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4T40–E AUTOMATIC TRANSAXLE 5A – 3

DAEWOO V–121 BL4

DTC P0723 AUTOMATIC TRANSMISSION

VEHICLE SPEED SENSOR (A/T VSS)
INTERMITTENT

5A–110

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

DTC P0724 BRAKE SWITCH

CIRCUIT HIGH

5A–112

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

DTC P0730 INCORRECT GEAR RATIO

5A–114

. . . .

DTC P0741 TCC CIRCUIT STUCK OFF

5A–116

. . . .

DTC P0742 TCC CIRCUIT STUCK ON

5A–119

. . . . .

DTC P0748 PC SOLENOID

CIRCUIT ELECTRICAL

5A–123

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

DTC P0751 1–2 SHIFT SOLENOID

PERFORMANCE

5A–126

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

DTC P0753 1–2 SHIFT SOLENOID

ELECTRICAL

5A–130

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

DTC P0756 2–3 SHIFT SOLENOID

PERFORMANCE

5A–133

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

DTC P0758 2–3 SHIFT SOLENOID

ELECTRICAL

5A–137

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

DTC P1790 ROM CHECKSUM ERROR

5A–140

. . . .

DTC P1792 EEPROM

CHECKSUM ERROR

5A–141

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

DTC P1810 AUTOMATIC TRANSMISSION

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

5A–142

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

DTC P1811 MAXIMUM ADAPT

AND LONG SHIFT

5A–147

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

DTC P1887 TCC RELEASE SWITCH

CIRCUIT MALFUNCTION

5A–151

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

MAINTENANCE AND REPAIR

5A–154

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

ON–VEHICLE SERVICE

5A–154

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

TRANSAXLE FLUID LEVEL CHECKING

PROCEDURE

5A–154

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

CHANGING THE FLUID

5A–155

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

REPAIRING FLUID LEAKS

5A–155

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

CASE POROSITY REPAIR

5A–156

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

FLUID LEVEL SET AFTER SERVICE

5A–157

. . . . . .

OIL COOLER FLUSHING

5A–157

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

SHIFT CONTROL LEVER

5A–158

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

SHIFT CONTROL CABLE

5A–164

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

CONTROL CABLE ADJUSTMENT

5A–167

. . . . . . . .

PARK/NEUTRAL POSITION SWITCH

5A–168

. . . . . .

BRAKE TRANSAXLE SHIFT INTERLOCK

5A–169

. .

KEY INTERLOCK

5A–170

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

AUTOMATIC TRANSMISSION VEHICLE

SPEED SENSOR (A/T VSS)

5A–172

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

PAN, GASKET, AND FILTER

5A–173

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

REVERSE/LOW SERVO ASSEMBLY

5A–174

. . . . . .

2ND/4TH SERVO ASSEMBLY

5A–175

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

CASE SIDE COVER PAN AND GASKETS

5A–176

. .

1–2 SHIFT SOLENOID

5A–177

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

2–3 SHIFT SOLENOID

5A–178

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

PRESSURE CONTROL SOLENOID

5A–178

. . . . . . .

TCC SOLENOID

5A–179

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

DRIVE AXLE OIL SEAL

5A–180

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

OIL COOLER PIPES

5A–180

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

OIL COOLER HOSES AND PIPE

5A–181

. . . . . . . . . .

TRANSAXLE MOUNT

5A–183

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

TRANSAXLE BRACKET

5A–185

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

TRANSAXLE ASSEMBLY

5A–187

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

TRANSAXLE BRACE

5A–193

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

UNIT REPAIR

5A–195

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

TORQUE CONVERTER REMOVAL

5A–195

. . . . . . . .

TRANSAXLE HOLDING

FIXTURE ASSEMBLY

5A–195

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

STUB SHAFT REMOVAL

5A–196

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

AUTOMATIC TRANSMISSION VEHICLE

SPEED SENSOR REMOVAL

5A–196

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

OIL PAN AND GASKET REMOVAL

5A–197

. . . . . . . .

OIL FILTER/SEAL, OIL LEVEL CONTROL

VALVE REMOVAL

5A–197

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

OIL FEED PIPES REMOVAL

5A–197

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

INTER 4TH SERVO REMOVAL

5A–198

. . . . . . . . . . .

LOW/REVERSE SERVO REMOVAL

5A–198

. . . . . . .

CASE SIDE COVER REMOVAL

5A–198

. . . . . . . . . . .

OIL PUMP AND OIL PUMP SHAFT

REMOVAL

5A–199

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

WIRE HARNESS DISCONNECT

5A–199

. . . . . . . . . .

PRESSURE SWITCH ASSEMBLY

REMOVAL

5A–199

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

CONTROL VALVE BODY ASSEMBLY

AND GASKET REMOVAL

5A–200

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

SPACER PLATE AND GASKET REMOVAL

5A–200

CHECKBALL REMOVAL

5A–200

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

MANUAL VALVE CLIP REMOVAL

5A–201

. . . . . . . . .

CHANNEL PLATE AND GASKET

REMOVAL

5A–201

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

ACCUMULATOR SPRING REMOVAL

5A–201

. . . . . .

OUTPUT SHAFT SLEEVE REMOVAL

5A–202

. . . . .

DRIVE, DRIVEN SPROCKETS, DRIVE LINK

REMOVAL

5A–202

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

INPUT SPEED SENSOR REMOVAL

5A–202

. . . . . . .

WIRING HARNESS REMOVAL

5A–203

. . . . . . . . . . .

DRIVEN SPROCKET SUPPORT

ASSEMBLY REMOVAL

5A–203

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

2ND CLUTCH PLATES REMOVAL

5A–203

. . . . . . . .

REVERSE INPUT CLUTCH

HOUSING REMOVAL

5A–204

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

INTERMEDIATE 4TH BAND REMOVAL

5A–204

. . . .

DIRECT/COAST CLUTCH AND

REACTION GEAR SET REMOVAL

5A–204

. . . . . .

Содержание NUBIRA

Страница 1: ......

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

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

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

Страница 5: ...ilizer con trol unit has recorded all of the new keys or after a deletion has reauthorized all of the remaining keys The immobilizer control unit can record a maximum of five keys 10 Return the system...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 68: ...body pillar This floating cage plate al lows the striker to be easily adjusted in or out and up or down The door is secured in the closed position when the door lock fork snaps over and engages the s...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 271: ...lide lengthwise along the splines of the in put shaft but which drives the input shaft through these same splines The driving and driven members are held in contact by spring pressure This pressure is...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 536: ...nly when it is not commanded by the PCM ECM or the scan tool while a short to voltage will appear in the short positions on the scan tool only while the component is being commanded by the PCM ECM or...

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

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

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

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

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

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

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

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

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

Страница 546: ...e specified Is the test light on 2 sec Go toStep 50 Go toStep 52 50 1 Turn the ignition OFF 2 Connect a test light between the fuel pump relay connector terminal 30 and ground Is the test light on Go...

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

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

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

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

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

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

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

Страница 554: ...nlet is due to a faulty one way check valve in the fuel pump CAUTION The fuel system is under pressure To avoid fuel spillage and the risk of personal injury or fire it is necessary to relieve the fue...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 632: ......

Страница 633: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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