M39i Waterleaks.pdf part of Daewoo Matiz 796cc (My 2003).part01.rar, Service Manual, Wiring Diagram - 16 Part File

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SECTION 9I

WATERLEAKS
TABLE OF CONTENTS
Diagnostic Information and Procedures . . . . . . Waterleak Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 9I-2 9I-2 9I-5 9I-5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9I-7 Recommended Materials for Waterleak Repairs . . . . . . . . . . . . . . . . . . . . . . . . 9I-7 Watertest Stand Specifications . . . . . . . . . . . . . . 9I-7

Waterleak Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 9I-5

DAEWOO M-150 BL2

9I 2 WATERLEAKS

DIAGNOSTIC INFORMATION AND PROCEDURES
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 1/2-inch by 36-inch Pipe 2 Full-jet Spray Nozzle #1/2 GG-25 or Equivalent Nozzle Height at 1,600 mm to the Floor 3 1/2-inch Coupling 4 1/2-inch by 1/2-inch by 1/4-inch Reducing T (Right Only) 5 1/2-inch Coupling (Left Only) 6 1/2-inch Cross (Right Only) 7 1/2-inch Tee (Left Only) 8 1/2-inch Pipe-to-Hose Nipple (Right Only) 9 5/8-inch Female Hose Coupling 10 5/8-inch Input Hose (2 Feet Long, Right Only) 11 1/2-inch Close Nipple 12 1/2-inch Cross with Weld-on 1/2-inch Cap 13 1/2-inch by 12-inch Nipple 14 1/2-inch Cap 15 5/8-inch Female Hose Coupling 16 5/8-inch Cross Hose (12 Feet Long) 17 5/8-inch Hose Quick Connect 18 1/2-inch Pipe-to-Hose Nipple 19 1/2-inch by 30-inch Pipe (Straight) 20 1/4-inch Water Pressure Gauge (Right Only)

Generalized Testing
1. Set up the watertest stands.

2. Set up the watertest stand leak test.

D109A301

D19A302A

DAEWOO M-150 BL2

WATERLEAKS 9I 3
3. Perform the watertest stand leak test. Refer to "Watertest Stand Specifications" in this section. 4. If the local water pressure does not allow the required water pressure of 155 kPa (22.5 psi), move both stands closer to the vehicle so that the water spray overlaps.

D109A303

Localized Testing (Spot Test)
1. Do localized testing with a water hose or an air hose. 2. Begin testing by spraying the air or the water at the base of the suspected leak area. Continue spraying the air or the water upward until the leak is found.

3. Begin spraying the water at the base of the suspected leak area. Continue spraying the water upward until the leak is found.

Water Hose Test
1. Place another person inside the vehicle in order to detect the location of the leak. 2. Use a water hose without a nozzle.

D109A305

D109A304

DAEWOO M-150 BL2

9I 4 WATERLEAKS Air Hose Test
1. Apply soapy water to the outside of the vehicle in the suspected leak area. 2. Blow air from inside the vehicle. The air pressure should not exceed 205 kPa (29.7 psi). 3. Determine the location of the leaks from the bubbles formed in the soapy water.

D109A306

DAEWOO M-150 BL2

WATERLEAKS 9I 5

REPAIR INSTRUCTIONS ONVEHICLE SERVICE
WATERLEAK REPAIR
Some waterleaks around the glass can be repaired without removing the glass. Important: This type of repair may be used only for urethaneinstalled glass. 1 Remove the reveal molding in the area of the leak. It may be necessary to remove the garnish molding or the trim strip lace in order to locate the leak. 2. While spraying water over leak area, carefully push the glass outward in order to determine the size of the leak. 3. Mark the location of the leak. 4. Use water to clean any dirt frame the area. Dry the area with an air hose.

D109A501

D109A502

5. Using a sharp knife, trim off the uneven edges of the adhesive caulking material around the leak for a distance of 75 to 100 mm (3 to 4 inches) on both side of the leak.

D109A503

DAEWOO M-150 BL2

9I 6 WATERLEAKS
6. Prime the trimmed area with the primer. 7. Using a sharp knife, trim off the uneven edges of the adhesive material around the leak 75 to 100 mm (3 to 4 inches) on both sides of the leak.

D109A504

8. Allow the primer to dry for 5 minutes. 9. Apply the adhesive over the leak and for a distance of 75 to 100 mm (3 to 4 inches) on both sides of the leak.

D109A505

10. Immediately after applying the adhesive, use a flat stick or a similar tool to work the adhesive into the leak area and into the joint between the original material and the vehicle body in order to ensure a watertight seal. 11. Spray warm or hot water over the repaired area in order to determine if the leak was repaired. Do not run a heavy stream of water directly on the freshly applied adhesive. 12. Install the trim strip lace if it was removed. 13. Install the garnish molding if it was removed. 14. Install the reveal molding.
D109A506

Important: After the completion of any waterleak repair, retest the area using the watertest stands. Do not use localized testing procedures on the newlyrepaired areas, as the repair material may dislodge under abnormal pressure.

D109A304

DAEWOO M-150 BL2

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Back Window and tailgate Test Stand Position B-Pillar Test Stand Position Windshield and A-Pillar Test Stand Position Pressure Volume of Flow Nozzle Height Nozzle Type Bolts, studs, and screws Weatherstrips Large holes Small cracks and pin holes Ventilation ducts Metal joints Windshield, back window

DAEWOO M-150 BL2

RECOMMENDED MATERIALS FOR WATERLEAK REPAIRS

Application

Leak Areas

WATERTEST STAND SPECIFICATIONS

SPECIFICATIONS

Approximately 30° down, 45° toward the front and aimed approximately 610 mm (24.0 in.) from the corner of the back window Approximately 30° down, 45° toward the rear, and aimed at the center of the rear door Approximately 30° down, 45° toward the rear, and aimed at the corner of the windshield 155 kPa (22.5 psi) measured at the nozzle 14L (3.7 gal) per minute Strip caulk 3MTM Automotive Joint and Seam Sealer 3MTM Drip-Check Sealer or the equivalent Repair Materials Description Approximately 1,600 mm (63.0 in.) from the floor Brushable seam sealer which can be painted Urethane adhesive, caulking kit, or the equivalent

Full jet spray nozzle #1/2 GG-25 or equivalent with a 60° included angle 3MTM Auto Bedding and Glazing Compound or the equivalent

3MTM 08011 Weatherstrip Adhesive or the equivalent

WATERLEAKS 9I 7