Daewoo MATIZ Service Manual
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Daewoo MATIZ Service Manual

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Table of Contents

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SERVICE
MANUAL
MATIZ
(MY2003)
FOREWORD
This manual includes procedure for maintenance,
adjustment, service operation and removal and
installation of components.
All information, illustrations and specifications con-
tained in this manual are based on the latest prod-
uct information available at the time of manual ap-
proval.
The right is reserved to make changes at any time
without notice.
DAEWOO MOTOR CO., LTD.
INCHON, KOREA
SECTION INDEX
FRONT MATTER
GENERAL INFORMATION
ENGINE
SUSPENSION
DRIVELINE/AXLE
BRAKES
TRANSAXLE
STEERING
HVAC
(HEATING, VENTILATION,
AND AIR CONDITIONING)
RESTRAINTS
BODY AND ACCESSORIES
0A
0B
1
2
3
4
5
6
7
8
9

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Summary of Contents for Daewoo MATIZ

  • Page 1 TRANSAXLE uct information available at the time of manual ap- proval. The right is reserved to make changes at any time STEERING without notice. HVAC (HEATING, VENTILATION, AND AIR CONDITIONING) RESTRAINTS DAEWOO MOTOR CO., LTD. INCHON, KOREA BODY AND ACCESSORIES...
  • Page 2 ENGINE CONTENTS SECTION 1A GENERAL ENGINE INFORMATION SECTION 1B SOHC ENGINE MECHANICAL SECTION 1D ENGINE COOLING SECTION 1E ENGINE ELECTRICAL SECTION 1F ENGINE CONTROLS SECTION 1G ENGINE EXHAUST...

  • Page 3: Suspension

    SUSPENSION CONTENTS SECTION 2A SUSPENSION DIAGNOSIS SECTION 2B WHEEL ALIGNMENT SECTION 2C FRONT SUSPENSION SECTION 2D REAR SUSPENSION SECTION 2E TIRES AND WHEELS...
  • Page 4 DRIVELINE/AXLE CONTENTS SECTION 3B MANUAL TRANSAXLE DRIVE AXLE...
  • Page 5 BRAKES CONTENTS SECTION 4A HYDRAULIC BRAKES SECTION 4B MASTER CYLINDER SECTION 4C POWER BOOSTER SECTION 4D FRONT DISC BRAKES SECTION 4E REAR DRUM BRAKES SECTION 4F ANTILOCK BRAKE SYSTEM SECTION 4G PARKING BRAKE...
  • Page 6 TRANSAXLE CONTENTS SECTION 5B FIVE–SPEED MANUAL TRANSAXLE SECTION 5C CLUTCH...
  • Page 7 STEERING CONTENTS SECTION 6A POWER STEERING SYSTEM SECTION 6B POWER STEERING PUMP SECTION 6C POWER STEERING GEAR SECTION 6D MANUAL STEERING GEAR SECTION 6E STEERING WHEEL AND COLUMN...

  • Page 8: Heating, Ventilation

    HVAC (HEATING, VENTILATION, AND AIR CONDITIONING) CONTENTS SECTION 7A HEATING AND VENTILATION SYSTEM SECTION 7B MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM...

  • Page 9: Restraints

    RESTRAINTS CONTENTS SECTION 8A SEAT BELTS SECTION 8B SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
  • Page 10 BODY AND ACCESSORIES CONTENTS SECTION 9A BODY WIRING SYSTEM SECTION 9B LIGHTING SYSTEMS SECTION 9C HORNS SECTION 9D WIPERS / WASHER SYSTEMS SECTION 9E INSTRUMENTATION / DRIVER INFORMATION SECTION 9F AUDIO SYSTEMS SECTION 9G INTERIOR TRIM SECTION 9H SEATS SECTION 9I WATERLEAKS SECTION 9J WINDNOISE...

  • Page 11: Table Of Contents

    Changing Engine Oil or Oil Filter ... . 1A-11 Engine Performance Curve ....1A-15 DAEWOO M-150 BL2...

  • Page 12: Cleanliness And Care

    Battery sive damage when the engine is started. cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables DAEWOO M-150 BL2...

  • Page 13: Component Locator

    8 Idle Air Control (IAC) Valve 20 Snorkel 9 Throttle Position (TP) Sensor 21 Engine 10 Throttle Body 22 Washer Fluid Reservoir 11 Brake Fluid Reservoir 23 Oil Level Gauge 12 Wiper Motor 24 Oil Filler Cap DAEWOO M-150 BL2...

  • Page 14: Engine Compartment (Euro Iii)

    6 Throttle Position (TP) Sensor 16 Exhaust Manifold 7 Throttle Body 17 Snorkel 8 Idle Air Control (IAC) Valve 18 Engine 9 Brake Fluid Reservoir 20 Washer Fluid Reservoir 10 Wiper Motor 19 Oil Level Gauge 21 Oil Filler Cap DAEWOO M-150 BL2...

  • Page 15: General Diagnosis

    D Replace the valve spring. the valve spring. D Abnormal interference of D Replace the piston ring. pistons and cylinders. D Excessive wear of pistons, D Replace the ring or the rings, or cylinders. piston and boring or replace the cylinder. DAEWOO M-150 BL2...
  • Page 16 D Electric leakage or poor D Connect the cable correctly connection of the high or replace it. tension cable. D Worn distributor cap terminal D Replace or clean the or accumulated carbon in distributor cap. the distributor cap. DAEWOO M-150 BL2...
  • Page 17 D Loosening or damage of the D Replace the distributor rotor distributor rotor or the cap. or the cap. D Poor ignition timing. D Adjust the ignition timing. DAEWOO M-150 BL2...
  • Page 18 D Refer to “Page 1A–5”. Poor Fuel Decline of Consumption Compression Pressure D Leakage of the fuel tank or D Repair or replace the fuel Malfunction of Fuel System the fuel pipe. tank or the fuel pipe. DAEWOO M-150 BL2...
  • Page 19 D Replace with the specified Low Oil Pressure Malfunction of one. Lubrication System D Loosening of the oil pressure D Tighten the switch. switch. D Lack of engine oil. D Refill oil. D Blocking oil strainer. D Clean the strainer. DAEWOO M-150 BL2...
  • Page 20 D Loosened bearing cap bolt. D Tighten to the specified torque. D Excessive clearance of the D Adjust or replace. crankshaft thrust bearing. D Low oil pressure. D Refer to “Low Oil Pressure” in this section. DAEWOO M-150 BL2...

  • Page 21: Checking Engine Fluid Level

    When checking engine oil level or condition, if needed, change engine oil (including the filter) as follows ; 1. After stopping the engine, wait for a few minutes to D102A303 accumulate oil into the oil pan. 2. Remove the oil filter cap (b). DAEWOO M-150 BL2...

  • Page 22: Checking Engine Timing Belt

    1. Pull the high tension cable cap portion (i), and discon- nect the high tension cable from the spark plug. If pulling the high tension cable (j), circuit could be disconnected. Therefore, the cap portion should be used. D102A306 DAEWOO M-150 BL2...

  • Page 23: Checking Air Cleaner Element

    ; Therefore, replace a new one within the specified peri- D Check the hose surface for damage by heat or ma- chine. D Check the hose for hardening, crack, tear, or coming off. DAEWOO M-150 BL2...

  • Page 24: Specifications

    35 L (9.2 gal), 38 L (10 gal) Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...

  • Page 25: Engine Performance Curve

    GENERAL ENGINE INFORMATION 1A – 15 ENGINE PERFORMANCE CURVE D Maximum Power : 51 PS (37.5 KW) (at 6,000 rpm) D Maximum Torque : 7 KgSm (68.6 NSm) (at 4,600 rpm) D12A101A DAEWOO M-150 BL2...
  • Page 26 ..... . . 1B-75 On-Vehicle Service ......1B-14 DAEWOO M-150 BL2...

  • Page 27: Description And Operation

    The combustion chambers are formed into the manifold (j), camshaft (k), etc. through the oil hole provided on the combustion chambers with increased squish parts for rocker arm shaft (h). better combustion efficiency and its intake and exhaust DAEWOO M-150 BL2...

  • Page 28: Engine Block

    The pin is used to transmit the power from the crown part of piston to connecting rod. D102B004 CONNECTING ROD D102B005 The connecting rods (n) are made of forged steel, and its section is typed “I” with its big end connected to DAEWOO M-150 BL2...

  • Page 29: Timing Belt And Pulley

    (z) that maintains the correct timing belt tension. The timing belt is made of a tough reinforced rubber similar to that used on the serpentine drive belt. The timing belt requires no lubrication. D102B007 D102B006 D102B008 DAEWOO M-150 BL2...

  • Page 30: Component Locator

    1 Oil Filler Cap 7 Cylinder Head Gasket 2 Cylinder Head Cover 8 Cylinder Head 3 Cylinder Head Cover (Euro III) 9 Intake Rocker Arm 4 Distributor Case 10 Exhaust Valve 5 Camshaft 11 Intake Valve 6 Exhaust Rocker Arm DAEWOO M-150 BL2...

  • Page 31: Engine Block

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

  • Page 32: Manifold & Air Flow System

    3 Exhaust Gas Recirculation (EGR) Valve and 9 Exhaust Manifold Solenoid 10 Exhaust Manifold Heat Shield 4 Throttle Body Assembly 11 Exhaust Manifold Heat Shield (Euro III) 5 Air Filter Assembly 12 Exhaust Manifold (Euro III) 6 Resonator DAEWOO M-150 BL2...

  • Page 33: Timing Belt & Engine Mount

    12 Timing Belt Lower Front Cover 5 Transaxle Mount Damping Block 13 Crankshaft Pulley 6 Engine Mount Front Bracket 14 Engine Mount Lower Bracket 7 Engine Mount Front Damping Bush 15 Engine Mount Upper Bracket 8 Timing Belt DAEWOO M-150 BL2...

  • Page 34: Diagnostic Information And Procedure

    12–16 NSm (106–144 lb-in). Compression 1,176.72– Pressure 6. Start the engine and check oil pressure switch for oil 1,225.75 1,274.78 kPa(psi) – 400 rpm (177.73) (170.62– leakage. 184.84) 7. After checking, remove the gauge and install the re- moved parts. DAEWOO M-150 BL2...

  • Page 35: Adjustment Of Valve Clearance

    360–degree arc. (When the camshaft sprocket point (h) is aligned with the timing belt rear cover triangle pointer (e), the exhaust top dead center is on the ignition sequence for No. 1 cyl- inder.) D102B306 DAEWOO M-150 BL2...

  • Page 36: Ignition Timing Check And Adjustment (Typical)

    Item Specified Value D102B307 Ignition timing – 950rpm 10_ BTDC Important: In flashing the timing light, if crankshaft pulley notch (p) is matched with the mark (10) for timing check, the ignition timing is 10_ BTDC. D102B309 DAEWOO M-150 BL2...

  • Page 37: Valve Timing Check And Adjustment

    D102B311 VALVE TIMING CHECK AND ADJUSTMENT Check the valve timing in the following procedures: 1. After removing the high headlamp, loosen the bolts D102B314 (a) and remove the timing belt front upper cover (b). D102B312 DAEWOO M-150 BL2...
  • Page 38 Turning the crankshaft clockwise twice, align the mark (m) with the pointer (n) and tighten the tensioner bolt to 15–23 NSm (11–17 lb-ft). D102B316 3. Remove the timing belt tensioner (k) and the timing D12B319A belt (l). 6. Install all removed parts. D102B317 DAEWOO M-150 BL2...
  • Page 39 ..1D-18 Thermostat Test ......1D-7 DAEWOO M-150 BL2...

  • Page 40: Description And Operation

    MAX marks on the surge tank when the system is cold. The cooling system for this vehicle has no radiator cap and drain cock. The coolant is added to the cooling sys- D102D001 DAEWOO M-150 BL2...

  • Page 41: Coolant Pump

    As the wax pellet cools, the contraction allows a spring to close the valve. The thermostat begins to open at 82_C (180_F) and is fully open at 95_C (203_F). The thermostat closes at 80_C (176_F). D102D003 DAEWOO M-150 BL2...

  • Page 42: Engine Coolant Temperature Sensor

    ECT sensor on an SOHC engine. The engine coolant temperature (ECT) sensor (n) uses a thermistor to control the signal voltage to the engine control module (ECM). DAEWOO M-150 BL2...

  • Page 43: Component Locator

    6 Throttle Body Assembly 16 Thermostat 7 Surge Tank hose 17 Thermostat Housing 8 Surge Tank 18 Throttle Body Inlet Hose 9 Coolant Temperature Sensor 19 Throttle Body Outlet Hose 10 Engine Coolant Temperature Sensor 20 Hose Bracket DAEWOO M-150 BL2...

  • Page 44: Radiator/Fan

    1D – 6 ENGINE COOLING RADIATOR/FAN D12D4021 1 Radiator Assembly 2 Electric Cooling Fan Assembly DAEWOO M-150 BL2...

  • Page 45: Diagnostic Information And Procedure

    5. Pressurize the cap to 90 to 120kPa (13 to 17psi). 6. Wait 10 seconds and check the pressure held by the tank cap tester. 7. If the pressure held by the cooling system pressure tester falls below 80kPa (11.6psi) replace the surge D102D303 tank cap. DAEWOO M-150 BL2...

  • Page 46: Cooling System Diagnosis

    Temperature or Cool Air D The coolant level below the MIN D Add sufficient coolant to raise the from the Heater mark on the surge tank. fluid to the specified mark on the surge tank. DAEWOO M-150 BL2...

  • Page 47: On-Vehicle Service

    3. Connect the lower radiator hose. 4. Clean the cooling system. D Remove all sludge and dirt from inside the surge tank. And install the surge tank. Refer to “Surge Tank” in this section (1). D102D502 DAEWOO M-150 BL2...

  • Page 48: Surge Tank

    3. Clean the inside and the outside of the surge tank and the surge tank cap with soap and water. 4. Rinse the surge tank and the cap thoroughly. 5. Check the surge tank and the cap for crack or other damage. DAEWOO M-150 BL2...

  • Page 49: Electric Cooling Fan

    3. Disconnect the upper radiator hose and the surge tank hose. D Loosen the upper radiator hose clamp and discon- nect the upper radiator hose (1). D Loosen the surge tank hose clamp and disconnect the surge tank hose (2). D12D5081 DAEWOO M-150 BL2...

  • Page 50: Thermostat (Typical)

    1. Remove air filter assembly. Refer to Section 1B, SOHC Engine Mechanical. 2. Disconnect the lower radiator hose and drain the coolant. Refer to “Drain and Refilling the Cooling Sys- tem” D102D512 3. Disconnect the upper radiator hose. DAEWOO M-150 BL2...

  • Page 51: Thermostat (Euro Iii)

    1. Remove air filter assembly. Refer to Section 1B, SOHC Engine Mechanical. 2. Disconnect the lower radiator hose and drain the coolant. Refer to “Drain and Refilling the Cooling Sys- tem” MAA1D010 3. Disconnect the upper radiator hose. DAEWOO M-150 BL2...

  • Page 52: Intake Manifold

    D Connect the electrical connector to the coolant temperature sensor (1). 2. Connect the lower radiator hose and refill the coolant. Refer to “Draining and refilling the cooling system” in this section. 3. Connect the negative battery cable. D12D516A DAEWOO M-150 BL2...

  • Page 53: Engine Coolant Temperature Sensor

    D Remove the rear timing belt cover (2). D102B533 5. Remove the coolant pump. D Remove the nuts (1). D Remove the bolts (2). D Remove the coolant pump (3). D Remove the gasket. Notice: Remove the coolant pump as shown figure (a). D102D519 DAEWOO M-150 BL2...
  • Page 54 3. Install the timing belt. Refer to Section 1B, Engine Mechanical. 4. Connect the lower radiator hose and drain the cool- ant. Refer to “Draining and Refilling the Cooling Sys- tem” in this section. 5. Connect the negative battery cable. D12D521A DAEWOO M-150 BL2...

  • Page 55: Specifications

    16/27(0.63/1.06) Resistance Ω 185.2 (Coolant Temperature 50°C(122.4°F)) Coolant Resistance Ω 49.2 Temperature (Coolant Temperature 85°C(185.4°F)) Sensor Resistance Ω 27.5 (Coolant Temperature 105°C(221.4°F)) Resistance Ω 3,520 Engine Coolant (Coolant Temperature 20°C(68.4°F)) Temperature Resistance Ω Sensor (Coolant Temperature 80°C(176.4°F)) DAEWOO M-150 BL2...

  • Page 56: Fastener Tightening Specifications

    Thermostat Housing Bolt 8 – 15 – 71 – 130 Water Inlet Cap Bolt 8 – 12 – 71 – 106 Coolant Pump Bolt/Nut 9–12 – 80 – 106 Coolant Pump Stud Bolt 9–12 – 80 – 106 DAEWOO M-150 BL2...
  • Page 57 ..1E-42 Battery Load Test ......1E-12 DAEWOO M-150 BL2...

  • Page 58: Description And Operation

    30 seconds at the specified temperature, while meeting a minimum voltage requirement of 7.2 volts. This rating is a measure of cold cranking ca- pacity. DAEWOO M-150 BL2...

  • Page 59: Charging Procedure

    Leave the hazard flasher on if the charge current will be very low, and it could take there may be other traffic and any other lights needed some time before the battery accepts the current in for the work area. DAEWOO M-150 BL2...

  • Page 60: Generator

    Distributor distributes the high tension voltage induced defect is indicated. from ignition coil, to each spark plug of each cylinder in The regulator voltage setting varies with temperature and limits the system voltage by controlling the rotor DAEWOO M-150 BL2...

  • Page 61: Ignition Coil

    IGNITION COIL Ignition coil is a sort of transformer to generate high volt- age (15,000–25,000V) which can bring spark at the spark plugs and has an iron cored closed magnetic type. DAEWOO M-150 BL2...

  • Page 62: Component Locator

    7 Pinion Gear Assembly 2 Starter Solenoid Assembly 8 Ring Set 3 Starter Housing 9 Field Frame Assembly 4 Shift Lever 10 Brush Holder Assembly 5 Armature Set 11 Contact End Frame Assembly 6 Armature 12 Starter Through - Bolts DAEWOO M-150 BL2...

  • Page 63: Charging System (A-Type: Mando)

    5 Generator Collar (Large) 14 Voltage Regulator / Brush Holder Assembly 6 Generator Front Bracket 15 Generator Rear Bracket 7 Front Bearing 16 Battery Positive Terminal Nut 8 Bearing Spot Plate 17 Through Bolt 9 Generator Collar (Small) DAEWOO M-150 BL2...

  • Page 64: Charging System (B-Type: Dac)

    5 Generator Collar 15 Rectifier Assembly 6 Generator Drive End Bracket 16 Shield 7 Generator Stator Assembly 17 Through - Bolt 8 Frame Bearing 18 Generator Cover 9 Generator Fan 19 Battery Positive Terminal Nut 10 Generator Rotor Assembly DAEWOO M-150 BL2...

  • Page 65: Ignition System

    16 Disc Wheel 6 Mounting Clamp 17 Inner Cover 7 Distributor Assembly 18 Outer Cover 8 Coupling 19 Distributor Rotor 9 Distributor Oil Seal 20 Distributor Cap Seal 10 Distributor Housing 21 Distributor Cap 11 Distributor Shaft DAEWOO M-150 BL2...

  • Page 66: Diagnostic Information And Procedure

    D Battery cable is corroded or D Repair or Replace the battery Starting the Engine damaged. cable. D Loosen the generator drive belt. D Adjust the belt tension or Replace the belt. D Faulty wiring harness. D Repair the wiring harness. DAEWOO M-150 BL2...
  • Page 67 Engine Idling State is Unstable the gap. D Faulty ignition coil. D Replace the ignition coil. D Poor ignition timing. D Reset the valve timing. D Poor ignition timing. D Reset the valve timing. Poor Engine Accelerating DAEWOO M-150 BL2...

  • Page 68: Battery Load Test

    0.5 volt or less. If the voltage drop is more than 0.5 volt, check the ground path from the generator housing to the negative battery cable. 14. Check, clean, tighten, and recheck all of the ground connections. DAEWOO M-150 BL2...

  • Page 69: Generator System Check

    If not, detach the harness at the generator and fore assuming that a grounded ‘‘L’’ terminal circuit has ground the ‘‘L’’ terminal in the harness with a fused, damaged the regulator. Refer to “Generator” in the Unit 5-ampere jumper lead. Repair section. DAEWOO M-150 BL2...

  • Page 70: Repair Instructions

    (41–48 lb-ft) (a). D Tighten the starter solenoid nut to 9–12 NSm (80–106 lb-in) (b). D Tighten the harness clip bolt to 9–12 NSm (80–106 lb-in) (c). D Tighten the ground bolt to 35–41 NSm (26–30 lb-ft) D12E5031 (d). DAEWOO M-150 BL2...

  • Page 71: Generator

    (1). D Remove the engine mounting lower bracket bolts (2). D Remove the engine mounting lower bracket (3). D102E506 5. Remove the generator. D Remove the generator adjusting bolt (1). D Carefully remove the genrator (2). D102E507 DAEWOO M-150 BL2...

  • Page 72: Battery

    D Remove the battery cable nut to disconnect the positive battery cable (3). D12E511A 2. Remove the battery. D Remove the battery rod nut (1). D Remove the battery rod (2). D Remove the battery (3). D102E512 DAEWOO M-150 BL2...

  • Page 73: Distributor

    D Carefully remove the distributor assembly (2). D102E515 Installation Procedure 1. Install in the reverse order of removal. 2. Install the distributor bolts. 10–16 NSm Tighten Tighten the distributor bolts to 10–16 NSm (89–142 lb- in). D12E516A DAEWOO M-150 BL2...

  • Page 74: Ignition Coil

    D Remove the ignition coil (2). D102E518 Installation Procedure 1. Install in the reverse order of removal. 2. Install the ignition coil screws. Tighten Tighten the ignition coil screws to 4–7 NSm (35–62 lb- in). 4–7 NSm D12E519A DAEWOO M-150 BL2...

  • Page 75: Unit Repair

    D Disconnect the starter motor terminal M (1). D Connect the 12-volt battery lead to the starter mo- tor terminals M and S. Notice: Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid. (in 10 seconds) D102E703 DAEWOO M-150 BL2...
  • Page 76 D Disconnect the starter motor terminal M (1). D Connect the 12-volt battery lead to the starter mo- tor terminal S and body. Notice: Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid. D102E707 DAEWOO M-150 BL2...
  • Page 77 D Replace the starter motor if necessary. D102E710 Disassembly Procedure 1. Remove the starter contact end frame. D Remove the through-bolts (1). D Remove the contact end frame bolts (2). D Remove the frame with the spacer (3). D102E711 DAEWOO M-150 BL2...
  • Page 78 D Remove the armature set (1). D Remove the rubber sealer (2). D Remove the shift lever plate (3). D Remove the shift lever (4). D Remove the solenoid (5). D Remove the gasket (6). D102E715 DAEWOO M-150 BL2...
  • Page 79 D Inspect the brushes, the pop-out springs and the brush holder for wear and damage. Replace the brushes, if necessary. a. Brushes wear limit. Desciption Standard Limit Brushes wear 11.3–11.5 mm 7.0–7.25 mm (0.445–0.453 in) (0.275–0.285 in) D102E719 DAEWOO M-150 BL2...

  • Page 80: Generator (A-Type: Mando)

    3. Remove the pulley and rotor assembly from the front bracket. D Cover the rotor with the cloth (1). D Place the pulley upwards and vice the rotor (2). D Remove the pulley nut (3). D Remove the pulley (4). D102E723 DAEWOO M-150 BL2...
  • Page 81 7. Remove the stator assembly from the rear bracket. D Remove the rectifier screw (1). D Remove the brush holder and regulator assembly screws (2). D Remove the stator assembly with the rectifier / brush holder / regulator (3). D102E727 DAEWOO M-150 BL2...
  • Page 82 D Test the rotor for open or ground circuit by using the ohmmeter (3). Replace the rotor if necessary. D102E730 2. Inspect the stator. D Test the stator for an open circuit by using the ohm- meter (1). Replace the stator if necessary. D102E731 DAEWOO M-150 BL2...
  • Page 83 Inspect the open circuit for stator coil lead termi- nals using the ohmmeter (2). Replace the rectifier if necessary. D102E734 4. Inspect trio diodes. D Inspect the open circuit for trio diodes using the ohmmeter (1). D Replace the heat sink if necessary (a). D102E735 DAEWOO M-150 BL2...
  • Page 84 9–12 NSm (80–106 lb-in) (a). D Tighten the battery positive terminal nut to 4–7 NSm (35–62 lb-in) (b). D12E738A D Tighten the front bearing spot plate screws to 6–8 NSm (53–71 lb-in) (c). 6–8 NSm D102E739 DAEWOO M-150 BL2...

  • Page 85: Generator (B-Type: Dac)

    D Remove the rectifier bolts (2). D Remove the rectifier / regulator screw (3). D Remove the brush holder / regulator screw (4). D Remove the regulator screw (5). D Remove the regulator / brush holder / rectifier as- sembly (6). D102E743 DAEWOO M-150 BL2...
  • Page 86 D Remove the collar (1). D Remove the rotor from the driver end bracket (2). D Remove the collar from the rotor shaft (3). D Inspect the front bearing for corrosion, wear, noisy and other damage (4). D102E747 DAEWOO M-150 BL2...
  • Page 87 D Inspect the fan blade for damage. D102E750 2. Inspect the stator. D Test the rotor for an open circuit by using the ohm- meter. The reading should be sufficiently low, or the stator must be replaced (1). D102E751 DAEWOO M-150 BL2...
  • Page 88 Inspect the open circuit for stator coil lead termi- nals using the ohmmeter (2). Replace the rectifier if necessary. D102E754 4. Inspect trio diodes. D Inspect the open circuit for trio diodes using the ohmmeter (1). Replace the heat sink if necessary (a). D102E755 DAEWOO M-150 BL2...
  • Page 89 D Tighten the brush holder / regulator screw to 9–12 NSm (80–106 lb-in) (c). D12E757A D Tighten the rectifier bolts to 9–12 NSm (80–106 lb- in) (d). 9–12 NSm D12E758A D Tighten the pulley nut to 80-110 NSm (59–81 lb-ft) (e). 80–110 NSm D12E759A DAEWOO M-150 BL2...

  • Page 90: Distributor Assembly

    D Inspect the rotor for damage or carbon traces (c). D102E762 3. Remove the inner / outer cover from the distributor housing. D Remove the outer cover (1). D Remove the screws (2). D Remove the inner cover (3). D102E763 DAEWOO M-150 BL2...
  • Page 91 D Remove the bearing plate (2). D102E766 7. Remove the coupling, shaft and bearing from the dis- tributor housing. D Remove the coupling (1). D Remove the shaft using the press (2). D Remove the bearing (3). D102E767 DAEWOO M-150 BL2...
  • Page 92 1E – 36 ENGINE ELECTRICAL Assembly Procedure 1. Install in the reverse order of removal. D Lubricate the shaft with clean engine oil. D102E768 DAEWOO M-150 BL2...

  • Page 93: Schematic And Routing Diagrams

    ENGINE ELECTRICAL 1E – 37 SCHEMATIC AND ROUTING DIAGRAMS STARTING SYSTEM D12E2011 DAEWOO M-150 BL2...

  • Page 94: Charging System

    1E – 38 ENGINE ELECTRICAL CHARGING SYSTEM D12E2021 DAEWOO M-150 BL2...

  • Page 95: Ignition System Circuit - Tipical

    ENGINE ELECTRICAL 1E – 39 IGNITION SYSTEM CIRCUIT – TYPICAL D12E2031 DAEWOO M-150 BL2...

  • Page 96: Ignition System Circuit - Euro Iii

    1E – 40 ENGINE ELECTRICAL IGNITION SYSTEM CIRCUIT – EURO III MAA1E010 DAEWOO M-150 BL2...

  • Page 97: Specifications

    – WR8DCX – Type Lead – BPR5EY – RN9YC – WR8DC – Spark Plug Unlead mm (in.) 1.1 (0.043) – 1.2 (0.047) – Lead mm (in.) 0.8 (0.031) – Ignition Wire Ignition Wire Resistance KΩ/m 2.5–12.0 – DAEWOO M-150 BL2...

  • Page 98: Battery Specifications

    Generator Belt Tension Adjusting Bolt 18–28 13–21 – Generator Shackle Bracket Bolt 45–55 33–41 – Generator Lower Bracket–to–Generator Bolt/Nut 18–28 13–21 – Ground Bolt 35–41 26–30 – Ignition Coil Screw 4–7 – 35–62 Ignition Coil Bracket Bolt 9–12 – 80–106 DAEWOO M-150 BL2...
  • Page 99 ......1F-74 Reading Diagnostic Trouble Codes ..1F-13 Primary System-Based Diagnostics ..1F-15 DAEWOO M-150 BL2...
  • Page 100 DTC P1385 Rough Road Sensor Circuit Fault (ABS) ....... . 1F-178 DAEWOO M-150 BL2...
  • Page 101 ....1F-324 Evaporator Emission Canister ... . . 1F-309 DAEWOO M-150 BL2...

  • Page 102: Description And Operation

    The ECM uses the CMP signal to indi- determine how much fuel to provide to the engine. The cate the position of the #1 piston during its power stroke. This allows the ECM to calculate true sequential fuel in- DAEWOO M-150 BL2...

  • Page 103: Evaporative Emission Control System Operation

    OPERATION D Increasing the fuel injector pulse width. A Positive Crankcase Ventilation (PCV) control system D Increasing the idle speed rpm. is used to provide complete use of the crankcase va- D Increasing the ignition dwell time. DAEWOO M-150 BL2...

  • Page 104: Engine Coolant Temperature Sensor

    0.4–0.8 volt. As the throttle valve opens, the out- cally by the Engine Control Module (ECM). The EEGR put increases so that, at Wide Open Throttle (WOT), the valve feeds small amounts of exhaust gas into the intake output voltage will be about 4.5–5 volts. DAEWOO M-150 BL2...

  • Page 105: Intake Air Temperature Sensor

    When manifold pressure is high, vacuum is low. The in damage to the Idle Air Control (IAC) valve or to the MAP sensor is also used to measure barometric pres- throttle body. sure. This is performed as part of MAP sensor calcula- DAEWOO M-150 BL2...

  • Page 106: Engine Control Module

    The find the shut down. Also, an extended crank time would be no- ticed on some engines. Dieseling could also occur be- DAEWOO M-150 BL2...

  • Page 107: Strategy-Based Diagnostics

    Many of the major fuel companies advertise that using “premium” gasoline will ing conditions present when the DTC was set as improve the performance of your vehicle. Most premium noted in Failure Records or Freeze Frame data. DAEWOO M-150 BL2...

  • Page 108: Serial Data Communications

    D The diagnostic test has been completed since the last Many of the EOBD system diagnostics will not run if the Engine Control Module (ECM) detects a fault on a re- ignition cycle. lated system or component. One example would be that DAEWOO M-150 BL2...

  • Page 109: Comprehensive Component Monitor Diagnostic Operation

    Passive and Active Diagnostic Tests “Enable criteria” is another way of saying “conditions re- quired.” A passive test is a diagnostic test which simply monitors a vehicle system or component. Conversely, an active DAEWOO M-150 BL2...
  • Page 110 When a if other diagnostics are performed first. malfunction is detected by the control module, a DTC is set, and the Malfunction Indicator Lamp (MIL) is illumi- nated. DAEWOO M-150 BL2...

  • Page 111: Dtc Types

    D “Armed” after two consecutive trip with a fail. procedure. When DTCs are cleared, the Freeze Frame and Failure Record data which may help diagnose an in- D “Disarmed” after one trip with a pass. DAEWOO M-150 BL2...
  • Page 112 DTC numbers that are DTC tests which run and pass will cause that DTC num- supported by the vehicle being tested. If an attempt is, ber to be removed from the scan tool screen. DAEWOO M-150 BL2...

  • Page 113: Primary System-Based Diagnostics

    This clean air refer- ence is obtained by way of the O2S wire(s). Any attempt This message display indicates that the selected diag- to repair the wires, connector or terminals could result in nostic test has done the following: DAEWOO M-150 BL2...
  • Page 114 DTC or HO2S DTC may set). Use a data on EOBD compliant vehicles. Knowing which spe- scan tool to observe fuel trim counts while the problem is cific cylinder(s) misfired can lead to the root cause, even occurring. DAEWOO M-150 BL2...

  • Page 115: Diagnostic Information And Procedures

    D Improperly formed or damaged terminals. All connec- 1. Turn the ignition ON for 10 seconds. tor terminals in a problem circuit should be carefully 2. Turn the ignition OFF for 10 seconds. DAEWOO M-150 BL2...

  • Page 116: Euro On-Board Diagnostic (Eobd) System Check

    The EOBD system check is an organized approach to connections, and damaged harness. identifying a problem created by an electronic engine control system malfunction. DAEWOO M-150 BL2...
  • Page 117 2. Attempt to display the ECM data with the scan – tool. Does the scan tool display ECM engine data? Go to Step 2 Go to Step 11 Replace the ECM. – – Is the repair complete? System OK DAEWOO M-150 BL2...

  • Page 118: Ecm Output Diagnosis

    Replace the Engine control Module (ECM). – – Is the repair complete? Go to Step 9 Operate the vehicle within the conditions under which the original symptom was noted. – Does the system now operate properly? System OK Go to Step 2 DAEWOO M-150 BL2...

  • Page 119: Multiple Ecm Information Sensor Dtcs Set

    A short to voltage in one of the sensor circuits can cause harnesses related to the affected sensors. A change one or more of the following DTCs to be set: P0108, in the affected sensor’s displayed value will indicate P0113, P0118, P0123, P1106. the location of the fault. DAEWOO M-150 BL2...
  • Page 120 Replace the EEGR valve. – – Is the repair complete? Go to Step 19 Locate and repair the short to voltage in the MAP sensor signal circuit. – – Is the repair complete? Go to Step 19 DAEWOO M-150 BL2...
  • Page 121 Does the scan tool indicate that this diagnostic ran and passed? Go to Step 20 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 122 1F – 24 ENGINE CONTROLS MAA1F020 DAEWOO M-150 BL2...

  • Page 123: Engine Cranks But Will Not Run

    D Terminal 1 of the CKP sensor connector and ground. D Terminal 2 of the CKP sensor connector and ground. ≈ 0.4 V Are the voltage measure within the value specified? Go to Step 13 Go to Step 12 DAEWOO M-150 BL2...
  • Page 124 D Between 2 and 3 Are the resistance within the value specified? 5.3 kΩ Go to Step 21 Go to Step 20 Replace the EI system ignition coil. – – Is the repair complete? Go to Step 2 DAEWOO M-150 BL2...
  • Page 125 1. Remove the fuel pump assembly from the fuel tank. 2. Inspect the fuel pump sender and the fuel – coupling hoses for a restriction. 3. Inspect the in-tank fuel filter for restriction. Is the problem found? Go to Step 33 Go to Step 25 DAEWOO M-150 BL2...
  • Page 126 4. Connect test light between fuel injector harness connector 1 and ground. 5. Repeat step 4 for each of the remaining fuel injectors. Does the test light on at all of the fuel injectors? Go to Step 42 Go to Step 45 DAEWOO M-150 BL2...
  • Page 127 Is the repair complete? Go to Step 2 Replace the fuse or repair the wiring as needed. – – Is the repair complete? Go to Step 2 Replace the ECM. – – Is the repair complete? Go to Step 2 DAEWOO M-150 BL2...

  • Page 128: No Malfunction Indicator Lamp

    Control Module (ECM) controls the MIL by providing a to-wiring connections or physical damage to the wiring ground path through the MIL control circuit to turn ON harness. the MIL. Diagnostic Aids An open ignition F16 fuse will cause the entire cluster to be inoperative. DAEWOO M-150 BL2...
  • Page 129 1. Check for an open circuit between fuse F16 and terminal 68 of ECM connector and repair as Go to “On needed. Board – – 2. Check the MIL bulb and replace if blown. Diagnostic System Check” Is the repair complete? DAEWOO M-150 BL2...

  • Page 130: Malfunction Indicator Lamp On Steady

    MIL control circuit to turn ON tor Lamp (MIL) will be turned ON and remain ON until the MIL. the engine is running, if no Diagnostic Trouble Codes (DTCs) are stored. Battery voltage is supplied through DAEWOO M-150 BL2...
  • Page 131 Go to Step 1 Allow the engine to idle until normal operating temperature is reached. Check if any DTCs are set. – Are any DTCs displayed that have not been Go to applicable diagnosed? DTC table System OK DAEWOO M-150 BL2...

  • Page 132: Fuel System Diagnosis

    Is the fuel pressure around the values specified and System OK Go to Step 8 (55 psi) holding steady? With the fuel system under pressure, inspect the fuel return outlet for leaking. – Go to Step 8 Go to Step 9 Is the problem found? DAEWOO M-150 BL2...
  • Page 133 (55 psi) holding steady? 1. Replace the fuel pressure regulator. 2. Start the engine. – 3. Allow the engine to idle. 380 kPa Is the fuel pressure around the values specified and (55 psi) System OK holding steady? DAEWOO M-150 BL2...

  • Page 134: Fuel Pump Relay Circuit Check

    Go to Step 2 1. Turn the ignition OFF. 2. Connect battery positive to fuel pump test connect. – 3. Listen for in-tank fuel pump operation. Does the fuel pump operate? Go to Step 4 Go to Step 3 DAEWOO M-150 BL2...
  • Page 135 Repair an open circuit as needed. – – Is the repair complete? System OK Replace the fuel pump relay. – Is the repair complete? System OK Go to Step 13 Replace the ECM. – – Is the repair complete? System OK DAEWOO M-150 BL2...

  • Page 136: Main Relay Circuit Check

    There will be no voltage supplied to the EI system The fuel injectors are supplied voltage through the en- ignition coil, or the fuel injectors. Without voltage sup- gine fuse block fuse EF25. plied to these components, they will not operate. DAEWOO M-150 BL2...
  • Page 137 Is the resistance within the specified value Go to Step 10 Go to Step 9 Repair open circuit. – – Is the repair complete? System OK Replace the main relay. – – Is the repair complete? System OK DAEWOO M-150 BL2...

  • Page 138: Manifold Absolute Pressure Check

    The ECM uses the MAP sensor for the delivery and igni- voltage output. The Engine Control Module (ECM) send tion timing changes. a 5-volt reference voltage to the MAP sensor. As the in- take manifold pressure changes, the output voltage of DAEWOO M-150 BL2...
  • Page 139 Is the problem found. Go to Step 4 Go to Step 5 Repair the MAP sensor connector terminals as needed. – – Is the repair complete? System OK Replace the MAP sensor. – – Is the repair complete? System OK DAEWOO M-150 BL2...

  • Page 140: Idle Air Control System Check

    11. Turn the ignition OFF. The idle learn procedure is Idle Air Control Valve Reset Procedure complete. Whenever the battery cable or the Engine Control Mod- ule (ECM) connector or the ECM fuse EF6 is discon- DAEWOO M-150 BL2...
  • Page 141 Go to Step 9 Go to Step 10 Repair or replace the throttle body assembly and/or ECM connector terminals as needed. – – Is the repair complete? System OK Replace the ECM. – – Is the repair complete? System OK DAEWOO M-150 BL2...
  • Page 142 1F – 44 ENGINE CONTROLS MAA1F080 DAEWOO M-150 BL2...

  • Page 143: Ignition System Check

    Is spark present from all of the ignition wires? System OK While cranking the engine, measure the voltage at the EI system ignition coil connector terminal 2. Does the voltage fluctuate within the values specified? 0.2–2.0 V Go to Step 10 Go to Step 9 DAEWOO M-150 BL2...
  • Page 144 System OK 1. Turn the ignition ON. 2. Measure the voltage between the CKP sensor connector terminals 2 and 3. Is the voltage within the value specified? 0.95–1.10 V Go to Step 24 Go to Step 21 DAEWOO M-150 BL2...
  • Page 145 – – connector terminal 87. Is the repair complete? System OK Check for a damage in the terminal of the EI system ignition coil connector and repair as needed. – – Is the repair complete? System OK DAEWOO M-150 BL2...

  • Page 146: Engine Cooling Fan Circuit Check

    ECM will change the cooling fans from high speed to low speed when the coolant temperature is 97_C D If the owner complained of an overheating problem, it (207_F). must be determined if the complaint was due to an DAEWOO M-150 BL2...
  • Page 147 – – Is the repair complete? System OK Check for a damaged terminals in main cooling fan connector and repair it or replace the main cooling – – fan. Is the repair complete? System OK DAEWOO M-150 BL2...
  • Page 148 Are the resistance within the value specified? Go to Step 18 Go to Step 17 Repair open circuit. – – Is the repair complete? System OK Replace the low speed cooling fan relay. – – Is the repair complete? System OK DAEWOO M-150 BL2...
  • Page 149 ENGINE CONTROLS 1F – 51 BLANK DAEWOO M-150 BL2...

  • Page 150: Data Link Connector Diagnosis

    D Physical damage to the wiring harness. Ensure that the correct application (model line, car year, etc.) has been selected on the scan tool. If communica- D Corrosion. tion still cannot be established, try the scan tool on DAEWOO M-150 BL2...
  • Page 151 Go to Step 1 1. Allow the engine to idle until normal operation temperature reached. 2. Check if any DTCs are set? – Are any DTCs displayed that have not been Go to applicable diagnosed? DTC table System OK DAEWOO M-150 BL2...

  • Page 152: Fuel Injector Balance Test

    14. Reconnect the fuel injector harness and review the 5. The ignition switch must be in the OFF position at symptom diagnostic tables. least 10 seconds in order to complete the electronic control module (ECM) shutdown cycle. DAEWOO M-150 BL2...

  • Page 153: Diagnostic Trouble Code Diagnosis

    Injector 3 Low Voltage P0268 Injector 3 high voltage P0300 Multifle Cylinder Misfire BLINKING/ON P1320 Crankshatft Segment Period Segment Adaptation At Limit P1321 Crankshatft Segment Period Tooth Error P0327 Knock Sensor Circuit Fault P0335 Magnetic Crankshaft Position Sensor Electrical Error DAEWOO M-150 BL2...
  • Page 154 Engine Control Module RAM Error P0605 Engine Control Module NMVY Write Error P1610 Main Relay High Voltage P1611 Main Relay Low Voltage P1628 Immobilizer No Successful Communication P1629 Immobilizer Wrong Computation P0656 Fuel Level Gauge High Circuit Fault DAEWOO M-150 BL2...
  • Page 155 ENGINE CONTROLS 1F – 57 Diagnostic Trouble Codes (Cont’d) Function Error Type Illuminate MIL P1660 Malfunction Indicator Lamp(MIL) High Voltage P1661 Malfunction Indicator Lamp(MIL) Low Voltage DAEWOO M-150 BL2...
  • Page 156 If a DTC P 0107 is intermittent, refer to “Manifold Abso- D No Throttle Position (TP) Sensor fails conditions lute Pressure Check” in this Section for further diagno- present. sis. D The Throttle Position (TP) angle greather than 20.0 DAEWOO M-150 BL2...

  • Page 157: Dtc P0107 Manifold Absolute Pressure Sensor Low Voltage

    2. Check for an open or short to ground in the wire between the MAP sensor connector terminal B – and the ECM connector terminal 73. Is the problem found ? Go to Step 10 Go to Step 12 DAEWOO M-150 BL2...
  • Page 158 – Is the replacement complete? Go to Step 13 Go to Step 2 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displaced that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 159 ENGINE CONTROLS 1F – 61 BLANK DAEWOO M-150 BL2...

  • Page 160: Voltage

    D The ECM will record operating conditions at the time function. the diagnostic fails. This information will be stored in the Freeze Frame and Failure Records buffers. DAEWOO M-150 BL2...
  • Page 161 Go to Step 10 Go to Step 12 1. Repair the wire or the connector terminal as needed. 2. Clear any DTCs from the ECM. – – 3. Perform the diagnostic system check. Is the repair complete? System OK DAEWOO M-150 BL2...
  • Page 162 – Is the replacement complete? Go to Step 13 Go to Step 2 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displaced that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 163 ENGINE CONTROLS 1F – 65 BLANK DAEWOO M-150 BL2...
  • Page 164 Resistance Values table to evaluate the possibility of a D Stores a History DTC on the third consecutive with a skewed sensor. Refer to “Temperature vs. Resistance” fail (The DTC will be armed after the second fail). in this Section. DAEWOO M-150 BL2...

  • Page 165: Dtc P0112 Intake Air Temperature Sensor Low Voltage

    4. Perform the diagnostic system check. Is the repair complete? Go to Step 10 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displaced that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 166 Use the temperature vs. Resistance Values table to D Stores a History DTC on the third consecutive with a evaluate the possibility of a skewed sensor. Refer to fail (The DTC will be armed after the second fail). “Temperature vs. Resistance” in this Section. DAEWOO M-150 BL2...

  • Page 167: Dtc P0113 Intake Air Temperature Sensor High Voltage

    1. Turn the ignition switch to LOCK. 2.Repair the wire of the connector terminals as needed. – – 3. Clear any DTCs from the ECM. 4. Perform the diagnostic system check. Is the repair complete? System OK DAEWOO M-150 BL2...
  • Page 168 2. Perform the diagnostic system check. – – Is the repair complete? Go to Step 12 Check if any additional DTCs are set. – Are any DTCs displaced that have not been Go to applicable diagnosed? DTC table System OK DAEWOO M-150 BL2...
  • Page 169 ENGINE CONTROLS 1F – 71 BLANK DAEWOO M-150 BL2...
  • Page 170 Refer to “Tem- D A low voltage condition exits. perature vs. Resistance” in this Section. D ECT voltage is less than 0.03V. Action Taken when the DTC Sets D The Malfunction Indicator Lamp (MIL) will illuminate. DAEWOO M-150 BL2...

  • Page 171: Dtc P0117 Engine Coolant Temperature Sensor Low Voltage

    3. Perform the diagnostic system check. Is the repair complete? Go to Step 10 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displaced that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 172 Use the temperature vs. resistance values table to eval- temperature is less than –40°C(–40°F). uate the possibility of a skewed sensor. Refer to “Tem- D ECT voltage is greater than 4.98V. perature vs. Resistance” in this Section. DAEWOO M-150 BL2...

  • Page 173: Dtc P0118 Engine Coolant Temperature Sensor High Voltage

    3. Perform the diagnostic system check. Is the repair complete? Go to Step 10 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displaced that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 174 D The ECM will record operating conditions at the time DTC. If the dc occurs intermittently, using the Diagnostic the diagnostic fails. This information will be stored in table may help isolate the problem. the Freeze Frame and Failure Records buffers. DAEWOO M-150 BL2...
  • Page 175 Go to Step 11 Replace the throttle body assembly. – – Is the action complete? Go to Step 12 1. Turn the ignition switch OFF. 2. Replace the ECM. – – Is the action complete? Go to Step 12 DAEWOO M-150 BL2...

  • Page 176: Dtc P0122 Throttle Position Sensor Low Voltage

    Does the scan tool indicate that this diagnostic has run and passed? Go to Step 13 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been Table System OK diagnosed? DAEWOO M-150 BL2...
  • Page 177 ENGINE CONTROLS 1F – 79 BLANK DAEWOO M-150 BL2...
  • Page 178 D A history DTC is stored. be result of an open sensor ground circuit. D The TP angle will default to 0% when the vehicle speed is less than 3 km/h (2 mph) and 10% when the DAEWOO M-150 BL2...

  • Page 179: Dtc P0123 Throttle Position Sensor High Voltage

    3. Operate the vehicle within the Conditions for setting this DTC as specified in the supporting text. Does the scan tool indicate that this diagnostic has run and passed? Go to Step 13 Go to Step 2 DAEWOO M-150 BL2...
  • Page 180 1F – 82 ENGINE CONTROLS DTC P0123 – Throttle Position Sensor High Voltage (Cont’d) Step Action Value(s) Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been Table System OK diagnosed? DAEWOO M-150 BL2...
  • Page 181 ENGINE CONTROLS 1F – 83 BLANK DAEWOO M-150 BL2...
  • Page 182 Action Taken when the DTC Sets An exhaust manifold gasket leak of a cracked exhaust D The Malfunction Indicator Lamp (MIL) will illuminate. manifold may cause outside air to be pulled into the ex- haust and past the sensor. DAEWOO M-150 BL2...

  • Page 183: Dtc P0131 Oxygen Sensor Low Voltage

    2. Clear the DTCs from the ECM. – – 3. Perform the diagnostic system check. Is the repair complete? System OK 1. Replace the ECM. 2. Perform the diagnostic system check. – – Is the repair complete? Go to Step 12 DAEWOO M-150 BL2...
  • Page 184 1F – 86 ENGINE CONTROLS DTC P0131 – Oxygen Sensor Low Voltage (Cont’d) Step Action Value(s) Check if any additional DTCs are set. – Are any DTCs displaced that have not been Go to applicable diagnosed? DTC table System OK DAEWOO M-150 BL2...
  • Page 185 ENGINE CONTROLS 1F – 87 BLANK DAEWOO M-150 BL2...
  • Page 186 D A history DTC is stored. haust and past the sensor. Conditions for Clearing the MIL/DTC D The MIL will turn off after consecutive ignition cycles in which the diagnostic runs without a fault. DAEWOO M-150 BL2...

  • Page 187: Dtc P0132 Oxygen Sensor High Voltage

    4. Perform the diagnostic system check. Is the replacement complete? Go to Step 7 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displaced that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 188 Diagnostic Aids onds. Normal scan tool voltage varies between 0.15 to 8.5mV D A number of glitches higher than 5 during the test. while in Closed Loop. If DTC P0133 is intermittent, refer to “Intermittent” in this Section. DAEWOO M-150 BL2...

  • Page 189: Dtc P0133 Oxygen Sensor No Activity

    Is the repair complete? Go to Step 12 Go to Step 10 1. Turn the ignition switch to LOCK – 2. Replace the ECM. – 3. Perform the diagnostic system check. Is the repair complete? System OK DAEWOO M-150 BL2...
  • Page 190 2. Perform the diagnostic system check – – Is the repair complete Go to Step 13 Check if any additional DTCs are set. – Are any DTCs displaced that have not been Go to applicable diagnosed? DTC table System OK DAEWOO M-150 BL2...
  • Page 191 ENGINE CONTROLS 1F – 93 BLANK DAEWOO M-150 BL2...
  • Page 192 D An exhaust manifold gasket leak of a cracked ex- D Emission related. haust manifold may cause outside air to be pulled into D “Armed” after two trip with a fail. the exhaust and past the sensor. D “Disarmed” after one trip with a pass. DAEWOO M-150 BL2...

  • Page 193: Dtc P0137 Heated Oxygen Sensor Low Voltage

    Is the replacement complete? Go to Step 10 1. Turn the ignition switch to LOCK. 2. Replace the ECM. 3. Road tests the vehicle. – – 4. Perform the diagnostic system check. Is the replacement complete? Go to Step 10 DAEWOO M-150 BL2...
  • Page 194 1F – 96 ENGINE CONTROLS DTC P0137 – Heated Oxygen Sensor Low Voltage (Cont’d) Step Action Value(s) Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displaced that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 195 ENGINE CONTROLS 1F – 97 BLANK DAEWOO M-150 BL2...
  • Page 196 (The DTC will be armed after the second fail). haust manifold may cause outside air to be pulled into D Stores a Freeze Frame on the third consecutive trip the exhaust and past the sensor. with a fail (if empty). DAEWOO M-150 BL2...

  • Page 197: Dtc P0138 Heated Oxygen Sensor High Voltage

    4. Perform the diagnostic system check. Is the replacement complete? Go to Step 7 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displaced that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 198 D Normal scan tool voltage varies between 0.15 to sensor controller. 8.5mV while in Closed Loop. If DTC P0140 is inter- D DTCs P0107, P0108, P0112, P0113, P0117, P0118, mittent, refer to “Intermittent” in this Section. P0122, P0123, P0137, P0138, P0137, P0138, DAEWOO M-150 BL2...

  • Page 199: Dtc P0140 Heated Oxygen Sensor No Activity

    4. Operate the vehicle within the conditions for setting this DTC as specified in the supporting text. Does the scan tool indicated that this diagnostic has run and passed? Go to Step 13 Go to Step 2 DAEWOO M-150 BL2...
  • Page 200 4. Perform the diagnostic system check. Is the replacement complete? Go to Step 15 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displaced that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 201 ENGINE CONTROLS 1F – 103 BLANK DAEWOO M-150 BL2...
  • Page 202 (The DTC will be armed after the second fail). the exhaust and past the sensor. D Stores a Freeze Frame on the third consecutive trip with a fail (if empty). DAEWOO M-150 BL2...

  • Page 203: Dtc P0141 Heated Oxygen Sensor Heater Malfunction

    4. Perform the diagnostic system check. Is the replacement complete? Go to Step 6 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displaced that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 204 Check the brake power booster check valve for possible D MIL on if failure is detected in three consecutive trips. leaks. D Stores a History DTC on the third consecutive with a fail (The DTC will be armed after the second fail). DAEWOO M-150 BL2...

  • Page 205: Dtc P0171 Fuel Trim System Too Lean

    Is the Long Term Fuel Trim value below the specified value? –22% Go to Step 8 Go to Step 9 Lean condition is not present. Go to – “Symptom Does a driveability problem exist? Diagnosis” Go to Step 16 DAEWOO M-150 BL2...
  • Page 206 Does the scan tool indicate that this diagnostic has run and passed? Go to Step 17 Go to Step 2 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 207 D Adaptive index is ready. A shorted 5 volt reference circuit may cause a DTC P0172 to set. Check the 5 volt reference sensors for ab- Action Taken when the DTC Sets normal readings. D Emission related. DAEWOO M-150 BL2...

  • Page 208: Dtc P0172 Fuel Trim System Too Rich

    3. Start the engine. 4. Operate the vehicle in Closed Loop while monitoring the Long Term Fuel Trim value. Does the Long Term Fuel Trim value increase above the specified value? Go to Step 20 Go to Step 12 DAEWOO M-150 BL2...
  • Page 209 3. If the screws are OK, replace the TP sensor. Is the repair complete? Go to Step 21 1. Turn the ignition OFF. 2. Replace the MAP sensor. – – Is the repair complete? Go to Step 21 DAEWOO M-150 BL2...
  • Page 210 Does the scan tool indicate that this diagnostic has Go to Step 21 Go to Step 2 run and passed? Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 211 ENGINE CONTROLS 1F – 113 BLANK DAEWOO M-150 BL2...
  • Page 212 D Poor terminals to wire connection D Coolant fan turns ON. D Physical damage to the wiring harness Conditions for Clearing the MIL/DTC D The MIL will turn off after 4 consecutive ignition cycles in which the diagnostic runs without a fault. DAEWOO M-150 BL2...

  • Page 213: Dtc P1230 Fuel Pump Relay Low Voltage . 1F-114

    Go to Step 10 Check for a short to ground wire between the fuel pump relay connector terminal 85 and the ECM – connector terminal 10. Is the problem found? Go to Step 12 Go to Step 13 DAEWOO M-150 BL2...
  • Page 214 Does the scan tool indicate that this diagnostic has run and passed? Go to Step 15 Go to Step 2 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 215 ENGINE CONTROLS 1F – 117 BLANK DAEWOO M-150 BL2...
  • Page 216 D Poor terminals to wire connection Conditions for Clearing the MIL/DTC D Physical damage to the wiring harness D The MIL will turn off after 4 consecutive ignition cycles in which the diagnostic runs without a fault. DAEWOO M-150 BL2...

  • Page 217: Dtc P1231 Fuel Pump Relay High Voltage

    2. Install the fuel pump relay. 3. Turn the ignition OFF for 10 seconds. 4. Clear any DTCs from ECM. 5. Turn the ignition switch to ON. Does the fuel pump operate? 2.55 seconds System OK Go to Step 10 DAEWOO M-150 BL2...
  • Page 218 Does the scan tool indicate that this diagnostic has run and passed? Go to Step 12 Go to Step 2 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 219 ENGINE CONTROLS 1F – 121 BLANK DAEWOO M-150 BL2...
  • Page 220 The injector resistance tested at the ECM connection is D The Malfunction Indicator Lamp (MIL) will illuminate. slightly more than it tested directly at the injector 2ecause it includes resistance of the harness wires. The normal value is about 13.5Ω. DAEWOO M-150 BL2...

  • Page 221: Dtc P0261 Injector 1 Low Voltage

    3. Perform the Diagnostic System Check. Does DTC P0261 reset? Go to Step 10 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displaced that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 222 The injector resistance tested at the ECM connection is D The Malfunction Indicator Lamp (MIL) will illuminate. slightly more than it tested directly at the injector 2ecause it includes resistance of the harness wires. The normal value is about 13.5Ω. DAEWOO M-150 BL2...

  • Page 223: Dtc P0262 Injector 1 High Voltage

    3. Perform the Diagnostic System Check. Is the repair complete? Go to Step 10 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displaced that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 224 The injector resistance tested at the ECM connection is D The Malfunction Indicator Lamp (MIL) will illuminate. slightly more than it tested directly at the injector 2ecause it includes resistance of the harness wires. The normal value is about 13.5Ω. DAEWOO M-150 BL2...

  • Page 225: Dtc P0264 Injector 2 Low Voltage

    3. Perform the Diagnostic System Check. Is the repair complete? Go to Step 10 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displaced that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 226 The injector resistance tested at the ECM connection is D The Malfunction Indicator Lamp (MIL) will illuminate. slightly more than it tested directly at the injector be- cause it includes resistance of the harness wires. The normal value is about 13.5Ω. DAEWOO M-150 BL2...

  • Page 227: Dtc P0265 Injector 2 High Voltage

    3. Perform the Diagnostic System Check. Is the repair complete? Go to Step 10 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displaced that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 228 The injector resistance tested at the ECM connection is D The Malfunction Indicator Lamp (MIL) will illuminate. slightly more than it tested directly at the injector be- cause it includes resistance of the harness wires. The normal value is about 13.5Ω. DAEWOO M-150 BL2...

  • Page 229: Dtc P0267 Injector 3 Low Voltage

    3. Perform the Diagnostic System Check. Is the repair complete? Go to Step 10 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displaced that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 230 Refer to “Fuel Injector 3alance Test” in Action Taken when the DTC Sets this Section to check for malfunctioning injectors. D The Malfunction Indicator Lamp (MIL) will illuminate. DAEWOO M-150 BL2...

  • Page 231: Dtc P0268 Injector 3 High Voltage

    3. Perform the Diagnostic System Check. Is the repair complete? Go to Step 10 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displaced that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 232 1F – 134 ENGINE CONTROLS MAA1F160 DAEWOO M-150 BL2...
  • Page 233 Start the engine and allow it to idle. – Are any Misfire Current counters incrementing? Go to Step 5 Go to Step 6 Are all counters equal (within a percentage of each – other)? Go to Step 7 Go to Step 11 DAEWOO M-150 BL2...
  • Page 234 Go to Step 27 Check the affected fuel injector driver circuit at terminals 90, 58 and 89 for an open, short, or short – to voltage. Is a problem found? Go to Step 18 Go to Step 24 DAEWOO M-150 BL2...
  • Page 235 Does the scan tool indicate that this diagnostic ran and passed? Go to Step 28 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 236 1F – 138 ENGINE CONTROLS MAA1F160 DAEWOO M-150 BL2...

  • Page 237: Dtc P0300 Multiple Cylinder Misfire

    1. Install a scan tool to the Data Link Connector (DLC). 2. Turn the ignition ON, with the engine OFF. – Go to 3. Request Diagnostic Trouble Codes (DTCs) Applicable DTC table Are DTCs P0201, P0202, P0203, P0204 set? Go to Step 3 DAEWOO M-150 BL2...
  • Page 238 2. With a test light connected to ground, probe the ignition feed terminal 1 of the injector harness – connector for each cylinder that had misfire. 3. Crank the engine. Does the test light illuminate? Go to Step 17 Go to Step 19 DAEWOO M-150 BL2...
  • Page 239 Does the scan tool indicate that this diagnostic ran and passed? Go to Step 28 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 240 Freeze Frame and Failure Records buffers. often the condition that caused the DTC to be set oc- D A history DTC is stored. curs. This may assist in diagnosing the condition. DAEWOO M-150 BL2...

  • Page 241: Dtc P1320 Crankshaft Segment Period Segment Adaptation At Limit

    Does the scan tool indicate that this diagnostic ran and passed? Go to Step 8 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 242 This may assist in diagnosing the condition. D A history DTC is stored. Conditions for Clearing the MIL/DTC D The MIL will turn off after four consecutive ignition cycles in which the diagnostic runs without a fault. DAEWOO M-150 BL2...

  • Page 243: Dtc P1321 Crankshaft Segment Period Tooth Error

    Does the scan tool indicate that this diagnostic ran and passed? Go to Step 8 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...

  • Page 244: Dtc P0327 Knock Sensor Circuit Fault

    D Engine Coolant Temperature is higher than 80°C D Improperly formed. (176°F). D Damaged terminals. D Engine rpm is more than 2,500rpm. D Poor terminal-to-wire connections. D Mass air flow is higer than 180mg/tdc. D Physical damage to the wiring harness. DAEWOO M-150 BL2...
  • Page 245 Check the KS signal circuit for an open or a low – voltage or voltage and repair as necessary. Is a repair necessary? Go to Step 12 Go to Step 11 Replace the KS. – – Is the replacement complete? Go to Step 12 DAEWOO M-150 BL2...
  • Page 246 Does the scan tool indicate that this diagnostic has run and passed? Go to Step 13 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 247 ENGINE CONTROLS 1F – 149 BLANK DAEWOO M-150 BL2...
  • Page 248 D The ECM will record operating conditions at the time condition that caused the DTC to be set occurs. This the diagnostic fails. This information will be stored in may assist in diagnosing the condition. the Freeze Frame and Failure Records buffers. DAEWOO M-150 BL2...

  • Page 249: Dtc P0335 Magnetic Crankshaft Position Sensor Electrical Error

    Does the scan tool indicate that this diagnostic run and passed? Go to Step 12 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displaced that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 250 DTC to be set occurs. This D The MIL will turn off after four consecutive ignition may assist in diagnosing the condition. cycles in which the diagnostic runs without a fault. DAEWOO M-150 BL2...

  • Page 251: Dtc P0336 58X Crankshaft Position Sensor No Plausible Signal

    Does the scan tool indicate that this diagnostic run and passed? Go to Step 12 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displaced that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 252 DTC to be set occurs. This may assist in diagnosing the condition. Conditions for Clearing the MIL/DTC D The MIL will turn off after four consecutive ignition cycles in which the diagnostic runs without a fault. DAEWOO M-150 BL2...

  • Page 253: Dtc P0337 58X Crankshaft Position Sensor No Signal

    Does the scan tool indicate that this diagnostic run and passed? Go to Step 12 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displaced that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 254 D Physical damage to the wiring harness. D A history DTC is stored. Conditions for Clearing the MIL/DTC D The MIL will turn off after four consecutive ignition cycles in which the diagnostic runs without a fault. DAEWOO M-150 BL2...

  • Page 255: Dtc P0341 Camshaft Position Sensor Rationality

    Does the scan tool indicate that this diagnostic run and passed? Go to Step 8 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 256 D Physical damage to the wiring harness. D A history DTC is stored. Conditions for Clearing the MIL/DTC D The MIL will turn off after four consecutive ignition cycles in which the diagnostic runs without a fault. DAEWOO M-150 BL2...

  • Page 257: Dtc P0342 Camshaft Position Sensor No Signal

    Does the scan tool indicate that this diagnostic run and passed? Go to Step 8 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 258 D This DTC can be stored in “key-on” status. D A history DTC will clear after 40 consecutive warm-up D Time of fault fall occurrence is greater than time of the cycles without a fault. DIS fall occurrence. DAEWOO M-150 BL2...

  • Page 259: Dtc P0351 Ignition Signal Coil A Fault

    Does the scan tool indicate that this diagnostic ran and passed? Go to Step 9 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 260 D The MIL will turn off after four consecutive ignition D This DTC can be stored in “key-on” status. cycles in which the diagnostic runs without a fault. D Time of fault fall occurrence is greater than time of the DIS fall occurrence. DAEWOO M-150 BL2...

  • Page 261: Dtc P0352 Ignition Signal Coil B Fault

    Does the scan tool indicate that this diagnostic ran and passed? Go to Step 9 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 262 D The MIL will turn off after four consecutive ignition D This DTC can be stored in “key-on” status. cycles in which the diagnostic runs without a fault. D Time of fault fall occurrence is greater than time of the DIS fall occurrence. DAEWOO M-150 BL2...

  • Page 263: Dtc P0353 Ignition Signal Coil C Fault

    Does the scan tool indicate that this diagnostic ran and passed? Go to Step 9 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 264 D DTC(s) can be cleared by using the scan tool. D No Vehicle Speed Sensor error not set. D Disconnecting the ECM battery feed for more than 10 D VR sensor output signal is higher than 0.26. seconds. DAEWOO M-150 BL2...

  • Page 265: Dtc P1382 Rough Road Data Invalid (Non Abs)

    2. Disconnect the ECM and check the VR sensor signal circuit for high resistance, an open, a low – voltage, or a short to the sensor ground circuit and repair as needed. Is the repair complete? Go to Step 14 Go to Step 9 DAEWOO M-150 BL2...
  • Page 266 Does the scan tool indicate that this diagnostic ran and passed? Go to Step 15 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 267 ENGINE CONTROLS 1F – 169 BLANK DAEWOO M-150 BL2...
  • Page 268 D DTC(s) can be cleared by using the scan tool. D No Vehicle Speed Sensor error not set. D Disconnecting the ECM battery feed for more than 10 seconds. D VR sensor output signal is higher than 0.26. DAEWOO M-150 BL2...

  • Page 269: Dtc P1382 Rough Road Data Invalid (Abs) 1F-170

    2. Disconnect the ECM and check the wheel speed sensor signal circuit for high resistance, an open, – a low voltage, or a short to the sensor ground circuit and repair as needed. Is the repair complete? Go to Step 14 Go to Step 9 DAEWOO M-150 BL2...
  • Page 270 Does the scan tool indicate that this diagnostic ran and passed? Go to Step 15 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 271 ENGINE CONTROLS 1F – 173 BLANK DAEWOO M-150 BL2...
  • Page 272 D No Vehicle Speed Sensor error not set. D Disconnecting the ECM battery feed for more than 10 D VR sensor output signal is higher than 0.26. seconds. D VR sensor output signal is not change for 30 sec- onds. DAEWOO M-150 BL2...

  • Page 273: Dtc P1385 Rough Road Sensor Circuit Fault (Non Abs)

    2. Disconnect the ECM and check the VR sensor signal circuit for high resistance, an open, a low – voltage, or a short to the sensor ground circuit and repair as needed. Is the repair complete? Go to Step 14 Go to Step 9 DAEWOO M-150 BL2...
  • Page 274 Does the scan tool indicate that this diagnostic ran and passed? Go to Step 15 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 275 ENGINE CONTROLS 1F – 177 BLANK DAEWOO M-150 BL2...
  • Page 276 D DTC(s) can be cleared by using the scan tool. D No Vehicle Speed Sensor error not set. D Disconnecting the ECM battery feed for more than 10 seconds. D VR sensor output signal is higher than 0.26. DAEWOO M-150 BL2...

  • Page 277: Dtc P1385 Rough Road Sensor Circuit Fault (Abs)

    2. Disconnect the ECM and check the Wheel speed sensor signal circuit for high resistance, an open, – a low voltage, or a short to the sensor ground circuit and repair as needed. Is the repair complete? Go to Step 14 Go to Step 9 DAEWOO M-150 BL2...
  • Page 278 Does the scan tool indicate that this diagnostic ran and passed? Go to Step 15 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 279 ENGINE CONTROLS 1F – 181 BLANK DAEWOO M-150 BL2...
  • Page 280 EEGR pintle. The actual cycles without a fault. EEGR position should always be near the commanded D DTC(s) can be cleared by using the scan tool. or Desired EEGR position. ThisDiagnostic Trouble Code(DTC) will detect an open or short circuit. DAEWOO M-150 BL2...
  • Page 281 Go to Step 19 Check the EEGR ground circuit for a poor connection or proper terminal tension at the ECM – and repair as necessary. Is a repair necessary? Go to Step 19 Go to Step 17 DAEWOO M-150 BL2...
  • Page 282 Does the scan tool indicate that this diagnostic ran Go to Step 20 Go to Step 2 and passed? Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 283 ENGINE CONTROLS 1F – 185 BLANK DAEWOO M-150 BL2...
  • Page 284 Conditions for Setting the DTC By watching the Actual EEGR and desired EEGR posi- D Engine Coolant Temperature(ECT) is greater than tions on a cold vehicle with a scan tool, the fault can be 80°C(176°F). DAEWOO M-150 BL2...
  • Page 285 – 3. Operate the vehicle within the conditions for setting the DTC as specifiec in the supporting text. Does the scan tool indicate that this diagnostic ran Go to Step 7 Go to Step 2 and passed? DAEWOO M-150 BL2...

  • Page 286: Valve Failure

    Due to moisture associated with exhaust systems, the Conditions for Setting THE DTC EEGR valve may freeze and stick in cold weather at D Engine Coolant Temperature(ECT) is greater than times. After the vehicle is brought into a warm shop for 80°C(176°F). DAEWOO M-150 BL2...
  • Page 287 Connect the test light to B+ and again probe the control circuit at terminal 4. – Does the test light illuminate? Go to Step 15 Go to Step 16 Replace the engine control module (ECM). – – Is the replacement complete? Go to Step 19 DAEWOO M-150 BL2...
  • Page 288 Does the scan tool indicate that this diagnostic ran Go to Step 20 Go to Step 2 and passed? Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 289 ENGINE CONTROLS 1F – 191 BLANK DAEWOO M-150 BL2...
  • Page 290 EEGR position should always be near the commanded mine if the DTC set when the vehicle was cold by view- or Desired EEGR position. ing the Engine Coolant Temperature (ECT). ThisDiagnostic Trouble Code(DTC) will detect an open or short circuit. DAEWOO M-150 BL2...
  • Page 291 Go to Step 19 Check the EEGR ground circuit for a poor connection or proper terminal tension at the ECM – and repair as necessary. Is a repair necessary? Go to Step 19 Go to Step 17 DAEWOO M-150 BL2...
  • Page 292 Does the scan tool indicate that this diagnostic ran Go to Step 20 Go to Step 2 and passed? Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 293 ENGINE CONTROLS 1F – 195 BLANK DAEWOO M-150 BL2...
  • Page 294 Check the Freeze Frame data to deter- ThisDiagnostic Trouble Code(DTC) will detect an open mine if the DTC set when the vehicle was cold by view- or short circuit. ing the Engine Coolant Temperature (ECT). DAEWOO M-150 BL2...
  • Page 295 – 3. Operate the vehicle within the conditions for setting the DTC as specifiec in the supporting text. Does the scan tool indicate that this diagnostic ran and passed? Go to Step 13 Go to Step 2 DAEWOO M-150 BL2...
  • Page 296 1F – 198 ENGINE CONTROLS DTC P1404 – Electric Exhaust Gas Recirculation Opend (Cont’d) Step Action Value(s) Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 297 ENGINE CONTROLS 1F – 199 BLANK DAEWOO M-150 BL2...

  • Page 298: Low Voltage

    ThisDiagnostic Trouble Code(DTC) will detect an open easily verified. Check the Freeze Frame data to deter- or short circuit. mine if the DTC set when the vehicle was cold by view- ing the Engine Coolant Temperature (ECT). DAEWOO M-150 BL2...
  • Page 299 – 3. Operate the vehicle within the conditions for setting the DTC as specifiec in the supporting text. Does the scan tool indicate that this diagnostic ran and passed? Go to Step 13 Go to Step 2 DAEWOO M-150 BL2...
  • Page 300 DTC P0405 – EEGR Pintle Position Sensor Low Voltage (Cont’d) Step Action Value(s) Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 301 ENGINE CONTROLS 1F – 203 BLANK DAEWOO M-150 BL2...
  • Page 302 Check the Freeze Frame data to deter- or Desired EEGR position. mine if the DTC set when the vehicle was cold by view- This Diagnostic Trouble Code(DTC) will detect an open ing the Engine Coolant Temperature (ECT). or short circuit. DAEWOO M-150 BL2...

  • Page 303: Dtc P0406 Eegr Pintle Position Sensor High Voltage

    – 3. Operate the vehicle within the conditions for setting the DTC as specifiec in the supporting text. Does the scan tool indicate that this diagnostic ran and passed? Go to Step 13 Go to Step 2 DAEWOO M-150 BL2...
  • Page 304 DTC P0406 – EEGR Pintle Position Sensor High Voltage (Cont’d) Step Action Value(s) Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 305 ENGINE CONTROLS 1F – 207 BLANK DAEWOO M-150 BL2...
  • Page 306 D Improperly formed Note: Test is aborted for this idle if: D Damaged terminals D Change in engine speed is greater than 80 rpm. D Poor terminal-to-wire connection. D A/C status changed. D Cooling fan status changed. DAEWOO M-150 BL2...

  • Page 307: Dtc P0420 Catalyst Low Efficiency

    Does the scan tool indicate that this diagnostic has run and passed? Go to Step 7 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 308 Disconnected or faulty fuel tank pressure sensor. equal to 24.9 in H2O. Disconnected, damaged, pinched, or blocked EVAP D System voltage is between 11V and 16V. purge line. Disconnected or faulty EVAP canister purge valve. Disconnected or faulty EVAP vent solenoid. DAEWOO M-150 BL2...
  • Page 309 DTC. The initial failure is purge, or fuel tank vapor line. Verify that the lines are not reported to the diagnostic executive or displayed on not restricted. a scan tool. A passing system always reports to the diagnostic executive immediately. DAEWOO M-150 BL2...

  • Page 310: Dtc P0444 Evap Purge Control Circuit No Signal

    Does the scan tool indicate that this diagnostic ran and passed? Go to Step 7 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 311 ENGINE CONTROLS 1F – 213 BLANK DAEWOO M-150 BL2...
  • Page 312 D Fuel level or change in tank pressure is less than or Disconnected or faulty fuel tank pressure sensor. equal to 24.9 in H2O. Disconnected, damaged, pinched, or blocked EVAP D System voltage is between 11V and 16V. purge line. Disconnected or faulty EVAP canister purge valve. DAEWOO M-150 BL2...
  • Page 313 Go to Step 4 Go to Step 6 1. Disconnect the ECM connector. 2. Connect a test light between the ECM connector – terminal 66 and ground. Is the test light ON? Go to Step 5 Go to Step 7 DAEWOO M-150 BL2...
  • Page 314 Does the scan tool indicate that this diagnostic ran and passed? Go to Step 11 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 315 ENGINE CONTROLS 1F – 217 BLANK DAEWOO M-150 BL2...
  • Page 316 D The ECM will store conditions which were present Half full = about 32.5 ohms. when the DTC was set as Failure Records data only. Full = 10 ohms or less. D This information will not be stored in the Freeze Frame data. DAEWOO M-150 BL2...
  • Page 317 – 3. Operate the vehicle within the conditions for setting the DTC as specifiec in the supporting text. Does the scan tool indicate that this diagnostic ran and passed? Go to Step 12 Go to Step 2 DAEWOO M-150 BL2...
  • Page 318 1F – 220 ENGINE CONTROLS DTC P0462 – Fuel Level Sensor Low Voltage (Cont’d) Step Action Value(s) Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 319 ENGINE CONTROLS 1F – 221 BLANK DAEWOO M-150 BL2...

  • Page 320: Voltage

    D The ECM will store conditions which were present Half full = about 32.5 ohms. when the DTC was set as Failure Records data only. Full = 10 ohms or less. D This information will not be stored in the Freeze Frame data. DAEWOO M-150 BL2...
  • Page 321 – 3. Operate the vehicle within the conditions for setting the DTC as specifiec in the supporting text. Does the scan tool indicate that this diagnostic ran and passed? Go to Step 12 Go to Step 2 DAEWOO M-150 BL2...
  • Page 322 1F – 224 ENGINE CONTROLS DTC P0463 – Fuel Level Sensor High Voltage (Cont’d) Step Action Value(s) Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 323 ENGINE CONTROLS 1F – 225 BLANK DAEWOO M-150 BL2...
  • Page 324 D Diagnostic Trouble Codes (DTCs) P0117, P0118 not mining how many miles since the DTC set. The fail set. counter and Pass Counter can also be used to deter- mine how many ignition cycles the diagnostics reported D Ignition ON. DAEWOO M-150 BL2...
  • Page 325 39 in the ECM harness connector. Does the relay operate? Go to Step 9 Go to Step 10 Check the connections at the relay. – Is a problem found and corrected? Go to Step 14 Go to Step 12 DAEWOO M-150 BL2...
  • Page 326 Does the scan tool indicate that this diagnostic ran and passed? Go to Step 15 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 327 ENGINE CONTROLS 1F – 229 BLANK DAEWOO M-150 BL2...
  • Page 328 D Diagnostic Trouble Codes (DTCs) P0117, P0118 not mining how many miles since the DTC set. The fail set. counter and Pass Counter can also be used to deter- mine how many ignition cycles the diagnostics reported D Ignition ON. DAEWOO M-150 BL2...
  • Page 329 5 in the ECM harness connector. Does the relay operate? Go to Step 9 Go to Step 10 Check the connections at the relay. – Is a problem found and corrected? Go to Step 14 Go to Step 12 DAEWOO M-150 BL2...
  • Page 330 Does the scan tool indicate that this diagnostic ran and passed? Go to Step 15 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 331 ENGINE CONTROLS 1F – 233 BLANK DAEWOO M-150 BL2...
  • Page 332 D Diagnostic Trouble Codes (DTCs) P0117, P0118 not mining how many miles since the DTC set. The fail set. counter and Pass Counter can also be used to deter- mine how many ignition cycles the diagnostics reported D Ignition ON. DAEWOO M-150 BL2...
  • Page 333 5 in the ECM harness connector. Does the relay operate? Go to Step 9 Go to Step 10 Check the connections at the relay. – Is a problem found and corrected? Go to Step 14 Go to Step 12 DAEWOO M-150 BL2...
  • Page 334 Does the scan tool indicate that this diagnostic ran and passed? Go to Step 15 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 335 ENGINE CONTROLS 1F – 237 BLANK DAEWOO M-150 BL2...
  • Page 336 D Diagnostic Trouble Codes (DTCs) P0117, P0118 not mining how many miles since the DTC set. The fail set. counter and Pass Counter can also be used to deter- mine how many ignition cycles the diagnostics reported D Ignition ON. DAEWOO M-150 BL2...
  • Page 337 4. Turn the Turn the ignition switch to ON. 5. With a fused jumper wire connected to ground, probe the relay control circuit at terminal 10 in the ECM harness connector. Does the relay operate? Go to Step 9 Go to Step 10 DAEWOO M-150 BL2...
  • Page 338 Does the scan tool indicate that this diagnostic ran and passed? Go to Step 15 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 339 ENGINE CONTROLS 1F – 241 BLANK DAEWOO M-150 BL2...
  • Page 340 Ensure the VSS is correctly torqued to the trnasaxle the diagnostic fails. This information will be stored in housing. the Freeze Frame and failure records buffers. Refer to “intermittents” in this Section. D A history DTC is stored. DAEWOO M-150 BL2...
  • Page 341 Is the resistance value within the specified value? Go to Step 11 Go to Step 10 Replace the VSS. – – Is the action complete? Go to Step 12 Replace the ECM. – – Is the action complete? Go to Step 12 DAEWOO M-150 BL2...
  • Page 342 Does the scan tool indicate that this diagnostic ran and passed? Go to Step 15 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been table diagnosed? System OK DAEWOO M-150 BL2...
  • Page 343 ENGINE CONTROLS 1F – 245 BLANK DAEWOO M-150 BL2...
  • Page 344 D The Intake Air Temperature (IAT) is greater than D Foreign material in the throttle body bore or in the air –20_C (–4_F). induction system. D Manifold Absolute Pressure is less than 60 kPa (8.7 D A leaking or restricted intake manifold. psi). DAEWOO M-150 BL2...
  • Page 345 Is the repair complete? Go to Step 15 Go to Step 10 Check the Engine control Module (ECM) connector for poor connections and repair as needed. – Is the repair complete? Go to Step 15 Go to Step 14 DAEWOO M-150 BL2...
  • Page 346 Does the scan tool indicate that this diagnostic has run and passed? Go to Step 16 Go to Step 2 Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been Table System OK diagnosed? DAEWOO M-150 BL2...
  • Page 347 ENGINE CONTROLS 1F – 249 BLANK DAEWOO M-150 BL2...
  • Page 348 2 seconds. D Usisng the scan tool can clear DTC(s). Action Taken When the DTC Sets D Disconnecting the ECM battery feed for 10 seconds. D The ECM will not illuminate the Malfunction Indicator Lamp (MIL). DAEWOO M-150 BL2...
  • Page 349 Does the scan tool indicate that this diagnostic has Go to Step 10 Go to Step 2 run and passed? Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displayed that that have not been table System OK diagnosed? DAEWOO M-150 BL2...
  • Page 350 2 seconds. D Usisng the scan tool can clear DTC(s). Action Taken When the DTC Sets D Disconnecting the ECM battery feed for 10 seconds. D The ECM will not illuminate the Malfunction Indicator Lamp (MIL). DAEWOO M-150 BL2...
  • Page 351 Does the scan tool indicate that this diagnostic has Go to Step 10 Go to Step 2 run and passed? Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displayed that that have not been table System OK diagnosed? DAEWOO M-150 BL2...
  • Page 352 Records vehicle mileage since the diagnostic test last D This information will not be stored in the Freeze failed may help determine how often the condition that Frame data. caused the DTC to set occurs. This may assist in diag- nosing the condition. DAEWOO M-150 BL2...
  • Page 353 Does the scan tool indicate that this diagnostic has Go to Step 10 Go to Step 2 run and passed? Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displayed that that have not been table System OK diagnosed? DAEWOO M-150 BL2...
  • Page 354 Records vehicle mileage since the diagnostic test last D This information will not be stored in the Freeze failed may help determine how often the condition that Frame data. caused the DTC to set occurs. This may assist in diag- nosing the condition. DAEWOO M-150 BL2...
  • Page 355 Does the scan tool indicate that this diagnostic has Go to Step 10 Go to Step 2 run and passed? Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displayed that that have not been table System OK diagnosed? DAEWOO M-150 BL2...
  • Page 356 D Damaged terminals when the DTC was set as Failure Records data only. D This information will not be stored in the Freeze D Poor terminals to wire connection Frame data. D Physical damage to the wiring harness DAEWOO M-150 BL2...
  • Page 357 Does the scan tool indicate that this diagnostic has run and passed? Go to Step 9 Go to Step 2 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displayed that have not been table System OK diagnosed? DAEWOO M-150 BL2...
  • Page 358 D Damaged terminals Frame data. D Poor terminals to wire connection Conditions for Clearing the MIL/DTC D Physical damage to the wiring harness D A history DTC will clear after 40 consecutive warm-up cycles without a fault. DAEWOO M-150 BL2...
  • Page 359 Does the scan tool indicate that this diagnostic has run and passed? Go to Step 9 Go to Step 2 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displayed that have not been table System OK diagnosed? DAEWOO M-150 BL2...
  • Page 360 Does the scan tool indicate that this diagnostic has run and passed? Go to Step 4 Go to Step 2 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displayed that have not been table System OK diagnosed? DAEWOO M-150 BL2...
  • Page 361 Does the scan tool indicate that this diagnostic has run and passed? Go to Step 4 Go to Step 2 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displayed that have not been table System OK diagnosed? DAEWOO M-150 BL2...
  • Page 362 Does the scan tool indicate that this diagnostic has run and passed? Go to Step 4 Go to Step 2 Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displayed that have not been table System OK diagnosed? DAEWOO M-150 BL2...
  • Page 363 ENGINE CONTROLS 1F – 265 BLANK DAEWOO M-150 BL2...
  • Page 364 D The MIL will turn off after four consecutive ignition caused the DTC to set occurs. This may assist in diag- cycles in which the diagnostic runs without a fault. nosing the condition. DAEWOO M-150 BL2...
  • Page 365 Does the scan tool indicate that this diagnostic has Go to Step 8 Go to Step 2 run and passed? Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displayed that that have not been table System OK diagnosed? DAEWOO M-150 BL2...
  • Page 366 Conditions for Clearing the MIL/DTC caused the DTC to set occurs. This may assist in diag- D The MIL will turn off after four consecutive ignition nosing the condition. cycles in which the diagnostic runs without a fault. DAEWOO M-150 BL2...
  • Page 367 Does the scan tool indicate that this diagnostic has Go to Step 8 Go to Step 2 run and passed? Check if any additional DTCs are set. Go to System OK applicable DTC – Are any DTCs displayed that that have not been table diagnosed? DAEWOO M-150 BL2...
  • Page 368 D Disable the ignition coil. cycles without a fault. D A Diagnostic Trouble Code (DTC) will stored if detect D DTC(s) can be cleared by using the scan tool. communication link failure between the ECM and im- mobilizer control unit. DAEWOO M-150 BL2...
  • Page 369 Does the scan tool indicate that this diagnostic has Go to Step 9 Go to Step 2 run and passed? Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been Table System OK diagnosed? DAEWOO M-150 BL2...
  • Page 370 D Disable the ignition coil. cycles without a fault. D DTC(s) can be cleared by using the scan tool. A Diagnostic Trouble Code (DTC) will stored if detect communication link failure between the ECM and immo- bilizer control unit. DAEWOO M-150 BL2...
  • Page 371 Does the scan tool indicate that this diagnostic has Go to Step 9 Go to Step 2 run and passed? Check if any additional DTCs are set. Go to Applicable DTC – Are any DTCs displayed that have not been Table System OK diagnosed? DAEWOO M-150 BL2...
  • Page 372 D The ECM will store conditions which were present D Half full = about 32.5 ohms. when the DTC was set as Failure Records data only. D Full = 10 ohms or less. D This information will not be stored in the Freeze Frame data. DAEWOO M-150 BL2...
  • Page 373 Does the scan tool indicate that this diagnostic has Go to Step 10 Go to Step 2 run and passed? Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displayed that that have not been table System OK diagnosed? DAEWOO M-150 BL2...
  • Page 374 D Poor terminals to wire connection D Physical damage to the wiring harness Conditions for Clearing the MIL/DTC D The MIL will turn off after four consecutive ignition cycles in which the diagnostic runs without a fault. DAEWOO M-150 BL2...
  • Page 375 Does the scan tool indicate that this diagnostic has Go to Step 7 Go to Step 2 run and passed? Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displayed that that have not been table System OK diagnosed? DAEWOO M-150 BL2...
  • Page 376 D Poor terminals to wire connection D Physical damage to the wiring harness Conditions for Clearing the MIL/DTC D The MIL will turn off after four consecutive ignition cycles in which the diagnostic runs without a fault. DAEWOO M-150 BL2...
  • Page 377 Does the scan tool indicate that this diagnostic has Go to Step 7 Go to Step 2 run and passed? Check if any additional DTCs are set. Go to applicable DTC – Are any DTCs displayed that that have not been table System OK diagnosed? DAEWOO M-150 BL2...
  • Page 378 – – 4. Inspect the ignition wires for cracking, hardness, proper routing, and carbon tracking. 5. Inspect the wiring for proper connections, Go to pinches, and cuts. Appropriate Are all checks complete? Symptom Table DAEWOO M-150 BL2...
  • Page 379 2. Disconnect the throttle position (TP) sensor. 3. Run the engine at idle until the MIL comes on. – 4. Turn the ignition OFF. Is DTC P0122 stored in memory? Go to Step 10 Go to Step 9 DAEWOO M-150 BL2...
  • Page 380 Go to Step 9 Go to Step 12 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? System OK DAEWOO M-150 BL2...
  • Page 381 Go to Step 8 Go to Step 27 Check for water contamination in the fuel. – Is fuel contaminated? Go to Step 9 Go to Step 10 Replace the contaminated fuel. – – Is the repair complete? System OK DAEWOO M-150 BL2...
  • Page 382 1. Remove the Crankshaft Position (CKP) sensor. 2. Inspect for faulty connections and repair as – needed. Is the problem found? Go to Step 22 Go to Step 25 Repair the faulty connections as needed. – – Is the repair complete? System OK DAEWOO M-150 BL2...
  • Page 383 Is the repair complete? System OK Repair the fuel system as needed. – – Is the repair complete? System OK 1. Turn the ignition OFF. 2. Replace the ECM. – – Is the repair complete? System OK DAEWOO M-150 BL2...
  • Page 384 System OK 1. Inspect the ECM grounds for being clean, tight, and in their proper locations. – 2. Inspect the vacuum lines for kinks or leaks. Is the problem found? Go to Step 13 Go to Step 14 DAEWOO M-150 BL2...
  • Page 385 Repair the fuel system as needed. – – Is the repair complete? System OK Replace the fuel filter. – – Is the repair complete? System OK Replace the leaking or restricted fuel injectors. – – Is the repair complete? System OK DAEWOO M-150 BL2...
  • Page 386 Repair or replace any components as needed. – – Is the repair complete? System OK 1. Check the cylinder compression and valve timing. 2. Inspect the camshaft for excessive wear. – Is the problem found? Go to Step 15 Go to Step 16 DAEWOO M-150 BL2...
  • Page 387 3. Check the torque converter clutch operation. – 4. Check the A/C system operation. 5. Check the generator output. 6. Repair the generator if the output is not within the specified range. Are all checks and repairs complete? 12–16 V System OK DAEWOO M-150 BL2...
  • Page 388 Check the fuel system pressure. 380 kPa Is the problem found? (55 psi) Go to Step 11 Go to Step 12 Repair or replace the fuel system components as needed. – – Is the repair complete? System OK DAEWOO M-150 BL2...
  • Page 389 – – 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? System OK DAEWOO M-150 BL2...
  • Page 390 Is the repair complete? System OK Check the fuel system pressure after a cold start or during moderate or full throttle acceleration. 380 kPa Is the fuel pressure within specifications? (55 psi) Go to Step 14 Go to Step 13 DAEWOO M-150 BL2...
  • Page 391 2. Repair or replace the generator if the generator output is less than the value specified. – – 3. Check the Electric Exhaust Gas Recirculation (EEGR) valve operation. Are all checks and needed repairs complete? System OK DAEWOO M-150 BL2...
  • Page 392 – 3. Note the test light while cranking the engine for each fuel injector. Does the test light blink for all of the fuel injectors? Go to Step 13 Go to Step 12 DAEWOO M-150 BL2...
  • Page 393 1. Inspect the routing of the ignition wires. 2. Inspect all of the ignition system grounds. – – 3. Correct the routing or repair the ground connections as needed. Are all checks and needed repairs complete? System OK DAEWOO M-150 BL2...
  • Page 394 2. Check for proper calibration of the speedometer. 3. Check the brakes for dragging. – – 4. Check the cylinder compression. 5. Repair, replace, or adjust any components as needed. Are all checks and needed repairs complete? System OK DAEWOO M-150 BL2...
  • Page 395 1. Road test the vehicle at the speed of the complaint. 2. Monitor the long term fuel trim reading using the scan tool. Is the long term fuel trim reading within the value specified? –20–25% Go to Step 14 Go to Step 12 DAEWOO M-150 BL2...
  • Page 396 4. Replace any ignition wires with a resistance over the value specified. 30000 Ω Is the problem found? Go to Step 23 Go to Step 24 Repair or replace any ignition system components as needed. – – Is the repair complete? System OK DAEWOO M-150 BL2...
  • Page 397 3. Perform a cylinder compression test. 4. Inspect for bent pushrods, worn rocker arms, – – broken or weak valve springs, and a worn camshaft. 5. Perform repairs as needed. Are all of the checks and needed repairs complete? System OK DAEWOO M-150 BL2...
  • Page 398 Is the problem found? Go to Step 9 Go to Step 10 1. Repair or replace any ignition system components as needed. – – 2. Perform an emission test. Did the vehicle pass the emission test? System OK DAEWOO M-150 BL2...
  • Page 399 Remove with a top engine cleaner. – – 4. Check the Electric Exhaust Gas Recirculation (EEGR) valve for not opening. 5. Check for proper Positive Crankcase Ventilation (PCV) operation. Are all checks and needed repairs complete? System OK DAEWOO M-150 BL2...
  • Page 400 2. Check for leaking fuel injectors. 3. Check the Idle Air Control (IAC) valve operation. – – 4. Inspect for vacuum leaks. 5. Check for the proper base idle setting. Are all checks and repairs complete? System OK DAEWOO M-150 BL2...
  • Page 401 3. Inspect the intake manifold gasket and the – – exhaust 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? System OK DAEWOO M-150 BL2...

  • Page 402: Fuel Pump

    (4). D Crank the engine for an additional 10 seconds. D102F502 2. Disconnect the fuel lines from the fuel pump. D Disconnect the fuel outlet line (1). D Disconnect the fuel tank return line (2). D102F503 DAEWOO M-150 BL2...

  • Page 403: Fuel Pressure Regulator

    1. Relieve the fuel system pressure after remove the fuel pump assembly. Refer to “Fuel Pump” in this section. D102F507 DAEWOO M-150 BL2...

  • Page 404: Fuel Filter

    D Disconnect the inlet/outlet fuel lines by pushing the line connector lock and pulling off the hose of the D102F510 fuel filter tube (1). D Remove the screw from the retaining clamp (2). D Remove the fuel filter (3). D102F511 DAEWOO M-150 BL2...

  • Page 405: Fuel Tank

    4. Remove the fuel filter. Refer to “Fuel Filter” in this section. 5. Install the jack to remove the fuel tank. D Install the jack on the center of the fuel tank. D Remove the strap bolts (1). D Remove the straps (2). D12F515A DAEWOO M-150 BL2...
  • Page 406 Refer to “Fuel Pump” in this section. 2. Remove the canister from the engine room. Refer to “Evaporative Emission Canister” in this section. 3. Disconnect the fuel inlet line (1). D102F518 4. Disconnect the fuel injector harness connectors (2). D102F519 DAEWOO M-150 BL2...
  • Page 407 Do not smoke in the area or permit an open flame. 1. Disconnect the negative battery cable. 2. Remove the canister. D Remove the bolt (1). D Remove the nut, then remove the cover (2). MAA1F400 DAEWOO M-150 BL2...
  • Page 408 MAA1F430 MANIFOLD ABSOLUTE PRESSURE SENSOR Removal Procedure 1. Disconnect the manifold absolute pressure (MAP) sensor connector and vacuum hose. D Disconnect the MAP connector (1). D Disconnect the vacuum hose from the MAP sensor (2). MAA1F440 DAEWOO M-150 BL2...

  • Page 409: Throttle Body

    D Open the throttle valve (1). D Disconnect the throttle cable (2). D Disconnect the idle air control valve connector (3). D Disconnect the throttle position sensor connector (4). D102F538 DAEWOO M-150 BL2...
  • Page 410 2. Install the throttle body with the bolts. Tighten Tighten the throttle body bolts to 9–12 NSm (80–106 lb-in). D12F542A ENGINE COOLANT TEMPERATURE (ECT) SENSOR Removal Procedure 1. Remove the engine coolant temperature (ECT) sen- sor. Refer to Section 1D, Engine Coolings. D12F543A DAEWOO M-150 BL2...
  • Page 411 D Disconnect the IAT sensor connector (1) D Disconnect the IAT sensor. D102F544 Installation Procedure 1. Install in the reverse order of removal. 2. Install the IAT sensor. Tighten Tighten the IAT sensor to 20–30 NSm (15–22 lb-ft). 20–30 NSm D12F545A DAEWOO M-150 BL2...
  • Page 412 3. Disconnect the HO2S2 connector. 4. Remove the front exhaust pipe. Refer to Section 1G, Engine Exhaust. 5. Remove the HO2S2 from the front exhaust pipe. Installation Procedure 1. Install in the reverse order of removal. MAA1F470 DAEWOO M-150 BL2...
  • Page 413 2. Remove the starter. Refer to Section 1E, Engine Electrical. 3. Disconnect the electrical connector at the knock sen- sor (1). D21F008 4. Remove the knock sensor. D Remove the knock sensor retaining bolt (1). D Remove the knock sensor. D21F009 DAEWOO M-150 BL2...
  • Page 414 (71–106 lb-in). MAA1F500 CRANKSHAFT POSITION (CKP) SENSOR Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the air cleaner assembly. 3. Disconnect the crankshaft position (CKP) sensor connector. 4. Remove the CKP sensor retaining bolt. UAA1F2C0 DAEWOO M-150 BL2...
  • Page 415 4. Remove the CMP sensor. UAA1F2E0 Installation Procedure 1. Install the CMP sensor. 2. Tighten the CMP sensor retaining bolt to 10–14 NSm (89–124 lb-in). MAA1F540 ENGINE CONTROL MODULE (ECM) Removal Procedure 1. Disconnect the ECM connector. MAA1F510 DAEWOO M-150 BL2...
  • Page 416 1. Install in the reverse order of removal. Notice: If disconnecting the battery cable to the ECM, the IAC valve resetting should be proceeded. 2. install the ECM with the bolts. Tighten Tighten the ECM mounting bolts to 6–8 NSm (53–71 lb-in). MAA1F530 DAEWOO M-150 BL2...
  • Page 417 35–44 26–33 – Heated Oxygen Sensor 35–44 26–33 – Throttle Body Retaining Bolt 9–12 – 80–106 ECM Mounting Bolts 6–8 – 53–71 SPECIAL TOOLS SPECIAL TOOLS TABLE DW–140–010A Scan Tool Fuel Pump Lock Ring Remover/Installer D102F101 D12F102A DAEWOO M-150 BL2...
  • Page 418 ECM WIRING DIAGRAM (SIRIUS D3 – 1 OF 5)
  • Page 419 ECM WIRING DIAGRAM (SIRIUS D3 – 2 OF 5)
  • Page 420 ECM WIRING DIAGRAM (SIRIUS D3 – 3 OF 5)
  • Page 421 ECM WIRING DIAGRAM (SIRIUS D3 – 4 OF 5)
  • Page 422 ECM WIRING DIAGRAM (SIRIUS D3 – 5 OF 5)
  • Page 423 ......1G-9 Fastener Tightening Specifications ... 1G-9 DAEWOO M-150 BL2...

  • Page 424: Description And Operation

    The three-way catalyst has coatings open seams or any deterioration is discovered upon in- which contain platinum and rhodium, which additionally spection of the front muffler and pipe assembly, the lower the levels of oxides of nitrogen (NOx). DAEWOO M-150 BL2...

  • Page 425: Component Locator

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

  • Page 426: Repair Instruction

    D Remove the nuts (1). D Remove the gasket (2). 4. Check the gasket for damage or crack. D102G501 5. Remove the front exhaust pipe from the front muffler pipe. D Remove the nuts (1). D102G502 DAEWOO M-150 BL2...

  • Page 427: Pup-Up Catalitic Converter

    Trim. PUP-UP CATALITIC CONVERTER Removal Procedure 1. Remove the front exhaust pipe from the pup-up cata- litic converter. D Remove the nuts (1). D Remove the gasket (2). 2. Check the gasket for damage or leak. D102G501 DAEWOO M-150 BL2...
  • Page 428 Tighten the bolts to 25–35 NSm (18–25 lb-ft). MAA1B041 2. Install exhaust manifold. Refer to Section 1B, SOHC Engine Mechanical. Tighten Tighten the bolts and nuts to 17–27 NSm (13–20 lb-ft). Tighten the exhaust manifold heat shield bolts to 8–12 NSm (71–106 lb-in). MAA1B011 DAEWOO M-150 BL2...

  • Page 429: Front Muffler

    1. Hang the front muffler to rubber hanger. 2. Install the front muffler-to-rear muffler nuts. Tighten Tighten the nuts to 25–35 NSm (18–25 lb-ft). 3. Install the exhaust pipe-to-front muffler nuts. Tighten Tighten the nuts to 25–35 NSm (18–25 lb-ft) (a). MAA1G031 DAEWOO M-150 BL2...

  • Page 430: Rear Muffler

    1. Remove the front muffler-to rear muffler nuts. Tighten Tighten the nuts to 25–35 NSm (18–25 lb-ft). 2. Detach the rear muffler from the rubber hangers. MAA1G030 3. Remove the rear muffler. 4. Installation should flow the removal procedure in re- verse order. MAA1G040 DAEWOO M-150 BL2...

  • Page 431: Specifications

    25 – 35 18 – 25 – Muffler Clamp Nut 24 – 28 18 – 21 – Catalytic Converter Heat Shield 8 – 12 – 71 – 106 Rear Muffler Heat Shield 8 – 12 – 71 – 106 DAEWOO M-150 BL2...
  • Page 432 D Tighten the power steering pump drive belt tension. belt. D Inspect the power steering system. D Repair any leaks. Also, check the power steering fluid D Perform a power steering gear test. level. D Add power steering fluid. DAEWOO M-150 BL2...
  • Page 433 D Replace the control arm and ball joint assembly. D Excessive wheel runout. D Measure the wheel runout. D Replace the wheel as needed. D Excessive loaded radial runout on the D Match–mount the tire and wheel tire and wheel assembly. assembly. DAEWOO M-150 BL2...
  • Page 434 D Replace the intermediate shaft. intermediate shaft. D Damaged suspension components. D Replace the damaged suspension Abnormal Noise, Front Suspension components. D Worn control arm bushings or tie rod D Replace the control arm bushings or ends. the tie rods. DAEWOO M-150 BL2...
  • Page 435 D Replace the coil spring. D Worn strut dampeners. D Replace the strut dampeners. Suspension Bottoms D An overloaded vehicle. D Maintain the proper load weight. D A broken or a sagging coil spring. D Replace the coil spring. DAEWOO M-150 BL2...
  • Page 436 D Replace the tires as needed. D Replace the wheels as needed. D A worn ball joints. D Replace the control arm and ball joint assembly. D The steering gear preload adjustment D Perform a rack bearing preload is out–of–adjustment. on–vehicle adjustment. DAEWOO M-150 BL2...
  • Page 437 It is constant and unwavering and ment, replace the noisy wheel bearings. Refer to Sec- increases with the speed of the vehicle. If the wheel tion 2D, Rear Suspension. bearing noise cannot be positively diagnosed, or if the 5. Lower the vehicle. DAEWOO M-150 BL2...
  • Page 438 ... 2B-6 Turning Angle ......2B-3 DAEWOO M-150 BL2...

  • Page 439: Description And Operation

    Always correct the toe dimension last. shoulder of the tire will wear. If the vehicle has too much negative camber, the inside shoulder of the tire will wear. Camber is measured in degrees and is not adjustable. DAEWOO M-150 BL2...

  • Page 440: Steering Axis Inclination

    The turning angle is the angle of each front wheel to the To determine the included angle, subtract the negative vertical when the vehicle is making a turn. DAEWOO M-150 BL2...

  • Page 441: Diagnostic Information And Procedures

    D Replace the tire. Vibration of The Steering Wheel D Inbalanced inflation pressure. D Inflate the tires to the proper pressure. D Damaged tire. D Replace the tire. D Bent or damaged wheel. D Replace the wheel. DAEWOO M-150 BL2...

  • Page 442: Front Toe Adjustment

    (ABS) or the rear axle assembly and the hub and bearing assembly on vehicles with ABS for possible damage. D106A303 4. Tighten the tie rod end lock nut to 45 NSm (33 lb-ft). 5. Install the rack and pinion boots clamp. DAEWOO M-150 BL2...

  • Page 443: Specifications

    0_ " 20′ Camber 2_48′ ± 30′ Caster–Manual Steering – 2_48′ ± 30′ Caster–Power Steering – 10′ ± 10′ 20′ " 20′ Toe–in (2–person load) FASTENER TIGHTENING SPECIFICATIONS Application Lb-Ft Lb-In Tie Rod End Lock Nut – DAEWOO M-150 BL2...
  • Page 444 ......2C-8 Special Tools Table ..... . . 2C-24 DAEWOO M-150 BL2...

  • Page 445: Description And Operation

    Specifications” in this section. ing to allow the wheel to turn. The lower end of the steering knuckle pivots on a ball joint bolted to the control arm. The ball joint is fastened to the steering knuckle with a bolt. DAEWOO M-150 BL2...

  • Page 446: Component Locator

    FRONT SUSPENSION 2C – 3 COMPONENT LOCATOR FRONT SUSPENSION D16B401A DAEWOO M-150 BL2...
  • Page 447 14. Inner Hub Bearing 32. Control Arm Bushing 15. Steering Knuckle 33. Control Arm Assembly 16. Dust Cover 34. Stabilizer Shaft 17. Hub Bearing Spacer 35. Stabilizer Shaft Mount 18. Outer Hub Bearing 36. Front Under Longitudinal Frame DAEWOO M-150 BL2...

  • Page 448: Diagnostic Information And Procedures

    D The ball seal is cut. Worn or damaged ball joints and knuckles must be re- placed. D The ball stud is disconnected from the knuckle. DAEWOO M-150 BL2...

  • Page 449: Front Wheel Bearing

    8. If the axial end play is above spec., replace the front 1. Lift and suitably support the vehicle. wheel bearing. 2. Inspect the end play of the bearing. 3. If excessive play is defeeted, free shoes from the disc or remove the calipers. DAEWOO M-150 BL2...

  • Page 450: Repair Instructions

    D Remove the ABS front speed sensor electrical wire from the bracket, if applicable (1). D Disconnect the brake hose from the bracket (2). D Remove the strut bracket bolts (3). 5. Remove the strut bracket assembly from the vehicle. D106B503 DAEWOO M-150 BL2...

  • Page 451: Knuckle Assembly

    D Remove the cotter pin (1). D Remove the castellated nut (2). D Install the ball joint remover KM 507–B. D Separate the tie rod end from the knuckle assem- bly using a ball joint remover KM 507–B (3). D105B501 DAEWOO M-150 BL2...
  • Page 452 Tighten Tighten the castellated nut to 30–55 NSm (22–41 lb- ft). 7. Install the caulking nut (2). D Bend the caulking nut flange (3). Tighten Tighten the caulking nut to 210 NSm (155 lb-ft). D16B510B DAEWOO M-150 BL2...

  • Page 453: Front Longitudinal Frame And Stabilizer Shaft

    D Remove the washer (3). D Remove the rear bushing with separating the sta- bilizer shaft from the control arm (4). D106B513 D Remove the bushing (5). D Remove the wire clamps (6). D Remove the mountings (7). D16B514A DAEWOO M-150 BL2...
  • Page 454 D Install the front under longitudinal frame bolt (2). Tighten 65 – 80 NSm Tighten to bolt to 10–14 NSm (89–124 lb-in). D Install the front under longitudinal frame nut (3). Tighten Tighten to nut to 65–80 NSm (48–59 lb-ft). 10 – 14 NSm D16B518B DAEWOO M-150 BL2...

  • Page 455: Control Arm

    2. Remove the strut bar from the vehicle. D Remove the purge control valve (1). D Remove the A/C low pressure pipe bracket–to– strut bar nut (2). D Remove the strut bar bolts at passenger side (3). D10B522A DAEWOO M-150 BL2...

  • Page 456: Crossmember

    D Place support jack under the crossmember. D Remove the bumper fascia screws. D Remove the rear bolts (1). D Remove the side bolts (2). D Lower the support jack and remove the crossmem- ber from the vehicle. D106B526 DAEWOO M-150 BL2...
  • Page 457 45–55 NSm D16B529A 3. Install the crossmember to the vehicle with the bolts. Tighten Tighten the bolts to 17–27 NSm (13–20 lb-ft). a. Crossmember right rear bolt. b. Crossmember right side bolt. 17–27 NSm 17–27 NSm D16B530A DAEWOO M-150 BL2...
  • Page 458 4. Install the front damping bush to the vehicle. Tighten 68–83 NSm Tighten the front damping bush bolt and nut to 68–83 NSm (51–61 lb-ft). 5. Install the front under longitudinal frame. Refer to “Stabilizer Shaft” in this section. D16B532A DAEWOO M-150 BL2...

  • Page 459: Unit Repair

    3. Remove the wheel hub from the knuckle assembly using the front wheel hub remover DW 340–010. D Remove the wheel hub using the front wheel hub remover DW 340–010 (1). D Remove the bearing spacer (2). D Remove the brake rotor (3). D106B702 DAEWOO M-150 BL2...
  • Page 460 Important: Do not use removed oil seal. D106B704 4. Remove the steering knuckle assembly. D Remove the oil seal (1). Important: Do not use removed oil seal. D Remove the wheel bearing (2). D106B705 D Remove the outer bearing race (3). D106B706 DAEWOO M-150 BL2...
  • Page 461 D Assemble the outer bearing race using the front wheel hub remover DW 340–010 and the front wheel bearing race installer DW 340–020 (2). D106B709 D Assemble the outer wheel bearing (3). D Assemble the outer wheel bearing oil seal (4). D106B710 DAEWOO M-150 BL2...
  • Page 462 Tighten the bolt to 65 NSm (48 lb-ft). D16B712A D Install the bearing spacer (5). D106B713 D Press the inner wheel bearing into the wheel hub using the front wheel hub remover DW 340–010 and the front wheel bearing installer DW 340–030 (6). D106B714 DAEWOO M-150 BL2...

  • Page 463: Front Strut

    09940–71430. Caution: During compressing spring, do not make spring end point to operator or dangerous direc- D106B716 tion. 3. Fix the strut support using the bench vise and remove the strut nut. a. Strut nut. D106B717 DAEWOO M-150 BL2...
  • Page 464 2. Tighten the strut nut. D Fix the strut support using the bench vise. D Tighten the nut. Tighten Tighten the strut nut to 50–60 NSm (36–44 lb-ft). D16B719A DAEWOO M-150 BL2...
  • Page 465 2C – 22 FRONT SUSPENSION 3. Inspect the installation of coil spring (1, 2). 4. Install the strut assembly. Refer to “Strut Assembly” in this section. D106B720 DAEWOO M-150 BL2...

  • Page 466: Specifications

    13 – 20 – Strut Bar Bolts 35 – 55 25 – 41 – ABS Front Speed Sensor Retaining Bolt 18 – 28 13 – 21 – Wheel Hub–to–Brake Disc Bolt 55 – 75 41 – 55 – DAEWOO M-150 BL2...

  • Page 467: Special Tools And Equipment

    Puller Installer D106B103 D13B112A DW 220–020A–04 KM 507–B Differential Bearing Ball Joint Remover Plate Adapter D13B113A D105B101 DW 340–010 09940–71430 Front Wheel Hub Front Spring Remover Compressor D16B101A D106B104 DW 340–020 Front Wheel Bearing Race Installer D106B102 DAEWOO M-150 BL2...
  • Page 468 ......2D-6 Special Tools Table ..... . . 2D-16 DAEWOO M-150 BL2...

  • Page 469: Description And Operation

    Each coil spring is retained between a seat in the under- arms and a lateral rod, two coil springs, two shock ab- body and a seat welded to the top of the rear axle. sorbers, two upper spring seats, and two bump stop- DAEWOO M-150 BL2...

  • Page 470: Component Locator

    3. Coil Spring Upper Seat 11. ABS Wheel Speed Ring 4. Coil Spring 12. Wheel Bearing Outer 5. Washer 13. Cotter Pin 6. Bushing 14. Castellated Nut 7. Lateral Rod 15. Spindle Cap 8. Rear Axle 16. Trailing Arm DAEWOO M-150 BL2...

  • Page 471: Diagnostic Information And Procedures

    D Faulty coil spring. D Replace the coil spring. D Lateral rod bushing is worn or D Replace the lateral rod bushing. damaged. D Trailing arm bushing is worn or D Replace the trailing arm bushing. damaged. DAEWOO M-150 BL2...

  • Page 472: Checking The Rear Wheel Bearing End Play

    5. If the bearing play is high after tightening, replace the 5. If the checked torque exceeds the specification, tight- wheel bearing. en the castellated nut. 6. If the checked torque exceeds the specification after tightening, replace the wheel bearing. DAEWOO M-150 BL2...

  • Page 473: Repair Instructions

    Tighten the bolt to 45–70 NSm (33–52 lb-ft). D Install the shock absorber–to–body bracket nut (2). Tighten Tighten the shock absorber nut to 45–70 NSm (33–52 lb-ft). 2. Remove the jack stand and lower the vehicle. D16C503B DAEWOO M-150 BL2...

  • Page 474: Lateral Rod

    D106C506 Installation Procedure 1. Install in the reverse order of removal. 2. Install the lateral rod–to–rear axle side nut. Tighten Tighten the lateral rod axle side nut to 35–55 NSm (25–41 lb-ft). D16C507A DAEWOO M-150 BL2...

  • Page 475: Trailing Arm

    D Loosen the shock absorber–to–body bracket nut (1). D Remove the shock absorber–to–rear axle bolt (2). D106C509 4. Remove the trailing arm. D Remove the trailing arm–to–rear axle bolts (1). D106C510 D Remove the trailing arm–to–body bracket bolt (2). D106C511 DAEWOO M-150 BL2...

  • Page 476: Rear Axle Assembly

    Carry out the opera- tion with co–worker. D106C517 4. Remove the rear axle from the vehicle. D Remove the coil spring by lowering the jack stand slowly (1). D Lower the support jack and remove the rear axle (2). D106C518 DAEWOO M-150 BL2...
  • Page 477 Upper spring diameter is smaller than lower spring diameter. Caution: Support the jack stand to the rear axle se- curely until installing the trailing arm bolts. D106C520 2. Install the rear bumper stopper and rear spring upper seat. D106C519 DAEWOO M-150 BL2...
  • Page 478 Tighten the shock absorber–to–rear axle bolt to 45–70 NSm (33–52 lb-ft). 4. Install the lateral rod. Refer to “Lateral Rod” in this section. 5. Install the rear brake drum, shoe and brake plate. Re- fer to Section 4E, Rear Drum Brake. D16C516C DAEWOO M-150 BL2...

  • Page 479: Unit Repair

    D Remove the outer tapered roller bearing (1). D106C701 D Remove the oil seal (2). D Remove the inner tapered roller bearing (3). D106C702 3. Remove the bearing races from the brake drum. D Remove the inner bearing race (1). D106C703 DAEWOO M-150 BL2...
  • Page 480 Important: Coat or fill all the hollow spaces of both wheel bearing, the ring seal lip and the brake drum with antifriction grease. D Install the inner bearing (1). D Install the oil seal (2). D106C707 DAEWOO M-150 BL2...
  • Page 481 D Install the outer bearing (3). 3. Install the brake drum. Refer to Section 4E, Rear Drum Brakes. 4. Adjust the end play and free load of the bearing. Re- fer to “Check and Adjustments” in this section. D106C708 DAEWOO M-150 BL2...

  • Page 482: Specifications

    25 – 41 – Rear Axle Castellated Nut* – – – ABS Rear Speed Sensor Retaining Bolt 9 – 13 – 80 – 115 Q Rear Axle Castellated Nut : Refer to Section 4E, Rear Drum Brakes DAEWOO M-150 BL2...

  • Page 483: Special Tools And Equipment

    2D – 16 REAR SUSPENSION SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE DW 340–010 DW 350–030 Front Wheel Hub Rear Wheel Bearing Remover Race Installer D16B101A D106C101 DAEWOO M-150 BL2...
  • Page 484 ....... . 2E-5 Irregular or Excessive Tires Wear ... . 2E-6 DAEWOO M-150 BL2...

  • Page 485: Description And Operation

    It is provided to improve the comfortable driving by pro- tecting carcass and cushion movement. Width (mm) Flatness ratio 60% Structure of Tubeless Tube (Height/Width) × 100 175/60R13 Radial Rim diameter (= Tire I.D, Inch) Max. load index Max. speed symbol D16A001A DAEWOO M-150 BL2...

  • Page 486: Replacement Tires

    SPARE TIRE durance, dimensions, noise, handling and rolling resist- This vehicle comes equipped with a full-sized spare tire ance. Usually a specific TPC number is assigned to and wheel. each tire size. DAEWOO M-150 BL2...

  • Page 487: Wheels

    100 grams (3.5 ounces). D High tire temperatures 3. Blanching the assemblies with factory aluminum Unequal tire pressures on same axle can cause: wheels requires the use of special nylon–coated, D Uneven braking clip–on wheel weights. D Steering lead DAEWOO M-150 BL2...

  • Page 488: Diagnostic Information And Procedures

    2. If the depth of the tread is below the specified value, replace the tire. D106A302 Limit of The Tread Wear 1.6mm (0.06 in.) 3. Indicators appear when the tire tread depth becomes shallow (less than 1.6mm (0.06 in.)). DAEWOO M-150 BL2...

  • Page 489: Irregular Or Excessive Tires Wear

    D Check the steering knuckle, control D Faulty suspensions. arm, drive axle, and suspensions. Repair or replace them, as needed. D Poor wheel balancing. D Adjust the wheel balancing. D Improper the tire rotation. D Rotate the tires. D16A305E DAEWOO M-150 BL2...

  • Page 490: Repair Instructions

    Penetrating oil is not effective in removing tight wheels. If it is used, however, apply it sparingly and only to the wheel’s centerhole area. DAEWOO M-150 BL2...

  • Page 491: On-Vehicle Balancing

    Tire truing with a blade-type machine is not recommended because it substantially reduces the tread life and often does not correct the problem permanently. DAEWOO M-150 BL2...

  • Page 492: Tire And Wheel Match-Mounting

    Before dismounting a tire from its wheel, scribe a line on the tire at the valve stem to assure that it is remounted in the same position. Replacement tires that are of original equipment quality will have their high and low spot marked in the same manner. DAEWOO M-150 BL2...

  • Page 493: Specifications

    Important: ( )* : 4 – 5 occupants INFLATION PRESSURE CONVERSION SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Lb-Ft Lb-In Wheel Nuts (Aluminum Wheel) 90 – 110 66 – 81 – Wheel Nuts (Steel Wheel) 90 – 110 66 – 81 – DAEWOO M-150 BL2...
  • Page 494 ..... . . 3B-13 Drive Axle Assembly ..... . . 3B-5 DAEWOO M-150 BL2...

  • Page 495: Description And Operation

    The drive axles use a Rzeppa–style joint on the out- semblies. Each axle assembly consists of an inner board side and a Tripot–style joint on the inboard side. constant-velocity joint and an outer constant-velocity joint connected to an axle shaft. The inner joint is com- DAEWOO M-150 BL2...

  • Page 496: Component Locator

    6. Inner Small Boot Clamp 2. Outer Large Boot Clamp 7. Inner Boot 3. Outer Boot 8. Inner Large Boot Clamp 4. Outer Small Boot Clamp 9. Inner Joint (Tripot) 5. Drive Axle Shaft 10. Inner Joint Housing DAEWOO M-150 BL2...

  • Page 497: Diagnostic Information And Procedures

    S Replace drive axle. shaft. S Worn joint by grease leakage. S Replace drive axle. Car Lead / Pull S Poor assembly of boot clamp. S Replace boot clamp. Boot Leak S Torn boot. S Replace Boot. DAEWOO M-150 BL2...

  • Page 498: Repair Instructions

    Tie rod end joint castellated nut. Notice: Use only the recommended tool for separating the tie rod from the knuckle/strut assembly. Failure to use the recommended tool may cause damage to the knuckle/strut assembly or the tie rod end. D104B501 DAEWOO M-150 BL2...
  • Page 499 D104B504 Installation Procedure 1. Clean the transaxle seal. 2. Install the drive axle into the transaxle. 3. Install the wheel hub onto the drive axle shaft. 4. Mount the knuckle onto the control arm ball joint. D14B502A DAEWOO M-150 BL2...
  • Page 500 (a). D Remove the oil level plug (1). D Refill recommended fluid to the proper level. D Tighten the oil level plug to 36-54 NSm (26–40 lb- ft) (b). Classification 75W–85 (GL–4) Capacity 2.1L (2.21 gt) D13BB520A DAEWOO M-150 BL2...
  • Page 501 3B – 8 MANUAL TRANSAXLE DRIVE AXLE 11. Install the transaxle under cover. Tighten Tighten the transaxle under cover bolts to 35–55 NSm (25–41 lb-ft) 35–55 NSm D13B521A DAEWOO M-150 BL2...

  • Page 502: Unit Repair

    D Remove the boot clamp (small) (2). D104B701 3. Remove the joint housing from boot. a. Boot. b. Joint housing. D104B702 4. Degrease the joint assembly. 5. Remove the tripot joint. D Remove the circlip (1). D Remove the tripot joint (2). D104B703 DAEWOO M-150 BL2...

  • Page 503: Outer Joint

    2. Remove the clamps on the joint boot. D Remove the boot clamps (1,2). D104B706 3. Degrease the joint assembly. 4. Remove the joint assembly. D Widen the circlip (1). D Remove the joint assembly while widening the cir- clip (2). D104B707 DAEWOO M-150 BL2...
  • Page 504 2. Inspect for a leaking boot through the clamp side. Important: Do not disassemble the outer joint assem- bly. Parts are match fit and can not be serviced sepa- rately. Improper reassembly will adversely affect both performance and safety. D104B710 DAEWOO M-150 BL2...

  • Page 505: Specifications

    90 – 110 66 – 81 – Transaxle Under Cover Bolt 35 – 55 25 – 41 – Oil Drain Plug 25 – 30 18 – 22 – Oil Level Plug 36 – 54 26 – 40 – DAEWOO M-150 BL2...

  • Page 506: Special Tools And Equipment

    MANUAL TRANSAXLE DRIVE AXLE 3B – 13 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE KM–507–B J–35566 Tie Rod End Boot Clamp Pliers Joint Remover D104B101 D105B101 DAEWOO M-150 BL2...
  • Page 507 Brake Pedal Free Play Inspection ... 4A-7 Stoplamp Switch Circuit ....4A-14 DAEWOO M-150 BL2...

  • Page 508: Description And Operation

    D The lamp should be on whenever the parking brake applied and the ignition switch is in the II position. D A low fluid level in the master cylinder will turn the BRAKE warning lamp on. D17A007A DAEWOO M-150 BL2...

  • Page 509: Component Locator

    13. Master Cylinder 30. Rear Drum Brake Hose 14. Proportioning Valve 31. E Ring 15. Stoplamp Switch 32. Front Disc Brake Hose 16. Brake Pedal Assembly 33. Brake Hose Coupling Bolt 17. Clutch Pedal Spring 34. Plain Washer DAEWOO M-150 BL2...

  • Page 510: Brake System Testing

    If the fluid level is nor- on the brake hose, adjust or replace the hose as neces- mal, check the vacuum booster pushrod length. If an in- sary. correct pushrod length is found, adjust or replace the rod. DAEWOO M-150 BL2...

  • Page 511: Warning Lamp Operation

    D Bleed the brake system. D Brake fluid lacks or leaks. D Repair the leaks or add the fluid. Pedal Over Stroke D Poor adjustment of the brake pedal D Adjust the push rod length of the free play. power booster. DAEWOO M-150 BL2...

  • Page 512: Manual Bleeding The Brakes

    5. Automatic clearance adjuster check is performed af- ter removing brake drums. If the faulty is found, repair or replace it. D107A303 4. Slowly push the brake pedal several times and hold the brake pedal. DAEWOO M-150 BL2...

  • Page 513: Brake Pedal Free Play Inspection

    1. Push the brake pedal several times to discharge the vacuum of the power booster. 2. Measure the pedal movement until the hardness is felt when pushing the brake pedal by hand. Unit : mm (in.) Specification 6–10 (0.24–0.31) D107A305 DAEWOO M-150 BL2...

  • Page 514: Repair Instructions

    2. Install the brake hose coupling bolt (2). Tighten Tighten the bolt to 25.5 NSm (19.1 lb-ft). Important: Use only Daewoo recommended brake fluid. D17A529B 3. Bleed the brake system. Refer to “Manual Bleeding the Brakes” in this section.

  • Page 515: Brake Hose (Rear)

    2. Install the fitting and E–rings. Tighten Tighten the fitting to 16 NSm (12 lb-ft). Important: Use only Daewoo recommended brake fluid. 3. Bleed the brake system. Refer to “Manual Bleeding the Brakes” in this section. 4. Check the brake system for leaks.

  • Page 516: Brake Pedal

    Switch” in this section. D17A527A BRAKE PEDAL (RIGHT–HAND DRIVE) Removal Procedure 1. Remove the instrument panel assembly. Refer to Section 9E, Instrument/Driver Information. 2. Disconnect the brake pedal rod from the power booster. Refer to Section 4C, Power Booster. D24C001A DAEWOO M-150 BL2...
  • Page 517 D24D003 8. Remove the brake pedal. D Remove the snap rings (1). D Remove the bushings (2). D Remove the brake pedal spring (3). D Remove the cushion (4). D Remove the brake pedal pad (5). D24D004 DAEWOO M-150 BL2...
  • Page 518 Tighten the mounting bolts to 9–12 NSm (80–106 lb- in.) 7. Connect the brake pedal rod to the power booster. Refer to Section 4C, Power Booster. 8. Install the instrument panel assembly. Refer to Sec- tion 9E, Instrument/Driver Information. D24D007 DAEWOO M-150 BL2...

  • Page 519: General Specifications

    – Brake Pedal Bracket Mounting Bolts 18 – 26 13 – 20 – Brake Pedal Bracket Mounting Nuts 18 – 26 13 – 20 – Stoplamp Switch Mounting Bracket Bolts 9 – 12 – 80 – 106 DAEWOO M-150 BL2...

  • Page 520: Schematic And Routing Diagrams

    4A – 14 HYDRAULIC BRAKES SCHEMATIC AND ROUTING DIAGRAMS BRAKE LAMP WARNING CIRCUIT D17A201B STOPLAMP SWITCH CIRCUIT D17A202B DAEWOO M-150 BL2...
  • Page 521 ......4B-4 Master Cylinder Assembly ....4B-4 DAEWOO M-150 BL2...

  • Page 522: Description And Operation

    Once the fluid level is cor- may damage rubber components. rected, the BRAKE light will go out. D If any hydraulic component is removed or discon- nected, it may be necessary to bleed all or part of the brake system. DAEWOO M-150 BL2...

  • Page 523: Diagnostic Information And Procedures

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

  • Page 524: Repair Instructions

    D Remove the nuts mounting the master cylinder (3). D107A514 Installation Procedure Important: Use only Daewoo recommended brake fluid. 1. Install the master cylinder assembly with the nuts. Tighten Tighten the attaching nuts to 16 NSm (12 lb-ft).

  • Page 525: Brake Fluid Reservoir

    Notice: Do not force one side strongly to prevent dam- age of reservoir when removing the reservoir. D17A517A Installation Procedure Important: Use only Daewoo recommended brake fluid. 1. Install the reservoir with the screw. Tighten Tighten the screw to 4 NSm (35 lb-ft).

  • Page 526: Brake Fluid Level Switch

    1. Remove the vacuum hose from the power booster. Refer to Section 4C, Power Booster. 2. Remove the brake fluid level switch. D Remove the brake fluid level switch locking system by the flathead screwdriver (1). D107A504 D Disconnect the electrical connector (2). D107A505 DAEWOO M-150 BL2...
  • Page 527 MASTER CYLINDER 4B – 7 Installation procedure 1. Install the brake fluid level switch. 2. Connect the electrical connector. 3. Install the vacuum hose to the power booster. Refer to Section 4C, Power Booster. D107A506 DAEWOO M-150 BL2...

  • Page 528: Unit Repair

    9. Install the master cylinder. Refer to “Master Cylinder D24B003 Assembly” in this section. 10. Raise and suitably support the vehicle. 11. Bleed the braking system. Refer to Section 4A, Hy- draulic Brakes. 12. Lower the vehicle. DAEWOO M-150 BL2...

  • Page 529: Specifications

    Master Cylinder Attaching Nuts – Brake Pipe Fittings to Master Cylinder – Brake Pipe Fittings to Proportioning Valve – Brake Pipe Fittings to Rear Wheel Cylinder – Brake Pipe Fittings to Front Caliper – Proportioning Valve – DAEWOO M-150 BL2...
  • Page 530 ......4C-4 Fastener Tightening Specifications ... 4C-8 DAEWOO M-150 BL2...

  • Page 531: Description And Operation

    When the brakes are applied, air at atmospheric pres- the brake system. sure is admitted to one side of the diaphragm to pro- DAEWOO M-150 BL2...

  • Page 532: Diagnostic Information And Procedures

    2. Suck the vacuum hose to power booster. And also, D17A301B suck the vacuum hose to engine. 3. If the air pass through the check valve or not, replace the check valve. And if the vacuum hose to engine is DAEWOO M-150 BL2...

  • Page 533: Repair Instructions

    D Disconnect the vacuum hose from the intake man- ifold (1). D107A501 D Disconnect the vacuum hose from the power booster (2). D17A502A Installation Procedure 1. Connect the vacuum hose to the power booster. 2. Connect the vacuum hose to the intake manifold. D107A503 DAEWOO M-150 BL2...

  • Page 534: Power Booster Assembly

    100mm (3.94 in.). 2. Install the master cylinder assembly. Refer to Section 4B, Master Cylinder. 3. Connect the vacuum hose to the power booster. 4. Bleed the brake system. Refer to Section 4A, Hy- draulic Brakes. D17A522A DAEWOO M-150 BL2...
  • Page 535 7B, Manual Control Heating, Ventilation, and Air Con- D24C001 ditioning System. 5. Remove the power booster. D Straighten the cotter pin and remove it (1). D Remove the clevis pin (2). D Remove the nuts (3). D24C002 D Remove the power booster (4). D107A521 DAEWOO M-150 BL2...
  • Page 536 Air Conditioning System. 3. Install the instrument panel assembly. Refer to Sec- D24C003 tion 9E, Instrument/Driver Information. 4. Connect the vacuum hose to the power booster. 5. Install the master cylinder assembly. Refer to Section 4B, Master Cylinder. DAEWOO M-150 BL2...

  • Page 537: Specifications

    Power Booster Servo Force Ratio – 3.7 : 1 Distance from the booster to mm (inch) 96(3.78) the center of the clevis bore FASTENER TIGHTENING SPECIFICATIONS Application Lb-Ft Lb-In Booster–to-Dash Panel Nuts – Master Cylinder Attaching Nuts – DAEWOO M-150 BL2...
  • Page 538 ..4D-11 Repair Instructions ......4D-6 DAEWOO M-150 BL2...

  • Page 539: Description And Operation

    D Replace the pads in axle sets only. D107B002 D The torque values specified are for dry, unlubricated fasteners. D Perform the service operations on a clean bench, free from all mineral oil materials. DAEWOO M-150 BL2...

  • Page 540: Component Locator

    1. Front Brake Caliper Assembly 8. Piston Boot 2. Front Brake Boot Assemblies 9. Piston 3. Pins 10. Piston Seal 4. Pin Boots 11. Cylinder 5. Front Brake Pads 12. Bleeder Screw Cap 6. Carrier 13. Bleeder Screw 7. Pad Spring DAEWOO M-150 BL2...

  • Page 541: Diagnostic Information And Procedures

    D Excessive rotor run out. D Replace the rotor. Noise and Vibration When Brake Applied D Interference of the dust cover. D Repair the dust cover. D Loose caliper mounting bolts. D Tighten the mounting bolts. DAEWOO M-150 BL2...

  • Page 542: Lining Inspection

    The maintenance of 7. Install the rotor. Refer to “Rotor” in this section. close tolerances on the shape of the braking surfaces is necessary to prevent brake roughness. D107B303 DAEWOO M-150 BL2...

  • Page 543: Repair Instructions

    Installation Procedure 1. Install the brake pads and the cylinder assembly with the pin bolt. Tighten Tighten the pin bolt to 26 NSm (19 lb-ft). 2. Install the front wheels. Refer to Section 2E, Tires and Wheels. D17B503A DAEWOO M-150 BL2...

  • Page 544: Caliper Assembly

    1. Install the rotor to the front wheel hub by tightening the detent bolts. Tighten Tighten the rotor–to–front wheel hub detent bolts to 65 NSm (48 lb-ft). 2. Install the steering knuckle. Refer to Section 2C, Front Suspension. D17B507A DAEWOO M-150 BL2...

  • Page 545: Unit Repair

    D Remove the front brake pad set (1). D Remove the springs (2). D Remove the guide pins and boots (3). Refer to “Shoe and Lining” in this section. D107B702 D Remove the bleeder plug (1). D Remove the bleeder plug cap (2). D17B703C DAEWOO M-150 BL2...
  • Page 546 D Remove the piston boot (3). Caution: Do not face in the direction of removing. D107B704 D Using compressed air, blow out the piston from the cylinder (4). D Remove the piston (5). D107B705 D Remove the piston seal (6). D107B706 DAEWOO M-150 BL2...
  • Page 547 D Install the pads. 3. Install the pin bolt connecting the cylinder assembly and carrier. Tighten Tighten the pin bolt to 26 NSm (19 lb-ft). 4. Install the caliper assembly. Refer to “Caliper Assem- bly” in this section. D17B707A DAEWOO M-150 BL2...

  • Page 548: Specifications

    (in.) 8 (0.31) Diameter of the Position mm (in.) 48 (1.89) FASTENER TIGHTENING SPECIFICATIONS Application Lb-Ft Lb-In Rotor Bolts – Caliper Mounting Bolts – Pin Bolts – Brake Hose Coupling Bolt 25.5 19.1 – Bleeder Screw – DAEWOO M-150 BL2...
  • Page 549 ..4E-11 On-Vehicle Service ......4E-6 DAEWOO M-150 BL2...

  • Page 550: Drum Brakes

    Do not switch the position of shoes that have been in service, as this may render the self-adjustment fea- ture inoperative and result in increased pedal travel. DAEWOO M-150 BL2...

  • Page 551: Rear Drum Brakes

    4. Rear Brake Plate 12. Brake Shoe Retain Spring 5. Wheel Cylinder 13. Brake Shoe Retain Spring Cap 6. Strut Assembly 14. Lower Return Spring 7. Brake Leading Shoe 15. Hub Bolt 8. Middle Return Spring 16. Rear Brake Drum DAEWOO M-150 BL2...
  • Page 552 Poor Braking Force of Parking Brake then replace the wheel cylinder or the lining, if needed. D Damaged self–adjustment feature. D Repair the self–adjustment feature. D Poor adjustment of parking brake D Adjust the parking brake cable. cable. DAEWOO M-150 BL2...
  • Page 553 3. If the measured value is over the limit value, or if the 3. If the measured value is within the limit value, or if the defect is found, replace the drum. defect is found, replace the lining. DAEWOO M-150 BL2...
  • Page 554 D Remove the hub bolts using a hammer (5). Important: Do not reuse removed hub bolts. D17C502A Installation Procedure 1. Install the brake drum. D Insert the new hub bolts using a hammer. D Install the bearing, race, oil seal and rear axle washer. D107C503 DAEWOO M-150 BL2...

  • Page 555: Brake Shoe

    D Turn the brake shoe retaining spring pin rectangu- larly by the pliers (2). D Remove the brake shoe retain spring cap (3). D Remove the retaining spring (4). D Remove the retaining spring pin (5). D Remove the leading shoe (6). D107C507 DAEWOO M-150 BL2...
  • Page 556 D Widen the leading shoe and trailing shoe (2). D107C510 D Disconnect the brake line fitting (3). D Plug the opening in the brake line to prevent fluid loss or contamination. D Remove the wheel cylinder–to–backing plate bolt (4). D107C511 DAEWOO M-150 BL2...
  • Page 557 Tighten the backing plate–to–rear axle bolts to 24 NSm (18 lb-ft). 2. Install the wheel cylinder assembly. Refer to “Wheel Cylinder Assembly” in this section. 3. Install the brake shoe components. Refer to “Brake Shoe” in this section. 4. Install the brake drum. D17C514A DAEWOO M-150 BL2...

  • Page 558: Wheel Cylinder

    D Install the spring and the new piston cup. D Install the piston and the new boots. 2. Inspect the piston for free movement. D17C702A 3. Install the wheel cylinder assembly. Refer to “Wheel Cylinder Assembly” in this section. DAEWOO M-150 BL2...

  • Page 559: Fastener Tightening Specifications

    – – – Wheel Cylinder Bolt – Brake Backing Plate Bolt – Brake Pipe Fitting – Bleeder Screw – Q Castellated Nut : 25 NSm – 180_ + 2.5 NSm (18 lb-ft – 180_ + 22 lb-in.) DAEWOO M-150 BL2...
  • Page 560 ......4F-78 DTC 0455 Left Rear Wheel Speed Sensor Poor Air Gap or Missing Tooth Ring ..4F-36 DAEWOO M-150 BL2...
  • Page 561 DTC 5610 RAM/ROM Error 8 Bit ..4F-118 DTC 5630 ROM Error 16 Bit ....4F-119 DAEWOO M-150 BL2...

  • Page 562: Description And Operation

    The HPA is in between the pump and the ISO valve (master cylinder side) and uses the bulk mode of the contained plastic damper and orifice size to dump out the pressure oscillations from the pump to reduce the D107E002 DAEWOO M-150 BL2...

  • Page 563: Ebcm (Electronic Brake Control Module)

    The pressure will continue until a stall point is reached and compression of the piston cannot generate enough differential pressure anymore to open the outlet ball seat. DAEWOO M-150 BL2...

  • Page 564: Wheel Speed Sensors And Rings

    If any malfunction or error, including an unplugged EBCM connector, is detected during vehicle operation, the light will come on, warning the driver that the ABS is not operative and brake operation is in conventional, non-ABS mode. D107E007 D17E010A D107E008 DAEWOO M-150 BL2...

  • Page 565: Ebcm Connector

    And a connector includes a warning switch which grounds and lights the ABS warning lamp if there is No EBCM unit plugged in, so that an indication is given that ABS is not available. Mechanical Switch D17E011A DAEWOO M-150 BL2...

  • Page 566: Hydraulic Fluid Flow Diagrams

    During non-antilock braking, pressure is applied through the brake pedal and fluid comes from the master cylinder into the hydraulic unit. The normally open isolation cartridge and normally closed dump cartridge would remain in these positions to allow fluid pressure to the calipers and the wheel cylinders. And each wheel begins locking. DAEWOO M-150 BL2...

  • Page 567: Isolation Mode (Pressure Maintain)

    Though each channel of the 4-channel system can operate inde- pendently, once any front channel (brake) sees excessive deceleration, both front isolation valves are energized and close thus, with the isolation valves closed, further unnecessary increases in the brake pressure will be prohibited. DAEWOO M-150 BL2...

  • Page 568: Dump Mode (Pressure Decrease)

    The fluid taken from the wheels forces the spring back and is stored in the LPA. A portion of the fluid also primes the pump. The dump cartridges are operated independently to control the deceleration of the wheel. DAEWOO M-150 BL2...

  • Page 569: Reapply Mode (Pressure Increase)

    As fluid is reapplied to the wheel, they begin to slow down. If they approach imminent lockup again, the EBCM will isolate, dump and reapply again. The control cycle (isolation, dump, reapply) occurs in milli-second intervals, allowing seveal cycles to occur each second. It is a much faster and more controlled way of “pumping the pedal”. DAEWOO M-150 BL2...

  • Page 570: Proportioning Function

    The EBCM then actuates the rear wheel isolation valves to reduce the rear brake pressure and keep the wheels rolling. DAEWOO M-150 BL2...

  • Page 571: Visual Identification

    Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...

  • Page 572: Component Locator

    COMPONENT LOCATOR D17E401A 1. Hydraulic Modulator Unit 6. Lower Mounting Bracket 2. Electronic Brake Control Module (EBCM) 7. Bracket Grommet 3. Bolt 8. Rear Wheel Speed Sensor 4. Upper Mounting Bracket 9. Front Wheel Speed Sensor 5. Grommet DAEWOO M-150 BL2...
  • Page 573 4F – 14 ANTILOCK BRAKE SYSTEM ABS (Cont’d) D17E402A DAEWOO M-150 BL2...
  • Page 574 ANTILOCK BRAKE SYSTEM 4F – 15 BLANK DAEWOO M-150 BL2...

  • Page 575: Diagnostic Information And Procedures

    When replacing a wheel speed sensor, inspect the sen- cuit. sor terminals and harness connector for corrosion and/ D The wheel speed sensor resistance is very high. or water intrusion. If evidence of corrosion or water D The EBCM is malfunctioning. DAEWOO M-150 BL2...

  • Page 576: Dtc 0354 Left Front Wheel Speed Sensor Circuit Open Or Shorted

    Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 577 Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 578 ANTILOCK BRAKE SYSTEM 4F – 19 BLANK DAEWOO M-150 BL2...
  • Page 579 If you find evidence of This is a critical operational fault. The ABS is disabled corrosion or water intrusion, replace the wheel speed and the ABS warning lamp is turned on. The proportion- ing is operation. DAEWOO M-150 BL2...

  • Page 580: Dtc 0355 Left Front Wheel Speed Sensor Poor Air Gap Or Missing Tooth Ring

    Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 581 When replacing a wheel speed sensor, inspect the sen- sor circuit. sor terminals and harness connector for corrosion and/ D There is a loose connection in the EBCM. or water intrusion. If evidence of corrosion or water D The EBCM is malfunctioning. DAEWOO M-150 BL2...

  • Page 582: Dtc 0356 Left Front Wheel Speed Sensor Circuit Intermittent Shorted

    Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 583 When replacing a wheel speed sensor, inspect the sen- cuit. sor terminals and harness connector for corrosion and/ D The wheel speed sensor resistance is very high. or water intrusion. If evidence of corrosion or water D The EBCM is malfunctioning. DAEWOO M-150 BL2...

  • Page 584: Dtc 0404 Right Front Wheel Speed Sensor Circuit Open Or Shorted

    Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 585 Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 586 ANTILOCK BRAKE SYSTEM 4F – 27 BLANK DAEWOO M-150 BL2...
  • Page 587 If you find evidence of This is a critical operational fault. The ABS is disabled corrosion or water intrusion, replace the wheel speed and the ABS warning lamp is turned on. The proportion- ing is operation. DAEWOO M-150 BL2...

  • Page 588: Dtc 0405 Right Front Wheel Speed Sensor Poor Air Gap Or Missing Tooth Ring

    Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 589 When replacing a wheel speed sensor, inspect the sen- sor circuit. sor terminals and harness connector for corrosion and/ D There is a loose connection in the EBCM. or water intrusion. If evidence of corrosion or water D The EBCM is malfunctioning. DAEWOO M-150 BL2...

  • Page 590: Dtc 0406 Right Front Wheel Speed Sensor Circuit Intermittent Shorted

    Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 591 When replacing a wheel speed sensor, inspect the sen- cuit. sor terminals and harness connector for corrosion and/ D The wheel speed sensor resistance is very high. or water intrusion. If evidence of corrosion or water D The EBCM is malfunctioning. DAEWOO M-150 BL2...

  • Page 592: Dtc 0454 Left Rear Wheel Speed Sensor Circuit Open Or Shorted

    Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 593 Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 594 Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 595 If you find evidence of This is a critical operational fault. The ABS is disabled corrosion or water intrusion, replace the wheel speed and the ABS warning lamp is turned on. The proportion- ing is operation. DAEWOO M-150 BL2...

  • Page 596: Dtc 0455 Left Rear Wheel Speed Sensor Poor Air Gap Or Missing Tooth Ring

    Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 597 When replacing a wheel speed sensor, inspect the sen- sor circuit. sor terminals and harness connector for corrosion and/ D There is a loose connection in the EBCM. or water intrusion. If evidence of corrosion or water D The EBCM is malfunctioning. DAEWOO M-150 BL2...

  • Page 598: Dtc 0456 Left Rear Wheel Speed Sensor Circuit Intermittent Shorted

    Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 599 Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 600 ANTILOCK BRAKE SYSTEM 4F – 41 BLANK DAEWOO M-150 BL2...
  • Page 601 When replacing a wheel speed sensor, inspect the sen- cuit. sor terminals and harness connector for corrosion and/ D The wheel speed sensor resistance is very high. or water intrusion. If evidence of corrosion or water D The EBCM is malfunctioning. DAEWOO M-150 BL2...

  • Page 602: Dtc 0504 Right Rear Wheel Speed Sensor Circuit Open Or Shorted

    Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 603 Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 604 Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 605 If you find evidence of This is a critical operational fault. The ABS is disabled corrosion or water intrusion, replace the wheel speed and the ABS warning lamp is turned on. The proportion- ing is operation. DAEWOO M-150 BL2...

  • Page 606: Dtc 0505 Right Rear Wheel Speed Sensor Poor Air Gap Or Missing Tooth Ring

    Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 607 When replacing a wheel speed sensor, inspect the sen- sor circuit. sor terminals and harness connector for corrosion and/ D There is a loose connection in the EBCM. or water intrusion. If evidence of corrosion or water D The EBCM is malfunctioning. DAEWOO M-150 BL2...

  • Page 608: Dtc 0506 Right Rear Wheel Speed Sensor Circuit Intermittent Shorted

    Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 609 Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 610 ANTILOCK BRAKE SYSTEM 4F – 51 BLANK DAEWOO M-150 BL2...
  • Page 611 ABS warning lamp is turned on. The proportion- EBCM may make the fault code. ing is operation. Cause(s) D EBCM internal fault (Left front dump voltage shorted or ground open). DAEWOO M-150 BL2...
  • Page 612 Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 613 ABS warning lamp is turned on. The proportion- EBCM may make the fault code. ing is operation. Cause(s) D EBCM internal fault (Left front dump voltage open or ground shorted). DAEWOO M-150 BL2...

  • Page 614: Dtc 0602 Left Front Dump Open Or Driver Shorted

    Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 615 ABS warning lamp is turned on. The proportion- EBCM may make the fault code. ing is operation. Cause(s) D EBCM internal fault (Left front isolation voltage shorted or ground open). DAEWOO M-150 BL2...

  • Page 616: Dtc 0651 Left Front Isolation Shorted Or Driver Open

    Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ Ñ DAEWOO M-150 BL2...
  • Page 617 ..... . . 4G-4 Parking Brake System ..... 4G-9 DAEWOO M-150 BL2...

  • Page 618: Parking Brake

    Check for frayed cables, rust, etc., or any should glow and go OFF when the parking brake lever is condition that may inhibit present (or future) free move- released. Whenever the parking brake is applied and the ment of the parking brake lever assembly. DAEWOO M-150 BL2...
  • Page 619 COMPONENT LOCATOR PARKING BRAKE D107D401 1. Parking Brake Cable Clip 6. Parking Brake Warning Lamp Switch 2. Parking Brake Cable 7. Cotter Pin 3. Strengthener 8. Cable Pulley 4. Cable Grommet 9. Pin 5. Parking Brake Lever Assembly DAEWOO M-150 BL2...

  • Page 620: Parking Brake Lever

    Important: The brake warning lamp switch screw should be removed with the lever fixed. D107D501 D Remove the bolts (3). D Remove the nut (4). D107D502 D Remove the cotter pin (5). D Remove the pin (6). D107D503 DAEWOO M-150 BL2...
  • Page 621 Installation Procedure 1. Install the parking brake warning lamp switch. 2. Release the parking brake. 3. Connect the parking brake warning lamp switch. 4. Install the gear shift lever cover. Refer to Section 5B, Five–Speed Manual Transaxle. D107D507 DAEWOO M-150 BL2...

  • Page 622: Parking Brake Cable

    (2). Refer to Section 4E, Rear Drum Brake. D107D510 5. Remove the parking brake cable. D Remove the clamp bolts fastening the brake cable (RH Rear Brake Side) (1). D Remove the fuel filter. Refer to Section 1F, Engine Controls. D107D511 DAEWOO M-150 BL2...
  • Page 623 5. Install the grommet and the strengthener. 6. Install the cable pulley with the adjustment nuts. Tighten Tighten the adjustment nuts to 10 NSm (89 lb-in) (3). 7. Install the parking brake lever. Refer to “Parking Brake Lever” in this section. D17D515A DAEWOO M-150 BL2...
  • Page 624 Parking Brake Lever Notch Number 5–7 (Loaded 44.1 lb) FASTENER TIGHTENING SPECIFICATIONS Application Lb-Ft Lb-In Parking Brake Cable Clamp Bolts – Parking Brake Lever Bolts – Parking Brake Lever Nut – Parking Brake Cable Adjusting Nuts – DAEWOO M-150 BL2...
  • Page 625 PARKING BRAKE 4G – 9 SCHEMATIC AND ROUTING DIAGRAMS PARKING BRAKE SYSTEM D17A201B DAEWOO M-150 BL2...
  • Page 626 ......5B-10 Special Tools Table ..... . . 5B-54 DAEWOO M-150 BL2...

  • Page 627: Five-Speed Manual Transaxle

    It changes the direction of power and increase torque by reducing speed. Reduction gear is installed parallel to counter shaft and is helical gear type. Differential gear is bevel gear type and is integrated with reduction gear. DAEWOO M-150 BL2...

  • Page 628: Component Locators

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

  • Page 629: Input Shaft And Counter Shaft Gear

    5B – 4 FIVE-SPEED MANUAL TRANSAXLE INPUT SHAFT AND COUNTER SHAFT GEAR D13B4031 DAEWOO M-150 BL2...
  • Page 630 19 3rd Gear Synchronizer Ring 44 Counter Shaft 1st Gear Input Shaft 3rd Gear 45 Counter Shaft 1st Gear Bearing 21 Input Shaft 3rd Gear Bearing 46 Counter Shaft 22 Input Shaft 47 Counter Shaft Bearing(Right) 23 Input Shaft Bearing(Right) DAEWOO M-150 BL2...

  • Page 631: Gear Shift Fork

    10 Low Speed Shift Fork 23 5th/Reverse Shift York 11 Low Speed Shift Shaft 24 5th/Shift Fork Guide Ball 12 Low Speed Shift Shaft Spring/Ball 25 5th/Shift Fork 13 Low Speed Shift York 26 Reverse Shift Lever DAEWOO M-150 BL2...

  • Page 632: Differential And Case

    21 Differential Side Gear Adjust Shim 9 Oil Drain Plug 22 Differential Side Gear 10 Oil Gutter 23 Differential Pinion Gear Shaft 11 Side Cover Plate 24 Differential Pinion Gear 12 Side Cover 25 Differential Pinion Gear Washer 13 Differential Ring Gear DAEWOO M-150 BL2...

  • Page 633: Diagnostic Information And Procedure

    D Worn or damaged gear in the D Replace gear. peculiar gear. D Worn or damaged bearing in the D Replace bearing. peculiar gear. D Damaged gasket, oil seal or D Replace gasket, oil seal or O-ing. Leak of Lubricant O-ring. DAEWOO M-150 BL2...

  • Page 634: Checking Fluid Level

    NEUTRAL. Since wheel bearings are not a. Oil drain plug. pre-loaded, a wheel bearing noise should diminish con- b. Oil level plug. siderably when the wheels are off the ground. 6. Reinstall the oil level plug and tighten it securely. DAEWOO M-150 BL2...

  • Page 635: Repair Instruction

    4. Remove the engine wiring harness bending strap. 5. Disconnect the ground wire and the backup lamp switch connector. D Remove the ground wire bolt (1). D Disconnect the ground wire (2). D Disconnect the backup lamp switch connector (3). D103B502 DAEWOO M-150 BL2...
  • Page 636 D Remove the cowl panel weatherstrip. D Position the engine support fixture DW110–021 on the cowl panel and the front upper panel. D Tighten the engine fixture joint with a bolt after re- moving exhaust manifold bolt (No.4). D13B5041 DAEWOO M-150 BL2...
  • Page 637 Refer to Section 2C, Front Suspension. 18. Remove the drive axle (only transaxle side). Refer to Section 3B, Manual Transaxle Drive Axle. 19. Remove the clutch housing lower plate. D Remove the bolts (1). D Remove the lower plate (2). D103B509 DAEWOO M-150 BL2...
  • Page 638 D Support the transaxle case and mount using a jack and the transaxle remove/install support. D13B5111 22. Remove the transaxle lower bolt and nut. a. Lower bolt. b. Lower nut. D103B512 23. Remove the transaxle mount bolts. D13B5131 DAEWOO M-150 BL2...
  • Page 639 D103B516 Installation Procedure 1. Install in the reverse order of removal. 2. Install the transaxle mounting bolts. Tighten Tighten the transaxle mounting bolts (body side) to 45–55 NSm (33–41 lb-ft). D13B5171 DAEWOO M-150 BL2...
  • Page 640 Tighten the bolts to 55–65 NSm (41–48 lb-ft). a. Exhaust manifold side bolt. b. Thermostat housing side bolt. D13B519A 6. Install the starter motor. Tighten Tighten the starter motor bolts to 18–28 NSm (13–21 lb-ft). 7. Connect all electric connectors. D13B548A DAEWOO M-150 BL2...

  • Page 641: Gear Shift Control Case Assembly

    3. Disconnect the select and the shift control cable. D Remove the cable pins (1). D Remove the washers (2). D Disconnect the select and the shift control cable (3). D Remove the cable E–rings (4). D Disconnect the cables from the cable bracket. D103B501 DAEWOO M-150 BL2...
  • Page 642 D Position the gear shift control case assembly to the vice with a protector. D Remove the lever pin with a pin punch and a ham- mer (1). D Remove the shift lever (2). D Remove the boot (3). D103B525 DAEWOO M-150 BL2...
  • Page 643 4. Inspect for bent or damaged select/shift shaft (4). D103B528 Installation Procedure 1. Install in the reverse order of removal. 2. Install the shift guide bolt. Tighten Tighten the shift guide bolt to 18–28 NSm (13–21 lb-ft). D13B529A DAEWOO M-150 BL2...

  • Page 644: Speedometer Driven Gear And Cable

    D Disconnect the vehicle speed sensor connector (If equipped). a. Vehicle speed sensor connector. D Disconnect the vehicle speed sensor. b. Vehicle speed sensor. Caution: Be careful to prevent personal injury while the exhaust pipe is hot. D103B533 DAEWOO M-150 BL2...
  • Page 645 D103B536 2. Install the speedometer driven gear assembly to transaxle housing. Tighten Tighten the speedometer driven gear assembly bolt to 4–7 NSm (35–62 lb-in). D13B537A DAEWOO M-150 BL2...

  • Page 646: Gear Shift Control Cable

    D Remove the shift control cable E–ring (6). D Ply off the shift control cable (7). D13B5381 6. Remove the select and shift control cable. D Remove the nuts (1). D Pull the cables out in the passenger room. D13B539A DAEWOO M-150 BL2...

  • Page 647: Gear Shift Control Lever

    “Gear Shift control cable” in this section. 3. Remove the gear shift control lever assembly. D Remove the bolts (1). D Remove the gear shift control lever assembly (2). D Remove the gear shift lever sensor connector. (If equipped with auto clutch). D103B543 DAEWOO M-150 BL2...
  • Page 648 1. Install in the reverse order of removal. 2. Install the gear shift control lever assembly. Tighten Tighten the bolts to 4–7 NSm (35–62 lb-in). 3. Adjust the select cables. Refer to “Gear Shift Control Cable” in this section. D13B544A DAEWOO M-150 BL2...

  • Page 649: Unit Repair

    5. Disconnect the backup light switch and speedometer driven gear assembly. D Remove the nut (1). D Disconnect the backup light switch (2). D Remove the bolt (3). D Remove the speedometer driven gear assembly (4). D103B703 DAEWOO M-150 BL2...
  • Page 650 D Remove the fifth–gear shift fork plug (1). D Remove the guide ball using a magnet. D Remove the fifth–gear shift fork snap ring (2). D Remove the fifth–gear snap ring (3). D Remove the fifth–gear synchronizer plate. D103B707 DAEWOO M-150 BL2...
  • Page 651 13. Remove the countershaft fifth–gear. D Shift the shift yoke using a driver to engage the first–gear and the third–gear or the second–gear and the fourth–gear (1). D Remove the caulking and the nut. (2, 3) D103B711 DAEWOO M-150 BL2...
  • Page 652 Mark it to distinguish easily when installing. D103B714 16. Remove the reverse idle gear shaft bolt. Important: The case (Left) can not be removed without removing the reverse idle gear shaft bolt. D103B715 DAEWOO M-150 BL2...
  • Page 653 D Push the reverse idle gear toward inner case. D Pulling shaft and remove the reverse idle gear and shaft (1). D Remove the reverse idle gear from the shaft. D103B718 20. Remove the fifth–reverse gear shift shaft. a. Fifth–reverse gear shift shaft. D103B719 DAEWOO M-150 BL2...
  • Page 654 D Remove the case cap O–ring (Left Side) (8). D Remove the oil level plug (including steel gasket) (9). D Remove the counter shaft bearing outer race us- ing a hammer and the gear, bearing installer DW 09940–53111. D103B723 DAEWOO M-150 BL2...
  • Page 655 D Install the oil level plug (including steel gasket). a. Oil level plug. Tighten Tighten the oil level plug to 36–54 NSm (26–40 lb-ft). D Install the left side case cap with the bolts (includ- ing O–ring) (1). D13B727A DAEWOO M-150 BL2...
  • Page 656 Important: Match the marking of the reverse idle gear shaft bolt hole with the protrusion of the transaxle case (Right Side). D Install the reverse gear shift lever (2). Tighten Tighten the bolts to 18–28 NSm (13–21 lb-ft). D13B730A DAEWOO M-150 BL2...
  • Page 657 12. Install the counter shaft bearing outer race. D Install the counter shaft bearing outer race using the gear, bearing installer DW09940–53111. a. Bearing outer race. Important: Check if the bearing and the outer race are correctly installed by rotating counter shaft. D103B734 DAEWOO M-150 BL2...
  • Page 658 D Install the side cover plate (1). Tighten Tighten the screws to 6–7 N.m (53–62 lb–in). Important: Use only new screws. D Install the counter shaft fifth gear (2). Important: Position the machined boss side toward the side cover plate. D13B736A DAEWOO M-150 BL2...
  • Page 659 19. Install the fifth gear fork and the synchronizer hub assembly to the input shaft. Important: Position the longer boss side of hub toward inner side and match the synchronizer key and the hub groove with the input shaft punched mark. D103B739 DAEWOO M-150 BL2...
  • Page 660 D Tighten the bolts to 18–28 NSm (13–21 lb-ft) (a). D Tighten the shift interlock bolt to 18–28 NSm (13– 21 lb-ft) (b). D Install the select lever. Tighten Tighten the bolts to 18–28 NSm (13–21 lb-ft) (c). D13B743A DAEWOO M-150 BL2...

  • Page 661: Input Shaft

    1. Remove the gear unit. Refer to “Gear Unit” in this section. 2. Remove the input shaft right side bearing. D Position the bearing to the gear, bearing remover DW09921–57810. D103B746 D Remove the bearing by pressing (1). DAEWOO M-150 BL2...
  • Page 662 7. Remove the third–fourth synchronizer hub assembly, the third gear 1 synchronizer ring. D Position the third gear to the gear, bearing remover DW09921–57810. D Remove the following parts. a. Third–fourth synchronizer hub assembly. b. Third gear and synchronizer ring. D103B750 DAEWOO M-150 BL2...
  • Page 663 Therefore, cone area and ring inner surface shall be inspected. In this case, ring inner surface shall be glossy. Black area is abnormal and if in- spection is difficult, check after applying red lead. Cone area can be worn in wave form. D103B754 DAEWOO M-150 BL2...
  • Page 664 1. Install the third gear bearing, the third gear / synchro- nizer ring. a. Third gear / synchronizer ring. b. Third gear bearing. Important: Coat the inner parts; gear, bearing, oil seal etc. with gear fluid. D103B758 DAEWOO M-150 BL2...
  • Page 665 DW09940–53111 and a hammer. If overpressed, the gear teeth may be damaged. D13B761A 4. Install the third–fourth synchronizer circlip. 5. Install the fourth synchronizer ring and wave spring. Important: Match the ring groove to the key of hub. D103B749 DAEWOO M-150 BL2...

  • Page 666: Counter Shaft

    Bushing, Seal Installer DW09913–80112 Gear, Bearing Installer DW09921–57810 Gear, Bearing Remover DW09925–98221 Gear, Bearing Installer DW09940–53111 Gear,Bearing Installer DW220–020–01 Differential Bearing Puller DW220–020–02 Differential Bearing Plate Adapter DW220–020–03 Differential Bearing Plate Adapter KM466–A Gear, Bearing Remover/Installer D103B765 DAEWOO M-150 BL2...
  • Page 667 D Remove the following parts by pressing a. Third gear. b. Second gear. D103B767 6. Remove the counter shaft second gear bearing. 7. Remove the second gear synchronizer ring. 8. Remove the first–second gear synchronizer circlip. D103B768 DAEWOO M-150 BL2...
  • Page 668 Synchronizer Hub and Sleeve Inspection D Check the sleeve for improper operation after assem- bling the hub and the sleeve. D Check the wear of hub and sleeve. D Replace synchronizer hub or sleeve if necessary. D103B772 DAEWOO M-150 BL2...
  • Page 669 D Insert the hub assembly into the counter shaft us- ing the gear, bearing installer DW09940–53111, the gear bearing remover/installer KM466–A and a hammer (1). Important: Position the synchronizer key to the first gear synchronizer ring groove. D103B776 DAEWOO M-150 BL2...
  • Page 670 DW09913–80112 and a hammer. a. Third–fourth gear spacer. b. Third gear. D103B778 8. Install the counter shaft fourth gear. D Install the fourth gear to the counter shaft using the gear, bearing installer DW09925–98221 and a hammer (1). D103B779 DAEWOO M-150 BL2...

  • Page 671: Gear Shift Fork

    D Remove the first–second gear shift yoke pin using a pin punch and a hammer (3). D Remove the first–second gear shift yoke (4). Important: Mark the place and direction of shift fork and yoke to install easily before removing them. D103B783 DAEWOO M-150 BL2...
  • Page 672 D Remove the fifth gear shift yoke pin using a pin punch and a hammer (4). D Remove the fifth gear shift yoke (5). D103B785 Inspection Procedure – Shift Shaft 1. Check for bent, deformed or damaged shift shaft. 2. Replace shift shaft if necessary. D103B786 DAEWOO M-150 BL2...

  • Page 673: Differential

    D Fix the differential assembly to a vise with protec- tor. D Remove the bolts (1). D Remove the ring gear (2). D103B789 3. Remove the pinion gear pin. D Remove the pin using a pin punch and a hammer (1). D103B790 DAEWOO M-150 BL2...
  • Page 674 DW220–020A–02. D Remove the speedometer drive gear (1). D13B793A 7. Remove the differential left side bearing. D Remove the left side bearing using the differential bearing puller DW220–020A–01 and the differen- tial bearing plate adapter DW220–020A–03. D13B794A DAEWOO M-150 BL2...
  • Page 675 2. Install the speedometer drive gear and differential right side bearing. D Insert the speedometer drive gear(1). D Insert the differential right side bearing (2). D Install the right side bearing using the bushing, seal installer 09913–76010 and a hammer. D103B798 DAEWOO M-150 BL2...
  • Page 676 D Fix the differential assembly to a vise. D Install the ring gear with the bolts (1). Tighten Tighten the bolts to 80–100 NSm (59–74 lb-ft). 6. Install the differential assembly. Refer to “Gear Unit” in this section. D13B801A DAEWOO M-150 BL2...

  • Page 677: Specifications

    Clearance between sleeve and shift fork mm(in.) 0.2 – 0.6 1.0 (0.039) (0.008 – 0.024) Thrust free play of differential side gear mm(in.) 0.05 – 0.33 – (0.002 – 0.013) Speedometer gear ratio(Driven/Drive) – 17/18 (0.944) – DAEWOO M-150 BL2...

  • Page 678: Fastener Tightening Specifications

    33 – 41 – Transaxle Mounting Bolt and Nut(Transaxle Side) 55 – 65 41 – 48 – Transaxle Upper Bolt(Engine Side) 55 – 65 41 – 48 – Transaxle Under Cover Bolt 35 – 55 25 – 41 – DAEWOO M-150 BL2...

  • Page 679: Special Tools

    Bushing, Seal Installer Gear, Bearing Installer D103B110 D103B105 DW09913–80112 DW09943–78210 Gear, Bearing Installer Bushing, Seal Installer D103B106 D103B109 DW110–021 DW09921–57810 Engine Assembly Gear, Bearing Remover Support Fixture D103B104 D103B103 DW09925–98221 DW220–010A Gear, Bearing Installer Transaxle Fixture D103B107 D13B101A DAEWOO M-150 BL2...
  • Page 680 SPECIAL TOOLS TABLE (Cont’d) DW220–020A–01 DW220–031 Differential Bearing Transaxle Remove/ Puller Install Support D13B112A D103B102 DW220–020A–02 KM466–A Differential Bearing Gear, Bearing Remover Plate Adapter / Installer D13B113A D103B108 DW220–020A–03 KM519 Differential Bearing Oil Seal Installer Plate Adapter D13B114A D103B111 DAEWOO M-150 BL2...
  • Page 681 ......5C-6 On-Vehicle Service ......5C-6 DAEWOO M-150 BL2...

  • Page 682: Description And Operation

    DAEWOO M-150 BL2...

  • Page 683: Component Locator

    7 Release Shaft Seal 2 Pressure Plate 8 Release Arm 3 Release Bearing 9 Clutch Cable Adjusting Nut 4 Release Shaft 10 Clutch Cable 5 Release Shaft Bushing (No.1) 11 Clutch Pedal 6 Release Shaft Bushing (No.2) DAEWOO M-150 BL2...

  • Page 684: Diagnostic Information And Procedures

    D Replace clutch disc. Grabbing Clutch D Excessively worn on clutch disc facing. D Replace clutch disc. D Rivet head showing out of facing. D Replace clutch disc. D Weakened clutch torsion spring. D Replace clutch disc. DAEWOO M-150 BL2...

  • Page 685: Clutch Pedal Operation

    Clearance Between Pedal and Floor 30–40 mm just Before Clutch Connection (1.2–1.6 in.) Caution: During inspection, take care on sudden departure. DAEWOO M-150 BL2...

  • Page 686: On-Vehicle Service

    3. Remove the pressure plate and the clutch disc. D Fix the fly wheel using the fly wheel holder 09924– 17810. D Remove the pressure plate bolts (1). D Remove the pressure plate and the clutch disc (2). D13C5021 DAEWOO M-150 BL2...
  • Page 687 D103C505 3. Clutch disc runout in rotational direction inspection. D Measure runout in rotational direction and replace if runout exceeds limit. Unit : mm (in.) Disc Runout Limit in Rotational 0.7 (0.028) Direction (Periphery) D103C506 DAEWOO M-150 BL2...

  • Page 688: Clutch Release Bearing, Shaft And Bushing

    Arm” in this section. 3. Remove the release bearing. 4. Remove the release shaft and bushing. D Remove the bushing (No.2) and seal using the bushing remover 09925–48220 and hammer. D Remove the release shaft (1). D103C510 DAEWOO M-150 BL2...
  • Page 689 D Check for a grabbing rotation of release bearing. D Replace the release bearing if necessary. D103C513 2. Release shaft inspection D Check for a warped shaft (1). D Check for a worn fork (2). D Replace the shaft if necessary. D103C514 DAEWOO M-150 BL2...

  • Page 690: Clutch Release Arm

    D Coat the release bearing bore and the connecting of release shaft with multi–purpose grease (2). D Install the release bearing. D103C517 CLUTCH RELEASE ARM Removal Procedure 1. Disconnect the clutch cable. D Remove the adjusting nut (1). D Disconnect the cable (2). D103C518 DAEWOO M-150 BL2...

  • Page 691: Clutch Cable

    D Disconnect the cable from the wire clip (2). D Pull and remove the cable from the transaxle mount hole (3). D103B506 2. Disconnect the clutch cable from the pedal. D Pull upward and disconnect the cable from the pedal hook (1). D13C5211 DAEWOO M-150 BL2...

  • Page 692: Clutch Pedal

    1. Install the pedal return spring. 2. Install the bushings. 3. Install the clutch pedal. 4. Install the nut. 5. Fix the pedal return spring. 6. Connect the clutch cable. 7. Adjust the clutch cable. Refer to “Diagnosis” in this section. D103C302 DAEWOO M-150 BL2...

  • Page 693: Specifications

    (in.) – before clutch connection (1.2 – 1.6) FASTENER TIGHTENING SPECIFICATIONS Application Lb-Ft Lb-In Pressure Plate Bolt 18 – 28 13 – 21 – Clutch Release Arm Bolt and Nut 10 – 16 7.5 – 12 – DAEWOO M-150 BL2...

  • Page 694: Special Tools

    09943–88211 09923–46040 Bushing, Bearing Bushing Joint Pipe Installer D103C105 D103C107 DW110–021 09924–17810 Engine Assembly Fly Wheel Holder Support Fixture D103B103 D102B116 09925–48220 DW210–010 Bushing Remover/ Clutch Center Guide Installer D103C104 D103C103 09925–98210 Input Shaft Bearing Installer D103C102 DAEWOO M-150 BL2...
  • Page 695 ......6B-5 Special Tools Table ......6B-9 DAEWOO M-150 BL2...

  • Page 696: Power Steering Pump

    6B – 2 POWER STEERING PUMP DESCRIPTION AND OPERATION POWER STEERING PUMP The pump has a remote fluid reservoir. A pressure-relief valve inside the flow control valve limits pump pressure. DAEWOO M-150 BL2...
  • Page 697 Steering Pump valve. D Scores of the pressure plate and the vanes. D Replace the power steering pump. Whining Noise in the Steering Pump D Scores of the pump shaft bearing D Replace the power steering pump. DAEWOO M-150 BL2...
  • Page 698 D Tighten the rear bracket adjusting bolt to 20–24 NSm (15–18 lb-ft) (2). 20–24 NSm D Tighten the power steering pump bolt to 20–24 20–24 NSm NSm (15–18 lb-ft) (3). 2. Install the front passenger side headlamp. Refer to Section 9B, Lighting Systems. D15C526A DAEWOO M-150 BL2...
  • Page 699 3. Remove the power steering pump. D Remove the pump drive belt. Refer to “Pump Drive Belt” in this section. D Disconnect the power steering pressure switch connector (1). Refer to Section 6A, Power Steering Systems. D Remove the bolts (2). D105C530 DAEWOO M-150 BL2...
  • Page 700 7. Refill the pump with new fluid and bleed the air from the system. Refer to Section 6A, Bleeding the Power Steering System. 8. Inspect for leaks. If leaks are found, correct the cause of the leak and bleed the system. DAEWOO M-150 BL2...
  • Page 701 POWER STEERING PUMP 6B – 7 UNIT REPAIR PUMP The power steering pump in this vehicle is not service- able. A faulty pump must be replaced. DAEWOO M-150 BL2...
  • Page 702 Power Steering Pump Rear Bracket Adjusting Bolt 20 – 24 15 – 18 – Power Steering Pump Pulley Nut 55 – 69 41– 51 – Power Steering Oil Pressure Line Fitting 21 – 35 16 – 26 – DAEWOO M-150 BL2...
  • Page 703 POWER STEERING PUMP 6B – 9 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE DW310–020 Power Steering Pulley Remove Holder D105C101 DAEWOO M-150 BL2...
  • Page 704 ....6C-6 Fastener Tightening Specifications ..6C-13 Power Steering Gear Rack and Pinion Boot . . . 6C-7 DAEWOO M-150 BL2...

  • Page 705: Description And Operation

    The meshs with the teeth on the rack, causing the rack to force is then transmitted through the tie rods and the tie move. DAEWOO M-150 BL2...
  • Page 706 D Replace the power steering pump. power steering pump flow control valve. D The slippage of the pump drive D Tighten the pump drive belt. belt. D Contaminated air in the power D Bleed the power steering system. steering system. DAEWOO M-150 BL2...
  • Page 707 D Insufficient pressure of the power D Replace the power steering pump. steering pump. D Internal leaks of power steering D Replace the power steering pump. pump. D Improper tension of the pump D Adjust the pump drive belt drive belt. tension. DAEWOO M-150 BL2...
  • Page 708 D Turn the steering wheel all the way to the right and in). the left about 5 times repeatedly. D Place the rack gear in the straight-ahead position. D Loosen the adjust plug to 67.5_. D Loosen the adjust plug. 6. Tighten the adjust plug locknut. DAEWOO M-150 BL2...
  • Page 709 (3). D Remove the power steering gear retaining bracket (4). Important: After moving the gear toward the passenger side and pulling the gear of the driver side into the un- derbody hole, remove the steering gear. D105C535 DAEWOO M-150 BL2...
  • Page 710 5. Inspect for leaks. If there are leaks, correct the cause of the leaks and bleed the system. Refer to Section 6A, Power Steering System. POWER STEERING GEAR RACK AND PINION BOOT Refer to Section 6D, Manual Steering Gear. DAEWOO M-150 BL2...
  • Page 711 3. Install the power steering line fittings at the cylinder end. Tighten D15C715A Tighten the power steering line fittings to 25–35 NSm (18–25 lb-ft) (2). 4. Install the rack and pinion steering assembly to the vehicle. Refer to “Rack and Pinion Assembly” in this section. DAEWOO M-150 BL2...
  • Page 712 While holding the stub shaft, remove the locknut from the pinion. D105C704 D Remove the steering pinion from the pinion bear- ing by hitting the pinion with the flated drift and hammer (5). D105C705 DAEWOO M-150 BL2...
  • Page 713 3. Inspect the metal part for damage. D Inspect the pinion gear for damage or wear (1). D105C708 D Inspect the rack gear for damage or wear (2). D Inspect the steering gear housing for damage or wear(3). D105C709 DAEWOO M-150 BL2...
  • Page 714 Tighten the pinion locknut to 40–50 NSm (30–36 lb-ft). 40–50 NSm D105C712 3. Install the dust cap (5). Tighten Tighten the dust cap to 45–55 NSm (33–41 lb-ft). 4. Install the retaining ring (6). 5. Install the plastic dust cap (7). 45–55 NSm D15C713A DAEWOO M-150 BL2...
  • Page 715 D Install the adjuster spring (1). D Tighten the adjuster plug (2). D Tighten the plug locknut (3). 7. Install the rack and pinion steering assembly to the vehicle. Refer to “ Rack and Pinion Assembly ” in this section. D105C714 DAEWOO M-150 BL2...
  • Page 716 Power Steering Gear Pinion Dust Cover 45–55 33–41 – Power Steering Gear Pressure Line Fitting 25–35 18–25 – Power Steering Oil Pressure Pipe Fitting (Gear Side) 21–35 16–25 – Power Steering Gear Ajuster Plug Refer to “DIAGNOSIS” in this section. DAEWOO M-150 BL2...
  • Page 717 ......6D-7 Special Tools Table ..... . . 6D-18 DAEWOO M-150 BL2...
  • Page 718 The force is then transmitted through the arms on the struts, which turn the wheels. DAEWOO M-150 BL2...
  • Page 719 8. Rack and Pinion Boot 20. Steering Pinion Gear 9. Rack and Pinion Boot Wire Clamp 21. Roller Bearing 10. Tie Rod 22. Rack Bearing 11. Shock Damper Ring 23. Adjuster Spring 12. Steering Rack Gear 24. Adjuster Plug DAEWOO M-150 BL2...

  • Page 720: Diagnostic Information And Procedures

    D Lubricate the rack and pinion D Improper and insufficient lubrication. assembly. Rattling Noise in the D Tighten the steering gear mounting D Improperly installed steering gear mounting. Steering Gear bolts. D Improperly installed tie rods. D Tighten the tie rods. DAEWOO M-150 BL2...
  • Page 721 Ahead Check” the angles match the value specified? in this section System OK Go to Step 6 The rack assembly was not assembled correctly. Repair as needed. – – Go to Step 5 Is the repair complete? DAEWOO M-150 BL2...

  • Page 722: Steering Gear

    3. If the values exceed the specified values, replace the tie rod end or the tie rod. 4. But, If the ball joint of the tie rod end or the tie rod falls down of itself, replace it. DAEWOO M-150 BL2...

  • Page 723: Repair Instructions

    3. Remove the tie rod end. D Mark the tie rod, tie rod end lock nut and tie rod end (1). D Loosen the tie rod end lock nut anticlockwise (2). D Loosen the tie rod end (3). D105B502 D105B503 DAEWOO M-150 BL2...
  • Page 724 1. Remove the tie rod end. Refer to “Tie Rod End” in this section. 2. Remove the tie rod end lock nut. D105B505 3. Remove the rack and pinion boot. D Remove the boot clamp (1). D Cut off the boot wire clamp (2). D105B506 DAEWOO M-150 BL2...
  • Page 725 1G, Engine Exhaust. 5. Remove the steering gear assembly from the vehicle. D Remove the steering gear bracket bolts (1). D Remove the steering gear bracket (2). D Remove the steering gear assembly. D Remove the packing (3). D105B510 DAEWOO M-150 BL2...
  • Page 726 5. Connect the tie rod end to the steering knuckle. Refer to “Tie Rod End” in this section. D15B511A 6. Install the wheels. Refer to Section 2E, Tires and Wheels. 7. Install the intermediate shaft lower pinch bolt. Refer to Section 6E, Steering Wheel and Column. DAEWOO M-150 BL2...

  • Page 727: Unit Repair

    D Remove the tie rod end. Refer to “Tie Rod End” in this section (1). D Remove the tie rod lock nut (2). D105B703 D Remove the rack and pinion boot clamp (3). D Cut off the rack and pinion boot wire (4). DAEWOO M-150 BL2...
  • Page 728 Important: Clothe the rack gear with a cloth before vis- ing the rack gear. Notice: Do not vise the rack gear over two teeth face. D15B706A D Remove the tie rod (4). D Remove the shock damper ring (5). D105B707 DAEWOO M-150 BL2...
  • Page 729 Rack gear. Notice: Remove the rack gear toward the driver side of the steering gear to prevent the bulk head in the steering gear housing from damaging in installing and removing the rack gear. D105B711 DAEWOO M-150 BL2...
  • Page 730 D Inspect the tie rod end boot for crack and wear (1). D Inspect the rack and pinion boot for crack and wear (2). D105B714 4. Inspect the steering gear housing for crack, deforma- tion and wear. a. Steering gear housing. D105B715 DAEWOO M-150 BL2...
  • Page 731 D Install the dust cover (4). D15B718A 4. Install the rack bearing. D Coat the rack bearing with grease. D Install the rack bearing (1). D Install the adjuster spring (2). D Tighten the adjuster plug softly (3). D105B719 DAEWOO M-150 BL2...
  • Page 732 9. Install the rack and pinion steering gear assembly to the vehicle. Refer to “Rack and Pinion Steering Gear Assembly” in this section. 10. Adjust the free load of the steering gear. Refer to “Diagnosis” in this section. D105B722 DAEWOO M-150 BL2...

  • Page 733: Specifications

    Steering Gear Bracket Bolts 50 – 55 36 – 41 – Tie Rod–to–Rack Gear 80 – 120 59 – 89 – Pinion Plug 40 – 60 30 – 44 – Pinion Preload Refer to “Diagnosis” in this section. DAEWOO M-150 BL2...

  • Page 734: Special Tools And Equipment

    6D – 18 MANUAL STEERING GEAR SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE KM–507–B Ball Joint Remover D105B101 DAEWOO M-150 BL2...
  • Page 735 ..... . . 6E-16 Ignition Switch ......6E-9 DAEWOO M-150 BL2...
  • Page 736 Notice: Apply a thin coat of lithium grease to all friction points when reassembling to ensure proper operation. D15A001A The column may be easily disassembled and assembled. D Safety Device A. Steering Column Upper Bracket. B. Steering Column. C. Steering Column Shaft. DAEWOO M-150 BL2...
  • Page 737 21. Steering Column Shaft 8. Windshield Wiper Switch 22. Pinch Bolt 9. Steering Column Assembly 23. Intermediate Shaft 10. Retaining Ring 24. Steering Column Upper Nut 11. Washer 25. Steering Column Lower Nut 12. Spring 13. Switch Housing 14. Bolt DAEWOO M-150 BL2...
  • Page 738 D A damaged bearing. D Replace the steering column housing. D The lack of free movement for the steering D Lubricate the steering shaft shaft universal joint. universal joint. D Replace the steering column shaft as needed. DAEWOO M-150 BL2...
  • Page 739 On, But Not Flashing D An inoperative blinker unit. D Replace the blinker unit. Front or Rear Turn Signal Lamps Not Flashing D An inoperative blinker unit. D Replace the blinker unit. Turn Signal Lamps Flash Very Slowly DAEWOO M-150 BL2...
  • Page 740 Correction D Damaged wiper switch. D Replace the wiper switch. Switch Inoperative : No I, Low, High, Int D Improperly installed wiper switch. D Remove and inspect the wiper or Wash switch. D Reinstall the wiper switch. DAEWOO M-150 BL2...

  • Page 741: Steering Wheel

    Tighten the steering wheel nut to 23–33 NSm (17–24 lb-ft). 3. Bend the tabs to secure the locking plate. D15A503A 4. Install the steering wheel horn cover (For vehicle without SIR). 5. Connect the negative battery cable. DAEWOO M-150 BL2...

  • Page 742: Wiper Switch And Lever

    (1). D Disconnect the connector (2). D105A506 4. Remove the wiper switch. D Disconnect the wiper switch by pushing the locking from the switch housing (1). D Disconnect the connector (2). D105A507 DAEWOO M-150 BL2...

  • Page 743: Ignition Switch

    1. Remove the steering wheel. Refer to “Steering Wheel” in this section. 2. Disconnect the electrical connector for the immobiliz- er detection coil. 3. Remove the lock cylinder. D With the key in the ignition, turn to the position des- D105A511 ignated I (1). DAEWOO M-150 BL2...
  • Page 744 2. Connect the horn electrical connector. 3. Install the turn signal switch and windshield wiper switch. Refer to “Turn Signal Switch and Lever/Wiper switch and Lever” in this section. 4. Install the steering wheel. Refer to “Steering Wheel” in this section. D105A514 DAEWOO M-150 BL2...

  • Page 745: Steering Column

    5. Install the turn signal switch and wiper switch. Refer to “Turn Signal Switch and Lever/Wiper Switch and Lever” in this section. 6. Install the steering wheel. Refer to “Steering Wheel” in this section. D15A518B DAEWOO M-150 BL2...

  • Page 746: Intermediate Shaft Cover And Intermediate Shaft

    D Tighten the intermediate shaft lower pinch bolt to 21–29 NSm (16–22 lb-ft) (1). D Tighten the intermediate shaft upper pinch bolt to 21–29 NSm (16–22 lb-ft) (2). Notice: Check the lower pinch bolt position correctly. D15A521A DAEWOO M-150 BL2...

  • Page 747: Unit Repair

    D Remove the retaining ring (1). D Remove the washer (2). D105A701 D Remove the spring (3). D Remove the washer (4). D Remove the locking of the alignment spacer (5). D Push strongly the steering column shaft downward (6). D15A702A D15A703A DAEWOO M-150 BL2...
  • Page 748 D Install the washer. D Install the spring. D Install the washer. D15A704A D Install the retaining ring. 2. Install the steering column to the vehicle. Refer to “Steering Wheel” in this section. DAEWOO M-150 BL2...

  • Page 749: General Specifications

    11 – 15 – Steering Column Lower Nuts 15 – 20 11 – 15 – Intermediate Shaft Upper Pinch Bolt 21 – 29 16 – 22 – Intermediate Shaft Lower Pinch Bolt 21 – 29 16 – 22 – DAEWOO M-150 BL2...

  • Page 750: Special Tools And Equipment

    6E – 16 STEERING WHEEL AND COLUMN SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE DW310–010 Steering Wheel Puller D105A101 DAEWOO M-150 BL2...
  • Page 751 ..... . . 7A-31 Control Assembly and Control Cables ..7A-18 Air Flow Through Ducts (Non–A/C) ..7A-32 DAEWOO M-150 BL2...

  • Page 752: Heating And Ventilation Systems

    D Turns to stop the blower. D Recirculates inside air when the lever is moved to D Operates completely independently both from the the right. mode control that regulates the defroster door and from the temperature control knob. DAEWOO M-150 BL2...

  • Page 753: Component Locator

    16. Panel 6. Cable Clamp 17. A/C Push Knob 7. Bulb Socket Assembly 18. Rotary Knob 8. Pinion Assembly 19. Recirculating Knob 9. A/C Switch 20. Rear Defogger Push Knob 10. Housing 21. Recirculation 11. Detent Cap DAEWOO M-150 BL2...

  • Page 754: Blower Module Assembly

    10. Cable Clamp 3. Blower Link 11. Blower Valve 4. Blower Lever 12. Blower Resistor 5. Air Intake Case 13. Lower Case 6. Valve Retainer 14. Cooling Hose 7. Heater Duct Assembly 15. Blower Motor 8. Blower Connector Duct DAEWOO M-150 BL2...

  • Page 755: Air Distributor And Heater Module Assembly

    7. Temperature Control Lever Bearing 19. Ventilation Valve 8. Defroster Link 20. Temperature Control Valve 9. Defroster Lever 21. Right Heater Case 10. Spring 22. Case Seal 11. Ventilation Link 23. Heater Core Cover 12. Ventilation Lever 24. Heater Core DAEWOO M-150 BL2...

  • Page 756: Heater System

    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? Go to Step 14 Go to Step 13 DAEWOO M-150 BL2...
  • Page 757 Is the repair complete? System OK Inspect the heater hoses for proper installation. – Are heater hoses reversed? Go to Step 22 Go to Step 23 Reinstall the heater hoses properly. – – Is the repair complete? System OK DAEWOO M-150 BL2...
  • Page 758 System OK 1. Set the blower on 4. 2. Rotate the temperature control from full hot to full cold. – 3. Listen for an airflow change. Does the airflow change? Go to Step 34 Go to Step 35 DAEWOO M-150 BL2...
  • Page 759 2. Verify the accuracy of the temperature controls at full hot. Is the repair complete? System OK 1. Check the system for any obstruction between the blower and the system outlets. – – 2. Remove any obstruction. Is the repair complete? System OK DAEWOO M-150 BL2...

  • Page 760: Blower Electrical

    Replace the blower motor switch. – – Is the repair complete? System OK 1. Check the ground of the blower motor. 2. Repair the ground of the blower motor. – – Is the repair complete? System OK DAEWOO M-150 BL2...

  • Page 761: Improper Air Delivery Or No Mode Shift

    Go to Step 9 1. Check the cable attachment at the control. 2. Check for a broken control. – Is there a problem with the cable attachment or the control? Go to Step 8 Go to Step 9 DAEWOO M-150 BL2...
  • Page 762 Is the repair complete? 1. Check the system for any obstruction between the blower and the system outlets. – – 2. Remove any obstruction between the blower and the system outlets. System OK Is the repair complete? DAEWOO M-150 BL2...

  • Page 763: Too Much Heat

    Do you hear the door slam just before you reached Go to Step 13 Go to Step 14 the end of the control travel? Adjust the vent door to vent more. – – Is the repair complete? System OK DAEWOO M-150 BL2...
  • Page 764 3. Check the temperature door for full hot. Is the temperature door travel correct? System OK 1. Check for hot air leaks from the engine compartment to the blower inlet. – – 2. Repair as needed. Is the repair complete? System OK DAEWOO M-150 BL2...

  • Page 765: Controls

    2. Check the control for binding. – Does the control bind? Go to Step 14 Go to Step 15 Replace the control. – – Is the repair complete? System OK Replace the cable. – – Is the repair complete? System OK DAEWOO M-150 BL2...

  • Page 766: Blower Noise

    – – 3. Check floor/defroster door seals. 4. Repair or replace, as needed. Is the repair complete? System OK Is the noise present in the floor mode only? – Go to Step 12 Go to Step 14 DAEWOO M-150 BL2...
  • Page 767 Is the repair complete? System OK 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? System OK Go to Step 2 DAEWOO M-150 BL2...

  • Page 768: Repair Instructions

    D Disconnect the temperature control cable from the heater module (5). D Remove the glove box from the instrument panel. Refer to Section 9E, Instrumentation/Driver Infor- mation. D108A502 D Disconnect the recirculating/fresh air door cable from the blower module (6). D108A503 DAEWOO M-150 BL2...
  • Page 769 5. Connect the electrical connectors. 6. Install the control assembly with the screws. 7. Install the instrument cluster housing trim panel. Re- fer to Section 9E, Instrumentation/Driver Information. D108A506 8. Connect the negative battery cable. DAEWOO M-150 BL2...

  • Page 770: Blower Motor And Cooling Hose

    2. Connect the motor electrical connector. 3. Install the blower motor cooling hose. D108A509 BLOWER RESISTOR (Left–Hand Drive Shown, Right–Hand Drive Similar) Removal Procedure 1. Remove the blower resistor. D Disconnect the blower resistor connector (1). D Remove the screws (2). D108A510 DAEWOO M-150 BL2...

  • Page 771: Blower Motor Switch

    D Turn the blower motor switch anticlockwise (3). D108A513 Installation Procedure 1. Install the blower motor switch with the screw. 2. Install the switch knob. 3. Install the control assembly. Refer to “Control Assem- bly and Control Cables” in this section. D108A514 DAEWOO M-150 BL2...

  • Page 772: Heater Hoses

    D Disconnect the hose from the heater module using a hose remover DW100–020 (1). D Disconnect the B terminal from the starter. Refer to Section 1E, Engine Electrical. D18A517A D Disconnect the heater hose from the engine (2). D108A518 DAEWOO M-150 BL2...
  • Page 773 D Connect the hose to the heater module using a hose installer DW100–020 (2). D Lower the vehicle. D Install the air cleaner housing. 3. Refill the coolant. Refer to Section 1D, Engine Cool- ing. 4. Connect the negative battery cable. DW100–020 D18A520A DAEWOO M-150 BL2...

  • Page 774: Heater Module

    A/C. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System. D108A524 5. Remove the heater module. D Remove the upper nuts (1). D108A525 D Remove the lower nuts (2). D Remove the heater module (3). D108A526 DAEWOO M-150 BL2...

  • Page 775: Blower Module

    5. Disconnect the blower motor connector. Refer to “Blower Motor and Cooling Hose” in this section. 6. Remove the blower module. D Remove the nuts (1). D Disconnect the wiring harness (2). D108A530 DAEWOO M-150 BL2...

  • Page 776: Defroster Duct And Hoses

    3. Remove the defroster duct and hoses. b. Defroster duct and hoses. D108A532 Installation Procedure 1. Install the defroster duct and hoses with the screws. 2. Install the instrument panel. Refer to Section 9E, In- strumentation/Driver Information. D108A533 DAEWOO M-150 BL2...

  • Page 777: Ventilation Duct

    2. Remove the ventilation duct retaining screws. a. Retaining screw. 3. Remove the ventilation duct. b. Ventilation duct. D18A534A Installation Procedure 1. Install the ventilation duct with the screws. 2. Install the instrument panel. Refer to Section 9E, In- strumentation/Driver Information. D108A535 DAEWOO M-150 BL2...

  • Page 778: Unit Repair

    D Remove the heater core (2). D108A701 Assembly Procedure 1. Install the heater core to the heater module. 2. Install the heater core cover. 3. Install the heater module. Refer to “Heater Module” in this section. D108A702 DAEWOO M-150 BL2...
  • Page 779 Blower Motor Resistance Ω 3 rd 0.36 – 0.44 Ω 4 th – FASTENER TIGHTENING SPECIFICATIONS Application Lb-Ft Lb-In Heater Module Nuts 3 – 5 – 27 – 44 Blower Module Nuts 3 – 5 – 27 – 44 DAEWOO M-150 BL2...

  • Page 780: Special Tools And Equipment

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

  • Page 781: Schematic And Routing Diagrams

    HEATING AND VENTILATION SYSTEM 7A – 31 SCHEMATIC AND ROUTING DIAGRAMS NON–A/C DIAGRAMS D18A201B DAEWOO M-150 BL2...
  • Page 782 7A – 32 HEATING AND VENTILATION SYSTEM AIR FLOW THROUGH DUCTS (NON–A/C) (Left–Hand Drive Shown, Right–Hand Drive Similar) D108A202 DAEWOO M-150 BL2...
  • Page 783 Discharging, Adding Oil, Evacuating, and A/C System (Typical) ..... 7B-33 Charging Procedures for A/C System ..7B-14 DAEWOO M-150 BL2...

  • Page 784: Description And Operation

    A restricted expansion valve will result in low suction ing or icing. pressure and no cooling. This may be caused by debris The thermistor is installed on the evaporator. DAEWOO M-150 BL2...

  • Page 785: Component Locator

    MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B – 3 COMPONENT LOCATOR A/C SYSTEM (Left–Hand Drive Shown, Right–Hand Drive Similar) D18B401B DAEWOO M-150 BL2...
  • Page 786 22. Dual Cut Switch 9. Evaporator Inlet Pipe 23. Receiver–Dryer Bracket 10. Plate 24. Compressor Bracket 11. Evaporator Lower Case 25. Compressor Stay 12. O–ring 26. A/C & Power Steering Bracket 13. High Pressure Pipe (Compressor → Condenser) DAEWOO M-150 BL2...

  • Page 787: Diagnostic Information And Procedures

    Refrigerant System” in this section. If you find a leak, discharge the system and repair the leak as required. After completing the repair, evacuate and charge the system. 9. If there is no leak, refer to “Insufficient Cooling Diag- nosis” in this section. DAEWOO M-150 BL2...
  • Page 788 CONDENSER RANGE: From 110 to 160_F, temperatures are not ambient. Add 19.4 to 22.2_C (35 to 40_F) for proper heat transfer, then refer to the pressure chart. Example: 32_C (90_F) ambient temperature + 22_C (40_F) 54_C (130_F) Condenser temperature = 1379 kPa (200 psig) Based on 48.3 km/h (30 mph) air flow. DAEWOO M-150 BL2...

  • Page 789: Leak Testing The Refrigerant System

    D Hold the probe tip within 6 mm (1/4 inch) of the sur- 2. Wait 1 to 2 minutes. face. 3. Probe the area in front of the pulley. If the detector D Do not block the air intake. emits a solid alarm, there is a leak. DAEWOO M-150 BL2...

  • Page 790: Air Conditioning System Diagnosis

    – 4. Connect a fused jumper wire from the positive battery terminal to the other A/C compressor clutch coil terminal. Does the A/C clutch engage? Go to Step 12 Go to Step 13 DAEWOO M-150 BL2...
  • Page 791 4. Turn the A/C switch ON and OFF every 1,500 kPa 20 seconds for 3 minutes. (217.5 psi) Are the A/C compressor high and the low side pressures within the specified value of each other? System OK Go to Step 22 DAEWOO M-150 BL2...
  • Page 792 System OK Go to Step 23 1. Recover the A/C system refrigerant. 2. Replace the compressor. 3. Evacuate and recharge the A/C system. – – 4. Check the A/C system for leaks. Is the repair complete? System OK DAEWOO M-150 BL2...

  • Page 793: Symptom Diagnosis

    D The expansion valve is D The expansion valve is D Clean or replace the frosted. clogged. expansion valve. D The receiver/dryer D The receiver/dryer is D Replace the outlet is cool and the clogged. receiver/dryer. inlet is warm. DAEWOO M-150 BL2...
  • Page 794 D The compressor gasket is D Repair or replace the is wet with oil. leaking. compressor. D Poor tightening in the D Retighten the connection – system. (coupling, bolt etc.) D O–ring is faulty. D Replace the O–ring. – DAEWOO M-150 BL2...

  • Page 795: Repair Instructions

    D Never allow a flexible hose line to come near the ex- to ensure proper locating and sealing. haust manifold. Install new DAEWOO-approved service replacement air D Inspect flexible hose lines regularly for leaks or brittle- conditioning O-rings whenever a joint or a fitting is disas- ness.

  • Page 796: Maintaining Chemical Stability In The Refrigeration System

    A/C system to the unit. are authorized for the charging station being used. The use of other tanks may cause personal injury or void the warranty. Refer to the manufacturer’s in- structions for the charging station. DAEWOO M-150 BL2...
  • Page 797 1. Close the low side valve on the control panel. ant needed for steps later in the procedure. Do not use 2. Open the high side valve on the control panel. any other type of tank. DAEWOO M-150 BL2...
  • Page 798 A/C system again. Refer to 6. Keep the A/C running. the manufacturer’s instructions for the charging sta- 7. Close the high side coupler valve. tion in use. 8. Disconnect the high side hose from the vehicle. DAEWOO M-150 BL2...

  • Page 799: Components

    To remove the blower resistor, refer to Section 7A, Heat- ing and Ventilation System (Without Air Conditioning). BLOWER MOTOR SWITCH To remove the blower motor switch, refer to Section 7A, Heating and Ventilation System (Without Air Condition- ing). DAEWOO M-150 BL2...

  • Page 800: A/C Push Knob

    9O, Bumpers and Fascias. 3. Remove the receiver dryer. D Disconnect the dual cut switch connector (1). D Remove the receiver dryer flange nuts (2). D Remove the bracket bolt (3). D18B503A D Discard the O–ring (4). DAEWOO M-150 BL2...
  • Page 801 4. Install the front bumper fascia. Refer to Section 9O, D18B506B Bumpers and Fascias. 5. Evacuate and recharge the system. Refer to “Dis- charging, Adding Oil, Evacuating, and Charging Pro- cedures for A/C System” in this section. DAEWOO M-150 BL2...

  • Page 802: Receiver-Dryer Bracket

    D Remove the bolt securing the high pressure pipe line to the compressor (2). D Disconnect the electrical connector (3). D Remove the upper bolt mounting the compressor– to–bracket (4). D Remove the lower bolts mounting the compres- sor–to–bracket (5). D18B510A DAEWOO M-150 BL2...

  • Page 803: Condenser

    3. Discharge and recover the refrigerant. Refer to “Dis- charging, Adding Oil, Evacuating, and Charging Pro- cedures for A/C system” in this section. 4. Remove the condenser. D Loosen the condenser pipe--to--compressor pipe fitting (1). D Loosen the condenser pipe--to--receiver dryer pipe fitting (2). D18B513A DAEWOO M-150 BL2...

  • Page 804: A/C High Pressure Pipe Line

    Adding Oil, Evacuating, and Charging Pro- cedures for A/C System” in this section. 4. Remove the A/C high pressure pipe line between the compressor and the condenser. D Remove the bolt securing the high pressure pipe D108B517 line to the compressor (1). DAEWOO M-150 BL2...
  • Page 805 6. Remove the A/C high pressure pipe line between the receiver dryer and the evaporator. D Remove the purge control valve. Refer to Section 1F, Engine Controls. D Remove the bracket nut (1). D Loosen the fitting (2). D18B521A DAEWOO M-150 BL2...
  • Page 806 3. Evacuate and recharge the system. Refer to “Dis- charging, Adding Oil, Evaculating, and Charging Pro- cedures for A/C System” in this section. 4. Install the front bumper fascia. Refer to Section 9O, D18B523B Bumpers and Fascias. 5. Connect the negative battery cable. D18B524A D18B525B DAEWOO M-150 BL2...

  • Page 807: A/C Low Pressure Pipe Line

    Installation Procedure Important: Discard the removed O--rings. 1. Install the A/C low pressure pipe line. Tighten D Tighten the nut securing the A/C low pressure pipe line at the evaporator to 14 NSm (10.5 lb-ft) (1). D18B529B DAEWOO M-150 BL2...

  • Page 808: Evaporator Unit And Drain Hose

    4. Remove the glove box. Refer to Section 9E, Instru- mentation/Driver information. 5. Remove the evaporator unit. D Remove the drain hose (1). D Disconnect the thermistor connector (2). D Remove the screws (3). D Remove the evaporator backward slowly (4). D108B533 DAEWOO M-150 BL2...
  • Page 809 (evaporator → compressor) nut to 14 NSm (10.5 lb-ft). 6. Evacuate and recharge the system. Refer to “Dis- charging, Adding Oil, Evacuating, and Charging Pro- cedures for A/C System” in this section. D18B534A 7. Connect the negative battery cable. DAEWOO M-150 BL2...

  • Page 810: Unit Repair

    (2). D18B702A 5. Install the thermistor. 6. Install the screws securing the evaporator case cov- 7. Install the clamp and the screw. 8. Install the evaporator unit. Refer to “Evaporator Unit and Drain Hose” in this section. DAEWOO M-150 BL2...

  • Page 811: Compressor Overhaul

    3. Use the clutch hub holding tool DW--610--010, install the clutch drive plate with the shaft bolt. Tighten Tighten the shaft bolt to 13 NSm (115 lb-in). 4. Install the compressor. Refer to “Compressor” in this section. D18B706B DAEWOO M-150 BL2...

  • Page 812: Specifications

    Low Pressure Pipe Line (Evaporator → Compressor) Clamp Nut Low Pressure Pipe Line(Evaporator→Compressor) Compressor Bolt Dual Cut Switch Receive--Dryer Bracket--to--Body Bolts Receive--Dryer Bracket Bolt Expansion Valve Coupling (Receiver--Dryer → Expansion Valve) Expansion Valve Coupling (Expansion Valve → Evaporator) Compressor Shaft Bolt Condenser Mounting Nuts DAEWOO M-150 BL2...

  • Page 813: Special Tools And Equipment

    MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B -- 31 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE DW- -610- -010 Clutch Hub Holding Tool D108B101 DAEWOO M-150 BL2...

  • Page 814: Schematic And Routing Diagrams

    7B -- 32 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM SCHEMATIC AND ROUTING DIAGRAMS A/C DIAGRAMS D18B201B DAEWOO M-150 BL2...
  • Page 815 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B -- 33 A/C AIRFLOW (Left- -Hand Drive Shown, Right- -Hand Drive Similar) D108B202 A/C SYSTEM (Left- -Hand Drive Shown, Right- -Hand Drive Similar) D18B203A DAEWOO M-150 BL2...
  • Page 816 Driver Seat Belt Warning ....8A-12 Seat Belt Warning Lamp is Inoperative ..8A-4 DAEWOO M-150 BL2...

  • Page 817: Description And Operation

    OUTBOARD SEAT BELT 5. Let the shoulder belt retract fully. The belt should re- The rear outboard seating positions use the three-point tract easily. emergency locking retractor (ELR) seat belts. The three-point emergency locking retractor (ELR) seat belt DAEWOO M-150 BL2...

  • Page 818: Component Locator

    SEAT BELTS 8A – 3 COMPONENT LOCATOR FRONT AND REAR SEAT BELT D1AA401B 1. Front Seat Belt 2. Front Seat Belt Buckle 3. Rear Seat Belt (Three–Point) 4. Rear Seat Belt (Two–Point) / Buckle (Three–Point) 5. Rear Seat Belt Buckle (Three–Point/Two–Point) DAEWOO M-150 BL2...

  • Page 819: Diagnostic Information And Procedures

    D The continuity between the terminal for the D Repair the open ground. BLK wire and ground is fail. D The warning lamp bulb in the instrument D Replace the warning lamp bulb. cluster is blown. DAEWOO M-150 BL2...

  • Page 820: On-Vehicle Service

    D Remove the spacer and the fiber washer (3). D11A502A 5. Remove the seat belt retractor bolt. D Remove the floor carpet to be seen the retractor. D Remove the bolt (1). D Remove the fiber washer (2). D Remove the seat belt retractor. D110A503 DAEWOO M-150 BL2...

  • Page 821: Three-Point Pretensioner Front Seat Belt (W/Europe Only)

    1. Slide the front seat forward and fold the seatback. 2. Remove the bolt on the lower B–pillar. D Remove the bolt (1). D Remove the spacer and the fiber washer (2). D Remove the plastic protector on the seat belt an- chor. D110A501 DAEWOO M-150 BL2...
  • Page 822 Seat belt upper bolt. D1AA504C 3. Install the seat belt retractor with the bolt. Tighten D Tighten the lower retractor bolt to 30–45 NSm (22–33 lb-ft). a. Lower retractor bolt. b. Connect the pretensioner front seat belt con- nector. D28A002A DAEWOO M-150 BL2...

  • Page 823: Front Seat Belt Buckle

    1. Remove the rear seat cushion and the rear seatback. 2. Pry off the rear interior trim panel. Refer to Section 9G, Interior Trim. D Pry off the backshelf trim panel. D Pry off the luggage compartment side load trim panel. D109E566 DAEWOO M-150 BL2...
  • Page 824 2. Install the seat belt retractor bolt and the upper bolt. Tighten D Tighten the seat belt upper bolt to 30–45 NSm (22–33 lb-ft). a. Seat belt upper bolt. D Tighten the seat belt retractor bolt to 30–45 NSm (22–33 lb-ft). b. Retractor bolt. D1AA511B DAEWOO M-150 BL2...
  • Page 825 3. Install the two–point rear seat belt with the bolt. D1AA514B Tighten Tighten the two–point and three–point rear seat belt buckle bolt to 30–45 NSm (22–33 lb-ft). b. Two–point and three–point rear seat belt buckle bolt. DAEWOO M-150 BL2...

  • Page 826: Specifications

    22 – 33 – Seat Belt Retractor Bolt 30 – 45 22 – 33 – Seat Belt Buckle Bolt 30 – 45 22 – 33 – Rear Seat Belt Buckle Bolt 30 – 45 22 – 33 – DAEWOO M-150 BL2...

  • Page 827: Schematic And Routing Diagrams

    8A – 12 SEAT BELTS SCHEMATIC AND ROUTING DIAGRAMS DRIVER SEAT BELT WARNING D1AA201A DAEWOO M-150 BL2...
  • Page 828 ....8B-65 Resistance Too High ....8B-30 DAEWOO M-150 BL2...
  • Page 829 ......8B-69 On-Vehicle Service ......8B-69 DAEWOO M-150 BL2...

  • Page 830: Description And Operation

    SIR WARNING LAMP D Has no user-serviceable parts. The supplemental inflatable restraints (SIR) system in- D Is under the front console assembly. cludes a self-diagnostic function. D Continuously monitors the system components. D Records any faults which are discovered. DAEWOO M-150 BL2...

  • Page 831: Clock Spring

    25 km/h (15 mph) speed. D More than three and one-quarter turns may damage The SIR consists of a the clock spring. D Driver airbag module. D Passenger airbag module. Caution: Disassembling the clock spring can cause injury and vehicle damage. DAEWOO M-150 BL2...

  • Page 832: General Precautions

    Only trained personnel at franchised Daewoo dealers and authorized Daewoo service dealerships may service the airbag system. Never attempt to disassemble, repair, or reuse the D Airbag modules.

  • Page 833: Airbag Deployment Procedure

    D110B003 4. Safety disc is broken and the compressed Ar gas is spouted out. D110B004 5. Compressed Ar gas and the burned initiator are car- bureted. And the airbag is deployed. D110B005 DAEWOO M-150 BL2...

  • Page 834: Component Locator

    SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B – 7 COMPONENT LOCATOR SIR COMPONENT (Left–Hand Drive Shown, Right–Hand Drive Similar) D110B401 1. Driver Airbag Module 4. Sensing and Diagnostic Module (SDM) 2. Passenger Airbag Module 5. Wiring Harness 3. Clock Spring DAEWOO M-150 BL2...

  • Page 835: Diagnostic Information And Procedures

    “Sxx” on the scan tool display. bars that are built into the SDM connector. The warning lamp: D Indicates a fault as soon as it occurs. D Stays ON, even if a fault is no longer active. DAEWOO M-150 BL2...
  • Page 836 SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B – 9 BLANK DAEWOO M-150 BL2...

  • Page 837: System Check

    4. Select “Fail Code View & Clear “ from the displayed menu of the diagnostic test codes Go to the DTC (DTC). table for the – fault indicated Go to Step 3 Are there any active fault codes? DAEWOO M-150 BL2...
  • Page 838 Is wiring harness shorted to ground or open? – Go to Step 15 Go to Step 16 Replace the SDM waring harness. Is the repair complete? – System OK – Replace the SDM. Is the repair complete? – System OK – DAEWOO M-150 BL2...

  • Page 839: Fault Codes

    Connection Between Passenger Firing Circuit and Passenger Pretensioner Circuit Connection Between Driver Pretensioner Circuit and Passenger Pretensioner Circuit Ignition Input Circuit, Voltage Too High Ignition Input Circuit, Voltage Too Low Warning Lamp Failure SDM Internal Fault SDM Crash Recorded DAEWOO M-150 BL2...
  • Page 840 SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B – 13 BLANK DAEWOO M-150 BL2...
  • Page 841 (SIR) wiring harness. A repair above a specified value, as with an open circuit. can create a high-resistance connection which can keep the airbags from deploying when needed, re- sulting in injury. DAEWOO M-150 BL2...

  • Page 842: Dtc 01 Driver Firing Circuit, Resistance Too High

    2. Reconnect the negative battery terminal. Diagnostic Is the repair complete? System Check – – 1. Replace the SIR wiring harness. Go to 2. Reconnect the negative battery cable. Diagnostic System Check Is the repair complete? – – DAEWOO M-150 BL2...
  • Page 843 D The combined resistance of the driver airbag module, the harness wiring, and the connector contacts is be- low a specified value, as with a short circuit between the wires to the driver airbag module. DAEWOO M-150 BL2...

  • Page 844: Dtc 02 Driver Firing Circuit, Resistance Too Low

    2. Reconnect the negative battery cable. Diagnostic Is the repair complete? System Check – – 1. Replace the supplemental inflatable restraints (SIR) wiring harness. Go to 2. Reconnect the negative battery cable. Diagnostic Is the repair complete? – System Check – DAEWOO M-150 BL2...
  • Page 845 The SDM monitors the voltage during this check. DTC 03 Will Set When D The firing circuit is shorted to ground. DAEWOO M-150 BL2...

  • Page 846: Dtc 03 Driver Firing Circuit, Short To Ground

    Is the resistance less than the specified value? Go to Step 2 Go to Step 7 1. Replace the clock spring. Go to 2. Reconnect the negative battery terminal. Diagnostic Is the repair complete? – System Check – DAEWOO M-150 BL2...
  • Page 847 Unintentional deployment of the airbags small amount of current to flow through the circuit. The can cause injury. SDM monitors voltage during this check. DTC 04 Will Set When D The firing circuit is shorted to voltage. DAEWOO M-150 BL2...

  • Page 848: Dtc 04 Driver Firing Circuit, Short To Battery Voltage

    Did the voltmeter indicate the specified value? Go to Step 7 Go to Step 2 1. Replace the clock spring. Go to 2. Reconnect the negative battery cable. Diagnostic Is the repair complete? – System Check – DAEWOO M-150 BL2...
  • Page 849 D The combined resistance of the passenger airbag erly, the meter’s battery can deploy the airbag and module, the harness wiring, and the connector con- cause injury. tacts is above a specified value, as in an open circuit. DAEWOO M-150 BL2...

  • Page 850: Dtc 05 Passenger Firing Circuit, Resistance Too High

    2. Reconnect the negative battery cable. Diagnostic Is the repair complete? – System Check – 1. Replace the supplemental inflatable restraints (SIR) wiring harness. Go to 2. Reconnect the negative battery cable. Diagnostic – System Check – Is the repair complete? DAEWOO M-150 BL2...
  • Page 851 DAEWOO M-150 BL2...

  • Page 852: Dtc 06 Passenger Firing Circuit, Resistance Too Low

    2. Reconnect the negative battery cable. Diagnostic Is the repair complete? System Check – – 1. Replace the supplemental inflatable restraints (SIR) wiring harness. Go to 2. Reconnect the negative battery cable. Diagnostic System Check Is the repair complete? – – DAEWOO M-150 BL2...
  • Page 853 Unintentional deployment of the airbags small amount of current to flow through the circuit. The can cause injury. SDM monitors the voltage during this check. DTC 07 Will Set When D The firing circuit is shorted to ground. DAEWOO M-150 BL2...

  • Page 854: Dtc 07 Passenger Firing Circuit, Short To Ground

    Does the code 07 still show as a current fault? – Go to Step 5 System OK 1. Replace the passenger side airbag module. Go to 2. Reconnect the negative battery cable. Diagnostic Is the repair complete? – System Check – DAEWOO M-150 BL2...
  • Page 855 Unintentional deployment of the air- small amount of current to flow through the circuit. The bags can cause injury. SDM monitors the voltage during this check. DTC 08 Will Set When D The firing circuit is shorted to the voltage. DAEWOO M-150 BL2...

  • Page 856: Dtc 08 Passenger Firing Circuit, Short To Battery Voltage

    Does the code 08 still show as a current fault? – Go to Step 5 System OK 1. Replace the passenger side airbag module. Go to 2. Reconnect the negative battery cable. Diagnostic Is the repair complete? – System Check – DAEWOO M-150 BL2...
  • Page 857 D The combined resistance of the driver pretensioner erly, the meter’s battery can deploy the airbag and module, the harness wiring, and the connector con- cause injury. tacts is above a specified value, as in an open circuit. DAEWOO M-150 BL2...

  • Page 858: Dtc 09 Driver Pretensioner Circuit, Resistance Too High

    2. Reconnect the negative battery cable. Diagnostic Is the repair complete? – System Check – 1. Replace the supplemental inflatable restraints (SIR) wiring harness. Go to 2. Reconnect the negative battery cable. Diagnostic – System Check – Is the repair complete? DAEWOO M-150 BL2...
  • Page 859 D The combined resistance of the driver pretensioner the harness wiring, and the connector contacts is be- low a specified value, as with a short circuit between the wires to the driver airbag module. DAEWOO M-150 BL2...

  • Page 860: Dtc 10 Driver Pretensioner Circuit, Resistance Too Low

    2. Reconnect the negative battery cable. Diagnostic Is the repair complete? – System Check – 1. Replace the supplemental inflatable restraints (SIR) wiring harness. Go to 2. Reconnect the negative battery cable. Diagnostic – System Check – Is the repair complete? DAEWOO M-150 BL2...
  • Page 861 Unintentional deployment of the airbags amount of current to flow through the driver pretensioner can cause injury. circuit. The SDM monitors the voltage during this check. DTC 11 Will Set When D The firing circuit is shorted to ground. DAEWOO M-150 BL2...

  • Page 862: Dtc 11 Driver Pretensioner Circuit, Short To Ground

    Does the code 11 still show as a current fault? – Go to Step 5 System OK 1. Replace the driver seat belt pretensioner module. Go to 2. Reconnect the negative battery cable. Diagnostic Is the repair complete? – System Check – DAEWOO M-150 BL2...
  • Page 863 Unintentional deployment of the airbags amount of current to flow through the circuit. The SDM can cause injury. monitors voltage during this check. DTC 12 Will Set When D The firing circuit is shorted to voltage. DAEWOO M-150 BL2...

  • Page 864: Dtc 12 Driver Pretensioner Circuit, Short To Battery Voltage

    Does the code 12 still show as a current fault? – Go to Step 5 System OK 1. Replace the driver seat belt pretensioner module. Go to 2. Reconnect the negative battery cable. Diagnostic Is the repair complete? – System Check – DAEWOO M-150 BL2...
  • Page 865 D The combined resistance of the passenger preten- erly, the meter’s battery can deploy the airbag and sioner module, the harness wiring, and the connector cause injury. contacts is above a specified value, as in an open cir- cuit. DAEWOO M-150 BL2...

  • Page 866: Dtc 13 Passenger Pretensioner Circuit, Resistance Too High

    2. Reconnect the negative battery cable. Diagnostic System Check Is the repair complete? – – 1. Replace the supplemental inflatable restraints (SIR) wiring harness. Go to 2. Reconnect the negative battery cable. Diagnostic System Check Is the repair complete? – – DAEWOO M-150 BL2...
  • Page 867 DAEWOO M-150 BL2...

  • Page 868: Dtc 14 Passenger Pretensioner Circuit, Resistance Too Low

    2. Reconnect the negative battery cable. Diagnostic System Check Is the repair complete? – – 1. Replace the supplemental inflatable restraints (SIR) wiring harness. Go to 2. Reconnect the negative battery cable. Diagnostic System Check Is the repair complete? – – DAEWOO M-150 BL2...
  • Page 869 Unintentional deployment of the airbags small amount of current to flow through the circuit. The can cause injury. SDM monitors the voltage during this check. DTC 15 Will Set When D The firing circuit is shorted to ground. DAEWOO M-150 BL2...

  • Page 870: Dtc 15 Passenger Pretensioner Circuit, Short To Ground

    Does the code 15 still show as a current fault? – Go to Step 5 System OK 1. Replace the passenger seat belt pretensioner module. Go to 2. Reconnect the negative battery cable. Diagnostic Is the repair complete? – System Check – DAEWOO M-150 BL2...
  • Page 871 Unintentional deployment of the air- small amount of current to flow through the circuit. The bags can cause injury. SDM monitors the voltage during this check. DTC 16 Will Set When D The firing circuit is shorted to the voltage. DAEWOO M-150 BL2...

  • Page 872: Dtc 16 Passenger Pretensioner Circuit, Short To Battery Voltage

    Does the code 16 still show as a current fault? – Go to Step 5 System OK 1. Replace the passenger seat belt pretensioner module. Go to 2. Reconnect the negative battery cable. Diagnostic System Check Is the repair complete? – – DAEWOO M-150 BL2...
  • Page 873 D Connection between the driver firing circuit and the cause injury. driver pretensioner circuit or the SDM internal con- nection problem may exist. DAEWOO M-150 BL2...

  • Page 874: Dtc 18 Connection Between Driver Firing Circuit And Driver Pretensioner Circuit

    2. Reconnect the negative battery cable. Diagnostic Is the repair complete? System Check – – 1. Replace the supplemental inflatable restraints (SIR) wiring harness. Go to 2. Reconnect the negative battery cable. Diagnostic Is the repair complete? – System Check – DAEWOO M-150 BL2...
  • Page 875 D Connection between the drive firing circuit and the cause injury. passenger pretensioner circuit or SDM internal con- nection problem may exist. DAEWOO M-150 BL2...
  • Page 876 2. Reconnect the negative battery cable. Diagnostic Is the repair complete? System Check – – 1. Replace the supplemental inflatable restraints (SIR) wiring harness. Go to 2. Reconnect the negative battery cable. Diagnostic Is the repair complete? – System Check – DAEWOO M-150 BL2...
  • Page 877 D Connection between the passenger firing circuit and cause injury. the driver pretensioner circuit or SDM internal con- nection problem may exist. DAEWOO M-150 BL2...

  • Page 878: Dtc 20 Connection Between Passenger Firing Circuit And Driver Pretensioner Circuit

    2. Reconnect the negative battery cable. Diagnostic Is the repair complete? System Check – – 1. Replace the supplemental inflatable restraints (SIR) wiring harness. Go to 2. Reconnect the negative battery cable. Diagnostic Is the repair complete? – System Check – DAEWOO M-150 BL2...
  • Page 879 D Connection between the passenger firing circuit and cause injury. the passenger pretensioner circuit or SDM internal connection problem may exist. DAEWOO M-150 BL2...
  • Page 880 2. Reconnect the negative battery cable. Diagnostic Is the repair complete? – System Check – 1. Replace the supplemental inflatable restraints (SIR) wiring harness. Go to 2. Reconnect the negative battery cable. Diagnostic – System Check – Is the repair complete? DAEWOO M-150 BL2...
  • Page 881 D Connection between the driver pretensioner circuit cause injury. and the passenger pretensioner circuit or SDM inter- nal connection problem may exist. DAEWOO M-150 BL2...
  • Page 882 2. Reconnect the negative battery cable. Diagnostic Is the repair complete? – System Check – 1. Replace the supplemental inflatable restraints (SIR) wiring harness. Go to 2. Reconnect the negative battery cable. Diagnostic System Check Is the repair complete? – – DAEWOO M-150 BL2...
  • Page 883 SDM may not receive the proper information can cause injury. when it attempts to use a known current to test the airbag module circuits. DTC 23 Will Set When D The SDM receives voltage higher than a specified value. DAEWOO M-150 BL2...

  • Page 884: Dtc 23 Ignition Input Circuit, Voltage Too High

    Go to Step 2 Repair the charging system. Go to Diagnostic Is the repair complete? System Check – – 1. Disconnect the negative battery cable. Go to 2. Replace the SDM. Diagnostic Is the repair complete? System Check – – DAEWOO M-150 BL2...
  • Page 885 Caution: As a safety precaution, disconnect the con- airbag module circuits. nector for the passenger airbag module. Uninten- DTC 24 Will Set When tional deployment of the airbags can cause injury. D The SDM receives the voltage lower than a specified value. DAEWOO M-150 BL2...

  • Page 886: Dtc 24 Ignition Input Circuit, Voltage Too Low

    Go to 2. Reconnect the battery. Diagnostic Is the repair complete? System Check – – Repair the open circuit between the fuse F2 and the Go to connector C208. Diagnostic System Check Is the repair complete? – – DAEWOO M-150 BL2...
  • Page 887 ON for approximately four seconds after the connection which can keep the airbags from deploy- ignition is first switched ON, and then The warning lamp ing when needed, resulting in injury. Replace the turns OFF. SIR wiring harness if it is damaged. DAEWOO M-150 BL2...

  • Page 888: Dtc 25 Warning Lamp Failure

    F1 and the warning lamp. 2. Make a repair, if needed. Go to 3. Replace the fuse F1. Diagnostic Is the repair complete? – System Check – DAEWOO M-150 BL2...
  • Page 889 Diagnostic System Check Is the repair complete? – – 1. Disconnect the negative battery terminal. 2. Wait at least 1 minute before proceeding. 3. Replace the SIR wiring harness. – System OK – Is the repair complete? DAEWOO M-150 BL2...

  • Page 890: Dtc 31 Sdm Internal Fault

    DIAGNOSTIC ILLUSTRATION 1 Checking the continuity between the terminal 9 of the sensing and diagnostic module and the terminal J (13) of the assembly line diagnostic link. D110B303 DAEWOO M-150 BL2...

  • Page 891: Diagnostic Illustration 2

    Checking the continuity of the driver airbag circuit on the sensing and diagnostic module (SDM) side of the clock spring connector. D110B306 DIAGNOSTIC ILLUSTRATION 5 Checking the driver airbag circuit for a short to ground with the sensing and diagnostic module disconnected. D110B307 DAEWOO M-150 BL2...

  • Page 892: Diagnostic Illustration 6

    D110B309 DIAGNOSTIC ILLUSTRATION 8 Checking the passenger airbag circuit continuity on the sensing and diagnostic module side of the connector. D110B310 DIAGNOSTIC ILLUSTRATION 9 Checking the passenger airbag circuit for a short to ground. D110B311 DAEWOO M-150 BL2...
  • Page 893 2 of the connector C208. D110B313 DIAGNOSTIC ILLUSTRATION 13 Checking for a short to ground on the sensing and diag- nostic module side of the supplemental inflatable re- straints harness at the terminal 3 of the connector C208. D110B314 DAEWOO M-150 BL2...
  • Page 894 DIAGNOSTIC ILLUSTRATION 16 Checking the driver seat belt pretensioner circuit conti- nuity on the sensing and driagnostic module side of the connector. D110B310 DIAGNOSTIC ILLUSTRATION 17 Checking the driver seat belt pretensioner circuit for a short to ground. D110B311 DAEWOO M-150 BL2...
  • Page 895 D110B310 DIAGNOSTIC ILLUSTRATION 20 Checking the passenger seat belt pretensioner circuit for a short to ground. D110B311 DIAGNOSTIC ILLUSTRATION 21 Checking the passenger seat belt pretensioner circuit for a short to voltage. D110B311 DAEWOO M-150 BL2...
  • Page 896 15 NSm 3. Install the driver airbag module torx bolt using a torx D1AB503A bolt wrench DS 401. Tighten Tighten the torx bolt to 15 NSm (11 lb-ft) 4. Connect the negative battery cable. DAEWOO M-150 BL2...
  • Page 897 3. Turn the label of the clock spring clockwise to lock. 4. Turn the label of the clock spring counterclockwise approximately three turns to the neutral positions with the front wheels ahead. D110B507 DAEWOO M-150 BL2...
  • Page 898 Passenger airbag module torx bolt. D Tighten the passenger airbag module nuts to 10 NSm (89 lb-in). b. Passenger airbag module nut. Notice : Do not reuse the removed torx bolts. Replace the torx bolts with the new ones. D1AB510A DAEWOO M-150 BL2...
  • Page 899 SDM label points toward the front of the vehicle. Notice : Ground the wiring harness to the mounting torx bolt (1). Tighten Tighten the SDM mounting torx bolts to 15 NSm (11 lb-ft). D1AB512A 2. Connect the SDM electrical connector. DAEWOO M-150 BL2...
  • Page 900 5. Check for proper operation of the system. D Turn the ignition ON while watching the supple- mental inflatable restraints warning lamp. D The warning lamp should turn ON for about 4 sec- onds, and then turn OFF. D110B009A DAEWOO M-150 BL2...
  • Page 901 Deploy the airbags before disposing of them. This in- cludes those in a whole vehicle being scrapped. If the vehicle is still within the warranty period, contact the Daewoo regional service manager for approval or special instructions before deploying the airbag mod- ules.
  • Page 902 24. Touch one wire to the positive battery terminal and touch the other wire to the negative battery terminal. The passenger airbag will deploy. 25. Using the proper precautions, dispose of the deployed airbag. Refer to “Deployed Airbag Module Disposal Procedure” in this section. DAEWOO M-150 BL2...
  • Page 903 30 minutes be- fore handling them. Deploy an airbag before disposing of it. This includes those in a whole vehicle being scrapped. DAEWOO M-150 BL2...
  • Page 904 SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B – 77 If the vehicle is still within the warranty period, contact the Daewoo regional service manager for approval or special instructions before deploying an airbag module. Deployed airbag modules should be disposed of in the...

  • Page 905: Fastener Tightening Specifications

    Driver Airbag Module Mounting Bolts – Passenger Airbag Module Mounting Nuts – Passenger Airbag Module Mounting Bolts – Sensing and Diagnostic Module Mounting Bolts – SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE DS 401 Scan Tool Torx Bolt Wrench D102F101 D110B101 DAEWOO M-150 BL2...
  • Page 906 SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B – 79 SCHEMATIC AND ROUTING DIAGRAMS SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) ELECTRICAL SCHEMATIC D1AB201B DAEWOO M-150 BL2...
  • Page 907 ....9A-21 Fuse Box Locator (Passenger Compartment) ....9A-9 DAEWOO M-150 BL2...

  • Page 908: Description And Operation

    9A – 2 BODY WIRING SYSTEM DESCRIPTION AND OPERATION HOW TO READ ELECTRICAL WIRING DIAGRAM D111001A DAEWOO M-150 BL2...
  • Page 909 – Ground line. – G402: Ground Position – In case of the ground numberless, this means the body ground. Circuit Identification Symbol Identification Symbol Meaning Connector Fuse in engine room fuse box Fuse in passenger compartment fuse box Ground DAEWOO M-150 BL2...

  • Page 910: How To Check Terminal Number Of Connector . 9A-4

    9A – 4 BODY WIRING SYSTEM HOW TO CHECK TERMINAL NUMBER OF CONNECTOR Terminal number is given based on female terminal connector. Example: Terminal number 4 of 6 pin connection. D111002A DAEWOO M-150 BL2...

  • Page 911: Special Tools And Equipment

    BODY WIRING SYSTEM 9A – 5 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE DW–540–010 Relay Remover D1011101 DAEWOO M-150 BL2...

  • Page 912: Schematic And Routing Diagrams

    SCHEMATIC AND ROUTING DIAGRAMS WIRE COLOR CHART Wire Color Abbreviation On Schematic Green DK GRN Blue DK BLU Brown Orange Yellow Grey Black White Purple Wires With Tracers Wire Color Abbreviation On Schematic Red with White Tracer RED/WHT DAEWOO M-150 BL2...
  • Page 913 BODY WIRING SYSTEM 9A – 7 POWER DISRIBUTION SCHEMATIC D111005B DAEWOO M-150 BL2...
  • Page 914 9A – 8 BODY WIRING SYSTEM RELAY & FUSE BOX LOCATOR (ENGINE ROOM: SIRIUS D3) D111003B RELAY & FUSE BOX LOCATOR (ENGINE ROOM: FENIX 5MR) D111003C DAEWOO M-150 BL2...
  • Page 915 BODY WIRING SYSTEM 9A – 9 FUSE BOX LOCATOR (PASSENGER COMPARTMENT: LHD) D111004A FUSE BOX LOCATOR (PASSENGER COMPARTMENT: RHD) D111004B DAEWOO M-150 BL2...

  • Page 916: Fuse Chart

    Stop Lamp Audio Cigar Light IGN 2 Wiper IGN 2 Rear Wiper Motor, Front & Rear Washer, Backup Lamp IGN 2 Auto Miror Switch IMMO, Audio, Room Lamp Hazard, Clock Anti-Theft Control Unit, Door Lock Starter Motor DAEWOO M-150 BL2...

  • Page 917: Front Harness Routing

    BODY WIRING SYSTEM 9A – 11 FRONT HARNESS ROUTING (Left–Hand Drive Shown, Right–Hand Drive Similar) D111401D DAEWOO M-150 BL2...

  • Page 918: Engine Harness Routing

    9A – 12 BODY WIRING SYSTEM ENGINE HARNESS ROUTING (SIRIUS D3) (Left–Hand Drive Shown, Right–Hand Drive Similar) D111402D DAEWOO M-150 BL2...
  • Page 919 BODY WIRING SYSTEM 9A – 13 ENGINE HARNESS ROUTING (FENIX 5NR) (Left–Hand Drive Shown, Right–Hand Drive Similar) D111411A DAEWOO M-150 BL2...

  • Page 920: Instrument Harness Routing

    9A – 14 BODY WIRING SYSTEM INSTRUMENT HARNESS ROUTING (Left–Hand Drive) D111403E DAEWOO M-150 BL2...
  • Page 921 BODY WIRING SYSTEM 9A – 15 INSTRUMENT HARNESS ROUTING (Right–Hand Drive) D111403F DAEWOO M-150 BL2...

  • Page 922: Airbag Harness Routing

    9A – 16 BODY WIRING SYSTEM AIRBAG HARNESS ROUTING (Left–Hand Drive Shown, Right–Hand Drive Similar) D111404D DAEWOO M-150 BL2...

  • Page 923: Body Harness Routing

    BODY WIRING SYSTEM 9A – 17 BODY HARNESS ROUTING D111405D DAEWOO M-150 BL2...
  • Page 924 9A – 18 BODY WIRING SYSTEM BODY HARNESS ROUTING (Cont’d) D111406D DAEWOO M-150 BL2...

  • Page 925: Front Door Harness Routing

    BODY WIRING SYSTEM 9A – 19 FRONT DOOR HARNESS ROUTING D111407D DAEWOO M-150 BL2...

  • Page 926: Rear Door Harness Routing

    9A – 20 BODY WIRING SYSTEM REAR DOOR HARNESS ROUTING D111408D DAEWOO M-150 BL2...

  • Page 927: Tailgate Harness Routing

    BODY WIRING SYSTEM 9A – 21 TAILGATE HARNESS ROUTING D111409D DAEWOO M-150 BL2...
  • Page 928 ..... . . 9B-27 Center High-Mounted Stoplamp ... . 9B-11 DAEWOO M-150 BL2...

  • Page 929: Description And Operation

    The rear fog lamp can the light switch is turned on. They revert to normal op- be turned on only when headlamps are on. eration when the light switch is on. The daytime running lamps (DRL) is optional. DAEWOO M-150 BL2...

  • Page 930: Diagnostic Information And Procedures

    6 of the headlamp combination switch. D Faulty headlamp combination D Replace the headlamp switch. combination switch. D The open ground (G201) circuit. D Repair or Replace the open ground circuit. DAEWOO M-150 BL2...

  • Page 931: Turn Signal Lamps And Hazard Lamps

    D The open circuit or a short circuit D Repair or Replace the wiring between the terminals 5,6 of the harness. hazard lamp switch connector and the terminals 2,5 of the turn signal lamp connectors. DAEWOO M-150 BL2...

  • Page 932: Stoplamps And Interior Courtesy Lamp

    F11 and the connector. terminal 1 of the interior courtesy lamp connector. D Interior courtesy lamp bulb is D Replace the bulb. blown. D Faulty interior courtesy lamp. D Replace the interior courtesy lamp. DAEWOO M-150 BL2...

  • Page 933: Rear Fog Lamp

    D Faulty rear fog lamp switch. D Replace the rear fog lamp switch. D The open grounds (G201, G401) D Repair or Replace the open circuits. ground circuit. D Rear fog lamp bulb is blown. D Replace the rear fog lamp bulb. DAEWOO M-150 BL2...
  • Page 934 D Remove the headlamp (2) . D19D502A Installation Procedure 1. Install the headlamp with the bolts. 2. Connect the headlamp connector and parking lamp connector. 3. Install the front bumper spacer with the bolts. 4. Connect the negative battery cable. D19D503A DAEWOO M-150 BL2...

  • Page 935: Turn Signal Lamps

    2. Slide the side turn signal lamp rearward. 3. Remove the lamp. 4. Disconnect the electrical connector. D29B001 Installation Procedure 1. Connect the electrical connector. 2. Install the side turn signal lamp. 3. Connect the negative battery cable. D29B002 DAEWOO M-150 BL2...

  • Page 936: Taillamps Assembly

    2. Raise and suitably support the vehicle. 3. Remove the front wheels. 4. Remove the front wheel house splash shield. D Remove the clip and bolts. a. Bolt and clips. D Remove the wheel house splash shield. b. Splash shield. D19C501A DAEWOO M-150 BL2...

  • Page 937: Rear Fog/Backup Lamp

    2. Remove the taillamp assembly. Refer to “Taillamps Assembly” in this section. 3. Remove the bulb(s). D19D508C Installation Procedure 1. Install the bulb(s). 2. Install the taillamp assembly. Refer to “Taillamps As- sembly” in this section. 3. Connect the negative battery cable. D19D509A DAEWOO M-150 BL2...

  • Page 938: Center High-Mounted Stoplamp

    1. Install the CHMSL bulb. 2. Install the CHMSL with the screws. 3. Install the CHMSL cover with the screws. 4. Install the tailgate trim panel. Refer to Section 9G, In- terior Trim. 5. Connect the negative battery cable. D19E554A DAEWOO M-150 BL2...

  • Page 939: Chmsl Mounting Bracket

    Section 9D, Wipers/Washer Systems. 4. Disconnect the electrical connector in the tailgate. 5. Remove the tailgate handle. Refer to Section 9M, Ex- terior Trim. 6. Remove the license plate lamp socket. D Remove the socket (1). D19D511A DAEWOO M-150 BL2...

  • Page 940: Door Jamb Switch

    1. Disconnect the negative battery cable. 2. Remove the interior courtesy lamp. D Pry off the interior courtesy lamp lens (1). D Remove the screws (2). D Disconnect the electrical connector (3). D Remove the interior courtesy lamp (4). D19D515A DAEWOO M-150 BL2...

  • Page 941: Daytime Running Lamp Module (W/Europe Only)

    2. Disconnect the electrical connector (1). 3. Remove the screws (2) and the daytime running lamp module. D29B007 Installation Procedure 1. Install the daytime running lamp module with the bolts. 2. Connect the electrical connector. 3. Connect the negative battery cable. D29B008 DAEWOO M-150 BL2...

  • Page 942: Luggage Room Lamp

    3. Remove the luggage room lamp. D Remove the luggage room lamp (1). D Disconnect the electrical connector (2). D209B104 Installation Procedure 1. Connect the electrical connector. 2. Install the luggage room lamp. 3. Connect the negative battery cable. D209B105 DAEWOO M-150 BL2...

  • Page 943: Specifications

    Center High Mounted Stoplamp Headlamps Double 60/55W Interior Courtesy Lamp License Plate Lamp Front Turn Signal Lamps Rear Fog Lamp Rear Turn Signal Lamps Side Marker Turn Signal Lamps Tail and Stoplamp Double 5/21W, 5W Parking Lamp DAEWOO M-150 BL2...

  • Page 944: Schematic And Routing Diagrams

    LIGHTING SYSTEMS 9B – 17 SCHEMATIC AND ROUTING DIAGRAMS BACKUP LAMP(S) CIRCUIT D19D201B DAEWOO M-150 BL2...

  • Page 945: Headlamps Circuit

    9B – 18 LIGHTING SYSTEMS HEADLAMPS CIRCUIT D19D202B DAEWOO M-150 BL2...

  • Page 946: Headlamp Leveling Circuit

    LIGHTING SYSTEMS 9B – 19 HEADLAMP LEVELING CIRCUIT D19B723B DAEWOO M-150 BL2...
  • Page 947 9B – 20 LIGHTING SYSTEMS TAIL AND LICENSE PLATE LAMPS CIRCUIT D19D203B DAEWOO M-150 BL2...

  • Page 948: Stoplamps Circuit

    LIGHTING SYSTEMS 9B – 21 STOPLAMPS CIRCUIT D19D204B DAEWOO M-150 BL2...

  • Page 949: Turn And Hazard Lamps Circuit

    9B – 22 LIGHTING SYSTEMS TURN AND HAZARD LAMPS CIRCUIT D19D205B DAEWOO M-150 BL2...

  • Page 950: Interior Courtesy Lamp Circuit

    LIGHTING SYSTEMS 9B – 23 INTERIOR COURTESY LAMP CIRCUIT D19D206B DAEWOO M-150 BL2...

  • Page 951: Front Fog Lamp Circuit

    9B – 24 LIGHTING SYSTEMS FRONT FOG LAMP CIRCUIT D19B724A1 DAEWOO M-150 BL2...

  • Page 952: Rear Fog Lamp Circuit

    LIGHTING SYSTEMS 9B – 25 REAR FOG LAMP CIRCUIT D19B724B DAEWOO M-150 BL2...

  • Page 953: Dimmer Control Circuit (Except W/Europe)

    9B – 26 LIGHTING SYSTEMS DIMMER CONTROL CIRCUIT (EXCEPT W/EUROPE) D29B009A DAEWOO M-150 BL2...

  • Page 954: Daytime Running Lamps Circuit (W/Europe Only)

    LIGHTING SYSTEMS 9B – 27 DAYTIME RUNNING LAMPS CIRCUIT (W/EUROPE ONLY) D29B010A DAEWOO M-150 BL2...
  • Page 955 ..... . . 9C-4 On-Vehicle Service ......9C-3 DAEWOO M-150 BL2...
  • Page 956 HORN ated by pressing the steering wheel pad, which grounds the horn’s electrical circuit. The horn is located under the hood. It is attached near the radiator at the front of the vehicle. The horn is actu- DAEWOO M-150 BL2...
  • Page 957 1. Install the horn with the bolt. 2. Connect the electrical connector. 3. Install the front wheel house splash shield with the clips and the bolts. 4. Install the front wheels. 5. Lower the vehicle. 6. Connect the negative battery cable. D19D518A DAEWOO M-150 BL2...
  • Page 958 9C – 4 HORN SCHEMATIC AND ROUTING DIAGRAMS HORN WIRING SYSTEM D19D207B DAEWOO M-150 BL2...
  • Page 959 ........9D-16 Rear Window Wiper Motor ....9D-8 DAEWOO M-150 BL2...

  • Page 960: Description And Operation

    And push more the switch forward and the rear wiper/washer system oper- WINDSHIELD WASHER SYSTEM ate. The windshield washer system is equipped with a wash- er fluid reservoir, a washer fluid pump, hoses, nozzles, DAEWOO M-150 BL2...

  • Page 961: Diagnostic Information And Procedures

    Speed, High Speed OK D The D Repair or Replace the wiring circuit between wiper/washer switch and the wiper harness. motor is the open circuit or a short circuit. D Faulty wiper motor. D Replace the wiper motor. DAEWOO M-150 BL2...
  • Page 962 D Faulty windshield washer pump. D Replace the windshield wash pump. D Poor ground G201. D Repair or Replace the wiring harness. DAEWOO M-150 BL2...
  • Page 963 D Faulty windshield washer pump. D Replace the windshield washer pump. D Poor ground G102. D Repair or Replace the wiring harness. DAEWOO M-150 BL2...

  • Page 964: On-Vehicle Service

    “Rear Washer Nozzle” in this section. 2. Remove the wiper blade. Refer to “Windshield Wiper Blade” in this section. 3. Remove the wiper arm. D Remove the cap (1). D Remove the nut (2). D Remove the wiper arm (3). D109D521 DAEWOO M-150 BL2...

  • Page 965: Windshield Wiper Motor

    D Disconnect the electrical connector (1). D Remove the bolts (2). D Remove the wiper motor assembly (3). D109D524 Caution: Because the wiper motor link plate is fixed, do not separate the wiper motor from the bracket. D109D525 DAEWOO M-150 BL2...

  • Page 966: Rear Window Wiper Motor

    3. Remove the tailgate inside trim. Refer to Section 9G, Interior Trim. 4. Remove the rear wiper motor assembly. D Disconnect the electrical connector (1). D Remove the screws (2). D Remove the rear wiper motor assembly (3). D19D529A DAEWOO M-150 BL2...

  • Page 967: Windshield Wiper Linkage

    3. Separate the wiper linkage from the wiper motor. D Separate the wiper linkage from the wiper motor linkage ball (1). D109D523 4. Remove the wiper linkage. D Remove the wiper linkage nuts (1). D Remove the wiper linkage (2). D109D532 DAEWOO M-150 BL2...

  • Page 968: Windshield Wiper Blade

    1. Install the wiper blade to the arm. D109D535 WASHER RESERVOIR Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the washer reservoir inlet. D Remove the bolt (1). D Remove the washer reservoir inlet (2). D109D536 DAEWOO M-150 BL2...

  • Page 969: Washer Pump

    1. Disconnect the negative battery cable. 2. Remove the washer reservoir assembly. Refer to “Washer Reservoir” in this section. 3. Drain the washer fluid. 4. Remove the wiper motor from the washer reservoir assembly. a. Washer pump. D109D540 DAEWOO M-150 BL2...

  • Page 970: Windshield Washer Nozzle

    3. Install the cowl vent grille. Refer to Sec- tion 9R, Body Front End. D109D542 REAR WINDOW WASHER NOZZLE Removal Procedure 1. Remove the washer nozzle from the wiper arm. D Disconnect the washer nozzle hose (1). D Remove the washer nozzle (2). D109D543 DAEWOO M-150 BL2...

  • Page 971: Washer Hose

    5. Remove the front RH wheel house splash shield. D Remove the screws (1). D Remove the clips (2). D Remove the wheel house splash shield (3). D19D537A 6. Disconnect the washer hose from the washer pump. a. Washer hose. D109D544 DAEWOO M-150 BL2...
  • Page 972 2. Install the front RH wheel house splash shield with the screws and the clips. 3. Install the front RH wheel. 4. Lower the vehicle. 5. Connect the washer hose connector. 6. Install the cowl vent grille. Refer to Section 9R, Body Front End. D19D546A DAEWOO M-150 BL2...

  • Page 973: Specifications

    WIPERS/WASHER SYSTEMS 9D – 15 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Lb-Ft Lb-In Wiper Linkage Conclusion Nut 1.5–2.0 – 13–18 DAEWOO M-150 BL2...

  • Page 974: Schematic And Routing Diagrams

    9D – 16 WIPERS/WASHER SYSTEMS SCHEMATIC AND ROUTING DIAGRAMS WINDSHIELD/REAR WINDOW WIPER AND WASHER SYSTEM D19D208B DAEWOO M-150 BL2...
  • Page 975 ......9E-8 Cigar Lighter ......9E-8 DAEWOO M-150 BL2...

  • Page 976: Description And Operation

    The indicator lamps are replaceable. For re- “Instrument Cluster Indicator Lamps Specifications” in placement of the indicator lamps contained in the instru- this section. ment cluster, refer to “Instrument Cluster Indicator Lamps Specifications” in this section. DAEWOO M-150 BL2...

  • Page 977: Instrument Panel Assembly

    6. Passenger’s Airbag Blank Cover 16. Ashtray Bracket 7. Demister Grille 17. Ashtray 8. Side Ventilation Grille 18. Ashtray Lamp 9. Glove Box Bracket 19. Cigar Lighter Housing 10. Glove Box 20. Instrument Cluster Bracket 21. Instrument Panel DAEWOO M-150 BL2...

  • Page 978: Instrument Cluster

    9E – 4 INSTRUMENTATION/DRIVER INFORMATION INSTRUMENT CLUSTER D109B404 1. Instrument Cluster Lens 5. Temperature Gauge 2. Instrument Cluster Window Plate 6. Instrument Cluster Case 3. Speedometer Gauge 7. Fronted Circuit Plate 4. Fuel Gauge 8. Instrument Cluster Bulb DAEWOO M-150 BL2...

  • Page 979: Diagnostic Information And Procedures

    D Faulty the cigar lighter connector. D Repair or Replace the cigar lighter connector. D Cigar lighter element is blown. D Replace the cigar lighter. D Open ground (G201) circuit. D Repair the open ground circuit. DAEWOO M-150 BL2...

  • Page 980: Hvac Panel Illumination

    D Faulty the HVAC panel illumination D Repair or Replace the connector. instrument panel illumination connector. D HVAC panel illumination bulb is blown. D Replace the bulb. D Open ground (G201) circuit. D Repair the open ground circuit. DAEWOO M-150 BL2...

  • Page 981: Digital Clock

    D The circuit between the Ef12 and the D Repair or Replace the wiring digital clock connector. harness. D Faulty digital clock. D Replace the digital clock. D Repair the open ground D Open ground (G201) circuit. circuit. DAEWOO M-150 BL2...

  • Page 982: On-Vehicle Service

    D Remove the socket (2). D19B502A Installation Procedure 1. Connect the electrical connector. 2. Install the cigar lighter socket. 3. Install the cigar lighter in the cigar lighter socket. 4. Install the ashtray. 5. Connect the negative battery cable. D109B503 DAEWOO M-150 BL2...

  • Page 983: Ashtray

    1. Remove the instrument cluster trim panel from the in- strument panel. Refer to “Instrument Cluster Trim Panel” in this section. 2. Remove the vent from the instrument cluster trim panel. D Remove the screws (1). D Remove the vents (2). D109B507 DAEWOO M-150 BL2...
  • Page 984 D Disconnect the electrical connector (1). D Remove the digital clock (2). D109B512 Installation Procedure 1. Connect the electrical connector. 2. Install the digital clock to the instrument panel. 3. Connect the negative battery cable. 4. Set the clock. D109B513 DAEWOO M-150 BL2...
  • Page 985 Panel” in this section. 3. Remove the instrument cluster assembly from the in- strument panel. D Remove the screws (1). D Disconnect the electrical connector and the speedometer cable (2). D19B514A D Remove the instrument cluster (3). DAEWOO M-150 BL2...

  • Page 986: Instrument Panel

    10. Remove the passenger’s airbag module from the in- strument panel. Refer to Section 8B, Supplemental Inflatable Restraints (SIR) (For vehicle equipped with the airbag). 11. Put aside the floor console after removing the screws (1). D109B517 DAEWOO M-150 BL2...
  • Page 987 5. Install the audio system to the instrument panel. Re- fer to Section 9F, Audio Systems. 6. Install the A/C controller to the instrument panel. Refer to Section 7B, Manual Control Heating, Ven- tilation, and Air Conditioning System. D109B521 DAEWOO M-150 BL2...
  • Page 988 D Remove the electrical wiring harness strip. D Disconnect the brake switch connector (1). D Disconnect the thermostat connector (2). D Disconnect the blow motor connector (3). D Disconnect the blow motor resistance connector (4). D Disconnect the electrical wiring harness (5). D19B547A DAEWOO M-150 BL2...
  • Page 989 8. Remove the bolts and the tie–bar center. b. Tie bar center. D109B525 Installation Procedure 1. Install the tie–bar with the bolts. 2. Install the tie–bar center with the bolts. 3. Install the defroster duct to the cowl upper panel with the screws. D109B526 DAEWOO M-150 BL2...

  • Page 990: Instrument Trim Panel Assembly

    2. Remove the instrument panel assembly. Refer to “In- strument Panel” in this section. 3. Remove the instrument cluster brackets from the in- strument panel. D Remove the screws. D Remove the instrument cluster brackets (1). D109B701 DAEWOO M-150 BL2...
  • Page 991 6. Remove the ventilation grilles from the instrument panel. D Remove the screws. D Remove the ventilation grilles (1). D109B704 7. Remove the cigar lighter housing from the instrument panel. D Remove the screws. D Remove the cigar lighter housing (1). D109B705 DAEWOO M-150 BL2...
  • Page 992 4. Install the cigar lighter housing to the instrument pan- el with the screws. 5. Install the ventilation grilles to the instrument panel with the screws. 6. Install the ventilation duct to the instrument panel with the screws. D109B521 DAEWOO M-150 BL2...

  • Page 993: Instrument Cluster Indicator Lamps

    Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the instrument cluster from the instrument panel. Refer to “Instrument Cluster” in this section. 3. Remove the instrument cluster lens and the face plate. a. Window plate. D109B713 DAEWOO M-150 BL2...

  • Page 994: Fuel Gauge/Temperature Gauge

    Window plate. D109B713 4. Remove the fuel gauge/temperature gauge from the cluster assembly. D Remove the screws on the circuit plate (1). D Remove the fuel gauge (2). D Remove the temperature gauge (3). D109B716 DAEWOO M-150 BL2...
  • Page 995 1. Install the fuel gauge/temperature gauge to the clus- ter assembly with the screws. 2. Install the instrument cluster lens and the face plate. 3. Install the instrument cluster. Refer to “Instrument Cluster” in this section. 4. Connect the negative battery cable. D19B717A DAEWOO M-150 BL2...

  • Page 996: Specifications

    Parking Brake Indicator and Brake Fluid Warning 14 v 1.4 W Service Engine Soon Warning Amber 14 v 1.4 W Turn Signal Indicators Green 14 v 1.4 W Instrument Cluster Illumination Blue 12 v Rear Fog Lamp Indicator Amber 14 v 1.4 W DAEWOO M-150 BL2...

  • Page 997: Schematic And Routing Diagrams

    INSTRUMENT/DRIVER INFORMATION 9E – 23 SCHEMATIC AND ROUTING DIAGRAMS D19B201B DAEWOO M-150 BL2...
  • Page 998 9E – 24 INSTRUMENT/DRIVER INFORMATION D19B201S DAEWOO M-150 BL2...

  • Page 999: Instrument Panel Illumination

    INSTRUMENT/DRIVER INFORMATION 9E – 25 INSTRUMENT PANEL ILLUMINATION D19B202B DAEWOO M-150 BL2...

  • Page 1000: Digital Clock

    9E – 26 INSTRUMENT/DRIVER INFORMATION DIGITAL CLOCK D19B203B DAEWOO M-150 BL2...

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