Text preview for : en_4j2_9i0.pdf part of Daewoo Nubira/Lacetti Also known as: Chevrolet Nubira / Lacetti, Chevrolet Optra Optra5, Suzuki Forenza Reno
Covers the 1.4L, 1.6L and 1.8L engine.
Back to : Service Manual - Daewoo L | HomeSECTION : 9IWATERLEAKSTABLE OF CONTENTSSPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 9I1 Recommended Materials for Waterleak Repairs . 9I1 Watertest Stand Specifications . . . . . . . . . . . . . . . 9I1 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9I2 Waterleak Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 9I2 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . . 9I5 ONVEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . 9I5 Waterleak Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 9I5SPECIFICATIONSRECOMMENDED MATERIALS FOR WATERLEAK REPAIRSLeak Areas Windshield, back window Metal joints Ventilation ducts Small cracks and pin holes Large holes Weatherstrips Bolts, studs, and screws Repair Materials Urethane adhesive, caulking kit, or the equivalent Brushable seam sealer which can be painted 3Mnv Auto Bedding and Glazing Compound or the equivalent 3Mnv DripCheck Sealer or the equivalent 3Mnv Automotive Joint and Seam Sealer 3Mnv 08011 Weatherstrip Adhesive or the equivalent Strip caulkWATERTEST STAND SPECIFICATIONSApplication Nozzle Type Nozzle Height Volume of Flow Pressure Windshield and APillar Test Stand Position BPillar Test Stand Position Back Window and Rear Deck Lid Test Stand Position Description Full jet spray nozzle #1/2 GG25 or equivalent with a 60° included angle Approximately 1 600 mm (63.0 in.) from the floor 14L (3.7 gal) per minute 155 kPa (22.5 psi) measured at the nozzle Approximately 30° down, 45° toward the rear, and aimed at the corner of the windshield Approximately 30° down, 45° toward the rear, and aimed at the center of the rear door Approximately 30° down, 30° toward the front and aimed approximately 610 mm (24.0 in.) from the corner of the back window9I 2IWATERLEAKSDIAGNOSISWATERLEAK DIAGNOSISThe repair of waterleaks in the body requires proper testing and diagnosis. Repair waterleaks by adjusting the misaligned parts and using the proper repair materials. First, determine what conditions cause the leak. For example, the leak may occur only when the vehicle is parked on an incline, or water may appear only in the spare tire compartment. Second, test the area for the source of the leak using the following testing methods. If the general leak area is found, determine the exact entry point of the leak by using a water hose or an air hose. If the general leak area is not obvious, use the watertest stands to determine the area of the leak. It may be necessary to remove some interior trim panels or some parts in order to locate the leaks. Important : It is necessary to find the origin of all the leaks before making any repairs. Random repairs may stop the leak only temporarily and may make future repairs more difficult. Continue localized testing in the general area in order to ensure that all leaks are found.1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 2.1/2inch by 36inch Pipe Fulljet Spray Nozzle #1/2 GG25 or Equivalent Nozzle Height at 1,600 mm to the Floor 1/2inch Coupling 1/2inch by 1/2inch by 1/4inch Reducing T (Right Only) 1/2inch Coupling (Left Only) 1/2inch Cross (Right Only) ) 1/2inch Tee (Left Only) 1/2inch PipetoHose Nipple (Right Only) 5/8inch Female Hose Coupling 5/8inch Input Hose (2 Feet Long, Right Only 1/2inch Close Nipple 1/2inch Cross with Weldon 1/2inch Cap 1/2inch by 12inch Nipple 1/2inch Cap 5/8inch Female Hose Coupling 5/8inch Cross Hose (12 Feet Long) 5/8inch Hose Quick Connect 1/2inch PipetoHose Nipple 1/2inch by 30inch Pipe (Straight) 1/4inch Water Pressure Gauge (Right Only)Generalized Testing1. Set up the watertest stands.Set up the watertest stand leak test.DAEWOO V121 BL4WATERLEAKS 9I 33. 4. Perform the watertest stand leak test. Refer to "Watertest Stand Specifications" in this section. 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.Localized Testing (Spot Test)1. 2. Do localized testing with a water hose or an air hose. Begin testing by spraying the air or the water at the base of the suspected leak area. Continue spraying the air or the water upward until the leak is found.3.Begin spraying the water at the base of the suspected leak area. Continue spraying the water upward until the leak is found.Water Hose Test1. 2. Place another person inside the vehicle in order to detect the location of the leak. Use a water hose without a nozzle.DAEWOO V121 BL49I 4IWATERLEAKS Air Hose Test1. 2. 3. Apply soapy water to the outside of the vehicle in the suspected leak area. Blow air from inside the vehicle. The air pressure should not exceed 205 kPa (29.7 psi). Determine the location of the leaks from the bubbles formed in the soapy water.DAEWOO V121 BL4WATERLEAKS 9I 5MAINTENANCE AND REPAIRONVEHICLE SERVICE WATERLEAK REPAIRSome waterleaks around the glass can be repaired without removing the glass. Important : This type of repair may be used only for urethane installed glass. 1. Remove the reveal molding in the area of the leak. It may be necessary to remove the garnish molding or the trim strip lace in order to locate the leak. 2. While spraying water over the leak area, carefully push the glass outward in order to determine the size of the leak. 3. Mark the location of the leak. 4. Use water to clean any dirt from the area. Dry the area with an air hose. 5. Using a sharp knife, trim off the uneven edges of the adhesive caulking material around the leak for a distance of 75 to 100 mm (3 to 4 inches) on both sides of the leak. 6. Using a sharp knife, trim off the uneven edges of the adhesive material around the leak 75 to 100 mm (3 to 4 inches) on both sides of the leak.7.Prime the trimmed area with the primer.DAEWOO V121 BL49I 6IWATERLEAKS8. 9. Allow the primer to dry for 5 minutes. Apply the adhesive over the leak and for a distance of 75 to 100 mm (3 to 4 inches) on both sides of the leak.10. Immediately after applying the adhesive, use a flat stick or a similar tool to work the adhesive into the leak area and into the joint between the original material and the vehicle body in order to ensure a watertight seal. 11. Spray warm or hot water over the repaired area in order to determine if the leak was repaired. Do not run a heavy stream of water directly on the freshly applied adhesive. 12. Install the trim strip lace if it was removed. 13. Install the garnish molding if it was removed. 14. Install the reveal molding. Important : After the completion of any waterleak repair, retest the area using the watertest stands. Do not use localized testing procedures on the newlyrepaired areas, as the repair material may dislodge under abnormal pressure.DAEWOO V121 BL4