2 9T 3 CONTROL MODULE RECEIVER CONNECTOR 9T 4 WIRING HARNESS CONNECTORS 9T 4 MAINTENANCE AND REPAIR 9T 5 ON VEHICLE SERVICE 9T 5 CONTROL MODULE RECEIVER 9T 5 SIREN 9T...

Page 14: ...9T 2IREMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM 1 OF 2...

Page 15: ...REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM 9T 3 DAEWOO V 121 BL4 REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM 2 OF 2...

Page 16: ...9T 4IREMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM DAEWOO V 121 BL4 CONTROL MODULE RECEIVER CONNECTOR WIRING HARNESS CONNECTORS...

Page 17: ...eceiver electrical connector 4 Slide the control module receiver toward the rear of the vehicle and remove it Installation Procedure 1 Install the control module receiver by sliding it onto its bracke...

Page 18: ...n electrical connector 3 Remove the siren bracket mounting bolt 4 Remove the siren Installation Procedure 1 Install the siren on the siren bracket with the mount ing screws Tighten Tighten the siren b...

Page 19: ...per switch Refer toSection 9P Doors Installation Procedure 1 Install the front door lock and the integral door tam per switch Refer toSection 9P Doors 2 Install the door tamper switch electrical conne...

Page 20: ...ct the rear deck lid tamper switch electrical connector to the tamper switch 3 Connect the negative battery cable HOOD OPEN SWITCH Removal Procedure 1 Disconnect the negative battery cable 2 Disconnec...

Page 21: ...V 121 BL4 Installation Procedure 1 Install the hood open switch with the mounting screw Tighten Tighten the hood open switch mounting screw to 8 NSm 71 lb in 2 Connect the electrical connector to the...

Page 22: ...de including a password which will be re corded by the control module receiver The control module receiver sends a response message to the scan tool to indicate that the first password has been record...

Page 23: ...URITY INDICATOR There is a security indicator on the instrument panel After the LOCK button of the transmitter is pressed the module is placed in the armed mode and the security indicator flashes The...

Page 24: ...dule receiver will not communicate with transmitters from other vehicles because there are over four billion possible electronic password combinations and passwords are not duplicated The control modu...

Page 25: ...mmed or reprogrammed during the programming procedure will no longer operate the Remote Keyless Entry System of that vehicle This Technical Service Bulletin provides information concerning the program...

Page 26: ...iate area are not activated during this procedure 13 Continue programming Transmitters when directed by the Scan 100 Scan Tool until all Transmitters have been programmed Note A maximum of five 5 Tran...

Page 27: ...R WINDOW WASHER SYSTEM HATCHBACK AND WAGON 9D 11 MAINTENANCE AND REPAIR 9D 12 ON VEHICLE SERVICE 9D 12 WINDSHIELD WIPER ARM 9D 12 WINDSHIELD WIPER MOTOR 9D 12 WINDSHIELD WIPER BLADE 9D 14 WINDSHIELD W...

Page 28: ...9D 2IWIPERS WASHER SYSTEMS DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS WIPERS AND WASHER SYSTEM NOTCHBACK...

Page 29: ...WIPERS WASHER SYSTEMS 9D 3 DAEWOO V 121 BL4 WIPERS AND WASHER SYSTEM HATCHBACK...

Page 30: ...voltage equal to the specified value 11 14 v Go to Step 6 Go to Step 7 6 Replace the wiper motor Is the repair complete System OK 7 1 The wiper switch is still disconnected 2 Turn the ignition ON 3 C...

Page 31: ...ircuit between wiper switch con nector terminal A9 and wiper motor connector termi nal 4 Is the repair complete System OK Wipers Do Not Work On LO Speed HI Speed OK Step Action Value s Yes No 1 1 Turn...

Page 32: ...e open circuit between wiper switch con nector terminal A7 and wiper relay connector termi nal I Is the repair complete System OK 7 1 Turn the ignition on 2 Turn the wiper switch to INT 3 Check for pu...

Page 33: ...wiper switch to HI 2 While turning the wiper switch OFF check the voltage at the wiper motor connector terminal 1 Is the specified voltage indicated when the wiper switch is turned OFF 11 14 v Go to...

Page 34: ...oir Is the repair complete System OK 6 Check the windshield washer hoses and nozzles Are the windshield washer hoses and nozzles clogged or damaged Go to Step 7 Go to Step 8 7 Repair the washer hoses...

Page 35: ...tep 6 6 Repair the open circuit between fuse F4 and rear window wiper motor connector terminal 3 Is the repair complete System OK 7 With the rear window wiper still disconnected use an ohmmeter to che...

Page 36: ...ve the rear window wiper switch to the WIPE position Does the ohmmeter indicate the specified value 0 W Go to Step 14 Go to Step 15 14 Repair the open circuit between terminal A1 of the rear window wi...

Page 37: ...hmmeter to check continuity between terminal 1 and ground Does the ohmmeter indicate the specified value 0 W Go to Step 9 Go to Step 8 8 Repair the open or high resistance ground connec tion Is the re...

Page 38: ...direct contact with each other may corrode rapidly Make sure to use the correct fasten ers to prevent premature corrosion 2 Secure the wiper arm with the nut Tighten Tighten the wiper arm nut to 11 N...

Page 39: ...dly Make sure to use the correct fasten ers to prevent premature corrosion 1 Install the wiper motor with the bolts Tighten Tighten the wiper motor bolts to 8 NSm 71 lb in 2 Connect the electrical con...

Page 40: ...arm 2 While pressing the retainer clip slide the wiper blade down the wiper arm and remove the blade Installation Procedure 1 Install the wiper blade by sliding it onto the arm until the retainer cli...

Page 41: ...HER RESERVOIR Typical Removal Procedure 1 Disconnect the negative battery cable 2 Remove the front left wheel Refer to Section 2E Tires and Wheels 3 Remove the bolts and the screws and the front wheel...

Page 42: ...s in direct contact with each other may corrode rapidly Make sure to use the correct fasten ers to prevent premature corrosion 1 Install the reservoir with the bolts Tighten Tighten the washer fluid r...

Page 43: ...ws and the front wheel well splash shield 4 Disconnect the electrical connector 5 Disconnect the washer hose from the washer pump 6 Remove the washer pump Installation Procedure 1 Install the washer p...

Page 44: ...Remove the nozzle from the cowl vent grille Installation Procedure 1 Install the nozzle onto the cowl vent grille 2 Connect the washer hose to the nozzle 3 Install the cowl vent grille Refer to Secti...

Page 45: ...e washer hose to the washer pump Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasten ers to prevent premature corrosion 3 Install the fro...

Page 46: ...ect fasten ers to prevent premature corrosion 1 Install the rear wiper arm with the nut Tighten Tighten the wiper arm nut to 11 NSm 97 lb in 2 Close the wiper arm access cap REAR WINDOW WIPER MOTOR HA...

Page 47: ...hback door lower garnish molding Refer toSection 9G Interior Trim 4 Install the rear window wiper arm Refer to Rear Window Wiper Arm in this section 5 Close the wiper arm access cap REAR WINDOW WIPER...

Page 48: ...in 2 Connect the electrical connector and the washer hose 3 Install the tailgate lower garnish molding 4 Install the wiper motor nut and exterior retaining clip to the tailgate 5 Install the rear win...

Page 49: ...STEMS 9D 23 DAEWOO V 121 BL4 Installation Procedure 1 Install the washer nozzle with the nut 2 Install the washer hose to the nozzle 3 Install the hatchback door upper garnish molding Refer toSection...

Page 50: ...ith a washer fluid reservoir a washer fluid pump hoses nozzles and a wiper washer switch The windshield washer reservoir is mounted behind the front left wheel well splash shield Attached to the reser...

Page 51: ...HICLE SERVICE 9N 2 ALIGNMENT CHECKING 9N 2 FLOOR PAN INSULATORS 9N 2 ENGINE UNDER COVER 9N 3 GENERAL DESCRIPTION AND SYSTEM OPERATION 9N 5 GENERAL BODY CONSTRUCTION 9N 5 ENGINE UNDER COVERS 9N 5 SPECI...

Page 52: ...t from the use of the cata lytic converter in the exhaust system Therefore when servicing a vehicle it is essential that any insulators that may have been disturbed or removed be reinstalled in the or...

Page 53: ...lash shield 3 Remove the screws the nuts and the engine under cover Installation Procedure 1 Install the engine under cover with the screws and the nuts Tighten Tighten the engine under cover nuts to...

Page 54: ...9N 4IFRAME AND UNDERBODY DAEWOO V 121 BL4 4 Install the front fascia splash shield with the screws Tighten Tighten the front fascia splash shield screw to 1 5 NSm 13 lb in 5 Lower the vehicle...

Page 55: ...and caster camber angles Since the individual underbody parts contribute directly to the overall strength of the body it is essential to observe proper welding techniques during service repair opera...

Page 56: ...DOOR LOCK STRIKER ADJUSTMENT 9P 13 FRONT DOOR LOCK 9P 14 CHILDPROOF REAR DOOR LOCK 9P 17 INSIDE DOOR HANDLE 9P 19 INSIDE LOCK ROD 9P 19 OUTSIDE DOOR HANDLE 9P 20 DOOR LOCK CYLINDER 9P 21 POWER FRONT W...

Page 57: ...O V 121 BL4 Application Lb In Lb Ft NSm Front and Rear Door Lock Screws 10 89 Inside Door Handle Screw 1 5 13 Outside Door Handle Bolts 4 35 Rear Door Exterior Garnish Molding Screws 1 5 13 Window Reg...

Page 58: ...DOORS 9P 3 DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS POWER DOOR LOCKS...

Page 59: ...9P 4IDOORS DAEWOO V 121 BL4 POWER WINDOWS FRONT AND REAR...

Page 60: ...ified value 11 14 v Go toStep 9 Go toStep 8 8 Repair the open circuit between fuse EF28 and ter minal 2 ORN of the door lock relay connecotor Is the repair complete System OK 9 Use an ohmmeter to chec...

Page 61: ...wire and touch it to terminal C WHT of the disconnected cen tral lock switch connector Do the doors lock and unlock when terminals C and A are alternately grounded Go toStep 16 Go toStep 17 16 1 Make...

Page 62: ...er to check the continuity between ground and terminal 4 BLK of the driver s side door power window switch connector Is the continuity equal to the specified value 0 W Go toStep 6 Go toStep 5 5 Repair...

Page 63: ...ween the terminal 2 of the window switch and the driver s side door power win dow switch Is the repair complete System OK 14 1 At the inoperative window switch use an ohm meter to check the continuity...

Page 64: ...9L Glass and Mirrors 3 Remove the glass run Installation Procedure 1 Install the glass run 2 Install the front door glass Refer to Section 9L Glass and Mirrors 3 Install the outside rearview mirror Re...

Page 65: ...each other may corrode rapidly Make sure to use the correct fasten ers to prevent premature corrosion 2 Install the exterior garnish molding with the screws Tighten Tighten the rear door exterior gar...

Page 66: ...d Mirrors 2 Remove the front door secondary weatherstrip Installation Procedure 1 Install the front door secondary weatherstrip 2 Install the outside rearview mirror Refer to Section 9L Glass and Mirr...

Page 67: ...ect contact with each other may corrode rapidly Make sure to use the correct fasten ers to prevent premature corrosion 2 Install the exterior garnish molding with the screws Tighten Tighten the rear d...

Page 68: ...body pillar This floating cage plate al lows 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 engages the s...

Page 69: ...cage plate to the desired position Notice It is important to use a flat end rotary file in order not to damage the tapped floating cage plate The striker screws and the tapped floating cage plate are...

Page 70: ...DOORS 9P 15 DAEWOO V 121 BL4 4 Disconnect the outside door handle and the lock rods 5 Remove the screws and the front door lock 6 Disconnect the electrical connector...

Page 71: ...end rotary file in order not to damage the tapped floating cage plate The striker screws and the tapped floating cage plate are important attaching parts that could affect the performance of vital com...

Page 72: ...the door seal trim Refer to Door Seal Trim in this section 3 Disconnect the inside door handle and the lock rods 4 Disconnect the outside door handle and the lock rods 5 Remove the screw and the guid...

Page 73: ...rosion 1 Install the rear door lock with the screws Tighten Tighten the rear door lock screws to 10 NSm 89 lbin 2 Connect the electrical connector 3 Install the guide rail with the screw 4 Connect the...

Page 74: ...sert the inside door handle into the slots in the door 3 Slide the door handle rearward Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fast...

Page 75: ...Disconnect the outside door handle and the lock rods 3 Remove the bolts and the door handle Installation Procedure 1 Connect the outside door handle and the lock rods Notice Dissimilar metals in dire...

Page 76: ...ip and the lock cylinder Installation Procedure 1 Install the lock cylinder with the retaining clip 2 Connect the outside door handle lock rod 3 Install the door seal trim Refer to Door Seal Trim in t...

Page 77: ...ther may corrode rapidly Make sure to use the correct fasten ers to prevent premature corrosion 1 Install the window regulator with the nuts Tighten Tighten the window regulator nuts to 8 NSm 71 lb in...

Page 78: ...and Mirrors 3 Disconnect the electrical connector 4 Remove the nuts and the window regulator Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make...

Page 79: ...or glass Refer to Section 9L Glass and Mirrors 3 Remove the nuts and the window regulator Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sur...

Page 80: ...ow regulator handle and the plas tic ring Installation Procedure 1 Install the plastic ring 2 Install the C clip onto the window regulator han dle 3 Install the window regulator handle FRONT DOOR ASSE...

Page 81: ...fasten ers to prevent premature corrosion 2 With the aid of another technician lightly secure the front door with the door hinge bolts 3 Adjust the door for proper fit Tighten Tighten the door hinge b...

Page 82: ...dure 1 Disconnect the negative battery cable 2 Remove the bolt and the door hold open link from the body 3 With the aid of another technician remove the door hinge bolts and the rear door 4 Disconnect...

Page 83: ...on 2 With the aid of another technician lightly secure the rear door with the door hinge bolts 3 Adjust the door for proper fit Tighten Tighten the door hinge bolts to 25 NSm 18 lb ft 4 Install the re...

Page 84: ...de rapidly Make sure to use the correct fasten ers to prevent premature corrosion 1 With the aid of another technician install the hinge to the door and the body with the bolts Tighten Tighten the doo...

Page 85: ...to door bolts to 6 NSm 53 lb in 2 Reposition the door seal trim 3 Install the door trim panel Refer toSection 9G Inte rior Trim INSIDE CHANNEL MOLDING Removal Procedure 1 Remove the door trim panel Re...

Page 86: ...e 1 Lower the window completely 2 Lift the outside channel molding off the door Installation Procedure 1 Press the outside channel molding onto the door 2 Raise the window DOOR WEATHERSTRIP Removal Pr...

Page 87: ...prevent premature corrosion 2 Install the door hold open link to the body with the bolt Tighten Tighten the door hold open link to body bolt to 27 NSm 20 lb ft DOOR SEAL TRIM Removal Procedure 1 Remov...

Page 88: ...e to use the correct fasten ers to prevent premature corrosion 3 Install the door pull bracket with the screws Tighten Tighten the door pull bracket screws to 3 5 NSm 31 lb in 4 Install the door trim...

Page 89: ...to Section 9G Inte rior Trim REAR DOOR OPENING WEATHERSTRIP Removal Procedure 1 Remove the rear rocker panel and the lower B pil lar trim panel Refer to Section 9G Interior Trim 2 Remove the door ope...

Page 90: ...tained in each door lock assembly The door locks are activated by the actuator on the inside door handle or by the lock cylin der on the driver s side door only When the driver s side door is locked o...

Page 91: ...5 POWER SUNROOF 9Q 5 ROOF RACK WAGON 9Q 8 FORMED HEADLINER 9Q 9 SUN VISORS 9Q 12 PASSENGER ASSIST HANDLES 9Q 13 INTERIOR COURTESY LAMP POWER SUNROOF CONTROL SWITCH 9Q 14 GENERAL DESCRIPTION AND SYSTE...

Page 92: ...9Q 2IROOF DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS POWER SUNROOF SYSTEM...

Page 93: ...the repair complete System OK 6 1 Temporarily substitute a known good relay for the Ignition 2 relay 2 Turn the ignition ON 3 Attempt to operate the sunroof Does the sunroof operate Go to Step 7 Go t...

Page 94: ...to Step 16 15 Repair the jammed sunroof mechanism Is the repair complete System OK 16 1 Disconnect both of the one wire connectors at the sunroof motor 2 Connect a voltmeter between the one wire conn...

Page 95: ...dure 1 Disconnect the negative battery cable 2 Remove the headliner Refer to Formed Headliner in this section 3 Remove the drain hoses 4 Disconnect the electrical connectors 5 Remove the screws and th...

Page 96: ...frame from the housing 14 Remove the plastic trim 15 Remove the screws and the glass from the frame Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapid...

Page 97: ...shade stops 7 Install the drain nozzles 8 Install the rubber end caps 9 Install the housing to the roof of the vehicle with the bolts Tighten Tighten the sunroof housing bolts to 7 NSm 62 lb in 10 Ins...

Page 98: ...ner Refer to Formed Headliner in this section 2 Remove the nuts and the roof rack Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use...

Page 99: ...ction 6 Remove the interior courtesy lamp or the interior courtesy lamp power sunroof control switch if equipped Refer to Section 9B Lighting Systems or Interior Courtesy Lamp Power Sunroof Control Sw...

Page 100: ...lar trim panel 16 Remove the plastic retainers in the headliner along the rear window 17 Recline both front seats 18 Remove the headliner through a rear door or the hatchback door Installation Proced...

Page 101: ...ct with each other may corrode rapidly Make sure to use the correct fasten ers to prevent premature corrosion 8 Install the rear seat belt anchors and the bolts to the left and the right C pillars Tig...

Page 102: ...sor Interior Courtesy Lamp Power Sunroof ControlSwitch in this section 15 Install the sun visor and the sun visor supports Re fer to Sun Visors in this section 16 Install the ticket holder Refer to Se...

Page 103: ...1 Install the sun visor support to the headliner with the screw Tighten Tighten the sun visor support screw to 2 NSm 18 lbin 2 Install the sun visor to the headliner with the screw Tighten Tighten th...

Page 104: ...he assist handle to the headliner with the screws Tighten Tighten the passenger assist handle screws to 3 5 NSm 31 lb in 2 Install the plastic caps over the assist handle screws INTERIOR COURTESY LAMP...

Page 105: ...contact with each other may corrode rapidly Make sure to use the correct fasten ers to prevent premature corrosion 2 Install the lamp power sunroof control switch with the screws Tighten Tighten the...

Page 106: ...n until the sunroof slides If the sun shade is closed the sunroof will pull the sunshade open when the sunroof slides open To close the sunroof from a slid open position press the forward portion of t...

Page 107: ...OOD LATCH RELEASE CABLE 9R 6 RADIATOR GRILLE 9R 8 FENDER 9R 9 GENERAL DESCRIPTION AND SYSTEM OPERATION 9R 14 BODY FRONT END 9R 14 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application NSm Lb F...

Page 108: ...which are medium blue When replacing fasteners avoid substituting otherwise similar fasteners in the same location ANTICORROSION MATERIALS In order to provide rust resistance anticorrosion materials h...

Page 109: ...milar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasten ers to prevent premature corrosion 2 Install the two piece grille and the cowl vent grille screws...

Page 110: ...th hinges 4 With the aid of another technician remove the hood from the hinges Installation Procedure 1 With the aid of another technician position the hood in the location marked during removal Notic...

Page 111: ...corrosion 1 Install the hinge with the bolts Tighten Tighten the hinge bolts to 27 NSm 20 lb ft 2 Install the hood Refer to Hood in this section HOOD PROP ROD Removal Procedure 1 Support the hood in...

Page 112: ...n Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasten ers to prevent premature corrosion 1 Connect the hood release cable to th...

Page 113: ...he cable and the grommet from inside the vehicle Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasten ers to preven...

Page 114: ...ghten Tighten the hood latch bolts to 8 NSm 71 lb in 5 Install the cable to the hood latch release assembly 6 Install the hood latch release assembly with the bolts Tighten Tighten the hood latch bolt...

Page 115: ...r grille with the nuts Tighten Tighten the radiator grille nuts to 4 NSm 35 lb in FENDER Removal Procedure 1 Raise and suitably support the vehicle 2 Remove the front wheel Refer toSection 2E Tires an...

Page 116: ...ove the bolt at the base of the fender 7 Open the front door 8 Remove the bolt at the base of the A pillar 9 Open the hood 10 Remove the headlamp Refer to Section 9B Light ing Systems 11 Remove the bo...

Page 117: ...ems 2 Install the fender Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasten ers to prevent premature corrosion 3 Install the bolts along...

Page 118: ...er bolt to 8 NSm 71 lb in 6 Install the bolt between the bumper fascia and the fender Tighten Tighten the fender bolt on the front of the fascia to 4 NSm 35 lb in 7 Install the fender to the front bum...

Page 119: ...nal lamp Refer to Section 9B Lighting Systems 9 Install the front wheel well splash shield with the screws and the bolts Tighten Tighten the splash shield bolts to 1 5 NSm 13 lb in 10 Install the fron...

Page 120: ...BL4 GENERAL DESCRIPTION AND SYSTEM OPERATION BODY FRONT END This vehicle has a unitized body with a frame assembly supporting the engine and the transaxle The fender pan els and the radiator support a...

Page 121: ...HBACK 9S 7 WEATHERSTRIP 9S 9 HATCHBACK DOOR 9S 9 GAS SUPPORT ASSEMBLIES HATCHBACK 9S 10 LUGGAGE COMPARTMENT LOCK STRIKER HATCHBACK 9S 11 REAR SPOILER HATCHBACK 9S 11 TAILGATE WAGON 9S 12 GAS SUPPORT A...

Page 122: ...tion Lb In Lb Ft NSm Luggage Compartment Lock Screws 6 53 Luggage Compartment Lock Striker Bolts 8 71 Rear Deck Lid Bolts 10 89 Rear Spoiler Nuts 4 35 Remote Cable Handle Screws 8 71 Tailgate Hinge Bo...

Page 123: ...Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasten ers to prevent premature corrosion 1 Install the fuel filler door with the screws Ti...

Page 124: ...e the bolts and the rear deck lid Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasten ers to prevent premature cor...

Page 125: ...rear deck lid hinge arm 3 Connect the electrical connector 4 Connect the negative battery cable REAR DECK LID SPRINGS NOTCHBACK Removal Procedure 1 Raise and support the deck lid in the open position...

Page 126: ...ecure the lock cylinder 3 Disconnect the lock rod 4 Remove the luggage compartment lock cylinder Installation Procedure 1 Install the luggage compartment lock cylinder 2 Connect the lock rod Notice Di...

Page 127: ...lease cable Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasten ers to prevent premature corrosion 2 Install the lock striker with the bo...

Page 128: ...ar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasten ers to prevent premature corrosion 2 Install the luggage compartment lock with the screws Tighten Ti...

Page 129: ...t S If there are no leaks present the weatherstrip does not need to be held in place No further repair is required S If leaks are present continue with the remainder of the installation procedure 4 Re...

Page 130: ...es Hatch back in this section 3 Connect the hatchback door electrical connectors washer hose and grommets 4 Close the hatchback door GAS SUPPORT ASSEMBLIES HATCHBACK Removal Procedure 1 Open and suita...

Page 131: ...3 Remove the screws that secure the lock striker Installation Procedure 1 Install the lock striker with the screws Tighten Tighten the hatchback door lock striker screws to 8 NSm 71 lb in 2 Install t...

Page 132: ...ort assemblies from the tail gate Refer to Gas Support Assemblies Hatch back in this section 4 With the aid of another technician remove the bolts and the tailgate from the hinges Installation Procedu...

Page 133: ...uitably support the tailgate 2 Remove the bolts and the gas support assembly from the body 3 Unscrew and remove the gas support assembly from the tailgate Installation Procedure 1 Install the gas supp...

Page 134: ...KER WAGON Removal Procedure 1 Open the tailgate 2 Remove the luggage compartment rear trim panel Refer to Section 9G Interior Trim 3 Remove the bolts that secure the lock striker Installation Procedur...

Page 135: ...9G Interior Trim 3 Remove the lock striker Refer to Luggage Compartment Lock Striker Notchback or Lug gage Compartment Lock Striker Hatchback in this section 4 Remove the driver s seat and the rear s...

Page 136: ...ower B pillar seat belt anchor with the bolt Tighten Tighten the lower B pillar seat belt bolt to 35 NSm 26 lb ft 7 Install the driver s seat and the rear seat Refer to Section 9H Seats 8 Install the...

Page 137: ...on the floor carpet on the left side of the vehicle 8 Remove the screws and the fuel filler door remote handle 9 Disconnect the cable from the handle 10 Remove the cable Installation Procedure 1 Feed...

Page 138: ...lar seat belt anchor with the bolt Tighten Tighten the lower B pillar seat belt anchor bolt to 35 NSm 26 lb ft 6 Install the front seat and the rear seat Refer to Section 9H Seats 7 Connect the cable...

Page 139: ...opening of the rear deck lid and hold it in the open position HATCHBACK DOOR The hatchback door consists of the rear hatch glass within a steel frame The steel frame is made of an inner and out er pan...

Page 140: ...NT BUMPER FASCIA 9O 2 FRONT BUMPER ENERGY ABSORBER 9O 6 FRONT BUMPER IMPACT BAR 9O 6 REAR BUMPER FASCIA 9O 8 REAR BUMPER ENERGY ABSORBER 9O 11 REAR BUMPER IMPACT BAR 9O 12 GENERAL DESCRIPTION AND SYST...

Page 141: ...Remove the front wheels Refer to Section 2E Tires and Wheels 3 Remove the bolts and the screws and reposition the front portion of the splash shields 4 Remove the fog lamps if equipped Refer to Sec ti...

Page 142: ...BUMPERS AND FASCIAS 9O 3 DAEWOO V 121 BL4 8 Remove the front fascia screws behind the fascia 9 Remove lower fascia screws 10 Remove the upper fascia screws 11 Remove the front bumper fascia...

Page 143: ...the front bumper fascia Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasten ers to prevent premature corrosion 2 Install the upper fasci...

Page 144: ...ten the front wheel well fascia bolts to 1 5 NSm 13 lb in 7 Install the headlamps Refer to Section 9B Lighting Systems 8 Remove the fog lamps if equipped Refer to Sec tion 9B Lighting Systems 9 Reposi...

Page 145: ...er Installation Procedure 1 Install the energy absorber 2 Install the front bumper fascia Refer to Front Bumper Fascia in this section FRONT BUMPER IMPACT BAR Removal Procedure 1 Remove the front bump...

Page 146: ...to use the correct fasten ers to prevent premature corrosion 2 Install the front impact bar bolts Tighten Tighten the front impact bar bolts to 22 NSm 16 lb ft 3 Install the front bumper impact bar nu...

Page 147: ...milar Removal Procedure 1 Remove the bolts and the rear wheel mud guards 2 Remove the bolts and the screws and the rear wheel well splash shields 3 Remove the fascia bolts at the top of the rear wheel...

Page 148: ...n the luggage compart ment 9 Remove the fascia Installation Procedure 1 Install the fascia Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct f...

Page 149: ...tment rear quarter trim panel 4 Install the lower fascia screws 5 Install the upper fascia screws 6 Install the taillamps Refer to Section 9B Lighting Systems 7 Install the rear wheel well fascia bolt...

Page 150: ...mud guards with the bolts Tighten Tighten the rear wheel mud guard bolts to 1 5 NSm 13 lb in REAR BUMPER ENERGY ABSORBER Notchback Shown Hatchback and Wagon Similar Removal Procedure 1 Remove the rear...

Page 151: ...olts 5 Remove the bolts securing the impact bar 6 Remove the impact bar from the vehicle 7 Remove the nuts and the impact bar brackets from the impact bar 8 Remove the screws and the rear fascia brack...

Page 152: ...rear impact bar bolts to 35 NSm 26 lb ft 5 Install the luggage compartment floor carpet to its original position 6 Install the rear impact bar to the vehicle with the bolts 7 Install the rear bumper...

Page 153: ...absorbing the energy of a col lision these bumper systems restore themselves to their original position Both the front and the rear bumpers fea ture an internal foam energy absorber and a polymer fas...

Page 154: ...930 62U Khaki Beige l l DAE62U F3186 28495 56933 74U Spinel Red Pearl l l l DAE74U F3185 74842 56937 83L Granada Black l DAE83L F1648 95089 53380 92U Poly Silver l l DAE92U F3130 36652 56939 93U Olive...

Page 155: ...23U F3538 190458 56927 24U Regatta Blue Pearl l DAE24U F3132 190079 56928 28U Royal Blue l DAE28U F3188 190461 56929 42U Deep Bluish Green l l l DAE42U F3017 48187 56930 43U Light Evergreen l DAE43U F...

Page 156: ...lephone Numbers Akzo Customer Assistance 800 618 1010 Dupont Customer Assistance 800 338 7668 PPG Color Library Codes Formulas 440 572 6100 Technical Assistance 440 572 6111 Sherwin Williams Customer...

Page 157: ...ed rear hatch lock rod which is 5 mm shorter than the original rod A supply of updated lock rods has been shipped to your location and are available for customer complaints concerns All applicable Sto...

Page 158: ...4 retaining screws and the three 3 trim panel clips 3 Verify the operation of the latch rod by first setting the alarm system then opening the rear hatch by slowly rotating the key in the cylinder Pa...

Page 159: ...AKE SYSTEM TESTING 4A 5 BRAKE HOSE INSPECTION 4A 5 WARNING LAMP OPERATION 4A 5 BRAKE LAMP WARNING CIRCUIT DIAGNOSIS 4A 6 MAINTENANCE AND REPAIR 4A 10 ON VEHICLE SERVICE 4A 10 MANUAL BLEEDING THE BRAKE...

Page 160: ...41 0 0004 Master Cylinder Bore Diameter Nomi nal Bore Diameter Maxi mum 23 81 23 86 0 937 0 937 Caliper Minimum Piston Diam eter Front Minimum Piston Diam eter Rear 57 00 35 00 2 244 1 377 Wheel Cyli...

Page 161: ...Rear Brake Pipe A 5 2nd Front Brake Pipe 6 RH Front Brake Hose 7 2nd Rear Brake Pipe B 8 ABS Modulator 9 Bracket 10 Front Brake Pipe 11 LH Front Brake Hose 12 Connector 13 1st Rear Brake Pipe A 14 1s...

Page 162: ...lip 4 2nd Rear Brake Pipe 5 2nd Front Brake Pipe 6 RH Front Brake Hose 7 2nd Rear Brake Pipe 8 Front Brake Pipe 9 LH Front Brake Hose 10 Connector 11 1st Rear Brake Pipe A 12 1st Front Brake Pipe 13 1...

Page 163: ...t abnormal S Check for a binding pedal linkage and for an incor rect pushrod length If both of these parts are in satisfactory condition disassemble the master cyl inder and check for an elongated or...

Page 164: ...l switch is stuck closed 9 If the brake warning lamp is still on after discon necting the parking brake switch there is a short to ground in the wire to the parking brake switch 12 If the other checks...

Page 165: ...Go toStep 9 Go toStep 8 8 Replace the brake fluid level switch Is the repair complete System OK 9 1 Connect the brake fluid level switch 2 Disconnect the parking brake switch Is the lamp on Go toStep...

Page 166: ...fuse Is the repair complete System OK 22 Inspect the brake warning lamp bulb Is the bulb OK Go toStep 24 Go toStep 23 23 Replace the bulb Is the repair complete System OK 24 1 Disconnect the instrume...

Page 167: ...m OK 32 1 Disconnect the brake fluid level switch 2 Turn the ignition ON 3 Jumper the brake fluid level switch connector terminals Is the lamp on Go toStep 8 Go toStep 33 33 1 Turn the ignition OFF 2...

Page 168: ...in the bore then it must be bled before any wheel cylinder or caliper is bled 2 Fill the master cylinder reservoir with brake fluid Keep the master cylinder at least one half full of fluid during the...

Page 169: ...it 15 seconds be fore proceeding to the next step 9 Repeat the sequence including the 15 second wait until all the air is removed from the master cylinder bore Notice Care must be taken to prevent bra...

Page 170: ...crew to purge the air from the cylinder 14 Slowly release the brake pedal Wait 15 seconds before proceeding with the next step Important Rapid pumping of the brake pedal pushes the master cylinder sec...

Page 171: ...kPa 20 to 25 psi 6 Connect the line to the adapter Open the line valve 7 Raise and suitably support the vehicle Important The bleeding sequence is as follows right rear left front left rear and right...

Page 172: ...disc brake hose from the caliper Installation Procedure 1 Install the rear disc brake hose to the caliper Tighten Tighten the rear disc brake hose to caliper bolt to 32 NSm 24 lb ft 2 Install the rea...

Page 173: ...ehicle 2 Disconnect the brake line from the brake hose sup port bracket on the wheel housing on each side of the vehicle 3 Remove the retainer 4 Disconnect the brake hose from the C bracket on the ste...

Page 174: ...ose to caliper bolt to 40 NSm 30 lb ft 2 Slide the brake hose on the steering knuckle shaft C bracket 3 Connect the brake line to the brake hose on the wheel housing bracket on each side of the vehicl...

Page 175: ...bracket Installation Procedure 1 Insert the stoplamp switch into the brake pedal bracket and rotate the switch to lock it 2 Connect the electrical connector to the stoplamp switch 3 Press the brake p...

Page 176: ...ke pedal shaft and remove the nut and the washer from the shaft 5 Remove the pedal shaft and the brake pedal Installation Procedure 1 Coat the pedal shaft with grease 2 Place the brake pedal and the r...

Page 177: ...d to boil and the rubber components to deteriorate Thoroughly cleanthemaster cylinder reservoir capbefore removing it Do not let any dirt or foreignmaterial fall into thefluidreservoir There is a flui...

Page 178: ...on non ABS braking systems These valves limit the out let pressure to the rear brakes after a predetermined mas ter cylinder pressure has been reached On ABS braking systems the hydraulic modulator mo...

Page 179: ...WOO V 121 BL4 Important If the pressure exceeds 10 000 kPa 1 450 psi the pressure reading on the rear gauge will not be ac curate 5 Remove the gauges from the tested brake circuit and repeat the test...

Page 180: ...icles with the non ABS braking system dis connect the brake lines from the proportioning valves 4 For vehicles with the manual transaxle disconnect the clip to the clutch hose connection to the master...

Page 181: ...cylinder body 3 For vehicles with the non ABS braking system connect the brake lines to the proportioning valves Tighten Tighten the brake lines to 16 NSm 12 lb ft 4 For vehicles with the manual trans...

Page 182: ...the reser voir cap 2 For vehicles with the manual transaxle disconnect the clip to the clutch hose connection to the master cylinder and move the clip out of the way 3 Remove the clutch hose from the...

Page 183: ...dy 3 For vehicles with the manual transaxle connect the clip to the clutch hose connection to the master cyl inder 4 Add brake fluid 5 Raise and suitably support the vehicle 6 Bleed the braking system...

Page 184: ...usted in pairs to the correct control range they must be replaced in pairs 1 Install the proportioning valves to the cylinder body Tighten Tighten the proportioning valves to 22 NSm 16 lb ft 2 Connect...

Page 185: ...ore Notice When removing the retaining ring avoid damag ing the piston or the cylinder wall Important A welding rod or its equivalent can be used in a compensating port to keep the piston depressed 4...

Page 186: ...ent replace the master cylinder body 3 Lubricate the master cylinder bore the non ABS master cylinder is shown with clean brake fluid 4 Carefully insert the secondary piston assembly bore until the se...

Page 187: ...ton 10 Install the brake fluid reservoir to the master cylin der Refer to Brake Fluid Reservoir in this section 11 Install the master cylinder assembly Refer to the Master Cylinder Assembly in this se...

Page 188: ...ase assembly S Do not use lubricated shop air on brake parts as this may damage rubber components S If any hydraulic component is removed or discon nected it may be necessary to bleed all or part of t...

Page 189: ...ASSEMBLY 4C 3 GENERAL DESCRIPTION AND SYSTEM OPERATION 4C 7 POWER BOOSTER 4C 7 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application NSm Lb Ft Lb In Booster to Dash Panel Nuts Right Hand Drive...

Page 190: ...on nut connection If the hose does not remove easily or is deteriorated pry off and discard the hose 3 Spread the clip on the vacuum hose connection to the brake booster and move the clip clear of the...

Page 191: ...the hydraulic modulator for vehicles equipped with ABS 3 Remove the shaft and the rubber O ring 4 Remove the clip on the vacuum hose connection on the booster 5 Disconnect the brake stoplamp switch fr...

Page 192: ...121 BL4 8 Remove the booster mounting nuts from the studs protruding from the dash panel and remove the booster 9 Remove the rubber boot 10 Holding the hex nut twist off the pushrod clevis 11 Remove t...

Page 193: ...per fit 2 Install the hex nut and the pushrod clevis on the booster shaft Tighten Tighten the booster hex nut and the pushrod clevis to 18 NSm 13 lb ft 3 Measure the distance from the booster to the c...

Page 194: ...Connect the brake line fittings to the hydraulic mod ulator if applicable Tighten Tighten the brake line fittings to 16 NSm 12 lb ft 9 Install the new vacuum hose to the booster Refer to Vacuum Hose...

Page 195: ...ied vacuum is present on one side of the diaphragm and air at atmospheric pressure is admitted to the other side Power assist is provided when there is unequal pressure on opposite sides of the diaphr...

Page 196: ...kle Screws 5 44 DIAGNOSIS LINING INSPECTION 1 Raise and suitably support the vehicle 2 Remove the front wheels Refer toSection 2E Tires and Wheels 3 Visually check the linings for minimum thickness an...

Page 197: ...between the rotor and the hub and that contact surfaces are smooth and free from burrs 1 Position the transaxle in NEUTRAL 2 Remove the rotor Refer to Rotor in this section 3 Fasten the brake rotor t...

Page 198: ...y support the vehicle 2 To preserve wheel balance mark the position of the front wheel relative to the wheel hub Remove the front wheel Refer to Section 2E Tires and Wheels 3 Remove the lower caliper...

Page 199: ...is pulled downward to reinstall the lowermounting bolt Tighten Tighten the caliper mounting bolt to 22 32 NSm 16 24 lb ft 4 Align the marks that were made when removing the front wheel and install th...

Page 200: ...n 5 Remove the caliper mounting bolts 6 Remove the caliper Installation Procedure 1 Install the caliper 2 Install the caliper mounting bolts Tighten Tighten the caliper mounting bolts to 22 32 NSm 16...

Page 201: ...r out of the brake system Refer toSec tion 4A Hydraulic BrakesorSec tion 4F Antilock Brake System 8 Recheck the fluid level in the master cylinder 9 Repeatedly press the brake pedal to bring the pads...

Page 202: ...detent screw Tighten Tighten the rotor detent screw to 4 NSm 35 lb in 2 Apply a few drops of thread locking compound to the bolts and install the caliper bracket Tighten Tighten the caliper bracket t...

Page 203: ...1 BL4 Installation Procedure 1 Install the splash shield 2 Secure the splash shield to the steering knuckle with the screws Tighten Tighten the splash shield screws to 5 NSm 44 lb in 3 Install the rot...

Page 204: ...ing to remove the piston with compressed air The piston will pop out of its bore with enough force to damage a hand or fingers Important When removing the caliper piston with com pressed air insert a...

Page 205: ...stall the caliper bleeder valve Important Do not use a hone or any other procedure to remove material from the caliper bore or piston 4 Lubricate a new piston inner seal with brake fluid 5 Install the...

Page 206: ...action on the rotor This clamping action forces the linings against the rotor creating friction to stop the ve hicle S Replace all components included in the repair kits used to service the caliper S...

Page 207: ...N VEHICLE SERVICE 4E 3 SHOE AND LINING 4E 3 CALIPER 4E 4 ROTOR 4E 6 SPLASH SHIELD BACKPLATE AND PARKING BRAKE LEVER 4E 7 UNIT REPAIR 4E 15 CALIPER OVERHAUL 4E 15 GENERAL DESCRIPTION AND SYSTEM OPERATI...

Page 208: ...than 0 10 mm 0 004 inches can cause pedal pulsations and or front end vibration during braking Thickness can be measured with a commercially available micrometer Light scoring of the rotor surfaces is...

Page 209: ...port the vehicle 2 To preserve wheel balance mark the position of the rear wheels relative to the wheel hubs and remove the wheels Refer toSection 2E Tires and Wheels 3 Remove the lower caliper mounti...

Page 210: ...d and install the lower bolt Tighten Tighten the lower caliper mounting bolt to 31 NSm 23 lb ft 5 Align the match marks that were made before re moval and install the rear wheels Refer toSection 2E Ti...

Page 211: ...mination 5 Remove the caliper mounting bolts and the caliper Installation Procedure 1 Install the caliper with the mounting bolts Tighten Tighten the caliper mounting bolts to 31 NSm 23 lbft 2 Connect...

Page 212: ...dly press the brake pedal to bring the pads into contact with the rotor Do not move the vehicle until a firm pedal is obtained ROTOR Removal Procedure 1 Raise and suitably support the vehicle 2 To pre...

Page 213: ...ghten Tighten the caliper bracket mounting bolts to 56 NSm 41 lb ft 4 Install the caliper Refer to Caliper in this section 5 Align the match marks that were made before re moval and install the rear w...

Page 214: ...spindle shaft castle nut 5 Remove the wheel hub assembly from the spindle shaft 6 Remove the bolts that secure the splash shield backplate parking brake shoe assembly to the steering knuckle 7 Remove...

Page 215: ...the screw that secures the parking brake shoe hold down spring assembly to the backplate 9 Remove the parking brake shoe sliding it away from the actuation mechanism 10 Remove the splash shield 11 Re...

Page 216: ...the pushrod 13 Using a 3 5 mm 0 14 inch drill remove the pop rivets holding the dust cover assembly and the ad juster pawl to the backplate 14 Remove and discard the dust cover and the dust cover reta...

Page 217: ...nhaled for prolonged periods of time 1 Clean the backing plate ensuring the actuation cavity is free from grease and any other contamina tion 2 Inspect the shoe assembly position The shoe should fit c...

Page 218: ...al bore of the cavity is covered with grease 9 Secure the splash shield and the backplate to the steering knuckle with the bolts and secure the parking brake shoe hold down spring assembly with the sc...

Page 219: ...tappet Ensure the pushrod is set correctly in the lever socket by hold ing the lever into the backing plate while inserting the pushrod and the tappet 13 Clean excess grease using a clean rag Importan...

Page 220: ...t Tighten Tighten the wheel hub assembly to spindle shaft castle nut to 25 NSm 18 lb ft plus 1 NSm 9 lb in 16 Install the shaft dust cover 17 Install the parking brake cable to the parking brake lever...

Page 221: ...caliper inlet port do not place fingers in front of the piston The piston will pop out of its bore with enough force to cause serious injury 3 Apply unlubricated compressed air to the caliper inlet p...

Page 222: ...to remove material from the piston or caliper bore 1 Clean all parts with denatured alcohol or brake fluid Dry the parts with unlubricated compressed air and blow out all passages in the caliper and t...

Page 223: ...ton is seated in the bore 10 Inspect the brake shoe linings for minimum thick ness Refer to Lining Inspection in this section If necessary install new shoes 11 Inspect the guide pins and boots If the...

Page 224: ...riction between the rotor and the brake shoes S When servicing a caliper replace all parts included in the caliper repair kit S During caliper overhaul lubricate the piston and the inner seal with cle...

Page 225: ...CHECK 4F 20 DTC A014 ABS ENABLE RELAY CONTACT CIRCUIT OPEN 4F 23 DTC A015 ABS ENABLE RELAY CIRCUIT SHORTED TO BATTERY OR ALWAYS CLOSED 4F 29 DTC A016 ABS ENABLE RELAY COIL CIRCUIT OPEN 4F 31 DTC A017...

Page 226: ...D TO BATTERY 4F 160 DTC A082 CALIBRATION MALFUNCTION 4F 162 DTC A086 EBCM TURNED ON THE RED BRAKE WARNING LAMP 4F 163 DTC A087 RED BRAKE WARNING LAMP CIRCUIT OPEN OR SHORT TO BATTERY 4F 164 DTC A091 O...

Page 227: ...SORS AND RINGS 4F 209 ABS ENABLE RELAY 4F 209 BRAKE FLUID LEVEL SWITCH 4F 209 WIRING HARNESS 4F 209 INDICATORS 4F 209 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application NSm Lb Ft Lb In ABS...

Page 228: ...ft Rear Wheel Speed Sensor 10 Connector C902 11 Body Wiring Harness 12 I P Fuse Block 13 ABS Relay 14 EBCM 15 EBCM Connector J1 16 EBCM Connector J2 17 Connector C207 18 Lamp Driver Module 19 Connecto...

Page 229: ...ANTILOCK BRAKE SYSTEM 4F 5 DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS ABS CIRCUIT 1 OF 4...

Page 230: ...4F 6IANTILOCK BRAKE SYSTEM DAEWOO V 121 BL4 ABS CIRCUIT 2 OF 4...

Page 231: ...ANTILOCK BRAKE SYSTEM 4F 7 DAEWOO V 121 BL4 ABS CIRCUIT 3 OF 4...

Page 232: ...4F 8IANTILOCK BRAKE SYSTEM DAEWOO V 121 BL4 ABS CIRCUIT 4 OF 4...

Page 233: ...heel Speed High A6 Not Used A7 ABSWARN LT GRN BLK ABS Warning Indicator A8 Not Used A9 IGN BRN Ignition A10 LFABSOL DK GRN Left Front ABS Isolation Solenoid A11 ENRELAY PNK ABS Enable Relay A12 Not Us...

Page 234: ...4F 10IANTILOCK BRAKE SYSTEM DAEWOO V 121 BL4 Pin Circuit Color Signal Name B11 Not Used B12 BATT ORN Battery...

Page 235: ...nal Name Color Circuit C1 LFMOTLO PNK Left Front Motor Low C2 LFMOTHI BLK Left Front Motor HIgh C3 RFMOTHI DK GRN Right Front Motor HIgh C4 RFMOTLO ORN Right Front Motor Low C5 RAMOTLO BLK Rear Axle M...

Page 236: ...CIFICATIONS 4G 1 FASTENER TIGHTENING SPECIFICATIONS 4G 1 MAINTENANCE AND REPAIR 4G 2 ON VEHICLE SERVICE 4G 2 PARKING BRAKE ADJUSTMENT 4G 2 PARKING BRAKE LEVER 4G 3 PARKING BRAKE CABLE 4G 5 PARKING BRA...

Page 237: ...ality This can be shown by discoloration from heat or stress 8 Adjust the shoe assembly to 167 6 to 167 8 mm 6 60 to 6 61 inches by turning the adjuster nut clockwise to increase the diameter Measure...

Page 238: ...efer toSection 9G Interior Trim 3 Measure the thread length from the end of the pull rod to the adjustment nut 4 Remove the split pin which holds the eye bolt pull rod to the parking brake lever assem...

Page 239: ...ached to the parking brake lever assembly by a small screw and remove the switch Installation Procedure Notice If the parking brake lever is bent or damaged re place the entire parking brake lever ass...

Page 240: ...oper ating pawl fastening the pull rod with a split pin 4 Check the parking brake adjustment referring to the original removal adjustment nut measurement tak en in the removal procedure Refer to Park...

Page 241: ...wheels Refer toSection 2E Tires and Wheels 6 Unfasten the parking brake cable from the lever at the rear of the backing plate 7 Remove the clip that holds the cable into the pro truding hole on the s...

Page 242: ...the fuel tank strap passenger side 10 Suitably support the fuel tank 11 Remove the fuel tank retaining strap nut on the driver s side and remove the parking brake cable Pull the cable through the loop...

Page 243: ...assem bly 4 Install the nut securing the parking brake cable to a bracket on both the driver and passenger sides of the vehicle Tighten Tighten the parking brake cable to underbody side bracket nuts t...

Page 244: ...Lower the vehicle 11 Attach the parking brake cable ends to the equaliz er 12 Attach the eye bolt pull rod to the parking brake lever assembly and fasten the split pin 13 Install the parking brake ge...

Page 245: ...e parking brake lever boot Refer toSection 9G Interior Trim 2 Slip the parking brake handle off the parking brake lever Installation Procedure 1 Push the parking brake handle as far as it will go on t...

Page 246: ...ning light should glow and go off when the the ignition switch returns to RUN Whenever the parking brake is applied and the ignition switch is ON the BRAKE warning light should glow When the brake is...

Page 247: ...ON VEHICLE SERVICE 5C0 7 CLUTCH PEDAL 5C0 7 CLUTCH PEDAL POSITION SWITCH 5C0 9 CLUTCH DISC AND RELATED COMPONENTS 5C0 10 CLUTCH PEDAL ADJUSTMENT HYDRAULIC 5C0 15 CLUTCH RELEASE POINT ADJUSTMENT HYDRAU...

Page 248: ...ub binding on the input shaft splines Repair or replace the clutch disc hub Check for a warped or bent clutch disc Replace the warped or bent clutch disc Slipping Checks Action Check for the driver im...

Page 249: ...h Clutch Fully Engaged Checks Action Check for the driver improperly operating the vehicle Correct the driver s operation of the vehicle as necessary Check for a binding release bearing Clean and re l...

Page 250: ...Hose 6 Bolt 7 Bolt 8 Bolt 9 Spring Washer 10 Release Cylinder Bracket 11 Release Cylinder 12 Air Bleeder 13 Bolt 14 Copper Washer 15 Bolt 16 O ring 17 Input Shaft Seal 18 Bearing Guide Sleeve 19 Rele...

Page 251: ...n Rod Bolt 9 Nut 10 Washer 11 Clutch Pedal Bushing 12 Clutch Pedal 13 Clutch Pedal Buffer 14 Nut 15 Bolt 16 Return Spring 17 Clutch Pedal Bushing 18 Pedal Mounting Shaft 19 Clutch Pedal Pad 20 Locking...

Page 252: ...5C0 6ICLUTCH DAEWOO V 121 BL4 1 Flywheel 2 Clutch Disc 3 Pressure Plate 4 Release Bearing...

Page 253: ...Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the return spring from the mount brace 3 Remove the nut the washer and the pedal mount ing shaft 4 Remove the locking washer and...

Page 254: ...d bolt with multi purpose grease 3 Install the piston rod bolt and the locking washer 4 Coat the pedal mounting shaft with multi purpose grease 5 Install the pedal mounting shaft the washer and the nu...

Page 255: ...nt Procedure After the clutch pedal position switch is installed adjust it in the following manner 1 Confirm that the engine starts when the clutch ped al is fully pressed down 2 If the engine does no...

Page 256: ...t front wheel Refer to Section 2E Tires and Wheels 4 Remove the engine under covers Refer to Section 9N Frame and Underbody 5 Remove the transaxle from the vehicle Refer to Section 5B Five Speed Manua...

Page 257: ...5C0 11 DAEWOO V 121 BL4 9 Pull the clutch release shaft upward out of the transaxle 10 Remove the fork and the release bearing from the release bearing guide sleeve 11 Remove the release lever shaft b...

Page 258: ...UTCH DAEWOO V 121 BL4 12 Remove the bolts and the release bearing guide sleeve 13 Remove the input shaft seal from the release bear ing guide sleeve 14 Remove the O ring from the groove in the trans a...

Page 259: ...O ring into the groove in the case 2 Install the input shaft seal into the release bearing guide sleeve Use input shaft seal installer J 36547 with a hammer 3 Install the release bearing guide sleeve...

Page 260: ...ing bores with multi purpose grease 6 Coat the release bearing bore with multi purpose grease 7 Install the release bearing with the clutch fork onto the release bearing guide sleeve 8 Install the rel...

Page 261: ...ten the pressure plate to flywheel bolts to 15 NSm 11 lb ft 13 Remove the clutch arbor J 42474 14 Install the transaxle into the vehicle Refer to Sec tion 5B Five Speed Manual Transaxle 15 Install the...

Page 262: ...5 inch Tighten the locknut after adjustment 3 Measure the clutch pedal travel Press the clutch pedal all the way to the floor Measure from the starting position to the ending position 4 Adjust the clu...

Page 263: ...red when the pipes were disconnected for repairs The clutch brake fluid in the clutch brake reservoir must be maintained at theMIN level or higher during air bleeding 1 Attach a vinyl hose to the blee...

Page 264: ...onnected to the master cylin der 6 Remove the locking washer and the piston rod bolt from the clutch pedal and piston rod clevis 7 Remove the locknuts on the master cylinder brack et 8 Remove the mast...

Page 265: ...l the master cylinder to the mounting bolts and install the locknuts Tighten Tighten the clutch master cylinder locknuts to 22 NSm 18 lb ft 2 Connect the pipe to the master cylinder 3 Connect the rese...

Page 266: ...Adjust the clutch pedal Refer to Clutch Pedal Ad justment in this section 8 Fill the reservoir with clutch brake fluid up to the MAX level 9 Connect the negative battery cable CLUTCH RELEASE CYLINDER...

Page 267: ...ot to stain the boot 4 Bleed the air Refer to Air Bleeding in this section 5 Adjust the clutch pedal Refer to Clutch Pedal Ad justment Hydraulic in this section 6 Fill the reservoir with clutch brake...

Page 268: ...shrod assembly and the piston as sembly 6 Inspect the pushrod for wear Repair the pushrod if necessary Assembly Procedure 1 Apply clean fluid to the piston assembly cup and insert the piston assembly...

Page 269: ...e clutch release cylinder assembly from the vehicle Refer to Clutch Master Cylinder As sembl in this section 2 Remove the bolts and brackets 3 Remove the boot and the pushrod 4 Compress the piston wit...

Page 270: ...to the piston and insert the as sembly into the cylinder body 3 Compress the piston with a driver then install the snap ring with snap ring pliers 4 Install the pushrod and the boot 5 Install the bra...

Page 271: ...lide lengthwise along the splines of the in put 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...

Page 272: ...SECTION 2 POSITION OF CONNECTORS AND GROUNDS...

Page 273: ...2 2WPOSITION OF CONNECTORS AND GROUNDS 1 CONNECTOR GROUND AND SPLICE PACK INFORMATION 1 WIRING HARNESS GROUND SPLICE PACK LOCATION...

Page 274: ...y Rear Upper Trunk Room Left Wheel House C402 4 White Body Trunk Tailgate H B S W Upper Trunk Room Left C403 3 White Body Tailgate H B Upper Trunk Room Left C404 6 White Body Tailgate Station Wagon Up...

Page 275: ...2 4WPOSITION OF CONNECTORS AND GROUNDS 2 WIRING HARNESS CONNECTOR GROUND LOCATION 1 W H FRONT FRONT BUMPER...

Page 276: ...POSITION OF CONNECTORS AND GROUNDSW2 5 2 ENGINE CONTROL BATTERY S 2 0 DOHC ENGINE...

Page 277: ...2 6WPOSITION OF CONNECTORS AND GROUNDS 3 INSTRUMENT PANEL INSIDE...

Page 278: ...POSITION OF CONNECTORS AND GROUNDSW2 7 4 AIR BAG INSTRUMENT PANEL 5 BODY...

Page 279: ...2 8WPOSITION OF CONNECTORS AND GROUNDS 6 W H DOOR 1 Front Door 2 Rear Door...

Page 280: ...POSITION OF CONNECTORS AND GROUNDSW2 9 7 ABS WHEEL SPEED SENSOR 1 With Sun Roof 2 Without Sun Roof...

Page 281: ...2 10WPOSITION OF CONNECTORS AND GROUNDS 8 ABS MODULE WHEEL SPEED SENSOR...

Page 282: ...POSITION OF CONNECTORS AND GROUNDSW2 11 9 REAR 10 FUEL TANK TRUNK LID...

Page 283: ...2 12WPOSITION OF CONNECTORS AND GROUNDS 11 SPLICE PACK S201 BROWN S202 BLUE S203 BROWN S204 GRAY S205 RED S206 BLUE...

Page 284: ...POSITION OF CONNECTORS AND GROUNDSW2 13 S207 BLUE S208 WHITE S301 BLUE N B S301 BLUE H B S301 BLUE S W S302 BLACK...

Page 285: ...2 14WPOSITION OF CONNECTORS AND GROUNDS S303 BLACK N B H B S303 BLACK S W...

Page 286: ...SECTION 3 WIRING DIAGRAM FOR POWER SUPPLIES...

Page 287: ...3 2WWIRING DIAGRAM FOR POWER SUPPLIES 1 IGNITION SWITCH CIRCUIT...

Page 288: ...WIRING DIAGRAM FOR POWER SUPPLIESW3 3 2 30 Ter BAT POWER SUPPLY CIRCUIT PASSENGER ROOM FUSE BOX...

Page 289: ...3 4WWIRING DIAGRAM FOR POWER SUPPLIES 3 15A IGN 2 15C ACC POWER SUPPLY CIRCUIT PASSENGER ROOM FUSE BOX...

Page 290: ...WIRING DIAGRAM FOR POWER SUPPLIESW3 5 4 ENGINE ROOM FUSE RELAY CIRCUIT...

Page 291: ...3 6WWIRING DIAGRAM FOR POWER SUPPLIES...

Page 292: ...WIRING DIAGRAM FOR POWER SUPPLIESW3 7...

Page 293: ...SECTION 4 USAGE AND CAPACITY OF FUSES...

Page 294: ...rd S Ef 13 25A Not Used Spare Ef 14 30A Not Used 30 BAT Ef 15 30A Defroster Ef 16 15A DIS IGN 1 15 Ef 17 15A Injector IGN 1 15 Ef 18 Not Used Ef 19 15A Fuel pump Ill i ti 58 Ef 20 10A Illumination RH...

Page 295: ...L 15 IGN 1 ON F4 25A Wiper System 15 IGN 1 ON F5 10A Cluster ABS Chime Bell PRND Switch Brake F6 10A SDM Air Bag F7 10A Reverse Back Up Lamp Blade Type F8 10A Cruise Control 15C ACC Blade Type F9 15A...

Page 296: ...ks ABS Relay 12088595 3 BEHIND DRIVER LEG ROOM CONNECTOR HOLDER Part Name Part No Remarks Blinker Unit Turn Signal Relay 96312545 Wiper Relay 96250544 Blower Motor 4th Speed Relay 96190189 BTSI Key In...

Page 297: ...SECTION 5 ELECTRICAL WIRING DIAGRAMS...

Page 298: ...ne Control Engine Room Fuse Box C106 2 Pin Colorless Engine Room Fuse Box Body Engine Room Fuse Box C203 15 Pin White I P Body Left Driver Leg Room Connector Holder C205 20 Pin Colorless I P Body Righ...

Page 299: ...ELECTRICAL WIRING DIAGRAMSW5 3 c POSITION OF CONNECTORS AND GROUNDS S ENGINE ROOM FUSE BLOCK S LEFT A PILLAR INSIDE S 2 0 DOHC ENGINE d SPLICE PACK S202 BLUE...

Page 300: ...1 WIRE COLOR CHART 9A 1 POWER DISTRIBUTION SCHEMATIC 9A 2 FUSE BLOCK LOCATOR ENGINE 9A 4 FUSE BLOCK LOCATOR PASSENGER COMPARTMENT 9A 4 FUSE CHART 9A 5 REAR HARNESS ROUTING 9A 7 FRONT HARNESS ROUTING 9...

Page 301: ...9A 2IBODY WIRING SYSTEM DAEWOO V 121 BL4 POWER DISTRIBUTION SCHEMATIC...

Page 302: ...BODY WIRING SYSTEM 9A 3 DAEWOO V 121 BL4...

Page 303: ...9A 4IBODY WIRING SYSTEM DAEWOO V 121 BL4 FUSE BLOCK LOCATOR ENGINE FUSE BLOCK LOCATOR PASSENGER COMPARTMENT...

Page 304: ...P Solenoid VGIS So lenoid Generator Terminal F Electronic Ignition System Coil EF17 15A B Injector 1 Injector 2 Injec tor 3 Injector 4 EF19 15A B Fuel Pump EF20 10A B Parking Lamp RH Taillamp EF21 10A...

Page 305: ...ard Switch Turn Signal Digital Clock F4 25A EF6 Wiper Switch Intermittent Wiper Relay Wiper Motor Rear Wiper Motor Rear Wiper Motor Switch F5 10A EF6 ABS Warning Lamp Chime Module Transmission Range S...

Page 306: ...BODY WIRING SYSTEM 9A 7 DAEWOO V 121 BL4 REAR HARNESS ROUTING...

Page 307: ...9A 8IBODY WIRING SYSTEM DAEWOO V 121 BL4 FRONT HARNESS ROUTING...

Page 308: ...BODY WIRING SYSTEM 9A 9 DAEWOO V 121 BL4 FLOOR HARNESS ROUTING...

Page 309: ...9A 10IBODY WIRING SYSTEM DAEWOO V 121 BL4 INSTRUMENT HARNESS ROUTING...

Page 310: ...BODY WIRING SYSTEM 9A 11 DAEWOO V 121 BL4 DOOR HARNESS ROUTING...

Page 311: ...R CHIME 9B 11 HEADLAMPS 9B 12 FOG LAMPS 9B 18 REAR COMBINATION LAMPS 9B 19 INTERIOR COURTESY AND LUGGAGE COMPARTMENT LAMPS 9B 28 MAINTENANCE AND REPAIR 9B 31 ON VEHICLE SERVICE 9B 31 HEADLAMPS FRONT T...

Page 312: ...and Front Turn Signal Lamp Double 27 8W Rear Turn Signal Lamp Single 27 8W Side Marker Lamp 8W Taillamp and Stoplamp Double 27 8W FASTENER TIGHTENING SPECIFICATIONS Application NSm Lb Ft Lb In CHMSL M...

Page 313: ...LIGHTING SYSTEMS 9B 3 DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS HEADLAMPS ON REMINDER CHIME CIRCUIT...

Page 314: ...9B 4ILIGHTING SYSTEMS DAEWOO V 121 BL4 PARKING TAIL POSITION AND LICENSE LAMPS CIRCUIT...

Page 315: ...LIGHTING SYSTEMS 9B 5 DAEWOO V 121 BL4 TURN AND HAZARD LAMPS CIRCUIT...

Page 316: ...9B 6ILIGHTING SYSTEMS DAEWOO V 121 BL4 BRAKE AND BACKUP LAMPS CIRCUIT...

Page 317: ...LIGHTING SYSTEMS 9B 7 DAEWOO V 121 BL4 INTERIOR COURTESY LAMP AND LUGGAGE COMPARTMENT LAMP CIRCUIT...

Page 318: ...9B 8ILIGHTING SYSTEMS DAEWOO V 121 BL4 HEADLAMPS CIRCUIT...

Page 319: ...LIGHTING SYSTEMS 9B 9 DAEWOO V 121 BL4 DAYTIME RUNNING LAMPS CIRCUIT...

Page 320: ...9B 10ILIGHTING SYSTEMS DAEWOO V 121 BL4 FOG LAMPS CIRCUIT...

Page 321: ...dule connector Is the voltage equal to the specified value 11 14 v Go to Step 9 Go to Step 8 8 Repair the open circuit between fuse EF20 and ter minal 6 of the chime module Is the repair complete Syst...

Page 322: ...ied value 11 14 v Go to Step 4 Go to Step 9 4 1 Disconnect both headlamp connectors 2 Turn the headlamps ON 3 Select the low beams Is the voltage at each headlamp connector terminal 5 equal to the spe...

Page 323: ...to the specified value 11 14 v Go to Step 5 Go to Step 10 5 1 Turn the high beam headlamps ON 2 Check the voltage at headlamp terminal 4 Does the voltage available at the headlamp connec tor terminal...

Page 324: ...n ground and the headlamp connector terminal 6 Is the resistance equal to the specified value 0 W Go to Step 8 Go to Step 7 7 Repair the ground circuit Is the repair complete System OK 8 1 Replace the...

Page 325: ...Go to Step 21 Go to Step 20 20 Replace the headlamp switch Is the repair complete System OK 21 Repair the open circuit between terminal 3 of head lamp switch connector C2 and ground Is the repair com...

Page 326: ...etween fuse EF34 and ter minal A of the DRL module connector Is the repair complete System OK 9 With the DRL module still disconnected use an ohmmeter to check the resistance between ground and termin...

Page 327: ...B 17 DAEWOO V 121 BL4 Step No Yes Value s Action 16 Repair the open circuit between fuse F3 and termi nal F of the DRL module Is the repair complete System OK 17 Replace the DRL module Is the repair c...

Page 328: ...F20 Is the repair complete System OK 7 1 Disconnect the connectors at the front fog lamps 2 Use an ohmmeter to check the resistance be tween ground and the BLK wire at the fog lamps Does the ohmmeter...

Page 329: ...cate the specified value 11 14 v Go to Step 18 Go to Step 17 17 Repair the open circuit between the headlamp switch and the front fog lamp switch Is the repair complete System OK 18 1 With the front f...

Page 330: ...tem OK 9 1 Temporarily substitute the headlamp relay in place of the illumination relay 2 Turn the illumination lamps ON Do the taillamps illuminate Go to Step 10 Go to Step 11 10 1 Return the headlam...

Page 331: ...the open circuit between terminal 85 of the il lumination relay and terminal 6 of headlamp switch connector C2 Is the repair complete System OK 19 1 Disconnect headlamp switch connector C2 2 On the di...

Page 332: ...Go to Step 5 5 Repair the ground circuit Is the repair complete System OK 6 1 Disconnect the wiring connector from the bra kelamp switch 2 Press the brake pedal 3 Use an ohmmeter to check the continu...

Page 333: ...ically check the CHMSL bulb Is the lamp bulb defective Go to Step 4 Go to Step 5 4 Replace the CHMSL bulb Is the repair complete System OK 5 1 Disconnect the CHMSL connector 2 Use an ohmmeter to measu...

Page 334: ...ch 3 Turn the ignition ON 4 Put the transaxle in REVERSE 5 Use a voltmeter to check the reverse switch terminal 1 On automatic transaxle vehicles test terminal B of the neutral safety backup switch Is...

Page 335: ...air the power supply circuit to fuses Is the repair complete System OK 8 Repair the open ground wires Is the repair complete System OK 9 1 Turn the hazard lamps ON 2 Test blinker unit connector termin...

Page 336: ...d value for both tests 0 W Go to Step 20 Go to Step 19 19 Replace the hazard switch Is the repair complete System OK 20 1 With the hazard switch still removed for testing turn the hazard switch to the...

Page 337: ...the specified value 11 14 v Go to Step 6 Go to Step 9 6 1 Remove the hazard lamp switch 2 Turn the hazard lamps ON 3 Use an ohmmeter to check the resistance be tween terminals 7 and 8 Is the resistan...

Page 338: ...2 Replace the bulb Is the repair complete System OK 3 1 Reinstall the interior courtesy lamp bulb 2 Check fuse EF29 Is fuse EF29 blown Go to Step 4 Go to Step 5 4 1 Check for a short circuit and repa...

Page 339: ...5 4 1 Check for a short circuit and repair it if neces sary 2 Replace the fuse Is the repair complete System OK 5 Check fuse EF29 Is the voltage equal to the specified value 11 14 v Go to Step 7 Go to...

Page 340: ...BL4 Step No Yes Value s Action 12 Replace the luggage compartment lamp tailgate switch Is the repair complete System OK 13 Repair the ground circuit for the interior courtesy lamp Is the voltage equa...

Page 341: ...rsonal injury and damage to the vehicle The ignition must also be in LOCK unless otherwise noted TABLE OF CONTENTS SPECIFICATIONS 9C 1 FASTENER TIGHTENING SPECIFICATIONS 9C 1 SCHEMATIC AND ROUTING DIA...

Page 342: ...9C 2IHORNS DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS HORN WIRING SYSTEM...

Page 343: ...t the negative battery cable 2 Disconnect the electrical connector 3 Remove the bolt and the horn Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly...

Page 344: ...9C 4IHORNS DAEWOO V 121 BL4 2 Connect the electrical connector 3 Connect the negative battery cable...

Page 345: ...SCRIPTION AND SYSTEM OPERATION HORNS The horns are located under the hood They are attached near the radiator at the front of the vehicle The horns are actuated by pressing the steering wheel pad whic...

Page 346: ...8 STEREO CASSETTE AM FM RADIO 9F 8 FRONT DOOR SPEAKERS 9F 9 TWEETER SPEAKERS 9F 10 REAR SPEAKERS NOTCHBACK 9F 10 REAR SPEAKERS HATCHBACK 9F 11 MAST ANTENNA 9F 12 ROOF ANTENNA 9F 13 POWER ANTENNA MAST...

Page 347: ...9F 2IAUDIO SYSTEMS DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS AUDIO SYSTEM CIRCUIT...

Page 348: ...rminals 4 and 5 Does the battery voltage match the specified value at both terminals 11 14 v Go to Step 7 Go to Step 6 6 Repair the open circuit between the radio connector and the fuse Is the repair...

Page 349: ...OK Step Action Value s Yes No 1 Replace the radio Is the repair comlpete FM Radio Does Not Work AM and Cassette OK Step Action Value s Yes No 1 1 Unplug the antenna cable from the antenna 2 Connect t...

Page 350: ...eaker connector and the radio connector Is the repair complete System OK 6 Substitute a known good speaker for the speaker causing the distortion Is the distortion eliminated Go to Step 7 Go to Step 8...

Page 351: ...the repair complete System OK 5 Use a voltmeter to test for battery voltage at power antenna connector terminal 1 Does the battery voltage match the specified value 11 14 v Go to Step 7 Go to Step 6...

Page 352: ...O V 121 BL4 Step No Yes Value s Action 12 Repair the open circuit between radio terminal 12 and power antenna connector terminal 3 Is the repair complete System OK 13 Replace the audio system Is the r...

Page 353: ...onnect the negative battery cable 2 Remove the audio system trim plate screws and the audio system trim plate 3 Remove the audio system bolts and the audio sys tem 4 Disconnect the audio system electr...

Page 354: ...AKERS Removal Procedure 1 Disconnect the negative battery cable 2 Remove the front door trim panel Refer to section 9G Interior Trim 3 Remove the front door speaker screws and the front door speaker 4...

Page 355: ...ector 2 Install the tweeter speaker by snapping the tweeter speaker onto the front door eschutcheon 3 Connect the negative battery cable REAR SPEAKERS NOTCHBACK Removal Procedure 1 Disconnect the nega...

Page 356: ...negative battery cable REAR SPEAKERS HATCHBACK Removal Procedure 1 Disconnect the negative battery cable 2 Remove the rear speaker access cover 3 Remove the screws and the rear speaker 4 Disconnect th...

Page 357: ...r metals in direct contact with each other may corrode rapidly Make sure to use the correct fasten ers to prevent premature corrosion 1 Install the mast antenna base with the nut Tighten Tighten the m...

Page 358: ...t contact with each other may corrode rapidly Make sure to use the correct fasten ers to prevent premature corrosion 1 Install the roof antenna with the nut Tighten Tighten the roof antenna nut to 10...

Page 359: ...a cap nut to 7 NSm 62 lb in POWER ANTENNA MOTOR NOTCHBACK Removal Procedure 1 Disconnect the negative battery cable 2 Remove the luggage compartment rear quarter trim panel Refer toSection 9G Interior...

Page 360: ...otor nuts to 7 NSm 62 lb in 3 Install the antenna cap nut 4 Install the luggage compartment rear quarter trim panel Refer to Section 9G Interior Trim Tighten Tighten the antenna cap nut to 7 NSm 62 lb...

Page 361: ...S DAEWOO V 121 BL4 Installation Procedure 1 Install the CD changer with the nuts Tighten Tighten the CD changer nuts to 7 NSm 62 lb in 2 Connect the CD changer electrical connector 3 Connect the negat...

Page 362: ...kers mounted in the rear A coaxial two way rear speaker is offered as an option TWEETER SPEAKERS The tweeter speakers are mounted on the front door es chutcheon next to the dash panel MAST ANTENNA The...

Page 363: ...9U 2 CRUISE CONTROL SYSTEM AUTOMATIC TRANSAXLE 1 OF 2 9U 2 CRUISE CONTROL SYSTEM AUTOMATIC TRANSAXLE 2 OF 2 9U 3 CRUISE CONTROL SYSTEM MANUAL TRANSAXLE 1 OF 2 9U 4 CRUISE CONTROL SYSTEM MANUAL TRANSA...

Page 364: ...9U 2ICRUISE CONRTOL SYSTEM DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS CRUISE CONTROL SYSTEM AUTOMATIC TRANSAXLE 1 OF 2...

Page 365: ...CRUISE CONRTOL SYSTEM 9U 3 DAEWOO V 121 BL4 CRUISE CONTROL SYSTEM AUTOMATIC TRANSAXLE 2 OF 2...

Page 366: ...9U 4ICRUISE CONRTOL SYSTEM DAEWOO V 121 BL4 CRUISE CONTROL SYSTEM MANUAL TRANSAXLE 1 OF 2...

Page 367: ...CRUISE CONRTOL SYSTEM 9U 5 DAEWOO V 121 BL4 CRUISE CONTROL SYSTEM MANUAL TRANSAXLE 2 OF 2...

Page 368: ...erved to be faulty in Step 1 Is the repair complete System OK 3 1 Connect a scan tool to the data link connector DLC 2 Check for engine control diagnostic trouble codes DTCs Is a vehicle speed sensor...

Page 369: ...tep 16 16 Repair the open circuit between the actuator con nector terminal 8 and the instrument splice pack S202 Is the repair complete System OK 17 1 Turn the ignition ON 2 With the electrical connec...

Page 370: ...the voltage at the GRY wire at the cruise main switch Is the voltage equal to the specified value 11 14 v Go to Step 27 Go to Step 25 27 Replace the cruise control main switch Is the repair complete S...

Page 371: ...8 at the switch side of the 6 pin connector 3 Observe the ohmmeter when moving the lever switch to the SET position Does the ohmmeter indicate the specified value 0 W Go to Step 38 Go to Step 37 37 R...

Page 372: ...es The YEL wire between cruise control ac tuator connector terminal 10 and VSS con nector terminal A The PPL wire between cruise control ac tuator connector terminal 5 and VSS con nector terminal B Do...

Page 373: ...cedure 1 Carefully pull the knee bolster trim panel until it is loose from its retaining clips 2 Remove the knee bolster Refer to Section 9G In terior Trim 3 Remove the actuator bracket with the actua...

Page 374: ...able housing to expose one of the slots in the actuator and insert the tip of a flathead screw driver into one of the slots 6 Tilt the cable housing toward the screwdriver to re lease the cable housin...

Page 375: ...he cable ball into the actuator rod 2 Align the cable housing and push the cable housing onto the actuator until it is locked in place by the retainers 3 If a new actuator is being installed attach it...

Page 376: ...adjuster spring to expand to a length of more than 2 cm 3 4 inch or the adjuster rack will come out of the adjuster and will have to be re inserted To keep the adjuster in one piece during adjustment...

Page 377: ...th of more than 2 cm 3 4 inch or the adjuster rack will come out of the adjuster and will have to be re inserted To keep the adjuster in one piece during adjustment hold the cable when the adjuster bu...

Page 378: ...t of the actuator and rotate the cable so it can be removed from the slot in the actuator rod 6 Remove the cable ball from the actuator rod Installation Procedure 1 Insert the ball nipple of the cable...

Page 379: ...able bushing into the pedal assembly 6 Press the cable release button and adjust the cable to achieve a gap of 0 5 mm 0 02 inches between the bushing and the nipple of the ball MAIN SWITCH Removal Pro...

Page 380: ...or to the cruise con trol main switch 2 Push the cruise control main switch into the instru ment panel until it is locked in place by its retainers 3 Reinstall the radio taking care not to scratch the...

Page 381: ...h plate with cable attachment S End switches S Plastic housing with noise reduction cover S Damping unit for clutch plate slap The electronics of the cruise control system include the following items...

Page 382: ...otherwise full throttle is ap plied When the switch is released the current speed will be stored and used as the new target speed The ACCEL function cannot be used for acceleration above 155 km h 96...

Page 383: ...LEAST TWICE A YEAR 0B 12 EACH TIME THE OIL IS CHANGED 0B 13 AT LEAST ANNUALLY 0B 13 RECOMMENDED FLUIDS AND LUBRICANTS 0B 15 GENERAL DESCRIPTION AND SYSTEM OPERATION 0B 16 GENERAL REPAIR INSTRUCTIONS 0...

Page 384: ...t Ignition System Ignition Timing 8 BTDC Ignition Sequence 1 3 4 2 Spark Plug Gap 0 8 mm 0 031 in Spark Plug Maker Bosch Spark Plug Type FR8LDC4 Clutch Manual Transaxle Application 2 0L DOHC Type Sing...

Page 385: ...2 0L DOHC Booster Size Single 228 6 mm 9 in Master Cylinder Diameter 22 2 mm 0 87 in Booster Ratio 5 0 1 Front Brake Disc Type Ventilated Disc Size 356 mm 14 0 in Rear Brake Disc Disc Type Solid Disc...

Page 386: ...Toe In 2 Occupants 3 to 17 Camber 1 35 to 5 Oil Capacity 1 0L 1 1 qt Suspension Application 2 0L DOHC Front Type MacPherson Strut Rear Type Compound Link Fuel System Application 2 0L DOHC Fuel Delive...

Page 387: ...aximum 90 Amps at 12 2 volts VEHICLE DIMENSIONS AND WEIGHTS Vehicle Dimensions Manual and Automatic Application 2 0L DOHC Overall Length 4 Door Notchback 4 470 mm 176 0 in 4 Door Wagon 4 514 mm 177 7...

Page 388: ...Curb Weight Standard 1 222 kg 2 694 lb Optional 1 291 kg 2 846 lb Gross Vehicle Weight 1 860 kg 4 101 lb Automatic Curb Weight Standard 1 258 kg 2 773 lb Optional 1 327 kg 2 925 lb Gross Vehicle Weig...

Page 389: ...62 lb ft 72 107 NSm 53 79 lb ft M14 X 1 5 76 115 NSm 56 85 lb ft 94 140 NSm 69 103 lb ft 114 171 NSm 84 126 lb ft M14 X 2 0 72 107 NSm 53 79 lb ft 88 132 NSm 65 97 lb ft 107 160 NSm 79 118 lb ft M16 X...

Page 390: ...n a separate belt drives the power steering pump the air conditioning compressor and the generator inspect it for cracks fraying wear and proper tension Adjust or re place the belt as needed Engine Oi...

Page 391: ...he direct ignition system DIS module and at the spark plugs Replace the wires as needed Brake System Service Check the disc brake pads or the drum brake linings every 9 600 km 6 000 mi or 6 months Che...

Page 392: ...system I I I I I Camshaft belt Timimg belt Out of Cali fornia Replace every 72 000 miles 115 200 km belt California Inspect every 60 000 miles 96 000 km and 90 000 miles 144 000 km Replace every 102 0...

Page 393: ...I I I I I I I I I I I I I I I Power steering fluid lines I I I I I I I I Drive shaft boots I I I I I I I I I I I I I I I I I Seat belts buckles anchors I I I I I I I I I I I I I I I I I Lubricate lock...

Page 394: ...il level indicator and look at the oil lev el on it 5 Add oil if needed to keep the oil level above the MIN line and within the area labeled Operating Range Avoid overfilling the engine since this may...

Page 395: ...ttle cable joints the intermediate throttle shaft bearing the return spring at the throttle valve assembly and the ac celerator pedal sliding face with suitable grease Check the throttle cable for fre...

Page 396: ...nspect the coolant and freeze protection fluid If the fluid is dirty or rusty drain flush and refill the engine cooling system with new coolant Keep the coolant at the proper mixture to ensure proper...

Page 397: ...xle 1 8L 2 qt Manual Transaxle Fluid B0400075 SAE80 or eqi valent Extremely cold area SAE 75W Manual Transaxle Shift Linkage As needed Multipurpose type grease meeting requirements NLGI No 1 or 2 Key...

Page 398: ...important for efficient and reliable performance of the service repairs S Use genuine DAEWOO parts S Discard used cotter pins gaskets O rings oil seals lock washers and self locking nuts Prepare new o...

Page 399: ...Liquid Seal system that assures the long term durability The Daewoo ORVR system provides nozzle compatibility with conventional and stage II vapor recovery nozzle The Daewoo ORVR system has been desig...

Page 400: ...4 Integrated Fuel Vapor Storage Canister 5 OBD II Valve Solenoid OBD II Valve Solenoid 6 Air Filter 7 Fuel Tank Steel 8 Fuel Fill Vent Control Valve Liquid Vapor Dis criminator 9 Pressure Relief Valve...

Page 401: ...GENERAL INFORMATION 0B 19 DAEWOO V 121 BL4 Component Locator 1 Fuel Tank 2 Filler Tube 3 Canister 4 OBD II Valve 5 Fuel Filter 6 Purge Valve 7 Service port 8 Fuel Filler Cap 9 Air Filter...

Page 402: ...N DAEWOO V 121 BL4 VEHICLE IDENTIFICATION Passenger Car VIN Certification plate 1 Production Date 2 Gross Vehicle Weight Rating 3 Gross Axle Weight Rating Front 4 Gross Axle Weight Rating Rear 5 Vehic...

Page 403: ...plate is attached to the top of the driver s side of the instrument panel Certification Label The Certification Label is attached to the driver s side B pillar near door strike Engraved VIN Location...

Page 404: ...RMATION DAEWOO V 121 BL4 Engine Number Family II 2 0L DOHC Engine Engine Number Plate Location Family II 2 0L DOHC Engine The engine number is stamped on the cylinder block under the No 4 exhaust mani...

Page 405: ...ual Transaxle Identification Number Plate Location The manual transaxle identification number is attached to the top of the transaxle case near the engine Automatic Transaxle Identification Number Pla...

Page 406: ...tice To raise the vehicle place the lifting equipment only at the points indicated Failure to use these precise positions may result in permanent body deformation Many dealer service facilities and se...

Page 407: ...GENERAL INFORMATION 0B 25 DAEWOO V 121 BL4...

Page 408: ...0B 26IGENERAL INFORMATION DAEWOO V 121 BL4 Vehicle Lifting Points...

Page 409: ...k plug port 2 Insert the engine compression gauge into each spark plug port 3 Crank test each cylinder with four to five compres sion strokes using the starter motor 4 The lowest reading should not be...

Page 410: ...o to Step 9 Go to Step 10 9 Install a new oil pressure gauge Is the repair complete Go to Step 1 10 Inspect the engine oil Is the engine oil in the crankcase diluted or of the im proper viscosity Go t...

Page 411: ...ther it is engine oil automatic transmission fluid power steering fluid etc 2 Identify where the fluid is leaking from 1 After running the vehicle at normal operating temperature park the vehicle over...

Page 412: ...ing is causing excess seal wear KNOCK DIAGNOSIS Definition for Knock Engine knock refers to the various types of engine noise Heavy knock is usually very loud and the result of broken or excessively w...

Page 413: ...to Step 7 Step 8 7 Replace and or tension the belts to specifications as necessary Is the repair complete Go to Step 1 8 Inspect the exhaust system Is the system grounded Go to Step 9 Go to Step 10 9...

Page 414: ...nds Go to Step 2 System OK 2 Check the engine oil Is the proper viscosity oil used in the crankcase Go to Step 4 Go to Step 3 3 Install oil of the proper viscosity for the expected seasonal temperatur...

Page 415: ...r viscosity for the expected seasonal temperatures Is the repair complete Go to Step 1 10 Inspect the piston pin clearance Is the clearance more than the specified value 2 0L DOHC 0 014 mm 0 0005 in G...

Page 416: ...Step 6 6 Inspect the crankshaft pulley Is the crankshaft pulley loose Go toCrank shaft Replace ment Proce dure System OK Connecting Rod Bearing Noise Symptom Step Action Value s Yes No 1 Is a knock n...

Page 417: ...the piston pin and the bushing Is the piston pin or the bushing worn or loose Go toPistons and Rods Re placement Pro cedure Go to Step 3 3 Inspect the piston Is the piston broken or cracked Go toPist...

Page 418: ...the valve lifters dirty stuck or worn Go toCylinder Head and Valve Train Components Replacement Procedure Go to Step 5 5 Inspect the camshaft lobes Are the camshaft lobes damaged or improperly ma chi...

Page 419: ...be kept in order They should be installed in the same locations and with the same mating surfaces as when they were removed Battery cables should be disconnected before any major work is performed on...

Page 420: ...PPER END 1C 8 LOWER END 1C 10 MAINTENANCE AND REPAIR 1C 12 ON VEHICLE SERVICE 1C 12 VALVE COVER 1C 12 CYLINDER HEAD AND GASKET 1C 14 CAMSHAFTS 1C 24 TIMING BELT CHECK AND ADJUST 1C 27 TIMING BELT 1C 3...

Page 421: ...ton Rings Ring End Gap Top Compression 0 3 0 5 mm 0 011 0 019 in Ring End Gap Second Compression 0 3 0 5 mm 0 011 0 019 in Piston Pin Diameter 20 9970 20 9985 mm 0 82665 0 82671 in Pin Offset 0 8 mm 0...

Page 422: ...52 in Valve Diameter Intake 32 0 1 mm 1 2598 0 0039 in Exhaust 29 0 1 mm 1 1417 0 0039 in Valve Seat Width Intake 1 0 1 5 mm 0 039 0 059 in Exhaust 1 7 2 2 mm 0 066 0 086 in Valve Face Angle 44 40 Val...

Page 423: ...ing Bracket Bolts 25 18 Engine Block Lower Support Bracket Splash Shield Bolts 35 26 Engine Mount Bracket Retaining Bolts and Nuts 55 41 Engine Mount Bracket to Engine Mount Retaining Bolts 60 44 Engi...

Page 424: ...s 10 89 Oil Pump Retaining Bolts 10 89 Pulse Pick up Sensor Disc 13 115 Rear Timing Belt Cover Bolts 7 62 Safety Relief Valve Bolt 30 22 Spark Plug Cover Bolts 8 71 Spark Plugs 20 15 Support Bracket B...

Page 425: ...4 SPECIAL TOOLS SPECIAL TOOLS TABLE KM 653 Adapter KM 135 Adapter KM 805 Valve Guide Reamer J 36792 Crankshaft Rear Oil Seal Installer MKM 571 B Gauge J 28467 B Engine Assembly Lift Support KM 412 Eng...

Page 426: ...DAEWOO V 121 BL4 KM 635 Crankshaft Rear Oil Seal Installer KM 427 Piston Pin Service Set KM 340 0 Cutter Set Includes KM 340 7 Guide Drift KM 340 13 Cutters KM 340 26 Cutters KM 470 B Angular Torque G...

Page 427: ...1C 8IDOHC ENGINE MECHANICAL DAEWOO V 121 BL4 COMPONENT LOCATOR UPPER END...

Page 428: ...t 22 Bolt 23 Bearing Cap 24 EGR Adapter 25 EGR Adapter Gasket 26 Cylinder Head 27 Exhaust Manifold Gasket 28 Exhaust Manifold 29 Nut 30 Exhaust Manifold Heat Shield 31 Cylinder Head Gasket 32 Bolt 33...

Page 429: ...1C 10IDOHC ENGINE MECHANICAL DAEWOO V 121 BL4 LOWER END...

Page 430: ...31 Gasket 32 Bolt 33 Oil Pump Cover 34 Ring Gear 35 Gear 36 Plug 37 Washer 38 Washer 39 Bypass Valve Plug 40 Special Screw 41 Seal 42 Oil Filter 43 Bypass Valve 44 Pressure Relief Valve Plunger 45 Pre...

Page 431: ...er tube from the valve cover 3 Disconnect the camshaft position sensor 4 Disconnect all of the necessary vacuum lines 5 Remove the spark plug cover bolts 6 Remove the spark plug cover 7 Disconnect the...

Page 432: ...valve cover 4 Install the valve cover washers 5 Install the valve cover bolts Tighten Tighten the valve cover bolts to 8 NSm 71 lb in 6 Connect the camshaft position sensor 7 Connect the ignition wir...

Page 433: ...nal 5 Drain the engine coolant Refer to Section 1D En gine Cooling 6 Disconnect the intake air temperature sensor con nector 7 Disconnect the breather tube from the valve cover 8 Disconnect the air in...

Page 434: ...sh shield 20 Install the engine assembly lift support J 28467 B 21 Remove the right engine mount bracket and bolts 22 Disconnect the upper radiator hose at the thermo stat housing 23 Remove the serpen...

Page 435: ...emove the valve cover washers 35 Remove the valve cover and the valve cover gas ket Notice Take extreme care to prevent any scratches nicks or damage to the camshafts 36 While holding the intake camsh...

Page 436: ...3 Remove the timing belt idler pulleys 44 Remove the engine mount bolts 45 Remove the engine mount 46 Remove the rear timing belt cover bolts 47 Remove the rear timing belt cover 48 Remove the auxilia...

Page 437: ...at the cylinder head and the intake manifold 57 Remove the generator support bracket 58 Remove the intake manifold to generator strap bracket bolt and loosen the bolt on the generator 59 Move the str...

Page 438: ...gradually and in the sequence shown Tighten Tighten the cylinder head bolts to 25 NSm 18 lb ft and turn the bolts another 3 turns of 90 degrees using the angular torque gauge KM 470 B 5 Connect the th...

Page 439: ...e rear timing belt cover 17 Install the rear timing belt cover bolts Tighten Tighten the rear timing belt cover bolts to 6 NSm 53 lb in 18 Install the engine mount and retaining bolts Tighten Tighten...

Page 440: ...Using the angular torque gauge KM 470 B tighten the bolt another 60 degrees plus 15 degrees 28 While holding the exhaust camshaft firmly in place install the exhaust camshaft gear bolt Tighten Tighten...

Page 441: ...the breather tube to the valve cover 37 Align the timing marks on the camshaft gears to the notches on the valve cover using the intake gear mark for the intake gear and the exhaust gear mark for the...

Page 442: ...olts to 60 NSm 44 lb ft 46 Remove the engine assembly lift support J 28467 B 47 Install the serpentine accessory drive belt Refer to Section 6B Power Steering Pump 48 Connect the upper radiator hose t...

Page 443: ...erter oxygen sensor connec tor 64 Connect the PCM ECM ground terminal 65 Install the fuel pump fuse 66 Connect the negative battery ground cable 67 Refill the engine cooling system Refer to Section 1D...

Page 444: ...The camshaft must detach evenly from the bearing seats in the front guide bearing 19 Check the camshaft and bearing seats for wear and replace them if necessary Installation Procedure Notice Take ext...

Page 445: ...orque gauge KM 470 B tighten the bolt another 60 degrees plus 15 degrees 12 Install the exhaust camshaft gear 13 While holding the exhaust camshaft firmly in place install the exhaust camshaft gear bo...

Page 446: ...ube to the valve cover 23 Install the timing belt Refer to Timing Belt in this section TIMING BELT CHECK AND ADJUST Adjustment Procedure 1 Disconnect the negative battery cable 2 Disconnect the intake...

Page 447: ...ve the crankshaft pulley 12 Remove the right engine mount bracket Refer to Engine Mount in this section 13 Remove the front timing belt cover bolts 14 Remove the front timing belt cover 15 Rotate the...

Page 448: ...tensioner bolt To relieve the belt tension turn the hex key tab counterclockwise 19 Rotate the automatic tensioner hex key tab clock wise until the adjust arm pointer of the timing belt automatic tens...

Page 449: ...25 NSm 18 lb ft 24 Install the front timing belt cover 25 Install the front timing belt cover bolts Tighten Tighten the front timing belt cover bolts to 6 NSm 53 lb in 26 Install the crankshaft pulle...

Page 450: ...housing bolts to 8 NSm 71 lb in 34 Connect the air intake tube to the throttle body 35 Connect the breather tube to the valve cover 36 Connect the intake air temperature sensor connec tor 37 Connect t...

Page 451: ...res and Wheels 8 Remove the right front splash shield 9 Remove the serpentine accessory drive belt Refer toSection 6B Power Steering Pump 10 Remove the crankshaft pulley bolts 11 Remove the crankshaft...

Page 452: ...ce The camshaft gears must align with the notch on the valve cover or damage to the engine could result 16 Align the camshaft gears with the notch on the valve cover Important Use the intake gear mark...

Page 453: ...lign the timing mark on the crankshaft gear with the notch on the bottom of the rear timing belt cov er 2 Align the timing marks on the camshaft gears us ing the intake gear mark for the intake gear a...

Page 454: ...rankshaft two full turns clockwise using the crankshaft pulley bolt 7 Recheck the automatic tensioner pointer 8 Install the front timing belt cover 9 Install the front timing belt cover bolts Tighten...

Page 455: ...e air intake tube to the throttle body 19 Connect the breather tube to the valve cover 20 Connect the intake air temperature sensor connec tor 21 Connect the negative battery cable OIL PAN Removal Pro...

Page 456: ...Remove the oil pan retaining bolts 9 Remove the oil pan from the engine block Cleaning Procedure 1 Clean the oil pan sealing surface 2 Clean the engine block sealing surface 3 Clean the oil pan retain...

Page 457: ...an 2 Install the oil pan to the engine block 3 Install the oil pan retaining bolts Tighten Tighten the oil pan retaining bolts to 10 NSm 89 lb in 4 Install the oil pan flange to transaxle retaining bo...

Page 458: ...UMP Tools Required KM 498 B Pressure Gauge KM 135 Adapter Engine Oil Pressure Inspection Procedure 1 Remove the right front wheel well splash shield 2 Disconnect the oil pressure switch connector 3 In...

Page 459: ...ll splash shield 10 Check the oil level Add oil until it reaches the full mark Removal Procedure 1 Disconnect the negative battery cable 2 Remove the rear timing belt cover Refer to Rear Timing Belt C...

Page 460: ...ate the oil pump and gasket from the engine block and oil pan 9 Remove the oil pump Inspection Procedure 1 Clean the oil pump and the engine block gasket mating surface areas 2 Remove the safety relie...

Page 461: ...il pump parts with clean engine oil Install the oil pump parts 10 Apply Loctite 242 to the oil pump rear cover bolts and install the cover and bolts Tighten Tighten the oil pump rear cover bolts to 6...

Page 462: ...pport bracket bolts with Loctite 242 5 Install the oil pump pickup tube and the bolts Tighten Tighten the oil pump pick up tube and support brack et bolts to 10 NSm 89 lb in 6 Install the oil pan Refe...

Page 463: ...r Head and Gasket in this section 2 Remove the coolant temperature sensor 3 Remove the camshaft position sensor 4 Remove the exhaust manifold heat shield bolts 5 Remove the exhaust manifold heat shiel...

Page 464: ...oil and EGRmount ing bracket and ignition wires 19 Remove the intake manifold studs 20 Remove the spark plugs 21 Remove the camshaft bearing cap bolts gradually and in the sequence shown for each cams...

Page 465: ...s for installation 33 Remove the valves Maintain the original position of the valves for installation 34 Remove the valve stem seals Cylinder Head Inspection 1 Clean the sealing surfaces 2 Inspect the...

Page 466: ...rooves and the oil seal grooves for chips and wear 3 Inspect the valves for burns or cracks 4 Inspect the valve stem for burrs and scratches 5 Inspect the valve stem The valve stem must be straight 6...

Page 467: ...der to distribute the paste 3 Check the contact pattern on the valve head and in the cylinder head 4 Clean the valves the valve guides and the cylinder head Valve Grind 1 Ensure that there are no crat...

Page 468: ...itted in production 2 An oversize service code is on the valve guide and the valve stem end The following table gives the correct size reamer and production code for each service Size Reamer Productio...

Page 469: ...4 to 1 8 mm 0 055 to 0 070 inch 5 Inspect the assembly height of the intake valves and the exhaust valves If the dimension is exceed ed install new valves Inspect the assembly height of the intake val...

Page 470: ...with engine oil 13 Install the valve lash adjusters 14 Install the intake camshaft 15 Install the intake camshaft bearing caps in their original positions 16 Install the exhaust camshaft 17 Install th...

Page 471: ...6 Install the intake manifold retaining nuts and retain ing bolt in the sequence shown Tighten Tighten the intake manifold retaining nuts and retain ing bolt to 22 NSm 16 lb ft 27 Install the fuel rai...

Page 472: ...to 8 NSm 71 lb in 38 Install the cylinder head with the intake manifold and the exhaust manifold attached Refer to Cylin der Head and Gasket in this section CRANKSHAFT Tools Required KM 412 Engine Ove...

Page 473: ...elease the tension 12 Remove the timing belt idler pulley bolt and nut 13 Remove the timing belt idler pulleys 14 Remove the timing belt 15 Remove the engine mount retaining bolts 16 Remove the engine...

Page 474: ...hile holding the intake camshaft firmly in place remove the intake camshaft bolt 25 Remove the intake camshaft gear 26 While holding the exhaust camshaft firmly in place remove the exhaust camshaft bo...

Page 475: ...32 Remove the oil pan 33 Remove the oil pump pickup tube bolts 34 Remove the oil pump pickup tube 35 Remove the lower block support bracket splash shield bolts 36 Remove the splash shield 37 Remove t...

Page 476: ...nd the lower connecting rod bearings 44 Mark the order of the crankshaft bearing caps 45 Remove the crankshaft bearing cap bolts 46 Remove the crankshaft bearing caps and the lower crankshaft bearings...

Page 477: ...tion Important Grease the crankshaft journals and lubricate the crankshaft bearings slightly so that the plastic gauging thread does not tear when the crankshaft bearing caps are removed 8 Inspect all...

Page 478: ...Use the angular torque gauge KM 470 B to tighten the crankshaft bearings 45 degrees another 15 degrees Important Grease the connecting rod journals and lubri cate the connecting rod bearings slightly...

Page 479: ...anges Refer to Engine Specifications in this section 23 Install the connecting rod bearing caps to the con necting rods 24 Tighten the connecting rod bearing caps using new bolts Tighten Tighten the c...

Page 480: ...bolts to 35 NSm 26 lb ft 29 Install the oil pump pick up tube 30 Install the oil pump pick up tube bolts Tighten Tighten the oil pump pick up tube bolts to 10 NSm 89 lb in 31 Install the oil pan gask...

Page 481: ...ner bolts to 25 NSm 18 lb ft 41 Install the timing belt idler pulley 42 Install the timing belt idler pulley bolt and nut Tighten Tighten the timing belt idler pulley bolt to 25 N m 18 lb ft Tighten T...

Page 482: ...l the valve cover bolts Tighten Tighten the valve cover bolts to 8 NSm 71 lb in 53 Connect the ignition wires to the spark plugs 54 Install the spark plug cover 55 Install the spark plug cover bolts T...

Page 483: ...GAUGING PLASTIC Tools Required KM 470 B Angular Torque Gauge Inspection Procedure Crankshaft 1 Coat the crankshaft bearings with engine oil 2 Install the upper crankshaft bearings into the engine blo...

Page 484: ...axially between the crank shaft journals and the crankshaft bearings 10 Install the crankshaft bearing caps 11 Install the crankshaft bearing cap bolts Tighten Tighten the crankshaft bearing cap bolts...

Page 485: ...plastic gauging ductile plastic threads 5 Cut the plastic gauging threads to the length of the bearing width Lay them axially between the con necting rod journals and the connecting rod bear ings 6 In...

Page 486: ...n the amount of oil being pumped increases the pressure be comes high enough to overcome the force of the spring This opens the valve of the oil pressure regulator allowing the excess oil to flow thro...

Page 487: ...DIAGNOSIS 1D 3 THERMOSTAT TEST 1D 3 SURGE TANK CAP TEST 1D 3 COOLING SYSTEM DIAGNOSIS 1D 4 COMPONENT LOCATOR 1D 5 RADIATOR FAN 1D 5 COOLANT PUMP THERMOSTAT 2 0L DOHC 1D 6 MAINTENANCE AND REPAIR 1D 7...

Page 488: ...ER TIGHTENING SPECIFICATIONS Application NSm Lb Ft Lb In Coolant Pump Mounting Bolts 20 15 Engine Coolant Temperature Sensor 10 89 Fan Assembly Mounting Bolts 4 35 Fan Motor Nut 3 2 28 Fan Motor Retai...

Page 489: ...these temperatures replace the thermostat SURGE TANK CAP TEST Tools Required KM 471 Adapter The surge tank cap maintains proper pressure protects the system from high pressure by opening a pressure v...

Page 490: ...amaged cylinder head or the damaged engine block Loss of Coolant Checks Action Check for a leak in the radiator Replace the damaged radiator Check for a leak in the following locations S Surge tank S...

Page 491: ...1 Holder Transmission Fluid Pipe Automatic Trans mission Only 2 Upper Radiator Bumper 3 Radiator Bracket 4 Bolts 5 Radiator 6 Radiator Bumper 7 Spring Clamp 8 Upper Radiator Hose 9 Bolts 10 Auxiliary...

Page 492: ...1D 6IENGINE COOLING DAEWOO V 121 BL4 COOLANT PUMP THERMOSTAT 2 0L DOHC 1 O Ring Seal 2 Thermostat 3 Thermostat Housing 4 Bolt 5 Bolt 6 Coolant Pump 7 Ring Seal...

Page 493: ...irt from inside the surge tank Refer to Surge Tank in this section 6 Plug the drain cock 7 Add the clean water to the surge tank 8 Fill the tank slowly so that the upper reservoir hose remains above t...

Page 494: ...g 3 Disconnect the upper radiator hose from the ther mostat housing 4 Remove the mounting bolts that hold the thermo stat housing to the cylinder head 5 Remove the thermostat housing from the cylinder...

Page 495: ...seal with Lubriplate 3 Install a new O ring seal into the recess in the ther mostat housing 4 Install the thermostat housing to the cylinder head 5 Secure the thermostat housing to the cylinder head...

Page 496: ...aining bolt 4 Remove the timing belt tension roller 5 Remove the coolant pump mounting bolts 6 Remove the coolant pump from the engine block 7 Remove the ring seal from the coolant pump Inspection Cle...

Page 497: ...l the timing belt tension roller to the oil pump with the flange inserted into the recess of the oil pump 6 Install the timing belt tension roller bolt Do not tighten the bolt at this time 7 Install t...

Page 498: ...de to repair or reuse the damaged part A bent or damaged fan assembly must be replaced with a new fan assembly It is essential that fan assemblies remain in proper balance A fan assembly that is not i...

Page 499: ...e fan assembly mounting bolts to 4 NSm 35 lb in 7 Connect the cooling fan electrical connector 8 Connect the negative battery cable SURGE TANK Removal Procedure CAUTION To prevent personal injury do n...

Page 500: ...edure 1 Install the surge tank to the support mount 2 Secure the surge tank with the attaching bolt Tighten Tighten the surge tank attaching bolt to 4 NSm 35 lbin 3 Connect the return hose and the thr...

Page 501: ...hose from the radia tor 8 Remove the hose clamp from the surge tank hose at the radiator 9 Disconnect the surge tank hose from the radiator 10 Disconnect the transaxle fluid cooler pipes from the lowe...

Page 502: ...e radiator retainers in place 3 Install the right upper radiator retainer bracket 4 Install the right upper radiator retaining bolt Tighten Tighten the right upper radiator retaining bolt to 4 NSm 35...

Page 503: ...ction 15 Connect the negative battery cable ENGINE COOLANT TEMPERATURE SENSOR Removal Procedure 1 Disconnect the negative battery cable 2 Drain the coolant to a level below the engine cool ant tempera...

Page 504: ...engine coolant cools and con tracts The displaced engine coolant is then drawn back into the radiator and the engine This keeps the radiator filled with the coolant to the desired level at all times a...

Page 505: ...gh speed when the coolant tem perature reaches 97 C 207 F S The PCM ECM will change the cooling fans from high speed to low speed at 94 C 201 F and will turn the cooling fans off at 90 C 194 F A C ON...

Page 506: ...RMATION SENSOR DTCS SET 1F 33 ENGINE CRANKS BUT WILL NOT RUN 1F 38 NO MALFUNCTION INDICATOR LAMP 1F 45 MALFUNCTION INDICATOR LAMP ON STEADY 1F 48 FUEL SYSTEM DIAGNOSIS 1F 50 FUEL PUMP RELAY CIRCUIT CH...

Page 507: ...ARGE LEAK LOW TANK VACUUM 1F 222 DTC P0442 EVAPORATIVE EMISSION SYSTEM SMALL LEAK 1F 227 DTC P0443 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL CIRCUIT 1F 231 DTC P0446 EVAPORATIVE EMISSION SYSTEM VENT C...

Page 508: ...OWER SLUGGISHNESS OR SPONGINESS 1F 364 DETONATION SPARK KNOCK 1F 365 HESITATION SAG STUMBLE 1F 367 CUTS OUT MISSES 1F 368 POOR FUEL ECONOMY 1F 370 ROUGH UNSTABLE OR INCORRECT IDLE STALLING 1F 371 EXCE...

Page 509: ...415 SPECIFICATIONS ENGINE DATA DISPLAY TABLES Engine Data Display At idle Upper Radiator Closed Throttle Park or Neutral Closed loop Acc OFF Scan Tool Parameter Units Displayed Typical Data Value Eng...

Page 510: ...Fuel Trim 100 to 100 Varies EVAP Purge Solenoid 0 100 EVAP Vent Solenoid On Off IAC Base Position Counts Fuel Trim Cell Cell Number 18 12 at idle Varies with the air flow RPM P N and A C Calculated A...

Page 511: ...12 42 C 54 108 F Varies with underhood temperature when starting Engine Run Time Seconds Varies Since start up Fuel Level Sensor Volt 0 4 4 5 Fuel Gauge On Off On EVAP Purge Solenoid 0 100 EVAP Vent S...

Page 512: ...gle 0 up to 100 at wide open throttle Throttle Position Sensor Volts 0 200 0 900v up to 5 0 at wide open throttle EGR Actual Position 0 EGR Desired Position 0 EGR Feedback Volt EGR Closed Pintle Posit...

Page 513: ...en start ing Engine Coolant Temperature C F 85 115 C 185 239 F Varies with the coolant temperature Start Up Intake Air Temperature C F 12 42 C 54 108 F Varies with the underhood temperature when start...

Page 514: ...255 counts 0 increase with a misfire Total Misfire Current Count 0 255 counts 0 increase with a misfire Weak Cylinder Engine Speed RPM 100 rpm from the Desired RPM TP Angle 0 up to 100 at wide open th...

Page 515: ...ys while the vehicle is being driven by second technician Refer to Powertrain On Board Diagnostic OBD II System Check for additional information A C Clutch The A C Relay represents the commanded state...

Page 516: ...with the engine idling EVAP Purge The Evaporative EVAP Emission purge valve solenoid is a proportional signal used in order to control the EVAP canister purge function At 0 the valve is commanded full...

Page 517: ...between 100 mv lean ex haust and 900 mv rich exhaust when the system is operating in a Closed Loop Oxygen Sensor Bank 1 Sensor 2 The post converter Heated Oxygen Sensor HO2S 2 represents the exhaust o...

Page 518: ...Cover 8 71 Evaporative Emission Canister Purge Solenoid Bracket Bolt 5 44 Exhaust Gas Recirculation Valve Retaining Bolts 20 15 Fuel Cutoff Switch Mounting Bolts 3 27 Fuel Filter Mounting Bracket Asse...

Page 519: ...nol You may use fuel containing ethanol ethyl alcohol or grain alcohol providing that there is not more than 10 per cent ethyl alcohol by volume Methanol Do not use fuels containing methanol Methanol...

Page 520: ...ENGINE CONTROLS 1F 15 DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS PCM ECM WIRING DIAGRAM 1 OF 6 IPCM 6KD ISFI 6TD...

Page 521: ...1F 16IENGINE CONTROLS DAEWOO V 121 BL4 PCM ECM WIRING DIAGRAM 2 OF 6 IPCM 6KD ISFI 6TD...

Page 522: ...ENGINE CONTROLS 1F 17 DAEWOO V 121 BL4 PCM ECM WIRING DIAGRAM 3 OF 6 IPCM 6KD ISFI 6TD...

Page 523: ...1F 18IENGINE CONTROLS DAEWOO V 121 BL4 PCM ECM WIRING DIAGRAM 4 OF 6 IPCM 6KD ISFI 6TD...

Page 524: ...ENGINE CONTROLS 1F 19 DAEWOO V 121 BL4 PCM ECM WIRING DIAGRAM 5 OF 6 IPCM 6KD ISFI 6TD...

Page 525: ...1F 20IENGINE CONTROLS DAEWOO V 121 BL4 PCM ECM WIRING DIAGRAM 6 OF 6 IPCM 6KD ISFI 6TD...

Page 526: ...ENGINE CONTROLS 1F 21 DAEWOO V 121 BL4 CONNECTOR END VIEW...

Page 527: ...1F 22IENGINE CONTROLS DAEWOO V 121 BL4...

Page 528: ...ENGINE CONTROLS 1F 23 DAEWOO V 121 BL4...

Page 529: ...1F 24IENGINE CONTROLS DAEWOO V 121 BL4...

Page 530: ...ENGINE CONTROLS 1F 25 DAEWOO V 121 BL4...

Page 531: ...1F 26IENGINE CONTROLS DAEWOO V 121 BL4 COMPONENT LOCATOR...

Page 532: ...gnition Coil 27 Evaporative Emission EVAP Controlled Canister Purge Solenoid 28 Ignition 1 Relay 29 A C Compressor Relay 30 Variable Geometry Induction System VGIS Information Sensors 31 Manifold Abso...

Page 533: ...will indicate that the problem is in that circuit If there are no wiring or connector problems found and a DTC was stored for a circuit having a sensor except for DTC P0171 and DTC P0172 replace the...

Page 534: ...ating broken locks improperly formed or dam aged terminals poor terminal to wire connection and damaged harness Test Description Numbers below refer to the step number on the Diagnostic Chart 1 The Ma...

Page 535: ...for DTCs P0107 P0108 P0113 P0118 P0122 P0123 P0712 P1392 Are two or more of the following DTCs stored Go to Multiple PCM ECM In formation Sen sor DTCs Set Go to applica ble DTC table 7 Compare the PCM...

Page 536: ...nly when it is not commanded by the PCM 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 PCM ECM or...

Page 537: ...change to a 1 Go to Step 7 Go to Step 5 5 Command the output being checked with a scan tool while watching the corresponding position for each circuit Does the component or function operate when com m...

Page 538: ...d in the 5 volt reference circuit or an open in the 5 volt reference circuit between the PCM ECM and the splice will cause one or more of the following DTCs to be set P0107 P0112 P0117 P0122 P1107 P11...

Page 539: ...or signal cir cuit at the PCM ECM harness connector and ground Does the voltage measure near the specified value 0 v Go to Step 5 Go to Step 9 5 Measure the voltage between the Manifold Absolute Press...

Page 540: ...age in the EGR Pintle Position sensor circuit Is the repair complete Go to Step 21 17 Locate and repair short to voltage in TFT sensor cir cuit Is the repair complete Go to Step 21 18 Measure the volt...

Page 541: ...1F 36IENGINE CONTROLS DAEWOO V 121 BL4...

Page 542: ...r restrict nylon fuel lines to avoid damage that could cause a fuel leak resulting in possible fire or personal injury Important If engine cranks but will not start make sure fuel cut off switch has n...

Page 543: ...rtrain control module PCM engine control module ECM con nector terminal C6 Is the problem found Go toStep 18 Go toStep 33 17 Check for an open or short in the wire between the CKP connector terminal 2...

Page 544: ...oes the voltage fluctuate within the values speci fied 0 2 2 0 v Go toStep 28 Go toStep 29 28 While cranking the engine measure the voltage at the EI system ignition coil connector terminal A Does the...

Page 545: ...gine Is the fuel pressure within the value specified 283 324 kPa 41 47 psi Go toStep 2 Go toStep 40 40 1 Disconnect the vacuum line from the fuel pres sure regulator 2 Inspect the vacuum line for the...

Page 546: ...e specified Is the test light on 2 sec Go toStep 50 Go toStep 52 50 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...

Page 547: ...s Is the test light on at all of the fuel injectors Go toStep 64 Go toStep 67 64 1 Turn the ignition OFF 2 Connect a test light between the fuel injector harness connector terminal 2 and battery posi...

Page 548: ...r complete Go toStep 2 70 Replace the fuse or repair the wiring as needed Is the repair complete Go toStep 2 71 1 Inspect the engine fuse block fuse EF34 2 Check for an open in the fuel injector conne...

Page 549: ...fer to the step number s on the diag nostic table 1 The On Board Diagnostic OBD II System Check prompts the technician to complete some basic checks and store the freeze frame and failure re cords dat...

Page 550: ...d repaired Go to Step 22 Go to Step 5 4 Attempt to start the engine Does the engine start Go to Step 6 Go to Step 5 5 Check for a faulty powertrain control module PCM engine control module ECM ground...

Page 551: ...s necessary Is the repair necessary Go to Step 22 Go to Step 20 18 Check for a poor connection in the battery feed ter minal A4 or the ignition feed terminal F16 and repair as necessary Is the repair...

Page 552: ...g nostic table 1 The On Board Diagnostic OBD II System Check prompts the technician to complete some basic checks and store the freeze frame and failure re cords data on then scan tool if applicable T...

Page 553: ...engine control module ECM connec tors 3 Turn the ignition switch ON Is the MIL off Go to Step 7 Go to Step 5 5 Check the MIL control circuit for a short to ground and repair if necessary Is the repair...

Page 554: ...nlet is due to a faulty one way check valve in the fuel pump 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 fue...

Page 555: ...ed but not holding steady 284 325 kPa 41 47 psi System OK 10 With the fuel system under pressure inspect the fuel return outlet for leaking Is the problem found Go to Step 11 Go to Step 12 11 1 Replac...

Page 556: ...e values speci fied and holding steady 284 325 kPa 41 47 psi Go to Step 19 19 Inspect the fuel lines for leaks Is the problem found Go to Step 7 Go to Step 20 20 1 Remove the fuel pump assembly 2 With...

Page 557: ...nds after the ignition switch is turned ON Diagnostic Aids An intermittent problem may be caused by a poor connec tion rubbed through wire insulation or a broken wire in side the insulation Test Descr...

Page 558: ...d ground Is the test light on Go to Step 5 Go to Step 11 5 Check for an open or short to ground in the wire be tween the fuel pump relay connector terminal 87 and the fuel cutoff switch terminal 1 Is...

Page 559: ...pair the wire between the fuel pump relay connector terminal 30 and the battery 2 Install the fuel pump relay 3 Turn the ignition OFF for 10 seconds 4 Turn the ignition ON Does the fuel pump operate f...

Page 560: ...the wiring for proper connections pinches and cuts Are all checks complete Go to Appropri ate Symptom Table INTERMITTENTS The problem may or may not illuminate the Malfunction Indicator Lamp MIL or s...

Page 561: ...om ignition wires ignition sys tem components and the generator 4 Check for a short to ground in the MIL circuit or the DLC test terminal 5 Inspect the PCM ECM ground connections 6 Correct or repair t...

Page 562: ...o specifications using the Temperature Vs Resistance tables for diagnostic trouble codes DTCs P0118 and P0113 3 If the resistance is not the same replace the faulty sensor Is the repair complete Syste...

Page 563: ...out of specifications Is the repair complete System OK 15 Perform an injector balance test Is the problem found Go toStep 16 Go toStep 17 16 Replace any restricted or leaking fuel injectors as needed...

Page 564: ...mplete System OK 29 Repair the fuel system as needed Is the repair complete System OK 30 Replace the PCM ECM Is the repair complete System OK SURGES OR CHUGGLES Engine power varies under steady thrott...

Page 565: ...k for proper ignition voltage output using a spark tester 2 Inspect the spark plugs for cracks wear im proper gap burned electrodes or heavy de posits Is the problem found Go toStep 11 Go toStep 12 11...

Page 566: ...CONTROLS 1F 363 DAEWOO V 121 BL4 Step No Yes Value s Action 18 Replace the fuel filter Is the repair complete System OK 19 Replace the leaking or restricted fuel injectors Is the repair complete Syst...

Page 567: ...ir the fuel system as needed Is the repair complete System OK 7 Check for a restricted fuel filter or contaminated fuel Is the problem found Go toStep 8 Go toStep 9 8 Repair or replace any components...

Page 568: ...e s Yes No 1 Were the Important Preliminary Checks performed Go toStep 2 Go to Impor tant Preliminary Checks 2 1 Fill the fuel tank with a known good grade of gasoline that has the octane rating of th...

Page 569: ...k the fuel system pressure Is the problem found 41 47 psi 284 325 kPa Go toStep 11 Go toStep 12 11 Repair or replace the fuel system components as needed Is the repair complete System OK 12 1 Inspect...

Page 570: ...AP sensor response and accuracy 2 Inspect the fuel for water contamination 3 Check the Evaporative EVAP Emission canis ter purge system for proper operation Is the problem found Go toStep 5 Go toStep...

Page 571: ...all checks and needed repairs complete 12 16 v System OK CUTS OUT MISSES This Involves a steady pulsation or jerking that follows engine speed usually more pronounced as engine load increases The exha...

Page 572: ...sconnect all of the fuel injector harness con nectors at the fuel injectors 2 Connect an injector test light to the harness terminals of each fuel injector connector 3 Note the test light while cranki...

Page 573: ...d the section in the owner s manual about fuel economy Step Action Value s Yes No 1 Were the Important Preliminary Checks performed Go toStep 2 Go to Impor tant Preliminary Checks 2 1 Inspect the air...

Page 574: ...Replace the contaminated O2S sensor as needed Is the repair complete System OK 5 1 Check for a sticking throttle shaft or binding throttle linkage that may cause incorrect Throttle Position TP sensor...

Page 575: ...e circuit harness the connector or the connector termi nals as needed 2 If the harness the connectors and the termi nals are OK replace the powertrain control module PCM engine control module ECM Is t...

Page 576: ...alve opera tion 4 Inspect the PCM ECM ground connections Is the problem found Go toStep 25 Go toStep 26 25 Repair or replace any components as needed Is the repair complete System OK 26 1 Check the Ex...

Page 577: ...y within the value specified 115 150 counts Go toStep 6 Go toStep 4 4 Is the long term fuel trim memory below the value specified 115 counts Go to Diagnos tic Aids for DTC P0172 Go toStep 5 5 Is the l...

Page 578: ...peration Are all checks and needed repairs complete System OK DIESELING RUN ON An engine continues to run after the ignition switch is turned OFF Step Action Value s Yes No 1 Were the Important Prelim...

Page 579: ...air complete System OK 4 1 Check the fuel system operation 2 Check the fuel injectors by performing an injec tor diagnosis Is the problem found Go toStep 5 Go toStep 6 5 Repair or replace any fuel sys...

Page 580: ...cable 3 Drain the fuel tank 4 Disconnect the right rear parking brake cable from the retaining bracket attached to the right side fuel tank strap 5 Remove the fuel tank filler tube clamp at the fuel t...

Page 581: ...aining nuts to 13 NSm 115 lb ft 4 Connect the fuel outlet line and the fuel return line 5 Connect the wiring harness clips and the fuel line clips as needed 6 Connect the fuel pump harness connector 7...

Page 582: ...e fuel pump assembly 6 Disconnect the fuel outlet line 7 Disconnect the fuel tank return line 8 Turn the lock ring counterclockwise to clear the tank tabs 9 Remove the fuel pump assembly from the tank...

Page 583: ...fuel pressure Refer to Fuel System Pressure Relief in this section 2 Disconnect the negative battery cable 3 Remove the rear seat Refer to Section 9H Seats 4 Remove the fuel pump access cover 5 Disco...

Page 584: ...ressure Refer to Fuel System Pressure Relief in this section 2 Disconnect the inlet outlet fuel lines by moving the line connector lock forward and pulling the hose off of the fuel filter tube 3 Remov...

Page 585: ...essure regulator Refer to Fuel Pressure Regulator in this section 9 Disconnect the fuel return line at the fuel rail 10 Disconnect the fuel inlet line at the fuel rail 11 Remove the fuel rail retainin...

Page 586: ...ed on the old injector 1 Lubricate the new fuel injector O rings with engine oil Install the new O rings on the fuel injectors 2 Install the fuel injectors into the fuel rail sockets with the fuel inj...

Page 587: ...cable 17 Perform a leak check of the fuel rail and fuel injec tors FUEL PRESSURE REGULATOR Removal Procedure CAUTION The fuel system is under pressure To avoid fuel spillage and the risk of personal i...

Page 588: ...el pressure regulator with the engine off and the ignition ON ENGINE COOLANT TEMPERATURE SENSOR Removal Procedure 1 Relieve the coolant system pressure 2 Disconnect the negative battery cable 3 Discon...

Page 589: ...d position the TP sen sor on the throttle shaft Align the TP sensor with the bolt holes 2 Install the TP sensor retaining bolts Tighten Tighten the throttle position sensor retaining bolts to 18 lb in...

Page 590: ...nectors 8 Disconnect the coolant hoses from the throttle body 9 Remove the throttle body retaining nuts Notice Cover the opening of the intake manifold after re moving the throttle body assembly This...

Page 591: ...lve Refer to Idle Air Control Valve in this section 5 Install the throttle body assembly with a new gasket to the intake manifold 6 Install the throttle body retaining nuts Tighten Tighten the throttl...

Page 592: ...man ifold Installation Procedure Important A special anti seize compound is used on the O2S 1 threads This compound consists of a liquid graph ite and glass beads The graphite will burn away but the...

Page 593: ...O V 121 BL4 3 Remove the heated oxygen sensor HO2S 2 Installation Procedure 1 Install the HO2S 2 Tighten Tighten the heated oxygen sensor to 30 lb ft 41 NSm 2 Connect the electrical connector 3 Connec...

Page 594: ...m drive 4 Remove the IAC valve 5 Clean the IAC valve O ring seal area the pintle valve seat and the air passage with a suitable fuel system cleaner Do not use methyl ethyl ketone Installation Procedur...

Page 595: ...ve battery cable 6 Start the engine and check for the proper idle speed MANIFOLD ABSOLUTE PRESSURE SENSOR Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the negative battery ca...

Page 596: ...rom the MAP sensor Installation Procedure 1 Connect theMAP sensor harness to the MAP sen sor 2 Install the MAP sensor into the intake manifold 3 Connect the throttle cable to the throttle body and bra...

Page 597: ...EI system ignition coil adapter Installation Procedure 1 Clean the EI system ignition coil adapter mating sur face 2 Install a new EGR valve gasket 3 Install the EGR valve with the bolts Tighten Tight...

Page 598: ...r rotective cover 2 Disconnect the canister fuel vapor hoses 3 Remove the bolt that secures the canister flange to the vehicle 4 Slide canister out of the track holder 5 Remove the canister Installati...

Page 599: ...e mounting bracket to the intake manifold with the bracket bolt Tighten Tighten the evaporative emission canister purge sole noid bracket bolt to 44 lb in 5 NSm 3 Connect the vacuum hoses to the EVAP...

Page 600: ...sor retaining bolt to 89 lb in 10 NSm 3 Connect the CKP sensor connector to the fuel in jector channel cover 4 Install the accessory mounting bracket Tighten Tighten the accessory mounting bracket bol...

Page 601: ...nnect the sensor electrical connector 4 Remove the timing belt front cover Refer to Sec tion 1C DOHC Engine Mechanical 5 Remove the camshaft position sensor bolts 6 Remove the camshaft position sensor...

Page 602: ...gative battery cable POWERTRAIN CONTROL MODULE ENGINE CONTROL MODULE Removal Procedure 1 Disconnect the negative battery cable 2 Remove the right side kick panel Refer to Section 9G Interior Trim 3 Di...

Page 603: ...in this section ELECTRONIC IGNITION SYSTEM IGNITION COIL Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the electronic ignition EI system igni tion coil connector 3 Note the i...

Page 604: ...e the lower B pillar trim panel Refer to Sec tion 9G Interior Trim 4 Reposition the carpet 5 Remove the fuel cutoff switch mounting bolts 6 Disconnect the electrical connector at the fuel cutoff switc...

Page 605: ...panel Refer to Section 9G Interior Trim 6 Connect the negative battery cable Important The fuel cutoff switch may have to be reset to enable the vehicle to start KNOCK SENSOR Removal Procedure 1 Disco...

Page 606: ...llation Procedure 1 Install the KS Tighten Tighten the knock sensor bolt to 15 lb ft 20 NSm 2 Connect the electrical connector at the KS 3 Remove the intake manifold Refer toSection 1C DOHC Engine Mec...

Page 607: ...ition CMP sensor sends a CMP sen sor signal to the powertrain control module PCM engine control module ECM The PCM ECM uses this signal as a sync pulse to trigger the injectors in the proper se quence...

Page 608: ...ed loop operation In closed loop the PCM ECM calculates the air fuel ratio fuel injector ontime based on the signal from the oxygen sensor This allows the air fuel ratio to stay very close to 14 7 to...

Page 609: ...pply line and a ground line both provided by the powertrain control mod ule PCM engine control module ECM The PCM ECM calculates the throttle position by monitoring the voltage on this signal line The...

Page 610: ...A failure in the IAT sensor circuit sets a diagnostic trouble code P0112 or P0113 IDLE AIR CONTROL VALVE Notice Do not attempt to remove the protective cap to readjust the stop screw Misadjustment may...

Page 611: ...blems alert the driver through the Malfunction Indicator Lamp MIL and store diagnostic trouble code s which identify problem areas to aid the technician in making repairs There are no serviceable part...

Page 612: ...on may be in termittent Verify the complaint under the conditions de scribed by the customer before releasing the vehicle Re examine the complaint When the complaint cannot be successfully found or is...

Page 613: ...uling of the spark plugs and will turn on the MIL with a set DTC P0300 Poor Vehicle Maintenance The sensitivity of OBD II diagnostics will cause the MIL to turn on if the vehicle is not maintained pro...

Page 614: ...the ECT sensor is monitored for its ability to achieve a steady state temperature to enable closed loop fuel con trol Output Components Output components are diagnosed for proper response to control m...

Page 615: ...consider it a trip No trip will occur for that particular diag nostic until the vehicle is driven in such a way as to meet all the enable criteria Diagnostic Information The diagnostic charts and fun...

Page 616: ...on emissions related are not utilized on certain vehicle applications S Non Emissions related S Does not request illumination of any lamp S Stores a History DTC on the first trip with a fail S Does no...

Page 617: ...on This selection will display all DTCs that have failed during the present ignition cycle History This selection will display only DTCs that are stored in the PCM ECM s history memory It will not dis...

Page 618: ...erification the vehicle is ready to be released to the customer If the indicated status of the vehicle is Failed This Ignition after a repair verification then the repair is incomplete and further dia...

Page 619: ...s fire Using the information in the misfire counters identify which cylinders are misfiring If the counters indicate cylin ders numbers 1 and 4 misfired look for a circuit or compo nent common to both...

Page 620: ...SYSTEM OPERATION 1G 12 EXHAUST SYSTEM 1G 12 MUFFLER 1G 12 CATALYTIC CONVERTERS 1G 12 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application NSm Lb Ft Lb In Auxiliary Catalytic Converter to Exha...

Page 621: ...XHAUST DAEWOO V 121 BL4 COMPONENT LOCATOR EXHAUST SYSTEM 1 Trim Ring if equipped 2 Muffler 3 Metal Clamp 4 Front Muffler 5 Catalytic Converter 6 Post Converter Heated Oxygen Sensor 7 Auxiliary Catalyt...

Page 622: ...E Removal Procedure 1 Remove the post converter heated oxygen sensor 2 Remove the connecting pipe nuts and the gasket from the auxiliary catalytic converter 3 Remove the catalytic converter nuts and t...

Page 623: ...ipe nuts to 30 NSm 22 lb ft 2 Connect the main catalytic converter and the con necting pipe to the rubber hanger 3 Install the gasket and the connecting pipe nuts to the auxiliary catalytic converter...

Page 624: ...ARY CATALYTIC CONVERTER Removal Procedure 1 Disconnect the pre converter oxygen sensor elec trical connector 2 Remove the exhaust manifold cover bolts and the exhaust manifold cover 3 Remove the auxil...

Page 625: ...osition the auxiliary catalytic converter onto the exhaust manifold flange with one upper flange nut and bolt 2 Install the auxiliary catalytic converter lower flange nuts and the bolts Tighten Tighte...

Page 626: ...t manifold cover bolts Tighten Tighten the exhaust manifold cover bolts to 15 NSm 11 lb ft 5 Connect the pre converter oxygen sensor electrical connector MUFFLER FRONT Removal Procedure 1 Remove the n...

Page 627: ...ffler pipe for holes damage open seams or other deteriora tion which could permit exhaust fumes to seep into the passenger compartment or the trunk Installation Procedure 1 Secure the front muffler pi...

Page 628: ...talytic converter with the nuts Tighten Tighten the front muffler pipe to catalytic converter nuts to 35 NSm 26 lb ft MUFFLER REAR Removal Procedure 1 Loosen the front muffler pipe to rear muffler pip...

Page 629: ...ffler and the pipes for holes damage open seams and other deterioration which could permit exhaust fumes to seep into the passenger compartment or the trunk Installation Procedure 1 Place the exhaust...

Page 630: ...e rear muffler pipe into the front muffler pipe 5 Secure the rear muffler pipe to the front muffler pipe with the holding clamp the washer and the nut Tighten Tighten the front muffler pipe to rear mu...

Page 631: ...int type If holes open seams or any deterioration is discovered upon inspection of the front muffler and pipe assembly the complete as sembly should be replaced The same procedure is appli cable to th...

Page 632: ......

Page 633: ......

Page 634: ...as a separate replacement part It is no longer necessary to replace the complete Fuel Pump Module to replace a faulty Fuel Level Sensor Refer to TSB 005 01 for complete Fuel Level Sensor removal and...

Page 635: ...ved Fuel Level Sensor is now available as a separate replacement part It is no longer necessary to replace the complete Fuel Pump Module to replace a faulty Fuel Level Sensor Included in this bulletin...

Page 636: ...it to idle until the engine stalls Crank the engine an additional 10 seconds then turn the Ignition Switch to the OFF position Note The engine should stall in less than 10 seconds once Fuel Pump Relay...

Page 637: ...Choose transmission type 8 Select Data Display 8 Select Engine Data 8 Select EVAP Data FUEL LEVEL SENSOR REPLACEMENT PROCEDURE Removal 1 The Fuel Pump Module has a single in tank sub harness that must...

Page 638: ...e Low Fuel Level Sensor from its bracket 7 Using a small flat blade screwdriver release the Low Fuel Level Sensor Bracket from the Fuel Pump Module Body by prying it in the direction shown The bracket...

Page 639: ...el Level Sensor is installed 13 Route the Fuel Level Sensor wires through the retaining hook on top of the Fuel Pump Module Body 14 Remove the electrical tape then insert the Fuel Level Sensor Termina...

Page 640: ...m open flame torches lit cigarettes heater pilots or other flames however minor or sparks mechanical electrical or otherwise that could cause fuel vapors to ignite 20 Using a suitable hammer and brass...

Page 641: ...el Tank O ring 96183170 1 Warranty Claim Information Operation Code Operation Description Labor Time 1711700 Fuel Level Sensor Replace 0 5 hr veh Claim Type 11 In Service Vehicles Field Fix Number TSB...

Page 642: ...ON VEHICLE SERVICE 3A 4 DRIVE AXLE ASSEMBLY 3A 4 UNIT REPAIR 3A 8 OUTER JOINT SEAL 3A 8 INNER TRIPOT SEAL 3A 9 GENERAL DESCRIPTION AND SYSTEM OPERATION 3A 13 FRONT DRIVE AXLE 3A 13 SPECIFICATIONS FAST...

Page 643: ...TRANSAXLE DRIVE AXLE DAEWOO V 121 BL4 SPECIAL TOOLS SPECIAL TOOLS TABLE J 8059 Snap Ring Pliers KM 507 B Ball Joint Separator KM 460 A Axle Shaft Remover J 35566 Seal Clamp Pliers COMPONENT LOCATOR FR...

Page 644: ...Ring 4 Axle Shaft right hand shown left hand similar 5 Seal Retaining Clamp 6 Drive Axle Outboard Seal 7 Seal Retaining Clamp 8 Seal Retaining Clamp 9 Drive Axle Inboard Seal 10 Seal Retaining Clamp 1...

Page 645: ...els Refer toSection 2E Tires and Wheels 3 Remove the engine under covers Refer toSection 9N Frame and Underbody 4 Remove the axle shaft caulking nut Discard the nut 5 Remove the lower ball joint nut a...

Page 646: ...M 507 B 9 Push the drive axle shaft from the wheel hub Important Support the unfastened end of the drive axle Do not allow the drive axle to dangle freely from the trans axle for any length of time af...

Page 647: ...Clean the hub seal and the transaxle seal 2 Install the drive axle into the transaxle 3 Install the wheel hub onto the axle shaft 4 Mount the steering knuckle onto the lower ball joint 5 Install the t...

Page 648: ...Lower the vehicle to the floor Tighten Tighten the wheel bolts to 90 N m 66 lb ft 10 Tighten the axle shaft caulking nut to 180 N m 134 lb ft Loosen the nut and re tighten the nut to 50 N m 37 lb ft...

Page 649: ...e the outer joint from the axle shaft CAUTION Do not disassemble the outer joint assem bly Parts are match fit and cannot be serviced sepa rately Improper reassembly will adversely affect both perform...

Page 650: ...clamp using the seal clamp pliers J 35566 6 Install the drive axle shaft to the vehicle Refer to Drive Axle Assembly in this section INNER TRIPOT SEAL Tools Required J 8059 Snap Ring Pliers Removal Pr...

Page 651: ...IVE AXLE DAEWOO V 121 BL4 4 Pry the tripot joint retaining ring from the tripot housing 5 Remove the tripot housing from the seal 6 Degrease the tripot assembly 7 Remove the shaft retaining ring using...

Page 652: ...le shaft Installation Procedure Tools Required J 35566 Seal Clamp Pliers 1 Install a new small seal retaining clamp onto the seal Do not crimp the seal retaining clamp 2 Install the seal onto the axle...

Page 653: ...grease 6 Install the tripot housing onto the tripot assembly 7 Install the tripot joint retaining ring into the tripot housing 8 Install a new large seal retaining clamp Crimp the large seal retaining...

Page 654: ...s Each axle assembly consists of an inner and an outer constant velocity joint connected to an axle shaft The inner joint is completely flexible and has the ability to move in and out The outer joint...

Page 655: ...ND CLUTCH 5A 21 REVERSE INPUT CLUTCH ASSEMBLY 5A 22 DIRECT AND COAST CLUTCH ASSEMBLIES 5A 23 REACTION CARRIER ASSEMBLY 5A 24 INPUT CARRIER ASSEMBLY 5A 25 INPUT INTERNAL GEAR AND FORWARD CLUTCH HUB 5A...

Page 656: ...RD AND FOURTH GEARS ONLY 5A 74 FIRST AND FOURTH GEARS ONLY 5A 74 SECOND AND THIRD GEARS ONLY 5A 74 NO PARK 5A 75 RATCHETING NOISE 5A 75 NO ENGINE BRAKING ALL MANUAL RANGES 5A 76 NO ENGINE BRAKING MANU...

Page 657: ...N GASKET AND FILTER 5A 173 REVERSE LOW SERVO ASSEMBLY 5A 174 2ND 4TH SERVO ASSEMBLY 5A 175 CASE SIDE COVER PAN AND GASKETS 5A 176 1 2 SHIFT SOLENOID 5A 177 2 3 SHIFT SOLENOID 5A 178 PRESSURE CONTROL S...

Page 658: ...SE BAND INSTALL 5A 224 FORWARD CLUTCH INSTALLATION 5A 224 INPUT INTERNAL GEAR FORWARD CLUTCH HUB DISASSEMBLE 5A 225 INPUT INTERNAL GEAR FORWARD CLUTCH HUB ASSEMBLE 5A 225 INPUT INTERNAL GEAR FORWARD C...

Page 659: ...ND GASKET INSTALL 5A 277 TORQUE CONVERTER INSTALLATION 5A 278 GENERAL DESCRIPTION AND SYSTEM OPERATION 5A 279 TRANSAXLE DEFINITIONS AND ABBREVIATIONS 5A 279 TRANSAXLE GENERAL DESCRIPTION 5A 280 TRANSA...

Page 660: ...101 29 101 59 Black 2 39 2 49 101 59 101 88 Orange 2 68 2 78 101 88 102 18 Violet 2 98 3 08 102 18 102 48 Yellow 3 28 3 38 102 48 102 77 Red 3 57 3 67 102 77 103 07 Green 3 87 3 97 TRANSAXLE GENERAL S...

Page 661: ...A A A Reverse Clutch A Coast Clutch A A A A A A A A Input Sprag H H H O H H H H H H H H Direct Clutch A A A A Forward Clutch A A A A A A A A A A A A LO Rev Band A A A LO Roll er Clutch H O O O H O O H...

Page 662: ...Pressure Control Solenoid Current Amp Approximate Line Pressure psi 0 00 152 160 0 10 149 151 0 30 141 143 0 50 124 127 0 60 111 115 0 70 97 101 0 80 81 84 0 90 64 67 0 95 56 58 1 00 50 51 1 05 50 1...

Page 663: ...t 58 43 Relay Box Securing Nuts 8 71 Servo Cover Bolts 12 106 Shift Control Assembly Bolts Shift Control Cable Adjuster Pinch Bolt Nut 8 71 Shift Control Cable Attachment Nut 6 53 Shift Control Cable...

Page 664: ...S TABLE Scan Tool J 21867 Universal Pressure Gauge Set J 28742 A Weather Pack Terminal Remover J 33095 Control Module Connector Terminal Remover J 34142 B Universal Test Lamp J 35616 Connector Test Ad...

Page 665: ...igital Volt Ohmmeter DVOM J 39775 Jumper Harness J 3289 20 Transmission Holding Fixture Base J 41230 Transmission Holding Fixture J 6125 1B Slide Hammer J 38868 Stub Shaft Sleeve Remover J 41227 Outpu...

Page 666: ...orque Converter Seal Installer J 28585 Snap Ring Screwdriver J 41239 1 Cooler Line Seal Installer J 41229 Manual Shaft to Case Pin J 23327 Clutch Spring Compressor J 41236 Coast Clutch Return Spring C...

Page 667: ...41231 Forward Clutch Inner Seal Assembly Installer J 41234 1 Input Shaft Seal Installer Pusher J 41234 2 Input Shaft Seal Installer Protector J 41234 3 Input Shaft Seal Installer Sizer J 34673 Input...

Page 668: ...4I4T40 E AUTOMATIC TRANSAXLE DAEWOO V 121 BL4 J 29569 2 J 29829 2 Turbine Shaft Seal Sizer J 21366 Torque Converter Holding Strap J 41103 Torque Converter Seal Remover Set J 28467 B Engine Support Fix...

Page 669: ...4T40 E AUTOMATIC TRANSAXLE 5A 15 DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS POWERTRAIN CONTROL MODULE 1 OF 3...

Page 670: ...5A 16I4T40 E AUTOMATIC TRANSAXLE DAEWOO V 121 BL4 POWERTRAIN CONTROL MODULE 2 OF 3...

Page 671: ...4T40 E AUTOMATIC TRANSAXLE 5A 17 DAEWOO V 121 BL4 POWERTRAIN CONTROL MODULE 3 OF 3...

Page 672: ...XLE DAEWOO V 121 BL4 VISUAL IDENTIFICATION TRANSAXLE IDENTIFICATION INFORMATION 1 Assembly Plant Windsor Canada 2 Model Year 1996 3 Broadcast Code 4 Model Name 4T40E 5 Update Level 6 Sequential Number...

Page 673: ...B 5 SYMPTOM DIAGNOSIS 5B 6 COMPONENT LOCATORS 5B 9 GEARS AND CASE 5B 9 DIFFERENTIAL AND CASE 5B 11 SHIFT LINKAGE 5B 12 MAINTENANCE AND REPAIR 5B 15 ON VEHICLE SERVICE 5B 15 CHECKING FLUID LEVEL 5B 15...

Page 674: ...55 Differential Cover Bolts 40 30 Fifth Gear Fork Bolts 22 16 Fifth Gearshift Connector Bolts 7 62 Gearshift Lever Cover Bolts 22 16 Input Driveshaft Detent Screw 15 11 Left Front Transaxle Support B...

Page 675: ...LS SPECIAL TOOLS TABLE J 6125 B Slide Hammer J 22888 20 A Bearing Puller with J 22888 35 Puller Legs J 22912 01 Universal Bearing Puller J 28467 B Engine Support Fixture KM 553 A Fifth Gear Puller J 3...

Page 676: ...5B 4IFIVE SPEED MANUAL TRANSAXLE DAEWOO V 121 BL4 J 42469 Shift Rod Remover KM 519 Ring Installer KM 520 Remover Installer KM 522 Installer KM 525 Installer KM 552 Fixture KM 554 Installer...

Page 677: ...xle is run with the wheels off the ground Wheel Bearing Noise Wheel bearings produce a rough growl or grating sound that will continue when the vehicle is coasting and the transaxle is in NEUTRAL Sinc...

Page 678: ...aft cluster gears S Replace any worn first gear bearing S Replace any worn second gear bearing S Replace any worn third gear bearing S Replace any worn fourth gear bearing S Replace any worn fifth gea...

Page 679: ...all gears S Add sufficient lubricant S Replace any worn bearings S Replace any chipped scored or worn input gear shaft or output gear shaft Check for the transaxle slipping out of gear S Adjust or rep...

Page 680: ...scored or worn input shaft gear cluster gears S Replace any worn fifth gear synchronizer S Replace any worn fifth gear bearing S Replace any worn first gear bearing S Replace any worn first second gea...

Page 681: ...FIVE SPEED MANUAL TRANSAXLE 5B 9 DAEWOO V 121 BL4 COMPONENT LOCATORS GEARS AND CASE...

Page 682: ...Shift Rod Plug 50 4 mm 34 Detent Rod Bolt 35 Bolt 36 Bolt 37 Support 38 Fifth Gearshift Fork 39 Pin 40 Fifth Gear Connector 41 Shoe 42 Key 43 Snap Ring 44 Gasket 45 Cover 46 Bolt 47 Plug 48 Bolt 49 S...

Page 683: ...Seal 9 Bearing Adjusting Ring 10 Side Bearing Race 11 Housing Cover Gasket 12 Differential Cover 13 Bolt 14 Differential Bearing 15 Pinion Gear Shaft 16 Differential Housing 17 Thrust Washer 18 Side...

Page 684: ...5B 12IFIVE SPEED MANUAL TRANSAXLE DAEWOO V 121 BL4 SHIFT LINKAGE...

Page 685: ...inkage Adjuster Bolt 14 Gearshift Control Rod 15 Linkage Ball Socket 16 Circlip Ring 17 Linkage Reverse Lever 18 Gearshift Boot 19 Bushing 20 Bushing 21 Rod U Joint Bushing 22 Clip 23 Gearshift Rod 24...

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