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Now downloading free:Daewoo Nubira/Lacetti  [report bad file]  

Download Daewoo Nubira/Lacetti docs - Car wirings and schematics,automobile documentation, auto repair guides,car audio manuals, car stereo

File information:
File name:Service Manual - Daewoo Lacetti.part01.rar
[preview Nubira/Lacetti] new window
Size:1953 kB
Extension:RAR
MD5 Checksum:6340faab330f8b3dd577771c84ced97d
Mfg:

Daewoo

Model:

Nubira/Lacetti

Original Chassis:
Descr:Also known as: Chevrolet Nubira / Lacetti, Chevrolet Optra Optra5, Suzuki Forenza Reno Covers the 1.4L, 1.6L and 1.8L engine. Year 2004
Group:Electronics > Automobile >
Uploaded:2005-07-28 04:08:45
User:john_doe
Multipart: 0  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  27  28  29  30  31  32  33  34  35  36  37  38  39  40  41  42  43  44  45  46  47  48  49  50  51

Information about the files in archive:
Decompress result:OK
Extracted files:139
File nameText
en_0.pdfCONTENTS 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 . . . . . . . . . . . . . . . .
en_10_p1.pdfPAINT 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
en_10_p2.pdf10 ­ 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
en_1b.pdfENGINE 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
en_1c.pdfENGINE 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 ­
en_1d.pdfENGINE 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 ­
en_1e.pdfENGINE 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 15105
en_1f.pdfENGINE 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.
en_1g.pdfENGINE 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 C
en_2c.pdfSUSPENSION 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 2
en_2d.pdfSUSPENSION 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.
en_2e.pdfSUSPENSION 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 : NUB
en_3.pdfDRIVE 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
en_4a.pdfBRAKE 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 B
en_4b.pdfBRAKE 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
en_4d.pdfBRAKE 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
en_4e.pdfBRAKE 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 R
en_4f.pdfBRAKE 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
en_4g.pdfBRAKE 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
en_4j2_0a.pdfPERSONAL 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
en_4j2_0b.pdfSECTION : 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 . . . . .
en_4j2_1.pdfSECTION 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 : P
en_4j2_1a.pdfSECTION : 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 ­ Co
en_4j2_1c1.pdfSECTION : 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 . . . . . . .
en_4j2_1c2.pdfSECTION : 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 . . . . . . . . . .
en_4j2_1d.pdfSECTION : 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 . . .
en_4j2_1e.pdfSECTION : 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
en_4j2_1f.pdfSECTION : 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/
en_4j2_1g.pdfSECTION : 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 Converte
en_4j2_2.pdfSECTION 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 Num
en_4j2_2a.pdfSECTION : 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
en_4j2_2b.pdfSECTION : 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 Fou
en_4j2_2c.pdfSECTION : 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 . . . . . . . .
en_4j2_2d.pdfSECTION : 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 . . . . . . . . . . . . . . . . . . .
en_4j2_2e.pdfSECTION : 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 . . . . . . . . . . . . . . . . . . . . . . . . .
en_4j2_3.pdfSECTION 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) 3­4WWIRI
en_4j2_3a.pdfSECTION : 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 . . . . . . . . . . . . . . . . . .
en_4j2_3b.pdfSECTION : 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 OPERA
en_4j2_4.pdfSECTION 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 1
en_4j2_4a.pdfSECTION : 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 Warn
en_4j2_4b.pdfSECTION : 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
en_4j2_4c.pdfSECTION : 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
en_4j2_4d.pdfSECTION : 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
en_4j2_4e1.pdfSECTION : 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
en_4j2_4e2.pdfSECTION : 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 OPERA
en_4j2_4f.pdfSECTION : 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 Dr
en_4j2_4g0.pdfSECTION : 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 Br
en_4j2_5.pdfSECTION 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
en_4j2_5a0.pdfSECTION : 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 . . . . . . . . . . . . . . . . .
en_4j2_5a2.pdfSECTION : 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 . . . . . . . . . . . . . . .
en_4j2_5b.pdfSECTION : 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 . . . . . . . . . . .
en_4j2_5c.pdfSECTION : 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 O
en_4j2_6a.pdfSECTION : 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 . . . . . . . . . . . . . . . .
en_4j2_6b.pdfSECTION : 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 SPECIFICA
en_4j2_6c.pdfSECTION : 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
en_4j2_6e.pdfSECTION : 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 Wipe
en_4j2_7a.pdfSECTION : 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
en_4j2_7b.pdfSECTION : 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 . . . . . . . . . . . . . . .
en_4j2_7d.pdfSECTION : 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) .
en_4j2_8a.pdfSECTION : 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 . . . . . . . .
en_4j2_8b.pdfSECTION : 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 . . . . . . . . .
en_4j2_9a.pdfSECTION : 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 . . . . . . . . . . . . . . . . . . .
en_4j2_9b.pdfSECTION : 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 .
en_4j2_9c.pdfSECTION : 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) . . . . . . . . . . . . . . . . . . . . . . . . . .
en_4j2_9d.pdfSECTION : 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 . . . . . . . . . . . . .
en_4j2_9e.pdfSECTION : 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 . . . . . . . . . . . . . . . . . .
en_4j2_9f.pdfSECTION : 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 R
en_4j2_9g0.pdfSECTION : 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 Pane
en_4j2_9h0.pdfSECTION : 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
en_4j2_9i0.pdfSECTION : 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 equiva
en_4j2_9j0.pdfSECTION : 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
en_4j2_9k0.pdfSECTION : 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
en_4j2_9l0.pdfSECTION : 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 Rea
en_4j2_9m0.pdfSECTION : 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 ­ 2IEXTE
en_4j2_9n0.pdfSECTION : 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 ­
en_4j2_9o0.pdfSECTION : 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 . . . . . . . . . . . . . .
en_4j2_9p0.pdfSECTION : 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 . . . . . . . . . . . . . .
en_4j2_9q0.pdfSECTION : 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 . . . .
en_4j2_9r0.pdfSECTION : 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 .
en_4j2_9s0.pdfSECTION : 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
en_4j2_9t01.pdfSECTION : 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 . . . . . . . . . . . . . . . .
en_4j2_9t02.pdfSECTION : 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 U
en_4n_0.pdfNUBIRA/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 replac
en_4n_01.pdfNUBIRA/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. CORROS
en_4n_02.pdfNUBIRA/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
en_4n_03.pdfNUBIRA/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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
en_4n_04.pdfNUBIRA/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 LONGITUDINA
en_4n_05.pdfNUBIRA/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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
en_4n_06.pdfNUBIRA/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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
en_4n_07.pdfNUBIRA/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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
en_4n_08.pdfNUBIRA/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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
en_4n_09.pdfNUBIRA/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/L
en_4n_10.pdfNUBIRA/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
en_4n_11.pdfSECTION 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 11­1
en_5a1.pdfTRANSMISSION / 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
en_5a2.pdfTRANSMISSION / 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 TRANSM
en_5b1.pdfTRANSMISSION / 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
en_5b2.pdfTRANSMISSION / 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 rel
en_5c.pdfTRANSMISSION / 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
en_6a.pdfSTEERING 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 : NUB
en_6d.pdfSTEERING 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
en_6e.pdfSTEERING 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 Wind
en_7a.pdfHEATING. 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
en_7b.pdfHEATING, 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
en_8a.pdfRESTRAINTS 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 (
en_8b.pdfRESTRAINTS 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
en_9a.pdfBODY & 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 ­ R
en_9b.pdfBODY & 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
en_9d.pdfBODY & 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
en_9e.pdfBODY & 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
en_9f.pdfBODY & 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 -- -- -
en_9g.pdfBODY & 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
en_9h.pdfBODY & 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
en_9l.pdfBODY & 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 946320
en_9m.pdfBODY & 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
en_9o.pdfBODY & 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
en_9p.pdfBODY & 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 & QU
en_9q.pdfBODY & 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.
en_9r.pdfBODY & 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
en_9s.pdfBODY & 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) ­
en_foreword.pdfFOREWORD 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 DAEWO
en_sec00.pdfFOREWORD 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
en_sec01.pdfSECTION 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
en_sec02.pdfSECTION 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 engin
en_sec03.pdfSECTION 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 3
en_sec04.pdfSECTION 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
en_sec05.pdfSECTION 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
en_sec06.pdfSECTION 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.
en_sec07.pdfSECTION 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
en_sect_1.pdfSECTION 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
en_sect_10.pdfSECTION 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
en_sect_2.pdfSECTION 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
en_sect_3.pdfSECTION 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 poli
en_sect_4.pdfSECTION 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, overflo
en_sect_5.pdfSECTION 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 Fl
en_sect_6.pdfSECTION 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 C
en_sect_7.pdfSECTION 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 braki
en_sect_8.pdfSECTION 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
en_sect_9.pdfSECTION 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .





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