Page 2: Specifications
SECTION : 0B GENERAL INFORMATION TABLE OF CONTENTS SPECIFICATIONS ......0B–1 AT LEAST MONTHLY ..... 0B–12 TECHNICAL DATA .
Page 3 Common Use; Brake Fluid Manual Transaxle Application 2.2L DOHC Maker DWMC Type or Model D–20 Gear Ratio: – 3.545:1 2.158:1 1.478:1 1.129:1 0.886:1 Reverse 3.333:1 Final Drive Ratio 3.550:1 Oil Capacity 1.8L (2 qt) * Puerto Rico only. DAEWOO V–121 BL4...
Page 4 0.5L (0.53 qt) Tire and Wheel Application 2.0L DOHC Standard Tire Size 185/65R14 Temporary Tire Size T125/70D15 Standard Wheel Size 5.5JX14 Inflation Pressure at Full Load: – 185/65R14: –– Front 30 psi Rear 28 psi T127/70D15 60 psi DAEWOO V–121 BL4...
Page 5 Fuel Filter Type Cartridge Fuel Capacity 52L (13.7 gal) Lubricating System Application 2.0L DOHC Lubricating Type Forced Feed Oil Pump Type Duocentric Rotor Oil Filter Type Cartridge (Full Flow) Oil Pan Capacity Including Oil Filter 3.8L (4.1 qt) DAEWOO V–121 BL4...
Page 6: Vehicle Dimensions And Weights
1 470 mm (58.0 in.) 5–Door 1 430 mm (56.2 in.) Minimum Ground Clearance 151 mm (5.9 in.) Wheel Base 2 570 mm (101.2 in.) Tread: – Front 1 464 mm (57.6 in.) Rear 1 454 mm (57.2 in.) DAEWOO V–121 BL4...
Page 7 1 720 kg (3,792 lb) Automatic: – Curb Weight: – Standard 1 191 kg (2,625 lb) Optional 1 260 kg (2,778 lb) Gross Vehicle Weight 1 720 kg (3,792 lb) Passenger Capacity Optional Weight: Air Conditioning, Power Steering, ABS, Sunroof, Airbag. DAEWOO V–121 BL4...
Page 8 317–476 NSm (234–351 lb–ft) M22 X 1.5 251–414 NSm (185–305 lb–ft) 363–544 NSm (268–401 lb–ft) 424–636 NSm (313–469 lb–ft) M24 X 2.0 359–540 NSm (265–398 lb–ft) 431–710 NSm (318–524 lb–ft) 555–831 NSm (409–613 lb–ft) * Diameter X pitch in millimeters DAEWOO V–121 BL4...
Page 9: Maintenance And Lubrication
Using oils of any viscosity other than those viscosities recommended could result in engine damage. Cooling System Service Drain, flush and refill the system with new coolant. Refer to ”Recommended Fluids and Lubricants”in this section. DAEWOO V–121 BL4...
Page 10 If irreg- ular or premature wear exists, check the wheel alignment and check for damaged wheels. While the tires and wheels are removed, inspect the brakes. Refer to ”Each Time The Oil Is Changed”in this section. DAEWOO V–121 BL4...
Page 11 * : Replacement or inspection of these emissions components is recommended to be performed at the indicated intervals however, the California Air Resources Board has determined that performing thesemaintenance items are not required to maintained your vehicle emission warranty. DAEWOO V–121 BL4...
Page 12 – Driving in heavy city traffic where the outside temperatures regularly reach 32³C (90³F) or higher. – Driving a taxi, or police or delivery vehicles. (8) If necessary, rotate and balance the wheels Note : Check the engine oil and radiator coolant levels ev- ery week. DAEWOO V–121 BL4...
Page 13: At Least Monthly
Check clutch pedal free travel and adjust, as necessary, Pull out the oil level indicator and look at the oil lev- every 16,000 km (10,000 miles). Measure the distance el on it. from the center of the clutch pedal to the outer edge of the DAEWOO V–121 BL4...
Page 14 To check the automatic transaxle P (PARK) mechanism’s Inspect all belts for cracks, fraying, wear, and proper ten- holding ability, release all brakes after shifting the trans- sion. Adjust or replace the belts, as needed. axle to P (PARK). DAEWOO V–121 BL4...
Page 15 Wash the filler cap Engine Cooling System and the neck. Pressure test the cooling system and the Inspect the coolant and freeze protection fluid. If the fluid cap to help ensure proper operation. DAEWOO V–121 BL4...
Page 16: Recommended Fluids And Lubricants
1. Pivots and Spring Anchor 2. Multipurpose–type grease meeting require- 2. Release Pawl ments NLGI No. 1 or 2 Hood and door hinges As needed Engine oil Fuel door hinge Rear compartment lid hinges Weatherstripping As needed Silicone grease DAEWOO V–121 BL4...
Page 17: General Repair Instructions
0B – 16IGENERAL INFORMATION Use genuine DAEWOO parts. GENERAL DESCRIPTION Discard used cotter pins, gaskets, O–rings, oil seals, lock washers and self–locking nuts. Prepare AND SYSTEM OPERATION new ones for installation. Normal functioning of the vehicle’s components cannot be maintained if these fasteners and seals are reused.
Page 18: General Description
RECOVERY SYSTEM To collect refueling vapors and to route to canister. The NUBIRA 2.0 DOHC model is equipped with an On To provide nozzle compatibility with conventional Board Diagnostic Stage II (OBD–II) system to meet en- and stage II vapor recovery nozzles.
Page 19 OBD–II Valve (Solenoid)OBD–II Valve (Solenoid) 12. 2–Way Check Valve Air Filter 13. Check Valve Fuel Tank (Steel) 14. Fuel Filler Tube (Dynamic Seal During Fill) Fuel Fill Vent Control Valve & Liquid–Vapor Dis- 15. Fuel Filler Cap (Pressure–Vacuum Relief) DAEWOO V–121 BL4...
Page 20: Component Locator
GENERAL INFORMATION 0B – 19 Component Locator Fuel Tank Purge Valve Filler Tube Service port Canister Fuel Filler Cap OBD– II Valve Air Filter Fuel Filter DAEWOO V–121 BL4...
Page 21: Vehicle Identification
0B – 20IGENERAL INFORMATION VEHICLE IDENTIFICATION Passenger Car VIN Production Date Certification plate Gross Vehicle Weight Rating Gross Axle Weight Rating Front Gross Axle Weight Rating Rear Vehicle Identification Number DAEWOO V–121 BL4...
Page 22: Certification Label
The vehicle identification number (VIN) is engraved in the top of the bulkhead, next to the ABS module. Certification Label The Certification Label is attached to the driver’s side B– pillar near door strike. DAEWOO V–121 BL4...
Page 23 0B – 22IGENERAL INFORMATION Engine Number – Family II (2.0L DOHC Engine) The engine number is stamped on the cylinder block under Engine Number Plate Location – Family II the No. 4 exhaust manifold of the engine. (2.0L DOHC Engine) DAEWOO V–121 BL4...
Page 24 2.0L DOHC 3.545 C/R Sequential Number Manual Transaxle Identification Number Manufacturer Part Number Plate Location Identification Code Engine 7ZZR 2.0L DOHC The manual transaxle identification number is attached to the top of the transaxle case near the engine. DAEWOO V–121 BL4...
Page 25 The automatic transaxle identification number plate is at- tached on the rear side of the transaxle near the bulkhead. DAEWOO V–121 BL4...
Page 26 GENERAL INFORMATION 0B – 25 DAEWOO V–121 BL4...
Page 27 0B – 26IGENERAL INFORMATION Vehicle Lifting Points DAEWOO V–121 BL4...
Page 28 SECTION : 1A GENERAL ENGINE INFORMATION TABLE OF CONTENTS DIAGNOSIS ....... . 1A–1 NOISE DIAGNOSIS .
Page 29: Oil Pressure Test
Is the repair complete? Inspect the oil pickup tube. Go to Step 19 Go to Step 20 Are there any holes in the oil pickup tube? Replace the oil pickup tube. Go to Step 1 Is the repair complete? DAEWOO V–121 BL4...
Page 30 If the leak still cannot be found, it may be neces- sary to clean the suspected area with a degreaser, Pour the specified amount of dye into the engine oil steam or spray solvent. fill tube. DAEWOO V–121 BL4...
Page 31 Replace the connecting rod. Go to Step 1 Is the repair complete? * Cold engine piston knock usually disappears when the cylinder is grounded out. Cold engine piston knock, which disap- pears in about 1.5 minutes, is considered acceptable. DAEWOO V–121 BL4...
Page 32 Is the repair complete? Inspect the rod bearing clearance. 0.019–0.070 Go to Step 15 System OK Is the clearance more than the specified value? (0.0007–0.0027 in.) Replace the rod bearings as necessary. Go toStep 1 Is the repair complete? DAEWOO V–121 BL4...
Page 33 Attempts to repair this should be made only if the problem is consistent. An engine that is only operated for short periods between start–ups may have lifter noise that lasts for a few minutes. This is a normal condition. DAEWOO V–121 BL4...
Page 34 Check the piston pin offset. 0.5–0.7 mm Go to Step 19 System OK Is the offset at the specified value? (0.019–0.027 in.) Toward Thrust Side Install the correct piston. Go to Step 1 Is the repair complete? DAEWOO V–121 BL4...
Page 35 Go to Step 6 Is there a misaligned connecting rod? and Rods Re- placement Pro- cedure Inspect the connecting rod bolts. System OK Go toPistons Are the connecting rod bolts torqued properly? and Rods Re- placement Pro- cedure DAEWOO V–121 BL4...
Page 36 Go to Step 5 Is there a misaligned connecting rod? and Rods Re- placement Pro- cedure Inspect the piston position. Go toPistons System OK Is the piston 180³ out of position? and Rods Re- placement Pro- cedure DAEWOO V–121 BL4...
Page 37 Go to Step 8 Are the valve guides worn? Head and Valve Train Components Replacement Procedure Inspect the valve spring seat. Go toCylinder System OK Is the valve spring seat incorrect? Head and Valve Train Components Replacement Procedure DAEWOO V–121 BL4...
Page 38: General Information
Battery cables should be disconnected before any major DAEWOO V–121 BL4...
Page 39: Table Of Contents
SECTION : 1C DOHC ENGINE MECHANICAL CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle.
Page 40: Engine Specifications
Diameter (All) Out of Round (Maximum) 0.003 mm (0.0001 in.) Main Bearing Clearance (All) 0.015–0.061 mm (0.00059~0.00239 in.) Crankshaft End Play 0.070~0.302 mm (0.0027~0.0118 in.) Service Oversize Available in 2 sizes 0.25 mm and 9.50 mm (0.0098~0.0196 in.) DAEWOO V–121 BL4...
Page 41 HN 1256 (Loctite± 242) Oil Pan Pickup Tube Bolts HN 1256 (Loctite± 242) Oil Gallery Plug HN 1256 (Loctite± 242) Coolant Jacket Caps and Plugs (Freeze Plugs) HN 1756 (Loctite± 176) Exhaust Manifold Studs/Nuts Anti–seize Compound (HMC Spec HN1325) DAEWOO V–121 BL4...
Page 42: Fastener Tightening Specifications
Generator–to–Intake Manifold and Cylinder Head Support – Bracket Bolts Generator–to–Intake Manifold Strap Bracket Bolt, Upper and – Lower Generator–to–Intake Manifold Support Bracket Bolts – Ignition Coil Mounting Bolts – Intake Manifold Retaining Nuts and Bolts – Intake Manifold Support Bracket Bolts – DAEWOO V–121 BL4...
Page 43 Throttle Cable Bracket Bolts – Timing Belt Automatic Tensioner Bolt – Timing Belt Idler Pulley Bolt – Timing Belt Idler Pulley Nut – Transmission/Transaxle Bell Housing Bolts – Transmission/Transaxle Torque Converter Bolts – Valve Cover Bolts – DAEWOO V–121 BL4...
Page 44: Special Tools
1C – 6IDOHC ENGINE MECHANICAL SPECIAL TOOLS SPECIAL TOOLS TABLE KM–653 MKM–571–B Adapter Gauge J–28467–B KM–135 Engine Assembly Lift Adapter Support KM–805 KM–412 Valve Guide Reamer Engine Overhaul Stand J–36792 KM–348 Crankshaft Rear Oil Seal Spring Compressor Installer DAEWOO V–121 BL4...
Page 45 DOHC ENGINE MECHANICAL 1C – 7 KM–635 KM–470–B Crankshaft Rear Oil Seal Angular Torque Gauge Installer KM–427 KM–498–B Piston Pin Service Set Pressure Gauge KM–340–0 Cutter Set Includes: KM–340–7 Guide Drift KM–340–13 Cutters KM–340–26 Cutters DAEWOO V–121 BL4...
Page 46: Upper End
1C – 8IDOHC ENGINE MECHANICAL COMPONENT LOCATOR UPPER END DAEWOO V–121 BL4...
Page 47 21. Head Bolt 47. Intake Manifold Gasket 22. Bolt 48. Intake Manifold 23. Bearing Cap 49. Throttle Body Gasket 24. EGR Adapter 50. Throttle Body 25. EGR Adapter Gasket 51. Nut 26. Cylinder Head 52. Exhaust Gas Recirculation Solenoid DAEWOO V–121 BL4...
Page 48: Lower End
1C – 10IDOHC ENGINE MECHANICAL LOWER END DAEWOO V–121 BL4...
Page 49 74. Water Pump 34. Ring Gear 75. Seal Ring 35. Gear 76. Crankshaft Revolution Sensor 36. Plug 77. Bolt 37. Washer 78. Knock Sensor 38. Washer 79. Bolt 39. Bypass Valve Plug 80. Bolt 40. Special Screw 41. Seal DAEWOO V–121 BL4...
Page 50: Exhaust Manifold
When the shaft journals. amount of oil being pumped increases, the pressure be- comes high enough to overcome the force of the spring. DAEWOO V–121 BL4...
Page 51 Remove the spark plug cover. Disconnect the ignition wires from the spark plugs. Remove the valve cover bolts. Remove the valve cover washers. 10. Remove the valve cover. 11. Remove the valve cover gasket from the valve cov- DAEWOO V–121 BL4...
Page 52: Installation Procedure
Install the spark plug cover bolts. Tighten Tighten the spark plug cover bolts to 3 NSm (27 lb–in). 10. Connect all of the necessary vacuum lines. 11. Connect the breather tube to the valve cover. 12. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 53 11. Disconnect the idle air control valve connector. 12. Disconnect the throttle position sensor connector. 13. Disconnect the engine coolant temperature sensor connector. 14. Disconnect the coolant temperature sensor connec- tor. 15. Disconnect the camshaft position sensor. DAEWOO V–121 BL4...
Page 54 23. Remove the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump. 24. Remove the crankshaft pulley bolts. 25. Remove the crankshaft pulley. 26. Remove the front timing belt cover bolts. 27. Remove the front timing belt cover. DAEWOO V–121 BL4...
Page 55 37. Remove the intake camshaft gear. 38. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt. 39. Remove the exhaust camshaft gear. 40. Remove the timing belt automatic tensioner bolts. 41. Remove the timing belt automatic tensioner. DAEWOO V–121 BL4...
Page 56 45. Remove the engine mount. 46. Remove the rear timing belt cover bolts. 47. Remove the rear timing belt cover. 48. Remove the auxiliary catalytic converter nuts at the exhaust manifold. 49. Disconnect all of the necessary vacuum hoses. DAEWOO V–121 BL4...
Page 57 64. Remove the cylinder head with the intake manifold and the exhaust manifold attached. Notice : Prevent any engine oil or coolant from entering the cylinders when removing the cylinder head. 65. Remove the cylinder head gasket. DAEWOO V–121 BL4...
Page 58 Tighten the intakemanifold support bracket bolt at the generator to 20 NSm (15 lb–ft). Connect the surge tank coolant hose at the throttle body. 10. Connect the coolant hose to the rear cylinder head and ignition coil EGR bracket. DAEWOO V–121 BL4...
Page 59 21. Install the timing belt idler pulleys. 22. Install the timing belt idler pulley nuts. Tighten Tighten the timing belt idler pulley bolt to 25 NSm (18 lb–ft). Tighten Tighten the timing belt idler pulley nut to 25 NSm (18 lb–ft). DAEWOO V–121 BL4...
Page 60 30. Install the valve cover and the valve cover gasket. 31. Install the valve cover washers. 32. Install the valve cover bolts. Tighten Tighten the valve cover bolts to 8 N·m (71 lb–in). DAEWOO V–121 BL4...
Page 61 38. Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover. 39. Install the timing belt. 40. Check and adjust the timing belt tension. Refer to ”Timing Belt Check and Adjust” in this section. DAEWOO V–121 BL4...
Page 62 Tighten the air filter housing bolts to 8 NSm (71 lb–in). 53. Connect the air intake tube to the throttle body. 54. Connect the breather tube to the valve cover. 55. Connect the intake air temperature sensor connec- tor. 56. Connect the camshaft position sensor. DAEWOO V–121 BL4...
Page 63 Remove the spark plug cover. Disconnect the ignition wires from the spark plugs. Disconnect the camshaft position sensor. Remove the valve cover bolts. Remove the valve cover washers. 10. Remove the valve cover and the valve cover gas- ket. DAEWOO V–121 BL4...
Page 64 Install the exhaust camshaft bearing caps in their original positions. Install the exhaust camshaft bearing cap bolts. Tighten the camshaft cap bolts gradually and in the sequence shown for each camshaft bearing cap. Tighten Tighten the camshaft cap bolts to 8 NSm (71 lb–in). DAEWOO V–121 BL4...
Page 65 14. Install the valve cover and the valve cover gasket. 15. Install the valve cover washers. 16. Install the valve cover bolts. Tighten Tighten the valve cover bolts to 8 NSm (71 lb–in). 17. Connect the camshaft position sensor. DAEWOO V–121 BL4...
Page 66: Timing Belt Check And Adjust
Remove the breather tube from the valve cover. Remove the air filter housing bolts. Remove the air filter housing. Remove the right front wheel. Refer to Section 2E, Tires and Wheels. Remove the right front splash shield. DAEWOO V–121 BL4...
Page 67 14. Remove the front timing belt cover. 15. Rotate the crankshaft at least one full turn clock- wise using the crankshaft gear bolt. 16. Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover. DAEWOO V–121 BL4...
Page 68 20. Tighten the automatic tensioner bolt. 21. Rotate the crankshaft two full turns clockwise using the crankshaft gear bolt. 22. Check the automatic tensioner pointer. DAEWOO V–121 BL4...
Page 69 Tighten the crankshaft pulley bolt to 20 NSm (15 lb–ft). 28. Install the right engine mount bracket. Refer to”En- gine Mount”in this section. 29. Install the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump. DAEWOO V–121 BL4...
Page 70: Timing Belt
37. Connect the negative battery cable. TIMING BELT Removal Procedure Disconnect the negative battery cable. Disconnect the intake air temperature sensor con- nector. Disconnect the air intake tube from the throttle body. Disconnect the breather tube from the valve cover. DAEWOO V–121 BL4...
Page 71 10. Remove the crankshaft pulley bolts. 11. Remove the crankshaft pulley. 12. Remove the right engine mount bracket. Refer to ”Engine Mount” in this section. 13. Remove the front timing belt cover bolts. 14. Remove the front timing belt cover. DAEWOO V–121 BL4...
Page 72 17. Remove the timing belt. 18. Loosen the automatic tensioner bolt. Turn the hexkey tab to relieve belt tension. DAEWOO V–121 BL4...
Page 73 Align the timing marks on the camshaft gears, us- ing the intake gear mark for the intake gear and the exhaust gear mark for the exhaust gear. Install the timing belt. DAEWOO V–121 BL4...
Page 74 10. Install the right engine mount bracket. Refer to ”En- gine Mounts” in this section. 11. Install the crankshaft pulley. 12. Install the crankshaft pulley bolts. Tighten Tighten the crankshaft pulley bolts to 20 NSm (15 lb– ft). DAEWOO V–121 BL4...
Page 75: Oil Pan
Remove the auxiliary catalytic converter upper flange nuts from the exhaust manifold and the sup- port bracket bolts. Remove the front muffler pipe retaining nuts from the main catalytic converter. Remove both catalytic converters as a unit. DAEWOO V–121 BL4...
Page 76 Cleaning Procedure Clean the oil pan sealing surface. Clean the engine block sealing surface. Clean the oil pan retaining bolts. Clean the oil pan attaching bolt holes in the engine block. Clean the oil pan splash shield. DAEWOO V–121 BL4...
Page 77 Tighten the oil pan retaining bolts to 10 NSm (89 lb–in). Install the oil pan flange–to–transaxle retaining bolts. Tighten Tighten the oil pan flange–to–transaxle bolts to 40 NSm (30 lb–ft). Install the catalytic converters. Tighten Tighten the auxiliary catalytic converter–to–exhaust manifold nuts to 40 NSm (30 lb–ft). DAEWOO V–121 BL4...
Page 78: Oil Pump
Start the engine and check the oil pressure at idle speed and engine temperature of 80³C (176³F). The minimum oil pressure should be 30 kPa (4.35 psi). Stop the engine and remove the pressure gauge KM–498–B and the adapter KM–135. DAEWOO V–121 BL4...
Page 79: Removal Procedure
Timing Belt Cover” in this section. Disconnect the oil pressure switch connector. Remove the oil pan. Refer to ”Oil Pan” in this sec- tion. Remove the oil pump/pickup tube and support bracket bolts. Remove the oil pump/pickup tube. DAEWOO V–121 BL4...
Page 80: Inspection Procedure
Remove the oil pump. Inspection Procedure Clean the oil pump and the engine block gasket mating surface areas. Remove the safety relief valve bolt. Remove the safety relief valve and the spring. Remove the oil pump–to–crankshaft seal. DAEWOO V–121 BL4...
Page 81 (RTV) sealant to the new oil pump gasket. Install the gasket to the oil pump and install the oil pump to the engine block with the bolts. Tighten Tighten the oil pump bolts to 10 NSm (89 lb–in). DAEWOO V–121 BL4...
Page 82 Install the oil pan. Refer to ”Oil Pan” in this section. Connect the oil pressure switch connector. Install the rear timing belt cover. Refer to ”Rear Timing Belt Cover” in this section. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 83 10. Remove the thermostat housing mounting bolts. 11. Remove the thermostat housing assembly. 12. Remove the fuel rail assembly. Refer to Section 1F, Engine Controls (DOHC). 13. Remove the coolant bypass housing mounting bolts and the housing. DAEWOO V–121 BL4...
Page 84 23. Remove the intake camshaft. 24. Remove the intake valve lash adjusters. 25. Remove the exhaust camshaft caps. Maintain the correct positions for installation. 26. Remove the exhaust camshaft. 27. Remove the exhaust valve lash adjusters. DAEWOO V–121 BL4...
Page 85 Inspect the length and width of the cylinder head using a feeler gauge and a straight edge. Check the sealing surfaces for deformation and warpage. The cylinder head sealing surfaces must be flat within 0.025 mm (0.001 inch) maximum. DAEWOO V–121 BL4...
Page 86: Valve Inspection
Inspect the valve spring seating surface of the valve rotators for wear or gouges. Replace as re- quired. Cleaning Procedure Clean the cylinder head. Clean the valve guides. Clean all of the threaded holes. Clean the valves of carbon, oil, and varnish. DAEWOO V–121 BL4...
Page 87 The valve may be reground only two times. Do not grind the valve stem end. Ensure that the angle at the valve face is 45 de- grees. Inspect the assembly height of the intake valves and the exhaust valves. DAEWOO V–121 BL4...
Page 88 Normal – – 0.075 KM–805 0.150 Ream the valve guide from the upper side of the cylinder head to the next oversize. After reaming, cross out the code and emboss the valve guide with the new code. DAEWOO V–121 BL4...
Page 89 Push the accompanying assembly sleeve onto the valve stem. Insert the new valve stem seat. Carefully drive the valve stem seal onto the stop with light taps. Install the valve springs in their original positions. Install the valve spring caps. DAEWOO V–121 BL4...
Page 90 18. Install the camshaft bearing cap bolts. 19. Tighten the camshaft bearing cap bolts gradually and in the sequence shown for each camshaft cap. Tighten Tighten the camshaft bearing cap bolts to 8 NSm (71 lb–in). DAEWOO V–121 BL4...
Page 91 30. Install the coolant bypass housing and mounting bolts. Tighten Tighten the coolant bypass housing and mounting bolts to 15 NSm (11 lb–ft). 31. Install the camshaft position sensor. Tighten Tighten the camshaft position sensor bolts to 12 NSm (106 lb–in). DAEWOO V–121 BL4...
Page 92 Remove the engine. Refer to ”Engine” in this sec- tion. Remove the flywheel or flexible plate bolts. Remove the flywheel or the flexible plate. Remove the crankshaft rear oil seal. Mount the engine assembly on the engine overhaul stand KM–412. DAEWOO V–121 BL4...
Page 93 19. Remove the spark plug cover. 20. Disconnect the ignition wires from the spark plugs. 21. Remove the valve cover bolts. 22. Remove the valve cover washers. 23. Remove the valve cover and the valve cover gas- ket. DAEWOO V–121 BL4...
Page 94 26. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft bolt. 27. Remove the exhaust camshaft gear. 28. Remove the crankshaft timing belt gear. 29. Remove the rear timing belt cover bolts and cover. DAEWOO V–121 BL4...
Page 95 35. Remove the lower block support bracket/splash shield bolts. 36. Remove the splash shield. 37. Remove the lower block support bracket bolts. 38. Remove the lower block support bracket. 39. Remove the oil pump retaining bolts. 40. Remove the oil pump. DAEWOO V–121 BL4...
Page 96 46. Remove the crankshaft bearing caps and the lower crankshaft bearings. 47. Remove the crankshaft. 48. Clean any necessary parts. Assembly Procedure Coat the crankshaft bearings with engine oil. If replacing the crankshaft, transfer the pulse pick– up sensor disc to the new crankshaft. DAEWOO V–121 BL4...
Page 97 10. Install the crankshaft bearing caps and the bolts. Tighten Tighten the crankshaft bearing cap bolts to 50 NSm (26 lb–ft). Use the angular torque gauge, KM–470–B, to tighten the crankshaft bearings +45 degrees + another 15 degrees. DAEWOO V–121 BL4...
Page 98 19. Install the connecting rod bearing caps. Tighten Tighten the connecting rod bearing cap bolts to 35 NSm (26 lb–ft). Use the angular torque gauge KM–470–B to tighten the connecting rod bearing cap bolts to +45 degrees plus one turn of 15 degrees. DAEWOO V–121 BL4...
Page 99 KM–470–B, to tighten the connecting rod cap bolts to +45 degrees plus one turn of 15 degrees. 25. Install the oil pump. 26. Install the oil pump retaining bolts. Tighten Tighten the oil pump retaining bolts to 10 NSm (89 lb– in). DAEWOO V–121 BL4...
Page 100 33. Install the oil pan retaining bolts. Tighten Tighten the oil pan retaining bolts to 10 NSm (89 lb–in). 34. Rotate the engine on the engine overhaul stand KM–412. DAEWOO V–121 BL4...
Page 101 Tighten Tighten the exhaust camshaft gear bolt to 50 NSm (37 lb–ft). Using the angular torque gauge KM–470–B, tighten the intake and the exhaust camshaft gear bolts another 60 degrees plus 15 degrees. DAEWOO V–121 BL4...
Page 102 Tighten the front timing belt cover bolts to 6 NSm (53 lb–in). 59. Install the engine lifting device. 60. Remove the engine from the engine overhaul stand KM–412. 61. Install a new crankshaft rear oil seal using installer J–36972 (or KM–635). DAEWOO V–121 BL4...
Page 103: Gauging Plastic
Check for permissible crankshaft end play. Refer to ”Engine Specifications”in this section. With the crankshaft mounted on the front and rear crankshaft bearings, check the middle crankshaft journal for permissible out–of–round (runout). Refer to ”Engine Specifications”in this section. DAEWOO V–121 BL4...
Page 104 13. Measure the width of the flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging is available for different tolerance ranges.) 14. Inspect the bearing clearances for permissible toler- ance ranges. Refer to ”Engine Specifications”in this section. DAEWOO V–121 BL4...
Page 105 Measure the width of the flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging is available for different tolerance ranges.) 10. Inspect the bearing clearance for permissible toler- ance ranges. Refer to ”Engine Specifications”in this section. DAEWOO V–121 BL4...
Page 106 SECTION : 1D ENGINE COOLING CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS .
Page 107: Specifications
Fan Assembly Mounting Bolts – Fan Motor Nut – Fan Motor Retaining Screws – Radiator Retaining Bolts, Left Upper and Right Upper – Surge Tank Attaching Bolt – Thermostat Housing Mounting Bolts – SPECIAL TOOLS SPECIAL TOOLS TABLE KM–471 Adapter DAEWOO V–121 BL4...
Page 108 Wash any sludge from the surge tank cap and the If the pressure held by the cooling system pressure valve seat of the vacuum pressure valve for the tester falls below 80 kPa (11.6 psi), replace the surge tank cap. surge tank cap. DAEWOO V–121 BL4...
Page 109 Install a new thermostat of the correct type and heat range. wrong type of thermostat. Check the coolant level to determine if it is below the MIN Add sufficient coolant to raise the fluid to the specified mark on the surge tank. mark on the surge tank. DAEWOO V–121 BL4...
Page 110 Holder Transmission Fluid Pipe (Automatic Trans- Spring Clamp mission Only) Upper Radiator Hose Upper Radiator Bumper Bolts Radiator Bracket 10. Auxiliary Cooling Fan (Air Conditioning Only) Bolts 11. Drain Cock Radiator 12. Main Cooling Fan Radiator Bumper DAEWOO V–121 BL4...
Page 111 1D – 6IENGINE COOLING COOLANT PUMP/THERMOSTAT (2.0L DOHC) O–Ring Seal Bolt Thermostat Coolant Pump Thermostat Housing Ring Seal Bolt DAEWOO V–121 BL4...
Page 112 The mixture must be at least 50 percent antifreeze, and not more than 60 percent antifreeze. 14. Fill the surge tank to the specified MAX mark on the outside of the tank. DAEWOO V–121 BL4...
Page 113 Inspect the valve seat for foreign matter that could prevent the valve from sealing properly. Inspect the thermostat for proper operation. Refer to ”Thermostat Test” in this section. 10. Clean the thermostat housing and the cylinder head mating surfaces. DAEWOO V–121 BL4...
Page 114 Connect the upper radiator hose to the thermostat housing. Secure the upper radiator hose to the thermostat housing with a hose clamp. Refill the engine cooling system. Refer to ”Draining and Refilling the Cooling System” in this section. DAEWOO V–121 BL4...
Page 115: Coolant Pump
Inspect the coolant pump bearing for play or abnor- mal noise. Inspect the coolant pump pulley for excessive wear. If the coolant pump is defective, replace the coolant pump as a unit. Clean the mating surfaces of the coolant pump and the engine block. DAEWOO V–121 BL4...
Page 116 ELECTRIC COOLING FAN– MAIN OR AUXILIARY Removal Procedure Disconnect the negative battery cable. Disconnect the cooling fan electrical connector. Remove the fan shroud mounting bolts. Lift the fan shroud assembly upward, and remove the fan shroud assembly from the vehicle. DAEWOO V–121 BL4...
Page 117 Install the fan motor to the shroud. Secure the motor to the shroud with the retaining screws. Tighten Tighten the fan motor retaining screws to 4 NSm (35 lb–in). Turn over the fan shroud assembly. DAEWOO V–121 BL4...
Page 118 Loosen the throttle body hose clamp and discon- nect the throttle body hose from the top of the surge tank. Loosen the feed hose clamp and disconnect the feed hose from the bottom of the surge tank. DAEWOO V–121 BL4...
Page 119 Secure the return hose, the throttle body hose, and the feed hose to the surge tank with the hose clamps. Fill the surge tank with the coolant to the center ridge, or to the MAX mark. DAEWOO V–121 BL4...
Page 120 15. Remove the right upper radiator retaining bracket. 16. Remove the radiator from the vehicle. Important : The radiator still contains a substantial amount of coolant. Drain the remainder of the coolant from the radiator into a drain pan. DAEWOO V–121 BL4...
Page 121 Tighten the right upper radiator retaining bolt to 4 NSm (35 lb–in). Install the left upper radiator retainer bracket. Install the left upper radiator retaining bolt. Tighten Tighten the left upper radiator retaining bolt to 4 NSm (35 lb–in). DAEWOO V–121 BL4...
Page 122: Engine Coolant Temperature Sensor
DOHC) to 10 NSm (89 lb–in). Connect the electrical connector to the engine cool- ant temperature sensor. Refill the engine cooling system. Refer to ”Draining and Refilling the Cooling System” in this section. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 123 The air trapped in the radiator and the engine is degassed injury. This fan is electric and can turn on whether or into the surge tank. not the engine is running. DAEWOO V–121 BL4...
Page 124: Engine Block Heater
97³C (207³F). The PCM/ECM will change the cooling fans from Contact your Daewoo Dealer for further information or high speed to low speed at 94³C (201³F) and will installation.
Page 125 SECTION : 1F ENGINE CONTROLS CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS .
Page 126 DTC P1133 O2 BANK 1 SENSOR 1 TOO FEW LARGE LEAK/LOW TANK VACUUM ..1F–222 TRANSITIONS ......1F–304 DAEWOO V–121 BL4...
Page 127 ......1F–405 POOR FUEL ECONOMY ....1F–370 EVAPORATIVE EMISSION CANISTER ..1F–406 DAEWOO V–121 BL4...
Page 128 IAC Position Counts 5–60 Cam Speed Activity Counts 0–255 Ignition Voltage Volts 12.0–15.0 Engine Run Time Seconds Varies (since start up) BPW Bank 1 0–999.9 Air Fuel Ratio Ratio 14.6:1 (Varies) Spark Degrees Varies Knock Retard Degrees Varies DAEWOO V–121 BL4...
Page 129 Low Fuel Lamp On/Off – Hot Open Loop Lamp On/Off – Variable Gate Intake Long/Short Long Fuel Trim Learned On/Off – Fan 1 On/Off OFF (Varies with fan request) Fan 2 On/Off OFF (Varies with fan request) Park/Neutral Yes/No DAEWOO V–121 BL4...
Page 130 Varies 25–35 kPa BARO 65–100 kPa (varies with altitude and with the BARO pressure) Calculated Load 0–100 Vehicle Speed Oxygen Sensor Bank 1 Sensor 1 0––1000 and varying Oxygen Sensor Bank 1 Sensor 2 0–1000 and varying DAEWOO V–121 BL4...
Page 131 Engine Run Time Seconds Varies (Since start up) BPW Bank 1 0–999.9 Air Fuel Ratio Ratio 14.6:1 (Varies) Spark Degrees Varies 25–35 kPa BARO 65–100 kPa (varies with altitude and with the BARO pressure) Calculated Load 0–100 Vehicle Speed DAEWOO V–121 BL4...
Page 132 Ignition 1 Volts 12.0–15.0 Air Fuel Ratio Ratio 14.6:1 (Varies) Decel Fuel Mode Inactive/Active – Power Enrichment Inactive/Active – O2S Warm Up Time Bank 1 – Senor Seconds Varies HO2S Bank 1 Sensor 2 0–1000 and varying DAEWOO V–121 BL4...
Page 133 Injector Pulse Bank 1 Varies O2S Bank 1 Sensor 1 0–1000 and varying HO2S Bank 1 Sensor 2 0–1000 and varying Short Term FT Bank 1 –100 to 100 (Varies) Long Term FT Bank 1 –100 to 100 (Varies) DAEWOO V–121 BL4...
Page 134 The A/C High Side helps to altitude changes. This value is updated at ignition ON and diagnose the diagnostic trouble code (DTC) P0533. also at Wide Open Throttle (WOT). DAEWOO V–121 BL4...
Page 135 The Knock Sensor (KS) Retard indicates the amount of control reference input. It should remain close to desired park advance the PCM/ECM is decreasing in response o idle under the various engine loads with the engine idling. the KS signal. DAEWOO V–121 BL4...
Page 136 900 mv (rich exhaust) when the system is ECM is 4000 pulses per mile. The scan tool uses the class operating in a Closed Loop. 2 serial data from the PCM/ECM to obtain vehicle speed, DAEWOO V–121 BL4...
Page 137 Manifold Absolute Pressure Sensor Mounting Bracket Nuts – Manifold Absolute Pressure Sensor Retaining Bolts and Nuts – Oxygen Sensor – Rear A/C Compressor Mounting Bracket Bolts – Spark Plug Cover Bolts – Throttle Body Retaining Nuts – Throttle Position Sensor Retaining Bolts – DAEWOO V–121 BL4...
Page 138 7280 You may use fuel containing Methyl Tertiary–Butyl Ether 9420 (MTBE) providing there is not more than 15 percent MTBE –5 12300 by volume. –10 16180 –15 21450 –20 –4 28680 –30 –22 52700 –40 –40 100700 DAEWOO V–121 BL4...
Page 139 ENGINE CONTROLS 1F – 15 SCHEMATIC AND ROUTING DIAGRAMS PCM/ECM WIRING DIAGRAM (1 OF 6) (IPCM–6KD/ISFI–6TD) DAEWOO V–121 BL4...
Page 140 1F – 16IENGINE CONTROLS PCM/ECM WIRING DIAGRAM (2 OF 6) (IPCM–6KD/ISFI–6TD) DAEWOO V–121 BL4...
Page 141 ENGINE CONTROLS 1F – 17 PCM/ECM WIRING DIAGRAM (3 OF 6) (IPCM–6KD/ISFI–6TD) DAEWOO V–121 BL4...
Page 142 1F – 18IENGINE CONTROLS PCM/ECM WIRING DIAGRAM (4 OF 6) (IPCM–6KD/ISFI–6TD) DAEWOO V–121 BL4...
Page 143 ENGINE CONTROLS 1F – 19 PCM/ECM WIRING DIAGRAM (5 OF 6) (IPCM–6KD/ISFI–6TD) DAEWOO V–121 BL4...
Page 144 1F – 20IENGINE CONTROLS PCM/ECM WIRING DIAGRAM (6 OF 6) (IPCM–6KD/ISFI–6TD) DAEWOO V–121 BL4...
Page 145 ENGINE CONTROLS 1F – 21 CONNECTOR END VIEW DAEWOO V–121 BL4...
Page 146 1F – 22IENGINE CONTROLS DAEWOO V–121 BL4...
Page 147 ENGINE CONTROLS 1F – 23 DAEWOO V–121 BL4...
Page 148 1F – 24IENGINE CONTROLS DAEWOO V–121 BL4...
Page 149 ENGINE CONTROLS 1F – 25 DAEWOO V–121 BL4...
Page 150 1F – 26IENGINE CONTROLS COMPONENT LOCATOR DAEWOO V–121 BL4...
Page 151 42. Evaporative Emission Canister (under vehicle, be- 26. Electronic Ignition (EI) System Ignition Coil hind right rear wheel) 27. Evaporative Emission (EVAP) Controlled Canister 43. Oil Pressure Switch Purge Solenoid 44. Air Cleaner 28. Ignition 1 Relay 29. A/C Compressor Relay DAEWOO V–121 BL4...
Page 152: System Diagnosis
10. Turn the A/C OFF for 10 seconds, if equipped. tool connected to a suspected circuit. An abnormal voltage 11. Turn the ignition OFF. The idle learn procedure is or scan tool reading will indicate that the problem is in that complete. circuit. DAEWOO V–121 BL4...
Page 153 (EEPROM). The replacement PCM/ aged terminals, poor terminal–to–wire connection, and ECM must be programmed. Refer to the latest damaged harness. Techline procedure for PCM/ECM reprogramming. DAEWOO V–121 BL4...
Page 154 Go to Step 11 1. Attempt to reprogram the PCM/ECM. 2. Attempt to display the PCM/ECM data with the scan tool. Does the scan tool display PCM/ECM engine data? Replace the PCM/ECM. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 155 10. If no faults have been found at this point, refer to component is being commanded by the PCM/ECM or ”Diagnostic Aids” in this section for additional scan tool. checks and information. DAEWOO V–121 BL4...
Page 156 Go to Step 10 gine control module (ECM) Is the repair complete? Operate the vehicle within the conditions under System OK Go to Step 2 which the original symptom was noted. Does the system now operate properly? DAEWOO V–121 BL4...
Page 157 DTCs to 21. The replacement PCM/ECM must be repro- be set: P0107, P0112, P0117, P0122, P1107, P1112, grammed. Refer to the latest Techline procedure for P1114, P1122. PCM/ECM reprogramming. DAEWOO V–121 BL4...
Page 158 Go to Step 16 1. Disconnect the EGR valve. 2. Measure the voltage between the EGR Pintle Position sensor signal circuit and the PCM/ ECM harness connector and ground. Does the voltage measure near the specified value? DAEWOO V–121 BL4...
Page 159 DTCs as specified in the supporting text. Does the scan tool indicate that this diagnostic ran and passed? Check if any additional DTCs are Go to applica- System OK Are any DTCs displayed that have not been diag- ble DTC table nosed? DAEWOO V–121 BL4...
Page 160 1F – 36IENGINE CONTROLS DAEWOO V–121 BL4...
Page 161 2. Replace any of the ignition wire(s) with a resist- ance above the value specified. 3. Check for the presence of spark from all of the ignition wires. Is spark present from all of the ignition wires? DAEWOO V–121 BL4...
Page 162 2. Disconnect the electrical connector at the EI system ignition coil. 3. Connect a test light between terminal D of the EI system ignition coil connector and ground. 4. Turn the ignition ON. Is the test light on? DAEWOO V–121 BL4...
Page 163 Is the repair complete? Replace the PCM/ECM. Go toStep 2 Is the repair complete? Go toStep 37 Go toStep 35 1. Turn the ignition OFF. 2. Connect a fuel pressure gauge. 3. Crank the engine. Is any fuel pressure present? DAEWOO V–121 BL4...
Page 164 3. Inspect the in–tank fuel filter for a restriction. Is the problem found? Replace the fuel pump sender, the in–tank fuel filter, Go toStep 2 and/or the fuel coupling hoses as needed. Is the repair complete? DAEWOO V–121 BL4...
Page 165 Is the repair complete? 11–14 v Go toStep 58 Go toStep 59 1. Reconnect the fuel cutoff switch. 2. Measure the voltage at terminal 3 of the fuel cutoff switch connector. Is the voltage within the specified value? DAEWOO V–121 BL4...
Page 166 ECM connector terminal C4 for the fuel injec- tors one and four. 2. Check for an open between the fuel injector harness connector terminal 2 and the PCM/ ECM connector terminal C6 for the fuel injec- tors two and three. Is the problem found? DAEWOO V–121 BL4...
Page 167 Go toStep 68 Go to”Ignition 1. Inspect the engine fuse block fuse EF34. System Check” 2. Check for an open in the fuel injector connector terminals 1 and the ignition 1 relay connector terminal 87. Is the problem found? DAEWOO V–121 BL4...
Page 168 It takes very little resistance for the battery and igni- Test Description tion feed circuits to cause an intermittent condition Number(s) below refer to the step number(s) on the diag- and should also be checked for a poor connection nostic table. as described in diagnostic aids. DAEWOO V–121 BL4...
Page 169 Does the test light illuminate? Go to Step 22 1. Check for a short to ground in the circuit of the fuse that was open and repair if necessary. 2. Replace the open fuse. Is the repair complete? DAEWOO V–121 BL4...
Page 170 System OK 1. Allow the engine to idle until normal operating cable DTC temperature is reached. table 2. Check if any Diagnostic Trouble Codes (DTCs) are set. Are any DTCs displayed that have not been diag- nosed? DAEWOO V–121 BL4...
Page 171 The On–Board Diagnostic (OBD II) System Check The replacement PCM/ECM must be repro- prompts the technician to complete some basic grammed. Refer to the latest Techline information checks and store the freeze frame and failure re- for reprogramming procedures. DAEWOO V–121 BL4...
Page 172 Go to the appli- System OK 1. Allow the engine to idle until normal operating cable DTC temperature is reached. table 2. Check if any DTCs are set. Are any DTCs displayed that have not been diag- nosed? DAEWOO V–121 BL4...
Page 173 Does the fuel pressure decrease? System OK 1. Locate and correct the cause of the vacuum restriction to the fuel pressure regulator. 2. Confirm the operation of the fuel pressure reg- ulator. Is the repair complete? DAEWOO V–121 BL4...
Page 174 Is the problem found? 284–325 kPa System OK 1. Replace the leaking fuel injector(s). (41–47 psi) 2. Install a fuel pressure gauge. 3. Turn the ignition ON. Is the fuel pressure within the values specified but not holding steady? DAEWOO V–121 BL4...
Page 175 Go to Step 15 Go to Step 13 1. Remove the fuel rail and the fuel injectors as an assembly. 2. With the fuel system under pressure, inspect all of the fuel injectors for leaking. Is the problem found? DAEWOO V–121 BL4...
Page 176 PCM/ECM to the fuel pump relay, the Diagnostic Aids fault is either the PCM/ECM or the wiring between An intermittent problem may be caused by a poor connec- the PCM/ECM and the fuel pump relay. DAEWOO V–121 BL4...
Page 177 Check for an open wire between the fuel pump relay Go to Step 10 Go to Step 12 connector terminal 85 to the powertrain control mod- ule (PCM)/engine control module (ECM) connector terminal E13. Is the problem found? DAEWOO V–121 BL4...
Page 178 3. Turn the ignition ON. Does the fuel pump operate for the time specified? Repair the wire between the fuel pump relay connec- System OK tor terminal 86 and the ignition 1 relay connector ter- minal 86. Is the repair complete? DAEWOO V–121 BL4...
Page 179: Symptom Diagnosis
4. Inspect for poor terminal to wire connections. This requires removing the terminal from the connector body to inspect it. Are any problems present? Repair the electrical connections as needed. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 180 System OK 1. Check for an open diode across the A/C clutch and for other open diodes. 2. Repair or replace any components as needed. Is the repair complete? DAEWOO V–121 BL4...
Page 181 Go toStep 8 Is the fuel pressure within the specifications? 41–47 psi Check for water contamination in the fuel. Go toStep 9 Go toStep 10 Is fuel contaminated? Replace the contaminated fuel. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 182 Go toStep 22 Go toStep 25 1. Remove the Crankshaft Position (CKP) sensor. 2. Inspect for faulty connections and repair as needed. Is the problem found? Repair the faulty connections as needed. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 183 Does the Oxygen Sensor (O2S) respond quickly to different throttle positions? System OK 1. Check the O2S sensor for silicone or other contaminants from fuel or use of improper Room Temperature Vulcanizing (RTV) sealant. 2. Replace the contaminated O2S sensor. Is the repair complete? DAEWOO V–121 BL4...
Page 184 1. Check for intermittent Exhaust Gas Recircula- tion (EGR) valve operation. 2. Check Torque Converter Clutch (TCC) opera- tion. 3. Repair or replace any components as needed. Is the repair complete? Repair the fuel system as needed. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 185 ENGINE CONTROLS 1F – 363 Step Action Value(s) Replace the fuel filter. System OK Is the repair complete? Replace the leaking or restricted fuel injectors. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 186 Is the repair complete? Inspect the exhaust system for restrictions and dam- Go toStep 13 Go toStep 14 aged or collapsed pipes. Is the problem found? Repair or replace any components as needed. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 187 (ECT) sensor if the resistance is not within specifications as listed in the Diagnostic Aids for diagnostic trouble code (DTC) P0118. Is the problem found? Replace the ECT sensor or repair the circuit as System OK needed. Is the repair complete? DAEWOO V–121 BL4...
Page 188 3. Check the Torque Converter Clutch (TCC) op- eration and transaxle shift points. 4. Check the service bulletins for Programmable Read–Only Memory (PROM) updates. 5. Check the cylinder compression. 6. Repair or replace any faulty components. Are all checks and repairs complete? DAEWOO V–121 BL4...
Page 189 Is the fuel injector resistance within the value speci- fied? Replace any of the fuel injectors with a resistance System OK that is out of specifications. Is the repair complete? Perform an injector balance test. Go toStep 11 Go toStep 12 Is the problem found? DAEWOO V–121 BL4...
Page 190 With the engine running, spray the ignition wires with Go toStep 6 Go toStep 7 a fine water mist to check for arcing and shorting to ground. Is the problem found? Replace the ignition wires. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 191 System OK out of specifications. Is the repair complete? Perform an injector balance test. Go toStep 16 Go toStep 17 Is the problem found? Replace any restricted or leaking fuel injectors. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 192 3. Check for proper calibration of the speedome- ter. 4. Check the brakes for dragging. 5. Check the cylinder compression. 6. Repair, replace, or adjust any components as needed. Are all checks and needed repairs complete? DAEWOO V–121 BL4...
Page 193 Check the Manifold Absolute Pressure (MAP) sen- Go toStep 10 Go toStep 11 sor for response and accuracy. Is the problem found? Replace the MAP sensor or repair the MAP sensor System OK circuit as needed. Is the repair complete? DAEWOO V–121 BL4...
Page 194 2. Thoroughly inspect the fuel pressure regulator vacuum port and the fuel pressure regulator vacuum hose for the presence of fuel. Is the problem found? Replace the fuel pressure regulator as needed. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 195 3. Perform a cylinder compression test. 4. Inspect for bent pushrods, worn rocker arms, broken or weak valve springs, and a worn cam- shaft. 5. Perform repairs as needed. Are all of the checks and needed repairs complete? DAEWOO V–121 BL4...
Page 196 1. Check the ignition system for proper operation. 2. Inspect the spark plugs for excessive wear, insulation cracks, improper gap, or heavy de- posits. 3. Check the ignition wires for cracking, hardness, or improper connections. Is the problem found? DAEWOO V–121 BL4...
Page 197 1. Check the evaporative emission system. 2. Check for leaking fuel injectors. 3. Check the Idle Air Control (IAC) valve opera- tion. 4. Inspect for vacuum leaks. 5. Check for the proper base idle setting. Are all checks and repairs complete? DAEWOO V–121 BL4...
Page 198 2. Check the engine compression. 3. Inspect the intake manifold gasket and the ex- haust manifold gasket for leaks. 4. Check for sticking or leaking valves. 5. Repair or replace any components as needed. Are all checks and corrections complete? DAEWOO V–121 BL4...
Page 199: Fuel Tank
10. Disconnect the fuel inlet line and the fuel return line near the right front of the fuel tank. 11. Disconnect the wiring harness clips and the fuel line clips as needed. DAEWOO V–121 BL4...
Page 200 11. Connect the right rear parking brake cable to the retaining bracket attached to the right side fuel tank strap. 12. Connect the negative battery cable. 13. Fill the fuel tank. 14. Perform a leak check of the fuel tank and the fuel line connections. DAEWOO V–121 BL4...
Page 201: Fuel Pump
Install the fuel pump outlet line. Install the fuel tank return line. Install the fuel pump access cover. Connect the negative battery cable. 10. Perform an operational check of the fuel pump. 11. Install the rear seat. Refer to Section 9H, Seats. DAEWOO V–121 BL4...
Page 202: Fuel Tank Pressure Sensor
Disconnect the fuel tank pressure sensor electrical connector. Bend the retaining tabs and remove the fuel tank pressure sensor. Installation Procedure Install the fuel tank pressure sensor and bend the retaining tabs into place. Connect the fuel tank pressure sensor electrical connector. DAEWOO V–121 BL4...
Page 203: Fuel Filter
Tighten the fuel filter mounting bracket assembly bolt to 89 lb–in (10 NSm). Connect the inlet/outlet lines. Secure the lines with the connector lock. Connect the negative battery cable. Perform a leak test of the fuel filter. DAEWOO V–121 BL4...
Page 204 O– ring seals and the retaining clip. 12. Remove the fuel rail with the fuel injector channel cover and the injectors attached. 13. Disconnect the fuel injector channel cover connec- tors. DAEWOO V–121 BL4...
Page 205 Make sure that the retaining clip should be parallel to the fuel injector harness connector. Install the fuel rail assembly into the cylinder head. Install the fuel rail retaining bolts. Tighten Tighten the fuel rail retaining bolts to 18 lb–ft (25 NSm). DAEWOO V–121 BL4...
Page 206: Fuel Pressure Regulator
Remove the air intake tube. Disconnect the vacuum hose from the fuel pressure regulator. Remove the fuel pressure regulator retaining clamp. Remove the fuel pressure regulator by turning it back and forth and then pulling it out. DAEWOO V–121 BL4...
Page 207 Install the ECT sensor into the EI system ignition coil adapter. Tighten Tighten the engine coolant temperature sensor to 18 lb–ft (25 NSm). Connect the ECT sensor connector. Fill the coolant system. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 208: Throttle Position Sensor
Connect the TP sensor connector. Connect the negative battery cable. THROTTLE BODY Removal Procedure Disconnect the negative battery cable. Disconnect the intake air temperature (IAT) sensor connector. Disconnect the breather hose from the valve cover. Remove the air intake tube. DAEWOO V–121 BL4...
Page 209 10. Remove the throttle body and discard the gasket. 11. Remove the TP sensor. Refer to ” Throttle Position Sensor ” in this section. 12. Remove the IAC valve. Refer to ”Idle Air Control Valve”in this section. DAEWOO V–121 BL4...
Page 210 10. Connect the throttle/cruise cables. 11. Install the air intake tube. 12. Connect the breather hose to the valve cover. 13. Connect the IAT sensor connector. 14. Connect the negative battery cable. 15. Fill the cooling system. DAEWOO V–121 BL4...
Page 211 Install the O2S into the exhaust manifold. Tighten Tighten the oxygen sensor to 41 NSm (30 lb–ft). Connect the O2S connector. Connect the negative battery cable. HEATED OXYGEN SENSOR Removal Procedure Disconnect the negative battery cable. Disconnect the electrical connector. DAEWOO V–121 BL4...
Page 212 1F – 390IENGINE CONTROLS Remove the heated oxygen sensor (HO2S 2). Installation Procedure Install the HO2S 2. Tighten Tighten the heated oxygen sensor to 30 lb–ft 41 NSm). Connect the electrical connector. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 213: Intake Air Temperature Sensor
This 28 mm setting is also an adequate setting for controlled idle on a restart. Lubricate a new O–ring with engine oil. Install the new O–ring onto the valve. Install the IAC valve into the throttle body. DAEWOO V–121 BL4...
Page 214: Manifold Absolute Pressure Sensor
Disconnect the negative battery cable. Disconnect the negative battery cable. Disconnect the Intake Air Temperature (IAT) sensor connector. Disconnect the breather hose from the valve cover. Remove the air intake tube. Disconnect the throttle cable from the throttle body and bracket. DAEWOO V–121 BL4...
Page 215 Install the MAP sensor into the intake manifold. Connect the throttle cable to the throttle body and bracket. Install the air intake tube. Connect the breather hose to the valve cover. Connect the IAT sensor connector. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 216 15 lb–ft (20 NSm). Connect the EGR valve electrical connector. Connect the negative battery cable. G SENSOR Removal Procedure Disconnect the negative battery cable. Disconnect the G sensor electrical connector and re–move the G sensor. DAEWOO V–121 BL4...
Page 217 Install the canister flange bolt. Tighten Tighten the evaporative emission canister flange bolt to 20 NSm(15 lb–ft). Connect the canister fuel vapor hoses. Install the canister protective cover. Tighten Tighten the evaporative emission canister protective cover to 71 lb–in (8 NSm). DAEWOO V–121 BL4...
Page 218: Crankshaft Position Sensor
Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System. Remove the rear A/C compressor mounting bracket bolts and the rear A/C compressor mounting brack- et, if equipped. Remove the accessory mounting bracket by remov- ing the bolts. DAEWOO V–121 BL4...
Page 219 (35 NSm). Install the A/C compressor, if equipped. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System. Install the power steering pump, if equipped. Refer toSection 6B, Power Steering Pump. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 220: Camshaft Position Sensor
1C, DOHC Engine Mechanical. Remove the camshaft position sensor bolts. Remove the camshaft position sensor from the top. Installation Procedure Install the camshaft position sensor and bolts. Tighten Tighten the camshaft position sensor bolts to 12 NSm (106 lb–in). DAEWOO V–121 BL4...
Page 221 Disconnect the powertrain control module (PCM)/engine control module (ECM) retaining clip from the PCM/ECM mounting base. Remove the retaining clip lower end from the mounting base. Remove the PCM/ECM from the mounting base. Disconnect the PCM/ECM connectors from the PCM/ ECM. DAEWOO V–121 BL4...
Page 222 Tighten Tighten the electronic ignition system ignition coil re– taining bolts to 89 lb–in (10 NSm). Connect the EI system ignition coil connector. Install the ignition wires. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 223: Fuel Cutoff Switch
Disconnect the electrical connector at the fuel cutoff switch. Installation Procedure Connect the electrical connector at the fuel cutoff switch. Install the fuel cutoff switch mounting bolts. Tighten Tighten the fuel cutoff switch mounting bolts to 27 lb– in (3 NSm). DAEWOO V–121 BL4...
Page 224: Knock Sensor
Important : The fuel cutoff switch may have to be reset to enable the vehicle to start. KNOCK SENSOR Removal Procedure Disconnect the negative battery cable. Remove the intake manifold. Refer toSection 1C, DOHC Engine Mechanical. Disconnect the electrical connector at the Knock Sensor (KS). Remove the KS. DAEWOO V–121 BL4...
Page 225 Installation Procedure Install the KS. Tighten Tighten the knock sensor bolt to 15 lb–ft (20 NSm). Connect the electrical connector at the KS. Remove the intake manifold. Refer toSection 1C, DOHC Engine Mechanical. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 226 14.7 to tion coils and to the fuel injectors. 1, which allows the catalytic converter to operate most effi- DAEWOO V–121 BL4...
Page 227 (fuel injector ontime) based on A damaged canister. the signal from the oxygen sensor. This allows the air/fuel Hoses that are split, cracked, or not connected to ratio to stay very close to 14.7 to 1. the proper tubes. DAEWOO V–121 BL4...
Page 228 DTC P0137, P0138, P0140 or P0141, lem or to replacing the sensor to repair a problem properly. depending on the special condition. DAEWOO V–121 BL4...
Page 229 If the IAC valve is suspected as the cause of improper idle a resistor in the PCM/ECM and measures the change in speed, refer to ”Idle Air Control System Check” in this sec- voltage to determine the IAT. The voltage will be high when tion. DAEWOO V–121 BL4...
Page 230: Fuel Injector
The PCM/ECM controls cylinders. The sensor produces an AC output voltage output circuits such as the fuel injectors, the idle air control which increases with the severity of the knock. This signal DAEWOO V–121 BL4...
Page 231 Fuel quality is not a new issue for the automotive industry, normally. The condition described by the customer may be but its potential for turning on the Malfunction Indicator normal. Verify the customer complaint against another ve- Lamp (MIL) with OBD II systems is new. DAEWOO V–121 BL4...
Page 232: Serial Data Communications
It will not be necessary to perform any turn on the MIL with a set DTC P0300. conversions from coded values to actual values. DAEWOO V–121 BL4...
Page 233 ECT sensor is monitored for its ability to achieve a that information for any fault which is stored in onboard steady state temperature to enable closed loop fuel con- memory, while Freeze Frame stores information only for trol. emission–related faults that command the MIL on. DAEWOO V–121 BL4...
Page 234: Common Obd Ii Terms
The MIL is on the instrument panel and has the following nostic will consider this cycle to be one trip. However, functions: DAEWOO V–121 BL4...
Page 235: Dtc Types
Important : Do not clear DTCs unless directed to do so Updates the Fail Record each time the diagnostic by the service information provided for each diagnostic test fails. procedure. When DTCs are cleared, the Freeze Frame DAEWOO V–121 BL4...
Page 236: Dtc Modes
The same applies to using the DTC trigger option in the tests which run and pass will cause that DTC number to Snapshot mode. If an invalid DTC is entered, the scan tool be removed from the scan tool screen. will not trigger. DAEWOO V–121 BL4...
Page 237 If the indicated status of the vehicle is ”Test Ran and shaft slows down momentarily. By monitoring the CKP and Passed” after a repair verification, the vehicle is ready to CMP sensor signals, the PCM/ECM can calculate when be released to the customer. a misfire occurs. DAEWOO V–121 BL4...
Page 238 DTC may set). Use a scan tool to observe fuel trim counts which cylinders are misfiring. If the counters indicate cylin- while the problem is occurring. ders numbers 1 and 4 misfired, look for a circuit or compo- nent common to both cylinders number 1 and 4. DAEWOO V–121 BL4...
Page 239 SECTION : 1G ENGINE EXHAUST TABLE OF CONTENTS SPECIFICATIONS ......1G–1 AUXILIARY CATALYTIC CONVERTER ..1G–5 FASTENER TIGHTENING SPECIFICATIONS 1G–1...
Page 240: Exhaust System
1G – 2IENGINE EXHAUST COMPONENT LOCATOR EXHAUST SYSTEM Trim Ring (if equipped) Catalytic Converter Muffler Post–Converter Heated Oxygen Sensor Metal Clamp Auxiliary Catalytic Converter Front Muffler DAEWOO V–121 BL4...
Page 241 Remove the connecting pipe nuts and the gasket from the auxiliary catalytic converter. Remove the catalytic converter nuts and the gasket from the front muffler. Disconnect the main catalytic converter and the connecting pipe from the rubber hanger. DAEWOO V–121 BL4...
Page 242 Tighten Tighten the front connecting pipe–to–auxiliary cata- lytic converter nuts to 35 NSm (26 lb–ft). Install the post–converter heated oxygen sensor. Tighten Tighten the post–converter heated oxygen sensor to 41 NSm (30 lb–ft). DAEWOO V–121 BL4...
Page 243 ENGINE EXHAUST 1G – 5 AUXILIARY CATALYTIC CONVERTER Removal Procedure Disconnect the pre–converter oxygen sensor elec- trical connector. Remove the exhaust manifold cover bolts and the exhaust manifold cover. Remove the auxiliary catalytic converter upper flange nuts. DAEWOO V–121 BL4...
Page 244 Tighten Tighten the front connecting pipe–to–auxiliary cata- lytic converter nuts to 35 NSm (26 lb–ft). Install the remaining auxiliary catalytic converter upper flange nuts. Tighten Tighten the auxiliary catalytic converter–to–exhaust manifold nuts to 35 NSm (26 lb–ft). DAEWOO V–121 BL4...
Page 245 Tighten the exhaust manifold cover bolts to 15 NSm (11 lb–ft). Connect the pre–converter oxygen sensor electrical connector. MUFFLER – FRONT Removal Procedure Remove the nuts and the gasket that secure the front muffler pipe to the catalytic converter flange. DAEWOO V–121 BL4...
Page 246 Place the front muffler pipe into the rear muffler pipe. Secure the front muffler pipe to the rear muffler pipe with the holding clamp, the washer, and the nut. Tighten Tighten the front muffler pipe–to–rear muffler pipe holding clamp nut to 50 NSm (37 lb–ft). DAEWOO V–121 BL4...
Page 247 Spread the loosened holding clamp and position it away from the junction of the front muffler pipe and the rear muffler pipe. Separate the rear muffler pipe from the front muffler pipe. DAEWOO V–121 BL4...
Page 248 Tighten an addi- tional quarter turn. Secure the rear muffler assembly to the rear rubber hangers near the exhaust tail pipe and near the junction of the rear muffler pipe with the front muf- fler pipe. DAEWOO V–121 BL4...
Page 249 Place the rear muffler pipe into the front muffler pipe. Secure the rear muffler pipe to the front muffler pipe with the holding clamp, the washer, and the nut. Tighten Tighten the front muffler pipe–to–rear muffler pipe holding clamp nut to 70 NSm (52 lb–ft). DAEWOO V–121 BL4...
Page 250: Catalytic Converters
(NOx). flange and seal joint design. The exhaust manifold– to–ex- haust pipe connection is of the flex joint type.If holes, open DAEWOO V–121 BL4...
Page 251 SECTION 3 WIRING DIAGRAM FOR POWER SUPPLIES...
Page 252 3–2WWIRING DIAGRAM FOR POWER SUPPLIES 1. IGNITION SWITCH CIRCUIT...
Page 253 WIRING DIAGRAM FOR POWER SUPPLIESW3–3 2. 30 Ter BAT+ POWER SUPPLY CIRCUIT(PASSENGER ROOM FUSE BOX)
Page 254 3–4WWIRING DIAGRAM FOR POWER SUPPLIES 3. 15A IGN 2, 15C ACC POWER SUPPLY CIRCUIT(PASSENGER ROOM FUSE BOX)
Page 255 WIRING DIAGRAM FOR POWER SUPPLIESW3–5 4. ENGINE ROOM FUSE & RELAY CIRCUIT...
Page 256 3–6WWIRING DIAGRAM FOR POWER SUPPLIES...
Page 257 WIRING DIAGRAM FOR POWER SUPPLIESW3–7...
Page 258 SECTION : 3A AUTOMATIC TRANSAXLE DRIVE AXLE TABLE OF CONTENTS SPECIFICATIONS ......3A–1 ON–VEHICLE SERVICE .
Page 259 3A – 2IAUTOMATIC TRANSAXLE DRIVE AXLE SPECIAL TOOLS SPECIAL TOOLS TABLE J–8059 KM–460–A Snap Ring Pliers Axle Shaft Remover KM–507–B J–35566 Ball Joint Separator Seal Clamp Pliers COMPONENT LOCATOR FRONT DRIVE AXLE DAEWOO V–121 BL4...
Page 260 Snap Ring 10. Seal Retaining Clamp Axle Shaft (right–hand shown, left–hand similar) 11. Tripot Joint Retaining Ring Seal Retaining Clamp 12. Tripot Joint Drive Axle Outboard Seal 13. Shaft Retaining Ring Seal Retaining Clamp 14. Tripot Housing DAEWOO V–121 BL4...
Page 261 Notice : Use only the recommended tool for separating the lower ball joint. Failure to use the recommended tool may cause damage to the ball joint and the seal. Separate the steering knuckle from the lower ball joint using the ball joint separator KM–507–B. DAEWOO V–121 BL4...
Page 262 Cap the transaxle drive opening after the drive axle has been removed to keep the fluid in and any contamination out. 10. Remove the drive axle from the transaxle using the axle shaft remover KM–460–A. DAEWOO V–121 BL4...
Page 263 Install the wheel hub onto the axle shaft. Mount the steering knuckle onto the lower ball joint. Install the tie rod into the knuckle/strut and install the tie rod nut. Tighten Tighten the tie rod nut to 60 Nm (44 lb–ft). DAEWOO V–121 BL4...
Page 264 12. Install the engine under covers. Refer toSection 9N, Frame and Underbody. 13. Refill the transaxle fluid to the proper level. Refer toSection 5A, 4T40E Automatic Transaxle. DAEWOO V–121 BL4...
Page 265 J–8059 and install the outer joint onto the axle shaft. Fill the joint seal with 175 to 195 g (6.2 to 6.9 ounces) of the recommended grease. Repack the joint with 175 to 195 g (6.2 to 6.9 ounces) of the recommended grease. DAEWOO V–121 BL4...
Page 266 J–8059 Snap Ring Pliers Removal Procedure Remove the drive axle from the vehicle. Refer to”Drive Axle Assembly” in this section. Remove the large seal retaining clamp. Discard the clamp. Remove the small seal retaining clamp. Discard the clamp. DAEWOO V–121 BL4...
Page 267 3A – 10IAUTOMATIC TRANSAXLE DRIVE AXLE Pry the tripot joint retaining ring from the tripot housing. Remove the tripot housing from the seal. Degrease the tripot assembly. Remove the shaft retaining ring using the snap ring pliers J–8059. DAEWOO V–121 BL4...
Page 268 Do not crimp the seal retaining clamp. Install the seal onto the axle shaft. Install the tripot joint retaining ring and the tripot onto the axle shaft. Install the shaft retaining ring onto the axle shaft using the snap ring pliers J–8059. DAEWOO V–121 BL4...
Page 269 J–35566. Crimp the new small seal retaining clamp using the seal clamp pliers J–35566. 10. Install the drive axle shaft to the vehicle. Refer to”Drive Axle Assembly” in this section. DAEWOO V–121 BL4...
Page 270 Drive axles are flexible shaft assemblies that transmit truding from the transaxle. rotational force from the transaxle to the front–wheel as- semblies. Each axle assembly consists of an inner and an DAEWOO V–121 BL4...
Page 271 SECTION 4 USAGE AND CAPACITY OF FUSES...
Page 272 USAGE AND CAPACITY OF FUSESW4–2 1. ENGINE COMPARTMENT RELAY AND FUSE BOX 2) USAGE OF FUSES IN ENGINE COMPARTMENT FUSE BOX 1) POSITION OF RELAY AND FUSE Power Supply Classification Fuse No Capacity Usage Ef 1 Battery Main (F10, F11, F12, F13, F14) Front View Ef 2 Blower Motor...
Page 273 4–3WUSAGE AND CAPACITY OF FUSES 2. PASSENGER ROOM FUSE BOX 2) USAGE OF FUSES IN PASSENGER ROOM FUSE BOX 1) POSITION OF FUSE AND RELAY Power Supply Classification Fuse No Capacity Usage PCM, Ignition Relay ”1” Airconditioning System Hazard, Clock, DRL Wiper System 15 IGN ”1”...
Page 274 USAGE AND CAPACITY OF FUSESW4–4 3. POSITION OF CONTROL UNIT, RELAY AND PART NUMBER 6) BEHIND DRIVER SIDE LEFT KICK PANEL 1) ENGINE ROOM FUSE BOX Part Name Part No Remarks Part Name Part No Remarks E B C M 96313430 Fuel Pump Relay 96190187...
Page 275 SECTION : 4A HYDRAULIC BRAKES CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS .
Page 276 (Rear) Wheel Cylinder Diameter: – – – – Maximum Nominal FASTENER TIGHTENING SPECIFICATIONS Application Lb–Ft Lb–In Bleeder Screw – Brake Lines – Front Disc Brake Hose–to–Caliper Bolt – Rear Disc Brake Hose–to–Caliper Bolt – Shaft Nut – DAEWOO V–121 BL4...
Page 277 14. 1st Front Brake Pipe RH Front Brake Hose 15. 1st Rear Brake Pipe (B) 2nd Rear Brake Pipe (B) 16. LHD Master Cylinder/Booster Assembly ABS Modulator 17. LH Rear Brake Hose Bracket 18. LH 3rd Rear Brake Pipe DAEWOO V–121 BL4...
Page 278 2nd Front Brake Pipe 13. 1st Rear Brake Pipe (B) RH Front Brake Hose 14. LHD Master Cylinder/Booster Assembly 2nd Rear Brake Pipe 15. LH Rear Brake Hose Front Brake Pipe 16. LH 3rd Rear Brake Pipe DAEWOO V–121 BL4...
Page 279: Brake Hose Inspection
As a test of the lamp circuit, vehicles with antilock Leaks are indicated only if there is at least one drop brakes will momentarily illuminate the lamp for of fluid. A damp condition is not abnormal. about 4 seconds when the ignition DAEWOO V–121 BL4...
Page 280 If the brake warning lamp is off after discon- 32. If the brake warning lamp is on after jumpering the necting the switch, the brake fluid level switch is brake fluid level switch terminals, the switch is stuck closed. faulty. DAEWOO V–121 BL4...
Page 281 Is the problem found? Check for a short to ground in the wiring between the Go toStep 17 Go toStep 16 instrument cluster terminal A2 and the parking brake switch. Is the problem found? DAEWOO V–121 BL4...
Page 282 Does the parking brake warning lamp operate with the cap from the brake fluid reservoir removed? Check for an open between the instrument cluster Go toStep 17 Go toStep 13 connector terminal B13 and the EBCM connector terminal 21. Is the problem found? DAEWOO V–121 BL4...
Page 283 Repair the open in the wiring between ground and System OK the brake fluid level switch. Is the repair complete? Repair the open in the wiring between the instrument System OK cluster connector terminal B13 and the brake fluid level switch. Is the repair complete? DAEWOO V–121 BL4...
Page 284 Allow the brake fluid to fill the master cylinder until it begins to flow from the front pipe connector port. Connect the front brake line(s) to the master cylin- der. Tighten Tighten the brake lines to 16 NSm (12 lb–ft). DAEWOO V–121 BL4...
Page 285 10. After all the air has been removed at the forward connection(s), bleed the master cylinder at the rear (cowl) connection(s) in the same manner as with the front connections. DAEWOO V–121 BL4...
Page 286 Tighten the bleeder screw to 8 NSm (71 lb–in). 17. Proceed to bleed the front brakes following the ap- propriate sequence, beginning with step 12. 18. Check the brake pedal for sponginess. Repeat the entire bleeding procedure to correct this condition. DAEWOO V–121 BL4...
Page 287 10. Inspect the brake pedal for sponginess. Repeat the entire bleeding procedure to correct this condition. 11. Tighten the bleeder valve and replace the dust cov- ers. Tighten Tighten the bleeder valve to 8 NSm (71 lb–in). DAEWOO V–121 BL4...
Page 288 Tighten Tighten the brake line to 16 NSm (12 lb–ft). Lower the vehicle. Bleed the brake system. Refer to”Manual Bleeding the Brakes”in this section, or Section 4F, Antilock Brakes, if applicable. Check the brake system for leaks. DAEWOO V–121 BL4...
Page 289 Remove the retainer. Disconnect the brake hose from the ”C” bracket on the steering knuckle shaft. Remove the bolt from the brake caliper. Remove the seal rings and the disc brake hose. DAEWOO V–121 BL4...
Page 290 Tighten Tighten the brake line to 16 NSm (12 lb–ft). Lower the vehicle. Bleed the brake system. Refer to”Manual Bleeding the Brakes” in this section. Check the brake system for leaks. DAEWOO V–121 BL4...
Page 291: Brake Pedal
Press the brake pedal and pull the switch plunger to its maximum setting to adjust the switch. Release the plunger and pull up on the pedal. Connect the negative battery cable. BRAKE PEDAL Removal Procedure Remove the stoplamp switch. DAEWOO V–121 BL4...
Page 292 Tighten the shaft nut to 18 NSm (13 lb–ft). Install the retaining clip into the hole in the pedal shaft. Align the clevis with the holes in the brake pedal, and install the clevis pin, the clevis retainer, and the clip. Install the stoplamp switch. DAEWOO V–121 BL4...
Page 293: Hydraulic Fluid
Fluid exposed to air will absorb moisture ervoir to the MAX indicator mark. from the air. Water in the brake fluid will cause the fluid to boil, and the rubber components to deteriorate. DAEWOO V–121 BL4...
Page 294 SECTION : 4B MASTER CYLINDER CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS .
Page 295 Important : If the pressure exceeds 10 000 kPa (1,450 Remove the gauges from the tested brake circuit psi), the pressure reading on the rear gauge will not be ac- and repeat the test on the remaining circuit. curate. DAEWOO V–121 BL4...
Page 296: Master Cylinder Assembly
Remove the clutch hose from the master cylinder if equipped. Plug the opening to the brake lines to prevent fluid loss and contamination. Remove the attaching nuts from the power booster. Remove the master cylinder assembly. Drain the brake fluid. DAEWOO V–121 BL4...
Page 297 Connect the electrical connector on the reservoir cap. Add brake fluid. Check for leaks and recheck the fluid level. Bleed the brake system. Refer to Section 4A, Hy- draulic Brakes DAEWOO V–121 BL4...
Page 298: Brake Fluid Reservoir
Remove the clutch hose from the master cylinder. Gently pry upwards with a screwdriver to release the reservoir. Tilt the reservoir and pull it upward in order to re- move it. Remove the reservoir seals from the master cylin- der body. DAEWOO V–121 BL4...
Page 299 Raise and suitably support the vehicle. Bleed the braking system. Refer toSection 4A, Hy- draulic Brakes orSection 4F, Antilock Brake Sys- tem. Bleed the clutch master cylinder. Refer toSection 5C, Clutch. Lower the vehicle. Connect the reservoir electrical connector. DAEWOO V–121 BL4...
Page 300: Proportioning Valve
Connect the brake lines to the valves. Tighten Tighten the brake lines to 16 NSm (12 lb–ft). Raise and suitably support the vehicle. Bleed the braking system. Refer toSection 4A, Hy- draulic Brakes or Section 4F, Antilock Brake Sys- tem. Lower the vehicle. DAEWOO V–121 BL4...
Page 301 (the non–ABS master cylinder body is shown) using a suitable screwdriver. Remove the primary piston (the ABS master cylin- der body is shown). Carefully remove the secondary piston assembly, including the springs, from the master cylinder bore. DAEWOO V–121 BL4...
Page 302 Insert the new retaining ring into the groove in the cylinder bore (the non–ABS cylinder body is shown). Remove the welding rod. Move the pistons backward and forward after instal- lation to check for free movement. DAEWOO V–121 BL4...
Page 303 11. Install the master cylinder assembly. Refer to the”Master Cylinder Assembly”in this section. 12. Raise and suitably support the vehicle. 13. Bleed the braking system. Refer toSection 4A, Hy- draulic Brakes or Section 4F, Antilock Brake Sys- tem. 14. Lower the vehicle. DAEWOO V–121 BL4...
Page 304: Master Cylinder
Lubricate rubber parts with clean brake fluid to ease condition is detected. Once the fluid level is corrected, the assembly. BRAKE light will go out. Do not use lubricated shop air on brake parts, as this may damage rubber components. DAEWOO V–121 BL4...
Page 305 SECTION : 4C POWER BOOSTER CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting thes cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS .
Page 306: Vacuum Hose
Remove the vacuum hose. Installation Procedure Mount the vacuum hose and ensure the connec- tions are tight on each end. Install the vacuum hose clips. Check the function of the booster. Refer to the”Power Booster Functional Check”in this sec- tion. DAEWOO V–121 BL4...
Page 307 Remove the clip on the vacuum hose connection on the booster. Disconnect the brake stoplamp switch from the brake pedal bracket. Remove the brake pedal spring. Disconnect the clip and the pushrod pin from the pedal bracket assembly. Refer toSection 4A, Hy- draulic Brakes. DAEWOO V–121 BL4...
Page 308 Remove the booster mounting nuts from the studs protruding from the dash panel and remove the booster. Remove the rubber boot. 10. Holding the hex nut, twist off the pushrod clevis. 11. Remove the hex nut from the pushrod. DAEWOO V–121 BL4...
Page 309 Tighten the booster hex nut and the pushrod clevis to 18 NSm (13 lb–ft). Measure the distance from the booster to the cen- ter of the clevis bore. Important : This measurement should be 203 mm (8 inch- es). Install the rubber boot on the booster. DAEWOO V–121 BL4...
Page 310 11. Install the pushrod pin to the brake pedal bracket assembly and connect the clip and the spring. Re- fer toSection 4A, Hydraulic Brakes. 12. Install the brake stoplamp switch onto the brake pedal bracket. DAEWOO V–121 BL4...
Page 311: Power Booster
(vacuum) exists on brake system. both sides of the power booster diaphragm. When the brakes are applied, vacuum is present on one side of the DAEWOO V–121 BL4...
Page 312 SECTION : 4D FRONT DISC BRAKES TABLE OF CONTENTS SPECIFICATIONS ......4D–1 CALIPER ....... . . 4D–4 FASTENER TIGHTENING SPECIFICATIONS 4D–1...
Page 313 Position the transaxle in NEUTRAL. Remove the rotor. Refer to ”Rotor” in this section. Install the rotor. Refer to ”Rotor” in this section. DAEWOO V–121 BL4...
Page 314 Remove the front wheel. Refer to Section 2E, Tires and Wheels. Remove the lower caliper mounting bolt. Important : Caliper removal is not necessary to service the brake shoes. Pivot the caliper upward. Remove the brake shoes. DAEWOO V–121 BL4...
Page 315 To preserve wheel balance, mark the position of the front wheel relative to the wheel hubs. Remove the wheel. Refer toSection 2E, Tires and Wheels. Remove the bolt which attaches the brake hose to the caliper. Remove the washers. DAEWOO V–121 BL4...
Page 316 Install the caliper mounting bolts. Tighten Tighten the caliper mounting bolts to 22–32 NSm (16–24 lb–ft). Connect the caliper inlet hose with the bolt and the washers. Tighten Tighten the brake hose–to–caliper bolt to 40 NSm (30 lb–ft). DAEWOO V–121 BL4...
Page 317 Do not move the vehicle until a firm pedal is obtained. ROTOR Removal Procedure Remove the caliper. Refer to ”Caliper”in this sec- tion. Remove the brake pads. Remove the caliper mounting bracket. Remove the rotor detent screw. Remove the rotor. DAEWOO V–121 BL4...
Page 318 Install the brake pads and the caliper. See”Caliper” in this section. SPLASH SHIELD Removal Procedure Remove the rotor. Refer to ”Rotor” in this section. Remove the screws for the splash shield from the steering knuckle. Remove the splash shield. DAEWOO V–121 BL4...
Page 319 Installation Procedure Install the splash shield. Secure the splash shield to the steering knuckle with the screws. Tighten Tighten the splash shield screws to 5 NSm (44 lb–in). Install the rotor. Refer to ”Rotor” in this section. DAEWOO V–121 BL4...
Page 320 Apply unlubricated compressed air at the hose inlet of the caliper. Remove the piston from its bore, and remove the piston dust seal. DAEWOO V–121 BL4...
Page 321 Make sure that the dust seal is in the correct groove in the piston and caliper. Reinstall the caliper. Refer to”Caliper”in this section. 10. Bleed the brake system. Refer toSection 4A, Hy- draulic brakesor Section 4F, Antilock Brakes, if ap- plicable. DAEWOO V–121 BL4...
Page 322 Perform the service operations on a clean bench, a clamping action on the rotor. This clamping action forces free from all mineral oil materials. the linings against the rotor, creating friction to stop the ve- hicle. DAEWOO V–121 BL4...
Page 323: Table Of Contents
SECTION : 4E REAR DISC BRAKES CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting thes cable will help prevent personal injury and damage to the vehicle.
Page 324 0.40 mm (0.016 inches) in depth. Scoring mea- Align the marks that weremade before the wheel surements can be made with a commercially available was removed and install the front wheel. brake micrometer. Lower the vehicle. DAEWOO V–121 BL4...
Page 325 Refer toSection 2E, Tires and Wheels. Remove the lower caliper mounting bolt. Important : It is not necessary to remove the caliper to service the brake shoes. Pivot the caliper upward. Remove the brake shoes. DAEWOO V–121 BL4...
Page 326 Raise and suitably support the vehicle. 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. Remove the brake hose caliper inlet bolt and the washers. DAEWOO V–121 BL4...
Page 327 Install the caliper with the mounting bolts. Tighten Tighten the caliper mounting bolts to 31 NSm (23 lbft). Connect the brake hose and the washers with the mounting bolt. Tighten Tighten the brake hose caliper inlet bolt to 32 NSm (24 lb–ft). DAEWOO V–121 BL4...
Page 328 Notice : To prevent damage to the brake hose, do not hang the caliper from the brake hose. Remove the caliper. Refer to”Caliper”in this section. Remove the caliper bracket. Remove the rotor detent screw. Remove the rotor. DAEWOO V–121 BL4...
Page 329 Refer toSection 2E, Tires and Wheels. Lower the vehicle. SPLASH SHIELD/BACKPLATE AND PARKING BRAKE LEVER Removal Procedure Remove the rotor. Refer to”Rotor”in this section. Disconnect the parking brake cable from the brake backplate operating lever. DAEWOO V–121 BL4...
Page 330 Remove the wheel hub assembly from the spindle shaft. Remove the bolts that secure the splash shield/ backplate/ parking brake shoe assembly to the steering knuckle. Remove the splash shield/backplate/parking brake shoe assembly from the steering knuckle. DAEWOO V–121 BL4...
Page 331 Remove the screw that secures the parking brake shoe hold–down spring assembly to the backplate. Remove the parking brake shoe, sliding it away from the actuation mechanism. 10. Remove the splash shield. 11. Remove and discard the adjuster screw and the nut. DAEWOO V–121 BL4...
Page 332 14. Remove and discard the dust cover, and the dust cover retainer from the backplate. 15. Remove and discard the lever and the adjuster pawl. DAEWOO V–121 BL4...
Page 333 Inspect the splash shield for rust or any other dam- age. Replace the splash shield, if necessary. Install the new adjuster pawl to the backing plate by securing it with a pop rivet. DAEWOO V–121 BL4...
Page 334 3.5 NSm (31 lb–in). 10. Connect the new parking brake adjustment screw to the new adjustment nut. Tighten the nut to where it meets the screw, and then back off one–quarter of a turn. DAEWOO V–121 BL4...
Page 335 Important : Clean hands are required when handling the parking brake shoe. 14. Install the parking brake shoe engaging the shoe tips in both the adjusting screw and the tappet slots. DAEWOO V–121 BL4...
Page 336 16. Install the shaft dust cover. 17. Install the parking brake cable to the parking brake lever on each side of the vehicle. 18. Adjust the parking brake. Refer toSection 4G, Park- ing Brake. 19. Install the rotor. Refer to”Rotor”in this section. DAEWOO V–121 BL4...
Page 337 Remove and discard the outer dust seal. Remove the inner seal and discard it. Do not scratch the piston bore or the seal groove when removing the inner seal. Remove the bleeder valve and the dust cover. DAEWOO V–121 BL4...
Page 338 Insert the bleeder valve and the dust cover. Tighten Tighten the bleeder valve to 11 NSm (97 lb–in). Lubricate a new piston inner seal with brake fluid. Install the piston inner seal into the groove in the cal–iper bore. DAEWOO V–121 BL4...
Page 339 Lubricate the guide pins with a lithium soap base glycol grease or other grease which will not deteriorate or swell the rubber boots. 12. Install the caliper. Refer to”Caliper”in this section. DAEWOO V–121 BL4...
Page 340 The vehicle is Perform the service operations on a clean bench stopped as a result of the friction between the rotor and the away from oily material. brake shoes. DAEWOO V–121 BL4...
Page 341 SECTION : 4F ANTILOCK BRAKE SYSTEM CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle.
Page 342 ....4F–164 GEAR REPLACEMENT ....4F–204 DAEWOO V–121 BL4...
Page 343 Gear Cover Torx± Head Screws – Gear Nuts – Hydraulic Modulator/Motor Pack Assembly Bolt – Motor Pack Torx± Head Screws – Rear Wheel Speed Sensor Bolt – Surge Tank Mounting Bolts – SPECIAL TOOLS SPECIAL TOOLS TABLE Scan Tool DAEWOO V–121 BL4...
Page 344 24. Motor Pack Electrical Connector 11. Body Wiring Harness 25. Left–Side Isolation Solenoid 12. I/P Fuse Block 26. Left–Side Hydraulic Modulator Bleeder Valve 13. ABS Relay 27. Left Front Wheel Speed Sensor Harness 14. EBCM 28. Left Front Wheel Speed Sensor DAEWOO V–121 BL4...
Page 345 ANTILOCK BRAKE SYSTEM 4F – 5 SCHEMATIC AND ROUTING DIAGRAMS ABS CIRCUIT (1 OF 4) DAEWOO V–121 BL4...
Page 346 4F – 6IANTILOCK BRAKE SYSTEM ABS CIRCUIT (2 OF 4) DAEWOO V–121 BL4...
Page 347 ANTILOCK BRAKE SYSTEM 4F – 7 ABS CIRCUIT (3 OF 4) DAEWOO V–121 BL4...
Page 348 4F – 8IANTILOCK BRAKE SYSTEM ABS CIRCUIT (4 OF 4) DAEWOO V–121 BL4...
Page 349 Right Front Wheel Speed Low LFWSLO Left Front Wheel Speed Low BRAKETT BRN/BLK BRAKE Lamp REABSOL LT BLU Right Front ABS Isolation Solenoid SDLUART BLK/WHT Serial Data – – Not Used BRAKESW BRN/BLK Stoplamp Switch – – Not Used DAEWOO V–121 BL4...
Page 350 4F – 10IANTILOCK BRAKE SYSTEM Signal Name Color Circuit – – Not Used BATT Battery (+) DAEWOO V–121 BL4...
Page 351 Left Front Motor Low LFMOTHI Left Front Motor HIgh RFMOTHI DK GRN Right Front Motor HIgh RFMOTLO Right Front Motor Low RAMOTLO Rear Axle Motor Low RAMOTHI Rear Axle Motor HIgh SWBATT Battery (+) through ABS relay Ground (– ) DAEWOO V–121 BL4...
Page 352 SECTION : 4G PARKING BRAKE CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS .
Page 353: Parking Brake Adjustment
13. Release the parking brake. 14. Turn the rear wheel by hand to check the drag. Re- adjust the cable, if necessary. 15. Repeat the process for the other rear wheel. 16. Lower the vehicle. DAEWOO V–121 BL4...
Page 354: Parking Brake Lever
Remove the split pin which holds the eye bolt pull rod to the parking brake lever assembly. Detach the eye bolt pull rod but leave the pull rod connected to the equalizer which is attached to the parking brake cables. DAEWOO V–121 BL4...
Page 355 Notice : If the parking brake lever is bent or damaged, re- place the entire parking brake lever assembly. Fasten the parking brake switch to the parking brake lever assembly with the screw. Tighten Tighten the parking brake switch–to–parking brake lever screw to 4 NSm (35 lb–in). DAEWOO V–121 BL4...
Page 356: Parking Brake Cable
Install the center console. Refer toSection 9G, Inte- rior Trim. PARKING BRAKE CABLE Removal Procedure Remove the center console. Refer toSection 9G, Interior Trim. Remove the split pin which holds the eye bolt pull rod to the parking brake lever assembly. DAEWOO V–121 BL4...
Page 357 Remove the clip that holds the cable into the pro- truding hole on the steering knuckle assembly. Remove the nut securing the parking brake cable to the underbody clip on both the driver and passen- ger sides of the vehicle. DAEWOO V–121 BL4...
Page 358 11. Remove the fuel tank retaining strap nut on the driver’s side and remove the parking brake cable. Pull the cable through the loop of the welded under- body bracket. 12. Remove the parking brake cable and rubber grom- met. DAEWOO V–121 BL4...
Page 359 Route the parking brake cable through the loop of a welded underbody bracket and under the fuel tank retaining strap (driver’s side). Tighten Tighten the fuel tank retaining strap nut to 12.5 NSm (111 lb–in). DAEWOO V–121 BL4...
Page 360 13. Install the parking brake/gearshift console hood. Refer toSection 9G, Interior Trim. 14. If the parking brake shoe lever was pressed back- ward before removing the brake drum, now press it forward and adjust the parking brake. Refer to”Parking Brake Adjustment”in this section. DAEWOO V–121 BL4...
Page 361 Slip the parking brake handle off the parking brake lever. Installation Procedure Push the parking brake handle as far as it will go on the parking brake lever. Install the center console and the parking brake lever boot. Refer toSection 9G, Interior Trim. DAEWOO V–121 BL4...
Page 362: Parking Brake
(or future) free movement of the parking The braking system uses a BRAKE warning light located brake lever assembly. in the instrument panel cluster. When the ignition switch is in START, the BRAKE warning light should glow and go DAEWOO V–121 BL4...
Page 363 SECTION 5 ELECTRICAL WIRING DIAGRAMS...
Page 364 5–2WELECTRICAL WIRING DIAGRAMS 1. STARTING & CHARGING SYSTEM a. CONNECTOR INFORMATION 1) BATTERY, IGNITION SWITCH, STARTER MOTOR, ALTERNATOR & SWITCH ( CLUTCH(M/T), CONNECTOR(NO) CONNECTING, WIRING HARNESS CONNECTOR POSITION NSBU(A/T) ) (PIN NO. COLOR) C102(68 Pin, Brown) Engine Room Fuse Box Body Engine Room Fuse Box C103(68Pin, Black)
Page 365 ELECTRICAL WIRING DIAGRAMSW5–3 c. POSITION OF CONNECTORS AND GROUNDS 2.0 DOHC ENGINE ENGINE ROOM FUSE BLOCK LEFT ”A” PILLAR INSIDE d. SPLICE PACK S202 (BLUE)
Page 366: Table Of Contents
SECTION : 5A 4T40–E AUTOMATIC TRANSAXLE CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical erminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle.
Page 367 ..... 5A–75 LOW INPUT ......5A–107 DAEWOO V–121 BL4...
Page 368 2ND/4TH SERVO ASSEMBLY ... . 5A–175 DIRECT/COAST CLUTCH AND CASE SIDE COVER PAN AND GASKETS 5A–176 REACTION GEAR SET REMOVAL ..5A–204 DAEWOO V–121 BL4...
Page 369 ..5A–225 ASSEMBLE ......5A–254 DAEWOO V–121 BL4...
Page 370 ......5A–279 MANUAL FIRST – FIRST GEAR ..5A–311 DAEWOO V–121 BL4...
Page 371 101.88–102.18 Violet 2.98–3.08 102.18–102.48 Yellow 3.28–3.38 102.48–102.77 3.57–3.67 102.77–103.07 Green 3.87–3.97 TRANSAXLE GENERAL SPECIFICATIONS Dimension A (mm) Backing Plate Identification 8.970–9.433 9.434–10.007 10.008–10.470 FLUID CAPACITY Litres Quarts Bottom Pan Removal Complete Overhaul 12.2 12.9 (Measurements are approximate) DAEWOO V–121 BL4...
Page 372 60 km/h (37 mph). ON = The solenoid is energized. NOTE: Manual First–Third gear is also possible at high ve- OFF = The solenoid is de–energized. hicle speed as a safety feature. * = Applied with no load. DAEWOO V–121 BL4...
Page 373 Channel Plate–to–Case Bolt – Channel Plate–to–Case Valve Body Bolts – Channel Plate–to–Case Valve Body Pressure Switch Manual – Bolts Channel Plate–to–Case Valve Body Pump Bolts – Channel Plate–to–Support–Driven Sprocket Bolt 10.5 – Channel Plate–to–Support–Driven Sprocket Spacer Bolts 10.5 – DAEWOO V–121 BL4...
Page 374 Transaxle Mounting Bracket Bolt – Transaxle Pan Bolts – Trans Oil–to–Cover LO/Reverse Servo Tube Assembly – Trans Oil–to–Support Forward Clutch Tube Assembly – Valve Body–to–Channel Plate Bolts – Valve Body–to–Channel Plate Pump Bolts – Wiring Harness Retainer Bolt – DAEWOO V–121 BL4...
Page 375 Universal Test Lamp J 21867 J 35616 Universal Pressure Connector Test Gauge Set Adapter Kit J 28742–A J 35689–A Weather Pack Metri–pack Terminal Terminal Remover Remover J 33095 Control Module J 36169–A Connector Terminal Fused Jumper Wire Remover DAEWOO V–121 BL4...
Page 376 Digital Volt–Ohmmeter Stub Shaft (DVOM) Sleeve Remover J 41227 J 39775 Output Shaft Jumper Harness Sleeve Remover J 3289–20 J 41101 Transmission Holding Pass Through Fixture Base Connector Remover J 41230 J 36850 Transmission Holding Assembly Lubricant Fixture DAEWOO V–121 BL4...
Page 377 Coast Clutch Return Torque Converter Spring Compressor Seal Installer Adapter J 41232 J 28585 Direct Reverse, Snap Ring Second Clutch Screwdriver Return Spring Compressor Adapter J 41239–1 J 41228 Cooler Line Stub Shaft Seal Installer Sleeve Installer DAEWOO V–121 BL4...
Page 378 Forward Clutch Reverse Clutch Inner Seal Assembly Inner Seal Installer Installer J 41234–1 J 41235 Input Shaft Seal Second Roller Installer Pusher Clutch Installer J 41234–2 J 29569–1/J 29829–1 Input Shaft Seal Turbine Shaft Seal Installer Protector Installer DAEWOO V–121 BL4...
Page 379 5A – 14I4T40–E AUTOMATIC TRANSAXLE J 29569–2/J 29829–2 J 41103 Turbine Shaft Torque Converter Seal Sizer Seal Remover Set J 21366 J 28467–B Torque Converter Engine Support Holding Strap Fixture DAEWOO V–121 BL4...
Page 380 4T40–E AUTOMATIC TRANSAXLE 5A – 15 SCHEMATIC AND ROUTING DIAGRAMS POWERTRAIN CONTROL MODULE (1 OF 3) DAEWOO V–121 BL4...
Page 381 5A – 16I4T40–E AUTOMATIC TRANSAXLE POWERTRAIN CONTROL MODULE (2 OF 3) DAEWOO V–121 BL4...
Page 382 4T40–E AUTOMATIC TRANSAXLE 5A – 17 POWERTRAIN CONTROL MODULE (3 OF 3) DAEWOO V–121 BL4...
Page 383 5A – 18I4T40–E AUTOMATIC TRANSAXLE VISUAL IDENTIFICATION TRANSAXLE IDENTIFICATION INFORMATION Sequential Number Assembly Plant (Windsor, Canada) Manufacturer Model Year (1996) Part Number Broadcast Code Model Name (4T40E) Update Level DAEWOO V–121 BL4...
Page 384 SECTION : 5B FIVE–SPEED MANUAL TRANSAXLE CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle.
Page 385 Left Front Transaxle Support Bracket Bolts Left Rear Transaxle Support Bracket Bolts Lower Transaxle–to–Engine Bolts Ring–Gear Bolts Rod Clamp Bolt Speedometer Housing Retaining Bolt Speedometer–Driven Gear Bolt Support Bracket Bolt Transaxle Cover Bolts, Bigger Transaxle Cover Bolts, Smaller Upper Transaxle–to–Engine Bolts DAEWOO V–121 BL4...
Page 386 FIVE–SPEED MANUAL TRANSAXLE 5B – 3 SPECIAL TOOLS SPECIAL TOOLS TABLE J–6125–B KM–553–A Slide Hammer Fifth–Gear Puller J–22888–20–A Bearing Puller with J–36633 J–22888–35 Snap Ring Retainer Puller Legs J–22912–01 KM–113–2 Universal Bearing Base Puller J–28467–B KM–334 Engine Support Fixture Installer Sleeve DAEWOO V–121 BL4...
Page 387 5B – 4IFIVE–SPEED MANUAL TRANSAXLE J–42469 KM–525 Shift Rod Remover Installer KM–519 KM–552 Ring Installer Fixture KM–520 KM–554 Remover/Installer Installer KM–522 Installer DAEWOO V–121 BL4...
Page 388 S Coast – with the transaxle in gear and the ments that are too tight. throttle partly or fully closed. After completing these checks, refer to the ”Diagnosis S All of the above. Chart” in this section. DAEWOO V–121 BL4...
Page 389 S Replace any chipped, scored, or worn third–gear constant mesh gears. S Replace any worn third–fourth gear synchronizer. S Replace any worn third–gear/bearing. S Replace any worn differential–gear/bearing. S Replace any worn–ring gear. S Adjust, repair, or replace the shift lever and the rods. DAEWOO V–121 BL4...
Page 390 S Replace any chipped, scored, or worn fifth–gear syn- chronizer. S Replace any chipped, scored, or worn first–second gear synchronizer. S Replace any worn third–fourth gear synchronizer. S Adjust, repair, or replace the shift lever and the rods. DAEWOO V–121 BL4...
Page 391 S Replace any worn first–gear/bearing. S Replace any worn first–second gear synchronizer. S Replace any worn second–gear/bearing. S Replace any worn third–gear/bearing. S Replace any worn third–fourth synchronizer. S Replace any worn fourth–gear/bearing. S Replace any worn reverse–idler gear. DAEWOO V–121 BL4...
Page 392: Component Locators
FIVE–SPEED MANUAL TRANSAXLE 5B – 9 COMPONENT LOCATORS GEARS AND CASE DAEWOO V–121 BL4...
Page 393 80. Reverse Lamp Switch 38. Fifth Gearshift Fork 81. Input Shaft Bearing 39. Pin 82. Second–Gear Needle Bearing 40. Fifth Gear Connector 83. Third–Gear Needle Bearing 41. Shoe 84. Fourth–Gear Needle Bearing 42. Key 85. Washer 43. Snap Ring DAEWOO V–121 BL4...
Page 394 22. Speedometer Drive Gear Bearing Adjusting Ring 23. Bolt 10. Side Bearing Race 24. Pinion Shaft Lock Pin 11. Housing Cover Gasket 25. Right Side Bearing Retainer 12. Differential Cover 26. Seal 13. Bolt 27. Retainer Bolt 14. Differential Bearing DAEWOO V–121 BL4...
Page 395 5B – 12IFIVE–SPEED MANUAL TRANSAXLE SHIFT LINKAGE DAEWOO V–121 BL4...
Page 396 15. Linkage Ball Socket 36. Shift Reverse Pivot Bolt 16. Circlip Ring 37. Boot 17. Linkage Reverse Lever 38. Gearshift Tube 18. Gearshift Boot 39. Bushing 19. Bushing 40. Gearshift Tube Bearing 20. Bushing 21. Rod U–Joint Bushing DAEWOO V–121 BL4...
Page 397 SECTION : 5C CLUTCH CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS .
Page 398 Replace the pressure plate. Check for a driven plate that is not seated. Start the engine 30 to 40 times. Do not overheat the en- gine. Check for a driven plate that is overheated. Allow the driven plate to cool. DAEWOO V–121 BL4...
Page 399 Check for weak pressure plate springs. Replace the pressure plate. Hard Pedal Effort Checks Action Check for binding in the linkage. Lubricate and free–up the binding linkage. Check for a worn driven plate. Replace the worn driven plate. DAEWOO V–121 BL4...
Page 400 22. Bolt Bolt 23. Bolt Spring Washer 24. Pressure Plate 10. Release Cylinder Bracket 25. Clutch Disc 11. Release Cylinder 26. Nut 12. Air Bleeder 27. Spring Washer 13. Bolt 28. Bushing 14. Copper Washer 15. Bolt DAEWOO V–121 BL4...
Page 401 Piston Rod Bolt 21. Clutch Pedal Bushing 22. Hydraulic Clutch Pipe 10. Washer 23. Clip 11. Clutch Pedal Bushing 24. Clutch Pedal Position Switch 12. Clutch Pedal 25. Clutch Pedal Position Switch Adjusting Screw 13. Clutch Pedal Buffer DAEWOO V–121 BL4...
Page 402 5C0 – 6ICLUTCH Flywheel Pressure Plate Clutch Disc Release Bearing DAEWOO V–121 BL4...
Page 403: Clutch Pedal
Disconnect the return spring from the mount brace. Remove the nut, the washer, and the pedal mount- ing shaft. Remove the locking washer and the piston rod bolt. Remove the clutch pedal with the return spring from the vehicle. DAEWOO V–121 BL4...
Page 404 Coat the pedal mounting shaft with multi–purpose grease. Install the pedal mounting shaft, the washer, and the nut. Tighten Tighten the clutch pedal nut to 18 NSm (13 lb–ft). Connect the return spring to the mount brace. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 405 Confirm that the engine does not start when the clutch pedal is released. If the engine starts when the clutch pedal is re- leased completely, replace the clutch pedal position switch. DAEWOO V–121 BL4...
Page 406 Remove the transaxle from the vehicle. Refer to .Section 5B, Five–Speed Manual Transaxle Remove the pressure plate bolts and the pressure plate. Support the pressure plate when you remove the last bolt. Remove the clutch disc. Remove the release fork bolt. DAEWOO V–121 BL4...
Page 407 CLUTCH 5C0 – 11 Pull the clutch release shaft upward, out of the transaxle. 10. Remove the fork and the release bearing from the release bearing guide sleeve. 11. Remove the release lever shaft bushings. DAEWOO V–121 BL4...
Page 408 5C0 – 12ICLUTCH 12. Remove the bolts and the release bearing guide sleeve. 13. Remove the input shaft seal from the release bear- ing guide sleeve. 14. Remove the O–ring from the groove in the trans- axle case. DAEWOO V–121 BL4...
Page 409 Use input shaft seal installer J–36547 with a hammer. Install the release bearing guide sleeve and the bolts. Tighten Tighten the release bearing guide sleeve bolts to 5 NSm (45 lb–in). Coat the sleeve surface with multi–purpose grease. DAEWOO V–121 BL4...
Page 410 Coat the release bearing bore with multi–purpose grease. Install the release bearing, with the clutch fork, onto the release bearing guide sleeve. Install the release lever shaft from the top of the transaxle. Guide the shaft through the clutch fork. DAEWOO V–121 BL4...
Page 411 17. Lower the vehicle. 18. Connect the negative battery cable. CLUTCH PEDAL ADJUSTMENT (HYDRAULIC) Removal Procedure Determine the clutch pedal play. Press the clutch pedal lightly with your hand andmeasure the dis- tance when you feel resistance. DAEWOO V–121 BL4...
Page 412 Measure from the starting position to the ending position. Adjust the clutch pedal travel. Loosen the locknut and turn the bolt. Clutch pedal travel should mea- sure more than 130 mm (5.1 inches). Tighten the locknut after adjustment. DAEWOO V–121 BL4...
Page 413: Air Bleeding
CLUTCH MASTER CYLINDER ASSEMBLY Removal Procedure Before disconnecting the reservoir tank hose, re- move the clutch/brake fluid from the reservoir tank. Disconnect the negative battery cable. Disconnect the spring clamp on the master cylinder. Remove the reservoir hose. DAEWOO V–121 BL4...
Page 414 Remove the locking washer and the piston rod bolt from the clutch pedal and piston rod clevis. Remove the locknuts on the master cylinder brack- Remove the master cylinder in the direction of the engine compartment. DAEWOO V–121 BL4...
Page 415 Install the master cylinder to the mounting bolts and install the locknuts. Tighten Tighten the clutch master cylinder locknuts to 22 NSm (18 lb–ft). Connect the pipe to the master cylinder. Connect the reservoir hose to themaster cylinder and tighten the spring clamp. DAEWOO V–121 BL4...
Page 416 CLUTCH RELEASE CYLINDER ASSEMBLY Removal Procedure Disconnect the negative battery cable. Remove the bolt and disconnect the hose from the clutch release cylinder. Remove the clutch release cylinder bolts and re- move the release cylinder from the transaxle. DAEWOO V–121 BL4...
Page 417: Clutch Master Cylinder
UNIT REPAIR CLUTCH MASTER CYLINDER Disassembly Procedure Remove the clutch master cylinder assembly from the vehicle. Refer to ”Clutch Master Cylinder As- sembl” in this section. Remove the boot and disconnect the piston stop ring using ring pliers. DAEWOO V–121 BL4...
Page 418 Install the piston stop ring using ring pliers. Install the boot. Install the clutch master cylinder assembly into the vehicle. Refer to ”Clutch Master Cylinder Assembl” in this section. DAEWOO V–121 BL4...
Page 419: Clutch Release Cylinder
Refer to”Clutch Master Cylinder As- sembl” in this section. Remove the bolts and brackets. Remove the boot and the pushrod. Compress the piston with a driver, then remove the snap ring with snap ring pliers. Remove the piston assembly. DAEWOO V–121 BL4...
Page 420 Compress the piston with a driver, then install the snap ring with snap ring pliers. Install the pushrod and the boot. Install the brackets and the bolts. Install the clutch release cylinder assembly. Refer to”Clutch Master Cylinder Assembl” in this section. DAEWOO V–121 BL4...
Page 421 The bearing then pushes against the release levers in the pressure plate assembly, thereby releasing the clutch. DRIVEN MEMBERS The driven member is the clutch disc with a splined hub DAEWOO V–121 BL4...
Page 422 SECTION : 7A HEATING AND VENTILATION SYSTEM CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle.
Page 423 FASTENER TIGHTENING SPECIFICATIONS Application Lb–Ft Lb–In Blower Motor Resistor Screws – Blower Resistor Retaining Screws – Heater Core Cover Screw – Heater Core Retaining Bracket Screw – Heater/Air Distributor Case Assembly Screws – HVAC Controller Retaining Screws – DAEWOO V–121 BL4...
Page 424 HEATING AND VENTILATION SYSTEM 7A – 3 AIRFLOW THROUGH VENTS WITH REAR HEATING DUCT* * Rear heating duct available on vehicles in cold climate countries. DAEWOO V–121 BL4...
Page 425 3. Turn the blower motor switch to 4. 4. With the engine sufficiently cool, remove the surge tank cap. 5. Start the vehicle and idle the engine. 6. Watch for the flow of the coolant. Is the coolant flow visible? DAEWOO V–121 BL4...
Page 426 29°C (84°F). Is the heater inlet hose hot and the heater outlet hose warm? Check the thermostat. Refer to 1D, Engine Cooling. Go to Step 20 Go to Step 21 Is the thermostat installed and seated properly? DAEWOO V–121 BL4...
Page 427 Are there any obstructions? Remove the obstructions in the system at the blower System OK inlet or replace a clogged filter. Are the repairs complete? DAEWOO V–121 BL4...
Page 428 S From the heater resistor block to the blow- er motor. S From the blower speed switch to the blower HI relay. 3. Repair any short. 4. Replace any blown fuse. Is the repair complete? DAEWOO V–121 BL4...
Page 429 S Fuse EF2 to the blower HI relay. S Blower speed switch to the blower HI relay. S Blower HI relay to ground. S Blower HI relay to the blower motor. 3. Repair any opens. Is the repair complete? DAEWOO V–121 BL4...
Page 430 Defroster Cold to Hot High No Airflow Minimum Cold to Hot Minimum Cold to Hot Airflow Cold to Hot Airflow Airflow If any of these settings does not produce the correct results, perform the following diagnostic procedure. DAEWOO V–121 BL4...
Page 431 3. Remove any obstructions in the heater outlet. Is the repair complete? Check the blower speeds fora change in the airflow. Go to Step 15 Go to ”Blower Does the blower speed increase as the control is Electrical” turned from 1 to 4? DAEWOO V–121 BL4...
Page 432 Does the airflow change as the setting for the blower motor speed switch is changed? System OK 1. Check the temperature door travel, the cable, and the linkage. 2. Turn the temperature control knob to full cold. 3. Check for full hot. Is the repair complete? DAEWOO V–121 BL4...
Page 433 Is the outlet air more than 5°C (41°F) warmer than the inlet air? System OK 1. Check for hot air leaks from the engine compartment to the blower inlet. 2. Repair, as needed. Is the repair complete? DAEWOO V–121 BL4...
Page 434 Go to Step 16 1. Remove the cable from the control. 2. Check the control for binding. Does the control bind? Replace the control. System OK Is the repair complete? Replace the cable. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 435 Is the repair complete? Is the noise present in the floor mode only? Go to Step 12 Go to Step 14 Is the noise present in the vent mode only? Go to Step 15 Go to Step 16 DAEWOO V–121 BL4...
Page 436 2. Repair or replace, as needed. Is the repair complete? System OK Go to Step 2 1. Check the system for obstructions or foreign materials between the fan and the temperature door. 2. Repair or replace, as needed. Is the repair complete? DAEWOO V–121 BL4...
Page 437 Pull out the controller to provide clearance for re- moval of the temperature control cable. Disconnect the temperature control cable eyelet from the post on the controller. Snap the cable housing connector out of the slide position on the controller. DAEWOO V–121 BL4...
Page 438 Install the audio system trim plate. Refer to Section 9F, Audio Systems. Connect the negative battery cable. 10. Operate the heating and cooling systems to verify proper function. 11. Install the glove box. Refer to Section 9E, Instru- mentation/Driver Information. DAEWOO V–121 BL4...
Page 439 Press the cable end eyelet onto the post on the controller. Attach the mechanical cable housing to its original control position. Connect the electrical connectors to the sockets on the back of the controller. DAEWOO V–121 BL4...
Page 440 Refer to ”Control Assembly” in this sec- tion Disconnect the small connector to the vacuum con- trol switch on the rear of the assembly case. Separate the control assembly case halves. Turn the bulb holder to the left and pull out the bulb. DAEWOO V–121 BL4...
Page 441 Disconnect the negative battery cable. Remove the instrument panel carrier assembly. Re- fer to Section 9E, Instrumentation/Driver Informa- tion. Drain the cooling system. Refer to Section 1D, En- gine Cooling. Turn the vacuum hose and pull the hose off. DAEWOO V–121 BL4...
Page 442 The case assembly will start to drop. 11. Pull the heater/air distributor case straight away from the bulkhead to free the alignment pegs from their openings in the bulkhead. 12. Remove the heater/air distributor case assembly from the vehicle. DAEWOO V–121 BL4...
Page 443 Install the two heater/air distributor case screws that flank the heater core pipes. Tighten Tighten the heater/air distributor case assembly screws to 4 NSm (35 lb–in). Install the vacuum hose. Install the two heater hoses. Slide the heater hose clamps into position. DAEWOO V–121 BL4...
Page 444: Blower Motor
Connect the blower motor electrical connector. Connect the negative battery cable. Confirm that the blower motor operates properly. Replace the footwell upper cover. Refer to Section 9E, Instrumentation/Driver Information. Replace the glove box. Refer to Section 9E, Instru- mentation/Driver Information. DAEWOO V–121 BL4...
Page 445: Blower Resistor
Remove the footwell upper cover. Refer to Section 9E, Instrumentation/Driver Information. Disconnect the electrical connector at the resistor. Remove the mount screws from the resistor. Remove the resistor from the heater/air distributor case by gently pulling the resistor downward. DAEWOO V–121 BL4...
Page 446 Install and seat the other end of each heater hose. Compress and slide the spring clamps into position on the heater hoses and release the tension. Fill the cooling system. Refer to Section 1D, Engine Cooling. Check the hoses for leaks. DAEWOO V–121 BL4...
Page 447: Heater Core
Secure the heater core lines to the case with the retaining bracket clamp and the screw. Tighten Tighten the heater core retaining bracket screw to NSm (lb–in). Install the heater core body with the retaining spring clamp. DAEWOO V–121 BL4...
Page 448 Should there be no airflow to the rear, look for any obstruc- tions, such as items on the floor under the front seats. Also, check for air leaks between the heater/air distributor assembly and the rear ducts. DAEWOO V–121 BL4...
Page 449 Is normally in the fresh air mode. Illuminates the indicator lamp when in the recircu- Rotary Temperature Control Knob lating mode. Actuates by cable. DAEWOO V–121 BL4...
Page 450 SECTION : 7B MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle.
Page 451 – Rear Compressor–to–Bracket Bolts – Suction Hose Connecting Block Retaining Nut – Suction Hose Support Clamp Retaining Bolt – Suction Hose Support Clamp Retaining Nut – Through–Bolts – Upper Condenser Mount Nuts – Vacuum Tank–to–Bulkhead Nuts – DAEWOO V–121 BL4...
Page 452 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B – 3 SPECIAL TOOLS SPECIAL TOOLS TABLE J–5403 J–8433–3 Snap Ring Pliers Forcing Screw J–6083 J–9398–A Snap Ring Pliers Bearing Remover J–8092 J–9481 Driver Handle Bearing Installer J–8433–1 J–9553–1 Puller Crossbar O–Ring Remover DAEWOO V–121 BL4...
Page 453 Assembly Installer J–33019 Bearing Staking Tool Set Includes: J–35372 J–33019–1 Support Block Bearing Staking Guide J–33019–2 Bearing Staking Pin J–33011 J–33020 O–Ring Installer Pulley Puller J–33013–B J–34614 Hub and Drive Plate Re- Shaft Seal Protector mover and Installer DAEWOO V–121 BL4...
Page 454 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B – 5 J–33022 J–33025 Shaft Nut Socket Clutch Coil Puller Legs J–34992 J–33023–A Compressor Holding Fix- Puller Pilot ture J–33024 J–33027 Clutch Coil Installer Clutch Hub Holding Tool Adapter DAEWOO V–121 BL4...
Page 455 7B – 6IMANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM SCHEMATIC AND ROUTING DIAGRAMS A/C SYSTEM – TYPICAL Compressor Receiver–Dryer Pressure Relief Valve Evaporator Condenser Expansion Valve DAEWOO V–121 BL4...
Page 456 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B – 7 AIRFLOW – TYPICAL Heater Outlets Outside Air Inlet Heater/Defroster Door Fresh Air/Recirculating Air Door Mode Door Inside Air Inlet Heater Core 10. Blower Evaporator (A/C Only) 11. Vent Outlets Expansion Valve 12. Defroster Outlets DAEWOO V–121 BL4...
Page 457 7B – 8IMANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM A/C SCHEMATIC DAEWOO V–121 BL4...
Page 458 Check for slippage of the compressor clutch. charge the system. Check the drive belt tension. If there is no leak, refer to ”Insufficient Cooling Diagnosis” in this section. INSUFFICIENT COOLING ”QUICK CHECK” PROCEDURE Perform the following ”hand–feel” procedure to get a quick DAEWOO V–121 BL4...
Page 459 15 59 1724 250 32 90 269 39 19 66 2137 310 21 70 207 30 2000 10 50 1379 200 27 81 248 36 17 63 1827 265 32 90 290 42 22 72 2275 330 DAEWOO V–121 BL4...
Page 460 CONDENSER RANGE: From 110 to 160³F, temperatures are not ambient. Add 19.4 to 22.2³C (35 to 40³F) for proper heat transfer, then refer to the pressure chart. Example: 32³C (90³F) ambient temperature + 22³C + (40³F) 54³C (130³F) Condenser temperature = 1379 kPa (200 psig) Based on 48.3 km/h (30 mph) air flow. DAEWOO V–121 BL4...
Page 461 Wait 1 to 2 minutes. Hold the probe tip within 6 mm (1/4 inch) of the sur- Probe the area in front of the pulley. If the detector face. emits a solid alarm, there is a leak. DAEWOO V–121 BL4...
Page 462 S The A/C to ON. S The fresh air control switch to fresh air (in- dicator lamp OFF). S The blower motor to 4. S The temperature control knob to full cold. Does the A/C compressor clutch engage? DAEWOO V–121 BL4...
Page 463 5. Repair the obstruction or replace the expansion valve, as needed. 6. Evacuate and recharge the A/C system. 7. Check the A/C system for leaks. 8. Note the discharge air temperature with the A/C ON. Is the discharge temperature normal? DAEWOO V–121 BL4...
Page 464 Go to Step 24 1. Turn the ignition to LOCK. 2. Make sure the compressor clutch is disen- gaged. 3. Attempt to turn the clutch driver (not the pulley). Can you turn the clutch driver freely by hand? DAEWOO V–121 BL4...
Page 465 Go to Step 13 1. Recover the A/C system refrigerant. 2. Replace the A/C compressor control valve. 3. Evacuate and recharge the A/C system. 4. Check the A/C system for leaks. Is the system free from leaks? DAEWOO V–121 BL4...
Page 466 The expansion valve is The expansion valve is clogged. Clean or replace the expan- frosted. sion valve. The receiver/drier outlet is The receiver/drier is clogged. Replace the receiver/drier. cool and the inlet is warm. DAEWOO V–121 BL4...
Page 467 There is leaking around a com- Tighten the bolt(s) or re- dirty. pressor housing bolt. place the compressor. The compressor gasket is The compressor gasket is leak- Repair or replace the com- wet with oil. ing. pressor. DAEWOO V–121 BL4...
Page 468 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B – 19 LOW AND HIGH SIDE PRESSURE RELATIONSHIP CHART DAEWOO V–121 BL4...
Page 469 SECTION : 9A BODY WIRING SYSTEM CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle.
Page 470 9A – 2IBODY WIRING SYSTEM POWER DISTRIBUTION SCHEMATIC DAEWOO V–121 BL4...
Page 471 BODY WIRING SYSTEM 9A – 3 DAEWOO V–121 BL4...
Page 472 9A – 4IBODY WIRING SYSTEM FUSE BLOCK LOCATOR (ENGINE) FUSE BLOCK LOCATOR (PASSENGER COMPARTMENT) DAEWOO V–121 BL4...
Page 473: Fuse Chart
Auto Door Lock EF29 Illumination Relay, Siren, Power Antenna, Luggage Compartment Lamp, Interi- or Courtesy Lamp, Head- lamp Relay EF30 EF12 Headlamp High LH EF31 EF12 Headlamp Low LH EF32 Electric Outside Rearview Mirror, Keyless Entry Sys- tem Unit DAEWOO V–121 BL4...
Page 474 Cluster. BTSI Solenoid SIR System Backup Switch Cruise Control, Immobilizer Radio, Key Interlock Sole- noid, Cigarette Lighter Instrument Cluster Engine Immobilizer Anti–Theft System Data Link Connector Ign 2 Relay, A/C Relay, De- fogger Relay, ABS Relay, ABS EBCM DAEWOO V–121 BL4...
Page 475 BODY WIRING SYSTEM 9A – 7 REAR HARNESS ROUTING DAEWOO V–121 BL4...
Page 476 9A – 8IBODY WIRING SYSTEM FRONT HARNESS ROUTING DAEWOO V–121 BL4...
Page 477 BODY WIRING SYSTEM 9A – 9 FLOOR HARNESS ROUTING DAEWOO V–121 BL4...
Page 478 9A – 10IBODY WIRING SYSTEM INSTRUMENT HARNESS ROUTING DAEWOO V–121 BL4...
Page 479 BODY WIRING SYSTEM 9A – 11 DOOR HARNESS ROUTING DAEWOO V–121 BL4...
Page 480 SECTION : 9B LIGHTING SYSTEMS CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS .
Page 481 Module Screws Door Jamb – Switch Screw Fog Lamp Nuts – Headlamp As- – sembly Bolts Headlamp As- – sembly Nut License Plate – Lamp Screws Lamp – Screws Rear Combina- – tion Lamp As- sembly Screws DAEWOO V–121 BL4...
Page 482 LIGHTING SYSTEMS 9B – 3 SCHEMATIC AND ROUTING DIAGRAMS HEADLAMPS–ON REMINDER CHIME CIRCUIT DAEWOO V–121 BL4...
Page 483 9B – 4ILIGHTING SYSTEMS PARKING, TAIL, POSITION AND LICENSE LAMPS CIRCUIT DAEWOO V–121 BL4...
Page 484 LIGHTING SYSTEMS 9B – 5 TURN AND HAZARD LAMPS CIRCUIT DAEWOO V–121 BL4...
Page 485 9B – 6ILIGHTING SYSTEMS BRAKE AND BACKUP LAMPS CIRCUIT DAEWOO V–121 BL4...
Page 486 LIGHTING SYSTEMS 9B – 7 INTERIOR COURTESY LAMP AND LUGGAGE COMPARTMENT LAMP CIRCUIT DAEWOO V–121 BL4...
Page 487 9B – 8ILIGHTING SYSTEMS HEADLAMPS CIRCUIT DAEWOO V–121 BL4...
Page 488 LIGHTING SYSTEMS 9B – 9 DAYTIME RUNNING LAMPS CIRCUIT DAEWOO V–121 BL4...
Page 489 9B – 10ILIGHTING SYSTEMS FOG LAMPS CIRCUIT DAEWOO V–121 BL4...
Page 490 1. Remove the driver door–open switch. 2. Use an ohmmeter to check the resistance be- tween terminal 4 of the chime module connec- tor and terminal 1 of the driver door–open switch. Does the ohmmeter show the specified value? DAEWOO V–121 BL4...
Page 491 1. Disconnect the headlamp combination switch connector C1. 2. Select the low beams. 3. Use an ohmmeter to check the continuity be- tween terminals 6 and 5 of the headlamp com- bination switch. Does the ohmmeter indicate the value specified? DAEWOO V–121 BL4...
Page 492 Is the repair complete? Repair the open circuit between headlamp combina- System OK tion switch connector C1 (terminal 4) and fuse EF30 or EF25. Is the repair complete? High–Beam and Low–Beam Headlamps Are Inoperative On Both Left and Right Sides DAEWOO V–121 BL4...
Page 493 1. Return the illumination relay to its original posi- tion, but do not install the headlamp relay. 2. Use a voltmeter to check the headlamp relay connector for terminal 30. Does the voltmeter indicate the value specified? DAEWOO V–121 BL4...
Page 494 The daytime running lamp (DRL) system will not work if the parking brake is applied. The system is designed to work only when the engine is running and the parking brake is released. If the parking brake circuit is shorted to ground or the switch stays closed when the engine is running, the DRL system will not work. DAEWOO V–121 BL4...
Page 495 Go to Step 17 Go to Step 16 S With the DRL module disconnected, turn the ignition ON. S Check the voltage at terminal F of the DRL module. Is the voltage equal to the specified value? DAEWOO V–121 BL4...
Page 496 LIGHTING SYSTEMS 9B – 17 Step Action Value(s) Repair the open circuit between fuse F3 and termi- System OK nal F of the DRL module. Is the repair complete? Replace the DRL module. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 497: Fog Lamps
3. Turn the fog lamps. Do the front fog lamps work with the substituted relay? System OK 1. Return the substituted relay to its original posi- tion. 2. Replace the front fog lamp relay. Is the repair complete? DAEWOO V–121 BL4...
Page 498: Rear Combination Lamps
Repair the ground circuit for the front fog lamp relay. System OK Is the repair complete? Repair the open circuit between the front fog lamp System OK relay and the front fog lamps. Is the repair complete? REAR COMBINATION LAMPS Exterior Illumination Lamps Do Not Work DAEWOO V–121 BL4...
Page 499 11–14 v Go to Step 16 Go to Step 12 1. Reinstall the illumination relay. 2. Turn the illumination lamps ON. 3. Check the voltage at EF20 and EF21. Is the voltage equal to the specified value? DAEWOO V–121 BL4...
Page 500 Is the resistance equal to the specified value? Repair the open circuit between headlamp switch System OK connector C2 terminal 3 and ground. Is the repair complete? Replace the headlamp switch. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 501 Does the voltmeter show the specified value? Repair the open circuit between the fuse EF24 and System OK the stoplamp switch. Is the repair complete? Repair the open circuit between the stoplamp switch System OK and the stoplamps. Is the repair complete? DAEWOO V–121 BL4...
Page 502 Repair the open circuit between ground and the BLK System OK wire in the CHMSL connector. Is the repair complete? Repair the open circuit between the stoplamp switch System OK and the CHMSL. Is the repair complete? DAEWOO V–121 BL4...
Page 503 System OK up switch in automatic transaxle vehicles). Is the repair complete? Repair the ground circuit between the REVERSE System OK switch (neutral safety/backup switch if equipped with A/T) and the backup lamps. Is the repair complete? DAEWOO V–121 BL4...
Page 504 Go to Step 15 1. Disconnect the hazard switch connector. 2. Check for voltage at terminal 8. 3. Turn the ignition ON. 4. Check for voltage at terminal 10. Does the voltage available at both terminals equal the specified value? DAEWOO V–121 BL4...
Page 505 Go to Step 22 between the hazard switch terminal 6 and C204 ter- minal 11. Does the ohmmeter show the specified value? Repair the open circuit between C204 and the turn System OK signal bulbs. Is the repair complete? DAEWOO V–121 BL4...
Page 506 Is the repair complete? Repair the open circuit between the hazard lamp System OK switch connector terminal H and fuse EF12. Is the repair complete? Replace the faulty hazard lamp switch. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 507 (harness side). Is the resistance equal to the specified value? Replace the interior courtesy lamp switch assembly. System OK Is the repair complete? Repair the ground circuit for the interior courtesy System OK lamp. Is the repair complete? DAEWOO V–121 BL4...
Page 508 Use an ohmmeter to check the resistance between Go to Step 12 Go to Step 13 ground and the BLK wire at the luggage compart- ment (tailgate) lamp switch connector (harness side). Is the resistance equal to the specified value? DAEWOO V–121 BL4...
Page 509 9B – 30ILIGHTING SYSTEMS Step Action Value(s) Replace the luggage compartment lamp (tailgate) System OK switch. Is the repair complete? Repair the ground circuit for the interior courtesy System OK lamp. Is the voltage equal to the specified value? DAEWOO V–121 BL4...
Page 510 SECTION : 9C HORNS CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS .
Page 511 9C – 2IHORNS SCHEMATIC AND ROUTING DIAGRAMS HORN WIRING SYSTEM DAEWOO V–121 BL4...
Page 512 Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasten- ers to prevent premature corrosion. Install the horn with the bolt. Tighten Tighten the horn bolt to 22 NSm (16 lb–ft) DAEWOO V–121 BL4...
Page 513 9C – 4IHORNS Connect the electrical connector. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 514 AND SYSTEM OPERATION HORNS The horns are located under the hood. They are attached near the radiator at the front of the vehicle. The horns are actuated by pressing the steering wheel pad, which grounds the horns’ electrical circuit. DAEWOO V–121 BL4...
Page 515: Table Of Contents
SECTION : 9D WIPERS/WASHER SYSTEMS CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS .
Page 516 9D – 2IWIPERS/WASHER SYSTEMS SCHEMATIC AND ROUTING DIAGRAMS WIPERS AND WASHER SYSTEM (NOTCHBACK) DAEWOO V–121 BL4...
Page 517 WIPERS/WASHER SYSTEMS 9D – 3 WIPERS AND WASHER SYSTEM (HATCHBACK) DAEWOO V–121 BL4...
Page 518: Windshield Wipers
A8 and A9. Does the ohmmeter indicate the specified value? Replace the wiper switch. System OK Is the repair complete? Repair the open circuit between the wiper switch and System OK the wiper motor. Is the repair complete? DAEWOO V–121 BL4...
Page 519 Does the ohmmeter indicate the specified value? Replace the wiper switch. System OK Is the repair complete? Repair the open circuit between wiper switch con- System OK nector terminal A5 and wiper motor connector termi- nal 3. Is the repair complete? DAEWOO V–121 BL4...
Page 520 Does the voltmeter indicate a pulsating voltage equal to the specified value? Replace the wiper relay. System OK Is the repair complete? Repair the open circuit between the wiper switch and System OK the wiper relay. Is the repair complete? DAEWOO V–121 BL4...
Page 521 31b and 53e. Does the ohmmeter indicate the specified value? Repair the open circuit between the wiper motor and System OK the wiper relay. Is the repair complete? Replace the wiper relay. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 522: Windshield Washer System
1. Is the resistance equal to the specified value? Repair the windshield washer pump ground circuit. System OK Is the repair complete? Replace the windshield washer pump. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 523 3. Check the voltage at wiper switch connector terminal A3 (PNK wire). Does the voltmeter indicate the specified value? Repair the open circuit between fuse F4 and rear System OK window wiper switch connector terminal A3. Is the repair complete? DAEWOO V–121 BL4...
Page 524 Repair the open circuit between terminal A1 of the System OK rear window wiper connector (WHT wire) and the rear window wiper motor. Is the repair complete? Replace the rear window wiper switch. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 525 GRN wire) of the rear window wiper switch connec- tor and terminal 2 (DK GRN wire) of the rear window washer pump. Is the repair complete? Replace the rear window wiper switch. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 526: Windshield Wiper Arm
Disconnect the negative battery cable. Remove the left–side portion of the cowl vent grille. Refer to Section 9R, Body Front End. Remove the nut and the washer that secure the wiper arm linkage to the motor drive shaft. DAEWOO V–121 BL4...
Page 527 Tighten Tighten the wiper arm linkage nut to 5 NSm (44 lb–in). Install the left side portion of the cowl vent grille. Refer toSection 9R, Body Front End. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 528: Windshield Wiper Blade
Installation Procedure Install the wiper blade by sliding it onto the arm until the retainer clip engages. WINDSHIELD WIPER BLADE INSERT (Front Shown, Rear Similar) Removal Procedure Slide the insert out of the wiper blade. DAEWOO V–121 BL4...
Page 529: Windshield Washer Reservoir
Remove the front left wheel. Refer to Section 2E, Tires and Wheels. Remove the bolts and the screws and the front wheel well splash shield. Disconnect the washer hose from the washer pump. Disconnect the reservoir pump electrical connector. DAEWOO V–121 BL4...
Page 530 Install the reservoir with the bolts. Tighten Tighten the washer fluid reservoir bolts to 8 NSm (71 lb–in). Connect the reservoir pump electrical connector. Connect the washer hose to the washer pump. DAEWOO V–121 BL4...
Page 531: Windshield Washer Pump(S)
Install the front wheel well splash shield with the bolts and the screws. Tighten Tighten the front wheel well splash shield bolts to 1.5 NSm (13 lb–in). Install the front left wheel. Refer to Section 2E, Tires and Wheels. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 532: Windshield Washer Nozzles
Install the cowl vent grille. Refer to Section 9R, Body Front End. WINDSHIELD WASHER HOSES (Typical) Removal Procedure Remove the cowl vent grille. Refer to Section 9R, Body Front End. Disconnect the windshield washer hose from the washer nozzles. DAEWOO V–121 BL4...
Page 533 Tighten the front wheel well splash shield bolts to 1.5 NSm (13 lb–in). Remove the front left wheel. Refer to Section 2E, Tires and Wheels. Connect the windshield washer hose to the washer nozzles. Install the cowl vent grille. Refer to Section 9R, Body Front End. DAEWOO V–121 BL4...
Page 534: Rear Window Wiper Arm
Remove the rear window wiper arm. Refer to ”Rear Window Wiper Arm” in this section. Remove the hatchback door lower garnish molding. Refer to Section 9G, Interior Trim. Remove the bolts and the rear wiper motor. Disconnect the electrical connector. DAEWOO V–121 BL4...
Page 535 Window Wiper Arm” in this section. Remove the wiper motor exterior retaining clip and nut from the tailgate. Remove the tailgate lower garnish molding. Disconnect the electrical connector and the washer hose. Remove the bolts and the rear wiper motor. DAEWOO V–121 BL4...
Page 536 Connect the negative battery cable. REAR WINDOW WASHER NOZZLE (HATCHBACK) Removal Procedure Remove the hatchback door upper garnish molding. Refer to Section 9G, Interior Trim. Remove the washer hose from the nozzle. Remove the nut and the washer nozzle. DAEWOO V–121 BL4...
Page 537 WIPERS/WASHER SYSTEMS 9D – 23 Installation Procedure Install the washer nozzle with the nut. Install the washer hose to the nozzle. Install the hatchback door upper garnish molding. Refer toSection 9G, Interior Trim. DAEWOO V–121 BL4...
Page 538: Windshield Wiper System
Attached to the reservoir is a washer pump, which pumps fluid through a hose to the WINDSHIELD WASHER SYSTEM rear washer nozzle. The windshield washer system is equipped with a washer DAEWOO V–121 BL4...
Page 539: Cigar Lighter
Remove the screws and the audio system trim plate. Disconnect the cigar lighter and ashtray lamp elec- trical connectors. Remove the cigar lighter from the cigar lighter housing. Remove the cigar lighter housing from the ashtray housing. DAEWOO V–121 BL4...
Page 540 Install the ashtray housing with the screw. Tighten Tighten the ashtray housing screw to 2.5 NSm (22 lbin). Install the audio system trim plate with the screws. Install glove box, driver/passenger knee bolster with the screws. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 541 Remove the screws and the audio system trim plate. Disconnect the ashtray electrical connector. Installation Procedure Connect the ashtray electrical connector. Install the screw and the ashtray housing. Tighten Tighten the ashtray housing screw to 2.5 NSm (22 lbin). DAEWOO V–121 BL4...
Page 542: Cup Holder
Connect the negative battery cable. CUP HOLDER Removal Procedure Remove the screws and the glove box. Remove the screw and driver/passenger knee bol- ster. Remove the screws and the cup holder from the audio system trim plate. DAEWOO V–121 BL4...
Page 543: Glove Box
Install the audio system trim plate with the screws. Install glove box, driver/passenger knee bolster with the screws. GLOVE BOX Removal Procedure Remove the screws at the base of the glove box. Open and remove the glove box. DAEWOO V–121 BL4...
Page 544: Digital Clock
Disconnect the electrical connector. Installation Procedure Connect the electrical connector. Install the digital clock with the screws. Tighten Tighten the digital clock screws to 4 NSm (35 lb–in). Install the cluster housing. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 545: Instrument Cluster
Tighten the instrument cluster screws to 4 NSm (35 lb–in). Connect the negative battery cable. SPEEDOMETER/ODOMETER/TRIP ODOMETER Removal Procedure Disconnect the negative battery cable. Remove the instrument cluster. Refer to ”Instru- ment Cluster” in this section. Push the locking and remove the instrument cluster lens. DAEWOO V–121 BL4...
Page 546 9E – 30IINSTRUMENT/DRIVER INFORMATION Remove the screws and the fuel gauge. Remove the screws and the speedometer/odome- ter from the instrument cluster. DAEWOO V–121 BL4...
Page 547 Install the fuel gauge with the screws. Tighten Tighten the fuel gauge screws to 2.5 NSm (22 lb–in). Install the instrument cluster lens with the screws. Install the instrument cluster. Refer to ”Instrument Cluster” in this section. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 548 Remove the screws and the instrument cluster lens. Remove the screws and the tachometer from the instrument cluster. Installation Procedure Install the tachometer to the instrument cluster with the screws. Tighten Tighten the tachometer screws to 2.5 NSm (22 lb–in). DAEWOO V–121 BL4...
Page 549: Fuel Gauge
FUEL GAUGE Removal Procedure Disconnect the negative battery cable. Remove the instrument cluster. Refer to”Instrument Cluster” in this section. Remove the instrument cluster lens. Remove the fuel gauge screws and the fuel gauge from the cluster assembly. DAEWOO V–121 BL4...
Page 550: Temperature Gauge
Connect the negative battery cable. TEMPERATURE GAUGE Removal Procedure Disconnect the negative battery cable. Remove the instrument cluster. Refer to ”Instru- ment Cluster” in this section. Remove the instrument cluster lens screws and the instrument cluster lens. DAEWOO V–121 BL4...
Page 551 Tighten Tighten the temperature gauge screws to 2.5 NSm (22 lb–in). Install the instrument cluster lens. Install the instrument cluster. Refer to ”Instrument Cluster” in this section. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 552: Instrument Cluster Indicator Lamps
Cluster” in this section Connect the negative battery cable. CHIME MODULE Removal Procedure Disconnect the negative battery cable. Remove the knee bolster trim panel beneath the steering column. Disconnect the electrical connector. Remove the screws and the chime module. DAEWOO V–121 BL4...
Page 553: Instrument Panel
Disconnect the sun sensor electrical connector. Remove the nuts and the bolts that secure the steering column. 10. Lower the steering column. 11. Remove the screw that secures the instrument pan- el to the heater air distributor case. DAEWOO V–121 BL4...
Page 554 9E – 38IINSTRUMENT/DRIVER INFORMATION 12. Remove the bolts that secure the instrument panel to the pedal assembly. 13. Remove the nuts that secure the back of the instru- ment panel to the bulkhead. DAEWOO V–121 BL4...
Page 555 Make sure to use the correct fasten- ers to prevent premature corrosion. Install the nuts securing the back of the instrument panel to the bulkhead. Tighten Tighten the instrument panel–to–bulkhead nuts to 10 NSm (89 lb–in). DAEWOO V–121 BL4...
Page 556 Tighten Tighten the instrument panel–to–body bolts to 22 NSm (16 lb–ft). Install the bolts securing the bottom of the instru- ment panel to the floor. Tighten Tighten the instrument panel–to–floor bolts to 22 NSm (16 lb–ft). DAEWOO V–121 BL4...
Page 557 Connect the steering column electrical connectors. 10. Install the nuts and the bolts securing the steering column. Tighten Tighten the steering column nuts to 22 NSm (16 lb–ft). Tighten the steering column bolts to 22 NSm (16 lb–ft). DAEWOO V–121 BL4...
Page 558: Table Of Contents
14. Remove the HVAC controls. Refer toSection 7A, Heating and Ventilation System. 15. Install the audio system. Refer toSection 9F, Audio Systems. 16. Install the floor console. Refer toSection 9G, Interi- or Trim. 17. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 559: Trip Odometer
Voltage is supplied at all times through the fuse block to The trip odometer measures the distance the vehicle has power the chime module. traveled since it was last reset. It consists of an instrument cluster gauge connected to the sending unit on the trans- DAEWOO V–121 BL4...
Page 560 SECTION : 9F AUDIO SYSTEMS CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS .
Page 561 9F – 2IAUDIO SYSTEMS SCHEMATIC AND ROUTING DIAGRAMS AUDIO SYSTEM CIRCUIT DAEWOO V–121 BL4...
Page 562 Go to Step 3 cassette player performs poorly or is inoperative. Does the cassette player perform poorly? Check the cassette player for obstructions behind Go to Step 4 Go to Step 8 the tape door. Is an obstruction found? DAEWOO V–121 BL4...
Page 563 4. Check the FM radio reception. Is the FM radio operating properly? Replace the antenna cable between the radio and System OK the antenna. Is the repair complete? Replace the radio. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 564 Is the repair complete? Go to Step 6 Go to Step 5 1. Disconnect the rear speakers. 2. Using an ohmmeter, test the speaker wires for a short to ground. Does the ohmmeter show the specified value? DAEWOO V–121 BL4...
Page 565 11–14 v Go to Step 12 Go to Step 13 1. Turn the ignition ON. 2. Turn the radio ON. 3. Use a voltmeter to test for battery voltage at radio terminal 12. Is the repair complete? DAEWOO V–121 BL4...
Page 566 AUDIO SYSTEMS 9F – 7 Step Action Value(s) Repair the open circuit between radio terminal 12 System OK and power antenna connector terminal 3. Is the repair complete? Replace the audio system. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 567 Remove the audio system bolts and the audio sys- tem. Disconnect the audio system electrical connector and the antenna cable. Installation Procedure Connect the audio system electrical connector and the antenna cable. DAEWOO V–121 BL4...
Page 568 Install the front door speaker with the screws. Tighten Tighten the front door speaker screws to 4 NSm (35 lb–in). Install the front door trim panel. Refer to section 9G, Interior Trim. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 569 Refer to Section 9H, Seats. Remove the right side C–pillar trim panel and the deck lid sill plate trim cover. Refer to section 9G, Interior Trim. Disconnect the electrical connector. Remove the screws and the rear speakers. DAEWOO V–121 BL4...
Page 570 Make sure to use the correct fasten- ers to prevent premature corrosion. Install the rear speaker with the screws. Tighten Tighten the rear speaker screws to 4 NSm (35 lb–in). Install the rear speaker access cover. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 571 Install the rubber grommet and the antenna cap nut. Tighten Tighten the antenna cap nut to 7 NSm (62 lb–in). Install the mast antenna. Install the luggage compartment rear quarter trim panel. Refer toSection 9G, Interior Trim. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 572: Roof Antenna
Install the formed headliner. Refer to Section 9Q, Roof. Connect the negative battery cable. POWER ANTENNA MAST(NOTCHBACK) Removal Procedure Remove the antenna cap nut and the rubber grom- met. Turn on the radio and remove the antenna mast and cable. Turn off the radio. DAEWOO V–121 BL4...
Page 573 Refer toSection 9G, Interior Trim. Remove the antenna cap nut and the rubber grom- met. Loosen the nuts securing the antenna motor to the vehicle. Remove the antenna motor. Disconnect the electrical connector and the drain hose from the antenna motor. DAEWOO V–121 BL4...
Page 574 Tighten the antenna cap nut to 7 NSm (62 lb–in). Connect the negative battery cable. COMPACT DISC CHANGER Removal Procedure Disconnect the negative battery cable. Disconnect the CD changer electrical connector. Remove the nuts and the CD changer. DAEWOO V–121 BL4...
Page 575 9F – 16IAUDIO SYSTEMS Installation Procedure Install the CD changer with the nuts. Tighten Tighten the CD changer nuts to 7 NSm (62 lb–in). Connect the CD changer electrical connector. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 576: Audio Systems
A coaxial two–way rear speaker is offered as an option. DAEWOO V–121 BL4...
Page 577 SECTION : 9M EXTERIOR TRIM TABLE OF CONTENTS SPECIFICATIONS ......9M–1 ROOF MOLDING ......9M–3 FASTENER TIGHTENING SPECIFICATIONS 9M–1...
Page 578 Tighten the B–pillar molding screws to 4 NSm (35 lbin). Install the weatherstrip to its original position. QUARTER WINDOW MOLDING (WAGON) Removal Procedure Open the rear passenger door. Remove the screws and the quarter window mold- ing. DAEWOO V–121 BL4...
Page 579 Tighten the quarter window molding screws to 4 NSm (35 lb–in). Close the rear passenger door. ROOF MOLDING Removal Procedure Remove the roof molding from the metal clips. Installation Procedure Press the roof molding onto the clips. DAEWOO V–121 BL4...
Page 580 Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasten- ers to prevent premature corrosion. Install the mud guard with the bolts. Tighten Tighten the mud guard bolts to 1.5 NSm (13 lb–in). DAEWOO V–121 BL4...
Page 581 The emblems and lettering on the vehicle are attached by adhesive. The company emblem appears on the hood. The lettering, which appears in several places on the body of the vehicle, features the model, the grade, and the com- pany name. DAEWOO V–121 BL4...
Page 582 SECTION : 9N FRAME AND UNDERBODY TABLE OF CONTENTS SPECIFICATIONS ......9N–1 ENGINE UNDER COVER .
Page 583 Any insulator service repair or replacement should be the same thickness, size, and location as the original installa- tion in the vehicle. DAEWOO V–121 BL4...
Page 584 Tighten Tighten the engine under cover nuts to 2 NSm (18 lbin). Install the front fascia splash shield with the screws. Tighten Tighten the front fascia splash shield screw to 1.5 NSm (13 lb–in). Lower the vehicle. DAEWOO V–121 BL4...
Page 585 9N – 4IFRAME AND UNDERBODY Install the front fascia splash shield with the screws. Tighten Tighten the front fascia splash shield screw to 1.5 NSm (13 lb–in). Lower the vehicle. DAEWOO V–121 BL4...
Page 586 DAEWOO V–121 BL4...
Page 587 SECTION : 9O BUMPERS AND FASCIAS CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle.
Page 588 Remove the fog lamps (if equipped). Refer to Sec- tion 9B, Lighting Systems. Remove the headlamps. Refer to Section 9B, Light- ing Systems. Remove the front wheel well fascia bolts. Remove the fender–to–fascia bolts.n. DAEWOO V–121 BL4...
Page 589 BUMPERS AND FASCIAS 9O – 3 Remove the front fascia screws behind the fascia. Remove lower fascia screws. 10. Remove the upper fascia screws. 11. Remove the front bumper fascia. DAEWOO V–121 BL4...
Page 590 Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasten- ers to prevent premature corrosion. Install the upper fascia screws. Install the lower fascia screws. Install the front fascia nuts. DAEWOO V–121 BL4...
Page 591 9B, Lighting Systems. Reposition the front portion of the splash shields and install the bolts and the screws. Tighten Tighten the front wheel well splash shield bolts to 1.5 NSm (13 lb–in). 10. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 592 FRONT BUMPER IMPACT BAR Removal Procedure Remove the front bumper fascia. Refer to”Front Bumper Fascia” in this section. Remove the front bumper energy absorber. Refer to”Front Bumper Energy Absorber” in this section. Remove the front bumper impact bar nuts. DAEWOO V–121 BL4...
Page 593 Tighten the front impact bar nuts to 30 NSm (22 lb–ft). Install the front bumper energy absorber. Refer to”Front Bumper Energy Absorber” in this section. Install the front bumper fascia. Refer to”Front Bumper Fascia” in this section. DAEWOO V–121 BL4...
Page 594 Remove the bolts and the screws and the rear wheel well splash shields. Remove the fascia bolts at the top of the rear wheel wells. Remove the taillamps. Refer to Section 9B, Lighting Systems. Remove the upper fascia screws. DAEWOO V–121 BL4...
Page 595 Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasten- ers to prevent premature corrosion. Install the luggage compartment fascia bolts. Tighten Tighten the luggage compartment fascia bolts to 8 NSm (71 lb–in). DAEWOO V–121 BL4...
Page 596 Install the lower fascia screws. Install the upper fascia screws. Install the taillamps. Refer to Section 9B, Lighting Systems. Install the rear wheel well fascia bolts. Tighten Tighten the rear wheel well fascia bolts to 1.5 NSm (13 lb–in). DAEWOO V–121 BL4...
Page 597 Removal Procedure Remove the rear bumper fascia. Refer to”Rear Bumper Fascia” in this section. Remove the energy absorber. Installation Procedure Install the energy absorber. Install the rear bumper fascia. Refer to”Rear Bump- er Fascia” in this section. DAEWOO V–121 BL4...
Page 598 Install the rear fascia brackets to the impact bar with the screws. Install the impact bar brackets to the impact bar with the nuts. Tighten Tighten the rear impact bar bracket nuts to 30 NSm (22 lb–ft). DAEWOO V–121 BL4...
Page 599 Install the rear impact bar to the vehicle with the bolts. Install the rear bumper energy absorber. Refer to”Rear Bumper Energy Absorber” in this section. Install the rear bumper fascia. Refer to”Rear Bump- er Fascia” in this section. DAEWOO V–121 BL4...
Page 600 The bumper systems are designed to sustain a collision separately. into a fixed barrier at either 8 km/h (5 mph) or 4 km/h (2.5 mph) without damage. After absorbing the energy of a col- DAEWOO V–121 BL4...
Page 601: Table Of Contents
SECTION : 9P DOORS CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS .
Page 602 9P – 2IDOORS Application Lb–Ft Lb–In Front and Rear Door Lock – Screws Inside Door Handle Screw – Outside Door Handle Bolts – Rear Door Exterior Garnish – Molding Screws Window Regulator Nuts – DAEWOO V–121 BL4...
Page 603 DOORS 9P – 3 SCHEMATIC AND ROUTING DIAGRAMS POWER DOOR LOCKS DAEWOO V–121 BL4...
Page 604: Power Windows ((Front And Rear)
9P – 4IDOORS POWER WINDOWS ((FRONT AND REAR)) DAEWOO V–121 BL4...
Page 605: Power Door Locks
5 (BRN) and the grounded jumper is connected to terminal 3 (GRY). Do the doors lock and unlock when power and ground are applied to terminals 3 and 5 of the door lock relay connector ? DAEWOO V–121 BL4...
Page 606 Use an ohmmeter to check the continuity between Go toStep 21 Go toStep 20 terminal C (WHT) of the disconnected central lock switch connector and terminal 8 (WHT) of the door lock relay connector. Is the continuity equal to the specified value ? DAEWOO V–121 BL4...
Page 607: Power Windows (Front And Rear)
Does the window move up when the motor is pow- ered directly by the battery, and down when the jumper connections are reversed ? Replace the window motor. System OK Is the repair complete DAEWOO V–121 BL4...
Page 608 Is the repair complete ? [ 0 W Repair the open circuit between the window switch Go toStep 21 Go toStep 20 and the driver's side power window switch. Is the continuity equal to the specified value ? DAEWOO V–121 BL4...
Page 609: Front Door Glass Run
Install the outside rearview mirror. Refer to Section 9L, Glass and Mirrors. REAR DOOR GLASS RUN Removal Procedure Remove the rear door glass. Refer to Section 9L, Glass and Mirrors. Remove the interior garnish molding. Remove the screws and the exterior garnish mold- ing. DAEWOO V–121 BL4...
Page 610 Install the exterior garnish molding with the screws. Tighten Tighten the rear door exterior garnish molding screws to 1.5 NSm (13 lb–in). Install the interior garnish molding. Install the rear door glass. Refer to Section 9L, Glass and Mirrors. DAEWOO V–121 BL4...
Page 611 Install the front door secondary weatherstrip. Install the outside rearview mirror. Refer to Section 9L, Glass and Mirrors. REAR DOOR SECONDARY WEATHERSTRIP Removal Procedure Remove the interior garnish molding. Remove the screws and the exterior garnish mold- ing. DAEWOO V–121 BL4...
Page 612 Install the exterior garnish molding with the screws. Tighten Tighten the rear door exterior garnish molding screws to 1.5 NSm (13 lb–in). Install the interior garnish molding. DOOR LOCK STRIKER Removal Procedure Remove the screws and the door lock striker. DAEWOO V–121 BL4...
Page 613: Door Lock Striker Adjustment
Do not use a replacement part of lesser quality or of a substitute design. The specified torque values must be used during reassembly in order to ensure the proper retention of the part. DAEWOO V–121 BL4...
Page 614: Front Door Lock
Tighten the door lock striker screws to 10 NSm (89 lb– in). FRONT DOOR LOCK Removal Procedure Disconnect the negative battery cable. Remove the seal trim. Refer to”Door Seal Trim” in this section. Disconnect the inside door handle and the lock rods. DAEWOO V–121 BL4...
Page 615 DOORS 9P – 15 Disconnect the outside door handle and the lock rods. Remove the screws and the front door lock. Disconnect the electrical connector. DAEWOO V–121 BL4...
Page 616 Install the front door lock with the screws. Tighten Tighten the front door lock screws to 10 NSm (89 lbin). Install the seal trim. Refer to”Door Seal Trim” in this section. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 617 Disconnect the inside door handle and the lock rods. Disconnect the outside door handle and the lock rods. Remove the screw and the guide rail. Disconnect the electrical connector. Disconnect the electrical connector. Disconnect the lock rods at the lock. DAEWOO V–121 BL4...
Page 618 Install the guide rail with the screw. Connect the outside door handle and the lock rods. Connect the inside door handle and the lock rods. Install the door seal trim. Refer to”Door Seal Trim” in this section. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 619: Inside Door Handle
Install the door seal trim. Refer to”Door Seal Trim” in this section. INSIDE LOCK ROD Removal Procedure Remove the door seal trim. Refer to”Door Seal Trim” in this section. Disconnect the inside lock rods from the door han- dle and the lock. DAEWOO V–121 BL4...
Page 620: Outside Door Handle
Make sure to use the correct fasten- ers to prevent premature corrosion. Install the door handle with the bolts. Tighten Tighten the outside door handle bolts to 4 NSm (35 lbin). Install the door seal trim. Refer to”Door Seal Trim” in this section. DAEWOO V–121 BL4...
Page 621: Door Lock Cylinder
Install the door seal trim. Refer to”Door Seal Trim” in this section. POWER FRONT WINDOW REGULATOR Removal Procedure Disconnect the negative battery cable. Remove the front door glass. Refer to Section 9L, Glass and Mirrors. Disconnect the electrical connector. DAEWOO V–121 BL4...
Page 622 Install the window regulator with the nuts. Tighten Tighten the window regulator nuts to 8 NSm (71 lb–in). Connect the electrical connector. Install the front door glass. Refer to Section 9L, Glass and Mirrors. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 623: Power Rear Window Regulator
Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasten- ers to prevent premature corrosion. Install the window regulator with the nuts. Tighten Tighten the window regulator nuts to 8 NSm (71 lb–in). DAEWOO V–121 BL4...
Page 624: Manual Rear Window Regulator
Install the window regulator with the nuts. Tighten Tighten the window regulator nuts to 8 NSm (71 lb–in). Install the rear door glass. Refer to Section 9L, Glass and Mirrors. Install the regulator handle. Refer to”Manual Rear Window Regulator Handle” in this section. DAEWOO V–121 BL4...
Page 625: Front Door Assembly
FRONT DOOR ASSEMBLY Removal Procedure Disconnect the negative battery cable. Remove the bolt and the door hold open link from the body. With the aid of another technician, remove the door hinge bolts and the front door. DAEWOO V–121 BL4...
Page 626 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). Connect the negative battery cable. Perform the waterleak test. Refer toSection 9I, Wa- terleaks. Check for windnoise. Refer toSection 9J, Wind- noise. DAEWOO V–121 BL4...
Page 627: Rear Door Assembly
Disconnect the negative battery cable. Remove the bolt and the door hold open link from the body. With the aid of another technician, remove the door hinge bolts and the rear door. Disconnect the body–to–door rubber grommet and the electrical connector. DAEWOO V–121 BL4...
Page 628 Tighten Tighten the door hold open link–to–body bolt to 27 NSm (20 lb–ft). Connect the negative battery cable. Perform the waterleak test. Refer to Section 9I, Waterleaks. Check for windnoise. Refer to Section 9J, Wind- noise. DAEWOO V–121 BL4...
Page 629: Door Hinge
DOOR HOLD OPEN LINK Removal Procedure Remove the door trim panel. Refer toSection 9G, Interior Trim. Reposition the door seal trim. Remove the bolts on the door and on the body. Remove the door hold open link. DAEWOO V–121 BL4...
Page 630: Inside Channel Molding
Installation Procedure Install the channel molding onto the door trim panel. Bend the retaining tabs to secure the channel mold- ing to the door trim panel. Install the door trim panel. Refer to Section 9G, In- terior Trim. DAEWOO V–121 BL4...
Page 631: Outside Channel Molding
Lower the window completely. Lift the outside channel molding off the door. Installation Procedure Press the outside channel molding onto the door. Raise the window. DOOR WEATHERSTRIP Removal Procedure Lower the window completely. Remove the door weatherstrip. DAEWOO V–121 BL4...
Page 632: Door Seal Trim
Removal Procedure Remove the door trim panel. Refer to Section 9G, Interior Trim. Remove the screws and the door pull bracket. Remove the inside door handle. Refer to”Inside Door Handle” in this section. Remove the door seal trim. DAEWOO V–121 BL4...
Page 633: Front Door Opening Weatherstrip
Install the door trim panel. Refer to Section 9G, In- terior Trim. FRONT DOOR OPENING WEATHERSTRIP Removal Procedure Remove the kick panel, the front rocker panel, and the lower B–pillar trim panel. Refer to Section 9G, Interior Trim. Remove the door opening weatherstrip. DAEWOO V–121 BL4...
Page 634: Rear Door Opening Weatherstrip
Refer to Section 9G, Interior Trim. Remove the door opening weatherstrip. Installation Procedure Install the door opening weatherstrip. Instal the rear rocker panel and the lower B–pillar trim panel. Refer to Section 9G, Interior Trim. DAEWOO V–121 BL4...
Page 635: Power Windows
Move the lever to the unlock position. The rear door will now work normally. DAEWOO V–121 BL4...
Page 636 SECTION : 9Q ROOF CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS .
Page 637 9Q – 2IROOF SCHEMATIC AND ROUTING DIAGRAMS POWER SUNROOF SYSTEM DAEWOO V–121 BL4...
Page 638: Power Sunroof
2. Disconnect the sunroof module six–pin electri- cal connector. 3. Use an ohmmeter to measure the resistance between the terminal 4 and ground. Is the resistance within the specified value? Repair the ground circuit. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 639 Does the voltmeter indicate the specified value when the switch is in either the OPEN or the CLOSE position? Replace the sunroof module. System OK Is the repair complete? Replace the sunroof motor. System OK Go to Step 17 Is the repair complete? DAEWOO V–121 BL4...
Page 640 Remove the headliner. Refer to”Formed Headliner” in this section. Remove the drain hoses. Disconnect the electrical connectors. Remove the screws and the motor. Remove the motor control module. Remove the bolts and the housing from the ve- hicle.V DAEWOO V–121 BL4...
Page 641 Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasten- ers to prevent premature corrosion. Install the glass to the frame with the screws. Tighten Tighten the sunroof glass screws to 7 NSm (62 lb–in). DAEWOO V–121 BL4...
Page 642 Tighten the sunroof housing bolts to 7 NSm (62 lb–in). 10. Install the motor control module. 11. Install the motor with the screws. Tighten Tighten the sunroof motor screws to 5 NSm (44 lb–in). 12. Connect the electrical connectors. DAEWOO V–121 BL4...
Page 643 Make sure to use the correct fasten- ers to prevent premature corrosion. Install the roof rack with the nuts. Tighten Tighten the roof rack nuts to 27 NSm (20 lb–ft). Install the headliner. Refer to”Formed Headliner” in this section. DAEWOO V–121 BL4...
Page 644 10. Remove the bolts and the seat belt anchors from the left and the right B–pillars. 11. Disconnect the top of the left and the right B–pillar trim panels. 12. Remove the bolts and the rear seat belt anchors from the left and the right C–pillars. DAEWOO V–121 BL4...
Page 645 Installation Procedure Recline both front seats. Insert the headliner through a rear door or the hatchback door. Install the headliner behind the trim panels and the seals around the doors. Install the plastic retainers along the rear window. DAEWOO V–121 BL4...
Page 646 Install the top of the left and the right B–pillar trim panels. 10. Install the seat belt anchors with the bolts in the left and the right B–pillar panels. Tighten Tighten the rear seat belt anchor bolts to 35 NSm (26 lb–ft). DAEWOO V–121 BL4...
Page 647: Sun Visors
18. Install the headliner/sunroof molding, if equipped. 19. Connect the negative battery cable. SUN VISORS Removal Procedure Remove the screw and the sun visor from the headliner. Remove the screw and the sun visor support from the headliner. DAEWOO V–121 BL4...
Page 648 Install the sun visor to the headliner with the screw. Tighten Tighten the sun visor screw to 2 NSm (18 lb–in). PASSENGER ASSIST HANDLES Removal Procedure Remove the plastic caps to reveal the assist handle screws. Remove the screws and the assist handle from the headliner. DAEWOO V–121 BL4...
Page 649 Install the plastic caps over the assist handle screws. INTERIOR COURTESY LAMP/POWER SUNROOF CONTROL SWITCH Removal Procedure Disconnect the negative battery cable. Pry off the lamp lens. Remove the screws and the lamp/power sunroof control switch. Disconnect the electrical connector. DAEWOO V–121 BL4...
Page 650 Make sure to use the correct fasten- ers to prevent premature corrosion. Install the lamp/power sunroof control switch with the screws. Tighten Tighten the lamp/power sunroof control switch screws to 4 NSm (35 lb–in). Install the lamp lens. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 651: Coat Hook
The coat hook will not interfere toggle button until the sunroof slides. If the sun shade is with passenger assist handle operation. closed, the sunroof will pull the sunshade open when the sunroof slides open. DAEWOO V–121 BL4...
Page 652 SECTION : 9R BODY FRONT END TABLE OF CONTENTS SPECIFICATIONS ......9R–1 HOOD HINGES ......9R–4 FASTENER TIGHTENING SPECIFICATIONS 9R–1...
Page 653 (Left–Hand Drive Shown, Right–Hand Drive Similar) Removal Procedure Raise the hood and support it with the hood prop. Remove the wiper arms. Refer toSection 9D, Wip- ers/ Washer Systems. Remove the cowl vent grille screws and the two– piece grille. DAEWOO V–121 BL4...
Page 654 Install the two–piece grille and the cowl vent grille screws. Tighten Tighten the cowl vent grille screws to 4 NSm (35 lbin). Install the wiper arms. Refer to Section 9D, Wipers/ Washer Systems. DAEWOO V–121 BL4...
Page 655 Install the two bolts securing the hood to each hinge. Tighten Tighten the hood–to–hinge bolts to 27 NSm (20 lb–ft). Inspect the hood for proper alignment. HOOD HINGES Removal Procedure Remove the hood. Refer to”Hood” in this section. Remove the bolts and the hinge. DAEWOO V–121 BL4...
Page 656 Support the hood in the open position. Remove the hood prop rod by gently prying the base from the radiator support. Installation Procedure Install the hood prop rod by snapping the base back into the radiator support. DAEWOO V–121 BL4...
Page 657 Install the hood latch with the bolts. Tighten Tighten the hood latch bolts to 8 NSm (71 lb–in). HOOD LATCH RELEASE CABLE (Left–Hand Drive Shown, Right–Hand Drive Similar) Removal Procedure Remove the nuts and the hood release handle from the instrument panel. DAEWOO V–121 BL4...
Page 658 Make sure to use the correct fasten- ers to prevent premature corrosion. Install the cable through the engine compartment. Install the cable into the hood latch release handle. Install the grommet in the fire wall. DAEWOO V–121 BL4...
Page 659: Radiator Grille
Install the cable to the hood latch release assembly. Install the hood latch release assembly with the bolts. Tighten Tighten the hood latch bolts to 8 NSm (71 lb–in). RADIATOR GRILLE Removal Procedure Open the hood. Remove the nuts and the radiator grille. DAEWOO V–121 BL4...
Page 660 Remove the screws, the bolts, and the front wheel well splash shield. Remove the side turn signal lamp. Refer to Section 9B, Lighting Systems. Remove the screw and the bolt that secure the front bumper fascia to the fender. DAEWOO V–121 BL4...
Page 661 Open the front door. Remove the bolt at the base of the A–pillar. Open the hood. 10. Remove the headlamp. Refer to Section 9B, Light- ing Systems. 11. Remove the bolt between the bumper fascia and the fender. DAEWOO V–121 BL4...
Page 662 Install the bolts along the top of the fender. Tighten Tighten the upper fender bolts to 8 NSm (71 lb–in). Install the bolt at the base of the A–pillar. Tighten Tighten the A–pillar fender bolt to 8 NSm (71 lb–in). DAEWOO V–121 BL4...
Page 663 Tighten the fender bolt on the front of the fascia to 4 NSm (35 lb–in). Install the fender to the front bumper fascia with the screw and the bolt. Tighten Tighten the front bumper fascia–to–fender bolt to 1.5 NSm (13 lb–in). DAEWOO V–121 BL4...
Page 664 Install the front wheel well splash shield with the screws and the bolts. Tighten Tighten the splash shield bolts to 1.5 NSm (13 lb–in). 10. Install the front wheel. Refer to Section 2E, Tires and Wheels. 11. Lower the vehicle. DAEWOO V–121 BL4...
Page 665: Body Front End
AND SYSTEM OPERATION BODY FRONT END This vehicle has a unitized body with a frame assembly supporting the engine and the transaxle. The fender pan- els and the radiator support are also integral parts of the body. DAEWOO V–121 BL4...
Page 666 SECTION : 9S BODY REAR END CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle.
Page 667 Application Lb–Ft Lb–In Luggage Compartment – Lock Screws Luggage Compartment – Lock Striker Bolts Rear Deck Lid Bolts – Rear Spoiler Nuts – Remote Cable Handle – Screws Tailgate Hinge Bolts – Tailgate Lock Striker Bolts – DAEWOO V–121 BL4...
Page 668: Fuel Filler Door
Install the fuel filler door with the screws. Tighten Tighten the fuel filler door screws to 4 NSm (35 lb–in). REAR DECK LID (NOTCHBACK) Removal Procedure Disconnect the negative battery cable. Disconnect the electrical connector. DAEWOO V–121 BL4...
Page 669 Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasten- ers to prevent premature corrosion. Install the rear deck lid with the bolts. Tighten Tighten the rear deck lid bolts to 10 NSm (89 lb–in). DAEWOO V–121 BL4...
Page 670 Connect the electrical connector. Connect the negative battery cable. REAR DECK LID SPRINGS (NOTCHBACK) Removal Procedure Raise and support the deck lid in the open position. Pull the spring out of the rear mount. Remove the spring from the hinge. DAEWOO V–121 BL4...
Page 671 Make sure to use the correct fasten- ers to prevent premature corrosion. Secure the luggage compartment lock cylinder with the nuts. Tighten Tighten the luggage compartment lock cylinder nuts to 4 NSm (35 lb–in). Install the lower garnish molding (hatchback and wagon only). DAEWOO V–121 BL4...
Page 672 Tighten the luggage compartment lock striker bolts to 8 NSm (71 lb–in). LUGGAGE COMPARTMENT LOCK (NOTCHBACK AND HATCHBACK) (Notchback Shown, Hatchback Similar) Removal Procedure Disconnect the negative battery cable. Remove the lock trim cover (hatchback only). Disconnect the electrical connector. DAEWOO V–121 BL4...
Page 673 Install the luggage compartment lock with the screws. Tighten Tighten the luggage compartment lock screws to 6 NSm (53 lb–in). Connect the electrical connector. Install the lock trim cover (hatchback only). Connect the negative battery cable. DAEWOO V–121 BL4...
Page 674 Remove the gas support assemblies from the hatchback door. Refer to”Gas Support Assemblies (Hatchback)” in this section. With the aid of another technician, remove the bolts and the hatchback door from the hinges. DAEWOO V–121 BL4...
Page 675 Installation Procedure Install the gas support assembly onto the hatch- back door and the body. Tighten Tighten the gas support assembly studs to 20 NSm (15 lb–ft). Close the hatchback door. DAEWOO V–121 BL4...
Page 676 Tighten the hatchback door lock striker screws to 8 NSm (71 lb–in). Install the luggage compartment rear trim panel. Refer to Section 9G, Interior Trim. Close the hatchback door. REAR SPOILER (HATCHBACK) Removal Procedure Open the hatchback door. Remove the nuts and the rear spoiler. DAEWOO V–121 BL4...
Page 677 Tighten the tailgate hinge bolts to 20 NSm (15 lb–ft). Install the gas support assemblies to the tailgate. Refer to”Gas Support Assemblies (Hatchback)” in this section. Connect the tailgate electrical connectors, washer hose, and grommets.. Close the tailgate. DAEWOO V–121 BL4...
Page 678 Remove the bolts and the gas support assembly from the body. Unscrew and remove the gas support assembly from the tailgate. Installation Procedure Install the gas support assembly onto the tailgate. Tighten Tighten the gas support assembly studs to 20 NSm (15 lb–ft). DAEWOO V–121 BL4...
Page 679 Installation Procedure Install the lock striker with the screws. Tighten Tighten the tailgate lock striker bolts to 10 NSm (89 lbin). Install the luggage compartment rear trim panel. Refer to Section 9G, Interior Trim. Close the tailgate. DAEWOO V–121 BL4...
Page 680 Remove the rear deck lid remote handle cover. Reposition the floor carpet on the left side of the vehicle. Remove the screws and the rear deck lid remote handle. Disconnect the cable from the handle. 10. Remove the cable. DAEWOO V–121 BL4...
Page 681 (Notchback Shown, Hatchback and Wagon Similar) (Left–Hand Drive Shown, Right–Hand Drive Similar) Removal Procedure Open the luggage compartment. Remove the luggage compartment wheelhouse trim panels. Refer to Section 9G, Interior Trim. Disconnect the cable from the fuel filler door. DAEWOO V–121 BL4...
Page 682 Feed the cable from the luggage compartment to the passenger compartment. Connect the cable to the handle. Install the handle with the screws. Tighten Tighten the fuel filler door remote cable handle screws to 8 NSm (71 lb–in). DAEWOO V–121 BL4...
Page 683 NSm (26 lb–ft). Install the front seat and the rear seat. Refer to Section 9H, Seats. Connect the cable to the fuel filler door. Install the luggage compartment wheelhouse trim panels. Refer to Section 9G, Interior Trim. DAEWOO V–121 BL4...
Page 684 The deck lid springs assist in the opening of the rear deck lid and hold it in the open position. DAEWOO V–121 BL4...
Page 685 SECTION : 9T IMMOBILIZER ANTI–THEFT SYSTEM CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle.
Page 686 OFF during the The following KEY STATUS messages may be shown on key coding process. Turn the ignition ON during key the scan tool after commanding SYSTEM DIAGNOSIS: coding, but do not start the engine. DAEWOO V–121 BL4...
Page 687 OK, replace the the immobilizer. Follow the steps below to diagnose immobilizer control unit. Refer to ”Immobilizer Con- the problem: trol Unit”in this section. DAEWOO V–121 BL4...
Page 688 Turn the ignition ON, but do not start the vehicle. Enter the four–digit password that enables service personnel to use the scan tool for ID code repro- gramming. Use the scan tool to command RESET ID CODE. DAEWOO V–121 BL4...
Page 689 If a transponder is faulty, the ignition key must be replaced. It is not possible to install a new transponder into a key. DETECTION COIL Removal Procedure Carefully pull the knee bolster trim panel until it is loose from its retaining clips. DAEWOO V–121 BL4...
Page 690 Remove the instrument panel side cover. Remove the bolts and the knee bolster. Remove the steering column lower cover. Refer toSection 6E, Steering Wheel and Column. Disconnect the two–pin connector from the immobi- lizer. DAEWOO V–121 BL4...
Page 691 Section 6E, Steering Wheel and Column. Install the knee bolster with the bolts. Tighten Tighten the knee bolster mounting bolts to 22 NSm (16 lb–ft) Install the instrument panel side cover. Install the knee bolster trim panel. DAEWOO V–121 BL4...
Page 692 Slide the knee bolster trim panel upward and pull it outward to remove it. Remove the instrument panel side cover. Remove the bolts and the knee bolster. Remove the bolts and the immobilizer control unit. Disconnect the electrical connectors from the im- mobilizer control unit. DAEWOO V–121 BL4...
Page 693 Important : After replacing the immobilizer, the keys must be re–authorized using the key coding procedure. Refer to”Key Coding Procedure” in this section. Also, the elec- tronic control module (ECM) identification (ID) code must be reset. Refer to”ID Code Reprogramming” in this sec- tion. DAEWOO V–121 BL4...
Page 694: Immobilizer System
When the driver turns the ignition OFF, the immobilizer mobilizer control unit. The immobilizer control unit reads control unit switches to the active mode. DAEWOO V–121 BL4...
Page 695 POWERTRAIN CONTROL MODULE A PCM/ECM with an immobilizer control unit is not ex- (PCM)/ENGINE CONTROL MODULE changeable with a PCM/ECM that does not have an immo- (ECM) bilizer control unit. When the powertrain control module (PCM)/engine con- DAEWOO V–121 BL4...
Page 696: Table Of Contents
SECTION : 9T REMOTE KEYLESS ENTRY AND PERIMETER/ULTRASONIC ANTI–THEFT SYSTEM CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle.
Page 697 9T – 2IREMOTE KEYLESS ENTRY AND ANTI–THEFT SYSTEM SCHEMATIC AND ROUTING DIAGRAMS REMOTE KEYLESS ENTRY AND ANTI–THEFT SYSTEM (1 OF 2) DAEWOO V–121 BL4...
Page 698 REMOTE KEYLESS ENTRY AND ANTI–THEFT SYSTEM 9T – 3 REMOTE KEYLESS ENTRY AND ANTI–THEFT SYSTEM (2 OF 2) DAEWOO V–121 BL4...
Page 699: Wiring Harness Connectors
9T – 4IREMOTE KEYLESS ENTRY AND ANTI–THEFT SYSTEM CONTROL MODULE/RECEIVER CONNECTOR WIRING HARNESS CONNECTORS DAEWOO V–121 BL4...
Page 700 Install the floor console left side forward trim panel. Refer to Section 9G, Interior Trim. Connect the negative battery cable. SIREN Removal Procedure Remove several screws to boosen the forward half of the right front wheel well splash shield. DAEWOO V–121 BL4...
Page 701 Remove the siren bracket mounting bolt. Remove the siren. Installation Procedure Install the siren on the siren bracket with the mount- ing screws. Tighten Tighten the siren bracket mounting bolts to 22 NSm (16 lb–in). Connect the siren electrical connector. DAEWOO V–121 BL4...
Page 702: Front Door Tamper Switch
Connect the negative battery cable. REAR DECK LID TAMPER SWITCH Removal Procedure Disconnect the negative battery cable. Disconnect the rear deck lid tamper switch electri- cal connector from the tamper switch. Remove the rear deck lid tamper switch. DAEWOO V–121 BL4...
Page 703: Hood Open Switch
Connect the negative battery cable. HOOD OPEN SWITCH Removal Procedure Disconnect the negative battery cable. Disconnect the electrical connector from the hood open switch. Remove the mounting screw from the hood open switch. Remove the hood open switch. DAEWOO V–121 BL4...
Page 704 Installation Procedure Install the hood open switch with the mounting screw. Tighten Tighten the hood open switch mounting screw to 8 NSm (71 lb–in). Connect the electrical connector to the hood open switch. Connect the negative battery cable. DAEWOO V–121 BL4...
Page 705: Password Programming
The control module/receiver automatically leaves the pro- gramming mode and switches to the normal operating mode when either of the following conditions occurs: The scan tool is disconnected from the ALDL. Five passwords are recorded in the control module/ receiver. DAEWOO V–121 BL4...
Page 706: Security Indicator
Pressing the LOCK button has the following effects: The ignition switch input is changed to battery volt- age. The doors are locked. The turn signal lamps flash once. The siren is disarmed when any of the following conditions The control module is armed. occurs: DAEWOO V–121 BL4...
Page 707: Panic Button
(ALDL) connector. seconds, and the parking lights will flash during that time. The control module/receiver will not communicate with transmitters from other vehicles because there are over four billion possible electronic password combinations, DAEWOO V–121 BL4...
Page 708 SECTION : 9U CRUISE CONTROL SYSTEM CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle.
Page 709 9U – 2ICRUISE CONRTOL SYSTEM SCHEMATIC AND ROUTING DIAGRAMS CRUISE CONTROL SYSTEM (AUTOMATIC TRANSAXLE) (1 OF 2) DAEWOO V–121 BL4...
Page 710 CRUISE CONRTOL SYSTEM 9U – 3 CRUISE CONTROL SYSTEM (AUTOMATIC TRANSAXLE) (2 OF 2) DAEWOO V–121 BL4...
Page 711 9U – 4ICRUISE CONRTOL SYSTEM CRUISE CONTROL SYSTEM (MANUAL TRANSAXLE) (1 OF 2) DAEWOO V–121 BL4...
Page 712 CRUISE CONRTOL SYSTEM 9U – 5 CRUISE CONTROL SYSTEM (MANUAL TRANSAXLE) (2 OF 2) DAEWOO V–121 BL4...
Page 713 Go to Step 10 1. Turn the ignition ON. 2. Check the voltage at fuses F5 and F8. Is the specified voltage available at fuses F5 andF8? Repair the power supply to the fuse(s). System OK Is the repair complete? DAEWOO V–121 BL4...
Page 714 2. Make sure that the cruise main switch is OFF. 3. With the electrical connector still disconnected from the cruise control actuator, use a voltme- ter to check the voltage at terminal 9 of the ac- tuator connector. Is the voltage equal to the specified value? DAEWOO V–121 BL4...
Page 715 Is the voltage equal to the specified value? Replace the cruise control lever switch. System OK Is the repair complete? Repair the short to voltage between the cruise con- System OK trol lever switch and the cruise control actuator. Is the repair complete? DAEWOO V–121 BL4...
Page 716 7 of the actuatorconnector. Does the ohmmeter indicate the specified value? Repair the open circuit between terminalB1 of the System OK leverswitch connectorand terminal 7 of the cruise control actuatorconnector. Is the repair complete? DAEWOO V–121 BL4...
Page 717 System OK actuatorconnector terminal 10 and theVSS, for ve- hicles with amanual transaxle, or the output shaft sensor forvehicles with an automatic transaxle. Is the repair complete? Replace the cruise control actuator. System OK Is the repair complete? DAEWOO V–121 BL4...
Page 718 Remove the knee bolster. Refer to Section 9G, In- terior Trim. Remove the actuator bracket with the actuator still attached. Press the tabs on the cable adjuster, and remove the cable and the adjuster from the adjuster brack- DAEWOO V–121 BL4...
Page 719 Tilt the cable housing toward the screwdriver to re- lease the cable housing retainers. Remove the cable ball from the actuator rod. DAEWOO V–121 BL4...
Page 720 Align the cable housing and push the cable housing onto the actuator until it is locked in place by the retainers. If a new actuator is being installed, attach it to the mounting bracket. Tighten Tighten the actuator bolts to 4 NSm (35 lb–in). DAEWOO V–121 BL4...
Page 721 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 cable ball. Install the knee bolster. Refer to Section 9G, Interi- or Trim. Install the knee bolster trim panel. DAEWOO V–121 BL4...
Page 722 Tilt the cable housing and insert a flathead screw- driver into one of the slots in the actuator. Tilt the cable housing toward the screwdriver, so that the cable housing retainers will release. DAEWOO V–121 BL4...
Page 723 Remove the cable ball from the actuator rod. Installation Procedure Insert the ball nipple of the cable assembly into the slot in the actuator rod, and then rotate the cable 90 degrees. DAEWOO V–121 BL4...
Page 724: Main Switch
Reach through the radio opening in the instrument panel and wiggle the cruise control main switch to loosen it. Push the cruise control main switch out of the in- strument panel. Disconnect the electrical connector from the cruise control main switch. DAEWOO V–121 BL4...
Page 725 Push the cruise control main switch into the instru- ment panel until it is locked in place by its retainers. Reinstall the radio, taking care not to scratch the instrument panel or trim when installing the radio case. Refer to Section 9F, Audio Systems. DAEWOO V–121 BL4...
Page 726 The mechanical components of the cruise control actuator to return to idle and the vehicle will coast. When the are listed below: COAST switch is released, the current speed will be main- tained as the new target speed. If the vehicle speed drops DAEWOO V–121 BL4...
Page 727 5 seconds, the memorized target speed is erased. 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 DAEWOO V–121 BL4...
Page 728 VIN Range: Prod. Dates: Daewoo has determined that some Lanos, Nubira and Leganza models have experienced incorrect fuel gauge readings caused by a faulty Fuel Level Sensor unit in the Fuel Tank. Reported conditions include the Fuel Gauge failing to read above the “3/4” mark or below the “1/4”...
Page 729: Paint Codes
To ensure correct paint color matching and the ability to acquire 1998-1999 Daewoo paint from your local supplier, we have compiled a list of paint codes for Daewoo paint colors from a number of the most predominant U.S. paint suppliers.
Page 730 Description Paint Codes Page 2 of 3 1998 Paint Codes Model Application Paint Manufacturer Codes Daewoo Sherwin Color Color Name Williams/ Lanos Nubira Leganza Akzo Dupont Code Martin Senour Galaxy White DAE11U F3540 91694 56925 Azurite Blue DAE21U F3133 190456...
Page 731 Description Paint Codes Page 3 of 3 Paint Manufacturer Telephone Numbers: Akzo Customer Assistance ....(800) 618-1010 Dupont Customer Assistance ....(800) 338-7668 Color Library/Codes/Formulas .
Page 732 Seat Cushion, then lift up the front edge of the cushion to release the two (2) retaining latches. Nubira & Leganza - Lift up on the front edge of the Rear Seat Cushion to release the two (2) retaining latches.
Page 733 Description Page Fuel Level Sensor Procedures 2 of 7 4. Disconnect the Wiring Harness Electrical Wiring Harness Electrical Connector Connector from the Fuel Pump Module. 5. Turn the ignition switch to the "ON" position. 6. Using a suitable DVOM, measure voltage at the Wiring Harness Electrical Connector between terminal 1 and chassis ground.
Page 734 Description Page Fuel Level Sensor Procedures 3 of 7 18. Reconnect the Wiring Harness Electrical Connector to the Fuel Pump Module. 19. Turn the Ignition Switch to the "ON" position. Fuel Pump Module 20. Connect the Scan 100 Scan Tool to the vehicle Data-Link Connector (DLC) and go to the EVAP Data Screen to view the Fuel Level Sensor voltage...
Page 735 Description Page Fuel Level Sensor Procedures 4 of 7 4. Using a suitable pair of diagonal cutters, cut off the two (2) Fuel Level Sensor Terminals previously released/removed from the sub- harness connector, then discard those terminals. Remove Terminals 5. Disengage the Fuel Level Sensor wires from the retaining hook at the top of the Fuel Pump Module Body, then pull the cut wire ends out of the fuel pump body through the built-in...
Page 736 Description Page Fuel Level Sensor Procedures 5 of 7 Installation 9. Temporarily wrap the new Fuel Level Sensor wire terminals with electrical tape. 10. Route the wire through the groove at the bottom Groove of the Fuel Level Sensor as you route it around to the back of the Fuel Level Sensor Body.
Page 737 Description Page Fuel Level Sensor Procedures 6 of 7 16. Guide the Low Fuel Level Sensor Bracket onto the retaining rail on the Fuel Pump Module Body. An audible "click" will be heard as it locks into it’s proper position. 17.
Page 738 Lanos - 96388929 Nubira - 96388676 Leganza - 96405140 If additional information is needed regarding this procedure, please contact your District Parts & Service Manager or the Daewoo Technical Assistance Center toll free at (877) 362-1234, selection 1. August, 2001...
Page 739 Affected customer vehicles, demonstrators, DCA vehicles, etc. should be updated as they come in for periodic service and/or repairs regardless if a complaint has been made. A list of applicable Nubira 5-Door Vehicle Identification Numbers (VIN’s) has been attached for your reference.
Page 740 Description Rear Hatch Lock Rod Page 2 of 2 Release the two (2) lock rod plastic lock tabs and remove the lock rod. “Old” Lock Rod Lock Rod Installation: Install the new lock rod and reattach the two (2) plastic lock tabs. Reinstall the rear hatch inner trim panel, the four (4) retaining screws and the three (3) trim panel clips.
Page 741 Prod. Dates: Remote Keyless Entry Transmitter Programming Information The Daewoo Remote Keyless Entry System allows for the use of as many as five (5) transmitters for each vehicle. Replacement Remote Keyless Entry System Transmitters must first be programmed to a specific vehicle using the Scan 100 Scan Tool. This process is completed using serial data communication between the Scan 100 Scan Tool and the Remote Keyless Entry Control Unit and is the only method available for programming Transmitters.
Page 742 16. Wait approximately 10 seconds, then test the operation of each programmed Transmitter to ensure it operates properly. If additional information is needed regarding this procedure, please contact your District Parts & Service Manager or the Daewoo Technical Assistance Center toll free at (877) 362-1234, selection 1. May, 2001...

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