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File information:
File name:796cc (My 2003).part01.rar
[preview Matiz]
Size:2145 kB
Extension:PDF
Mfg:Daewoo
Model:Matiz 🔎
Original:M-150 BL2 🔎
Descr:Service Manual, Wiring Diagram - 16 Part File - 62 File
Group:Electronics > Automobile
Uploaded:09-11-2006
User:salvacolnome
Multipart: 0  1  2  3  4  5  6  7  8  9  10  11  12  13  14  15

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Extracted files:61
File name 7b1 Heating, Ventilation and AC 1-20.pdf

SECTION 7B MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . System Components Functional . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing the Refrigerant System . . . . . . . . . . . . . . Insufficient Cooling "Quick Check" Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-2 7B-2 7B-3 7B-3 7B-5 7B-5 7B-5 7B-5 Serviceable Components . . . . . . . . . . . . . . . . . . . . Control Assembly and Control Cables . . . . . . . Blower Motor and Cooling Hose . . . . . . . . . . . . Blower Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Motor Switch . . . . . . . . . . . . . . . . . . . . . . A/C Push Knob . . . . . . . . . . . . . . . . . . . . . . . . . . ReceiverDryer and Dual Cut Switch . . . . . . . . ReceiverDryer Bracket . . . . . . . . . . . . . . . . . . . 7B-17 7B-17 7B-17 7B-17 7B-17 7B-18 7B-18 7B-20 Pressure-Temperature Relationship of R-134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-6 Leak Testing the Refrigerant System . . . . . . . . . 7B-7 Air Conditioning System Diagnosis . . . . . . . . . . . . . 7B-8 Insufficient Cooling Diagnosis . . . . . . . . . . . . . . . 7B-8 Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 7B-11 Pressure Test Chart (R-134a System) . . . . . . . 7B-11 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . 7B-13 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . 7B-13 General A/C System Service Procedures . . . . . . O-Ring Replacement . . . . . . . . . . . . . . . . . . . . . Handling Refrigerant . . . . . . . . . . . . . . . . . . . . . . Handling of Refrigerant Lines and Fittings . . . 7B-13 7B-13 7B-13 7B-13 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-20 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-21 A/C High Pressure Pipe Line . . . . . . . . . . . . . . . 7B-22 A/C Low Pressure Pipe Line . . . . . . . . . . . . . . . Evaporator Unit and Drain Hose . . . . . . . . . . . . Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Evaporator Core and Expansion Valve . . . . . . Compressor Overhaul . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . .
File name M31a General Engine Information.pdf

SECTION 1A GENERAL ENGINE INFORMATION TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Cleanliness and Care . . . . . . . . . . . . . . . . . . . . . . On-Engine Service . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Engine Compartment (Typical) . . . . . . . . . . . . . . Engine Compartment (Euro III) . . . . . . . . . . . . . . Diagnoctic Information and Procedure . . . . . . . General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2 1A-2 1A-2 1A-3 1A-3 1A-4 1A-5 1A-5 Checking Engine Timing Belt . . . . . . . . . . . . . . . Checking Accessory Belt . . . . . . . . . . . . . . . . . . Checking Spark Plug . . . . . . . . . . . . . . . . . . . . . Checking Air Cleaner Element . . . . . . . . . . . . . Checking Fuel Filter . . . . . . . . . . . . . . . . . . . . . . Checking Fuel System . . . . . . . . . . . . . . . . . . . . Checking Hose System . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-12 1A-12 1A-12 1A-13 1A-13 1A-13 1A-13 1A-14 Checking Engine Fluid Level . . . . . . . . . . . . . . . 1A-11 Changing Engine Oil or Oil Filter . . . . . . . . . . . . 1A-11 General Specifications . . . . . . . . . . . . . . . . . . . . 1A-14 Engine Performance Curve . . . . . . . . . . . . . . . . 1A-15 DAEWOO M-150 BL2 1A 2 GENERAL ENGINE INFORMATION DESCRIPTION AND SYSTEMOPERATION CLEANLINESS AND CARE An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the tenthousandths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly, to protect and lubricate the surfaces on initial operation. Proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever valve train components are removed for service, they should be kept in order. They should be installed in the same locations, and with the same mating surfaces, as when they were removed. Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts. ON-ENGINE SERVICE 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 B unless otherwise noted. Notice: Any time the air cleaner is removed, the intake opening should be covered. This will protect against accidental entrance of foreign material, which could follow the intake passage into the cylinder an
File name M31b1 SOHC Engine Mechanical.pdf

SECTION 1B SOHC 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 B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Engine Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head and Valve Train . . . . . . . . . . . . . . Engine Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston, Piston Ring and Piston Pin . . . . . . . . . . . 1B-2 1B-2 1B-2 1B-2 1B-3 1B-3 1B-3 1B-3 Air Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . Positive Crankcase Ventilation (PCV) Hose and Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Manifold (Typical) . . . . . . . . . . . . . . . . . Exhaust Manifold (Euro III) . . . . . . . . . . . . . . . . Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distributor Case . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head and Gasket . . . . . . . . . . . . . . . . . Engine Mount Damping Block . . . . . . . . . . . . . . Engine Mount Front Damping Bush . . . . . . . . . Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head and Valve Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Block Components . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Specifications . . . . . . . . . . . . . . . . . . . . . Fastener Tightening Specifications . . . . . . . . . . 1B-14 1B-15 1B-15 1B-16 1B-18 1B-20 1B-21 1B-23 1B-24 1B-26 1B-28 1B-32 1B-34 1B-35 1B-47 1B-47 1B-59 1B-71 1B-71 1B-73 Timing Belt and Pulley . . . . . . . . . . . . . . . . . . . . . 1B-4 Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-4 Component Locator . . . . . . . . . . . . . . . . . . . . . . . . 1B-5 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manifold & Air Flow System . . . . . . . . . . . . . . . . . Timing Belt & Engine Mount . . . . . . . . . . . . . . . . 1B-5 1B-6 1B-7 1B-8 Diagnostic Information and Procedure . . . . . . . 1
File name M31d Engine Cooling.pdf

SECTION 1D ENGINE COOLING CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . . . Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Surge Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . Engine Coolant Temperature Sensor . . . . . . . . . 1D-2 1D-2 1D-2 1D-2 1D-3 1D-3 1D-3 1D-4 Cooling System Diagnosis . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Draining and Refilling the Cooling System . . . . Surge Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric Cooling Fan . . . . . . . . . . . . . . . . . . . . . . Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat (Typical) . . . . . . . . . . . . . . . . . . . . . . 1D-8 1D-9 1D-9 1D-9 1D-10 1D-11 1D-11 1D-12 Coolant Temperature Sensor . . . . . . . . . . . . . . . . 1D-4 Component Locator . . . . . . . . . . . . . . . . . . . . . . . . 1D-5 Coolant Hose and Components . . . . . . . . . . . . . 1D-5 Radiator/Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedure . . . . . . . Coolant Leaks Test . . . . . . . . . . . . . . . . . . . . . . . . Surge Tank Cap Test . . . . . . . . . . . . . . . . . . . . . . . 1D-6 1D-7 1D-7 1D-7 Thermostat (Euro III) . . . . . . . . . . . . . . . . . . . . . . 1D-13 Coolant Temperature Sensor . . . . . . . . . . . . . . . 1D-14 Engine Coolant Temperature Sensor . . . . . . . . 1D-15 Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . Fastener Tightening Specifications . . . . . . . . . . 1D-15 1D-17 1D-17 1D-18 Thermostat Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-7 DAEWOO M-150 BL2 1D 2 ENGINE COOLING DESCRIPTION AND OPERATION GENERAL DESCRIPTION The cooling system maintains the engine temperature at an efficient level during all engine operating conditions. When the engine is cold the cooling system cools the engine slowly or not at all. This slow cooling of the engine allows the engine to warm up quickly. The cooling system includes a radiator(a) and cooling fan(b), a thermostat and housing(c), a coola
File name M31e1 Engine Electrical 1-18.pdf

SECTION 1E ENGINE ELECTRICAL CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reserve Capacity . . . . . . . . . . . . . . . . . . . . . . . . . Cold Cranking Amperage . . . . . . . . . . . . . . . . . . . Built-In Hydrometer . . . . . . . . . . . . . . . . . . . . . . . . Charging Procedure . . . . . . . . . . . . . . . . . . . . . . . Charging Time Required . . . . . . . . . . . . . . . . . . . . Charging a Completely Discharged Battery (Off the Vehicle) . . . . . . . . . . . . . . . . . . . . . . . . . Jump Starting Procedure . . . . . . . . . . . . . . . . . . . Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-2 1E-2 1E-2 1E-2 1E-2 1E-2 1E-3 1E-3 1E-3 1E-3 1E-4 1E-4 1E-4 1E-4 1E-4 1E-5 Generator Output Test . . . . . . . . . . . . . . . . . . . . Generator System Check . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-12 1E-13 1E-14 1E-14 1E-14 1E-15 1E-16 1E-17 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-18 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-19 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-19 Generator (A-type: MANDO) . . . . . . . . . . . . . . . Generator (B-type: DAC) . . . . . . . . . . . . . . . . . . Distributor Assembly . . . . . . . . . . . . . . . . . . . . . . Schematic and Routing Diagrams . . . . . . . . . . Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . Charging System . . . . . . . . . . . . . . . . . . . . . . . . . Ignition System Circuit Tipical . . . . . . . . . . . . Ignition System Circuit Euro III . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . .
File name M31e2 Engine Electrical 19-42.pdf

ENGINE ELECTRICAL 1E 19 REPAIR INSTRUCTIONS UNIT REPAIR STARTER MOTOR Inspection / Measurement (Before the Overhaul) 1. Remove the starter. Refer to "Starter" in this section. 2. Pinion clearance inspection. D Disconnect the starter motor terminal M (1). D Connect the 12-volt battery lead to the starter motor terminals M and S. Notice: Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid. (in 10 seconds) D Switch on to move the pinion gear (2). D Now check the clearance between the pinion and the stopper with the filler gauge (3). D If the clearance does not fall within the limits, check for improper installation and replace all worn parts. D102E701 D102E702 3. Magnetic switch pull-in test. D Disconnect the starter motor terminal M (1). D Connect the 12-volt battery lead to the starter motor terminals M and S. Notice: Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid. (in 10 seconds) D102E703 DAEWOO M-150 BL2 1E 20 ENGINE ELECTRICAL D Inspect the pinion gear's moving to the outside (2). D If the pinion gear does not move outside, replace the magnetic switch. D102E704 4. Solenoid hold-in test. D Disconnect the starter motor terminal M (1). D Connect the 12-volt battery lead to the starter motor terminal S and body. Notice: Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid. D102E705 D Check the pinion gear's moving to the outside (2). D If the pinion gear move to the inside, the circuit is open. Replace the magnetic switch. D102E706 5. Solenoid return test. D Disconnect the starter motor terminal M (1). D Connect the 12-volt battery lead to the starter motor terminal S and body. Notice: Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid. D102E707 DAEWOO M-150 BL2 ENGINE ELECTRICAL 1E 21 D Check the returning speed of pinion gear (2). If the returning speed is fast, the operation is normal. D Replace the solenoid if the operation is abnormal. D102E708 5. No-road test. D Connect the 12-volt battery lead to the starter circuit. D Connect the current and the voltage (1). D Install the starter motor rpm gage (2). D Start the starter motor with the switch on (3). D Measure the speed of pinion gear and the current. D If the measurement satisfy the limit, the starter motor is normal. D102E709 Desciption The speed of pinion gear Condition: Voltage/Current Limit Minimum: 2,000 rpm Maximum: 9V / 150A D Replace the starter motor if necessary. D102E710 Disassembly Procedure 1. Remove the starter contact end frame. D Remove the through-bolts (1). D Remove the contact end frame bolts (2). D Remove the frame with the spacer (3). D102E711 DAEWOO M-150 BL2 1E 22 ENGINE ELECTRICAL 2. Remove the brush holder assembly. D Remove the starter motor terminal M nut (1). D Remove the brush holder assembly (2). D102E712 3. Remove the field frame assembly
File name M31f1 Engine Controls 1-54.pdf

SECTION 1F ENGINE CONTROLS CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Ignition System Operation . . . . . . . . . . . . . . . . . . Electronic Ignition System Ignition Coil . . . . . . . Crankshaft Position Sensor . . . . . . . . . . . . . . . . . Camshaft Position Sensor . . . . . . . . . . . . . . . . . . Idle Air System Operation . . . . . . . . . . . . . . . . . . Fuel Control System Operation . . . . . . . . . . . . . . Evaporative Emission Control System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controlled Charcoal Canister . . . . . . . . . . . . . . . . Positive Crankcase Ventilation Control System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Coolant Temperature Sensor . . . . . . . . . Throttle Position Sensor . . . . . . . . . . . . . . . . . . . . Catalyst Monitor Oxygen Sensors . . . . . . . . . . . 1F-4 1F-4 1F-4 1F-4 1F-4 1F-4 1F-4 1F-5 1F-5 1F-5 1F-6 1F-6 1F-6 Diagnostic Information and Procedures . . . . System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . Idle Learn Procedure . . . . . . . . . . . . . . . . . . . . . Euro On-Board Diagnostic (EOBD) System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECM Output Diagnosis . . . . . . . . . . . . . . . . . . . . Multiple ECM Information Sensor DTCs Set . . Engine Cranks But Will Not Run . . . . . . . . . . . . No Malfunction Indicator Lamp . . . . . . . . . . . . . Malfunction Indicator Lamp On Steady . . . . . . Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . . Fuel Pump Relay Circuit Check . . . . . . . . . . . . Main Relay Circuit Check . . . . . . . . . . . . . . . . . . Manifold Absolute Pressure Check . . . . . . . . . . Idle Air Control System Check . . . . . . . . . . . . . Ignition System Check . . . . . . . . . . . . . . . . . . . . 1F-17 1F-17 1F-17 1F-17 1F-18 1F-20 1F-21 1F-25 1F-30 1F-32 1F-34 1F-36 1F-38 1F-40 1F-42 1F-45 Electric Exhaust Gas Recirculation Valve . . . . . 1F-6 Intake Air Temperature Sensor . . . . . . . . . . . . . . 1F-7 Idle Air Control Valve . . . . . . . . . . . . . . . . . . . . . . 1F-7 Manifold Absolute Pressure Sensor . . . . . . . . . . Engine Control Module . . . . . . . . . . . . . . . . . . . . . Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Cutoff Switch (Inertia Switch) . . . . . . . . . . . Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable Reluctance (VR) Sensor . . . . . . . . . . . . Octane Number Connector . . . . . . . . . . .
File name M31f2 Engine Controls 55-151.pdf

ENGINE CONTROLS 1F 55 DIAGNOSTIC TROUBLE CODE DIAGNOSIS CLEARING TROUBLE CODES Notice: To prevent Engine Control Module (ECM) damage, the key must be OFF when disconnecting or reconnecting the power to the ECM (for example battery cable, ECM pigtail connector, ECM fuse, jumper cables, etc.).When the ECM sets a Diagnostic Trouble Code (DTC), the Malfunction Indicator Lamp (MIL) lamp will be turned on only for type A, B and E but a DTC will be stored in the ECM's memory for all types of DTC. If the problem is intermittent, the MIL will go out after 10 seconds if the fault is no longer present. The DTC will stay in the ECM's memory until cleared by scan tool. Removing battery voltage for 10 seconds will clear some stored DTCs. DTCs should be cleared after repairs have been completed. Some diagnostic tables will tell you to clear the codes before using the chart. This allows the ECM to set the DTC while going through the chart, which will help to find the cause of the problem more quickly. DIAGNOSTIC TROUBLE CODES DTC P0107 P0108 P0112 P0113 P0117 P0118 P0122 P0123 P0131 P0132 P0133 P0137 P0138 P0140 P0141 P0171 P0172 P1230 P1231 P0261 P0262 P0264 P0265 P0267 P0268 P0300 P1320 P1321 P0327 P0335 Function Manifold Absolute Pressure Sensor Low Voltage Manifold Absolute Pressure Sensor High voltage Intake Air Temperature Sensor Low Voltage Intake Air Temperature Sensor High voltage Engine Coolant Temperature Sensor Low Voltage Engine Coolant Temperature Sensor High voltage Throttle Position Sensor Low Voltage Throttle Position Sensor Hig voltage Oxygen Sensor Low Voltage Oxygen Sensor High Voltage Oxygen Sensor No Activity Heated Oxygen Sensor Low Voltage Heated Oxygen Sensor high voltage Heated Oxygen Sensor No Activity Heated Oxygen Sensor Heater Malfuction Fuel Trim System Too Lean Fuel Trim System Too Rich Fuel Pump Relay Low Voltage Fuel Pump Relay High Voltage Injector 1 Low Voltage Injector 1 high voltage Injector 2 Low Voltage Injector 2 high voltage Injector 3 Low Voltage Injector 3 high voltage Multifle Cylinder Misfire Crankshatft Segment Period Segment Adaptation At Limit Crankshatft Segment Period Tooth Error Knock Sensor Circuit Fault Magnetic Crankshaft Position Sensor Electrical Error Error Type A A E E A A A A A A E E E E E E E A A A A A A A A A/E E E E E Illuminate MIL YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES BLINKING/ON YES YES YES YES DAEWOO M-150 BL2 1F 56 ENGINE CONTROLS Diagnostic Trouble Codes (Cont'd) DTC P0336 P0337 P0341 P0342 P0351 P0352 P0353 P1382 P1382 P1385 P1385 P0400 P1402 P1403 P0404 P1404 P0405 P0406 P0420 P0444 P0445 P0462 P0463 P0480 P0480 P0481 P0481 P0501 P0505 P1535 P1536 P1537 P1538 P0562 P0563 P0601 P0604 P0605 P1610 P1611 P1628 P1629 P0656 Function 58X Crankshaft Position Sensor Extra/missing Pulse 58X Crankshaft Sensor No Signal Camshaft Position Sensor Rationality Camshaft Position Sensor No Signal Ignition Signal Coil A Fault Ignition Signal
File name M31f3 Engine Controls 152-279.pdf

1F 152 ENGINE CONTROLS MAA1F180 DIAGNOSTIC TROUBLE CODE (DTC) P0336 58X CRANKSHAFT POSITION SENSOR NO PLAUSIBLE SIGNAL Circuit Description The 58X reference signal is produced by the crankshaft position (CKP) sensor. During one crankshaft revolution, 58 crankshaft pulses will be produced. The engine control module(ECM) uses the 58X reference signal to calculate engine rpm and CKP. The ECM constantly monitors the number of pulses on the 58X reference circuit and compares them to the number of camshaft position (CKP) signal pulses being received. If the ECM receive and incorrect number of pulses on the 58X reference circuit, DTC P0336 will set. Conditions for Setting the DTC D This DTC can be stored in "key-on" status. D Detected number of teeth is differs by 3 or higher. Action Taken When the DTC Sets D The Malfunction Indicator Lamp (MIL) will illuminate. D The ECM will record operating conditions at the time the diagnostic fails. This information will be stored in the Freeze Frame and Failure Records buffers. D A history DTC is stored. Conditions for Clearing the MIL/DTC D The MIL will turn off after four consecutive ignition cycles in which the diagnostic runs without a fault. D A history DTC will clear after 40 consecutive warm-up cycles without a fault. D DTC(s) can be cleared by using the scan tool. D Disconnecting the ECM battery feed for more than 10 seconds. DIAGNOSTIC AIDS An intermittent may be caused by a poor connection, rubbed-through wire insulation or a wire broken inside the insulation. Check for : Poor connection inspect the ECM harness and connectors for improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. Damaged harness inspect the wiring harness for damage. If the harness appears to be OK, disconnect the ECM, turn the ignition ON and observe a voltmeter connected to the 58X reference circuit at the ECM harness connector while moving the connectors and the wiring harness related to the ECM. A change in voltage will indicate the location of the fault. Review the failure records vehicle mileage since the diagnostic test failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition. DAEWOO M-150 BL2 ENGINE CONTROLS 1F 153 DTC P0336 58X Crankshaft Position Sensor No Plausible Signal Step 1 Action Perform an Euro On-Board Diagnostic (EOBD) System Check. Is the system check complete? Attempt to start the engine. Does the engine start? Value(s) Go to Step 2 Go to Step 3 1. Review and record Failure Records information. 2. Clear the DTC P0336. 3. Start the engine and idle for 1 minute. 4. Observe the diagnostic trouble codes (DTCs). Is the DTC P0336 set? 1. Disconnect the engine control module(ECM) and the crankshaft position (CKP) sensor. 2. Check for an open or a low voltage in the CKP sensor connector and the ECM harness connector. Is the problem found? Repair the open or low voltage in t
File name M31f4 Engine Controls 280-324.pdf

1F 280 ENGINE CONTROLS SYMPTOM DIAGNOSIS IMPORTANT PRELIMINARY CHECKS Important: Several symptom procedures call for a careful visual/physical inspection. Always perform the visual/ physical test first. Visual inspections may lead to Step 1 Action Perform the On-Board Diagnostic (EOBD) System Check. Are any Diagnostic Trouble Code(s) (DTCs) stored in the Engine Control Module (ECM) memory? 1. Inspect all of the ECM ground connections. 2. Inspect all of the vacuum hoses for splits, kinks, and proper connections. 3. Check for air leaks at all of the mounting areas of the intake manifold sealing surfaces. 4. Inspect the ignition wires for cracking, hardness, proper routing, and carbon tracking. 5. Inspect the wiring for proper connections, pinches, and cuts. Are all checks complete? correcting a problem without further checks and can save valuable time. Value(s) Yes Go to Appropriate DTC Table No Go to Step 2 2 Go to Appropriate Symptom Table DAEWOO M-150 BL2 ENGINE CONTROLS 1F 281 INTERMITTENT Definition: The problem may or may not illuminate the Malfunction Indicator Lamp (MIL) or store a Diagnostic Trouble Code (DTC). Important: Do not use the Diagnostic Trouble Code (DTC) tables for intermittent problems. A fault must be Step 1 1. Perform a careful inspection of any suspect circuits. 2. Inspect for poor mating of the connector halves, or terminals not fully seated into the connector body. 3. Inspect for improperly formed or damaged terminals. 4. Inspect for poor terminal-to-wire connections. This requires removing the terminal from the connector body to inspect it. Are any problems present? Repair the electrical connections as needed. Is the repair complete? Road test the vehicle with a voltmeter connected to a suspected circuit or a scan tool connected to the Data Link Connector (DLC). Did the voltmeter or the scan tool indicate an abnormal voltage or scan reading? Replace the sensor in the affected circuit, if a Diagnostic Trouble Code (DTC) was stored for this circuit (except for the DTCs P0171 and P0172). Is the repair complete? Does an intermittent Malfunction Indicator Lamp (MIL) or DTC occur? 1. Check for a faulty relay, Engine Control Module (ECM) driven solenoid, or switch. 2. Check for improper installation of electrical devices, such as lights, two-way radios, electric motors, etc. 3. Inspect the ignition control wires for proper routing (away from ignition wires, ignition system components, and the generator). 4. Check for a short-to-ground in the MIL circuit or the DLC "test" terminal. 5. Inspect the ECM ground connections. 6. Correct or repair the affected circuits as needed. Is the repair complete? 1. Check for a loss of DTC memory. 2. Disconnect the throttle position (TP) sensor. 3. Run the engine at idle until the MIL comes on. 4. Turn the ignition OFF. Is DTC P0122 stored in memory? Action Were the Important Preliminary Checks performed? Go to Step 2 Value(s) Yes No Go to "Important Preliminary Checks" pr
File name M31g Engine Exhaust.pdf

SECTION 1G ENGINE EXHAUST TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Catalytic Converter . . . . . . . . . . . . . . . . . . . . . . . . 1G-2 1G-2 1G-2 1G-2 Repair Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Pipe/Catalytic Converter . . . . . . . . . . . . Pup-up Catalitic Converter . . . . . . . . . . . . . . . . . . Front Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fastener Tightening Specifications . . . . . . . . . . . 1G-4 1G-4 1G-4 1G-5 1G-7 1G-8 1G-9 1G-9 Component Locator . . . . . . . . . . . . . . . . . . . . . . . . 1G-3 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-3 DAEWOO M-150 BL2 1G 2 ENGINE EXHAUST DESCRIPTION AND OPERATION EXHAUST SYSTEM Notice: When you are inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to avoid possible overheating of the floor pan and possible damage to the passenger compartment insulation and trim materials. Check the complete exhaust system and the nearby body areas and tailgate for broken, damaged, missing or mispositioned parts, open seams, holes, loose connections or other deterioration which could permit exhaust fumes to seep into the luggage or passenger compartment. Dust or water in the luggage may be an indication of a problem in one of these areas. Any defects should be corrected immediately. complete assembly should be replaced. The same procedure is applicable to the rear muffler assembly. Heat shields in the front and rear muffler assembly positions, as well as for the catalytic converter and front exhaust pipe, protect the vehicle and the environment from high temperatures the exhaust system develops. CATALYTIC CONVERTER Notice: When jacking or lifting the vehicle from the body side rails, be certain that the lift pads do not contact the catalytic converter as this could damage the catalytic converter. Notice: The catalytic converter requires the use of unleaded fuel only, or damage to the catalyst will result. The catalytic converter is an emission control device added to the exhaust system to reduce pollutants from the exhaust pipes. The oxidation catalyst is coated with a catalytic material containing platinum and palladium, which reduces levels of hydrocarbon (HC) and carbon monoxide (CO) from the exhaust gas. The three-way catalyst has coatings which contain platinum and rhodium, which additionally lower the levels of oxides of nitrogen (NOx). MUFFLER The muffler reduces the temperature, pressure, and noise of the exhaust gas. Aside from
File name M32a Suspension Diagnostics.pdf

SECTION 2A SUSPENSION DIAGNOSIS TABLE OF CONTENTS Diagnostic Information and Procedures . . . . . 2A-1 General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Wheel Bearing Diagnosis . . . . . . . . . . . . . . . . . . . 2A-6 DIAGNOSTIC INFORMATION AND PROCEDURES GENERAL DIAGNOSIS Problems in the steering, the suspension, the tires, and the wheels involve several systems. Consider all systems when you diagnose 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. Application Checks Correction Preliminary Checks D Inspect the tires for improper pressure and uneven wear. D Inspect the joint from the steering column to the intermediate shaft for loose connections or wear. D Inspect the joint from the intermediate shaft to the steering gear for loose connections or wear. D Inflate the tires to the proper pressure. D Tighten the coupling flange pinch bolts. D Replace the intermediate shaft as needed. D Inspect the front and the rear suspension, the steering gear, and the linkage for loose or damaged parts. D Tighten the front and the rear suspension. D Tighten the steering gear mounting bracket bolts. D Replace the front and the rear suspension as needed. D Replace the steering gear as needed. D Replace the coupling flange as needed. D Perform free runout test. D Matchmount the tires. D Balance the wheels. D Replace the wheels. D Replace the wheel bearings. D Tighten the power steering pump drive belt. D Repair any leaks. D Perform a power steering gear test. D Add power steering fluid. D Inspect for outofround tires. D Inspect for outofbalance tires, bent wheels, and worn or loose wheel bearings. D Check the power steering pump drive belt tension. D Inspect the power steering system. Also, check the power steering fluid level. DAEWOO M-150 BL2 2A 2 SUSPENSION DIAGNOSIS Condition Probable Cause Correction Car Lead/Pull D Mismatched or uneven tires. D Replace the tires. D A broken or a sagging coil spring. D Replace the coil spring. D A improperly radial tire lateral force. D Check the wheel alignment. D Switch the tire and wheel assemblies. D Replace the tires as needed. D Align the front wheels. D Reseat the pinion valve assembly. D Replace the pinion valve assembly as needed. D Adjust the front brakes. D Align the front and the rear wheels. D Adjust the toe. D Replace the coil spring. D Balance the tires. D Replace the strut dampeners. D Rotate the tires. D Replace the tires as needed. D Maintain the proper load weight. D Inflate the tires to the proper pressure. D Adjust the toe. D Replace the suspension arm. D Balance the tire or
File name M32b Wheel Alignment.pdf

SECTION 2B WHEEL ALIGNMENT TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Four Wheel Alignment . . . . . . . . . . . . . . . . . . . . . Toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Axis Inclination . . . . . . . . . . . . . . . . . . . . Included Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scrub Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 2B-2 2B-2 2B-2 2B-2 2B-3 2B-3 2B-3 Diagnostic Information and Procedures . . . . . Tire Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Toe Adjustment . . . . . . . . . . . . . . . . . . . . . . Front Camber and Caster Check . . . . . . . . . . . . Rear Camber Check . . . . . . . . . . . . . . . . . . . . . . . Rear Toe Check . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Alignment Specifications . . . . . . . . . . . . . 2B-4 2B-4 2B-5 2B-5 2B-5 2B-5 2B-6 2B-6 Setback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Turning Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Fastener Tightening Specifications . . . . . . . . . . . 2B-6 DAEWOO M-150 BL2 2B 2 WHEEL ALIGNMENT DESCRIPTION AND OPERATION FOUR WHEEL ALIGNMENT The first responsibility of engineering is to design safe steering and suspension systems. Each component must be strong enough to withstand and absorb extreme punishment. Both the steering system and the front and the rear suspension must function geometrically with the body mass. The steering and the suspension systems require that the front wheels self-return and that the tire rolling effort and the road friction be held to a negligible force in order to allow the customer to direct the vehicle with the least effort and the most comfort. A complete wheel alignment check should include measurements of the rear toe and camber. Four-wheel alignment assures that all four wheels will be running in precisely the same direction. When the vehicle is geometrically aligned, fuel economy and tire life are at their peak, and steering and performance are maximized. CASTER D16A008A TOE Caster is the tilting of the uppermost point of the steering axis either forward or backward from the vertical when viewed from the side of the vehicle. A backward tilt is positive, and a forward tilt is negative. Caster influences directional control of the steering but does not affect tire wear. Weak springs or overloading a vehicle will affect caster. One wheel with more positive caster will pull toward the center of the car. This condition will cause the car to move or lean toward the side with the least amount of positive caster. Caster is measured in degrees and is not adjustable. CAMBER D
File name M32c Front Suspension.pdf

SECTION 2C FRONT SUSPENSION TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Strut Dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . Ball Joint and Knuckle . . . . . . . . . . . . . . . . . . . . . Front Wheel Bearing . . . . . . . . . . . . . . . . . . . . . . . 2C-2 2C-2 2C-3 2C-3 2C-5 2C-5 2C-5 2C-6 Front Longitudinal Frame and Stabilizer Shaft . . . . . . . . . . . . . . . . . . . . . . . . . 2C-10 Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-12 Strut Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-12 Crossmember . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-13 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hub, Bearing and Knuckle . . . . . . . . . . . . . . . . . Front Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . Fastener Tightening Specifications . . . . . . . . . . Special Tools and Equipment . . . . . . . . . . . . . . Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . 2C-16 2C-16 2C-20 2C-23 2C-23 2C-23 2C-24 2C-24 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 2C-7 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-7 Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-7 Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2C-8 DAEWOO M-150 BL2 2C 2 FRONT SUSPENSION DESCRIPTION AND OPERATION FRONT SUSPENSION The front suspension for this vehicle is a combination knuckle/strut and spring design. The control arms pivot from the body. The lower control arm pivots use rubber bushing. The upper end of the strut is isolated by a rubber mount and contains a bearing to allow the wheel to turn. The lower end of the steering knuckle pivots on a ball joint bolted to the control arm. The ball joint is fastened to the steering knuckle with a bolt. When servicing the control arm-to-body attachment and the stabilizer shaft-to-body insulators, make sure the attaching bolts are loose until the control arms are moved to the trim height, which is curb height. Trim height is the normal position to which the control arms move when the vehicle is sitting on the ground. Refer to "General Specifications" in this section. DAEWOO M-150 BL2 FRONT SUSPENSION 2C 3 COMPONENT LOCATOR FRONT SUSPENSION D16B401A DAEWOO M-150 BL2 2C 4 FRONT SUSPENSION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Strut Bar Front Suspension Strut Assembly Strut Inner Support Strut Mount Assembly Strut Mount Seat Strut Bearing Se
File name M32d Rear Suspension.pdf

SECTION 2D REAR SUSPENSION TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the Rear Wheel Bearing End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wheel Bearing Free Load . . . . . . . . . . . . . . 2D-2 2D-2 2D-3 2D-3 2D-4 2D-4 2D-5 2D-5 Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . Lateral Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trailing Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hub and Bearing Assembly . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . 2D-6 2D-7 2D-8 2D-9 2D-12 2D-12 2D-15 2D-15 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 2D-6 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-6 Fastener Tightening Specifications . . . . . . . . . . 2D-15 Special Tools and Equipment . . . . . . . . . . . . . . 2D-16 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . 2D-16 DAEWOO M-150 BL2 2D 2 REAR SUSPENSION DESCRIPTION AND OPERATION REAR SUSPENSION The rear suspension consists of an axle with trailing arms and a lateral rod, two coil springs, two shock absorbers, two upper spring seats, and two bump stoppers. The axle structure maintains the relationship of the wheels to the body. Each coil spring is retained between a seat in the underbody and a seat welded to the top of the rear axle. DAEWOO M-150 BL2 REAR SUSPENSION 2D 3 COMPONENT LOCATOR REAR SUSPENSION D106C401 1. 2. 3. 4. 5. 6. 7. 8. Shock Absorber Bumper Stopper Coil Spring Upper Seat Coil Spring Washer Bushing Lateral Rod Rear Axle 9. 10. 11. 12. 13. 14. 15. 16. Oil Seal Wheel Bearing Inner ABS Wheel Speed Ring Wheel Bearing Outer Cotter Pin Castellated Nut Spindle Cap Trailing Arm DAEWOO M-150 BL2 2D 4 REAR SUSPENSION DIAGNOSTIC INFORMATION AND PROCEDURES REAR SUSPENSION Condition Probable cause Correction Noise D The loosened joints. D Tighten the joints. D Wheel bearing is worn or damaged. D Faulty shock absorber. D Faulty shock absorber. D Faulty coil spring. D Lateral rod bushing is worn or damaged. D Trailing arm bushing is worn or damaged. Vehicle Leans Toward the Side D Rear axle deformation. D Lateral rod deformation. D Trailing arm deformation. D Faulty coil spring. D L
File name M32e Tires and Wheels.pdf

SECTION 2E TIRES AND WHEELS TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Tires . . . . . . . . . . . . . . . . . . . . . . . . All Season Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . Tire Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inflation of Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-2 2E-2 2E-3 2E-3 2E-3 2E-3 2E-4 2E-4 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Balancing . . . . . . . . . . . . . . . . . . . . . . 2E-7 2E-7 2E-7 2E-8 Off-Vehicle Balancing . . . . . . . . . . . . . . . . . . . . . . 2E-8 Correcting Non-Uniform Tires . . . . . . . . . . . . . . . 2E-8 Tire and Wheel Match-Mounting . . . . . . . . . . . . . 2E-9 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-10 Tire Size and Pressure Specifications . . . . . . . 2E-10 Inflation Pressure Conversion Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-10 Fastener Tightening Specifications . . . . . . . . . . 2E-10 Rotation Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-4 Wheel Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-4 Diagnostic Information and Procedures . . . . . 2E-5 Tire Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E-5 Irregular or Excessive Tires Wear . . . . . . . . . . . . 2E-6 DAEWOO M-150 BL2 2E 2 TIRES AND WHEELS DESCRIPTION AND OPERATION TIRE Tread A part (that contacts) road surfaces directly is fixed on the outside of carcass and breaker. It is a strong rubber coat made of high antiabrasion rubber. Its running performance depends on is surface profile. Nomenclature Breaker A cord belt between tread and carcass prevents damages of inner code due to outer shock and vibration. Carcass This major part made by pilling code papers of strong synthetic fiber forms a structure of tire. Since it maintains tire pressure and endures applied load and shock to tire, it should have a high antifatigue characteristic. Bead A steel wire winding the ending part of carcass code, coated with rubber film and wrapped with nylon cord papers. It fixes tire to a rim. Tube Tires used in mostly current vehicle are mostly tubeless tires. Side Wall It is provided to improve the comfortable driving by protecting carcass and cushion movement. 175 60 R Width (mm) D16A002A Structure of Tubeless Tube D16A001A Flatness ratio 60% (Height/Width) 10
File name M33b Manual Transaxle Drive Axle.pdf

SECTION 3B MANUAL TRANSAXLE DRIVE AXLE TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Front Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Drive Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 3B-2 3B-3 3B-3 3B-4 3B-4 3B-5 3B-5 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-9 Inner Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-9 Outer Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-10 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-12 General Specifications . . . . . . . . . . . . . . . . . . . . Fastener Tightening Specifications . . . . . . . . . . Special Tools and Equipment . . . . . . . . . . . . . . Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . 3B-12 3B-12 3B-13 3B-13 Drive Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . 3B-5 DAEWOO M-150 BL2 3B 2 MANUAL TRANSAXLE DRIVE AXLE DESCRIPTION AND OPERATION FRONT DRIVE AXLE Drive axles are flexible shaft assemblies that transmit a rotational force from the transaxle to the front wheel assemblies. Each axle assembly consists of an inner constant-velocity joint and an outer constant-velocity joint connected to an axle shaft. The inner joint is completely flexible and has the ability to move in and out. The outer joint is also flexible, but it cannot move in and out. The drive axles use a Rzeppastyle joint on the outboard side and a Tripotstyle joint on the inboard side. DAEWOO M-150 BL2 MANUAL TRANSAXLE DRIVE AXLE 3B 3 COMPONENT LOCATOR DRIVE AXLE ASSEMBLY D104B401 1. 2. 3. 4. 5. Outer Joint (Rzeppa) Outer Large Boot Clamp Outer Boot Outer Small Boot Clamp Drive Axle Shaft 6. 7. 8. 9. 10. Inner Small Boot Clamp Inner Boot Inner Large Boot Clamp Inner Joint (Tripot) Inner Joint Housing DAEWOO M-150 BL2
File name M34a Hydraulic Brakes.pdf

SECTION 4A HYDRAULIC BRAKES CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Warning Lamp Operation . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Brake System (Non-ABS) . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Brake System Testing . . . . . . . . . . . . . . . . . . . . . . Brake Hose Inspection . . . . . . . . . . . . . . . . . . . . . Warning Lamp Operation . . . . . . . . . . . . . . . . . . . 4A-2 4A-2 4A-3 4A-3 4A-4 4A-4 4A-4 4A-5 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Hose (Front) . . . . . . . . . . . . . . . . . . . . . . . . Brake Hose (Rear) . . . . . . . . . . . . . . . . . . . . . . . . 4A-8 4A-8 4A-8 4A-9 Stoplamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-9 Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-10 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-13 General Specifications . . . . . . . . . . . . . . . . . . . . 4A-13 Fastener Tightening Specifications . . . . . . . . . . 4A-13 Schematic and Routing Diagrams . . . . . . . . . . 4A-14 Brake Lamp Warning Circuit . . . . . . . . . . . . . . . 4A-14 Stoplamp Switch Circuit . . . . . . . . . . . . . . . . . . . 4A-14 Brake System Fault . . . . . . . . . . . . . . . . . . . . . . . . 4A-5 Manual Bleeding the Brakes . . . . . . . . . . . . . . . . 4A-6 Pedal Travel Check . . . . . . . . . . . . . . . . . . . . . . . . 4A-6 Brake Pedal Free Play Inspection . . . . . . . . . . . 4A-7 DAEWOO M-150 BL2 4A 2 HYDRAULIC BRAKES DESCRIPTION AND OPERATION WARNING LAMP OPERATION This brake system uses a BRAKE warning lamp located in the instrument panel cluster. When the ignition switch is in the III position, the BRAKE warning lamp should illuminate. It should go off when the ignition switch return to II position. The following conditions will activate the BRAKE warning lamp. D The lamp should be on whenever the parking brake applied and the ignition switch is in the II position. D A low fluid level in the master cylinder will turn the BRAKE warning lamp on. D17A007A DAEWOO M-150 BL2 HYDRAULIC BRAKES 4A 3 COMPONENT LOCATOR BRAKE SYSTEM (NONABS) (LeftHand Drive Shown, RightHand Drive Similar) MAB4A001 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Power Booster Power Booster Boot Cotter Pin Clevis Clevis Pin Packing Spacer Master Cylinder Assembly Fluid Reservoir Assembly Reservoir Cap Reservoir Grommet Seal Master Cylinder Proportio
File name M34b Master Cylinder.pdf

SECTION 4B MASTER CYLINDER TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . Proportioning Valve . . . . . . . . . . . . . . . . . . . . . . . . Fluid Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Checking the Brake Fluid Level . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 4B-2 4B-2 4B-2 4B-3 4B-3 4B-4 4B-4 Brake Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . Proportioning Valve (For Vehicle With the NonABS Braking System) . . . . . . . . . . . . . . . Brake Fluid Level Switch . . . . . . . . . . . . . . . . . . . Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-5 4B-5 4B-6 4B-8 Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-8 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-9 Fastener Tightening Specifications . . . . . . . . . . . 4B-9 Master Cylinder Assembly . . . . . . . . . . . . . . . . . . 4B-4 DAEWOO M-150 BL2 4B 2 MASTER CYLINDER DESCRIPTION AND OPERATION MASTER CYLINDER The master cylinder is designed for use in a directsplit system. Front right brake and rear left brake are served by the primary piston. Front left brake and rear right brake are served by the secondary piston. The master cylinder incorporates the functions of the standard dual master cylinder, plus a low fluid level indicator and the proportioning valve in the nonantilock braking system. The proportioning valves limit the outlet pressure to the rear brakes after a predetermined master cylinder has been reached. Important: D Replace all the components included in the repair kits used to service this master cylinder. D Lubricate rubber parts with clean brake fluid to ease assembly. D Do not use lubricated shop air on brake parts, as this may damage rubber components. D If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. D The torque values specified are for dry, unlubricated fasteners. D Perform all service operations on a clean bench, free from all traces of mineral oil. PROPORTIONING VALVE The proportioning valve limits the outlet pressure to the rear brakes on the non-ABS after a predetermined master cylinder pressure has been reached. This is used when less rear apply force is needed to obtain optimum braking and is usually found on disc/drum brake configurations. On ABS-equipped vehicles, refer to Section 4F, Antilock Brake System. FLUID LEVEL SENSOR Fluid level sensor is attached at the brake fluid reservoir. This sensor will activate the BRAKE light if a low fluid level condition is detected. Once the fluid level is corrected, the BRAKE light will go out. DAEWOO M-150 BL2 MASTER CYLINDER 4B 3 DIAGNO
File name M34c Power Booster.pdf

SECTION 4C POWER BOOSTER TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Power Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Power Booster Functional Check . . . . . . . . . . . . 4C-2 4C-2 4C-3 4C-3 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Hose and Check Valve . . . . . . . . . . . . . Power Booster Assembly . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-4 4C-4 4C-5 4C-8 Check Valve Functional Check . . . . . . . . . . . . . . 4C-3 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 4C-4 General Specifications . . . . . . . . . . . . . . . . . . . . . 4C-8 Fastener Tightening Specifications . . . . . . . . . . . 4C-8 DAEWOO M-150 BL2 4C 2 POWER BOOSTER DESCRIPTION AND OPERATION POWER BOOSTER This booster is a single diaphragm, vacuum-suspended unit. In a normal operating mode, with the service brakes in the release position, a vacuum-suspended booster operates with a vacuum on both sides of its diaphragm. When the brakes are applied, air at atmospheric pressure is admitted to one side of the diaphragm to provide the power assist. When the brakes are released, atmospheric air is shut off from that side of the diaphragm. The air is then drawn from the booster through the vacuum check valve by the vacuum source. Important: If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. DAEWOO M-150 BL2 POWER BOOSTER 4C 3 DIAGNOSTIC INFORMATION AND PROCEDURES POWER BOOSTER FUNCTIONAL CHECK 1. With the engine stopped, eliminate the vacuum in the booster by pumping the brake pedal several times. 2. Push the pedal down and hold it in this position. 3. Start the engine. 4. The booster is OK if the pedal drops further because of extra force produced. If the brake pedal does not drop, the vacuum system (vacuum hoses, check valve, etc.) is probably defective and should be checked. If no defect is revealed by checking the vacuum system, the defect is in the booster itself. only sucked, the check valve OK. CHECK VALVE FUNCTIONAL CHECK 1. Remove the vacuum hose. 2. Suck the vacuum hose to power booster. And also, suck the vacuum hose to engine. 3. If the air pass through the check valve or not, replace the check valve. And if the vacuum hose to engine is D17A301B DAEWOO M-150 BL2 4C 4 POWER BOOSTER REPAIR INSTRUCTIONS ONVEHICLE SERVICE VACUUM HOSE AND CHECK VALVE Removal Procedure 1. Remove the vacuum hose. D Disconnect the vacuum hose from the intake manifold (1). D107A501 D Disconnect the vacuum hose from the power booster (2). D17A502A Installation Procedure 1. Connect the vacuum hose to the power booster. 2. Connect the vacuum hose to the intake manifold. D107A503 DAEWOO M-150 BL2 POWER BOOSTER 4C 5 POWER BOOSTER ASSEMBLY (LEFTHAND DRIVE) Removal Procedure
File name M34d Front Disc Brakes.pdf

SECTION 4D FRONT DISC BRAKES TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Disc Brake Caliper Assembly . . . . . . . . . . . . . . . Clearance Calibration . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Front Disc Brakes . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Front Disc Brake . . . . . . . . . . . . . . . . . . . . . . . . . . Lining Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-2 4D-2 4D-2 4D-3 4D-3 4D-4 4D-4 4D-5 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Shoe and Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . Caliper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-6 4D-6 4D-7 4D-7 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-8 Caliper Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-8 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-11 General Specifications . . . . . . . . . . . . . . . . . . . . 4D-11 Fastener Tightening Specifications . . . . . . . . . . 4D-11 Rotor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-5 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . 4D-6 DAEWOO M-150 BL2 4D 2 FRONT DISC BRAKES DESCRIPTION AND OPERATION DISC BRAKE CALIPER ASSEMBLY This caliper has a single bore and is mounted to the steering knuckle with two mounting bolts. Hydraulic pressure, created by applying the brake pedal, is converted by the caliper to a stopping force. This force acts equally against the piston and the bottom of the caliper bore to move the piston outward and to slide the caliper inward, resulting in a clamping action on the rotor. This clamping action forces the linings against the rotor, creating friction to stop the vehicle. CLEARANCE CALIBRATION When the hydraulic pressure is applied to the piston, the piston moves leftward. The piston seal, which extent considerable pressure against the piston, moves with cylinder. However, as a part of the piston seal is fixed into a grove in the cylinder shape of the seal is as shown in below figure, distorted toward the piston moving direction. When the pressure is taken off from the brake pedal and the hydraulic pressure is released from the piston, a restoring elastic force is generated at the seal and pushes the piston rightward and back it in original position. As the pads wear away and the clearance between rotor and pads becomes larger, the piston moves larger. The seal then could change in shape further, but since end of the seal is fixed into the groove in the cylinder, the distortion is limited to the same amount as previously described. The piston moves further to cover the distance of clearance. As the piston returns by the same distance and the rubber seal
File name M34e Rear Drum Brakes.pdf

SECTION 4E REAR DRUM BRAKES TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Drum Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Rear Drum Brakes . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Rear Drum Brake . . . . . . . . . . . . . . . . . . . . . . . . . . Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E-2 4E-2 4E-3 4E-3 4E-4 4E-4 4E-5 4E-5 Rear Brake Drum . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Cylinder Assembly . . . . . . . . . . . . . . . . . . Backing Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . 4E-6 4E-7 4E-8 4E-9 4E-10 4E-10 4E-11 4E-11 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 4E-6 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 4E-6 Fastener Tightening Specifications . . . . . . . . . . 4E-11 DAEWOO M-150 BL2 4E 2 REAR DRUM BRAKES DESCRIPTION AND OPERATION DRUM BRAKES This drum brake assembly is a leading/trailing shoe design. Both brake shoes are held against the wheel cylinder pistons by the lower return spring and the fixed anchor plate near the lower return spring. When the brakes are applied, the wheel cylinder pistons move both shoes out to contact the drum. With forward wheel rotation, the forward brake shoe will wrap into the drum and become self-energized. With reverse wheel rotation, the rear brake shoe is self-energized. Force from the brake shoes is transferred to the anchor plate through the backing plate to the axle flange. Adjustment is automatic and occurs on any service brake application. Do not switch the position of shoes that have been in service, as this may render the self-adjustment feature inoperative and result in increased pedal travel. Notice: D Replace all the components included in the repair kits used to service this drum brake. D Do not use lubricated shop air on the brake parts, as damage to the rubber components may result. D If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the braking system. D The torque values specified are for dry, unlubricated fasteners. D Perform service operations on a clean bench that is free from all mineral oil materials. DAEWOO M-150 BL2 REAR DRUM BRAKES 4E 3 COMPONENT LOCATOR REAR DRUM BRAKES D107C401 1. 2. 3. 4. 5. 6. 7. 8. Bleeder Screw Bleeder Screw Rear Brake Assembly Rear Brake Plate Wheel Cylinder St
File name M34f1 ABS.pdf

SECTION 4F ANTILOCK BRAKE SYSTEM CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. CAUTION: Don't diagnosis the Antilock Brake System (ABS) under the vehicle moving status. Because the ABS function will be stopped. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . ABS System Components . . . . . . . . . . . . . . . . . . Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EBCM (Electronic Brake Control Module) . . . . . Wheel Speed Sensors and Rings . . . . . . . . . . . . Electronic Brake Distribution . . . . . . . . . . . . . . . . Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EBCM Connector . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-3 4F-3 4F-3 4F-4 4F-5 4F-5 4F-5 4F-6 DTC 0456 Left Rear Wheel Speed Sensor Circuit Intermittent Shorted . . . . . . . . . . . . . . 4F-38 DTC 0504 Right Rear Wheel Speed Sensor Circuit Open or Shorted . . . . . . . . . . . . . . . . . DTC 0505 Right Rear Wheel Speed Sensor Poor Air Gap or Missing Tooth Ring . . . . . . . DTC 0506 Right Rear Wheel Speed Sensor Circuit Intermittent Shorted . . . . . . . . . . . . . . DTC 0601 Left Front Dump Shorted or Driver Open . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC 0602 Left Front Dump Open or Driver Shorted . . . . . . . . . . . . . . . . . . . . . . . . . DTC 0651 Left Front Isolation Shorted or Driver Open . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC 0652 Left Front Isolation Open or Driver Shorted . . . . . . . . . . . . . . . . . . . . . . . . . DTC 0701 Right Front Dump Shorted or Driver Open . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC 0702 Right Front Dump Open or Driver Shorted . . . . . . . . . . . . . . . . . . . . . . . . . DTC 0751 Right Front Isolation Shorted or Driver Open . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-42 4F-46 4F-48 4F-52 4F-54 4F-56 4F-58 4F-60 4F-62 4F-64 Hydraulic Fluid Flow Diagrams . . . . . . . . . . . . . . 4F-7 Normal Braking Mode . . . . . . . . . . . . . . . . . . . . 4F-7 Isolation Mode (Pressure Maintain) . . . . . . . . 4F-8 Dump Mode (Pressure Decrease) . . . . . . . . . 4F-9 Reapply Mode (Pressure Increase) . . . . . . . 4F-10 Proportioning Function . . . . . . . . . . . . . . . . . . 4F-11 Visual Identification . . . . . . . . . . . . . . . . . . . . . . . 4F-12 EBCM Connector Face View . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . DTC 0354 Left Front Wheel Speed Sensor Circuit Open or Shorted . . . . . . . . . . . . . . . . . DTC 0355 Left
File name M34g Parking Brake.pdf

SECTION 4G PARKING BRAKE TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-2 4G-2 4G-3 4G-3 Parking Brake Warning Lamp Switch . . . . . . . . . Parking Brake Cable . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . . 4G-5 4G-6 4G-8 4G-8 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 4G-4 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 4G-4 Parking Brake Lever . . . . . . . . . . . . . . . . . . . . . . . 4G-4 Fastener Tightening Specifications . . . . . . . . . . . 4G-8 Schematic and Routing Diagrams . . . . . . . . . . . 4G-9 Parking Brake System . . . . . . . . . . . . . . . . . . . . . 4G-9 DAEWOO M-150 BL2 4G 2 PARKING BRAKE DESCRIPTION AND OPERATION PARKING BRAKE This braking system uses a BRAKE warning light located in the instrument panel cluster. When the ignition switch is in the III position, the BRAKE warning light should glow and go OFF when the parking brake lever is released. Whenever the parking brake is applied and the ignition switch is II, the BRAKE warning light should glow. When the brake is firmly applied, the parking brake should securely hold the vehicle with ample pedal travel remaining. Check for frayed cables, rust, etc., or any condition that may inhibit present (or future) free movement of the parking brake lever assembly. DAEWOO M-150 BL2 PARKING BRAKE 4G 3 COMPONENT LOCATOR PARKING BRAKE D107D401 1. 2. 3. 4. 5. Parking Brake Cable Clip Parking Brake Cable Strengthener Cable Grommet Parking Brake Lever Assembly 6. 7. 8. 9. Parking Brake Warning Lamp Switch Cotter Pin Cable Pulley Pin DAEWOO M-150 BL2 4G 4 PARKING BRAKE REPAIR INSTRUCTIONS ON-VEHICLE SERVICE PARKING BRAKE LEVER Removal Procedure 1. Remove the parking brake lever cover. Refer to Section 9G, Interior Trim. 2. Remove the parking brake cable cover. Refer to Section 9G, Interior Trim. 3. Remove the parking brake lever. D Disconnect the brake warning lamp switch (1). D Remove the brake warning switch lamp screw (2). Important: The brake warning lamp switch screw should be removed with the lever fixed. D Remove the bolts (3). D Remove the nut (4). D107D501 D107D502 D Remove the cotter pin (5). D Remove the pin (6). D107D503 DAEWOO M-150 BL2 PARKING BRAKE 4G 5 Installation Procedure 1. Install the parking brake lever with the cotter pin, pin, bolts, and nut. Tighten D Tighten the parking brake nut to 10 NSm (89 lb-in) (1). D Tighten the parking brake bolts to 10 NSm (89 lb-in) (2). Connect the brake warning lamp switch. Install the brake warning lamp switch screw. Install the parking brake cable cover. Refer to Secti
File name M35b Five Speed Manual Transaxle.pdf

SECTION 5B FIVE-SPEED MANUAL TRANSAXLE CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Five-Speed Manual Transaxle . . . . . . . . . . . . . . . Reverse Gear Misshift Preventing Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Locators . . . . . . . . . . . . . . . . . . . . . . . Gear Shift Control . . . . . . . . . . . . . . . . . . . . . . . . . Input Shaft and Counter Shaft Gear . . . . . . . . . . Gear Shift Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential and Case . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedure . . . . . . . General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . Checking Fluid Level . . . . . . . . . . . . . . . . . . . . . . . 5B-2 5B-2 5B-2 5B-2 5B-3 5B-3 5B-4 5B-6 5B-7 5B-8 5B-8 5B-9 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . Manual Transaxle Assembly . . . . . . . . . . . . . . . Gear Shift Control Case Assembly . . . . . . . . . . Speedometer Driven Gear and Cable . . . . . . . Gear Shift Control Cable . . . . . . . . . . . . . . . . . . Gear Shift Control Lever . . . . . . . . . . . . . . . . . . . Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-10 5B-10 5B-17 5B-19 5B-21 5B-23 5B-24 5B-24 Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-36 Counter Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-41 Gear Shift Fork . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-46 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . Fastener Tightening Specifications . . . . . . . . . . 5B-48 5B-52 5B-52 5B-53 Changing Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-9 Checking Transaxle Noise . . . . . . . . . . . . . . . . . . 5B-9 Checking Bearing Noise . . . . . . . . . . . . . . . . . . . . 5B-9 Repair Instruction . . . . . . . . . . . . . . . . . . . . . . . . . 5B-10 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-54 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . 5B-54 DAEWOO M-150 BL2 5B 2 FIVE-SPEED MANUAL TRANSAXLE DESCRIPTION AND OPERATION FIVE-SPEED MANUAL TRANSAXLE This five-speed transaxle assembly adopts the synchronized mesh type of 5 forward speed. The reverse speed gear is driven by slidin
File name M35c Clutch.pdf

SECTION 5C CLUTCH CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Driving Members . . . . . . . . . . . . . . . . . . . . . . . . . . Driven Members . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Members . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Clutch Components . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 5C-2 5C-2 5C-2 5C-2 5C-3 5C-3 5C-4 5C-4 Pressure Plate, Clutch Disc and Input Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . 5C-6 Clutch Release Bearing, Shaft and Bushing . . . 5C-8 Clutch Release Arm . . . . . . . . . . . . . . . . . . . . . . 5C-10 Clutch Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-11 Clutch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . Fastener Tightening Specifications . . . . . . . . . . 5C-12 5C-13 5C-13 5C-13 Clutch Pedal Operation . . . . . . . . . . . . . . . . . . . . 5C-5 Clutch Cable Adjustment . . . . . . . . . . . . . . . . . . . 5C-5 Repair Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-6 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-14 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . 5C-14 DAEWOO M-150 BL2 5C 2 CLUTCH DESCRIPTION AND OPERATION DRIVING MEMBERS The driving members consist of two flat surfaces machined to a smooth finish. One of these is the rear face of the engine flywheel, and the other is the pressure plate. The pressure plate is fitted into a steel cover, which is bolted to the flywheel. The driving and driven members are held in contact by spring pressure. This pressure is exerted by a diaphragm spring in the pressure plate assembly. OPERATING MEMBERS The clutch release system consists of the clutch pedal, the clutch release shaft, the clutch cable, the release arm and the release bearing. When pressure is applied to the clutch pedal, the clutch release shaft pushes against the release bearing by rotating. The bearing then pushes against the diaphragm spring in the pressure plate assembly, thereby releasing the clutch. DRIVEN MEMBERS The driven member is the clutch disc with a splined hub which is free to slide lengthwise along the splines of the input shaft, but which drives the input shaft through
File name M36b Power Steering Pump.pdf

SECTION 6B POWER STEERING PUMP TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . 6B-2 6B-2 6B-3 6B-3 6B-4 6B-4 6B-4 6B-5 Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . . Fastener Tightening Specifications . . . . . . . . . . . Special Tools and Equipment . . . . . . . . . . . . . . . Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 6B-5 6B-7 6B-7 6B-8 6B-8 6B-8 6B-9 6B-9 DAEWOO M-150 BL2 6B 2 POWER STEERING PUMP DESCRIPTION AND OPERATION POWER STEERING PUMP The pump has a remote fluid reservoir. A pressure-relief valve inside the flow control valve limits pump pressure. DAEWOO M-150 BL2 POWER STEERING PUMP 6B 3 DIAGNOSTIC INFORMATION AND PROCEDURES POWER STEERING PUMP Condition Foaming, Milky Power Steering Fluid, Low Fluid Level, and Possible Low Pressure Probable Cause D Insufficient power steering fluid level. D Contaminated air in the power steering fluid. D Internal leaks and overflow of the power steering pump. D Leaks of the power steering pump housing and the soft plug. Low Pressure Due to Steering Pump D Stuck and improperly operated power steering pump flow control valve. D Worn power steering pump seats. D Scores, cracks, or breaks of the pressure plate, the pump ring, the thrust plate, and the rotor. D Sticking of the vanes in the rotor slots. D Internal leaks and overflow of the power steering pump. Growling Noise in Steering Pump D Restricted flow of the pump hoses and the steering gear pipes. D Scores, cracks, or breaks of the pressure plate, the pump ring, the thrust plate, and the rotor. D Improperly contacted power steering hose with the body. D Insufficient power steering fluid level. Ratting Noise in the Steering Pump D Contaminated air in the power steering fluid. D Improperly contacted power steering hose with the body. D Insufficient power steering fluid level. D Improperly installed pump mounting. Swishing Noise in the Steering Pump Whining Noise in the Steering Pump D Damaged power steering pump flow control valve. D Scores of the pressure plate and the vanes. D Scores of the pump shaft bearing Correction D Fill the power steering fluid reservoir. D Bleed the power steering system. D Replace the power steering
File name M36c Power Steering Gear.pdf

SECTION 6C POWER STEERING GEAR CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Power Rack and Pinion . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Power Rack and Pinion Steering Gear . . . . . . . Adjust the Free Load of the Steering Gear . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Rack and Pinion Assembly . . . . . . . . . . . . . . . . . 6C-2 6C-2 6C-3 6C-3 6C-5 6C-6 6C-6 6C-6 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tie Rod End Boot . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Cylinder Lines . . . . . . . . . . . . . . . . . . . . Rack and Pinion Steering Gear . . . . . . . . . . . . . . 6C-8 6C-8 6C-8 6C-9 Assembly Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-13 General Specifications . . . . . . . . . . . . . . . . . . . . 6C-13 Fastener Tightening Specifications . . . . . . . . . . 6C-13 Power Steering Gear Rack and Pinion Boot . . . 6C-7 DAEWOO M-150 BL2 6C 2 POWER STEERING GEAR DESCRIPTION AND OPERATION POWER RACK AND PINION The power rack and pinion steering system has a rotary control valve which directs the hydraulic fluid coming from the hydraulic pump to one side or the other side of the rack piston. The integral rack piston is attached to the rack. The rack piston converts hydraulic pressure to a linear force which moves the rack left or right. The force is then transmitted through the tie rods and the tie rod ends to the steering knuckles, which turn the wheels. If hydraulic assist is not available, manual control is maintained. However, under these conditions, more steering effort is required. The movement of the steering wheel is transferred to the pinion. The movement of the pinion is then transferred through the pinion teeth, which meshs with the teeth on the rack, causing the rack to move. DAEWOO M-150 BL2 POWER STEERING GEAR 6C 3 DIAGNOSTIC INFORMATION AND PROCEDURES POWER RACK AND PINION STERING GEAR Condition Hissing Noise Probable Cause D Loose steering coupling joints. D Improperly contacted the power steering hose with other components. Rattling Noise in Steering Gear D Improperly contacted the power steering line with the body. D Insufficient lubricant. D Loose steering gear mounting. D Improperly installed tie rod ends. Poor Return of Steering Wheel to Center D Improperly contacted the steering wheel with the turn signal housing. D Improper binding or looseness of steering coupling. D Stuck and improperly aligned power steering
File name M36d Manual Sterring Gear.pdf

SECTION 6D MANUAL 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 B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Manual Rack and Pinion . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Manual Rack and Pinion Steering Gear . . . . . . . Diagnostic Information and Procedures . . . . . Manual Rack and Pinion Steering Gear . . . . . . . Straight-Ahead Check . . . . . . . . . . . . . . . . . . . . . . Steering Wheel Restoration . . . . . . . . . . . . . . . . . 6D-2 6D-2 6D-3 6D-3 6D-4 6D-4 6D-5 6D-6 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Tie Rod End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rack and Pinion Boot . . . . . . . . . . . . . . . . . . . . . . Rack and Pinion Steering Gear Assembly . . . . Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tie Rod End Boot . . . . . . . . . . . . . . . . . . . . . . . . Rack and Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D-7 6D-7 6D-8 6D-9 6D-11 6D-11 6D-11 6D-17 Check The Turning Resistance of the Tie Rod End or Tie Rod . . . . . . . . . . . . . . . . . . . . 6D-6 Adjust the Free Load of the Steering Gear . . . . 6D-6 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 6D-7 General Specifications . . . . . . . . . . . . . . . . . . . . 6D-17 Fastener Tightening Specifications . . . . . . . . . . 6D-17 Special Tools and Equipment . . . . . . . . . . . . . . 6D-18 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . 6D-18 DAEWOO M-150 BL2 6D 2 MANUAL STEERING GEAR DESCRIPTION AND OPERATION MANUAL RACK AND PINION The manual rack and pinion steering system consists of two main components: the rack and the pinion. The motion of the pinion is transferred through the pinion teeth that mesh with the teeth on the rack, which moves the rack. The force is then transmitted through the arms on the struts, which turn the wheels. DAEWOO M-150 BL2 MANUAL STEERING GEAR 6D 3 COMPONENT LOCATOR MANUAL RACK AND PINION STEERING GEAR (LeftHand Drive Shown, RightHand Drive Similar) D105B401 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Manual Steering Gear Steering Gear Bracket Cotter Pin Castellated Nut Tie Rod End Tie Rod End Lock Nut Rack and Pinion Boot Clamp Rack and Pinion Boot Rack and Pinion Boot Wire Clamp Tie Rod Shock Damper Ring Steering Rack Gear 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Bulkhead Retainer Bulkhead Bushing Steering Gear Housing Steering Gear Bracket Bushing Packing Dust Cover Pinion Plug Steering Pinion Gear Ro
File name M36e Steering Wheel and Column.pdf

SECTION 6E STEERING WHEEL AND COLUMN CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Steering Wheel and Column . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Steering Wheel and Column . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Steering Column Diagnosis . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Column Cover . . . . . . . . . . . . . . . . . . . . Turn Signal Switch and Lever/ Wiper Switch and Lever . . . . . . . . . . . . . . . . . . Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-2 6E-2 6E-3 6E-3 6E-4 6E-4 6E-7 6E-7 6E-7 6E-8 6E-8 6E-9 Ignition Lock Cylinder and Switch with Immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . 6E-9 Switch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . Intermediate Shaft cover and Intermediate Shaft . . . . . . . . . . . . . . . . . . . . . . Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Steering Column . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . Fastener Tightening Specifications . . . . . . . . . . 6E-10 6E-11 6E-12 6E-13 6E-13 6E-15 6E-15 6E-15 Special Tools and Equipment . . . . . . . . . . . . . . 6E-16 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . 6E-16 DAEWOO M-150 BL2 6E 2 STEERING WHEEL AND COLUMN DESCRIPTION AND OPERATION STEERING WHEEL AND COLUMN In addition to the steering function, the steering column provides safety and security. Caution: To ensure energy-absorbing action, it is important to use only the specified screws, bolts, and nuts, tightened to the specified torque. The energy-absorbing column is designed to compress in a front-end collision to lessen the chance of driver injury. The ignition switch and the lock are mounted on the column, allowing the ignition and steering operations to be locked to inhibit theft of the car. The column levers trigger the turn signals, the headlight beams, and the windshield washer and wipers. Notice: Apply a thin coat of lithium grease to all friction points when reassembling to ensure proper operation. The column may be easily disassembled and assembled. D Safety Device A. Steering Column Upper Bracket. B. Steer
File name M37a1 Heating and Ventilation System 1-17.pdf

SECTION 7A HEATING AND VENTILATION SYSTEM CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . 7A-2 Heating and Ventilation Systems . . . . . . . . . . . . 7A-2 Component Locator . . . . . . . . . . . . . . . . . . . . . . . . 7A-3 Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 7A-3 Blower Module Assembly . . . . . . . . . . . . . . . . . . . 7A-4 Air Distributor and Heater Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-5 Diagnostic Informatin and Procedures . . . . . . . 7A-6 Heater System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-6 Insufficient Heating or Defrosting . . . . . . . . . . . . 7A-6 Blower Electrical . . . . . . . . . . . . . . . . . . . . . . . . . 7A-10 Improper Air Delivery or No Mode Shift . . . . . . 7A-11 Too Much Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-13 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-15 Blower Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-16 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . 7A-18 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . 7A-18 Control Assembly and Control Cables . . . . . . . 7A-18 Blower Motor and Cooling Hose . . . . . . . . . . . . Blower Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Motor Switch . . . . . . . . . . . . . . . . . . . . . . Heater Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Module . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Module . . . . . . . . . . . . . . . . . . . . . . . . . . . Defroster Duct and Hoses . . . . . . . . . . . . . . . . . Ventilation Duct . . . . . . . . . . . . . . . . . . . . . . . . . . Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . Fastener Tightening Specifications . . . . . . . . . . Special Tools and Equipment . . . . . . . . . . . . . . Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . Schematic and Routing Diagrams . . . . . . . . . . Non-A/C Diagrams . . . . . . . . . . . . . . . . . . . . . . . Air Flow Through Ducts (NonA/C) . . . . . . . . . 7A-20 7A-20 7A-21 7A-22 7A-24 7A-25 7A-26 7A-27 7A-28 7A-28 7A-29 7A-29 7A-29 7A-30 7A-30 7A-31 7A-31 7A-32 DAEWOO M-150 BL2 7A 2 HEATING AND VENTILATION SYSTEM DESCRIPTION AND SYSTEM OPERATION HEATING AND VENTILATION SYSTEMS The base heater system is
File name M37a2 Heating and Ventilation System 18-32.pdf

7A 18 HEATING AND VENTILATION SYSTEM REPAIR INSTRUCTIONS ON-VEHICLE SERVICE CONTROL ASSEMBLY AND CONTROL CABLES (LeftHand Drive Shown, RightHand Drive Similar) Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the instrument cluster housing trim panel. Refer to Section 9E, Instrumentation/Driver information. 3. Remove the control assembly. D108A501 D Remove the control assembly retaining screws (1). D Separate the control assembly from the instrument panel (2). D Disconnect the electrical connectors (3). D Disconnect the mode control cable from the heater module (4). D Disconnect the temperature control cable from the heater module (5). D Remove the glove box from the instrument panel. Refer to Section 9E, Instrumentation/Driver Information. D108A502 D Disconnect the recirculating/fresh air door cable from the blower module (6). D108A503 DAEWOO M-150 BL2 HEATING AND VENTILATION SYSTEM 7A 19 D108A504 4. Disconnect the control cables from the control assembly. D Disconnect the temperature control cable (1). D Disconnect the mode control cable (2). D Disconnect the recirculating/fresh air door cable (3). D108A505 Installation Procedure 1. Connect the control cables to the control assembly. 2. Connect the recirculating/fresh air door cable to the blower module. 3. Install the glove box to the instrument panel. Refer to Section 9E, Instrumentation/Driver Information. 4. Connect the temperature control cable and the mode control cable to the heater module. 5. Connect the electrical connectors. 6. Install the control assembly with the screws. 7. Install the instrument cluster housing trim panel. Refer to Section 9E, Instrumentation/Driver Information. 8. Connect the negative battery cable. D108A506 DAEWOO M-150 BL2 7A 20 HEATING AND VENTILATION SYSTEM BLOWER MOTOR AND COOLING HOSE (LeftHand Drive Shown, RightHand Drive Similar) Removal Procedure 1. Remove the blower motor cooling hose. D108A507 2. Remove the blower motor. D Disconnect the motor electrical connector (1). D Turn the blower motor (2). D108A508 Installation Procedure 1. Install the blower motor by turning the motor clockwise. 2. Connect the motor electrical connector. 3. Install the blower motor cooling hose. D108A509 BLOWER RESISTOR (LeftHand Drive Shown, RightHand Drive Similar) Removal Procedure 1. Remove the blower resistor. D Disconnect the blower resistor connector (1). D Remove the screws (2). D108A510 DAEWOO M-150 BL2 HEATING AND VENTILATION SYSTEM 7A 21 Installation Procedure 1. Install the blower resistor with the retaining screws. 2. Connect the blower resistor connector. D108A511 BLOWER MOTOR SWITCH (LeftHand Drive Shown, RightHand Drive Similar) Removal Procedure 1. Remove the control assembly. Refer to "Control Assembly and Control Cables" in this section. 2. Remove the blower motor switch. D Remove the switch knob (1). D108A512 D Remove the blower motor switch retaining screw (2). D Turn the blower motor switch a
File name M37b2 Heating, Ventilation and AC 21-33.pdf

MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B -- 21 Installation Procedure 1. Install the compressor with the mounting bolts. Tighten D Tighten the compressor--to--bracket upper bolt to 20 NSm (15 lb-ft) (1). D Tighten the compressor--to--bracket lower bolts to 22 NSm (16 lb-ft) (2). 2. Connect the electrical connector. D18B511B 3. Install the A/C high pressure pipe line to the compressor with the bolt. Tighten Tighten the A/C high pressure pipe line bolt to 23 NSm (17 lb-ft) (3). 4. Install the A/C low pressure pipe line to the compressor with the bolt. Tighten Tighten the A/C low pressure pipe line bolt to 23 NSm (17 lb-ft) (4). 5. Evacuate and charge the system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedure for A/C System" in this section. 6. Install the A/C belt. Refer to Section 6B, Power Steering Pump. 7. Install the receiver dryer. Refer to "Receiver Dryer and Dual Cut Switch" in this section. D18B512A CONDENSER 1. Disconnect the negative battery cable. 2. Remove the front bumper fascia. Refer to Section 9O, Bumpers and Fascias. 3. Discharge and recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C system" in this section. 4. Remove the condenser. D Loosen the condenser pipe--to--compressor pipe fitting (1). D Loosen the condenser pipe--to--receiver dryer pipe fitting (2). D18B513A DAEWOO M-150 BL2 7B -- 22 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM D Remove the condenser mounting nuts (3). D Push the top of the condenser (4). D Take off the condenser from the lower bracket by lifting the condenser (5). D Remove the condenser (6). D18B514A Installation Procedure Important: Discard the removed O--rings. 1. Install the condenser with the nuts. Tighten Tighten the condenser mounting nuts to 4 NSm (36 lbin). D18B515B 2. Tighten the fittings and the bolt. Tighten D Tighten the condenser pipe--to--compressor pipe fitting to 23 NSm (17 lb-ft) (1). D Tighten the condenser pipe--to--receiver dryer pipe fitting to 14 NSm (10.5 lb-ft) (2). 3. Evacuate and recharge the system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section. 4. Install the front bumper fascia. Refer to Section 9O, Bumpers and Fascias. 5. Connect the negative battery cable. D18B516B A/C HIGH PRESSURE PIPE LINE (Left-Hand Drive Shown, Right-Hand Drive Similar) Removal Procedure D108B517 1. Disconnect the negative battery cable. 2. Remove the front bumper fascia. Refer to Section 9O, Bumpers and Fascias. 3. Discharge and recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section. 4. Remove the A/C high pressure pipe line between the compressor and the condenser. D Remove the bolt securing the high pressure pipe line to the compressor (1). DAEWOO M-150 BL2 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B -- 23 D
File name M38a Seat Belts.pdf

SECTION 8A SEAT BELTS CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Driver Seat Belt Warning . . . . . . . . . . . . . . . . . . . Three-Point Pretensioner Front Seat Belt (W/EUROPE Only) . . . . . . . . . . . . . . . . . . . . . . Three-Point WLR Front Seat Belt . . . . . . . . . . . . Three-Point ELR Front Seat Belt . . . . . . . . . . . . Three-Point ELR Rear Outboard Seat Belt . . . . Two-Point Lap Rear Center Seat Belt . . . . . . . . Operational and Functional Checks . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Front and Rear Seat Belt . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Seat Belt Warning Lamp is Inoperative . . . . . . . 8A-2 8A-2 8A-2 8A-2 8A-2 8A-2 8A-2 8A-2 8A-3 8A-3 8A-4 8A-4 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Three-Point WLR/ELR Front Seat Belt . . . . . . . Three-Point Pretensioner Front Seat Belt (W/EUROPE Only) . . . . . . . . . . . . . . . . . . . . . . 8A-5 8A-5 8A-5 8A-6 Front Seat Belt Buckle . . . . . . . . . . . . . . . . . . . . . 8A-8 ThreePoint ELR Rear Outboard Seat Belt . . . 8A-8 Two-Point Lap Rear Center Seat Belt . . . . . . . 8A-10 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-11 Fastener Tightening Specifications . . . . . . . . . . 8A-11 Schematic and Routing Diagrams . . . . . . . . . . 8A-12 Driver Seat Belt Warning . . . . . . . . . . . . . . . . . . 8A-12 DAEWOO M-150 BL2 8A 2 SEAT BELTS DESCRIPTION AND OPERATION DRIVER SEAT BELT WARNING The driver's safety belt incorporates a safety belt reminder light in the instrument cluster to remind the driver if the safety belt is not fastened when the ignition is turned ON. is always unlocked, allowing the passenger freedom of movement, except in emergencies (rapid deceleration, rapid acceleration, or hard cornering maneuvers). TWO-POINT LAP REAR CENTER SEAT BELT The two-point lap rear center seat belt is a single continuous length of webbing. The webbing is routed from the anchor through a latch plate and into a single retractor. THREE-POINT PRETENSIONER FRONT SEAT BELT (W/EUROPE ONLY) The pretensioner front seat belt is optional. It contains a electrically-controlled pyrotechnical retractor, which reduces seat belt slack when it is activated in a head-on or angled front collision. The pretensioner front seat belt must be replaced after an accident that causes its activation. OPERATIONAL AND FUNCTIONAL CHECKS Caution: D Keep sharp objects and potentially damaging objects away fro
File name M38b1 Airbags 1-6.pdf

SECTION 8B SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Airbag Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensing and Diagnostic Module (SDM) . . . . . . . SIR Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . Clock Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness/Connectors . . . . . . . . . . . . . . . . . SIR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Precautions . . . . . . . . . . . . . . . . . . . . . . . 8B-3 8B-3 8B-3 8B-3 8B-4 8B-4 8B-4 8B-5 DTC 10 Driver Pretensioner Circuit, Resistance Too Low . . . . . . . . . . . . . . . . . . . . 8B-32 DTC 11 Driver Pretensioner Circuit, Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . 8B-34 DTC 12 Driver Pretensioner Circuit, Short to Battery Voltage . . . . . . . . . . . . . . . . . 8B-36 DTC 13 Passenger Pretensioner Circuit, Resistance Too High . . . . . . . . . . . . . . . . . . . . 8B-38 DTC 14 Passenger Pretensioner Circuit, Resistance Too Low . . . . . . . . . . . . . . . . . . . . 8B-40 DTC 15 Passenger Pretensioner Circuit, Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . 8B-42 DTC 16 Passenger Pretensioner Circuit, Short to Battery Voltage . . . . . . . . . . . . . . . . . 8B-44 DTC 18 Connection Between Driver Firing Circuit and Driver Pretensioner Circuit . . . . . 8B-46 DTC 19 Connection Between Driver Firing Circuit and Passenger Pretensioner Circuit 8B-48 DTC 20 Connection Between Passenger Firing Circuit and Driver Pretensioner Circuit . . . . . 8B-50 DTC 21 Connection Between Passenger Firing Circuit and Passenger Pretensioner Circuit 8B-52 DTC 22 Connection Between Driver Pretensioner Circuit and Passenger Pretensioner Circuit 8B-54 DTC 23 Ignition Input Circuit, Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-56 DTC 24 Ignition Input Circuit, Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-58 DTC 25 Warning Lamp Failure . . . . . . . . . . . . . 8B-60 DTC 31 SDM Internal Fault . . . . . . . . . . . . . . . . 8B-63 DTC 32 SDM Crash Recorded . . . . . . . . . . . . . 8B-63 Diagnostic Illustration 1 Diagnostic Illustration 2 Diagnostic Illustration 3 Diagnostic Illustration 4 ... ... ... ... 8B-63 8B-64 8B-64 8B-64 Airbag Deployment Condition . . . . . . . . . . . . . . . 8B-5 Airbag Deployment Procedure . . . . . . . . . . . . . . 8B-6 Component Locator . . . . . . . . . . . . . . . . . . . . . . . . 8B-7 SIR Component . . . . . .
File name M38b2 Airbags 7-79.pdf

SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B 7 COMPONENT LOCATOR SIR COMPONENT (LeftHand Drive Shown, RightHand Drive Similar) D110B401 1. Driver Airbag Module 2. Passenger Airbag Module 3. Clock Spring 4. Sensing and Diagnostic Module (SDM) 5. Wiring Harness DAEWOO M-150 BL2 8B 8 SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) DIAGNOSTIC INFORMATION AND PROCEDURES A scan tool connected to the data link connector (DLC): D Reveals the fault codes. D Receives serial data transmission through the terminal J (13) of the DLC. D Receives ground through the terminal A (4) of the DLC. CLEARING FAULT CODES When the sensing and diagnostic module (SDM) receives the CODE ERASE command from the scan tool, the SDM: D Clears the entire fault memory. D Turns OFF the warning lamp. D Resets for fault detection. D110B009A External Fault Service personnel can reset the SDM and turn OFF the warning lamp if the fault is an external fault. Internal Fault An internal fault of the SDM or a CRASH RECORDED fault code cannot be reset. In the case of an internal fault of the SDM or a CRASH RECORDED fault code, the SDM must be replaced. Voltage-Low Fault The SDM will turn OFF the VOLTAGE LOW fault as soon as the voltage recovers. BULB CHECK As soon as the operating voltage is applied to the sensing and diagnostic module (SDM) ignition input, the SDM activates the warning lamp for a bulb check. The SDM turns the lamp ON for 4 seconds, and then the SDM turns the lamp OFF. During the bulb check, the SDM is not ready to detect a crash or deploy the supplemental inflatable restraints. FAULT INDICATION The sensing and diagnostic module records the system's faults in two categories: D Current faults and the fault code appears "Axx" on the scan tool display. D Historic faults, which are those that were detected in the past, but are no longer active. And the fault code appears "Sxx" on the scan tool display. The warning lamp: D Indicates a fault as soon as it occurs. D Stays ON, even if a fault is no longer active. MICROPROCESSOR INDEPENDENT LAMP ACTIVATION If the sensing and diagnostic module (SDM) electrical connector is not properly attached, the SDM cannot function and cannot control the warning lamp. If this fault is present, the warning lamp will operate independently from the SDM through the use of shorting bars that are built into the SDM connector. DAEWOO M-150 BL2 SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B 9 BLANK DAEWOO M-150 BL2 8B 10 SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) SYSTEM CHECK D1AB301B Caution: Use only the scan tool to check the airbag modules and the sensing and diagnostic module (SDM). Never measure the resistance of an airbag module with an ohmmeter. An ohmmeter's battery can deploy the airbag and cause injury. Caution: Before testing, disconnect the negative battery cable. Wait 1 minute for the SDM capacitor to discharge. The capacitor supplies reserve power to deploy the airbags, even if the battery is disconnected. Unintentional d
File name M39a Body Wiring System.pdf

SECTION 9A BODY WIRING SYSTEM CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . How to Read Electrical Wiring Diagram . . . . . . . How to Check Terminal Number of Connector . Special Tools and Equipment . . . . . . . . . . . . . . . Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . Schematic and Routing Diagrams . . . . . . . . . . . Wire Color Chart . . . . . . . . . . . . . . . . . . . . . . . . . . Power Distribution Schematic . . . . . . . . . . . . . . . 9A-2 9A-2 9A-4 9A-5 9A-5 9A-6 9A-6 9A-7 Fuse Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Harness Routing . . . . . . . . . . . . . . . . . . . . Engine Harness Routing . . . . . . . . . . . . . . . . . . . Instrument Harness Routing . . . . . . . . . . . . . . . Airbag Harness Routing . . . . . . . . . . . . . . . . . . . Body Harness Routing . . . . . . . . . . . . . . . . . . . . Front Door Harness Routing . . . . . . . . . . . . . . . Rear Door Harness Routing . . . . . . . . . . . . . . . . 9A-10 9A-11 9A-12 9A-14 9A-16 9A-17 9A-19 9A-20 Relay & Fuse Box Locator (Engine Room) . . . . 9A-8 Fuse Box Locator (Passenger Compartment) . . . . . . . . . . . . . . . . 9A-9 Tailgate Harness Routing . . . . . . . . . . . . . . . . . . 9A-21 DAEWOO M-150 BL2 9A 2 BODY WIRING SYSTEM DESCRIPTION AND OPERATION HOW TO READ ELECTRICAL WIRING DIAGRAM D111001A DAEWOO M-150 BL2 BODY WIRING SYSTEM 9A 3 Contents of Electrical Wiring Diagram Position A Explanation The box above the fuse box: Power supply lines Power supply lines: 30, 15, 15A, Ka, 58, 50 Refer to "Circuit Identification Symbol" in this section for more details. Ef10 or F3: Fuse Number S Ef10: Fuse No 10 in the engine room fuse box S F3: Fuse No 3 in the passenger room fuse box 40A: Fuse Capacity Refer to "Relay Box Locator" and "Fuse Box Locator" in this section. Connector Connector No C202, terminal No 10 Refer to "How to Check Terminal Number of Connect" in this section Internal circuit of component (Relay) (Component Name, Terminal Number) Internal circuit of component (Switch) (Terminal Number) Wiring Harness Color Refer to "Wire Color Chart" in this section Ground line. G402: Ground Position In case of the ground numberless, this means the body ground. B C D E F G Circuit Identification Symbol Identification Symbol C Ef F G Connector Fuse in engine room fuse box Fuse in passenger compartment fuse box Ground Meaning DAEWOO M-150 BL2 9A 4 BODY WIRING SYSTEM HOW TO CHECK TERMINAL NUMBER OF CONNECTOR Terminal number is given based on female terminal connector. Example: Terminal number 4
File name M39b Lighting Systems.pdf

SECTION 9B LIGHTING SYSTEMS CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Headlamps and Parking Lamps . . . . . . . . . . . . . Front Turn Signal Lamps . . . . . . . . . . . . . . . . . . . Rear Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . Taillamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . License Plate Lamp . . . . . . . . . . . . . . . . . . . . . . . . Interior Courtesy Lamp . . . . . . . . . . . . . . . . . . . . . Backup Lamp(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . Daytime Running Lamps (DRL) (W/Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turn Signal Lamps and Hazard Lamps . . . . . . . Stoplamps and Interior Courtesy Lamp . . . . . . . Rear Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B-2 9B-2 9B-2 9B-2 9B-2 9B-2 9B-2 9B-2 9B-2 9B-3 9B-3 9B-4 9B-5 9B-6 9B-7 9B-7 CHMSL Mounting Bracket . . . . . . . . . . . . . . . . . License Plate Lamps . . . . . . . . . . . . . . . . . . . . . . Door Jamb Switch . . . . . . . . . . . . . . . . . . . . . . . . Interior Courtesy Lamp . . . . . . . . . . . . . . . . . . . . Daytime Running Lamp Module (W/Europe Only) . . . . . . . . . . . . . . . . . . . . . . . Ashtray Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . Luggage Room Lamp . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bulb Usage Chart . . . . . . . . . . . . . . . . . . . . . . . . Schematic and Routing Diagrams . . . . . . . . . . Backup Lamp(s) Circuit . . . . . . . . . . . . . . . . . . . Headlamps Circuit . . . . . . . . . . . . . . . . . . . . . . . . Headlamp Leveling Circuit . . . . . . . . . . . . . . . . . Tail and Licence Plate Lamps Circuit . . . . . . . . Stoplamps Circuit . . . . . . . . . . . . . . . . . . . . . . . . Turn and Hazard Lamps Circuit . . . . . . . . . . . . 9B-12 9B-12 9B-13 9B-13 9B-14 9B-14 9B-15 9B-16 9B-16 9B-17 9B-17 9B-18 9B-19 9B-20 9B-21 9B-22 Turn Signal Lamps . . . . . . . . . . . . . . . . . . . . . . . . 9B-8 Side Turn Signal Lamps . . . . . . . . . . . . . . . . . . . . 9B-8 Taillamps Assembly . . . . . . . . . . . . . . . . . . . . . . . . 9B-9 Front Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B-9 Rear Fog/Backup Lamp(s) . . . . . . . . . . . . . . . . . 9B-10 Center High-Mounted Stoplamp . . . .
File name M39c Horns.pdf

SECTION 9C HORNS CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 9C-2 9C-2 9C-3 9C-3 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9C-3 Schematic and Routing Diagrams . . . . . . . . . . . 9C-4 Horn Wiring System . . . . . . . . . . . . . . . . . . . . . . . 9C-4 DAEWOO M-150 BL2 9C 2 HORN DESCRIPTION AND OPERATION HORN The horn is located under the hood. It is attached near the radiator at the front of the vehicle. The horn is actuated by pressing the steering wheel pad, which grounds the horn's electrical circuit. DAEWOO M-150 BL2 HORN 9C 3 REPAIR INSTRUCTIONS ONVEHICLE SERVICE HORN Removal Procedure 1. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. 3. Remove the front wheels. 4. Remove the front wheel house splash shield. D Remove the clip and bolts. a. Bolts and clips. D Remove the wheel house splash shield. b. Splash shield. D19C501A 5 Remove the horn. D Remove the bolt (1). D Disconnect the electrical connector (2). D19D517A Installation Procedure 1. Install the horn with the bolt. 2. Connect the electrical connector. 3. Install the front wheel house splash shield with the clips and the bolts. 4. Install the front wheels. 5. Lower the vehicle. 6. Connect the negative battery cable. D19D518A DAEWOO M-150 BL2 9C 4 HORN SCHEMATIC AND ROUTING DIAGRAMS HORN WIRING SYSTEM D19D207B DAEWOO M-150 BL2
File name M39d Wipers - Washer Systems.pdf

SECTION 9D WIPERS / WASHER SYSTEMS CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Windshield Wiper System . . . . . . . . . . . . . . . . . . Windshield Washer System . . . . . . . . . . . . . . . . . Rear Window Wiper/Washer System . . . . . . . . . Diagnostic Information and Procedures . . . . . Windshield/Rear Window Wiper and Washer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Windshield Wiper Arm . . . . . . . . . . . . . . . . . . . . . Rear Window Wiper Arm . . . . . . . . . . . . . . . . . . . Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . Rear Window Wiper Motor . . . . . . . . . . . . . . . . . . 9D-2 9D-2 9D-2 9D-2 9D-3 9D-3 9D-6 9D-6 9D-6 9D-6 9D-7 9D-8 Windshield Wiper Linkage . . . . . . . . . . . . . . . . . . 9D-9 Windshield Wiper Blade . . . . . . . . . . . . . . . . . . . 9D-10 Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . . . 9D-10 Washer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 9D-11 Windshield Washer Nozzle . . . . . . . . . . . . . . . . Rear Window Washer Nozzle . . . . . . . . . . . . . . Washer Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9D-12 9D-12 9D-13 9D-15 Fastener Tightening Specifications . . . . . . . . . . 9D-15 Schematic and Routing Diagrams . . . . . . . . . . 9D-16 Windshield/Rear Window Wiper/Washer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9D-16 DAEWOO M-150 BL2 9D 2 WIPERS/WASHER SYSTEMS DESCRIPTION AND OPERATION WINDSHIELD WIPER SYSTEM The windshield wiper system consists of a wiper motor, a linkage, a wiper arm and a blade, and a wiper/washer switch. The windshield wiper circuit incorporates a selfparking device which consists of a worm gear and a cam plate in order to keep the circuit engage temporarily when the switch is turned off. The wiper system is driven by a permanent magnet-type motor. The windshield wiper motor is mounted on the dash panel and is directly connected to the windshield wiper linkage. The windshield wiper motor has two speeds, LOW and HIGH, and also has intermittent wiper capability. The wiper switch is an integral part of the wiper/washer switch. Windshield wiper operation is actuated through the lever on the right side of the steering column. and a wiper/washer switch. The windshield washer reservoir is mounted inner the front right wheel well splash shield. Attached to the reserv
File name M39e1 Instrumentation - Driver Information 1-14.pdf

SECTION 9E INSTRUMENTATION/DRIVER INFORMATION CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ashtray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel Vents . . . . . . . . . . . . . . . . . . . . Glove Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . Speedometer/Odometer/Trip Odometer . . . . . . 9E-2 9E-2 9E-2 9E-2 9E-2 9E-2 9E-2 9E-2 Ashtray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E-9 Instrument Cluster Trim Panel Vents . . . . . . . . . 9E-9 Digital Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E-10 Glove Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E-11 Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . TieBar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Cluster Trim Panel . . . . . . . . . . . . . . 9E-11 9E-12 9E-14 9E-16 Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E-2 Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . 9E-2 Instrument Cluster Indicator Lamps . . . . . . . . . . 9E-2 Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel Assembly . . . . . . . . . . . . . . . . . Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HVAC Panel Illumination . . . . . . . . . . . . . . . . . . . Digital Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 9E-3 9E-3 9E-4 9E-5 9E-5 9E-6 9E-7 9E-8 Instrument Trim Panel Assembly . . . . . . . . . . . 9E-16 Instrument Cluster Indicator Lamps . . . . . . . . . 9E-19 Speedometer/Odometer/Trip Odometer . . . . . 9E-19 Fuel Gauge/Temperature Gauge . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fastener Tightening Specifications . . . . . . . . . . Instrument Cluster Indicator Lamps Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic and Routing Diagrams . . . . . . . . . . 9E-20 9E-22 9E-22 9E-22 9E-23 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 9E-8 Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . .
File name M39e2 Instrumentation - Driver Information 15-26.pdf

INSTRUMENT/DRIVER INFORMATION 9E 15 6. Remove the defroster duct from the cowl upper panel. D Remove the screws (1). D Remove the defroster duct (2). D109B523 7. Remove the bolts and the tiebar. a. Tie bar. D109B524 8. Remove the bolts and the tiebar center. b. Tie bar center. D109B525 Installation Procedure 1. Install the tiebar with the bolts. 2. Install the tiebar center with the bolts. 3. Install the defroster duct to the cowl upper panel with the screws. D109B526 DAEWOO M-150 BL2 9E 16 INSTRUMENT/DRIVER INFORMATION 4. 5. 6. 7. 8. 9. 10. 11. Connect the electrical wiring harness. Connect the blow motor resistance connector. Connect the blow motor connector. Connect the thermostat connector. Connect the brake switch connector. Bind the electrical wiring harness strip. Install the steering column with the nuts. Install the defroster duct hose with the screws. 12. Install the instrument panel assembly. Refer to "Instrument Panel" in this section. 13. Connect the negative battery cable. INSTRUMENT CLUSTER TRIM PANEL (LeftHand Drive Shown, RightHand Drive Similar) Removal Procedure 1. Remove the instrument cluster trim panel from the instrument panel. D Remove the screws (1). D Using a flathead screwdriver, remove the central console cover (2). Notice: To prevent the instrument panel damage, cover the flathead screwdriver with a soft cloth. D109B516 Installation Procedure 1. Install the instrument cluster trim panel with the screws. D109B527 INSTRUMENT TRIM PANEL ASSEMBLY (LeftHand Drive Shown, RightHand Drive Similar) Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the instrument panel assembly. Refer to "Instrument Panel" in this section. 3. Remove the instrument cluster brackets from the instrument panel. D Remove the screws. D Remove the instrument cluster brackets (1). DAEWOO M-150 BL2 D109B701 INSTRUMENT/DRIVER INFORMATION 9E 17 4. Remove the passenger's airbag module blank cover from the instrument panel. D Remove the screws. D Remove the passenger's airbag module blank cover (1). D109B702 5. Remove the ventilation duct from the instrument panel. D Remove the screws. D Remove the ventilation duct (1). D109B703 6. Remove the ventilation grilles from the instrument panel. D Remove the screws. D Remove the ventilation grilles (1). D109B704 7. Remove the cigar lighter housing from the instrument panel. D Remove the screws. D Remove the cigar lighter housing (1). D109B705 DAEWOO M-150 BL2 9E 18 INSTRUMENT/DRIVER INFORMATION 8. Remove the glove box striker and bracket from the instrument panel. D Remove the screws (1). D Remove the glove box striker and bracket (2). D109B706 9. Remove the instrument panel guide from the instrument panel. D Remove the screws (1). D Remove the instrument panel guide (2). D109B707 10. Remove the defroster grilles and the demister grilles from the instrument panel. a. Defroster grille. b. Demister grille. D109B708 Installation Procedure 1. Install
File name M39f Audio.pdf

SECTION 9F AUDIO SYSTEMS CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . 9F-2 Stereo Cassette AM/FM Radio with CD Changer and RDS/Audio Security System . . . . . . . . . . . . . 9F-2 Front and Rear Speakers . . . . . . . . . . . . . . . . . . . 9F-2 Roof Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F-2 Tape Player and Cassette Care . . . . . . . . . . . . . Compact Disc Care . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Audio Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F-2 9F-2 9F-3 9F-3 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . OnVehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Audio System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CD Changer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F-6 9F-6 9F-6 9F-6 Front Speakers . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F-8 Front Speaker Covers . . . . . . . . . . . . . . . . . . . . . . 9F-9 Rear Speakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F-9 Roof Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F-10 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F-11 Fastener Tightening Specifications . . . . . . . . . . 9F-11 Schematic and Routing Diagrams . . . . . . . . . . 9F-12 Audio System Circuit . . . . . . . . . . . . . . . . . . . . . . 9F-12 Diagnostic Information and Procedures . . . . . 9F-4 Audio System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F-4 DAEWOO M-150 BL2 9F 2 AUDIO SYSTEMS DESCRIPTION AND OPERATION STEREO CASSETTE AM/FM RADIO WITH CD CHANGER AND RDS/AUDIO SECURITY SYSTEM The stereo digital logic cassette AM/FM radio with electronic tape ejection and the stereo digital logic cassette AM/FM radio with a CD changer located under the front seat (LH) are optional equipment. The radio data system (RDS) uses a single button to select a specific radio station once it is set to the listener's preference. The audio security system is activated whenever the audio system circuit is disconnected from the battery. A four-digit security code must be entered in order for the audio system to be functional once again. The security code is stamped on a card located in the vehicle (usually in the glove box). One of the following security code entering procedures can be followed. With RDS 1. With the ignition switch in the I or II position, turn the radio ON. At this time, "CODE" will be shown on the radio display. 2. Press the P-UP button until the correct first digit is
File name M39g Interior Trim.pdf

SECTION 9G INTERIOR TRIM CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Interior Trim Panels . . . . . . . . . . . . . . . . . . . . . . . . Pressure Relief Vent . . . . . . . . . . . . . . . . . . . . . . . Floor Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Cable Cover . . . . . . . . . . . . . . . . . Floor Carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Interior Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G-2 9G-2 9G-2 9G-2 9G-2 9G-2 9G-3 9G-3 Tailgate Trim Panel . . . . . . . . . . . . . . . . . . . . . . . . 9G-9 APillar Trim Panel . . . . . . . . . . . . . . . . . . . . . . . 9G-10 Upper BPiller Trim Panel . . . . . . . . . . . . . . . . . 9G-10 Lower BPillar Trim Panel . . . . . . . . . . . . . . . . . 9G-11 CPillar Trim Panel . . . . . . . . . . . . . . . . . . . . . . . 9G-11 Rear Parcel Shelf . . . . . . . . . . . . . . . . . . . . . . . . 9G-12 Rear Parcel Side Shelf . . . . . . . . . . . . . . . . . . . . 9G-13 Front Rocker Trim Panel . . . . . . . . . . . . . . . . . . 9G-13 Rear Rocker Trim Panel . . . . . . . . . . . . . . . . . . . 9G-14 Floor Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G-15 Parking Brake Cable Cover . . . . . . . . . . . . . . . . 9G-15 Floor Carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G-16 Luggage Compartment Wheelhouse Trim Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G-17 Special Tools and Equipment . . . . . . . . . . . . . . 9G-18 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . 9G-18 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 9G-4 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 9G-4 Front Door Trim Panel (Standard) . . . . . . . . . . . 9G-4 Front Door Trim Panel (Deluxe) . . . . . . . . . . . . . Rear Door Trim Panel (Standard) . . . . . . . . . . . . Rear Door Trim Panel (Deluxe) . . . . . . . . . . . . . . Rear Door Interior Garnish Molding . . . . . . . . . . 9G-5 9G-6 9G-7 9G-8 Rear Door Exterior Garnish Molding . . . . . . . . . 9G-9 DAEWOO M-150 BL2 9G 2 INTERIOR TRIM DESCRIPTION AND OPERATION INTERIOR TRIM PANELS The interior trim panels are molded plastic and fasten with screws or plastic clips. FLOOR CONSOLE The floor console fits over the tunnel in the floor of the vehicle and extends from under the center of the instrument panel to the front seat area. The floor console contains the transaxle shift lever and a cupholder. The sensing and diagnosis module (SD
File name M39h Seats.pdf

SECTION 9H SEATS CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Front Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Front Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9H-2 9H-2 9H-3 9H-3 9H-4 9H-5 9H-5 9H-5 Front Seat Cushion . . . . . . . . . . . . . . . . . . . . . . . . 9H-7 Front Seats Guide Rail . . . . . . . . . . . . . . . . . . . . 9H-9 Front Seat Cushion Frame . . . . . . . . . . . . . . . . . . 9H-9 Rear Seatback . . . . . . . . . . . . . . . . . . . . . . . . . . . 9H-10 Rear Seat Cushion . . . . . . . . . . . . . . . . . . . . . . . Rear Seatback Latch . . . . . . . . . . . . . . . . . . . . . Rear Seatback Hinge . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9H-11 9H-11 9H-12 9H-13 Head Restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9H-5 Front Seatback . . . . . . . . . . . . . . . . . . . . . . . . . . . 9H-6 Fastener Tightening Specifications . . . . . . . . . . 9H-13 DAEWOO M-150 BL2 9H 2 SEATS DESCRIPTION AND OPERATION SEATS Important: Do not attempt to change the designed seat position by altering the designed seat adjuster-to-floor pan anchor provisions or the seat adjuster-to-seat frame anchor provisions. Changing the seat position could affect the performance of the seat system. This vehicle is equipped with low-backed front seats with separate head restraints and a three-passenger folding rear seat. Split folding rear seat is optional. Seats cushions and seatbacks have formed foam pads, which fit the contours of the fullpanel seatback frame assembly and the designed contour of the seat cushion frame. There are no front seat forward or rearward relocation provisions provided at either the seat adjustertoseat frame or the seat adjustertofloor pan anchor attachments. DAEWOO M-150 BL2 SEATS 9H 3 COMPONENT LOCATOR FRONT SEAT D109B402 1. 2. 3. 4. 5. Head Restraint Guide Sleeve Seatback Seatback Frame Seat Cushion 6. 7. 8. 9. 10. Seat Cushion Frame Recliner Recliner Knob Seat Side Cover Guide Rail DAEWOO M-150 BL2 9H 4 SEATS REAR SEAT D19B403A 1. 2. 3. 4. 5. Rear Seatback Cushion Rear Seatback Frame Rear Seat Hinge Rear Seat Lock Rear Seat Cushion 6. 7. 8. 9. Se
File name M39i Waterleaks.pdf

SECTION 9I WATERLEAKS TABLE OF CONTENTS Diagnostic Information and Procedures . . . . . . Waterleak Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 9I-2 9I-2 9I-5 9I-5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9I-7 Recommended Materials for Waterleak Repairs . . . . . . . . . . . . . . . . . . . . . . . . 9I-7 Watertest Stand Specifications . . . . . . . . . . . . . . 9I-7 Waterleak Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 9I-5 DAEWOO M-150 BL2 9I 2 WATERLEAKS DIAGNOSTIC INFORMATION AND PROCEDURES WATERLEAK DIAGNOSIS The repair of waterleaks in the body requires proper testing and diagnosis. Repair waterleaks by adjusting the misaligned parts and using the proper repair materials. First, determine what conditions cause the leak. For example, the leak may occur only when the vehicle is parked on an incline, or water may appear only in the spare tire compartment. Second, test the area for the source of the leak using the following testing methods. If the general leak area is found, determine the exact entry point of the leak by using a water hose or an air hose. If the general leak area is not obvious, use the watertest stands to determine the area of the leak. It may be necessary to remove some interior trim panels or some parts in order to locate the leaks. Important: It is necessary to find the origin of all the leaks before making any repairs. Random repairs may stop the leak only temporarily and may make future repairs more difficult. Continue localized testing in the general area in order to ensure that all leaks are found. 1 1/2-inch by 36-inch Pipe 2 Full-jet Spray Nozzle #1/2 GG-25 or Equivalent Nozzle Height at 1,600 mm to the Floor 3 1/2-inch Coupling 4 1/2-inch by 1/2-inch by 1/4-inch Reducing T (Right Only) 5 1/2-inch Coupling (Left Only) 6 1/2-inch Cross (Right Only) 7 1/2-inch Tee (Left Only) 8 1/2-inch Pipe-to-Hose Nipple (Right Only) 9 5/8-inch Female Hose Coupling 10 5/8-inch Input Hose (2 Feet Long, Right Only) 11 1/2-inch Close Nipple 12 1/2-inch Cross with Weld-on 1/2-inch Cap 13 1/2-inch by 12-inch Nipple 14 1/2-inch Cap 15 5/8-inch Female Hose Coupling 16 5/8-inch Cross Hose (12 Feet Long) 17 5/8-inch Hose Quick Connect 18 1/2-inch Pipe-to-Hose Nipple 19 1/2-inch by 30-inch Pipe (Straight) 20 1/4-inch Water Pressure Gauge (Right Only) Generalized Testing 1. Set up the watertest stands. 2. Set up the watertest stand leak test. D109A301 D19A302A DAEWOO M-150 BL2 WATERLEAKS 9I 3 3. Perform the watertest stand leak test. Refer to "Watertest Stand Specifications" in this section. 4. If the local water pressure does not allow the required water pressure of 155 kPa (22.5 psi), move both stands closer to the vehicle so that the water spray overlaps. D109A303 Localized Testing (Spot Test) 1. Do localized testing w
File name M39j Windnoise.pdf

SECTION 9J WINDNOISE TABLE OF CONTENTS Diagnostic Information and Procedures . . . . . 9J-1 Windnoise Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 9J-1 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 9J-2 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 9J-2 Windnoise Repair . . . . . . . . . . . . . . . . . . . . . . . . . 9J-2 DIAGNOSTIC INFORMATION AND PROCEDURES 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. D D D D A mechanics stethoscope or vacuum hose Masking tape Strip caulk A china marking pencil 5. Internal windnoise is air leaving the vehicle and should be repaired in the following manner. D In order to locate the leak, tape off the body lock pillar pressure relief valves. This will cause air pressure to build up inside the vehicle and enhance the windnoise. D Use a stethoscope or a vacuum hose to locate the leak. D Temporarily repair the leak with masking tape. D A screwdriver Perform the following steps in order to conduct the road test: 1. Choose a route that includes smooth straight streets that run in all four directions (north, south, east, and west). 2. Choose streets with little traffic or noise that would interfere with the test. 3. Drive the vehicle at the speeds at which the noise was noticed by the customer or until the noise is produced. Do not exceed legal speed limits. 4. The windnoise is external if any of the following conditions occur: D The windnoise is caused by the wind. D The windnoise can be heard with the door glass lowered and while the vehicle is being driven. D The windnoise is eliminated when tape is placed over various moldings and gaps. D109A307 D Continue testing in order to determine if the noise has been eliminated or if other leaks exist. D When all leaks have been found, return to the shop and make permanent repairs with the proper alignment techniques and sealing materials. DAEWOO M-150 BL2 9J 2 WINDNOISE REPAIR INSTRUCTIONS ON-VEHICLE SERVICE WINDNOISE REPAIR Windnoise leak repairs are very similar to waterleak repairs. Refer to Section 9I, Waterleaks. The actual procedure depends on the type of seal being repaired. Leaks around the door opening weatherstrips do not always indicate a faulty weatherstrip. A door or window adjustment may resolve the condition. Refer to Section 9L, Glass and Mirrors. DAEWOO M-150 BL2
File name M39k Squeaks and Rattles.pdf

SECTION 9K SQUEAKS AND RATTLES TABLE OF CONTENTS Diagnostic Information and Procedures . . . . . 9K-1 Squeak and Rattle Diagnosis . . . . . . . . . . . . . . . 9K-1 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 9K-3 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 9K-3 Squeak and Rattle Repair . . . . . . . . . . . . . . . . . . 9K-3 DIAGNOSTIC INFORMATION AND PROCEDURES SQUEAK AND RATTLE DIAGNOSIS Condition Rattle Coming From the Side Rail Probable Cause D Improperly connected brake lines. Correction D Tap lightly on the brake lines and listen for a rattle. D Install plastic tie straps to secure the brake lines tightly together. D Raise the vehicle and perform a visual inspection. D Bend the heat shield slightly to gain clearance from the underbody. D While the vehicle is cold, perform a test drive and achieve full front suspension travel by driving through a dip in the road. D Remove the insulators and wrap teflon tape around the stabilizer shaft. Reinstall the insulators over the tape. D Open the rear compartment and perform a visual inspection of the spare tire and the tools. D Tightly secure the spare tire and all tools. D Perform a road test to verify that the noise is eliminated. D Test drive the vehicle in order to verify this condition. D Loosen the latch nuts and adjust the latch downward. D Remove the door trim panel and check if the solenoid is loose. D Tighten the solenoid bolts. D Tap on the trim panel and listen for a rattle. D Remove the trim panel and wrap foam padding around the connectors as required. D Operate the doors and listen for squeaks. D Lubricate the door hinge pins with light oil and coat with lithium grease. D Lubricate the door hold open link arm with light oil and coat with lithium grease. Rattle Under Vehicle at Higher RPM D The heat shield contacts with the underbody. Squeak From the Front of the Vehicle in Cold Weather D Poor front stabilizer shaft insulators taping. Thump From Rear of Vehicle on Bumps D Improperly secured spare tire in the rear compartment. Glass Knock Coming From the Rear of the Vehicle When Driving Over Bumps Rattle Coming From Door D An out-of-adjustment hatchback latch. D The door lock solenoid is loose. D Rattling electrical connectors inside the door trim panel. Squeak When Operating Doors D A lack of lubrication of the door hinge pins. D A lack of lubrication of the door hold open link arm. DAEWOO M-150 BL2 9K 2 SQUEAKS AND RATTLES SQUEAK AND RATTLE DIAGNOSIS (Cont'd) Condition Squeak Coming From Console When Shifting Manual Transaxle (Condition Occurs In Cold Weather with a Cold Engine) Squeak Coming From Instrument Cluster Trim Plate Probable Cause D The faulty manual transaxle control lever lower boot. Correction D Move the control lever between gears and listen for squeaks. D Remove the floor console and replace the lower shift boot or apply talcum powder to the lower shift boot. D Test drive the vehicle in order to veri
File name M39l Glass and Mirrors.pdf

SECTION 9L GLASS AND MIRRORS CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and System Operation . . . . . . . . . . Stationary Glass . . . . . . . . . . . . . . . . . . . . . . . . . . Inside Rearview Mirror . . . . . . . . . . . . . . . . . . . . . Outside Rearview Mirrors . . . . . . . . . . . . . . . . . . . Components Locator . . . . . . . . . . . . . . . . . . . . . . . Glass and Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . Testing Rear Window Defogger Grid Line . . . . . 9L-2 9L-2 9L-2 9L-2 9L-3 9L-3 9L-4 9L-4 Rear Window Defogger Braided Lead Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L-10 Front Door Glass . . . . . . . . . . . . . . . . . . . . . . . . . 9L-10 Front Door Quarter Glass . . . . . . . . . . . . . . . . . 9L-12 Rear Door Glass . . . . . . . . . . . . . . . . . . . . . . . . . 9L-13 Inside Rearview Mirror . . . . . . . . . . . . . . . . . . . . Outside Rearview Mirror (Manual) . . . . . . . . . . Outside Rearview Mirror (Cable) . . . . . . . . . . . . Outside Rearview Mirror (Electric) . . . . . . . . . . Special Tools and Equipment . . . . . . . . . . . . . . Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . Schematic and Routing Diagrams . . . . . . . . . . Rear Window Defogger . . . . . . . . . . . . . . . . . . . 9L-13 9L-14 9L-15 9L-16 9L-17 9L-17 9L-18 9L-18 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 9L-5 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 9L-5 Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L-5 Rear Window Glass . . . . . . . . . . . . . . . . . . . . . . . 9L-7 Rear Window Defogger Grid Line Repair . . . . . 9L-9 DAEWOO M-150 BL2 9L 2 GLASS AND MIRRORS DESCRIPTION AND OPERATION STATIONARY GLASS Stationary glass consists of all the glass on the vehicle which is immovable within its frame, such as the windshield glass, the back glass, and the inside rearview mirror. INSIDE REARVIEW MIRROR The inside rearview mirror can be manually adjusted up/ down, fore/aft, and left/right. The rearview mirror pivots in two places: the ball-and-socket mirror pivot and the up/down hinge lever at the mirror support. OUTSIDE REARVIEW MIRRORS Three types of outside rearview mirrors are available. The outside rearview mirrors are adjusted by hand which is standard. The remote control and the electric outside rearview mirrors are optional. The outside rearview mirrors are installed on the front doors. DAEWOO M-150 BL2 GLASS AND MIRRORS 9L 3 COMPONENTS LOCATOR GLASS AND MIRROR D19E401B 1. 2. 3. 4. 5. 6. Windshield Molding Wi
File name M39m Exterior Trim.pdf

SECTION 9M EXTERIOR TRIM TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . 9M-2 Emblems and Lettering . . . . . . . . . . . . . . . . . . . . . 9M-2 Mud Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9M-2 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 9M-3 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 9M-3 Roof Molding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9M-3 Rear Spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9M-3 Front Bumper Spacer . . . . . . . . . . . . . . . . . . . . . . 9M-4 Tailgate Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . 9M-5 DAEWOO M-150 BL2 9M 2 EXTERIOR TRIM DESCRIPTION AND OPERATION EMBLEMS AND LETTERING The emblems and lettering on the vehicle are attached by adhesive. The company emblem appears on the hood. The lettering, which appears in several places on the body of the vehicle, features the model, the grade, and the company name. MUD GUARDS Front and rear mud guards are optional equipment on all models. Mud guards will help prevent an excessive buildup of mud on the body. DAEWOO M-150 BL2 EXTERIOR TRIM 9M 3 REPAIR INSTRUCTIONS ONVEHICLE SERVICE ROOF MOLDING Removal Procedure 1. Remove the roof molding from the plastic clips (1). D109E586 Installation Procedure 1. Press the roof molding onto the plastic clips. D109E587 REAR SPOILER Removal Procedure 1. Open the tailgate. 2. Remove the spoiler seals. D19E588A DAEWOO M-150 BL2 9M 4 EXTERIOR TRIM 3. Remove the rear spoiler from the tailgate. D Remove the nuts (1). D Remove the rear spoiler (2). D19E589A Installation Procedure 1. Install the rear spoiler on the tailgate with the nuts. 2. Install the spoiler seals. D19E590A FRONT BUMPER SPACER Removal Procedure 1. Support the hood suitably. 2. Disconnect the negative battery cable. 3. Remove the front bumper spacer. D Remove the bolts (1). D Remove the front bumper spacer from the bumper fascia (2). 4. Remove the turn signal lamps. Refer to Section 9B, Lighting Systems. D209B109 Installation Procedure 1. Install the turn signal lamps. Refer to Section 9B, Lighting Systems. 2. Install the front bumper spacer with the bolts. 3. Connect the negative battery cable. D209B110 DAEWOO M-150 BL2 EXTERIOR TRIM 9M 5 TAILGATE HANDLE Removal Procedure 1. Disconnect the negative battery cable. 2. Open the tailgate. 3. Remove the tailgate lock cylinder. Refer to Section 9P, Doors. 4. Remove the license plate lamps. Refer to Section 9B, Lighting Systems. 5. Remove the tailgate handle. D Remove the screws (1). D Remove the tailgate handle (2). D209B111 Installation Procedure 1. Install the tailgate handle with the screws. 2. Install the license plate lamps. Refer to Section 9B, Lighting Systems. 3. Remove the tailgate lock cylinder. Refer to Section 9P, Doors. 4. Connect the negative battery cable. D209B112 DAEWOO M-150 BL2
File name M39n Frame and Underbody.pdf

SECTION 9N FRAME AND UNDERBODY TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . General Body Construction . . . . . . . . . . . . . . . . . Transaxle Under Covers . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 9N-2 9N-2 9N-2 9N-3 Alignment Checking . . . . . . . . . . . . . . . . . . . . . . . Floor Pan Insulators . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Underbody Dimensions . . . . . . . . . . . . . . . . . . . . 9N-3 9N-3 9N-4 9N-4 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 9N-3 DAEWOO M-150 BL2 9N 2 FRAME AND UNDERBODY DESCRIPTION AND OPERATION GENERAL BODY CONSTRUCTION This vehicle is constructed with a unitized body which incorporates integral front and rear frame side rails. The front suspension lower control arms are bolted to and retained by supports, one each on the right and left sides. The front suspension lower control arm supports are attached to the underbody with three bolts at two locations. The engine is bolted to the integral front side rails. The suspension strut towers must be dimensionally correct in relation to the remainder of the underbody in order to maintain specified suspension strut and caster/ camber angles. Since the individual underbody parts contribute directly to the overall strength of the body, it is essential to observe proper welding techniques during service repair operations. The underbody parts should be properly sealed and rustproofed whenever body repair operations destroy or damage the original sealing and rustproofing. When rustproofing critical underbody parts, use a good-quality type of air-dry primer, such as a corrosionresistant chromate or an equivalent material. Combination-type primer/surfacers are not recommended. TRANSAXLE UNDER COVER The transaxle under cover is one piece of steel that serve as shields for the underside of the transaxle. The covers help protect the engine from small rocks, gravel and other objects that would otherwise come into contact with the transaxle during normal driving conditions. DAEWOO M-150 BL2 FRAME AND UNDERBODY 9N 3 REPAIR INSTRUCTIONS ONVEHICLE SERVICE ALIGNMENT CHECKING An accurate method of determining the alignment of the underbody uses a measuring tram gauge. The tram gauge set used to perform the recommended measuring checks must include a vertical pointer able to reach 457 mm (18 inches). Two types of measurements can be made with a tram gauge: direct point-to-point measurements and measurements calculated on a horizontal plane (datum line) parallel to the underbody. Point-to-point measurements are generally taken on steering and suspension engine compartment parts and simply require the vertical pointers to be set equally. For horizontal plane measurements, the vertical pointers must be set as specified for each point to be measured. Dimensions-t
File name M39o Bumpers and Facials.pdf

SECTION 9O BUMPERS AND FASCIAS TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Bumpers and Fascias . . . . . . . . . . . . . . . . . . . . . . 9O-2 9O-2 9O-3 9O-3 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Front Bumper Fascia . . . . . . . . . . . . . . . . . . . . . . Front Bumper Impact Bar . . . . . . . . . . . . . . . . . . . Rear Bumper Fascia . . . . . . . . . . . . . . . . . . . . . . . 9O-4 9O-4 9O-5 9O-6 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 9O-4 Rear Bumper Bracket . . . . . . . . . . . . . . . . . . . . . . 9O-8 DAEWOO M-150 BL2 9O 2 BUMPERS AND FASCIAS DESCRIPTION AND OPERATION BUMPERS The bumper systems are installed with the body color bumper and the general bumper according to the vehicle grade. The bumper systems are designed to sustain a collision into a fixed barrier at 4 km/h (2.5 mph) without damage. After absorbing the energy of a collision, these bumper systems restore themselves to their original position. Both the front and the rear bumpers feature an internal foam energy absorber and a polymer fascia cover. The front bumper consists of the bumper fascia and the impact bar. Remove the fascia before removing the impact bar. The rear bumper consists of the bumper fascia and the bracket. Removal of rear bumper brackets can be possible without removing the bumper fascia. DAEWOO M-150 BL2 BUMPERS AND FASCIAS 9O 3 COMPONENT LOCATOR BUMPERS AND FASCIAS D19C401A 1. 2. 3. 4. Front Towing Cover Front Bumper Front Bumper Impact Beam Front Bumper Reinforcement 5. 6. 7. 8. Rear Bumper Reinforcement Rear Bumper Rear Bumper Bracket Rear Towing Cover DAEWOO M-150 BL2 9O 4 BUMPERS AND FASCIAS REPAIR INSTRUCTIONS ONVEHICLE SERVICE FRONT BUMPER FASCIA Removal Procedure 1. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. 3. Remove the front wheels. 4. Remove the front wheel house splash shields. D Remove the clip and bolts. a. Bolt and clip. D Remove the wheel house splash shield. b. Splash shield. D19C501A 5. Remove the bolts on the both side of the fascia. a. Bolt. D109C502 6. Remove the clips under the fascia. a. Clip. D109C503 DAEWOO M-150 BL2 BUMPERS AND FASCIAS 9O 5 7. Lower the vehicle. 8 Remove the front bumper spacer from the bumper. Refer to Section 9M, Exterior Trim. 9. Remove the front bumper fascia. D Remove the bolts (1). D Remove the clips (2). D Remove the front bumper fascia (3). 10 Remove the front fog lamps. Refer to Section 9B, Lighting Systems. D19C504A Installation Procedure Notice: Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. 1. Install the front fog lamps. Refer to Section 9B, Lighting Systems. 2. Install the bumper fascia. 3. I
File name M39p Doors.pdf

SECTION 9P DOORS CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Door Lock Striker . . . . . . . . . . . . . . . . . . . . . . . . . . Childproof Rear Door Lock . . . . . . . . . . . . . . . . . . Power Door Locks . . . . . . . . . . . . . . . . . . . . . . . . . Power Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P-2 9P-2 9P-2 9P-2 9P-2 9P-2 9P-3 9P-3 Outside Front Door Handle . . . . . . . . . . . . . . . . Outside Rear Door Handle . . . . . . . . . . . . . . . . . Door Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . Manual Window Regulator . . . . . . . . . . . . . . . . . Power Front Window Regulator . . . . . . . . . . . . Front Door Assembly . . . . . . . . . . . . . . . . . . . . . Rear Door Assembly . . . . . . . . . . . . . . . . . . . . . . Tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P-17 9P-18 9P-18 9P-19 9P-19 9P-20 9P-21 9P-22 Rear Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P-5 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 9P-7 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 9P-7 Front Door Glass Run . . . . . . . . . . . . . . . . . . . . . . Rear Door Glass Run . . . . . . . . . . . . . . . . . . . . . . Door Lock Striker . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Lock Striker . . . . . . . . . . . . . . . . . . . . . . . Door Lock Striker Adjustment . . . . . . . . . . . . . . Tailgate Lock Striker Adjustment . . . . . . . . . . . . Front Door Lock . . . . . . . . . . . . . . . . . . . . . . . . . . Childproof Rear Door Lock . . . . . . . . . . . . . . . . . 9P-7 9P-8 9P-9 9P-9 Tailgate Lock Cylinder . . . . . . . . . . . . . . . . . . . . . 9P-23 Door Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P-23 Door Hold Open Link . . . . . . . . . . . . . . . . . . . . . 9P-24 Inside Channel Weatherstrip (Standard) . . . . . Inside Channel Weatherstrip (Deluxe) . . . . . . . Door Outside Channel Weatherstrip . . . . . . . . . Door Weatherstrip . . . . . . . . . . . . . . . . . . . . . . . . Door Seal Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Opening Weatherstrip . . . . . . . . . . . . . . . . Manual Window Regulator Handle . . . . . . . . . . Tailgate Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P-24 9P-25 9P-25 9P-26 9P-27 9P-27 9P-28 9P-28 9P-10 9P-11 9P-13
File name M39q Roof.pdf

SECTION 9Q ROOF TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual SunRoof . . . . . . . . . . . . . . . . . . . . . . . . . . Sun Visors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Passenger Assist Handles . . . . . . . . . . . . . . . . . . Coat Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q-2 9Q-2 9Q-2 9Q-2 9Q-2 9Q-2 9Q-3 9Q-3 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Formed Headliner . . . . . . . . . . . . . . . . . . . . . . . . . Manual SunRoof . . . . . . . . . . . . . . . . . . . . . . . . . . Sun Visors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q-4 9Q-4 9Q-5 9Q-6 Passenger Assist Handle and the Coat Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q-6 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q-8 Fastener Tightening Specifications . . . . . . . . . . . 9Q-8 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 9Q-4 DAEWOO M-150 BL2 9Q 2 ROOF DESCRIPTION AND OPERATION ROOF The roof is a one-piece painted metal unit which incorporates a single, solid headliner and two moldings, one on each side of the vehicle's roof. The moldings, which enclose and hide the roof rail seams, are serviceable as individual units. The one-piece formed headliner, common to both the notchback and the hatchback, consists of a molded substrate covered with a foam-backed cloth facing. The one-piece construction requires servicing the headliner as a complete assembly. SUN VISORS The sun visors swing down or side in order to block out glare. They also swing to the side when they are released from the support. PASSENGER ASSIST HANDLE There is a passenger assist handle for the front passenger seat. Passengers can use these handles to assist in keeping their balance over rough roads or during sharp turns. MANUAL SUNROOF The sunroof is D Intended to provide light and air through the roof of the vehicle during the driving. D Built into the roof. D Made of glass. COAT HOOK The coat hook is fastened to the headliner above the left-hand rear passenger seat for LeftHand Drive or right hand rear passenger seat for RightHand Drive. This position has a coat hook in the place of a passenger assist handle. DAEWOO M-150 BL2 ROOF 9Q 3 COMPONENT LOCATOR ROOF D19C402B 1. 2. 3. 4. 5. 6. 7. Sunroof Handle Sunroof Screen Sunroof Screen Seal Sunroof Upper Frame Roof Seal Sunroof Lower Frame Sunroof Cover 8. 9. 10. 11. 12. 13. 14. Roof Rail Rear Spoiler Roof Molding Roof Rack Bracket Roof Rack Pad Cap Roof Rack DAEWOO M-150 BL2 9Q 4 ROOF REPAIR INSTRUCTIONS ONVEHICLE SERVICE FORMED HEADLINER Removal Procedure 1. Disconnect the negative battery cable
File name M39r Body Front End.pdf

SECTION 9R BODY FRONT END TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Body Front End . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anticorrosion Materials . . . . . . . . . . . . . . . . . . . . . Front End Sealing . . . . . . . . . . . . . . . . . . . . . . . . . 9R-2 9R-2 9R-3 9R-3 9R-3 9R-3 9R-3 9R-4 Cowl Vent Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Prop Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Latch Release Lever . . . . . . . . . . . . . . . . . . Hood Latch Release Cable . . . . . . . . . . . . . . . . . Fender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R-4 9R-5 9R-5 9R-6 9R-7 9R-8 9R-9 9R-9 DAEWOO M-150 BL2 9R 2 BODY FRONT END DESCRIPTION AND OPERATION BODY FRONT END This vehicle has a unitized body with a frame assembly supporting the engine and the transaxle. The fender panels and the radiator support are also integral parts of the body. DAEWOO M-150 BL2 BODY FRONT END 9R 3 REPAIR INSTRUCTIONS ONVEHICLE SERVICE LUBRICATION The hood hinges and the locking mechanisms require periodic lubrication for proper operation. Refer to Section 0B, General Information for the specific types and intervals of lubrication. D109C517 FASTENERS Notice: Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. Many aluminum components are used on current models. Aluminum in contact with steel may corrode rapidly if it is not protected by special finishes or isolators. The fasteners used have a special finish which provides adequate protection from corrosion. These special fasteners differ in color in order to easily identify them from the standard metric fasteners, which are medium blue in color. When replacing fasteners, avoid substituting otherwise similar fasteners in the same location. D109C518 ANTICORROSION MATERIALS In order to provide rust resistance, anticorrosion materials have been applied to the interior surfaces of most of the metal panels. When you service these panels, properly re-coat them with a service-type anticorrosion material if any of the original material has been disturbed. D109C519 DAEWOO M-150 BL2 9R 4 BODY FRONT END FRONT END SEALING All locations where waterleaks may occur are sealed during production with high quality, durable sealers. If it becomes necessary to reseal specific areas, use a high quality
File name M39s Body Rear End.pdf

SECTION 9S BODY REAR END TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Fuel Filler Door . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 9S-2 9S-2 9S-3 9S-3 Fuel Filler Door . . . . . . . . . . . . . . . . . . . . . . . . . . . 9S-3 Fuel Filler Door Remote Cable and Handle . . . . 9S-3 Tailgate Remote Cable and Handle . . . . . . . . . . 9S-5 DAEWOO M-150 BL2 9S 2 BODY REAR END DESCRIPTION AND OPERATION FUEL FILLER DOOR The fuel filler door attaches to the fuel tank pocket on the right side of the vehicle. DAEWOO M-150 BL2 BODY REAR END 9S 3 REPAIR INSTRUCTIONS ONVEHICLE SERVICE FUEL FILLER DOOR Removal Procedure 1. Pull the fuel filler door opening lever and open the fuel filler door. 2. Remove the fuel filler door. D Remove the bolts (1). D Remove the fuel filler door (2). D109C546 Installation Procedure 1. Install the fuel filler door with the bolts. D109C547 FUEL FILLER DOOR REMOTE CABLE AND HANDLE (LeftHand Drive Shown, RightHand Drive Similar) Removal Procedure 1. Pry off the front rocker trim panel. Refer to Section 9G, Interior Trim. 2. Remove the fuel filler door remote handle. D Remove the screws (1). D Disconnect the cable (2). D Remove the fuel filler door remote handle (3). D109C548 DAEWOO M-150 BL2 9S 4 BODY REAR END 3. Pry off the lower Bpillar trim panel. Refer to Section 9G, Interior Trim. 4. Pry off the rear rocker trim panel. Refer to Section to 9G, Interior Trim. 5. Pry off the luggage compartment wheelhouse trim panel. Refer to Section to 9G, Interior Trim. 6. Remove the lock striker of the fuel filler. D Remove the lock striker by turning it rectangularly. a. Lock striker D109C549 7. Remove the fuel filler door remote cable. D Remove the cable retaining strip. D Disconnect the fuel filler door remote cable (1). D19C550B Installation Procedure 1. Connect the fuel filler door remote cable to the fuel filler door. 2. Retain the cable with the strip. D19C550C 3. Install the lock striker of the fuel filler. 4. Install the luggage compartment wheelhouse trim panel. Refer to Section 9G, Interior Trim. 5. Install the rear rocker trim panel. Refer to Section 9G, Interior Trim. 6. Install the lower Bpillar trim panel. Refer to Section 9G, Interior Trim. D19C549A DAEWOO M-150 BL2 BODY REAR END 9S 5 7. Connect the fuel filler door remote cable to the handle. 8. Install the fuel filler door remote handle with the screws. D109C551 TAILGATE REMOTE CABLE AND HANDLE (LeftHand Drive Shown, RightHand Drive Similar) Removal Procedure 1. Pry off the front rocker trim panel. Refer to Section 9G, Interior Trim. 2. Remove the tailgate remote handle. D Remove the screws (1). D Disconnect the cable (2). D Remove the tailgate remote handle (3). 3. Pry off the lower Bpillar trim panel. Refer to Section 9G, Interior Trim. 4. Pry off the
File name M39t1 Remote Keyless Entry and Anti-theft System.pdf

REMOTE KEYLESS ENTRY AND ANTITHEFT SYSTEM 9T i SECTION 9T REMOTE KEYLESS ENTRY AND ANTI-THEFT SYSTEM TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Remote Keyless Entry and Anti-Theft System . . . . . . . . . . . . . . . . . . . . . . . Remote Locking and Unlocking . . . . . . . . . . . . . . Security Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . Intrusion Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . Siren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . Autolocking (Safety Lock) . . . . . . . . . . . . . . . . . . 9T-2 9T-2 9T-2 9T-2 9T-2 9T-2 9T-2 9T-3 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Siren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Password Programming . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fastener Tightening Specifications . . . . . . . . . . . Schematic and Routing Diagrams . . . . . . . . . . . Remote Keyless Entry and Anti-Theft System . . . . . . . . . . . . . . . . . . . . . . . 9T-4 9T-4 9T-4 9T-5 9T-6 9T-6 9T-7 9T-7 Control Module/Receiver . . . . . . . . . . . . . . . . . . . 9T-3 IMMOBILIZER ANTI-THEFT SYSTEM TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . Immobilizer System . . . . . . . . . . . . . . . . . . . . . . . Electronically Coded Keys . . . . . . . . . . . . . . . . . Detection Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . Immobilizer Control Unit . . . . . . . . . . . . . . . . . . . Serial Data Link . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control Module (ECM) . . . . . . . . . . . Security Indicator . . . . . . . . . . . . . . . . . . . . . . . . . 9T-10 9T-10 9T-10 9T-10 9T-10 9T-11 9T-11 9T-12 Key Status Errors (FENIX 5MR) . . . . . . . . . . . . Key Status Errors (SIRIUS D3) . . . . . . . . . . . . . Communication Between Immobilizer and Test Equipment (FENIX 5MR) . . . . . . . . . . . . Communication Between Immobilizer and Test Equipment (SIRIUS D3) . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . Key Coding Procedure . . . . . . . . . . . . . . . . . . . . ID Code Reprogramming . . . . . . . . . . . . . . . . . . Transponder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Detection Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . Immobilizer Control Unit . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fastener Tightening Specifications . . . . . . . . . . 9T-24 9T-24 9T-25 9T-25 9T-26 9T-26 9T-26 9T-26 9T-27 9T-27 9T-28 9T-30 9T-30 Diagnostic Information and Procedures . . . . 9T-13 Im
File name M39t2 Remote Keyless Entry and Anti-theft System.pdf

REMOTE KEYLESS ENTRY AND ANTI-THEFT SYSTEM 9T 1 SECTION 9T REMOTE KEYLESS ENTRY AND ANTI-THEFT SYSTEM CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . . Remote Keyless Entry and Anti-Theft System . . . . . . . . . . . . . . . . . . . . . . . Remote Locking and Unlocking . . . . . . . . . . . . . . Security Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . Intrusion Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . Siren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . Autolocking (Safety Lock) . . . . . . . . . . . . . . . . . . 9T-2 9T-2 9T-2 9T-2 9T-2 9T-2 9T-2 9T-3 Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Siren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Password Programming . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fastener Tightening Specifications . . . . . . . . . . . Schematic and Routing Diagrams . . . . . . . . . . . Remote Keyless Entry and Anti-Theft System . . . . . . . . . . . . . . . . . . . . . . . 9T-4 9T-4 9T-4 9T-5 9T-6 9T-6 9T-7 9T-7 Control Module/Receiver . . . . . . . . . . . . . . . . . . . 9T-3 DAEWOO M-150 BL2 9T 2 REMOTE KEYLESS ENTRY AND ANTI-THEFT SYSTEM DESCRIPTION AND OPERATION REMOTE KEYLESS ENTRY AND ANTI-THEFT SYSTEM The remote keyless entry and anti-theft system can perform the following functions: D Remotely lock and unlock the vehicle doors with a hand-held high-frequency transmitter. D Sense intrusion into the vehicle through the doors, the tailgate, or the hood. D Activate a warning to signal an intrusion. D Help the driver find the vehicle in a parking area. D Automatically re-lock the doors if a door or the trunk is not opened within 30 seconds after the vehicle has been unlocked by the remote keyless entry. D Communicate serial data to a scan tool to help diagnose system faults. The remote keyless entry and anti-theft system consists of the following components: D D D D D D D D Keyless entry and anti-theft control module/receiver. Security indicator. Tailgate open switch. Door open switches. Central locking unit. Flashing turn signal lamps. Siren. Hood open switch. SECURITY INDICATOR There is a security indicator on the instrument panel. After the LOCK button of the transmitter is pressed, the module is placed in the armed mode, and the security indicator flashes. The security indicator turns ON for 1/8 second and OFF for 7/8 seco
File name M39t3 Imobiliser Anti-theft System.pdf

IMMOBILIZER ANTI-THEFT SYSTEM 9T 9 SECTION 9T IMMOBILIZER ANTI-THEFT SYSTEM CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS Description and Operation . . . . . . . . . . . . . . . . . Immobilizer System . . . . . . . . . . . . . . . . . . . . . . . Electronically Coded Keys . . . . . . . . . . . . . . . . . Detection Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . Immobilizer Control Unit . . . . . . . . . . . . . . . . . . . Serial Data Link . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control Module (ECM) . . . . . . . . . . . Security Indicator . . . . . . . . . . . . . . . . . . . . . . . . . 9T-10 9T-10 9T-10 9T-10 9T-10 9T-11 9T-11 9T-12 Key Status Errors (FENIX 5MR) . . . . . . . . . . . . Key Status Errors (SIRIUS D3) . . . . . . . . . . . . . Communication Between Immobilizer and Test Equipment (FENIX 5MR) . . . . . . . . . . . . Communication Between Immobilizer and Test Equipment (SIRIUS D3) . . . . . . . . . . . . . Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . Key Coding Procedure . . . . . . . . . . . . . . . . . . . . ID Code Reprogramming . . . . . . . . . . . . . . . . . . Transponder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Detection Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . Immobilizer Control Unit . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fastener Tightening Specifications . . . . . . . . . . 9T-24 9T-24 9T-25 9T-25 9T-26 9T-26 9T-26 9T-26 9T-27 9T-27 9T-28 9T-30 9T-30 Diagnostic Information and Procedures . . . . 9T-13 Immobilizer System (FENIX 5MR) . . . . . . . . . . 9T-13 Immobilizer System (SIRIUS D3) . . . . . . . . . . . 9T-13 DTC 1600 ECM Immobilizer Error (No Answer) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9T-14 DTC 1601 ECM Immobilizer Error (Incorrect Answer) . . . . . . . . . . . . . . . . . . . . . . 9T-16 DTC 1602 ECM Immobilizer Error (ECM Locked) . . . . . . . . . . . . . . . . . . . . . . . . . 9T-18 P1628 ECM Immobilizer Error . . . . . . . . . . . . . . 9T-20 P1629 ECM Immobilizer Error . . . . . . . . . . . . . . 9T-22 Schematic and Routing Diagrams . . . . . . . . . . 9T-31 Immobilizer Anti-Theft System . . . . . . . . . . . . . 9T-31 Remote Keyless Entry and Immobilizer Anti-theft System . . . . . . . . . . . . . . . . . . . . . . . 9T-32 DAEWOO M150 BL2 9T 10 IMMOBILIZER ANTI-THEFT SYSTEM DESCRIPTION AND OPERATION IMMOBILIZER SYSTEM The purpose of the Immobilizer system is to provide additional theft deterrence to the vehicle in which it is installed and to pr
File name M3CONTS.PDF

SECTION INDEX SERVICE MANUAL FRONT MATTER 0A MATIZ (MY2003) 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. GENERAL INFORMATION 0B ENGINE 1 SUSPENSION 2 DRIVELINE/AXLE 3 BRAKES 4 TRANSAXLE 5 STEERING HVAC (HEATING, VENTILATION, AND AIR CONDITIONING) RESTRAINTS 6 7 8 DAEWOO MOTOR CO., LTD. INCHON, KOREA BODY AND ACCESSORIES 9
File name SECTION.PDF

ENGINE CONTENTS SECTION 1A SECTION 1B SECTION 1D SECTION 1E SECTION 1F SECTION 1G GENERAL ENGINE INFORMATION SOHC ENGINE MECHANICAL ENGINE COOLING ENGINE ELECTRICAL ENGINE CONTROLS ENGINE EXHAUST SUSPENSION CONTENTS SECTION 2A SECTION 2B SECTION 2C SECTION 2D SECTION 2E SUSPENSION DIAGNOSIS WHEEL ALIGNMENT FRONT SUSPENSION REAR SUSPENSION TIRES AND WHEELS DRIVELINE/AXLE CONTENTS SECTION 3B MANUAL TRANSAXLE DRIVE AXLE BRAKES CONTENTS SECTION 4A SECTION 4B SECTION 4C SECTION 4D SECTION 4E SECTION 4F SECTION 4G HYDRAULIC BRAKES MASTER CYLINDER POWER BOOSTER FRONT DISC BRAKES REAR DRUM BRAKES ANTILOCK BRAKE SYSTEM PARKING BRAKE TRANSAXLE CONTENTS SECTION 5B SECTION 5C FIVESPEED MANUAL TRANSAXLE CLUTCH STEERING CONTENTS SECTION 6A SECTION 6B SECTION 6C SECTION 6D SECTION 6E POWER STEERING SYSTEM POWER STEERING PUMP POWER STEERING GEAR MANUAL STEERING GEAR STEERING WHEEL AND COLUMN HVAC (HEATING, VENTILATION, AND AIR CONDITIONING) CONTENTS SECTION 7A SECTION 7B HEATING AND VENTILATION SYSTEM MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM RESTRAINTS CONTENTS SECTION 8A SECTION 8B SEAT BELTS SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) BODY AND ACCESSORIES CONTENTS SECTION 9A SECTION 9B SECTION 9C SECTION 9D SECTION 9E SECTION 9F SECTION 9G SECTION 9H SECTION 9I SECTION 9J SECTION 9K SECTION 9L SECTION 9M SECTION 9N SECTION 9O SECTION 9P SECTION 9Q SECTION 9R SECTION 9S SECTION 9T BODY WIRING SYSTEM LIGHTING SYSTEMS HORNS WIPERS / WASHER SYSTEMS INSTRUMENTATION / DRIVER INFORMATION AUDIO SYSTEMS INTERIOR TRIM SEATS WATERLEAKS WINDNOISE SQUEAKS AND RATTLES GLASS AND MIRRORS EXTERIOR TRIM FRAME AND UNDERBODY BUMPERS AND FASCIAS DOORS ROOF BODY FRONT END BODY REAR END IMMOBILIZER ANTITHEFT SYSTEM



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