Daewoo Nubira/Lacetti free download

File name en_0.pdf

CONTENTS PAGE 0. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 ­ 1 1. ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ­ 1 2. SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ­ 1 3. DRIVE LINE / AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ­ 1 4. BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ­ 1 5. TRANSMISSION / TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . 5 ­ 1 6. STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ­ 1 7. HVAC (HEATING, VENTILATION & AIR CONDITIONING) . . . 7 ­ 1 8. RESTRAINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ­ 1 9. BODY AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ­ 1 10. PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ­ 1 GENERAL INFORMATION 0 ­ 1 SECTION 0 GENERAL INFORMATION 1. INTRODUCTION 1­1. PAGE LAYOUT This Labor Time Guide is designed for convenient and accurate use. For fast, efficient location of Labor Operation Codes, a detailed illustration and corresponding Labor Operation Code information is provided. 1­2. TYPES OF OPERATION Major Operation The Labor Operation Codes consist of seven digits. All operation numbers having "0" in the seventh digit of operation number are classified as "major" operations. A major operation time allowance is sufficient to do the work described as a single operation. Supplementary Operation (Adds) All operation numbers having an alphabetical letter in the seventh digit of the operation number are classified as "supplementary" operations. These operations cannot be used as a single operation and must be used as additions to the major operation. 1­3. TIME ALLOWANCES The time allowances published in this guide have been determined by performing the operation a sufficient number of times to establish an average time or to determine that a fair and equitable time has been developed. Standard technician's hand tools and dealer essential and available tools are used in performing time studies. No power operated tools are used for time studies. Procedures outlined in Service Manuals, other Service Publications and standard shop practices are used as a guide when performing the work necessary to establish time allowances. The time allowance includes the actual time required to perform the operation plus an additional allowance to provide for operating variables. Time allowances include time to remove and reinstall manufacturer options and accessories but do not include time to remove and reinstall special or aftermarket equipment. "Repair diagnosis" time is included in all published labor time operations when it is required to perform the operation. It is the responsibility of

File name en_10_p1.pdf

PAINT 10 ­ 1 SECTION 10 PAINT 98A. MAIN PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ­ 6 98B. PILLAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ­ 6 98C. DOOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ­ 7 98D. SIDE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ­ 8 98E. FRONT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ­ 9 98F. FRONT FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ­ 9 98G. FRONT PILLAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ­ 10 98H. REAR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ­ 10 98J. REAR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ­ 11 98K. BACK DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ­ 11 98L. PAINT ETC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ­ 13 10 ­ 2 PAINT PAINT 10 ­ 3 10 ­ 4 PAINT PAINT 10 ­ 5

File name en_10_p2.pdf

10 ­ 6 PAINT 10 PAINT EXTERIOR NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 20.6 N 21.3 L 21.3 CAR ALL REF 9802060 CAR ALL CC 9802080 11.9 11.9 11.9 COATING : UNDER (ALL) CC 9803080 2.0 2.5 2.5 COATING : UNDER FRONT CC 9804080 0.8 1.0 1.0 COATING : UNDER, CENTER CC 9805080 0.8 1.0 1.0 COATING : UNDER, REAR CC 9806080 0.8 2.0 2.0 1 PANEL : DASH REF 9807060 1.0 1.0 1.0 PANEL : DASH CC 9807080 0.8 0.8 0.8 2 PANEL : ROOF REF 9808060 4.5 4.8 4.8 PANEL : ROOF CC 9808080 3.2 3.5 3.5 PANEL : ROOF (WAGON/MPV) REF 9808160 -- -- -- PANEL : ROOF (WAGON/MPV) CC 9808180 -- -- -- 3 PILLAR : CENTER LH REF 9809060 1.3 1.3 1.3 PILLAR : CENTER LH CC 9809080 1.2 1.2 1.2 4 PILLAR : CENTER RH REF 9810060 1.3 1.3 1.3 PILLAR : CENTER RH CC 9810080 1.2 1.2 1.2 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA PAINT 10 ­ 7 10 PAINT EXTERIOR NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 1.3 N 1.3 L 1.3 5 PILLAR : FRONT, LH REF 9811060 PILLAR : FRONT, LH CC 9811080 1.2 1.2 1.2 6 PILLAR : FRONT, RH REF 9812060 1.3 1.3 1.3 PILLAR : FRONT, RH CC 9812080 1.2 1.2 1.2 7 DOOR : FR, LH REF 9813060 2.4 2.5 2.5 DOOR : FR, LH CC 9813080 1.9 2.0 2.0 DOOR : FR, LH (3 DOOR) REF 9814060 2.7 -- -- DOOR : FR, LH (3 DOOR) CC 9814080 2.5 -- -- 8 DOOR : FR, RH REF 9815060 2.4 2.5 2.5 DOOR : FR, RH CC 9815080 1.9 2.0 2.0 DOOR : FR, RH (3 DOOR) REF 9816060 2.7 -- -- DOOR : FR, RH (3 DOOR) CC 9816080 2.5 -- -- 9 DOOR : RR, LH REF 9817060 2.1 2.1 2.1 DOOR : RR, LH CC 9817080 1.7 1.7 1.7 10 DOOR : RR, RH REF 9818060 2.1 2.1 2.1 DOOR : RR, RH CC 9818080 1.7 1.7 1.7 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 10 ­ 8 PAINT 10 PAINT EXTERIOR NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 1.6 N 1.9 L 1.9 11 PANEL : STEP, LH REF 9819060 PANEL : STEP, LH CC 9819080 1.3 1.6 1.6 12 PANEL : STEP, RH REF 9820060 1.6 1.9 1.9 PANEL : STEP, RH CC 9820080 1.3 1.6 1.6 13 DOOR : FR, UPPER, LH REF 9821060 1.7 1.8 1.8 DOOR : FR, UPPER, LH CC 9821080 1.5 1.6 1.6 DOOR : FR, UPPER, LH (3 DOOR) REF 9822060 2.0 -- -- DOOR : FR, UPPER, LH (3 DOOR) CC 9822080 1.9 -- -- 14 DOOR : FR, LOWER, LH REF 9823060 1.5 1.7 1.7 DOOR : FR, LOWER, LH CC 9823080 1.4 1.5 1.5 DOOR : FR, LOWER, LH (3 DOOR) REF 9824060 2.0 -- -- DOOR : FR, LOWER, LH (3 DOOR) CC 9824080 1.9 -- -- 15 DOOR : FR, UPPER, RH REF 9825060 1.7 1.8 1.8 DOOR : FR, UPPER, RH CC 9825080 1.5 1.6 1.6 DOOR : FR, UPPER, RH (3 DOOR) REF 9826060 2.0 -- -- DOOR : FR, UPPER, RH (3 DOOR) CC 9826080 1.9 -- -- S : KALOS, N : NUBIRA/LACETTI, L : EVANDA PAINT 10 ­ 9 10 PAINT EXTERIOR NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 1.5 N 1.7 L 1.7 16 DOOR : FR, LOWER, RH REF 9827060 DOOR : FR, LOWER, RH CC 9827080 1.4 1.5 1.5 DOOR : FR, LOWER, RH (3 DOOR) REF

File name en_1b.pdf

ENGINE 1B ­ 1 SECTION 1B ENGINE (SOHC ENGINE MECHANICAL) 111. ENGINE UNIT (SOHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B ­ 3 113. BELT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B ­ 5 121. ENGINE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B ­ 7 122. CRANK SHAFT & PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B ­ 9 123. OIL PAN & PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B ­ 13 131. CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B ­ 15 132. CAM SUPPORT & SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B ­ 19 133. TIMING COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B ­ 21 138. ENGINE & TRANSAXLE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B ­ 23 1B ­ 2 ENGINE ENGINE 1B ­ 3 SOHC ENGINE MECH. ­ SOHC ENGINE UNIT (111) S NO. OPERATION DESCRIPTION OPERATION CODE 1.2S 7.9 1.4/ 1.5S 8.5 1 ENGINE ASSEMBLY (M/T) ­ OVERHAUL INC : R & I Engine ass'y, Flywheel, Intake and exhaust manifold ass'y, Timing belt, Engine adjust. A * With air conditioning B * With power steering ENGINE ASSEMBLY (A/T) ­ OVERHAUL INC : R & I Engine ass'y, Flywheel, Intake and exhaust manifold ass'y, Timing belt, Engine adjust. A * With air conditioning B * With power steering 1110100 111010A 111010B 1110300 1.1 0.5 7.9 1.1 0.5 5.7 111030A 111030B 1110800 1.1 0.5 3.9 1.1 0.5 6.8 2 ENGINE ASSEMBLY (M/T) ­ REPLACE INC : R & I Engine ass'y, Flywheel, Intake and exhaust manifold ass'y, Timing belt, Engine adjust. A * With air conditioning B * With power steering ENGINE ASSEMBLY (A/T) ­ REPLACE INC : R & I Engine ass'y, Flywheel, Intake and exhaust manifold ass'y, Timing belt, Engine adjust. A * With air conditioning B * With power steering 111080A 111080B 1110900 1.1 0.5 3.9 1.1 0.5 4.4 111090A 111090B 1.1 0.5 1.1 0.5 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 1B ­ 4 ENGINE ENGINE 1B ­ 5 SOHC ENGINE MECH. ­ BELT SYSTEM (113) S NO. OPERATION DESCRIPTION OPERATION CODE 1.2S 0.5 0.3 -- 1.4/ 1.5S -- 0.2 0.4 1 2 3 BELT, ALTERNATOR DRIVE ­ REPLACE BELT, ACCESSORY ­ REPLACE AUTO TENSIONER, ACCESSORY BELT ­ REPLACE 1131900 1132200 1132400 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 1B ­ 6 ENGINE ENGINE 1B ­ 7 SOHC ENGINE MECH. ­ ENGINE BLOCK (121) NO. OPERATION DESCRIPTION OPERATION CODE S 1.2S 0.2 0.3 -- 0.7 1.4/ 1.5S 0.2 0.3 0.5 0.4 1 2 3 4 OIL LEVEL INDICATOR ­ REPLACE TUBE, OIL LEVEL INDICATOR ­ REPLACE VALVE, OIL FILTER BY­PASS ­ REPLACE PLUG, EXPANSION ­

File name en_1c.pdf

ENGINE 1C ­ 1 SECTION 1C ENGINE (DOHC ENGINE MECHANICAL) 111. ENGINE UNIT (DOHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C ­ 3 113. BELT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C ­ 5 121. ENGINE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C ­ 7 122. CRANK SHAFT & PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C ­ 9 123. OIL PAN & PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C ­13 131. CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C ­15 132. CAM SUPPORT & SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C ­19 133. TIMING COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C ­21 138. ENGINE & TRANSAXLE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C ­25 1C ­ 2 ENGINE ENGINE 1C ­ 3 DOHC ENGINE MECH. ­ DOHC ENGINE UNIT (111) NO. NO OPERATION DESCRIPTION OPERATION CODE S 1.4D 8.7 1.4D 6.7 N 1.6D 6.7 1.8D 6.7 L 2.0D 6.9 1 ENGINE ASSEMBLY (M/T) ­ OVERHAUL INC : R & I Engine ass'y, Flywheel, Intake and exhaust manifold ass'y, Timing belt, Engine adjust. A * With air conditioning B * With power steering ENGINE ASSEMBLY (A/T) ­ OVERHAUL INC : R & I Engine ass'y, Flywheel, Intake and exhaust manifold ass'y, Timing belt, Engine adjust. A * With air conditioning B * With power steering 1110100 111010A 111010B 1110300 1.1 0.5 6.3 -- -- 6.7 -- -- 6.7 -- -- 6.7 -- -- 6.9 111030A 111030B 1110800 1.1 0.5 6.8 -- -- 4.6 -- -- 4.6 -- -- 4.6 -- -- 4.8 2 ENGINE ASSEMBLY (M/T) ­ REPLACE INC : R & I Engine ass'y, Flywheel, Intake and exhaust manifold ass'y, Timing belt, Engine adjust. A * With air conditioning B * With power steering ENGINE ASSEMBLY (A/T) ­ REPLACE INC : R & I Engine ass'y, Flywheel, Intake and exhaust manifold ass'y, Timing belt, Engine adjust. A * With air conditioning B * With power steering 111080A 111080B 1110900 1.1 0.5 4.4 -- -- 4.6 -- -- 4.6 -- -- 4.6 -- -- 4.8 111090A 111090B 1.1 0.5 -- -- -- -- -- -- -- -- S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 1C ­ 4 ENGINE ENGINE 1C ­ 5 DOHC ENGINE MECH. ­ BELT SYSTEM (113) NO. NO OPERATION DESCRIPTION OPERATION CODE S 1.4D 0.2 0.4 1.4D 0.2 0.4 N 1.6D 0.2 0.4 1.8D 0.2 0.4 L 2.0D 0.2 0.4 1 2 BELT, ACCESSORY ­ REPLACE AUTO TENSIONER, ACCESSORY BELT ­ REPLACE 1132200 1132400 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 1C ­ 6 ENGINE ENGINE 1C ­ 7 DOHC ENGINE MECH. ­ ENGINE BLOCK (121) NO. NO OPERATION DESCRIPTION OPERATION CODE S 1.4D 0.2 0.3 0.5 0.4 1.4D 0.2 0.3 0.5 0.4

File name en_1d.pdf

ENGINE 1D ­ 1 SECTION 1D ENGINE (ENGINE COOLING) 141. RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D ­ 3 143. COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D ­ 5 145. RADIATOR HOSE & PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D ­ 7 148. THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D ­ 9 1D ­ 2 ENGINE ENGINE 1D ­ 3 ENGINE COOLING ­ RADIATOR (141) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.4 0.8 0.1 0.8 N 0.6 1.1 0.1 0.8 L 0.6 1.1 0.1 0.8 1 2 COCK OR PLUG, RADIATOR DRAIN ­ REPLACE RADIATOR ASSEMBLY ­ REPLACE A * With automatic transaxle COOLING SYSTEM ­ FLUSH 1410300 1410500 141050A 1411700 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 1D ­ 4 ENGINE ENGINE 1D ­ 5 ENGINE COOLING ­ COOLING FAN (143) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.2 0.3 0.4 0.1 N 0.2 0.4 0.4 0.1 L 0.2 0.3 0.4 -- 1 2 3 SUPPORT, RADIATOR (UPPER) ­ REPLACE DEFLECTOR AND/OR SEAL, RADIATOR (LOWER) ­ REPLACE SHROUD, RADIATOR FAN (ONE PIECE) ­ REPLACE A * Shroud, radiator fan (All) 1430300 1430500 1430700 143070A 4 MOTOR AND/OR BLADE, ELECTRIC COOLING FAN ­ REPLACE Right Left Both 1431100 1431200 1431300 0.4 0.4 0.5 0.4 0.4 0.5 0.4 -- -- S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 1D ­ 6 ENGINE ENGINE 1D ­ 7 ENGINE COOLING ­ RADIATOR HOSE & PIPE (145) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.2 0.4 0.4 0.1 0.4 0.4 0.5 0.7 0.4 0.9 0.5 0.5 0.6 0.2 0.9 0.5 0.4 N 0.2 0.4 0.8 0.1 0.6 0.8 1.0 0.7 0.4 0.9 0.5 0.5 0.6 0.2 0.9 0.5 0.4 L 0.2 0.4 0.8 0.1 0.6 0.8 1.0 0.6 0.4 0.9 0.5 0.5 0.6 0.2 0.9 -- 0.4 1 2 3 TUBE, OVERFLOW ­ REPLACE RESERVOIR, RADIATOR COOLANT ­ REPLACE CLAMP, RADIATOR HOSE ­ REPLACE A * Replace each additional 1450300 1450400 1450500 145050A 1450700 1450800 1450900 1451100 1451200 1452100 1453100 1453200 1453300 1454100 1454300 1454500 1454700 4 HOSE, UPPER ENGINE COOLANT ­ REPLACE HOSE, LOWER ENGINE COOLANT ­ REPLACE HOSE, BOTH ENGINE COOLANT ­ REPLACE HOSE, COOLANT (PIPE TO PUMP) ­ REPLACE HOSE, COOLANT (PIPE TO RESERVOIR) ­ REPLACE PIPE, COOLANT ­ REPLACE 5 HOSES, INLET HEATER ­ REPLACE HOSES, OUTLET HEATER ­ REPLACE HOSES, ALL HEATER ­ REPLACE 6 7 8 9 CAP, RADIATOR ­ REPLACE PIPE, RADIATOR PUMP ­ REPLACE DISTRIBUTOR, WATER ­ REPLACE HOSE, THROTTLE BODY ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 1D ­ 8 ENGINE ENGINE 1D ­ 9 ENGINE COOLING ­ THERMOSTAT (148) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 THERMOSTAT, OUTLET AND/OR GASKET ­ REPLACE SOHC DOHC 1480300 1480500 2.4 0.3 -- 0.3 -- 0.5 2 HOUSING, THERMOSTAT ­ REPLACE SOHC DOHC 1480700 1480900 2.4 0.3 -- 0.3 -- 0.4 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA

File name en_1e.pdf

ENGINE 1E ­ 1 SECTION 1E ENGINE (ENGINE ELECTRICAL) 151. IGNITION CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E ­ 3 154. ALTERNATOR UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E ­ 5 156. STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E ­ 7 157. BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E ­ 9 158. FUSE & RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E ­ 11 1E ­ 2 ENGINE ENGINE 1E ­ 3 ENGINE ELECTRICAL ­ IGNITION CABLE (151) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 WIRES, SPARK PLUG ­ REPLACE (ONE OR TWO) SOHC DOHC WIRES, SPARK PLUG ­ REPLACE (ALL) SOHC DOHC 1510400 1510500 0.2 0.2 -- 0.2 -- 0.1 1510100 1510200 0.2 0.2 -- 0.2 -- 0.2 2 PLUGS, SPARK ­ REPLACE (ONE OR TWO) SOHC DOHC PLUGS, SPARK ­ REPLACE (ALL) SOHC DOHC 1511100 1511200 0.3 0.3 -- 0.3 -- 0.3 1510800 1510900 0.2 0.3 -- 0.3 -- 0.2 3 COIL, ELECTRONIC IGNITION CONTROL ­ REPLACE SOHC DOHC 1511300 1511400 0.2 0.2 -- 0.3 -- 0.3 4 ADAPTER, COIL AND/OR GASKET ­ REPLACE SOHC DOHC 1511600 1511700 0.3 0.4 -- 0.5 -- 0.5 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 1E ­ 4 ENGINE ENGINE 1E ­ 5 ENGINE ELECTRICAL ­ ALTERNATOR UNIT (154) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 PULLEY AND/OR FAN, ALTERNATOR ­ REPLACE SOHC DOHC 1540100 1540200 0.3 1.1 -- 0.8 -- 0.3 2 BEARING, REAR ALTERNATOR ­ REPLACE SOHC DOHC 1540500 1540600 0.9 1.6 -- 1.2 -- 0.9 3 RECTIFIER, ALTERNATOR ­ TEST AND REPLACE SOHC DOHC 1541300 1541400 0.8 1.9 -- 1.5 -- 0.8 4 ALTERNATOR ASSEMBLY ­ REPLACE SOHC DOHC 1541700 1541800 0.6 1.1 -- 0.7 -- 0.6 5 STATOR, ALTERNATOR ­ REPLACE SOHC DOHC 1542100 1542200 1542400 0.9 1.3 0.9 -- 1.3 1.1 -- 0.9 -- 6 7 FRAME & BEARING ­ REPLACE REGULATOR, ALTERNATOR ­ REPLACE SOHC DOHC 1542600 1542700 0.8 1.9 -- 1.5 -- 0.8 8 BRACKET, ALTERNATOR MOUNTING ­ REPLACE SOHC DOHC 1544100 1544200 0.6 0.6 -- 0.7 -- 0.6 9 SHACKLE, ALTERNATOR ­ REPLACE SOHC DOHC 1544500 1544600 0.3 0.3 -- 0.4 -- 0.3 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 1E ­ 6 ENGINE ENGINE 1E ­ 7 ENGINE ELECTRICAL ­ STARTER (156) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 SOLENOID, STARTER MOTOR ­ REPLACE SOHC DOHC SOLENOID, STARTER MOTOR (RHD, A/T) ­ REPLACE DOHC 1560300 -- 2.0 -- 1560100 1560200 0.9 0.9 -- 0.8 -- 0.8 2 DRIVE ASSEMBLY, STARTER MOTOR ­ REPLACE SOHC DOHC DRIVE ASSEMBLY, STARTER MOTOR (RHD, A/T) ­ REPLACE DOHC 1560600 -- 1.8 -- 1560400 1560500 0.7 0.7 -- 0.6 -- 0.6 3 MOTOR ASSEMBLY, STARTER ­ REPLACE SOHC DOHC MOTOR ASSEMBLY, STARTER (RHD, A/T) ­ REPLACE DOHC 1561100 -- 1.7 -- 1560800 1560900 0.6 0.6 -- 0.5 -- 0.5 S : KALOS, N : NUBIRA/LACETTI,

File name en_1f.pdf

ENGINE 1F ­ 1 SECTION 1F ENGINE (ENGINE CONTROLS) 171. FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F ­ 3 172. FUEL LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F ­ 5 173. CANISTER & FUEL VACUUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F ­ 7 181. FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F ­ 9 182. ACCELERATOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F ­ 11 186. EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F ­ 13 1F ­ 2 ENGINE ENGINE 1F ­ 3 ENGINE CONTROLS ­ FUEL TANK (171) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.3 -- 0.4 1.0 0.3 0.5 N 0.3 0.5 0.4 1.2 0.3 0.5 L 0.3 -- 0.5 1.2 0.3 0.5 1 2 3 4 5 6 PUMP, FUEL AND/OR GAGE, O­RING (IN TANK) ­ REPLACE NECK, FUEL TANK FILLER ­ REPLACE HOSES, FUEL TANK FILLER NECK VENT ­ REPLACE TANK, FUEL ­ REPLACE RING, FUEL PUMP ­ REPLACE SENDER, FUEL ­ REPLACE 1710300 1710500 1710700 1710900 1711100 1711700 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 1F ­ 4 ENGINE ENGINE 1F ­ 5 ENGINE CONTROLS ­ FUEL LINE (172) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 1.2 0.6 0.5 -- N 1.6 0.5 0.4 -- L 1.2 0.5 0.4 0.5 FUEL SYSTEM ­ CLEAN AND FLUSH 1720100 1720300 1720500 1720700 1 2 3 4 FILTER, FUEL ELEMENT ­ REPLACE PIPE, FUEL RETURN OR FEED ­ REPLACE PIPE, FUEL RETURN ­ REPLACE HOSE, FUEL FEED ­ REPLACE Filter to Rail Pipe to Filter Fliter to Pipe Tank to Filter 1720800 1720900 1720910 1720920 1721100 1721300 1721500 1721700 -- -- 0.4 0.4 -- -- -- -- -- -- 0.6 0.6 -- -- -- -- -- -- 0.5 0.5 0.2 0.4 0.4 -- 5 6 7 8 HOSE, FUEL RETURN ­ REPLACE (PIPE TO REGULATOR) HOSE, FUEL FEED ­ REPLACE (TANK TO PIPE) HOSE, FUEL RETURN ­ REPLACE (TANK TO PIPE) SWITCH, FUEL CUTTER ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 1F ­ 6 ENGINE ENGINE 1F ­ 7 ENGINE CONTROLS ­ CANISTER & FUEL VACUUM (173) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.2 N 0.2 L 0.2 1 2 SOLENOID, EVAP. EMISSION CANISTER PURGE ­ REPLACE HOSE, EVAP. EMISSION CONTROL ­ REPLACE Pipe to throttle Body Pipe to Canister 1730300 1730700 1730900 1731100 1731300 1731500 1731600 1731900 0.3 0.3 0.3 -- 0.3 0.5 0.5 0.2 0.4 0.4 0.4 0.4 0.5 0.5 0.3 0.4 0.3 0.3 0.3 -- 0.5 3 4 5 6 7 HOSE, FUEL VAPOR ­ REPLACE (TANK TO CANISTER) BRACKET, FUEL VAPOR CANISTER MOUNTING ­ REPLACE CANISTER, FUEL VAPOR ­ REPLACE TUBE, FUEL VAPOR RETURN ­ REPLACE PIPE, EVAPORATIVE EMISSION CONTROL ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 1F ­ 8 ENGINE ENGINE 1F ­ 9 ENGINE CONTROLS ­ FUEL INJECTION (181) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 BODY, THROTTLE ­ REPLACE & REI

File name en_1g.pdf

ENGINE 1G ­ 1 SECTION 1G ENGINE (ENGINE INTAKE & EXHAUST) 191. AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G ­ 3 193. INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G ­ 5 194. EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G ­ 7 195. VACUUM HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G ­ 9 196. EXHAUST PIPE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G ­11 1G ­ 2 ENGINE ENGINE 1G ­ 3 ENGINE INTAKE & EXHAUST ­ AIR INTAKE SYSTEM (191) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.3 0.2 0.3 0.2 0.7 0.7 -- 0.2 -- N 0.3 0.2 0.3 0.2 0.7 0.7 0.3 0.2 -- L 0.3 0.2 0.3 0.2 -- 0.7 0.4 0.2 0.2 1 2 3 4 5 6 7 8 9 AIR CLEANER ­ REPLACE FILTER, AIR CLEANER ­ REPLACE DUCT AND/OR HOSE, OUTSIDE AIR ­ REPLACE SENSOR, MAT ­ REPLACE DUCT AND/OR HOSE, OUTSIDE AIR ­ REPLACE RESONATOR, AIR CLEANER MAIN ­ REPLACE RESONATOR, AUXILIARY ­ REPLACE HOSE, BREATHER ­ REPLACE DUCT, AIR INLET ­ REPLACE 1910300 1910500 1910700 1910900 1911100 1911300 1911500 1912900 1913000 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 1G ­ 4 ENGINE ENGINE 1G ­ 5 ENGINE INTAKE & EXHAUST ­ INTAKE MANIFOLD (193) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 MANIFOLD AND/OR GASKET, INTAKE ­ REPLACE SOHC DOHC 1930100 1930200 1.8 1.6 -- 1.4 -- 1.8 2 BRACE, INTAKE MANIFOLD ­ REPLACE SOHC DOHC 1930400 1930500 1930700 1931500 1932700 -- 0.5 0.3 0.2 0.3 -- 0.5 0.3 0.2 0.3 -- 0.5 0.2 -- -- 3 4 5 VALVE AND/OR GASKET, EGR ­ REPLACE ACTUATOR, VGIS ­ REPLACE PIPE, EGR ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 1G ­ 6 ENGINE ENGINE 1G ­ 7 ENGINE INTAKE & EXHAUST ­ EXHAUST MANIFOLD (194) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 MANIFOLD AND/OR GASKET EXHAUST ­ REPLACE SOHC DOHC 1940200 1940300 1.0 0.7 -- 1.1 -- 1.1 2 SENSOR, OXYGEN ­ REPLACE SOHC DOHC 1940500 1940600 1940700 0.3 0.3 0.2 -- 0.3 0.2 -- 0.3 0.2 3 CO POTENTIOMETER ­ REPLACE INC : CO POTENTIOMETER Adjust. 4 COVER, EXHAUST MANIFOLD ­ REPLACE 1940800 0.5 0.6 0.5 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 1G ­ 8 ENGINE ENGINE 1G ­ 9 ENGINE INTAKE & EXHAUST ­ VACUUM HOSE (195) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 VACUUM HOSE ­ REPLACE Map Sensor ­ Manifold Regulator ­ Manifold EGR ­ Manifold VGIS ­ Actuator PCV ­ Mainfold 1950100 1950200 1950300 1950400 1950500 1950900 0.2 -- -- 0.2 0.2 0.3 0.2 -- -- 0.2 0.2 0.3 0.3 0.2 -- -- -- 0.2 2 VALVE, FILTER, HOSE AND/OR PIPE, VACUUM POWER BRAKE ­ REPLACE 3 4 SOLENOID, VGIS ­ REPLACE VACUUM TANK, VGIS ­ REPLACE 1951100 1951300 0.2 0.2 0.2 0.2 -- -- S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 1G ­ 10 ENGINE ENGINE 1G ­ 11 ENGINE INTAKE &

File name en_2c.pdf

SUSPENSION 2C ­ 1 SECTION 2C SUSPENSION (FRONT SUSPENSION) 213. KNUCKLE & HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C ­ 3 214. FRONT SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C ­ 7 215. CONTROL ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C ­ 9 2C ­ 2 SUSPENSION SUSPENSION 2C ­ 3 FRONT SUSPENSION ­ KNUCKLE & HUB (213) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.6 1.0 N 0.6 1.0 L 0.6 1.0 TOE, FRONT ­ ADJUST. WHEEL ALIGNMENT ­ CHECK AND/OR ADJUST. 2130100 2130300 1 BEARING AND HUB ASSEMBLY, FRONT WHEEL ­ REPLACE Right Left Both RUNOUT, BRAKE DISC ­ MEASURE RUNOUT, BRAKE DISC ­ ADDITIONAL 2130500 2130600 2130700 2131900 213190A 1.5 1.5 2.8 0.3 0.3 0.5 0.5 0.9 0.3 0.3 0.5 0.5 0.9 0.3 0.3 2 KNUCKLE ASSEMBLY, STEERING ­ REPLACE Right Left Both 2131100 2131200 2131300 2.1 2.1 3.8 1.3 1.3 2.3 1.3 1.3 2.5 3 ROTOR ASSEMBLY ­ REPLACE Right Front Left Front Both Front ROTOR ASSEMBLY ­ GRINDING Right Front Left Front Both Front 2131510 2131610 2131710 0.8 0.8 1.4 0.8 0.8 1.4 0.8 0.8 1.4 2131500 2131600 2131700 0.6 0.6 0.8 0.5 0.5 0.7 0.6 0.6 0.8 4 SHIELD, DISC BRAKE SPLASH ­ REPLACE Right Front Left Front Both Front 2132100 2132200 2132300 0.6 0.6 0.9 0.6 0.6 0.9 0.6 0.6 0.9 5 STUD, FRONT ­ REPLACE Right Left Both 2132500 2132600 2132700 -- -- -- -- -- -- -- -- -- S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 2C ­ 4 SUSPENSION SUSPENSION 2C ­ 5 FRONT SUSPENSION ­ KNUCKLE & HUB (213) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 6 NUT, DRIVE SHAFT ­ REPLACE Right Left Both 2134100 2134200 2134300 0.3 0.3 0.4 0.3 0.3 0.4 0.3 0.3 0.4 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 2C ­ 6 SUSPENSION SUSPENSION 2C ­ 7 FRONT SUSPENSION ­ FRONT SHOCK ABSORBER (214) NO. NO OPERATION DESCRIPTION SPRING, FRONT COIL ­ REPLACE Right Left Both 2140100 2140200 2140300 1.6 1.6 3.0 1.2 1.2 2.2 1.2 1.2 2.2 OPERATION CODE MODEL S N L 1 2 CARTRIDGE, FRONT STRUT ­ REPLACE Right Left Both 2140500 2140600 2140700 -- -- -- -- -- -- -- -- -- 3 STRUT ASSEMBLY, FRONT ­ REPLACE Right Left Both 2140900 2141100 2141200 1.3 1.3 1.9 0.6 0.6 1.0 0.6 0.6 1.0 4 SEAT AND/OR INSULATOR, FRONT SPRING (UPPER/LOWER) ­ REPLACE Right Left Both 2141500 2141600 2141700 1.6 1.6 2.9 1.0 1.0 1.8 1.0 1.0 1.8 5 MOUNT ASSEMBLY, FRONT STRUT BEARING ­ REPLACE Right Left Both 2141900 2142100 2142200 1.4 1.4 2.6 1.0 1.0 1.8 1.0 1.0 1.8 6 HOLLOW BUMPER ­ REPLACE Right Left Both 2142400 2142500 2142600 1.6 1.6 3.0 1.2 1.2 2.2 1.2 1.2 2.2 7 RING, SPRING LOWER INSULATION ­ REPLACE Right Left Both 2142700 2142800 2142900 -- -- -- 1.2 1.2 2.2 1.2 1.2 2.2 8 SHOCK ABSORBER ­ REPLACE Right Left Both 2143100 2143200 2143300 1.2 1.2 2.2 1.2 1.2 2.2 1.2 1.2 2.2 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 2C ­ 8 SUSPENSION SUSPENSION 2C ­ 9 FRONT SUSPENSION ­

File name en_2d.pdf

SUSPENSION 2D ­ 1 SECTION 2D SUSPENSION (REAR SUSPENSION) 231. REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D ­ 3 232. REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D ­ 9 2D ­ 2 SUSPENSION SUSPENSION 2D ­ 3 REAR SUSPENSION ­ REAR AXLE (231) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S -- -- N 0.4 -- L 0.4 -- 1 2 3 STABILIZER, REAR ­ REPLACE DAMPER, STABILIZER ­ REPLACE BEARING, REAR WHEEL ­ REPLACE Right Left Both 2310100 2310300 2310500 2310600 2310700 2310900 0.7 0.7 1.2 2.3 -- -- -- -- -- -- -- -- 4 5 AXLE ASSEMBLY, REAR ­ BALANCE BUSHING, REAR AXLE ­ REPLACE Right Left Both 2311100 2311200 2311300 1.4 1.4 1.5 -- -- -- -- -- -- 6 SPINDLE, WHEEL BEARING ­ REPLACE Right Left Both 2311500 2311600 2311700 0.6 0.6 1.1 -- -- -- -- -- -- 7 CAP, HUB ­ REPLACE Right Left Both 2312100 2312200 2312300 0.2 0.2 0.3 -- -- -- -- -- -- 8 LINK, FRONT PARALLEL ­ REPLACE Right Left Both 2312500 2312600 2312700 -- -- -- 0.4 0.4 0.6 0.4 0.4 0.6 9 BUSH, SUSPENSION LINK ­ REPLACE Right Left Both 2313100 2313200 2313300 -- -- -- -- -- -- -- -- -- S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 2D ­ 4 SUSPENSION SUSPENSION 2D ­ 5 REAR SUSPENSION ­ REAR AXLE (231) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 10 LINK, REAR PARALLEL ­ REPLACE Right Left Both 2313400 2313500 2313600 -- -- -- 0.4 0.4 0.6 0.4 0.4 0.6 11 BUSH, TOE ADJUST LINK ­ REPLACE Right Left Both 2313700 2313800 2313900 -- -- -- -- -- -- -- -- -- 12 LINK, REAR STABILIZER ­ REPLACE Right Left Both 2314100 2314200 2314300 -- -- -- 0.3 0.3 0.4 0.3 0.3 0.4 13 KNUCKLE, REAR (DRUM) ­ REPLACE Right (Non ABS) Left (Non ABS) Both (Non ABS) Right (ABS) Left (ABS) Both (ABS) KNUCKLE, REAR (DISC) ­ REPLACE Right Left Both 2315100 2315200 2315300 -- -- -- 0.8 0.8 1.4 0.8 0.8 1.4 2314400 2314500 2314600 2314700 2314800 2314900 -- -- -- -- -- -- 1.3 1.3 2.0 1.1 1.1 1.7 -- -- -- -- -- -- 14 LINK, REAR TRAILING ­ REPLACE Right Left Both 2315400 2315500 2315600 -- -- -- 0.3 0.3 0.4 0.3 0.3 0.5 15 BRACKET, TRAILING LINK ­ REPLACE Right Left Both 2315700 2315800 2315900 -- -- -- -- -- -- -- -- -- S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 2D ­ 6 SUSPENSION SUSPENSION 2D ­ 7 REAR SUSPENSION ­ REAR AXLE (231) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S -- N 0.6 L 0.6 16 17 CROSSMEMBER, REAR SUSPENSION ­ REPLACE ARM, UPPER ­ REPLACE Right Left Both 2316100 2318100 2318200 2318300 -- -- -- -- -- -- 0.4 0.4 0.6 18 BEARING AND HUB ASSEMBLY, REAR WHEEL ­ REPLACE Right Left Both 2318400 2318500 2318600 -- -- -- 0.5 0.5 0.9 0.5 0.5 0.9 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 2D ­ 8 SUSPENSION SUSPENSION 2D ­ 9 REAR SUSPENSION ­ REAR SHOCK ABSORBER (232) NO. NO OPERATION DESCRIPTION SPRINGS, REAR COIL ­ REPLACE Right Left Both 2320100 2320300 2320400 0.7 0.7 0.8 1.0 1.0 1.6 1.0 1.0 1.6 OPERATION COD

File name en_2e.pdf

SUSPENSION 2E ­ 1 SECTION 2E SUSPENSION (TIRES & WHEEL) 241. WHEELS & WHEEL COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E ­ 3 2E ­ 2 SUSPENSION SUSPENSION 2E ­ 3 TIRES & WHEEL ­ WHEELS & WHEEL COVER (241) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.2 0.2 0.2 N 0.2 0.2 0.2 L 0.2 0.2 0.2 1 2 3 4 COVER, WHEEL (FRONT) ­ REPLACE COVER, WHEEL (RR) ­ REPLACE COVER, WHEEL (ALL) ­ REPLACE WHEEL ­ BALANCE One Two Four 2410100 2410300 2410500 2410700 2410800 2410900 0.4 0.7 1.2 0.4 0.7 1.2 0.4 0.7 1.2 5 WHEEL ­ REPLACE One Two Three Four 2411100 2411110 2411120 2411130 0.6 1.0 1.4 1.8 0.6 1.0 1.4 1.8 0.6 1.0 1.4 1.8 6 TIRE ­ REPLACE One Two Three Four 2411300 2411310 2411320 2411330 0.6 1.0 1.4 1.8 0.6 1.0 1.4 1.8 0.6 1.0 1.4 1.8 7 STEM, VALVE ­ REPLACE One Two Three Four 2411500 2411510 2411520 2411530 2411700 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 8 NUT, WHEEL ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA

File name en_3.pdf

DRIVE LINE / AXLE 3 ­ 1 SECTION 3 DRIVE LINE / AXLE 321. AXLE SHIFT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ­ 3 3 ­ 2 DRIVE LINE / AXLE DRIVE LINE / AXLE 3 ­ 3 DRIVE AXLE ­ AXLE SHIFT PARTS (321) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 BOOT (SEAL), AXLE SHAFT JOINT ­ REPLACE One Two Three Four 3210100 3210200 3210300 3210400 1.3 1.6 2.6 2.9 1.1 1.4 2.4 2.7 1.1 1.4 2.4 2.7 2 JOINT, AXLE SHAFT CV ­ REPLACE One Two Three Four 3210600 3210700 3210800 3210900 1.2 1.5 2.3 2.5 1.0 1.3 2.1 2.3 1.0 1.3 2.1 2.3 3 AXLE ASSEMBLY, FRONT DRIVE ­ REPLACE Right Left Both 3211100 3211200 3211300 3211500 3211600 1.0 1.0 1.7 1.6 -- 0.8 0.8 1.4 1.4 -- 0.8 0.8 1.4 1.4 1.1 4 5 SHAFT, AXLE ­ REPLACE SHAFT AXLE, INTERMEDIATE ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA

File name en_4a.pdf

BRAKE 4A ­ 1 SECTION 4A BRAKE (HYDRAULIC BRAKE) 425. BRAKE PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A ­ 3 428. BRAKE PEDAL & MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A ­ 5 4A ­ 2 BRAKE BRAKE 4A ­ 3 HYDRAULIC BRAKE ­ BRAKE PIPE (425) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 HOSE, BRAKE ­ REPLACE Right Front Left Front Both Front Right Rear Left Rear Both Rear 4250100 4250200 4250300 4250400 4250500 4250600 4250800 4251100 0.4 0.4 0.6 0.5 0.5 0.7 0.5 0.5 0.4 0.4 0.6 0.5 0.5 0.7 1.4 1.4 0.4 0.4 0.6 0.5 0.5 0.7 1.4 1.4 2 3 4 PIPE, REAR BRAKE (RIGHT) ­ REPLACE PIPE, REAR BRAKE (LEFT) ­ REPLACE PIPE, BRAKE ­ REPLACE Master Cylinder to Modulator Valve Front Rear Modulator to Junction Block Right Front Left Front Modulator to Hose Right Front Left Front Junction Block to Wheel Right Front Left Front Modulator to Junction Block Right Rear Left Rear Modulator to Valve Junction Block to Hose Right Rear Junction Block to Junction Block Left Rear Junction Block to Hose Left Rear Hose to Wheel Right Rear Left Rear Modulator to Hose Right Rear 4251500 4251600 4251700 4251800 4251900 4252100 4252200 4252300 4252400 4252500 4252600 4252700 4252800 4252900 4253100 4253200 4253300 0.3 0.3 -- -- 0.6 0.5 -- -- 0.8 0.8 -- -- -- 0.6 0.6 0.6 -- 0.3 0.3 -- -- 0.6 0.5 -- -- 0.8 0.8 -- -- -- 0.6 0.6 0.6 -- 0.3 0.3 -- -- 0.6 0.5 -- -- 0.8 0.8 -- -- -- 0.6 0.6 0.6 -- S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 4A ­ 4 BRAKE BRAKE 4A ­ 5 HYDRAULIC BRAKE ­ BRAKE PEDAL & MOUNT (428) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.4 0.3 0.2 0.2 0.4 N 0.4 0.3 0.2 0.2 0.4 L 0.4 0.3 0.2 0.2 0.4 1 2 3 4 5 PEDAL AND/OR BUSHING, BRAKE ­ REPLACE SPRING, BRAKE PEDAL RETURN ­ REPLACE PAD, BRAKE PEDAL ­ REPLACE SWITCH, STOP LAMP ­ REPLACE SHAFT, BRAKE PEDAL ­ REPLACE 4280100 4280300 4280500 4280700 4280900 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA

File name en_4b.pdf

BRAKE 4B ­ 1 SECTION 4B BRAKE (MASTER CYLINDER & POWER BOOSTER) 431. MASTER CYLINDER & BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B ­ 3 4B ­ 2 BRAKE BRAKE 4B ­ 3 MASTER CYLINDER & POWER BOOSTER ­ MASTER CYLINDER & BOOSTER (431) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 CYLINDER, BRAKE MASTER OH Replace BRAKE SYSTEM ­ BLEED 4310100 4310200 4310400 4310600 4310800 4311100 4311300 4311500 4312100 0.6 0.5 0.4 0.9 0.6 0.2 0.6 1.1 0.2 0.8 0.8 0.5 0.9 0.6 0.2 0.6 1.1 0.2 0.8 0.8 0.4 1.2 0.5 0.2 0.6 1.3 0.2 2 3 4 5 6 7 BOOSTER, VACUUM POWER BRAKE ­ REPLACE RESERVOIR, BRAKE MASTER CYLINDER ­ REPLACE SWITCH AND/OR CAP, RESERVOIR VALVE, BRAKE PROPORTIONER ­ REPLACE CYLINDER ASS'Y, BRAKE MASTER ­ REPLACE HOSE, BRAKE BOOSTER VACUUM ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA

File name en_4d.pdf

BRAKE 4D ­ 1 SECTION 4D BRAKE (FRONT BRAKES) 445. FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D ­ 3 4D ­ 2 BRAKE BRAKE 4D ­ 3 FRONT BRAKES ­ FRONT BRAKE (445) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 PADS, DISC BRAKE (FRONT) ­ REPLACE Right Left Both 4450100 4450110 4450120 0.4 0.4 0.6 0.5 0.5 0.8 0.5 0.5 0.8 2 CALIPER ASSEMBLY ­ REPLACE Right Front Left Front Both Front 4450300 4450400 4450500 4450700 4450900 0.7 0.7 0.9 0.9 0.4 0.7 0.7 1.0 0.9 0.5 0.7 0.7 1.0 0.9 0.5 3 4 5 SEAL KIT, PISTON ­ REPLACE SPRING, PAD ­ REPLACE PIN KIT (UPPER/LOWER) ­ REPLACE Right Left Both 4451100 4451200 4451300 4451500 0.9 0.9 1.1 0.2 0.7 0.7 1.1 0.3 0.7 0.7 1.1 0.3 6 BLEEDER SCREW ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA

File name en_4e.pdf

BRAKE 4E ­ 1 SECTION 4E BRAKE (REAR BRAKES) 456. REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E ­ 3 4E ­ 2 BRAKE BRAKE 4E ­ 3 REAR BRAKES ­ REAR BRAKE (456) NO. NO OPERATION DESCRIPTION DRUM, BRAKE ­ REPLACE (NON ABS) Right Rear Left Rear Both Rear DRUM, BRAKE ­ MACHINING Right Rear Left Rear Both Rear DRUM, BRAKE ­ REPLACE (ABS) Right Rear Left Rear Both Rear 4560500 4560600 4560700 0.4 0.4 0.6 0.4 0.4 0.6 -- -- -- 4560400 4560410 4560420 0.3 0.3 0.5 0.3 0.3 0.5 -- -- -- 4560100 4560200 4560300 0.6 0.6 0.9 0.6 0.6 0.9 -- -- -- OPERATION CODE MODEL S N L 1 2 SHOES AND LININGS, DRUM BRAKE ­ REPLACE (NON ABS) Both Rear Right Rear Left Rear SHOES AND LININGS, DRUM BRAKE ­ REPLACE (ABS) Both Rear Right Rear Left Rear 4561100 4561110 4561120 0.9 0.6 0.6 0.9 0.6 0.6 -- -- -- 4560900 4560910 4560920 1.2 0.7 0.7 1.2 0.7 0.7 -- -- -- 3 SPRINGS, SHOE RETURN AND/OR HOLD DOWN ­ REPLACE (NON ABS) Right Rear Left Rear Both Rear SPRINGS, SHOE RETURN AND/OR HOLD DOWN ­ REPLACE (ABS) Right Rear Left Rear Both Rear 4561700 4561800 4561900 0.6 0.6 0.8 0.6 0.6 0.8 -- -- -- 4561300 4561400 4561500 0.7 0.7 1.2 0.7 0.7 1.2 0.7 0.7 1.2 4 SELF ADJUSTER, BRAKE ­ REPLACE (NON ABS) Right Rear Left Rear Both Rear 4562100 4562200 4562300 0.6 0.6 1.2 0.6 0.6 1.2 0.6 0.6 1.2 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 4E ­ 4 BRAKE BRAKE 4E ­ 5 REAR BRAKES ­ REAR BRAKE (456) NO. NO OPERATION DESCRIPTION SELF ADJUSTER, BRAKE ­ REPLACE (ABS) Right Rear Left Rear Both Rear 4562500 4562600 4562700 0.5 0.5 0.8 0.5 0.5 0.8 -- -- -- OPERATION CODE MODEL S N L 5 CYLINDER, BRAKE WHEEL ­ REPLACE (NON ABS) Right Rear Left Rear Both Rear CYLINDER, BRAKE WHEEL ­ REPLACE (ABS) Right Rear Left Rear Both Rear 4563400 4563500 4563600 0.9 0.9 1.4 0.9 0.9 1.4 -- -- -- 4562900 4563100 4563200 1.1 1.1 1.6 1.1 1.1 1.6 1.1 1.1 1.6 6 PLATE, BRAKE BACKING ­ REPLACE Right Rear Left Rear Both Rear 4563800 4563900 4564100 1.0 1.0 1.6 1.0 1.0 1.6 1.0 1.0 1.6 7 SLIDING CALIPER, REAR ­ REPLACE Right Left Both SLIDING CALIPER, REAR ­ OH Right Left Both 4564700 4564800 4564900 -- -- -- 1.0 1.0 1.6 1.0 1.0 1.6 4564300 4564400 4564500 -- -- -- 0.7 0.7 0.9 0.7 0.7 0.9 8 DISC, REAR BRAKE ­ REPLACE Right Left Both 4565100 4565200 4565300 -- -- -- 0.6 0.6 0.8 0.6 0.6 0.8 9 PIN, CALIPER GUIDE (UPPER/LOWER) ­ REPLACE Right Left Both 4565500 4565600 4565700 4565900 4566100 -- -- -- -- 0.2 0.9 0.9 1.1 0.9 0.2 0.9 0.9 1.1 0.9 0.2 10 11 12 PISTON, CALIPER ­ REPLACE BLEEDER SCREW ­ REPLACE PAD, REAR BRAKE ­ REPLACE Right Left Both 4566300 4566400 4566500 -- -- -- 0.4 0.4 0.6 0.4 0.4 0.6 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 4E ­ 6 BRAKE BRAKE 4E ­ 7 REAR BRAKES ­ REAR BRAKE (456) NO. NO OPERATION DESCRIPTION HUB, REAR ­ REPLACE Right Left Both 4566700 4566800 4566900 -- -- -- 0.5 0.5 0.9 0.5 0.5 0.9 OPERATION CODE MODEL S N L 13 14 STUD, REAR ­ REPLACE Right Left Both 4567100 4567200 4567300 -- --

File name en_4f.pdf

BRAKE 4F ­ 1 SECTION 4F BRAKE (ANTI­LOCK BRAKES SYSTEM) 462. ANTI­LOCK BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F ­ 3 4F ­ 2 BRAKE BRAKE 4F ­ 3 ANTI­LOCK BRAKES SYSTEM ­ ANTI­LOCK BRAKE SYSTEM (462) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 SENSOR, WHEEL SPEED ­ REPLACE Right Front Left Front Both Front Right Rear Left Rear Both Rear 4620100 4620200 4620300 4620400 4620500 4620600 4620800 0.3 0.3 0.4 0.6 0.6 0.7 0.7 0.3 0.3 0.4 0.5 0.5 0.9 0.9 0.5 0.5 0.9 0.5 0.5 0.9 1.3 2 HYDRAULIC MODULATOR ASSEMBLY (ABS) ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA

File name en_4g.pdf

BRAKE 4G ­ 1 SECTION 4G BRAKE (PARKING BRAKES) 478. PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G ­ 3 4G ­ 2 BRAKE BRAKE 4G ­ 3 PARKING BRAKES ­ PARKING BRAKE (478) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.3 0.2 0.4 N 0.3 0.2 0.4 L 0.3 0.2 0.4 PARKING BRAKE ­ ADJUST 4780100 4780200 4780300 1 2 3 GRIP, PARKING BRAKE HANDLE ­ REPLACE CONTROL ASSEMBLY, PARKING BRAKE ­ REPLACE CABLE, PARKING BRAKE ­ REPLACE Front Rear, Both 4780500 4780600 4780800 4781100 4781300 0.5 0.8 0.2 -- -- 0.5 0.7 0.5 0.6 0.8 -- 0.7 0.5 0.6 0.8 4 5 6 SWITCH, PARK BRAKE LAMP SHOE, PARKING BRAKE ­ REPLACE SHOE ASS'Y, PARKING BRAKE ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA

File name en_4j2_0a.pdf

PERSONAL INJURY CAUTION Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as for the personal safety of the person doing the repair. There are many variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skills of the people doing the work. This manual cannot possibly anticipate all such variations and provide advice or precautions for each. Anyone who deviates from the instructions provided in this manual must ensure their own safety and preserve the safety and integrity of the vehicle. The following list contains general precautions that should always be followed while working on a vehicle. D Safety stands are required whenever a procedure calls for underbody work. D Do not smoke when you work on a vehicle. D To prevent serious burns, do not touch any hot metal parts. D Set the parking brake when you work on the vehicle. D Turn the ignition switch OFF unless a procedure states otherwise. D The engine may operate only in a well-ventilated area. D Avoid moving parts when the engine is running. D Safety glasses must be worn for eye protection. i 00000000 We support voluntary technician certification through the National Institute for Automotive Service Excellence. ii . NUBIRA/LACETTI Service Manual (MY2004) FOREWORD This manual includes procedures for maintenance, adjustment, service operations, and removal and installation of components for the NUBIRA/LACETTI vehicle. When reference is made in this manual to a brand name, number, or specific tool, an equivalent product may be used in place of the recommended item. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication approval. The right is reserved to make changes at any time without notice. GM Daewoo Auto & Technology Co., Ltd. Service Engineering Team 199­1 Cheong Cheon­Dong, Bupyung­Gu, Incheon, Korea Tel: 82-32-520­2737, 5752 Fax: 82-32-520­4808 E-mail: [email protected] [email protected] GM Daewoo Auto & Technology Co., Ltd. All Rights Reserved No part of this publication may be reproduced, stored in any retrieval system or transmitted, in any form or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of GM Daewoo Auto & Technology Co., Ltd. Printed in the Republic of Korea iii iv TABLE OF CONTENTS Section 0B Section 1 Section 1A Section 1C1 Section 1C2 Section 1D Section 1E Section 1F Section 1G Section 2 Section 2A Section 2B Section 2C Section 2D Section 2E Section 3 Section 3A Section 3B Section 4 Section 4A Section 4B Section 4C Section 4D Section 4E1 Section 4E2 Section 4F Section 4G Section 5 Section 5A1 Section 5A2 Section 5B Section 5C Section 6 Section 6A Section 6B General Information Engine General Engine Information 1.4L/1.6L DOHC Engine Mechanica

File name en_4j2_0b.pdf

SECTION : 0B GENERAL INFORMATION TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle Dimensions and Weights . . . . . . . . . . . . Standard Bolt Specifications . . . . . . . . . . . . . . . . 0B­1 0B­1 0B­6 0B­8 At Each Fuel Fill . . . . . . . . . . . . . . . . . . . . . . . . . At least Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . At least Twice a Year . . . . . . . . . . . . . . . . . . . . . Each Time The Oil is Changed . . . . . . . . . . . . . 0B­12 0B­12 0B­12 0B­13 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 0B­9 MAINTENANCE AND LUBRICATION . . . . . . . . . . 0B­9 Normal Vehicle Use . . . . . . . . . . . . . . . . . . . . . . . 0B­9 Explanation of Scheduled Maintenance Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B­9 Scheduled Maintenance Charts . . . . . . . . . . . . 0B­10 OWNER INSPECTIONS AND SERVICES . . . . . 0B­12 Whle Operating The Vehicle . . . . . . . . . . . . . . . 0B­12 At Least Annually . . . . . . . . . . . . . . . . . . . . . . . . 0B­13 Recommended Fluids and Lubricants . . . . . . . 0B­14 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B­15 General Repair Instructions . . . . . . . . . . . . . . . . 0B­15 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . 0B­16 Vehicle and Component Identification . . . . . . . 0B­16 Vehicle Lifting Procedures . . . . . . . . . . . . . . . . . 0B­21 SPECIFICATIONS TECHNICAL DATA Performance ­ Manual Transaxle Application Maximum Speed Minimum Turning Radius 1.4L DOHC 175 km/h (108.7 mph) 5.2 m (17.1 ft) 1.6L DOHC 187 km/h (116.2 mph) І 1.8L DOHC 194 km/h (120.5 mph) І Performance ­ Automatic Transaxle Application Maximum Speed Minimum Turning Radius 1.4L DOHC ­ ­ 1.6L DOHC 175 km/h (108.7 mph) 5.2 m (17.1 ft) 1.8L DOHC 184 km/h (114.3 mph) І 0B ­ 2IGENERAL INFORMATION Engine Application Engine Type Bore Stroke Total Displacement Compression Ratio Maximum Power Maximum Torque 1.4L DOHC Dual Overhead Cam L­4 77.9 mm (3.06 in.) 73.4 mm (2.89 in.) 1399 cm3 (85.4 in.3) 9.5 : 1 69.5 kw (93.2 hp) (at 6,300 rpm) 131 N_m (96.6 lb­ft) (at 4,400 rpm) 1.6L DOHC І 79 mm (3.11 in.) 81.5 mm (3.21 in.) 1598 cm3 (97.5 in.3) І 80 kw (107.3 hp) (at 5,800 rpm) 150 NSm (110.6 lb­ft) (at 4,000 rpm) 1.8L DOHC І 81.6 mm (3.21 in.) 86 mm (3.38 in.) 1799 cm3 (109.7 in3) 9.8 : 1 90 kw (120.7 hp) (at 5,800 rpm) 165 NSm (121.7 lb­ft) (at 4,000 rpm) Ignition System Application Ignition Type Ignition Timing (BTDC) Ignition Sequence Spark Plug Gap Spark Plug Maker Spark Plug Type 1.4L DOHC Direct Ignition System 4° 1­3­4­2 1.0 ~ 1.1 mm (0.039 ~ 0.043 in.) Woojin BKR6E­11 1.6L DOHC І 5° І І І І 1.8L DOHC І І І 0.9 ~ 1.1 mm (0.035 ~ 0.043 in.) Boach FLR8LDCU Clutch Application Type Outside Diameter Inside Diameter Thickness Fluid 1.4L DOHC Single Dry Plate 215 mm (8.5 in.) 145 mm (5.7 in.) 8.4 mm

File name en_4j2_1.pdf

SECTION 1 HOW TO USE ELECTRICAL WIRING DIAGRAM CONTENTS 1. 2. 3. 4. 5. HOW TO READ ELECTRICAL WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1­2 CIRCUIT IDENTIFICATION SYMBOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1­3 FUNCTION OF POWER SUPPLY LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1­3 WIRING HARNESS COLOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1­3 HOW TO CHECK TERMINAL NUMBER OF CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1­3 1­2WHOW TO USE ELECTRICAL WIRING DIAGRAM 1. HOW TO READ ELECTRIC WIRING DIAGRAM 1) CONTENTS OF ELECTRICAL WIRING DIAGRAM (CIRCUIT) POSITION A B " " " EXPLANATION Upper horizontal lines : Power supply lines Power supply lines : 30, 15, 15A, 15C, 58 Ef20 or F2 : Fuse Number S Ef20 : Fuse No #20 in engine room fuse box S F2 : Fuse No #2 in passenger room fuse box Connector (C101~C902) S Connector No C203 terminal No1 S Refer to Major Connector Position (Section 2) S201 : Splice pack (S101~S303) S Refer to Major Splice Pack Position (Section2) Internal circuit of component (Relay) (Component Name and Terminal Number) Internal circuit of component (switch) (Component Name, Terminal Number and Connecting Wiring Circuit) Wiring Harness Color S Refer to Wiring Harness Color Abbreviation Lower horizontal line : Ground line S Ground position(G101~G401) S B : Body Ground S Refer to Major Ground Position (Section2) C " D E F G H " " " " " HOW TO USE ELECTRICAL WIRING DIAGRAMW1­3 2. CIRCUIT IDENTIFICATION SYMBOL IDENTIFICATION SYMBOL C D Ef F G S Connector Diode Fuse in engine room fuse box Fuse in passenger room fuse box Ground Splice pack(Junction connector) 5. HOW TO CHECK TERMINAL NUMBER OF CONNECTOR MEANING " Terminal number is given based on Female Terminal Connector ex) Terminal Number 4 of C901 connection 3. FUNCTION OF POWER SUPPLY LINE (NUMBER) Power supply No 15 15A 15C 30 31 58 Power supply condition Battery Voltage(B+) supply in Ignition Switch "ON" and "ST" (IGN 1) Battery Voltage(B+) supply in Ignition Switch "ON" (IGN 2) Battery Voltage(B+) supply in Ignition Switch "ON" and "ACC" Battery Voltage(B+) supply directly regardless of Ignition Switch Ground connected to battery( ) Battery Voltage(B+) supply in Head Lamp Switch 1st and 2nd step (Illumination circuit) 4. WIRING HARNESS COLOR IDENTIFICATION Abbreviation Br G V P W Or Lg Color Brown Green Violet Pink White Orange Light Green Abbreviation Sb R L Y Gr B Color Sky Blue Red Blue Yellow Gray Black

File name en_4j2_1a.pdf

SECTION : 1A GENERAL ENGINE INFORMATION TABLE OF CONTENTS DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Leak Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 1A­1 1A­1 1A­2 1A­3 Noise Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1A­8 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1A­11 Cleanliness and Care . . . . . . . . . . . . . . . . . . . . . 1A­11 On­Engine Service . . . . . . . . . . . . . . . . . . . . . . . 1A­11 4. The lowest reading should not be less than 70% of the highest reading. The compression gauge reading should not be less than 689 kPa (100 psi) for any of the cylinders. Examine the gauge readings obtained after the four "puffs" per cylinder are obtained from cranking the starter motor. The readings are explained in the following descriptions: Normal Condition ­ Compression builds up quickly and evenly to the specified compression on each cylinder. Piston Rings Faulty ­ Compression is low on the first stroke and tends to build up on following strokes, but the compression pressure does not reach normal. The compression pressure improves considerably with the addition of oil into the cylinder. Valves Faulty ­ Low compression pressure on the first stroke. The compression pressure does not tend to build up on the following strokes. The compression pressure does not improve much with the addition of oil into the cylinder. Knock Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1A­4 DIAGNOSIS COMPRESSION TEST Important : Disconnect the Crankshaft Position (CKP) Sensor connector to disable the fuel and the ignition systems. Test the compression pressure for each cylinder. Low compression pressure may be the fault of the valves or the pistons. The following conditions should be considered when you check the cylinder compression: S The engine should be at normal operating temperature. S The throttle must be wide open. S All the spark plugs should be removed. S The battery must be at or near full charge. 1. Place approximately three squirts of oil from a plunger­ type oiler into each spark plug port. 2. Insert the engine compression gauge into each spark plug port. 3. Crank test each cylinder with four to five compression strokes using the starter motor. 5. S S S 1A ­ 2IGENERAL ENGINE INFORMATION OIL PRESSURE TEST Step 1 2 3 Action Is the oil pressure warning lamp on? Check the oil level in the crankcase. Is the oil level low? Add oil so that the oil level is up to the fullmark on the indicator. Is the repair complete? Check the idle speed. Is the idle speed below the specified value ? Increase the idle speed. Is the speed increased? Inspect the oil pressure switch. Is the oil pressure switch incorrect or malfunctioning? Install a new oil pressure switch. Is the repair complete? Inspect the oil pressure gauge. Is th

File name en_4j2_1c1.pdf

SECTION : 1C1 1.4L/1.6L DOHC ENGINE MECHANICAL CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­2 Engine Specifications . . . . . . . . . . . . . . . . . . . . . 1C1­2 Fastener Tightening Specifcations . . . . . . . . . . 1C1­5 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­7 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . 1C1­7 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . 1C1­9 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­9 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­10 Intake & Exhaust Manifold . . . . . . . . . . . . . . . . 1C1­12 Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­13 Engine Mounting . . . . . . . . . . . . . . . . . . . . . . . . 1C1­14 MAINTENANCE AND REPAIR . . . . . . . . . . . . . 1C1­15 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 1C1­15 Engine Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­15 Camshaft Cover . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­15 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­16 Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . 1C1­20 Cylinder Head and Gasket . . . . . . . . . . . . . . . . 1C1­21 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­29 Timing Belt Check and Adjust . . . . . . . . . . . . . 1C1­30 Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­34 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Gears . . . . . . . . . . . . . . . . . . . . . . . . . Rear Timing Belt Cover . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistons and Rods . . . . . . . . . . . . . . . . . . . . . . . . UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­38 1C1­40 1C1­43 1C1­45 1C1­46 1C1­48 1C1­53 1C1­58 Cylinder Head and Valve Train Components . 1C1­58 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­65 Crankshaft Bearing and Connecting Rod Beadings ­ Gauging Plastics . . . . . . . . . . . . 1C1­74 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head and Gasket . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C1­77 1C1­7

File name en_4j2_1c2.pdf

SECTION : 1C2 1.8L DOHC ENGINE MECHANICAL CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1C2­2 Engine Specifications . . . . . . . . . . . . . . . . . . . . . 1C2­2 Fastener Tightening Specifcations . . . . . . . . . . 1C2­4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 1C2­6 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . 1C2­6 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . 1C2­8 Upper End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C2­8 Lower End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C2­10 MAINTENANCE AND REPAIR . . . . . . . . . . . . . 1C2­12 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 1C2­12 Camshaft Cover . . . . . . . . . . . . . . . . . . . . . . . . . 1C2­12 Cylinder Head and Gasket . . . . . . . . . . . . . . . . 1C2­13 Camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C2­22 Timing Belt Check and Adjust . . . . . . . . . . . . . 1C2­24 Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C2­28 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C2­32 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C2­33 Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C2­37 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 1C2­38 Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Gears . . . . . . . . . . . . . . . . . . . . . . . . . Rear Timing Belt Cover . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistions and Rods . . . . . . . . . . . . . . . . . . . . . . . UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head and Valve Train Components . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C2­41 1C2­43 1C2­44 1C2­46 1C2­51 1C2­56 1C2­56 1C2­63 Crankshaft Bearing and Connecting Rod Beadings ­ Gauging Plastics . . . . . . . . . . . . 1C2­72 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C2­75 Cylinder Head and Gasket . . . . . . . . . . . . . . . . 1C2­75 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C2­75 1C2­75 1C2­75 1C2­75 Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . 1C2­75 Intake Manifold . . . . . . . . . . . . . .

File name en_4j2_1d.pdf

SECTION : 1D ENGINE COOLING CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1D­2 Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D­2 Fastener Tightening Specifications . . . . . . . . . . . 1D­2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D­2 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 1D­2 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D­3 Thermostat Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D­3 Surge Tank Cap Test . . . . . . . . . . . . . . . . . . . . . . . 1D­3 Cooling System Diagnosis . . . . . . . . . . . . . . . . . . 1D­4 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 1D­5 Radiator/Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D­5 Water Pump/Thermostat (1.4L/1.6L DOHC) . . . 1D­6 Water Pump/Thermostat (1.8L DOHC) . . . . . . . 1D­7 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 1D­8 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 1D­8 Draining and Refilling the Cooling System . . . . . 1D­8 Thermostat (1.4L/1.6L DOHC) . . . . . . . . . . . . . . . 1D­9 Thermostat (1.8L DOHC) . . . . . . . . . . . . . . . . . . 1D­10 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D­11 Electric Cooling Fan ­ Main or Auxiliary . . . . . . 1D­13 Surge Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D­14 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D­16 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D­18 General Description . . . . . . . . . . . . . . . . . . . . . . . 1D­18 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D­18 Surge Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . 1D­18 1D­18 1D­18 1D­19 Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . 1D­19 1D ­ 2IENGINE COOLING SPECIFICATIONS CAPACITY Application Coolant in the Cooling System (1.4L/1.6L DOHC MPFI System) Coolant in the Cooling System (1.8L DOHC MPFI System) Description 7.0L (1.85 gal) for automatic transaxle 7.0L (1.85 gal) for manual transaxle 7.1L (1.88 gal) for automatic transaxle 7.1L (1.88 gal) for manual transaxle FASTENER TIGHTENING SPECIFICATIONS Application Water Pump Mounting Bolts (1.4L/1.6L DOHC) Water Pump Mounting Bolts (1.8L DOHC) Fan Assembly Mounting

File name en_4j2_1e.pdf

SECTION : 1E ENGINE ELECTRICAL CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1E­2 Starter Specifications . . . . . . . . . . . . . . . . . . . . . . 1E­2 Battery Specifications . . . . . . . . . . . . . . . . . . . . . . 1E­2 Fastener Tightening Specifications . . . . . . . . . . 1E­3 SCHEMATIC AND ROUTING DIAGRAMS . . . . . 1E­4 Startimg System . . . . . . . . . . . . . . . . . . . . . . . . . . 1E­4 Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . 1E­5 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E­6 No Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E­6 Starter Motor Noise . . . . . . . . . . . . . . . . . . . . . . . 1E­9 Battery Load Test . . . . . . . . . . . . . . . . . . . . . . . . . 1E­9 Genrator Output Test . . . . . . . . . . . . . . . . . . . . . 1E­10 Generator System Check . . . . . . . . . . . . . . . . . 1E­10 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 1E­11 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 1E­11 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E­11 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E­14 Battery and Battery Tray . . . . . . . . . . . . . . . . . . . 1E­15 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E­17 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E­17 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E­25 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reserve Capacity . . . . . . . . . . . . . . . . . . . . . . . . . 1E­30 1E­30 1E­30 1E­30 Cold Cranking Amperage . . . . . . . . . . . . . . . . . . 1E­30 Built­In Hydrometer . . . . . . . . . . . . . . . . . . . . . . . 1E­30 Charging Procedure . . . . . . . . . . . . . . . . . . . . . . . 1E­30 Charging Time Required . . . . . . . . . . . . . . . . . . . Charging a Completely Discharged Battery (OFF the Vehicle) . . . . . . . . . . . . . . . . . . . . . . . Jump Starting Procedure . . . . . . . . . . . . . . . . . . Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging System . . . . . . . . . . . . . . . . . . . . . . . . . 1E­31 1E­31 1E­31 1E­32 1E­32 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E­32 Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . 1E­32 1E ­ 2IENGINE ELECTRICAL SP

File name en_4j2_1f.pdf

SECTION : 1F ENGINE CONTROLS CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit o r w hen a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1F­6 Engine Data Display Tables . . . . . . . . . . . . . . . . . 1F­6 Engine Data Display Table Definitions . . . . . . . . 1F­7 Fastener Tightening Specifications . . . . . . . . . 1F­10 Fuel System Specifications . . . . . . . . . . . . . . . . . 1F­11 Temperature Vs Resistance . . . . . . . . . . . . . . . . 1F­11 SCHEMATIC AND ROUTING DIAGRAMS . . . . 1F­12 ECM Wiring Diagram (1.4L/1.6L DOHC ­ 1 OF 6) . . . . . . . . . . . . . . 1F­12 ECM Wiring Diagram (1.4L/1.6L DOHC ­ 2 OF 6) . . . . . . . . . . . . . . 1F­13 ECM Wiring Diagram (1.4L/1.6L DOHC ­ 3 OF 6) . . . . . . . . . . . . . . 1F­14 ECM Wiring Diagram (1.4L/1.6L DOHC ­ 4 OF 6) . . . . . . . . . . . . . . 1F­15 ECM Wiring Diagram (1.4L/1.6L DOHC ­ 5 OF 6) . . . . . . . . . . . . . . 1F­16 ECM Wiring Diagram (1.4L/1.6L DOHC ­ 6 OF 6) . . . . . . . . . . . . . . 1F­17 ECM Wiring Diagram (1.8L DOHC ­ 1 OF 6) . 1F­18 ECM Wiring Diagram (1.8L DOHC ­ 2 OF 6) . 1F­19 ECM Wiring Diagram (1.8L DOHC ­ 3 OF 6) . 1F­20 ECM Wiring Diagram (1.8L DOHC ­ 4 OF 6) . 1F­21 ECM Wiring Diagram (1.8L DOHC ­ 5 OF 6) . 1F­22 ECM Wiring Diagram (1.8L DOHC ­ 6 OF 6) . 1F­23 Connector End View . . . . . . . . . . . . . . . . . . . . . . 1F­24 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . 1F­28 Component Locator (1.4L/1.6L DOHC) . . . . . . 1F­28 Component Locator (1.8L DOHC) . . . . . . . . . . . 1F­29 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F­30 SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 1F­30 Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F­30 Idle Learn Procedure . . . . . . . . . . . . . . . . . . . . . . 1F­30 TEC (Tooth Error Correction) Learn Procedure 1F­31 ON­Board Diagnostic (EOBD) System Check (1.4L/1.6L DOHC) . . . . . . . . . . . . . . . . . . . . . . . 1F­32 ON­Board Diagnostic (EOBD) System Check (1.8L DOHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F­34 Multiple ECM Informationn Sensor Dtcs Set . . 1F­36 Engine Cranks But Will Not Run (1.4L/1.6L DOHC) . . . . . . . . . . . . . . . . . . . . . . . 1F­40 Engine Cranks But Will Not Run (1.8L DOHC) 1F­47 No Malfunction Indicator Lamp ( 1.4L/1.6L DOHC) . . . . . . . . . . . . . . . . . . . . . . . 1F­54 No Malfunction Indicator Lamp (1.8L DOHC) . 1F­56 Malfunction Indicator Lamp On Steady (1.4L/1.6L DOHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F­58 Malfunction Indicator Lamp On Steady (1.8L DOHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F­60 Fuel System Diagnosis . . . . .

File name en_4j2_1g.pdf

SECTION : 1G ENGINE EXHAUST TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1G­1 Fastener Tightening Specifications . . . . . . . . . . 1G­1 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 1G­2 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 1G­2 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 1G­3 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 1G­3 Catalytic Converter . . . . . . . . . . . . . . . . . . . . . . . . 1G­3 Exhaust Front Pipe . . . . . . . . . . . . . . . . . . . . . . . . 1G­4 Muffler ­ Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G­6 Muffler ­ Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G­7 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Catalytic Converters . . . . . . . . . . . . . . . . . . . . . . . 1G­9 1G­9 1G­9 1G­9 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Catalytic Converter­to­Exhaust Manifold Nuts Exhaust Front Pipe­to­Catalytic Converter Nuts Exhaust Manifold Cover Bolts Exhaust Front Pip­to­Front Muffler Front Muffler­to­Rear Muffler Nuts Front Bracket­to­Cylinder Block Bolt Catalytic Converter­to­Underbody Shield Front Muffler­to­Underbody Shield Rear Muffler­to­Underbody Shield NSm 40 40 15 30 30 50 2.5 2.5 2.5 Lb­Ft 37 30 11 22 22 37 ­ ­ ­ Lb­In ­ ­ ­ ­ ­ ­ 22 22 22 1G ­ 2IENGINE EXHAUST COMPONENT LOCATOR EXHAUST SYSTEM 1. 2. 3. 4. 5. 6. 7. Exhaust Rear Muffler Muffler Gasket Exhaust Front Muffler Muffler Gasket Exhaust Front Pipe (1.8D) Exhaust Front Pipe (1.6D) Catalytic Converter 8. 9. 10. 11. 12. 13. Exhaust Pipe Front Gasket Exhaust Front Pipe Gasket Exhaust Manifold Catalytic Converter Protective Shield Front Muffler Protective Shield Rear Muffler Protective Shield DAEWOO V­121 BL4 ENGINE EXHAUST 1G ­ 3 MAINTENANCE AND REPAIR ON­VEHICLE SERVICE CATALYTIC CONVERTER Removal Procedure 1. 2. 3. Disconnect the negative battery cable. Disconnect the oxygen sensor electrical connector. Remove the exhaust manifold cover with the bolts. 4. Remove the catalytic converter upper flange nuts. Important : The nuts and the stud may unscrew as a unit because of the high temperature associated with the exhast manifold, but they can be re­used as such 5. 6. 7. 8. 9. Remove the exhaust front pipe mounting bracket bolt. Remove the nuts from the exhaust front pipe­to­ catalytic converter flange. Remove the catalytic converter and the gasket. Clean the sealing surfaces on the exhaust front pipe flange and the exhaust manifold. Check the exhaust front pipe and the exhaust manifold for holes, damage, open seams or other deterioration which could permit exhaust fumes to seep into the passenger compartment. DAEWOO V­121 BL4 1G ­ 4IENGINE EXHAUST Installation Procedure 1. Install the cat

File name en_4j2_2.pdf

SECTION 2 POSITION OF CONNECTORS AND GROUNDS CONTENTS 1. 2. CONNECTOR, GROUND AND SPLICE PACK INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2­2 WIRING HARNESS & CONNECTOR & GROUND LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2­4 2­2WPOSITION OF CONNECTORS AND GROUNDS 1.CONNECTOR, GROUND AND SPLICE PACK INFORMATION 1) WIRING HARNESS, GROUND & SPLICE PACK LOCATION POSITION OF CONNECTORS AND GROUNDSW2­3 2) CONNECTOR INFORMATION Connector Number C101 C102 C103 C104 C105 C106 C107 C108 C109 C110 C111 C112 C113 C201 C202 C204 C204 C206 C207 C208 C209 C210 C301 C302 C351 C361 C371 C381 C401 (N/B) C401 (H/B) C402 C403 C404 C405 C406 3) GROUND INFORMATION Connecting Wiring Harness Body Body Engine Front Body Engine ABS Body Engine ABS ABS Engine Fuse Block Engine Fuse Block Engine Fuse Block Engine Fuse Block Engine Fuse Block Engine Fuse Block Engine Fuse Block Engine Front Body Front Terminal Number 21 Pin 11 Pin 10 Pin 24 Pin 4 Pin 20 Pin 2 Pin 24 Pin 4 Pin 12 Pin 2 Pin 2 Pin 16 Pin 76 Pin 89 Pin 8 Pin 14 Pin 22 Pin 6 Pin 15 Pin 20 Pin 6 Pin 8 Pin 4 Pin 33 Pin 33 Pin 12 Pin 12 Pin 8 Pin 6 Pin 6 Pin 6 Pin 8 Pin 8 Pin 6 Pin Color White White White White White White White Black White White Black Black Black Black White White White White White White Black White White Black Gray Gray White White White White White White White White White Connector Position Engine Fuse Block Engine Fuse Block Engine Fuse Block Engine Fuse Block Engine Fuse Block Engine Fuse Block Engine Fuse Block Left Engine Fuse Block Under Engine Fuse Block Below Engine Fuse Block Below Engine Fuse Block Center Cross Member Panel Behind ECM Bracket I.P Fuse Block Left CO­Driver Leg Room Left CO­Driver Leg Room Left CO­Driver Leg Room Upper Driver Leg Room Upper Left Driver Leg Room Behind Glove Box Between Heater Core and Evaporator Core Below Console Box Front SDM Center Rear Cross Member Under CO­Driver A Pillar Under Driver A Pillar Under Left B Pillar Under Right B Pillar Inside Right Trunk Side Cover Inside Right Trunk Side Cover Inside Right Trunk Side Cover Inside Left C Pillar Inside Left C Pillar Beside Left Rear Wiper Motor Beside Left Rear Wiper Motor Ground Number G101 G102 G103 G104 G105 G106 G107 G201 G202 G203 G205 G301 G302 G303 G401 G402 Wiring Harness Front Front Battery Engine Battery ABS Engine(MR­140/HV­240) I.P Air Bag I.P Roof Body Body Body Trunk T/Gate. EXT. Ground Position Behind Left Head Lamp Behind Right Head Lamp Left Battery Under Start Motor Under Start Motor Below EBCM Under Start Motor Left I/P Fuse Block Behind Left Audio Bracket Behind Left Audio Bracket Upper Driver Leg Room Below Driver Cross Member Floor Panel Below Left C Pillar Below Left CO­Driver Leg Room Center Trunk Lower Back Panel Inside Driver C Pillar Front ­ Horn Body I.P I.P Roof Roof I.P Front I.P Fuse Block Body Body (W/O Rain Sensor) Body(W/ Rain Sensor) TCM I.P 4) SPLICE PACK INFORM

File name en_4j2_2a.pdf

SECTION : 2A SUSPENSION DIAGNOSIS TABLE OF CONTENTS DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A­1 General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 2A­1 Torque Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A­5 Tapered Roller Bearing . . . . . . . . . . . . . . . . . . . . . 2A­6 DIAGNOSIS GENERAL DIAGNOSIS Problems in the steering, the suspension, the tires, and the wheels involve several systems. Consider all systems when diagnosing a complaint. Some problems, such as abnormal or excessive tire wear and scuffed tires, may be the result of hard driving. Always road test the vehicle first. If possible, do this road test with the customer. Proceed with the following preliminary checks. Correct any substandard conditions. Preliminary Checks Checks Inspect the tires for improper pressure and uneven wear. Inspect the joint from the steering column to the steering gear for loose connections or wear. Inspect the front and the rear suspension, the steering gear, and the linkage for loose or damaged parts. Action Inflate the tires to the proper pressure. Tighten the intermediate shaft pinch bolts. Replace the intermediate shaft as needed. Tighten the front and the rear suspension. Tighten the steering gear mounting bracket bolts. Tighten the coupling flange pinch bolts. Replace the front and the rear suspension as needed. Replace the steering gear as needed. Replace the intermediate shaft as needed. Perform a free runout test. Match­mount the tires. Balance the wheels. Replace the wheels. Replace the wheel bearings. Tighten the power steering pump serpentine belt. Repair any leaks. Perform a power steering gear test. Add power steering fluid. Inspect for out­of­round tires. Inspect for out­of­balance tires, bent wheels, and worn or loose wheel bearings. Check the power steering pump serpentine belt tension. Inspect the power steering system for leaks. Check the power steering fluid level. Car Lead/Pull Checks Inspect for mismatched or uneven tires. Inspect for a broken or a sagging spring. Inspect for a radial tire lateral force. Check the front­wheel alignment. Inspect for an off­center steering gear. Inspect for front­brake dragging. Replace the tires. Replace the spring. Check the wheel alignment. Switch the wheels. Replace the tires as needed. Align the front wheels. Reseat the pinion valve assembly. Replace the pinion valve assembly as needed. Adjust the front brakes. Action 2A ­ 2ISUSPENSION DIAGNOSIS Abnormal or Excessive Tire Wear Checks Check the front­wheel and the rear­wheel alignment. Inspect for excessive toe on the front and the rear wheels. Inspect for a broken or a sagging spring. Inspect for out­of­balance tires. Inspect for worn strut dampeners. Check for a failure to rotate tires. Check for an overloaded vehicle. Inspect for low tire inflation. Action Align the front and the rear wheels. Adjust the toe on the front and the rear wheels. Replace the spring. Bala

File name en_4j2_2b.pdf

SECTION : 2B WHEEL ALIGNMENT TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2B­1 Wheel Alignment Specifications . . . . . . . . . . . . . . 2B­1 Fastener Tightening Specifications . . . . . . . . . . . 2B­1 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B­2 Tire Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B­2 Radial Tire Lead/Pull . . . . . . . . . . . . . . . . . . . . . . . 2B­3 Vibration Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 2B­5 Preliminary Inspection . . . . . . . . . . . . . . . . . . . . . . 2B­8 Front Toe Adjustment . . . . . . . . . . . . . . . . . . . . . . 2B­8 Front Camber and Caster Check . . . . . . . . . . . . . 2B­8 Rear Camber Check . . . . . . . . . . . . . . . . . . . . . . . 2B­8 Rear Toe Adjustment . . . . . . . . . . . . . . . . . . . . . . . 2B­9 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B­10 Four Wheel Alignment . . . . . . . . . . . . . . . . . . . . . 2B­10 Toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Axis Inclination . . . . . . . . . . . . . . . . . . . 2B­10 2B­10 2B­10 2B­10 Included Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B­10 Scrub Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B­10 Setback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B­10 Turning Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B­10 SPECIFICATIONS WHEEL ALIGNMENT SPECIFICATIONS Application Camber Caster Toe­in (No person, full tank) Front ­0°20' ± 45' 4°00' ± 45' 0°00 ± 10' Rear ­1°00' ± 45' ­ 0°12' ± 10' FASTENER TIGHTENING SPECIFICATIONS Application Rear Parallel Link­to­Crossmember Nut NSm 90 Lb­Ft 66 Lb­In ­ 2B ­ 2IWHEEL ALIGNMENT DIAGNOSIS TIRE DIAGNOSIS Irregular and Premature Wear Irregular and premature tire wear has many causes. Some of them are incorrect inflation pressures, lack of regular rotation, poor driving habits, or improper wheel alignment. If the wheel alignment is reset because of tire wear, always reset the toe as close to zero degrees as the specification allows. Refer to "Rear Toe Adjustment" in this section. Rotate the tires if: S S S S S S The front tire wear is different from the rear. The left and right front tire wear is unequal. The left and right rear tire wear is unequal. The left and right front tire wear is unequal. The wear is uneven across the tread of either front tire. The front tire treads are scuffed with "feather" edges on the side of the tread ribs or blocks. Tread Wear Indicators The original equipment tires have built­in tread wear indicators to show when the tires need replacement. These indicators appear as bands when the tire tread depth becomes shallow. Tire replacemen

File name en_4j2_2c.pdf

SECTION : 2C FRONT SUSPENSION CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2C­2 General Specifications . . . . . . . . . . . . . . . . . . . . . 2C­2 Fastener Tightening Specifications . . . . . . . . . . . 2C­2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C­3 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 2C­3 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C­5 Strut Dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C­5 Ball Joint and Knuckle . . . . . . . . . . . . . . . . . . . . . . 2C­6 Excessive Friction Check . . . . . . . . . . . . . . . . . . . 2C­6 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 2C­7 Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . 2C­7 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 2C­9 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 2C­9 Stabilizer Shaft and Insulators . . . . . . . . . . . . . . . 2C­9 Stabilizer Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C­10 Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . 2C­10 Hub and Bearing . . . . . . . . . . . . . . . . . . . . . . . . . 2C­13 Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C­14 Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C­16 Crossmember Assembly . . . . . . . . . . . . . . . . . . . 2C­18 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C­21 Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C­21 Control Arm Bushings . . . . . . . . . . . . . . . . . . . . . 2C­21 Front Strut Assembly . . . . . . . . . . . . . . . . . . . . . . 2C­22 Knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C­23 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C­25 Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . 2C­25 2C ­ 2IFRONT SUSPENSION SPECIFICATIONS GENERAL SPECIFICATIONS Application Center of Front Wheel to Bottom of Front Wheel Well Center of Rear Wheel to Bottom of Rear Wheel Well * CONDITION : Full Fuel in the Tank Trim Height 368 mm (14.4 in.) 367 mm (14.4 in.) FASTENER TIGHTENING SPECIFICATIONS Application Ball Joint Pinch Bolt Nut Ball Joint­to­Control Arm Nuts Front Control Arm­to­Crossmember Bolt Rear Contral Arm­to­Crossmember Bolt Crossmember Link­to­Crossmember Bolt Crossmember Link­to­Transaxle Bracket Nut Drive Axle­to­Hub Caulking Nut Front Crossmember­to­Body Bolts Piston Rod Nut Rear Crossmember­to­Body Bolts Stabilizer Link­to­Stru

File name en_4j2_2d.pdf

SECTION : 2D REAR SUSPENSION CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­2 Fastener Tightening Specifications . . . . . . . . . . . 2D­2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­2 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 2D­2 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­3 Excessive Friction Check . . . . . . . . . . . . . . . . . . . 2D­3 Strut Dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­3 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 2D­4 Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­4 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 2D­6 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 2D­6 Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­6 Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2D­9 Trailing Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­10 Trailing Link Bracket . . . . . . . . . . . . . . . . . . . . . . 2D­11 Front Parallel Link . . . . . . . . . . . . . . . . . . . . . . . . 2D­12 Rear Parallel Link . . . . . . . . . . . . . . . . . . . . . . . . . 2D­13 Stabilizer Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­13 Stabilizer Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­14 Crossmember . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­14 Hub and Bearing Assembly . . . . . . . . . . . . . . . . 2D­15 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­17 Springs and Insulators . . . . . . . . . . . . . . . . . . . . . 2D­17 Knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­18 Hub and Bearing . . . . . . . . . . . . . . . . . . . . . . . . . 2D­19 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­20 Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . 2D­20 2D ­ 2IREAR SUSPENSION SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Crossmember­to­Body Bolts Strut Dampener­to­Strut Mount Nut Rear Parallel Link­to­Crossmember Bolt Front Parallel Link­to­Knuckle Bolt Fuel Filler Hose Shield Bolt Knuckle­to­Strut Assembly Nuts Rear Parallel Link­to­Knuckle Bolt Rear Trailing Link­to­Trailing Link Bracket Nut Rear Trailing Link­to­Knuckle Nut Stabilizer Link­to­Strut Assembly Nut Stabilizer Shaft Clamp Bolts Stabilizer Shaft­to­Stabilizer Link Nut Strut Mount­to­Body Nuts Trailing Link Bracket­to­Body Bolts Trailing Link­to­Trailing Link Bracket Nut Rear Hub Assembly Bolts NSm 112

File name en_4j2_2e.pdf

SECTION : 2E TIRES AND WHEELS TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . Tire Size and Pressure Specifications . . . . . . . . Inflation Pressure Conversion Specifications . . Fastener Tightening Specifications . . . . . . . . . . . 2E­1 2E­1 2E­2 2E­2 Correcting Non­Uniform Tires . . . . . . . . . . . . . . . 2E­7 Tire and Wheel Match­Mounting . . . . . . . . . . . . . 2E­8 Tire Mounting and Dismounting . . . . . . . . . . . . . . 2E­8 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E­9 Tire and Wheel Balancing . . . . . . . . . . . . . . . . . . . 2E­9 Tire Chain Usage . . . . . . . . . . . . . . . . . . . . . . . . . . 2E­9 Replacement Tires . . . . . . . . . . . . . . . . . . . . . . . . 2E­10 All Season Tires . . . . . . . . . . . . . . . . . . . . . . . . . . 2E­10 Passenger Metric Sized Tires . . . . . . . . . . . . . . 2E­10 Tire Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E­10 Spare Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E­10 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E­10 Inflation o Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E­11 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E­2 Wheel Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E­2 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 2E­3 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 2E­3 Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On­Vehicle Balancing . . . . . . . . . . . . . . . . . . . . . . UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alloy Wheel Porosity . . . . . . . . . . . . . . . . . . . . . . . 2E­3 2E­4 2E­5 2E­5 Alloy Wheel Refinishing . . . . . . . . . . . . . . . . . . . . . 2E­5 Off­Vehicle Balancing . . . . . . . . . . . . . . . . . . . . . . 2E­7 SPECIFICATIONS TIRE SIZE AND PRESSURE SPECIFICATIONS Inflation Pressure at Full Load Tires 175 / 70R14 175 / 70R14 T125 / 70D15 185 / 65R14 185 / 65R14 T125 / 70D15 195 / 55R15 195 / 55R15 195 / 55R15 T125 / 70D15 Wheel kPa 5.5J x 14(Steel) 5.5J x 14(Alloy) 4T x 15 5.5J x 14(Steel) 5.5J x 14(Alloy) 4T x 15 6J x 15(Steel) 6J x 15(Alloy) 6J x 15 (Alloy, Sporty) 4T x 15 205 205 415 205 205 415 205 205 205 415 Front psi 30 30 60 30 30 60 30 30 30 60 kPa 205 205 415 205 205 415 205 205 205 415 Rear psi 30 30 60 30 30 60 30 30 30 60 2E ­ 2ITIRES AND WHEELS INFLATION PRESSURE CONVERSION SPECIFICATIONS kPa 140 145 155 160 165 170 Psi 20 21 22 23 24 25 kPa 185 190 200 205 215 220 Psi 27 28 29 30 31 32 kPa 235 240 250 275 310 345 Psi 34 35 36 40 45 50 FASTENER TIGHTENING SPECIFICATIONS Application Wheel Bolt (Alloy Wheel) Wheel Bolt (Steel Wheel) NSm 100 100 Lb­Ft 74 74 Lb­In ­ ­ DIAGNOSIS WHEEL RUNOUT Measure wheel runout with an accurate dial indicator. Measurements may be taken with the wheels either on

File name en_4j2_3.pdf

SECTION 3 WIRING DIAGRAM FOR POWER SUPPLIES CONTENTS 1. 2. 3. 4. 5. IGNITION SWITCH CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3­2 30 TER "BAT+" POWER SUPPLY CIRCUIT(I.P FUSE BLOCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3­2 15 TER "IGN 1" POWER SUPPLY CIRCUIT(I.P FUSE BLOCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3­3 15A TER "IGN2", 15C TER "ACC" POWER SUPPLY CIRCUIT(I.P FUSE BLOCK) . . . . . . . . . . . . . . . . . . . . . . 3­4 ENGINE FUSE BLOCK & RELAY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3­5 3­2WWIRING DIAGRAM FOR POWER SUPPLIES 1. IGNITION SWITCH CIRCUIT 2. 30 TER "BAT+" POWER SUPPLY CIRCUIT (I.P FUSE BLOCK) WIRING DIAGRAM FOR POWER SUPPLIESW3­3 3. 15 TER "IGN1" POWER SUPPLY CIRCUIT (I.P FUSE BLOCK) 3­4WWIRING DIAGRAM FOR POWER SUPPLIES 4. 15A TER "IGN2", 15C TER "ACC" POWER SUPPLY CIRCUIT (I.P FUSE BLOCK) WIRING DIAGRAM FOR POWER SUPPLIESW3­5 5. ENGINE FUSE BLOCK & RELAY CIRCUIT 3­6WWIRING DIAGRAM FOR POWER SUPPLIES WIRING DIAGRAM FOR POWER SUPPLIESW3­7 3­8WWIRING DIAGRAM FOR POWER SUPPLIES WIRING DIAGRAM FOR POWER SUPPLIESW3­9 3­10WWIRING DIAGRAM FOR POWER SUPPLIES WIRING DIAGRAM FOR POWER SUPPLIESW3­11 3­12WWIRING DIAGRAM FOR POWER SUPPLIES WIRING DIAGRAM FOR POWER SUPPLIESW3­13 3­14WWIRING DIAGRAM FOR POWER SUPPLIES WIRING DIAGRAM FOR POWER SUPPLIESW3­15 3­16WWIRING DIAGRAM FOR POWER SUPPLIES

File name en_4j2_3a.pdf

SECTION : 3A AUTOMATIC TRANSAXLE DRIVE AXLE TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3A­1 Fastener Tightening Specifications . . . . . . . . . . 3A­1 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A­2 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 3A­2 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 3A­2 Front Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . 3A­2 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . Drive Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outer Joint Seal . . . . . . . . . . . . . . . . . . . . . . . . . . 3A­4 3A­4 3A­7 3A­7 Inner Tripot Seal . . . . . . . . . . . . . . . . . . . . . . . . . . 3A­8 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A­10 Front Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . 3A­10 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 3A­4 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Axle Shaft Caulking Nut Lower Ball Joint Pinch Bolt and Nut Tie Rod Nut Wheel Nuts NSm 300 60 55 100 Lb­Ft 221 44 41 74 Lb­In ­ ­ ­ ­ 3A ­ 2IAUTOMATIC TRANSAXLE DRIVE AXLE SPECIAL TOOLS SPECIAL TOOLS TABLE J­8059 Snap Ring Pliers DW340­110 Axle Shaft Remover KM­507­B Ball Joint Remover J­35566 Seal Clamp Pliers COMPONENT LOCATOR FRONT DRIVE AXLE DAEWOO V­121 BL4 AUTOMATIC TRANSAXLE DRIVE AXLE 3A ­ 3 1. 2. 3. 4. 5. 6. C/V Joint Assembly C/V Joint Seal Retaining Clamp Drive Axle Outboard Seal Seal Retaining Clamp Axle Shaft (Left­hand Drive Shown, Right­hand Drive Similar) 7. 8. 9. 10. 11. 12. Seal Retaining Clamp Drive Axle Inboard Seal Seal Retaining Clamp Tripot Housing Snap Ring Tripot Joint Assembly DAEWOO V­121 BL4 3A ­ 4IAUTOMATIC TRANSAXLE DRIVE AXLE MAINTENANCE AND REPAIR ON­VEHICLE SERVICE DRIVE AXLE ASSEMBLY Tools Required KM­507­B Ball Joint Separator DW340­110 Axle Shaft Remover Removal Procedure 1. 2. Raise and suitably support the vehicle. Remove the wheels. Refer to Section 2E, Tires and Wheels. 3. Remove the axle shaft caulking nut. Discard the nut. Notice : Use only the recommended tool for separating the lower ball joint. Failure to use the recommended tool may cause damage to the ball joint and the seal. 4. 5. 6. Remove the lower ball joint pinch bolt and nut. Separate the steering knuckle from the lower ball joint using the ball joint separator KM­507­B. Remove the tie rod 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. 7. Separate the tie rod end using the ball joint separator KM­507­B. DAEWOO V­121 BL4 AUTOMATIC TRANSAXLE DRIVE AXLE 3A ­ 5 8. 9. Remove the damping block connection nut and bolt. Remove the rear mounting bracket bolts and the br

File name en_4j2_3b.pdf

SECTION : 3B MANUAL TRANSAXLE DRIVE AXLE TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3B­1 Fastener Tightening Specifications . . . . . . . . . . 3B­1 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B­2 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 3B­2 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 3B­2 Front Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . 3B­2 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 3B­5 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 3B­5 Drive Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . 3B­5 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B­8 Outer Joint Seal . . . . . . . . . . . . . . . . . . . . . . . . . . 3B­8 Inner Tripot Seal . . . . . . . . . . . . . . . . . . . . . . . . . . 3B­9 Cross Groove Joint Seal . . . . . . . . . . . . . . . . . . . 3B­11 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B­13 Front Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . 3B­13 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Axle Shaft Caulking Nut Lower Ball Joint Pinch Bolt and Nut Tie Rod Nut Wheel Nuts NSm 300 60 55 100 Lb­Ft 221 44 41 74 Lb­In ­ ­ ­ ­ 3B ­ 2IMANUAL TRANSAXLE DRIVE AXLE SPECIAL TOOLS SPECIAL TOOLS TABLE J­8059 Snap Ring Pliers KM­460­A Axle Shaft Remover KM­507­B Ball Joint Remover J­35566 Seal Clamp Pliers COMPONENT LOCATOR FRONT DRIVE AXLE DAEWOO V­121 BL4 MANUAL TRANSAXLE DRIVE AXLE 3B ­ 3 1. 2. 3. 4. 5. 6. Caulking Nut C/V Joint Axle Shaft Seal Retaining Clamp Drive Axle Outboard Seal Seal Retaining Clamp 7. 8. 9. 10. 11. 12. Seal Retaining Clamp Drive Axle Inboard Seal Seal Retaining Clamp Race Retaining Ring Cross Groove Joint Retaining Ring DAEWOO V­121 BL4 3B ­ 4IMANUAL TRANSAXLE DRIVE AXLE 1. 2. 3. 4. 5. 6. C/V Joint Assembly C/V Joint Seal Retaining Clamp Drive Axle Outboard Seal Seal Retaining Clamp Axle Shaft 7. 8. 9. 10. 11. 12. Seal Retaining Clamp Drive Axle Inboard Seal Seal Retaining Clamp Tripot Housing Snap Ring Tripot Joint Assembly DAEWOO V­121 BL4 MANUAL TRANSAXLE DRIVE AXLE 3B ­ 5 MAINTENANCE AND REPAIR ON­VEHICLE SERVICE DRIVE AXLE ASSEMBLY Tools Required KM­507­B Ball Joint Separator KM­460­A Axle Shaft Remover Removal Procedure 1. 2. Raise and suitably support the vehicle. Remove the wheels. Refer to Section 2E, Tires and Wheels. 3. Remove the axle shaft caulking nut. Discard the nut. Notice : Use only the recommended tool for separating the lower ball joint. Failure to use the recommended tool may cause damage to the ball joint and the seal. 4. 5. 6. Remove the lower ball joint pinch bolt and nut. Separate the steering knuckle from the lower ball joint using the ball joint separator KM­507­B. Remove the tie rod nut. Notice : Use only the recommended tool for separating the tie rod from the knuckle/strut assembly

File name en_4j2_4.pdf

SECTION 4 USAGE AND CAPACITY OF FUSES IN FUSE BLOCK CONTENTS 1. 2. 3. ENGINE ROOM RELAY AND FUSE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4­2 I.P FUSE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4­3 POSITION OF CONTROL UNIT, RELAY AND PART NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4­4 4­2WUSAGE AND CAPACITY OF FUSES IN FUSE BLOCK 1. ENGINE ROOM RELAY AND FUSE BLOCK 1) POSITION OF RELAY AND FUSE 2) USAGE OF FUSE IN ENGINE FUSE BLOCK Power Supply Classification Fuse No Ef1 Ef2 Ef3 30 BAT (+) SB (Slow­Blown Fuse) Ef4 Ef5 Ef6 Ef7 Ef8 IGN2 (15A) IGN1 (15) 30 BAT(+) Ef9 Ef10 Ef11 Ef12 Ef13 IGN2 (15A) 56 LIGHT 30 BAT(+) IGN1 (15) 30 BAT(+) Ef14 Ef15 Ef16 Ef17 Ef18 Ef19 Capacity 30A 60A 30A 30A 30A 20A 30A 30A 20A 15A 10A 25A 15A 20A 15A 15A 10A 15A 15A Usage Battery Main(F13~F16, F21~F24) EBCM, Oil Feeding Conenctor Blower Relay Ignition Switch­2 Ignition Switch­1 Cooling Fan Low Relay Defog Relay Cooling Fan HI Relay Power Window Switch Fuel Connector, ECM (MR­140), LEGR, EI System ECM, Main Relay (Sirius D4) Head lamp Relay, ILLUM. Relay Brake Switch Power Window Switch Head Lamp HI Horn Relay, siren, Hood Contact Switch A/C Comp. Relay Fuel Pump Cluster, Key Remind S/W, Folding Mirror Unit, MAP Lamp, Room Lamp, Trunk Open lamp, Trunk Open S/W Head Lamp Low EVAP Canister Purge Solenoid, HO2S, Cooling Fan Relay injector, EGR, EEGR License Plate Lamp, Chime Bell, Tail Lamp, Head Lamp Fog Lamp Relay Electric OSRV Mirror Central Door Lock Unit Head Lamp Low ILLUM. Circuit, Head Lamp, Tail Lamp Not Used Not Used Not Used 56 LIGHT IGN1 (15)/ 30 BAT(+) ILLUM. (58) 30 BAT (+) IGN2 (15A) 30 BAT (+) 56 LIGHT ILLUM. (58) SPARE Blade Type Fuse Ef20 Ef21 Ef22 Ef23 Ef24 Ef25 Ef26 Ef27 Ef28 Ef29 Ef30 Ef31 10A 15A 15A 10A 15A 10A 15A 10A 10A 10A 15A 25A USAGE AND CAPACITY OF FUSES IN FUSE BLOCKW4­3 2. I.P FUSE BLOCK 1) POSITION OF FUSE AND RELAY 2) USAGE OF FUSE IN I.P FUSE BLOCK Power Supply IGN1 (15) Classification Blade Type Fuse Fuse No F1 F2 F3 F4 Capacity 10A 10A 15A 10A ­ 10A 20A 15A 25A ­ 10A 10A 10A 15A 15A 10A 10A 15A 15A 10A 15A 15A 15A 10A SDM Usage TCM, ECM, Generator, VGIS,VSS Hazard Switch Cluster, Chime Bell, Brake Switch, SSPS Module, A/C Control Switch ­ A/C Comp. Relay, Defog Relay, Power Window Relay, Head Lamp Relay Blower Relay, A/C Control Switch, FATC Electric Mirror Switch, Folding Mirror, Sun Roof Module Wiper Motor, Wiper Switch ­ EBCM, Oil Feeding Connector Immobilizer, Anti Theft Control Unit, Rain Sensor Unit TCM Hazard Switch Anti Theft Control Unit DLC Audio, Clock Extra Power Jack Cigar Lighter Reverse Lamp Switch, PNP Switch Rear Fog Relay Clock, FATC, A/C Control Switch Audio Immobilizer ­ IGN2 (15A) F5 F6 F7 F8 IGN1 (15) ­ IGN1 (15) F9 F10 F11 F12 30 BAT(+) F13 F14 F

File name en_4j2_4a.pdf

SECTION : 4A HYDRAULIC BRAKES CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 4A­2 General Specifcations . . . . . . . . . . . . . . . . . . . . . 4A­2 Fastener Tightening Specifications . . . . . . . . . . 4A­2 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 4A­3 Brake System (ABS) . . . . . . . . . . . . . . . . . . . . . . . 4A­3 Brake System (NON­ABS) . . . . . . . . . . . . . . . . . 4A­4 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A­5 Brake System Testing . . . . . . . . . . . . . . . . . . . . . 4A­5 Brake Hose Inspection . . . . . . . . . . . . . . . . . . . . . 4A­5 Warning Lamp Operation . . . . . . . . . . . . . . . . . . . 4A­5 Stop Lamp Warning Circuit Diagnosis . . . . . . . . 4A­6 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 4A­10 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 4A­10 Manual Bleeding the Brakes . . . . . . . . . . . . . . . 4A­10 Pressure Bleeding the Brakes . . . . . . . . . . . . . . 4A­12 Brake Hose Rear . . . . . . . . . . . . . . . . . . . . . . . . . 4A­13 Brake Hose Front . . . . . . . . . . . . . . . . . . . . . . . . . 4A­14 Stoplamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . 4A­15 Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A­16 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A­17 Warning Lamp Operation . . . . . . . . . . . . . . . . . . 4A­17 4A ­ 2IHYDRAULIC BRAKES SPECIFICATIONS GENERAL SPECIFCATIONS 1.4/1.6/1.8/2.0 DOHC Engine Application Brake Drums: Inside Diameter Maximum Rebore Diameter Out­of­Round Front Brake Rotors: Discard Thickness Lateral Runout (Installed) Rotor Diameter Rotor Thickness (New) Thickness Variation Rear Brake Rotors: Discard Thickness Lateral Runout (Installed) Rotor Diameter Rotor Thickness (New) Thickness Variation Master Cylinder: Bore Diameter (Nominal) Bore Diameter (Maximum) Caliper: Minimum Piston Diameter (Front) Minimum Piston Diameter (Rear) Wheel Cylinder Diameter: Maximum Nominal 20.7 20.64 0.815 0.812 54.00 32 2.126 1.260 22.22 22.29 0.875 0.878 8 0.030 258 10.4 0.01 0.31 0.001 10.15 0.40 0.0004 22.00 0.030 256 24.00 0.01 0.87 0.001 10.07 0.95 0.0004 200.00 201.00 0.04 7.87 7.91 0.0016 Millimeters Inches FASTENER TIGHTENING SPECIFICATIONS Application Bleeder Screw Brake Lines Brake Pedal­to­Pedal Bracket Hex Nut Front Disc Brake Hose­to­Caliper Bolt Rear Disc Brake Hose­to­Caliper Bol NSm 8 16 18 40 32 Lb­Ft ­ 12 13 30 24 Lb­In 71 ­ ­ ­ ­ DAEWOO V­121 BL4 HYDRAULIC BRAKES 4A ­ 3 COMPONENT LOCATOR BRAKE SYSTEM (ABS) 1. 2. 3. 4. 5. 6. 7. 8. RH

File name en_4j2_4b.pdf

SECTION : 4B MASTER CYLINDER TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 4B­1 Fastener Tightening Specifications . . . . . . . . . . 4B­1 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B­2 Checking Brake Proportioning Valve . . . . . . . . . 4B­2 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 4B­3 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 4B­3 Master Cylinder Assembly . . . . . . . . . . . . . . . . . . 4B­3 Brake Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . 4B­4 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B­7 Master Cylinder Overhaul . . . . . . . . . . . . . . . . . . . 4B­7 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B­9 Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B­9 Fluid Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . 4B­9 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Brake Lines Master Cylinder Attaching Nuts Proportioning Valves NSm 16 18 22 Lb­Ft 12 13 16 Lb­In ­ ­ ­ 4B ­ 2IMASTER CYLINDER DIAGNOSIS CHECKING BRAKE PROPORTIONING VALVE Use two brake pressure gauges to check the brake proportioning valves that are attached to the master cylinder on non­ABS braking systems. These valves limit the outlet pressure to the rear brakes after a predetermined master cylinder pressure has been reached. (On ABS braking systems, the hydraulic modulator/motor pack assembly controls the hydraulic pressure to both the rear wheel cylinders or rear calipers, and the front calipers.) When checking the brake proportioning valves, be sure that the hydraulic line pressure is measured simultaneously and diagonally on the front and the rear axles. Model Reference Number for Gradient and Switching Pressure on the Valve Housing 0.3/30 To measure the pressure, use the following steps. 1. Remove the bleeder valve and install a pressure gauge to one of the rear brake cylinders. 2. Install another bleeder valve and install another pressure gauge to the diagonally opposite front brake. 3. Build pressure by pressing firmly on the brake pedal several times. (The pressure indicated on the gauge is not regulated and represents the actual brake system hydraulic pressure.) 4. Build pressure until the test values in the following proportioning valve test chart are achieved. Input Pressure Read on the Manometer at the Front Axle in kPa (psi) 500 (73) Output Pressure Read on the Manometer at the Front Axle in kPa (psi) 500 (73) 3 450 ± 200(500 ± 29) 5 100 ± 300(740 ± 44) 500 (73) 4 450 ± 200(645 ± 29) 5 800 ± 300(841 ± 44) N/B, H/B 4 500 (653) 10 000 (1,450) 500 (73) WAGON 0.3/40 5 500 (798) 10 000 (1,450) Important : If the pressure exceeds 10 000 kPa (1,450 psi), the pressure reading on the rear gauge will not be accurate. 5. Remove the gauges from the tested brake circuit and repeat the test on the remaining circu

File name en_4j2_4c.pdf

SECTION : 4C POWER BOOSTER TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 4C­1 Fasrener Tightening Specifications . . . . . . . . . . 4C­1 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C­1 Power Booster Functional Check . . . . . . . . . . . . 4C­1 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 4C­2 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 4C­2 Vacuum Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C­2 Power Booster Assembly . . . . . . . . . . . . . . . . . . . 4C­2 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C­6 Power Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C­6 SPECIFICATIONS FASRENER TIGHTENING SPECIFICATIONS Application Booster­to­Bracket Nuts (Right­Hand Drive) Booster­to­Dash Drive) Brake Line Fittings Panel Nut (Left­Hand NSm 22 22 18 16 Lb­Ft 16 16 13 12 Lb­In ­ ­ ­ ­ Booster Hex Nut and Pushrod Clevis DIAGNOSIS POWER BOOSTER FUNCTIONAL CHECK 1. 2. 3. With the engine stopped, eliminate vacuum in the booster by pumping the brake pedal several times. Push the pedal down and hold in this position. Start the engine. 4. The booster is OK if the pedal drops further because of extra force produced. If the brake pedal does not drop, the vacuum system (vacuum hoses, check valve, etc.) is probably defective and should be checked. If no defect is revealed by checking the vacuum system, the defect is in the booster itself. 4C ­ 2IPOWER BOOSTER MAINTENANCE AND REPAIR ON­VEHICLE SERVICE VACUUM HOSE Removal Procedure 1. Spread the clip on the vacuum hose connection at the intake manifold and move the clip slightly toward the brake booster. Pull the hose from the union nut connection. If the hose does not remove easily or is deteriorated, pry off and discard the hose. Spread the clip on the vacuum hose connection to the brake booster, and move the clip clear of the booster. Remove the vacuum hose. 2. 3. 4. Installation Procedure 1. 2. Mount the vacuum hose and ensure the connections are tight on each end. Check the function of the booster. Refer to the "Power Booster Functional Check" in this section. POWER BOOSTER ASSEMBLY Removal Procedure 1. Remove the master cylinder. Refer to Section 4B, Master Cylinder Assembly. DAEWOO V­121 BL4 POWER BOOSTER 4C ­ 3 2. Remove the shaft and the rubber O­ring. 3. 4. 5. 6. Remove the clip on the vacuum hose connection on the booster. Disconnect the brake stoplamp switch. Remove the brake pedal spring. Disconnect the clip and the pushrod pin from the pedal bracket assembly. Refer to Section 4A, Hydraulic Brakes. 7. 8. Remove the booster mounting nuts from the studs protruding from the dash panel and remove the booster. Remove the rubber boot. 9. Holding the hex nut, twist off the pushrod clevis. 10. Remove the hex nut from the pushrod. DAEWOO V­121 BL4 4C ­ 4IPOWER BOOSTER Installation Procedure 1. 2. Check the

File name en_4j2_4d.pdf

SECTION : 4D FRONT DISC BRAKES TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 4D­1 Fastener Tightening Specirications . . . . . . . . . . 4D­1 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D­1 Lining Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 4D­1 Rotor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 4D­1 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 4D­3 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 4D­3 Shoe and Lining . . . . . . . . . . . . . . . . . . . . . . . . . . 4D­3 Caliper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D­3 Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D­4 Splash Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D­5 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D­6 Caliper Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . 4D­6 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D­9 Disc Brake Caliper Assembly . . . . . . . . . . . . . . . . 4D­9 SPECIFICATIONS FASTENER TIGHTENING SPECIRICATIONS Application Brake Hose Inlet Fitting­to­Caliper Bolt Caliper Bleeder Valve Caliper­to­Steering Knuckle Mounting Bolts Retaining Frame­to­Caliper Housing Bolts Rotor­to­Front Wheel Hub Detent Screw Splash Shield­to­Steering Knuckle Screws NSm 40 8 95 27 4 4 Lb­Ft 30 ­ 70 20 ­ ­ Lb­In ­ 71 ­ ­ 35 35 DIAGNOSIS LINING INSPECTION 1. 2. Raise and suitably support the vehicle. Remove the front wheels. Refer to Section 2E, Tires and Wheels. 3. Visually check the linings for minimum thickness and wear. 4. Measure the thickness. Important : The minimum thickness of the inner or the outer pad is 7 mm (0.28 inch). 5. Install the brake pads in axle sets only. 6. Install the front wheels. Refer to Section 2E, Tires and Wheels. 7. Lower the vehicle. ROTOR INSPECTION Thickness variation can be checked by measuring the thickness of the rotor at four or more points around the circumference of the rotor. All measurements must be made at the same distance in from the edge of the rotor. A rotor that varies by more than 0.01 mm (0.0004 inch) can cause pedal pulsations and/or front end vibration during brake applications. A rotor that does not meet these specifications should be refinished to specifications or replaced. 4D ­ 2IFRONT DISC BRAKES During manufacturing, the brake rotor and the tolerances of the braking surface regarding flatness, thickness variation, and lateral runout are held very close. The maintenance of close tolerances on the shape of the braking surfaces is necessary to prevent brake roughness. Remove the rotor. Refer to "Rotor" in this section. Fasten the brake rotor to the wheel hub with two wheel bolts. 4. Fasten a dial indicator to the brake caliper. 5. Set the gauge probe tip to approximately 10 mm (0.39 inch) from the outer edge of the brake rotor, p

File name en_4j2_4e1.pdf

SECTION : 4E1 REAR DISC BRAKES TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 4E1­1 Fastener Tightening Specifications . . . . . . . . . . 4E1­1 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E1­1 Lining Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 4E1­1 Rotor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 4E1­1 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 4E1­3 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 4E1­3 Shoe and Lining . . . . . . . . . . . . . . . . . . . . . . . . . . 4E1­3 Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E1­4 Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E1­5 Hub and Parking Brake Shoe/Backplate . . . . . 4E1­6 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E1­10 Caliper Overhaul . . . . . . . . . . . . . . . . . . . . . . . . 4E1­10 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E1­12 Disc Brake Caliper Assembly . . . . . . . . . . . . . . 4E1­12 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Brake Hose Inlet Bolt and Ring Seals Caliper Mounting Bolts Lower Caliper Mounting Bolt Parking Brake Shoe Hold­Down Spring Assembly Screw Rotor Detent Screw Hub Bolts NSm 32 56 27 4 4 65 Lb­Ft 24 41 20 ­ ­ 48 Lb­In ­ ­ ­ 35 35 ­ DIAGNOSIS LINING INSPECTION 1. 2. 3. 4. Raise and suitably support the vehicle. Remove the rear wheels. Refer to Section 2E, Tires and Wheels. Visually check the brake shoe linings for minimum thickness and wear. Measure the thickness. ROTOR INSPECTION Brake rotors are manufactured with close tolerances for thickness variation, flatness, and lateral runout, but pits and grooves are created in rotors during usage. Lack of uniformity of the braking surfaces of the rotor can cause inadequate braking and a pulsating pedal during braking. The surface finish of the rotor is also important because an unsuitable surface finish can cause pulling and rapid wear of the brake shoe lining. If a rotor does not meet the specification, it should be refinished to specification or replaced. Refinishing of the rotor should only be done with precision equipment. Thickness variation can be checked by measuring the thickness of the rotor at four or more points around the circumference of the rotor. All measurements must be made at the same distance from the edge of the rotor. A rotor that varies by more than. 1.0 mm (0.04 inch) can cause pedal Important : The minimum discard thickness of the brake shoe lining is 2 mm (0.08 inch). 5. 6. 7. Install the shoes in axle sets only. Install the rear wheels. Refer to Section 2E, Tires and Wheels. Lower the vehicle. 4E1 ­ 2IREAR DISC BRAKES pulsation and/or front end vibration during braking. Thickness can be measured with a commercially available micrometer and should be 10 mm(0.39 inch) or over. 2. To preserve wheel bala

File name en_4j2_4e2.pdf

SECTION : 4E2 REAR DRUM BRAKES TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 4E2­1 Fastener Tightening Specifications . . . . . . . . . 4E2­1 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E2­1 Lining Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 4E2­1 Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E2­1 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 4E2­3 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 4E2­3 Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 4E2­3 Shoe and Lining . . . . . . . . . . . . . . . . . . . . . . . . . 4E2­4 Wheel Cylinder Assembly . . . . . . . . . . . . . . . . . 4E2­7 Backing Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E2­8 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E2­10 Wheel Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 4E2­10 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E2­12 Drum Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E2­12 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Brake Line Brake Wheel Hub/Backing Plate­to­Rear Axle Nuts Wheel Cylinder­to­Backing Plate Bolt NSm 16 28 8 Lb­Ft 12 21 ­ Lb­In ­ ­ 71 DIAGNOSIS LINING INSPECTION 1. 2. 3. 4. 5. Raise and suitably support the vehicle. Remove the wheel. Refer to Section 2E, Tires and Wheels. Release the parking brake. Remove the drum. Refer to " Drum" in this section. Measure the lining thickness. The minimum lining thickness is 0.5 mm (0.02 inch). DRUMS Whenever brake drums are removed, they should be thoroughly cleaned and inspected to see if the drums are cracked, scored, deeply grooved, or beyond the specified out­of­round limit. S A cracked drum is unsafe for further service andmust be replaced. Do not attempt to weld a cracked drum. Smooth out any slight scores. Heavy or extensive scoring will cause excessive brake lining wear and may require refinishing the drum braking surface. If the brake linings are slightly worn but are still reusable and the drum is grooved, polish the drum with a fine emery cloth but do not refinish it. Eliminating all grooves in the drum and smoothing the ridges on the lining would remove too much metal and lining. If left alone, the grooves and ridges match, and satisfactory service can be obtained. If the brake linings need to be replaced, refinish a grooved drum. A grooved drum, used with a new CAUTION : To avoid injury when servicing brake parts, do not create dust by grinding or sanding the brake linings or by cleaning the wheel brake parts with a dry brush or with compressed air. Important : Replace the shoe and lining assembly in axle sets only. 6. 7. 8. Install the drum, if removed. Refer to "One­Piece Drum" or "Two­Piece Drum" in this section. Install the wheel, if removed. Refer to Section 2E, Tires and Wheels. Lower the vehicle. S S 4E

File name en_4j2_4f.pdf

SECTION : 4F ANTILOCK BRAKE SYSTEM CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 4F­2 Fastener Tightening Specifications . . . . . . . . . . 4F­2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F­2 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 4F­2 SCHEMATIC AND ROUTING DIAGRAMS . . . . . 4F­3 Abs System Circuit (I) . . . . . . . . . . . . . . . . . . . . . . 4F­3 Abs System Circuit (II) . . . . . . . . . . . . . . . . . . . . . 4F­4 Ebcm Connector Face View . . . . . . . . . . . . . . . . . 4F­5 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 4F­6 ABS/EBD System Drive . . . . . . . . . . . . . . . . . . . . 4F­6 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F­7 Diagnostic Circuit Check . . . . . . . . . . . . . . . . . . . 4F­7 ABS Indicator Lamp Inoperative . . . . . . . . . . . . . 4F­9 Power Supply to Control Module, No DTCs Stored . . . . . . . . . . . . . . . . . . . . . . . . 4F­12 ABS Indicator Lamp Illuminated Continuously, No DTCs Stored . . . . . . . . . . . . . . . . . . . . . . . . 4F­16 Electronic Brake­Force Distribution (EBD) System Indicator Lamp Inoperative . . . . . . . . 4F­18 SELF­DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . 4F­22 DISPLAYING DTCs . . . . . . . . . . . . . . . . . . . . . . . 4F­22 CLEARING DTCs . . . . . . . . . . . . . . . . . . . . . . . . 4F­22 INTERMITTENTS AND POOR CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . 4F­22 DTC C0035 Left Front Wheel Speed Sensor Circuit Malfunction . . . . . . . . . . . . . . . . . . . . . . 4F­23 DTC C0040 Right Front Wheel Speed Sensor Circuit Malfunction . . . . . . . . . . . . . . . . . . . . . . 4F­26 DTC C0045 Left Rear Wheel Speed Sensor Circuit Malfunction . . . . . . . . . . . . . . . . . . . . . . 4F­29 DTC C0050 Right Rear Wheel Speed Sensor Circuit Malfunction . . . . . . . . . . . . . . . . . . . . . . 4F­32 DTC C0060/C0065 Left Front Inlet and Outlet Valve Solenoid Fault . . . . . . . . . . . . . . . 4F­35 DTC C0070/C0075 Right Front Inlet and Outlet Valve Solenoid Fault . . . . . . . . . . . . . . . 4F­37 DTC C0080/C0085 Left Rear Inlet and Outlet Valve Solenoid Fault . . . . . . . . . . . . . . . 4F­39 DTC C0090/C0095 Right Rear Inlet and Outlet Valve Solenoid Fault . . . . . . . . . . . . . . . DTC C0110 Pump Motor Circuit Malfunction . . DTC C0121 Valve Relay Circuit Malfunction . . DTC C0161 ABS Brake Switch Circuit Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC C0245 Wheel Speed Sensor Frequency Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

File name en_4j2_4g0.pdf

SECTION : 4G PARKING BRAKE TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 4G­1 Fastener Tightening Specifications . . . . . . . . . . 4G­1 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . Parking Brake Adjustment Rear Drum Brakes . Parking Brake Adjustment Rear Disc Brakes . . 4G­2 4G­2 4G­2 4G­2 Parking Brake Lever . . . . . . . . . . . . . . . . . . . . . . . 4G­3 Parking Brake Cable . . . . . . . . . . . . . . . . . . . . . . . 4G­5 Parking Brake Handle . . . . . . . . . . . . . . . . . . . . . . 4G­8 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G­9 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G­9 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Parking Brake Cable­to­Underbody Side Bracket bolts Parking Brake Lever Assembly­to­Vehicle Underbody Bolts Parking Brake Switch­to­Parking Brake Lever Screw Rear Brake Drum Detent Screw NSm 6 22 4 4 Lb­Ft ­ 16 ­ ­ Lb­In 53 ­ 35 35 4G ­ 2IPARKING BRAKE MAINTENANCE AND REPAIR ON­VEHICLE SERVICE PARKING BRAKE ADJUSTMENT REAR DRUM BRAKES Adjustment Procedure 1. 2. 3. 4. Adjust the rear brakes. Refer to Section 4E1, Rear Disc Brakes. Release the parking brake. Raise and suitably support the vehicle. Check the parking brake cables for free movement. Lower the vehicle Remove the parking brake/gearshift console hood. Refer to Section 9G, Interior Trim. 7. Partially raise the vehicle. 8. Turn the self­locking nut on the parking brake lever assembly until the wheels are difficult to turn. 9. Back off the nut until the rear wheels are just free to turn. 10. Lower the vehicle 11. Install the parking brake/gearshift console hood. Refer to Section 9G, Interior Trim. 5. 6. PARKING BRAKE ADJUSTMENT REAR DISC BRAKES Adjustment Procedure 1. 2. 3. 4. 5. 6. Release the parking brake. Raise and suitably support the vehicle. Remove the rear wheels. Refer to Section 2E, Tires and Wheels. Remove the caliper and rotor assemblies. Refer to Section 4E1, Rear Disc Brakes. Remove the brake rotors on each side of the vehicle. Refer to Section 4E1, Rear Disc Brakes. Disconnect the parking brake cable from the backplate operating lever on each side of the vehicle. DAEWOO V­121 BL4 PARKING BRAKE 4G ­ 3 7. Inspect and replace any parts of doubtful strength or quality. This can be shown by discoloration from heat or stress. Using a vernier caliper, adjust the shoe assembly to 167.6 to 167.8 mm (6.60 to 6.61 inches) by turning the adjuster nut clockwise to increase the diameter. Measure the shoe assembly diameter as closely as possible to the center of the lining material. 8. 9. 10. 11. 12. 13. 14. 15. 16. Inspect and install the rotors and calipers. Refer to Section 4E1, Rear Disc Brakes. Install the parking brake cable to the backplate lever on each side of the vehicle. In the vehicle cabin, pull on the parking brake handle. St

File name en_4j2_5.pdf

SECTION 5 ELECTRICAL WIRING DIAGRAMS CONTENTS 1. 2. STARTING & CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5­8 1) 1) 2) 3) 4) 5) 6) BATTERY, IGNITION SWITCH, STARTER MOTOR, GENERATOR & PNP SWITCH CIRCUIT . . . . . . . . . . 5­8 BATTERY POWER SUPPLY, GROUND, EI SYSTEM & CKP SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . FUEL PUMP, INJECTOR & HEATED O2 SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IAC, SENSOR(MAP, ECT, TP, KNOCK, ACP & ROUGH ROAD) & LEGR CIRCUIT . . . . . . . . . . . . . . . . . . . EVAP CANISTER PURGE SOLENOID, CMP SENSOR, CLUSTER & VSS CIRCUIT . . . . . . . . . . . . . . . . . CLUSTER, FUEL PUMP & TCM CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DLC, MIL LAMP & IMMOBILIZER CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY POWER SUPPLY, GROUND, EI SYSTEM & CKP SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . FUEL PUMP, INJECTOR & O2 SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IAC, SENSOR(MAP, ECT, TP, IAT, KNOCK & ACP) & EGR VALVE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . EVAP CANISTER PURGE SOLENOID, CMP SENSOR, CLUSTER & VSS CIRCUIT . . . . . . . . . . . . . . . . . CLUSTER, FUEL PUMP & TCM CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DLC, MIL LAMP, IMMOBILIZER CONTROL & RON SWITCH CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5­10 5­12 5­14 5­16 5­18 5­20 5­22 5­24 5­26 5­28 5­30 5­32 ECM (ENGINE CONTROL MODULE) : MR­140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5­10 3. ECM (ENGINE CONTROL MODULE) : HV­240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5­22 1) 2) 3) 4) 5) 6) ELECTRICAL WIRING DIAGRAMSW5­3 4. ECM (ENGINE CONTROL MODULE) : SIRIUS D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5­34 1) BATTERY POWER SUPPLY, GROUND, EI SYSTEM & CKP SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . 2) FUEL PUMP, INJECTOR, FUEL CONNECTOR & CMP SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . 3) MTIA, SENSOR(ECT, KNOCK, IAT, MAP, ACP & HO2S) & POWER STEERING PRESSURE SWITCH CIRCUIT : EOBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4) MTIA, SENSOR(ECT, KNOCK, IAT, MAP, ACP & O2) & POWER STEERING PRESSURE SWITCH CIRCUIT : NON EOBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

File name en_4j2_5a0.pdf

SECTION : 5A1 ZF 4 HP 16 AUTOMATIC TRANSAXLE CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­3 ZF 4HP 16 Automatic Transaxle . . . . . . . . . . . . 5A1­3 Transaxle Components . . . . . . . . . . . . . . . . . . . . 5A1­4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­5 General Specifications . . . . . . . . . . . . . . . . . . . . 5A1­5 Transaxle Gear Ratio . . . . . . . . . . . . . . . . . . . . . . 5A1­5 Fluid Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­5 Fastener Tightening Specifications . . . . . . . . . . 5A1­5 Shift Speed Chart . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­7 Line Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­8 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­9 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . 5A1­9 SCHEMATIC AND ROUTING DIAGRAMS . . . 5A1­11 Transaxle Control Module (1 of 2) . . . . . . . . . . 5A1­11 Transaxle Control Module (2 of 2) . . . . . . . . . . 5A1­12 Shift Mode Diagram . . . . . . . . . . . . . . . . . . . . . . 5A1­13 Power Flow Diagram . . . . . . . . . . . . . . . . . . . . . 5A1­17 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . 5A1­33 Transaxle Identification Information . . . . . . . . 5A1­33 Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . 5A1­34 Transaxle Housing . . . . . . . . . . . . . . . . . . . . . . . 5A1­35 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­36 Rear Cover & Oil Pan Cover . . . . . . . . . . . . . . 5A1­37 Parking Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­38 Input Shaft & Shift Gear . . . . . . . . . . . . . . . . . . 5A1­39 Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­41 Gear Shift Control . . . . . . . . . . . . . . . . . . . . . . . 5A1­42 DIAGNOSTIC INFORMATION AND PROCEDURES DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­43 Basic Knowledge Required . . . . . . . . . . . . . . . . 5A1­43 Functional Check Procedure . . . . . . . . . . . . . . 5A1­43 Line Pressure Check Procedure . . . . . . . . . . . 5A1­43 Clutch Plate Diagnosis . . . . . . . . . . . . . . . . . . . 5A1­45 Cooler Flushing and Flow Test . . . . . . . . . . . . . 5A1­45 Transaxle Fluid Level Service Procedure . . . . 5A1­45 Electrical/Garage Shift Test . . . . . . . . . . . . . . . 5A1­47 Road Test Procedure . . . . . . . . . . . . . . . . . . . . . 5A1­47 Torque Converter Lock­Up Clutch(TCC) Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1­48 TCM Initialization Procedure .

File name en_4j2_5a2.pdf

SECTION : 5A2 AISIN AUTOMATIC TRANSAXLE CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical erminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 5A2­3 General Specifications . . . . . . . . . . . . . . . . . . . . 5A2­3 Transaxle Gear Ratio . . . . . . . . . . . . . . . . . . . . . . 5A2­3 Fluid Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2­3 Line Pressure Specification . . . . . . . . . . . . . . . . 5A2­3 Fastener Tightening Specifications . . . . . . . . . . 5A2­4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2­5 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . 5A2­5 SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . 5A2­8 Transmission Control Module (1 of 4) . . . . . . . . 5A2­8 Transmission Control Module (2 of 4) . . . . . . . . 5A2­9 Transmission Control Module (3 of 4) . . . . . . . 5A2­10 Transmission Control Module (4 of 4) . . . . . . . 5A2­11 Shift Mode Diagram . . . . . . . . . . . . . . . . . . . . . . 5A2­12 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . 5A2­17 Shift Select Control . . . . . . . . . . . . . . . . . . . . . . 5A2­17 Automatic Transaxle Components . . . . . . . . . 5A2­18 Bearing and Races Installation Position Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2­24 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2­25 Electrical Connector View . . . . . . . . . . . . . . . . . 5A2­25 Wiring Harness and Connector Inspection . . . 5A2­27 Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2­27 Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2­28 Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2­30 On­Vehicle Repair (Matrix Chart) . . . . . . . . . . 5A2­34 DIAGNOSIS TROUBLE CODE DIAGNOSIS . 5A2­36 Diagnosis Trouble Code Chart . . . . . . . . . . . . . 5A2­36 DTC P0562 System Voltage Low . . . . . . . . . . 5A2­37 DTC P0563 System Voltage High . . . . . . . . . . 5A2­40 DTC P0601 Internal Control Module Memory Checksum Error . . . . . . . . . . . . . . . . . . . . . . . 5A2­43 DTC P0604 Internal Transmission Control Module (TCM) Random Access Memory (RAM) Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2­45 DTC P0705 Transmission Range (TR) Switch Circuit Malfunction . . . . . . . . . . . . . . . . . . . . . 5A2­47 DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input . . . . . . . . . . 5A2­50 DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input . . . . . . . . . . 5A2­53 DTC P0717 Input Shaft Speed (ISS) Sensor Circuit No Signal . . . . . . . . . . . . . . . . . . . .

File name en_4j2_5b.pdf

SECTION : 5B FIVE­SPEED MANUAL TRANSAXLE CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 5B­2 Fastener Tightening Specifications . . . . . . . . . . . 5B­2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B­3 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 5B­3 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B­5 Isolate Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B­5 Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 5B­6 COMPONENT LOCATORS . . . . . . . . . . . . . . . . . . 5B­9 Gears and Case . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B­9 Bearing Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B­11 Differential Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 5B­12 Shift Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B­13 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . Checking Fluid Level . . . . . . . . . . . . . . . . . . . . . . Shift Linkage Adjustment . . . . . . . . . . . . . . . . . . 5B­15 5B­15 5B­15 5B­15 Gearshift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B­17 Gearshift Lever Housing . . . . . . . . . . . . . . . . . . . 5B­18 Speedometer Driven Gear . . . . . . . . . . . . . . . . . 5B­18 Shift Linkage Assembly . . . . . . . . . . . . . . . . . . . . 5B­19 Drive Axle Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B­20 Transaxle Assembly . . . . . . . . . . . . . . . . . . . . . . . 5B­21 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B­26 Major Component Disassembly . . . . . . . . . . . . . 5B­26 Input Shaft and Cluster Gear . . . . . . . . . . . . . . . 5B­35 Mainshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B­37 Housing Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B­48 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B­50 Major Component Assembly . . . . . . . . . . . . . . . 5B­56 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B­63 Five­Speed Manual Transaxle . . . . . . . . . . . . . . 5B­63 5B ­ 2IFIVE­SPEED MANUAL TRANSAXLE SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Backup Lamp Switch Bearing Plate Bolts Bearing Retainer Bolts, Right Side Bearing­Adjusting Ring­Retainer Plate Bolt Clutch­Release Cylinder Retaining Bolts Damping Block Connection Nut and Bolt Differential Cover Bolts Fifth­Gear Fork Bolts Fifth­Gearshift Connector Bolts Flywheel I

File name en_4j2_5c.pdf

SECTION : 5C CLUTCH CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 5C­1 Fastener Tightening Specifications . . . . . . . . . . . 5C­1 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C­2 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 5C­2 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C­2 Clutch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 5C­2 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 5C­4 Clutch Components . . . . . . . . . . . . . . . . . . . . . . . . 5C­4 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 5C­6 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 5C­6 Clutch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C­6 Clutch Pedal Adjustment . . . . . . . . . . . . . . . . . . . . 5C­7 Clutch Release Point Adjustment . . . . . . . . . . . . 5C­8 Air Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C­8 Pressure Plate and Clutch Disc . . . . . . . . . . . . . . 5C­8 Clutch Master Cylinder Assembly . . . . . . . . . . . 5C­10 Concentric Slave Cylinder . . . . . . . . . . . . . . . . . . 5C­12 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C­14 Driving Members . . . . . . . . . . . . . . . . . . . . . . . . . 5C­14 Driven Members . . . . . . . . . . . . . . . . . . . . . . . . . . 5C­14 Operating Members . . . . . . . . . . . . . . . . . . . . . . . 5C­14 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Clutch Master Cylinder nuts Concentric Slave Cylinder Retaining Bolts Concentric Slave Cylinder­to­Clutch Oil Pipe Screw Pressure Plate­to­Flywheel Bolts NSm 22 7 15 15 Lb­Ft 16 ­ 11 11 Lb­In ­ 62 ­ ­ 5C ­ 2ICLUTCH SPECIAL TOOLS SPECIAL TOOLS TABLE J­42474 Clutch Arbor DIAGNOSIS CLUTCH OPERATION Intermittent Clutch Operation Checks Check for the driver improperly operating the vehicle. Check for the improper clutch pedal play. Check for the insufficient oil or the leak at oil pressure line. Check for a warped or worn clutch disc. Check for worn splines on the input shaft. Check for a weak diaphragm spring. Action Correct the driver's operation of the vehicle as necessary. Adjust the clutch pedal play. Repair the leak or add the oil. Replace the clutch disc. Repair or Replace the splines on the input shaft. Replace the pressure plate. Clutch Slipping Checks Check for a stuck concentric slave cylinder. Check for improper return of clutch oil. Check for a worn clutch disc or oil contamination. Check for a warped pressure plate. Action Replace the concent

File name en_4j2_6a.pdf

SECTION : 6A POWER STEERING SYSTEM TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 6A­1 Fastener Tightening Specifications . . . . . . . . . . . 6A­1 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A­1 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 6A­1 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A­2 Power Steering System Pressure Test . . . . . . . . 6A­2 Power Steering System Leak Test . . . . . . . . . . . 6A­2 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 6A­3 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6A­3 Bleeding the Power Steering System . . . . . . . . . 6A­3 Checking and Adding Fluid . . . . . . . . . . . . . . . . . . 6A­3 Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A­4 Hoses and Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . 6A­4 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A­8 Power Steering System . . . . . . . . . . . . . . . . . . . . . 6A­8 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Power Steering Pump Pressure Line Fitting Return Line Clip Bolts Steering Gear Inlet and Outlet Pipe Fittings NSm 28 8 28 Lb­Ft 21 ­ 21 Lb­In ­ 71 ­ SPECIAL TOOLS SPECIAL TOOLS TABLE KM­354­B Pressure Test Gauge Kit 6A ­ 2IPOWER STEERING SYSTEM DIAGNOSIS POWER STEERING SYSTEM PRESSURE TEST Tools Required KM­354­B Pressure Test Gauge Kit Check the fluid pressure as follows to determine whether the trouble is in the pump or the gear unit. POWER STEERING SYSTEM LEAK TEST General Procedure Inspect the following: S S S S S The fluid reservoir for overfill. Fluid for aeration and overflow. The hoses for loose connections. The torsion bar, stub shaft and adjuster seals for leaks. The component sealing surfaces for damage. Test Procedure 1. Check the power steering fluid level and the power steering pump belt tension. Refer to "Checking and Adding Fluid" in this section and Section 6B, Power Steering Pump. 2. Disconnect the high pressure line at the pump. Use a small container to catch any fluid. 3. Connect the hose of the pressure test gauge kit KM­354­B to the power steering pressure hose from the power steering pump. 4. Place the gear selector lever in PARK (automatic transaxle­equipped vehicles) or NEUTRAL (manual transaxle­equipped vehicles). Set the parking brake. 5. Open the gauge valve fully. 6. Start the engine and let it idle. 7. Turn the steering wheel from lock to lock several times to warm the fluid to operating temperature. 8. Increase the engine speed to 1,500 rpm. Notice : The power steering pump could be damaged if the valve is fully closed for more than 5 seconds. 9. Close the gauge valve fully, and read the pressure. The pump pressure with the valve closed should be between 8,330 kPa to 8,820 kPa (1,208 psi to 1,279 psi). With electronic variable orifice, the pressure should be between

File name en_4j2_6b.pdf

SECTION : 6B POWER STEERING PUMP TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 6B­1 General Specifications . . . . . . . . . . . . . . . . . . . . . 6B­1 Fastener Tightening Specifications . . . . . . . . . . . 6B­1 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B­2 Power Steering Pump Diagnosis . . . . . . . . . . . . . 6B­2 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 6B­3 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6B­3 Serpentine Accessory Drive Belt . . . . . . . . . . . . . 6B­3 Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B­4 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B­7 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B­7 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B­8 Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . 6B­8 SPECIFICATIONS GENERAL SPECIFICATIONS Application Lubricant Pressure ­ without EVO ­ with EVO 8330 kPa ~ 8820 kPa (1208 psi ~ 1279 psi) 8500 kPa ~ 8960 kPa (1233 psi ~ 1299 psi) Description Power Steering Fluid DEXRON®­II or III FASTENER TIGHTENING SPECIFICATIONS Application Air Filter Housing Assembly Bolts High­Pressure Hose Fitting Power Steering Pump Bolts Right Side Power Steering Pump Bracket Bolts NSm 6 28 25 35 Lb­Ft ­ 21 18 26 Lb­In 53 ­ ­ ­ 6B ­ 2IPOWER STEERING PUMP DIAGNOSIS POWER STEERING PUMP DIAGNOSIS Foaming or Milky Power Steering Fluid (Air in Fluid) Checks Check for internal leakage in the power steering pump, causing an overflow. Check for a low fluid level. Action Repair the internal pump leakage. Bleed the system. Repair the internal pump leakage. Bleed the system. Cold temperatures will cause the air bubbles in the system if the fluid level is low. Low Pressure Due to Power Steering Pump Checks Check for an external leakage of the power steering pump at the seals. Check for a worn serpentine accessory drive belt. Replace the seals. Repair the leak. Bleed the system. Replace the serpentine accessory drive belt. Action Low Pressure Due to Power Steering Gear Checks Check for a scored housing bore. Check for leakage at the valve rings or the seals. Repair the leak. Bleed the system. Action Replace the housing bore. Groaning Noise in the Power Steering Pump Checks Check for air in the power steering fluid. Check for a low level of power steering fluid. Check for a loose mounting of the power steering pump. Action Perform the checks listed in "Foaming or Milky Power Steering Fluid (Air in Fluid)" above. Repair any internal or external leaks. Bleed the system. Tighten the pump mounting to specifications. DAEWOO V­121 BL4 POWER STEERING PUMP 6B ­ 3 MAINTENANCE AND REPAIR ON­VEHICLE SERVICE SERPENTINE ACCESSORY DRIVE BELT Removal Procedure 1. 2. Remove the air filter housing assembly bolts and the air intake tube. Remove the air filter housing assembl

File name en_4j2_6c.pdf

SECTION : 6C POWER STEERING GEAR CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 6C­1 General Specifications . . . . . . . . . . . . . . . . . . . . . 6C­1 Fastener Tightening Specifications . . . . . . . . . . . 6C­2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C­2 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 6C­2 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C­3 Power Rack and Pinion Steering Gear . . . . . . . . 6C­3 Power Rack and Pinion Steering Gear Bench Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C­5 Speed Sensitive Power Steering System . . . . . . 6C­6 Speed Sensitive Power Steering System Operating With Full Assist At All Times . . . . . . . . . . . . . . . 6C­7 Speed Sensitive Power Steering System Operating with Decreased Assist At All Times . . . . . . . . . 6C­9 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 6C­11 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 6C­11 Rack and Pinion Assembly . . . . . . . . . . . . . . . . . 6C­11 Outer Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dust Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Straight­Ahead Check . . . . . . . . . . . . . . . . . . . . Intermediate Shaft and Dash Seal . . . . . . . . . . Hydraulic Cylinder Lines . . . . . . . . . . . . . . . . . . . Speed Sensitive Power Steering Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rack and Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . 6C­14 6C­15 6C­16 6C­17 6C­20 6C­21 6C­22 6C­22 Stub Shaft Seals and Upper and Lower Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C­26 Rack Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C­29 Rack Bearing Preload Adjustment . . . . . . . . . . . 6C­30 Valve and Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . 6C­30 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C­33 Power Rack and Pinion . . . . . . . . . . . . . . . . . . . . 6C­33 Speed Sensitive Power Steering System . . . . . 6C­33 SPECIFICATIONS GENERAL SPECIFICATIONS Application Capacity Lubricant 1.1 Liter (1.16 qt) Power Steering Fluid DEXRON®­II or III Description 6C ­ 2IPOWER STEERING GEAR FASTENER TIGHTENING SPECIFICATIONS Application Adjuster Plug Adjuster Plug Locknut Control Module Bracket Bolts Dash Seal Retaining Ring Nuts Hydraulic Cylinder Line Fittings ­ Cylinder End Hydraulic Cylin

File name en_4j2_6e.pdf

SECTION : 6E STEERING WHEEL AND COLUMN CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 6E­1 Fastener Tightening Specifications . . . . . . . . . . . 6E­1 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E­2 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 6E­2 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E­2 Steering Column Diagnosis . . . . . . . . . . . . . . . . . 6E­2 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 6E­8 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6E­8 Headlamp/Turn Signal Switch and Lever . . . . . . 6E­8 Wiper Switch and Lever . . . . . . . . . . . . . . . . . . . . 6E­9 Steering Wheel Rotation Sensor . . . . . . . . . . . . Steering Wheel Without SIR . . . . . . . . . . . . . . . . Steering Wheel With SIR . . . . . . . . . . . . . . . . . . Ignition Lock Cylinder and Switch . . . . . . . . . . . 6E­10 6E­11 6E­13 6E­13 Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . 6E­15 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E­19 Tilt Steering Column . . . . . . . . . . . . . . . . . . . . . . 6E­19 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E­20 Steering Wheel and Column . . . . . . . . . . . . . . . . 6E­20 Ignition Key Reminder . . . . . . . . . . . . . . . . . . . . . 6E­20 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Ignition Switch Housing Shear Bolts Ignition Switch Retaining Screw Steering Column Jacket Assembly Front Bracket Bolts Steering Column Jacket Assembly Rear Bracket Nuts Steering Shaft Universal Joint Pinch Bolt Steering Wheel Horn Cap Screws Steering Wheel Nut Steering Wheel Rotation Sensor Retaining Screw Support Housing Screws Turn Signal Switch Housing Screws Upper and Lower Steering Column Cover Panel Screws NSm 11 2.5 22 22 25 4.5 38 2 16 3 2.5 Lb­Ft ­ ­ 16 16 18 ­ 28 ­ 12 ­ ­ Lb­In 97 22 ­ ­ ­ 40 ­ 18 ­ 27 22 6E ­ 2ISTEERING WHEEL AND COLUMN SPECIAL TOOLS SPECIAL TOOLS TABLE KM­210­A Steering Wheel Puller DIAGNOSIS STEERING COLUMN DIAGNOSIS Lock System Lock System Will Not Unlock Checks Check the lock cylinder for damage. Check the ignition switch for lack of free movement. Check the steering column housing for binding or damage. Action Replace the lock cylinder. Lubricate the ignition switch. Remove the steering shaft and clear the steering column housing. Replace the steering column housing as needed. Lock System Will Not Lock Checks Check the lock cylinder for damage. Check the ignition switch for a lack of free movement. Che

File name en_4j2_7a.pdf

SECTION : 7A HEATING AND VENTILATION SYSTEM CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 7A­1 Heater Temperature Specifications . . . . . . . . . . . 7A­1 Fastener Tightening Specifications . . . . . . . . . . . 7A­1 SCHEMATIC AND ROUTING DIAGRAMS . . . . . 7A­3 Non­A/C Diagrams . . . . . . . . . . . . . . . . . . . . . . . . 7A­3 Airflow ­ Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A­4 Airflow with Rear Heating Duct . . . . . . . . . . . . . . 7A­5 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A­6 HEATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 7A­6 Insufficient Heating or Defrosting . . . . . . . . . . . . . 7A­6 Blower Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A­9 Improper Air delivery or No Mode Shift . . . . . . 7A­11 Too Much Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A­13 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A­15 Blower Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A­16 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 7A­18 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 7A­18 Temperature Cable Adjustment . . . . . . . . . . . . . 7A­18 Temperature Control Cable . . . . . . . . . . . . . . . . . 7A­18 Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 7A­20 Control Assembly Knob Lighting . . . . . . . . . . . . 7A­21 Heater/Air Distributor Case Assembly . . . . . . . 7A­21 Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A­23 High­Blower Relay . . . . . . . . . . . . . . . . . . . . . . . . 7A­24 Blower Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . 7A­25 Heater Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A­25 Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A­26 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A­28 Heating and Ventilation Systems . . . . . . . . . . . . 7A­28 SPECIFICATIONS HEATER TEMPERATURE SPECIFICATIONS Ambient Air Temperature ­18°C (0°F) ­ 4°C (25°F) 10°C (50°F) 24°C (75°F) Heater Outlet Air Temperature 54°C (129°F) 59°C (138°F) 64°C (147°F) 68°C (154°F) FASTENER TIGHTENING SPECIFICATIONS Application Blower Motor­to­A/C Assembly Screws Blower Motor Resistor Screws Blower Motor Retaining Screws Controller Retaining Screws Heater/Air Distributor Case Assembly Screw NSm 1.2 1.2 1.2 2 4 Lb­Ft ­ ­ ­ ­ ­ Lb­In 11 11 11 18 35 7A ­ 2IHEATING AND VENTILATION SYSTEM Application Heater Core Cover Screws Heater Core Housing­to­Evaporator

File name en_4j2_7b.pdf

SECTION : 7B MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 7B­2 General Specifications . . . . . . . . . . . . . . . . . . . . . 7B­2 Fastener Tightening Specifications . . . . . . . . . . . 7B­2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B­3 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 7B­3 SCHEMATIC AND ROUTING DIAGRAMS . . . . . 7B­6 A/C System ­ Typical . . . . . . . . . . . . . . . . . . . . . . 7B­6 Manual Control A/C Diagram . . . . . . . . . . . . . . . . 7B­7 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B­8 GENERAL DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 7B­8 Testing the Refrigerant System . . . . . . . . . . . . . . 7B­8 Insufficient Cooling "Quick Check" Procedure . . 7B­8 A/C Performance Test . . . . . . . . . . . . . . . . . . . . . . 7B­9 Pressure­Temperature Relationship of R­134A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B­10 Leak Testing Refrigerant System . . . . . . . . . . . . 7B­11 V5 SYSTEM AIR CONDITIONING DIAGNOSIS 7B­12 Insufficient Cooling Diagnosis . . . . . . . . . . . . . . 7B­12 SYMPTOM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 7B­16 Pressure Test Chart (R­134A System) . . . . . . 7B­16 Low and High Side Pressure Relationship Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B­18 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 7B­19 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 7B­19 GENERAL A/C SYSTEM SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . 7B­19 O­Ring Replacement . . . . . . . . . . . . . . . . . . . . . 7B­19 Handling Refrigerant . . . . . . . . . . . . . . . . . . . . . . 7B­19 Handling of Refrigerant Lines and Fittings . . . . 7B­19 Maintaining Chemical Stability in the Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B­20 Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System . . . . . . . . . . . . . . 7B­20 SERVICEABLE COMPONENTS . . . . . . . . . . . . . 7B­23 Components Used In Non­A/C Systems . . . . . A/C Pressure Transducer . . . . . . . . . . . . . . . . . . A/C Compressor Relay . . . . . . . . . . . . . . . . . . . . Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A/C Expansion Valve . . . . . . . . . . . . . . . . . . . . . . A/C High­Pressure Pipe Line . . . . . . . . . . . . . . . Evaporator Core . . . . . . . . . . . . . . . . . . . . . . . . . . A/C Suction Hose Assembly . . . . . . . . . .

File name en_4j2_7d.pdf

SECTION : 7D AUTOMATIC TEMPERATURE CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 7D­2 Fastener Tightening Specifications . . . . . . . . . . . 7D­2 SCHEMATIC AND ROUTING DIAGRAMS . . . . . 7D­3 A/C Sensors/Defoggers and A/C Compressor Controls Diagram . . . . . . . . . . . . . . . . . . . . . . . . 7D­3 A/C Blower and Motor Controls Diagram . . . . . . 7D­4 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7D­5 GENERAL A/C DIAGNOSTICS . . . . . . . . . . . . . . . 7D­5 V5 SYSTEM AIR CONDITIONING AND AUTOMATIC TEMPERATURE CONTROL (ATC) . . . . . . . . . . 7D­5 Self­Diagnostic Circuit Check . . . . . . . . . . . . . . . 7D­5 Automatic Temperature Controller Does Not Operate When Ignition Is ON . . . . . . . . . . . . . . 7D­6 Controller Does Not Illuminate When Light Switch Is ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7D­7 No Hot Air From Blower . . . . . . . . . . . . . . . . . . . . 7D­8 No Cool Air From Blower . . . . . . . . . . . . . . . . . . 7D­10 Blower Motor Does Not Run At All . . . . . . . . . . 7D­12 Mode Control Do Not Work . . . . . . . . . . . . . . . . Air Source Selection Not Controlled . . . . . . . . . Compressor Magnetic Clutch Does Not Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . Code 1 ­ In­Car Sensor Error . . . . . . . . . . . . . 7D­14 7D­16 7D­17 7D­18 7D­18 Code 5 ­ Sun Sensor Error . . . . . . . . . . . . . . . . 7D­27 Code 6 ­ Power Transistor Error . . . . . . . . . . . . 7D­29 Code 7 ­ Max­Hi Relay Error . . . . . . . . . . . . . . 7D­31 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 7D­32 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 7D­32 GENERAL A/C SYSTEM SERVICE PROCEURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7D­32 General Service Procedures . . . . . . . . . . . . . . . 7D­32 SERVICEABLE COMPONENTS . . . . . . . . . . . . . 7D­33 Common HVAC Components . . . . . . . . . . . . . . . 7D­33 Automatic Temperature Control Assembly . . . . 7D­33 Inlet Air Door Motor . . . . . . . . . . . . . . . . . . . . . . . 7D­34 Mode Door Motor . . . . . . . . . . . . . . . . . . . . . . . . . 7D­35 Air Mix Door Motor . . . . . . . . . . . . . . . . . . . . . . . . 7D­35 Water Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7D­36 Ambient Air Temperature Sensor . . . . . . . . . . . 7D­36 In­Car Temperature Sensor . . . . . . . . . . . . . . . . 7D­37 Sun Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7D­37 UNIT

File name en_4j2_8a.pdf

SECTION : 8A SEAT BELTS CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8A­1 Fastener Tightening Specifications . . . . . . . . . . . 8A­1 SCHEMATIC AND ROUTING DIAGRAMS . . . . . 8A­2 Driver Seat Belt Warning . . . . . . . . . . . . . . . . . . . . 8A­2 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A­3 Driver Seat Belt Warning . . . . . . . . . . . . . . . . . . . . 8A­3 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . Pretensioner Front Seat Belt . . . . . . . . . . . . . . . . Front Seat Belt Height Adjuster . . . . . . . . . . . . . . 8A­4 8A­4 8A­4 8A­5 Three­Point Rear Seat Belt (LH,CENTER, RH) 8A­6 Front Seat Belt Buckle . . . . . . . . . . . . . . . . . . . . . 8A­7 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A­9 Driver Seat Belt Warning . . . . . . . . . . . . . . . . . . . . Three­Point ELR Front Seat Belt With Pretensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three­Point CLR (ELR) Rear Outboard Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operational and Functional Checks . . . . . . . . . . Child Seat Tether Anchor . . . . . . . . . . . . . . . . . . . 8A­9 8A­9 8A­9 8A­9 8A­9 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Child Seat Tether Anchor Bolt Front Seat Belt Height Adjuster Bolts Seat Belt Anchor Bolt Seat Belt Retractor Bracket Screws Seat Belt Retractor Bolt NSm 25 23 38 3 38 Lb­Ft 18 17 28 ­ 28 Lb­In ­ ­ ­ 27 ­ 8A ­ 2ISEAT BELTS SCHEMATIC AND ROUTING DIAGRAMS DRIVER SEAT BELT WARNING DAEWOO V­121 BL4 SEAT BELTS 8A ­ 3 DIAGNOSIS DRIVER SEAT BELT WARNING Seat Belt Warning Lamp Does Not Turn On at Any Time Step 1 2 Action Check the seat belt warning fuse F4. Is fuse F4 blown? 1. Check for a short circuit and repair if necessary. 2. Replace the fuse. Is the repair complete? 1. Turn the ignition ON. 2. Check the voltage at fuse F4. Is the voltage equal to the specified value? Repair the open power supply circuit for fuse F4. Is the repair complete? 1. Disconnect the seat belt switch connector (located under the driver's seat). 2. Connect a jumper between the terminals on the harness side of the seat belt switch connector. 3. Turn the ignition ON. Does the seat belt warning lamp turn on? Replace the seat belt switch. Is the repair complete? 1. Remove the instrument cluster. 2. Check the seat belt warning lamp bulb. Is the bulb OK? Replace the warning lamp bulb. Is the repair complete? Repair the open circuit between instrument cluster term

File name en_4j2_8b.pdf

SECTION : 8B SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition mujst be also be in LOCK unless otherwise noted TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8B­3 General Specifications . . . . . . . . . . . . . . . . . . . . . 8B­3 Fastener Tightening Specifications . . . . . . . . . . . 8B­3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B­3 SPECIAL TOOLS TABLE . . . . . . . . . . . . . . . . . . . 8B­3 SCHEMATIC AND ROUTING DIAGRAMS . . . . . 8B­4 Supplemental Inflatable Restraints(SIR) Electronical Schematic . . . . . . . . . . . . . . . . . . . . 8B­4 SIR Component Locator . . . . . . . . . . . . . . . . . . . . 8B­5 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B­6 Diagnostic Trouble Code (DTC) . . . . . . . . . . . . . . 8B­6 Scan Tool Diagnostics . . . . . . . . . . . . . . . . . . . . . . 8B­7 SIR Diagnostic System Check . . . . . . . . . . . . . . . 8B­8 Sensing and Diagnostic Module (SDM) Integrity check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B­10 DTC 1 Driver Airbag Deployment Loop Resistance Is High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B­12 DTC 2 Driver Airbag Deployment Loop Resistance Is Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B­14 DTC 3 Driver Airbag Deployment Loop Is Shorted To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B­16 DTC 4 Driver Airbag Deployment Loop Is Shorted To Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B­18 DTC 5 Passenger Airbag Deployment Loop Resistance Is High . . . . . . . . . . . . . . . . . . . . . . 8B­20 DTC 6 Passenger Airbag Deployment Loop Resistance Is Low . . . . . . . . . . . . . . . . . . . . . . 8B­22 DTC 7 Passenger Airbag Deployment Loop Is Shorted To Ground . . . . . . . . . . . . . . . . . . . . . . 8B­24 DTC 8 Passenger Airbag Deployment Loop Is Shorted To Power . . . . . . . . . . . . . . . . . . . . . . . 8B­26 DTC 9 Driver Belt Pretensioner Deployment Loop Resistance Is High . . . . . . . . . . . . . . . . . 8B­28 DTC 10 Driver Belt Pretensioner Deployment Loop Resistance Is Low . . . . . . . . . . . . . . . . . . 8B­30 DTC 11 Driver Belt Pretensioner Deployment Loop Is Shorted To Ground . . . . . . . . . . . . . . . 8B­32 DTC 12 Driver Belt Pretensioner Deployment Loop Is Shorted To Power . . . . . . . . . . . . . . . . 8B­34 DTC 13 Passenger Belt Pretensioner Deployment Loop Resistance Is High . . . . . . . . . . . . . . . . . 8B­36 DTC 14 Passenger Belt Pretensioner Deployment Loop Resistance Is Low . . . . . . . . . . . . . . . . . . 8B­38 DTC 15 Passenger Belt Pretensioner Deployment Loop I

File name en_4j2_9a.pdf

SECTION : 9A BODY WIRING SYSTEM CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SCHEMATIC AND ROUTING DIAGRAMS . . . . . 9A­1 Wire Color Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A­1 Power Distribution Schematic . . . . . . . . . . . . . . . 9A­3 Fuse Block Locator (Engine) . . . . . . . . . . . . . . . 9A­12 Fuse Block Locator (Passenger Compartment) 9A­12 Fuse Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A­13 Front Harness Routing . . . . . . . . . . . . . . . . . . . . Rear Harness Routing . . . . . . . . . . . . . . . . . . . . . Hatchback Rear Harness Routing . . . . . . . . . . . Floor Harness Routing . . . . . . . . . . . . . . . . . . . . 9A­15 9A­16 9A­17 9A­18 Instrument Harness Routing . . . . . . . . . . . . . . . . 9A­19 Door Harness Routing . . . . . . . . . . . . . . . . . . . . . 9A­20 SCHEMATIC AND ROUTING DIAGRAMS WIRE COLOR CHART Wire Color Green Light Green Blue Brown Orange Yellow Grey Sky Blue Red Black Pink White Purple DK GRN LT GRN DK BLU BRN ORN YEL GRY LT BLU RED BLK PNK WHT PPL Abbreviation On Schematic 9A ­ 2IBODY WIRING SYSTEM Wires With Tracers Wire Color Red with White Tracer Red with Black Tracer Brown with White Tracer Black with White Tracer Black with Yellow Tracer Green with Black Tracer Green with White Tracer Light Green with Black Tracer Red with Yellow Tracer Red with Blue Tracer Black with Brown Tracer RED/WHT RED/BLK BRN/WHT BLK/WHT BLK/YEL DK GRN/BLK DK GRN/WHT LT GRN/BLK RED/YEL RED/DK BLU BLK/BRN Abbreviation On Schematic DAEWOO V­121 BL4 BODY WIRING SYSTEM 9A ­ 3 POWER DISTRIBUTION SCHEMATIC DAEWOO V­121 BL4 9A ­ 4IBODY WIRING SYSTEM DAEWOO V­121 BL4 BODY WIRING SYSTEM 9A ­ 5 DAEWOO V­121 BL4 9A ­ 6IBODY WIRING SYSTEM C404 C406 (H/B) (N/B) Defog(+) DAEWOO V­121 BL4 7 3 BODY WIRING SYSTEM 9A ­ 7 DAEWOO V­121 BL4 9A ­ 8IBODY WIRING SYSTEM DAEWOO V­121 BL4 BODY WIRING SYSTEM 9A ­ 9 DAEWOO V­121 BL4 9A ­ 10IBODY WIRING SYSTEM DAEWOO V­121 BL4 BODY WIRING SYSTEM 9A ­ 11 DAEWOO V­121 BL4 9A ­ 12IBODY WIRING SYSTEM FUSE BLOCK LOCATOR (ENGINE) J3B19A10 FUSE BLOCK LOCATOR (PASSENGER COMPARTMENT) DAEWOO V­121 BL4 BODY WIRING SYSTEM 9A ­ 13 FUSE CHART Engine Room Fuse Block Fuse EF1 EF2 EF3 EF4 EF5 EF6 EF7 EF8 EF9 EF10 EF11 EF12 EF13 EF14 EF15 EF16 EF17 EF18 EF19 30A 60A 30A 30A 30A 20A 30A 30A 20A 15A 10A 25A 15A 20A 15A 15A 10A 15A 15A Rating/Source B+ B+ B+ B+ B+ B+ B+ B+ IGN 2 IGN 1 B+ B+ B+ IGN 2 Light B+ B+ IGN 1 B+ Circuit Battery Main (F13~F16, F21~F24) EBCM, Oil Feeding Connector Blower Relay Ignition Switch­2 Ignition Switch­1 Cooling Fan Low Relay Defog Relay Cooling Fan HI Relay Power Window Switch Fuel Connector, ECM (MR­1

File name en_4j2_9b.pdf

SECTION : 9B LIGHTING SYSTEMS CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9B­2 Bulb Usage Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 9B­2 Fastener Tightening Specifications . . . . . . . . . . . 9B­2 SCHEMATIC AND ROUTING DIAGRAMS . . . . . Backup Lamps Circuit . . . . . . . . . . . . . . . . . . . . . . Instruments Circuit (W/O Dimmer Control : General Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . Instruments Circuit (W/ Dimmer Control) . . . . . . 9B­3 9B­3 9B­4 9B­5 Headlamps/Front Turn Signal Lamps . . . . . . . . Daytime Running Lamp Module . . . . . . . . . . . . . Parking Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . Side Turn Signal Lamps . . . . . . . . . . . . . . . . . . . Front Fog Lamps . . . . . . . . . . . . . . . . . . . . . . . . . Notchback Rear Combination Lamps . . . . . . . . Hatchback Rear Combination Lamps . . . . . . . . Hatchback Extension Lamps . . . . . . . . . . . . . . . 9B­36 9B­37 9B­37 9B­38 9B­38 9B­39 9B­40 9B­40 Front And Rear Fog Lamps Circuit . . . . . . . . . . . 9B­6 Headlamps­On Reminder Chime Circuit . . . . . . 9B­7 Headlamps and Headlamp Leveling Circuit . . . . 9B­8 Daytime Running Lamps Circuit . . . . . . . . . . . . . 9B­9 Parking, Tail and License Lamps Circuit . . . . . . 9B­10 Stoplamps Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 9B­11 Turn and Hazard Lamps Circuit . . . . . . . . . . . . . 9B­12 Interior Courtesy and Luggage Compartment Lamp Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B­13 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B­14 Headlamps­On Reminder Chime . . . . . . . . . . . 9B­14 Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlamp Leveling . . . . . . . . . . . . . . . . . . . . . . . Daytime Running Lamps . . . . . . . . . . . . . . . . . . . Parking Lamps and Taillamps . . . . . . . . . . . . . . 9B­16 9B­20 9B­22 9B­23 Notchback Center High­Mounted Stoplamp . . 9B­41 Hatchback Center High­Mounted Stoplamp . . 9B­41 License Plate Lamps . . . . . . . . . . . . . . . . . . . . . . 9B­42 Door Jamb Switch . . . . . . . . . . . . . . . . . . . . . . . . Center Room Lamp . . . . . . . . . . . . . . . . . . . . . . . Map Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Luggage Compartment Lamp . . . . . . . . . . . . . . . 9B­42 9B­43 9B­43 9B­44 Ashtray and Cigar Lighter Lamp . . . . . . . . . . . . 9B­44 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B­46 Headlamps­On Reminder Chime . . . . . . . . . .

File name en_4j2_9c.pdf

SECTION : 9C HORN(S) CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9C­1 Fastener Tightening Specifications . . . . . . . . . . . 9C­1 SCHEMATIC AND ROUTING DIAGRAMS . . . . . 9C­2 Horn Wiring System . . . . . . . . . . . . . . . . . . . . . . . . 9C­2 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 9C­3 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9C­3 Horn(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9C­3 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9C­4 Horn(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9C­4 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Horn Bolt NSm 20 Lb­Ft 15 Lb­In ­ 9C ­ 2IHORN(S) SCHEMATIC AND ROUTING DIAGRAMS HORN WIRING SYSTEM DAEWOO V­121 BL4 HORN(S) 9C ­ 3 MAINTENANCE AND REPAIR ON­VEHICLE SERVICE HORN(S) Removal Procedure 1. 2. 3. Disconnect the negative battery cable. Disconnect the electrical connector. Remove the bolt and the horn. (Left horn shown, right horn similar, if equipped.) Installation Procedure Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. 1. Install the horn with the bolt. Tighten Tighten the horn bolt to 20 NSm (15 lb­ft). (Left horn shown, right horn similar, if equipped.) 2. 3. Connect the electrical connector. Connect the negative battery cable. DAEWOO V­121 BL4 9C ­ 4IHORN(S) GENERAL DESCRIPTION AND SYSTEM OPERATION HORN(S) The horns are located under the hood. They are attached near the radiator at the front of the vehicle. The horns are actuated by pressing the steering wheel pad, which grounds the horns' electrical circuit. DAEWOO V­121 BL4

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SECTION : 9D WIPERS/WASHER SYSTEMS CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9D­1 Fastener Tightening Specifications . . . . . . . . . . . 9D­1 SCHEMATIC AND ROUTING DIAGRAMS . . . . . Wipers and Washer System . . . . . . . . . . . . . . . . . Wipers and Washer System . . . . . . . . . . . . . . . . . Wipers and Washer System (HatchBack) . . . . . 9D­2 9D­2 9D­3 9D­4 Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . 9D­14 Windshield Wiper Blade . . . . . . . . . . . . . . . . . . . 9D­15 Windshield Wiper Blade Insert . . . . . . . . . . . . . . 9D­16 Windshield Washer Reservoir . . . . . . . . . . . . . . 9D­16 Windshield Washer Pump(s) . . . . . . . . . . . . . . . 9D­17 Windshield Washer Nozzles . . . . . . . . . . . . . . . . 9D­18 Windshield Washer Hoses . . . . . . . . . . . . . . . . . 9D­18 Rear Window Wiper Arm (HATCHBACK) . . . . 9D­19 Rear Window Wiper Motor (HATCHBACK) . . . 9D­20 Rear Window Washer Nozzle (HATCHBACK) 9D­20 Wipers and Washer System (HatchBack) . . . . . 9D­5 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9D­6 Windshield Wipers . . . . . . . . . . . . . . . . . . . . . . . . . 9D­6 Windshield Washer System . . . . . . . . . . . . . . . . 9D­10 Rear Window Wiper (Hatchback) . . . . . . . . . . . 9D­11 Rear Window Washer System (Hatchback) . . . 9D­13 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 9D­14 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 9D­14 Windshield Wiper Arm . . . . . . . . . . . . . . . . . . . . . 9D­14 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9D­22 Windshield Wiper System . . . . . . . . . . . . . . . . . . 9D­22 Windshield Washer System . . . . . . . . . . . . . . . . 9D­22 Rear Window Wiper/Washer System . . . . . . . . 9D­22 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Front Wheel Well Splash Shield Bolts Washer Fluid Reservoir Bolts Wiper Arm Linkage Nut Wiper Arm Nut Wiper Motor Bolts Rear Wiper Arm Nut NSm 1.5 8 5 22 8 11 Lb­Ft ­ ­ ­ 16 ­ ­ Lb­In 13 71 44 ­ 71 97 9D ­ 2IWIPERS/WASHER SYSTEMS SCHEMATIC AND ROUTING DIAGRAMS WIPERS AND WASHER SYSTEM DAEWOO V­121 BL4 WIPERS/WASHER SYSTEMS 9D ­ 3 WIPERS AND WASHER SYSTEM DAEWOO V­121 BL4 9D ­ 4IWIPERS/WASHER SYSTEMS WIPERS AND WASHER SYSTEM (HATCHBACK) DAEWOO V­121 BL4 WIPERS/WASHER SYSTEMS 9D ­ 5 WIPERS AND WASHER SYSTEM (HATCHBACK) DAEWOO V­121 BL4 9D ­ 6IWIPERS/WASHER SYSTEMS DIAGNOSIS WINDSHIELD WIPERS Windshield Wipers Do Not Work At Any Speed Step 1 2 Check fuse F9. Is fuse F9 blown? 1. Check for a short circuit and repair it, if

File name en_4j2_9e.pdf

SECTION : 9E INSTRUMENTATION/DRIVER INFORMATION CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9E­2 Fastener Tightening Specifications . . . . . . . . . . . 9E­2 Instrument Cluster Indicator Lamps Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E­2 SCHEMATIC AND ROUTING DIAGRAMS . . . . . Instrument Cluster Circuit (1 of 2) . . . . . . . . . . . . Instrument Cluster Circuit (2 of 2) . . . . . . . . . . . . Cigar Lighter And Extra Power Jack Circuit . . . . 9E­3 9E­3 9E­4 9E­5 Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E­20 Glove Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E­20 Notchback Deposit Box . . . . . . . . . . . . . . . . . . . . 9E­21 Notchback Digital Clock . . . . . . . . . . . . . . . . . . . 9E­21 Hatchback Digital Clock . . . . . . . . . . . . . . . . . . . 9E­22 Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . 9E­23 Instrument Cluster Dimmer/Headlamp Leveling Switch . . . . . . . . . . . . . . . . . . . . . . . . . 9E­23 Instrument Cluster Indicator Lamps . . . . . . . . . 9E­24 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . 9E­24 Chime Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E­28 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E­30 Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E­30 Ashtray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E­30 Instrument Panel Vents . . . . . . . . . . . . . . . . . . . . 9E­30 Glove Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E­30 Digital Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E­30 Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . 9E­30 Speedometer/Odometer/Trip Odometer . . . . . . 9E­30 Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E­30 Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . 9E­30 Instrument Cluster Indicator Lamps . . . . . . . . . 9E­30 Chime Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E­30 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E­6 Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E­6 Digital Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E­7 Instrument Panel Illumination . . . . . . . . . . . . . . . . 9E­9 Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E­10 Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Gauge . . . . . .

File name en_4j2_9f.pdf

SECTION : 9F AUDIO SYSTEMS CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9F­1 Fastener Tightening Specifications . . . . . . . . . . . 9F­1 SCHEMATIC AND ROUTING DIAGRAMS . . . . . 9F­2 Audio System Circuit . . . . . . . . . . . . . . . . . . . . . . . 9F­2 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F­3 Stereo Cassette AM/FM Radio . . . . . . . . . . . . . . 9F­3 Speakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F­5 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 9F­7 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9F­7 Stereo Cassette AM/FM Radio . . . . . . . . . . . . . . 9F­7 Audio Remote Controller . . . . . . . . . . . . . . . . . . . . 9F­7 Notchback CD Changer . . . . . . . . . . . . . . . . . . . . Door Speakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tweeter Speakers . . . . . . . . . . . . . . . . . . . . . . . . . Glass Antenna Module . . . . . . . . . . . . . . . . . . . . . 9F­8 9F­8 9F­9 9F­9 Hatchback Windshield Antenna Module . . . . . . 9F­10 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F­11 Stereo Cassette AM/FM Radio . . . . . . . . . . . . . . 9F­11 Audio Scurity System . . . . . . . . . . . . . . . . . . . . . . 9F­11 Speakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F­11 Tape Player and Cassette Care . . . . . . . . . . . . . . 9F­11 Compact Disc Care . . . . . . . . . . . . . . . . . . . . . . . . 9F­11 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Door Speaker Screws Rear Speaker Screws Glass Antenna Screws NSm 2 2 2 Lb­Ft ­ ­ ­ Lb­In 18 18 18 9F ­ 2IAUDIO SYSTEMS SCHEMATIC AND ROUTING DIAGRAMS AUDIO SYSTEM CIRCUIT DAEWOO V­121 BL4 AUDIO SYSTEMS 9F ­ 3 DIAGNOSIS STEREO CASSETTE AM/FM RADIO CD Player Inoperative, AM/FM Functions OK Step 1 Action Using a good­quality CD, determine if the CD player performs poorly or is inoperative. Does the CD player function correctly? Inform the customer that the problem is with the CD, not the CD player. Has the customer been informed? Check the CD player for obstructions behind the tape door. Is an obstruction found? Check to see if the obstruction can be removed. Can the obstruction be removed? Remove the obstruction. Is the repair complete? Replace the CD player. Is the repair complete? Value(s) ­ Yes Go to Step 2 No Go to Step 3 2 ­ System OK ­ 3 ­ Go to Step 4 Go to Step 6 4 5 6 ­ ­ ­ Go to Step 5 System OK System OK Go to Step 6 ­ ­ AM/FM Cassette Radio Inoperative Step 1 2 Action Check fuses F23 and F17. A

File name en_4j2_9g0.pdf

SECTION : 9G INTERIOR TRIM CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9G­1 Fastener Tightening Specifications . . . . . . . . . . . 9G­1 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G­2 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 9G­2 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . Front Door Trim Panel . . . . . . . . . . . . . . . . . . . . . . Rear Door Trim Panel . . . . . . . . . . . . . . . . . . . . . . A­pillar Trim Panel . . . . . . . . . . . . . . . . . . . . . . . . . Upper B­pillar Trim Panel . . . . . . . . . . . . . . . . . . . Lower B­pillar Trim Panel . . . . . . . . . . . . . . . . . . . C­pillar Trim Panel . . . . . . . . . . . . . . . . . . . . . . . . . 9G­3 9G­3 9G­3 9G­4 9G­4 9G­5 9G­5 9G­6 Floor Carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G­10 Luggage Compartment Rear Low Cover . . . . . 9G­11 Luggage Compartment Wheelhouse Trim Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G­12 Driver's Side Knee Bolster . . . . . . . . . . . . . . . . . 9G­12 Hatchback Door Lower Garnish Molding . . . . . 9G­13 Hatchback Door Upper Garnish Molding . . . . . 9G­14 Luggage Compartment Wheelhouse Trim Panel (HATCHBACK) . . . . . . . . . . . . . . . . . . . . . . . . . 9G­14 Luggage Compartment Rear Trim Panel . . . . . 9G­14 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G­16 Interior Trim Panels . . . . . . . . . . . . . . . . . . . . . . . 9G­16 Pressure Relief Vent . . . . . . . . . . . . . . . . . . . . . . 9G­16 Floor Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G­16 Floor Carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G­16 Rear Compartment Security Cover (HATCHBACK) . . . . . . . . . . . . . . . . . . . . . . . . . 9G­16 Deck Lid Sill Plate Cover . . . . . . . . . . . . . . . . . . . 9G­6 Front Rocker Trim Panel . . . . . . . . . . . . . . . . . . . . 9G­7 Rear Rocker Trim Panel . . . . . . . . . . . . . . . . . . . . 9G­7 Front Wheelhouse Trim . . . . . . . . . . . . . . . . . . . . . 9G­8 Rear Wheelhouse Trim . . . . . . . . . . . . . . . . . . . . . 9G­8 Floor Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G­9 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Door Trim Panel Screws Driver's Side Knee Bolster Mounting Bolts Floor Console Screws Gearshift Housing Bolts Hood Latch Release Handle Mounting Screw Seat Belt Anchor Bolt NSm 2.5 10 2.5 8 3 38 Lb­Ft ­ ­ ­ ­ ­ 28 Lb­In 2

File name en_4j2_9h0.pdf

SECTION : 9H SEATS CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9H­2 Fastener Tightening Specifications . . . . . . . . . . . 9H­2 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 9H­3 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9H­3 Front Bucket Seat . . . . . . . . . . . . . . . . . . . . . . . . . 9H­3 Front Seatback . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9H­4 Front Seat Cushion . . . . . . . . . . . . . . . . . . . . . . . . 9H­5 Lumbar Support Lever . . . . . . . . . . . . . . . . . . . . . . 9H­5 Height Adjustment Knobs . . . . . . . . . . . . . . . . . . . 9H­6 Front Seat Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9H­6 Head Restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Seat Cushion . . . . . . . . . . . . . . . . . . . . . . . . . Split Rear Seatback . . . . . . . . . . . . . . . . . . . . . . . . Split Rear Seatback Hinge . . . . . . . . . . . . . . . . . . 9H­7 9H­8 9H­8 9H­9 Rear Seat Center Armrest . . . . . . . . . . . . . . . . . . 9H­9 Seat Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9H­10 Child Seat Anchorage . . . . . . . . . . . . . . . . . . . . . 9H­10 Hatchback Child Seat Anchorage . . . . . . . . . . . 9H­11 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9H­12 Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9H­12 9H ­ 2ISEATS SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Armrest Nuts Front Seatback Bolts Front Seat Cover Screws Front Seat Cushion Bolts Front Seat Trim Screws Front Seat­to­Floor Bolts Rear Seatback Bolts Rear Seat Hinge Bolts Seat Recliner Lever Screw Slide Assembly Bolts Slide Assembly Screws NSm 24 45 12 12 12 25 25 45 12 25 10 Lb­Ft 18 33 ­ ­ ­ 18 18 33 ­ 18 ­ Lb­In ­ ­ 106 106 106 ­ ­ ­ 106 ­ 89 DAEWOO V­121 BL4 SEATS 9H ­ 3 MAINTENANCE AND REPAIR ON­VEHICLE SERVICE FRONT BUCKET SEAT Removal Procedure 1. 2. Disconnect the negative battery cable. Remove the plastic caps and the bolts securing the rear portion of the front seat to the floor. 3. 4. 5. Remove the plastic caps and the bolts securing the front portion of the front seat to the floor. Disconnect the electrical connectors. Remove the seat. Installation Procedure 1. Install the seat. 2. Connect the electrical connectors. Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. 3. Install the bolts into the front portion of the front seat. Tighten 4. Tighten the front seat­to­floor b

File name en_4j2_9i0.pdf

SECTION : 9I WATERLEAKS TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 9I­1 Recommended Materials for Waterleak Repairs . 9I­1 Watertest Stand Specifications . . . . . . . . . . . . . . . 9I­1 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9I­2 Waterleak Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 9I­2 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . . 9I­5 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . 9I­5 Waterleak Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 9I­5 SPECIFICATIONS RECOMMENDED MATERIALS FOR WATERLEAK REPAIRS Leak Areas Windshield, back window Metal joints Ventilation ducts Small cracks and pin holes Large holes Weatherstrips Bolts, studs, and screws Repair Materials Urethane adhesive, caulking kit, or the equivalent Brushable seam sealer which can be painted 3Mnv Auto Bedding and Glazing Compound or the equivalent 3Mnv Drip­Check Sealer or the equivalent 3Mnv Automotive Joint and Seam Sealer 3Mnv 08011 Weatherstrip Adhesive or the equivalent Strip caulk WATERTEST STAND SPECIFICATIONS Application Nozzle Type Nozzle Height Volume of Flow Pressure Windshield and A­Pillar Test Stand Position B­Pillar Test Stand Position Back Window and Rear Deck Lid Test Stand Position Description Full jet spray nozzle #1/2 GG­25 or equivalent with a 60° included angle Approximately 1 600 mm (63.0 in.) from the floor 14L (3.7 gal) per minute 155 kPa (22.5 psi) measured at the nozzle Approximately 30° down, 45° toward the rear, and aimed at the corner of the windshield Approximately 30° down, 45° toward the rear, and aimed at the center of the rear door Approximately 30° down, 30° toward the front and aimed approximately 610 mm (24.0 in.) from the corner of the back window 9I ­ 2IWATERLEAKS DIAGNOSIS WATERLEAK DIAGNOSIS The repair of waterleaks in the body requires proper testing and diagnosis. Repair waterleaks by adjusting the misaligned parts and using the proper repair materials. First, determine what conditions cause the leak. For example, the leak may occur only when the vehicle is parked on an incline, or water may appear only in the spare tire compartment. Second, test the area for the source of the leak using the following testing methods. If the general leak area is found, determine the exact entry point of the leak by using a water hose or an air hose. If the general leak area is not obvious, use the watertest stands to determine the area of the leak. It may be necessary to remove some interior trim panels or some parts in order to locate the leaks. Important : It is necessary to find the origin of all the leaks before making any repairs. Random repairs may stop the leak only temporarily and may make future repairs more difficult. Continue localized testing in the general area in order to ensure that all leaks are found. 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 2. 1/2­inch by 36­inch Pip

File name en_4j2_9j0.pdf

SECTION : 9J WINDNOISE TABLE OF CONTENTS DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J­1 Windnoise Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 9J­1 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . . 9J­2 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . 9J­2 Windnoise Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J­2 DIAGNOSIS WINDNOISE DIAGNOSIS CAUTION : An assistant should drive the vehicle while the technician checks for the location of the windnoise, in order to prevent personal injury or vehicle damage. A test drive in the vehicle is necessary to accurately determine the location of the windnoise. Often there is a primary leak and secondary leaks. Failure to repair all leaks will only reduce the windnoise, not eliminate it. During the test drive the technician should bring the following items to aid in determining the location of the windnoise. S A mechanics stethoscope or vacuum hose S Masking tape S Strip caulk S A china marking pencil S A screwdriver Perform the following steps in order to conduct the road test: 1. Choose a route that includes smooth straight streets that run in all four directions (north, south, east, and west). Choose streets with little traffic or noise that would interfere with the test. Drive the vehicle at the speeds at which the noise was noticed by the customer or until the noise is produced. Do not exceed legal speed limits. The windnoise is external if any of the following conditions occur: S The windnoise is caused by the wind. 5. The windnoise can be heard with the door glass lowered and while the vehicle is being driven. S The windnoise is eliminated when tape is placed over various moldings and gaps. Internal windnoise is air leaving the vehicle and should be repaired in the following manner. S In order to locate the leak, tape off the body lock pillar pressure relief valves. This will cause air pressure to build up inside the vehicle and enhance the windnoise. S Use a stethoscope or a vacuum hose to locate the leak. S Temporarily repair the leak with masking tape. S 2. 3. S S 4. Continue testing in order to determine if the noise has been eliminated or if other leaks exist. When all leaks have been found, return to the shop and make permanent repairs with the proper alignment techniques and sealing materials. 9J ­ 2IWINDNOISE MAINTENANCE AND REPAIR ON­VEHICLE SERVICE WINDNOISE REPAIR Windnoise leak repairs are very similar to waterleak repairs. Refer to Section 9I, Waterleaks. The actual procedure depends on the type of seal being repaired. Leaks around the door opening weatherstrips do not always indicate a faulty weatherstrip. A door or window adjustment may resolve the condition. Refer to Section 9P, Doors or Section 9L, Glass and Mirrors. DAEWOO V­121 BL4

File name en_4j2_9k0.pdf

SECTION : 9K SQUEAKS AND RATTLES TABLE OF CONTENTS DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9K­1 Squeak and Rattle Diagnosis . . . . . . . . . . . . . . . . 9K­1 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 9K­3 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9K­3 Squeak and Rattle Repair . . . . . . . . . . . . . . . . . . . 9K­3 DIAGNOSIS SQUEAK AND RATTLE DIAGNOSIS Rattle Coming From the Side Rail Checks Check the brake lines. S S Action Tap lightly on the brake lines and listen for a rattle. Install plastic tie straps to secure the brake lines tightly together. Rattle Under Vehicle at Higher RPM Checks Check for heat shield contact with the underbody. S S Action Raise the vehicle and perform a visual inspection. Bend the heat shield slightly to gain clearance from the underbody. Squeak From the Front of the Vehicle in Cold Weather Checks Check the front stabilizer shaft insulators. S Action While the vehicle is cold, perform a test drive and achieve full front suspension travel by driving through a dip in the road. Remove the insulators and wrap teflon tape around the stabilizer shaft. Reinstall the insulators over the tape. S Thump From Rear of Vehicle on Bumps Checks Check for a properly secured spare tire in the rear compartment. S S S Action Open the rear compartment and perform a visual inspection of the spare tire and the tools. Tightly secure the spare tire and all tools. Perform a road test to verify that the noise is eliminated. 9K ­ 2ISQUEAKS AND RATTLES Glass Knock Coming From the Rear of the Vehicle When Driving Over Bumps Checks Check for an out­of­adjustment hatchback latch. S S Action Test drive the vehicle in order to verify this condition. Loosen the latch nuts and adjust the latch downward. Rattle Coming From Door Checks Check the door lock solenoid. S S Check for rattling electrical connectors inside the door trim panel. S S Action Remove the door trim panel and check if the solenoid is loose. Tighten the solenoid bolts. Tap on the trim panel and listen for a rattle. Remove the trim panel and wrap foam padding around the connectors as required. Squeak When Operating Doors Checks Check for a lack of lubrication of the door hinge pins. S S Action Operate the doors and listen for squeaks. Lubricate the door hinge pins with light oil and coat with lithium grease. Squeak Coming From Console When Shifting Manual Transaxle (Condition Occurs In Cold Weather with a Cold Engine) Checks Check the manual transaxle control lever lower boot. S S Action Move the control lever between gears and listen for squeaks. Remove the floor console and replace the lower shift boot or apply talcum powder to the lower shift boot. Buzz From the Left Side of Instrument Panel Checks Check for vibration of the fuse box cover against the instrument panel side trim. S S Action Tap on the cover with a finger and listen for a buzz. Apply 6.35 mm (0.250 inch) by 25.4 mm (1.00 inch) felt pads to t

File name en_4j2_9l0.pdf

SECTION : 9L GLASS AND MIRRORS CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L­2 Fastener Tightening Specifications . . . . . . . . . . . . 9L­2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L­2 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . . 9L­2 SCHEMATIC AND ROUTING DIAGRAMS . . . . . . 9L­3 Defogger System . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L­3 Electric Control OSRV (Outside Rear View) Mirror System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L­4 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Rear Window Defogger Grid Line . . . . . . Outside Rearview Mirror Defoggers . . . . . . . . . . . Electric Control Outside Rearview Mirrors . . . . . . 9L­5 9L­5 9L­5 9L­6 Rear Window Glass . . . . . . . . . . . . . . . . . . . . . . . . 9L­11 Rear Window Defogger Grid Line Repair . . . . . . 9L­13 Rear Window Defogger Braided Lead Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L­15 Front Door Glass . . . . . . . . . . . . . . . . . . . . . . . . . . 9L­15 Rear Door Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L­16 Rear Door Quarter Glass . . . . . . . . . . . . . . . . . . . 9L­16 Inside Rearview Mirror . . . . . . . . . . . . . . . . . . . . . 9L­17 Outside Rearview Mirrors . . . . . . . . . . . . . . . . . . . 9L­18 Folding Mirrors Unit . . . . . . . . . . . . . . . . . . . . . . . . 9L­18 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L­19 Stationary Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L­19 Electric Control Heated Outside Rearview Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L­19 Inside Rearview Mirror . . . . . . . . . . . . . . . . . . . . . 9L­19 Folding Mirror Unit . . . . . . . . . . . . . . . . . . . . . . . . . 9L­19 Folding Mirror Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 9L­8 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 9L­10 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9L­10 Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L­10 9L ­ 2IGLASS AND MIRRORS SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Glass Screws Guide Rail Bolts Guide Rail Screw Outside Rearview Mirror Assembly Bolts Screws Rearview Mirror Mounting Bolt Folding Mirror Unit Bolt NSm 7 7 4 4.5 1.2 10 Lb­Ft ­ ­ ­ ­ ­ ­ Lb­In 62 62 35 40 11 89 SPECIAL TOOLS SPECIAL TOOLS TABLE J­24402 Glass Sealant Remover DAEWOO V­121 BL4 GLASS AND MIRRORS 9L ­ 3

File name en_4j2_9m0.pdf

SECTION : 9M EXTERIOR TRIM TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9M­1 Fastener Tightening Specifications . . . . . . . . . . . 9M­1 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . B­Pillar Molding . . . . . . . . . . . . . . . . . . . . . . . . . . . Roof Molding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9M­2 9M­2 9M­2 9M­2 Mud Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9M­3 Hatchback Rear Spoiler . . . . . . . . . . . . . . . . . . . . 9M­3 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9M­5 Emblems and Lettering . . . . . . . . . . . . . . . . . . . . . 9M­5 Mud Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9M­5 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application B­Pillar Molding Screws Mud Guard Bolts NSm 1.3 2 Lb­Ft ­ ­ Lb­In 12 18 9M ­ 2IEXTERIOR TRIM MAINTENANCE AND REPAIR ON­VEHICLE SERVICE B­PILLAR MOLDING Removal Procedure 1. 2. 3. Remove the outside channel molding. Refer to Section 9P, Doors. Reposition the weatherstrip in order to access the screws. Remove the screws and the B­pillar molding (front door B­pillar molding shown, rear door C­pillar molding similar). Installation Procedure Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. 1. Install the screws and the B­pillar molding (front door B­pillar molding shown, rear door C­pillar molding similar). Tighten 2. 3. Tighten the B­pillar molding screws to 1.3 NSm 12 (lb­in). Install the weatherstrip to its original position. Install the outside channel molding. Refer to Section 9P, Doors. ROOF MOLDING Removal Procedure 1. Remove the roof molding from the metal clips. DAEWOO V­121 BL4 EXTERIOR TRIM 9M ­ 3 Installation Procedure 1. Press the roof molding onto the metal clips. MUD GUARDS Removal Procedure 1. Remove the screw and the bolts and the mud guard. Installation Procedure Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. 1. Install the mud guard with the bolts and the screw. Tighten Tighten the mud guard bolts to 2 NSm (18 lb­in). HATCHBACK REAR SPOILER Removal Procedure 1. 2. 3. Open the tailgate. Remove the Hatchback Door upper Garnish molding. Remove the rear spoiler from the tailgate. J4D39M01 DAEWOO V­121 BL4 9M ­ 4IEXTERIOR TRIM Installation Procedure 1. Install the rear spoiler on the tailgate with the nuts. J4D39M01 DAEWOO V­121 BL4 EXTERIOR TRIM 9M ­ 5 GENERAL DESCRIPTION AND SYSTEM OPERATION EMBLEMS AND LETTERING The emblems and lettering on the vehicle are attached by adhesive. The company emblem appears on the hood. The lettering, which appears in several places on the body of the vehicle, features the model, th

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SECTION : 9N FRAME AND UNDERBODY TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9N­1 Fastener Tightening Specifications . . . . . . . . . . . 9N­1 Notchback Underbody Dimensions . . . . . . . . . . . 9N­2 Hatchback Underbody Dimensions . . . . . . . . . . . 9N­4 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 9N­6 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9N­6 Alignment Checking . . . . . . . . . . . . . . . . . . . . . . . . 9N­6 Floor Pan Insulators . . . . . . . . . . . . . . . . . . . . . . . . 9N­6 Engine Under Covers . . . . . . . . . . . . . . . . . . . . . . 9N­7 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9N­8 General Body Construction . . . . . . . . . . . . . . . . . 9N­8 Engine Under Covers . . . . . . . . . . . . . . . . . . . . . . 9N­8 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Engine Under Cover Bolts NSm 3.5 Lb­Ft ­ Lb­In 31 9N ­ 2IFRAME AND UNDERBODY NOTCHBACK UNDERBODY DIMENSIONS DAEWOO V­121 BL4 FRAME AND UNDERBODY 9N ­ 3 DAEWOO V­121 BL4 9N ­ 4IFRAME AND UNDERBODY HATCHBACK UNDERBODY DIMENSIONS DAEWOO V­121 BL4 FRAME AND UNDERBODY 9N ­ 5 DAEWOO V­121 BL4 9N ­ 6IFRAME AND UNDERBODY MAINTENANCE AND REPAIR ON­VEHICLE SERVICE ALIGNMENT CHECKING An accurate method of determining the alignment of the underbody uses a measuring tram gauge. The tram gauge set used to perform the recommended measuring checks must include a vertical pointer able to reach 457 mm (18 inches). Two types of measurements can be made with a tram gauge: direct point­to­point measurements and measurements calculated on a horizontal plane (datum line) parallel to the underbody. Point­to­point measurements are generally taken on steering and suspension engine compartment parts and simply require the vertical pointers to be set equally. For horizontal plane measurements, the vertical pointers must be set as specified for each point to be measured. Dimensions­to­gauge holes are measured to the center of the holes and flush to the adjacent surface metal unless otherwise specified. It is recommended that the diagonal dimensions to the cross­body be checked on both sides in order to verify the dimensional accuracy of the vehicle underbody. FLOOR PAN INSULATORS The floor pan insulators have been designed for the higher floor pan temperatures that result from the use of the catalytic converter in the exhaust system. Therefore, when servicing a vehicle, it is essential that any insulators that may have been disturbed or removed be reinstalled in the original sequence and location. Also, if an insulator needs to be replaced, use only the insulation specified for that location on the floor pan. When servicing or replacing interior insulators, observe the following instructions. S Install the insulators in the original position and sequence. Butt the pieces together in order to avoid gapping or overlapping. S If it is nece

File name en_4j2_9o0.pdf

SECTION : 9O BUMPERS AND FASCIAS CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9O­1 Fastener Tightening Specifications . . . . . . . . . . . 9O­1 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 9O­2 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9O­2 Front Bumper Fascia . . . . . . . . . . . . . . . . . . . . . . . 9O­2 Front Bumper Energy Absorber . . . . . . . . . . . . . . 9O­3 Front Bumper Impact Bar . . . . . . . . . . . . . . . . . . . Notchback Rear Bumper Fascia . . . . . . . . . . . . . Hatchback Rear Bumper Fascia . . . . . . . . . . . . . Rear Bumper Impact Bar . . . . . . . . . . . . . . . . . . . 9O­4 9O­4 9O­6 9O­7 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9O­9 Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9O­9 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Fender­to­Fascia Bolts Fender­to­Fascia Screws Front Impact Bar Bolts Lower Fascia Screws Luggage Compartment Fascia Bolts Luggage Compartment Fascia Screws Rear Wheel Well Fascia Bolts NSm 10 2 39 2 10 2 2 Lb­Ft ­ ­ 29 ­ ­ ­ ­ Lb­In 89 18 ­ 18 89 18 18 9O ­ 2IBUMPERS AND FASCIAS MAINTENANCE AND REPAIR ON­VEHICLE SERVICE FRONT BUMPER FASCIA Removal Procedure 1. 2. 3. 4. Disconnect the negative battery cable. Remove the front wheel well splash shields. Refer to Section 9R, Body Front End. Remove the fog lamps and the headlamps. Refer to Section 9B, Lighting Systems. Remove the fender­to­fascia bolts and the screws. 5. Remove the lower fascia clips. 6. 7. Remove the upper fascia clips. Remove the front bumper fascia. DAEWOO V­121 BL4 BUMPERS AND FASCIAS 9O ­ 3 Installation Procedure 1. Install the front bumper fascia. Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. 2. Install the upper fascia screws. 3. Install the lower fascia clips. 4. Install the fender­to­fascia bolts and the screws. Tighten Tighten the fender­to­fascia bolts to 10 NSm (89 lb­ in). Tighten the fender­to­fascia screws to 2 NSm (18 lb­ in). Install the headlamps and the fog lamps. Refer to Section 9B, Lighting Systems. Install the front wheel well splash shields. Refer to Section 9B, Lighting Systems. Connect the negative battery cable. 5. 6. 7. FRONT BUMPER ENERGY ABSORBER Removal Procedure 1. 2. Remove the front bumper fascia. Refer to "Front Bumper Fascia" in this section. Remove the energy absorber. DAEWOO V­121 BL4 9O ­ 4IBUMPERS AND FASCIAS Installation Procedure 1. 2. Install the energy absorber. I

File name en_4j2_9p0.pdf

SECTION : 9P DOORS CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9P­2 Fastener Tightening Specification . . . . . . . . . . . . . 9P­2 SCHEMATIC AND ROUTING DIAGRAMS . . . . . 9P­3 Power Door Locks Circuit . . . . . . . . . . . . . . . . . . . . 9P­3 Power Windows Circuit (Front Only) . . . . . . . . . . 9P­4 Power Windows Circuit (Front and Rear) . . . . . . 9P­5 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P­6 Power Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P­6 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 9P­16 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 9P­16 Outside Channel Molding . . . . . . . . . . . . . . . . . . . 9P­16 Front Door Glass Run . . . . . . . . . . . . . . . . . . . . . . 9P­16 Door Weatherstrip . . . . . . . . . . . . . . . . . . . . . . . . . 9P­17 Rear Door Glass Run . . . . . . . . . . . . . . . . . . . . . . 9P­18 Front Door Secondary Weatherstrip . . . . . . . . . . 9P­18 Rear Door Secondary Weatherstrip . . . . . . . . . . 9P­19 Front Door Opening Weatherstrip . . . . . . . . . . . . 9P­19 Rear Door Opening Weatherstrip . . . . . . . . . . . . 9P­20 Door Seal Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Lock Striker . . . . . . . . . . . . . . . . . . . . . . . . . . Door Lock Striker Adjustment . . . . . . . . . . . . . . . Front Door Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . Childproof Rear Door Lock . . . . . . . . . . . . . . . . . . Inside Door Handle . . . . . . . . . . . . . . . . . . . . . . . . Outside Door Handle . . . . . . . . . . . . . . . . . . . . . . . Inside Lock Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P­20 9P­21 9P­22 9P­23 9P­23 9P­24 9P­24 9P­25 Door Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 9P­25 Power Window Regulator . . . . . . . . . . . . . . . . . . . 9P­26 Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P­26 Door Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P­27 Door Hold­Open Link . . . . . . . . . . . . . . . . . . . . . . 9P­28 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P­29 Door Lock Striker . . . . . . . . . . . . . . . . . . . . . . . . . . Childproof Rear Door Lock . . . . . . . . . . . . . . . . . . Power Door Locks . . . . . . . . . . . . . . . . . . . . . . . . . Power Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P­29 9P­29 9P­29 9P­29 9P ­ 2IDOORS SPECIFICATIONS FASTENER TIGHTENING SPECIFICATION Application Door Hinge­to­Body Bolts Door Hinge­

File name en_4j2_9q0.pdf

SECTION : 9Q ROOF CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q­2 Fastener Tightening Specifications . . . . . . . . . . . 9Q­2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q­2 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 9Q­2 SCHEMATIC AND ROUTING DIAGRAMS . . . . . 9Q­3 Power Sunroof System . . . . . . . . . . . . . . . . . . . . . 9Q­3 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q­4 Power Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q­4 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . Power Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sun Shade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q­6 9Q­6 9Q­6 9Q­7 Sunroof Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q­8 Formed Headliner . . . . . . . . . . . . . . . . . . . . . . . . . 9Q­8 Sun Visors with Vanity Mirror . . . . . . . . . . . . . . . 9Q­10 Passenger Assist Handles . . . . . . . . . . . . . . . . . 9Q­10 Power Sunroof Control Switch . . . . . . . . . . . . . . 9Q­11 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q­12 Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q­12 Power Sunroof/Sunroof Control Switch . . . . . . 9Q­12 Sun Visors with Vanity Mirror . . . . . . . . . . . . . . . 9Q­12 Passenger Assist Handles . . . . . . . . . . . . . . . . . 9Q­12 Coat Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q­12 9Q ­ 2IROOF SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Power Sunroof Control Switch Screws Passenger Assist Handle Screws Sun Visor Screws Sun Visor Support Screw Sunroof Housing Bolts Sunroof Motor Screws NSm 2 3 4 1.5 10 3 Lb­Ft ­ ­ ­ ­ ­ ­ Lb­In 18 27 35 13 89 27 SPECIAL TOOLS SPECIAL TOOLS TABLE KM­475­B Trim Remover DAEWOO V­121 BL4 ROOF 9Q ­ 3 SCHEMATIC AND ROUTING DIAGRAMS POWER SUNROOF SYSTEM DAEWOO V­121 BL4 9Q ­ 4IROOF DIAGNOSIS POWER SUNROOF Power Sunroof Does Not Work Step 1 2 Check fuse F8. Is either fuse blown? 1. Check for a short circuit and repair it, if necessary. 2. Replace the blown fuse. Is the repair complete? 1. Turn the ignition on. 2. Check the voltages at fuse F8. Are both voltages equal to the specified value? Repair the power supply to the fuse which did not indicate battery voltage with the ignition on. Is the repair complete? 1. Disconnect the interior courtesy lamp/power sunroof control switch connector. 2. Turn the ignition on. 3. Ch

File name en_4j2_9r0.pdf

SECTION : 9R BODY FRONT END TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9R­1 Fastener Tightening Specifications . . . . . . . . . . . 9R­1 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 9R­2 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9R­2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R­2 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R­2 Anticorrosion Materials . . . . . . . . . . . . . . . . . . . . . 9R­2 Front End Sealing . . . . . . . . . . . . . . . . . . . . . . . . . 9R­2 Cowl Vent Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R­2 Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R­3 Hood Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Prop Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Secondary Latch . . . . . . . . . . . . . . . . . . . . . Hood Latch Release Cable . . . . . . . . . . . . . . . . . . Notchback Radiator Grille . . . . . . . . . . . . . . . . . . . Hatchback Radiator Grille . . . . . . . . . . . . . . . . . . . Front Wheel Well Splash Shield . . . . . . . . . . . . . Fender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R­3 9R­4 9R­4 9R­5 9R­5 9R­6 9R­6 9R­7 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R­10 Body Front End . . . . . . . . . . . . . . . . . . . . . . . . . . 9R­10 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application A­Pillar Fender Bolt Fender Bolt (Front of Fascia) Front Bumper Fascia­to­Fender Bolt Hinge Bolts Hood­to­Hinge Bolts Hood Latch Bolts Hood Release Handle Nuts Lower Fender Bolt Radiator Grille Nuts Splash Shield screws Upper Fender Bolts NSm 10 4 2.5 27 27 8 4 10 4 2 10 Lb­Ft ­ ­ ­ 20 20 ­ ­ ­ ­ ­ ­ Lb­In 89 35 22 ­ ­ 71 35 89 35 18 89 9R ­ 2IBODY FRONT END MAINTENANCE AND REPAIR ON­VEHICLE SERVICE LUBRICATION The hood hinges and the locking mechanisms require periodic lubrication for proper operation. Refer to Section 0B, General Information for the specific types and intervals of lubrication. FASTENERS Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. Many aluminum components are used on current models. Aluminum in contact with steel may corrode rapidly if it is not protected by special finishes or isolators. The fasteners used have a special finish which provides adequate protection from corrosion. These special fasteners differ in color in order to easily identify them from the standard metric fasteners, which are medium blue. When replacing fasteners, avoid substituting otherwise similar fasteners in the same location. ANTICORROSION MATERIALS In order to provide rust resistance, anticorrosion materials have been applied to the interior surfaces of most of the metal panels. When you servi

File name en_4j2_9s0.pdf

SECTION : 9S BODY REAR END CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9S­1 Fastener Tightening Specifications . . . . . . . . . . . 9S­1 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . Fuel Filler Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filler Door Remote Handle and Cable . . . . Rear Deck Lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Deck Lid Torque Rods . . . . . . . . . . . . . . . . . Luggage Compartment Lock Cylinder . . . . . . . . Luggage Compartment Lock Striker . . . . . . . . . . 9S­2 9S­2 9S­2 9S­2 9S­4 9S­5 9S­5 9S­6 Weatherstrip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9S­7 Hatchback Weatherstrip . . . . . . . . . . . . . . . . . . . . 9S­7 Hatchback Door . . . . . . . . . . . . . . . . . . . . . . . . . . . 9S­8 Gas Support Assemblies . . . . . . . . . . . . . . . . . . . 9S­8 Hatchback Door Lock Striker . . . . . . . . . . . . . . . . 9S­9 Hatchback Door Lock . . . . . . . . . . . . . . . . . . . . . . 9S­9 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9S­10 Fuel Filler Door . . . . . . . . . . . . . . . . . . . . . . . . . . . 9S­10 Rear Deck Lid (Notchback) . . . . . . . . . . . . . . . . 9S­10 Hatchback Door . . . . . . . . . . . . . . . . . . . . . . . . . . 9S­10 Luggage Compartment Lock . . . . . . . . . . . . . . . . 9S­6 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Fuel Filler Door Screws Fuel Filler Door Remote Cable Handle Cover Screw Fuel Filler Door Remote Cable Handle Screws Lower B­Pillar Seat Belt Anchor Bolt Luggage Compartment Lock Cylinder Nuts Luggage Compartment Lock Screws Luggage Compartment Lock Striker Bolts Rear Deck Lid Bolts NSm 4 3 10 38 8 6 8 10 Lb­Ft ­ ­ ­ 28 ­ ­ ­ ­ Lb­In 35 27 89 ­ 71 53 71 89 9S ­ 2IBODY REAR END MAINTENANCE AND REPAIR ON­VEHICLE SERVICE FUEL FILLER DOOR Removal Procedure 1. Remove the screws and the fuel filler door. Installation Procedure Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. 1. Install the fuel filler door with the screws. Tighten Tighten the fuel filler door screws to 4 NSm (35 lb­in). FUEL FILLER DOOR REMOTE HANDLE AND CABLE Removal Procedure 1. 2. Open the luggage compartment. Remove the luggage compartment wheelhouse trim panels and the luggage compartment rear trim panel. Refer to Section 9G, Interior Trim. Disconnect the cable from the fuel filler door. 3. DAEWOO V­121 BL4 BODY REAR

File name en_4j2_9t01.pdf

SECTION : 9T1 REMOTE KEYLESS ENTRY AND ANTI­THEFT SYSTEM CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 9T1­1 Fastener Tightening Specifications . . . . . . . . . . 9T1­1 SCHEMATIC AND ROUTING DIAGRAMS . . . . 9T1­2 Notchback Remote Keyless Entry and Anti­Theft System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9T1­2 Hatchback Remote Keyless Entry and Anti­Theft System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9T1­3 Control Module/Receiver Connector . . . . . . . . . 9T1­4 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 9T1­5 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 9T1­5 Control Module/Receiver . . . . . . . . . . . . . . . . . . . 9T1­5 Siren (General Only) . . . . . . . . . . . . . . . . . . . . . . 9T1­5 Remote Keyless Entry Transmitter Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . 9T1­7 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9T1­8 Remote Keyless Entry and Anti­Theft System 9T1­8 Remote Locking and Unlocking . . . . . . . . . . . . . Security Indicator . . . . . . . . . . . . . . . . . . . . . . . . . Intrusion Sensing . . . . . . . . . . . . . . . . . . . . . . . . . Siren (General Only) . . . . . . . . . . . . . . . . . . . . . . Vehicle Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . Autolocking (Safety Lock) . . . . . . . . . . . . . . . . . . Control Module/Receiver . . . . . . . . . . . . . . . . . . . Fault or Alarm Indication . . . . . . . . . . . . . . . . . . . 9T1­8 9T1­8 9T1­8 9T1­8 9T1­8 9T1­9 9T1­9 9T1­9 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application Siren Braket Mounting Bolts. NSm 8 Lb­Ft ­ Lb­In 71 9T1 ­ 2IREMOTE KEYLESS ENTRY AND ANTI­THEFT SYSTEM SCHEMATIC AND ROUTING DIAGRAMS NOTCHBACK REMOTE KEYLESS ENTRY AND ANTI­THEFT SYSTEM DAEWOO V­121 BL4 REMOTE KEYLESS ENTRY AND ANTI­THEFT SYSTEM 9T1 ­ 3 HATCHBACK REMOTE KEYLESS ENTRY AND ANTI­THEFT SYSTEM DAEWOO V­121 BL4 9T1 ­ 4IREMOTE KEYLESS ENTRY AND ANTI­THEFT SYSTEM CONTROL MODULE/RECEIVER CONNECTOR Terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Color YEL BLK ­ LT BLU PNK/BLK ­ PNK/DKBLU PPL LT BLU/BLK LT GRN/WHT YEL LT GRN DK BLU ­ PNK ­ LT GRN LT GRN/RED YEL/DK GRN PPL ­ ­ ­ BRN ORN LT BLU Description Siren Ground ­ Door and Trunk Tamper Switch Trunk Open Switch ­ Hood Open Switch Door contact Switch Unlock Lock Unlock Anti­Theft Door Locking Switch Right Turn Signal Bulb ­ Ignition+ ­ Diagnostic Communication Key Reminder Switch Security Indicator Anti­Theft Door Locking Switch ­ ­ ­ Trunk Open Sw

File name en_4j2_9t02.pdf

SECTION : 9T2 IMMOBILIZER ANTI­THEFT SYSTEM CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SCHEMATIC AND ROUTING DIAGRAMS . . . . 9T2­2 Immobilizer Anti­Theft System . . . . . . . . . . . . . 9T2­2 DIAGNOSTIC INFORMATION AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . 9T2­3 Immobilizer System (MR­140, HV­240, SIRIUS D4) . . . . . . . . . . . 9T2­3 Diagnostic Trouble Code (DTC) P1626 (MR­140, HV­240), P1628 (SIRIUS) . . . . . . . . . . . . . . . 9T2­4 Diagnostic Trouble Code (DTC) P1631 (MR­140, HV­240), P1629 (SIRIUS D4) . . . . . . . . . . . . 9T2­6 Key Status Errors (MR­140, HV­240, SIRIUS D4) . . . . . . . . . . . 9T2­8 Communication Between Immobilizer Control Unit and Test Equipment (MR­140, HV­240, SIRIUS D4) . . . . . . . . . . . 9T2­8 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . Key Coding Procedure . . . . . . . . . . . . . . . . . . . . ID Code Reprogramming . . . . . . . . . . . . . . . . . . 9T2­9 9T2­9 9T2­9 9T2­9 Transponder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9T2­9 Immobilizer Control Unit . . . . . . . . . . . . . . . . . . . 9T2­9 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9T2­11 Immobilizer System . . . . . . . . . . . . . . . . . . . . . . 9T2­11 Electronically Coded Keys . . . . . . . . . . . . . . . . 9T2­11 Detection Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . 9T2­11 Immobilizer Control Unit . . . . . . . . . . . . . . . . . . 9T2­11 Serial Data Link . . . . . . . . . . . . . . . . . . . . . . . . . 9T2­12 Electronic Control Moudle (ECM) . . . . . . . . . . 9T2­12 9T2 ­ 2IIMMOBILIZER ANTI­THEFT SYSTEM SCHEMATIC AND ROUTING DIAGRAMS IMMOBILIZER ANTI­THEFT SYSTEM DAEWOO V­121 BL4 IMMOBILIZER ANTI­THEFT SYSTEM 9T2 ­ 3 DIAGNOSTIC INFORMATION AND PROCEDURES IMMOBILIZER SYSTEM (MR­140, HV­240, SIRIUS D4) The immobilizer anti­theft system requires diagnosis when it is not possible to start the engine. If the no­start condition occurs because of the immobilizer system, a diagnostic trouble code (P) 1626, 1628, 1629, 1631 should be set. The immobilizer control unit monitors the detection and the reading of the ignition key. The self­test capacity is limited to those functions. Faults are communicated to a scan tool during diagnosis, but they are not stored in the immobilizer control unit's memory. Unauthorized use of a scan tool could be a method of defeating the immobilizer anti­theft system, so certain scan tool procedures require the use of a password. The following functions are password protected: S S Coding of an additional key. Deleting all key cod

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NUBIRA/LACETTI SERVICE NOTICE 0­1 FOREWORD This manual includes procedure for maintenance, adjustment, service operation and removal and installation of components. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of manual approval. The right is reserved to make changes at any time without notice. 0­2 SERVICE NOTICE NUBIRA/LACETTI SECTION 0 SERVICE NOTICE CONTENTS 1. HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 ­ 3 2. SPECIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 ­ 3 3. SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . . . . . . . . . . . . . . . . . . . . . . . . 0 ­ 4 NUBIRA/LACETTI SERVICE NOTICE 0­3 1. HOW TO USE THIS MANUAL . This manual covers the repairs of NUBIRA/LACETTI automobile which has been involved in accidents, and it describes the work related to the replacement of damaged body parts. Please read through these instructions and familiarize yourself with them before actually using this manual. . Note : Refer to NUBIRA/LACETTI Service Manual for specifications, wire harness locations, safety stand support points, etc. 2. SPECIAL INFORMATION . Indicates a strong possibility of personal injury or equipment damage if instructions are not followed. . Note : Gives helpful information. . CAUTION : Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. Please note that this manual does contain warnings and cautions against some specific service methods which could cause PERSONAL INJURY, or could damage a vehicle or make it unsafe. Please understand that these warnings cannot cover all conceivable ways in which service, whether or not recommended by GM DAEWOO might be done or of the possible hazardous consequences of each conceivable way, not could GM DAEWOO investigate all such ways. Anyone using service procedures or tools, whether or not recommended by GM DAEWOO, must satisfy himself thoroughly that neither personal safety or tools, whether or not recommended by GM DAEWOO, must satisfy himself thoroughly that neither personal safety or vehicle safety will be jeopardized. . All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at any time without notice. No part of this publication may be reproduced, stored in retrieval system, or transmitted, in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes text, figures and tables. 0­4 SERVICE NOTICE NUBIRA/LACETTI 3. SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . The following precautions should be observed when performing sheet metal work, paint work and repair work around the locations of the SRS parts. . 1. SDM(Sensing and Diag

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NUBIRA/LACETTI GENERAL INFORMATION 1­1 SECTION 1 GENERAL INFORMATION CONTENTS 1. GENERAL INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ­ 2 2. IMPORTANT SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ­ 2 2.1.BEFORE BEGINNING WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1­2 2.2.DURING WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1­2 3. BODY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ­ 3 4. LOADS ON BODY PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ­ 3 5. USE OF NEW HIGH­QUALITY MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ­ 3 6. CORROSION PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ­ 3 7. SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ­ 4 8. ZINC TREATED STEEL PLATE REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ­ 4 9. TECHNICAL ILLUSTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ­ 5 10. BODY REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ­ 12 1­2 GENERAL INFORMATION NUBIRA/LACETTI 1. GENERAL INSTRUCTION This publication is designed to help you the body repair technician with your specialized work. Vehicle bodywork has changed a great deal over the years. As vehicles have developed technically, vehicle bodywork has also had to meet new requirements with design, changes to reconcile apparently conflicting demands to name just a few examples: S strength and safety ; low weight S spaciousness ; good aerodynamices S high quality ; low price . The durability and ease of repair of the bodywork also plays an important part. . Nowadays, the use of highly automated production equipment makes it possible to maintain the tightest tolerances and thus ensure a high level of quality. . When bodywork is damaged, the customer rightly expects it to be expertly repaired to the same quality standards. . At the same time, for his safety, the customer expects you to have comprehensive knowledge of materials, measuring and straightening methods, possible distortion, optimum corrosion prevention and much more besides. . This publication is designed to help you update your knowledge and give you an idea of what you require to rectify moderate or severe accident damage, for your own safety and for the satisfaction of your customers. 2. IMPORTANT SAFETY NOTICE 2­1. BEFORE BEGINNING WORK S Disconnect the battery to reduce the possibility of fire caused by electrical shorts. S Check for

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NUBIRA/LACETTI PREPARATIONS OF BODYWORK 2­1 SECTION 2 PREPARATIONS OF BODYWORK CONTENTS 1. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ­ 2 2. CHECKPOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ­ 4 3. CORRECTION OF THE DAMAGED AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ­ 5 4. MEASURING SYSTEMS (WITHOUT SMALL DAMAGE) . . . . . . . . . . . . . . . . 2 ­ 6 2­2 PREPARATIONS OF BODYWORK NUBIRA/LACETTI 1. GENERAL DESCRIPTION S Most monocoque bodies are composed as a single unit by welding together pressed parts made of steel plates which come in a variety of different shapes and sizes. Each part is responsible for displaying a certain strength and durability in order that it may play its role in meeting NOTCHBACK the functions of the body as a whole. S Damage to the exterior of the body can be inspected visually, but where there has been an external impact, it is necessary to inspect the extent of the damage. In some cases, the deformation has spread beyond the actual areas which were in the collision and so this has to be inspected closely. Unit: mm (in.) Fig. 1 NUBIRA/LACETTI PREPARATIONS OF BODYWORK 2­3 HATCHBACK Unit: mm (in.) Fig. 2 2­4 PREPARATIONS OF BODYWORK NUBIRA/LACETTI 2. CHECKPOINTS S Accurate Inspection of Damaged Parts(Visual) . Seat Belts Always replace the seat belt if : 1. The belt material is cut, punctured, burned or in any way damaged. 2. The buckle or retractor does not work properly. 3. They were being worn at the time of a collision(also check for damage at the seat belt anchor points). 4. Their condition is questionable. . Front Section : 1. Is there any bending, splitting, denting or other damage to the suspension and its related parts? 2. Is there any deformation of the front panel or radiator crossmember? Have any of the connected sections come apart? 3. Are there any creases or distortion in the front wheelhouse or side frame? Have any of the connected sections come apart? 4. Is there any bending or twisting of the whole front area? 5. Is there any deformation like creases, bulges, or dents in the front pillar, dash panel, floor, etc.? 6. Is there any vertical twisting or misaligned clearance in the door? 7. Is the windshield seal broken? 8. Is there any deformation in the vicinity of the top part of the roof panel's center pillar? 9. Is there any damage inside the automobile(is there any twisting of the dash panel, or anything irregular with the clearances or sheet­mounting parts)? 10. Is there any damage to the steering wheel? Is there any deformation in the column and the column­mounted parts? 11. Is there any oil or water leakage and damage to the engine, transmission or brakes? 12. Is there any irregular noise in the gear changing operation, engine and transmission rotation? 13. Are there any traces of contact between the engine block and the center crossm

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NUBIRA/LACETTI WELDING AND TOOLS 3­1 SECTION 3 WELDING AND TOOLS CONTENTS 1. SPOT WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ­ 2 1.1.GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3­2 1.2.WELDING CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3­2 1.3.WELDING STRENGTH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3­3 2. GAS WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ­ 4 3. CARBON DIOXIDE ARC WELDER(MIG ARC WELDING) . . . . . . . . . . . . . . . 3 ­ 5 4. REPAIR TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ­ 6 3­2 WELDING AND TOOLS NUBIRA/LACETTI 1. SPOT WELDING 1­1. GENERAL DESCRIPTION . Spot welding is also known as resistance spot welding and it is the most suitable method of welding for automobiles. It has three main features: the welding can be performed instantaneously, it exercises very little effect on the mother material, and it reduces the generation of distortion to the absolute minimum. However, please remember to remove all paint and other impurities from the surface of the material you intend to weld for reliable results. . 1­2. WELDING CONDITIONS . When performing spot welding, make absolutely sure that you conform to the conditions governed by the current, conductivity time, welding pressure, holding time, and shutdown time recommended for the spot welder. Please bear in mind the following points when welding : . S Plate thickness and minimum welding pitch Note : When the welding intervals are too small, this leads to branching, making it impossible to maintain the desired soldering state. Plate thickness Minimum intervals 0.6mm 11mm 0.9mm 16mm 1.2mm 20mm 1.6mm 24mm Fig. 2 Fig. 1 Welders NUBIRA/LACETTI WELDING AND TOOLS 3­3 S Plate thickness and tip diameter Plate thickness Minimum intervals 0.6mm 4.5Ш 0.9mm 5.0Ш 1.2mm 5.5Ш 1.6mm 6.0Ш Even if you perform the welding in accordance with the conditions, the strength of the welded sections may fluctuate widely with drops in the voltage and other factors. The quality of the welding cannot be evaluated unless the welded sections are destroyed. . Provide yourself with a steel plate of the same thickness and conduct a destruction test. . S If holes appear in the steel plates, this means that the welding is standard strength. S Drive a wedge between two panels near the nugget. If the welded parts do not come apart and the diameter of the nugget appears more than 3 mm, the welding should be satisfactory. Fig. 3 1­3. WELDING STRENGTH TEST . Fig. 4 3­4 WELDING AND T

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NUBIRA/LACETTI FRONT 4­1 SECTION 4 FRONT CONTENTS 1. FRONT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ­ 2 1.1.GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4­2 1.2.REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4­3 2. FRONT WHEELHOUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ­ 6 2.1.GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4­6 2.2.REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4­7 3. FRONT LONGITUDINAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ­ 10 3.1.GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4­10 3.2.REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4­11 4. FRONT PILLAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ­ 14 4.1.GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4­14 4.2.REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4­15 4­2 FRONT NUBIRA/LACETTI 1. FRONT PANEL 1­1. GENERAL DESCRIPTION . The front panel is joined to the front wheelhouse and front longitudinal. It forms the base for the headlamps and other parts and maintains the rigidity of the front section of the body. Pay particular attention to twists and parallelism and check mounting of related parts when welding. . Fig. 1 Front Welding Assembly NUBIRA/LACETTI FRONT 4­3 1­2. REPAIR PROCEDURE 1. Remove the related parts. S S S S S Hood, radiator grill and front bumper. Head lamps and fender. Engine, radiator and related parts. Aircon condenser and related parts. Others. Fig. 3 5. Mold damaged related parts. S Use a hammer and dolly to mold damaged areas of the front wheelhouse and longitudinal. S Even out the welding flanges with a hammer and dolly. S Fill any holes drilled by welding. Fig. 2 2. Roughly pull out and straighten the damaged area. S Check the damage to the front wheelhouse and front longitudinal before removing the front panel. Use the frame straightener to roughly pull out and repair the damaged front panel before removing

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NUBIRA/LACETTI ROOF, BACK PANEL AND REAR FLOOR PANEL 5­1 SECTION 5 ROOF, BACK PANEL AND REAR FLOOR PANEL CONTENTS 1. ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ­ 2 1.1.GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5­2 1.2.REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5­3 2. BACK PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ­ 6 2.1.GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5­6 2.2.REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5­7 3. REAR FLOOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ­ 9 3.1.GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5­9 3.2.REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5­11 5­2 ROOF, BACK PANEL AND REAR FLOOR PANEL NUBIRA/LACETTI 1. ROOF 1­1. GENERAL DESCRIPTION Deformation of the roof panel is highly noticeable in terms of the vehicle's outer appearance. Before replacing the roof, make sure that the body is horizontal. Be- fore welding the roof panel, adjust the frame door opening flanges so that they contact the roof panel. Pay particular attention to twists and parallelism. Fig. 1 NUBIRA/LACETTI ROOF, BACK PANEL AND REAR FLOOR PANEL 5­3 1­2. REPAIR PROCEDURE 1. Remove the related parts. S Room lamp, door weatherstrip and pillar trims. S Headlining and wiring harness. S Wiper, cowl and windshield. S Rear glass and others. 2. Pull out and straighten the damaged area to approximately the original shape. Note : Use heat­resistant protective cover for protect painting areas, seats, carpets and other parts. S Attach the car to the frame straightener by tightening the underbody clamps at the horizontal pinch welds. S Before cutting off the roof panel, pull them out so that they are restored to the original shape. S Do not pull out more than necessary. S Pull out and straighten the related damaged parts to approximately their original shape. Note : Make sure that the right and left pillars are parallel with the windshield surface. Check the door for proper opening and closing. 3. Keep the body, level. S Jack up the body, and place safety stands at the four designated places of the frame door opening. 4. Cut off the shad

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NUBIRA/LACETTI FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 6­1 SECTION 6 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER CONTENTS 1. FRAME DOOR OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ­ 2 1.1.GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6­2 1.2.REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6­3 2. DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ­ 6 2.1.REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6­6 3. SIDE PANEL OUTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ­ 8 3.1.GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6­8 3.2.REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6­10 6­2 FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER NUBIRA/LACETTI 1. FRAME DOOR OPENING 1­1. GENERAL DESCRIPTION The frame door opening consist of frame door area and side outer area. It forms the base for the front, rear doors and other parts and maintains the rigidity of the doors and roof. The frame door opening area should, depending on the degree of damage, be repaired as much as possible rather than repalced.(Repair by pulling out) Fig. 1 Frame Door Opening Welding Assembly NUBIRA/LACETTI FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER 6­3 1­2. REPAIR PROCEDURE 1. Remove the related parts. S S S S S S S Doors. Weather strips, pillar trims and related parts. Carpet. Seat belt assembly Door switch and wiring harness. Fuel pipe and brake oil pipe. Other related parts. Note : Pull out and straighten the damaged area to approximately the original shape. 2. Remove the related parts. S Damage may extend to the inner roof frame, the inner frame door opening and the floor. Determine the extent of the damage first, so the frame can be pulled out properly. Note : Use heat­resistant protective cover for protect painting areas, seats, carpets and other parts. S Pull out and straighten the damaged areas. S Do not pull out more than necessary. 3. Cut and pry off the frame door opening. S Check the damage on the frame door opening, then cut the new frame door opening so it will overlap by 30mm(1.18in.) in the pillar, front and rear. S Cut the damaged area with a hand saw along the bold line as shown. Note : Be careful not to cut the inner panel. This could result in extensive repair. Fig. 3 S Center punch around the

File name en_4n_07.pdf

NUBIRA/LACETTI FENDER, HOOD, TAILGATE AND TRUNK LID 7­1 SECTION 7 FENDER, HOOD, TAILGATE AND TRUNK LID CONTENTS 1. FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ­ 2 1.1.REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7­2 2. HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ­ 3 2.1.REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7­3 3. TAILGATE(HATCHBACK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ­ 4 3.1.REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7­4 4. TRUNK LID (NOTCHBACK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ­ 5 4.1.REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7­5 7­2 FENDER, HOOD, TAILGATE AND TRUNK LID NUBIRA/LACETTI 1. FENDER 1­1. REPAIR PROCEDURE 1. Remove the related parts. S Front bumper and mud guard. . 2. Remove the fender . 3. Preparation of the new fender. S Preparation of the new fender and check damaged areas. . 4. Apply the paint. . CAUTION S Ventilate when spraying paint. Most paint contains substances that are harmful if inhaled or swallowed, Read the paint label before opening paint container. S Avoid contact with skin, Wear an approved respirator, gloves, eye protection and appropriate clothing when painting. S Paint is flammable. Store in a safe place, and keep it away from sparks, flames or cigarettes. 5. Apply the mastic sealer. S Apply the mastic sealer to the mounting bolts. Fig. 2 7. Tighten fully. S After checking and adjusting the mounting position, tighten all bolts fully. . 8. Install the related parts. S Install in the reverse order in which they were removed. . 9. Check clearance S Check clearance of front bumper. Fig. 1 6. Preinstall the fender. S Fasten to the wheelhouse at two places with bolts. Close the hood and check the front and rear clearances and level differences of the hood and door. NUBIRA/LACETTI FENDER, HOOD, TAILGATE AND TRUNK LID 7­3 2. HOOD 2­1. REPAIR PROCEDURE 1. Remove the related parts. 2. Remove the hood. S Remove the hood mounting bolts from two hinge bows. and level difference of hood. fender and head lamps. Fig. 3 3. Preparation of the new hood. S Preparation of the new hood and check damaged areas. . 4. Apply the paint. . CAUTION S Ventilate when spraying paint. Most paint contains substances that are harmful if inhaled or swallowed. S Read the paint label be

File name en_4n_08.pdf

NUBIRA/LACETTI BODY DIMENSION 8­1 SECTION 8 BODY DIMENSION CONTENTS 1. BODY DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ­ 2 1.1.UNDER BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8­2 1.2.FRONT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8­7 1.3.ENGINE ROOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8­8 1.4.BACK PANEL LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8­9 1.5.SIDE OUTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8­11 2. REPAIR DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ­ 13 2.1.FRAME DOOR OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8­13 2.2.WINDSHIELD AND REAR GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8­15 3. GAP CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ­ 17 8­2 BODY DIMENSION NUBIRA/LACETTI 1. BODY DRAWING 1­1. UNDER BODY NOTCHBACK Unit: mm (in.) Fig. 1 NUBIRA/LACETTI BODY DIMENSION 8­3 HATCHBACK Fig. 2 8­4 BODY DIMENSION NUBIRA/LACETTI FRONT FRAME Unit: mm (in.) Fig. 3 NUBIRA/LACETTI BODY DIMENSION 8­5 REAR FRAME NOTCHBACK Unit: mm (in.) Fig. 4 8­6 BODY DIMENSION NUBIRA/LACETTI HATCHBACK Fig. 5 NUBIRA/LACETTI BODY DIMENSION 8­7 1­2. FRONT PANEL Unit: mm(in.) Fig. 6 8­8 BODY DIMENSION NUBIRA/LACETTI 1­3. ENGINE ROOM Unit: mm(in.) Fig. 7 NUBIRA/LACETTI BODY DIMENSION 8­9 1­4. BACK PANEL LOWER NOTCHBACK Unit: mm(in.) Fig. 8 8­10 BODY DIMENSION NUBIRA/LACETTI HATCHBACK Fig. 9 NUBIRA/LACETTI BODY DIMENSION 8­11 1­5. SIDE OUTER NOTCHBACK Unit: mm(in.) Fig. 10 8­12 BODY DIMENSION NUBIRA/LACETTI HATCHBACK Fig. 11 NUBIRA/LACETTI BODY DIMENSION 8­13 2. REPAIR DRAWING 2­1. FRAME DOOR OPENING NOTCHBACK Fig. 12 8­14 BODY DIMENSION NUBIRA/LACETTI HATCHBACK Fig. 13 NUBIRA/LACETTI BODY DIMENSION 8­15 2­2. WINDSHIELD AND REAR GLASS NOTCHBACK Unit: mm (in.) Fig. 14 8­16 BODY DIMENSION NUBIRA/LACETTI HATCHBACK Fig. 15 NUBIRA/LACETTI BODY DIMENSION 8­17 3. GAP CHART NOTCHBACK Fig. 16 8­18 BODY DIMENSION NUBIRA/LACETTI Fig. 17 NUBIRA/LACETTI BODY DIMENSION 8­19 HATCHBACK Fig. 18 8­20 BODY DIMENSION NUBIRA/LACET

File name en_4n_09.pdf

NUBIRA/LACETTI SEALING, CAULKING AND DEADNER 9­1 SECTION 9 SEALING, CAULKING AND DEADNER CONTENTS 1. SEALING & CAULKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ­ 2 2. DEADNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ­ 14 2.1.GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9­14 2.2.REPAIR PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9­14 9­2 SEALING, CAULKING AND DEADNER NUBIRA/LACETTI 1. SEALING & CAULKING Note : Seal the following areas to prevent air leaks water leaks, and rust. ENGINE ROOM . Fig. 1 Engine Room NUBIRA/LACETTI SEALING, CAULKING AND DEADNER 9­3 ENGINE ROOM Fig. 2 Engine Room 9­4 SEALING, CAULKING AND DEADNER NUBIRA/LACETTI DASH Fig. 3 Dash NUBIRA/LACETTI SEALING, CAULKING AND DEADNER 9­5 FLOOR & TRUNK ROOM Fig. 4 Floor & Trunk Room 9­6 SEALING, CAULKING AND DEADNER NUBIRA/LACETTI REAR LAMP & TRUNK ROOM Fig. 5 Rear Lamp NUBIRA/LACETTI SEALING, CAULKING AND DEADNER 9­7 Fig. 6 Rear Lamp 9­8 SEALING, CAULKING AND DEADNER NUBIRA/LACETTI ROOF Fig. 7 Roof NUBIRA/LACETTI SEALING, CAULKING AND DEADNER 9­9 ROOF Fig. 8 Roof 9­10 SEALING, CAULKING AND DEADNER NUBIRA/LACETTI SUN ROOF Fig. 9 Sun Roof NUBIRA/LACETTI SEALING, CAULKING AND DEADNER 9­11 HOOD & TRUNK LID Fig. 10 Hood & Trunk Lid 9­12 SEALING, CAULKING AND DEADNER NUBIRA/LACETTI TAILGATE Fig. 11 Tailgate NUBIRA/LACETTI SEALING, CAULKING AND DEADNER 9­13 FRONT & REAR DOOR Fig. 12 Front & Rear Door 9­14 SEALING, CAULKING AND DEADNER NUBIRA/LACETTI 2. DEADNER 2­1. GENERAL DESCRIPTION . Deadner is properly designed and applied for reduce the vibration and noise. Also, it plays in maintaining the structural rigidity of the panel. . 2­2. REPAIR PROCEDURE . 1. Remove the related parts. S Seats, carpet. S Trims, others. . 2. Removal of the damaged deadner. S Peel off the damaged deadner with a steel spatula, carefully. . 3. Clean and dry. S Before applying the deadner, thoroughly clean and dry the areas to be applied. . 4. Prelocation the new deadner on the panels to be applied. . Note : Avoid the parts mounting holes and service holes. . 5. Adhension of deadner. S Heat the surface of deadner with a torch or heating gun until it adheres itself. S Push and adhere to the panel with a rubber spatula. . Note : In order to take full advantage of the deadner, its face must adhere and contact the panels perfectly. . CAUTION : Be careful not to burn the composite parts when beating. Fig. 13 6. Install the related parts. S Install in the reverse order in which they were removed. Fig. 14 NUBIRA/LACETTI SEALING, CAULKING AND DEADNER 9­15 Fig. 15 Deadner Chart

File name en_4n_10.pdf

NUBIRA/LACETTI RUST PREVENTION 10­1 SECTION 10 RUST PREVENTION CONTENTS 1. ZINC TREATED STEEL PLATE REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ­ 2 2. RUST PREVENTIVE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ­ 3 2.1.GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10­3 2.2.AREA COVERED BY ANTI­RUST AGENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10­5 2.3.UNDERCOATING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10­6 10­2 RUST PREVENTION NUBIRA/LACETTI 1. ZINC TREATED STEEL PLATE REPAIR Avoid puttying as much as possible when repairing a new car. Use alternative methods as much as possible. . CAUTION S Most paints contain substances that are harmful if inhaled or swallowed. Read the paint label before opening Operation 1. Prep the repair area. 2. Apply putty Tools/Materials Double­action sander, #80 sandpaper. the container. Spray paint only in a well ventilated area. S Cover spilled paint with sand, or wipe it up at once. S Wear an approved respirator, gloves, eye protection and appropriate clothing when painting. Avoid contact with skin. S If paint gets in your mouth or on your skin, rinse or wash thoroughly with water. If paint gets in your eyes, flush with water and get prompt medical attention. S Paint is flammable. Store it in a safe place, and keep it away from sparks, flames or cigarettes. Procedure Sand the area with a double­action sander and #80 sandpaper. Clean with wax and grease remover. Remarks . . Apply in several thin coats if necessary. Try Note : Putty can be Epoxy­based putty. applied after priming S Mix the putty and hardener ac- to avoid leaving pinholes in the putty. as described in step 4. cording to the manufacturer's di- S Follow the manufacturer's recommendarecctions. tions for preparaton. S Polyester resin putty. Body filler. 3. Sand and clean the puttied area. Double­action sander, orbital sander, hand sanding file, #80, #120, #240 sandpaper, wax and grease remover, shop towels. Rough­sand the area with a double­ action sander and #80 sandpaper, then sand with #120 sandpaper. Featheredge with #240 sandpaper. Clean with wax and grease remover. . 4. Coat with primer. Apply 2­4 coats, allowing sufficient flash time Epoxy­based primer and harden- between coats. Note : Apply to bare Force dry at 60­70RC(140­158RF) for at sheet metal and put- er, epoxy thinner. least 30 minutes. tied area. S Mix and thin the primer according to the manufacturer's directions. 5. Sand and clean the whole area. Double­action sander, #400 sandpaper, wax and greases remover, shop towels. Spray to a thickness of 30­35 microns. Sand the whole area to be repainted with a . double­action sander and #400 sandp

File name en_4n_11.pdf

SECTION 11 BODY­FRAME REPAIR EQUIPMENT CONTENTS 1. SCHEMATIC DIAGRAM OF STRAIGHTENING JIG . . . . . . . . . . . . . . . . . . 11­2 2. EXAMPLE: STRAIGHTENING BODY­DAMAGE . . . . . . . . . . . . . . . . . . . . 11­5 11­2 BODY­FRAME REPAIR EQUIPMENT NUBIRA/LACETTI 1. SCHEMATIC DIAGRAM OF STRAIGHTENING JIG Fig. 1 NUBIRA/LACETTI BODY­FRAME REPAIR EQUIPMENT 11­3 Fig. 2 11­4 BODY­FRAME REPAIR EQUIPMENT NUBIRA/LACETTI Fig. 3 NUBIRA/LACETTI BODY­FRAME REPAIR EQUIPMENT 11­5 2. EXAMPLE: STRAIGHTENING BODY­DAMAGE HIGH­POINT TRACTION Fig. 4 11­6 BODY­FRAME REPAIR EQUIPMENT NUBIRA/LACETTI TWO­POINT SIMULTANEOUS TRACTION Fig. 5 NUBIRA/LACETTI BODY­FRAME REPAIR EQUIPMENT 11­7 TWO­POINT TRACTION Fig. 6 11­8 BODY­FRAME REPAIR EQUIPMENT NUBIRA/LACETTI MULTI­DIRECTIONAL TRACTION Fig. 7 NUBIRA/LACETTI BODY­FRAME REPAIR EQUIPMENT 11­9 SIDE­TRACTION Fig. 8 11­10 BODY­FRAME REPAIR EQUIPMENT NUBIRA/LACETTI SIDE­TRACTION Fig. 9 NUBIRA/LACETTI BODY­FRAME REPAIR EQUIPMENT 11­11 PUSH AND TRACTION SIMULTANEOUS WORK Fig. 10 11­12 BODY­FRAME REPAIR EQUIPMENT NUBIRA/LACETTI PUSH AND TRACTION SIMULTANEOUS WORK Fig. 11 NUBIRA/LACETTI BODY­FRAME REPAIR EQUIPMENT 11­13 UP­WARDS TRACTION Fig. 12 11­14 BODY­FRAME REPAIR EQUIPMENT NUBIRA/LACETTI DOWN­WARDS TRACTION Fig. 13 NUBIRA/LACETTI BODY­FRAME REPAIR EQUIPMENT 11­15 DOWN­WARDS TRACTION Fig. 14 11­16 BODY­FRAME REPAIR EQUIPMENT NUBIRA/LACETTI DOWN­WARDS TRACTION Fig. 15 NUBIRA/LACETTI BODY­FRAME REPAIR EQUIPMENT 11­17 DOWN­WARDS TRACTION Fig. 16 11­18 BODY­FRAME REPAIR EQUIPMENT NUBIRA/LACETTI DOWN­WARDS TRACTION Fig. 17 NUBIRA/LACETTI BODY­FRAME REPAIR EQUIPMENT 11­19 DOWN­WARDS TRACTION Fig. 18

File name en_5a1.pdf

TRANSMISSION / TRANSAXLE 5A1 ­ 1 SECTION 5A1 TRANSMISSION / TRANSAXLE (ZF 16HP AUTO TRANSAXLE) 524. ZF 16HP AUTO T/A ­ AUTOMATIC TRANSAXLE I . . . . . . . . . . . . . . . . . . . . . . . . . 5A1 ­ 3 525. ZF 16HP AUTO T/A ­ AUTOMATIC TRANSAXLE II . . . . . . . . . . . . . . . . . . . . . . . . . 5A1 ­ 5 526. ZF 16HP AUTO T/A ­ AUTOMATIC TRANSAXLE III . . . . . . . . . . . . . . . . . . . . . . . . 5A1 ­ 7 527. ZF 16HP AUTO T/A ­ AUTOMATIC TRANSAXLE IV . . . . . . . . . . . . . . . . . . . . . . . . 5A1 ­ 9 5A1 ­ 2 TRANSMISSION / TRANSAXLE LT5A017 TRANSMISSION / TRANSAXLE 5A1 ­ 3 ZF 16HP AUTO T/A ­ AUTOMATIC TRANSAXLE I (524) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 AUTO TRANSAXLE OH Replace 5240100 5240300 5240400 -- -- -- 7.1 3.7 6.0 7.5 4.1 6.4 2 3 HOUSING, TRANSAXLE ­ REPLACE SEAL, AXLE SHAFT ­ REPLACE Right Left Both 5240500 5240600 5240700 5240900 5241000 5241100 5241200 5241300 5241400 5241500 5241600 5241700 -- -- -- -- -- -- -- -- -- -- -- -- 0.9 0.9 1.7 0.3 4.5 4.4 4.4 1.6 1.8 1.6 0.6 0.6 0.9 0.9 1.7 0.3 4.9 4.8 4.8 1.6 1.8 1.6 0.6 0.6 4 5 6 7 8 9 10 11 12 SWITCH, PARKING & NEUTRAL ­ REPLACE DISC, DETENT ­ REPLACE SHAFT, SIDE ­ REPLACE GEAR ASSEMBLY, DIFFENTIAL ­ REPLACE BODY ASSEMBLY, CONTROL VALVE ­ REPLACE VALVE, SOLENOID ­ REPLACE WIRING HARNESS, VALVE BODY ­ REPLACE GASKET, OIL PAN ­ REPLACE PAN, OIL ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 5A1 ­ 4 TRANSMISSION / TRANSAXLE TRANSMISSION / TRANSAXLE 5A1 ­ 5 ZF 16HP AUTO T/A ­ AUTOMATIC TRANSAXLE II (525) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S -- -- -- -- -- -- -- N 4.0 0.6 3.9 4.4 4.4 4.4 4.5 L 4.1 0.9 4.3 4.8 4.8 4.8 4.9 1 2 3 4 5 6 7 8 TORQUE CONVERTER ­ REPLACE BOLTS, TORQUE CONVERTER TO FLYWHEEL ­ REPLACE HOUSING, TORQUE CONVERTER ­ REPLACE GASKET, TORQUE CONVERTER ­ REPLACE PLATE, OIL BAFFLE ­ REPLACE FILTER, OIL ­ REPLACE PUMP ASSEMBLY, OIL ­ REPLACE PIPE, OIL COOLER ­ REPLACE Inlet Outlet Both 5250100 5250200 5250300 5250400 5250500 5250600 5250700 5251100 5251200 5251300 5251400 -- -- -- -- 0.7 0.9 1.4 0.2 0.7 0.9 1.4 0.2 9 HOSE, BREATHER ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 5A1 ­ 6 TRANSMISSION / TRANSAXLE LT5A019 TRANSMISSION / TRANSAXLE 5A1 ­ 7 ZF 16HP AUTO T/A ­ AUTOMATIC TRANSAXLE III (526) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- N 5.0 4.9 5.3 5.1 5.5 5.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 3.9 L 5.4 5.3 5.7 5.5 5.9 5.9 4.9 4.9 4.9 4.9 4.9 4.9 4.9 4.9 4.9 4.9 4.3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 CARRIER, INNER GEAR ­ REPLACE F CLUTCH SET ­ REPLACE F PISTON ­ REPLACE NUT, SLOTTED ­ REPLACE PLATE, BEARING ­ REPLACE GEAR, SPUR ­ REPLACE D PISTON ­ REPLACE C & D CLUTCH SET ­ REPLACE C PISTON ­ REPLACE GEAR, PLANETARY ­ REPLACE GEAR, SUN ­ REPLACE B PISTON ­ REPLACE B CLUTCH SET ­ REPLACE E CLUTCH SET ­ REPLACE E PISTON ­ REPLACE SHAFT, INPUT ­ REPLACE COVER, TRANSAXLE REAR ­ REPLACE 5260100 5260200 5260300 5

File name en_5a2.pdf

TRANSMISSION / TRANSAXLE 5A2 ­ 1 SECTION 5A2 TRANSMISSION / TRANSAXLE (AISIN AUTO TRANSAXLE) 531. AUTOMATIC TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2 ­ 3 532. CASE & RELATED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2 ­ 5 533. INTERNAL POWERTRAIN PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2 ­ 7 534. GEAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2 ­ 9 535. CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2 ­ 11 536. FLUID COOLER PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2 ­13 537. AUTOMATIC TRANSAXLE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2 ­15 5A2 ­ 2 TRANSMISSION / TRANSAXLE TRANSMISSION / TRANSAXLE 5A2 ­ 3 AISIN AUTO T/A ­ AUTOMATIC TRANSAXLE (531) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 2.9 0.6 2.9 6.5 0.7 0.2 N 3.0 0.6 3.0 6.6 0.7 0.2 L -- -- -- -- -- -- 1 2 3 TORQUE CONVERTER ­ REPLACE BOLTS, TORQUE CONVERTER TO FLYWHEEL ­ REPLACE AUTO TRANSAXLE ASSEMBLY ­ REPLACE AUTO TRANSAXLE ASSEMBLY ­ OVERHAUL 5310100 5310200 5310300 5310400 5310500 5310600 4 5 TUBE, OIL FILLER ­ REPLACE STICK, OIL GAUGE ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 5A2 ­ 4 TRANSMISSION / TRANSAXLE TRANSMISSION / TRANSAXLE 5A2 ­ 5 AISIN AUTO T/A ­ CASE & RELATED PARTS (532) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.2 0.2 0.2 1.5 3.2 3.3 3.3 3.3 1.1 3.1 N 0.2 0.2 0.2 1.5 3.3 3.4 3.4 3.4 1.1 3.2 L -- -- -- -- -- -- -- -- -- -- 1 2 3 4 5 6 7 8 9 10 11 SENSOR, INPUT SHAFT SPEED (ISS) ­ REPLACE SENSOR, OUTPUT SHAFT SPEED (OSS) ­ REPLACE SWITCH, PARK/NEUTRAL POSITION (PNP) ­ REPLACE HARNESS, TRANSAXLE WIRING ­ REPLACE HOUSING, TRANSAXLE ­ REPLACE TUBE, DIFFERENTIAL BEARING LUBE APPLY ­ REPLACE PLATE, TRANSAXLE HOUSING OIL RESERVOIR ­ REPLACE TUBE, LUBRICATION APPLY ­ REPLACE FILTER, TRANSAXLE OIL ­ REPLACE REAR CASE, TRANSAXLE ­ REPLACE SEAL, DRIVE AXLE FLUID ­ REPLACE Right Left Both 5320100 5320200 5320500 5320600 5320700 5320900 5321100 5321500 5321600 5321800 5321900 5322100 5322200 5322300 5322400 5322500 5322600 1.1 1.1 2.0 4.5 1.1 0.2 3.8 0.9 0.9 1.6 4.6 1.1 0.2 3.9 -- -- -- -- -- -- -- 12 13 14 15 PARKING SYSTEM ­ REPLACE PAN AND/OR GASKET, OIL ­ REPLACE HOSE, BREATHER ­ REPLACE PISTONS, ACCUMULATOR ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 5A2 ­ 6 TRANSMISSION / TRANSAXLE TRANSMISSION / TRANSAXLE 5A2 ­ 7 AISIN AUTO T/A ­ INTERNAL POWERTRAIN PARTS (533) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 3.3 3.5 3.3 3.4 3.3 3.4 3.5 3.2 3.2 3.8 3.6 N 3.4 3.6 3.4 3.5 3.4 3.5 3.6 3.3 3.3 3.9 3.7 L -- -- -- -- -- -- -- -- -- -- -- 1 2 3 4 5 6 7 8 9 10 11 OIL PUMP ­ REPLACE CLU

File name en_5b1.pdf

TRANSMISSION / TRANSAXLE 5B1 ­ 1 SECTION 5B1 TRANSMISSION / TRANSAXLE (FIVE­SPEED MANUAL TRANSAXLE: D16, D20) 561. MANUAL TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B1 ­ 3 563. TRANSAXLE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B1 ­ 5 564. REVERSE & COUNTER GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B1 ­ 9 565. BEARING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B1 ­ 11 566. GEAR SHIFT COVER & FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B1 ­ 13 567. DIFFERENTIAL GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B1 ­ 15 569. SHIFT CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B1 ­ 17 5B1 ­ 2 TRANSMISSION / TRANSAXLE 1 LT5B001 TRANSMISSION / TRANSAXLE 5B1 ­ 3 FIVE­SPEED M/T(D16, D20) ­ MANUAL TRANSAXLE (561) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 3.5 N 3.5 L 3.4 1 TRANSAXLE ASSEMBLY ­ REPLACE INC : Replace clutch release bearing necessary TRANSAXLE ASSEMBLY ­ OVERHAUL INC : Replace clutch release bearing necessary 5610100 5610300 7.6 7.6 7.5 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 5B1 ­ 4 TRANSMISSION / TRANSAXLE 1 7 10 9 8 3 5 12 4 2 8 11 6 LT5B002 TRANSMISSION / TRANSAXLE 5B1 ­ 5 FIVE­SPEED M/T(D16, D20) ­ TRANSAXLE GEAR (563) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 4.5 N 4.5 L 4.4 1 GEAR, 5TH SPEED ­ REPLACE INC : Shim selection time INC : R&R transaxle and replace clutch release bearing necessary 5630100 2 GEAR, 4TH SPEED ­ REPLACE INC : Shim selection time INC : R&R transaxle and replace clutch release bearing necessary 5630300 6.5 6.5 6.4 3 GEAR, 3RD SPEED ­ REPLACE INC : Shim selection time INC : R&R transaxle and replace clutch release bearing necessary 5630500 6.1 6.1 6.0 4 GEAR, 2ND SPEED ­ REPLACE INC : Shim selection time INC : R&R transaxle and replace clutch release bearing necessary 5630700 6.0 6.0 5.9 5 GEAR, 1ST SPEED ­ REPLACE INC : Shim selection time INC : R&R transaxle and replace clutch release bearing necessary 5630900 5.6 5.6 5.5 6 SHAFT, TRANSAXLE MAIN ­ REPLACE INC : Shim selection time INC : R&R transaxle and replace clutch release bearing necessary 5631100 6.6 6.6 6.5 7 SYNCHRONIZERS (5TH) ­ REPLACE INC : Shim selection time INC : R&R transaxle and replace clutch release bearing necessary 5631300 4.4 4.4 4.3 8 SYNCHRONIZERS (3RD­4TH) ­ REPLACE INC : Shim selection time INC : R&R transaxle and replace clutch release bearing necessary 5631500 5.5 6.5 6.4 9 SYNCHRONIZERS (1ST­2ND) ­ REPLACE INC : Shim selection time INC : R&R transaxle and replace clutch release bearing necessary 5631700 6.0 6.0 5.9 10

File name en_5b2.pdf

TRANSMISSION / TRANSAXLE 5B2 ­ 1 SECTION 5B2 TRANSMISSION / TRANSAXLE (FIVE­SPEED MANUAL TRANSAXLE: Y4M) 571. MANUAL TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B2 ­ 3 572. TRANSAXLE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B2 ­ 5 573. GEAR SHIFT COVER & FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B2 ­11 574. DIFFERENTIAL GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B2 ­13 575. SHIFT CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B2 ­15 5B2 ­ 2 TRANSMISSION / TRANSAXLE TRANSMISSION / TRANSAXLE 5B2 ­ 3 FIVE­SPEED M/T(Y4M) ­ MANUAL TRANSAXLE (571) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 3.4 N -- L -- 1 TRANSAXLE ASSEMBLY ­ REPLACE INC : Replace clutch release bearing necessary TRANSAXLE ASSEMBLY ­ OVERHAUL INC : Replace clutch release bearing necessary TRANSAXLE OIL ­ REPLACE 5710100 5710200 6.4 -- -- 5710300 5710400 5710500 5710600 5710700 0.4 4.7 5.1 3.7 4.2 -- -- -- -- -- -- -- -- -- -- 2 3 4 5 HOUSING, T/M (LEFT SIDE) ­ REPLACE HOUSING, T/M (RIGHT SIDE) ­ REPLACE COVER, T/M RR SIDE ­ REPLACE PLATE, BEARING ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 5B2 ­ 4 TRANSMISSION / TRANSAXLE G125B02 TRANSMISSION / TRANSAXLE 5B2 ­ 5 FIVE­SPEED M/T(Y4M) ­ TRANSAXLE GEAR (572) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 4.1 N -- L -- 1 GEAR, 5TH SPEED ­ REPLACE INC : Shim selection time INC : R&R transaxle and replace clutch release bearing necessary 5720100 2 GEAR, 4TH SPEED ­ REPLACE INC : Shim selection time INC : R&R transaxle and replace clutch release bearing necessary 5720200 4.8 -- -- 3 GEAR, 3RD SPEED ­ REPLACE INC : Shim selection time INC : R&R transaxle and replace clutch release bearing necessary 5720300 4.8 -- -- 4 GEAR, 2ND SPEED ­ REPLACE INC : Shim selection time INC : R&R transaxle and replace clutch release bearing necessary 5720400 4.8 -- -- 5 GEAR, 1ST SPEED ­ REPLACE INC : Shim selection time INC : R&R transaxle and replace clutch release bearing necessary 5720500 4.9 -- -- 6 SHAFT, TRANSAXLE COUNTER ­ REPLACE INC : Shim selection time INC : R&R transaxle and replace clutch release bearing necessary 5720600 5.0 -- -- 7 SYNCHRONIZERS (5TH) ­ REPLACE INC : Shim selection time INC : R&R transaxle and replace clutch release bearing necessary 5720700 3.8 -- -- 8 SYNCHRONIZERS (3RD­4TH) ­ REPLACE INC : Shim selection time INC : R&R transaxle and replace clutch release bearing necessary 5720800 4.9 -- -- 9 SYNCHRONIZERS (1ST­2ND) ­ REPLACE INC : Shim selection time INC : R&R transaxle and replace clutch release bearing necessary 5720900 4.9 -- -- 10 GEAR, SLIDING ­ REPLACE INC : Shim selection time INC : R&R transaxle and rep

File name en_5c.pdf

TRANSMISSION / TRANSAXLE 5C ­ 1 SECTION 5C TRANSMISSION / TRANSAXLE (CLUTCH) 581. CLUTCH PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C ­ 3 582. HYDRAULIC CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C ­ 5 583. CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C ­ 7 5C ­ 2 TRANSMISSION / TRANSAXLE TRANSMISSION / TRANSAXLE 5C ­ 3 CLUTCH ­ CLUTCH PARTS (581) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.2 0.3 3.7 N 0.2 0.3 -- L 0.2 0.3 3.7 1 2 3 COVER, FLYWHEEL ­ REPLACE GEAR AND/OR SEAL, SPEEDOMETER DRIVEN ­ REPLACE SHAFT AND/OR BUSHING, CLUTCH FORK ­ REPLACE INC : Replace clutch release bearing if necessary and adjust linkage 5810100 5810300 5810500 4 BEARING, CLUTCH RELEASE ­ REPLACE INC : R & R transaxle and adjust linkage 5810700 3.4 -- 3.3 5 6 FORK AND/OR BALL STUD, CLUTCH RELEASE ­ REPLACE DISC AND/OR CLUTCH COVER, CLUTCH ­ REPLACE INC : R & R transaxle, Replace release bearing and adjust linkage A * To replace clutch fork shaft and/or bushings B * To replace flywheel 5810900 5811100 3.7 3.5 -- 3.5 3.7 3.6 581110A 581110B 5811300 5811500 5811700 5811900 581190A 5812100 0.3 0.3 0.2 0.4 3.7 0.6 0.3 0.4 -- 0.3 0.3 0.4 -- -- -- -- 0.3 0.3 0.3 0.4 3.7 -- -- -- 7 8 9 10 SWITCH, BACK­UP LAMP ­ REPLACE COVER AND/OR GASKET, DIFF GEAR ­ REPLACE GUIDE, CLUTCH RELEASE BEARING ­ REPLACE CABLE, CLUTCH ­ REPLACE A * Cable adjustment 11 ARM, CLUTCH RELEASE ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 5C ­ 4 TRANSMISSION / TRANSAXLE TRANSMISSION / TRANSAXLE 5C ­ 5 CLUTCH ­ HYDRAULIC CLUTCH (582) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.7 0.5 0.6 0.6 0.3 0.6 0.2 0.5 -- -- -- N 0.7 0.4 0.5 -- 0.3 0.5 0.2 -- 3.7 3.7 3.7 L 0.7 0.4 0.5 0.5 0.3 0.5 0.2 0.5 -- -- -- 1 2 3 4 CYLINDER, ACTUATOR CLUTCH MASTER ­ REPLACE HOSE, HYDRAULIC CLUTCH RESERVOIR ­ REPLACE PIPE, HYDRAULIC CLUTCH ­ REPLACE CYLINDER, HYDRAULIC RELEASE ­ REPLACE CLUTCH HYDRAULIC SYSTEM ­BLEED 5820100 5820300 5820500 5820700 5820900 5821300 5821500 5821700 5822500 5822600 5822700 5 6 7 8 9 10 HOSE, HYDRAULIC CLUTCH ­ REPLACE CLIP ­ REPLACE BRACKET, RELEASE CYLINDER ­ REPLACE CONCENTRIC SLAVE CYLINDER ­ REPLACE PIPE, CONCENTRIC SLAVE ­ REPLACE BUSHING, CONCENTRIC SLAVE PIPE ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 5C ­ 6 TRANSMISSION / TRANSAXLE TRANSMISSION / TRANSAXLE 5C ­ 7 CLUTCH ­ CLUTCH PEDAL (583) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.3 0.3 0.2 0.3 0.2 0.3 N 0.3 -- -- 0.3 0.2 0.3 L 0.3 0.3 0.2 0.3 0.2 0.3 1 2 3 4 5 6 PEDAL, SHAFT AND/OR BUSHING, CLUTCH ­ REPLACE SPRING, CLUTCH PEDAL RETURN ­ REPLACE COVER, PEDAL PLATE ­ REPLACE SHAFT, CLUTCH PEDAL ­ REPLACE SWITCH, CLUTCH START ­ REPLACE BRACKET, CLUTCH PEDAL ­ REPLACE 5830100 5830300 5830700 5830900 5831100 5831300 S : KALOS, N

File name en_6a.pdf

STEERING 6A ­ 1 SECTION 6A STEERING (POWER STEERING SYSTEM) 621. POWER STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A ­ 3 623. POWER STEERING PIPE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A ­ 5 6A ­ 2 STEERING STEERING 6A ­ 3 POWER STEERING SYSTEM ­ POWER STEERING GEAR (621) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 LINE, POWER STEERING GEAR CYLINDER ­ REPLACE Right Left Both 6210100 6210200 6210300 6210500 621050A 0.6 0.6 0.6 1.4 0.1 0.5 0.5 0.6 0.5 0.3 0.5 0.5 0.6 0.5 0.3 2 COUPLING, STEERING FLEXIBLE ­ REPLACE A * With driver's air bag 3 GEAR ASSEMBLY, POWER STEERING Adjust Replace Overhaul GEAR ASSEMBLY, POWER STEERING (RHD) ­ REPLACE 6210700 6210800 6210900 6211100 0.4 1.7 2.9 2.1 -- 1.6 -- 1.6 -- 1.6 -- 1.6 4 GROMMET, POWER STEERING GEAR ­ REPLACE Right Left Both 6211600 6211700 6211800 0.5 0.5 0.7 0.5 -- -- 0.5 -- -- S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 6A ­ 4 STEERING STEERING 6A ­ 5 POWER STEERING SYSTEM ­ POWER STEERING PIPE LINE (623) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.2 0.5 0.7 0.6 N 0.2 0.4 0.5 0.6 L 0.2 0.4 0.5 0.6 1 2 3 4 5 CAP, POWER STEERING PUMP RESERVOIR ­ REPLACE HOSES, SUCTION LINE ­ REPLACE PIPE, POWER STEERING PRESSURE ­ REPLACE PIPE, POWER STEERING RETURN ­ REPLACE PUMP ASSEMBLY, POWER STEERING ­ REPLACE SOHC DOHC 6230100 6230500 6230900 6231500 6231700 6231900 6232100 6232300 6232500 6232700 6232900 6233100 6233200 2.2 2.4 0.6 0.5 -- -- -- -- -- -- 0.9 0.4 -- -- -- -- -- 0.6 -- 0.9 0.4 -- -- -- -- -- 0.6 6 7 8 9 10 11 12 RESERVOIR ASSEMBLY, PS FLUID (REMOTE) ­ REPLACE HOSE, GEAR RETURN ­ REPLACE PIPE, GEAR HIGH PRESSURE ­ REPLACE PIPE, PUMP HIGH PRESSURE ­ REPLACE PIPE, GEAR RETURN ­ REPLACE HOSE, HIGH PRESSURE ­ REPLACE HOSE, RETURN (RESERVOIR) ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA

File name en_6d.pdf

STEERING 6D ­ 1 SECTION 6D STEERING (MANUAL STEERING GEAR) 635. MANUAL STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D ­ 3 6D ­ 2 STEERING STEERING 6D ­ 3 MANUAL STEERING GEAR ­ MANUAL STEERING GEAR (635) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 1.4 0.1 N -- -- L -- -- 1 COUPLING, STEERING FLEXIBLE ­ REPLACE A * With driver's air bag 6350400 635040A 2 GEAR ASSEMBLY, MANUAL STEERING Replace Replace & Reinstall 6350100 6350200 1.0 1.0 -- -- -- -- S : KALOS, N : NUBIRA/LACETTI, L : EVANDA

File name en_6e.pdf

STEERING 6E ­ 1 SECTION 6E STEERING (STEERING WHEEL & COLUMN) 641. STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E ­ 3 642. STEERING COLUMN COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E ­ 5 643. STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E ­ 7 647. TIE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E ­ 11 6E ­ 2 STEERING STEERING 6E ­ 3 STEERING WHEEL & COLUMN ­ STEERING WHEEL (641) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.3 0.1 0.4 0.2 0.4 0.4 0.4 0.2 0.1 0.2 0.1 0.2 0.1 N 0.3 0.1 0.4 0.2 0.4 0.4 0.4 0.2 0.1 0.2 0.1 0.2 0.1 L 0.3 0.1 0.4 0.2 0.4 0.4 0.4 0.2 0.1 0.2 0.1 0.2 0.1 1 WHEEL, STEERING ­ REPLACE A * With driver's air bag 6410100 641010A 6410300 641030A 6410500 Windshield Wiper Multifunction 6410600 6410700 6411300 641130A 6411500 641150A 6411700 641170A 2 HORN CONTACT AND/OR CANCELING CAM ­ REPLACE A * With driver's air bag 3 SWITCH ­ REPLACE 4 CAP, HORN ­ REPLACE A * With driver's air bag 5 PLATE, LOCKING ­ REPLACE A * With driver's air bag 6 NUT, STEERING WHEEL ­ REPLACE A * With driver's air bag S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 6E ­ 4 STEERING STEERING 6E ­ 5 STEERING WHEEL & COLUMN ­ STEERING COLUMN COVER (642) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 COVER, STEERING WHEEL ­ REPLACE Lower Upper Both 6420100 6420300 6420500 0.2 0.2 0.3 0.2 0.2 0.3 0.2 0.2 0.3 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 6E ­ 6 STEERING STEERING 6E ­ 7 STEERING WHEEL & COLUMN ­ STEERING COLUMN (643) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 1.0 0.1 1.0 0.1 -- -- -- -- -- -- -- -- -- -- -- 1.7 0.1 2.1 0.1 -- -- -- -- 0.4 0.1 0.4 0.1 N 1.0 0.1 1.0 0.1 0.1 -- -- -- -- -- -- -- -- -- -- 1.7 0.1 2.1 0.1 0.1 -- 0.3 0.5 0.4 0.1 0.4 0.1 L -- -- 1.0 0.1 0.1 -- -- 2.1 0.1 -- -- 2.3 0.1 -- -- -- -- 2.2 0.1 0.1 -- 0.3 -- 0.4 0.1 0.4 0.1 1 COLUMN ASSEMBLY, STEERING ­ REPLACE A * With driver's air bag 6430100 643010A 6430300 643030A 643030B 6430500 643050A 6430700 643070A 6430900 643090A 6431100 643110A 6431300 643130A 6431500 643150A 6431700 643170A 643170B 6431900 6432100 6432300 6432500 643250A 6432700 643270A 2 COLUMN ASSEMBLY, TILT STEERING ­ REPLACE A * With driver's air bag B ­ With SSPS 3 HOUSING, STEERING COLUMN ­ REPLACE A * With driver's air bag HOUSING, TILT STEERING COLUMN ­ REPLACE A * With driver's air bag 4 SHAFT, STEERING COLUMN ­ REPLACE A * With driver's air bag SHAFT, TILT STEERING COLUMN ­ REPLACE A * With driver's air bag 5 SUPPORT, STEERING COLUMN (TILT) ­ REPLACE A * With driver's air bag 6 JACKET, STEERING COLUMN ­ REPLACE A * With driver's air bag JACKET, TILT STEERING COLUMN ­ REPLACE A * With driver's air bag B ­ With SSPS 7 8 9 10 SPACER, STEERING COLUMN ­

File name en_7a.pdf

HEATING. VENTILATION & AIR CONDITIONING 7A ­ 1 SECTION 7A HEATING & VENTILATION 711. AIR DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A ­ 3 713. EVAPORATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A ­ 5 714. BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A ­ 9 7A ­ 2 HEATING, VENTILATION & AIR CONDITIONING HEATING. VENTILATION & AIR CONDITIONING 7A ­ 3 HEATING & VENTILATION ­ AIR DISTRIBUTION (711) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 DUCT ASSEMBLY, DEFROSTER ­ REPLACE Right Side Glass Left Side Glass Center 7110300 7110400 7110500 2.0 2.0 2.1 -- -- 2.7 2.6 2.6 2.7 2 DUCT, SIDE DEFROSTER ­ REPLACE Right Left Both 7110700 7110800 7110900 7111300 2.0 2.0 2.1 2.0 2.6 2.6 2.7 2.7 2.6 2.6 2.7 3.0 3 4 DUCT, AIR DISTRIBUTION MAIN (CENTER) ­ REPLACE HOSE, DEFROSTER ­ REPLACE Right Left Both 7111500 7111600 7111700 7111900 7112100 -- -- -- -- -- -- -- -- -- -- -- -- -- 2.8 -- 5 6 7 JUNCTION BLOCK ­ REPLACE JUNCTION BLOCK, LOWER ­ REPLACE CONNECTOR, AIR DISTRIBUTION ­ REPLACE Right Left Both 7112300 7112400 7112500 0.5 0.5 0.6 0.5 0.5 0.6 -- -- -- 8 DUCT, AIR LEG ROOM REAR ­ REPLACE Right Left Both 7112700 7112800 7112900 0.5 0.5 0.6 0.5 0.5 0.6 0.5 0.5 0.6 9 DUCT, EXTENSION REAR ­ REPLACE Right Left Both 7113100 7113200 7113300 -- -- -- -- -- -- 0.2 0.2 0.3 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 7A ­ 4 HEATING, VENTILATION & AIR CONDITIONING HEATING. VENTILATION & AIR CONDITIONING 7A ­ 5 HEATING & VENTILATION ­ EVAPORATOR (713) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S -- -- -- 2.6 0.7 2.8 0.7 2.6 0.7 2.8 0.7 1.0 N -- -- -- 3.6 0.7 3.9 0.7 3.8 0.7 3.9 0.7 1.0 L -- -- -- 4.2 0.7 4.5 0.7 4.5 0.7 4.1 0.7 1.0 1 COVER, HEATER CORE (A/C) ­ REPLACE A * Recover/Recharge A/C system COVER, HEATER CORE (NON A/C) ­ REPLACE 7130100 713010A 7130200 7130300 713030A 7130500 713050A 7130700 713070A 7130900 713090A 7131100 2 MODULE, HEATER ­ REPLACE A * Recover/Recharge A/C system 3 CORE, HEATER ­ REPLACE A * Recover/Recharge A/C system 4 EVAPORATOR ­ REPLACE A * Recover/Recharge A/C system 5 EVAPORATOR CORE ­ REPLACE A * Recover/Recharge A/C system 6 O RING, EVAPORATOR INLET ­ REPLACE INC : Recover/Recharge A/C system 7 O RING, EVAPORATOR OUTLET ­ REPLACE INC : Recover/Recharge A/C system 7131200 1.0 1.0 1.0 8 O RING, DASH INLET ­ REPLACE INC : Recover/Recharge A/C system 7131300 1.0 1.0 1.0 9 O RING, DASH OUTLET ­ REPLACE INC : Recover/Recharge A/C system 7131400 1.0 1.0 1.0 10 VALVE, EXPANSION ­ REPLACE INC : Recover/Recharge A/C system VALVE, EXPANSION (RHD) ­ REPLACE INC : Recover/Recharge A/C system 7131600 1.0 1.0 1.0 7131700 1.0 1.0 1.0 11 12 AIR INLET ­ REPLACE MODULE, AIR CON ­ REPLACE INC : Recover/Recharge A/C system 7

File name en_7b.pdf

HEATING, VENTILATION & AIR CONDITIONING 7B ­ 1 SECTION 7B HVAC CONTROL 732. COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B ­ 3 733. COMPRESSOR MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B ­ 5 734. A/C HOSE & PIPE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B ­ 7 735. A/C CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B ­ 11 7B ­ 2 HEATING, VENTILATION & AIR CONDITIONING HEATING, VENTILATION & AIR CONDITIONING 7B ­ 3 HVAC CONTROL ­ COMPRESSOR (732) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.6 0.7 0.7 0.7 0.8 0.6 0.7 1.2 0.6 0.7 1.2 0.6 0.7 1.3 0.7 1.6 0.7 1.6 0.7 1.7 0.7 1.6 0.7 0.6 0.7 N 0.5 0.7 0.5 0.7 1.2 -- 0.7 1.5 -- 0.7 1.6 -- 0.7 1.7 0.7 2.0 0.7 2.0 0.7 2.0 0.7 1.9 0.7 1.0 0.7 L 0.5 0.7 0.5 0.7 1.2 -- 0.7 1.5 -- 0.7 1.6 -- 0.7 1.7 0.7 2.0 0.7 2.0 0.7 2.0 0.7 1.9 0.7 1.0 0.7 1 VALVE, COMPRESSOR PRESSURE ­ REPLACE A * Recover/Recharge AC system VALVE, COMPRESSOR CONTROL ­ REPLACE A * Recover/Recharge AC system 7320100 732010A 7320200 732020A 7320400 7320410 732040A 7320600 7320610 732060A 7320800 7320810 732080A 7321100 732110A 7321300 732130A 7321400 732140A 7321600 732160A 7321900 732190A 7322100 732210A 2 CLUTCH PLATE AND HUB ASSEMBLY, COMPRESSOR ­ REPLACE CLUTCH PLATE AND HUB ASSEMBLY, COMPRESSOR (KALOS 1.2S ONLY) ­ REPLACE A * Recover/Recharge AC system 3 ROTOR AND/OR BEARING, COMPRESSOR ­ REPLACE ROTOR AND/OR BEARING, COMPRESSOR (KALOS 1.2S ONLY) ­ REPLACE A * Recover/Recharge AC system 4 COIL AND/OR PULLEY RIM, COMPRESSOR CLUTCH ­ REPLACE COIL AND/OR PULLEY RIM, COMPRESSOR CLUTCH (KALOS 1.2S ONLY) ­ REPLACE A * Recover/Recharge AC system 5 SEAL, SEAT AND/OR O­RING, COMPRESSOR SHAFT ­ REPLACE A * Recover/Recharge AC system 6 REED ASSEMBLY, GASKET AND/OR O­RING, FRONT ­ REPLACE A * Recover/Recharge AC system REED ASSEMBLY, GASKET AND/OR O­RING, REAR ­ REPLACE A * Recover/Recharge AC system 7 VALVE PLATE ASSEMBLY, COMPRESSOR DISCHARGE ­ REPLACE A * Recover/Recharge AC system 8 CYLINDER AND SHAFT ASSEMBLY, COMPRESSOR ­ REPLACE A * Recover/Recharge AC system 9 COMPRESSOR ASSEMBLY ­ REPLACE A * Recover/Recharge AC system S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 7B ­ 4 HEATING, VENTILATION & AIR CONDITIONING HEATING, VENTILATION & AIR CONDITIONING 7B ­ 5 HVAC CONTROL ­ COMPRESSOR MOUNT (733) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 1.4 -- N 1.7 0.7 L 2.1 0.7 1 2 BRACKET, COMPRESSOR LOWER SUPPORT ­ REPLACE BRACKET, COMPRESSOR REAR ­ REPLACE 7330100 7330300 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 7B ­ 6 HEATING, VENTILATION & AIR CONDITIONING HEATING, VENTILATION & AIR CONDITIONING 7B ­ 7 HVAC CONTROL ­ A/C HOSE & PIPE LINE (734) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.2 0.2 N 0.2 0.2 L 0.2 0.2 1 2

File name en_8a.pdf

RESTRAINTS 8A ­ 1 SECTION 8A RESTRAINTS (SEAT BELTS) 812. FRONT SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A ­ 3 822. REAR SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A ­ 5 8A ­ 2 RESTRAINTS RESTRAINTS 8A ­ 3 SEAT BELTS ­ FRONT SEAT BELT (812) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 BUCKLE, FRONT SEAT BELT ­ REPLACE Right Left Both 8120100 8120200 8120300 0.3 0.3 0.5 0.3 0.3 0.5 0.3 0.3 0.5 2 BELT, SAFETY FRONT (RETRACTOR SIDE) ­ REPLACE Right Left Both 8120500 8120600 8120700 0.4 0.4 0.6 0.4 0.4 0.7 0.4 0.4 0.7 3 GUIDE AND/OR COVER, SAFETY BELT ­ REPLACE Right Left 8120900 8121100 0.2 0.2 0.2 0.2 0.2 0.2 4 ADJUSTER, FRONT SAFETY BELT ­ REPLACE Right Left 8121300 8121400 0.3 0.3 0.4 0.4 0.4 0.4 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 8A ­ 4 RESTRAINTS RESTRAINTS 8A ­ 5 SEAT BELTS ­ REAR SEAT BELT (822) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.2 N 0.3 L 0.3 1 2 BUCKLE, REAR SEAT BELT CENTER ­ REPLACE BELT, SAFETY REAR (RETRACTOR SIDE) ­ REPLACE Right Left Center 8220100 8220400 8220500 8220600 8220900 0.6 0.6 0.7 0.3 0.6 0.6 -- 0.3 0.6 0.6 -- 0.3 3 BUCKLE, REAR SEAT BELT ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA

File name en_8b.pdf

RESTRAINTS 8B ­ 1 SECTION 8B RESTRAINTS S. I. R (SUPPLEMENTAL INFLATABLE RESTRAINTS) 832. AIR BAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B ­ 3 833. IMMOBILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B ­ 5 8B ­ 2 RESTRAINTS RESTRAINTS 8B ­ 3 S. R. S (SUPPLEMENTAL INFLATABLE RESTRAINTS) ­ AIR BAG SYSTEM (832) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.6 0.4 1.3 0.3 1.9 N 0.6 0.5 2.4 0.4 0.5 L 0.6 0.5 2.4 0.4 0.5 1 2 3 4 5 6 COIL, SRS ­ REPLACE SDM, AIR BAG ­ REPLACE WIRING, AIR BAG ­ REPLACE MODULE, STEERING WHEEL INFLATOR ­ REPLACE MODULE, PASSENGER INFLATABLE CUSHION ­ REPLACE SENSOR, SIDE AIRBAG ­ REPLACE Right Left Both 8320100 8320300 8320500 8320700 8320900 8321000 8321100 8321200 0.3 0.3 0.5 0.3 0.3 0.5 0.3 0.3 0.5 7 MODULE, SIDE AIRBAG ­ REPLACE Right Left Both 8321300 8321400 8321500 0.8 0.8 1.4 0.8 0.8 1.4 0.8 0.8 1.4 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 8B ­ 4 RESTRAINTS RESTRAINTS 8B ­ 5 S. R. S (SUPPLEMENTAL INFLATABLE RESTRAINTS) ­ IMMOBILIZER (833) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.5 N 0.5 L 0.5 1 HEAD AMP. OR IMMOBILIZER CONTROL UNIT ­ REPLACE 8330500 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA

File name en_9a.pdf

BODY & ACCESSORIES 9A ­ 1 SECTION 9A BODY & ACCESSORIES (BODY WIRING SYSTEM) 911. WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A ­ 3 9A ­ 2 BODY & ACCESSORIES BODY & ACCESSORIES 9A ­ 3 BODY WIRING SYSTEM ­ WIRING HARNESS (911) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 CABLES, BATTERY ­ REPLACE Battery to Alternator Negative 9110100 9110300 9110500 9110700 9110900 9111100 9111300 9111500 9111700 9112100 9112300 9112500 9112700 9112900 9113100 9113300 9113400 0.8 0.5 2.6 2.2 1.3 4.0 2.6 1.3 0.4 0.5 0.5 0.5 2.6 1.2 0.5 0.3 1.3 0.6 0.5 4.2 3.2 1.7 0.6 1.7 -- 0.6 0.5 0.9 0.9 -- 1.4 0.5 0.3 1.4 0.6 -- 4.7 3.2 1.3 0.6 1.2 1.2 0.4 0.7 1.1 0.8 -- 2.5 0.5 0.3 -- 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 WIRING, FLOOR ­ REPLACE WIRING, INST PANEL ­ REPLACE WIRING, ROOF ­ REPLACE WIRING, ABS ­ REPLACE WIRING, FRONT ­ REPLACE WIRING, FRONT BUMPER ­ REPLACE WIRING, REAR ­ REPLACE WIRING, TRUNK LID ­ REPLACE WIRING, FRONT DOOR ­ REPLACE WIRING, REAR DOOR ­ REPLACE WIRING, ECM & ABS ­ REPLACE WIRING, ENGINE CONTROL ­ REPLACE WIRING, FUEL PUMP ­ REPLACE WIRING, REAR ABS ­ REPLACE WIRING, AIRBAG ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA

File name en_9b.pdf

BODY & ACCESSORIES 9B ­ 1 SECTION 9B BODY & ACCESSORIES (LIGHTING SYSTEM) 916/917. FRONT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B ­ 3 918. REAR LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B ­ 7 9B ­ 2 BODY & ACCESSORIES BODY & ACCESSORIES 9B ­ 3 LIGHTING SYSTEM ­ FRONT LAMP (916/917) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 HEADLAMP ASSEMBLY, COMPOSITE ­ REPLACE Right Left Both 9160100 9160200 9160300 0.3 0.3 0.5 0.3 0.3 0.5 0.3 0.3 0.5 2 BULB, HEADLAMP ­ REPLACE Right Left Both 9160400 9160500 9160600 0.3 0.3 0.5 0.3 0.3 0.5 0.3 0.3 0.5 3 CAP, HEADLAMP ­ REPLACE Right Left 9160800 9160900 0.2 0.2 0.2 0.2 0.2 0.2 4 BULB, TURN SIGNAL ­ REPLACE Right Left Both 9161100 9170100 9170200 0.3 0.3 0.4 0.3 0.3 0.4 0.2 0.2 0.3 5 BULB, POSITION ­ REPLACE Right Left Both 9161300 9170300 9170400 0.2 0.2 0.3 0.3 0.3 0.5 0.3 0.3 0.5 6 LAMP, FOG ­ REPLACE Right Left Both 9161500 9170500 9170600 0.5 0.5 0.8 0.4 0.4 0.6 0.3 0.3 0.5 7 BULB, FOG LAMP ­ REPLACE Right Left Both 9161700 9170700 9170800 0.4 0.4 0.6 0.3 0.3 0.5 0.3 0.3 0.5 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 9B ­ 4 BODY & ACCESSORIES BODY & ACCESSORIES 9B ­ 5 LIGHTING SYSTEM ­ FRONT LAMP (916/917) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 8 SPACER, HEADLAMP ­ REPLACE Right Left Both 9161900 9170900 9171100 -- -- -- -- -- -- -- -- -- 9 LAMP, TURN SIGNAL SIDE ­ REPLACE Right Left Both 9162100 9171200 9171300 0.2 0.2 0.3 0.2 0.2 0.3 0.2 0.2 0.3 10 BULB, TURN SIGNAL SIDE LAMP ­ REPLACE Right Left Both 9162200 9171400 9171500 0.2 0.2 0.3 0.2 0.2 0.3 0.2 0.2 0.3 11 LAMP, FRONT SIDEMARKER ­ REPLACE Right Left 9162400 9162500 -- -- -- -- -- -- 12 BULB, FRONT SIDEMARKER LAMP ­ REPLACE Right Left 9162700 9162800 -- -- -- -- -- -- 13 LAMP, TURN SIGNAL ­ REPLACE Right Left Both 9163500 9163600 9163700 0.4 0.4 0.6 -- -- -- -- -- -- S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 9B ­ 6 BODY & ACCESSORIES BODY & ACCESSORIES 9B ­ 7 LIGHTING SYSTEM ­ REAR LAMP (918) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 LAMP, REAR COMBINATION ­ REPLACE Right Left Both LAMP, REAR COMBINATION (HATCH BACK) ­ REPLACE Right Left Both 9180410 9180420 9180430 -- -- -- 0.2 0.2 0.2. -- -- -- 9180100 9180200 9180300 0.2 0.2 0.3 0.3 0.3 0.5 0.3 0.3 0.5 2 BULB, COMBINATION LAMP ­ REPLACE Right Left Both 9180500 9180600 9180700 9180800 9180900 9181100 9181200 9181400 9181600 9181700 0.2 0.2 0.3 0.2 0.2 0.2 0.2 -- 0.2 -- 0.2 0.2 0.3 0.2 0.2 0.2 0.2 0.2 -- -- 0.2 0.2 0.3 0.2 0.2 0.2 0.2 -- 0.2 -- 3 4 5 LAMP, LICENSE ­ REPLACE BULB, LICENSE LAMP ­ REPLACE BULB, BACK­UP LAMP ­ REPLACE BULB, TURN SIGNAL ­ REPLACE 6 7 LAMP, EXTENSION ­ REPLACE LAMP, HIGH MOUNTED STOP (N/B, H/B) ­ REPLACE LAMP, HIGH MOUNTED STOP (WAGON) ­ REPLACE 8 LAMP, REAR SIDEMARKER ­ REPLACE Right Left 9182100 9182200 -- -- -

File name en_9d.pdf

BODY & ACCESSORIES 9D ­ 1 SECTION 9D BODY & ACCESSORIES (WIPER/WASHER SYSTEM) 921. WINDSHIELD WIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9D ­ 3 923. WINDSHIELD WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9D ­ 5 9D ­ 2 BODY & ACCESSORIES BODY & ACCESSORIES 9D ­ 3 WIPER / WASHER SYSTEM ­ WINDSHIELD WIPER (921) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 MOTOR, WIPER Replace & Reinstall (Windshield) Replace (Windshield) MOTOR, BACK WINDOW WIPER ­ REPLACE 9210100 9210200 9210300 9210700 9210900 9211000 9211100 0.4 0.4 0.3 0.2 0.2 0.2 0.4 0.5 0.5 -- 0.2 0.2 0.2 0.4 0.5 0.5 -- 0.2 0.2 -- 0.6 2 3 BLADE, WIPER (WINDSHIELD) ­ REPLACE ARM, WIPER (WINDSHIELD) ­ REPLACE ARM, WIPER (WINDSHIELD)(HATCH BACK, WAGON) ­ REPLACE 4 LINKAGE, WIPER (BOTH) ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 9D ­ 4 BODY & ACCESSORIES BODY & ACCESSORIES 9D ­ 5 WIPER / WASHER SYSTEM ­ WINDSHIELD WASHER (923) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.4 0.6 N 0.6 0.7 L 0.7 0.7 1 2 RESERVOIR, WASHER FLUID ­ REPLACE HOSES, NOZZLES, WASHER AND/OR WIPER STOPS ­ REPLACE (WINDSHIELD) HOSES, NOZZLES, WINDSHIELD (HATCH BACK, WAGON) ­ REPLACE 9230100 9230300 9230400 0.2 0.2 -- 3 4 PUMP, ASSEMBLY, WASHER ­ R&R OR REPLACE (WINDSHIELD) SENSOR, LEVEL WASHER ­ REPLACE 9230700 9231200 0.4 -- 0.6 -- 0.5 0.5 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA

File name en_9e.pdf

BODY & ACCESSORIES 9E ­ 1 SECTION 9E BODY & ACCESSORIES (INSTRUMENT DRIVER SYSTEM) 925. INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E ­ 3 9E ­ 2 BODY & ACCESSORIES BODY & ACCESSORIES 9E ­ 3 INSTRUMENT DRIVER SYSTEM ­ INSTRUMENT CLUSTER (925) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.3 0.3 0.4 0.4 N 0.4 0.4 0.4 ­ L 0.5 0.4 0.4 -- 1 2 3 4 LENS, INSTRUMENT CLUSTER ­ REPLACE CLUSTER ASSEMBLY, I/P ­ REPLACE BULB, CLUSTER ­ REPLACE CAP, INSTRUMENT ­ REPLACE 9250100 9250300 9251700 9252400 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA

File name en_9f.pdf

BODY & ACCESSORIES 9F ­ 1 SECTION 9F BODY & ACCESSORIES (AUDIO & ANTI­THEFT SYSTEM) 928. ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F ­ 3 929. ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F ­ 5 9F ­ 2 BODY & ACCESSORIES BODY & ACCESSORIES 9F ­ 3 AUDIO SYSTEM ­ ELECTRICAL PARTS (928) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S -- N -- L -- 1 2 RESISTOR, COOLING FAN ­ REPLACE SPEAKER, RADIO ­ REPLACE Right Front Left Front Both Front Right Rear Left Rear Both Rear SPEAKER, REAR, RADIO ­ REPLACE Hatch Back Wagon 9280100 9280300 9280400 9280500 9280600 9280700 9280800 0.3 0.3 0.5 0.2 0.2 0.3 0.5 0.5 0.8 0.5 0.5 0.8 0.5 0.5 0.8 0.5 0.5 0.8 9280900 9281000 9281100 9281300 9281400 9281500 9281600 9281700 9281800 9281900 9282000 9282100 9282300 9283100 9283200 9283300 0.2 -- 0.2 0.2 -- -- -- 0.2 0.2 -- -- -- 0.2 0.2 -- 0.2 -- -- 0.3 0.2 -- 0.3 0.2 0.3 0.2 -- -- -- 0.2 0.5 -- 0.5 -- -- 0.3 0.2 0.2 0.2 0.2 0.3 0.2 0.2 0.2 0.2 0.2 0.3 0.2 0.3 3 4 5 6 7 8 9 10 11 12 13 14 15 16 HORN ASSEMBLY ­ REPLACE LAMP, REAR COMPARTMENT ­ REPLACE LAMP, DOOR STEP ­ REPLACE LAMP, ROOM (CENTRAL) ­ REPLACE BULB, ROOM LAMP (CENTRAL) ­ REPLACE LAMP ASS'Y (ROOM) ­ REPLACE BULB, LAMP ASS'Y (ROOM) ­ REPLACE LAMP, GLOVE BOX ­ REPLACE BULB, GLOVE BOX LAMP ­ REPLACE SWITCH, GLOVE BOX LAMP ­ REPLACE SWITCH, HOOD CONTACT ­ REPLACE CASSETTE ­ REPLACE EQUALIZER, CASSETTE ­ REPLACE PLAYER, COMPACT DISK ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 9F ­ 4 BODY & ACCESSORIES BODY & ACCESSORIES 9F ­ 5 AUDIO SYSTEM ­ ELECTRICAL PARTS (928) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S -- N 0.4 L 0.4 17 18 CD CHANGER ­ REPLACE TWEETER, INNER COVER ­ REPLACE Right Left 9283400 9283600 9283700 9283800 9283900 9284200 9284300 9284500 9284600 0.2 0.2 -- -- -- -- 0.2 -- 0.2 0.2 0.2 1.5 0.3 0.2 -- 0.4 0.2 0.2 0.2 1.5 -- -- -- -- 19 20 21 22 23 24 SWITCH, AUDIO REMOTE CONTROL CABLE, CD CHANGER ­ REPLACE SENSOR, RAIN ­ REPLACE COVER, RAIN SENSOR ­ REPLACE BATTERY SAVER ­ REPLACE FOLDING MIRROR UNIT S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 9F ­ 6 BODY & ACCESSORIES BODY & ACCESSORIES 9F ­ 7 AUDIO & ANTI­THEFT SYSTEM ­ ANTENNA (929) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 CABLE, ANTENNA ­ REPLACE Antenna to Connector Radio to Connector 9290300 9290400 9290700 9290900 9291100 9291200 9291300 9291500 9291700 9291800 9291900 9293600 1.5 0.9 -- -- 0.3 -- 0.2 -- 1.1 0.3 -- -- 1.5 0.9 -- -- 0.5 -- 0.2 -- -- 0.3 -- -- 1.5 0.9 -- -- -- -- 0.2 -- -- 0.3 -- 0.5 2 3 4 5 6 7 8 9 10 11 POWER ANTENNA ASSEMBLY ­ REPLACE POLE, ANTENNA ­ REPLACE CONTROL UNIT, REMOTE ­ REPLACE CABLE, REMOTE CONTROL UNIT ­ REPLACE SIREN ­ REPLACE ANTENNA, MAST ­ REPLACE ANTENNA ASSEMBLY, ROOF ­ REPLACE MODULE, GLASS ANTENNA SENSOR, ULTRASONIC ­ REPLACE SWITCH UNIT, INTELLIGENT ­ REPLACE S : KA

File name en_9g.pdf

BODY & ACCESSORIES 9G ­ 1 SECTION 9G BODY & ACCESSORIES (INTERIOR TRIM) 931. INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G ­ 3 932. MOLDING & SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G ­ 7 933. INSTRUMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G ­ 9 934. CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G ­11 935. FRONT DOOR TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G ­13 936. REAR DOOR TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G ­15 938. PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G ­17 939. FLOOR CARPET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G ­19 9G ­ 2 BODY & ACCESSORIES BODY & ACCESSORIES 9G ­ 3 INTERIOR TRIM ­ INSTRUMENT PANEL (931) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.2 0.2 N 0.2 0.3 L 0.2 0.2 1 2 LOCK, COMPARTMENT I/P ­ REPLACE HINGE AND/OR STRIKER, COMPARTMENT I/P ­ ADJUST OR REPLACE 9310100 9310300 3 4 BOX, GLOVE ­ REPLACE PANEL, CARRIER ASSEMBLY INSTRUMENT CONTROL ­ REPLACE INC : Enable and disable SIR system if nec. INC : Transfer of all nec. parts A * W/Passenger side air bag 9310700 9310900 0.2 2.1 0.3 2.5 0.3 2.5 931090A 0.2 0.2 0.2 5 PANEL, SHROUD SIDE TRIM (KICK PAD) ­ REPLACE Right Left 9311100 9311200 9311400 9311600 9311800 0.2 0.2 0.2 0.2 0.3 0.2 0.2 0.2 0.2 0.4 0.2 0.2 0.3 0.2 0.4 6 7 8 9 COVER, INSTRUMENT LOWER ­ REPLACE COVER, BLANK ­ REPLACE NOZZLE, VENTILATION CENTER ­ REPLACE NOZZLE, VENTILATION ­ REPLACE Left Right Both 9311900 9311910 9311920 2.1 2.1 2.1 0.6 0.6 1.0 2.7 2.7 2.7 10 NOZZLE, DEFROSTER ­ REPLACE Right Left Both 9312100 9312200 9312300 -- -- -- 0.3 0.3 0.5 0.2 0.2 0.3 11 KNEE BOLSTER ­ REPLACE Right Left 9312400 9312500 0.4 0.4 0.4 0.4 0.4 0.4 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 9G ­ 4 BODY & ACCESSORIES BODY & ACCESSORIES 9G ­ 5 INTERIOR TRIM ­ INSTRUMENT PANEL (931) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 12 GRILLE, WINDSHIELD DEFROSTER ­ REPLACE Right Left Both 9312600 9312700 9312800 9313000 9313200 9314000 9314100 -- -- -- 0.2 0.3 -- -- -- -- -- -- -- -- -- 0.2 0.2 0.3 0.2 -- 0.2 0.4 13 14 15 16 BOX, COIN ­ REPLACE COVER, PASSENGER AIR BAG (RHD ONLY) ­ REPLACE COVER, A/C I/P ­ REPLACE HOUSING, GLOVE BOX ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 9G ­ 6 BODY & ACCESSORIES BODY & ACCESSORIES 9G ­ 7 INTERIOR TRIM ­ MOLDING & SWITCH (932) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S -- N 0.3 L 0.6 1 2 PLATE, I

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BODY & ACCESSORIES 9H ­ 1 SECTION 9H BODY & ACCESSORIES (SEATS) 941. FRONT SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9H ­ 3 942. REAR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9H ­ 7 9H ­ 2 BODY & ACCESSORIES BODY & ACCESSORIES 9H ­ 3 SEATS ­ FRONT SEAT (941) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 GUIDE RAIL, FRONT SEAT MANUAL ­ REPLACE Passenger Driver GUIDE RAIL, FRONT SEAT POWER ­ REPLACE 9410100 9410300 9410400 0.4 0.4 -- 0.5 0.5 -- 0.5 0.5 1.0 2 KNOB, FRONT SEAT BACK ACTUATOR ­ REPLACE Passenger Driver 9410500 9410600 0.2 0.2 0.2 0.2 0.2 0.2 3 REGULATOR, FRONT SEAT ­ REPLACE Passenger Driver 9410800 9410900 0.2 0.2 0.2 0.2 0.2 0.2 4 COVER, FRONT SEAT SIDE ­ REPLACE Passenger Driver 9412100 9412200 0.2 0.2 0.2 0.2 0.2 0.2 5 SEAT BACK ASSEMBLY ­ REPLACE Passenger Driver 9412400 9412500 0.6 0.6 0.5 0.5 0.5 0.5 6 HEADREST AND/OR COVER, FRONT SEAT ­ REPLACE Passenger Driver 9412700 9412800 0.2 0.2 0.2 0.2 0.2 0.2 7 COVER AND/OR PAD, FRONT SEAT CUSHION ­ REPLACE Passenger Driver 9413100 9413200 0.8 0.8 0.8 0.8 1.0 1.0 8 COVER AND/OR PAD, FRONT SEAT BACK CUSHION ­ REPLACE Passenger Driver 9413400 9413500 0.8 0.8 0.8 0.8 0.8 0.8 9 RECLINING, FRONT SEAT ­ REPLACE Passenger Driver 9413700 9413800 0.6 0.6 0.6 0.6 0.6 0.6 10 SLEEVE, HEADREST ­ REPLACE Passenger Driver 9414100 9414200 9414400 0.3 0.3 0.2 0.3 0.3 0.2 0.3 0.3 0.2 11 12 KNOB, HEIGHT ADJUSTER ­ REPLACE SEAT ASSEMBLY, FRONT ­ REPLACE Passenger Driver 9414600 9414700 0.3 0.3 0.3 0.3 0.3 0.3 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 9H ­ 4 BODY & ACCESSORIES BODY & ACCESSORIES 9H ­ 5 SEATS ­ FRONT SEAT (941) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S -- 0.2 0.2 0.5 0.7 N -- -- -- 0.6 0.8 L 0.3 -- -- 0.6 0.8 13 14 15 16 17 SWITCH, FRONT POWER SEAT ­ REPLACE TABLE, FRONT SEAT BACK ­ REPLACE ARMREST, FRONT SEAT ­ REPLACE SEAT CUSHION ASSEMBLY ­ REPLACE FRAME, FRONT SEAT CUSHION ­ REPLACE 9414900 9415100 9415300 9415600 9415700 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 9H ­ 6 BODY & ACCESSORIES BODY & ACCESSORIES 9H ­ 7 SEATS ­ REAR SEAT (942) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.2 0.2 0.2 0.9 1.4 -- N 0.3 0.3 0.2 0.9 1.4 0.3 L 0.3 0.3 0.2 0.9 1.4 0.3 1 2 3 4 5 6 7 SEAT ASS'Y, REAR ­ REPLACE SEAT, REAR BACK CUSHION ­ REPLACE SEAT, REAR CUSHION ­ REPLACE COVER, REAR CUSHION ­ REPLACE COVER, REAR BACK CUSHION ­ REPLACE ARMREST, REAR SEAT BACK ­ REPLACE LATCH, REAR SEAT BACK ­ REPLACE Right Left 9420100 9420300 9420500 9420700 9420900 9421100 9421300 9421400 0.4 0.4 -- -- -- -- 8 KNOB, REAR SEAT BACK ­ REPLACE Right Left 9421600 9421700 0.2 0.2 0.2 0.2 0.2 0.2 9 STRIKER, REAR SEAT BACK ­ REPLACE Right Left 9422100 9422200 9422300 9422500 9422600 9422700 9422800 9422900 9423000 -- -- 0.2 0.2 0.3 -- -- -- 0.2 -- -- 0.2 0.2 0.3 -- -- -- 0.7 --

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BODY & ACCESSORIES 9L ­ 1 SECTION 9L BODY & ACCESSORIES (GLASS & MIRRORS) 946. GLASS & OUT SIDE MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L ­ 3 9L ­ 2 BODY & ACCESSORIES BODY & ACCESSORIES 9L ­ 3 GLASS & MIRRORS ­ GLASS & OUT SIDE MIRRORS (946) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.9 0.9 N 0.9 0.9 L 0.9 0.9 1 2 3 GLASS, WINDSHIELD ­ REPLACE MOLDING, WINDSHIELD FRONT ­ REPLACE GLASS, FRONT DOOR ­ REPLACE Right Left 9460100 9460600 9461100 9461200 0.4 0.4 0.6 0.6 0.6 0.6 4 GLASS, REAR DOOR ­ REPLACE Right Left 9461400 9461500 9461700 9461900 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.7 0.7 0.6 0.6 5 6 7 GLASS, BACK WINDOW ­ REPLACE MOLDING, WINDSHIELD REAR ­ REPLACE MIRROR, OUTSIDE REAR VIEW ­ REPLACE Right Left 9462300 9462400 0.3 0.3 0.3 0.3 0.3 0.3 8 GLASS, OUTSIDE REAR VIEW MIRROR ­ REPLACE Right Left 9462600 9462700 0.2 0.2 0.2 0.2 0.2 0.2 9 GLASS, REAR FIXED DOOR ­ REPLACE Right Left 9463100 9463200 -- -- 0.4 0.4 0.6 0.6 10 MOLDING, REAR FIXED DOOR GLASS ­ REPLACE Right Left 9463400 9463500 9463700 9463800 -- -- 0.8 -- 0.4 0.4 0.8 -- 0.6 0.6 -- -- 11 12 13 GLASS, TAILGATE (HATCH BACK, WAGON) ­ REPLACE MOLDING, TAILGATE GLASS ­ REPLACE GLASS, QUARTER WINDOW ­ REPLACE Right Left 9464100 9464200 0.5 0.5 -- -- -- -- S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 9L ­ 4 BODY & ACCESSORIES BODY & ACCESSORIES 9L ­ 5 GLASS & MIRRORS ­ GLASS & OUT SIDE MIRRORS (946) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 14 DAM, QUARTER GLASS ­ REPLACE Right Left 9464400 9464500 0.5 0.5 -- -- -- -- 15 COVER, C PILLAR OUTER ­ REPLACE Right Left 9464700 9464800 -- -- -- -- -- -- 16 GLASS AND/OR MOLDING, FRONT QUARTER WINDOW (MPV) ­ REPLACE Right Left 9465300 9465400 9465500 9465910 9465900 -- -- -- 0.6 0.6 -- -- 0.2 -- 0.6 -- -- 0.2 -- 0.6 17 18 19 PLATE, CARRIER ­ REPLACE DAM, TAILGATE GLASS ­ REPLACE DAM, BACK WINDOW GLASS ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA

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BODY & ACCESSORIES 9M ­ 1 SECTION 9M BODY & ACCESSORIES (EXTERIOR PARTS) 951. EMBLEM & LETTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9M ­ 3 952. MUD GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9M ­ 5 9M ­ 2 BODY & ACCESSORIES BODY & ACCESSORIES 9M ­ 3 EXTERIOR PARTS ­ EMBLEM & LETTERING (951) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.2 0.2 N 0.2 0.2 L 0.2 0.2 1 2 EMBLEM ­ REPLACE LETTERING ­ REPLACE 9510100 9510300 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 9M ­ 4 BODY & ACCESSORIES BODY & ACCESSORIES 9M ­ 5 EXTERIOR TRIM ­ MUD GUARD (952) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 GUARD, MUD FRONT ­ REPLACE Right Left Both GUARD, MUD REAR ­ REPLACE Right Left Both 9520600 9520700 9520800 0.2 0.2 0.3 0.2 0.2 0.3 0.2 0.2 0.3 9520100 9520200 9520300 0.2 0.2 0.3 0.2 0.2 0.3 0.2 0.2 0.3 2 MOLDING, ROCKER PANEL ­ REPLACE Right Left Both 9520900 9520910 9520920 -- -- -- -- -- -- 0.6 0.6 1.0 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA

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BODY & ACCESSORIES 9O ­ 1 SECTION 9O BODY & ACCESSORIES (BUMPERS & FASCIAS) 956. FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9O ­ 3 957. REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9O ­ 5 9O ­ 2 BODY & ACCESSORIES BODY & ACCESSORIES 9O ­ 3 BUMPERS & FASCIAS ­ FRONT BUMPER (956) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 1.1 1.2 -- N 1.0 1.1 1.0 L 0.9 1.1 1.0 1 2 3 FASCIA, FRONT BUMPER ­ REPLACE BEAM, IMPACT FRONT ­ REPLACE (ONE PIECE) ABSORBER AND/OR BRACKET, FRONT BUMPER ENERGY ­ REPLACE (ONE) 9560100 9560300 9560500 4 5 BUMPER ASS'Y, FRONT ­ REPLACE STAY, FRONT BUMPER (ONE OR TWO) ­ REPLACE 9560700 9561500 1.2 -- 1.1 -- 1.1 1.1 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 9O ­ 4 BODY & ACCESSORIES BODY & ACCESSORIES 9O ­ 5 BUMPERS & FASCIAS ­ REAR BUMPER (957) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.7 -- -- 0.9 0.9 0.9 -- N 0.9 -- 1.3 -- 1.0 -- -- L 0.8 -- 1.0 0.9 1.0 -- 1.0 1 2 3 4 5 6 7 FASCIA, REAR BUMPER ­ REPLACE STRIP­RUBBING, FASCIA, REAR ­ REPLACE BEAM, IMPACT REAR ­ REPLACE ABSORBER AND/OR BRACKET, RR BUMPER ENERGY ­ REPLACE (ONE) BUMPER ASS'Y, REAR ­ REPLACE BRACKET, REAR ENERGY ABSORBER ­ REPLACE STAY, REAR BUMPER (ONE OR TWO) ­ REPLACE 9570100 9570300 9570600 9570800 9571100 9571300 9571600 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA

File name en_9p.pdf

BODY & ACCESSORIES 9P ­ 1 SECTION 9P BODY & ACCESSORIES (DOORS) 961A. FRONT DOOR & LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P ­ 3 961B. FRONT WINDOW LIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P ­ 7 961C. FRONT WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P ­ 9 963A. REAR DOOR & LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P ­ 11 963B. REAR WINDOW LIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P ­ 15 963C. REAR WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P ­ 17 965. 966. 967. 968. ELECTRIC DOOR LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P ­ 19 FUEL FILLER LOCK & QUARTER WINDOW LOCK . . . . . . . . . . . . . . . . . . . . . . . . 9P ­ 21 TRUNK LID LOCK & TAILGATE LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P ­ 23 CAR LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P ­ 25 9P ­ 2 BODY & ACCESSORIES BODY & ACCESSORIES 9P ­ 3 DOORS ­ FRONT DOOR & LOCK (961A) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 DOOR ASSEMBLY, FRONT ­ REPLACE Right Left DOOR ASSEMBLY, FRONT ­ ALIGN Right Left 9610400 9610500 0.3 0.3 0.3 0.3 0.3 0.3 9610100 9610200 1.5 1.5 1.7 1.7 1.8 1.8 2 HINGE, FRONT DOOR (BOLT ON) ­ REPLACE Right Upper Left Upper Right Lower Left Lower Both Right Both Left 9610700 9610800 9610900 9611100 9611200 9611300 0.9 0.9 0.9 0.9 1.0 1.0 0.9 0.9 0.9 0.9 1.0 1.0 0.9 0.9 0.9 0.9 1.0 1.0 3 LINK OR SPRING, FRONT DOOR HOLD OPEN ­ REPLACE Right Left 9611500 9611600 0.5 0.5 0.5 0.5 0.5 0.5 4 HANDLE, FRONT DOOR OUTSIDE ­ REPLACE Right Left Both 9612100 9612200 9612300 0.5 0.5 0.9 0.5 0.5 0.9 0.6 0.6 1.0 5 STRIKER, FRONT DOOR LOCK ­ REPLACE Right Left 9612500 9612600 0.2 0.2 0.2 0.2 0.2 0.2 6 LATCH, FRONT DOOR ­ R&R OR REPLACE Right Left Both 9612800 9612900 9613000 0.5 0.5 0.9 0.6 0.6 1.1 0.8 0.8 1.5 7 ROD, FRONT DOOR INSIDE LOCKING ­ REPLACE Right Left 9613100 9613200 0.5 0.5 0.6 0.6 0.6 0.6 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 9P ­ 4 BODY & ACCESSORIES BODY & ACCESSORIES 9P ­ 5 DOORS ­ FRONT DOOR & LOCK (961A) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 8 SWITCH, DOOR CONTACT ­ REPLACE Right Front Left Front both 9613400 9613500 9613600 0.2 0.2 0.3 0.2 0.2 0.3 -- -- -- S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 9P ­ 6 BODY & ACCESSORIES BODY & ACCESSORIES 9P ­ 7 DOORS ­ FRONT WINDOW LIFTER (961B) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 RAIL, FRONT DOOR GUIDE ­ REPLACE Right Left 9615100 9615200 0.5 0.5 0.5 0.5 0.5 0.5 2 REGULATOR, FRONT DOOR WINDOW

File name en_9q.pdf

BODY & ACCESSORIES 9Q ­ 1 SECTION 9Q BODY & ACCESSORIES (ROOF) 971. HEADLINING & ROOF PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q ­ 3 972A. SUNSHADE & INSIDE MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q ­ 5 972B. SUN ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q ­ 7 9Q ­ 2 BODY & ACCESSORIES BODY & ACCESSORIES 9Q ­ 3 ROOF ­ HEADLINING & ROOF PANEL (971) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 1.0 N 1.0 L 1.3 1 2 HEADLINING ASSEMBLY ­ REPLACE HANDLE AND/OR ESCUTCHEON, ASSIST ­ REPLACE Right Rear Left Rear Right Front Left Front 9710100 9710200 9710300 9710400 9710500 9710700 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.3 0.2 0.2 0.2 0.2 0.3 3 4 SHELF, BACK PANEL (UPPER) ­ REPLACE MOLDING, ROOF ­ REPLACE Right Left Both 9711100 9711200 9711300 9711500 9711700 9711900 0.4 0.4 0.7 -- 0.2 0.2 0.4 0.4 0.7 -- 0.2 0.2 0.4 0.4 0.7 -- -- -- 5 6 7 8 ROOF RACK ­ REPLACE (ONE OR TWO) COVER, BACK SHELF (HATCH BACK) ­ REPLACE STRIP, BACK SHELF COVER (ONE OR TWO) ­ REPLACE GRILLE, REAR SPEAKER ­ REPLACE Right Left Both 9712100 9712200 9712300 0.3 0.3 0.4 -- -- -- -- -- -- S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 9Q ­ 4 BODY & ACCESSORIES BODY & ACCESSORIES 9Q ­ 5 ROOF ­ SUNSHADE & INSIDE MIRROR (972A) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.2 N 0.2 L 0.2 1 2 MIRROR, VISOR VANITY ­ REPLACE SUNSHADE AND/OR SUPPORT ­ REPLACE Right Left 9720100 9720300 9720400 9720600 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 3 MIRROR, INSIDE REAR VIEW ­ REPLACE S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 9Q ­ 6 BODY & ACCESSORIES BODY & ACCESSORIES 9Q ­ 7 ROOF ­ SUN ROOF (972B) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 1.1 0.3 N 1.1 0.4 L 1.4 0.4 1 2 MOTOR, SUN ROOF ­ REPLACE GLASS, SUN ROOF ­ REPLACE INC : Adjustment of Glass 9725100 9725200 3 4 5 6 7 8 CONTROL UNIT, SUN ROOF ­ REPLACE FRAME, SUN ROOF ­ REPLACE DEFLECTOR, WINDOW ­ REPLACE WEATHERSTRIP, SUN ROOF ­ REPLACE SIDE INNER COVER, ONE OR TWO ­ REPLACE SIDE OUTER COVER, ONE OR TWO ­ REPLACE 9725300 9725400 9725500 9725600 9725700 9725800 1.1 1.6 0.2 0.4 0.2 0.3 1.1 1.6 0.2 0.3 0.2 0.2 1.3 1.7 0.2 0.2 0.2 0.2 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA

File name en_9r.pdf

BODY & ACCESSORIES 9R ­ 1 SECTION 9R BODY & ACCESSORIES (BODY FRONT END) 973. HOOD PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R ­ 3 974. FRONT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R ­ 5 975. FENDER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R ­ 7 976. DASH PANEL & COWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R ­ 9 977. GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R ­ 11 9R ­ 2 BODY & ACCESSORIES BODY & ACCESSORIES 9R ­ 3 BODY FRONT END ­ HOOD PANEL (973) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.4 0.3 0.7 N 0.4 0.3 0.7 L 0.5 0.3 0.4 1 HOOD PANEL ­ REPLACE HOOD PANEL ­ ALIGN 9730100 9730300 9730500 2 3 CABLE, HOOD LATCH ­ REPLACE HINGE, HOOD ­ REPLACE Right Left Both 9731100 9731200 9731300 9731500 9731700 9731900 0.3 0.3 0.4 0.2 -- -- 0.3 0.3 0.4 0.2 0.2 0.2 0.3 0.3 0.4 0.2 0.2 0.2 4 5 6 7 BUMPER, HOOD ­ REPLACE INSULATION, ENGINE HOOD ­ REPLACE SEAL, HOOD ­ REPLACE SPRING, HOOD GAS ­ REPLACE Right Left Both 9732100 9732110 9732120 -- -- -- -- -- -- 0.2 0.2 0.3 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 9R ­ 4 BODY & ACCESSORIES BODY & ACCESSORIES 9R ­ 5 BODY FRONT END ­ FRONT PANEL (974) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.3 0.4 0.2 -- -- 2.0 4.0 0.8 N 0.3 0.2 0.2 0.2 -- 2.0 4.0 -- L 0.3 0.2 -- 0.2 -- 1.8 -- 1.0 1 2 3 4 5 6 7 8 LATCH, HOOD ­ R&R OR REPLACE HANDLE, HOOD LATCH RELEASE ­ REPLACE ROD, HOOD SUPPORT ­ REPLACE BUMPERS, HOOD ­ REPLACE AIR DAM, FRONT ­ REPLACE CROSSMEMBER, RADIATOR ­ REPLACE PANEL, FRONT SIDE ­ REPLACE SUPPORT, PANEL FRONT ­ REPLACE 9740100 9740120 9740300 9740500 9740700 9740900 9741100 9741300 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 9R ­ 6 BODY & ACCESSORIES BODY & ACCESSORIES 9R ­ 7 BODY FRONT END ­ FENDER PANEL (975) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 SKIRT, FRONT FENDER INNER ­ REPLACE Right Left 9750100 9750200 0.5 0.5 0.5 0.5 0.5 0.5 2 FENDER, FRONT ­ REPLACE Right Left FENDER, FRONT ­ ALIGN Right Left 9750700 9750800 9751100 975110A 0.4 0.4 0.6 0.1 0.4 0.4 0.5 0.1 0.4 0.4 0.5 0.1 9750400 9750500 0.8 0.8 0.8 0.8 0.8 0.8 3 4 TRAY, BATTERY ­ REPLACE A * With manual transaxle PANEL, WHEELHOUSE ­ REPLACE Right Left 9751300 9751400 5.0 5.0 5.0 5.0 5.5 5.5 5 SHIELD, SPLASH ­ REPLACE Right Left 9751700 9751800 -- -- 0.3 0.3 0.3 0.3 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 9R ­ 8 BODY & ACCESSORIES BODY & ACCESSORIES 9R ­ 9 BODY FRONT END ­ DASH PANEL & COWL (976) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 0.3 N 0.4 L 0.4 1 2 SHIELD, COWL ­ REPLACE PANEL, DASH LOWER ­ REPLACE Upper Lower Both 9760100 9760300 9760

File name en_9s.pdf

BODY & ACCESSORIES 9S ­ 1 SECTION 9S BODY & ACCESSORIES (BODY REAR END) 978. TRUNK LID PANEL & SPOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9S ­ 3 9S ­ 2 BODY & ACCESSORIES BODY & ACCESSORIES 9S ­ 3 BODY REAR END ­ TRUNK LID PANEL & SPOILER (978) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S N L 1 HINGE, REAR COMPARTMENT LID ­ REPLACE Right Left Both 9780100 9780200 9780300 1.0 1.0 1.1 1.0 1.0 1.1 1.0 1.0 1.1 2 ROD, SPRING TORQUE ­ REPLACE Right Left Both SPRING, TRUNK LID ­ REPLACE Right Left Both 9781100 9781200 9781300 -- -- -- -- -- -- -- -- -- 9780500 9780600 9780700 0.3 0.3 0.5 0.3 0.3 0.5 0.3 0.3 0.5 3 SUPPORT, TRUNK LID ­ REPLACE Right Left Both 9781400 9781410 9781420 9781500 9781700 9781800 -- -- -- 0.2 0.7 -- -- -- -- 0.2 0.7 -- -- -- -- 0.2 0.7 -- 4 5 6 7 WEATHERSTRIP, REAR COMPARTMENT OPENING ­ ALIGN OR REPLACE REAR COMPARTMENT LID ­ REPLACE COVER­INNER TRUNK LID ­ REPLACE HANDLE A­LID TRUNK (TAILGATE) ­ REPLACE 3H/B, 5H/B, 4N/B Station Wagon 9781810 9781820 0.2 -- -- -- -- -- 8 SUPPORT, REAR COMPARTMENT (HATCH BACK) ­ REPLACE Right Left Both SUPPORT, REAR COMPARTMENT (WAGON/MPV) ­ REPLACE Right Left Both 9782500 9782600 9782700 -- -- -- -- -- -- -- -- -- 9782100 9782200 9782300 0.2 0.2 0.3 0.2 0.2 0.3 -- -- -- S : KALOS, N : NUBIRA/LACETTI, L : EVANDA 9S ­ 4 BODY & ACCESSORIES BODY & ACCESSORIES 9S ­ 5 BODY REAR END ­ TRUNK LID PANEL & SPOILER (978) NO. NO OPERATION DESCRIPTION OPERATION CODE MODEL S 1.0 0.2 0.2 N 1.0 0.2 0.2 L -- -- -- 9 10 11 TAILGATE ­ REPLACE WEATHER STRIP, REAR COMPARTMENT OPENING ­ REPLACE SPOILER, REAR (HATCH BACK) ­ REPLACE 9782900 9783100 9783300 S : KALOS, N : NUBIRA/LACETTI, L : EVANDA

File name en_foreword.pdf

FOREWORD This Labor Time Guide has been prepared for the purpose of implementing the terms of the current Dealer Sales and Service Agreement and is intended solely for the purpose of computing the compensation payable by GM Daewoo Auto & Technology Co., Ltd. to the authorized Daewoo dealers for the performance of warranty, policy and campaign adjustment and other work authorized and performed for the account of GM Daewoo Auto & Technology Co., Ltd.. This use of this guide for any other purpose is neither intended not authorized by GM Daewoo Auto & Technology Co., Ltd.. Please read the Introduction of this guide thoroughly to acquaint with Daewoo warranty system. All time allowances in this guide are subject to change at any time by GM Daewoo Auto & Technology Co., Ltd. based on time studies by the company related to improved methods, techniques or equipment or other advances in the industry. LABOR TIME GUIDE (KALOS, NUBIRA/LACETTI, EVANDA) ISSUED BY SERVICE ENGINEERING TEAM GM DAEWOO AUTO & TECHNOLOGY CO., LTD. 199­1 CHEONG CHEON­DONG, BUPYUNG­GU INCHON, KOREA TELEPHONE : 82­32­520­2737,2064 FACSIMILE : 82­32­520­4808

File name en_sec00.pdf

FOREWORD This pre-delivery inspection manual describes the inspection items and procedures required before delivery of vehicle to the customer. The descriptions and service procedures contained in this manual are based on design and method studies for the TACUMA/REZZO up to May, 2000. Options and trims including vehicle specifications described in this manual can be changed without notice, please refer to the latest product information on option and trim availability. Changes in design, service procedures, etc., judged to have a significant bearing on this manual, will subsequently be issued in service bulletins. GM DAEWOO AUTO & TECHNOLOGY CO., LTD INCHEON, KOREA PRE-DELIVERY INSPECTION MANUAL (TACUMA/REZZO, KALOS, EVANDA) ISSUED BY SERVICE ENGINEERING TEAM GM DAEWOO AUTO & TECHNOLOGY CO., LTD. 199-1 CHEONG CHEON-DONG, BUPYUNG-GU, INCHEON, KOREA TELEPHONE : 82-32-520-2737, 2064 FACSIMILE : 82-32-520-4808

File name en_sec01.pdf

SECTION 1 GENERAL INTRODUCTION SECTION 1 GENERAL INTRODUCTION 1. EQUIPMENT AND MATERIAL FOR PDI AND SERVICE 2. PRE-DELIVERY INSPECTION FORM 1­1 SECTION 1 GENERAL INTRODUCTION 1. EQUIPMENT AND MATERIAL FOR PDI AND SERVICE Following tools and fluids should be prepared for the Pre-Delivery Inspection process and its service. TOOLS · Tire pressure gauge · Tire inflator · Rubber hammer (for wheel cover/cap) · Torque wrench (for wheel lug nut torque) · Wrenches 8 mm - 21 mm · Small flat blade screwdriver · Screwdriver(+) · Pliers · Cassette tape (for cassette operation inspection) · Headlight aim tester · Tachometer with tacho pulse pick-up · Shop towels FLUIDS · Brake/clutch fluid · Engine oil · Manual transmission fluid · Automatic transmission fluid · Power steering fluid · Engine coolant · Windshield washer fluid · Spray lubricant(s) 1­2 SECTION 1 GENERAL INTRODUCTION 2. PRE-DELIVERY INSPECTION FORM · Pre-delivery inspection form as shown in next pages shall be prepared, and the performances of inspection, checking, related services and remedial actions should be described in the check form. · Prior to pre-delivery inspection, the upper column appears at first page of PDI form should be fully filled up as follows. ­ Vehicle model, vehicle identification number and body color code is stamped on the vehicle identification number(VIN) plate attached to the top of the cross member, above the radiator. ­ The engine number is stamped on the cylinder block under the No. 4 exhaust manifold of the engine. ­ Fill up the other blanks in the column, for instance dealer stock number, repair order number, owner's name, address, city, state, delivered by dealer name, dealer code and date, is necessary. · Inspect the vehicle, and record the inspection result on the PDI form as following order in accordance with the detail items in the PDI form. ­ Engine compartment ­ Body ­ accessories ­ Under vehicle ­ Road test ­ Appearance · Delivery report column shall be checked and confirmed only after all the defects, that might have been found during inspection, had been completely corrected. 1­3 SECTION 1 GENERAL INTRODUCTION PRE­DELIVERYINSPECTION PRE-DELIVERY INSPECTION Vehicle Model Vehicle Identification Number Engine Number Color Code Dealer Stock No. Repair Order No. Owner's Name Address City Delivered by Dealer Name Dealer Code Date State CHECK, INSPECT AND/OR PERFORM THE FOLLOWING OPERATIONS 1. Engine compartment Check Engine Compartment for components which may be loose; kinked or pinched vacuum hoses or electrical connections, and for any other missing or disconnected components. Check to assure that hoses and electrical wires are properly routed to provide sufficient clearance with adjacent moving or hot parts. Observe the movement or freeness of movement of linkage, valves and other components. Check for unusual noises within the engine compartment. Visually inspect for seepage and leaks at hoses and pipe connections, seals, gaskets and plugs. Ti

File name en_sec02.pdf

SECTION 2 ENGINE COMPARTMENT SECTION 2 ENGINE COMPARTMENT 1. COMPONENTS CONNECTION LOOSE 2. HOSE AND ELECT. WIRES ROUTING 3. FREENESS OF MOVEMENT OF LINKAGE, VALVES AND OTHER COMPONENTS 4. UNUSUAL NOISES 5. SEEPAGE AND LEAKS AT HOSES AND PIPE CONNECTIONS, ETC. 6. POWER STEERING SYSTEM 7. ENGINE COOLANT PROTECTION 8. ALL FLUID LEVELS CHECK 9. THROTTLE LINKAGE 10. BELTS TENSION 2­1 SECTION 2 ENGINE COMPARTMENT 1. COMPONENTS CONNECTION LOOSE Check engine compartment for components which may be loose; kinked or pinched vacuum hoses or electrical connections, and for any other missing or disconnected components as below. 1 2 3 4 5 6 10 9 8 7 1. 2. 3. 4. Air cleaner Engine oil filler cap Brake fluid reservoir* Clutch fluid reservoir* 5. 6. 7. 8. Coolant reservoir Fuse and relay box Battery Washer fluid reservoir 9. Power steering fluid reservoir 10. Engine oil level dipstick * Kalos, Nubira/Lacetti and Evanda have one reservoir for both the brake and clutch fluid. Check engine components for missing or disconnection. Check electrical connections for loose or misconnection. Check vacuum hoses for kink, pinch, damage, twist and swelling. Check hose clamps and pipe connections for leak or loose for following systems. ­ Fuel system ­ Cooling system ­ Power steering system ­ Airconditioning system · Check engine components which may be loose. If remedy is required, tighten clamps, connections, bolts and nuts, and replace or repair defective hose and its connections. · · · · 2. HOSE AND ELECT. WIRES ROUTING Check to assure that following hoses and electrical wires are properly routed to provide sufficient clearance with adjacent moving or hot parts. · Fuel hose · Airconditioning hose · Vacuum hoses · High-tension cable for ignition system · Electric wires 2­2 SECTION 2 ENGINE COMPARTMENT 3. FREENESS OF MOVEMENT OF LINKAGE, VALVES AND OTHER COMPONENTS Observe the movement or freeness of movement of linkage, valves and other components. · Accelerator cable Check the accelerator cable free play when the engine is warm as follow. 1) Pull the accelerator cable toward the throttle lever. 2) Push the cable away from the throttle lever until the lever begins to move. (free play) If adjustment is required, refer to "9. Throttle linkage" of this section. · Clutch pedal Check the clutch pedal free play when depress the clutch pedal. · Steering linkage system The best method for checking condition is with the vehicle on a flat surface and two mechanics working as a team. One of the mechanics turns the steering wheel one way and then the other, and checks its function mounting and condition, also the mounting for the steering column (with or without power assistance) while the other mechanic checks for play in the following places; ­ Tie rods (there must be no looseness) ­ Steering gear mounting on frame ­ Steering shaft universal joints from steering gear and upwards (there must be no looseness) ­ Check all clamps for proper mounting and tightness ·

File name en_sec03.pdf

SECTION 3 BODY ­ ACCESSORIES SECTION 3 BODY ­ ACCESSORIES 1. HEADLIGHTS OPERATION AND AIM 2. TURN SIGNAL LIGHTS 3. HAZARD WARNING LIGHTS 4. BACK-UP LIGHTS 5. STOP LIGHTS 6. TAIL LIGHTS, POSITION LIGHTS, LICENSE PLATE LIGHTS,ADDITIONAL TURN SIGNAL LAMPS AND INDICATORS 7. INSTRUMENT PANEL WARNING LAMPS AND INDICATORS 8. DOME AND COURTESY LIGHTS 9. GLOVE BOX ILLUMINIZATION 10. HEAD LAMP LEVELING SWITCH (OPTION) 11. INSTRUMENT PANEL GAUGE OPERATION 12. FRONT FOG LAMP SWITCH 13. REAR FOG LAMP SWITCH (OPTION) 14. REAR WINDOW AND OUTSIDE MIRROR DEMISTER BUTTON 15. INSTRUMENT ILLUMINATION CONTROL SWITCH (OPTION) 16. HORN SWITCH 17. WIPER AND WASHER OPERATION 18. TAIL GATE WINDOW WIPER AND WASHER SWITCH 3­1 SECTION 3 BODY ­ ACCESSORIES 19. RADIO/CASSETTE, SPEAKERS, ANTENNA 20. CUP HOLDER 21. CIGARETTE LIGHTER 22. CLOCK 23. DOOR LOCK 24. DOOR WINDOW 25. OUTSIDE REARVIEW MIRRORS 26. TILTABLE STEERING WHEEL (OPTION) 27. POWER SUN ROOF (OPTION) 28. SEAT 29. FUEL TANK FILLER DOOR RELEASE LEVER 30. TRUNK LID RELEASE LEVER 31. ENGINE HOOD RELEASE LEVER 32. THEFT DETERRENT SYSTEM 33. KEYLESS ENTRY SYSTEM WITH ANTITHEFT FUNCTION (OPTION) 34. SUNGLASSES HOLDER 35. SEAT HEATER SWTICH (OPTION) 3­2 SECTION 3 BODY ­ ACCESSORIES 1. HEADLIGHTS OPERATION AND AIM · Headlights operation ­ lights on/off Twist the knob on the end of the combination switch lever, and check for the function of headlight. 1) OFF position All lights are off. 2) position Parking, tail, license plate and instrument panel lights are illuminated. 3) position Headlight (low beam) and all the above lights are illuminated. 4) Head lamp warning chime bell(Option) Chime bell sounds when the light switch turned on and the ignition switch was in "LOCK" or " ACC " position. ­ high beam switch Push the light switch lever towards the instrument panel with the low beam head lights on ( ). Check for the function of high beam switch. Headlight high beam indicator in the instrument panel lights up when the headlights are on high beam. Pull the lever back to the normal position and check for the function of low beam head lights. ­ passing light switch Pull the light switch lever to the direction of driver's seat and check that passing light flashes. ­ day time running light(option) Check if parking, tail, license plate and instrument panel lights illuminate when ignition switch is ON position with the light switch off. And check if the head lights(low beam) also come on when the engine is started. They remain on until the ignition switch is turned off or the light switch is turned on. 3­3 SECTION 3 BODY ­ ACCESSORIES · Headlight aim ­ Check the headlight aim. 1) Place the vehicle on a level floor. 2) Bounce the front suspension several times. 3) Rock the vehicle sideways several times then allow the vehicle to assume its normal position. 4) Clean the headlight lenses and check the headlight aim. · Headlight levelling switch (option) ­ Check the operation of the headlight levelling switch. 0 = Front seat

File name en_sec04.pdf

SECTION 4 UNDER VEHICLE SECTION 4 UNDER VEHICLE 1. STEERING GEAR AND LINKAGE 2. PROPER TIE ROD CLAMP POSITION 3. EXHAUST SYSTEM FOR PROPER ALIGNMENT AND CLEARANCE 4. FRONT AND REAR SUSPENSION 5 CHECK AXLE AND MANUAL TRANSMISSION FLUID LEVEL 6. BRAKE SYSTEM 7. FUEL SYSTEM 8. DRIVE SHAFT OF FRONT DRIVE AXLES 9. VISUALLY INSPECT WHEEL STUD AND AXLE FLANGE NUTS 10. INFLATE TIRES TO SPECIFIED PRESSURE 4­1 SECTION 4 UNDER VEHICLE UNDER VEHICLE INSPECTION Raise the vehicle to overhead height to perform all inspections in this section. Visually inspect vehicle under carriage for looseness, missing components and line routing and clipping, and fluid leaks. ­ Tighten clamps, couplings · Condition of brake lines, hoses and connections ­ Damage ­ Fluid leaks ­ Twisting ­ Swelling 1. STEERING GEAR AND LINKAGE Check steering gear and linkage. 4­2 SECTION 4 UNDER VEHICLE 2. PROPER TIE ROD CLAMP POSITION Check tie rod clamp. 3. EXHAUST SYSTEM FOR PROPER ALIGNMENT AND CLEARANCE Check exhaust system. B TYPE A TYPE 4. FRONT AND REAR SUSPENSION Check front and rear suspension. Front suspension Rear suspension 4­3 SECTION 4 UNDER VEHICLE 5. CHECK AXLE AND MANUAL TRANSMISSION FLUID LEVEL ­ add as required 6. BRAKE SYSTEM Check brake fluid, brake cylinder, pipes, hoses and parking brake. ABS should be checked, if adopted. Brake pipe Master cylinder Brake hose Brake hose Brake hose Brake hose Brake pipe 7. FUEL SYSTEM Check the fuel tank, fuel pump, connection of fuel hoses and pipes, fuel injectors, fuel gauge and canister. 4­4 SECTION 4 UNDER VEHICLE 8. DRIVE SHAFT OF FRONT DRIVE AXLES Check the drive shaft for rust, damage, bend and assembly condition. 9. VISUALLY INSPECT WHEEL STUD AND FLANGE NUTS Taking off the wheel covers, and check wheel studs and flange nuts. Torque of wheel stud: 12 kgf·m (120 N·m) 10. INFLATE TIRES TO SPECIFIED PRESSURE Check inflation pressure of tires. Tire size 155/80 R13 KALOS [kPa(psi)] underinflation Front 210(30) 210(30) 210(30) 207(30) 207(30) 207(30) 220(32) 220(32) 210(30) 230(33) 210(30) Rear 210(30) 210(30) 210(30) 207(30) 207(30) 207(30) 220(32) 220(32) 210(30) 210(30) 210(30) proper inflation overinflation 175/70 R13 185/60 R14 175/70 R14 NUBIRA/ LACETTI 185/65 R14 195/55 R15 185/70 R14 TACUMA / REZZO 195/60 R15 195/70 R14 EVANDA 205/65 R15 205/55 R16 4­5

File name en_sec05.pdf

SECTION 5 ROAD TEST SECTION 5 ROAD TEST 1. SEAT BELTS 2. FREE PLAY OF BRAKE AND CLUTCH 3. HORN 4. WIND NOISE 5. OPTIONS AND ACCESSORIES 6. HEATER AND AIR CONDITIONING 7. OPERATION OF WINDSHIELD WIPER AND WASHER FOR PATTERN, SPEED, AND PARKING POSITION (INCLUDES AIM WASHER IF NECESSARY) 8. ENGINE AND TRANSMISSION PERFORMANCE DURING ACCELERATION, DECELERATION, IDLE, CRUISE AND DOWN SHIFTS 9. SQUEAKS AND RATTLES 10. STEERING COLUMN IGNITION LOCK 11. INSTRUMENTS AND GAUGES 12. THROTTLE CONTROL FOR FREE OPERATIONS 13. STEERING (WHEEL CENTER POSITION AND HANDLING) 14. BRAKES (INCLUDES PARKING BRAKE AND WARNING LIGHT) 5­1 SECTION 5 ROAD TEST 1. SEAT BELTS Check the operation of the seat belts. · Buckle the front seat belts and off the latches. · Buckle the rear seat belts and off the latches (if equipped). · Pull the belt evenly out of the retractor and guide it across the body by inserting the metal latch plate "1" into the buckle "2". · Seat belt height adjuster Pull belt out, depress the center of the adjuster and adjust the height. Too high position can impair comfort. · Seat belt warning chime (option) The seat belt warning chime will sound for about 4 to 8 seconds when the ignition switch is in the "ON" position unless the driver's seat belt is securely fastened. 1 1 2 2 2. FREE PLAY OF BRAKE AND CLUTCH Check the brake pedal and clutch pedal. · Brake pedal After turning off the engine and depressing the brake pedal several times to deplete the vacuum in the brake system, gently depress the brake pedal by hand and measure the distance it moves until slight resistance is felt. Brake pedal free play 1~8 mm · Clutch pedal Depress the pedal by hand until clutch resistance is felt and measure the distance. Clutch pedal free play 6~12 mm If the free play does not satisfy the specification, check the system or linkage and adjust. 3. HORN Check the operation of the horn. · Horn sounds whenever the horn pad is pushed. · If there is high effort to push horn pad, the horn should be checked. (with air bag) (without air bag) 5­2 SECTION 5 ROAD TEST 4. WIND NOISE Check the wind noise by driving the car with high speed. 5. OPTIONS AND ACCESSORIES Check the following items for proper operation and function with the evaluation of squeaks and rattles. · Automatic transaxle · Power sun roof · Power steering system · Anti-lock braking system · Power window · Tiltable steering system · Fuel tank filler door release lever · Keyless entry system 6. HEATER AND AIR CONDITIONING 1. Temperature control knob 2. Fan control knob 4 5 3. Air distribution mode knob 4. Air conditioning (A/C) button 5. Recirculation button 1 2 3 5­3 SECTION 5 ROAD TEST CONTROL PANEL (FULL AUTOMATIC TEMPERATURE CONTROL AIR CONDITIONING) 2 3 4 5 6 7 8 1 18 13 10 9 17 16 15 14 12 11 1. Temperature control button Up : Increase the temperature by 0.5°C (1°F) with each push Down : Decrease the temperature by 0.5°C (1°F) with each push 2.Selected temperature 3. Defrost indica

File name en_sec06.pdf

SECTION 6 APPEARANCE SECTION 6 APPEARANCE 1. INSPECT CONDITION AND PERFORM DETAIL OPERATION 2. CHECK FOR PROPER ASSEMBLY, FIT AND RETENTION OF PARTS AND COMPONENTS 3. EXTERIOR FINISH 4. INTERIOR TRIM AND CARPETS PROTECTIVE COVERINGS 5. SPARE WHEEL, JACK AND VEHICLE TOOLS 6. BATTERY 6­1 SECTION 6 APPEARANCE 1. INSPECT CONDITION AND PERFORM DETAIL OPERATION · Remove exterior protective shipping material(s), and check that protective shipping material should be completely removed. The removal operation should be performed as the attached directions. · Wash vehicle Check the washing condition of vehicle. If required, perform the following steps to insure exterior washing. ­ Rinse the loose dirt from the vehicle with a fine spray or water. ­ Wash the vehicle using a sponge and water mixed with a mild detergent. ­ Rinse the soap with a fine spray of water. ­ Rinse the vehicle completely with water. ­ Wipe the vehicle dry from top to bottom using a clean chamois or soft, absorbent towel. 2. CHECK FOR PROPER ASSEMBLY, FIT AND RETENTION OF PARTS AND COMPONENTS Check for proper assembly, fit and retention of following parts and component. ­ Bumpers ­ Moldings ­ Grille ­ Sill plates ­ Emblems ­ Mud guard ­ Roof rack(option) 3. EXTERIOR FINISH Check exterior and perform the remedial actions if defects are found, and then finish work is required as follows. ­ Detail clean up ­ remove over spray, cement, weatherstrip sealer, etc. ­ Touch up ­ chipped paint (brush or aerosol spray) ­ Hand polish ­ minor paint imperfections by wet sanding with 600-grit paper or hand compounding. 6­2 SECTION 6 APPEARANCE 4. INTERIOR TRIM AND CARPETS PROTECTIVE COVERINGS Inspect the followings clean, as required. ­ Instrument panel and sun visor. ­ Kick pads, seats and carpet. ­ Door trim panels, consoles and headliner. ­ Interior moldings and hard trim for fit, over spray, polish, sealer and adhesive clean as required. ­ Trunk trim. 5. SPARE WHEEL, JACK AND VEHICLE TOOLS Check for the spare wheel, jack and vehicle tools which are accommodated in the luggage/load compartment. The spare wheel is retained by a bolt under a floor cover. The jack and vehicle tools are located at the very rear of spare wheel compartment. DESCRIPTION Spare wheel Bag - Tool Wrench - Wheel nut Tool - Spanner Jack Jack Lever Tool - Driver 6. BATTERY Check the battery condition through the hydrometer(test indicator) in the top of the battery. GREEN DOT 'BLACK' DARK TRANSPARENCY normal discharged If the engine is not started, replace the battery and check the charging system charging Hydrometer BUILT-IN HYDROMETER 6­3

File name en_sec07.pdf

SECTION 7 ANNEX SECTION 7 ANNEX 1. RECEIVING INSPECTION 2. DIRECTION FOR THE USE OF HY-500 TRANSIT COATING REMOVER IN A HAND WASH OPERATION 3. STORAGE AND MAINTENANCE OF NEW VEHICLE IN EXTREMELY HOT AND HUMID LOCATIONS 7­1 SECTION 7 ANNEX 1. RECEIVING INSPECTION When receiving a new vehicle, Dealer is to inspect it immediately for damage, obvious missing or incorrect part and / or options. This inspection is to be completed before accepting the receipt of vehicle. 1) Inspection of new vehicle The inspection of each received for possible damage is very important because new vehicles have usually traveled a long distance from the factory to the Dealer, often passing through several methods of transportation. The following should be included in the inspection; a. Walk around inspection of the exterior and visible areas of the vehicle's undercarriage b. Under hood inspection c. Trunk or cargo area inspection, including all parts and / or options normally stored or transported in this area d. Interior inspection, including all trim panels, headline carpets, and upholstery. 2) Transportation damage GMDAT's (GM Daewoo Auto & Technology Co., Ltd.) responsibility for damages and / or shortages extends only to the passage of vehicle through the ship's rail at the port of shipment. Thereafter such responsibility shall be for the carrier and / or insurance company until the delivery documents is signed by the Dealer's representative as having received the vehicles either in good order or with exceptions noted. Any transportation damage including stolen or missing part should be noted in detail and reported to the insurance company and the carrier immediately after receipt and inspection of new vehicles. 3) Missing or incorrect parts and production shortages If any missing or incorrect parts and options are discovered while receiving inspection of new vehicles, claims have to be made to whomever is responsible, either to the carrier / insurance company or to GMDAT. In case GMDAT is responsible for any missing or incorrect parts and production shortages i. e. those were omitted in production of the vehicle the Dealer may request compensation for the costs incurred by correction of such discrepancies under warranty. Claims for missing parts, noticeable at the time of vehicle inspection, such as audio equipment, antenna, spare tire and wheel, wheel cover, jack assembly, tools and so on, which are to be considered as having been removed during transit, are not reimbursable under warranty provisions of this manual. Such claims rather should be presented to the representative of the carrier to the insurance company. 7­2 SECTION 7 ANNEX 2. DIRECTION FOR THE USE OF HY-600 TRANSIT COATING REMOVER IN A HAND WASH OPERATION Material Required: One bottle (0.8 L) of transit coating remover per vehicle Equipment Required: Bucket, wash mitt, safety glasses, rubber boots and glove, hose. The removal operation should be performed in a well ventilated and shaded area to

File name en_sect_1.pdf

SECTION 1 ENGINE SOHC ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B ­ 1 DOHC ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C ­ 1 ENGINE COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D ­ 1 ENGINE ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E ­ 1 ENGINE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F ­ 1 ENGINE INTAKE & EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G ­ 1 ENGINE DEFECT CODE NATURE CODE N01 N02 N03 N04 N05 N06 N07 N08 N09 N11 N12 N13 N14 N15 N16 N17 N18 N20 N21 N22 N23 N24 N25 N26 N27 N28 N29 N30 N31 N32 N33 N34 N35 N36 Hard start, no start Poor idle Surge, hesitate, stumble Engine noise, engine knocking noise Choke malfunction Engine stalled (general) Excessive fuel consumption Excessive oil consumption Overheated Engine run­on Flooded, overflowing Poor acceleration, uneven acceleration Abnormal combustion Lack of engine power Percolation Improper exhaust gas (black gas, white gas) Backfire, afterfire Blocked Shuddering, pulsation, vibration, chattering Slippage ( = slipping) Difficult engagement Difficult disengagement Abnormal shifts Impossible shifts Squeaking, squealing, abnormal(wind) noise Dragging Pulls Stalled while driving Stalled while idling Stalled between shifts Stalling during sudden braking Fails to reach normal operating temperature RPM too low RPM high N37 N38 N39 N40 N43 N46 N47 N51 N52 N55 N57 N60 N61 N62 N63 N64 N65 N66 N67 N68 N71 N72 N73 N77 N82 N84 N85 N86 N91 N92 N93 N94 N99 Jumping­out Improper synchronizing Oil diluted Misfire Excessive shock Misaligned or mismatched Weak Deteriorated Distortion, rainbow, waving Rust, corrosion, perforation. Loose, poor fit Excessive vibration Dead battery Inaccurate (meter, gauge, etc.) Poor sound (horn, radio, etc.) Overcharged, discharged Electrical failures Blown fuse Warning light on Intermittent operation Oil leak, oil entering Water leak, water entering Leaks­other (air, fuel, refrigerant, vacuum) Improper memory Loosening, falling­off, sagged Improper opening and/or closing Grabbed Poor maneuverability Interference or hitting Inoperative High/low operating effort Special policy Undefined CAUSE CODE R01 R02 R03 R04 R05 R06 R07 R08 R09 R11 R12 R13 R14 R15 R16 R17 Scored, scratched or chipped Frozen Peeling, come­off Rusty, corroded Split, cut or torn Broken or cracked Porous, pin holes, cavity Bent, kinky, twisted, distorted, warped or wrinkled Stripped ­ bolts, holes, nuts Weakened, loss of tension or resilience (spring, cushion, etc.) Abnormal wear Out of balance Out of round Loose or improper connection Open circuit or short

File name en_sect_10.pdf

SECTION 10 PAINT PAINT PAINT P01 P02 P03 P04 P05 P06 P07 P08 P09 P10 P11 P12 P13 P14 P15 P16 P17 Oversprayed, drip Undersprayed, bare Color mismatched Low Gloss Mottled, cloudy Sags or runs, drips Pin hole Faded / Chalked / Dulled Metal filings in paint (Rusty spots on paint) Excessive transit coating Peeling, scaling Orange peel Slow drying Thin no paint Wavy Tape mark, touch mark Chemical damage P18 P19 P20 P21 P22 P23 P24 P25 P26 P27 P30 P31 P32 P33 P34 P99 Acid rain Atmospheric fallout Polishing mark, sanding mark Touch up Dust, dirt Poor welding Rust Blistered / Bubbled Chipped Cracked / Crazed Surface scratch Scab corrosion Dent Rust perforation Discolored, faded Undefined

File name en_sect_2.pdf

SECTION 2 SUSPENSION FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C ­ 1 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D ­ 1 TIRES & WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E ­ 1 SUSPENSION DEFECT CODE NATURE CODE N02 N03 N12 N15 N16 N19 N20 N21 N22 N23 N24 N27 N28 N29 N42 N43 N44 N45 N46 N47 N50 N51 N52 N53 N55 Poor idle Surge, hesitate, stumble Flooded, overflowing Lack of engine power Percolation Vapor lock Blocked Shuddering, pulsation, vibration, chattering Slippage ( = slipping) Difficult engagement Difficult disengagement Squeaking, squealing, abnormal(wind) noise Dragging Pulls Unstable steering Excessive shock Poor release Unusual tire wear Misaligned or mismatched Weak Vehicle bouncing Deteriorated Distortion, rainbow, waving Color mismatched Rust, corrosion, perforation. N57 N58 N59 N60 N61 N62 N63 N65 N66 N67 N68 N69 N71 N72 N73 N82 N83 N85 N86 N91 N92 N93 N94 N99 Loose, poor fit Bubbles Vehicle vibration Excessive vibration Dead battery Inaccurate (meter, gauge, etc.) Poor sound (horn, radio, etc.) Electrical failures Blown fuse Warning light on Intermittent operation Pulls to left or right Oil leak, oil entering Water leak, water entering Leaks­other (air, fuel, refrigerant, vacuum) Loosening, falling­off, sagged Gas leak, gas entering Grabs Poor maneuverability Interference or hitting Inoperative High/low operating effort Special policy Undefined CAUSE CODE R01 R02 R03 R04 R05 R06 R07 R08 R09 R10 R11 R12 R13 R14 R15 R18 Scored, scratched or chipped Frozen Peeling, come­off Rusty, corroded Split, cut or torn Broken or cracked Porous, pin holes, cavity Bent, kinked, twisted, distorted, warped or wrinkled Stripped ­ bolts, holes, nuts Soiled Weakened, loss of tension or resilience (spring, cushion, etc.) Abnormal wear Out of balance Out of round Loose or improper connection Grounded or shorted R20 R21 R22 R23 R24 R25 R26 R27 R28 R31 R32 R33 R34 R35 R36 R99 Faulty casting Improper clearance, back lash, free play Lack of lubricants Improper welding or soldering, welding or soldering omitted Improper tightening, fit or assembly Sticks, binds, seized Foreign material, clogged Improper sealing, sealer omitted or skipped Improper adjustment Incorrect part Improperly installed Improperly routed Missing part Flaw in material Contaminants Undefined

File name en_sect_3.pdf

SECTION 3 DRIVE LINE / AXLE DRIVE LINE / AXLE DEFECT CODE NATURE CODE N03 N12 N16 N20 N21 N22 N23 N24 N27 N28 N29 N38 N45 N46 N47 N48 N49 N50 N51 N52 Surge, hesitate, stumble Flooded, overflowing Percolation Blocked Shuddering, pulsation, vibration, chattering Slippage ( = slipping) Difficult engagement Difficult disengagement Squeaking, squealing, abnormal(wind) noise Dragging Pulls Improper synchronizing Unusual tire wear Misaligned or mismatched Weak Hard to turn Impossible to turn Vehicle bouncing Deteriorated Distortion, rainbow, waving N55 N56 N57 N58 N59 N60 N62 N66 N67 N68 N69 N71 N72 N73 N91 N92 N93 N94 N99 Rust, corrosion, perforation Glazed Loose, poor fit Bubbles Vehicle vibration Excessive vibration Inaccurate (meter, gauge, etc.) Blown fuse Warning light on Intermittent operation Pulls to left or right Oil leak, oil entering Water leak, water entering Leaks­other (air, fuel, refrigerant, vacuum) Interference or hitting Inoperative High/low operating effort Special policy Undefined CAUSE CODE R01 R02 R03 R04 R05 R06 R07 R08 R09 R10 R11 R12 R13 R14 R15 R18 Scored, scratched or chipped Frozen Peeling, come­off Rusty, corroded Split, cut or torn Broken or cracked Porous, pin holes, cavity Bent, kinky, twisted, distorted, warped or wrinkled Stripped ­ bolts, holes, nuts Soiled Weakened, loss of tension or resilience (spring, cushion, etc.) Abnormal wear Out of balance Out of round Loose or improper connection Grounded or shorted R24 R25 R26 R27 R28 R31 R32 R33 R34 R35 R36 R99 R20 R21 R22 R23 Faulty casting Improper clearance, back lash, free play Lack of lubricants Improper welding or soldering, welding or soldering omitted Improper tightening, fit or assembly Sticks, binds, seized Foreign material, clogged Improper sealing, sealer omitted or skipped Improper adjustment Incorrect part Improperly installed Improperly routed Missing part Flaw in material Contaminants Undefined

File name en_sect_4.pdf

SECTION 4 BRAKES HYDRAULIC BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A ­ 1 MASTER CYLINDER & POWER BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B ­ 1 FRONT BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D ­ 1 REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E ­ 1 ANTI­LOCK BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F ­ 1 PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G ­ 1 BRAKES DEFECT CODE NATURE CODE N03 N08 N12 N13 N16 N19 N20 N21 N22 N23 N24 N27 N28 N29 N39 N41 N44 N45 N46 N47 Surge, hesitate, stumble Excessive oil consumption Flooded, overflowing Poor acceleration, uneven acceleration Percolation Vapor lock Blocked Shuddering, pulsation, vibration, chattering Slippage ( = slipping) Difficult engagement Difficult disengagement Squeaking, squealing, abnormal(wind) noise Dragging Pulls Oil diluted Spongy pedal Poor release Unusual tire wear Misaligned or mismatched Weak N51 N52 N55 N56 N57 N58 N62 N66 N67 N71 N72 N73 N87 N88 N91 N92 N93 N94 N99 Deteriorated Distortion, rainbow, waving Rust, corrosion, perforation. Glazed Loose, poor fit Bubbles Inaccurate (meter, gauge, etc.) Blown fuse Warning light on Oil leak, oil entering Water leak, water entering Leaks­other (air, fuel, refrigerant, vacuum) Insufficient brake Brake judder Interference or hitting Inoperative High/low operating effort Special policy Undefined CAUSE CODE R01 R02 R03 R04 R05 R06 R07 R08 R09 R10 R11 R12 R13 R14 R20 Scored, scratched or chipped Frozen Peeling, come­off Rusty, corroded Split, cut or torn Broken or cracked Porous, pin holes, cavity Bent, kinky, twisted, distorted, warped or wrinkled Stripped ­ bolts, holes, nuts Soiled Weakened, loss of tension or resilience (spring, cushion, etc.) Abnormal wear Out of balance Out of round Faulty casting R21 R22 R23 R24 R25 R26 R27 R28 R31 R32 R33 R34 R35 R36 R99 Improper clearance, back lash, free play Lack of lubricants Improper welding or soldering, welding or soldering omitted Improper tightening, fit or assembly Sticks, binds, seized Foreign material, clogged Improper sealing, sealer omitted or skipped Improper adjustment Incorrect part Improperly installed Improperly routed Missing part Flaw in material Contaminants Undefined

File name en_sect_5.pdf

SECTION 5 TRANSMISSION / TRANSAXLE ZF 16HP AUTO TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1 ­ 1 AISIN AUTO TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2 ­ 1 FIVE SPEED MANUAL TRANSAXLE (D16, D20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B1 ­ 1 FIVE SPEED MANUAL TRANSAXLE (Y4M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B2 ­ 1 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C ­ 1 TRANSMISSION / TRANSAXLE DEFECT CODE NATURE CODE N01 N02 N03 N06 N07 N08 N10 N12 N13 N15 N16 N17 N18 N19 N20 N21 N22 N23 N24 N25 N26 N27 N28 N29 N30 N31 N32 N33 N34 N35 N36 N37 Hard start, no start Poor idle Surge, hesitate, stumble Engine stalled (general) Excessive fuel consumption Excessive oil consumption Shift shock Flooded, overflowing Poor acceleration, uneven acceleration Lack of engine power Percolation Improper exhaust gas (black gas, white gas) Backfire, afterfire Vapor lock Blacked Shuddering, pulsation, vibration, chattering Slippage ( = slipping) Difficult engagement Difficult disengagement Abnormal shifts Impossible shifts Squeaking, squealing, abnormal(wind) noise Dragging Pulls Stalled while driving Stalled while idling Stalled between shifts Stalling during sudden braking Fails to reach normal operating temperature RPM too low RPM too high Jumping­out N38 N39 N41 N43 N44 N46 N47 N51 N52 N55 N56 N57 N58 N59 N60 N62 N65 N66 N67 N68 N71 N72 N73 N77 N82 N85 N86 N91 N92 N93 N94 N99 Improper synchronizing Oil diluted Spongy pedal Excessive shock Poor release Misaligned or mismatched Weak Deteriorated Distortion, rainbow, waving Rust, corrosion, perforation. Glazed Loose, poor fit Bubbles Vehicle vibration Excessive vibration Inaccurate (meter, gauge, etc.) Electrical failures Blown fuse Warning light on Intermittent operation Oil leak, oil entering Water leak, water entering Leaks­other (air, fuel, refrigerant, vacuum) Improper memory Loosening, falling­off, sagged Grabs Poor maneuverability Interference or hitting Inoperative High/low operating effort Special policy Undefined CAUSE CODE R01 R02 R03 R04 R05 R06 R07 R08 R09 R10 R11 R12 R13 R14 R15 R16 R17 Scored, scratched or chipped Frozen Peeling, come­off Rusty, corroded Split, cut or torn Broken or cracked Porous, pin holes, cavity Bent, kinked, twisted, distorted, warped or wrinkled Stripped ­ bolts, holes, nuts Soiled Weakened, loss of tension or resilience (spring, cushion, etc.) Abnormal wear Out of balance Out of round Loose or improper connection Open circuit or short circuit Burned or burned out R18 R20 R21 R22 R23 R24 R25 R26 R27 R28 R31 R32 R33 R34 R35 R36 R99 Grounded or shorted Faulty casting Improper clearance, back lash, free play Lack of lubricants Improper welding or soldering, welding or soldering omitt

File name en_sect_6.pdf

SECTION 6 STEERING POWER STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A ­ 1 MANUAL STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D ­ 1 STEERING WHEEL & COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E ­ 1 STEERING DEFECT CODE NATURE CODE N02 N03 N08 N12 N16 N20 N21 N22 N23 N24 N27 N28 N29 N42 N43 N44 N45 N46 N47 N48 N49 N50 N51 N52 N53 Poor idle Surge, hesitate, stumble Excessive oil consumption Flooded, overflowing Percolation Blocked Shuddering, pulsation, vibration, chattering Slippage ( = slipping) Difficult engagement Difficult disengagement Squeaking, squealing, abnormal(wind) noise Dragging Pulls Unstable steering Excessive shock Poor release Unusual tire wear Misaligned or mismatched Weak Hard to turn Impossible to turn Vehicle bouncing Deteriorated Distortion, rainbow, waving Color mismatched N55 N56 N57 N58 N59 N60 N62 N63 N64 N65 N66 N67 N68 N69 N71 N72 N73 N82 N85 N86 N91 N92 N93 N94 N99 Rust, corrosion, perforation. Glazed Loose, poor fit Bubbles Vehicle vibration Excessive vibration Inaccurate (meter, gauge, etc.) Poor sound (horn, radio, etc.) Overcharged, discharged Electrical failures Blown fuse Warning light on Intermittent operation Pulls to left or right Oil leak, oil entering Water leak, water entering Leaks­other (air, fuel, refrigerant, vacuum) Loosening, falling­off, sagged Grabbed Poor maneuverability Interference or hitting Inoperative High/low operating effort Special policy Undefined CAUSE CODE R01 R02 R03 R04 R05 R06 R07 R08 R09 R10 R11 R12 R13 R14 R17 R18 Scored, scratched or chipped Frozen Peeling, come­off Rusty, corroded Split, cut or torn Broken or cracked Porous, pin holes, cavity Bent, kinky, twisted, distorted, warped or wrinkled Stripped ­ bolts, holes, nuts Soiled Weakened, loss of tension or resilience (spring, cushion, etc.) Abnormal wear Out of balance Out of round Burnt or burned­out Grounded or shorted R20 R21 R22 R23 R24 R25 R26 R27 R28 R31 R32 R33 R34 R35 R36 R99 Faulty casting Improper clearance, back lash, free play Lack of lubricants Improper welding or soldering, welding or soldering omitted Improper tightening, fit or assembly Sticks, binds, seized Foreign material, clogged Improper sealing, sealer omitted or skipped Improper adjustment Incorrect part Improperly installed Improperly routed Missing part Flaw in material Contaminants Undefined

File name en_sect_7.pdf

SECTION 7 HEATING, VENTILATION, AND AIR CONDITIONING (HVAC) HEATING & VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A ­ 1 HVAC CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B ­ 1 HEATING, VENTILATION & AIR CONDITIONING DEFECT CODE NATURE CODE N02 N03 N06 N07 N08 N09 N12 N13 N15 N16 N20 N21 N22 N23 N24 N27 N28 N29 N30 N31 N32 N33 N34 N35 N36 N37 N38 Poor idle Surge, hesitate, stumble Engine stalled (general) Excessive fuel consumption Excessive oil consumption Overheated Flooded, overflowing Poor acceleration, uneven acceleration Lack of engine power Percolation Blocked Shuddering, pulsation, vibration, chattering Slippage ( = slipping) Difficult engagement Difficult disengagement Squeaking, squealing, abnormal(wind) noise Dragging Pulls Stalled while driving Stalled while idling Stalled between shifts Stalling during sudden braking Fails to reach normal operating temperature RPM too low RPM too high Jumping­out Improper synchronizing N42 N43 N44 N46 N47 N51 N52 N55 N56 N57 N58 N62 N65 N66 N68 N71 N72 N73 N82 N85 N86 N91 N92 N93 N94 N99 Unstable steering Excessive shock Poor release Misaligned or mismatched Weak Deteriorated Distortion, rainbow, waving Rust, corrosion, perforation. Glazed Loose, poor fit Bubbles Inaccurate (meter, gauge, etc.) Electrical failures Blown fuse Intermittent operation Oil leak, oil entering Water leak, water entering Leaks­other (air, fuel, refrigerant, vacuum) Loosening, falling­off, sagged Grabbed Poor maneuverability Interference or hitting Inoperative High/low operating effort Special policy Undefined CAUSE CODE R01 R02 R03 R04 R05 R06 R07 R08 R09 R10 R11 R12 R13 R14 R15 R16 R17 Scored, scratched or chipped Frozen Peeling, come­off Rusty, corroded Split, cut or torn Broken or cracked Porous, pin holes, cavity Bent, kinky, twisted, distorted, warped or wrinkled Stripped ­ bolts, holes, nuts Soiled Weakened, loss of tension or resilience (spring, cushion, etc.) Abnormal wear Out of balance Out of round Loose or improper connection Open circuit or short circuit Burnt or burned­out R18 R20 R21 R22 R23 R24 R25 R26 R27 R28 R31 R32 R33 R34 R35 R36 R99 Grounded or shorted Faulty casting Improper clearance, back lash, free play Lack of lubricants Improper welding or soldering, welding or soldering omitted Improper tightening, fit or assembly Sticks, binds, seized Foreign material, clogged Improper sealing, sealer omitted or skipped Improper adjustment Incorrect part Improperly installed Improperly routed Missing part Flaw in material Contaminants Undefined

File name en_sect_8.pdf

SECTION 8 RESTRAINTS SEAT BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A ­ 1 S. R. S (SUPPLEMENTAL INFLATABLE RESTRAINTS) . . . . . . . . . . . . . . . . . . . . . . . . . . 8B ­ 1 RESTRAINTS DEFECT CODE NATURE CODE N01 N03 N06 N11 N16 N19 N20 N21 N22 N23 N24 N27 N44 N46 N47 N51 N52 N55 N56 N57 Hard start, no start Surge, hesitate, stumble Engine stalled (general) Engine run­on Percolation Vapor lock Blocked Shuddering, pulsation, vibration, chattering Slippage ( = slipping) Difficult engagement Difficult disengagement Squeaking, squealing, abnormal(wind) noise Poor release Misaligned or mismatched Weak Deteriorated Distortion, rainbow, waving Rust, corrosion, perforation. Glazed Loose, poor fit N58 N61 N62 N65 N66 N67 N68 N71 N72 N73 N82 N83 N85 N86 N91 N92 N93 N94 N99 Bubbles Dead battery Inaccurate (meter, gauge, etc.) Electrical failures Blown fuse Warning light on Intermittent operation Oil leak, oil entering Water leak, water entering Leaks­other (air, fuel, refrigerant, vacuum) Loosening, falling­off, sagged Gas leak, gas entering Grabbed Poor maneuverability Interference or hitting Inoperative High/low operating effort Special policy Undefined CAUSE CODE R01 R02 R03 R04 R05 R06 R07 R08 R09 R10 R11 R12 R13 R14 R15 R16 R18 Scored, scratched or chipped Frozen Peeling, come­off Rusty, corroded Split, cut or torn Broken or cracked Porous, pin holes, cavity Bent, kinky, twisted, distorted, warped or wrinkled Stripped ­ bolts, holes, nuts Soiled Weakened, loss of tension or resilience (spring, cushion, etc.) Abnormal wear Out of balance Out of round Loose or improper connection Open circuit or short circuit Grounded or shorted R19 R20 R21 R22 R23 R24 R25 R26 R27 R28 R31 R32 R33 R34 R35 R36 R99 Improperly machined Faulty casting Improper clearance, back lash, free play Lack of lubricants Improper welding or soldering, welding or soldering omitted Improper tightening, fit or assembly Sticks, binds, seized Foreign material, clogged Improper sealing, sealer omitted or skipped Improper adjustment Incorrect part Improperly installed Improperly routed Missing part Flaw in material Contaminants Undefined

File name en_sect_9.pdf

SECTION 9 BODY & ACCESSORIES BODY WIRING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A ­ 1 LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B ­ 1 WIPER / WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9D ­ 1 INST. DRIVER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E ­ 1 AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F ­ 1 INTERIOR TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G ­ 1 SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9H ­ 1 GLASS & MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L ­ 1 EXTERIOR PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9M ­ 1 BUMPERS & FASCIAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9O ­ 1 DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P ­ 1 ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q ­ 1 BODY FRONT END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R ­ 1 BODY REAR END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9S ­ 1 BODY & ACCESSORIES DEFECT CODE NATURE CODE N02 N03 N08 N12 N16 N19 N20 N21 N22 N25 N26 N27 N28 N29 N43 N44 N46 N47 N51 N52 N53 N55 N56 N57 N58 N62 N63 N65 Poor idle Surge, hesitate, stumble Excessive oil consumption Flooded, overflowing Percolation Vapor lock Blocked Shuddering, pulsation, vibration, chattering Slippage (= slipping) Abnormal shifts Impossible shifts Squeaking, squealing, abnormal(wind) noise Dragging Pulls Excessive shock Poor release Misaligned or mismatched Weak Deteriorated Distortion, rainbow, waving Color mismatched Rust, corrosion, perforation. Glazed Loose, poor fit Bubbles Inaccurate (meter, gauge, etc.) Poor sound (horn, radio, etc.) Electrical failures N66 N67 N68 N70 N71 N72 N73 N74 N75 N76 N77 N78 N80 N82 N83 N84 N85 N86 N91 N92 N93 N94 N95 N96 N97 N98 N99 Blown fuse Warning light on Intermittent operation Poor AM reception / interference Oil leak, oil entering Water leak, water entering Leaks­other (air, fuel, refrigerant, vacuum) Poor