Daewoo NUBIRA Owner'S Manual Download Page 299

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4B – 6

MASTER CYLINDER

DAEWOO V–121 BL4

Installation Procedure

1. Lubricate the new seals with clean brake fluid.

Install the seals into the cylinder body.

2. Install the reservoir on the master cylinder body.

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. Refer toSection 4A, Hy-

draulic Brakes orSection 4F, Antilock Brake Sys-
tem.

7. Bleed the clutch master cylinder. Refer toSection

5C, Clutch.

8. Lower the vehicle.
9. Connect the reservoir electrical connector.

Summary of Contents for NUBIRA

Page 1: ......

Page 2: ...EAST 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 0B 16 GENERAL DESCRIPTION 0B 17 ON BOARD REFUELING VAPOR RECOVERY SYSTEM 0B 17 VEHICLE IDENTIFICATION 0B 20 VEHICLE LIFTING PROCEDURES 0B 24 SPECIFICATIONS TECHNICAL DATA Performance Manual Transaxle Ap...

Page 3: ...ct 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 Single Dry Plate Outside Diameter 225 mm 9 0 in Inside Diameter 150 mm 5 9 in Thickness 3 4 mm 0 13 in Fluid Capacity Common Use Brake Fluid Manual Transaxle Application 2 2L DOHC Maker DWMC Type or Mode...

Page 4: ...n 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 Size 32 mm 1 3 in Fluid Capacity 0 5L 0 53 qt Tire and Wheel Application 2 0L DOHC Standard Tire Size 185 65R14 Temporary Tire Size T125 70D15 Standard Wheel Size 5 5JX14 Inflation Pressure at Full ...

Page 5: ...l 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 Delivery MPI Fuel Pump Type Electric Motor Pump Fuel Filter Type Cartridge Fuel Capacity 52L 13 7 gal Lubricating System Application 2 0L DOHC Lubricating Type Forced Feed Oil Pump Type Duocentric Rotor Oi...

Page 6: ...Maximum 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 in 5 Door 4 248 mm 167 2 in Overall Width 1 700 mm 66 9 in Overall Height 4 Door Notchback 1 425 mm 56 1 in 4 Door Wagon 1 432 mm 56 4 in 5 Door 1 425 mm 56 1 in Overall Height Overall Height 4 Door ...

Page 7: ...l 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 Weight 1 860 kg 4 101 lb Passenger Capacity 5 Vehicle Weights 5 Door Application 2 0L DOHC Manual Curb Weight Standard 1 155 kg 2 546 lb Optional 1 224 kg 2 698 lb Gross Vehicle Weight 1 720 kg 3 792 lb ...

Page 8: ... 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 1 5 104 157 NSm 77 116 lb ft 136 203 NSm 100 150 lb ft 160 240 NSm 118 177 lb ft M16 X 2 0 100 149 NSm 74 110 lb ft 129 194 NSm 95 143 lb ft 153 229 NSm 113 169 lb ft M18 X 1 5 151 225 NSm 111 166 l...

Page 9: ...en 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 Oil and Oil Filter Change API Classifications of Engine Oil The International Lubricant Standardization and Approval Committee ILSAC and American Petroleum Institute classifies engine oils according to...

Page 10: ...the 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 Check the pad and the lining thickness carefully If the pads or the linings are not expected to last another 9 600 km 6 000 mi replace the pads or the linings Check the breather hole in the brake fluid ...

Page 11: ... 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 102 000 miles 163 200 km Chart Symbols I Inspect these items and their related parts If necessary correct clean replenish adjust or replace R Replace or change 1 Change the engine oil every 3 000 miles 4 ...

Page 12: ... 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 locks hinges hood latch I I I I I I I I Chart Symbols I Inspect these items and their related parts If necessary correct clean replenish adjust or replace R Replace or change 2 More frequent maintenance ...

Page 13: ...oil 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 cause engine damage 6 Push the indicator all the way back down into the engine after taking the reading If checking the oil level when the oil is cold do not run the engine first The cold oil will n...

Page 14: ...ottle 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 free movement Engine Drive Belts Inspect all belts for cracks fraying wear and proper ten sion Adjust or replace the belts as needed Hood Latch Operation When opening the hood note the operation of the ...

Page 15: ...Inspect 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 freeze protection corrosion protection and engine operating temperature Inspect the hoses Replace the cracked swollen or deteriorated hoses Tighten the clamps Clean the outside of the radia tor and t...

Page 16: ...axle 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 Lock Cylinders As needed Silicone lubricant Automatic Transaxle Shift Link age As needed Engine oil Clutch Linkage Pivot Points As needed Engine oil Floor Shift Linkage Points As needed Engine oil Ho...

Page 17: ... 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 ones for installation Normal functioning of the vehicle s components cannot be maintained if these fasteners and seals are reused S Keep the disassembled parts to assist in reassemb ly S Keep attachin...

Page 18: ... 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 designed to have the following functional features S To collect refueling vapors and to route to canister S To provide nozzle compatibility with conventional and stage II vapor recovery nozzles S To provi...

Page 19: ... 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 10 Tank Pressure Transducer OBD II 11 Rollover Valve 12 2 Way Check Valve 13 Check Valve 14 Fuel Filler Tube Dynamic Seal During Fill 15 Fuel Filler Cap Pressure Vacuum Relief ...

Page 20: ...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 21: ...ON 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 Vehicle Identification Number ...

Page 22: ...N 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 The vehicle identification number VIN is engraved in the top of the bulkhead next to the ABS module ...

Page 23: ...ORMATION 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 manifold of the engine ...

Page 24: ...nual 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 Plate 1 Assembly Plant Windsor Canada 2 Model Year 1996 3 Broadcast Code 4 Model Name 4T40E 5 Update Level 6 Sequential Number 7 Manufacturer 8 Part Number Identification Code Engine 7ZZR 2 0L DOHC ...

Page 25: ...otice 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 service stations are equipped with automotive hoists that bear upon some parts of the frame to lift the vehicle If any other hoist meth od is used use special care to avoid damaging the fuel tank the f...

Page 26: ...GENERAL INFORMATION 0B 25 DAEWOO V 121 BL4 ...

Page 27: ...0B 26IGENERAL INFORMATION DAEWOO V 121 BL4 Vehicle Lifting Points ...

Page 28: ...rk 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 less than 70 of the highest reading The compression gauge read ing should not be less than 689 kPa 100 psi for any of the cylinders 5 Examine the gauge readings obtained after the four puffs per cyl...

Page 29: ...Go 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 to Step 11 Go to Step 12 11 Install new engine oil of the proper viscosity for the expected temperatures Is the repair complete Go to Step 1 12 Inspect the oil pump Is the pump worn or dirty Go to Ste...

Page 30: ...ether 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 a large sheet of paper 2 Wait a few minutes 3 You should be able to find the approximate loca tion of the leak by the drippings on the paper 3 Visually check around the suspected component Check aro...

Page 31: ...ring 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 worn internal engine components Light knock is a noticeable noise but not as loud Light knock can be caused by worn internal engine components Loose or broken external engine components can also cause...

Page 32: ...o 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 Reposition the system as necessary Is the repair complete Go to Step 1 10 Inspect the flywheel Is the flywheel cracked Go to Step 11 Go to Step 12 11 Replace the flywheel Is the repair complete Go t...

Page 33: ...onds 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 temperatures Is the repair complete Go to Step 1 4 Inspect the hydraulic lifters Is there evidence of hydraulic lifter bleed down Go to Step 5 Go to Step 6 5 Clean test and replace the lifters as necessary Is ...

Page 34: ...er 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 Go to Step 11 Go to Step 12 11 Replace the piston and the pin Is the repair complete Go to Step 1 12 Check the connecting rod alignment Is the alignment faulty Go to Step 13 Go to Step 14 13 Check and...

Page 35: ...o 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 noise heard under all engine speeds Go to Step 2 System OK 2 Inspect the crankshaft connecting rod journal Is the crankshaft connecting rod journal worn Go toCrank shaft Replace ment Proce dure Go to ...

Page 36: ...t 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 toPistons and Rods Re placement Pro cedure Go to Step 4 4 Inspect the connecting rods Is there a misaligned connecting rod Go toPistons and Rods Re placement Pro cedure Go to Step 5 5 Inspect the piston po...

Page 37: ...e 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 chined Go toCamshaft Replacement Procedure Go to Step 6 6 Check the oil supply to the valve train Is the oil supply insufficient or poor Go toCylinder Head and Valve Train Components Replacement Procedu...

Page 38: ... 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 the engine Failure to disconnect cables may result in damage to wire harness or other elec trical parts ON ENGINE SERVICE CAUTION Disconnect the negative battery cable be fore removing or installing ...

Page 39: ...UPPER 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 31 OIL PAN 1C 36 OIL PUMP 1C 39 ENGINE MOUNT 1C 44 INTAKE MANIFOLD 1C 46 EXHAUST MANIFOLD 1C 49 CAMSHAFT GEARS 1C 51 REAR TIMING BELT COVER 1C 53 ENGINE 1C 55 PISTONS AND RODS 1C 63 UNIT REPAIR 1C 68 ...

Page 40: ...ston 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 03 in Toward Thrust Side Clearance In Piston 0 0035 0 0140 mm 0 00013 0 00055 in Clearance In Rod Interference Fit in Rod Length 61 5 mm 2 42 in Camshaft Lift Intake 10 0 mm 0 39 in Lift Exhaust 10 ...

Page 41: ...752 in Valve Diameter Intake 32µ0 1 mm 1 2598µ0 0039 in Exhaust 29µ0 1 mm 1 1417µ0 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 Valve Guide Inside Diameter 6 000 6 012 mm 0 236 0 237 in Oil Pump Gear Lash 0 10 0 20 mm 0 003 0 007 in Outer Gear to Body 0 11 0 19 mm 0 004 0 007 in Outer Gear to Crescent 0 40 0 50 mm 0 015 0 019 in...

Page 42: ...ting 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 Engine Mount Retaining Bolts 60 44 Engine to Intake Manifold Support Bracket Bolts 20 15 Evaporative Emission Canister Purge Solenoid Bracket Bolt 5 44 Exhaust Gas Recirculation Valve Bolts 20 15 Exhaust...

Page 43: ...ts 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 Bolts 40 30 Thermostat Housing Mounting Bolts 15 11 Throttle Cable Bracket Bolts 8 71 Timing Belt Automatic Tensioner Bolt 25 18 Timing Belt Idler Pulley Bolt 25 18 Timing Belt Idler Pulley Nut 25 18 ...

Page 44: ...L4 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 Engine Overhaul Stand KM 348 Spring Compressor ...

Page 45: ... 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 Gauge KM 498 B Pressure Gauge ...

Page 46: ...1C 8IDOHC ENGINE MECHANICAL DAEWOO V 121 BL4 COMPONENT LOCATOR UPPER END ...

Page 47: ...lt 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 Thermostat Housing 34 Thermostat Housing Gasket 35 Stud 36 Sleeve 37 Plug 38 Bolt 39 Camshaft Position Sensor 40 Oil Gallery Plug 41 Exhaust Camshaft 42 Oil Seal Ring 43 Camshaft Gear 44 Washer 45 Ca...

Page 48: ...1C 10IDOHC ENGINE MECHANICAL DAEWOO V 121 BL4 LOWER END ...

Page 49: ... 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 Pressure Relief Valve Spring 46 Washer 47 Pressure Relief Valve Plug 48 Ring Seal 49 Bolt 50 Oil Suction Pipe 51 Bolt 52 Rear Timing Belt Cover 53 Bolt 54 Special Bolt 55 Idler Pulley 56 Stud 57 Nut 58 ...

Page 50: ...en 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 through the valve and drain back to the oil pan OIL PAN The engine oil pan is mounted to the bottom of the cylinder block The engine oil pan houses the crankcase and is made of cast aluminum Engine oil i...

Page 51: ...her 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 ignition wires from the spark plugs 8 Remove the valve cover bolts 9 Remove the valve cover washers 10 Remove the valve cover 11 Remove the valve cover gasket from the valve cov er ...

Page 52: ...e 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 wires to the spark plugs 8 Install the spark plug cover 9 Install the spark plug cover bolts Tighten Tighten the spark plug cover bolts to 3 NSm 27 lb in 10 Connect all of the necessary vacuum lines 11 ...

Page 53: ... 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 intake tube from the throttle body 9 Disconnect the electronic ignition system EI sys tem ignition coil connector 10 Disconnect the pre converter oxygen sensor con nector 11 Disconnect the idle air con...

Page 54: ...ash 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 serpentine accessory drive belt Refer to Section 6B Power Steering Pump 24 Remove the crankshaft pulley bolts 25 Remove the crankshaft pulley 26 Remove the front timing belt cover bolts 27 Remove the front...

Page 55: ...Remove 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 camshaft firmly in place remove the intake camshaft gear bolt 37 Remove the intake camshaft gear 38 While holding the exhaust camshaft firmly in place remove the exhaust camshaft gear bolt 39 Remove the e...

Page 56: ...43 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 auxiliary catalytic converter nuts at the exhaust manifold 49 Disconnect all of the necessary vacuum hoses ...

Page 57: ...s 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 strap clear of the intake manifold 60 Remove the evaporative emission canister purge solenoid bracket bolt and move the bracket clear 61 Disconnect the throttle cable at the throttle body and the intake...

Page 58: ... 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 throttle cable at the throttle body and the intake manifold 6 Install the generator to intake manifold support bracket 7 Install the intake generator to manifold support bracket bolts Tighten Tighten t...

Page 59: ...he 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 the engine mount retaining bolts to 60 N m 44 lb ft 19 Install the timing belt automatic tensioner 20 Install the timing belt automatic tensioner bolt Tighten Tighten the timing belt automatic tensio...

Page 60: ... 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 the exhaust camshaft gear bolt to 50 NSm 37 lb ft Using the angular torque gauge KM 470 B tighten the bolt another 60 degrees plus 15 degrees 29 Apply a small amount of gasket sealant to the cor ner...

Page 61: ... 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 exhaust gear 38 Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover 39 Install the timing belt 40 Check and adjust the timing belt tension Refer to Timing...

Page 62: ...bolts 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 to the thermostat housing 49 Install the right front splash shield 50 Install the right front wheel Refer to Section 2E Tires and Wheels 51 Install the air filter housing 52 Install the air filter hou...

Page 63: ...verter 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 Engine Cooling CAMSHAFTS Removal Procedure 1 Remove the timing belt Refer to Timing Belt in this section 2 Disconnect the breather tube at the valve cover 3 Disconnect the crankcase ventilation tube...

Page 64: ...t 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 extreme care to prevent any scratches nicks or damage to the camshafts 1 Lubricate the camshaft journals and the camshaft caps with engine oil 2 Install the intake camshaft 3 Install the intake camshaft...

Page 65: ...torque 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 bolt Tighten Tighten the exhaust camshaft gear bolt to 50 NSm 37 lb ft Using the angular torque gauge KM 470 B tighten the bolt another 60 degrees plus 15 degrees 14 Install the valve cover and the val...

Page 66: ...tube 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 air temperature sensor con nector 3 Remove the air intake tube from the throttle body 4 Remove the breather tube from the valve cover 5 Remove the air filter housing bolts 6 Remove the air filter ho...

Page 67: ...ove 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 crankshaft at least one full turn clock wise using the crankshaft gear bolt 16 Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover ...

Page 68: ... 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 tensioner is aligned with the notch in the timing belt automatic tensioner bracket 20 Tighten the automatic tensioner bolt 21 Rotate the crankshaft two full turns clockwise using the crankshaft gear bolt...

Page 69: ...o 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 pulley 27 Install the crankshaft pulley bolts Tighten Tighten the crankshaft pulley bolt to 20 NSm 15 lb ft 28 Install the right engine mount bracket Refer to En gine Mount in this section 29 Install the ...

Page 70: ... 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 the negative battery cable TIMING BELT Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the intake air temperature sensor con nector 3 Disconnect the air intake tube from the thr...

Page 71: ...ires 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 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 ...

Page 72: ...ice 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 for the intake cam shaft gear and the exhaust gear mark for the exhaust cam shaft gear since both gears are interchangeable 17 Remove the timing belt 18 Loosen the automatic tensioner bolt Turn the ...

Page 73: ...Align 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 and the exhaust gear mark for the exhaust gear 3 Install the timing belt ...

Page 74: ...crankshaft 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 Tighten the front timing belt cover bolts to 6 NSm 53 lbin 10 Install the right engine mount bracket Refer to En gine Mounts in this section 11 Install the crankshaft pulley 12 Install the crankshaft...

Page 75: ...he 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 Procedure 1 Disconnect the negative battery cable 2 Drain the engine oil from the engine crankcase 3 Disconnect the post converter heated oxygen sen sor 4 Remove the auxiliary catalytic converter upper ...

Page 76: ... 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 retaining bolts 4 Clean the oil pan attaching bolt holes in the engine block 5 Clean the oil pan splash shield ...

Page 77: ...pan 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 bolts Tighten Tighten the oil pan flange to transaxle bolts to 40 NSm 30 lb ft 5 Install the catalytic converters Tighten Tighten the auxiliary catalytic converter to exhaust manifold nuts to 40 NSm 30...

Page 78: ...PUMP 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 Install the adapter KM 135 in place of the oil pres sure switch 4 Connect the pressure gauge KM 498 B to the adapter 5 Start the engine and check the oil pressure at idle speed and engine temperature o...

Page 79: ...ell 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 Cover in this section 3 Disconnect the oil pressure switch connector 4 Remove the oil pan Refer to Oil Pan in this sec tion 5 Remove the oil pump pickup tube and support bracket bolts 6 Remove the oil...

Page 80: ...rate 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 relief valve bolt 3 Remove the safety relief valve and the spring 4 Remove the oil pump to crankshaft seal ...

Page 81: ...oil 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 NSm 53 lb in 11 Install the safety relief valve the spring washer and the bolt Tighten Tighten the safety relief valve bolt to 30 NSm 22 lb ft Installation Procedure 1 Apply Loctite 242 to the oil pu...

Page 82: ...upport 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 Refer to Oil Pan in this section 7 Connect the oil pressure switch connector 8 Install the rear timing belt cover Refer to Rear Timing Belt Cover in this section 9 Connect the negative battery cable ...

Page 83: ...er 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 shield 6 Remove the exhaust manifold retaining nuts in the sequence shown 7 Remove the exhaust manifold 8 Remove the exhaust manifold gasket 9 Remove the exhaust manifold studs 10 Remove the thermostat ho...

Page 84: ...coil 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 camshaft cap 22 Remove the intake camshaft bearing caps Main tain the correct positions for installation 23 Remove the intake camshaft 24 Remove the intake valve lash adjusters 25 Remove the exhaust cams...

Page 85: ...gs 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 cylinder head gasket and mating sur faces for leaks corrosion and blow by 3 Inspect the cylinder head for cracks 4 Inspect the length and width of the cylinder head using a feeler gauge and a straig...

Page 86: ...grooves 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 Inspect the valve face for grooving If the groove is so deep that refacing the valve would result in a sharp edge replace the valve 7 Inspect the valve spring If the valve spring ends are not paralle...

Page 87: ...rder 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 crater line burns on the valve cone 2 The valve may be reground only two times Do not grind the valve stem end 3 Ensure that the angle at the valve face is 45 de grees 4 Inspect the assembly height of th...

Page 88: ...fitted 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 n Code Service Code Normal K 0 075 KM 805 1 K1 0 150 2 K2 3 Ream the valve guide from the upper side of the cylinder head to the next oversize 4 After reaming cross out the code and emboss the valve...

Page 89: ... 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 valves and the exhaust valves again If the valve assembly height is still too large despite replacing the valves replace the cylinder head Assembly Procedure 1 Coat the valve stems with engine oil 2 Ins...

Page 90: ... 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 the exhaust camshaft bearing caps in their original positions 18 Install the camshaft bearing cap bolts 19 Tighten the camshaft bearing cap bolts gradually and in the sequence shown for each camshaft c...

Page 91: ...26 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 rail assembly Refer to Section 1F Engine Controls 28 Install the thermostat housing assembly 29 Install the thermostat housing mounting bolts Tighten Tighten the thermostat housing mounting bolts to 15 ...

Page 92: ... 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 Overhaul Stand KM 470 B Angular Torque Gauge KM 635 or J 36972 Crankshaft Rear Oil Seal Installer Notice Take extreme care to prevent any scratches nicks or damage to the camshafts Disassembly Procedure...

Page 93: ...release 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 mount 17 Disconnect the crankcase breather tubes from the valve cover 18 Remove the spark plug cover bolts 19 Remove the spark plug cover 20 Disconnect the ignition wires from the spark plugs 21 Rem...

Page 94: ...While 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 bolt 27 Remove the exhaust camshaft gear 28 Remove the crankshaft timing belt gear 29 Remove the rear timing belt cover bolts and cover ...

Page 95: ...s 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 the lower block support bracket bolts 38 Remove the lower block support bracket 39 Remove the oil pump retaining bolts 40 Remove the oil pump ...

Page 96: ...and 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 47 Remove the crankshaft 48 Clean any necessary parts Assembly Procedure 1 Coat the crankshaft bearings with engine oil 2 If replacing the crankshaft transfer the pulse pick up sensor disc to the ne...

Page 97: ...ction 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 of the crankshaft bearing clearances us ing a commercially available plastic gauging ductile plastic threads 9 Cut the plastic gauging threads to the length of the bearing width Lay them axially bet...

Page 98: ... 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 so that the plastic gauging thread does not tear when the connecting rod bearing caps are removed 17 Inspect all of the connecting rod bearing clearances using a commercially available plastic gaugin...

Page 99: ...ranges 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 connecting rod bearing cap bolts to 35 NSm 26 lb ft Use the angular torque gauge KM 470 B to tighten the connecting rod cap bolts to 45 degrees plus one turn of 15 degrees 25 Install the oil pump 26 I...

Page 100: ...d 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 gasket to the oil pan 32 Install the oil pan Important Install the oil pan within 5 minutes after apply ing the liquid gasket to the oil pan 33 Install the oil pan retaining bolts Tighten Tighten the oil...

Page 101: ...oner 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 Tighten the timing belt idler pulley nut to 25 NSm 18 lb ft Notice Take extreme care to prevent any scratches nicks or damage to the camshafts 43 Install the intake camshaft gear 44 Install the intake...

Page 102: ...ll 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 Tighten Tighten the spark plug cover bolts to 8 NSm 71 lb in 56 Connect the crankcase breather tube to the valve cover 57 Install the front timing belt cover 58 Install the front timing belt cover bol...

Page 103: ...S 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 block crankshaft journals 3 Install the lower crankshaft bearings into the crank shaft bearing caps 4 Install the crankshaft 5 Inspect the crankshaft end play with the crankshaft bearings installed 6 Ch...

Page 104: ... 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 to 50 NSm 37 lb ft Using the angular torque gauge KM 470 B tighten the crankshaft bearing cap bolts to 45 degrees 15 degrees 12 Remove the crankshaft bearing caps 13 Measure the width of the flatten...

Page 105: ... 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 Install the connecting rod bearing caps 7 Install the connecting rod bearing cap bolts Tighten Tighten the connecting rod cap bolts to 35 NSm 26 lb ft Using the angular torque gauge KM 470 B tight en t...

Page 106: ...2 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 On Vehicle Service 1D 7 DRAINING AND REFILLING THE COOLING SYSTEM 1D 7 THERMOSTAT 1D 8 COOLANT PUMP 1D 10 ELECTRIC COOLING FAN MAIN OR AUXILIARY 1D 11 SURGE TANK 1D 13 RADIATOR 1D 15 ENGINE COOLANT T...

Page 107: ...NER 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 Retaining Screws 4 35 Radiator Retaining Bolts Left Upper and Right Upper 4 35 Surge Tank Attaching Bolt 4 35 Thermostat Housing Mounting Bolts 15 11 SPECIAL TOOLS SPECIAL TOOLS TABLE KM 471 Adapter ...

Page 108: ...t 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 valve and protects the coolant hoses from collapsing be cause of a vacuum 1 Wash any sludge from the surge tank cap and the valve seat of the vacuum pressure valve for the surge tank cap 2 Check for a...

Page 109: ...damaged 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 Hose Replace the following parts as needed S Surge tank S Hose Check for loose or damaged radiator hoses heater hoses and connections Reseat the hoses Replace the hoses or the clamps Check for leaks ...

Page 110: ... 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 Cooling Fan Air Conditioning Only 11 Drain Cock 12 Main Cooling Fan ...

Page 111: ...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 112: ...dirt 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 the water line This allows the air inside the cooling system to escape 9 Start the engine 10 Run the engine until the thermostat opens When both radiator hoses are hot to the touch the ther mostat is ...

Page 113: ...ng 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 head 6 Remove the O ring seal from the thermostat hous ing 7 Remove the thermostat from the thermostat hous ing by pressing the thermostat mounting flange downward and then rotating the flange clock...

Page 114: ...g 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 with the mounting bolts Tighten Tighten the thermostat housing mounting bolts 2 0L DOHC to 15 NSm 11 lb ft 6 Connect the upper radiator hose to the thermostat housing 7 Secure the upper radiator hose...

Page 115: ...taining 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 Cleaning Procedure 1 Inspect the coolant pump body for cracks and leaks 2 Inspect the coolant pump bearing for play or abnor mal noise 3 Inspect the coolant pump pulley for excessive wear If the coolant...

Page 116: ...ll 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 the timing belt Refer toSection 1C DOHC En gine Mechanical 8 Refill the engine cooling system Refer to Draining and Refilling the Cooling System in this section ELECTRIC COOLING FAN MAIN OR AUXILIARY ...

Page 117: ...ade 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 in proper balance can fail and fly apart during use creating extreme danger Proper balance cannot be assured on a fan assembly that has been bent or damaged 1 Install the fan motor to the shroud 2 Sec...

Page 118: ...he 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 not remove the surge tank cap while the engine and the radiator are hot because the heat causes the system to re main under pressure Scalding fluid and steam may be blown out under pressure 1 Drain th...

Page 119: ...cedure 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 throttle body hose to the top of the surge tank 4 Connect the feed hose to the bottom of the surge tank 5 Secure the return hose the throttle body hose and the feed hose to the surge tank with the hose ...

Page 120: ... 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 lower radiator tank if equipped 11 Remove the bolt and the transaxle pipe support clamp from the radiator 12 Remove the left upper radiator retaining bolt 13 Remove the left upper radiator retaining brac...

Page 121: ...he 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 lb in 5 Install the left upper radiator retainer bracket 6 Install the left upper radiator retaining bolt Tighten Tighten the left upper radiator retaining bolt to 4 NSm 35 lb in ...

Page 122: ...ection 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 temperature sensor 3 Disconnect the electrical connector from the engine coolant temperature sensor 4 Remove the temperature sensor from the exhaust gas recirculation EGR valve mounting adapter Installation...

Page 123: ... 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 and increases the cooling efficiency Maintain the coolant level between the MIN and the MAX marks on the surge tank when the system is cold COOLANT PUMP The belt driven centrifugal coolant pump consis...

Page 124: ...igh 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 S The PCM ECM will turn the cooling fans on at low speed when the A C system is on The PCM ECM will change to high speed when the coolant temper ature reaches 115 C 239 F or the high side A C pressur...

Page 125: ...ORMATION 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 CHECK 1F 53 IGNITION 1 RELAY CIRCUIT CHECK 1F 56 MANIFOLD ABSOLUTE PRESSURE CHECK 1F 58 PARK NEUTRAL POSITION SWITCH 1F 60 IDLE AIR CONTROL SYSTEM CHECK 1F 61 IGNITION SYSTEM CHECK 1F 64 ENGINE COOLING...

Page 126: ...LARGE 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 CONTROL MALFUNCTION 1F 234 DTC P0449 EVAPORATIVE EMISSION SYSTEM VENT SOLENOID CIRCUIT FAULT 1F 237 DTC P0452 FUEL TANK PRESSURE SENSOR LOW VOLTAGE 1F 240 DTC P0453 FUEL TANK PRESSURE SENSOR HIGH VOLT...

Page 127: ...POWER 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 EXCESSIVE EXHAUST EMISSIONS OR ODORS 1F 374 DIESELING RUN ON 1F 375 BACKFIRE 1F 376 MAINTENANCE AND REPAIR 1F 377 ON VEHICLE SERVICE 1F 377 FUEL TANK 1F 377 FUEL PUMP 1F 379 FUEL TANK PRESSURE SENSOR 1F ...

Page 128: ...F 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 Engine Speed RPM µ100 rpm from the Desired rpm Desired Idle Speed RPM PCM ECM Idle Command Varies with the calibration Engine Coolant Temperature C F 85 115 C 185 239 F Varies with the coolant temperatu...

Page 129: ...m 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 Air Flow g sec Varies Weak Cylinder Rough Road Sensor Volt 5 Volt Reference Volt Throttle at Idle Yes No Power Steering Cramp Yes No Air Conditioning Request On Off OFF Air Conditioning Clutch On Off ...

Page 130: ...F 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 Solenoid On Off Off EVAP Tank Vacuum Inches of H2O Depends on Pressure Vacuum Throttle Position Angle 0 up to 100 at wide open throttle Throttle Position Sensor Volts 0 200 0 900 v up to 5 0 at wide ...

Page 131: ...ngle 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 Position Counts EGR Trip Sample Count Counts 0 EGR EWMA Threshold Counts signed EGR EWMA Counts signed EGR Pintle Position Error Counts signed Engine Run Time Seconds Varies Since start up BPW Bank 1 mS 0...

Page 132: ...when 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 starting Intake Air Temperature C F Varies with the underhood tempera ture O2S Time to Activity Bank 1 Sensor 1 Seconds Varies Short Term FT Bank 1 100 to 100 Varies Long Term FT Bank 1 100 to 100 Varies...

Page 133: ...255 counts 0 increase with a misfire Total Misfire Current Count 0 255 counts 0 increase with a misfire Weak Cylinder Engine Speed RPM µ100 rpm from the Desired RPM TP Angle 0 up to 100 at wide open throttle Calculated Load 0 100 Engine Coolant Temperature CSF 85 115 C 185 239 F Varies with the coolant temperature Intake Air Temperature CSF 10 80 C 50 176 F Varies with the underhood temperature Ca...

Page 134: ...lays 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 of the A C clutch control relay The A C clutch should be en gaged when the scan tool displays ON A C Pressure The A C High Side displays the pressure value of the A C refrigerant pressure sensor Th...

Page 135: ... 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 fully closed 100 implies that the valve is fully open EVAP Purge Solenoid When energized the EVAP Emission Canister Purge So lenoid allows the fuel vapor to flow from the EVAP Canister to the engine The ...

Page 136: ... 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 oxygen output voltage past the catalytic converter This voltage remains inactive or the voltage will appear lazy within a range of 100 mv lean ex haust and 900 mv rich exhaust when operating in a Clos...

Page 137: ... 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 Assembly Bolt 10 89 Fuel Pressure Regulator Retaining Screw 12 106 Fuel Rail Retaining Bolts 25 18 Fuel Tank Strap Retaining Nuts 13 115 Heated Oxygen Sensor 41 30 Idle Air Control Valve Retaining Bolts ...

Page 138: ...anol 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 can cor rode metal parts and also cause damage to plastic and rubber parts in the fuel system Methyl Tertiary Butyl Ether MTBE You may use fuel containing Methyl Tertiary Butyl Ether MTBE providing t...

Page 139: ...ENGINE CONTROLS 1F 15 DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS PCM ECM WIRING DIAGRAM 1 OF 6 IPCM 6KD ISFI 6TD ...

Page 140: ...1F 16IENGINE CONTROLS DAEWOO V 121 BL4 PCM ECM WIRING DIAGRAM 2 OF 6 IPCM 6KD ISFI 6TD ...

Page 141: ...ENGINE CONTROLS 1F 17 DAEWOO V 121 BL4 PCM ECM WIRING DIAGRAM 3 OF 6 IPCM 6KD ISFI 6TD ...

Page 142: ...1F 18IENGINE CONTROLS DAEWOO V 121 BL4 PCM ECM WIRING DIAGRAM 4 OF 6 IPCM 6KD ISFI 6TD ...

Page 143: ...ENGINE CONTROLS 1F 19 DAEWOO V 121 BL4 PCM ECM WIRING DIAGRAM 5 OF 6 IPCM 6KD ISFI 6TD ...

Page 144: ...1F 20IENGINE CONTROLS DAEWOO V 121 BL4 PCM ECM WIRING DIAGRAM 6 OF 6 IPCM 6KD ISFI 6TD ...

Page 145: ...ENGINE CONTROLS 1F 21 DAEWOO V 121 BL4 CONNECTOR END VIEW ...

Page 146: ...1F 22IENGINE CONTROLS DAEWOO V 121 BL4 ...

Page 147: ...ENGINE CONTROLS 1F 23 DAEWOO V 121 BL4 ...

Page 148: ...1F 24IENGINE CONTROLS DAEWOO V 121 BL4 ...

Page 149: ...ENGINE CONTROLS 1F 25 DAEWOO V 121 BL4 ...

Page 150: ...1F 26IENGINE CONTROLS DAEWOO V 121 BL4 COMPONENT LOCATOR ...

Page 151: ...Ignition 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 Absolute Pressure MAP Sensor 32 Pre Converter Oxygen Sensor O2S 1 33 Throttle Position TP Sensor 34 Engine Coolant Temperature ECT Sensor 35 Intake Air Temperature IAT Sensor 36 Vehicle Speed Sensor VSS ...

Page 152: ...g 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 sensor Intermittent Service Reminder Indicator SRI Lamp An intermittent service reminder indicator SRI lamp with no DTC present may be caused by the following S Electrical system interference caused ...

Page 153: ...mating 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 Malfunction Indicator Lamp MIL should be ON steady with the ignition ON and the engine OFF If not go to Diagnostic Aids 2 Checks the Class 2 data circuit and ensures that the PCM ECM is able to transmi...

Page 154: ... 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 ECM data values displayed on the scan tool to the typical engine scan data values Are the displayed values normal or close to the typi cal values Go to PCM ECM Output Diagnosis Go to indicated compo...

Page 155: ...only 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 scan tool Test Description Number s below refer to the step number s on the Diag nostic Table 1 The Powertrain On Board Diagnostic OBD II Sys tem Check prompts the technician to complete some basic c...

Page 156: ... 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 manded Go to Step 10 Go to the ap propriate com ponent repair 6 Repair the short to voltage in the corresponding cir cuit for position circuit that displayed a 1 Is the repair complete Go to Step 10 7...

Page 157: ...nd 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 P1112 P1114 P1122 Check for the following conditions S Inspect for a poor connection at the PCM ECM Inspect harness connectors for backed out termi nals improper mating broken locks improperly formed or...

Page 158: ...sor 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 Pressure MAP sensor signal circuit and the PCM ECM harness connector and ground Does the voltage measure near the specified value 0 v Go to Step 6 Go to Step 12 6 Measure the voltage between the Throttle ...

Page 159: ...tage 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 voltage between the Fuel Tank Pres sure sensor signal circuit and the PCM ECM har ness connector and ground Does the voltage measure near the specified value 0 v Go to Step 20 Go to Step 19 19 Locate and...

Page 160: ...1F 36IENGINE CONTROLS DAEWOO V 121 BL4 ...

Page 161: ...or 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 not been tripped Step Action Value s Yes No 1 Perform an On Board Diagnostic OBD II System Check Is the system check complete Go to Step 2 Go to On Board Diagnos tic System Check 2 Crank the engine Do...

Page 162: ...ertrain 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 and the PCM ECM con nector terminal C5 Is the problem found Go toStep 18 Go toStep 33 18 Repair the wiring as needed Is the repair complete Go toStep 2 19 1 Disconnect the electronic ignition EI sys...

Page 163: ...Does 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 voltage fluctuatewithin the values speci fied 0 2 2 0 v Go toStep 32 Go toStep 30 29 Check for an open in the wire from the EI system ignition coil connector terminal B to the PCM ECM connector term...

Page 164: ...ngine 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 presence of fuel 3 Inspect the fuel pressure regulator vacuum port for the presence of fuel Is any fuel present Go toStep 43 Go toStep 44 41 Check the fuel for contamination Is the fuel contaminated ...

Page 165: ...me 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 toStep 51 Go toStep 63 51 1 Turn the ignition ON 2 Measure the voltage at the fuse EF19 connec tion Is the voltage within the specified value 11 14 v Go toStep 53 Go toStep 52 52 Replace the fuel pum...

Page 166: ...rs 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 tive 3 Crank the engine 4 Repeat Steps 3 and 4 for each of the remain ing fuel injectors Does the test light flash for all of the fuel injectors Go toStep 65 Go toStep 68 65 Measure the resistance of...

Page 167: ...ir 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 connector terminals 1 and the ignition 1 relay connector terminal 87 Is the problem found Go toStep 68 Go to Ignition System Check ...

Page 168: ...efer 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 data on then scan tool if applicable This creates an electronic copy of the data taken when the malfunction occurred The information is stored in the scan tool for later reference 3 Connections that are...

Page 169: ...nd 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 con nection at the engine block or PCM ECM connector ground terminals and repair as necessary Is the repair complete Go to Step 22 6 1 Turn the ignition OFF 2 Disconnect the PCM ECM connectors from t...

Page 170: ...as 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 necessary Go to Step 22 Go to Step 21 19 Repair the open in the ignition feed circuit from termi nal F16 Is the repair complete Go to Step 22 20 Replace the instrument panel cluster Refer to Sec tion...

Page 171: ...ag 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 This creates an electronic copy of the data taken when the malfunction occurred The information is stored in the scan tool for later reference 2 When the ignition is turned ON the MIL should mo mentar...

Page 172: ... 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 necessary Go to Step 8 Go to Step 6 6 Replace the instrument panel cluster Refer to Sec tion 9E Instrumentation Driver Information Is the repair complete Go to Step 8 7 Replace the PCM ECM Is the re...

Page 173: ...inlet 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 fuel system pressure before disconnecting the fuel lines CAUTION Do not pinch or restrict nylon fuel lines to avoid damage that could cause a fuel leak resulting in possible fire or personal injury Fuel...

Page 174: ...ied 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 Replace the fuel pressure regulator 2 Install a fuel pressure gauge 3 Turn the ignition ON Is the fuel pressure within the values specified but not holding steady 284 325 kPa 41 47 psi System OK 12 With th...

Page 175: ...he 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 the fuel pump under pressure inspect the fuel pump coupling hoses for leaking Is the problem found Go to Step 9 Go to Step 21 21 1 Remove the fuel pump assembly 2 With the fuel system under pressure...

Page 176: ...onds 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 Description The number s below refer to step s on the diagnostic table 3 This step checks for the PCM ECM providing a ground for the operation of the fuel pump relay 7 By confirming that the wiring is OK ...

Page 177: ...nd 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 the problem found Go to Step 6 Go to Step 7 6 1 Repair the wire between the fuel pump relay connector terminal 87 and the fuel cutoff switch terminal 1 2 Install the fuel pump relay 3 Turn the igniti...

Page 178: ...epair 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 for the time specified 2 sec System OK 12 1 Replace the PCM ECM 2 Turn the ignition OFF for 10 seconds 3 Turn the ignition ON Does the fuel pump operate for the time specified 2 sec System OK 13 Repai...

Page 179: ...t 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 store a diagnostic trouble code DTC Important Do not use the DTC tables for intermittent problems A fault must be present in order to locate the problem If a fault is intermittent use of DTC tables ma...

Page 180: ...rom 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 the affected circuits as need ed Is the repair complete System OK 8 1 Check for a loss of DTC memory 2 Disconnect the Throttle Position Sensor 3 Run the engine at idle until the MIL comes on 4 Turn th...

Page 181: ...to 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 System OK 4 1 Check for a sticking throttle shaft or a binding linkage that may cause a high Throttle Position TP sensor voltage Repair or replace as needed 2 Check the TP sensor voltage reading with the ...

Page 182: ...is 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 Is the repair complete System OK 17 1 Check for the proper ignition voltage output for each cylinder with a spark tester 2 Inspect the spark plugs for cracks wear im proper gap burned electrodes or...

Page 183: ...omplete 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 throttle or cruise making it feel as if the vehicle speeds up and slows down with no change in the accelerator pedal position Important Make sure the driver understands Torque Converter Clutch TCC and A C ...

Page 184: ...ck 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 Repair or replace any ignition system components as needed Is the repair complete System OK 12 1 Inspect the powertrain control module PCM engine control module ECM grounds to make sure they are cle...

Page 185: ...E 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 System OK ...

Page 186: ...air 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 as needed Is the repair complete System OK 9 1 Check the ignition system output for all of the cylinders using a spark tester 2 Check for proper ignition control operation Is the ignition system oper...

Page 187: ...ue 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 the value specified 2 Reevaluate the vehicle s performance Does the detonation problem still exist 87 89 octane Go toStep 3 System OK 3 1 Inspect for low engine coolant 2 Check for restricted airflow t...

Page 188: ...ck 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 for carbon buildup inside the engine 2 Remove the carbon with a top engine cleaner Follow the instructions supplied with the prod uct 3 Check the basic engine parts such as the cam shaft the cylinder...

Page 189: ...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 6 5 Repair or replace any components as needed Is the repair complete System OK 6 1 Disconnect all of the fuel injector harness con nectors 2 Connect an injector test light between the har ness termin...

Page 190: ...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 exhaust has a steady spitting sound at idle or low speed Step Action Value s Yes No 1 Were the Important Preliminary Checks performed Go toStep 2 Go to Impor tant Preliminary Checks 2 Check the ignition s...

Page 191: ...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 cranking the engine for each fuel injector Does the test light blink for all of the fuel injectors Go toStep 13 Go toStep 12 12 1 Repair or replace the faulty injector drive circuit harness the connector or...

Page 192: ...ad 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 filter for excessive contamina tion 2 Inspect for fuel system leaks Are all needed checks complete Go toStep 3 3 1 Inspect the spark plugs for excessive wear insulation cracks improper gap or heavy d...

Page 193: ...4 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 voltage 2 Check the TP sensor voltage reading with the throttle closed Is the TP sensor voltage within the value specified 0 4 0 8 v Go toStep 6 Go to Diagnos tic Aids for DTC P0123 6 1 Check the En...

Page 194: ...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 the repair complete System OK 16 Measure the resistance of each of the fuel injectors The resistance will increase slightly at higher tem peratures Is the resistance within the value specified 11 6 12 ...

Page 195: ... valve 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 Exhaust Gas Recirculation EGR valve for proper operation 2 Inspect the battery cables and the ground straps for proper connections 3 Check the generator voltage output Repair or replace the generator ...

Page 196: ...ry 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 long term fuel trim memory above the value specified 150 counts Go to Diagnos tic Aids for DTC P0171 6 1 Check for a properly installed fuel cap 2 Check the fuel system pressure 3 Perform an injector ...

Page 197: ...operation 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 Preliminary Checks performed Go toStep 2 Go to Impor tant Preliminary Checks 2 Does the engine run smoothly after the ignition switch is turned OFF Go toStep 3 Go toStep 4 3 1 Check the ignition switch and...

Page 198: ...pair 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 system components as needed Is the repair complete System OK 6 1 Inspect the Exhaust Gas Recirculation EGR gasket for a leak or a loose fit 2 Check the EGR valve for proper operation 3 Inspect the intak...

Page 199: ... 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 tank 6 Disconnect the fuel tank filler tube 7 Disconnect the fuel tank vent tube at the fuel tank 8 Disconnect the fuel vapor line near the fuel tank filler tube 9 Disconnect the fuel pump harness con...

Page 200: ...taining 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 Connect the fuel vapor line 8 Connect the fuel tank filler tube 9 Connect the fuel tank vent tube 10 Install the fuel tank filler tube clamp at the fuel tank 11 Connect the right rear parking brake ...

Page 201: ...he 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 10 Remove and discard the gasket Installation Procedure 1 Clean the gasket mating surface on the fuel tank 2 Position the new gasket in place 3 Install the fuel pump into the fuel tank in the same l...

Page 202: ...e 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 Disconnect the fuel tank pressure sensor electrical connector 6 Bend the retaining tabs and remove the fuel tank pressure sensor Installation Procedure 1 Install the fuel tank pressure sensor and bend the...

Page 203: ...pressure 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 Remove the fuel filter mounting bracket assembly bolt 4 Remove the fuel filter Installation Procedure 1 Install the new fuel filter into the retaining clamp Note the flow direction 2 Install the outer fue...

Page 204: ...ressure 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 retaining bolts Notice Before removal the fuel rail assembly may be cleaned with a spray type cleaner following package in structions Do not immerse the fuel rails in liquid cleaning solvent Use care in remo...

Page 205: ...bed 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 injector terminals facing outward 3 Install the fuel injector retaining clips onto the fuel injector and the fuel rail ledge 4 Make sure that the retaining clip should be parallel to the fuel injector h...

Page 206: ... 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 injury or fire it is necessary to relieve the fuel system pressure before disconnecting the fuel lines 1 Relieve the fuel pressure Refer to Fuel System Pressure Relief in this section 2 Disconnect the...

Page 207: ...uel 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 Disconnect the engine coolant temperature ECT sensor connector Notice Take care when handling the engine coolant tem perature sensor Damage to the sensor will affect the prop er operation of the fuel injec...

Page 208: ...ed 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 2 NSm 3 Connect the TP sensor connector 4 Connect the negative battery cable THROTTLE BODY Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the intake air temperature IAT senso...

Page 209: ...nnectors 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 will prevent any objects or debris from entering the engine which may cause damage 10 Remove the throttle body and discard the gasket 11 Remove the TP sensor Refer to Throttle Position Sensor in this...

Page 210: ...alve 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 throttle body retaining nuts to 80 lb in 9 NSm 7 Connect the TP sensor connector and the IAC valve connector 8 Connect the coolant hoses to the throttle body 9 Connect the vacuum hoses to the throttle body ...

Page 211: ...t 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 glass beads will remain making the sensor easier to re move New or service sensors will already have the com pound applied to the threads If a sensor is removed from any engine and if for any reason ...

Page 212: ...OO 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 Connect the negative battery cable ...

Page 213: ...rm 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 Procedure Important If installing a new IAC valve be sure to re place it with an identical part The IAC valve pintle shape and diameter are designed for the specific application Measure the distance between ...

Page 214: ...ive 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 cable 3 Disconnect the Intake Air Temperature IAT sensor connector 4 Disconnect the breather hose from the valve cover Remove the air intake tube 5 Disconnect the throttle cable from the throttle body ...

Page 215: ...from 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 bracket 4 Install the air intake tube 5 Connect the breather hose to the valve cover 6 Connect the IAT sensor connector 7 Connect the negative battery cable ...

Page 216: ... 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 Tighten the exhaust gas recirculation valve retaining bolts to 15 lb ft 20 NSm 4 Connect the EGR valve electrical connector 5 Connect the negative battery cable G SENSOR Removal Procedure 1 Disconnect the...

Page 217: ...er 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 Installation Procedure 1 Insert the canister into the track and slide it into posi tion 2 Install the canister flange bolt Tighten Tighten the evaporative emission canister flange bolt to 20 NSm 15 lb ft 3 Con...

Page 218: ...he 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 emission canister purge solenoid 4 Connect the EVAP emission canister purge sole noid connector 5 Connect the negative battery cable CRANKSHAFT POSITION SENSOR Removal Procedure 1 Disconnect the nega...

Page 219: ...nsor 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 bolts to 35 NSm 26 lb ft 5 Install the rear A C mounting bracket if equipped Tighten Tighten the rear A C mounting bracket bolts to 26 lb ft 35 NSm 6 Install the A C compressor if equipped Refer to Sect...

Page 220: ...onnect 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 from the top Installation Procedure 1 Install the camshaft position sensor and bolts Tighten Tighten the camshaft position sensor bolts to 12 NSm 106 lb in ...

Page 221: ...egative 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 Disconnect the powertrain control module PCM engine control module ECM retaining clip from the PCM ECM mounting base 4 Remove the retaining clip lower end from the mounting base 5 Remove the PCM ECM fr...

Page 222: ...6 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 ignition wire location and remove the igni tion wires 4 Remove the EI system ignition coil retaining bolts 5 Remove the EI system ignition coil Installation Procedure 1 Install the EI system ignition ...

Page 223: ...ve 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 switch Installation Procedure 1 Connect the electrical connector at the fuel cutoff switch 2 Install the fuel cutoff switch mounting bolts Tighten Tighten the fuel cutoff switch mounting bolts to 27 lb in...

Page 224: ... 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 Disconnect the negative battery cable 2 Remove the intake manifold Refer toSection 1C DOHC Engine Mechanical 3 Disconnect the electrical connector at the Knock Sensor KS 4 Remove the KS ...

Page 225: ...allation 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 Mechanical 4 Connect the negative battery cable ...

Page 226: ...sition 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 The PCM ECM uses the CMP sensor signal to in dicate the position of the 1 piston during its power stroke This allows the PCM ECM to calculate true sequential fuel injection mode of operation If the ...

Page 227: ...sed 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 1 Acceleration Mode The PCM ECM responds to rapid changes in throttle posi tion and airflow and provides extra fuel Deceleration Mode The PCM ECM responds to changes in throttle position and airflow ...

Page 228: ...upply 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 TP sensor output changes as the accelerator pedal is moved changing the throttle valve angle At a closed throttle position the output of the TP sensor is low about 0 5 volt As the throttle valve ope...

Page 229: ... 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 result in dam age to the Idle Air Control IAC valve or to the throttle body The IAC valve is mounted on the throttle body where it controls the engine idle speed under the command of the powertrain ...

Page 230: ...oblems 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 parts in the PCM ECM The cal ibrations are stored in the PCM ECM in the Programmable Read Only Memory PROM The PCM ECM supplies either 5 or 12 volts to power the sensors or switches This is done through ...

Page 231: ...ion 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 iso lated a re evaluation is necessary The complaint should be re verified and could be intermittent as defined in In termittents or could be normal After isolating the cause the repairs should be made...

Page 232: ...ouling 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 properly Restricted air filters fuel filters and crankcase deposits due to lack of oil changes or improper oil viscosity can trigger actual vehicle faults that were not previously monitored prior to OBD...

Page 233: ... 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 module commands Components where functional monitoring is not feasible will be monitored for circuit conti nuity and out of range values if applicable Output com ponents to be monitored include but ar...

Page 234: ...t 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 functional checks are designed to locate a faulty circuit or component through a process of logical decisions The charts are prepared with the re quirement that the vehicle functioned correctly at the t...

Page 235: ...non 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 not store a Freeze Frame S Stores Fail Record when test fails S Updates the Fail Record each time the diagnostic test fails Important Only four Fail Records can be stored Each Fail Record is for a diff...

Page 236: ...ion 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 display type B DTCs that have not requested the Malfunction Indicator Lamp MIL It will display all type A and B DTCs that have requested the MIL and have failed within the last 40 warm up cycles In addi...

Page 237: ...verification 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 diagnosis is required Prior to repairing a vehicle status information can be used to evaluate the state of the diagnostic test and to help identify an intermittent problem The technician can con clude t...

Page 238: ...is 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 cylinders number 1 and 4 The misfire diagnostic may indicate a fault due to a tempo rary fault not necessarily caused by a vehicle emission system malfunction Examples include the following items S ...

Page 239: ... 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 Exhaust Manifold Nuts 40 30 Catalytic Converter to Front Muffler Pipe 30 22 Exhaust Manifold Cover Bolts 15 11 Front Connecting Pipe to Auxiliary Catalytic Converter Nuts 40 30 Front Muffler Pipe to Cata...

Page 240: ...EXHAUST 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 Catalytic Converter ...

Page 241: ...PE 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 the gasket from the front muffler 4 Disconnect the main catalytic converter and the connecting pipe from the rubber hanger ...

Page 242: ...pipe 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 Tighten Tighten the front connecting pipe to auxiliary cata lytic converter nuts to 35 NSm 26 lb ft 4 Install the post converter heated oxygen sensor Tighten Tighten the post converter heated oxygen ...

Page 243: ...IARY 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 auxiliary catalytic converter upper flange nuts ...

Page 244: ...Position 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 Tighten the front connecting pipe to auxiliary cata lytic converter nuts to 35 NSm 26 lb ft 3 Install the remaining auxiliary catalytic converter upper flange nuts Tighten Tighten the auxiliary catalytic c...

Page 245: ...st 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 nuts and the gasket that secure the front muffler pipe to the catalytic converter flange ...

Page 246: ...uffler 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 pipe to the rear rubber hanger near the rear muffler pipe holding clamp 2 Place the front muffler pipe into the rear muffler pipe 3 Secure the front muffler pipe to the rear muffler pipe with the holdi...

Page 247: ...atalytic 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 pipe holding clamp nut and the washer 2 Spread the loosened holding clamp and position it away from the junction of the front muffler pipe and the rear muffler pipe 3 Separate the rear muffler pipe from...

Page 248: ...uffler 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 tail pipe trim ring if equipped on the rear muffler pipe 2 Secure the exhaust pipe trim ring on the rear muf fler pipe and tighten the exhaust trim ring bolt until it bottoms out on the exhaust pipe ...

Page 249: ...he 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 muffler pipe holding clamp nut to 70 NSm 52 lb ft ...

Page 250: ...oint 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 the rear muffler assembly Heat shields in the front and the rear muffler assembly positions as well as in the catalytic converter protect the vehicle and the environment from high temperatures de velop...

Page 251: ...SECTION 3 WIRING DIAGRAM FOR POWER SUPPLIES ...

Page 252: ...3 2WWIRING DIAGRAM FOR POWER SUPPLIES 1 IGNITION SWITCH CIRCUIT ...

Page 253: ...WIRING DIAGRAM FOR POWER SUPPLIESW3 3 2 30 Ter BAT POWER SUPPLY CIRCUIT PASSENGER ROOM FUSE BOX ...

Page 254: ...3 4WWIRING DIAGRAM FOR POWER SUPPLIES 3 15A IGN 2 15C ACC POWER SUPPLY CIRCUIT PASSENGER ROOM FUSE BOX ...

Page 255: ...WIRING DIAGRAM FOR POWER SUPPLIESW3 5 4 ENGINE ROOM FUSE RELAY CIRCUIT ...

Page 256: ...3 6WWIRING DIAGRAM FOR POWER SUPPLIES ...

Page 257: ...WIRING DIAGRAM FOR POWER SUPPLIESW3 7 ...

Page 258: ... 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 FASTENER TIGHTENING SPECIFICATIONS Application N m Lb Ft Lb In Axle Shaft Caulking Nut Initial Torque 180 134 Axle Shaft Caulking Nut Final Torque 50 60 37 60 Lower Ball Joint Nut and Bolt 60 44 Tie Rod ...

Page 259: ... 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 FRONT DRIVE AXLE ...

Page 260: ... 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 11 Tripot Joint Retaining Ring 12 Tripot Joint 13 Shaft Retaining Ring 14 Tripot Housing ...

Page 261: ...eels 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 and bolt Notice Use only the recommended tool for separating the lower ball joint Failure to use the recommended tool may cause damage to the ball joint and the seal 6 Separate the steering knuckle fr...

Page 262: ...KM 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 after it has been removed from the wheel hub Important Place a drain pan below the transaxle to catch the escaping fluid Cap the transaxle drive opening after the drive axle has been removed to keep th...

Page 263: ... 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 tie rod into the knuckle strut and install the tie rod nut Tighten Tighten the tie rod nut to 60 N m 44 lb ft ...

Page 264: ...9 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 Then tighten the nut further by 60 degrees 11 Peen the caulking nut with a punch and a hammer until the nut is locked into place on the axle shaft hub 12 Install the engine under covers Refer toSecti...

Page 265: ...ve 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 performance and safety 6 Remove the seal from the joint assembly Installation Procedure Tools Required J 35566 Seal Clamp Pliers 1 Install the seal onto the axle shaft 2 Spread the snap ring using the snap ...

Page 266: ... 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 Procedure 1 Remove the drive axle from the vehicle Refer to Drive Axle Assembly in this section 2 Remove the large seal retaining clamp Discard the clamp 3 Remove the small seal retaining clamp Discard...

Page 267: ...RIVE 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 the snap ring pliers J 8059 ...

Page 268: ...xle 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 shaft 3 Install the tripot joint retaining ring and the tripot onto the axle shaft 4 Install the shaft retaining ring onto the axle shaft using the snap ring pliers J 8059 ...

Page 269: ... 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 clamp using the seal clamp pli ers J 35566 9 Crimp the new small seal retaining clamp using the seal clamp pliers J 35566 10 Install the drive axle shaft to the vehicle Refer to Drive Axle Assembly ...

Page 270: ...es 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 is also flexible but it can not move in and out The drive axles use one type of outboard joint and one type of inboard joint The inboard ends of both drive axles incor porate a female spline that ins...

Page 271: ...SECTION 4 USAGE AND CAPACITY OF FUSES ...

Page 272: ...ard 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 Illumination 58 Ef 21 10A Illumination LH Ef 22 15A ECM 30 BAT Blade Type Fuse Ef 23 Not Used 30 BAT Blade Type Fuse Ef 24 15A Brake Lamp Stop Lamp Li ht 58 Ef 25 10A Head Lamp Hi Beam RH Light 58 Ef...

Page 273: ...RL 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 Audio Cigarette Lighter Key BTSI F10 15A Auto Antenna Audio F11 Not Used BAT 30A F12 Not Used BAT 30A F13 15A Anti Theft F14 10A DLC 16 Terminal System Voltage F15 10A ABS A C Defroster Ignition Rela...

Page 274: ...rks 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 Interlock Unit 96312299 4 UPPER DRIVER LEG ROOM Part Name Part No Remarks Chime Bell 96219056 5 BEHIND LEFT HEAD LAMP Part Name Part No Remarks Radiator Cooling Fan Control Relay 96312958 6 BEHIND DRIV...

Page 275: ...RAKE 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 BRAKES 4A 10 PRESSURE BLEEDING THE BRAKES 4A 13 BRAKE HOSE REAR 4A 14 BRAKE HOSE FRONT 4A 15 STOPLAMP SWITCH 4A 17 BRAKE PEDAL 4A 17 GENERAL DESCRIPTION AND SYSTEM OPERATION 4A 19 HYDRAULIC FLUID 4A 19 SP...

Page 276: ...0 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 Cylinder Diameter Maximum Nominal FASTENER TIGHTENING SPECIFICATIONS Application NSm Lb Ft Lb In Bleeder Screw 8 53 Brake Lines 16 12 Front Disc Brake Hose to Caliper Bolt 40 30 Rear Disc Brake Hose to C...

Page 277: ...d 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 1st Front Brake Pipe 15 1st Rear Brake Pipe B 16 LHD Master Cylinder Booster Assembly 17 LH Rear Brake Hose 18 LH 3rd Rear Brake Pipe ...

Page 278: ...Clip 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 1st Rear Brake Pipe B 14 LHD Master Cylinder Booster Assembly 15 LH Rear Brake Hose 16 LH 3rd Rear Brake Pipe ...

Page 279: ...ot 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 swollen primary cylinder or piston seals If swollen seals are found substandard or contaminated brake fluid should be suspected If contaminated brake fluid is found all the components should be disas...

Page 280: ...el 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 have been properly performed and the brake warning lamp is off after disconnect ing the electronic brake control module EBCM J1 connector the EBCM is faulty 19 If the brake warning lamp does not ope...

Page 281: ...n 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 11 Go toStep 10 10 Replace the parking brake switch Is the repair complete System OK 11 Connect the parking brake switch Is the vehicle equipped with ABS Go toStep 12 Go toStep 14 12 1 Turn the igni...

Page 282: ...e 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 instrument cluster connector 2 Turn the ignition ON 3 Measure the voltage at the instrument cluster connector terminal A2 Does the voltagemeasurewithin the value specified 11 14 v Go toStep 25 Go toStep 26 2...

Page 283: ...em 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 Connect a test light between battery positive and the BRN WHT wire terminal of the brake fluid level switch Is the test light on Go toStep 34 Go toStep 35 34 Repair the open in the wiring between gro...

Page 284: ... 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 bleeding operation 3 Disconnect the front brake line s at the master cyl inder 4 Allow the brake fluid to fill the master cylinder until it begins to flow from the front pipe connector port 5 Connect...

Page 285: ...ait 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 brake fluid from contacting any painted surface to prevent damage to the paint finish 10 After all the air has been removed at the forward connection s bleed the master cylinder at the rear cowl connect...

Page 286: ...screw 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 secondary piston down the bore in a man ner that makes it difficult to bleed the system 15 Repeat the sequence including the 15 second wait until all the air is removed It may be neces sary to repeat th...

Page 287: ...2 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 front 8 Attach the bleeder hose to the bleeder valve Sub merge the opposite end of the hose in a clean con tainer partially filled with brake fluid 9 A107A006 Open the bleeder valve one half to thre...

Page 288: ...r 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 rear disc brake hose and retainer on the bracket on the steering knuckle shaft 3 Install the rear disc brake line to the brake hose on the wheel housing bracket Tighten Tighten the brake line to 16 NSm ...

Page 289: ...vehicle 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 steering knuckle shaft 5 Remove the bolt from the brake caliper 6 Remove the seal rings and the disc brake hose ...

Page 290: ...hose 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 vehicle Tighten Tighten the brake line to 16 NSm 12 lb ft 4 Lower the vehicle 5 Bleed the brake system Refer to Manual Bleeding the Brakes in this section 6 Check the brake system for leaks ...

Page 291: ...l 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 pedal and pull the switch plunger to its maximum setting to adjust the switch 4 Release the plunger and pull up on the pedal 5 Connect the negative battery cable BRAKE PEDAL Removal Procedure 1 Remove...

Page 292: ...ake 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 return spring in the brake pedal bracket and install the shaft the wash er and the nut Tighten Tighten the shaft nut to 18 NSm 13 lb ft 3 Install the retaining clip into the hole in the pedal shaft 4 ...

Page 293: ...id 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 fluid level switch in the master cylinder reservoir When the fluid level is low the BRAKE lamp in the instru ment cluster will turn on The correct brake fluid level is marked on the driver s side of the ...

Page 294: ... 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 motor pack assembly controls the hydraulic pressure to both the rear wheel cyl inders or rear calipers and the front calipers When checking the brake proportioning valves be sure that the hydraulic lin...

Page 295: ...EWOO 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 on the remaining circuit ...

Page 296: ...hicles 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 cylinder and move the clip out of the way 5 Remove the clutch hose from the master cylinder if equipped 6 Plug the opening to the brake lines to prevent fluid loss and contamination 7 Remove the att...

Page 297: ... 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 transaxle connect the clip to the clutch hose connection to the master cyl inder reservoir if equipped 5 Connect the electrical connector on the reservoir cap 6 Add brake fluid 7 Check for leaks and reche...

Page 298: ...m 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 master cylinder 4 Gently pry upwards with a screwdriver to release the reservoir 5 Tilt the reservoir and pull it upward in order to re move it 6 Remove the reservoir seals from the master cylin der...

Page 299: ...ody 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 Refer toSection 4A Hy draulic Brakes orSection 4F Antilock Brake Sys tem 7 Bleed the clutch master cylinder Refer toSection 5C Clutch 8 Lower the vehicle 9 Connect the reservoir electrical connector...

Page 300: ...justed 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 the brake lines to the valves Tighten Tighten the brake lines to 16 NSm 12 lb ft 3 Raise and suitably support the vehicle 4 Bleed the braking system Refer toSection 4A Hy draulic Brakes or Section 4...

Page 301: ...bore 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 Remove and discard the retaining ring from the cyl inder body the non ABS master cylinder body is shown using a suitable screwdriver 5 Remove the primary piston the ABS master cylin der body is shown...

Page 302: ...dent 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 secondary piston contacts the base of the cylinder body Use a wood or a plastic drift if nec essary 5 Insert the primary piston 6 Press the pistons into the cylinder bore using a wooden or a plastic dr...

Page 303: ...ston 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 section 12 Raise and suitably support the vehicle 13 Bleed the braking system Refer toSection 4A Hy draulic Brakes or Section 4F Antilock Brake Sys tem 14 Lower the vehicle ...

Page 304: ...ease 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 the brake system S The torque values specified are for dry unlubri cated fasteners S Perform all service operations on a clean bench free from all traces of mineral oil PROPORTIONING VALVE The proport...

Page 305: ... 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 22 16 Booster Pushrod Hex Nut 18 13 Brake Line Fittings 16 12 DIAGNOSIS POWER BOOSTER FUNCTIONAL CHECK 1 With the engine stopped eliminate vacuum in the booster by pumping the brake pedal several ti...

Page 306: ...ion 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 booster 4 Remove the vacuum hose Installation Procedure 1 Mount the vacuum hose and ensure the connec tions are tight on each end 2 Install the vacuum hose clips 3 Check the function of the booster ...

Page 307: ... 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 from the brake pedal bracket 6 Remove the brake pedal spring 7 Disconnect the clip and the pushrod pin from the pedal bracket assembly Refer toSection 4A Hy draulic Brakes ...

Page 308: ... 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 the hex nut from the pushrod ...

Page 309: ...oper 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 cen ter of the clevis bore Important This measurement should be 203 mm 8 inch es 4 Install the rubber boot on the booster ...

Page 310: ...8 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 in this section 10 Install the hose clamps on the vacuum hose and snap the vacuum hose in the revolving clip 11 Install the pushrod pin to the brake pedal bracket assembly and connect the clip and th...

Page 311: ...lied 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 diaphragm When the brakes are released atmospheric pressure is shut off and the vacuum source creates equal pressure on both sides of the diaphragm by means of a one way valve in the power booster Importan...

Page 312: ...ckle 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 and wear 4 Measure the thickness Important The minimum thickness of the inner or outer pad is 9 mm 0 35 inch 1 Install the brake pads in axle sets only 2 Install the front wheels Refer toSection 2E Tir...

Page 313: ... 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 to the wheel hub with two wheel bolts 4 Fasten a dial indicator to the brake caliper 5 Set the gauge probe tip to approximately 10 mm 0 39 inch from the outer edge of the brake rotor perpendicular to t...

Page 314: ...ly 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 mounting bolt Important Caliper removal is not necessary to service the brake shoes 4 Pivot the caliper upward 5 Remove the brake shoes ...

Page 315: ...r 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 the wheel Refer toSection 2E Tires and Wheels 5 Lower the vehicle CALIPER Removal Procedure 1 Raise and suitably support the vehicle 2 To preserve wheel balance mark the position of the front wheel rel...

Page 316: ...on 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 24 lb ft 3 Connect the caliper inlet hose with the bolt and the washers Tighten Tighten the brake hose to caliper bolt to 40 NSm 30 lb ft ...

Page 317: ...ir 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 into contact with the rotor Do not move the vehicle until a firm pedal is obtained ROTOR Removal Procedure 1 Remove the caliper Refer to Caliper in this sec tion 2 Remove the brake pads 3 Remove the ...

Page 318: ...e 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 to steering knuckle mounting bolts to 95 NSm 70 lb ft 3 Install the brake pads and the caliper See Caliper in this section SPLASH SHIELD Removal Procedure 1 Remove the rotor Refer to Rotor in this sec...

Page 319: ...21 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 rotor Refer to Rotor in this section ...

Page 320: ...ting 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 piece of hardwood into the caliper to prevent damage to the piston 2 Apply unlubricated compressed air at the hose inlet of the caliper 3 Remove the piston from its bore and remove the piston dust se...

Page 321: ...nstall 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 piston inner seal into the groove in the caliper bore 6 Install the piston dust seal in its groove 7 Lubricate the piston with brake fluid 8 Push the piston inward until it is properly seated Make s...

Page 322: ... 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 Lubricate the rubber parts with clean brake fluid to ease assembly S Do not use lubricated shop air on brake parts as damage to the rubber components may result S If any hydraulic component is remove...

Page 323: ...ON 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 OPERATION 4E 18 DISC BRAKE CALIPER 4E 18 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application NSm Lb Ft Lb In Bleeder Valve 11 97 Brake Hose Caliper Inlet Bolt 32 24 Caliper Bracket Mounting Bolts ...

Page 324: ... 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 acceptable if it does not exceed 0 40 mm 0 016 inches in depth Scoring mea surements can be made with a commercially available brake micrometer Lateral runout cannot exceed 0 10 mm 0 004 inches If l...

Page 325: ...pport 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 mounting bolt Important It is not necessary to remove the caliper to service the brake shoes 4 Pivot the caliper upward 5 Remove the brake shoes ...

Page 326: ...rd 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 Tires and Wheels 6 Lower the vehicle CALIPER Removal Procedure 1 Raise and suitably support the vehicle 2 To preserve wheel balance mark the position of the rear wheels relative to the wheel hubs and r...

Page 327: ...amination 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 the brake hose and the washers with the mounting bolt Tighten Tighten the brake hose caliper inlet bolt to 32 NSm 24 lb ft ...

Page 328: ...edly 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 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 Notice To prevent damage to the brake hose do not hang th...

Page 329: ...ighten 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 wheels Refer toSection 2E Tires and Wheels 6 Lower the vehicle SPLASH SHIELD BACKPLATE AND PARKING BRAKE LEVER Removal Procedure 1 Remove the rotor Refer to Rotor in this section 2 Disconnect the park...

Page 330: ...e 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 the splash shield backplate parking brake shoe assembly from the steering knuckle ...

Page 331: ...e 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 Remove and discard the adjuster screw and the nut ...

Page 332: ... 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 retainer from the backplate 15 Remove and discard the lever and the adjuster pawl ...

Page 333: ...inhaled 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 centered on the splash shield with the shoe tips located correctly in the slots 3 Inspect the splash shield for rust or any other dam age Replace the splash shield if necessary 4 Install the new adjus...

Page 334: ...nal 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 screw Tighten Tighten the splash shield bolts to 25 NSm 18 lb ft Tighten the parking brake shoe hold down spring as sembly screw to 3 5 NSm 31 lb in 10 Connect the new parking brake adjustment screw to...

Page 335: ... 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 Important The shoe assembly must be resting on the splash shield with the brand side up Important Clean hands are required when handling the parking brake shoe 14 Install the parking brake shoe engaging the ...

Page 336: ...ut 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 on each side of the vehicle 18 Adjust the parking brake Refer toSection 4G Park ing Brake 19 Install the rotor Refer to Rotor in this section ...

Page 337: ...e 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 port and progressively increase the air pres sure until the piston is forced out of the bore 4 Remove and discard the outer dust seal 5 Remove the inner seal and discard it Do not scratch the piston b...

Page 338: ... 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 the bleeder valve 2 Inspect the piston and the caliper for scoring and corrosion Replace any components that show these conditions 3 Insert the bleeder valve and the dust cover Tighten Tighten the ble...

Page 339: ...ston 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 boots are damaged or if the guide pins do not slide easily replace these parts Lubricate the guide pins with a lithium soap base glycol grease or other grease which will not deteriorate or swell the ...

Page 340: ...friction 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 clean brake fluid to ease assembly S Do not use lubricated shop air on brake parts be cause oil will deteriorate rubber seals S If any hydraulic component is removed or discon nected it may be necessary...

Page 341: ... 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 ABS ENABLE RELAY COIL CIRCUIT SHORTED TO GROUND 4F 34 DTC A018 ABS RELAY COIL CIRCUIT SHORTED TO BATTERY 4F 36 DTC A021 LEFT FRONT WHEEL SPEED 0 4F 38 DTC A022 RIGHT FRONT WHEEL SPEED 0 4F 42 DTC A02...

Page 342: ...ED 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 OPEN STOPLAMP SWITCH DURING DECELERATION 4F 168 DTC A092 OPEN STOPLAMP SWITCH WHEN ABS WAS REQUIRED 4F 171 DTC A093 CODE A091 OR A092 SET IN CURRENT OR PREVIOUS IGNITION CYCLE 4F 174 DTC A094 STOPLAMP...

Page 343: ...NSORS 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 Solenoid Torx Head Bolts 4 5 40 Bleeder Valve 9 80 Brake Pipe Nuts 15 11 Front Wheel Speed Sensor Bolt 7 8 69 Gear Cover Torx Head Screws 4 35 Gear Nuts 8 5 75 Hydraulic Modulator Motor Pack Assembly...

Page 344: ...eft 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 Connector C206 20 Right Side Hydraulic Modulator Bleeder Valve 21 Right Side Isolation Solenoid 22 Proportioning Valves 23 Hydraulic Modulator Motor Pack Assembly 24 Motor Pack Electrical Connector 25 Left S...

Page 345: ...ANTILOCK BRAKE SYSTEM 4F 5 DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS ABS CIRCUIT 1 OF 4 ...

Page 346: ...4F 6IANTILOCK BRAKE SYSTEM DAEWOO V 121 BL4 ABS CIRCUIT 2 OF 4 ...

Page 347: ...ANTILOCK BRAKE SYSTEM 4F 7 DAEWOO V 121 BL4 ABS CIRCUIT 3 OF 4 ...

Page 348: ...4F 8IANTILOCK BRAKE SYSTEM DAEWOO V 121 BL4 ABS CIRCUIT 4 OF 4 ...

Page 349: ...Wheel 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 Used B1 RRWSLO WHT Right Rear Wheel Speed Low B2 LRWSLO RED Left Rear Wheel Speed Low B3 RFWSLO WHT Right Front Wheel Speed Low B4 LFWSLO WHT Left Front Wheel Speed Low B5 BRAKETT BRN BLK BRAKE Lamp B6...

Page 350: ...4F 10IANTILOCK BRAKE SYSTEM DAEWOO V 121 BL4 Pin Circuit Color Signal Name B11 Not Used B12 BATT ORN Battery ...

Page 351: ...gnal 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 Motor Low C6 RAMOTHI PPL Rear Axle Motor HIgh C7 SWBATT RED Battery through ABS relay C8 GND BLK Ground ...

Page 352: ...ECIFICATIONS 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 BRAKE HANDLE 4G 10 GENERAL DESCRIPTION AND SYSTEM OPERATION 4G 11 PARKING BRAKE 4G 11 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application NSm Lb Ft Lb In Fuel Tank Retaining Strap Nut 12 5 111...

Page 353: ...uality 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 the shoe assembly diameter as closely as possible to the center of the lining material 9 Inspect and install the rotors and calipers Refer toSection 4E Rear Brakes 10 Install the parking brake cable ...

Page 354: ...Refer 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 assembly 5 Detach the eye bolt pull rod but leave the pull rod connected to the equalizer which is attached to the parking brake cables ...

Page 355: ...tached 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 assembly 1 Fasten the parking brake switch to the parking brake lever assembly with the screw Tighten Tighten the parking brake switch to parking brake lever screw to 4 NSm 35 lb in ...

Page 356: ...r 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 Parking Brake Adjustment in this section 5 Install the center console Refer toSection 9G Inte rior Trim PARKING BRAKE CABLE Removal Procedure 1 Remove the center console Refer toSection 9G Interior Trim ...

Page 357: ...r 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 steering knuckle assembly 8 Remove the nut securing the parking brake cable to the underbody clip on both the driver and passen ger sides of the vehicle ...

Page 358: ... 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 of the welded under body bracket 12 Remove the parking brake cable and rubber grom met ...

Page 359: ... 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 to 12 NSm 106 lb in 5 Install the parking brake cable passenger s side to the clip near the fuel tank strap 6 Route the parking brake cable through the loop of a welded underbody bracket and under the...

Page 360: ...0 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 gearshift console hood Refer toSection 9G Interior Trim 14 If the parking brake shoe lever was pressed back ward before removing the brake drum now press it forward and adjust the parking brake Refer t...

Page 361: ...he 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 the parking brake lever 2 Install the center console and the parking brake lever boot Refer toSection 9G Interior Trim ...

Page 362: ...rning 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 firmly applied the parking brake should hold the vehicle with ample pedal travel remaining Check for frayed cables rust etc or any condition that many in hibit present or future free movement of the ...

Page 363: ...SECTION 5 ELECTRICAL WIRING DIAGRAMS ...

Page 364: ...e Control Engine Room Fuse Box C106 2 Pin Colorless Engine Room Fuse Box Ĉ Body Engine Room Fuse Box C203 15 Pin White I P Ĉ Body Left Driver Leg Room Connector Holder C205 20 Pin Colorless I P Ĉ Body Right Driver Leg Room Connector Holder C209 20 Pin Colorless I P Ĉ Engine Control Upper Co driver Right Kick Panel S202 Blue IP Upper Driver Leg Room G102 Battery ABS Between Battery and Fuse Box G10...

Page 365: ...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 366: ...2ND 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 26 FORWARD CLUTCH ASSEMBLY 5A 27 FORWARD CLUTCH SUPPORT ASSEMBLY 5A 28 FINAL DRIVE AND DIFFERENTIAL ASSEMBLY 5A 29 MANUAL SHAFT PARKING PANEL AND ACTUATOR ASSEMBLY 5A 30 CASE AND ASSOCIATED PARTS 1 O...

Page 367: ...IRD 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 MANUAL SECOND SECOND GEAR 5A 76 NO ENGINE BRAKING MANUAL FIRST FIRST GEAR 5A 77 DRIVES IN NEUTRAL 5A 77 NO GEAR SELECTION 5A 77 SHIFT OCCURS WITHOUT ENGAGING BRAKE PEDAL 5A 77 SHIFT INDICATOR INDICATES W...

Page 368: ...AN 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 TRANSA...

Page 369: ...RSE 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 CLUTCH HUB INSTALL 5A 226 REACTION INTERNAL GEAR INPUT CARRIER DISASSEMBLE 5A 226 INPUT CARRIER PINION GEAR CLEARANCE CHECK 5A 226 REACTION INTERNAL GEAR INPUT CARRIER ASSEMBLE 5A 227 REACTION INTERNA...

Page 370: ...AND 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 TRANSAXLE COMPONENT AND SYSTEM DESCRIPTION 5A 280 RANGE REFERENCE CHART 5A 283 BTSI AND KEY INTERLOCK SYSTEM 5A 284 AUTOMATIC TRANSMISSION VEHICLE SPEED SENSOR A T VSS 5A 284 AUTOMATIC TRANSMISSION INPUT S...

Page 371: ... 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 SPECIFICATIONS Dimension A mm Backing Plate Identification 8 970 9 433 A 9 434 10 007 B 10 008 10 470 C FLUID CAPACITY Litres Quarts Bottom Pan Removal 6 5 6 9 Complete Overhaul 9 0 9 5 Dry 12 2 12 9 ...

Page 372: ... 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 O O H O A Applied H Holding O Overrunnig ON The solenoid is energized OFF The solenoid is de energized Applied with no load Manual Second Third gear is only available above approximately 100 km h 62...

Page 373: ...E 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 10 50 FASTENER TIGHTENING SPECIFICATIONS Application NSm Lb Ft Lb In A T VSS Stud 12 106 Bell Housing Bolts 75 55 Channel Plate to Case Bolt 12 9 Channel Plate to Case Valve Body Bolts 12 106 Channel...

Page 374: ...lt 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 Mounting Bracket Nuts 6 53 Shift Control Lever Bolt Shift Interlock Solenoid Bolts Side Cover Bolts 20 15 Side to Case Stud Cover 20 15 Speed Sensor Stud 12 9 Transaxle Brace Mounting Bolts 75 55 Tra...

Page 375: ...LS 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 Adapter Kit J 35689 A Metri pack Terminal Remover J 36169 A Fused Jumper Wire ...

Page 376: ...Digital 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 Output Shaft Sleeve Remover J 41101 Pass Through Connector Remover J 36850 Assembly Lubricant ...

Page 377: ...Torque 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 Compressor Adapter J 41232 Direct Reverse Second Clutch Return Spring Compressor Adapter J 41228 Stub Shaft Sleeve Installer ...

Page 378: ...J 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 Shaft End Play Gauge Block J 41233 Reverse Clutch Inner Seal Installer J 41235 Second Roller Clutch Installer J 29569 1 J 29829 1 Turbine Shaft Seal Installer ...

Page 379: ...14I4T40 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 Fixture ...

Page 380: ...4T40 E AUTOMATIC TRANSAXLE 5A 15 DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS POWERTRAIN CONTROL MODULE 1 OF 3 ...

Page 381: ...5A 16I4T40 E AUTOMATIC TRANSAXLE DAEWOO V 121 BL4 POWERTRAIN CONTROL MODULE 2 OF 3 ...

Page 382: ...4T40 E AUTOMATIC TRANSAXLE 5A 17 DAEWOO V 121 BL4 POWERTRAIN CONTROL MODULE 3 OF 3 ...

Page 383: ...AXLE 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 7 Manufacturer 8 Part Number ...

Page 384: ...5B 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 SHIFT LINKAGE ADJUSTMENT 5B 15 GEARSHIFT LEVER 5B 17 GEARSHIFT TUBE BOOT BUSHING AND OR BEARING RING 5B 18 CONTROL SHIFT ROD 5B 23 LINKAGE LEVER AND OR BUSHINGS 5B 24 SPEEDOMETER DRIVEN GEAR 5B 30 SH...

Page 385: ...5 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 Bracket Bolts 47 35 Left Rear Transaxle Support Bracket Bolts 47 35 Lower Transaxle to Engine Bolts 75 55 Ring Gear Bolts 70 52 Rod Clamp Bolt 14 124 Speedometer Housing Retaining Bolt 4 35 Speedomete...

Page 386: ...OLS 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 36633 Snap Ring Retainer KM 113 2 Base KM 334 Installer Sleeve ...

Page 387: ...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 388: ...axle 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 Since wheel bearings are not pre loaded a wheel bearing noise should diminish con siderably when the wheels are off the ground Other Noise Brinelling A brinelled bearing causes a knock or click approxi m...

Page 389: ...haft 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 gear bearing S Replace any worn mainshaft bearings Check for a noise in the first gear 1 only S Replace any chipped scored or worn first gear constant mesh gears S Replace any worn first second gear syn...

Page 390: ... 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 replace the linkage as needed S Adjust repair or replace any binding shift linkage S Tighten or replace the input gear bearing retainer as needed S Repair or replace any worn or bent shift fork Check fo...

Page 391: ... 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 gear synchronizer S Replace any worn second gear bearing S Replace any worn third gear bearing S Replace any worn third fourth synchronizer S Replace any worn fourth gear bearing S Replace any worn reve...

Page 392: ...FIVE SPEED MANUAL TRANSAXLE 5B 9 DAEWOO V 121 BL4 COMPONENT LOCATORS GEARS AND CASE ...

Page 393: ...3 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 Screw 50 Synchronizer Gear 51 Spring 52 Synchronizer Sleeve 53 Synchronizer Blocking Ring 54 Mainshaft Driven Fifth Gear 55 Ring 56 Thrust Washer 57 Ring 58 Input Drive Fifth Gear 59 Bolt 60 Cluster G...

Page 394: ...8 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 Gear 19 Washer 20 Pinion Gear 21 Ring Gear 22 Speedometer Drive Gear 23 Bolt 24 Pinion Shaft Lock Pin 25 Right Side Bearing Retainer 26 Seal 27 Retainer Bolt ...

Page 395: ...5B 12IFIVE SPEED MANUAL TRANSAXLE DAEWOO V 121 BL4 SHIFT LINKAGE ...

Page 396: ...Linkage 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 Shift Finger Lever 25 Cover Bolt 26 Intermediate Lever 27 Shift Lever Thrust Spring 28 Bushing 29 Snap Ring 30 Oil Filler Plug 31 Oil Plug Cap 32 Gearshift Lever Cover 33 Pin 34 Bolt 35 Gearshift Ad...

Page 397: ... 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 HYDRAULIC 5C0 17 AIR BLEEDING 5C0 17 CLUTCH MASTER CYLINDER ASSEMBLY 5C0 17 CLUTCH RELEASE CYLINDER ASSEMBLY 5C0 20 UNIT REPAIR 5C0 21 CLUTCH MASTER CYLINDER 5C0 21 CLUTCH RELEASE CYLINDER 5C0 23 GENERAL D...

Page 398: ...hub 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 improperly operating the vehicle Correct the driver s operation of the vehicle as necessary Check for an oil soaked clutch disc Correct the leak at its source and install a new clutch disc Check for a ...

Page 399: ...th 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 lubricate the release bearing Inspect the re lease bearing for burrs and nicks Check for an improperly installed release lever Remove and reinstall the release lever properly Check for a weak linkage ...

Page 400: ...5 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 Release Bearing 20 Fork 21 Bushing 22 Bolt 23 Bolt 24 Pressure Plate 25 Clutch Disc 26 Nut 27 Spring Washer 28 Bushing ...

Page 401: ...on 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 Washer 21 Clutch Pedal Bushing 22 Hydraulic Clutch Pipe 23 Clip 24 Clutch Pedal Position Switch 25 Clutch Pedal Position Switch Adjusting Screw ...

Page 402: ...5C0 6ICLUTCH DAEWOO V 121 BL4 1 Flywheel 2 Clutch Disc 3 Pressure Plate 4 Release Bearing ...

Page 403: ... 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 the piston rod bolt 5 Remove the clutch pedal with the return spring from the vehicle ...

Page 404: ...od 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 nut Tighten Tighten the clutch pedal nut to 18 NSm 13 lb ft 6 Connect the return spring to the mount brace 7 Connect the negative battery cable ...

Page 405: ...ent 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 not start when the clutch pedal is fully pressed down turn the clutch pedal position switch adjusting screw until the clutch pedal posi tion switch is engaged so that the engine will start Do not adjus...

Page 406: ...ft 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 Manual Transaxle 6 Remove the pressure plate bolts and the pressure plate Support the pressure plate when you remove the last bolt 7 Remove the clutch disc 8 Remove the release fork bolt ...

Page 407: ... 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 bushings ...

Page 408: ...LUTCH 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 axle case ...

Page 409: ... 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 and the bolts Tighten Tighten the release bearing guide sleeve bolts to 5 NSm 45 lb in 4 Coat the sleeve surface with multi purpose grease ...

Page 410: ...hing 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 release lever shaft from the top of the transaxle Guide the shaft through the clutch fork ...

Page 411: ...hten 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 engine under covers Refer to Section 9N Frame and Underbody 16 Install the left front wheel Refer to Section 2E Tires and Wheels 17 Lower the vehicle 18 Connect the negative battery cable CLUTCH PED...

Page 412: ... 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 clutch pedal travel Loosen the locknut and turn the bolt Clutch pedal travel should mea sure more than 130 mm 5 1 inches Tighten the locknut after adjustment ...

Page 413: ...ered 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 bleeder plug Place the other end of the vinyl tube in a glass container half filled with brake fluid 2 Slowly pump the clutch pedal several times 3 While you press the clutch pedal loosen the bleed er sc...

Page 414: ...connected 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 master cylinder in the direction of the engine compartment ...

Page 415: ...ll 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 reservoir hose to themaster cylinder and tighten the spring clamp ...

Page 416: ... 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 ASSEMBLY Removal Procedure 1 Disconnect the negative battery cable 2 Remove the bolt and disconnect the hose from the clutch release cylinder 3 Remove the clutch release cylinder bolts and re move th...

Page 417: ...not 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 fluid up to the MAX level 7 Connect the negative battery cable UNIT REPAIR CLUTCH MASTER CYLINDER Disassembly Procedure 1 Remove the clutch master cylinder assembly from the vehicle Refer to Clutch M...

Page 418: ...ushrod 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 and the pushrod assem bly into the master cylinder body 2 Install the piston stop ring using ring pliers Install the boot 3 Install the clutch master cylinder assembly into the vehicle Refer to Clutc...

Page 419: ...he 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 with a driver then remove the snap ring with snap ring pliers 5 Remove the piston assembly ...

Page 420: ...g 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 brackets and the bolts 6 Install the clutch release cylinder assembly Refer to Clutch Master Cylinder Assembl in this section ...

Page 421: ...slide 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 exerted by a diaphragm spring in the pressure plate assembly OPERATING MEMBERS The clutch release system consists of the clutch pedal the clutch shaft the fork and the release bearing When pres sure...

Page 422: ...UFFICIENT HEATING OR DEFROSTING 7A 4 BLOWER ELECTRICAL 7A 7 IMPROPER AIR DELIVERY OR NO MODE SHIFT 7A 9 TOO MUCH HEAT 7A 11 CONTROLS 7A 13 BLOWER NOISE 7A 14 MAINTENANCE AND REPAIR 7A 16 ON VEHICLE SERVICE 7A 16 TEMPERATURE CABLE ADJUSTMENT 7A 16 TEMPERATURE CONTROL CABLE 7A 16 CONTROL ASSEMBLY 7A 18 CONTROL ASSEMBLY KNOB LIGHTING 7A 19 HEATER AIR DISTRIBUTOR CASE ASSEMBLY 7A 20 BLOWER MOTOR 7A 23...

Page 423: ...TENING SPECIFICATIONS Application NSm Lb Ft Lb In Blower Motor Resistor Screws 6 53 Blower Resistor Retaining Screws 6 53 Heater Core Cover Screw Heater Core Retaining Bracket Screw Heater Air Distributor Case Assembly Screws 8 71 HVAC Controller Retaining Screws 2 18 ...

Page 424: ...HEATING AND VENTILATION SYSTEM 7A 3 DAEWOO V 121 BL4 AIRFLOW THROUGH VENTS WITH REAR HEATING DUCT Rear heating duct available on vehicles in cold climate countries ...

Page 425: ...lem with the coolant hoses Is the repair complete System OK Go to Step 8 8 Check the surge tank cap Refer to Section 1D En gine Cooling Is the surge tank cap OK Go to Step 10 Go to Step 9 9 Repair or replace the surge tank cap as needed Is the repair complete System OK Go to Step 10 10 1 Turn the A C OFF on vehicles equipped with air conditioning 2 Turn the blower motor switch to 4 3 Turn the heat...

Page 426: ...bstructions 3 Repair any leaks or obstructions Are the repairs complete System OK 16 1 Turn the ignition OFF 2 Turn the temperature control knob from full cold to full hot 3 Listen for the sound of the temperature door slam just before reaching the end of the travel range of the control knob Does the door slam Go to Step 18 Go to Step 17 17 1 Check the following aspects of the temperature door S T...

Page 427: ...Mode Shift in this section Is the repair complete System OK Go to Step 27 27 Check for airflow from the defroster or the vent out lets Is there high airflow from the defroster or vent out lets Go to Step 28 Go to Step 29 28 Check the heater door at the floor and the vent door to get the proper airflow verify proper operation and repair as required Is the repair complete System OK 29 Turn the mode ...

Page 428: ...wer run at any speed Go to Step 14 Go to Step 3 3 1 Disconnect the power connector from the blow er motor under the dashboard on the passen ger s side of the vehicle 2 Turn the ignition ON 3 Turn the blower ON 4 Test the voltage on the connector The terminal connected to the PPL wire is positive and the terminal connected to the BLK wire is negative Is this voltage within the specified range 11 14...

Page 429: ... OK 14 Does the blower fail to operate at speed 4 Go to Step 15 Go to Step 21 15 Check fuse EF2 in the engine fuse block Is the fuse blown Go to Step 16 Go to Step 17 16 1 Turn the ignition ON 2 Turn the blower motor switch to 4 3 Use a short detector to locate the following possible shorts S From the engine fuse panel to the blower HI relay S From the blower HI relay to the blower mo tor 4 Repair...

Page 430: ...ree wires Go to Step 25 Go to Step 24 24 Replace the blower speed switch Is the repair complete System OK 25 Repair the open in the affected wire Is the repair complete System OK IMPROPER AIR DELIVERY OR NO MODE SHIFT This procedure provides a test of all functions of the heater defroster unit 1 Warm up the vehicle 2 Keep the engine running 3 Perform the tests outlined in the table below and look ...

Page 431: ...ct Results tests in this procedure Does the system perform properly System OK Go to Step 9 7 1 Check the vacuum hose at the control 2 Check for a broken control Is there a problem with the vacuum hose or the con trol Go to Step 8 Go to Step 9 8 Repair the vacuum hose or control as necessary Is the repair complete System OK Go to Step 9 9 Recheck the system using the Control Settings Correct Result...

Page 432: ... No 1 Verify the customer s complaint Are the customer s concerns verified Go to Step 2 System OK 2 Is there too much heat when the mode switch is in the floor position Go to Step 3 Go to Step 9 3 Is there objectionable defroster bleed Go to Step 4 Go to Step 5 4 1 Check the door travel the cable the vacuum actuators and the linkage for the heater and the defroster 2 Adjust or repair as required I...

Page 433: ...range at the control knob Does the door slam Go to Step 13 Go to Step 14 13 Adjust the vent door to allow more ventilation Is the repair complete System OK 14 1 Check the temperature door travel the cable and the linkage 2 Verify that the temperature door goes to full cold 3 Check the temperature door for full hot Is the temperature door travel correct System OK 15 1 Turn the fresh air recirculati...

Page 434: ...o Step 7 Go to Step 8 7 Repair as needed Is the repair complete System OK 8 1 Remove the cable from the temperature door 2 Cycle the door manually 3 Check for door binding Is there any door binding Go to Step 9 Go to Step 12 9 Check the door seal for proper installation Is the door seal OK Go to Step 10 Go to Step 11 10 1 Check a binding door for shaft alignment a bent shaft a bent door or a warpe...

Page 435: ...move all foreign material Is the repair complete System OK Go to Step 6 6 1 Examine the blower fan for wear spots cracked blades a cracked hub a loose fan re taining nut or bad alignment 2 Examine the blower case for wear spots Are there any problems Go to Step 7 Go to Step 9 7 Repair as required Is the repair complete System OK Go to Step 8 8 Replace the motor and the fan assembly Is the repair c...

Page 436: ... replace as needed Is the repair complete System OK 16 Is the noise present in all modes but not all tempera ture positions Go to Step 17 Go to Step 18 17 1 Check the temperature door seals 2 Repair or replace as needed Is the repair complete System OK 18 1 Check the system for obstructions or foreign materials between the fan and the temperature door 2 Repair or replace as needed Is the repair co...

Page 437: ...EMPERATURE CONTROL CABLE Removal Procedure 1 Disconnect the negative battery cable 2 Remove the glove box Refer to Section 9E Instru mentation Driver Information 3 Slide the cable eyelet off the post on the tempera ture door lever 4 Disconnect the cable retainer from the blower hous ing 5 Remove the audio system trim plate Refer to Sec tion 9F Audio Systems 6 Remove the four controller retaining s...

Page 438: ...ghten the HVAC controller retaining screws to 2 NSm 18 lb in 5 Install the temperature control cable eyelet to the post on the temperature door lever 6 Snap the cable retainer to the blower housing 7 Move the temperature control to verify the smooth operation and function of the door and the cable 8 Install the audio system trim plate Refer to Section 9F Audio Systems 9 Connect the negative batter...

Page 439: ... prying the cable eyelet from the post on the control ler Unsnap the cable housing from the mechanical slide Note the location of the cable and the housing for ease of installation 6 Disconnect the electrical connectors 7 Remove the vacuum hose connection block from the mode control switch Installation Procedure 1 Connect the vacuum hose connection block to the mode control switch 2 Press the cabl...

Page 440: ...through all of the controller s possible functioning positions 9 Install the audio system trim plate Refer to Section 9F Audio Systems CONTROL ASSEMBLY KNOB LIGHTING Removal Procedure 1 Disconnect the negative battery cable 2 Remove the heating and ventilation system control assembly Refer to Control Assembly in this sec tion 3 Disconnect the small connector to the vacuum con trol switch on the re...

Page 441: ...he two case halves 3 Install the connector into the vacuum control switch 4 Install the control assembly Refer to Control As sembly in this section 5 Connect the negative battery cable 6 Check the knob light for proper operation HEATER AIR DISTRIBUTOR CASE ASSEMBLY Removal Procedure 1 Disconnect the negative battery cable 2 Remove the instrument panel carrier assembly Re fer to Section 9E Instrume...

Page 442: ...ilter on the engine compart ment side of the bulkhead 9 Have an assistant support the heater air distributor case from inside the vehicle Notice Handle the case carefully to avoid damage to the mechanical door operating linkage 10 Remove the screws from the connecting block opening mount on the engine compartment side of the bulkhead on the right hand side of the vehicle The case assembly will sta...

Page 443: ...ead while installing and tightening the screws on the engine side of the bulkhead 3 Install the screws through the bulkhead from the engine compartment side S Install the two screws at the connecting block mount S Install the screw above the fuel filter Tighten Tighten the heater air distributor case assembly screws to 4 NSm 35 lb in 4 Install the two heater air distributor case screws that flank ...

Page 444: ...ctrical connector 5 Remove the blower motor cooling hose 6 Remove the screws that secure the motor to the heater air distributor case 7 Remove the motor the seal and the shock mount pads from the heater air distributor case by gently pulling the motor straight down and out Installation Procedure 1 Install the blower motor and the seal with the shock mount pads in the heater air distributor case Ho...

Page 445: ...the relay terminal slots 2 Push the relay firmly into the base The relay must be seated and flush with the base edge 3 Connect the negative battery cable BLOWER RESISTOR Removal Procedure 1 Disconnect the negative battery cable 2 Remove the glove box Refer to Section 9E Instru mentation Driver Information 3 Remove the footwell upper cover Refer to Section 9E Instrumentation Driver Information 4 Di...

Page 446: ...n to loosen the bond between the hose and the tube 4 Remove the end of the hose from the tube 5 Repeat Steps 3 and 4 with the other hose 6 Compress the heater hose spring clamp on the inlet coolant line and slide the clamp rearward 7 Remove the heater hose from the vehicle 8 Compress the heater hose spring clamp at the con nection below the intake manifold and slide the clamp rearward 9 Remove the...

Page 447: ...air distributor case 6 Remove the screws that secure the heater core cover to the heater air distributor case assembly 7 Slowly separate the lower heater core cover from the rest of the assembly 8 Remove the screw and the bracket clamp that se cure the heater core lines to the case 9 Remove the spring clamp that secures the heater core body to the case 10 Remove the heater core from the case Insta...

Page 448: ...nstall the heater air distributor case Refer to Heater Air Distributor Case Assembly in this sec tion 8 Install the instrument panel Refer to Section 9E Instrumentation Driver Information 9 Fill the cooling system 10 Connect the negative battery cable REAR HEATING DUCT Some vehicles are equipped with rear seat heating ducts Should there be no airflow to the rear look for any obstruc tions such as ...

Page 449: ...tary control knobs and two push control knobs which operate as follows Rotary Temperature Control Knob S Actuates by cable S Raises the temperature of air entering the vehicle by rotation toward the right or the red portion of the knob Rotary Mode Control Knob S Actuates by vacuum S Regulates the air distribution between the wind shield the instrument panel and the floor vents Rotary Blower Contro...

Page 450: ...OLING DIAGNOSIS 7B 13 SYMPTOM DIAGNOSIS 7B 17 PRESSURE TEST CHART R 134a SYSTEM 7B 17 LOW AND HIGH SIDE PRESSURE RELATIONSHIP CHART 7B 19 MAINTENANCE AND REPAIR 7B 20 ON VEHICLE SERVICE 7B 20 GENERAL A C SYSTEM SERVICE PROCEDURES 7B 20 O RING REPLACEMENT 7B 20 HANDLING REFRIGERANT 7B 20 HANDLING OF REFRIGERANT LINES AND FITTINGS 7B 20 MAINTAINING CHEMICAL STABILITY IN THE REFRIGERATION SYSTEM 7B 2...

Page 451: ... FASTENER TIGHTENING SPECIFICATIONS Application NSm Lb Ft Lb In A C Suction Hose Clamp Bolt 10 89 Air Cleaner Housing Assembly Retaining Bolts 10 89 Band Clamp Bolt 5 44 Clamp Bolts 4 35 Clutch Plate and Hub Assembly Retaining Nut 17 13 Discharge Hose Connecting Block to Compressor Retaining Nut 33 24 Discharge Hose Mounting Block to Condenser Nut 16 12 Evaporator Flange Connecting Block Retaining...

Page 452: ...G SYSTEM 7B 3 DAEWOO V 121 BL4 SPECIAL TOOLS SPECIAL TOOLS TABLE J 5403 Snap Ring Pliers J 6083 Snap Ring Pliers J 8092 Driver Handle J 8433 1 Puller Crossbar J 8433 3 Forcing Screw J 9398 A Bearing Remover J 9481 Bearing Installer J 9553 1 O Ring Remover ...

Page 453: ...and Installer J 35372 Support Block J 33011 O Ring Installer J 33013 B Hub and Drive Plate Re mover and Installer J 34993 Cylinder Alignment Rods J 33017 Pulley Rotor and Bearing Assembly Installer J 33019 Bearing Staking Tool Set Includes J 33019 1 Bearing Staking Guide J 33019 2 Bearing Staking Pin J 33020 Pulley Puller J 34614 Shaft Seal Protector ...

Page 454: ... AND AIR CONDITIONING SYSTEM 7B 5 DAEWOO V 121 BL4 J 33022 Shaft Nut Socket J 33023 A Puller Pilot J 33024 Clutch Coil Installer Adapter J 33025 Clutch Coil Puller Legs J 34992 Compressor Holding Fix ture J 33027 Clutch Hub Holding Tool ...

Page 455: ...TROL HEATING VENTILATION AND AIR CONDITIONING SYSTEM DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS A C SYSTEM TYPICAL 1 Compressor 2 Pressure Relief Valve 3 Condenser 4 Receiver Dryer 5 Evaporator 6 Expansion Valve ...

Page 456: ...7B 7 DAEWOO V 121 BL4 AIRFLOW TYPICAL 1 Heater Outlets 2 Heater Defroster Door 3 Mode Door 4 Heater Core 5 Evaporator A C Only 6 Expansion Valve 7 Outside Air Inlet 8 Fresh Air Recirculating Air Door 9 Inside Air Inlet 10 Blower 11 Vent Outlets 12 Defroster Outlets ...

Page 457: ...7B 8IMANUAL CONTROL HEATING VENTILATION AND AIR CONDITIONING SYSTEM DAEWOO V 121 BL4 A C SCHEMATIC ...

Page 458: ...essor clutch 6 Check the drive belt tension INSUFFICIENT COOLING QUICK CHECK PROCEDURE Perform the following hand feel procedure to get a quick idea of whether the A C system has the proper charge of Refrigerant 134a The air temperature must be above 21 C 70 F for most models 1 Warm up engine Run the engine at idle 2 Open the hood and all the doors 3 Turn the A C switch ON 4 Turn the temperature c...

Page 459: ...27 265 2241 325 40 21 70 27 81 32 90 38 100 200 29 207 30 221 32 269 39 2000 7 45 9 48 13 55 18 64 1138 165 1482 215 1931 280 2379 345 50 21 70 27 81 32 90 38 100 207 30 221 32 234 34 276 40 2000 8 46 12 54 15 59 21 70 1241 180 1620 235 2034 295 2413 350 60 21 70 27 81 32 90 38 100 207 30 228 33 248 36 296 43 2000 9 48 13 56 17 63 23 73 1241 180 1655 240 2068 300 2482 360 70 21 70 27 81 32 90 38 1...

Page 460: ... 12 188 27 10 00 50 309 58 44 90 53 33 128 1337 35 193 96 12 77 55 349 51 50 69 54 44 130 1377 35 199 76 15 56 60 392 33 56 90 57 22 135 1480 91 214 78 18 33 65 438 18 63 55 60 00 140 1589 57 230 54 21 11 70 487 27 70 67 62 78 145 1703 62 247 08 23 89 75 539 67 78 27 65 56 150 1823 04 264 40 26 67 80 609 38 88 38 68 33 155 1948 04 282 53 29 44 85 655 09 95 01 71 11 160 2078 77 301 49 32 22 90 718 ...

Page 461: ...o the de tector General Testing Instructions S Follow the entire path of the refrigerant system S Completely circle each joint at 25 to 50 mm 1 to 2 inches per second S Hold the probe tip within 6 mm 1 4 inch of the sur face S Do not block the air intake The audible tone changes from 1 to 2 clicks per second into a solid alarm if there is a leak Adjust the balance con trol to maintain 1 to 2 click...

Page 462: ...discharge air temperature normal At least 7 C 12 F below ambient air temperature System OK Go to Step 3 3 1 Turn the ignition to LOCK 2 Connect the high and the low pressure gauges Are both pressures within the specified value 69 345 kPa 10 50 psi Go to Step 4 Go to Step 5 4 1 Check the A C system for leaks 2 Repair any refrigerant leaks as needed 3 Recover evacuate and recharge the A C sys tem 4 ...

Page 463: ...ressor clutch coil Does the A C clutch engage Go to Step 8 12 Replace the A C compressor clutch coil Does the A C clutch engage Go to Step 8 13 1 Close all of the vehicle s windows and doors 2 Set the A C controls to the following positions S The A C to ON S The fresh air control switch to fresh air S The blower motor to 4 S The temperature control knob to full cold 3 Start the engine and allow it...

Page 464: ...ver evacuate and recharge the A C sys tem 2 Check the A C system for leaks Is the system free from leaks Go to Step 13 20 Observe the readings on the pressure gauges Are the A C compressor high and low side pres sures within the specified value of each other 207 kPa 30 psi Go to Step 21 Go to Step 26 21 1 Run the engine at 3 000 rpm 2 Set the A C controls to the following positions S The A C to ON...

Page 465: ...he A C system Does the cooling performance improve 0 40 kg 14 oz Go to Step 30 Go to Step 31 30 1 Check the A C system for leaks 2 Repair any refrigerant leaks as needed 3 Evacuate and recharge the A C system 4 Check the A C system for leaks Is the system free from leaks Go to Step 13 31 1 Recover the refrigerant 2 Check the expansion valve for obstructions 3 Repair or replace the expansion valve ...

Page 466: ...e condenser is not hot Insufficient refrigerant in the sys tem S Check the system for a leak S Charge the system The high and low pressures are balanced soon after stopping the compressor Low side pressure is higher than normal Faulty compressor pressure relief valve Repair or replace the com pressor Faulty compressor seal The outlet of the expansion valve is not frosted low pressure gauge indicat...

Page 467: ...ondenser or the radiator fins are clogged Clean the condenser and the radiator charge pressure ab normally high charge The radiator cooling fans are not working properly S Check the voltage and the ra diator cooling fan rpm S Check the fan direction The condenser is exces sively hot There is excessive refrigerant in the system Recover evacuate and re charge the system Suction and dis charge pressu...

Page 468: ...MANUAL CONTROL HEATING VENTILATION AND AIR CONDITIONING SYSTEM 7B 19 DAEWOO V 121 BL4 LOW AND HIGH SIDE PRESSURE RELATIONSHIP CHART ...

Page 469: ... 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 9A 8 FLOOR HARNESS ROUTING 9A 9 INSTRUMENT HARNESS ROUTING 9A 10 DOOR HARNESS ROUTING 9A 11 SCHEMATIC AND ROUTING DIAGRAMS WIRE COLOR CHART Wire Color Abbreviation On Schematic Green DK GRN Light Gree...

Page 470: ...9A 2IBODY WIRING SYSTEM DAEWOO V 121 BL4 POWER DISTRIBUTION SCHEMATIC ...

Page 471: ...BODY WIRING SYSTEM 9A 3 DAEWOO V 121 BL4 ...

Page 472: ...9A 4IBODY WIRING SYSTEM DAEWOO V 121 BL4 FUSE BLOCK LOCATOR ENGINE FUSE BLOCK LOCATOR PASSENGER COMPARTMENT ...

Page 473: ...AP 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 B Parking Lamp License Lamp LH Taillamp EF23 20A B Cigar Lighter EF24 15A B Stoplamp Switch EF25 10A EF12 Headlamp High RH EF26 10A EF12 Headlamp Low RH EF27 10A EF32 Electric Outside Rearview Mirro...

Page 474: ...zard 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 Switch Instrument Cluster BTSI Solenoid F6 10A EF6 SIR System F7 10A EF6 Backup Switch F8 10A EF6 Cruise Control Immobilizer F9 15A EF6 Radio Key Interlock Sole noid Cigarette Lighter F10 10A EF1 Inst...

Page 475: ...BODY WIRING SYSTEM 9A 7 DAEWOO V 121 BL4 REAR HARNESS ROUTING ...

Page 476: ...9A 8IBODY WIRING SYSTEM DAEWOO V 121 BL4 FRONT HARNESS ROUTING ...

Page 477: ...BODY WIRING SYSTEM 9A 9 DAEWOO V 121 BL4 FLOOR HARNESS ROUTING ...

Page 478: ...9A 10IBODY WIRING SYSTEM DAEWOO V 121 BL4 INSTRUMENT HARNESS ROUTING ...

Page 479: ...BODY WIRING SYSTEM 9A 11 DAEWOO V 121 BL4 DOOR HARNESS ROUTING ...

Page 480: ...ER 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 TURN SIGNAL LAMPS 9B 31 HEADLAMP AIMING 9B 34 PARKING LAMPS 9B 35 SIDE MARKER LAMPS 9B 36 FOG LAMPS 9B 37 REAR COMBINATION LAMPS 9B 39 CENTER HIGH MOUNTED STOPLAMP NOTCHBACK 9B 40 CENTER HIGH MOUNTED ...

Page 481: ... 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 Mounting Nuts 4 35 CHMSL Mounting Screws 4 35 Daytime Run ning Lamp Module Screws 4 35 Door Jamb Switch Screw 4 35 Fog Lamp Nuts 4 35 Headlamp As sembly Bolts 4 35 Headlamp As sembly Nut 4 35 License ...

Page 482: ...LIGHTING SYSTEMS 9B 3 DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS HEADLAMPS ON REMINDER CHIME CIRCUIT ...

Page 483: ...9B 4ILIGHTING SYSTEMS DAEWOO V 121 BL4 PARKING TAIL POSITION AND LICENSE LAMPS CIRCUIT ...

Page 484: ...LIGHTING SYSTEMS 9B 5 DAEWOO V 121 BL4 TURN AND HAZARD LAMPS CIRCUIT ...

Page 485: ...9B 6ILIGHTING SYSTEMS DAEWOO V 121 BL4 BRAKE AND BACKUP LAMPS CIRCUIT ...

Page 486: ...LIGHTING SYSTEMS 9B 7 DAEWOO V 121 BL4 INTERIOR COURTESY LAMP AND LUGGAGE COMPARTMENT LAMP CIRCUIT ...

Page 487: ...9B 8ILIGHTING SYSTEMS DAEWOO V 121 BL4 HEADLAMPS CIRCUIT ...

Page 488: ...LIGHTING SYSTEMS 9B 9 DAEWOO V 121 BL4 DAYTIME RUNNING LAMPS CIRCUIT ...

Page 489: ...9B 10ILIGHTING SYSTEMS DAEWOO V 121 BL4 FOG LAMPS CIRCUIT ...

Page 490: ...odule 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 System OK 9 With the chime module disconnected use an ohm meter to check the resistance between ground and terminal 5 of the chime module connector Is the resistance equal to the specified value 0 W Go t...

Page 491: ...fied 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 specified value 11 14 v Go to Step 6 Go to Step 5 5 Repair the open circuit between fuses EF31 or EF26 and the low beam headlamps Is the repair complete System OK 6 1 Disconnect the headlamp connectors ...

Page 492: ...l 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 4 equal the value specified 11 14 v Go to Step 7 Go to Step 6 6 Repair the open circuit between fuse EF30 or EF25 and the high beam headlamps Is the repair complete System OK 7 Replace the faulty he...

Page 493: ...en 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 faulty headlamps 2 Check the charging system to make sure that charging voltage is not excessively high Re pair if necessary Is the repair complete System OK 9 Use a voltmeter to check for power to ...

Page 494: ...W 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 complete System OK 22 Check the voltage at headlamp switch connector C1 terminal 6 Does the voltage equal the specified value 11 14 v Go to Step 24 Go to Step 23 23 Repair the open circuit between headl...

Page 495: ...between 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 terminal E of the DRL module connector Is the resistance equal to the specified value 0 W Go to Step 11 Go to Step 10 10 Repair the circuit between ground and terminal E of the DRL module connector Is the ...

Page 496: ...9B 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 complete System OK ...

Page 497: ...EF20 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 indicate the specified value 0 W Go to Step 9 Go to Step 8 8 Repair the open ground circuit for the front fog lamps Is the repair complete System OK 9 1 With the fog lamps disconnected turn the front...

Page 498: ...icate 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 fog lamp switch disconnected connect an ohmmeter between the two termi nals of the front fog lamp switch 2 Turn the front fog lamp switch to the ON posi tion Does the ohmmeter indicate the specified v...

Page 499: ...stem 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 headlamp relay to its original posi tion 2 Replace the illumination relay Is the repair complete System OK 11 1 Remove the illumination relay 2 Use a voltmeter to check the illumination relay socket at conn...

Page 500: ... 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 disconnected switch select the illumi nation lamp ON position 3 At the switch side of the connector C2 use an ohmmeter to check resistance between termi nal 3 and terminal 6 Is the resistance equal to ...

Page 501: ...6 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 continuity be tween terminals 2 and 1 of the stoplamp switch Is the resistance equal to the specified value 0 W Go to Step 8 Go to Step 7 7 Replace the brakelamp switch Is the repair complete System OK 8 1 ...

Page 502: ...sically 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 measure the resistance between ground and the BLK wire in the CHMSL connector Is the resistance equal to the specified value 0 W Go to Step 7 Go to Step 6 6 Repair the open circuit between ground and the ...

Page 503: ...tch 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 the voltage equal to the specified value 11 14 v Go to Step 7 Go to Step 6 6 Repair the open circuit between the backup lamps and the reverse switch or the neutral safety backup switch if equipped w...

Page 504: ...pair 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 terminal 49a with a voltmeter Is the voltage equal to the specified value 11 14 v Go to Step 15 Go to Step 10 10 1 Turn the hazard lamps ON 2 Test blinker unit connector terminal 49 with a voltmeter Is the...

Page 505: ...ed 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 ON position 2 Use an ohmmeter to check the continuity be tween terminals 5 6 and 9 Is there continuity between terminals 5 6 and 9 Go to Step 19 Go to Step 21 21 1 Disconnect connector C204 2 Use an...

Page 506: ...o 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 resistance equal to the specified value 0 W Go to Step 7 Go to Step 10 7 1 With the hazard lamp switch still removed and disconnected for testing turn the hazard lamp switch to the ON position 2 Use an ohmme...

Page 507: ... 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 repair 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 Step 6 6 Repair the open circuit between t...

Page 508: ... 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 Step 6 6 Repair the open circuit between the battery and fuse EF29 Is the repair complete System OK 7 1 Disconnect the luggage compartment lamp electrical connector 2 Check the voltage at the ORN wi...

Page 509: ...1 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 equal to the specified value System OK ...

Page 510: ...ersonal 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 DIAGRAMS 9C 2 HORN WIRING SYSTEM 9C 2 MAINTENANCE AND REPAIR 9C 3 ON VEHICLE SERVICE 9C 3 HORNS 9C 3 GENERAL DESCRIPTION AND SYSTEM OPERATION 9C 5 HORNS 9C 5 SPECIFICATIONS FASTENER TIGHTENING SPECIFICA...

Page 511: ...9C 2IHORNS DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS HORN WIRING SYSTEM ...

Page 512: ...ct 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 Make sure to use the correct fasten ers to prevent premature corrosion 1 Install the horn with the bolt Tighten Tighten the horn bolt to 22 NSm 16 lb ft ...

Page 513: ...9C 4IHORNS DAEWOO V 121 BL4 2 Connect the electrical connector 3 Connect the negative battery cable ...

Page 514: ...ESCRIPTION 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 which grounds the horns electrical circuit ...

Page 515: ...AR 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 WIPER BLADE INSERT 9D 14 WINDSHIELD WASHER RESERVOIR 9D 15 WINDSHIELD WASHER PUMP S 9D 17 WINDSHIELD WASHER NOZZLES 9D 18 WINDSHIELD WASHER HOSES 9D 18 REAR WINDOW WIPER ARM 9D 20 REAR WINDOW WIPER MO...

Page 516: ...9D 2IWIPERS WASHER SYSTEMS DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS WIPERS AND WASHER SYSTEM NOTCHBACK ...

Page 517: ...WIPERS WASHER SYSTEMS 9D 3 DAEWOO V 121 BL4 WIPERS AND WASHER SYSTEM HATCHBACK ...

Page 518: ...e 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 Check for battery voltage at the wiper switch connector terminal A8 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 the wiper switch con...

Page 519: ...circuit 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 the ignition ON 2 Turn the wiper switch to LO 3 Check the voltage at the wiper motor connec tor terminal 3 Is the voltage equal to the specified value 11 14 v Go to Step 2 Go to Step 3 2 Replace the...

Page 520: ...he 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 pulsing voltage at wiper switch con nector terminal A6 Does the voltmeter indicate a pulsating voltage equal to the specified value 11 14 v Go to Step 11 Go to Step 8 8 Using an ohmmeter check the resi...

Page 521: ...e 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 Step 5 Go to Step 4 4 Replace the wiper motor Is there an open circuit System OK 5 1 Disconnect the wiper relay 2 Check continuity between wiper relay terminal 31b and 53e Does the ohmmeter indicate ...

Page 522: ...voir 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 and nozzles Is the repair complete System OK 8 1 Turn the ignition ON 2 With the windshield washer activated test the voltage at the windshield washer pump Is the voltage equal to the specified value...

Page 523: ...Step 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 check continuity between rear wiper motor connector terminal 2 and ground Does the ohmmeter indicate the specified value 0 W Go to Step 9 Go to Step 8 8 Repair the open ground circuit for the rear windo...

Page 524: ...ove 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 wiper connector WHT wire and the rear window wiper motor Is the repair complete System OK 15 Replace the rear window wiper switch Is the repair complete System OK ...

Page 525: ...ohmmeter 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 repair complete System OK 9 1 Turn the rear window washer ON 2 Check the voltage at terminal 2 of the rear win dow washer pump connector DK GRN wire Is the voltage equal to the specified value 11 14 v ...

Page 526: ...n 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 NSm 97 lb in 3 Install the wiper arm nut cap if necessary 4 Close the hood WINDSHIELD WIPER MOTOR Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Disconnect the negative battery cab...

Page 527: ...idly 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 connector 3 Press the wiper arm linkage onto the motor drive shaft 4 Install the wiper arm linkage to the motor drive shaft with the washer and the nut Tighten Tighten the wiper arm linkage nut to 5 NSm...

Page 528: ...e 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 clip engages WINDSHIELD WIPER BLADE INSERT Front Shown Rear Similar Removal Procedure 1 Slide the insert out of the wiper blade ...

Page 529: ...SHER 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 well splash shield 4 Disconnect the washer hose from the washer pump 5 Disconnect the reservoir pump electrical connector ...

Page 530: ...ls 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 reservoir bolts to 8 NSm 71 lb in 2 Connect the reservoir pump electrical connector 3 Connect the washer hose to the washer pump ...

Page 531: ...ews 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 pump 2 Connect the washer hose to the washer pump 3 Connect the electrical connector Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasten ...

Page 532: ...3 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 Section 9R Body Front End WINDSHIELD WASHER HOSES Typical Removal Procedure 1 Remove the cowl vent grille Refer to Section 9R Body Front End 2 Disconnect the windshield washer hose from the washer nozzles...

Page 533: ...he 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 front wheel well splash shield with the bolts and the screws Tighten Tighten the front wheel well splash shield bolts to 1 5 NSm 13 lb in 4 Remove the front left wheel Refer to Section 2E Tires and Whee...

Page 534: ...rect 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 HATCHBACK Removal Procedure 1 Disconnect the negative battery cable 2 Remove the rear window wiper arm Refer to Rear Window Wiper Arm in this section 3 Remove the hatchback door lower garnish molding R...

Page 535: ...chback 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 MOTOR WAGON Removal Procedure 1 Disconnect the negative battery cable 2 Remove the rear window wiper arm Refer to Rear Window Wiper Arm in this section 3 Remove the wiper motor exterior retaining cli...

Page 536: ...b 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 window wiper arm Refer to Rear Window Wiper Arm in this section 6 Connect the negative battery cable REAR WINDOW WASHER NOZZLE HATCHBACK Removal Procedure 1 Remove the hatchback door upper garnish moldi...

Page 537: ...YSTEMS 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 9G Interior Trim ...

Page 538: ...with 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 reservoir is a washer pump which pumps fluid through the hoses to the two nozzles mounted on the hood The washer switch is an integral part of the wiper washer switch Windshield washer operation is actuat...

Page 539: ...ole Refer to Glove Box in this section 3 Remove the screw and driver passenger knee bol ster Refer to Driver passenger Knee Bolster in this section 9G 4 Remove the screws and the audio system trim plate 5 Disconnect the cigar lighter and ashtray lamp elec trical connectors 6 Remove the cigar lighter from the cigar lighter housing 7 Remove the cigar lighter housing from the ashtray housing ...

Page 540: ...igar lighter in the cigar lighter housing 3 Connect the cigar lighter electrical connector 4 Install the ashtray housing with the screw Tighten Tighten the ashtray housing screw to 2 5 NSm 22 lbin 5 Install the audio system trim plate with the screws 6 Install glove box driver passenger knee bolster with the screws 7 Connect the negative battery cable ...

Page 541: ...and the glove box 3 Remove the screw and driver passenger knee bol ster 4 Remove the screws and the audio system trim plate 5 Disconnect the ashtray electrical connector Installation Procedure 1 Connect the ashtray electrical connector 2 Install the screw and the ashtray housing Tighten Tighten the ashtray housing screw to 2 5 NSm 22 lbin ...

Page 542: ...screws 4 Install glove box driver passenger knee bolster with the screws 5 Connect the negative battery cable CUP HOLDER Removal Procedure 1 Remove the screws and the glove box 2 Remove the screw and driver passenger knee bol ster 3 Remove the screws and the cup holder from the audio system trim plate ...

Page 543: ...stem trim plate with the screws Tighten Tighten the cup holder screws to 2 5 NSm 22 lb in 2 Install the audio system trim plate with the screws 3 Install glove box driver passenger knee bolster with the screws GLOVE BOX Removal Procedure 1 Remove the screws at the base of the glove box 2 Open and remove the glove box ...

Page 544: ...GITAL CLOCK Removal Procedure 1 Disconnect the negative battery cable 2 Remove the plastic cover to reveal the screws 3 Remove the screws and the digital clock 4 Disconnect the electrical connector Installation Procedure 1 Connect the electrical connector 2 Install the digital clock with the screws Tighten Tighten the digital clock screws to 4 NSm 35 lb in 3 Install the cluster housing 4 Connect t...

Page 545: ...ion Procedure 1 Connect the electrical connectors 2 Install the instrument cluster with the screws Tighten Tighten the instrument cluster screws to 4 NSm 35 lb in 3 Connect the negative battery cable SPEEDOMETER ODOMETER TRIP ODOMETER Removal Procedure 1 Disconnect the negative battery cable 2 Remove the instrument cluster Refer to Instru ment Cluster in this section 3 Push the locking and remove ...

Page 546: ...9E 30IINSTRUMENT DRIVER INFORMATION DAEWOO V 121 BL4 4 Remove the screws and the fuel gauge 5 Remove the screws and the speedometer odome ter from the instrument cluster ...

Page 547: ...he screws Tighten Tighten the speedometer odometer screws to 2 5 NSm 22 lb in 2 Install the fuel gauge with the screws Tighten Tighten the fuel gauge screws to 2 5 NSm 22 lb in 3 Install the instrument cluster lens with the screws 4 Install the instrument cluster Refer to Instrument Cluster in this section 5 Connect the negative battery cable ...

Page 548: ...he instrument cluster Refer to Instru ment Cluster in this section 3 Remove the screws and the instrument cluster lens 4 Remove the screws and the tachometer from the instrument cluster Installation Procedure 1 Install the tachometer to the instrument cluster with the screws Tighten Tighten the tachometer screws to 2 5 NSm 22 lb in ...

Page 549: ...to Instrument Cluster in this section 4 Connect the negative battery cable FUEL GAUGE Removal Procedure 1 Disconnect the negative battery cable 2 Remove the instrument cluster Refer to Instrument Cluster in this section 3 Remove the instrument cluster lens 4 Remove the fuel gauge screws and the fuel gauge from the cluster assembly ...

Page 550: ... 5 NSm 22 lb in 2 Install the instrument cluster lens 3 Install the instrument cluster Refer to Instrument Cluster in this section 4 Connect the negative battery cable TEMPERATURE GAUGE Removal Procedure 1 Disconnect the negative battery cable 2 Remove the instrument cluster Refer to Instru ment Cluster in this section 3 Remove the instrument cluster lens screws and the instrument cluster lens ...

Page 551: ...sembly Installation Procedure 1 Install the temperature gauge to the cluster assem bly with the temperature gauge screws Tighten Tighten the temperature gauge screws to 2 5 NSm 22 lb in 2 Install the instrument cluster lens 3 Install the instrument cluster Refer to Instrument Cluster in this section 4 Connect the negative battery cable ...

Page 552: ...n 3 Remove the bulb from the rear of the cluster Installation Procedure 1 Install the new bulb 2 Install the instrument cluster Refer to Instrument Cluster in this section 3 Connect the negative battery cable CHIME MODULE Removal Procedure 1 Disconnect the negative battery cable 2 Remove the knee bolster trim panel beneath the steering column 3 Disconnect the electrical connector 4 Remove the scre...

Page 553: ... to Section 9G Interior Trim 3 Remove the audio system Refer to Section 9F Audio Systems 4 Remove the HVAC controls Refer toSection 7A Heating and Ventilation System 5 Remove the instrument cluster Refer to Instru ment Cluster in this section 6 Remove the A pillar trim panels Refer toSection 9G Interior Trim 7 Install the driver and passenger knee bolsters Re fer toSection 9G Interior Trim 8 Disco...

Page 554: ...38IINSTRUMENT DRIVER INFORMATION DAEWOO V 121 BL4 12 Remove the bolts that secure the instrument panel to the pedal assembly 13 Remove the nuts that secure the back of the instru ment panel to the bulkhead ...

Page 555: ...nnec tors 17 Remove the Instrument panel Installation Procedure 1 Position the instrument panel in the vehicle 2 Connect the instrument panel electrical connectors 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 nuts securing the back of the instrument panel to the bulkhead Tighten T...

Page 556: ... securing the sides of the instrument panel to the body Tighten Tighten the instrument panel to body bolts to 22 NSm 16 lb ft 5 Install the bolts securing the bottom of the instru ment panel to the floor Tighten Tighten the instrument panel to floor bolts to 22 NSm 16 lb ft ...

Page 557: ...screw securing the instrument panel to the heater air distribution case Tighten Tighten the instrument panel to heater air distribu tion case screw to 2 NSm 18 lb in 8 Raise the steering column 9 Connect the steering column electrical connectors 10 Install the nuts and the bolts securing the steering column Tighten Tighten the steering column nuts to 22 NSm 16 lb ft Tighten the steering column bol...

Page 558: ...trim panels Refer toSection 9G Interior Trim 13 Remove the instrument cluster Refer to Instru ment Cluster in this section 14 Remove the HVAC controls Refer toSection 7A Heating and Ventilation System 15 Install the audio system Refer toSection 9F Audio Systems 16 Install the floor console Refer toSection 9G Interi or Trim 17 Connect the negative battery cable ...

Page 559: ...auge connected to the sending unit on the trans axle output shaft The trip odometer can be reset to zero at any time so that the driver can record the distance trav eled from any starting point FUEL GAUGE The fuel gauge consists of an instrument cluster gauge connected to a sending unit in the fuel tank The fuel gauge indicates the quantity of fuel in the tank only when the ignition switch is turn...

Page 560: ... 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 NOTCHBACK 9F 13 POWER ANTENNA MOTOR NOTCHBACK 9F 14 COMPACT DISC CHANGER 9F 15 GENERAL DESCRIPTION AND SYSTEM OPERATION 9F 17 AUDIO SYSTEMS 9F 17 AUDIO SECURITY SYSTEM 9F 17 FRONT AND REAR SPEAKERS 9...

Page 561: ...9F 2IAUDIO SYSTEMS DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS AUDIO SYSTEM CIRCUIT ...

Page 562: ...erminals 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 complete System OK 7 Use an ohmmeter to test the ground circuit at the ra dio connector terminal 14 Does the resistance match the specified value 0 0 5 W Go to Step 9 Go to Step 8 8 Repair the open g...

Page 563: ...e 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 the test antenna to the antenna cable 3 Check the FM radio reception Is the FM radio operating properly Go to Step 2 Go to Step 3 2 Replace the antenna Is the repair complete System OK 3 1 Remove the ...

Page 564: ...peaker 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 7 Replace the speaker Is the repair complete System OK 8 Replace the radio Is the repair complete System OK Rear Speakers Distorted or Inoperative Rest of Audio System OK Step Action Value s Yes No ...

Page 565: ...s 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 6 Repair the open circuit between power antenna con nector terminal 1 and fuse EF29 Is the repair complete System OK 7 Use an ohmmeter to test the ground circuit at power antenna connector terminal 2...

Page 566: ...OO 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 repair complete System OK ...

Page 567: ...connect 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 electrical connector and the antenna cable Installation Procedure 1 Connect the audio system electrical connector and the antenna cable ...

Page 568: ...EAKERS 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 Disconnect the electrical connector Installation Procedure 1 Connect the electrical connector 2 Install the front door speaker with the screws Tighten Tighten the front door speaker screws to 4 NSm ...

Page 569: ...nector 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 negative battery cable 2 Remove the rear seat cushion and the rear seat back Refer to Section 9H Seats 3 Remove the right side C pillar trim panel and the deck lid sill plate trim cover Refer to section ...

Page 570: ... 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 the electrical connector Installation Procedure 1 Connect the electrical connector Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasten ers...

Page 571: ...ar 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 mast antenna base nut to 4 NSm 35 lbin 2 Connect the antenna cable 3 Install the rubber grommet and the antenna cap nut Tighten Tighten the antenna cap nut to 7 NSm 62 lb in 4 Install the mast antenna...

Page 572: ...ct 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 NSm 89 lb in 2 Connect the antenna cable and the electrical con nector 3 Install the formed headliner Refer to Section 9Q Roof 4 Connect the negative battery cable POWER ANTENNA MAST NOTCHBACK Remova...

Page 573: ...na 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 Trim 3 Remove the antenna cap nut and the rubber grom met 4 Loosen the nuts securing the antenna motor to the vehicle 5 Remove the antenna motor 6 Disconnect the electrical connector and the drain h...

Page 574: ...motor 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 in 5 Connect the negative battery cable COMPACT DISC CHANGER Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the CD changer electrical connector 3 Remove the nuts and the CD c...

Page 575: ...MS 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 negative battery cable ...

Page 576: ...akers 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 manual antenna is designed to withstand most car washes without damage If the mast becomes slightly bent it can be straightened by hand The manual antenna can be replaced if it is severely bent Manu...

Page 577: ...E 9M 2 B PILLAR MOLDING 9M 2 QUARTER WINDOW MOLDING WAGON 9M 2 ROOF MOLDING 9M 3 MUD GUARDS 9M 4 GENERAL DESCRIPTION AND SYSTEM OPERATION 9M 5 EMBLEMS AND LETTERING 9M 5 MUD GUARDS 9M 5 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application NSm Lb Ft Lb In B Pillar Molding Screws 4 35 Mud Guard Bolts 1 5 13 Quarter Window Molding Screws 4 35 ...

Page 578: ...e 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 screws and the B pillar molding Tighten Tighten the B pillar molding screws to 4 NSm 35 lbin 2 Install the weatherstrip to its original position QUARTER WINDOW MOLDING WAGON Removal Procedure 1 Open the rear passenger door 2 Remove th...

Page 579: ...arter window molding with the screws Tighten Tighten the quarter window molding screws to 4 NSm 35 lb in 2 Close the rear passenger door ROOF MOLDING Removal Procedure 1 Remove the roof molding from the metal clips Installation Procedure 1 Press the roof molding onto the clips ...

Page 580: ...and the mud guard 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 corrosion 1 Install the mud guard with the bolts Tighten Tighten the mud guard bolts to 1 5 NSm 13 lb in ...

Page 581: ...icle are attached by adhesive The company emblem appears on the hood The lettering which appears in several places on the body of the vehicle features the model the grade and the com pany name MUD GUARDS Front and rear mud guards are standard equipment on all models Mud guards will help prevent an excessive build up of mud on the body ...

Page 582: ...EHICLE 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 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application NSm Lb Ft Lb In Engine Under Cover Screw 2 18 Front Fascia Splash Shield Screw 1 5 13 ...

Page 583: ...lt 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 original sequence and location Also if an insulator needs to be replaced use only the insulation specified for that location on the floor pan When servicing or replacing interior insulators observe the...

Page 584: ...plash 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 2 NSm 18 lbin 2 Install the front fascia splash shield with the screws Tighten Tighten the front fascia splash shield screw to 1 5 NSm 13 lb in 3 Lower the vehicle ...

Page 585: ...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 586: ...t 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 tions The underbody parts should be properly sealed and rustproofed whenever body repair operations destroy or damage the original sealing and rustproofing When rust proofing critical underbody parts...

Page 587: ...ONT 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 SYSTEM OPERATION 9O 14 BUMPERS 9O 14 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application NSm Lb Ft Lb In Fender to Fascia Bolts 1 5 13 Front Impact Bar Bolts 35 26 Front Impact Bar Nuts 22 16 F...

Page 588: ... 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 tion 9B Lighting Systems 5 Remove the headlamps Refer to Section 9B Light ing Systems 6 Remove the front wheel well fascia bolts 7 Remove the fender to fascia bolts n ...

Page 589: ...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 590: ...l 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 fascia screws 3 Install the lower fascia screws 4 Install the front fascia nuts ...

Page 591: ...hten 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 Reposition the front portion of the splash shields and install the bolts and the screws Tighten Tighten the front wheel well splash shield bolts to 1 5 NSm 13 lb in 10 Connect the negative battery cable ...

Page 592: ...ber 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 bumper fascia Refer to Front Bumper Fascia in this section 2 Remove the front bumper energy absorber Refer to Front Bumper Energy Absorber in this section 3 Remove the front bumper impact bar nuts ...

Page 593: ... 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 nuts Tighten Tighten the front impact bar nuts to 30 NSm 22 lb ft 4 Install the front bumper energy absorber Refer to Front Bumper Energy Absorber in this section 5 Install the front bumper fascia Refe...

Page 594: ...imilar 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 wells 4 Remove the taillamps Refer to Section 9B Lighting Systems 5 Remove the upper fascia screws ...

Page 595: ...in 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 fasten ers to prevent premature corrosion 2 Install the luggage compartment fascia bolts Tighten Tighten the luggage compartment fascia bolts to 8 NSm 71 lb in ...

Page 596: ...rtment 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 bolts Tighten Tighten the rear wheel well fascia bolts to 1 5 NSm 13 lb in ...

Page 597: ... 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 bumper fascia Refer to Rear Bumper Fascia in this section 2 Remove the energy absorber Installation Procedure 1 Install the energy absorber 2 Install the rear bumper fascia Refer to Rear Bump er Fas...

Page 598: ...bolts 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 brackets from the impact bar 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 corrosion 1 ...

Page 599: ...e 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 energy absorber Refer to Rear Bumper Energy Absorber in this section 8 Install the rear bumper fascia Refer to Rear Bump er Fascia in this section ...

Page 600: ... 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 cia cover The rear bumper fascia must be removed before access can be gained to the energy absorber and the bumper impact bar The front bumper assembly can be re moved as a whole unit or the fascia c...

Page 601: ... 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 WINDOW REGULATOR 9P 21 POWER REAR WINDOW REGULATOR 9P 23 MANUAL REAR WINDOW REGULATOR 9P 24 MANUAL REAR WINDOW REGULATOR HANDLE9P 25 FRONT DOOR ASSEMBLY 9P 25 REAR DOOR ASSEMBLY 9P 27 DOOR HINGE 9P 29...

Page 602: ...OO 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 Regulator Nuts 8 71 ...

Page 603: ...DOORS 9P 3 DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS POWER DOOR LOCKS ...

Page 604: ...9P 4IDOORS DAEWOO V 121 BL4 POWER WINDOWS FRONT AND REAR ...

Page 605: ...cified 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 check the continuity between terminal 6 BLK of the power door lock relay con nector and ground Is the continuity equal to the specified value 0 W Go toStep 11 Go toStep 10 10 Repair the open circuit betw...

Page 606: ... 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 sure all the lock rods are connected to the driver s side door lock 2 If no disconnected lock rods are found replace the driver s side door lock with the integral door lock switch Do not confuse the ...

Page 607: ...ter 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 the open circuit between ground and terminal 4 BLK of the driver s side door power window switch Is the repair complete System OK 6 Replace the driver s side power window switch Is the repair comple...

Page 608: ...tween 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 between ground and terminal 4 2 At the inoperative window switch use an ohm meter to check the continuity between ground and terminal 1 Are the continuities equal to the specified value 11 14 v Go t...

Page 609: ... 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 Refer to Section 9L Glass and Mirrors REAR DOOR GLASS RUN Removal Procedure 1 Remove the rear door glass Refer to Section 9L Glass and Mirrors 2 Remove the interior garnish molding 3 Remove the screws ...

Page 610: ...h 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 garnish molding screws to 1 5 NSm 13 lb in 3 Install the interior garnish molding 4 Install the rear door glass Refer to Section 9L Glass and Mirrors ...

Page 611: ...nd 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 Mirrors REAR DOOR SECONDARY WEATHERSTRIP Removal Procedure 1 Remove the interior garnish molding 2 Remove the screws and the exterior garnish mold ing ...

Page 612: ...rect 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 door exterior garnish molding screws to 1 5 NSm 13 lb in 3 Install the interior garnish molding DOOR LOCK STRIKER Removal Procedure 1 Remove the screws and the door lock striker ...

Page 613: ...e 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 striker Notice The door lock striker is an important attaching part that can affect the performance of vital components and systems and can cause major repair expenses If re placement becomes necessar...

Page 614: ...g 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 important attaching parts that could affect the performance of vital components and systems 4 If proper adjustment requires that the floating cage plate be moved more than is possible use an elec tr...

Page 615: ...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 616: ... 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 components and systems 4 Install the front door lock with the screws Tighten Tighten the front door lock screws to 10 NSm 89 lbin 5 Install the seal trim Refer to Door Seal Trim in this section 6 Connec...

Page 617: ...e 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 guide rail 6 Disconnect the electrical connector 7 Disconnect the electrical connector 8 Disconnect the lock rods at the lock ...

Page 618: ...rrosion 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 outside door handle and the lock rods 5 Connect the inside door handle and the lock rods 6 Install the door seal trim Refer to Door Seal Trim in this section 7 Connect the negative battery cable ...

Page 619: ...nsert 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 fasten ers to prevent premature corrosion 4 Install the inside door handle screw Tighten Tighten the inside door handle screw to 1 5 NSm 13 lb in 5 Install the door seal trim Refer to Door Seal Trim in t...

Page 620: ...2 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 direct contact with each other may corrode rapidly Make sure to use the correct fasten ers to prevent premature corrosion 2 Install the door handle with the bolts Tighten Tighten the outside door handle ...

Page 621: ...lip 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 this section POWER FRONT WINDOW REGULATOR Removal Procedure 1 Disconnect the negative battery cable 2 Remove the front door glass Refer to Section 9L Glass and Mirrors 3 Disconnect the electrical conn...

Page 622: ...other 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 2 Connect the electrical connector 3 Install the front door glass Refer to Section 9L Glass and Mirrors 4 Connect the negative battery cable ...

Page 623: ... 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 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 624: ...oor 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 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 2 Install the rear door glass R...

Page 625: ...dow 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 ASSEMBLY Removal Procedure 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 fro...

Page 626: ... 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 bolts to 25 NSm 18 lb ft 4 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 5 Connect the negative battery cable 6 Perf...

Page 627: ...edure 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 the body to door rubber grommet and the electrical connector ...

Page 628: ...ion 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 rear 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 5 Connect the negative battery cable 6 Perform the waterleak test Refer to Sec...

Page 629: ...ode 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 door hinge bolts to 25 NSm 18 lb ft DOOR HOLD OPEN LINK Removal Procedure 1 Remove the door trim panel Refer toSection 9G Interior Trim 2 Reposition the door seal trim 3 Remove the bolts on the door and...

Page 630: ... 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 Refer to Section 9G Interior Trim 2 Straighten the retaining tabs in order to release the channel molding from the door trim panel 3 Remove the channel molding Installation Procedure 1 Install the chan...

Page 631: ...re 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 Procedure 1 Lower the window completely 2 Remove the door weatherstrip ...

Page 632: ... 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 Remove the door trim panel Refer to Section 9G Interior Trim 2 Remove the screws and the door pull bracket 3 Remove the inside door handle Refer to Inside Door Handle in this section 4 Remove the door sea...

Page 633: ...re 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 panel Refer to Section 9G In terior Trim FRONT DOOR OPENING WEATHERSTRIP Removal Procedure 1 Remove the kick panel the front rocker panel and the lower B pillar trim panel Refer to Section 9G Interio...

Page 634: ...r 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 opening weatherstrip Installation Procedure 1 Install the door opening weatherstrip 2 Instal the rear rocker panel and the lower B pillar trim panel Refer to Section 9G Interior Trim ...

Page 635: ...ntained 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 or unlocked by the actuator or the lock cylin der all the doors are locked or unlocked accordingly POWER WINDOWS The power windows are controlled by electrical switches on the door panels and are oper...

Page 636: ...Q 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 SYSTEM OPERATION 9Q 16 ROOF 9Q 16 POWER SUNROOF 9Q 16 ROOF RACK WAGON 9Q 16 SUN VISORS 9Q 16 PASSENGER ASSIST HANDLES 9Q 16 INTERIOR COURTESY LAMP POWER SUNROOF CONTROL SWITCH 9Q 16 COAT HOOK 9Q 16 SPECIF...

Page 637: ...9Q 2IROOF DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS POWER SUNROOF SYSTEM ...

Page 638: ...s 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 to Step 8 7 1 Return the substituted relay to its original posi tion 2 Replace the Ignition 2 relay Is the repair complete System OK 8 1 Disconnect the lamp sunroof switch 2 Turn the ignition ON 3 At ...

Page 639: ...o 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 connectors 3 Turn the ignition ON 4 Turn the sunroof switch to the CLOSE position and observe the voltmeter reading 5 Turn the sunroof switch to the OPEN position and observe the voltmeter reading 6 The ...

Page 640: ...edure 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 the motor 6 Remove the motor control module 7 Remove the bolts and the housing from the ve hicle V ...

Page 641: ...e 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 rapidly Make sure to use the correct fasten ers to prevent premature corrosion 1 Install the glass to the frame with the screws Tighten Tighten the sunroof glass screws to 7 NSm 62 lb in ...

Page 642: ... 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 Install the motor control module 11 Install the motor with the screws Tighten Tighten the sunroof motor screws to 5 NSm 44 lb in 12 Connect the electrical connectors ...

Page 643: ...iner 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 the correct fasten ers to prevent premature corrosion 1 Install the roof rack with the nuts Tighten Tighten the roof rack nuts to 27 NSm 20 lb ft 2 Install the headliner Refer to Formed Headliner in...

Page 644: ...ection 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 Switch in this section 7 Remove the cargo area lamp wagon only Refer to Section 9B Lighting Systems 8 Remove the clock Refer toSection 9E Instrumen tation Driver Information 9 Remove the left and the r...

Page 645: ...l 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 Procedure 1 Recline both front seats 2 Insert the headliner through a rear door or the hatchback door 3 Install the headliner behind the trim panels and the seals around the doors 4 Install the plastic ret...

Page 646: ...act 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 Tighten Tighten the rear seat belt anchor bolts to 35 NSm 26 lb ft 9 Install the top of the left and the right B pillar trim panels 10 Install the seat belt anchors with the bolts in the left and the ri...

Page 647: ...msor 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 Section 9E Instru mentation Driver Information 17 Install the passenger assist handles Refer to Pas senger Assist Handles in this section 18 Install the headliner sunroof molding if equipped 19 Connect...

Page 648: ...n 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 the sun visor screw to 2 NSm 18 lb in PASSENGER ASSIST HANDLES Removal Procedure 1 Remove the plastic caps to reveal the assist handle screws 2 Remove the screws and the assist handle from the headline...

Page 649: ...the 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 POWER SUNROOF CONTROL SWITCH Removal Procedure 1 Disconnect the negative battery cable 2 Pry off the lamp lens 3 Remove the screws and the lamp power sunroof control switch 4 Disconnect the electric...

Page 650: ...t 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 lamp power sunroof control switch screws to 4 NSm 35 lb in 3 Install the lamp lens 4 Connect the negative battery cable ...

Page 651: ...on 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 the toggle button until the sunroof slides closed To close the sunroof from a slid open position ROOF RACK WAGON The sun visors swing down in order to block out glare They also swing to the side when ...

Page 652: ...HOOD 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 Ft Lb In A Pillar Fender Bolt 8 71 Cowl Vent Grille Screws 4 35 Fender Bolt Front of Fas cia 4 35 Front Bumper Fascia to Fender Bolt 1 5 13 Hinge Bolts 27 20 Hood to Hinge Bolts 27 20 Hood Latch Bolts...

Page 653: ... 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 have been applied to the interior surfaces of most of the metal panels When you service these panels properly re coat them with a service type anticorrosion material if any of the original material ha...

Page 654: ...imilar 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 Tighten Tighten the cowl vent grille screws to 4 NSm 35 lbin 3 Install the wiper arms Refer to Section 9D Wipers Washer Systems ...

Page 655: ...oth 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 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 two bolts securing the hood to each hing...

Page 656: ...e 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 the open position 2 Remove the hood prop rod by gently prying the base from the radiator support Installation Procedure 1 Install the hood prop rod by snapping the base back into the radiator support...

Page 657: ...on 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 the latch 2 Position the hood latch in the location marked dur ing removal 3 Install the hood latch with the bolts Tighten Tighten the hood latch bolts to 8 NSm 71 lb in HOOD LATCH RELEASE CABLE Left H...

Page 658: ...the 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 prevent premature corrosion 1 Install the cable through the engine compartment 2 Install the cable into the hood latch release handle 3 Install the grommet in the fire wall ...

Page 659: ...ighten 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 bolts to 8 NSm 71 lb in RADIATOR GRILLE Removal Procedure 1 Open the hood 2 Remove the nuts and the radiator grille ...

Page 660: ...or 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 and Wheels 3 Remove the screws the bolts and the front wheel well splash shield 4 Remove the side turn signal lamp Refer to Section 9B Lighting Systems 5 Remove the screw and the bolt that secure the f...

Page 661: ...move 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 bolt between the bumper fascia and the fender ...

Page 662: ...tems 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 the top of the fender Tighten Tighten the upper fender bolts to 8 NSm 71 lb in 4 Install the bolt at the base of the A pillar Tighten Tighten the A pillar fender bolt to 8 NSm 71 lb in ...

Page 663: ...der 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 bumper fascia with the screw and the bolt Tighten Tighten the front bumper fascia to fender bolt to 1 5 NSm 13 lb in ...

Page 664: ...gnal 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 front wheel Refer to Section 2E Tires and Wheels 11 Lower the vehicle ...

Page 665: ... 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 are also integral parts of the body ...

Page 666: ...CHBACK 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 ASSEMBLIES WAGON 9S 13 LUGGAGE COMPARTMENT LOCK STRIKER WAGON 9S 14 REAR DECK LID HATCHBACK DOOR REMOTE CABLE AND HANDLE NOTCHBACK 9S 15 FUEL FILLER DOOR REMOTE CABLE AND HANDLE 9S 16 GENERAL DESCRIPT...

Page 667: ...ation 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 Bolts 20 15 Tailgate Lock Striker Bolts 10 89 ...

Page 668: ...e 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 Tighten Tighten the fuel filler door screws to 4 NSm 35 lb in REAR DECK LID NOTCHBACK Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the electrical connector ...

Page 669: ...ve 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 corrosion 1 Install the rear deck lid with the bolts Tighten Tighten the rear deck lid bolts to 10 NSm 89 lb in ...

Page 670: ...e 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 2 Pull the spring out of the rear mount 3 Remove the spring from the hinge ...

Page 671: ...secure 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 Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasten ers to prevent premature corrosion 3 Secure the luggage compartment lock cylinder with the nu...

Page 672: ...elease 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 bolts Tighten Tighten the luggage compartment lock striker bolts to 8 NSm 71 lb in LUGGAGE COMPARTMENT LOCK NOTCHBACK AND HATCHBACK Notchback Shown Hatchback Similar Removal Procedure 1 Disconnect the ...

Page 673: ...lar 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 Tighten the luggage compartment lock screws to 6 NSm 53 lb in 3 Connect the electrical connector 4 Install the lock trim cover hatchback only 5 Connect the negative battery cable ...

Page 674: ...nt 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 Remove the weatherstrip 5 Install the new weatherstrip onto the gutter flange HATCHBACK DOOR Removal Procedure 1 Open and suitably support the hatchback door 2 Disconnect the hatchback door grommets el...

Page 675: ...ies 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 suitably support the hatchback door 2 Unscrew and remove the gas support assembly from the hatchback door and the body Installation Procedure 1 Install the gas support assembly onto the hatch back door an...

Page 676: ...m 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 the luggage compartment rear trim panel Refer to Section 9G Interior Trim 3 Close the hatchback door REAR SPOILER HATCHBACK Removal Procedure 1 Open the hatchback door 2 Remove the nuts and the rear s...

Page 677: ...port 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 Procedure 1 With the aid of another technician install the tail gate to the hinges with the bolts Tighten Tighten the tailgate hinge bolts to 20 NSm 15 lb ft 2 Install the gas support assemblies to the tail...

Page 678: ...suitably 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 support assembly onto the tailgate Tighten Tighten the gas support assembly studs to 20 NSm 15 lb ft ...

Page 679: ...IKER 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 Procedure 1 Install the lock striker with the screws Tighten Tighten the tailgate lock striker bolts to 10 NSm 89 lbin 2 Install the luggage compartment rear trim panel Refer to Section 9G Interior Trim 3 Cl...

Page 680: ...n 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 seat Refer to Section 9H Seats 5 Remove the lower B pillar seat belt bolt and the anchor 6 Remove the rear deck lid remote handle cover 7 Reposition the floor carpet on the left side of the vehicle 8 ...

Page 681: ...lower 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 lock striker Refer to Luggage Compart ment Lock Striker Notchback or Luggage Compartment Lock Striker Hatchback in this sec tion 9 Install the luggage compartment left side wheel house trim panel Ref...

Page 682: ...ion 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 the cable from the luggage compartment to the passenger compartment 2 Connect the cable to the handle 3 Install the handle with the screws Tighten Tighten the fuel filler door remote cable handle scr...

Page 683: ...llar 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 to the fuel filler door 8 Install the luggage compartment wheelhouse trim panels Refer to Section 9G Interior Trim ...

Page 684: ... 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 panel hemmed around the perimeter and bonded to gether with structural adhesive The gas support assem blies assist in the opening of the hatchback door and can hold it in the open position TAILGATE WAGO...

Page 685: ...9T 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 ID CODE REPROGRAMMING 9T 4 TRANSPONDER 9T 5 DETECTION COIL 9T 5 IMMOBILIZER CONTROL UNIT 9T 8 GENERAL DESCRIPTION AND SYSTEM OPERATION 9T 10 IMMOBILIZER SYSTEM 9T 10 ELECTRONICALLY CODED KEYS 9T 10 ...

Page 686: ... 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 the en gine Is communication established between the scan tool and the immobilizer control unit Go to Step 2 Go to Commu nication Be tween Immobi lizer and Test Equipment 2 Select SYSTEM DIAGNOSIS fro...

Page 687: ...nit 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 a different key works the problem is in the original key 2 If trying a different key results in the same error message check the connection of the detection coil 3 If the connection of the detection ...

Page 688: ...bilizer con trol unit has recorded all of the new keys or after a deletion has reauthorized all of the remaining keys The immobilizer control unit can record a maximum of five keys 10 Return the system to the normal mode 11 Turn the ignition OFF 12 Turn the ignition ON 13 Start the engine ID CODE REPROGRAMMING Reprogram the identification ID code in the following si tuations 1 An immobilizer contr...

Page 689: ...9 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 reprogramming procedure does not result in match ing ID codes check the electrical connectors for the serial data wire between the immobilizer control unit and the PCM ECM TRANSPONDER If a transpond...

Page 690: ...r 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 Steering Wheel and Column 6 Disconnect the two pin connector from the immobi lizer ...

Page 691: ...the 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 steering column lower cover Refer to Section 6E Steering Wheel and Column 4 Install the knee bolster with the bolts Tighten Tighten the knee bolster mounting bolts to 22 NSm 16 lb ft 5 Install the i...

Page 692: ... 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 and the knee bolster 6 Remove the bolts and the immobilizer control unit 7 Disconnect the electrical connectors from the im mobilizer control unit ...

Page 693: ...e 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 battery cable Important After replacing the immobilizer the keys must be re authorized using the key coding procedure Refer to Key Coding Procedure in this section Also the elec tronic control module ...

Page 694: ...ducted 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 control mod ule ECM if the key is authorized New keys are coded by using a scan tool Refer to in this section Key Coding Procedure DETECTION COIL A detection coil is mounted at the ignition lock as an int...

Page 695: ...rtrain 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 re ceived within a specified time the PCM ECM disables the engine The engine is also disabled if the identification ID code transmitted by the immobilizer control unit does not match the code stored i...

Page 696: ... 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 5 FRONT DOOR TAMPER SWITCH 9T 7 REAR DECK LID TAMPER SWITCH 9T 7 HOOD OPEN SWITCH 9T 8 PASSWORD PROGRAMMING 9T 10 GENERAL DESCRIPTION AND SYSTEM OPERATION 9T 11 REMOTE KEYLESS ENTRY AND ANTI THEFT SY...

Page 697: ...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 698: ...REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM 9T 3 DAEWOO V 121 BL4 REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM 2 OF 2 ...

Page 699: ...9T 4IREMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM DAEWOO V 121 BL4 CONTROL MODULE RECEIVER CONNECTOR WIRING HARNESS CONNECTORS ...

Page 700: ...receiver 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 bracket 2 Connect the control module receiver electrical con nector 3 Install the floor console left side forward trim panel Refer to Section 9G Interior Trim 4 Connect the negative battery cable SIREN Rem...

Page 701: ...en 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 bracket mounting bolts to 22 NSm 16 lb in 2 Connect the siren electrical connector ...

Page 702: ...mper 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 connector 3 Install the front door trim panel Refer to Section 9G Interior Trim 4 Connect the negative battery cable REAR DECK LID TAMPER SWITCH Removal Procedure 1 Disconnect the negative battery cable 2...

Page 703: ...ect 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 Disconnect the electrical connector from the hood open switch 3 Remove the mounting screw from the hood open switch 4 Remove the hood open switch ...

Page 704: ...O 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 hood open switch 3 Connect the negative battery cable ...

Page 705: ...ode 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 recorded 6 Press any button of the transmitter to generate a data code including a password which will be re corded by the control module receiver The control module receiver sends a response message to th...

Page 706: ...CURITY 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 security indicator turns ON for 0 1 second and OFF for 0 7 second It then flashes at that frequency until the control module receiver is disarmed If the vehicle is equipped with an immobilizer the se...

Page 707: ...odule 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 module re ceiver has an attached antenna to detect signals from the transmitter FAULT OR ALARM INDICATION When the UNLOCK button on the remote transmitter is pressed the control module receiver will flas...

Page 708: ...S 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 TRANSAXLE 2 OF 2 9U 5 DIAGNOSIS 9U 6 CRUISE CONTROL DIAGNOSIS 9U 6 MAINTENANCE AND REPAIR 9U 11 ON VEHICLE SERVICE 9U 11 CRUISE CONTROL ACTUATOR 9U 11 ACTUATOR CONTROL CABLE 9U 15 MAIN SWITCH 9U 17 GENERAL...

Page 709: ...9U 2ICRUISE CONRTOL SYSTEM DAEWOO V 121 BL4 SCHEMATIC AND ROUTING DIAGRAMS CRUISE CONTROL SYSTEM AUTOMATIC TRANSAXLE 1 OF 2 ...

Page 710: ...CRUISE CONRTOL SYSTEM 9U 3 DAEWOO V 121 BL4 CRUISE CONTROL SYSTEM AUTOMATIC TRANSAXLE 2 OF 2 ...

Page 711: ...9U 4ICRUISE CONRTOL SYSTEM DAEWOO V 121 BL4 CRUISE CONTROL SYSTEM MANUAL TRANSAXLE 1 OF 2 ...

Page 712: ...CRUISE CONRTOL SYSTEM 9U 5 DAEWOO V 121 BL4 CRUISE CONTROL SYSTEM MANUAL TRANSAXLE 2 OF 2 ...

Page 713: ...served 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 VSS DTCorDTC722 or DTC723 present Go to Step 5 Go to Step 4 4 Diagnose and repair the cause of theDTCs Is the cruise control still inoperative Go to Step 5 System OK 5 Observe the brake lamps when th...

Page 714: ...Step 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 connector still disconnected from the cruise control actuator use a voltme ter to check the voltage at terminal 4 of the connector Is the voltage equal to the specified value 11 14 v Go to Step 19 Go to St...

Page 715: ... 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 System OK 28 Repair the open circuit between the cruise control main switch connector terminal 5 and the cruise con trol actuatorconnector terminal 9 Is the repair complete System OK 29 1 Turn the ign...

Page 716: ...d 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 Replace the lever switch Is the repair complete System OK 38 Repair the open circuit between the leverswitch con nector terminalB6 and the cruise control actuator connector terminal 2 Is the repair co...

Page 717: ...res 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 Does the ohmmeter indicate the specified value when checking the wire s between the cruise con trol module and the VSS for vehicles with amanual transaxle or the output shaft sensor for vehicles with a...

Page 718: ...ocedure 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 actuator still attached 4 Press the tabs on the cable adjuster and remove the cable and the adjuster from the adjuster brack et ...

Page 719: ...cable 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 housing retainers 7 Remove the cable ball from the actuator rod ...

Page 720: ...the 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 to the mounting bracket Tighten Tighten the actuator bolts to 4 NSm 35 lb in ...

Page 721: ...e 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 hold the cable when the adjuster button is pressed 6 Insert the cable adjuster into the adjuster bracket 7 Press the cable release button and adjust the cable to achieve a gap of 0 5 mm 0 02 inches ...

Page 722: ...gth 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 button is pressed 2 Press the retaining tabs of the cable adjuster and remove the adjuster from the mounting bracket 3 Tilt the cable housing and insert a flathead screw driver into one of the slots in...

Page 723: ...ut 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 assembly into the slot in the actuator rod and then rotate the cable 90 degrees ...

Page 724: ...cable 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 Procedure 1 Remove the radio taking care not to scratch the instrument panel or trim with the corners of the ra dio case Refer to Section 9F Audio Systems 2 Reach through the radio opening in the instru...

Page 725: ...tor 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 instrument panel or trim when installing the radio case Refer to Section 9F Audio Systems ...

Page 726: ...ch 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 S A microprocessor which controls speed regulation and monitors input signals S A clutch activation circuit which energizes the clutch magnet in order to couple the DC motor to the control cable S A ...

Page 727: ...t 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 mph If 155 km h 96 mph is attained acceleration will stop and 155 km h 96 mph will be set as the new tar get speed Tap Up If the cruise control has been set and RESUME is selected again for more than...

Page 728: ...e 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 replacement procedures Important Daewoo has also noted a small number of customer comments regarding the rate of Fuel Gauge Indicator movement as compared to the actual amount of fuel used If the Fue...

Page 729: ...6930 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 SIlver l DAE93U F7117 37211 56940 To ensure correct paint color matching and the ability to acquire 1998 1999 Daewoo paint from your local supplier we have compiled a list of paint codes for Daewoo ...

Page 730: ...E23U 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 F3135 48188 56931 62U Khaki Beige l l DAE62U F3186 28495 56933 73L Super Red l l DAE73L F1608 74482 55994 74U Spinel Red Pearl l l l DAE74U F3185 74842 56937 83L Granada Black l DAE83L F1648 95089 533...

Page 731: ...elephone 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 Assistance 800 798 5872 Martin Senour Customer Assistance 800 526 6704 ...

Page 732: ...oved 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 is a procedure for diagnosing the Fuel Level Sensor commonly referred to as a Fuel Level Sending Unit and the replacement procedure if necessary which involves the partial disassembly of the Fuel Pu...

Page 733: ... 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 is removed 12 Remove the Fuel Filler Cap 13 Disconnect the Fuel Outlet Hose from the Fuel Pump Module 14 Disconnect the Fuel Tank Return Hose from the Fuel Pump Module 15 Disconnect the Wiring Harne...

Page 734: ... 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 be disconnected from the Fuel Pump Module Mounting Flange Connector 2 Using a small pair of needle nosed pliers remove and retain the secondary terminal lock from the sub harness electrical connecto...

Page 735: ...he 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 will slide through the retaining rail as you pull it free of the Fuel Pump Module Body Note Prying in the opposite direction may cause damage to the lock that retains the Low Fuel Sensor Bracket 8 R...

Page 736: ...uel 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 Terminals into the Fuel Pump Module Sub harness Electrical Connector Ensure that the terminals are properly reinstalled as noted previously and that the correct wire colors are in their proper connector loc...

Page 737: ...om 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 drift reinstall the Fuel Pump Module Retaining Ring by rotating it clockwise until it reaches it s stops 21 Reconnect the Wiring Harness Connector to the Mounting Flange Connector on the Fuel Pump M...

Page 738: ...uel 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 004 01 Nature Code N62 Cause Code R18 Causal Part Number Lanos 96388929 Nubira 96388676 Leganza 96405140 If additional information is needed regarding this procedure please contact your District Par...

Page 739: ...ted 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 Store stock units should be immediately updated with the new lock rod Affected customer vehicles demonstrators DCA vehicles etc should be updated as they come in for periodic service and or repairs rega...

Page 740: ...r 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 Parts Information Part Name Part Number Qty Req d Rod Key Cyl T Gate 96237711 1 Warranty Information Operation Code Operation Description Labor Time F896112 Rod T Gate Lock Replace 0 2 hr Causal Part N...

Page 741: ...ammed 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 programming procedure for the Remote Keyless Entry Transmitter s REMOTE KEYLESS ENTRY TRANSMITTER PROGRAMMING PROCEDURE Note Ensure that the doors hood and trunk rear hatch are closed prior to starting the ...

Page 742: ...diate 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 Transmitters may be programmed to a vehicle 14 Once all Transmitters have been programmed press the ESC Button on the Key Pad The display will confirm the number of Transmitters programmed If the number ...

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