Daewoolanos2002 PDF

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SECTION : 0B
GENERAL INFORMATION
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–1 AT LEAST MONTHLY . . . . . . . . . . . . . . . . . . . . . 0B–13
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . 0B–1 AT LEAST TWICE A YEAR . . . . . . . . . . . . . . . . 0B–13
VEHICLE DIMENSIONS AND WEIGHTS . . . . . 0B–6 EACH TIME THE OIL IS CHANGED . . . . . . . . 0B–14
STANDARD BOLT SPECIFICATIONS . . . . . . . . 0B–8 AT LEAST ANNUALLY . . . . . . . . . . . . . . . . . . . . 0B–14
RECOMMENDED FLUIDS AND LUBRICANTS 0B–15
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 0B–9
MAINTENANCE AND LUBRICATION . . . . . . . . . . 0B–9 GENERAL DESCRIPTION AND SYSTEM
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–16
NORMAL VEHICLE USE . . . . . . . . . . . . . . . . . . . 0B–9
GENERAL REPAIR INSTRUCTIONS . . . . . . . 0B–16
EXPLANATION OF SCHEDULED MAINTENANCE
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . 0B–17
SERVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–9
ON BOARD REFUELING VAPOR RECOVERY
SCHEDULED MAINTENANCE CHARTS . . . . 0B–11
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–17
OWNER INSPECTIONS AND SERVICES . . . . . 0B–13 VEHICLE AND COMPONENT IDENTIFICATION 0B–
WHILE OPERATING THE VEHICLE . . . . . . . . 0B–13 20
AT EACH FUEL FILL . . . . . . . . . . . . . . . . . . . . . . 0B–13 VEHICLE LIFTING PROCEDURES . . . . . . . . . 0B–25
SPECIFICATIONS
TECHNICAL DATA
Performance – Manual Transaxle
Application 1.5L SOHC 1.6L DOHC
Maximum Speed 170 km/h (106 mph) 175 km/h (108.7 mph)
Gradeability 0.5 (tan Ø) 0.5 (tan Ø)
Minimum Turning Radius 4.9 m (16 ft) 4.9 m (16 ft)
Performance – Automatic Transaxle

Maximum Speed 158 km/h (98.2 mph) 168 km/h (104.4 mph)
Gradeability 0.59 (tan Ø) 0.59 (tan Ø)
Minimum Turning Radius 4.9 m (16 ft) 4.9 m (16 ft)
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0B – 2IGENERAL INFORMATION
Engine
Manual and Automatic Manual and Automatic
Engine Type Overhead Cam L–4 Overhead Cam L–4
Bore 76.5 mm (3.01 in.) 79.0 mm (3.11 in.)
Stroke 81.5 mm (3.21 in.) 81.5 mm (3.21 in.)
Total Displacement 1 498 cm3 (91.4 in3) 1 598 cm3 (97.5 in3)
Compression Ratio 9.5:1 9.5:1
Maximum Power 63 kw (83.8 bhp) 77.8 kw (105.3 bhp)
(at 5,600 rpm) (at 5,800 rpm)
Maximum Torque 125.4 NSm (92.5 lb–ft) 143.4 NSm (105.8 lb–ft)
(at 3,400 rpm) (at 3,800 rpm)
Ignition System
Ignition Type Direct Ignition System Direct Ignition System
Ignition Timing 10³ (BTDC) 10³ (BTDC)
Ignition Sequence 1–3–4–2 1–3–4–2
Spark Plug Gap 0.70–0.80 mm (0.028–0.031 in.) 1.00–1.17 mm (0.039–0.46 in.)
Spark Plug Maker Champion / Woojin Delphi
Spark Plug Type RN9YC / BPR6ES FR2LS
Clutch – Manual Transaxle

Type Single Dry Plate Single Dry Plate
Outside Diameter 200 mm (7.9 in.) 215 mm (8.5 in.)
Inside Diameter 134 mm (5.3 in.) 145 mm (5.7 in.)
Thickness 7.65 mm (0.301 in.) 7.65 mm (0.301 in.)
Fluid Common Use; Common Use;
Brake Fluid Brake Fluid
Manual Transaxle
Wide Ratio Wide Ratio
Maker DWMC DWMC
Type or Model D–16 D–16
Gear Ratio: 3.545:1 3.545:1
1st
2nd 1.952:1 1.952:1
3rd 1.276:1 1.276:1
4th 0.892:1 0.892:1
5th 0.707:1 0.707:1
Reverse 3.333:1 3.333:1
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GENERAL INFORMATION 0B – 3

Wide Ratio Wide Ratio
Final Drive Ratio 3.944:1 4.176:1
Oil Capacity 1.8L (2 qt) 1.8L (2 qt)
Automatic Transaxle
Maker General Motors General Motors
Type or Model 4T40E 4T40E
Gear Ratio: 2.957:1 2.957:1
1st
2nd 1.623:1 1.623:1
3rd 1.000:1 1.000:1
4th 0.682:1 0.682:1
Reverse 2.143:1 2.143:1
Final Drive Ratio 3.91:1 3.91:1
Oil Capacity 11.5L (12 qt) 11.5L (12 qt)
Brake
Booster Size 228.6 mm (9.00 in.) 228.6 mm (9.00 in.)
Master Cylinder Diameter 20.64 mm (0.813 in.) 22.22 mm (0.875 in.)
Booster Ratio 5.0:1 5.0:1
Front Brake: Ventilated Ventilated
Disc Type 330 mm (13.0 in.) 330 mm (13.0 in.)
Disc Size
Rear Brake: 200 mm (7.9 in.) 200 mm (7.9 in.)
Drum Inside Diameter
Wheel Cylinder Diameter 17.46 mm (0.687 in.) 19.05 mm (0.750 in.)
Fluid Capacity 0.5L (0.5 qt) 0.5L (0.5 qt)
Tire and Wheel

Standard Tire Size 175/70R13 185/60R14
Temporary Spare Tire Size T105/70D14 T105/70D14
Standard Wheel Size 5J X 13 (Steel) 5.5J X 14 (Steel)
Optional Wheel Size 5.5J X 14 (Aluminum)
Temporary Spare Wheel Size 4Tx14 4Tx14
Inflation Pressure at Full Load:
155/80R13 35 psi
175/70R13 35 psi
185/60R14 32 psi
T125/70D14 60 psi 60 psi
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Steering System
Gear Type Power/Manual Power
Rack and Pinion Rack and Pinion
Overall Gear Ratio 24.5:1
Manual Steering 16.12:1 16.12:1
Power Steering
Wheel Diameter 380 mm (15.0 in.) 380 mm (15.0 in.)
Wheel Alignment: –10′–+10′ (–1µ1 mm) –10′µ10′ (–1µ1 mm)
Front: (–0.04µ0.04 in.) (–0.04µ0.04 in.)
Toe–In
Caster: 30′~2³30′
Manual Steering
Power Steering 1³45′–3³45′ 1³45′–3³45′
Camber –1³10′µ20′ –1³10′µ20′
Rear: –10′µ40′ (–1µ4 mm) –10′µ40′ (–1µ4 mm)
Toe–In (–0.04µ0.16 in.) (–0.04µ0.16 in.)
Camber –2³10′– –1³10′ –2³10′– –1³10′
Oil Capacity 1.0L (1.1 qt) 1.0L (1.1 qt)
Suspension
Front Type MacPherson Strut MacPherson Strut
Rear Type Compound Link Compound Link
Fuel System
Fuel Delivery MPI MPI
Fuel Pump Type Electric Motor Pump Electric Motor Pump
Fuel Filter Type Cartridge Cartridge
Fuel Capacity 48L (12.7 gal) 48L (12.7 gal)
Lubricating System
Lubricating Type Forced Feed Forced Feed
Oil Pump Type Duocentric Rotor Duocentric Rotor
Oil Filter Type Cartridge (Full Flow) Cartridge (Full Flow)
Oil Pan Capacity 3.75L (4 qt) 3.75L (4 qt)
Including Oil Filter

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Cooling System
Cooling Type Forced Water Forced Water
Circulation Circulation
Radiator Type Cross–flow Cross–flow
Water Pump Type Centrifugal Centrifugal
Thermostat Type Pellet Type Pellet Type
Coolant Capacity: 7.0L (7.4 qt) 7.0L (7.4 qt)
Standard
Heavy Duty 7.0L (7.4 qt) 7.0L (7.4 qt)
Electric System
Battery General Area 550 Cold 550 Cold
Cranking Amps Cranking Amps
Alternator General Area 85 Amps 85 Amps
Starter 1.4 (kW) Minimum 40 Amps Minimum 40 Amps
(No–Load Test Current Draw) Maximum 90 (Amps) (at Maximum 90 (Amps) (at
12.2 Volts) 12.2 Volts)
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VEHICLE DIMENSIONS AND WEIGHTS

Vehicle Dimensions – Manual and Automatic
Application 1.5L SOHC 1.6L SOHC
Overall Length: 4 074 mm (160.4 in.) 4 074 mm (160.4 in.)
3 Door
4 Door 4 237 mm (166.8 in.) 4 237 mm (166.8 in.)
Overhang: 838 mm (33.0 in.) 838 mm (33.0 in.)
Front:
3 Door
4 Door 838 mm (33.0 in.) 838 mm (33.0 in.)
Rear: 716 mm (28.2 in.) 716 mm (28.2 in.)
3 Door
4 Door 879 mm (34.6 in.) 879 mm (34.6 in.)
Overall Width 1 678 mm (66.1 in.) 1 678 mm (66.1 in.)
Overall Height 1 432 mm (56.4 in.) 1 432 mm (56.4 in.)
Minimum Ground Clearance 160 mm (6.3 in.) 160 mm (6.3 in.)
Wheel Base 2 520 mm (99.2 in.) 2 520 mm (99.2 in.)
Tread: 1 405 mm (55.3 in.) 1 405 mm (55.3 in.)
Front
Rear 1 425 mm (56.1 in.) 1 425 mm (56.1 in.)
Vehicle Weights Ĉ 3 Door

Manual: 1,068 kg (2,354 lb) 1,110 kg (2,447 lb)
Curb Weight:
Standard
Optional 1,085 kg (2,392 lb) 1,127 kg (2,485 lb)
Gross Vehicle Weight 1,468 kg (3,236 lb) 1,510 kg (3,329 lb)
Automatic: 1,103 kg (2,433 lb) 1,146 kg (2,527 lb)
Curb Weight:
Standard
Passenger Capacity 5 5

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Vehicle Weights Ĉ 4 Door

Manual: 1,092 kg (2,408 lb) 1,144 kg (2,522 lb)
Curb Weight:
Standard
Automatic: 1,130 kg (2,492 lb) 1,177 kg (2,595 lb)
Curb Weight:
Standard
Passenger Capacity 5 5
Optional Weight: ABS, Sun Roof
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STANDARD BOLT SPECIFICATIONS

Bolt* 4T – Low Carbon Steel 7T – High Carbon Steel 7T – Alloy Steel
M6 X 1.0 4.1–8.1 NSm (36–72 lb–in) 5.4–9.5 NSm (48–84 lb–in) –
M8 X 1.25 8.1–17.6 NSm (72–156 lb–in) 12.2–23.0 NSm (108–204 lb– 16–30 NSm (12–22 lb–ft)
in)
M10 X 1.25 20–34 NSm (15–25 lb–ft) 27–46 NSm (20–34 lb–ft) 37–62 NSm (27–46 lb–ft)
* Diameter X pitch in millimeters

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tions require higher viscosity engine oils for satisfactory lu-

MAINTENANCE AND REPAIR brication. Using oils of any viscosity other than those
viscosities recommended could result in engine damage.
Cooling System Service
MAINTENANCE AND LUBRICATION Drain, flush and refill the system with new coolant. Refer
to ”Recommended Fluids And Lubricants” in this section.
NORMAL VEHICLE USE
The maintenance instructions contained in the mainte- Fuel Micro–Filter Replacement
nance schedule are based on the assumption that the ve- Replace the engine fuel filter every 48,000 km (30,000
hicle will be used for the following reasons: miles).
S To carry passengers and cargo within the limitation The engine fuel filter is located on the center dash panel
indicated on the tire placard located on the edge of near the brake booster.
the driver’s door. Air Cleaner Element Replacement
S To be driven on reasonable road surfaces and with- Replace the air cleaner element every 48 000 km (30,000
in legal operating limits. miles).
Replace the air cleaner more often under dusty conditions.
EXPLANATION OF SCHEDULED
Throttle Body Mounting Bolt Torque
MAINTENANCE SERVICES Check the torque of the mounting bolts.
The services listed in the maintenance schedule are fur- Tighten the throttle body mounting bolts to 17 NSm (12 lb–
ther explained below. When the following maintenance ft) if necessary.
services are performed, make sure all the parts are re-
placed and all the necessary repairs are done before driv- Spark Plug Replacement
ing the vehicle. Always use the proper fluid and lubricants. Replace spark plugs with the same type.
Type: AC Type RN9YC (SOHC)
Drive Belt Inspection BPR6ES (SOHC)
When a separate belt drives the power steering pump, the FR2LS (DOHC)
air conditioning compressor and the generator, inspect it Gap
for cracks, fraying, wear and proper tension. Adjust or re- 0.7–0.8 mm (SOHC)
place the belt as needed. 1.0–1.17 mm (DOHC)
Engine Oil and Oil Filter Change Spark Plug Wire Replacement
Clean wires and inspect them for burns, cracks or other
API Classifications of Engine Oil damage. Check the wire boot fit at the DIS module and at
The International Lubricant Standardization and Approval the spark plugs. Replace the wires as needed.
Committee (ILSAC) and American Petroleum Institute
classifies engine oils according to their performance quali- Brake System Service
ty. Always use oil rated API–SJ (ILSAC GF–II) or better. Check the disc brake pads or the drum brake linings every
9,600 km (6,000 miles) or 6 months. Check the pad and
Engine Oil Viscosity the lining thickness carefully. If the pads or the linings are
Engine oil viscosity (thickness) has an effect on fuel econ- not expected to last another 9,600 km (6,000 miles), re-
omy and cold weather operation. Lower viscosity engine place the pads or the linings. Check the breather hole in
oils can provide better fuel economy and cold weather per- the brake fluid reservoir cap to be sure it is free from dirt
formance; however, higher temperature weather condi- and the passage is open.
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wear and obtain maximum tire life, rotate the tires. If irreg-
Transaxle Service ular or premature wear exists, check the wheel alignment
The manual transaxle fluid does not require changing. For and check for damaged wheels. While the tires and
automatic transaxles, refer to ”Scheduled Maintenance wheels are removed, inspect the brakes. Refer to ”Each
Charts” in this section. Time The Oil Is Changed” in this section.
Tire and Wheel Inspection and Rotation
Check the tires for abnormal wear or damage. To equalize Tire Rotation

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SCHEDULED MAINTENANCE CHARTS

Engine
Maintenance Item Maintenance Interval
Miles (Kilometers) or time in months, whichever comes first
x 1,000 miles 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102
x 1,000 km 9.6 19.2 28.8 38.4 48 57.6 67.2 76.8 86.46 96 105.6 115.2 124.8 134.4 144 153.6 163.2
# Months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102
Drive belt 1.5L I R I R I

(Generato-
rand power 1.6L
Steering)
I I I I I
Engine oil & engine oil filter (1)(3) R R R R R R R R R R R R R R R R R

Cooling system hose & connec- I I I I I I I I
tions
Engine coolant (3) I I I I R I I I I R I I I I R I I

Fuel filter R* R* R*
Fuel line and connections I* I* I* I* I* I* I* I*
Air cleaner element (2) I* I* I* I* R I* I* I* I* R I* I* I* I* R I* I*
Ignition timing I* I* I* I* I* I* I* I*
Spark plugs I* R I* R I* R
Ignition cable Replace every 60,000 miles (96,000 km)
Evaporative emission canister & I* I* I*
vapor lines
PCV system I* I* I* I* I*
Timimg belt Out of Cali- Replace every 60,000 miles (96,000 km)
fornia
California Inspect every 60,000 miles (96,000 km) and 90,000 miles (144,000 km)* Replace every 102,000 miles
(163,200 km)
Chart Symbols:
I – Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.
R – Replace or change.
(1) Change the engine oil and the filter every 3,000 miles (4,800 km) or 3 months, whichever comes first, if the vehicle
is operated under any of the following conditions:
S Short distance driving.
S Extensive idling.
S Driving on dusty roads.
(2) More frequent maintenance is required if driving under dusty conditions.
(3) Refer to ”Recommended Fluids And Lubricants”
Note : Check the engine oil and radiator coolant levels every week.
* Replacement of these emissions components is recommended to be performed at the indicated intervals however, the
Califonia Air Resources Board has determined that performing these maintenance items are not required to maintained
your vehicle emission warranty.
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Chassis and Body
Maintenance Item Maintenance Interval

Miles (Kilometers) or time in months, whichever comes first
x 1,000 miles 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102
x 1,000 km 9.6 19.2 28.8 38.4 48 57.6 67.2 76.8 86.46 96 105.6 115.2 124.8 134.4 144 153.6 163.2
# Months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102
Exhaust pipes & mountings I* I* I* I* I* I* I* I*

Brake/Clutch fluid (3)(5) I I R I I R I I R I I R I I R I I
Front brake pads & discs(6) I I I I I I I I I I I I I I I I I
Rear brake drums & linings (6) I I I I I I I I
Parking brake I I I I I I I I
Brake line & connections Includ- I I I I I I I I I I I I I I I I I
ing booster)
Rear hub bearing & clearance I I I I I I I I

Manual Transaxle Oil (3) I I I I I I I I
Clutch & brake pedal free play I I I I I I I I I I I I I I I I I
Automatic transaxle fluid* (3) (7) I I I I I I I I
Chassis & underbody bolts & I I I I I I I I I I I I I I I I I
nuts, tighten/secure
Tire condition & inflation pres- I I I I I I I I I I I I I I I I I

sure
Wheel alignment (8) Inspect when abnormal condition is noted.

Steering wheel & linkage I I I I I I I I I I I I I I I I I
Power steering fluid & lines* (3) I I I I I I I I
Drive shaft boots I I I I I I I I I I I I I I I I I
Seat belts, buckles & anchors I I I I I I I I I I I I I I I I I
Lubricate locks, hinges & hood I I I I I I I I
latch
Tire rotation Rotate every 6,000 miles (9,600 km)
Chart Symbols:
I – Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace.
R – Replace or change.
(3) Refer to”Recommended Fluids And Lubricants.”
(5) Change the brake/clutch fluid every 9,000 miles (14,400 km) or 9 months, whichever comes first, if the vehicle is oper-
ated under any of the following conditions:
S Operating in hilly or mountainous terrain.
(6) More frequent maintenance is required if the vehicle is operated under any of the following conditions:
S Short distance driving. go traffic.
S Extensive idling or slow speed driving in stop–and– S Driving on dusty roads.
(7) Change the automatic transaxle fluid every 50,000 miles (80,000 km) or 50 months, whichever comes first, if the vehicle
is operated under any of the following conditions:
S Operating in heavy city traffic where the outside temperatures regularly reach 32³C (90³F) or higher.
S Operating in hilly or mountainous terrain.
S Taxi driving, police vehicles, or delivery services.
(8) If necessary, rotate and balance the wheels.
* Replacement of these emissions components is recommended to be performed at the indicated intervals however, the
Califonia Air Resources Board has determined that performing these maintenance items are not required to maintained
your vehicle emission warranty.

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If you check the oil level when the oil is cold, do not run the
OWNER INSPECTIONS AND engine first. The cold oil will not drain back to the pan fast
SERVICES enough to give a true oil level reading.
Engine Coolant Level and Condition

WHILE OPERATING THE VEHICLE Check the coolant level in the coolant reservoir tank and
Horn Operation add coolant if necessary. Inspect the coolant. Replace
dirty or rusty coolant.
Blow the horn occasionally tomake sure it works. Check
all the button locations. Windshield Washer Fluid Level
Brake System Operation Check the washer fluid level in the reservoir. Add fluid if
necessary.
Be alert for abnormal sounds, increased brake pedal trav-
el or repeated pulling to one side when braking. Also, if the AT LEAST MONTHLY
brake warning light goes on, or flashes, something may be
wrong with part of the brake system. Tire And Wheel Inspection and Pressure
Exhaust System Operation Check
Be alert to any changes in the sound of the system or the Check the tires for abnormal wear or damage. Also check
smell of the fumes. These are signs that the system may for damaged wheels. Check the tire pressure when the
be leaking or overheating. Have the system inspected and tires are cold (check the spare also, unless it is a stow-
repaired immediately. away). Maintain the recommended pressures that are on
the tire placard that is in the glove box.
Tires,Wheels and Alignment Operation
Be alert to any vibration of the steering wheel or the seats Light Operation
at normal highway speeds. This may mean a wheel needs Check the operation of the license plate light, the head-
to be balanced. Also, a pull right or left on a straight, level lights (including the high beams), the parking lights, the
road may show the need for a tire pressure adjustment or fog lights, the taillight, the brake lights, the turn signals, the
a wheel alignment. backup lights and the hazard warning flasher.
Steering System Operation Fluid Leak Check

Be alert to changes in the steering action. An inspection Periodically inspect the surface beneath the vehicle for
is needed when the steering wheel is hard to turn or has water, oil, fuel or other fluids, after the vehicle has been
too much free play, or if unusual sounds are noticed when parked for a while. Water dripping from the air conditioning
turning or parking. system after use is normal. If you notice fuel leaks or
fumes, find the cause and correct it at once.
Headlight Aim
Take note of the light pattern occasionally. Adjust the AT LEAST TWICE A YEAR
headlights if the beams seem improperly aimed.
Power Steering System Reservoir Level
AT EACH FUEL FILL Check the power steering fluid level. Keep the power
A fluid loss in any (except windshield washer) system may steering fluid at the proper level. Refer to Section 6A, Pow-
indicate a problem. Have the system inspected and re- er Steering System.
paired immediately. Brake Master Cylinder Reservoir Level
Engine Oil Level Check the fluid and keep it at the proper level. A low fluid
Check the oil level and add oil if necessary. The best time level can indicate worn disc brake pads which may need
to check the engine oil level is when the oil is warm. to be serviced. Check the breather hole in the reservoir
cover to be free from dirt and check for an open passage.
1. After stopping the engine, wait a few minutes for
the oil to drain back to the oil pan. Clutch Pedal Free Travel
2. Pull out the oil level indicator (dip stick). Check clutch pedal free travel and adjust as necessary ev-
3. Wipe it clean, and push the oil level indicator back ery 9,600 km (6,000 miles). Measure the distance from the
down all the way. center of the clutch pedal to the outer edge of the steering
4. Pull out the oil level indicator and look at the oil lev- wheel with the clutch pedal not depressed. Then measure
el on it. the distance from the center of the clutch pedal to the outer
5. Add oil, if needed, to keep the oil level above the edge of the steering wheel with the clutch pedal fully de-
MIN line and within the area labeled ”Operating pressed. The difference between the two values must be
Range.” Avoid overfilling the engine, since this may greater than 130 mm (5.19 inches).
cause engine damage.
6. Push the indicator all the way back down into the Weather–Strip Lubrication
engine after taking the reading. Apply a thin film silicone grease using a clean cloth.
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EACH TIME THE OIL IS CHANGED AT LEAST ANNUALLY

Lap and Shoulder Belts Condition and
Automatic Transaxle Fluid Operation
Refer to 4T40E fluid level service procedure of Section Inspect the belt system including: the webbing, the
5A, 4T40E Automatic Transaxle. buckles, the latch plates, the retractor, the guide loops and
the anchors.
Manual Transaxle
Check the fluid level and add fluid as required. Refer to Movable Head Restraint Operation
Section 5B, Five–Speed Manual Transaxle. On vehicles with movable head restraints, the restraints
must stay in the desired position.
Brake System Inspection Spare Tire and Jack Storage
This inspection should be done when the wheels are re- Be alert to rattles in the rear of the vehicle. The spare tire,
moved for rotation. Inspect the lines and the hoses for all the jacking equipment, and the tools must be securely
proper hookup, binding, leaks, cracks, chafing, etc. In- stowed at all times. Oil the jack ratchet or the screw mech-
spect the disc brake pads for wear. Inspect the rotors for anism after each use.
surface condition. Also inspect the drum brake linings for
wear and cracks. Inspect other brake parts, including the Key Lock Service
drums, the wheels cylinders, the parking brake, etc., at the Lubricate the key lock cylinder.
same time. Check the parking brake adjustment. Inspect Body Lubrication Service
the brakes more often if habit or conditions result in fre-
Lubricate all the body door hinges including the hood, the
quent braking.
fuel door, the rear compartment hinges and the latches,
the glove box and the console doors, and any folding seat
Steering, Suspension and Front Drive Axle
hardware.
Boot And Seal Inspection
Inspect the front and rear suspension and the steering Transaxle Neutral Switch Operation on
system for damaged, loose or missing parts, signs of wear Automatic Transaxle
or lack of lubrication. Inspect the power steering lines and CAUTION : Take the following precautions because
the hoses for proper hookup, binding, leaks, cracks, chaf- the vehicle could move without warning and possibly
ing, etc. Clean and inspect the drive axle boot and seals cause personal injury or property damage:
for damage, tears or leakage. Replace the seals if neces- S Firmly apply the parking brake and the regular
sary. brakes.
S Do not use the accelerator pedal.
Exhaust System Inspection S Be ready to promptly turn off the ignition if the
Inspect the complete system (including the catalytic con- vehicle starts.
verter if equipped). Inspect the body near the exhaust sys-
On automatic transaxle vehicles, try to start the engine in
tem. Look for broken, damaged, missing, or out–of–posi-
each gear. The starter should crank only in P (Park) or N
tion parts as well as open seams, holes, loose
(Neutral).
connections, or other conditions which could cause heat
buildup in the floor pan or could let exhaust fumes seep Parking Brake and Transaxle P (Park)
into the trunk or passenger compartment. Mechanism Operation
CAUTION : In order to reduce the risk of personal in-
Throttle Linkage Inspection jury or property damage, be prepared to apply the reg-
Inspect the throttle linkage for interference or binding, ular brakes promptly if the vehicle begins to move.
damaged, or missing parts. Lubricate all linkage joints and
Park on a fairly steep hill with enough room for movement
throttle cable joints, the intermediate throttle shaft bearing,
in the downhill direction. To check the parking brake, with
the return spring at throttle valve assembly, and the accel-
the engine running and the transaxle in N (Neutral), slowly
erator pedal sliding face with suitable grease. Check the
remove foot pressure from the regular brake pedal (until
throttle cable for free movements.
only the parking brake is holding the vehicle).
To check the automatic transaxle P (Park) mechanism’s
Engine Drive Belts
holding ability, release all brakes after shifting the trans-
Inspect all belts for cracks, fraying, wear and proper ten-
axle to P (Park).
sion. Adjust or replace the belts as needed.
Underbody Flushing
Hood Latch Operation Flushing the underbody will remove any corrosive materi-
When opening the hood, note the operation of the secon- als used for ice and snow removal and dust control. At
dary latch. It should keep the hood from opening all the least every spring clean the underbody. First, loosen the
way when the primary latch is released. The hood must sediment packed in closed areas of the vehicle. Then flush
close firmly. the underbody with plain water.

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sion protection and engine operating temperature. Inspect

Engine Cooling System the hoses. Replace the cracked, swollen, or deteriorated
Inspect the coolant and freeze protection fluid. If the fluid hoses. Tighten the clamps. Clean the outside of the radia-
is dirty or rusty, drain, flush and refill the engine cooling tor and the air conditioning condenser. Wash the filler cap
system with new coolant. Keep the coolant at the proper and the neck. Pressure test the cooling system and the
mixture in order to ensure proper freeze protection, corro- cap in order to help ensure proper operation.
RECOMMENDED FLUIDS AND LUBRICANTS

Usage Capacity Fluid/Lubricant
Engine Oil 3.75L (4 qt) ILSAC GF–II (API SJ) grade SAE 5W–30,
SAE10W–30
Engine Coolant 7.0L (7.4 qt) Mixture of water and good quality ethylene glycol
base antifreeze (year–round coolant)
Brake Fluid and Clutch Fluid 0.5L (0.5 qt) DOT–3 or DOT–4
Power Steering System 1.0L (1.1 qt) DEXRON±–III
Automatic Transaxle 11.5L (12.2 qt) DEXRON±–III
Manual Transaxle 1.8L (2 qt) Manual Transaxle Fluid (B0400075, SAE80 or
equivalent)
Manual Transaxle Shift Linkage As required Multipurpose type grease meeting requirements
NLGI No. 1 or 2
Key Lock Cylinders As required Silicone lubricant
Automatic Transaxle Shift Link- As required Engine oil
age
Clutch Linkage Pivot Points As required Engine oil
Floor Shift Linkage Points As required Engine oil
Hood Latch Assembly As required a. Engine oil
a. Pivots and Spring Anchor b. Multipurpose type grease meeting requirements
b. Release Pawl NLGI No. 1 or 2
Hood and door hinges As required Engine oil
Fuel door hinge
Rear compartment lid hinges
Weatherstrips As required Silicone grease
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S Use genuine DAEWOO parts.

GENERAL DESCRIPTION S Discard used cotter pins, gaskets, O–rings, oil
seals, lock washers and self–locking nuts. Prepare
AND SYSTEM OPERATION new ones for installation. Normal function of these
parts cannot be maintained if these parts are re-
GENERAL REPAIR INSTRUCTIONS used.
S If a floor jack is used, the following precautions are S Keep the disassembled parts neatly in groups to
recommended. facilitate proper and smooth reassembly.
S Park the vehicle on level ground, block" the front S Keep attaching bolts and nuts separated, as they
or rear wheels, set the jack against the frame, raise vary in hardness and design depending on the posi-
the vehicle and support it with chassis stands and tion of the installation.
then perform the service operation. S Clean the parts before inspection or reassembly.
S Before performing the service operation, disconnect S Also clean the oil parts, etc. Use compressed air to
the negative battery cable in order to reduce the make certain they are free of restrictions.
chance of cable damage and burning due to short– S Lubricate rotating and sliding faces of parts with oil
circuiting. or grease before installation.
S Use a cover on the body, the seats and the floor to S When necessary, use a sealer on gaskets to pre-
protect them against damage and contamination. vent leakage.
S Handle brake fluid and antifreeze solution with care S Carefully observe all specifications for bolt and nut
as they can cause paint damage. torques.
S The use of proper tools, and the recommended es- S When service operation is completed, make a final
sential and available tools where specified, are im- check to be sure service was done properly and the
portant for efficient and reliable performance of the problem was corrected.
service repairs.

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GENERAL DESCRIPTION
The Daewoo ORVR system has been designed to have
ON BOARD REFUELING VAPOR the following functional features.
RECOVERY SYSTEM S To collect refueling vapors and to route to canister.
The LANOS is equipped with an On Board Diagnostic S To provide nozzle compatibility with conventional
Stage II (OBD–II) system to meet enhanced emission and stage II vapor recovery nozzles.
control requirements. Within this OBD–II system, an On S To provide fill shut off signal.
Board Refueling Vapor Recorvery (ORVR) system has S To prevent canister from liquid fuel during normal
been developed and equipped to meet enhanced evapo- driving and vehicle rollover.
rative emission control requirements during vehicle mov- S To provide fuel tank venting to canister during ve-
ing, parking, and refueling at gas stations. The Daewoo hicle operation.
ORVR system adopts one canister to collect both evapo- S To protect fuel tank from over–pressure.
rative vapors during the moving & parking as well as re- S To protect fuel vapor dome from overfill.
fueling vapor. Collected vapor is consurmed by the engine Any failures or malfunction of the ORVR system will be
through the intake manfold during vehicle operation. The identified by OBD–II system and warned through Malfunc-
mechanism of Daewoo ORVR system to meet the ORVR tion Indicator Lamp (MIL) on the instrument cluster.
requirement is to create suction inside filler neck by the aid No special refueling procedures and mainternance on
of fuel flow through a reduced diameter section in the filler ORVR system are required.
pipe. The Daewoo ORVR system and all fuel system compo-
Therefore, Daewoo ORVR system adopts the so called nents have been designed to prevent the electrostatic dis-
”Liquid Trap” or ”Liquid Seal” system that assures the long charge phenomenon by adopting mitigation techniques
term durability. recommended in SAE J1645. Daewoo’s own test proce-
The Daewoo ORVR system provides nozzle compatibility dure (EDS–T–5005) is similar to SAE J1113.
with conventional and stage II vapor recovery nozzle.
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Schemetic Of On Board Refueling Vapor Recovery System
1. Manifold (Intake) 9. Discriminator

2. Canister Purge Valve (Electronic Pwm Control) 10. Pressure Relife Valve
3. Service port 11. Tank Pressure Transducer (OBD–II)
4. Integrated Fuel Vapor stdrage Canister 12. Rollover Valve
5. OBD–II Valve (Solenoid) 13. 2–Way Check Valve
6. Air Filter 14. Check Valve
7. Fuel Tank (Steel) 15. Fuel Filler Tube (Dynamic Seal During Fill)
8. Fuel fill Vent Control Valve & Liquid–Vapor Discrimi- 16. Fuel Filler Cap (Pressure–Vacuum Relife)
nator

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Component Locator
1. Fuel Tank 6. Purge Valve

2. Filler Tube 7. Service Port
3. Canister 8. Fuel Filler Cap
4. OBD–II Valve 9. Air filter
5. Fuel Filter
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VEHICLE AND COMPONENT IDENTIFICATION

Passenger Car Vehicle Identification Number
Certification plate 1. Production Date

2. Gross Vehicle Weight Rating
3. Gross Axle Weight Rating – Front
4. Gross Axle Weight Rating – Rear
5. Vehicle identification Number

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VIN Plate Location

The vehicle identification number (VIN) plate is attached
to the top of the left–side of the instrument panel.
Certification Label Engraved VIN Location

The Certification Label is attached to the driver’s side B–
pillar near door strike.
The vehicle identification number (VIN) is engraved in the

top of the bulkhead, next to the ABS module.
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Engine Number Location – SOHC The engine number is stamped on the cylinder block under
the No. 4 exhaust manifold of the engine.

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Engine Number
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Engine Number Location – DOHC Body Identification Number Plate Location
The body identification number plate is attached to the top

The engine number is stamped on the cylinder block under of the front panel support.
the No. 4 exhaust manifold of the engine.
Manual Transmission Identification
Body Identification Number Plate Number Plate
1. Identification Code
1. P/O Number 2. Sequential Number
2. Check Digit
3. Drive Identification Engine Gear Ratio
4. Body Type Code
5. P/O Date VG 1.5L SOHC 3.944 W/R
6. Sequential Number
7. Exterior Color XG 1.6L DOHC 4.176 W/R

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1. Assembly Plant (Windsor, Canada)

Manual Tranaaxle Identification Number 2. Model Year (1996)
Plate Location 3. Broadcast Code
4. Model Name (4T40E)
5. Update Level
6. Sequential Number
7. Manufacturer
8. Part Number
Automatic Transaxle Identification Number

Plate Location
The manual transaxle identification number is attached to

the top of the transmission case near the engine.
Automatic Transmission Identification
Number Plate
The automatic transaxle identification number plate is at-

tached on the rear side of the transmission near the bulk-
head.
VEHICLE LIFTING PROCEDURES

Notice : To raise the vehicle, place the lifting equipment
only at the points indicated. Failure to use these precise
positions may result in permanent vehicle body deforma-
tion. Many dealer service facilities and service stations are
equipped with automotive hoists that bear upon some
parts of the frame in order to lift the vehicle. If any other
hoist method is used, use special care to avoid damaging
the fuel tank, the filler neck, the exhaust system, or the un-
derbody.
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Vehicle Lifting Points

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Vehicle Lifting Points
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SECTION : 1A
GENERAL ENGINE INFORMATION
TABLE OF CONTENTS
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–1 NOISE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 1A–8
COMPRESSION TEST . . . . . . . . . . . . . . . . . . . . . 1A–1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1A–11
OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . 1A–2
OIL LEAK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . 1A–3 CLEANLINESS AND CARE . . . . . . . . . . . . . . . . 1A–11
KNOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 1A–4 ON–ENGINE SERVICE . . . . . . . . . . . . . . . . . . . 1A–11
4. The lowest reading should not be less than 70% of

DIAGNOSIS the highest reading. The compression gauge read-
ing should not be less than 689 kPa (100 psi) for
COMPRESSION TEST any of the cylinders.
Important : Disconnect the Crankshaft Position (CKP) 5. Examine the gauge readings obtained after the four
Sensor connector to disable the fuel and the ignition sys- ”puffs” per cylinder are obtained from cranking the
tems. starter motor. The readings are explained in the
following descriptions:
Test the compression pressure for each cylinder. Low
compression pressure may be the fault of the valves or the
S Normal Condition – Compression builds up quickly
pistons. The following conditions should be considered
and evenly to the specified compression on each
when you check the cylinder compression:
cylinder.
S The engine should be at normal operating tempera- S Piston Rings Faulty – Compression is low on the
ture. first stroke and tends to build up on following
S The throttle must be wide open. strokes, but the compression pressure does not
S All the spark plugs should be removed. reach normal. The compression pressure improves
S The battery must be at or near full charge. considerably with the addition of oil into the cylin-
1. Place approximately three squirts of oil from a der.
plunger– type oiler into each spark plug port. S Valves Faulty – Low compression pressure on the
2. Insert the engine compression gauge into each first stroke. The compression pressure does not
spark plug port. tend to build up on the following strokes. The com-
3. Crank test each cylinder with four to five compres- pression pressure does not improve much with the
sion strokes using the starter motor. addition of oil into the cylinder.
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1A – 2IGENERAL ENGINE INFORMATION
OIL PRESSURE TEST

Step Action Value(s) Yes No
1 Is the oil pressure warning lamp on? Go to Step 2 System OK
2 Check the oil level in the crankcase. Go to Step 3 Go to Step 4
Is the oil level low?
3 Add oil so that the oil level is up to the fullmark on the Go to Step 1
indicator.
Is the repair complete?
4 Check the idle speed. 825 rpm Go to Step 5 Go to Step 6
Is the idle speed below the specified value ?
5 Increase the idle speed. Go to Step 1
Is the speed increased?
6 Inspect the oil pressure switch. Go to Step 7 Go to Step 8
Is the oil pressure switch incorrect or malfunction-
ing?
7 Install a new oil pressure switch. Go to Step 1
8 Inspect the oil pressure gauge. Go to Step 9 Go to Step 10
Is the oil pressure gauge incorrect or malfunction-
ing?
9 Install a new oil pressure gauge. Go to Step 1
10 Inspect the engine oil. Go to Step 11 Go to Step 12
Is the engine oil in the crankcase diluted or of the im-
proper viscosity?
11 Install new engine oil of the proper viscosity for the Go to Step 1
expected temperatures.
12 Inspect the oil pump. Go to Step 13 Go to Step 14
Is the pump worn or dirty?
13 Replace the oil pump. Go to Step 1
14 Inspect the oil filter. Go to Step 15 Go to Step 16
Is the oil filter plugged?
15 Install a new oil filter. Go to Step 1
16 Inspect the oil pickup screen. Go to Step 17 Go to Step 18
Is the oil pickup screen loose or plugged?
17 Tighten or replace the oil pickup screen, as neces- Go to Step 1
sary.
18 Inspect the oil pickup tube. Go to Step 19 Go to Step 20
Are there any holes in the oil pickup tube?
19 Replace the oil pickup tube. Go to Step 1

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GENERAL ENGINE INFORMATION 1A – 3

20 Inspect the bearing clearances. Crankshaft Go to Step 21 Go to Step 22
Are the bearing clearances more than the specified 0.005 mm
values? (0.002 in.)
Connecting
Rod 0.019 ~
0.070 mm
(0.0007 ~
0.0027 in.)
21 Replace the bearing, if necessary. Go to Step 1
22 Inspect the oil galleries. Go to Step 23 Go to Step 24
Are the oil galleries cracked, porous, or plugged?
23 Repair or replace the engine block. Go to Step 1
24 Inspect the gallery plugs. Go to Step 25 Go to Step 26
Are any of the gallery plugs missing or installed im-
properly?
25 Install the plugs or repair, as necessary. Go to Step 1
26 Inspect the camshaft. Go to Step 27 System OK
Is the camshaft worn or is there evidence of poor
machining?
27 Replace the camshaft. Go to Step 1
3) Operate the vehicle for several miles at normal

OIL LEAK DIAGNOSIS operating temperature and varying speeds.
Most fluid oil leaks are easily located and repaired by visu- 4) After operating the vehicle, visually check the
ally finding the leak and replacing or repairing the neces- suspected component.
sary parts. On some occasions, a fluid leak may be difficult 5) If you still cannot locate the leak, try using the
to locate or repair. The following procedures may help you powder or black light and dye method.
in locating and repairing most leaks.
Powder Method:
Finding the Leak:
1. Clean the suspected area.
1. Identify the fluid. Determine whether it is engine oil,
2. Apply an aerosol–type powder, (such as foot pow-
automatic transmission fluid, power steering fluid,
der), to the suspected area.
etc.
3. Operate the vehicle under normal operating condi-
2. Identify where the fluid is leaking from.
tions.
1) After running the vehicle at normal operating 4. Visually inspect the suspected component. Trace
temperature, park the vehicle over a large sheet the leak path over the white powder surface to the
of paper. source.
2) Wait a few minutes.
3) Find the approximate location of the leak by the
drippings on the paper. Black Light and Dye Method:
3. Visually check around the suspected component. A dye and light kit is available for finding leaks. Refer to the
Check around all the gasket mating surfaces for manufacturer’s directions when using the kit.
leaks. A mirror is useful for finding leaks in areas
that are hard to reach. 1. Pour the specified amount of dye into the engine oil
4. If the leak still cannot be found, it may be neces- fill tube.
sary to clean the suspected area with a degreaser, 2. Operate the vehicle under normal operating condi-
steam, or spray solvent. tions as directed in the kit.
3. Direct the light toward the suspected area. The
1) Thoroughly clean the area. dyed fluid will appear as a yellow path leading to
2) Dry the area. the source.
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S There are scratches, burrs or other damage to the

Repairing the Leak sealing surface.
S The gasket is damaged or worn.
Once the origin of the leak has been pinpointed and traced
S There is cracking or porosity of the component.
back to its source, the cause of the leak must be deter-
S An improper seal was used, (where applicable).
mined in order for it to be repaired properly. If a gasket is
replaced, but the sealing flange is bent, the new gasket will Seals:
not repair the leak. The bent flange must be repaired also.
S The fluid level/pressure is too high.
Before attempting to repair a leak, check for the following
S The crankcase ventilation system is malfunctioning.
conditions and correct them as they may cause a leak.
S The seal bore is damaged, scratched, burred or
nicked.
Gaskets: S The seal is damaged or worn.
S The fluid level/pressure is too high. S Improper installation is evident.
S The crankcase ventilation system is malfunctioning. S There are cracks in the component.
S The fasteners are improperly tightened or the S The shaft surface is scratched, nicked or damaged.
threads are dirty or damaged. S A loose or worn bearing is causing excess seal
S The flanges or the sealing surface is warped. wear.
KNOCK DIAGNOSIS
knock is a noticeable noise, but not as loud. Light knock
Definition for Knock
can be caused by worn internal engine components.
Engine knock refers to various types of engine noise. Loose or broken external engine components can also
Heavy knock is usually very loud and the result of broken cause heavy or light knock.
or excessively worn internal engine components. Light
Engine Knocks Cold and Continues for Two–Three Minutes and/or
Knock Increases with Engine Torque
1 Does the engine knock when it is cold and continue Go to Step 2 System OK
for two to three minutes or does the knock increase
with torque?
2 Inspect the flywheel. Go to Step 3 Go to Step 4
Is the flywheel contacting the splash shield?
3 Reposition the splash shield. Go to Step 1
4 Inspect the balancer and the drive pulleys. Go to Step 5 Go to Step 6
Is either the balancer or the drive pulleys loose or
broken?
5 Tighten or replace the balancer or the drive pulleys. Go to Step 1
6 Inspect the piston–to–bore clearance. 0.030 mm Go to Step 7 Go to Step 8
Is the clearance more than the specified value? (0.001 in.)
7 1. Rebore the cylinder and hone to size. Go to Step 1
2. Replace the piston.
Is the repair complete?*
8 Inspect the connecting rod. Go to Step 9 System OK
Is the connecting rod bent?
9 Replace the connecting rod. Go to Step 1
* Cold engine piston knock usually disappears when the cylinder is grounded out. Cold engine piston knock, which disap-
pears in about 1.5 minutes, is considered acceptable.

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Heavy Knock Hot with Torque Applied

1 Is there a heavy knock when the engine is hot and Go to Step 2 System OK
torque is applied?
2 Inspect the balancer and the pulley hub. Go to Step 3 Go to Step 4
Is the balancer or the pulley hub broken?
3 Replace the broken balancer or the pulley hub. Go to Step 1
4 Inspect the torque converter bolts. 45 NSm Go to Step 5 Go to Step 6
Are the bolts tightened to specified value? (33 lb–ft)
5 Tighten the torque converter bolts. Go to Step 1
6 Inspect the accessory belts. Go to Step 7 Go to Step 8
Are the belts too tight or nicked?
7 Replace and/or tension the belts to specifications, Go to Step 1
as necessary.
8 Inspect the exhaust system. Go to Step 9 Go to Step 10
Is the system grounded?
9 Reposition the system, as necessary. Go to Step 1
10 Inspect the flywheel. Go to Step 11 Go to Step 12
Is the flywheel cracked?
11 Replace the flywheel. Go to Step 1
12 Inspect the main bearing clearance. 0.050 mm Go to Step 13 Go to Step 14
13 Replace the main bearings, as necessary. Go to Step 1
14 Inspect the rod bearing clearance. 0.019 ~ Go to Step 15 System OK
Is the clearance more than the specified value? 0.070 mm
(0.0007 ~
0.0028 in.)
15 Replace the rod bearings, as necessary. Go to Step 1
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Light Knock Hot

1 Is there a light knock when the engine is hot? Go to Step 2 System OK
2 Is detonation or spark knock evident? Go to Step 3 Go to Step 4
3 Check the engine timing and the fuel quality. Go to Step 1
Was the problem found?
4 Inspect the torque converter bolts. 45 NSm Go to Step 5 Go to Step 6
Are the bolts tightened to the specified value? (33 lb–ft)
5 Tighten the torque converter bolts. Go to Step 1
6 Inspect the manifold. Go to Step 7 Go to Step 8
Is there an exhaust leak at the manifold?
7 Tighten the bolts or replace the gasket. Go to Step 1
8 Check the rod bearing clearance. 0.019 ~ Go to Step 9 System OK
Is the clearance within the specified value? 0.070 mm
(0.0007 ~
0.0028 in.)
9 Replace the rod bearings, as necessary. Go to Step 1
Knocks During Initial Start–Up But Last Only a Few Seconds

1 Does the engine knock during initial start–up but last Go to Step 2 System OK
only a few seconds?
2 Check the engine oil. Go to Step 4 Go to Step 3
Is the proper viscosity oil used in the crankcase?
3 Install oil of the proper viscosity for the expected Go to Step 1
seasonal temperatures.
4 Inspect the hydraulic lifters. Go to Step 5 Go to Step 6
Is there evidence of hydraulic lifter bleed–down?
5 Clean, test and replace the lifters, as necessary. Go to Step 1
Is the repair complete?*
6 Inspect the crankshaft end clearance. 0.1 mm Go to Step 7 Go to Step 8
Is the clearance more than specified value? (0.0039 in.)
7 Replace the crankshaft thrust bearing. Go to Step 1
8 Inspect the front main bearing clearance. 0.005 mm Go to Step 9 System OK
9 Replace the worn parts of the front main bearing. Go to Step 1
* When the engine is stopped, some valves will be open. Spring pressure against the lifters will tend to bleed lifter down.
Attempts to repair this should be made only if the problem is consistent.
An engine that is only operated for short periods between start–ups may have lifter noise that lasts for a few minutes. This
is a normal condition.

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Knocks at Idle Hot

1 Does the engine knock at idle when hot? Go to Step 2 System OK
2 Inspect the drive belts. Go to Step 3 Go to Step 4
Are the belts loose or worn?
3 Tension or replace the belts, as necessary. Go to Step 1
4 Inspect the A/C compressor and the generator. Go to Step 5 Go to Step 6
Is either the compressor or the generator faulty?
5 Replace the faulty A/C compressor or the generator. Go to Step 1
6 Inspect the valve train. Go to Step 7 Go to Step 8
Are valve train components faulty?
7 Replace the faulty valve train components. Go to Step 1
8 Check the engine oil. Go to Step 10 Go to Step 9
Is the proper viscosity oil used in the crankcase?
9 Install oil of the proper viscosity for the expected Go to Step 1
seasonal temperatures.
10 Inspect the piston pin clearance. 0.020 mm Go to Step 11 Go to Step 12
11 Replace the piston and the pin. Go to Step 1
12 Check the connecting rod alignment. Go to Step 13 Go to Step 14
Is the alignment faulty?
13 Check and replace rods, as necessary. Go to Step 1
14 Inspect the piston–to–bore clearance. 0.030 mm Go to Step 16 Go to Step 15
Is the clearance within the specified value? (0.0012 in.)
15 Hone the bore and fit a new piston. Go to Step 1
16 Inspect the crankshaft balancer. Go to Step 17 Go to Step 18
Is the balancer loose?
17 Torque or replace worn parts. Go to Step 1
18 Check the piston pin offset. 0.5 ~ 0.7 mm Go to Step 19 System OK
Is the offset at the specified value? (0.020 ~ 0.028
in.)
Toward Thrust
Side
19 Install the correct piston. Go to Step 1
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NOISE DIAGNOSIS
Main Bearing Noise
1 Are dull thuds or knocks heard with every engine Go to Step 2 System OK
revolution?
2 Check the oil pump pressure. Go to Oil Pres- Go to Step 3
Is the oil pump pressure low? sure Test
3 Inspect the crankshaft end play. 0.1 mm Go to Crank- Go to Step 4
Does the crankshaft end play exceed the specified (0.0039 in.) shaft Replace-
value? ment Proce-
dure
4 Inspect the crankshaft journals. 0.004 mm Go to Crank- Go to Step 5
Are the crankshaft journals out–of–round? (0.0002 in.) shaft Replace-
max. ment Proce-
dure
5 Inspect the belt tension. Go to Timing Go to Step 6
Does the belt tension exceed the specified value? Belt Replace-
ment Proce-
dure
6 Inspect the crankshaft pulley. Go to Crank- System OK
Is the crankshaft pulley loose? shaft Replace-
ment Proce-
dure
Connecting Rod Bearing Noise Symptom

1 Is a knock noise heard under all engine speeds? Go to Step 2 System OK
2 Inspect the crankshaft connecting rod journal. Go to Crank- Go to Step 3
Is the crankshaft connecting rod journal worn? shaft Replace-
ment Proce-
dure
3 Check the oil pump pressure. Go to Oil Pres- Go to Step 4
Is the oil pump pressure low? sure Test
4 Inspect the crankshaft connecting rod journals. Go to Crank- Go to Step 5
Are the journals out–of–round? shaft Replace-
ment Proce-
dure
5 Inspect the connecting rods. Go to Pistons Go to Step 6
Is there a misaligned connecting rod? and Rods Re-
placement Pro-
cedure
6 Inspect the connecting rod bolts. System OK Go to Pistons
Are the connecting rod bolts torqued properly? and Rods Re-
placement Pro-
cedure

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Piston Noises
1 Are any of the following noises heard: a sharp double Go to Step 2 System OK
knock when the engine is idling, a light ticking with
no load on the engine, or a ”slapping” noise when the
engine is cold?
2 Inspect the piston pin and the bushing. Go to Pistons Go to Step 3
Is the piston pin or the bushing worn or loose? and Rods Re-
placement Pro-
cedure
3 Inspect the piston. Go to Pistons Go to Step 4
Is the piston broken or cracked? and Rods Re-
placement Pro-
cedure
4 Inspect the connecting rods. Go to Pistons Go to Step 5
Is there a misaligned connecting rod? and Rods Re-
placement Pro-
cedure
5 Inspect the piston position. Go to Pistons System OK
Is the piston 180³ out of position? and Rods Re-
placement Pro-
cedure
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Valve Mechanism or Valve Train Noises

1 Is a light tapping sound heard from the engine? Go to Step 2 System OK
2 Inspect the valve springs. Go to Cylinder Go to Step 3
Are the springs weak or broken? Head and
Valve Train
Components
Replacement
Procedure
3 Inspect the valves. Go to Cylinder Go to Step 4
Are the valves sticking or warped? Head and
Valve Train
Components
Replacement
Procedure
4 Inspect the valve lifters. Go to Cylinder Go to Step 5
Are the valve lifters dirty, stuck or worn? Head and
Valve Train
Components
Replacement
Procedure
5 Inspect the camshaft lobes. Go to Cam- Go to Step 6
Are the camshaft lobes damaged or improperly ma- shaft Replace-
chined? ment Proce-
dure
6 Check the oil supply to the valve train. Go to Cylinder Go to Step 7
Is the oil supply insufficient or poor? Head and
Valve Train
Components
Replacement
Procedure
7 Inspect the valve guides. Go to Cylinder Go to Step 8
Are the valve guides worn? Head and
Valve Train
Components
Replacement
Procedure
8 Inspect the valve spring seat. Go to Cylinder System OK
Is the valve spring seat incorrect? Head and
Valve Train
Components
Replacement
Procedure

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Battery cables should be disconnected before any major

GENERAL INFORMATION work is performed on the engine. Failure to disconnect
cables may result in damage to wire harness or other elec-
trical parts.
CLEANLINESS AND CARE
An automobile engine is a combination of many machined,
ON–ENGINE SERVICE
honed, polished and lapped surfaces with tolerances that CAUTION : Disconnect the negative battery cable be-
are measured in the ten–thousandths of an inch. When fore removing or installing any electrical unit, or
any internal engine parts are serviced, care and cleanli- when a tool or equipment could easily come in con-
ness are important. A liberal coating of engine oil should tact with exposed electrical terminals. Disconnecting
be applied to friction areas during assembly, to protect and this cable will help prevent personal injury and dam-
lubricate the surfaces on initial operation. Proper cleaning age to the vehicle. The ignition must also be in LOCK
and protection of machined surfaces and friction areas is unless otherwise noted.
part of the repair procedure. This is considered standard Notice : Any time the air cleaner is removed, the intake
shop practice even if not specifically stated. opening should be covered. This will protect against acci-
Whenever valve train components are removed for ser- dental entrance of foreign material, which could follow the
vice, they should be kept in order. They should be installed intake passage into the cylinder and cause extensive
in the same locations, and with the same mating surfaces, damage when the engine is started.
as when they were removed.
DAEWOO V–121 BL4
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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 erminals. Disconnecting this cable will help
prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1B–2 CAMSHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . 1B–58
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . 1B–2 REAR TIMING BELT COVER . . . . . . . . . . . . . . 1B–60
FASTENER TIGHTENING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B–61
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 1B–4 PISTONS AND RODS . . . . . . . . . . . . . . . . . . . . 1B–71
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B–6 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B–76
SPECIAL TOOLS TABLE . . . . . . . . . . . . . . . . . . . 1B–6 CYLINDER HEAD AND VALVE TRAIN
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . 1B–76
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 1B–8
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B–84
UPPER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B–8
CRANKSHAFT BEARINGS AND
LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B–10
CONNECTING ROD BEARINGS –
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 1B–12 GAUGING PLASTIC . . . . . . . . . . . . . . . . . . . . 1B–92
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 1B–12 GENERAL DESCRIPTION AND SYSTEM
VALVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B–12 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B–95
CYLINDER HEAD AND GASKET . . . . . . . . . . . 1B–13 CYLINDER HEAD AND GASKET . . . . . . . . . . . 1B–95
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B–27 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B–95
TIMING BELT CHECK AND ADJUST . . . . . . . 1B–31 TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B–95
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B–36 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B–95
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B–47 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B–95
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B–47 EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 1B–95
ENGINE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . 1B–50 INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 1B–95
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 1B–52 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B–95
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 1B–57 EGR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B–95
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1B – 2ISOHC ENGINE MECHANICAL
SPECIFICATIONS
ENGINE SPECIFICATIONS
Application Description (Manual and Automatic)
General Data:
Engine Type 4 Cylinder (In–Line)
Displacement:
1.5 SOHC 1 498 cm3 (91.44 in3)
Bore Stroke:
1.5 SOHC 76.5 X 81.5 mm (3.01 in. X 3.21 in.)
Compression Ratio 9.6µ0.2 :1
Firing Order 1–3–4–2
Cylinder Bore:
Diameter 76.5 mm (3.01 in.)
Out of Round (Maximum) 0.0065 mm (0.00025 in.)
Taper (Maximum):
1.5 SOHC 0.0065 mm (0.00025 in.)
Piston :
Clearance to Bore 0.030 mm (0.0012 in.)
Piston Rings:
Ring, End Gap: 0.3 mm (0.019 in.)
Top Compression
2nd Compression 0.3 mm (0.019 in.)
Groove Clearance: 0.02 mm (0.0008 in)
Top Impression
2nd Impression 0.02 mm (0.0008 in.)
Piston Pin :
Pin Off–Set 0.5~0.7 mm (0.019~0.027 in.)
Camshaft:
Lift Intake: 6.12 mm (0.240 in.)
1.5 SOHC
Lift Exhaust 6.12 mm (0.240 in.)
End Play 0.09~0.21 mm (0.0035~0.0082 in.)
Journal OD: 39.445 mm (1.552 in.)
No. 1
No. 2 39.700 mm (1.562 in.)
No. 3 39.945 mm (1.572 in.)
No. 4 40.200 mm (1.582 in.)
No. 5 40.445 mm (1.592 in.)
Bearing OD: 39.500 mm (1.555 in.)
No. 1
No. 2 39.750 mm (1.564 in.)

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SOHC ENGINE MECHANICAL 1B – 3
Application Description (Manual and Automatic)

No. 3 40.000 mm (1.574 in.)
No. 4 40.250 mm (1.584 in.)
No. 5 40.500 mm (1.594 in.)
Crankshaft :
Main Journal 54.982~54.994 mm (2.164~2.165 in.)
Diameter (All)
Taper (Maximum) 0.005 mm (0.0001 in.)
Main Bearing Clearance (All) 0.005 mm (0.0001 in.)
Crankshaft End Play 0.1 mm (0.003 in.)
Connecting Rod Journal: 42.971~42.987 mm (1.691~1.692 in.)
Diameter (All)
Rod Bearing Clearance (All) 0.019~0.070 mm (0.0007~0.0027 in.)
Rod Side Clearance 0.070~0.242 mm (0.0027~0.009 in.)
Valve System:
Valve Lash Compensators Hydraulic
Face Angle (All) 46³
Seat Angle (All) 46³
Seat Runout (Maximum, All) 0.03 mm (0.019 in.)
Face Runout (Maximum, All) 0.03 mm (0.019 in.)
Seat Width: 1.3~1.5 mm (0.051~0.059 in.)
Intake
Exhaust 1.6~1.8 mm (0.063~0.071 in. )
Valve Guide Inside Diameter (All) 7.030~7.050 mm (0.276~0.277 in.)
Valve Stem Diameter (All) 7 mm (0.275 in.)
Valve Diameter (All): 38.0µ0.15 mm (1.49µ0.0059 in.)
Intake
Exhaust 31.0µ0.15 mm (1.22µ0.0059 in.)
Valve Spring Free Length: 40.9 mm
SOHC
DOHC 41.2 mm
Valve Spring Loads: 625µ25 N (461µ18 lbs) @ 21.5 mm (0.846 in.)
Valve Open
Valve Closed 275µ15 N (202µ11 lbs) @ 31.5 mm (1.240 in.)
Oil Pump :
Gap Between Oil Pump Body and Out Rotor 0.400~0.484 mm (0.0157~0.0191 in.)
Out Rotor Side Clearance 0.045~0.100 mm (0.0018~0.0039 in.)
Inner Rotor Side Clearance 0.035~0.085 mm (0.0014~0.0033 in.)
Relief Valve Spring Free Length 81 mm (3.2 in.)
DAEWOO V–121 BL4
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FASTENER TIGHTENING SPECIFICATIONS

Application NSm Lb–Ft Lb–In
A/C Compressor Hose Assembly Retaining Bolt 33 24 –
A/C Compressor Mounting Bolts 27 20 –
A/C Compressor Mounting Bracket Bolts 50 37 –
Air Filter Housing Bolts 8 – 71
Alternator Adjusting Bolt 20 15 –
Alternator Adjusting Bracket Retaining Bolt 20 15 –
Auxiliary Catalytic Converter–to–Exhaust Manifold Nuts and 40 30 –
Bracket Bolts
Camshaft Gear Bolt 45 33 –
Camshaft Pressure Plate Bolts 10 – 89
Connecting Rod Bearing Cap Bolts 25 + 30³ 18 + 30³ –
Coolant Pump Retaining Bolts 10 – 89
Coolant Temperature Sensor 20 15 –
Crankshaft Bearing Cap Bolts 50 + 45³ + 15³ 37 + 45³ + –
15³
Crankshaft Pulley Bolt 95 + 30³ + 15³ 70 + 30³ + –
15³
Crankshaft Position Sensor Retaining Bolt 10 – 89
Cylinder Head Bolts (Camshaft Support Housing & Cylinder 25 + 70³ 18 + 70³ –
Head Mounting Bolts) + 70³ + 30³ + 70³ + 30³
Electronic Ignition System Ignition Coil Mounting Bolts 10 – 89
Electronic Ignition System Ignition Coil Mounting Plate Bolts 10 – 89
Engine Lift Bracket Bolt 25 18 –
Engine Mount Attaching Nuts 40 30 –
Engine Mount Bracket Retaining Bolts 60 44 –
Engine Mount Bracket–to–Engine Mount Retaining Bolts 60 44 –
Exhaust Manifold Heat Shield Bolts 15 11 –
Exhaust Manifold Nuts 25 18 –
Flexible Plate Bolts 60 44 –
Flexible Plate Inspection Cover Bolts 10 – 89
Flywheel Bolts 35 26 –
+ 30³ + 15³ + 30³ + 15³
Flywheel Inspection Cover Bolts 12 – 106
FrontMuffler–to–Main Catalytic Converter Nuts 30 22 –
Fuel Rail Retaining Bolts 25 18 –
Intake Manifold Retaining Nuts 25 18 –
Intake Manifold Support Bracket Retaining Bolts 22 16 –
Lower Timing Belt Cover Bolts 10 – 89
Oil Pan Retaining Bolts 10 – 89
Oil Pan Drain Plug 55 41 –
Oil Pressure Switch 40 30 –
Oil Pump Retaining Bolts 10 – 89

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Oil Pump/Pickup Tube and Support Bracket Bolts 10 – 89
Oil Pump Safety Relief Valve Bolt 30 22 –
Oil Pump Rear Cover Bolts 6 – 53
Power Steering Pump Mounting Bolts 25 18 –
Power Steering Pump Pulley Bolts 25 18 –
Rear Timing Belt Cover Bolts 10 – 89
Right Transaxle Brace Bolts 60 44 –
Spark Plugs 25 18 –
Thermostat Housing Mounting Bolts 20 15 –
Throttle Cable Bracket Bolts 8 – 71
Timing Belt Automatic Tensioner Bolt 20 15 –
Transaxle Bell Housing Bolts 75 55 –
Transaxle Torque Converter Bolts 65 48 –
Upper Timing Belt Cover Bolts 10 – 89
Valve Cover Bolts 9 – 80
DAEWOO V–121 BL4
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SPECIAL TOOLS
SPECIAL TOOLS TABLE
KM–565–A
MKM–571–B
Valve Spring
Gauge
Compressor
J–42492 KM–253
Timing Belt Adjuster Valve Guide Reamer
J–28467–B
KM–254
Engine Assembly Sup-
Valve Guide Reamer
port Fixture
KM–427 KM–255
Piston Pin Service Set Valve Guide Reamer

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KM–340–0
Cutter Set
KM–498–B
Includes: KM–340–7
Pressure Gauge
KM–340–13
KM–340–26
KM–348 KM–470–B
Valve Spring Compressor Angular Torque Gauge
J–36972
KM–419
Crankshaft Rear Oil Seal
Distance Gauge
Installer
KM–635
KM–135
Crankshaft Rear Oil Seal
Adapter
Installer
MKM–412
Engine Overhaul Stand
DAEWOO V–121 BL4
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COMPONENT LOCATOR
UPPER END

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1. Wiring Bracket 32. Valve Key

2. Bolt 33. Valve Spring Plate
3. Bolt 34. Valve Spring
4. Cap, Bayonet Joint 35. Valve Stem Seal
5. Seal, Bayonet Cap 36. Exhaust Valve Spring Seat
6. Valve Cover 37. Valve Guide
7. Bolt 38. Cam Follower
8. Throttle Position Sensor 39. Cam Follower Lifter
9. Idle Air Control Valve 40. Intake Valve Spring Seat
10. Throttle Body 41. Bolt
11. Throttle Body Gasket 42. Thermostat Housing
12. Nut 43. Thermostat Housing Seal Ring
13. Engine Coolant Temperature Sensor 44. Thermostat
14. Intake Manifold 45. Screw Plug
15. Camshaft Position Sensor 46. Oil Duct Cap
16. EGR Valve 47. Oil Duct Cap
17. Bolt 48. Adapter
18. EGR Gasket 49. Coolant Temperature Sensor
19. Shaft Seal Ring 50. Exhaust Valve
20. Camshaft Support 51. Intake Valve
21. Valve Cover Gasket 52. Cylinder Head Oil Duct Sleeve
22. Tube 53. Bolt–Stud
23. Cylinder Head Bolt 54. Exhaust Manifold Gasket
24. Washer 55. Cylinder Head Gasket
25. Camshaft 56. Exhaust Manifold
26. Camshaft Pressure Plate 57. Nut
27. Bolt 58. Exhaust Oxygen Sensor
28. Bolt–Stud 59. Exhaust Manifold Heat Shield
29. Intake Manifold Gasket 60. Bolt
30. Bolt–Stud 61. EGR Solenoid
31. Valve Thrust Piece 62. Bracket
DAEWOO V–121 BL4
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LOWER END

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1. Piston Ring Seat 34. Bolt (Manual Transaxle)

2. Piston 35. Bolt (Automatic Transaxle)
3. Piston Pin 36. Flex Plate (Automatic Transaxle)
4. Connecting Rod 37. Bolt
5. Connecting Rod Bearing Set 38. Threaded Ring
6. Connecting Rod Bolt 39. Drain Plug
7. Oil Level Gauge Stick 40. Bolt
8. Gauge Stick Tube 41. Oil Pan
9. Connecting Piece 42. Main Bearing Cap Bolt
10. Oil Filter 43. Main Bearing
11. Camshaft Pulley Bolt 44. Bolt
12. Washer 45. Bracket
13. Camshaft Gear 46. Oil Pickup Tube
14. Rear Cover Bolt 47. Timing Belt
15. Rear Timing Belt Cover 48. Upper Timing Belt Front Cover
16. Bolt 49. Bolt
17. Coolant Pump 50. Lower Timing Belt Front Cover
18. Oil Pump 51. Crankshaft Pulley
19. Seal Ring 52. Washer
20. Oil Pump Body Gasket 53. Bolt
21. Engine Block 54. Bolt
22. Bolt 55. Bolt
23. Auto Tensioner 56. Crankshaft Position Sensor
24. Bolt 57. Bracket
25. Crankshaft Gear 58. Gear
26. Pressure Relief Valve Plunger 59. Gear
27. Spring 60. Cover
28. Oil Pump Seal Ring 61. Bolt
29. Bolt Plug 62. Seal
30. Crankshaft Bearing Set 63. Knock Sensor
31. Crankshaft
32. Shaft Seal Ring
33. Flywheel (Manual Transaxle)
DAEWOO V–121 BL4
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SECTION : 1C
DOHC ENGINE MECHANICAL

or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1C–2 INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 1C–49
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . 1C–2 EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 1C–53
FASTENER TIGHTENING CAMSHAFT GEARS . . . . . . . . . . . . . . . . . . . . . . 1C–55
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 1C–4 REAR TIMING BELT COVER . . . . . . . . . . . . . . 1C–56
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C–6 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C–59
SPECIAL TOOLS TABLE . . . . . . . . . . . . . . . . . . . 1C–6 PISTONS AND RODS . . . . . . . . . . . . . . . . . . . . 1C–69
UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C–74
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 1C–8
CYLINDER HEAD AND VALVE TRAIN
UPPER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C–8
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . 1C–74
LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C–10
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C–84
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 1C–12 CRANKSHAFT BEARINGS AND
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 1C–12 CONNECTING ROD BEARINGS –
VALVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C–12 GAUGING PLASTIC . . . . . . . . . . . . . . . . . . . . 1C–96
CYLINDER HEAD AND GASKET . . . . . . . . . . . 1C–14 GENERAL DESCRIPTION AND SYSTEM
CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C–24 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C–99
TIMING BELT CHECK AND ADJUST . . . . . . . 1C–28 CYLINDER HEAD AND GASKET . . . . . . . . . . . 1C–99
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C–32 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C–99
ENGINE OIL PRESSURE INSPECTION TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C–99
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 1C–38 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C–99
ENGINE OIL PRESSURE INSPECTION OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C–99
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 1C–38 EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 1C–99
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C–39 INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 1C–99
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C–43 CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C–99
ENGINE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . 1C–47 EXHAUST GAS RECIRCULATION VALVE . . . 1C–99
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1C – 2IDOHC ENGINE MECHANICAL
SPECIFICATIONS
ENGINE SPECIFICATIONS
Application Description (1.6L DOHC)
General Data:
Engine Type 4 Cylinder (In–Line)
Displacement 1 598 cm3 (97.51 in3)
Bore Stroke 79.0 X 81.5 mm (3.11 in. X 3.21 in.)
Compression Ratio 9.5µ 0.02:1
Firing Order 1–3–4–2
Cylinder Bore:
Out–of–Round (Maximum) 0.0065 mm (0.00025 in.)
Piston :
Diameter 78.970 mm (3.1090 in.)
Clearance to Bore 0.030 mm (0.0012 in.)
Piston Rings:
Ring, End Gap: 0.3 mm (0.019 in.)
Top Compression
2nd Compression 0.3 mm (0.019 in.)
Groove Clearance: 0.02 mm (0.0008 in.)
Top Compression
2nd Impression 0.02 mm (0.0008 in.)
Piston Pin:
Pin Offset 0.6~0.8 mm (0.02~0.03 in.) Toward Thrust Side
Camshaft:
Lift – Intake 8.75 mm (0.344 in.)
Lift – Exhaust 8.75 mm (0.344 in.)
End Play 0.10~0.25 mm (0.003~0.009 in.)
Journal OD: 30 mm (1.18 in.)
No. 1
No. 2 27 mm (1.06 in.)
No. 3 27 mm (1.06 in.)
No. 4 27 mm (1.06 in.)
No. 5 27 mm (1.06 in.)
Crankshaft:
Main Journal: 54.982~54.994 mm (2.164~2.165 in.)
Diameter (All)
Main Bearing Clearance (All) 0.01~0.026 mm (0.0004~0.001 in.)

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DOHC ENGINE MECHANICAL 1C – 3
Application Description (1.6L DOHC)

Crankshaft End Play 0.01 mm (0.003 in.)
Connecting Rod Journal: 42.971~42.987 mm (1.691~1.692 in.)
Diameter (All)
Rod Bearing Clearance (All) 0.019~0.071 mm (0.0007~0.0028 in.)
Rod Side Clearance 0.070~0.242 mm (0.0027~0.009 in.)
Valve System:
Valve Lash Compensators Hydraulic
Face Angle (All) 45³ + 1³
Seat Angle (All) 45³ + 1³
Seat Runout (Maximum, All) 0.03 mm (0.019 in.)
Face Runout (Maximum, All) 0.03 mm (0.019 in.)
Seat Width: 1.17~1.57 mm (0.046~0.062 in.)
Intake
Exhaust 1.07~1.47 mm (0.042~0.058 in.)
Valve Guide Inside Diameter (All) 6.00~6.02 mm (0.236~0.237 in.)
Valve Stem Diameter (All) 6 mm (0.236 in.)
Valve Diameter (All): 30.3 µ 0.12 mm (1.19 µ 0.0047 in.)
Intake
Exhaust 26.0 µ 0.14 mm (1.02 µ 0.0055 in.)
Valve Spring Loads: 580 µ 26 N (428 µ 19 lbs) @ 23.0 mm (0.90 in.)
Valve Open
Valve Closed 260 µ 13 N (192 µ 9 lbs) @ 32.0 mm (1.25 in.)
Valve Spring Free Length –
Cylinder Head:
Overall Height 138.18 mm (5.440 in.)
Minimum Height After Machining 138.13 mm (5.438 in.)
Distortion 0.1 mm (0.002 in.)
Oil Pump:
Gap Between Oil Pump Body and Out Rotor 0.4~0.484 mm (0.016~0.019 in.)
Out Rotor Side Clearance 0.45~0.100 mm (0.017~0.003 in.)
Inner Rotor Side Clearance 0.035~0.085 mm (0.001~0.003 in.)
Relief Valve Spring Free Length 81 mm (3.188 in.)
Sealants and Adhesives:
Rear Main Bearing Cap GE p/n RTV 159
Camshaft Carrier to Cylinder Head HN 1581 (Loctite± 515)
Oil Pan Bolts HN 1256 (Loctite± 242)
Oil Pump Bolts HN 1256 (Loctite± 242)
Oil Pan Pickup Tube Bolts HN 1256 (Loctite± 242)
Oil Gallery Plug HN 1256 (Loctite± 242)
Coolant Jacket Caps and Plugs (Freeze Plugs) HN 1756 (Loctite± 176)
Exhaust Manifold Studs/Nuts Anti–seize Compound (HMC Spec HN1325)
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A/C Compressor Hose Assembly Retaining Bolt 33 24 –
A/C Compressor Mounting Bolts 27 20 –
A/C Compressor Mounting Bracket Bolts 50 37 –
Air Filter Housing Bolts 8 – 71
Alternator Adjusting Bracket Retaining Bolt 20 15 –
Auxiliary Catalytic Converter–to–Exhaust Manifold Nuts 40 30 –
Camshaft Cap Bolts 16 12 –
Connecting Rod Bearing Cap Bolts 25 + 30³ 18 + 30³ –
Coolant Pump Retaining Bolts 10 – 89
Coolant Temperature Sensor 20 15 –
Crankshaft Bearing Cap Bolts 50 + 45³ + 15³ 37 + 45³ + 15³ –
Crankshaft Pulley Bolt 95 + 30³ + 15³ 70 + 30³ + 15³ –
Cylinder Head Bolts (Camshaft Support Housing & Cylinder 25 + 70³ + 70³ 18 + 70³ + 70³ –
Head Mounting Bolts) + 30³ + 30³
Electronic Ignition System Ignition Coil Mounting Bracket Bolts 10 – 89
Electronic Ignition System Ignition Coil Mounting Bolts 10 – 89
Engine Mount Bracket Retaining Bolts 60 44 –
Engine Mount Retaining Nuts 40 30 –
Engine Mount–to–Engine Mount Bracket Retaining Bolts 60 44 –
Exhaust Camshaft Gear Bolt 67.5 49 –
Exhaust Flexible Pipe Bracket Bolts 50 37 –
Exhaust Gas Recirculation Valve Adapter Bolts 25 18 –
Exhaust Manifold Heat Shield Bolts 15 11 –
Exhaust Manifold Retaining Nuts 25 18 –
Flexible Plate Bolts 60 44 –
Flexible Plate Inspection Cover Bolts 10 – 89
Flywheel Bolts 35 + 30³ + 15³ 25 + 30³ + 15³ –
Front Muffler–to–Main Catalytic Converter Nuts 30 22 –
Intake Camshaft Gear Bolt 67.5 49 –
Intake Manifold Retaining Nuts/Bolts 25 18 –
Intake Manifold Support Bracket Upper Bolts 25 18 –
Intake Manifold Support Bracket Lower Bolt–to–Engine Block 40 30 –
Lower Front Timing Belt Cover Bolts 10 – 89
Oil Pan Retaining Bolts 10 – 89
Oil Pressure Switch 40 30 –
Oil Pump Rear Cover Bolts 6 – 53
Oil Pump Retaining Bolts 10 – 89

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Oil Pump Pickup Tube and Support Bracket Bolts 10 – 89
Oil Pump Safety Relief Valve Bolt 30 22 –
Power Steering Pump Mounting Bolts 25 18 –
Rear Timing Belt Cover Bolts 10 – 89
Spark Plug Cover Bolts 3 – 27
Spark Plugs 25 18 –
Thermostat Housing Mounting Bolts 20 15 –
Throttle Cable Bracket Bolts 8 71
Timing Belt Automatic Tensioner Bolt 25 18 –
Timing Belt Idler Pulley Bolts 40 30 –
Transaxle Bell Housing Bolts 75 55 –
Transaxle Brace Bolts 40 30 –
Transaxle Torque Converter Bolts 65 48 –
Upper Front Timing Belt Cover Bolts 10 – 89
Valve Cover Nuts 9 – 80
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SPECIAL TOOLS
SPECIAL TOOLS TABLE
KJ–42492 MKM–571–B
Timing Belt Adjuster Gauge
KM–340–0
Cutter Set
Includes: KM–340–7
KM–470–B Guide Drift
Angular Torque Gauge KM–340–13
Cutters
KM–340–26
Cutters
J–28467–B KM–348
Engine Support Fixture Valve Spring Compressor
KM–427
KM–653
Piston Pin Service Set
Adapter
Adapter

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KM–635
KM–805 Crankshaft Rear Oil Seal
Valve Guide Reamer Installer
J–36972
KM–412 Crankshaft Rear Oil Seal
Engine Overhaul Stand Installer
KM–498–B KM–135
Pressure Gauge Adapter
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COMPONENT LOCATOR
UPPER END

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1. Spark Plug Cover 28. Intake Valve

2. Oil Filler Cap 29. Camshaft Oil Seal Ring
3. Oil Filler Cap Seal 30. Camshaft Gear
4. Valve Cover 31. Camshaft Position Sensor
5. Valve Cover Nut 32. Washer
6. Valve Cover Washer 33. Camshaft Gear Bolt
7. Valve Cover Gasket 34. Camshaft
8. Seal 35. Plug
9. Hydraulic Tappet 36. Stud
10. Valve Key 37. Engine Coolant Temperature Sensor
11. Valve Spring Retainer 38. Coolant Temperature Sensor
12. Valve Spring 39. Bolt
13. Valve Stem Seal 40. Front Camshaft Bearing Cap
14. Valve Cover Stud 41. Plug
15. Freeze Plug 42. Valve Guide
16. Exhaust Manifold 43. Camshaft Bearing Cap
17. Nut 44. Washer
18. Exhaust Manifold Heat Shield 45. Head Bolt
19. Oxygen Sensor 46. Exhaust Gas Recirculation Pipe
20. Bolt 47. Intake Manifold
21. Bolt 48. Plenum Gasket
22. Thermostat Housing 49. Throttle Body
23. Thermostat Adapter Seal 50. Plenum
24. Nut 51. Intake Manifold Gasket
25. Washer 52. Exhaust Manifold Gasket
26. Cylinder Head Gasket 53. Cylinder Head
27. Exhaust Valve
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LOWER END

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1. Piston Ring Set 40. Flexible Plate (Automatic Transaxle)

2. Piston 41. Bolt (Automatic Transaxle)
3. Piston Pin 42. Crankshaft Main Bearing Cap
4. Connecting Rod 43. Bolt
5. Connecting Rod Bearing Set 44. Bolt
6. Connecting Rod Bolt 45. Knock Sensor
7. Oil Level Gauge Stick 46. Oil Pan
8. Gauge Stick Tube 47. Threaded Ring
9. Connecting Piece 48. Bolt
10. Oil Filter 49. Bolt
11. Hose Clamp 50. Bracket
12. Engine Ventilation Hose 51. Oil Pickup Tube
13. Engine Ventilation Pipe 52. Bolt
14. Bolt 53. Bolt
15. Oil Separator Gasket 54. Timing Belt
16. Crankshaft Pulley Bolt 55. Cover Seal
17. Washer 56. Cover
18. Crankshaft Pulley 57. Bolt
19. Crankshaft Gear 58. Clamp
20. Rear Timing Belt Cover 59. Bolt
21. Bolt 60. Washer
22. Coolant Pump 61. Cover Bracket
23. Oil Pump 62. Idler Pulley
24. Engine Block Seal Ring 63. Rear Cover Bolt
25. Oil Pump Body Gasket 64. Bolt
26. Engine Block 65. Auto Tensioner
27. Pressure Relief Valve Plunger 66. Seal
28. Spring 67. Bolt
29. Oil Pump Seal Ring 68. Seal
30. Bolt Plug 69. Gear
31. Crankshaft Bearing Set 70. Gear
32. Crankshaft 71. Cover
33. Shaft Seal Ring 72. Bolt
34. Flywheel (Manual Transaxle) 73. Plug
35. Bolt (Manual Transaxle) 74. Oil Pressure Sensor
36. Bolt 75. Intake Manifold Support Bracket
37. Bracket
38. Bolt
39. Crankshaft Position Sensor
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SECTION : 1D
ENGINE COOLING
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1D–1 COOLANT PUMP . . . . . . . . . . . . . . . . . . . . . . . . 1D–11
CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D–1 ELECTRIC COOLING FAN – MAIN . . . . . . . . . 1D–12
FASTENER TIGHTENING ELECTRIC COOLING FAN – AUXILIARY . . . . 1D–14
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 1D–2
SURGE TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D–15
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D–2 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D–16
SPECIAL TOOLS TABLE . . . . . . . . . . . . . . . . . . . 1D–2 ENGINE COOLANT TEMPERATURE
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D–3 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D–18
THERMOSTAT TEST . . . . . . . . . . . . . . . . . . . . . . 1D–3 GENERAL DESCRIPTION AND SYSTEM
SURGE TANK CAP TEST . . . . . . . . . . . . . . . . . . 1D–3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D–20
COOLING SYSTEM DIAGNOSIS . . . . . . . . . . . . 1D–4 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . 1D–20
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 1D–5 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D–20
RADIATOR/FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D–5 SURGE TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D–20
COOLANT PUMP/THERMOSTAT (DOHC) . . . 1D–6 COOLANT PUMP . . . . . . . . . . . . . . . . . . . . . . . . 1D–20
COOLANT PUMP/THERMOSTAT (SOHC) . . . . 1D–7 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D–20
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 1D–8 ELECTRIC COOLING FAN . . . . . . . . . . . . . . . . 1D–20
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 1D–8 COOLANT TEMPERATURE SENSOR . . . . . . 1D–21
DRAINING AND REFILLING THE COOLING ENGINE COOLANT TEMPERATURE
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D–8 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D–21
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D–9 ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . 1D–21
SPECIFICATIONS
CAPACITY
Application Description
Coolant in the Cooling System (SOHC MPFI System) 7.0L (7.4 qt) for automatic transaxle
7.0L (7.4 qt) for manual transaxle
Coolant in the Cooling System (DOHC MPFI System) 7.0L (7.4 qt) for automatic transaxle
7.0L (7.4 qt) for manual transaxle
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1D – 2IENGINE COOLING

Coolant Pump Mounting Bolts 10 – 89
Electric Cooling Fan (Auxiliary) Motor Retaining Nuts 3.2 – 28
Electric Cooling Fan (Auxiliary) Retaining Nut 4 – 35
Electric Cooling Fan (Main) Motor Nut 3.2 – 28
Electric Cooling Fan (Main) Motor Retaining Screws 4 – 35
Electric Cooling Fan Assembly (Auxiliary) Mounting Bolts 4 – 35
Electric Cooling Fan Assembly (Main) Mounting Bolts 4 – 35
Engine Coolant Temperature Sensor (DOHC) 20 15 –
Engine Coolant Temperature Sensor (SOHC) 20 15 –
Lower Transaxle Cooler Pipe Bolt 12 – 106
Negative Battery Terminal Retainer Bolt 15 11 –
Surge Tank Attaching Bolt 10 – 89
Thermostat Housing Mounting Bolts (DOHC) 20 15 –
Thermostat Housing Mounting Bolts (SOHC) 20 15 –
Upper Left Radiator Retaining Bolt 4 – 35
Upper Right Radiator Retaining Bolt 4 – 35
Upper Transaxle Cooler Pipe Bolt 12 – 106
SPECIAL TOOLS
SPECIAL TOOLS TABLE
KM–471 Adapter

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ENGINE COOLING 1D – 3
1. Wash any sludge from the surge tank cap and the
DIAGNOSIS valve seat of the vacuum pressure valve for the
surge tank cap.
2. Check for any damage or deformity to the vacuum
pressure valve for the surge tank cap. If any dam-
THERMOSTAT TEST age or deformity is found, replace the cap.
1. Remove the thermostat from the vehicle. Refer 3. Install a suitable cooling system pressure tester to
to”Thermostat”in this section. the cap using the KM–471 adapter.
2. Make sure the valve spring is tight when the ther- 4. Pull the vacuum pressure valve open. If the surge
mostat is fully closed. If the spring is not tight, re- tank cap does not seal properly, replace the surge
place the thermostat. tank cap.
3. Suspend the thermostat and a thermometer in a 5. Pressurize the cap to 90 to 120 kPa (13 to 17 psi).
pan of 50/50 mixture of ethylene glycol and water. 6. Wait 10 seconds and check the pressure held by
Do not let the thermostat or the thermometer rest the tank cap tester.
on the bottom of the pan because the uneven con-
centration of heat on the bottom could result in in-
accurate temperature measurements.
4. Heat the pan on a burner.
5. Use the thermometer to measure the temperature
of the heated solution.
6. The thermostat should begin to open at 87³C
(189³F) and it should be fully open at 102³C
(216³F). If it does not open at these temperatures,
replace the thermostat.
SURGE TANK CAP TEST

SPECIAL TOOLS
Tools Required
KM–471 Adapter
The surge tank cap maintains proper pressure, protects
the system from high pressure by opening a pressure 7. If the pressure held by the cooling system pressure
valve, and protects the coolant hoses from collapsing be- tester falls below 80 kPa (11.6 psi) replace the
cause of a vacuum. surge tank cap.
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COOLING SYSTEM DIAGNOSIS

Engine Overheats
Checks Action
Check for a loss of the coolant. Add the coolant.
Check for a weak coolant solution. Confirm that the coolant solution is a 50/50 mixture of eth-
ylene glycol and water.
Check the front of the radiator for any dirt, any leaves, or Clean the front of the radiator.
any insects.
Check for leakage from the hoses, the coolant pump, the Replace any damaged components.
heater, the thermostat housing, the radiator, the core
plugs, or the head gasket.
Check for a faulty thermostat. Replace a damaged thermostat.
Check for retarded ignition timing. Perform a code diagnosis using the powertrain control
module (PCM) for a vehicle with an automatic transaxle or
the engine control module (ECM) for a vehicle with a
manual transaxle. Confirm the integrity of the timing belt.
Check for an improperly operating electric cooling fan. Replace the electric cooling fan.
Check for radiator hoses that are plugged or rotted. Replace any damaged radiator hoses.
Check for a faulty water pump. Replace a faulty water pump.
Check for a faulty surge tank cap. Replace a faulty surge tank cap.
Check for a cylinder head or an engine block that is Replace a faulty water pump.Repair the damaged cylinder
cracked or plugged. head or the damaged engine block.
Loss of Coolant
Checks Action
Check for a leak in the radiator. Replace a damaged radiator.
Check for a leak in the following locations: Replace the following parts:
S Surge tank. S Surge tank.
S Hose. S Hose.
Check for the following loose or damaged parts: Reseat the hoses.
S Radiator hoses. Replace the hoses or the clamps.
S Heater hoses.
S Connections.
Check for leaks in the coolant pump seal. Replace the coolant pump seal.
Check for leaks in the coolant pump gasket. Replace the coolant pump gasket.
Check for an improper cylinder head torque. Tighten the cylinder head bolts to specifications.
Replace the cylinder head gasket, if needed.
Check for leaks in the following locations: Repair or replace any components, as needed, to correct
S Intake manifold. the leak.
S Cylinder head gasket.
S Cylinder block plug.
S Heater core.
S Radiator drain plug.

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Engine Fails to Reach Normal Operating Temperature or Cool Air

from the Heater
Checks Action
Check to determine if the thermostat is stuck open, or if Install a new thermostat of the correct type and heat
it is the wrong type of thermostat. range.
Check the coolant level to determine if it is below the Add sufficient coolant to raise the fluid to the specified
MIN mark on the surge tank. mark on the surge tank.
COMPONENT LOCATOR
RADIATOR/FAN
1. Bolt 5. Upper Radiator Hose

2. Main Cooling Fan 6. Spring Clamp
3. Transaxle Fluid Pipe Holder (Automatic Transaxle 7. Auxiliary Cooling Fan (Air Conditioning Only)
Only) 8. Radiator Bumper
4. Radiator 9. Drain Cock
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COOLANT PUMP/THERMOSTAT (DOHC)
1. Cylinder Block Seal Ring 4. Bolt

2. Seal Ring 5. Bolt
3. Thermostat Housing 6. Coolant Pump

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COOLANT PUMP/THERMOSTAT (SOHC)
1. Thermostat Housing Bolt 5. Coolant Pump Mounting Bolts

2. Thermostat Housing 6. Coolant Pump
3. Seal Ring 7. O–Ring
4. Thermostat
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MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
DRAINING AND REFILLING THE

COOLING SYSTEM
CAUTION : To avoid injury, do not remove the surge

tank cap while the engine and the radiator are hot.
Scalding fluid and steam may be blown out under
pressure.
1. Place a pan below the vehicle to catch the draining
coolant.
2. Remove the surge tank cap.
3. Unplug the drain cock.
CAUTION : Dispose of the used coolant in a used
coolant holding tank to be picked up with the used oil
for disposal. Never pour the used coolant down the
drain. Ethylene glycol antifreeze is an extremely toxic
chemical. Disposing of it into the sewer system or the
ground water can contaminate the local environment.
4. Catch the escaping fluid in a drain pan.
5. Remove all sludge and dirt from inside the surge
tank. Refer to ”Surge Tank”in this section.
6. Plug the drain cock.
7. Add clean water to the surge tank.
8. Fill the tank slowly so that the upper reservoir hose
remains above the water line. This allows the air
inside the cooling system to escape.
9. Start the engine.
10. Run the engine until the thermostat opens. You can
tell the thermostat is open when both radiator
hoses are hot to the touch.
11. Stop the engine.

12. Repeat Steps 1 through 9 until the drained water is
clear and free of coolant and rust.
Notice : To avoid damaging the vehicle, never use an anti-
freeze mixture more concentrated than 60 percent anti-
freeze to 40 percent water. The solution freezing point in-
creases above this concentration.
13. Fill the cooling system through the surge tank with
a mixture of ethylene glycol antifreeze and water.
The mixture must be at least 50 percent antifreeze,
but not more than 60 percent antifreeze.
14. Fill the surge tank to the specified MAX fill mark on
the outside of the tank.

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THERMOSTAT
Single Overhead Cam Engine
Removal Procedure
CAUTION : To prevent personal injury, do not remove

the surge tank cap while the engine and the radiator
are hot because the heat causes the system to remain
under pressure. Scalding fluid and steam may be
blown out under pressure.
1. Drain the coolant. Refer to ”Draining and Refilling
the Cooling System”in this section.
2. Remove the rear timing belt cover. Refer toSection
1B, SOHC Engine Mechanical.
3. Loosen the hose clamp on the upper radiator hose
at the thermostat housing.
4. Disconnect the upper radiator hose from the ther-
mostat housing.
5. Remove the mounting bolts that hold the thermo-
stat housing to the cylinder head.
6. Remove the thermostat housing from the cylinder
head.
7. Remove the thermostat from its recess in the cylin-
der head.
8. Inspect the valve seat for foreign matter that could
prevent the valve from sealing properly.
9. Inspect the thermostat for proper operation. Refer
to ”Thermostat Test” in this section.
10. Clean the thermostat housing and the cylinder head
mating surfaces.
Installation Procedure
1. Install the thermostat into the cylinder head recess.
2. Install the thermostat housing.
3. Secure the thermostat housing to the cylinder head
with the mounting bolts.
Tighten
Tighten the thermostat housing mounting bolts to 20
NSm (15 lb–ft).
4. Connect the upper radiator hose to the thermostat
housing.
5. Secure the upper radiator hose to the thermostat
housing with a hose clamp.
6. Install the rear timing belt cover. Refer to Section
1B, SOHC Engine Mechanical.
7. Refill the engine cooling system. Refer to ”Draining
and Refilling the Cooling System”
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Dual Overhead Cam Engine
Removal Procedure

are still hot because the heat causes the system to re-
main under pressure. Scalding fluid and steam may
be blown out under pressure.
1. Drain the coolant. Refer to ”Draining and Refilling
the Cooling System”in this section.
2. Loosen the hose clamp on the upper radiator hose
at the thermostat housing.
3. Disconnect the upper radiator hose from the ther-
mostat housing.
4. Loosen the clamp on the bypass hose.
5. Disconnect the bypass hose from the thermostat
adapter.
6. Remove the mounting bolts that hold the thermo-
stat housing to the cylinder head.
7. Remove the thermostat housing from the head.
8. Remove the O–ring seal from the head.
9. Check the valve seat for foreign matter that could
prevent the valve from seating properly.
10. Check the thermostat for proper operation. Refer to
”Thermostat Test”in this section.
11. Clean the thermostat housing and the cylinder head
mating surfaces.
1. Coat the sealing surface of a new O–ring seal with

Lubriplate±.
2. Install a new O–ring seal into the recess in the cyl-
inder head.
3. Secure the thermostat housing to the cylinder head
with the mounting bolts.
Tighten
Tighten the thermostat housing mounting bolts to 20
NSm (15 lb–ft).

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4. Connect the bypass hose to the thermostat adapt-

er.
5. Secure the bypass hose with a hose clamp.
6. Connect the upper radiator hose to the thermostat
housing.
7. Secure the upper radiator hose to the thermostat
housing with a hose clamp.
and Refilling the Cooling System” in this section.
COOLANT PUMP
Removal Procedure
1. Drain the engine cooling system to a level below
the thermostat housing. Refer to”Draining and Refil-
ling the Cooling System”in this section.
2. Remove the rear timing belt cover. Refer toSection
1B, SOHC Engine Mechanical, or Section 1C,
DOHC Engine Mechanical.
3. Remove the coolant pump mounting bolts.
4. Remove the coolant pump from the cylinder block.
5. Remove the ring seal from the coolant pump.
Inspection Cleaning Procedure

1. Inspect the coolant pump body for cracks and
leaks.
2. Inspect the coolant pump bearing for play or abnor-
mal noise.
3. Inspect the coolant pump pulley for excessive wear.
If the coolant pump is defective, replace the coolant
pump as a unit.
4. Clean the mating surfaces of the coolant pump and
cylinder block.
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1. Install a new ring seal to the coolant pump.
2. Coat the sealing surface of the ring seal with Lubri-
plate±.
3. Install the coolant pump to the engine block.
4. Secure the coolant pump to the engine block with
the mounting bolts.
Tighten
Tighten the coolant pump mounting bolts to 10 NSm
(89 lb–in).
5. Install the timing belt cover. Refer toSection 1B,
DOHC Engine Mechanical.
ELECTRIC COOLING FAN – MAIN

Removal Procedure
1. Disconnect the negative battery cable.

2. Disconnect the cooling fan electrical connector.
3. Remove the fan shroud mounting bolts.
4. Lift the fan shroud assembly upward, and remove
the fan shroud assembly from the vehicle.
5. Remove the fan blade from the fan moter by re-
moving the nut at the center of the fan hub.
6. Remove the fan motor retaining screws.

7. Remove the fan motor from the shroud.

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CAUTION : If a fan blade is bent or damaged in any

way, no attempt should be made to repair or reuse the
damaged part. A bent or damaged fan assembly must
be replaced with a new fan assembly. It is essential
that fan assemblies remain in proper balance. A fan
assembly that is not in proper balance can fail and fly
apart during use, creating extreme danger. Proper
balance cannot be assured on a fan assembly that
has been bent or damaged.
1. Install the fan motor to the shroud.
2. Secure the motor to the shroud with the retaining
screws.
Tighten
Tighten the fan motor retaining screws to 4 NSm (35
lb–in).
3. Install the fan to the motor with the single nut in the
center of the fan hub.
Tighten
Tighten the electric cooling fan (main) motor nut to 3.2
NSm (28 lb–in).
4. Install the electric cooling fan shroud assembly to

the radiator.
Important : Be careful to seat the mounting post on the
fan shroud into the socket at the radiator left tank. Be sure
to slip the tab at the bottom edge of the shroud into the re-
taining clip near the center of the radiator.
5. Secure the shroud to the top of the radiator with the
mounting bolts.
Tighten
Tighten the electric cooling fan assembly (main)
mounting bolts to 4 NSm (35 lb–in).
6. Install the electrical connector to the cooling fan.
7. Connect the negative battery cable.
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ELECTRIC COOLING FAN –

AUXILIARY
Removal Procedure

2. Disconnect the cooling fan electrical connector.
3. Remove the fan shroud mounting bolts.
4. Lift the fan shroud assembly upward, and remove
the fan shroud assembly from the vehicle.
5. Remove the fan motor nuts that secure the fan mo-
tor to the shroud.
6. Remove the fan motor from the shroud.

7. Remove the fan retaining nut which secures the fan
to the motor.
CAUTION : If a fan blade is bent or damaged in any

way, no attempt should be made to repair or reuse the
damaged part. A bent or damaged fan assembly must
be replaced with a new fan assembly. It is essential
that fan assemblies remain in proper balance. A fan
assembly that is not in proper balance can fail and fly
apart during use, creating an extremely dangerous
condition. Proper balance cannot be assured on a fan
assembly that has been bent or damaged.
1. Install the fan to the motor.
2. Attach the fan retaining nut.
Tighten
Tighten the electric cooling fan (auxiliary) retaining re-
taining screws to 4 NSm (35 lb–in).
3. Attach the fan motor to the shroud.

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4. Secure the fanmotor to the shroud with the retain-

ing nuts.
Tighten
Tighten the electric cooling fan (auxiliary) motor re-
taining nuts to 3.2 NSm (28 lb–in).
5. Install the electric cooling fan shroud assembly to
the radiator.
6. Be careful to seat the mounting post on the fan
shroud into the socket at the radiator right tank.
7. Also be sure to slip the bottom edge of the shroud
into the retaining clip near the center of the radiator.
8. Secure the shroud to the top of the radiator with the
mounting bolts.
Tighten
Tighten the electric cooling fan assembly (auxiliary)
mounting bolts to 4 NSm (35 lb–in).
9. Install the electrical connector to the cooling fan.
SURGE TANK
Removal Procedure
are hot, because the heat causes the system to re-
main under pressure. Scalding fluid and steam may
be blown out under pressure.
1. Drain the engine coolant to below the level of the
surge tank.
2. Loosen the overflow hose clamps and disconnect
the overflow hose from the top of the surge tank.
3. Remove the tank attaching nuts.
4. Remove the tank from the vehicle.
5. Clean the inside and the outside of the surge tank
and the surge tank cap with soap and water.
6. Rinse the surge tank and the cap thoroughly.
1. Install the surge tank to the vehicle.
2. Secure the surge tank with the attaching nuts.
Tighten
Tighten the surge tank attaching nuts to 10 NSm (89
lb–in).
3. Connect the overflow hose to the surge tank.
4. Secure the overflow hose to the surge tank with the
hose clamps.
5. Fill the surge tank with the coolant to the center
ridge, or to the MAX mark.
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RADIATOR
Removal Procedure

2. Drain the engine cooling system. Refer to ”Draining
3. Remove the main cooling fans. Refer to ”Electric
Cooling Fan–Main” in this section.
4. Remove the auxiliary cooling fans. Refer to ”Elec-
tric Cooling Fan–Auxiliary" in this section.
5. Remove the lower radiator hose clamp.
6. Disconnect the lower radiator hose from the radia-
tor.
7. Remove the upper radiator hose clamp.
8. Disconnect the upper radiator hose from the radia-
tor.
9. Remove the hose clamp from the surge tank hose

at the radiator.
10. Disconnect the surge tank hose from the radiator.
11. Disconnect the upper and lower transaxle fluid cool-
er hoses from the pipes at the left radiator tank, if
equipped.
12. Remove the left upper radiator retaining bolt.
13. Remove the left upper radiator retaining bracket.
14. Remove the right upper radiator retaining bolt.

15. Remove the right upper radiator retaining bracket.
16. Remove the radiator from the vehicle.
Important : The radiator still contains a substantial
amount of coolant. Drain the remainder of the coolant from
the radiator into a drain pan.

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1. If installing a new radiator, remove the transaxle

cooler pipes from the old radiator and install them
onto the left tank of the new radiator.
2. Install the upper transaxle cooler pipe to the radia-
tor and secure the pipe with a pipe bolt.
Tighten
Tighten the upper transaxle cooler pipe bolt to 12 NSm
(106 lb–in).
3. Install the pipe holder as it was in the old radiator.
4. Install the lower transaxle cooler pipe to the radiator
and secure the pipe with a pipe bolt.
Tighten
Tighten the lower transaxle cooler pipe bolt to 12 NSm
(106 lb–in).
5. Set the radiator into place in the vehicle with the
radiator bottom posts in the rubber shock bumpers.
6. Position the radiator retainers in place.
7. Install the upper right radiator retainer bracket.
8. Install the upper right radiator retaining bolt.
Tighten
Tighten the upper right radiator retaining bolt to 4 NSm
(35 lb–in).
9. Install the upper left radiator retainer bracket.

10. Install the upper left radiator retaining bolt.
Tighten
Tighten the upper left radiator retaining bolt to 4 NSm
(35 lb–in).
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11. Connect the transaxle cooler hoses to the pipes, if

equipped.
12. Connect the surge tank hose to the radiator.
13. Secure the surge tank hose with a hose clamp.
14. Connect the upper radiator hose and the lower ra-
diator hose to the radiator.
15. Secure each hose with a hose clamp.
16. Install the main cooling fans. Refer to ” Electric
Cooling Fan–Main” in this section.
17. Install the auxiliary cooling fan, if equipped. Refer to
”Electric Cooling Fan–Auxiliary” in this section.
ENGINE COOLANT TEMPERATURE

SENSOR
Single Overhead Cam Engine
Removal Procedure
2. Drain the coolant to a level below the engine cool-
ant temperature sensor level.
3. Disconnect the electrical connector from the engine
coolant temperature sensor.
4. Remove the temperature sensor from the intake
manifold.
1. Install the coolant temperature sensor into the
threaded hole in intake manifold.
Tighten
Tighten the coolant temperature sensor(SOHC) to 20
NSm (15 lb–ft).
2. Connect the electrical connector to the engine cool-
ant temperature sensor.
3. Refill the coolant system. Refer to”Draining and
Refilling the Cooling System” in this section.

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Dual Overhead Cam Engine

Removal Procedure
2. Drain the coolant below the engine coolant temper-
ature sensor level.
3. Disconnect the electrical connector from the engine
coolant temperature sensor.
4. Remove the temperature sensor from the cylinder
head.
1. Install the coolant temperature sensor into the
threaded hole in the cylinder head.
Tighten
Tighten the coolant temperature sensor(DOHC) to 20
NSm (15 lb–ft).
2. Connect the electrical connector to the engine cool-
ant temperature sensor.
3. Refill the coolant system. Refer to”Draining and
Refilling the Cooling System” in this section.
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When the engine stops, the engine coolant cools and con-
GENERAL DESCRIPTION tracts. The displaced engine coolant is then drawn back
into the radiator and the engine. This keeps the radiator
AND SYSTEM OPERATION filled with coolant to the desired level at all times and in-
creases the cooling efficiency.
Maintain the coolant level between the MIN and the MAX
GENERAL DESCRIPTION marks on the surge tank when the system is cold.
The cooling system maintains the engine temperature at
an efficient level during all engine operating conditions. COOLANT PUMP
When the engine is cold, the cooling system cools the en- The belt–driven centrifugal coolant pump consists of an
gine slowly, or not at all. This slow cooling of the engine al- impeller, a drive shaft, and a belt pulley. The coolant pump
lows the engine to warm up quickly. is mounted on the front of the transverse–mounted en-
gine, and is driven by the timing belt.
The cooling system includes a radiator and recovery sub-
system, cooling fans, a thermostat and housing, a coolant The impeller is supported by a completely sealed bearing.
pump, and a coolant pump drive belt. The timing belt The coolant pump is serviced as an assembly and, there-
drives the coolant pump. fore, cannot be disassembled.
All components must function properly in order for the
cooling system to operate. The coolant pump draws the
THERMOSTAT
coolant from the radiator. The coolant then circulates A wax pellet–type thermostat controls the flow of the en-
through water jackets in the engine block, the intake man- gine coolant through the engine cooling system. The ther-
ifold, and the cylinder head. When the coolant reaches the mostat is mounted in the thermostat housing to the front
operating temperature of the thermostat, the thermostat of the cylinder head.
opens. The coolant then goes back to the radiator where The thermostat stops the flow of the engine coolant from
it cools. the engine to the radiator to provide faster warm–up, and
to regulate the coolant temperature. The thermostat re-
This system directs some coolant through the hoses to the
mains closed while the engine coolant is cold, preventing
heater core. This provides for heating and defrosting. The
surge tank is connected to the radiator to recover the cool- circulation of the engine coolant through the radiator. At
ant displaced by expansion from the high temperatures. this point, the engine coolant is allowed to circulate only
The surge tank maintains the correct coolant level. throughout the heater core to warm it quickly and evenly.
As the engine warms, the thermostat opens. This allows
The cooling system for this vehicle has no radiator cap or the engine coolant to flow through the radiator where the
filler neck. The coolant is added to the cooling system heat is dissipated through the radiator. This opening and
through the surge tank. closing of the thermostat permits enough engine coolant
to enter the radiator to keep the engine within proper en-
RADIATOR gine temperature operating limits.
This vehicle has a lightweight tube–and–fin aluminum ra- The wax pellet in the thermostat is hermetically sealed in
diator. Three models of radiators are available: small, a metal case. The wax wax element of the thermostat ex-
standard, and heavy duty. The three models vary only by pands when it is heated and contracts when it is cooled.
capacity. Plastic tanks are mounted on the right and the As the vehicle is driven and the engine warms, the engine
left sides of the radiator core. coolant temperature increases. When the engine coolant
On vehicles equipped with automatic transaxles, the reaches a specified temperature, the wax pellet element
transaxle fluid cooler lines run through the left radiator in the thermostat expands and exerts pressure against the
tank. A radiator drain plug is on this radiator. metal case, forcing the valve open. This allows the engine
coolant to flow through the engine cooling system and cool
To drain the cooling system, open the drain cock. the engine.
As the wax pellet cools, the contraction allows a spring to
SURGE TANK close the valve.
The surge tank is a transparent plastic reservoir, similar to The thermostat begins to open at 87³C (189³F) and is fully
the windshield washer reservoir. open at 102³C (216 ³F). The thermostat closes at 86³C
The surge tank is connected to the radiator by a hose and (187³F).
to the engine cooling system by another hose. As the ve-
hicle is driven, the engine coolant heats and expands. The ELECTRIC COOLING FAN
portion of the engine coolant displaced by this expansion CAUTION : Keep hands, tools, and clothing away
flows from the radiator and the engine into the surge tank. from the engine cooling fans to help prevent personal
The air trapped in the radiator and the engine is degassed injury. This fan is electric and can turn ON whether or
into the surge tank. not the engine is running.

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CAUTION : If a fan blade is bent or damaged in any A/C ON

way, no attempt should be made to repair or reuse the S The PCM or the ECM will turn the cooling fans on
damaged part. A bent or damaged fan assembly at low speed when the A/C system is on. The PCM
should always be replaced with a new one. or the ECM will change to high speed when the
The cooling fans are mounted behind the radiator in the coolant temperature reaches 115³C (239³F) or
engine compartment. The electric cooling fans increase high–side A/C pressure reaches 1 882 kPa (273
the flow of air across the radiator fins and across the con- psi).
denser on air conditioned (A/C)–equipped vehicles. This S The cooling fans will return to low speed when the
helps to speed cooling when the vehicle is at idle or moving coolant temperature reaches 112³C (234³F) or
at low speeds. high–side A/C pressure reaches 1 448 kPa (210
The main fan size is 320 mm (12.6 inches) in diameter with psi).
five blades to aid the airflow through the radiator and the COOLANT TEMPERATURE SENSOR
condenser. An electric motor attached to the radiator sup-
The coolant temperature sensor (CTS) uses a thermistor
port drives the fan.
to control the signal voltage to the powertrain control mod-
A/C models have two fans – the main fan, and the auxiliary ule (PCM) or the engine control module (ECM).
fan. The auxiliary fan is 250 mm (9.8 inches) in diameter.
Non–A/C models have only the main fan. ENGINE COOLANT TEMPERATURE
SENSOR
A/C Off or Non–A/C Model
The engine coolant temperature sensor controls the in-
S The cooling fan(s) are actuated by the powertrain strument panel temperature indicator. The engine coolant
control module (PCM) in vehicles with an automatic temperature sensor is located on the intake manifold near
transaxle or the engine control module (ECM) using the throttle body on an SOHC engine, and on the cylinder
a low–speed cooling fan relay and a high–speed head, under the intake manifold on a DOHC engine.
cooling fan relay. On A/C–equipped vehicles, a se-
ries/parallel cooling fan relay is also used. ENGINE BLOCK HEATER
S The PCM or the ECM will turn the cooling fan(s) on The vehicle is designed to accept an engine block heater.
at low speed when the coolant temperature reaches The engine block heater helps to warm the engine for im-
93³C (199³F) and high speed at 97³C (207³F). proved cold weather starting. It can also help reduce fuel
S The PCM or the ECM will change the cooling fan(s) consumption when a cold engine is warming up.
from high speed to low speed at 94³C (201³F) and The engine block heater utilizes an existing expansion
turn the cooling fans off at 90³C (194³F). plug for installation and is located under the intake man-
ifold.
Contact your Daewoo dealer for further information or
installation.
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SECTION : 1E
ENGINE ELECTRICAL
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1E–1 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E–20
STARTER SPECIFICATIONS . . . . . . . . . . . . . . . 1E–1 STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . 1E–20
GENERATOR SPECIFICATIONS . . . . . . . . . . . . 1E–2 GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E–31
BATTERY SPECIFICATIONS . . . . . . . . . . . . . . . 1E–2
GENERAL DESCRIPTION AND SYSTEM
FASTENER TIGHTENING SPECIFICATIONS . 1E–2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E–39
SCHEMATIC AND ROUTING DIAGRAMS . . . . . 1E–3 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E–39
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 1E–3 RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E–39
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1E–4 RESERVE CAPACITY . . . . . . . . . . . . . . . . . . . . 1E–39
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E–5 COLD CRANKING AMPERAGE . . . . . . . . . . . . 1E–39
NO CRANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E–5 BUILT–IN HYDROMETER . . . . . . . . . . . . . . . . . 1E–39
STARTER MOTOR NOISE . . . . . . . . . . . . . . . . . 1E–9 CHARGING PROCEDURE . . . . . . . . . . . . . . . . 1E–39
BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . 1E–9 CHARGING TIME REQUIRED . . . . . . . . . . . . . 1E–40
GENERATOR OUTPUT TEST . . . . . . . . . . . . . 1E–10 CHARGING A COMPLETELY DISCHARGED
GENERATOR SYSTEM CHECK . . . . . . . . . . . . 1E–10 BATTERY (OFF THE VEHICLE) . . . . . . . . . . 1E–40
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 1E–12 JUMP STARTING PROCEDURE . . . . . . . . . . . 1E–40
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 1E–12 GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E–41
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E–12 CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . 1E–41
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E–16 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E–41
BATTERY/BATTERY TRAY . . . . . . . . . . . . . . . . 1E–17 STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1E–41
SPECIFICATIONS
STARTER SPECIFICATIONS
Starter Minimum 40 – Maximum 90 amps
No Load Test @ 12.2 Volts 3,200–4,800 rpm
Drive Pinion Speed at:
Solenoid 12–20 amps
Hold–in Windings @ 12.2 Volts 60–90 amps
Pull–in Windings @ 12.2 volts
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1E – 2IENGINE ELECTRICAL
GENERATOR SPECIFICATIONS
Types CS–121D
BATTERY SPECIFICATIONS
L4 Engine
Cold Cranking Amps 550 amps
RC (Minimum) 90 minutes
Load Test 270 amps
Replacement 85B–60
Minimum Voltage: Estimated Temperature:
9.6 21³C (60³F)
9.4 20³C (68³F)
9.1 0³C (32³F)
8.8 –10³C (14³F)
8.5 –18³C (0³F)
8.0 Below –18³C (Below 0³F)

Battery Cable Nuts 4.5 – 40
Battery Carrier Tray Lower Bolts 20 15 –
Battery Carrier Tray Upper Bolts 20 15 –
Battery Retainer Clamp–to–Battery Rod Nuts 4 – 35
Generator Battery Lead Nut 15 11 –
Generator Drive End Bearing Nut 81 60 –
Generator Lower Bracket–to–Generator Nuts 20 15 –
Generator Shackle Bracket Bolt 20 15 –
Generator Through–Bolts 10 – 89
Starter Field Coil Connector Nut 8 – 71
Starter Mounting Bolts 43 32 –
Starter Solenoid Assembly Screws 8 – 71
Starter Solenoid Nuts 15 11 –
Starter Through–Bolts 6 – 53

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ENGINE ELECTRICAL 1E – 3
SCHEMATIC AND ROUTING DIAGRAMS

STARTING SYSTEM
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CHARGING SYSTEM

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DIAGNOSIS
NO CRANK
1 1. Press the clutch pedal completely down. System OK Go to Step 2
2. Turn the key to START.
Does the vehicle start?
2 1. Disconnect the clutch pedal position switch Go to Step 4 Go to Step 3
wires.
2. Check for continuity between the switch termi-
nals when the clutch pedal switch is pushed to
the ON position.
Does the ohmmeter indicate the value specified?
3 Replace the clutch pedal position switch. System OK Go to Step 4
Does the vehicle start?
4 1. Turn the headlamps ON. Go to Step 5 Go to Step 11
2. Turn the dome lamps ON.
3. Turn the key to START.
Do the lights dim or go out?
5 Check the battery state of charge. Go to Step 6 Go to ”Charg-
Is the green eye showing from the built–in hydrome- ing Procedure”
ter?
6 1. Connect the voltmeter positive lead to the start- < 9.6 v Go to ”Charg- Go to Step 7
er ”B” terminal. ing Procedure”
2. Connect the voltmeter negative lead to the
negative battery terminal.
3. Turn the ignition to START.
Does the voltmeter indicate the value specified?
7 1. Connect the voltmeter negative lead to the > 0.5 v Go to Step 8 Go to Step 9
2. Connect the voltmeter positive lead to the en-
gine block.
3. Place the ignition in the START position.
8 1. Clean and tighten the negative battery cable System OK
connections both at the battery end and at the
ground end.
2. Replace the cable if needed.
9 1. Connect the voltmeter positive lead to the start- <9v Go to Step 10 Go to Step 16
er ”B” terminal.
3. Check the cranking voltage.
10 Clean, tighten, or replace the positive battery cable. System OK
11 Check system fuse EF3 in the engine fuse block. Go to Step 12 Go to Step 13
Is fuse EF3 blown?
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12 Replace system fuse EF3. System OK
13 Check the connection at the starter S"terminal. Go to Step 15 Go to Step 14
Is the connection in good condition?
14 Repair the starter S"terminal. System OK
15 1. Connect the voltmeter positive lead to the start- >7v Go to Step 16 Go to Step 17
er S"terminal.
4. Read the voltage present at the S" terminal.
Does the voltmeter indicate the specified value?
16 Repair or replace the starter. System OK
17 Turn on the heater blower. Go to Step 27 Go to Step 18
Does the blower operate?
18 1. Disconnect connector C201. 12 v Go toStep 20 Go to Step 19
2. Connect the voltmeter positive lead to terminal
1 of connector C201.
3. Connect the voltmeter negative terminal to
ground.
19 Repair the open in the RED/WHT wire from fuse EF3 System OK
to Connector C201.
20 Check the contacts of terminal 1 on connector C201. Go to Step 22 Go to Step 21
Are the contacts OK?
21 Repair the faulty contact of connector C201. System OK
22 1. Reconnect connector C201. 11–14 v Go to Step 24 Go to Step 23
2. Disconnect the ignition switch connector.
5 of the ignition switch connector.
4. Connect the voltmeter negative terminal to
ground.
23 Repair the open in the RED/WHT wire from terminal System OK
1 of connector C201 to terminal 5 of the ignition
switch connector.
24 Check the contacts of terminal 5 of the ignition Go to Step 26 Go to Step 25
switch connector.
Are the contacts OK?
25 Repair the faulty contact of the ignition switch con- System OK
nector.
26 Replace the ignition switch. System OK
27 Does the vehicle have an automatic transmission? Go to Step 28 Go to Step 38

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28 1. Disconnect the Park/Neutral switch connector. <7v Go to Step 29 Go to Step 34
2. Connect the voltmeter positive lead to the
Park/Neutral switch connector terminal E, con-
nected to the RED/BLK wire.
29 Check continuity between the Park/Neutral switch 0Ω Go to Step 30 Go to Step 33
connector terminal G, connected to the RED wire,
and the Park/Neutral switch connector terminal E,
connected to the RED/BLK wire.
Does the ohmmeter indicate the specified value?
30 Check the condition of terminals E and G on both the Go to Step 31 Go to Step 32
Park/Neutral switch connector and on the Park/Neu-
tral switch.
Are any of these terminals faulty?
31 Replace the p/n position switch relay. System OK
32 Repair the open in the RED wire between terminal System OK
G of the Park/Neutral switch connector and the start-
er ”S"terminal.
33 Replace the Park/Neutral switch. System OK
34 1. Reconnect the Park/Neutral switch. 12 v Go to Step 35 Go to Step 42
2. Disconnect connector C104.
10 of connector C104 on the ECM/ABS har-
ness.
4. Connect the voltmeter negative lead to ground.
5. Turn the ignition switch to START.
35 Check terminal 10 on both sides of connector C104. Go to Step 36 Go to Step 37
Is one of them faulty?
36 Check terminal 10 on both sides of connector C104. System OK
37 Repair the open in the RED/BLK wire from terminal System OK
10 of connector C104 to terminal E of the Park/Neu-
tral switch.
38 1. Disconnect connector C104. 12 v Go to Step 39 Go to Step 42
10 of connector C104 on the ECM/ABS har-
ness.
39 Check terminal 10 on both sides of connector C104. Go toStep 40 Go to Step 41
40 Replace the faulty terminal. System OK
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41 Repair the open in the RED wire from terminal 10 of System OK
connector C104 to the starter S"terminal.
42 1. Disconnect connector C210. 12 v Go to Step 43 Go to Step 46
14 of connector C210 on the I/P harness.
43 Check terminal 14 on both sides of connector C210. Go to Step 44 Go to Step 45
44 Repair the faulty terminal. System OK
45 Repair the open in the RED wire from terminal 14 of System OK
connector C210 to terminal 10 of connector C104.
46 1. Disconnect the ignition switch connector. 12 v Go to Step 48 Go to Step 47
ST of the ignition switch.
48 Check terminal ST on the ignition switch and termi- Go to Step 49 Go to Step 50
nal 3 of the ignition switch connector.
Are the terminals in good condition?
49 Repair the open in RED wire between terminal 3 of System OK
the ignition switch connector and terminal 14 of con-
nector C210.
50 Repair the faulty terminal. System OK

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STARTER MOTOR NOISE

To correct starter motor noise during starting, use the following procedure:
Checks Action
Check for a high–pitched whine during cranking, before The distance is too great between the starter pinion and
the engine fires. The engine cranks and fires properly. the flywheel. Shimming the starter toward the flywheel is
required.
Check for a high–pitched whine after the engine fires, as The distance is too small between the starter pinion and
the key is being released. The engine cranks and fires the flywheel. Shimming the starter away from the flywheel
properly. This intermittent complaint is often diagnosed as is required.
”starter hang–in” or ”solenoid weak.”
Check for a loud ”whoop” after the engine fires but while The most probable cause is a defective clutch. A new
the starter is still held engaged. The sound is like a siren clutch will often correct this problem.
if the engine is revved while the starter is engaged.
Check for a ”rumble,” a ”growl,” or, in severe cases, a The most probable cause is a bent or unbalanced starter
”knock” as the starter is coasting down to a stop after start- armature. A new armature will often correct this problem.
ing the engine.
If the complaint is noise, correction can be achieved by 1. Check the battery for obvious damage, such as a
proper shimming as follows: cracked or broken case or cover, which could per-
1. Check for a bent or a worn flywheel. mit the loss of electrolyte. If obvious damage is
2. Start the engine and carefully touch the outside di- noted, replace the battery.
ameter of the rotating flywheel ring gear with chalk CAUTION : Do not charge the battery if the hydrome-
or a crayon to show the high point of the tooth run- ter is clear or light yellow. Instead, replace the battery.
out. Turn the engine OFF and rotate the flywheel so If the battery feels hot, or if violent gassing or spew-
that the marked teeth are in the area of the starter ing of electrolyte through the vent hole occurs, dis-
pinion gear. continue charging or reduce the charging rate to
3. Disconnect the negative battery cable to prevent avoid personal injury.
cranking the engine.
2. Check the hydrometer. If the green dot is visible, go
4. Check the pinion–to–flywheel clearance by using a
to the load test procedure. If the indicator is dark
wire gauge of 0.5 mm (0.02 inch) minimum thick-
but green is not visible, charge the battery. For
ness (or diameter). Center a pinion tooth between
charging a battery removed from the vehicle, refer
two flywheel teeth and the gauge. Do not gauge in
to”Charging a Completely Discharged Battery” in
the corners, where a misleading larger dimension
this section.
may be observed. If the clearance is under this
3. Connect a voltmeter and a battery load tester
minimum, shimming the starter away from the fly-
across the battery terminals.
wheel is required.
4. Apply a 300–ampere load for 15 seconds to remove
5. If the clearance approaches 1.5 mm (0.06 inch) or
any surface charge from the battery.
more, shimming the starter toward the flywheel is
5. Remove the load.
required. This condition is generally the cause of
6. Wait 15 seconds to let the battery recover, and ap-
broken flywheel teeth or the starter housing. Shim
ply a 270–ampere load.
the starter toward the flywheel by shimming only
the outboard starter mounting pad. A shim of 0.40 Important : The battery temperature must be estimated
mm (0.016 inch) thickness at this location will de- by touch and by the temperature condition the battery has
crease the clearance by approximately 0.30 mm been exposed for the preceding few hours.
(0.012 inch). If normal starter shims are not avail- 7. If the voltage does not drop below the minimum
able, plain washers or other suitable material may listed, the battery is good and should be reinstalled.
be used as shims. If the voltage is less than the minimum listed, re-
place the battery. Refer to ”Battery Specifications”
BATTERY LOAD TEST in this section.
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GENERATOR OUTPUT TEST

1. Perform the generator system test. Refer to ”Gen-
erator System Check”in this section.
2. Replace the generator if it fails that test. Refer to
”Generator” in the On–Vehicle Service portion of
this section. If it passes the test, perform the on–
vehicle output check which follows.
Important : Always check the generator for output before
assuming that a grounded ”L” terminal circuit has dam-
aged the regulator.
3. Attach a digital multimeter, an ammeter, and a car-
bon pile load to the vehicle.
Important : Be sure the vehicle battery is fully charged,
and the carbon pile load is turned off.
4. With the ignition switch in the OFF position, check
and record the battery voltage.
5. Remove the harness connector from the generator.
6. Turn the ignition to RUN with the engine not run-
ning. Use a digital multimeter to check for voltage in
GENERATOR SYSTEM CHECK
the harness connector ”L” terminal. When operating normally, the generator indicator lamp will
7. The reading should be near the specified battery come on when the ignition is in RUN position and go out
voltage of 12 volts. If the voltage is too low, check when the engine starts. If the lamp operates abnormally
the indicator L" terminal circuits for open and or if an undercharged or overcharged battery condition oc-
grounded circuits causing voltage loss. Correct any curs, the following procedure may be used to diagnose the
open wires, terminal connections, etc., as neces- charging system. Remember that an undercharged bat-
sary. Refer to”Charging System” in this section. tery is often caused by accessories being left on overnight
8. Attach the generator harness connector. or by a defective switch that allows a lamp, such as a trunk
9. Run the engine at a moderate idle, and measure or a glove box lamp, to stay on.
the voltage across the battery terminals. The read- Diagnose the generator with the following procedure:
ing should be above that recorded in step 14, but 1. Visually check the belt and the wiring.
less than 16 volts. If the reading is over 16 volts or 2. With the ignition in the ON position and the engine
below the previous reading, replace the generator. stopped, the charge indicator lamp should be on. If
Refer to”Generator” in the On–Vehicle Service sec- not, detach the harness at the generator and
tion. ground the ”L” terminal in the harness with a 5–am-
10. Run the engine at a moderate idle, and measure pere jumper lead.
the generator amperage output.
S If the lamp lights, replace the generator. Refer to
11. Turn on the carbon pile, and adjust it to obtain the
”Generator” in the On–Vehicle Service section.
maximum amps while maintaining the battery volt-
S If the lamp does not light, locate the open circuit
age above 13 volts.
between the ignition switch and the harness
12. If the reading is within 15 amps of the generator’s
connector. The indicator lamp bulb may be
rating noted on the generator, the generator is
burned out.
good. If not, replace the generator. Refer to”Gener-
ator” in the On–Vehicle Service section. 3. With the ignition switch in the ON position and the
13. With the generator operating at the maximum out- engine running at moderate speed, the charge indi-
put, measure the voltage between the generator cator lamp should be off. If not, detach the wiring
housing and the battery negative terminal. The volt- harness at the generator.
age drop should be 0.5 volt or less. If the voltage S If the lamp goes off, replace the generator. Re-
drop is more than 0.5 volt, check the ground path fer to ”Generator” in the On–Vehicle Service
from the generator housing to the negative battery section.
cable. S If the lamp stays on, check for a short to ground
14. Check, clean, tighten, and recheck all of the ground in the harness between the connector and the
connections. indicator lamp.

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Important : Always check the generator for output before

assuming that a grounded ”L” terminal circuit has dam-
aged the regulator. Refer to”Generator” in the Unit Repair
section.
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GENERATOR
Removal Procedure

2. Disconnect the intake air temperature (IAT) sensor
electrical connector from the air intake tube.
3. Remove the breather tube clamp and all other

clamps to remove the air intake tube.
4. Remove the battery harness connector nut from the

generator.

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5. Remove the generator shackle bracket bolt and the

washer.
6. Remove the serpentine accessory drive belt. For
vehicles equipped with power steering and air con-
ditioning, refer toSection 6B, Power Steering Pump.
7. Remove the bolt and the retaining clamp of the har-

ness.
8. For vehicles with the SOHC engine, remove the

nuts and the washers which hold the generator low-
er bracket–to–generator bolts.
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9. For vehicles with the DOHC engine, remove the

throttle body. Refer to Section 1F, Engine Controls.
10. Remove the fuel rail mounting bolts.
Notice : Take extreme care not to damage the fuel injector
O–rings to prevent fuel leaks when the fuel rail is reseated.
11. Unseat the fuel rails from the cylinder head, and
slightly push the fuel rail assembly clear of the cyl-
inder head in the direction of the master cylinder.
12. Remove the nut and the washers which hold the
generator lower bracket–to–generator bolt.
13. Carefully remove the generator.
1. Install the generator at the generator lower bracket

and insert the generator bolts.
2. Install the nut and the washers on the generator
lower bracket–to–generator bolt (SOHC engine is
shown).
Tighten
Tighten the generator lower bracket–to–generator
nuts to 20 NSm (15 lb–ft).
3. Install the generator and the lower support bracket

assembly to the engine block with the bolts.
4. Secure the generator to the shackle bracket with
the bolt (SOHC engine is shown). For vehicles
equipped with power steering and air conditioning,
refer to Section 6B, Power Steering Pump.
Tighten
Tighten the generator shackle bracket bolt to 20 NSm
(15 lb–ft).

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5. Connect the harness connector to the back of the

generator.
6. Install the generator lead to the battery and fasten
the lead with the nut.
Tighten
Tighten the generator battery lead nut to 15 NSm (11
lb–ft).
7. Lubricate the injector O–rings on the DOHC engine
with engine oil.
8. Install the fuel rail assembly.
Tighten
Tighten the fuel rail retaining bolts to 20 NSm (15 lb–
ft).
9. Install the throttle body. Refer to Section 1F, Engine
Controls.
10. Install the harness retaining clamp bolt.
11. Install the air intake tube and the connector.
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12. Install the IAT electrical connector to the air intake

tube.
STARTER
Removal Procedure
1. Remove the upper and the lower starter mounting

bolts.
2. Remove the starter solenoid nuts to disconnect the

electrical cable.
3. Remove the starter assembly.

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1. Place the starter assembly in position.

2. Install the upper and the lower starter mounting
bolts.
Tighten
Tighten the starter mounting bolts to 43 NSm (32 lb–
ft).
3. Position the starter electrical wire on the solenoid

terminal.
4. Install the starter solenoid nuts.
Tighten
Tighten the starter solenoid nuts to 15 NSm (11 lb–ft).
BATTERY/BATTERY TRAY
Removal Procedure
1. Disconnect the negative battery cable and then dis-

connect the positive battery cable.
2. Remove the nuts from the battery rods that fasten
the battery hold–down bar clamp.
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3. Check the battery carrier tray for obvious cracks or

damage. Detach the carrier tray if necessary by
removing the upper and the lower bolts.
1. Install the battery carrier by fastening the carrier

tray upper and lower bolts.
Tighten
Tighten the battery carrier tray upper and the lower
bolts to 20 NSm (15 lb–ft).
2. Install the battery into the tray.

3. Fasten the bar clamp to the battery by loosely at-
taching the battery rods from the battery tray cut-
outs through the bar clamp holes, and loosely tight-
ening the nuts.
Tighten
Tighten the battery retainer clamp–to–battery rod
nuts to 4 NSm (35 lb–in).

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4. Connect the negative battery cables.

Tighten
Tighten the battery cable nuts to 4.5 NSm (40 lb–in).
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UNIT REPAIR
STARTER MOTOR
Disassembly Procedure
1. Remove the starter. Refer to ”Starter” in this sec-

tion.
2. Remove the starter through–bolts.
3. Remove the commutator end frame and brush

holder assembly.
4. Inspect the brushes, the pop–out springs, and the
brush holders for wear and damage. Replace the
assembly, if needed.
Important : This test should be made for each ground or

insulated brush to ensure continuity through both brushes
and leads. If the lamp fails to light, the field coil is open and
will require replacement.
5. For only those starters having a shunt coil connec-
tion, use a test lamp, placing one lead on the shunt
coil terminal while connecting the other lead to a
ground brush or an insulated brush.

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6. When testing a series coil for ground, separate the

series and the shunt coil strap terminals during the
test.
1) With the strap terminals not touching the case or
the other ground, using a test lamp, place one
lead on the grounded brush holder and the other
lead on either insulated brush.
2) If the lamp is lit, a grounded series coil is indi-
cated and must be repaired or replaced.
3) Test for an open circuit on each insulated brush
by placing one lead on the series coil terminal
and the other lead on the insulated brush.
4) If the test lamp is not lit, the series coil is open
and will require repair or replacement.
7. Check the armature to see if it turns freely. If the

armature does not turn freely, break down the as-
sembly immediately, starting with Step 14. Other-
wise, give the armature a no–load test.
Notice : Complete the testing in a minimum amount of

time to prevent overheating and damaging the solenoid.
Important : If the specified current draw does not include

the solenoid, deduct from the armature reading the speci-
fied current draw of the solenoid hold–in winding.
8. To begin the no–load test, close the switch and
compare the rpm, the current, and the voltage read-
ings with the specifications. Refer to ”Starter Speci-
fications” in this section. Make disconnections only
with the switch open. Use the test results as fol-
lows:
1) Rated current draw and no–load speed indicate

a normal condition for the starter motor.
2) Low rpm combined with high current draw is an
indication of excessive friction caused by tight,
dirty, or worn bearings; a bent armature shaft; a
shorted armature; or a shorted field coils.
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1) Failure to operate with high current draw indi-

cates a direct ground in the terminal or fields, or
”frozen” bearings.
2) Failure to operate with no current draw indicates
an open field circuit, open armature coils, bro-
ken brush springs, worn brushes, high insulation
between the commutator bars, or other causes
which would prevent good contact between the
brushes and the commutator.
3) Low, no–load speed and low current indicate
high internal resistance and high current draw,
which usually mean shorted fields.
9. Remove the solenoid assembly screws.
10. Remove the field connector nut. Disconnect the

field connector.

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11. Rotate the solenoid 90 degrees and remove it along

with the plunger return spring.
Important : If the solenoid is not removed from the starting

motor, the connector strap terminals must be removed
from the terminal on the solenoid before making these
tests.
12. Test the solenoid windings by checking the current
draw.
1) Check the hold–in windings by connecting an
ammeter in series with a 12–volt battery, the
switch terminal, and to ground.
2) Connect the carbon pile across the battery.
3) Adjust the voltage to 10 volts. The ammeter
reading should be 13 to 19 amperes.
Important : Current will decrease as the windings heat up.

Current draw readings that are over specifications indicate
shorted turns or a ground in the windings of the solenoid.
Both conditions require replacement of the solenoid. Cur-
rent draw readings that are under specifications indicate
excessive resistance. No reading indicates an open cir-
cuit.
13. Check both windings, connecting them according to
the preceding test.
1) Ground the solenoid motor terminal.
2) Adjust the voltage to 10 volts. The ammeter
reading should be 59 to 79 amperes.
3) Check the connections and replace the sole-
noid, if necessary.
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14. Slide the field frame with enclosed armature as-

sembly away from the starter assembly.
15. Remove the shield.
16. Separate the field frame from the armature.
17. Inspect the shaft, the bearing, and the pinion for
discoloration, damage, or wear. Replace, if neces-
sary.
18. Inspect the armature commutator. If the commuta-
tor is rough, it should be turned down. The outside
diameter of the commutator must measure at least
41.91 mm (1.650 inches) after it is undercut or
turned. Do not turn out–of–round commutators.
19. Inspect the points where the armature conductors
join the commutator bars. Make sure they have a
good connection. A burned commutator bar is usu-
ally evidence of a poor connection.
20. If test equipment is available, check the armature
for short circuits by placing it on a growler, and
holding back a saw blade over the armature core
while the armature is rotated. If the saw blade vi-
brates, replace the armature.
21. Recheck the armature after cleaning between the
commutator bars. If the saw blade vibrates, replace
the armature.

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22. Remove the gears, the bushing, and the washer.

23. Remove the cushion and the driveshaft assembly
from the starter housing.
24. Disassemble the driveshaft assembly by first sepa-

rating the needle bearing from the driveshaft.
25. Remove the collar and the locking ring from the
groove in the driveshaft.
26. Remove the pinion stop and the drive from the dri-
veshaft.
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27. Remove the gear support from the driveshaft.
28. If not done in the previous steps, remove the

screws that hold the solenoid assembly into the
housing, and remove the nut from the field coil con-
nector.
29. Rotate the solenoid 90 degrees and remove it along

with the return spring.

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30. Remove the plunger with the boot and the shift le-
ver assembly. Test the solenoid windings, if not
done in Step 12.
Important : The pinion clearance must be correct to pre-

vent the buttons on the shift lever yoke from rubbing on the
clutch collar during the cranking.
31. When the starter motor is disassembled and the
solenoid is replaced, it is necessary to check the
pinion clearance.
32. Disconnect the motor field coil connector from the

solenoid motor terminal and carefully insulate the
connector.
33. Connect one 12–volt battery lead to the solenoid
switch terminal and the other to the starter frame.
34. Flash a jumper lead momentarily from the solenoid
motor terminal to the starter frame, allowing shifting
of the pinion in the cranking position, where it will
remain until the battery is disconnected.
Important : A means for adjusting the pinion clearance is
not provided on the starter motor. If the clearance does not
fall within the limits, check for improper installation and re-
place all worn parts.
35. Push the pinion back as far as possible to take up
any movement, and check the clearance with a
feeler gauge. The clearance should be 0.25 to 3.56
mm (0.01 to 0.14 inch).
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Assembly Procedure
1. Clean all of the starter motor partsparts, but do not

use grease–dissolving solvents for cleaning the ar-
mature and the field coils.
2. Lubricate the gears with lubricant.(Begin at Step 7 if
proceeding with just the reassembly of the sole-
noid.)
3. If full disassembly of the starter and the solenoid
was performed, begin reassembly by placing the
gear support on the driveshaft assembly.
4. Install the drive and the pinion stop on the drive-

shaft.
5. Install the lock ring into the groove on the driveshaft

and insert the collar.
6. Install the needle bearing.

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7. Install the shift lever assembly with the plunger and

the boot.
8. Lubricate the gears with lubricant and install the

driveshaft assembly with the bushing and the wash-
er on the gear end.
9. Install the cushion and the gears.
10. Lubricate the drive end of the armature shaft with

lubricant and install the new gear and the bearing, if
necessary.
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11. Position the solenoid assembly and the return

spring against the plunger, applying sealer to the
solenoid flange.
12. Fasten the solenoid assembly with the screws.

Tighten
Tighten the starter solenoid assembly screws to 8
NSm (71 lb–in).
13. Install the field coil connection to the starter termi-
nal. Install the nut.
Tighten
Tighten the starter field coil connector nut to 8 NSm
(71 lb–in).
14. Position the armature assembly into the field frame.

15. Place the shield on the armature and field frame
assembly.
16. Install the armature and field frame assembly with
the shield into the starter housing.

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17. Position the commutator end frame/brush holder

assembly, lining up the end frame holes with the
through–bolt holes in the housing.
18. Install the starter through–bolts.

19. Install the starter. Refer to ”Starter”in this section.
Tighten
Tighten the starter through–bolts to 6 NSm (53 lb–in).
GENERATOR
1. Remove the generator. Refer to ”Generator”in the

On–Vehicle Service section.
2. Mark a match line that cannot easily be removed on
the end frame to make assembly easier.
3. Pry off the plastic cover to expose the stator con-
nections.
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Notice : If the stator connections are not welded, melt the

lead. Avoid excessive heating, as it can damage the
diodes in the rectifier bridge.
4. Remove the stator connections from the rectifier
bridge terminals by cutting the wires.
5. Remove the generator through–bolts.
Important : The fastening torque of this nut is 81 NSm (60

lb–ft) and may not normally be unfastened using hand
strength.
6. Move to the drive end of the generator and remove
the drive end bearing nut.

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7. Remove the pulley and the collars.
8. Test the rotor for an open circuit by using the ohm-

meter with the drive end frame assembled. The
reading should be sufficiently high, or the rotor must
be replaced.
9. Test the rotor for open and short circuits. The read-
ing should be 1.7 to 2.3 ohms, or the rotor should
be replaced.
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10. Remove the drive end frame from the shaft.

11. For vehicles with an internal generator fan, remove
the drive end frame and the fan.
12. Remove the rotor assembly.
13. Remove the stator.

14. Test the stator for an open circuit using the ohmme-
ter.

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15. Pry off the baffle.

16. Remove the rectifier/regulator/brush holder assem-
bly screws.
17. Remove the brush holder assembly and the regula-
tor, cutting the terminal between the regulator and
the rectifier bridge.
Important : If the brush can be reused, reassemble the
brush to the holder with the retaining pin, after cleaning the
brush with a soft, clean cloth.
18. Test the rectifier bridge by connecting the ohmme-

ter terminals to the bridge and the heat sink.
19. Retest by connecting the ohmmeter terminals in

reverse.
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20. Replace the rectifier bridge, if each reading is the

same.
21. Test the remaining two diodes after the above pro-
cedure.
Notice : Some kinds of digital ohmmeters are not suited
for the test of the bridge diode. In this case, consult the
manufacturer regarding the test capacity.
22. Test the diodes by connecting the ohmmeter termi-
nals to the bridge terminal and the base plate. If the
reading is the same, the rectifier bridge should be
replaced.
23. Remove the ring in the slip ring end frame.
Assembly Procedure
1. Install the new ring in the slip ring end frame.

2. Push the new bearing outer lace into the bottom of
the end frame casting.

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3. Weld the brush holder terminal to the regulator ter-

minal, if removed.
4. Fix the brush holder with the retainer pin, and weld
the regulator/brush holder assembled terminal to
the rectifier terminal.
5. Apply silicone grease between the bridge and the
end frame for radiation purposes.
6. Fasten the screws holding the rectifier regulator/
brush holder assembly to the end frame.
7. Punch the new baffle with the pin into the brush.
8. Install the stator.
Notice : Take care to prevent damage to the vehicle by

protecting the diode in the rectifier bridge from excessive
heat while welding.
9. Weld the connectors of the rectifier bridge.
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10. Install the outside cover.
11. Position the rotor assembly shaft with the drive end
frame in the slip ring end assembly until the gap
between the outer lace and the end frame casting
is 1.9 mm (0.075 inch).
12. Install the generator through–bolts.
Tighten
Tighten the generator through–bolts to 10 NSm (89 lb–
in).
13. Position the fan, the collars, and the pulley on the
rotor shaft and secure with the nut.
Tighten
Tighten the generator drive end bearing nut to 81 NSm
(60 lb–ft).
14. Install the generator. Refer to ”Generator”inthe On–
Vehicle Service section.

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The battery is not designed to last indefinitely. However,

GENERAL DESCRIPTION with proper care, the battery will provide many years of
service.
AND SYSTEM OPERATION If the battery tests well, but fails to perform satisfactorily
in service for no apparent reason, the following factors
BATTERY may point to the cause of the trouble:
The battery has three major functions in the electrical sys- S Vehicle accessories are left on overnight.
tem. First, the battery provides a source of energy for S Slow average driving speeds are used for short pe-
cranking the engine. Second, the battery acts as a voltage riods.
stabilizer for the electrical system. Finally, the battery can, S The vehicle’s electrical load is more than the gener-
for a limited time, provide energy when the electrical de- ator output, particularly with the addition of after-
mand exceeds the output of the generator. market equipment.
S There are defects in the charging system, such as
The sealed battery is standard on all cars. There are no electrical shorts, a slipping generator belt, a faulty
vent plugs in the cover. The battery is completely sealed, generator, or a faulty voltage regulator.
except for two small vent holes in the sides. These vent S There has been battery abuse, including failure to
holes allow the small amount of gas produced in the bat- keep the battery cable terminals clean and tight, or
tery to escape. a loose battery hold–down.
The sealed battery has the following advantages over con- S There are mechanical problems in the electrical
ventional batteries: system, such as shorted or pinched wires.
S No water need be added for the life of the battery.
S It is protected against overcharge. If too much volt-
BUILT–IN HYDROMETER
age is applied to the battery, it will not accept as The sealed battery has a built–in, temperature–compen-
much current as a conventional battery. In a con- sated hydrometer in the top of the battery. This hydrome-
ventional battery, the excess voltage will still try to ter is to be used with the following diagnostic procedure:
charge the battery, leading to gassing, which 1. When observing the hydrometer, make sure that
causes liquid loss. the battery has a clean top.
S It is not as liable to self–discharge as a convention- 2. Under normal operation, two indications can be ob-
al battery. This is particularly important when a bat- served:
tery is left standing for long periods of time. S GREEN DOT VISIBLE – Any green appearance
S It has more power available in a lighter and a small- is interpreted as a ”green dot,” meaning the bat-
er case. tery is ready for testing.
S DARK GREEN DOT IS NOT VISIBLE – If there
RATINGS is a cranking complaint, the battery should be
A battery has two ratings: (1) a reserve capacity rating tested. The charging and electrical systems
designated at 27?C (80?F), which is the time a fully should also be checked at this time.
charged battery will provide 25 amperes current flow at or 3. Occasionally, a third condition may appear:
above 10.5 volts; (2) A cold cranking amp rating deter-
mined under testing at –18?C (0?F), which indicates the S CLEAR OR BRIGHT YELLOW – This means
cranking load capacity. the fluid level is below the bottom of the hydrom-
eter. This may have been caused by excessive
RESERVE CAPACITY or prolonged charging, a broken case, excessive
tipping, or normal battery wear. Finding a battery
The reserve capacity is the maximum length of time it is in this condition may indicate high charging by a
possible to travel at night with the minimum electrical load faulty charging system. Therefore, the charging
and no generator output. Expressed in minutes, Reserve and the electrical systems may need to be
Capacity (or RC rating) is the time required for a fully checked if a cranking complaint exists. If the
charged battery, at a temperature of 27?C (81?F) and be- cranking complaint is caused by the battery, re-
ing discharged at a current of 25 amperes, to reach a ter- place the battery.
minal voltage of 10.5 volts.
CHARGING PROCEDURE
COLD CRANKING AMPERAGE 1. Batteries with the green dot showing do not require
The cold cranking amperage test is expressed at a battery charging unless they have just been discharged,
temperature of –18?C (0?F). The current rating is the mini- such as in cranking a vehicle.
mum amperage, which must be maintained by the battery 2. When charging sealed–terminal batteries out of the
for 30 seconds at the specified temperature, while meeting vehicle, install the adapter kit. Make sure all the
a minimum voltage requirement of 7.2 volts. This rating is charger connections are clean and tight. For best
a measure of cold cranking capacity. results, batteries should be charged while the elec-
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trolyte and the plates are at room temperature. A Important : Some chargers feature polarity protection cir-
battery that is extremely cold may not accept cur- cuitry, which prevents charging unless the charger leads
rent for several hours after starting the charger. are correctly connected to the battery terminals. A com-
3. Charge the battery until the green dot appears. The pletely discharged battery may not have enough voltage
battery should be checked every half–hour while to activate this circuitry, even though the leads are con-
charging. Tipping or shaking the battery may be nected properly, making it appear that the battery will not
necessary to make the green dot appear. accept charging current. Therefore, follow the specific
4. After charging, the battery should be load tested. charger manufacturer’s instruction for bypassing or over-
Refer to ”Starter Motor” in this section. riding the circuitry so that the charger will turn on and
charge a low–voltage battery.
CHARGING TIME REQUIRED 3. Battery chargers vary in the amount of voltage and
current provided. The time required for the battery
The time required to charge a battery will vary depending
to accept a measurable charger current at various
upon the following factors:
voltages may be as follows:
S Size of Battery – A completely discharged large Voltage Hours
heavy–duty battery requires more than twice the re-
charging as a completely discharged small passen- 16.0 or more Up to 4 hours
ger car battery. 14.0–15.9 Up to 8 hours
S Temperature – A longer time will be needed to 13.9 or less Up to 16 hours
charge any battery at –18?C (0?F) than at 27?C
S If the charge current is not measurable at the
(81?F). When a fast charger is connected to a cold
end of the above charging times, the battery
battery, the current accepted by the battery will be
should be replaced.
very low at first. The battery will accept a higher cur-
S If the charge current is measurable during the
rent rate as the battery warms.
charging time, the battery is good, and charging
S Charger Capacity – A charger which can supply should be completed in the normal manner.
only 5 amperes will require a much longer charging Important : It is important to remember that a completely
period than a charger that can supply 30 amperes or discharged battery must be recharged for a sufficient num-
more. ber of ampere hours (AH) to restore the battery to a usable
S State–of–Charge – A completely discharged bat- state. As a general rule, using the reserve capacity (RC)
tery requires more than twice as much charge as a rating as the number of ampere hours of charge usually
onehalf charged battery. Because the electrolyte is brings the green dot into view.
nearly pure water and a poor conductor in a complete- S If the charge current is still not measurable after
ly discharged battery, the current accepted by the bat- using the charging time calculated by the above
tery is very low at first. Later, as the charging current method, the battery should be replaced.
causes the electrolyte acid content to increase, the S If the charge current is measurable during the
charging current will likewise increase. charging time, the battery is good, and charging
should be completed in the normal manner.
CHARGING A COMPLETELY JUMP STARTING PROCEDURE
DISCHARGED BATTERY (OFF THE 1. Position the vehicle with the good(charged) battery
VEHICLE) so that the jumper cables will reach from the one
battery to the other.
Unless this procedure is properly followed, a perfectly 2. Turn off the ignition, all the lights, and all the electri-
good battery may be needlessly replaced. cal loads in both vehicles. Turn on the hazard flash-
The following procedure should be used to recharge a ers if jump starting where there is traffic. In addition,
completely discharged battery: turn on any other lights needed for the work area.
3. In both vehicles, apply the parking brake firmly.
1. Measure the voltage at the battery terminals with
an accurate voltmeter. If the reading is below 10 Notice : Make sure the cables are not on or near pulleys,
volts, the charge current will be very low, and it fans, or other parts that will move when the engine starts,
could take some time before the battery accepts damaging the parts.
the current in excess of a few milliamperes. Refer 4. Shift an automatic transaxle to PARK, or a manual
to ”Charging Time Required” in this section, which transaxle to NEUTRAL.
focuses on the factors affecting both the charging CAUTION : Do not use cables that have loose or miss-
time required and the rough estimates in the table ing insulation, or injury could result.
below. Such low current may not be detectable on 5. Clamp one end of the first jumper cable to the posi-
ammeters available in the field. tive terminal on the battery. Make sure it does not
2. Set the battery charger on the high setting. touch any other metal parts. Clamp the other end of

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the same cable to the positive terminal on the other at a fixed frequency of about 400 hertz. By varying the on–
battery. Never connect the other end to the nega- off time, correct average field current for proper system
tive terminal of the discharged battery. volate control is obtained. At high speeds, the on–time
CAUTION : Do not attach the cable directly to the neg- may be 10 percent and the offtime 90 percent. At low
ative terminal of the discharged battery. Doing so speeds, with high electrical loads, on–time may be 90 per-
could cause sparks and possible battery explosion. cent and the off–time 10 percent.
6. Clamp one end of the second cable to the negative
terminal of the booster battery. Make the final con-
CHARGING SYSTEM
nection to a solid engine ground, such as the en- The Delco–Remy CS charging system has several mod-
gine lift bracket, at least 450 millimeters (18 inches) els available, including the CS–121D. The number de-
from the discharged battery. notes the outer diameter in millimeters of the stator lami-
7. Start the engine of the vehicle with the good bat- nations.
tery. Run the engine at a moderate speed for sever- CS generators use a new type of regulator that incorpo-
al minutes. Then start the engine of the vehicle rates a diode trio. A Delta stator, a rectifier bridge, and a
which has the discharged battery. rotor with slip rings and brushes are electrically similar to
8. Remove the jumper cables by reversing the above earlier generators. A conventional pulley and fan are used.
sequence exactly. Remove the negative cable from There is no test hole.
the vehicle with the discharged battery first. While
removing each clamp, take care that it does not STARTER
touch any other metal while the other end remains Wound field starter motors have pole pieces, arranged
attached. around the armature, which are energized by wound field
coils.
GENERATOR
Enclosed shift lever cranking motors have the shift lever
The Delco–Remy CS charging system has several mod- mechanism and the solenoid plunger enclosed in the drive
els available, including the CS–121D. The number de- housing, protecting them from exposure to dirt, icy condi-
notes the outer diameter, in millimeters of the stator lami- tions, and splashes.
nation.
In the basic circuit, solenoid windings are energized when
CS generators are equipped with internal regulators. A the switch is closed. The resulting plunger and shift lever
Delta stator, a rectifier bridge, and a rotor with slip rings movement causes the pinion to engage the engine fly-
and brushes are electrically similar to earlier generators. wheel ring gear. The solenoid main contacts close. Crank-
A conventional pulley and fan are used. There is no test ing then takes place.
hole.
When the engine starts, pinion overrun protects the arma-
Unlike three–wire generators, the CS–121Dmay be used ture from excessive speed until the switch is opened, at
with only two connections: battery positive and an ”L” ter- which time the return spring causes the pinion to disen-
minal to the charge indicator lamp. Use of the ”P,””I,” and gage. To prevent excessive overrun, the switch should be
”S”terminals is optional. The ”P”terminal is connected to released immediately after the engine starts.
the stator and may be connected externally to a tachome-
ter or other device. STARTING SYSTEM
As with other charging systems, the charge indicator lamp The engine electrical system includes the battery, the igni-
lights when the ignition switch is turned to ON, and goes tion, the starter, the generator, and all the related wiring.
out when the engine is running. If the charge indicator is Diagnostic tables will aid in troubleshooting system faults.
on with the engine running, a charging system defect is in- When a fault is traced to a particular component, refer to
dicated. This indicator light will glow at full brilliance for that component section of the service manual.
several kinds of defects, as well as when the system volt- The starting system circuit consists of the battery, the
age is too high or too low. starter motor, the ignition switch, and all the related electri-
The regulator voltage setting varies with temperature and cal wiring. All of these components are connected electri-
limits the system voltage by controlling the rotor field cur- cally.
rent. The regulator switches rotor field current on and off
DAEWOO V–121 BL4
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SECTION : 1F
ENGINE CONTROLS
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–5 NO MALFUNCTION INDICATOR LAMP . . . . . 1F–56
ENGINE DATA DISPLAY TABLES . . . . . . . . . . . 1F–5 MALFUNCTION INDICATOR LAMP ON STEADY 1F–
ENGINE DATA DISPLAY TABLE DEFINITIONS1F–17 59
FASTENER TIGHTENING SPECIFICATIONS 1F–20 FUEL SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . 1F–61
FUEL SYSTEM SPECIFICATIONS . . . . . . . . . 1F–21 FUEL PUMP RELAY CIRCUIT CHECK . . . . . . 1F–64
MANIFOLD ABSOLUTE PRESSURE CHECK 1F–67
TEMPERATURE VS RESISTANCE . . . . . . . . . 1F–21
IDLE AIR CONTROL SYSTEM CHECK . . . . . 1F–69
SCHEMATIC AND ROUTING DIAGRAMS . . . . 1F–22
IGNITION SYSTEM CHECK . . . . . . . . . . . . . . . 1F–72
PCM/ECM WIRING DIAGRAM (1.5L SOHC AND
ENGINE COOLING FAN CIRCUIT CHECK ––
1.6L DOHC – 1 OF 7) (IPCM–6KD/ISFI–6TD) 1F–22
WITHOUT A/C . . . . . . . . . . . . . . . . . . . . . . . . . 1F–76
ENGINE COOLING FAN CIRCUIT CHECK –– WITH
A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–80
PCM/ECM WIRING DIAGRAM (1.5L SOHC AND DATA LINK CONNECTOR DIAGNOSIS . . . . . 1F–87
FUEL INJECTOR BALANCE TEST . . . . . . . . . 1F–90
1.6L DOHC – 4 OF 7) (IPCM–6KD/ISFI–6TD) 1F–2 EVAP CONTROL SYSTEM DIAGNOSIS . . . . 1F–91
5 TROUBLE CODE DIAGNOSIS . . . . . . . . . . . . . . . 1F–93
PCM/ECM WIRING DIAGRAM (1.5L SOHC AND CLEARING TROUBLE CODES . . . . . . . . . . . . 1F–93
1.6L DOHC – 5 OF 7) (IPCM–6KD/ISFI–6TD) 1F–26 DIAGNOSTIC TROUBLE CODES . . . . . . . . . . 1F–93
PCM/ECM WIRING DIAGRAM (1.5L SOHC AND DTC P0106 MANIFOLD ABSOLUTE PRESSURE
1.6L DOHC – 6 OF 7) (IPCM–6KD/ISFI–6TD) 1F–27 RATIONALITY . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–98
PCM/ECM WIRING DIAGRAM (1.5L SOHC AND DTC P0107 MANIFOLD ABSOLUTE PRESSURE
1.6L DOHC – 7 OF 7) (IPCM–6KD/ISFI–6TD) 1F–28 LOW VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . 1F–107
CONNECTOR END VIEW . . . . . . . . . . . . . . . . . 1F–29 DTC P0108 MANIFOLD ABSOLUTE PRESSURE
HIGH VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . 1F–108
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . 1F–34
DTC P0112 INTAKE AIR TEMPERATURE LOW
COMPONENT LOCATOR (SOHC) . . . . . . . . . . 1F–34
VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–107
COMPONENT LOCATOR (DOHC) . . . . . . . . . . 1F–36 DTC P0113 INTAKE AIR TEMPERATURE HIGH
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–38 VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–109
SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 1F–38 DTC P0117 ENGINE COOLANT TEMPERATURE
LOW VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . 1F–112
DIAGNOSTIC AIDS . . . . . . . . . . . . . . . . . . . . . . . 1F–38
DTC P0118 ENGINE COOLANT TEMPERATURE
IDLE LEARN PROCEDURE . . . . . . . . . . . . . . . 1F–39 HIGH VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . 1F–114
ON–BOARD DIAGNOSTIC (OBD II) SYSTEM DTC P0121 THROTTLE POSITION SENSOR
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–40 RATIONALITY . . . . . . . . . . . . . . . . . . . . . . . . 1F–117
PCM/ECM OUTPUT DIAGNOSIS . . . . . . . . . . 1F–42 DTC P0122 THROTTLE POSITION SENSOR LOW
MULTIPLE PCM/ECM INFORMATION SENSOR VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–120
DTCS SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–44 DTC P0123 THROTTLE POSITION SENSOR HIGH
ENGINE CRANKS BUT WILL NOT RUN . . . . 1F–49 VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–123
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1F – 2IENGINE CONTROLS
DTC P0125 ENGINE COOLANT TEMPERATURE DTC P0402 EXHAUST GAS RECIRCULATION
INSUFFICIENT FOR CLOSED LOOP FUEL EXCESSIVE FLOW . . . . . . . . . . . . . . . . . . . 1F–225
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–126 DTC P0404 EXHAUST GAS RECIRCULATION
DTC P0128 STUCK OPEN THERMOSTAT . 1F–130 OPEN VALVE POSITION ERROR . . . . . . . 1F–229
DTC P0131 O2 BANK 1 SENSOR 1 LOW VOLTAGE DTC P0405 EXHAUST GAS RECIRCULATION
1F–134 PINTLE POSITION LOW VOLTAGE . . . . . 1F–233
DTC P0132 O2 BANK 1 SENSOR 1 HIGH VOLTAGE DTC P0406 EXHAUST GAS RECIRCULATION
1F–137 PINTLE POSITION HIGH VOLTAGE . . . . . 1F–237
DTC P0133 O2 BANK 1 SENSOR 1 SLOW DTC P0420 CATALYST BANK 1 LOW EFFICIENCY 1
RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–140 F–241
DTC P0134 O2 BANK 1 SENSOR 1 NO ACTIVITY 1F DTC P0440 EVAPORATIVE EMISSION SYSTEM
–143 LARGE LEAK/LOW TANK VACUUM . . . . . 1F–243
DTC P0442 EVAPORATIVE EMISSION SYSTEM
DTC P0137 HO2 BANK 1 SENSOR 2 LOW
SMALL LEAK . . . . . . . . . . . . . . . . . . . . . . . . . 1F–248
VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–146
DTC P0138 HO2 BANK 1 SENSOR 2 HIGH
PURGE CONTROL CIRCUIT . . . . . . . . . . . . 1F–252
VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–149
DTC P0140 HO2 BANK 1 SENSOR 2 NO ACTIVITY 1 VENT CONTROL MALFUNCTION . . . . . . . 1F–255
F–152
DTC P0141 HO2 BANK 1 SENSOR 2 HEATER 1F–1 VENT SOLENOID CIRCUIT FAULT . . . . . . 1F–259
55
DTC P0452 FUEL TANK PRESSURE SENSOR LOW
DTC P0171 BANK 1 SYSTEM TOO LEAN . . 1F–158 VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–262
DTC P0172 BANK 1 SYSTEM TOO RICH . . 1F–162 DTC P0453 FUEL TANK PRESSURE SENSOR
DTC P0201 INJECTOR 1 CIRCUIT FAULT . 1F–166 HIGH VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . 1F–265
DTC P0202 INJECTOR 2 CIRCUIT FAULT . 1F–169 DTC P0461 FUEL LEVEL STUCK . . . . . . . . . 1F–268
DTC P0203 INJECTOR 3 CIRCUIT FAULT . 1F–203 DTC P0462 FUEL LEVEL LOW VOLTAGE . . 1F–271
DTC P0204 INJECTOR 4 CIRCUIT FAULT . 1F–175 DTC P0463 FUEL LEVEL HIGH VOLTAGE . 1F–274
DTC P0464 FUEL LEVEL RATIONALITY . . . 1F–277
DTC P0300 MULTIPLE CYLINDER MISFIRE 1F–178
DIAGNOSTIC TROUBLE CODE (DTC) P0480 LOW
DTC P0301 CYLINDER 1 MISFIRE . . . . . . . . 1F–183
SPEED COOLING FAN CONTROL CIRCUIT
DTC P0302 CYLINDER 2 MISFIRE . . . . . . . . 1F–187 FAULT (WITHOUT A/C) . . . . . . . . . . . . . . . . 1F–280
DTC P0303 CYLINDER 3 MISFIRE . . . . . . . . 1F–191 DIAGNOSTIC TROUBLE CODE (DTC) P0480 LOW
DTC P0304 CYLINDER 4 MISFIRE . . . . . . . . 1F–195 SPEED COOLING FAN CONTROL CIRCUIT
FAULT (WITH A/C) . . . . . . . . . . . . . . . . . . . . . 1F–283
DTC P0325 KNOCK SENSOR DSNEF INTERNAL
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . 1F–325 DIAGNOSTIC TROUBLE CODE (DTC) P0481 HIGH
SPEED COOLING FAN CONTROL CIRCUIT
DTC P0327 KNOCK SENSOR CIRCUIT FAULT 1F–2
FAULT (WITHOUT A/C) . . . . . . . . . . . . . . . . 1F–286
01
DIAGNOSTIC TROUBLE CODE (DTC) P0481 HIGH
DTC P0336 58X CRANK POSITION EXTRA/ SPEED COOLING FAN CONTROL CIRCUIT
MISSING PULSES . . . . . . . . . . . . . . . . . . . . 1F–204 FAULT (WITH A/C) . . . . . . . . . . . . . . . . . . . . . 1F–289
DTC P0337 58X CRANK POSITION NO SIGNAL 1F– DTC P0502 VEHICLE SPEED SENSOR (ENGINE
206 SIDE) NO SIGNAL . . . . . . . . . . . . . . . . . . . . . 1F–291
DIAGNOSTIC TROUBLE CODE (DTC) P0341 CAM DTC P0506 IDLE SPEED RPM LOWER THAN
RATIONALITY (1.5L SOHC) . . . . . . . . . . . . . 1F–209 DESIRED IDLE SPEED . . . . . . . . . . . . . . . . 1F–294
DIAGNOSTIC TROUBLE CODE (DTC) P0341 CAM DTC P0507 IDLE SPEED RPM HIGHER THAN
RATIONALITY (1.6L DOHC) . . . . . . . . . . . . 1F–212 DESIRED IDLE SPEED . . . . . . . . . . . . . . . . 1F–297
DIAGNOSTIC TROUBLE CODE (DTC) P0342 CAM DTC P0532 A/C PRESSURE SENSOR LOW 1F–300
POSITION NO SIGNAL (1.6L DOHC) . . . . 1F–215 DTC P0533 A/C PRESSURE SENSOR HIGH 1F–303
DTC P0351 IGNITION CONTROL CIRCUIT A FAULT DTC P0562 SYSTEM VOLTAGE (ENGINE SIDE)
1F–218 TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–306
DTC P0352 IGNITION CONTROL CIRCUIT B FAULT DTC P0563 SYSTEM VOLTAGE (ENGINE SIDE)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–220 TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–309
DTC P0401 EXHAUST GAS RECIRCULATION DTC P0601 ECM (ENGINE SIDE) CHECKSUM
INSUFFICIENT FLOW . . . . . . . . . . . . . . . . . 1F–222 FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–311

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ENGINE CONTROLS 1F – 3
DIAGNOSTIC TROUBLE CODE (DTC) P1106 DIAGNOSTIC TROUBLE CODE (DTC) P1546 A/C
MANIFOLD ABSOLUTE PRESSURE CLUTCH OUTPUT CIRCUIT FAULT . . . . . 1F–369
INTERMITTENT HIGH VOLTAGE . . . . . . . . 1F–312 DIAGNOSTIC TROUBLE CODE (DTC) P1618
DIAGNOSTIC TROUBLE CODE (DTC) P1107 PCM/ECM INTERNAL SPI COMMUNICATIONS
MANIFOLD ABSOLUTE PRESSURE DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . 1F–372
INTERMITTENT LOW VOLTAGE . . . . . . . . 1F–314 DIAGNOSTIC TROUBLE CODE (DTC) P1625
DIAGNOSTIC TROUBLE CODE (DTC) P1109 PCM/ECM INTERNAL SYSTEM RESET . 1F–373
VARIABLE GEOMETRY INDUCTION SOLENOID DIAGNOSTIC TROUBLE CODE (DTC) P1627
ELECTRICAL FAULT . . . . . . . . . . . . . . . . . . . 1F–316 PCM/ECM A/D CONVERSION ERROR . . 1F–375
DTC P1111 INTAKE AIR TEMPERATURE DIAGNOSTIC TROUBLE CODE (DTC) P1635
INTERMITTENT HIGH VOLTAGE . . . . . . . . 1F–319 PCM/ECM 5 VOLT REFERENCE LINE LOW 1F–37
DTC P1112 INTAKE AIR TEMPERATURE 6
INTERMITTENT LOW VOLTAGE . . . . . . . . 1F–322 DIAGNOSTIC TROUBLE CODE (DTC) P1640 ODM
DTC P1114 ENGINE COOLANT TEMPERATURE INTERNAL SPI COMMUNICATION . . . . . . 1F–379
INTERMITTENT LOW VOLTAGE . . . . . . . . 1F–324 SYMPTOM DIAGNOSIS . . . . . . . . . . . . . . . . . . . 1F–382
DTC P1115 ENGINE COOLANT TEMPERATURE IMPORTANT PRELIMINARY CHECKS . . . . . 1F–382
INTERMITTENT HIGH VOLTAGE . . . . . . . . 1F–326
INTERMITTENTS . . . . . . . . . . . . . . . . . . . . . . . 1F–382
DTC P1121 THROTTLE POSITION SENSOR
HARD START . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–382
INTERMITTENT HIGH VOLTAGE . . . . . . . . 1F–329
SURGES OR CHUGGLES . . . . . . . . . . . . . . . . 1F–385
DTC P1122 THROTTLE POSITION SENSOR
INTERMITTENT LOW VOLTAGE . . . . . . . . 1F–331 LACK OF POWER, SLUGGISHNESS, OR
SPONGINESS . . . . . . . . . . . . . . . . . . . . . . . . 1F–386
DTC P1130 O2 BANK 1 SENSOR 1 LOW SIGNAL
VARIANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–333 DETONATION/SPARK KNOCK . . . . . . . . . . . . 1F–388
DTC P1133 O2 BANK 1 SENSOR 1 TOO FEW HESITATION, SAG, STUMBLE . . . . . . . . . . . . 1F–389
TRANSITIONS . . . . . . . . . . . . . . . . . . . . . . . . 1F–336 CUTS OUT, MISSES . . . . . . . . . . . . . . . . . . . . . 1F–391
DTC P1134 O2 BANK 1 SENSOR 1 TRANSITION POOR FUEL ECONOMY . . . . . . . . . . . . . . . . . 1F–393
RATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–340 ROUGH, UNSTABLE, OR INCORRECT IDLE,
DTC P1171 FUEL SUPPLY SYSTEM LEAN DURING STALLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–393
POWER ENRICHMENT . . . . . . . . . . . . . . . . 1F–343 EXCESSIVE EXHAUST EMISSIONS OR ODORS 1F
DTC P1336 58X CRANK POSITION TOOTH ERROR –396
NOT LEARNED . . . . . . . . . . . . . . . . . . . . . . . 1F–345 DIESELING, RUN–ON . . . . . . . . . . . . . . . . . . . 1F–397
DIAGNOSTIC TROUBLE CODE (DTC) P1380 ABS BACKFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–397
ROUGH ROAD ROUGH ROAD DATA INVALID 1F–
MAINTENANCE AND REPAIR . . . . . . . . . . . . . 1F–399
347
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 1F–399
DIAGNOSTIC TROUBLE CODE (DTC) P1381 ABS
ROUGH ROAD ROUGH SERIAL DATA FAULT 1F– FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–399
349 FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–401
DIAGNOSTIC TROUBLE CODE (DTC) P1391 G FUEL TANK PRESSURE SENSOR . . . . . . . . 1F–402
SENSOR ROUGH ROAD RATIONALITY . 1F–351 FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–403
DIAGNOSTIC TROUBLE CODE (DTC) P1392 G FUEL RAIL AND INJECTORS (DOHC) . . . . . 1F–404
SENSOR ROUGH ROAD LOW VOLTAGE 1F–354
FUEL RAIL AND INJECTORS (SOHC) . . . . . 1F–409
DIAGNOSTIC TROUBLE CODE (DTC) P1393 G FUEL RAIL AND INJECTORS (DOHC) . . . . . 1F–410
SENSOR ROUGH ROAD HIGH VOLTAGE 1F–357
THROTTLE POSITION SENSOR (TYPICAL) 1F–411
DIAGNOSTIC TROUBLE CODE (DTC) P1404
EXHAUST GAS RECIRCULATION CLOSED THROTTLE BODY (TYPICAL) . . . . . . . . . . . . 1F–411
VALVE PINTLE ERROR . . . . . . . . . . . . . . . . 1F–357 OXYGEN SENSOR (O2S) (TYPICAL) . . . . . . 1F–413
DIAGNOSTIC TROUBLE CODE (DTC) P1441 HEATED OXYGEN SENSOR (HO2S) (TYPICAL) 1F–
EVAPORATIVE EMISSION CONTINUOUS PURGE 414
FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–360 INTAKE AIR TEMPERATURE SENSOR (TYPICAL) 1
DIAGNOSTIC TROUBLE CODE (DTC) P1508 IDLE F–415
AIR CONTROL COUNTS TOO LOW . . . . . 1F–363 IDLE AIR CONTROL VALVE (TYPICAL) . . . . 1F–416
DIAGNOSTIC TROUBLE CODE (DTC) P1509 IDLE VARIABLE GEOMETRY INDUCTION SYSTEM
AIR CONTROL COUNTS TOO HIGH . . . . 1F–366 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–417
DAEWOO V–121 BL4
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MANIFOLD ABSOLUTE PRESSURE SENSOR ON BOARD REFUELING VAPOR RECOVERY

(TYPICAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–417 (ORVR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1F–429
EXHAUST GAS RECIRCULATION VALVE (SOHC) 1F VARIABLE GEOMETRY INDUCTION SYSTEM
–418 OPERATION (DOHC) . . . . . . . . . . . . . . . . . . 1F–429
EXHAUST GAS RECIRCULATION VALVE (DOHC)1F POSITIVE CRANKCASE VENTILATION CONTROL
–418 SYSTEM OPERATION . . . . . . . . . . . . . . . . . 1F–429
KNOCK SENSOR . . . . . . . . . . . . . . . . . . . . . . . 1F–419 ENGINE COOLANT TEMPERATURE SENSOR 1F–4
G SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–420 29
EVAPORATIVE EMISSION CANISTER . . . . 1F–421 THROTTLE POSITION SENSOR . . . . . . . . . . 1F–430
EVAPORATIVE EMISSION CANISTER PURGE CATALYST MONITOR OXYGEN SENSORS 1F–430
SOLENOID (TYPICAL) . . . . . . . . . . . . . . . . . 1F–421 EXHAUST GAS RECIRCULATION VALVE . . 1F–430
CRANKSHAFT POSITION SENSOR (TYPICAL) 1F–4 KNOCK SENSOR . . . . . . . . . . . . . . . . . . . . . . . 1F–430
22
G SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–431
CAMSHAFT POSITION SENSOR (SOHC) . 1F–423
INTAKE AIR TEMPERATURE SENSOR . . . . 1F–431
CAMSHAFT POSITION SENSOR (DOHC) . 1F–423
IDLE AIR CONTROL VALVE . . . . . . . . . . . . . . 1F–431
POWER CONTROL MODULE/ENGINE CONTROL
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–425 MANIFOLD ABSOLUTE PRESSURE SENSOR1F–43
1
ELECTRONIC IGNITION SYSTEM IGNITION COIL 1
F–425 POWERTRAIN CONTROL MODULE/ENGINE
CONTROL MODULE . . . . . . . . . . . . . . . . . . . 1F–432
FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . 1F–432
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–427
STRATEGY–BASED DIAGNOSTICS . . . . . . 1F–432
IGNITION SYSTEM OPERATION . . . . . . . . . 1F–427
OBD II SERVICEABILITY ISSUES . . . . . . . . . 1F–433
ELECTRONIC IGNITION SYSTEM IGNITION COIL 1
F–427 SERIAL DATA COMMUNICATIONS . . . . . . . . 1F–434
CRANKSHAFT POSITION SENSOR . . . . . . . 1F–427 ON–BOARD DIAGNOSTIC (OBD II) . . . . . . . 1F–434
CAMSHAFT POSITION SENSOR . . . . . . . . . 1F–427 COMPREHENSIVE COMPONENT MONITOR
IDLE AIR SYSTEM OPERATION . . . . . . . . . . 1F–427 DIAGNOSTIC OPERATION . . . . . . . . . . . . . 1F–434
FUEL CONTROL SYSTEM OPERATION . . . 1F–427 COMMON OBD TERMS . . . . . . . . . . . . . . . . . . 1F–435
EVAPORATIVE EMISSION CONTROL SYSTEM DTC TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F–436
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 1F–428 READING DIAGNOSTIC TROUBLE CODES 1F–437
EVAPORATIVE EMISSION CANISTER . . . . 1F–428 PRIMARY SYSTEM–BASED DIAGNOSTICS 1F–439

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SPECIFICATIONS
ENGINE DATA DISPLAY TABLES
Engine Data Display 01 Selected by 2: Data Display 1: Engine Data 1.6L Manual
Transmission
Parameter Scaling Value

Engine Speed rpm=N/4 µ100 rpm from the Desired rpm
Desired Idle Speed rpm=N*12.5 PCM/ECM Idle Command
Engine Coolant Temperature Celsius=n–40 –40³– 151³C (–40³– 304³F)
Intake Air Temperature Celsius=n–40 –40³– 151³C (–40³– 304³F)
Throttle Position Angle %=n/2.56 0% (up to 100% at wide open
throttle)
Throttle Position Volts=n/51 0.200–0.900v (up to 5.0 at wide
open throttle)
Actual EGR Position %=n/2.56 0–100%
Desired EGR Position %=n/2.56 0–100%
EGR Feedback Volt=5n/255 0–5 volts
IAC Position Counts=N 5–60
Cam Active Counter Counts=N 0–255
Engine Run Time Seconds=N 00:00:00–18:12:15 (hours:min-
utes:seconds)
Base PWM Bank 1 ms=N/65.535 0–999.9 ms
Ignition Voltage Volts=n/10 11.0–16.0 volts
Air Fuel Ratio x:1=n/10 0:1–25.5:1
Spark Advance Degrees=(n/2)–64 64 to –64³
Vehicle Speed mph=n/1.61 0–255 mph
Engine Load %=N/2.56 0–100%
Air Condition Pressure Volt=5n/255 0–5 volts
O2 Sensor Bank 1 Sensor 1 mV=N/0.2304 0–1132 mV
Malfunction Indicator Lamp 1=ON/0=OFF –
VGIS Status 1=ON/0=OFF –
Decel Fuel Mode 1=ON/0=OFF –
Fuel Trim Learned 1=YES/0=NO –
Power Enrichment Mode 1=YES/0=NO –
Rich/Lean Bank 1 1=RICH/0=LEAN –
Hot Loop Open 1=YES/0=NO –
Short Term Fuel Trim %=(N–128)/1.28 –100 to 100%
Loop Status 1=CLOSE LOOP/0=OPEN LOOP –
Long Term Fuel Trim %=(N–128)/1.28 –100 to 100%
EVAP Purge Solenoid %=N/2.56 0–100%
IAC Base Position Counts=N 0–255
Fuel Trim Cell Cell=N –
DAEWOO V–121 BL4
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Weak Cylinder Misfire DCT/No Misfire DTC –
Rough Road Sensor Volt=5n/255 0–5 volts
Calculated Air Flow g/sec=N/128 0–512 g/sec
5 Volt Reference Volt=5n/255 0–5 volts
Power Steering Cramp 1=YES/0=NO –
Air Conditioning Request 1=ON/0=OFF –
Air Conditioning Clutch 1=ON/0=OFF –
Fuel Pump 1=ON/0=OFF –
Fan Speed Low 1=ON/0=OFF –
Fan Speed High 1=ON/0=OFF –
EVAP Vent Solenoid 1=ON/0=OFF –
MAP kPa=N 12–103 kPa
BARO kPa=(n+28)/2.71 65–100 kPa (varies with altitude and
with the BARO pressure)
Knock Retard Degrees=N/(256/22.5) 0–90³
Knock Active Counter Counts=N 0–255
Knock Present 1=YES/0=NO –
Engine Data Display 02 Selected by 2: Data Display 1: Engine Data 1.5L Manual
Transmission

Desired Idle rpm=N*12.5 PCM/ECM Idle Command
Engine Coolant Temperature Celsius=n–40 85³–115³C (185³–239³F)
Intake Air Temperature Celsius=n–40 10³– 80³C (50³– 176³F)
Throttle Position %=n/2.56 0% (up to 100% at wide open
throttle)
open throttle)
EGR Actual Position %=n/2.56 0%
EGR Desired Position %=n/2.56 0–100%
EGR Feedback Volt=5n/255
utes:seconds)
BPW Bank 1 ms=N/65.535 0–999.9
Spark Degrees=(n/2)–64 64 to –64
Calculated Load %=N/2.56 0–100

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Vehicle Speed mph=n/1.61 0–255
Air Condition Pressure Volt=5n/255 0–5
Oxygen Bank 1 Sensor 1 mV=N/0.2304 0–1132
Decel Fuel Mode 1=YES/0=NO –
Closed Loop 1=YES/0=NO –
Loop Status See Table 3 –
Short Term Fuel Trim %=(N–128)/1.28 –100 to 100
Long Term Fuel Trim %=(N–128)/1.28 –100 to 100
EVAP Purge Solenoid %=N/2.56 0–100
Fuel Trim Cell Cell=N
Calculated Air Flow g/sec=N/128 0–512
Weak Cylinder See Table 01 –
Rough Road Sensor Volt=5n/255
5 Volt Reference Volt=5n/255
Throttle at Idle 1=YES/0=NO –
Upshift Lamp 1=ON/0=OFF –
Low Fuel Lamp 1=ON/0=OFF –
Hot Open Loop Lamp 1=ON/0=OFF –
Variable Gate Intake 1=LONG/0=SHORT –
Fuel Trim Learned 1=ON/0=OFF –
Fan 1 1=ON/0=OFF –
DAEWOO V–121 BL4
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Engine Data Display 03 Selected by 2: Data Display 1: Engine Data 1.6L

Automatic Transmission

Desired Idle Speed rpm=N*12.5 PCM/ECM Idle Command
throttle)
open throttle)
utes:seconds)
Air Condition Pressure Volt=5n/255 0–5 volts
VGIS Status 1=ON/0=OFF –
Fuel Trim Learned 1=YES/0=NO –
Short Term Fuel Trim %=(N–128)/1.28 –100 to 100%
Loop Status 1=CLOSE LOOP/0=OPEN LOOP –
Long Term Fuel Trim %=(N–128)/1.28 –100 to 100%
Fuel Trim Cell Cell=N –
Weak Cylinder Misfire DCT/No Misfire DTC –
Rough Road Sensor Volt=5n/255 0–5 volts
5 Volt Reference Volt=5n/255 0–5 volts

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Fan Speed Low 1=ON/0=OFF –
Fan Speed High 1=ON/0=OFF –
Park/Neutral 1=YES/0=NO –
TCC Engaged 1=YES/0=NO –
Engine Data Display 04 Selected by 2: Data Display 1: Engine Data 1.5L


Desired Idle rpm=N*12.5 PCM/ECM Idle Command
Engine Coolant Temperature Celsius=n–40 85³– 115³C (185³– 239³F)
Intake Air Temperature Celsius=n–40 10³– 80³C (50³– 176³F)
Throttle Position %=n/2.56 0% (up to 100% at wide open
throttle)
open throttle)
EGR Feedback Volt=5n/255 –
Cam Speed Activity Counts=N 0–255
Ignition Voltage Volts=n/10 12.0–15.0
utes:seconds)
BPW Bank 1 ms=N/65.535 0–999.9
Spark Degrees=(n/2)–64 64 to –64
Knock Retard Degrees=N/(256/22.5) 0–90
DAEWOO V–121 BL4
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Air Condition Pressure Volt=5n/255 0–5
Closed Loop 1=YES/0=NO –
Loop Status See Table 3 –
Short Term Fuel Trim %=(N–128)/1.28 –100 to 100
Long Term Fuel Trim %=(N–128)/1.28 –100 to 100
EVAP Purge Solenoid %=N/2.56 0–100
Fuel Trim Cell Cell=N
Calculated Air Flow g/sec=N/128 0–512
Rough Road Sensor Volt=5n/255 –
5 Volt Reference Volt=5n/255 –
Throttle at Idle 1=YES/0=NO –
Upshift Lamp 1=ON/0=OFF –
Low Fuel Lamp 1=ON/0=OFF –
Hot Open Loop Lamp 1=ON/0=OFF –
Variable Gate Intake 1=LONG/0=SHORT –
Fuel Trim Learned 1=ON/0=OFF –
TCC Engaged 1=YES/0=NO –

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EVAP Data Display 01 Selected by 2: Data Display 2: Specific Data 1:EVAP All
Manual Transmission

Fuel Tank Pressure Volt=5n/255 0.2–4.8 volts
Fuel Level Sensor Volt=5n/255 0.4–4.5 volts
Start Up Coolant Temperature Celsius=n–40 –40³– 151³C (–40³– 304³F)
utes:seconds)
Fuel Gauge %=N/2.56 0–100%
Start Up Intake Air Temperature Celsius=n–40 –40³– 151³C (–40³– 304³F)
EVAP Tank Vacuum in H2O=n(25/65535)–7.5 0–100 in H2O
throttle)
open throttle)
Base PWM Bank 1 ms=N/65.535 0–999.9
EVAP Service Max TPS %=N/2.56 0–100%
O2 Sensor Bank 1 Sensor 1 mV=N/0.2304 0–1132
O2 Sensor Bank 1 Sensor 2 mV=N/0.2304 0–1132
EVAP Service Results Test ABORT/Test not ABORT –
EVAP Service Abort Reason Test ABORT/Test not ABORT –
EVAP Service Test State Test RAN/Test not RAN –
EVAP Service Min TPS %=N/2.56 0–100%
EVAP Data Display 02 Selected by 2: Data Display 2: Specific Data 1: EVAP All
Fuel Tank Pressure Volt=5n/255 0.2–4.8 volts
DAEWOO V–121 BL4
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Fuel Level Sensor Volt=5n/255 0.4–4.5 volts
utes:seconds)
Fuel Gauge %=N/2.56 0–100%
EVAP Tank Vacuum in H2O=n(25/65535)–7.5 0–100 in H2O
throttle)
open throttle)
EVAP Service Max TPS %=N/2.56 0–100%
EVAP Service Results Test ABORT/Test not ABORT –
EVAP Service Abort Reason Test RAN/Test not RAN –
EVAP Service Test State Test RAN/Test not RAN –
EVAP Service Min TPS %=N/2.56 0–100%
EGR Data Display Selected by 2: Data Display 2: EGR All Displays EGR01

Ignition Voltage Volts=N/10 11.0–16.0 volts
throttle)
open throttle)

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EGR Duty Cycle %=N/2.56 0–100%
EGR Closed Pintle Position Counts=N 0–255
EGR EWMA Threshold N=Counts(signed) 0–255
EGR Trip Sample Count Tests=N
EGR EWMA Counts=N(signed) –
EGR Pintle Position Error Counts=N(signed) –
utes:seconds)
BPW Bank 1 ms=N/65.535 0–999.9 ms
Air Fuel Ratio x:1=N/10 0:1–25.2:1
MAP kPa=n 12–103 kPa
BARO kPa=(n+28)/2.71 65–100 kPa (varies with altitute and
Vehicle Speed mph=N/1.61 0–255 mph
Oxygen Sensor Data Display Selected by F2: Data Display F2: Specific Data F4:
Oxygen Sensors All Displays O2SO1

Engine Run Time N=seconds 00:00:00–18:12:15 (hours:min-
utes:seconds)
Loop Status 0=Open/1=Closed –
O2S1 Bank 1 Sensor 1 Status 0=Not Ready, 1=Ready –
Power Enrichment 0=Inactive, 1=Active –
Rich/Lean Bank 1 0=LEAN, 1=RICH –
O2S1 Bank 1 Sensor 1 mv=N/0.2304 0–1132 mV
Injector Pulse Bank 1 msec=N/65.535 msec
O2S1 Time to Activity Bank 1 Sensor Seconds=N 00:00:00
1
Short Term FT Bank 1 %=(N–128)1.28 –100 to 100%
Long Term FT Bank 1 %=(N–128)1.28 –100 to 100%
TP Angle %=N/2.56 0–100%
EVAP Purge PWM %=N/2.56 0–100%
Ignition 1 Volts=N/10 11.0–16.0 volts
Air Fuel Ratio x:1=N/10 0:1–25.5:1
DAEWOO V–121 BL4
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Decel Fuel Mode 0=Inactive, 1=Active –
HO2S2 Warm Up Time Bank 1 Senor Seconds=N 00:00:00
1
HO2S2 Bank 1 Sensor 2 mv=N/0.2304 0–1132 mV

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Misfire Data Display Selected by F2: Data Display F2: Specific Data F5: Misfire
All 1.6L Displays MISF01

Misfire Current #1 Count=N 0–255
Misfire History #1 Count=N 0–255
Misfire Failures 1st Fail N=decimal –
Misfire Passes 1st Fail N=decimal –
Total Misfire Count Count=N 0–255
Weak Cylinder Misfire DCT/No Misfire DCT –
TP Angle %=N/2.56 0–100%
Engine Coolant Temperature Celsius=N–40 –40³– 151³C (–40³– 304³F)
Intake Air Temperature Celsius=N–40 –40³– 151³C (–40³– 304³F)
Spark Advance Degrees=(N/2)–64 64 to –64³
G Sensor Volts=N/51 0–5 volts
Desired EGR Position %=N/2.56 0–100%
Actual EGR Position %=N/2.56 0–100%
Vehicle Speed mph=N/1.61 0–255 mph
Decel Fuel Mode 1=ACTIVE/0=INACTIVE –
Power Enrichment Mode 1=ACTIVE/0=INACTIVE –
O2S 1 Bank 1 Sensor 1 mv=N/0.2304 0–1132 mV
HO2S 2 Bank 2 Sensor 1 mv=N/0.2304 0–1132 mV
DAEWOO V–121 BL4
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Misfire Data Display Selected by F2: Data Display F2: Specific Data F5: Misfire
All 1.5L Applications MISF02

Misfire Current #1 Count=n 0–255
Misfire History #1 Count=n 0–255
Misfire Failures 1st Fail N=decimal –
Misfire Passes 1st Fail N=decimal –
Total Misfire Count Count=n 0–255
TP Angle %=N/2.56 0–100
Spark Degrees=(n/2)–64 64 to –64³
G Sensor Volts=n/51 –
Injector Pulse Bank 1 msec=N/65.535 –
O2S1 Bank 1 Sensor 1 mv=N/0.2304 0–1132
HO2S2 Bank 2 Sensor 1 mv=N/0.2304 0–1132

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TEC Display Table Selected by 5: Engine Outputs 5: Engine Outputs TEC01
Parameter Scaling Range

TP Angle %=N/2.56 0–100%
Cam Active Counter N=decimal 0–255
Attempts to Learn Counts=N –
Crank Error Latched 1=YES/0=NO –
Sum Out Of Range 1=YES/0=NO –
Opposing Factor Out Of Range 1=YES/0=NO –
Factor Out Of Range 1=YES/0=NO –
Enable Criteria Not Met 1=YES/0=NO –
Cat Damaging Misfire 1=YES/0=NO –
Test is Running 1=YES/0=NO –
Learned This Key Cycle 1=YES/0=NO –
Universal asynchronous receiver transmitter (UART) seri-

ENGINE DATA DISPLAY TABLE al data to the PCM/ECM and finally to the scan tool over
class 2 serial data.
DEFINITIONS
Air Fuel Ratio
PCM/ECM Data Description
The Air Fuel Ratio indicates the air to fuel ratio based on
The following information will assist in diagnosing emis-
the Oxygen Sensor (O2S 1) inputs. The PCM/ECM uses
sion or driveability problems. A first technician can view
the fuel trims to adjust fueling in order to attempt to main-
the displays while the vehicle is being driven by second
tain an air fuel ratio of 14.7:1.
technician. Refer to Powertrain On–Board Diagnostic
(OBD II) System Check for additional information.
BARO
A/C Clutch The Barometric Pressure (BARO) sensor measures the
change in the intake manifold pressure which results from
The A/C Relay represents the commanded state of the altitude changes. This value is updated at ignition ON and
A/C clutch control relay. The A/C clutch should be en- also at Wide Open Throttle (WOT).
gaged when the scan tool displays ON.
BPW Bank 1
A/C Pressure
Indicates the base Pulse Width Modulation (PWM) or ON
The A/C High Side displays the pressure value of the A/C time of the indicated cylinder injector in milliseconds.
refrigerant pressure sensor. The A/C High Side helps to When the engine load is increased, the injector pulse width
diagnose the diagnostic trouble code (DTC) P0533. will increase.
A/C Request Calculated Air Flow

The A/C Request represents whether the air conditioning The calculated air flow is a calculation based on manifold
is being requested from the HVAC selector. The input is re- absolute pressure. The calculation is used in several diag-
ceived by the instrument panel cluster and then sent over nostics to determine when to run the diagnostics.
DAEWOO V–121 BL4
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EVAP Vent Solenoid

Camshaft Activity Counter
The EVAP Vent Solenoid allows fresh outside air to the
The Camshaft Position (CMP) activity counter displays EVAP canister during purge mode. The EVAP Vent Sole-
the activity sent to the PCM/ECM from the CMP sensor. noid allows the diagnostic to pull a vacuum on the fuel tank
The counter will continually increment while the engine is by closing the vent solenoid.
running. The CMP activity counter is helpful in diagnosing
DTC P0342. Fan
The Fan Control (FC) Relay is commanded by the PCM/
Desired Idle Speed ECM. The FC Relay displays the command as ON or OFF.
The PCM/ECM commands the idle speed. The PCM/ECM Fuel Level Sensor
compensates for various engine loads in order to maintain The Fuel Level Sensor monitors the fuel level in the tank.
the desired idle speed. The actual engine speed should re- The Fuel Level Sensor monitors the rate of change of the
main close to the desired idle under the various engine air pressure in the EVAP system. Several of the Enhanced
loads with the engine idling. EVAP System diagnostics are dependent upon the correct
fuel level.
Engine Coolant Temperature
Fuel Tank Pressure Sensor
The Engine Coolant Temperature (ECT) sensor sends en-
The fuel tank pressure sensor measures the difference
gine temperature information to the PCM/ECM. The PCM/
between the pressure or the vacuum in the fuel tank and
ECM supplies 5 volts to the engine coolant temperature
the outside air pressure. When the air pressure in the fuel
sensor circuit. The sensor is a thermistor which changes
tank equals the outside air pressure, the output voltage of
internal resistance as temperature changes. When the
the sensor is 1.3 to 1.7 volts.
sensor is cold (internal resistance high), the PCM/ECM
monitors a high voltage which it interprets as a cold en- IAC Position
gine. As the sensor warms (internal resistance de- The scan tool displays the PCM/ECM command for the
creases), the voltage signal will decrease and the PCM/ Idle Air Control (IAC) pintle position in counts. The higher
ECM will interpret the lower voltage as a warm engine. the number of counts, the greater the commanded idle
speed reads. The Idle Air Control responds to changes in
EGR Desired Position the engine load in order to maintain the desired idle rpm.
The desired exhaust gas recirculation (EGR) position is Intake Air Temperature
the commanded EGR position. The PCM/ECM calculates
The PCM/ECM converts the resistance of the Intake Air
the desired EGR position. The higher the percentage, the
Temperature (IAT) sensor to degrees in the same manner
longer the PCM/ECM is commanding the EGR valve ON.
as the engine coolant temperature (ECT) sensor. Intake
air temperature is used by the PCM/ECM to adjust fuel de-
Engine Run Time livery and spark timing according to incoming air density.
The engine run time is a measure of how long the engine
Ignition 1 (Voltage)
has been running. When the engine stops running, the tim-
er resets to zero. The ignition volts represent the system voltage measured
by the PCM/ECM at the ignition feed circuit.
Engine Speed Knock Retard
Engine Speed is computed by the PCM/ECM from the fuel The Knock Sensor (KS) Retard indicates the amount of
control reference input. It should remain close to desired spark advance the PCM/ECM is decreasing in response
idle under the various engine loads with the engine idling. to the KS signal.
Knock Present
EVAP Purge The KS Noise Channel indicates when the PCM/ECM de-
The Evaporative Emission (EVAP) purge valve solenoid is tects the KS signal. The PCM/ECM should display NO at
a proportional signal used in order to control the EVAP idle.
canister purge function. At 0% the valve is commanded
fully closed. 100% implies that the valve is fully open. Calculated Load
Indicates engine load based on manifold absolute pres-
sure. The higher the percentage, the more load the engine
EVAP Purge Solenoid
is under.
When energized, the EVAP Solenoid allows the fuel vapor
to flow from the EVAP canister to the engine. The EVAP Long Term FT
Solenoid is normally closed. The EVAP Solenoid is pulse The Long Term Fuel Trim (FT) is derived from the short
width modulated by the PCM/ECM. The EVAP Solenoid term fuel trim value. The Long Term FT is used for the long
reads 0% when closed and 100% when fully opened. term correction of the fuel delivery. A value of 128 counts

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(0%) indicates that the fuel delivery requires no com-

pensation in order to maintain a 14.7:1 air to fuel ratio. A Short Term FT
value below 128 counts means that the fuel system is too The Short Term FT represents a short term correction to
rich and the fuel delivery is being reduced. The PCM/ECM fuel delivery by the PCM/ECM in response to the amount
is decreasing the injector pulse width. A value above 128 of time the oxygen sensor voltage spends above or below
counts indicates that a lean condition exists for which the the 450 mv threshold. If the oxygen sensor has mainly
PCM/ECM is compensating. been below 450 mv, indicating a lean air/fuel mixture, short
term fuel trim will increase to tell the PCM/ECM to add fuel.
Long Term FT Average If the oxygen sensor voltage stays mainly above the
Long Term FT Average is derived from the long term fuel threshold, the PCM/ECM will reduce fuel delivery to com-
trim from all of the cells. The PCM/ECM then takes all of pensate for the indicated rich condition.
the values and then creates one average value.
Short Term FT Average
Loop Status
The Short Term FT Average is derived from the short term
The Closed Loop is displayed indicating that the PCM/ fuel trim from all of the cells. The PCM/ECM takes all of the
ECM is controlling the fuel delivery according to the Oxy- values and then creates one average value.
gen Sensor (O2S 1) voltage as close to an air/fuel ratio of
14.7 to 1 as possible. Spark
MAP This is a display of the spark advance Ignition Coil (IC) cal-
The Manifold Absolute Pressure (MAP) sensor measures culation which the PCM/ECM is programming in the igni-
the change in the intake manifold pressure which results tion system. It computes the desired spark advance using
from engine load and speed changes. As the intake man- data such as engine temperature, rpm, engine load, ve-
ifold pressure increases, the air density in the intake also hicle speed and operating mode.
increases and the additional fuel is required.
TCC Brake Switch
Misfire Current #1–4 When the brake pedal is applied, the Torque Converter
Indicates the number of current misfires that are present Clutch (TCC) brake switch sends a signal to the PCM/
in the indicated cylinder. Increments only when misfire is ECM to disengage the TCC and disable the cruise control.
current.
Total Misfire Current Counter
Misfire History #1–4
Indicates the total number of misfires that have been de-
Indicates the number of misfires that have occurred after tected in all the cylinders after 100 engine cycles. One
195 current misfires have been counted. The current mis- cycle equals one complete 4 stroke cycle. The total misfire
fire counter will add its misfires to the history misfire count- only increments during the steady state cruise conditions.
er after 195 total misfires have taken place. If 1 cylinder is
misfiring, the misfiring current counter will have 195 mis- TP Angle
fires counted before adding to its history counter. If 2 cylin- From the Throttle Position (TP) Sensor voltage input, the
ders are misfiring, the misfiring current counter will add to PCM/ECM computes the TP. The TP Angle will auto zero
their history counters after 97 misfires. The counter incre- to 0% at idle (TP voltage below 0.90 volt). The TP Angle
ments only after a misfire diagnostic trouble code (DTC) will read 100% at WOT.
has been set.
Oxygen Sensor Bank 1 Sensor 1 TP Sensor
The pre–converter Oxygen Sensor (O2S 1) reading repre- The PCM/ECM uses the TP Sensor in order to determine
sents the exhaust oxygen sensor output voltage. This volt- the amount of the throttle demanded by the vehicle’s oper-
age will fluctuate constantly between 100 mv (lean ex- ator. The TP Sensor reads between 0.36–0.96 volts at idle
haust) and 900 mv (rich exhaust) when the system is to above 4 volts at WOT.
operating in a Closed Loop.
Vehicle Speed
Oxygen Sensor Bank 1 Sensor 2 The vehicle speed sensor signal is converted into mph or
The post–converter Heated Oxygen Sensor (HO2S 2) km/h for display. The vehicle speed output from the PCM/
represents the exhaust oxygen output voltage past the ECM is 4000 pulses per mile. The scan tool uses the class
catalytic converter. This voltage remains inactive, or the 2 serial data from the PCM/ECM to obtain vehicle speed,
voltage will appear lazy within a range of 100 mv (lean ex- while the Instrument Panel Cluster (IPC), cruise control
haust) and 900 mv (rich exhaust) when operating in a module and the chime alarm module use the 4000 ppm
Closed Loop. output.
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Camshaft Position Sensor 12 – 106
Electronic Ignition System Ignition Coil Retaining Bolts 10 – 89
Engine Coolant Temperature Sensor 20 15 –
Evaporative Emission Canister Flange Bolt 20 15 –
Exhaust Gas Recirculation Valve Retaining Bolts 20 15 –
Fuel Pressure Regulator Retaining Bolt – SOHC 12 – 106
Fuel Pressure Regulator Retaining Screw – DOHC 12 – 106
Fuel Rail Mounting Bolts 25 18 –
Fuel Tank Retaining Bolts 20 15 –
Heated Oxygen Sensor 41 30 –
Idle Air Control Valve Retaining Bolts 3 – 27
Knock Sensor Bolt 20 15 –
MAP Sensor Mounting Bracket Bolt 4 – 35
MAP Sensor Retaining Bolts and Nuts 8 – 71
Oxygen Sensor 41 30 –
Parking Brake Cable Retainer Clamps 10 – 89
Throttle Body Retaining Bolts 15 11 –
Throttle Cable Bracket Bolts 2 – 18
VGIS Actuator Assembly Mounting Bracket Bolts 16 12 –

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³C ³F OHMS
FUEL SYSTEM SPECIFICATIONS Temperature vs Resistance Values (Approximate)
Gasoline 100 212 177
All engines are designed to use unleaded fuel only. Un- 90 194 241
leaded fuel must be used for proper emission control sys- 80 176 332
tem operation. Its use will also minimize spark plug fouling 70 158 467
and extend engine oil life. Using leaded fuel can damage
the emission warranty coverage. The fuel should meet 60 140 667
specification ASTM D4814 for the U.S. or CGSB 3.5 M93 50 122 973
for Canada. All engines are designed to use unleaded fuel
45 113 1188
with a minimum U(R+M)/2e (pump) octane number of 87,
where R=research octane number, and M=motor octane 40 104 1459
number. 35 95 1802
30 86 2238
Ethanol
25 77 2796
You may use fuel containing ethanol (ethyl alcohol) or
grain alcohol providing that there is no more than 10 per- 20 68 3520
cent ethyl alcohol by volume. 15 59 4450
10 50 5670
Methanol
5 41 7280
Do not use fuels containing methanol. Methanol can cor-
0 32 9420
rode metal parts and cause damage to plastic and rubber
parts in the fuel system. –5 23 12300
–10 14 16180
Methyl Tertiary–Butyl Ether (MTBE) –15 5 21450
You may use fuel containing Methyl Tertiary–Butyl Ether –20 –4 28680
(MTBE) providing there is no more than 15 percent MTBE
by volume. –30 –22 52700
–40 –40 100700
TEMPERATURE VS RESISTANCE
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SECTION : 1G
ENGINE EXHAUST
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1G–1 AUXILIARY CATALYTIC CONVERTER . . . . . . . 1G–5
FASTENER TIGHTENING SPECIFICATIONS . 1G–1 MUFFLER – FRONT . . . . . . . . . . . . . . . . . . . . . . . 1G–8
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 1G–2 MUFFLER – REAR . . . . . . . . . . . . . . . . . . . . . . . 1G–10
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 1G–2 GENERAL DESCRIPTION AND SYSTEM
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 1G–3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G–12
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 1G–3 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1G–12
MAIN CATALYTIC CONVERTER AND MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G–12
CONNECTING PIPE . . . . . . . . . . . . . . . . . . . . . 1G–3 CATALYTIC CONVERTERS . . . . . . . . . . . . . . . 1G–12
SPECIFICATIONS
Auxiliary Catalytic Converter–to–Exhaust Manifold Nuts 50 37 –
Exhaust Manifold Cover Bolts 15 11 –
Front Connecting Pipe–to–Auxiliary Catalytic Converter Nuts 30 22 –
Front Muffler–to–Main Catalytic Converter and Connecting Pipe 30 22 –
Nuts
Front Muffler–to–Rear Muffler Nuts 30 22 –
Post–Converter Heated Oxygen Sensor 41 30 –
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1G – 2IENGINE EXHAUST
COMPONENT LOCATOR
EXHAUST SYSTEM
1. Trim Ring 6. Main Catalytic Converter

2. Rear Muffler 7. Connecting Pipe
3. Metal Gasket 8. Post–Converter Heated Oxygen Sensor
4. Front Muffler 9. Auxiliary Catalytic Converter
5. Metal Gasket

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ENGINE EXHAUST 1G – 3

MAIN CATALYTIC CONVERTER AND
CONNECTING PIPE
Removal Procedure
1. Remove the post–converter heated oxygen sensor.
2. Remove the connecting pipe nuts and the gasket

from the auxiliary catalytic converter.
3. Disconnect the connecting pipe from the rubber

hanger.
4. Remove the nuts from the front muffler pipe to the
main catalytic converter.
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5. Remove the catalytic converter and the connecting

pipe and the gasket.
6. Clean the sealing surfaces on the front muffler pipe
flange and the auxiliary catalytic converter.
7. Check the catalytic converter and the connecting
pipe for holes, damage, open seams, or other dete-
rioration which could permit exhaust fumes to seep
into the passenger compartment.
1. Install the main catalytic converter and the connect-

ing pipe and the gasket to the front muffler pipe
flange. Use the nuts to secure the converter and
the connecting pipe.
Tighten
Tighten the front muffler–to–main catalytic converter
and connecting pipe nuts to 30 NSm (22 lb–ft).
2. Connect the connecting pipe to the rubber hanger.

3. Using the nuts and the gasket, secure the connect-
ing pipe to the auxiliary catalytic converter.
Tighten
Tighten the front connecting pipe–to–auxiliary cata-
lytic converter nuts to 30 NSm (22 lb–ft).

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4. Install the post–converter heated oxygen sensor.

Tighten
Tighten the post–converter heated oxygen sensor to
41 NSm (30 lb–ft).
AUXILIARY CATALYTIC CONVERTER

Removal Procedure
1. Disconnect the post–converter oxygen sensor elec-

trical connector.
2. Remove the exhaust manifold cover bolts and the

exhaust manifold cover.
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3. Remove the auxiliary catalytic converter upper

flange nuts.
4. Remove the auxiliary catalytic converter lower

flange nuts.
5. Remove the auxiliary catalytic converter and the
gaskets.
1. Install the auxiliary catalytic converter and the gas-

kets.
Important : Position the auxiliary catalytic converter onto
the exhaust manifold flange with one upper flange nut and
bolt.
2. Install the auxiliary catalytic converter lower flange
nuts and the bolts.
Tighten
Tighten the front connecting pipe–to–auxiliary cata-
lytic converter nuts to 30 NSm (22 lb–ft).

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3. Install the remaining auxiliary catalytic converter

upper flange nuts.
Tighten
Tighten the auxiliary catalytic converter–to–exhaust
manifold nuts to 50 NSm (37 lb–ft).
4. Install the exhaust manifold cover and the exhaust

manifold cover bolts.
Tighten
Tighten the exhaust manifold cover bolts to 15 NSm
(11 lb–ft).
5. Connect the post–converter oxygen sensor electri-

cal connector.
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MUFFLER – FRONT
Removal Procedure
1. Remove the nuts and the gasket from the front

muffler pipe to the main catalytic converter and
connecting pipe flange.
2. Detach the front muffler from the rubber hanger.
3. Remove the nuts and the gasket from the the rear
muffler pipe flange. Disconnect the front muffler
from the rubber hanger.
4. Remove the front muffler.
5. Check the exhaust pipe and the front muffler for
holes, damage, open seams, or other deterioration
which could permit exhaust fumes to seep into the
passenger compartment or the trunk.

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1. Attach the front muffler and the gasket to the rear

muffler using the nuts. Secure the front muffler to
the rubber hanger.
Tighten
Tighten the front muffler–to–rear muffler nuts to 30
NSm (22 lb–ft).
2. Attach the front muffler assembly to the rubber

hanger. Loosely secure the front muffler assembly
to the catalytic converter or the connecting pipe
flange.
3. Secure the front muffler assembly to the main cata-

lytic converter and connecting pipe flange with the
nuts.
Tighten
Tighten the front muffler–to–main catalytic converter
and connecting pipe nuts to 30 NSm (22 lb–ft).
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MUFFLER – REAR
Removal Procedure
1. Remove the nuts and the gasket from the rear muf-
fler pipe flange–to–front muffler pipe flange.
2. Detach the rear muffler assembly from the rubber

hangers on the tail pipe end.
3. Remove the rear muffler assembly.
4. Remove the trim ring from the rear muffler pipe.

5. Check the rear muffler and the pipes for holes,
damage, open seams, and other deterioration
which could permit exhaust fumes to seep into the
passenger compartment or the trunk.

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1. Install the trim ring on the rear muffler pipe.

Tighten
Tighten the trim ring bolt until it bottoms on the ex-
haust pipe. Tighten an additional quarter turn.
2. Secure the rear muffler assembly to the rubber
hangers on the tail pipe end.
3. Secure the nuts and the gasket from the rear muf-
fler pipe flange–to–front muffler pipe flange.
Tighten
Tighten the front muffler–to–rear muffler nuts to 30
NSm (22 lb–ft).
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inspection of the front muffler and pipe assembly, the com-

GENERAL DESCRIPTION plete assembly should be replaced. The same procedure
is applicable to the rear muffler assembly.
AND SYSTEM OPERATION Heat shields in the front and the rear muffler assembly
positions, as well as for the main catalytic converter and
EXHAUST SYSTEM the connecting pipe, protect the vehicle and the environ-
ment from high temperatures the exhaust system devel-
Notice : When you are inspecting or replacing the exhaust ops.
system components, make sure there is adequate clear-
ance from all points on the underbody to avoid possible CATALYTIC CONVERTERS
overheating of the floor pan and possible damage to the
Notice : When jacking or lifting the vehicle from the body
passenger compartment insulation and trim materials.
side rails, be certain that the lift pads do not contact the
CAUTION : Check the complete exhaust system and main catalytic converter as this could damage the main
the nearby body areas and the trunk lid for broken, catalytic converter.
damaged, missing, or mispositioned parts, open
Notice : The catalytic converter requires the use of un-
seams, holes, loose connections, or other deteriora-
leaded fuel only, or damage to the catalyst will result.
tion which could permit hazardous exhaust fumes to
seep into the trunk or the passenger compartment. The catalytic converters are emission control devices add-
Dust or water in the trunk may be an indication of a ed to the exhaust system to reduce pollutants from the ex-
problem in one of these areas. Any defects should be haust pipes.
corrected immediately. The oxidation catalyst is coated with a catalytic material
containing platinum and palladium, which reduces levels
MUFFLER of hydrocarbon (HC) and carbon monoxide (CO) from the
Aside from the exhaust manifold connection, the exhaust exhaust gas. The three–way catalyst has coatings which
system uses a flange and seal joint design as opposed to contain platinum and rhodium, which additionally lower the
a slip joint coupling design with clamps and U–bolts. If levels of oxides of nitrogen (NOx).
holes, open seams or any deterioration is discovered upon

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SECTION : 2A
SUSPENSION DIAGNOSIS
TABLE OF CONTENTS
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–1 TAPERED ROLLER BEARING . . . . . . . . . . . . . . 2A–8
GENERAL DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 2A–1 SEALED WHEEL BEARING DIAGNOSIS . . . . . 2A–8
TORQUE STEER . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–8
DIAGNOSIS
GENERAL DIAGNOSIS
Problems in the steering, the suspension, the tires, and If possible, do this road test with the customer.
the wheels involve several systems. Consider all systems Proceed with the following preliminary checks. Correct
when you diagnose a complaint. Some problems, such as any substandard conditions.
abnormal or excessive tire wear and scuffed tires, may be
the result of hard driving. Always road test the vehicle first.
Preliminary Checks
Checks Action
Inspect the tires for improper pressure and uneven wear. Inflate the tires to the proper pressure.
Inspect the joint from the steering column to the steering Tighten the coupling flange pinch bolts. Replace the cou-
gear for loose connections or wear. pling flange as needed.
Inspect the front and the rear suspension, the steering Tighten the front and the rear suspension. Tighten the
gear, and the linkage for loose or damaged parts. steering gear mounting bracket bolts. Tighten the coupling
flange pinch bolts. Replace the front and the rear suspen-
sion as needed. Replace the steering gear as needed. Re-
place the coupling flange as needed.
Inspect for out–of–round tires. Perform free runout test. Match–mount the tires.
Inspect for out–of–balance tires, bent wheels, and worn or Balance the wheels. Replace the wheels. Replace the
loose wheel bearings. wheel bearings.
Check the power steering pump drive belt tension. Tighten the power steering pump drive belt.
Inspect the power steering system for leaks. Also check Repair any leaks. Perform a power steering gear test.
the power steering fluid level. Add power steering fluid.
Car Lead/Pull
Checks Action
Inspect for mismatched or uneven tires. Replace the tires.
Inspect for a broken or a sagging spring. Replace the spring.
Inspect for a radial tire lateral force. Check the wheel alignment. Switch the tire and wheel as-
semblies. Replace the tires as needed.
Check the front–wheel alignment. Align the front wheels.
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2A – 2ISUSPENSION DIAGNOSIS
Checks Action
Inspect for an off–center steering gear. Reseat the pinion valve assembly. Replace the pinion
valve assembly as needed.
Inspect for front–brake dragging. Adjust the front brakes.

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SUSPENSION DIAGNOSIS 2A – 3
Abnormal or Excessive Tire Wear

Checks Action
Check the front–wheel and rear–wheel alignment. Align the front and the rear wheels.
Inspect for excessive toe. Adjust the toe.
Inspect for out–of–balance tires. Balance the tires.
Inspect for worn strut dampeners. Replace the strut dampeners.
Check for a failure to rotate tires. Rotate the tires. Replace the tires as needed.
Check for an overloaded vehicle. Maintain the proper load weight.
Inspect for low tire inflation. Inflate the tires to the proper pressure.
Scuffed Tires
Checks Action
Inspect for incorrect toe. Adjust the toe.
Inspect for a twisted or a bent suspension arm. Replace the suspension arm.
Wheel Tramp
Checks Action
Inspect for an out–of–balance tire or wheel. Balance the tire or the wheel.
Inspect for improper strut dampener action. Replace the strut dampeners.
Shimmy, Shake, or Vibration

Checks Action
Inspect for an out–of–balance tire or wheel. Balance the tire or the wheel.
Inspect for excessive wheel hub runout. Measure the hub flange runout. Replace the hub as need-
ed.
Inspect for excessive brake drum or brake rotor imbal- Adjust the brakes. Replace the brake rotor or the brake
ance. drum as needed.
Inspect for worn tie rod ends. Replace the outer tie rods.
Inspect for wheel trim imbalance. Balance the wheel.
Inspect for a worn lower ball joint. Replace the lower ball joint.
Inspect for excessive wheel runout. Measure the wheel runout. Replace the wheel as needed.
Inspect for excessive loaded radial runout on the tire and Match–mount the tire and wheel assembly.
wheel assembly.
Hard Steering (Manual)

Checks Action
Inspect for a lack of lubrication of the ball joints, the tie rods Lubricate the ball joints, the tie rods, and the steering gear.
and the steering gear. Replace the ball joints, the tie rods, and the steering gear
as needed.
Check the steering gear adjusment. Adjust the steering gear.
Hard Steering (Power)
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Checks Action
Check the steering gear preload adjustment. Perform a rack bearing preload on–vehicle adjustment.
Check the hydraulic system. Test the power steering sys- Replace the seals and the hoses as needed.
tem pressure with a gauge.
Inspect for binding or catching in the steering gear. Lubricate the steering gear. Repair or replace the steering
gear as needed.
Inspect for a loose steering gear mounting. Tighten the steering gear mounting bracket nuts.
Too Much Play in Steering

Checks Action
Inspect for worn or loose wheel bearings. Tighten the drive axle nut. Replace the wheel bearings as
needed.
Inspect the joint from the column to the steering gear for Tighten the coupling flange pinch bolts. Replace the cou-
loose connections or wear. pling flange as needed.
Poor Returnability (Manual)

Checks Action
Inspect for a lack of lubrication of the ball joints, the tie rods Lubricate the ball joints, the tie rods, and the steering gear.
and the steering gear. Replace the ball joints, the tie rods, and the steering gear
as needed.
Inspect for binding in the ball joints. Replace the ball joints.
Inspect for binding in the steering column. Lubricate the steering column. Replace the steering col-
umn as needed.
Inspect for a lack of lubrication in the steering gear. Lubricate the steering gear. Repair or replace the steering
gear as needed.
Poor Returnability (Power)

Checks Action
Inspect for lack of lubrication of the ball joints and the tie Lubricate the ball joints and the tie rod ends. Replace the
rod ends. ball joints and the outer tie rods as needed.
Inspect for binding in the ball joints. Replace the ball joint.
Inspect for binding in the steering column. Lubricate the steering column. Replace the steering col-
umn as needed.
Inspect for a sticking valve. Lubricate the pinion valve assembly. Replace the pinion
valve assembly as needed.
Inspect for binding in the coupling flange on the steering Replace the coupling flange.
gear.

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Abnormal Noise, Front Suspension

Checks Action
Inspect for a lack of lubrication of the ball joints and the tie Lubricate the ball joints and the tie rod ends. Replace the
Inspect for damaged suspension components. Replace the damaged suspension components.
Inspect for worn control arm bushings or tie rod ends. Replace the control arm bushings or the tie rods.
Inspect for a loose stabilizer shaft link. Tighten the stabilizer shaft link.
Inspect for loose wheel bolts. Tighten the wheel bolts.
Inspect for loose suspension bolts or nuts. Tighten the suspension bolts or the nuts.
Inspect for loose wheel covers. Tighten the wheel covers.
Inspect for worn strut dampeners or strut mountings. Replace the strut dampeners. Tighten the strut mounting
bolts.
Inspect for an improperly positioned strut spring. Adjust the strut spring to the proper position.
Wander or Poor Steering Ability

Checks Action
Inspect for mismatched or uneven tires. Replace the tires.
Inspect for lack of lubrication of the ball joints and the tie Lubricate the ball joints and the tie rod ends. Replace the
Check the front–wheel and the rear–wheel alignment. Align the front and the rear end wheels.
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Erratic Steering when Braking

Checks Action
Inspect for worn or loose wheel bearings. Replace the wheel bearings.
Inspect for a leaking wheel cylinder or caliper. Replace the wheel cylinder or the caliper.
Inspect for warped rotors. Replace the rotors.
Inspect for an incorrect or an uneven caster. If the caster is beyond specifications, check the frame and
repair it as needed.
Low or Uneven Trim Height

Checks Action
Inspect for an incorrect or weak spring. Replace the spring.
Ride Too Soft

Checks Action
Ride Too Harsh

Checks Action
Inspect for incorrect strut dampeners. Replace the strut dampeners.
Inspect for an incorrect spring. Replace the spring.
Body Leans or Sways in Corners

Checks Action
Inspect for worn strut dampeners or strut mountings. Replace the strut dampeners. Tighten the strut assembly
mounting bolts.
Suspension Bottoms
Checks Action
Steering Wheel Kickback (Power)

Checks Action
Inspect for air in the power steering system. Purge the power steering system of air.

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Checks Action
Inspect the joint from the column to the steering gear for Tighten the coupling flange pinch bolts. Replace the cou-
loose connections or wear. pling flange as needed.
Inspect for loose tie rod ends. Tighten the tie rod ends. Replace the outer tie rods as
needed.
Inspect for loose or worn wheel bearings. Tighten the drive axle nut. Replace the wheel bearings as
needed.
Steering Wheel Surges or Jerks (Power)

Checks Action
Check the hydraulic system. Test the power steering sys- Replace the seals and the hoses as needed.
tem pressure with a gauge.
Inspect for a sluggish steering gear valve. Clean the pinion valve assembly. Replace the pinion valve
assembly as needed.
Inspect for a loose power steering pump drive belt. Adjust the power steering pump drive belt.
Cupped Tires
Checks Action
Check the front–wheel and the rear–wheel alignment. Align the front and the rear wheels.
Inspect for worn or loose wheel bearings. Tighten the drive axle nut. Replace the wheel bearings as
needed.
Inspect for excessive tire or wheel runout. Match–mount the tires. Replace the tires as needed.
Inspect for a worn ball joint. Replace the ball joint.
Replace the wheels as needed.
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1. Raise and suitably support the vehicle.

TORQUE STEER 2. Remove the rear wheel. Refer to Section 2E, Tires
A degree of torque steer to the right may normally be expe- and Wheels.
rienced during the use of heavy throttle on some front– 3. Remove the brake drum detent screw and the
wheel drive cars with drive axles of unequal length. This brake drum. Refer to Section 4E, Rear Drum
torque steer to the right results from the right drive axle be- Brakes.
ing longer than the left drive axle, which creates a differ- 4. Mount a dial indicator set with a magnetic base to a
ence in the drive axle angle. Cars with intermediate shaft control arm or any other stationary part of the ve-
assemblies have axles of almost equal length. hicle.
5. Push and pull the wheel hub by hand. If the wheel
A difference in the drive axle lengths results in more torque
hub movement exceeds 0.05 mm (0.002 inch), re-
toe–in in the left front wheel. You will notice the torque toe–
place the wheel bearing. Refer to Section 2D, Rear
in when the vehicle accelerates from a standing start or at
Suspension.
lower speeds.
6. Install the rear brake drum. Refer to Section 4E,
Inspection Procedure Rear Drum Brakes.
7. Install the rear wheel. Refer to Section 2E, Tires
1. Place a small piece of tape at the top center of the and Wheels.
steering wheel. 8. Lower the vehicle.
2. Note the inches of steering wheel deflection re-
quired to keep the vehicle straight during heavy ac-
celeration.
3. Compare this finding with similar cars.
Factors that may cause torque steer to be more apparent
on a particular vehicle include:
S Variations in the tire and wheel assemblies. This
has the most significant effect on torque steer. A
slightly smaller diameter on the right front tire will
increase a right torque lead.
S Large differences in the right and the left front tire
pressure.
S Looseness in the control arm bushings, the tie rod
assemblies, or the steering gear mounting. This
looseness permits a front wheel to pull forward and
toe–in under a torque greater than the wheel on the
opposite side. A loose suspension component may
result in an opposite lead upon deceleration.
S A high front trim height. This height would increase
the drive axle angle and could cause wobble at
speeds between 24 to 48 km/h (15 to 30 mph). SEALED WHEEL BEARING
S Binding or a tight drive axle joint. A tight drive axle
joint or a high front trim height may also cause a
DIAGNOSIS
wobble at speeds between 24 to 48 km/h (15 to 30 Vehicles with antilock braking systems have sealed, non–
mph). serviceable cartridge bearings in the rear wheels. If any
S Incorrect, worn, or loose engine mounts causing fault is found with a wheel bearing, it must be replaced.
adverse drive angles.
Wheel Bearing Noise
Refer to ”General Diagnosis” in this section for actions to A road test usually reveals excessive wheel bearing noise.
remedy these problems. Sealed wheel bearings emit a howling sound when loose
Conditions that may produce an effect similar to torque or damaged. Wheel bearing noise is present only when the
steer include: vehicle is moving. It is constant and unwavering and in-
creases with the speed of the vehicle. If the wheel bearing
S Incorrect front or rear alignment.
noise cannot be positively diagnosed, or if the origin of the
S Frame misalignment or defect.
noise cannot be determined, perform the following test:
S Front suspension damage.
S Incorrectly mounted rear crossmember. 1. Raise and suitably support the vehicle.
2. Spin the wheels using your hand. Check for out–of–
TAPERED ROLLER BEARING round or out–of–balance tires, bent rims, or loose
wheel bearings.
Perform the following test to check for looseness in the
3. Spin the rear wheels using a commerical wheel
bearing cartridge assembly:
spinner.

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4. If a noise can be heard from the passenger

compartment, replace the noisy wheel bearing car-
tridge. Refer to Section 4D, Rear Suspension.
5. Lower the vehicle
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SECTION : 2B
WHEEL ALIGNMENT
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2B–1 REAR TOE CHECK . . . . . . . . . . . . . . . . . . . . . . . . 2B–9
WHEEL ALIGNMENT SPECIFICATIONS . . . . . 2B–1 GENERAL DESCRIPTION AND SYSTEM
DIFFERENCE BETWEEN LEFT AND RIGHT . 2B–1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B–10
FASTENER TIGHTENING SPECIFICATIONS . 2B–1 FOUR WHEEL ALIGNMENT . . . . . . . . . . . . . . . 2B–10
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B–2 TOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B–10
TIRE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . 2B–2 CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B–10
RADIAL TIRE LEAD/PULL . . . . . . . . . . . . . . . . . . 2B–4 CAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B–10
VIBRATION DIAGNOSIS . . . . . . . . . . . . . . . . . . . 2B–5 STEERING AXIS INCLINATION . . . . . . . . . . . . 2B–10
PRELIMINARY INSPECTION . . . . . . . . . . . . . . . 2B–9 INCLUDED ANGLE . . . . . . . . . . . . . . . . . . . . . . . 2B–10
FRONT TOE ADJUSTMENT . . . . . . . . . . . . . . . . 2B–9 SCRUB RADIUS . . . . . . . . . . . . . . . . . . . . . . . . . 2B–10
FRONT CAMBER AND CASTER CHECK . . . . 2B–9 SETBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B–10
REAR CAMBER CHECK . . . . . . . . . . . . . . . . . . . 2B–9 TURNING ANGLE . . . . . . . . . . . . . . . . . . . . . . . . 2B–10
SPECIFICATIONS
WHEEL ALIGNMENT SPECIFICATIONS
Application Front Rear
Camber –1³ 10’ to 20’ –2³ 10’ to –1³10’
Caster – Manual Str’g 30’ to 2³ 30’ –
Caster – Power Str’g 1³ 45’ to 3³ 45’ –
Toe–in (2–person load) –10’ to 10’ –10’ to 40’
Note : The above alignment specifications are with the ve-

hicle in a normally loaded condition. Prior to inspectionor
alignment, place a weight of approximately 150 lbs. (68
kg) on each front seat cushion.
DIFFERENCE BETWEEN LEFT AND RIGHT
Application Front Rear
Camber 1³max 30’ max
Caster 1³max –
Toe–in – 15’ max

Front Toe Adjusting Nut 22 16 –
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2B – 2IWHEEL ALIGNMENT
Tread Wear Indicators

DIAGNOSIS The original equipment tires have built–in tread wear indi-
cators to show when the tires need replacement. These in-
dicators appear as bands when the tire tread depth be-
TIRE DIAGNOSIS comes shallow. Tire replacement is recommended when
the indicators appear in three or more grooves at six loca-
Irregular and Premature Wear tions.
Irregular and premature tire wear has many causes. Some
of them are incorrect inflation pressures, lack of regular
rotation, poor driving habits, or improper wheel alignment.
If the wheel alignment is reset because of tire wear, always
reset the toe as close to zero degrees as the specification
allows. Refer to ”Rear Toe Check” in this section.
Rotate the tires if
S The front tire wear is different from the rear.
S The front tire wear is different from the rear.
S The left and right front tire wear is unequal.
S The left and right rear tire wear is unequal.
Check wheel alignment if:
S The left and right front tire wear is unequal.
S The wear is uneven across the tread of either front
tire.
S The front tire treads are scuffed with ”feather”
edges on the side of the tread ribs or blocks.
Radial Tire Waddle

Waddle is side–to–side movement at the front or rear of
the vehicle. It is caused by the steel belt not being straight
within the tire, or by excessive lateral runout of the tire or
wheel. It is most noticeable at low speeds, 8 to 48 km/h (5
to 30 mph), but may appear as ride roughness at 80 to 113
km/h (50 to 70 mph).
The vehicle must be road tested to determine which end
of the vehicle has the faulty tire. The rear end of the vehicle
will shake from side to side or ‘‘waddle’’ if the waddle tire
is on the rear of the vehicle. From the driver’s seat, it feels
as though someone is pushing on the side of the vehicle.
If the faulty tire is on the front of the vehicle, the waddle is
more visual. The front sheet metal appears to be moving
back and forth, and the driver’s seat feels like the pivot
point in the vehicle.
Waddle can be diagnosed using the method of substituting
known good tire and wheel assemblies on the problem ve-
hicle.
1. Road test the vehicle to determine if the waddle is
coming from the front or the rear of the vehicle.
2. Install good tires and wheels from a similar vehicle
in place of those on the offending end of the prob-
lem vehicle. If the source of the waddle is not ob-
vious, change the rear tires.
3. Road test the vehicle. If there is improvement,
install the original tires to find the offending tire. If
there is no improvement, install good tires in place
of all four offending tires.

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WHEEL ALIGNMENT 2B – 3
4. Install original tires one at a time to find the offend-

ing tire.
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the road. If one side of the tire has even a little larger diam-
RADIAL TIRE LEAD/PULL eter than the diameter of the other side, the tire will tend
to roll to one side. Unequal diameters will cause the tire to
Lead/pull is the deviation of the vehicle from a straight path
develop a side force which can produce vehicle lead/pull.
on a level road with no pressure on the steering wheel.
Lead is usually caused by:
The radial lead/pull diagnosis chart should be used to de-
S Incorrect alignment. termine whether the problem originates from an alignment
S Uneven brake adjustment. problem or from the tires. Part of the lead diagnosis proce-
S Tire construction. dure calls for tire rotation that is different from the proper
tire rotation pattern. If a medium– to highmileage tire is
The way in which a tire is built can produce lead/pull in the
moved to the other side of the vehicle, be sure to check for
vehicle. Off–center belts on radial tires can cause the tire ride roughness. Rear tires will not cause lead/pull.
to develop a side force while the vehicle rolls straight down
Radial Tire Lead/Pull Diagnosis Chart

1 1. Perform wheel alignment preliminary inspec- Go to Step 2 System OK
tion.
2. Check the brakes for dragging.
3. Road test the vehicle.
Does the vehicle lead/pull?
2 1. Cross switch the front tire and wheel assem- – Go to Step 3 System OK
blies.
Does the vehicle lead/pull?
3 1. Check the front wheel alignment. Go to Step 4 Adjust
Is the alignment within specifications? alignment
4 1. Compare the front camber and front caster to Go to Step 7 Go to Step 5

specifications.
Are they within specifications?
5 1. Check the vehicle frame. – Go to Step 6 Go to Step 1
Is the frame bent?
6 1. Straighten the frame. Go to Step 3
7 1. The probable cause is the tires. – Go to Step 9 Go to Step 8
2. Switch the left front tire and wheel assembly
with the left rear tire and wheel assembly.
Does the vehicle still lead/pull?
8 1. Switch the left front tire and wheel assembly – System OK Go to Step 1
with the left rear tire and wheel assembly and
replace the left front tire.
9 1. Switch the right front tire and wheel assembly Go to Step 1 Go to Step 10
with the right rear tire and wheel assembly.
Does the vehicle still lead/pull?
10 1. Switch the right front tire and wheel assembly – System OK Go to Step 1
with the right rear tire and wheel assembly and
replace the right front tire.

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VIBRATION DIAGNOSIS Preliminary Checks

Wheel imbalance causes most highway speed vibration
problems. A vibration can remain after dynamic balancing Prior to performing any work, always road test the car and
because: perform a careful visual inspection for:
S A tire is out of round. S Obvious tire and wheel runout.
S A rim is out of round. S Obvious drive axle runout.
S A tire stiffness variation exists. S Improper tire inflation.
Measuring tire and wheel free runout will uncover only part S Incorrect trim height.
of the problem. All three causes, known as loaded radial S Bent or damaged wheels.
runout, must be checked using method of substituting S Debris build–up on the tire or the wheel.
known good tire and wheel assemblies on the problem ve- S Irregular or excessive tire wear.
hicle. S Improper tire bead seating on the rim.
S Imperfections in the tires, including: tread deforma-
Low–speed vibrations, which occur below 64 km/h (40
tions, separations, or bulges from impact damage.
mph), are usually caused by runout. High–speed vibra-
Slight sidewall indentations are normal and will not
tions, which occur above 64 km/h (40 mph), can be caused
affect ride quality.
by either imbalance or runout.
Tire Balancing Runout

Balance is the easiest procedure to perform and should be Runout can be caused by the tire, the wheel, or the way
done first if the vibration occurs at high speeds. Do an off– the wheel is attached to the vehicle. To investigate the pos-
vehicle, two–plane dynamic balance first to correct any im- sibility of wheel runout, refer to the following procedures
balance in the tire and wheel assembly. as well as the wheel runout diagnosis chart in this section:
An on–vehicle finish balance will correct any brake drum, 1. If runout is suspected, measure the on–vehicle free
rotor, or wheel cover imbalance. If balancing does not cor- lateral and free radial runout of the tire and wheel
rect the high–speed vibration, or if the vibration occurs at assembly. Refer to Section 2E, Tires and Wheels.
low speeds, runout is the probable cause. Both the free lateral and the free radial runout
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should be less than 1.5 mm (0.06 inch). If either when measured on the vehicle, the attachment of
measurement exceeds this number, proceed to the tire and wheel assembly to the hub is the prob-
Step 2. able cause of the vibration. Rotate the assembly’s
2. Mount the tire and the wheel on a dynamic balanc- two wheel studs and recheck the runout. Refer to
ing machine and remeasure the free lateral and the Section 2E, Tires and Wheels. Several positions
free radial runout. Record the amount of the free may have to be tried to find the best location for the
lateral and the free radial runout and the location of studs.
the highest measurement. Refer to Section 2E, 6. If the tire and wheel assembly free runout cannot
Tires and Wheels. If the free radial or the free later- be reduced to 1.3 mm (0.05 inch) or less, remove
al runout exceeds 1.3 mm (0.05 inch) at the tire the assembly.
tread, proceed to Step 4.
3. Measure the wheel runout. Refer to Section 2E, 1) Measure the wheel stud runout using a dial indi-
Tires and Wheels. If the wheel exceeds specifica- cator set with a magnetic base.
tions, replace it. 2) Zero the dial indicator set button on one stud.
4. Deflate the tire and match–mount the high radial 3) Gently lift the set button off the stud. Rotate the
runout point of the tire to the low radial runout point flange to position the next stud against the dial
of the wheel. Reinflate the tire and mount it on the indicator set.
dynamic balancing machine. Measure and record 4) Record the runout of all the studs. The dial indi-
the free radial and the free lateral runout and their cator should read zero when it is repositioned on
locations. In many cases, match mounting the tire the first stud that was checked.
on the wheel will bring the tire and wheel assem- 5) If the runout exceeds 0.76 mm (0.03 inch), the
bly’s free runout into an acceptable range of 1.3 hub or the hub and bearing assembly should be
mm (0.05 inch) or less. replaced.
5. If the free runout of the tire and wheel assembly is
1.3 mm (0.05 inch) or less when it was measured Whenever a tire is rotated on the wheel, or whenever a tire
off the vehicle, yet exceeds 1.3 mm (0.05 inch) or wheel is replaced, rebalance the assembly.

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Wheel Runout Diagnosis Chart

1 Road test the vehicle to verify the vibration com- – Go to Step 2 System OK
plaint.
Are the customer’s concerns verified?
2 1. Perform a vibration diagnosis preliminary – Go to Step 3 System OK
check.
2. Repair any of the problems found.
Is the vibration still present? Is the vibration still pres-
ent?
3 Determine at what speed the vibration is present. Go to Step 4 Go to Step 6
Is the vibration over 64 km/h (40 mph)?
4 Perform an off–vehicle dynamic wheel balance. Go to Step 5 System OK
Is the vibration still present?
5 Perform an on–vehicle finish balance. Go to Step 6 System OK
6 Perform a free lateral and a radial on–vehicle runout 1.5 mm Go to Step 4 Go to Step 7
check. (0.06 in.)
Does the runout match the value specified?
7 Perform a free lateral and a free radial off–vehicle 1.3 mm Go to Step 8 Go to Step 12
runout check. (0.05 in.)
8 1. Index the tire and wheel assembly on the hub 0.76 mm Go to Step 9 Go to Step 14
studs. (0.03 in.)
2. Obtain the least amount of runout possible.
9 Perform an off–vehicle dynamic wheel balance. Go to Step 10 System OK
10 Perform an on–vehicle finish balance. Go to Step 11 System OK
11 1. Check for any engine driveline imbalance. – Go to Step 1 –
2. Thoroughly inspect the drive axles and the
constant velocity joints.
3. Repair any problems found.
Are the repairs complete?
12 1. Match–mount the tire on the wheel. 1.5mm Go to Step 9 Go to Step 13
2. Perform a free lateral and a free radial off–ve- (0.06 in.)
hicle runout check.
13 1. Dismount the tire from the wheel of the sus- 0.8 mm Go to Step 15 Go to Step 16
pected assembly. (0.03 in.)
2. Measure the runout of the wheel.
14 Measure the hub flange runout. 0.76 mm Go to Step 9 Go to Step 17
Does the runout match the value specified? (0.03 in.)
15 Replace the tire. Go to Step 1
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16 Replace the wheel. Go to Step 1
17 Replace the hub. Go to Step 1

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PRELIMINARY INSPECTION
Checks Action
Check the tires for proper inflation pressures and normal Inflate the tires to the proper tire pressure. Replace the
tread wear. tires as needed.
Check the wheel bearings for looseness. Tighten the axle nut to the proper specification. Replace
the strut wheel bearing as needed.
Check for loose ball joints and tie rod ends. Tighten the ball joints and the tie rods.
Check the runout of the wheels and the tires. Measure and correct the tire runout.
Check the vehicle trim heights. Correct the trim heights. Make the correction before ad-
justing the toe.
Check for loose rack and pinion mounting. Tighten the mounting brackets for the rack and pinion as-
sembly.
Check for improperly operating struts. Replace the strut assembly.
Check for loose control arms. Tighten the control arm attachment bolts. Replace the con-
trol arm bushings as needed.
FRONT TOE ADJUSTMENT FRONT CAMBER AND CASTER

1. Loosen the right and the left inner and outer tie rod CHECK
pinch bolts.
The front camber and caster are not adjustable. Refer to
2. Turn the right and the left tie rod adjusters to align
”Wheel Alignment Specifications” in this section. Jounce
the toe to 0 degrees – 10 to +10 minutes.
the bumper three times before measuring the camber or
In this adjustment, the right and left tie rods must be equal the caster in order to prevent an incorrect reading. If the
in length. front camber or caster measurements deviate from the
Tighten specifications, locate and replace or repair any damaged,
Tighten the inner and outer tie rod pinch bolts to 22 NSm loose, bent, dented, or worn suspension part. If the prob-
(16 lb–ft). lem is body related, repair the body.
REAR CAMBER CHECK

The rear camber is not adjustable. Refer to ”Wheel Align-
ment Specifications” in this section. If the rear camber
deviates from the specification, locate the cause and cor-
rect it. If damaged, loose, bent, dented, or worn suspen-
sion parts are found, they should be repaired or replaced.
If the problem is body related, repair the body.
REAR TOE CHECK

The rear toe is not adjustable. Refer to ‘ ”Wheel Alignment
Specifications” in this section. If the toe deviates from the
specification, check the rear axle assembly and the wheel
spindle on vehicles without an anti–lock braking system
(ABS) or the rear axle assembly and the hub and bearing
assembly on vehicles with ABS for possible damage.
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GENERAL DESCRIPTION CAMBER

AND SYSTEM OPERATION Camber is the tilting of the top of the tire from the vertical
when viewed from the front of the vehicle. When the tires
tilt outward, the camber is positive. When the tires tilt in-
FOUR WHEEL ALIGNMENT ward, the camber is negative. The camber angle is mea-
The first responsibility of engineering is to design safe sured in degrees from the vertical. Camber influences
steering and suspension systems. Each component must both directional control and tire wear.
be strong enough to withstand and absorb extreme pun- If the vehicle has too much positive camber, the outside
ishment. Both the steering system and the front and the shoulder of the tire will wear. If the vehicle has too much
rear suspensionmust function geometrically with the body negative camber, the inside shoulder of the tire will wear.
mass. Camber is not adjustable.
The steering and the suspension systems require that the
front wheels self–return and that the tire rolling effort and STEERING AXIS INCLINATION
the road friction be held to a negligible force in order to al-
Steering Axis Inclination (SAI) is the tilt at the top of the
low the customer to direct the vehicle with the least effort
steering knuckle from the vertical. Measure the SAI angle
and the most comfort.
from the true vertical to a line through the center of the strut
A complete wheel alignment check should include mea- and the lower ball joint as viewed from the front of the ve-
surements of the rear toe and camber. hicle.
Four–wheel alignment assures that all four wheels will be SAI helps the vehicle track straight down the road and as-
running in precisely the same direction. sists the wheel back into the straight ahead position. SAI
When the vehicle is geometrically aligned, fuel economy on front wheel drive vehicles should be negative.
and tire life are at their peak, and steering and perfor-
mance are maximized. INCLUDED ANGLE
TOE The included angle is the angle measured from the cam-
ber angle to the line through the center of the strut and the
Toe–in is the turning in of the tires, while toe–out is the
lower ball joint as viewed from the front of the vehicle.
turning out of the tires from the geometric centerline or
thrust line. The toe ensures parallel rolling of the wheels. The included angle is calculated in degrees. Most align-
ment racks will not measure the included angle directly. To
The toe serves to offset the small deflections of the wheel
determine the included angle, subtract the negative or add
support system which occur when the vehicle is rolling for-
the positive camber readings to the Steering Axis Inclina-
ward. The specified toe angle is the setting which achieves
tion (SAI).
0 degrees of toe when the vehicle is moving.
Incorrect toe–in or toe–out will cause tire wear and re-
duced fuel economy. As the individual steering and sus-
SCRUB RADIUS
pension components wear from vehicle mileage, addition- The scrub radius is the distance between true vertical and
al toe will be needed to compensate for the wear. the line through the center of the strut and lower ball joint
to the road surface. Scrub radius is built into the design of
Always correct the toe dimension last.
the vehicle. Scrub radius is not adjustable.
CASTER
Caster is the tilting of the uppermost point of the steering
SETBACK
axis either forward or backward from the vertical when The setback is the distance in which one front hub and
viewed from the side of the vehicle. A backward tilt is posi- bearing assembly may be rearward of the other front hub
tive, and a forward tilt is negative. Caster influences direc- and bearing assembly. Setback is primarily caused by a
tional control of the steering but does not affect tire wear. road hazard or vehicle collision.
Weak springs or overloading a vehicle will affect caster.
One wheel with more positive caster will pull toward the TURNING ANGLE
center of the car. This condition will cause the car to move
or lean toward the side with the least amount of positive The turning angle is the angle of each front wheel to the
caster. Caster is measured in degrees and is not adjust- vertical when the vehicle is making a turn.
able.

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SECTION : 2C
FRONT SUSPENSION
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2C–1 STABILIZER SHAFT AND INSULATORS . . . . . 2C–8
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 2C–1 KNUCKLE/STRUT ASSEMBLY . . . . . . . . . . . . . . 2C–9
FASTENER TIGHTENING CONTROL ARM . . . . . . . . . . . . . . . . . . . . . . . . . . 2C–13
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 2C–1
UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C–16
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C–2 BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C–16
SPECIAL TOOLS TABLE . . . . . . . . . . . . . . . . . . . 2C–2 HUB AND BEARING . . . . . . . . . . . . . . . . . . . . . . 2C–16
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C–4 CONTROL ARM BUSHINGS . . . . . . . . . . . . . . . 2C–18
STRUT DAMPENER . . . . . . . . . . . . . . . . . . . . . . . 2C–4 FRONT SPRING/STRUT CARTRIDGE . . . . . . 2C–20
BALL JOINT AND KNUCKLE . . . . . . . . . . . . . . . 2C–4 SUPPORT BEARING . . . . . . . . . . . . . . . . . . . . . 2C–24
EXCESSIVE FRICTION CHECK . . . . . . . . . . . . 2C–5 KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C–25
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 2C–6 GENERAL DESCRIPTION AND SYSTEM
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 2C–6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C–26
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 2C–8 FRONT SUSPENSION (SOHC ENGINE) . . . . 2C–26
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 2C–8 FRONT SUSPENSION DOHC ENGINE) . . . . 2C–26
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Trim Height
Rocker Panel, Front to Ground 195 mm (7.7 in.)
Rocker Panel, Rear to Ground 191 mm (7.5 in.)

Ball Joint–to–Control Arm Nuts 65 48 –
Ball Joint–to–Knuckle/Strut Nut 70 52 –
Control Arm Front Mounting Bolt 140 103 –
Control Arm Rear Mounting Bolts 70 52 –
Drive Axle–to–Hub Caulking Nut (First Torque) 180 133 –
Drive Axle–to–Hub Caulking Nut (Last Torque) 50 + 60³ 37 + 60³ –
Piston Rod Nut 55 41 –
Stabilizer Shaft–to–Body Clamp Bolt 40 30 –
Strut Assembly–to–Body Nuts 35 26 –
Strut Cartridge Closure Nut 200 148 –
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2C – 2IFRONT SUSPENSION
SPECIAL TOOLS
SPECIAL TOOLS TABLE
500–20 J–37105–B–3
Hex Nut Hub Adapter
J–36661–2 KM–158
Forcing Screw Remover/Installer
J–37105–B–1 KM–307–B
Support Bridge Removal Plate
J–37105–B–2 KM–329–A
Bearing Adapter Spring Compressor

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FRONT SUSPENSION 2C – 3
J–42468
KM–507–B
Front Strut Mount
Ball Joint Remover
Nut Wrench
KM–331
KM–508–A
Strut Cartridge
Remover/Installer
Closure Nut Wrench
KM–465–A
Front Spring
Compressor
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DIAGNOSIS
STRUT DAMPENER
A strut dampener is basically a shock absorber. However, on the front inmost vehicles, including this vehicle. Shock
strut dampeners are easier to extend and retract by hand absorbers are used on the rear wheels.
than are shock absorbers. Strut dampeners are used only
Struts Seem Weak
Checks Action
Check the tire pressures. Adjust the tire pressures to the specifications on the tire
placard.
Check the load conditions under which the vehicle is nor- Consult with the owner to confirm the owner’s understand-
mally driven. ing of normal load conditions.
Check the compression and rebound effectiveness of the Quickly push down and then lift up on the corner of the
strut dampener. bumper nearest the strut dampener being tested.
Compare the compression and rebound with those of a
similar vehicle that has an acceptable ride quality.
Replace the strut dampener, if needed.
Struts Are Noisy

Checks Action
Check the mountings for looseness or damage. Tighten the strut dampener. Replace the strut dampener,
if needed.
Check the compression and rebound effectiveness of the Quickly push down and then lift up on the corner of the
strut dampener. bumper nearest the strut dampener being tested.
Compare the compression and rebound with those of a
similar vehicle that has an acceptable ride quality.
Replace the strut dampener, if needed.
Leaks
Checks Action
Check for a slight trace of fluid. The strut dampener is OK.
Check the seal cover on the fully extended strut. Replace the strut dampener.
Check for an excessive amount of fluid on the strut damp- Replace the strut dampener.
ener.
S The ball stud is loose at the knuckle.

BALL JOINT AND KNUCKLE S The ball stud can be twisted in its socket with
finger pressure.
Ball Joint Inspection
1. Raise the front of the vehicle to allow the front sus- Ball Stud Inspection
pension to hang free. Make sure to check the tightness of the ball stud in the
2. Grasp the tire at the top and the bottom. knuckle boss during each inspection of the ball joint. One
3. Move the top of the tire in an in–and–out motion. way to inspect the ball stud for wear is to shake the wheel
4. Look for any horizontal movement of the knuckle and feel for movement of the stud end or the castellated
relative to the control arm. nut at the knuckle boss.
5. Ball joints must be replaced under the following Another way to inspect the ball stud for wear is to check
conditions: the fastener torque at the castellated nut. A loose nut can
S The joint is loose. indicate a stressed stud or a hole in the knuckle boss.
S The ball seal is cut. Worn or damaged ball joints and knuckles must be re-
S The ball stud is disconnected from the knuckle. placed.

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3. Measure the distance from the street level to the

EXCESSIVE FRICTION CHECK center of the bumper.
Use the following procedure to check for excessive friction 4. Push down on the bumper, release slowly, and al-
in the front suspension: low the vehicle to assume its normal trim height.
1. Enlist the help of another technician to lift up on the 5. Measure the distance from the street level to the
front bumper, raising the vehicle as high as pos- center of the bumper.
sible. 6. The difference between the two measurements
2. Slowly release the bumper, allowing the vehicle to should be less than 12.7 mm (0.5 inch). If the differ-
assume its normal trim height. See ”General Speci- ence exceeds this limit, inspect the control arms,
fications” in this section. the struts, and the ball joints for damage or wear.
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COMPONENT LOCATOR
FRONT SUSPENSION

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1. Upper Bearing Dust Cover 26. Lower Control Arm Rear Bushing Mounting Bracket
2. Piston Nut 27. Lower Control Arm Rear Bushing Mounting Bracket
3. Strut Assembly–to–Body Nut Bolt
4. Piston Nut Washer 28. Lower Ball Joint
5. Upper Strut Mount Bearing 29. Front Stabilizer Shaft Link Assembly Bolt
6. Bearing Support Washer 30. Front Stabilizer Shaft Link Grommet Washer
7. Plastic Mount 31. Front Stabilizer Shaft Link Grommet
8. Strut Shield 32. Lower Control Arm Front Mounting Bracket Bolt
9. Upper Spring Insulator Ring 33. Lower Control Arm Front Mounting Bracket Bolt
10. Coil Spring Washer
11. Strut Bumper 34. Lower Control Arm
12. Snap Ring 35. Lower Control Arm Front Bushing
13. Front Wheel Bearing 36. Vehicle Body
14. Front Wheel Hub 37. Lower Control Arm Front Mounting Bracket Nut
15. Rotor Washer
16. Drive Axle–to–Hub Nut Lock Washer 38. Lower Control Arm Front Mounting Bracket Nut
17. Drive Axle–to–Hub Caulking Nut 39. Front Stabilizer Shaft Link Assembly Spacer
18. Detent Screw 40. Front Stabilizer Shaft Insulator
19. Front Brake Caliper 41. Front Stabilizer Shaft Clamp Bolt
20. Brake Shield Attachment Screw 42. Front Stabilizer Shaft Clamp
21. Brake Shield Attachment Screw Washer 43. Front Stabilizer Shaft
22. Brake Shield 44. Front Stabilizer Shaft Link Assembly Nut
23. Lower Control Arm Rear Bushing 45. Strut Cartridge Closure Nut
24. Lower Ball Joint Cotter Pin 46. Strut Cartridge
25. Lower Ball Joint Nut 47. Knuckle and Support Tube
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STABILIZER SHAFT AND

INSULATORS
Removal Procedure
1. Lift and suitably support the vehicle, allowing the

front suspension to hang free.
2. Remove the front wheel. Refer to Section 2E, Tires
and Wheels.
3. Remove the stabilizer shaft–to–body clamp bolts,
the stabilizer shaft clamps, and the insulators from
the vehicle.
4. Disconnect the stabilizer shaft from the lower con-
trol arm by removing the stabilizer shaft link assem-
bly.
1. Install the stabilizer shaft into the vehicle.

2. Install the stabilizer shaft clamp insulators, the sta-
bilizer shaft clamps, and the stabilizer shaft–to–
body clamp bolts. Do not tighten the bolts.

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3. Connect the stabilizer shaft to the lower control arm

with the stabilizer shaft link assembly.
4. Make certain the stabilizer shaft is centered side–

toside.
Tighten
Tighten the stabilizer shaft–to–body clamp bolt to 40
NSm (30 lb–ft).
5. Connect the stabilizer shaft to the control arm with
a new self–locking nut.
6. Tighten the self–locking nut to achieve 34 mm 1.34
inch) between the self–locking nut and the control
arm spacer.
7. Install the wheel. Refer to Section 2E, Tires and
Wheels.
8. Lower the vehicle.
KNUCKLE/STRUT ASSEMBLY
Tools Required
KM–507–B Ball Joint Remover
Removal Procedure
1. Loosen the nuts that attach the top of the strut as-
sembly to the vehicle.
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2. Uncrimp the caulking nut sleeve and remove the

caulking nut and the washer.

4. Place the jackstands under the frame of the ve-
hicle.
5. Lower the vehicle slightly so the weight of the ve-
hicle rests on the jackstands and not on the control
arms.
6. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
7. Disconnect the brake caliper from the knuckle/strut
assembly and support the caliper. Do not hang the
caliper from the hydraulic brake hose. Refer to Sec-
tion 4D, Front Disc Brakes.
8. Disconnect the ABS speed sensor electrical con-
nector, if applicable.
9. Remove the ball joint cotter pin by lifting up on the

rear of the clip and using the two loops on the front
of the clip to pull the clip out.
10. Remove the ball joint–to–knuckle–strut nut.

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Notice : Failure to use the recommended tool for separat-

ing the ball joint from the steering knuckle assembly may
damage the ball joint and seal.
11. Separate the steering knuckle assembly from the
ball joint using the ball joint remover KM–507–B.
12. Remove the outer tie rod from the steering knuckle
assembly. Refer to Section 6C, Power Steering
Gear [Includes Rack & Pinion Gear] or Section 6D,
Manual Steering Gear [Includes Rack & Pinion
Gear].
Notice : Take care to prevent the axle joints from being
overextended. When either end of the shaft is discon-
nected, the joint can become overextended. This overex-
tension can cause the internal components to separate.
This separation can cause joint failure. Use drive axle joint
seal protectors during any service on or near the drive
axles. Failure to use joint seal protectors can damage the
interior joint seal and cause joint failure.
13. Push the drive axle shaft from the front wheel hub.
14. Support the drive axle.
15. Lower the vehicle in order to gain access to the
strut–to–body nuts and the washers.
Notice : Chipping or scratching the spring coating when
handling the front suspension coil spring can cause the
spring to fail.
16. Remove the strut assembly–to–body nuts.
17. Remove the strut assembly from the vehicle.
Notice : Chipping or scratching the spring coating when

handling the front suspension coil spring can cause the
spring to fail.
1. Chipping or scratching the spring coating when
handling the front suspension coil spring can cause
the spring to fail.
Tighten
Tighten the strut assembly–to–body nuts to 35 NSm
26 lb–ft).
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2. Connect the drive axle to the front wheel hub.
3. Connect the outer tie rod to the steering knuckle

assembly. Refer toSection 6C, Power Steering
Gear [Includes Rack & Pinion Gear] or Section 6D,
Manual Steering Gear [Includes Rack & Pinion
Gear].
4. Connect the ball joint to the steering knuckle as-
sembly.
5. Install the ball joint–to–knuckle/strut nut and the ball
joint cotter pin.
Tighten
Tighten the ball joint–to–knuckle/strut nut to 70 NSm
(52 lb–ft).
6. Connect the ABS speed sensor electrical connec-

tor, if applicable.

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7. Connect the brake caliper to the knuckle/strut as-

sembly. Refer to Section 4D, Front Disc Brakes.
Wheels.
9. Install a new drive axle–to–hub caulking nut.
Tighten
Tighten the drive axle–to–hub caulking nut to 180
NSm (133 lb–ft). Loosen the nut and retighten the nut
to 50 NSm (37 lb–ft). Then tighten the nut an additional
60 degrees.
10. Crimp the caulking nut sleeve onto the drive axle
shaft.
CONTROL ARM
Tools Required
KM–507–B Ball Joint Remover
Removal Procedure

2. Place the jackstands under the frame of the ve-
hicle.
3. Lower the vehicle slightly so the weight of the ve-
hicle rests on the jackstands and not on the control
arms.
Wheels.
5. Disconnect the stabilizer shaft from the control arm
by removing the control armlink bolt assembly.Refer
to ”Stabilizer Shaft and Insulators” in this section.
6. Remove the retaining clip and the ball joint–to–
knuckle/strut nut from the ball joint.
7. Disconnect the ball joint from the steering knuckle
using the ball joint remover KM–507–B.
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8. Remove the control arm front mounting bolt.

9. Remove the control arm rear mounting bolts and
the bracket.
10. Remove the control arm from the vehicle.
1. Install the control arm onto the vehicle.

2. Connect the front of the control arm to the body of
the vehicle with the front mounting bolt and the
washer.
3. Apply a thread sealer to the control arm rear
mounting bolts.
4. Connect the rear of the control arm to the body of
the vehicle with the rear mounting bracket and
bolts.
Important : Do not tighten the control arm bolts at this
point.
Notice : Use a new self–locking nut to install the control
arm link bolt assembly. Failure to do so will allow the nor-
mal vibration of the vehicle to loosen the nut and damage
the vehicle.
5. Install the stabilizer shaft link bolt assembly. Refer
to ”Stabilizer Shaft and Insulators” in this section.
6. Connect the ball joint to the steering knuckle.
7. Tighten the ball joint–to–knuckle/strut nut.
Tighten
Tighten the ball joint–to–knuckle/strut nut to 70 NSm
(52 lb–ft).
8. Connect the retaining clip to the ball joint stud.
Wheels.
10. Raise the vehicle.
11. Place the jackstands under the control arms.

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Important : The control arms must support the weight of

the vehicle while the control arm mounting bolts are being
tightened.
13. Tighten the control arm rear mounting bolts.
Tighten
Tighten the control arm rear mounting bolts to 70 NSm
(52 lb–ft).
14. Tighten the control arm front mounting bolt.
Tighten
Tighten the control arm front mounting bolt to 140
NSm (103 lb–ft).
16. Remove the jackstands.
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UNIT REPAIR
BALL JOINT
2. Place the jackstands under the frame of the vehicle
and lower the vehicle slightly so the weight of the
vehicle rests on the jackstands and not on the con-
trol arms.
Wheels.
4. Remove the control arm. Refer to ”Control Arm” in
this section.
5. Drill off the heads of the rivets with a 12 mm
(0.47–inch) drill bit.
6. Punch out the rivets with a drift.
Assembly Procedure
1. Connect the ball joint to the control arm by inserting
the ball joint bolts.
2. Install the nuts to secure the bolts from below the
control arm.
Tighten
Tighten the ball joint–to–control arm nuts to 65 NSm
(48 lb–ft).
3. Install the control arm. Refer to ”Control Arm” in this
section.
HUB AND BEARING

Tools Required
500–20 Hex Nut
J–36661–2 Forcing Screw
J–37105–B–1 Support Bridge
J–37105–B–2 Bearing Adapter
J–37105–B–3 Hub Adapter
1. Remove the drive axle from the front wheel hub.

Refer to ”Knuckle/Strut Assembly” in this section.
2. Remove the inner snap ring.

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3. Remove the wheel hub with the support bridge

J–37105–B–1, the hub adapter J–37105–B–3, the
hex nut 500–20, and the forcing screw J–36661–2.
4. Remove the brake shield. Refer to Section 4D,

Front Disc Brakes.
5. Remove the outer snap ring.
6. Remove the wheel bearing with the support bridge

J–37105–B–1, the bearing adapter J–37105–B–2,
the hex nut 500–20, and the forcing screw
J–36661–2.
7. Clean the bore of the knuckle.
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Assembly Procedure
1. Install the outer snap ring and push the wheel bear-
ing into place with the support bridge
J–37105–B–1, the bearing adapter J–37105–B–2,
the hex nut 500–20, and the forcing screw
J–36661–2.
2. Install the brake shield. Refer to Section 4D, Front

Disc Brakes.
3. Install the inner snap ring and push the wheel hub
into place with the hub adapter J–37105–B–3, the
bearing adapter J–37105–B–2, the hex nut 500–20,
and the forcing screw J–36661–2.
4. Install the drive axle into the front wheel hub. Refer
to ”Knuckle/Strut Assembly” in this section.
CONTROL ARM BUSHINGS

Tools Required
KM–508–A Remover/Installer
KM–158 Remover/Installer
KM–307–B Removal Plate
1. Remove the control arm. Refer to ”Control Arm” in

this section.
2. Press off the rear bushing using a press, the re-
mover/installer KM–158, and the removal plate
KM–307–B.

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3. Press out the front bushing using the remover/in-

staller KM–508–A, and the remover/installer
KM–158.
Assembly Procedure
1. Coat the control arm rear shaft with a multipurpose

lubricant. Refer to Section 0B, General Information.
2. Press the rear bushing onto the shaft. The flat of
the bushing must be on the top side, the same as
the ball joint. Use the remover/installer KM–508–A
to support the control arm.
3. Coat the outside of the front bushing and the inside

of the lower control arm with a multipurpose lubri-
cant. Refer to Section 0B, General Information.
4. Press the new bushing into the control arm from the
back to the front, using the remover/installer
KM–508–A.
5. Center the bushing.
6. Install the control arm. Refer to ”Control Arm” in this
section.
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FRONT SPRING/STRUT CARTRIDGE

Tools Required
J–42468 Front Strut Mount Nut Wrench
KM–329–A Spring Compressor
KM–331 Strut Cartridge Closure Nut Wrench
KM–465–A Front Spring Compressor
1. Mount the front spring compressor KM–465–A and

the spring compressor KM–329–A on amounting
trestle, a workbench, or any other suitable surface.

Wheels.
4. Remove the strut assembly. Refer to ”Knuckle/Strut
Assembly” in this section.
5. Fasten the strut assembly to the spring compres-
sor. Make sure the hooks are seated on the strut
spring properly.
6. Compress the front spring with the front spring
compressor KM–465–A and the spring compressor
KM–329–A.
7. Remove the dust cover from the support bearing

assembly.
8. Use an open end wrench to hold the threaded pis-
ton rod while removing the piston rod nut with the
front strutmount nut wrench J–42468. Remove the
washer.

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9. Remove the support bearing, the washer, the plas-

tic mount, the shield, and the upper insulator.
10. Release the spring compressor.

11. Remove the spring and the bumper.
12. Remove the strut cartridge closure nut with the

strut cartridge closure nut wrench KM–331. This nut
is under high torque.
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13. Remove the strut cartridge.

14. Clean the threaded area of the strut opening.
Assembly Procedure
1. Install the strut cartridge and secure it with the strut

cartridge closure nut using the strut cartridge clo-
sure nut wrench KM–331.
Important : Use a new strut cartridge closure nut. The
new nut is coated in wax. Do not wipe off the wax. It is both
a lubricant and a corrosion preventative.
Tighten
Tighten the strut cartridge closure nut to 200 NSm
(148 lb–ft).
2. Lubricate the upper strut mount bearing withmulti-

purpose grease. Refer to Section 0B, General Infor-
mation.
3. Install the bumper and the spring.

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4. Compress the front spring with the front spring

compressor KM–465–A and the spring compressor
KM–329–A.
5. Install the upper insulator, the shield, the plastic

mount, the washer, and the support bearing.
6. Tighten the piston rod nut using the front strut

mount nut wrench J–42468.
Tighten
Tighten the piston rod nut to 55 NSm (41 lb–ft).
7. Remove the strut assembly from the spring com-
pressor and install the strut assembly onto the ve-
hicle. Refer to ”Knuckle/Strut Assembly” in this sec-
tion.
Wheels.
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SUPPORT BEARING
Tools Required
J–42468 Front Strut Mount Nut Wrench
Wheels.
3. Remove the strut assembly. Refer to ”Knuckle/Strut
Assembly” in this section.
4. Compress the spring and remove the support bear-
ing. Refer to ”Front Spring/Strut Cartridge” in this
section.
Important : The support bearing is only supplied as an as-
sembly with the ball bearing. This assembly cannot be fur-
ther disassembled.
Assembly Procedure
1. Lubricate the support bearing assembly with a mul-

tipurpose grease. Refer toSection 0B, General In-
formation.
2. Push the support bearing assembly onto the piston
rod. Make sure that the metal washer with the
raised edge is below the bearing and that the thrust
washer is on top of the bearing.
3. Use the lug on the plastic front spring mount as an

installation guide. When looking in the direction of
travel, the lug should point forward on the spring
strut for the left side of the vehicle, and backward
for the right side of the vehicle.

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4. Tighten the piston rod nut using the front strut

mount nut wrench J–42468.
Tighten
Tighten the piston rod nut to 55 NSm (41 lb–ft).
5. Remove the strut assembly from the spring com-
pressor. Refer to ”Knuckle/Strut Assembly/” in this
section.
6. Install the strut assembly onto the vehicle. Refer to
”Knuckle/Strut Assembly/” in this section.
Wheels.
KNUCKLE
2. Remove the knuckle/strut assembly from the ve-
hicle. Refer to ”Knuckle/Strut Assembly/” in this
section.
3. Remove the wheel hub and the wheel bearing. Re-
fer to in this section.”Hub and Bearing” in this sec-
tion.
4. Remove the spring and the strut cartridge. Refer to
”Front Spring/Strut Cartridge” in this section.
Assembly Procedure
1. Install the strut cartridge and the spring. Refer
to”Front Spring/Strut Cartridge” in this section.
2. Install the wheel bearing and hub. Refer to ”Hub
and Bearing” in this section.
3. Install the knuckle/strut assembly. Refer to
”Knuckle/Strut Assembly” in this section.
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GENERAL DESCRIPTION FRONT SUSPENSION DOHC

ENGINE)
AND SYSTEM OPERATION The front suspension for this vehicle is a combination
knuckle/strut and spring design.
FRONT SUSPENSION (SOHC The control arms pivot from the body. The lower control
ENGINE) arm pivots use rubber bushings. The upper end of the strut
The front suspension for this vehicle is a combination is isolated by a rubber mount and contains a bearing to al-
knuckle/strut and spring design. low the wheel to turn.
The control arms pivot from the body. The lower control The lower end of the steering knuckle pivots on a ball joint
arm pivots use rubber bushings. The upper end of the strut bolted to the control arm. The ball joint is fastened to the
is isolated by a rubber mount and contains a bearing to al- steering knuckle with a nut, and to the lower control arm
low the wheel to turn. with rivets.
The lower end of the steering knuckle pivots on a ball joint When servicing the control arm–to–body attachment and
bolted to the control arm. The ball joint is fastened to the the stabilizer shaft–to–body insulators, make sure that the
steering knuckle with a nut, and to the lower control arm attaching bolts are loose until the control arms are moved
with rivets. to the trim height, which is curb height. Trim height is the
normal position to which the control arms move when the
When servicing the control arm–to–body attachment and vehicle is sitting on the ground. Refer to ”General Specifi-
the stabilizer shaft–to–body insulators, make sure the at- cations” in this section.
taching bolts are loose until the control arms are moved to
the trim height, which is curb height. Trim height is the nor- The springs in Front Suspension (DOHC engine) are
mal position to which the control arms move when the ve- stronger and the shocks are heavier than are the springs
hicle is sitting on the ground. Refer to ”General Specifica- and shocks in Front Suspension (SOHC engine).
tions” in this section.

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SECTION : 2D
REAR SUSPENSION
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2D–1 SPRINGS AND INSULATORS . . . . . . . . . . . . . . 2D–5
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 2D–1 REAR AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . 2D–6
FASTENER TIGHTENING HUB AND BEARING ASSEMBLY
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 2D–1 WITHOUT ABS . . . . . . . . . . . . . . . . . . . . . . . . . . 2D–8
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D–2 HUB AND BEARING ASSEMBLY
SPECIAL TOOLS TABLE . . . . . . . . . . . . . . . . . . . 2D–2 WITH ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D–11
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D–2 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D–13

EXCESSIVE FRICTION TEST . . . . . . . . . . . . . . 2D–2 CONTROL ARM BUSHINGS . . . . . . . . . . . . . . . 2D–13
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 2D–3 REAR AXLE WITHOUT ABS . . . . . . . . . . . . . . . 2D–14

ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 2D–3 REAR AXLE WITH ABS . . . . . . . . . . . . . . . . . . . 2D–15
WHEEL BEARING ADJUSTMENT . . . . . . . . . . . 2D–3 GENERAL DESCRIPTION AND SYSTEM
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . 2D–3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D–16
STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D–4 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . 2D–16
SPECIFICATIONS
Shock Absorber Stud Thread Above Upper Mounting Nut 9.0 mm (0.36 in.)
Lubrication Wheel Bearing Lubricant GM P/N 1051344

Brake Anchor Plate–to–Rear Axle Arm Bolts 28 21 –
Rear Axle–to–Body Bracket Nuts 105 78 –
Shock Absorber–to–Axle Bolt 20 15 –
Stabilizer Shaft–at–Axle Nuts 80 59 –
Wheel Bearing Spindle Nut 25 – 180³ + 2 18 – 180³+ 1.5 –
Wheel Hub and Bearing Assembly Nuts 40 + 60³+ 15³ 30 + 60³+ 15³ –
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2D – 2IREAR SUSPENSION
SPECIAL TOOLS
SPECIAL TOOLS TABLE
J–29376–A, Rear Control
Arm Bushing Service
Set. Includes:
S J–29376–6A Rear
Control Arm Bushing
KM–266–A Remover/Installer
Remover S J–29376–7 Rear Con-
trol Arm Bushing Plate
S J–29376–A Rear Con-
trol Arm Bushing
Housing
J–21474–18 J–36791
Nut Installer
J–21474–19
Puller Bolt/Thrust Washer
DIAGNOSIS
2. Measure the distance from the floor to the center of
the bumper.
EXCESSIVE FRICTION TEST 3. Push down on the bumper, release slowly, and al-
Check excessive friction in the rear suspension as follows: low the car to assume normal trim height.
4. Measure the distance from the floor to the center of
1. With the aid of a helper, lift up on the rear bumper the bumper.
and raise the vehicle as high as possible. Slowly The difference between the two measurements should be
release the bumper and allow the car to assume less than 12.7 mm (0.50 inch). If the difference exceeds
normal trim height. this limit, inspect the control arms for damage or wear.

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REAR SUSPENSION 2D – 3

WHEEL BEARING ADJUSTMENT
Adjustment Procedure
Notice : The wheel bearings can only be adjusted on cars

without the anti–lock braking system.
1. Remove the dust cap from the hub and the cotter
pin from the spindle.
Tighten
Tighten the wheel bearing spindle nut to 25 NSm (18
lb–ft) while turning the wheel assembly forward by
hand to fully seat the bearings. This will remove any
grease or burrs which could cause excessive wheel
bearing play. Loosen the wheel bearing spindle nut
180 degrees. Tighten the wheel bearing spindle nut to
2 NSm (18 lb–in).
2. Install the new cotter pin and bend the ends.
3. Measure the end play. There will be from 0.03 to
0.13mm (0.001 to 0.005 inch) end play when prop-
erly adjusted.
4. Install the dust cap on the hub.
SHOCK ABSORBER
Removal Procedure
Notice : Remove only one shock at a time when both

shocks are being replaced. Suspending the rear axle at full
length can result in damage to brake lines and hoses.
1. Open the trunk and remove the section of the trim
cover covering the upper mount nut.
2. Counterhold the threaded shock absorber shaft and
remove the upper mounting nut.
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Important : When lifting the vehicle with a body hoist, it

will be necessary to support the rear axle with adjustable
jack stands.
3. Raise the vehicle and support the rear axle assem-
bly.
4. Remove the lower shock absorber–to–axle nut and
the bolt. Remove the shock.
Important : It will be necessary to bring the axle assembly
to trim height prior to tightening the shock absorber attach-
ment bolts.
1. Insert the lower shock absorber–to–axle bolt
through the shock absorber lower attachment
bracket and into the axle. Loosely attach the nut.
2. Lower the vehicle enough to guide the upper shock
stud through the body opening and loosely install
the attaching nut.
Tighten
Tighten the lower shock absorber–to–axle bolt to 20
NSm (15 lb–ft).
3. Remove the axle support, lower the vehicle all the
way, and tighten the upper nut until 9.0 mm (0.36
inch) of thread is visible.
4. Replace the trim cover.
STABILIZER
Removal Procedure
2. Remove the rear wheel. Refer to Section 2E, Tires
and Wheels.
3. Remove the nut, the washer, and the bolt at both
sides of the axle.
4. Remove the insulator and the stabilizer shaft.
5. Pull the stabilizer toward the side of the car without
the wheel.

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1. Install the stabilizer shaft inside the axle.
2. Install the bolts with the washers through the con-
trol arms of the axle and the stabilizer shaft. Attach
the nuts onto the bolts.
Tighten
Tighten the stabilizer shaft–at–axle nuts to 80 NSm
(59 lb–ft).
3. Coat the insulators with lubricant and insert them
into the rear axle.
4. Replace the rear wheel. Refer to Section 2E, Tires
and Wheels.
SPRINGS AND INSULATORS

CAUTION : When removing the rear springs, do not
use a twin–post type hoist. The tendency of the rear
axle assembly to swing when certain fasteners are re-
moved may cause it to slip from the hoist. This may
result in personal injury. Perform the operation on the
floor if necessary.
Removal Procedure
1. Raise and suitably support the vehicle. Use a frame
contact hoist if possible and support the rear control
arms with jack stands. If it becomes necessary to
lift the vehicle with a twin–post hoist, lift the body
and support the control arms with jack stands.
2. Remove the wheel. Refer toSection 2E, Tires and
Wheels.
3. Remove the right and the left shock absorber bolts.
Refer to ”Shock Absorber” in this section.
4. Lower the rear axle and remove the springs and the
top insulator.
Important : Prior to installing the springs, it will be neces-

sary to install the upper insulators to the body with adhe-
sive to keep them in position while raising the axle assem-
bly and the springs.
1. Install the upper insulator and seat the lower bump-
er.
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2. Install the springs and raise the axle.

3. Install the shock absorbers. Refer to”Shock Absorb-
er” in this section.
Important : It will be necessary to bring the axle assembly
to trim height prior to tightening the shock absorber attach-
ment bolts.
Wheels.
5. Remove the jack stands and lower the vehicle.
REAR AXLE ASSEMBLY

Removal Procedure

2. Remove the rear wheels. Refer to Section 2E, Tires
and Wheels.
3. Disconnect the parking brake. Refer to SectIon 4G,
Parking Brake.
4. Disconnect the ABS sensor line.
5. Disconnect the brake pipes from the brake hoses at

the rear axle brackets by removing the cap screws
and the retaining clip. Cap or tape the brake hose
openings to prevent entry of foreign matter. Unclip
the brake hose from the rear axle brackets. Refer
to Section 4E, Rear Drum Brakes.
6. Place support jacks under the arms of the rear axle
and raise the rear axle arms slightly. Remove the
shock absorbers. Refer to ”Shock Absorbers” in this
section.
7. Remove the shock absorbers. Refer to Shock Ab-
sorbers" in this section.
8. Lower the support jacks and remove the rear
springs. Refer to Springs and Insulators" in this
section.”Springs and Insulators” in this section.
9. Remove the rear axle support bolts and nuts from
the underbody. Pry the rear axle slightly with a
screwdriver, if required.
10. Remove the rear axle.

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1. Raise the rear axle and loosely fasten it to the ve-

hicle underbody mountings with the rear axle–to–
body bracket nuts and bolts.
2. Install the rear springs and insulators. Refer to
”Springs and Insulators” in this section.
3. Raise the rear axle arm with the support jacks. At-
tach the shock absorber to the axle with the lower
attachment bolt. Refer to”Shock Absorbers” in this
section.
4. Connect the brake pressure hoses into the bracket
on the rear axle. Mount the retaining clips. Connect
the brake pipes to the brake hoses. Bleed the
brakes. Refer toSection 4E, Rear Drum Brakes.
5. Install the parking brake. Refer toSectIon 4G, Park-
ing Brake.
6. Lower the vehicle slightly and install the rear

wheels. Refer to Section 2E, Tires and Wheels.
7. Adjust the wheel bearing (if applicable). Refer to
”Wheel Bearing Adjustment” in this section.
8. At curb height, tighten the rear axle–to–body brack-
et nuts
Tighten
Tighten the rear axle–to–body bracket nuts to 105
NSm (78 lb–ft).
9. Adjust the rear wheel brakes. Bleed the brake sys-
tem and check for leaks. Refer to Section 4E, Rear
Drum Brakes.
10. Connect the ABS sensor line.

11. Adjust the parking brake. Refer to SectIon 4G,
Parking Brake.
12. Lower the vehicle completely.nuts
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HUB AND BEARING ASSEMBLY

WITHOUT ABS
Tools Required
J–36791 Installer
KM–266–A Installer
Removal Procedure

Wheels.
3. Loosen the parking brake cable. Refer to SectIon
4G, Parking Brake.
4. Remove the dust cap, the cotter pin, the spindle nut
and the lock washer.
5. Remove the wheel hub and the outer tapered roller

bearing.
6. Pry the seal ring from the inside of the wheel hub
with a screwdriver.

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7. Remove the inner tapered roller bearing from the

wheel hub.
8. Remove the races of the inner and the outer bear-

ings from the wheel hub using a drift.
9. Clean the spindle and check it for damage.
1. Press the outer race of the outer bearing into the

wheel hub using installers J–36791 and KM–266–A.
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2. Press the outer race of the inner bearing into the

wheel hub using installers J–36791 and KM–266–A.
3. Install the inner tapered roller bearing.
4. Coat or fill all the hollow spaces of both wheel bear-

ings, the ring seal lip, and the wheel hub with anti-
friction grease. Press the seal into the hub.

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5. Install the hub and bearing assembly onto the rear

axle spindle.
6. Install the lock washer and spindle nut. Hand tight-

en the spindle nut.
7. Install the brake drum detent screw. Refer to Sec-
tion 4E, Rear Drum Brakes.
8. Mount the rear wheel. Refer to Section 2E, Tires
and Wheels.
9. Adjust the wheel bearing. Refer to ”Wheel Bearing
Adjustment” in this section.
10. Adjust the parking brake. Refer to Section 4G,
Parking Brake.
11. Install the dust cap.
HUB AND BEARING ASSEMBLY

WITH ABS
Removal Procedure

Wheels.
Notice : Do not hammer on the brake drum. Damage to
the bearing could result.
3. Remove the brake drum and the detent screw. Re-
fer to Section 4E, Rear Drum Brakes.
4. Loosen the parking brake cable. Refer to Section
4G, Parking Brake.
5. Disconnect the ABS sensor line.
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6. Remove the wheel hub and bearing assembly by

removing the bolts and the nuts.
Notice : The wheel hub and bearing assembly is not to be

serviced. The assembly must be replaced.
1. Install the wheel hub and bearing assembly with the
bolts and the nuts.
Tighten
Tighten the wheel hub and bearing assembly nuts to
40 NSm (30 lb–ft). Turn the nut an additional 60 de-
grees followed by an additional 15 degrees.
2. Connect the ABS sensor line.

3. Install the brake drum and tighten the brake detent
screw. Refer to Section 4E, Rear Drum Brakes.
4. Mount the rear wheel. Refer to Section 2E, Tires
and Wheels.
Parking Brake.

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UNIT REPAIR
CONTROL ARM BUSHINGS
Tools Required
KM–266–A Remover
J–21474–18 Nut
J–21474–19 Puller Bolt/Thrust Washer
J–29376–A Control Arm Bushing Housing
J–29376–6A Rear Control Arm Bushing Remover/Install-
er
J–29376–7 Rear Control Arm Bushing Plate

2. Remove the rear axle and secure it to a workbench.
Refer to ”Rear Axle Assembly” in this section
Notice : To facilitate removal of damping bushings, warm
the rear axle in the area of the bushings to approximately
50 to 75?C (122 to 158?F) using an industrial hot air dryer.
3. Place the control arm bushing housing J–29376–A
on the rear axle. Slide the puller bolt/thrust washer
J–21474–19 through the control arm bushing re-
mover/ installer J–29376–6A, the rear control arm
bushing, the control arm bushing plate J–29376–7
and into the nut J–21474–18.
4. Partially remove the rear axle bushing by turning
the nut J–21474–18 and counterholding the puller
bolt J–21474–19.
5. Remove the rear axle bushing completely by strik-

ing the control arm bushing remover/installer
J–29376–6A with the remover KM–266–A.
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Assembly Procedure
1. Place the control arm bushing housing J–29376–A

on the rear axle. Slide the puller bolt J–21474–19
through the thrust washer J–1474–19, the control
arm bushing plate J–29376–7, the rear control arm
bushing, the control arm bushing remover/installer
J–29376–6A and into the nut J–21474–18.
2. Install the rear axle bushing by turning the nut
J–21474–18 and counterholding the puller bolt
J–21474–19.
3. Be sure the bushing angle is 40 to 50 degrees to

the axis of the rear axle.
4. Install the rear axle. Refer to ”Rear Axle Assembly”
in this section
REAR AXLE WITHOUT ABS

1. Remove the rear axle. Refer to ”Rear Axle Assem-
bly” in this section.
2. Remove the hub and bearing assembly. Remove
the spindle from the rear axle. Refer to ”Hub and
Bearing Assembly Without ABS” in this section.
3. Remove the rear brake assembly. Refer to Section
4E, Rear Drum Brakes.
4. Remove the stabilizer shaft. Refer to ”Stabilizer” in
this section.
5. Remove the rear control arm bushings. Refer
to”Control Arm Bushings” in this section.
Assembly Procedure
1. Install the rear control arm bushings. Refer to”Con-
trol Arm Bushings” in this section.
2. Install the stabilizer shaft. Refer to”Stabilizer” in this
section.

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3. Install the rear brake assembly. Refer to Section 3. Remove the rear brake assembly. Refer to Section
4E, Rear Drum Brakes. 4E, Rear Drum Brakes.
4. Thinly coat the wheel spindle with antifriction bear- 4. Remove the stabilizer shaft. Refer to ”Stabilizer” in
ing grease in the area of the brake anchor plate. this section.
Install the spindle and the hub and bearing assem- 5. Remove the rear control arm bushings. Refer
bly. Refer to ”Hub and Bearing Assembly Without to”Control Arm Bushings” in this section.
ABS” in this section.
5. Install the rear axle. Refer to”Rear Axle Assembly”
in this section.
Assembly Procedure
6. Adjust the wheel bearing. Refer to ”Wheel Bearing 1. Install the rear control arm bushings. Refer to ”Con-
Adjustment” in this section. trol Arm Bushings” in this section.
2. Insert the stabilizer shaft into new rear axle and
REAR AXLE WITH ABS screw the shaft into place. Refer to ”Stabilizer” in
this section.
Disassembly Procedure 3. Install the rear brake assembly. Refer to Section
1. Remove the rear axle. Refer to”Rear Axle Assem- 4E, Rear Drum Brakes.
bly” in this section. 4. Install the hub and bearing assembly. Refer to”Hub
2. Remove the hub and bearing assembly. Refer and Bearing Assembly Without ABS” in this section.
to”Hub and Bearing Assembly Without ABS” in this 5. Install the rear axle. Refer to ”Rear Axle Assembly
section. with ABS” in this section.
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front of each of the control arms. The brackets are integral

GENERAL DESCRIPTION with the underbody side rails. The axle structure maintains
the relationship of the wheels to the body. A serviceable
AND SYSTEM OPERATION stabilizer shaft, incorporated with the axle beam, attaches
to each of the control arms.
REAR SUSPENSION Each coil spring is retained between a seat in the under-
General Description body and a seat welded to the top of the rear axle control
arm. The coil spring lower end rests on a compression
The rear suspension consists of an axle with trailing arms
bumper in the welded bracket on top of the rear axle, while
and a twisting cross beam, two coil springs, two shock ab-
a rubber insulator is used to isolate the coil spring upper
sorbers, two upper spring insulators, and two spring com-
end from the vehicle underbody seat.
pression bumper. The axle support assembly attaches to
the underbody through a rubber bushing located at the

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SECTION : 2E
TIRES AND WHEELS
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2E–1 OFF–VEHICLE BALANCING . . . . . . . . . . . . . . . . 2E–5
TIRE SIZE AND PRESSURE SPECIFICATIONS 2E– CORRECTING NON–UNIFORM TIRES . . . . . . 2E–5
1 TIRE AND WHEEL MATCH–MOUNTING . . . . . 2E–6
INFLATION PRESSURE CONVERSION TIRE MOUNTING AND DISMOUNTING . . . . . . 2E–6
PECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 2E–2
FASTENER TIGHTENING SPECIFICATIONS . 2E–2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E–7
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E–2 TIRE AND WHEEL BALANCING . . . . . . . . . . . . 2E–7
WHEEL RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . 2E–2 TIRE CHAIN USAGE . . . . . . . . . . . . . . . . . . . . . . 2E–8
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 2E–3 REPLACEMENT TIRES . . . . . . . . . . . . . . . . . . . . 2E–8
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 2E–3 ALL SEASON TIRES . . . . . . . . . . . . . . . . . . . . . . 2E–8
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E–3 PASSENGER METRIC SIZED TIRES . . . . . . . . 2E–9
ON–VEHICLE BALANCING . . . . . . . . . . . . . . . . . 2E–4 TIRE LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E–9
UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E–4 SPARE TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E–9
ALUMINUM WHEEL POROSITY . . . . . . . . . . . . 2E–4 WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2E–9
ALUMINUM WHEEL REFINISHING . . . . . . . . . . 2E–5 INFLATION OF TIRES . . . . . . . . . . . . . . . . . . . . . 2E–9
SPECIFICATIONS
TIRE SIZE AND PRESSURE SPECIFICATIONS
Inflation Pressure at Full Load
Engine Tires Wheel Front Rear
kPa psi kPa psi
1.5 SOHC 175/70R13 5Jx13 220 32 220 32
185/60R14 5.5Jx14 (steel) 220 32 220 32
185/60R14 5.5Jx14 (Alu- 220 32 220 32
minum)
1.6 DOHC 185/60R14 5.5Jx14 (Steel) 220 32 220 32
185/60R14 5.5Jx14 (Alu- 220 32 220 32
minum)
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2E – 2ITIRES AND WHEELS
INFLATION PRESSURE CONVERSION PECIFICATIONS

kPa kPa kPa psi kPa psi
140 20 185 27 235 34
145 21 190 28 240 35
155 22 200 29 250 36
160 23 205 30 275 40
165 24 215 31 310 45
170 25 220 32 345 50
180 26 230 33 380 55

Wheel Bolt (Aluminum Wheel) 120 88 –
Wheel Bolt (Steel Wheel) 120 88 –
S Free radial runout: 1.5 mm (0.06 inch)
DIAGNOSIS S Free lateral runout: 1.5 mm (0.06 inch)
WHEEL RUNOUT
Measure wheel runout with an accurate dial indicator.
Measurements may be taken with the wheels either on or
off the vehicle, using an accurate mounting surface such
as a wheel balancer. Measurements may be taken with or
without the tire mounted on the wheel.
Measure radial runout and lateral runout on both the in-
board and the outboard rim flanges. With the dial indicator
firmly seated next to the wheel and tire assembly, slowly
rotate the wheel one revolution and record the indicator
reading. If any measurement exceeds the following speci-
fications and there is a vibration that wheel balancing will
not correct, replace the wheel. Disregard any indicator
readings due to welds, paint runs, or scratches.
Steel Wheels
S Radial runout: 0.8 mm (0.03 inch)
S Lateral runout: 1.0 mm (0.04 inch)
Aluminum Wheels
S Radial runout: 0.8 mm (0.03 inch)
S Lateral runout: 0.8 mm (0.03 inch)
Measure free radial runout on the center of the tire tread.
The tread can be taped to present a smooth surface. Mea-
sure free lateral runout on the outboard side of the tire
nearest to the tread.
Steel and Aluminum Wheels

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TIRES AND WHEELS 2E – 3

WHEEL
Removal Procedure
1. Loosen the wheel bolts.
3. Remove the wheel bolts.
Notice : Never use heat to loosen a tight wheel. It can
shorten the life of the wheel, the wheel nuts and the wheel
bearings. Excessive force, such as hammering the wheel
or tire, can also cause damage and is not recommended.
Slight tapping of the wheel sidewall with one’s hand or with
a rubber mallet is acceptable.
4. Remove the wheel.
Difficulty in removing the wheels from the vehicle can be
due to foreign material or to a tight fit between the wheel
centerhole and the hub or the rotor. These wheels can be
removed by
1. Retightening the wheel bolts on the affected wheel
and then loosening the wheel bolts by two turns.
2. Lowering the vehicle and rocking it from side to side
as hard as possible, using one or more person’s
body weight to loosen the wheel.
3. Raising the vehicle and removing the wheel.
CAUTION : Do not allow the penetrating oil to get on
the vertical surfaces between the wheel and the drum
(or rotor) because penetrating oil in this area could
cause the wheel to work loose as the vehicle is driven,
resulting in loss of control and an injury accident.
Penetrating oil is not effective in removing tight wheels. If
it is used, however, apply it sparingly and only to the
wheel’s centerhole area.
Notice : Before installing the wheels, remove any buildup
of corrosion on the wheel mounting surface and the brake
drum or the rotor mounting surface by scraping and brush-
ing them with a wire brush. Installing the wheels without
good metal–to–metal contact at the mounting surfaces
can cause the wheel nuts to loosen, which can later allow
a wheel to come off while the vehicle is moving. Wheel
bolts must be tightened in sequence and to the proper
torque to avoid bending the wheel, the brake drum or the
rotor.
1. Mount the wheel.
2. Install the wheel bolts in the sequence shown. Do
not tighten the wheel bolts.
Tighten
Tighten the wheel bolts to 120 NSm (88 lb–ft).
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ON–VEHICLE BALANCING
On–vehicle balancing will help correct vibrations due to
brake drum, rotor, and wheel cover imbalances.
Notice : Do not allow the front suspension to hang free.
When the drive axle is run at an extreme angle, extra vibra-
tions can occur, as well as damage to seals and joints.
1. During on–vehicle balancing, do not remove the
balance weights from the off–vehicle dynamic bal-
ance.
2. If more than 1 ounce of additional weight is re-
quired, split the weight between the inner and the
outer rim flanges.
CAUTION : Do not spin the drive wheels faster than
55km/h (35 mph) as indicated by the speedometer.
This limit is necessary because the speedometer indi-
cates only one–half of the actual wheel speed when
one drive wheel is spinning and the other drive wheel
is stopped. Personal injury and damage may result
from high–speed spinning.
3. Spin the driven tire and wheel assemblies using the
engine.
UNIT REPAIR
ALUMINUM WHEEL POROSITY
Wheel repairs that use welding, heating or peening are not
approved.
2. Remove the tire and wheel assembly. Refer to
”Wheel” in this section.
CAUTION : To avoid serious injury, do not stand over
the tire when inflating, because the bead may break
when it snaps over the safety hump. Do not exceed
275 kPa (40 psi) of air pressure in any tire if the beads
are not seated. If 275 kPa (40 psi) of air pressure will
not seat the beads, deflate the tire. Relubricate the
beads. Reinflate the tire. Overinflation may cause the
bead to break and cause serious injury.
3. Locate leaking areas by inflating the tire to 345 kPa
(50 psi) and dipping the tire and wheel assembly
into a water bath.
4. Mark the leak areas and remove the tire from the
wheel.
5. Scuff the inside wheel surface at the leak area with
80–grit sandpaper. Clean the leak area with a gen-
eral–purpose cleaner.
6. Apply a 3.3 mm (0.13 inch) thick layer of adhesive/
sealant to the leak area. Allow it to dry for 12 hours.
7. Install the tire on the wheel. Inflate the tire to 345
kPa (50 psi) and check for leaks as in step 3.
8. Adjust the tire pressure to meet specifications. Re-
fer to ”Tire Size and Pressure Specifications” in this
section.
9. Balance the tire and wheel assembly. Refer to”Tire
and Wheel Balancing” in this section.
10. Install the tire and wheel assembly. Refer to
”Wheel” in this section.

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11. Lower the vehicle. 2. Remove the stripper according to manufacturer’s

recommendations.
ALUMINUM WHEEL REFINISHING CAUTION : To avoid serious personal injury, do not
A protective clear or color coating is applied to the surface use engine power to rotate the wheel while sanding.
of the original equipment cast aluminum wheels. Surface 3. Sand the wheel with 240–grit sandpaper by rotating
degradation can develop if this clear coating is damaged the wheel on a slow–spinning brake lathe or by
or removed. This can happen at some automatic car wash mounting the wheel on the car and spinning it by
facilities that use silicone carbide–tipped tire brushes to hand. Sanding restores the machined appearance
clean white walls and tires. Once the protective coating is and promotes adhesion.
damaged, exposure to caustic cleaners or road salt After repairing the aluminum or clear coat damage, the
causes further surface degradation. The following proce- wheels must be recoated.
dure details how to strip, clean and recoat aluminum
wheels.
Recoating Procedure
CAUTION : To avoid serious personal injury when ap-
CAUTION : Follow the manufacturer’s recommenda- plying any two–part component paint system, follow
tions and cautions when using these materials. the specific precautions provided by the paint
Required materials: manufacturer. Failure to follow these precautions
may cause lung irritation and an allergic respiratory
Amchem Alumi Prep No. 23, stock No. DX533 or equiva- reaction.
lent cleaning and conditioning chemical for aluminum.
1. Clean the surface.
Amchem Alodine No. 101, stock No. DX50T or equivalent 2. Soak the wheel with Amchem Alumi Prep No. 33 or
coating chemical for aluminum. equivalent for 1 to 3 minutes. Rinse the wheel with
water and blow it dry.
Ditzler Delclear Acrylic Urethane Clear, Stock No.
3. Soak the wheel with Amchem Alodine No. 1001 or
DAU–75 or equivalent.
equivalent for 1 to 3 minutes. Rinse the wheel with
Ditzler Delthane Ultra–Urethane Additive, Stock DXR–80 water and blow it dry.
or equivalent. 4. Finish with Ditzler Delclear Urethane and Ditzler
Before repairing the aluminum damage or the clear coat Ultra– Urethane Additive or equivalent, using three
coats.
damage, prepare the wheels and the tires.
1st coat – spray on a light mist coat; let dry.
1. Remove the wheel from the vehicle.
2nd coat – spray or paint on a light coat; let dry.
2. Mark the location of the outboard weights and re-
3rd coat – spray or paint on a heavy double wet
move them.
coat; let dry.
3. Wash the wheel inside and out with a water–based,
all–purpose cleaner. Remove the grease and oil 5. Let the urethane dry for 24 hours or flash for 30
with a solvent cleaner. minutes and force dry at 60³C (140³F) for 30 min-
4. Mask the tire prior to painting. utes. Allow the urethane to cool for 5 minutes be-
5. Using a 400–grit wet or dry sandpaper, sand over fore mounting the wheel on the vehicle.
the painted areas that will not require recoloring. OFF–VEHICLE BALANCING
Sanding will promote the adhesion of the clear coat.
Perform wheel balancing with an electronic off–vehicle ba-
Aluminum Damage on Wheel Surface lancer. The balancer is easy to use and gives both a static
1. Mount the wheel on a brake lathe and spin the as- and a dynamic balance. Unlike on–vehicle balancing, the
sembly slowly. off–vehicle balancer does not correct for drum or rotor im-
2. Sand the wheel with a backing block or pad. Hold balance. This drawback is overcome by its accuracy (usu-
the backing block or pad flat to the surface of the ally to within 1/8 ounce). Secure the wheel on the balancer
wheel and sand slowly back and forth from the cen- with a cone through the back side of the centerhole, not
ter to the outer edge of the tire to remove the dam- through the wheel bolt holes.
age. Use the following sandpaper grits in the order CORRECTING NON–UNIFORM TIRES
listed:
There are two ways to correct properly balanced tires
1) 80 grit. which still vibrate. One method uses an automatic ma-
2) 150 grit. chine which loads the tire and buffs small amounts of rub-
3) 240 grit. ber from high spots on the outer two tread rows. Correction
by this method is usually permanent and, if it is done prop-
Clear Coat Damage on Unpainted Wheels erly, does not significantly affect the appearance or the
1. Apply the chemical stripper Amchem Alumi Prep tread life of the tire. Tire truing with a bladetype machine
No. 23. Use a small 1/4–inch detail brush to apply is not recommended because it substantially reduces the
the stripper around the perimeter and spoke–like tread life and often does not correct the problem perma-
areas. nently.
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Another method is to dismount the tire and rotate it 180 de- Notice : Use a tire–changing machine to mount or dis-
grees on the rim. Do this only on the tire and wheel assem- mount the tires. Follow the equipment manufacturer’s in-
blies which are known to be causing a vibration because structions. Do not use hand tools or tire irons to change
this method is just as likely to cause good assemblies to tires. These tools may damage the beads or the wheel rim.
vibrate. 1. Clean the rim bead seats with a wire brush or
coarse steel wool to remove lubricants, old rubber,
TIRE AND WHEEL and light rust. Before mounting or dismounting a
MATCH–MOUNTING tire, lubricate the bead area well with an approved
The tires and wheels are match–mounted at the assembly tire lubricant.
plant. Match–mounting aligns the radially stiffest part of CAUTION : To avoid serious injury, do not stand over
the tire, or high spot, to the smallest radius, or low spot, of the tire when inflating it, because the bead may break
the wheel. when it snaps over the safety hump. Do not exceed
The high spot of the tire is originally marked by a red paint 275 kPa (40 psi) of air pressure in any tire if the beads
mark or an adhesive label on the outboard sidewall. are not seated. If 275 kPa (40 psi) of air pressure will
not seat the beads, deflate the tire. Relubricate the
The low spot of the wheel will be at the location of the valve
bead and reinflate the tire. Overinflation may cause
stem.
the bead to break and cause serious injury.
Before dismounting a tire from its wheel, scribe a line on
2. After mounting the tire, inflate it until the beads are
the tire at the valve stem to assure that it is remounted in
seated. Never exceed 275 kPa (40 psi) to seat the
the same position.
beads.
Replacement tires that are of original equipment quality 3. Install the valve core and inflate the tire to the prop-
will have their high and low spot marked in the same man- er pressure. Make sure the locating ring outside of
ner. the bead of the tire shows around the rim flanges of
the wheel on both sides. This positioning of the tire
TIRE MOUNTING AND DISMOUNTING will insure that the bead of the tire is seated.

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GENERAL DESCRIPTION
AND SYSTEM OPERATION
TIRE AND WHEEL BALANCING
There are two types of tire and wheel balancing: static and
dynamic.
Static balance is the equal distribution of weight around
the wheel. Assemblies that are statically unbalanced
cause a bouncing action called wheel tramp. This condi-
tion may eventually cause uneven tire wear.
General Balance Precautions

Remove all deposits of foreign material from the inside of
the wheel.
CAUTION : Remove stones from the tread in order to
avoid operator injury during spin balancing.
Inspect the tire for any damage. Balance the tire according
to the equipment manufacturer’s recommendations.
Wheel Weights
If more than 85 grams (3.0 ounces) are needed to static
balance the wheel, split the wheel weights as equally as
possible between the inboard and the outboard flanges.
Balancing the assemblies with factory aluminum wheels
requires the use of special nylon–coated, clip–on wheel
Dynamic balance is the equal distribution of weight on weights. These weights are designed to fit over the thicker
each side of the centerline so that when the assembly rim flange of the aluminum wheel. Install these weights
spins there is no tendency for it to move from side to side. with a plastic–tipped hammer.
Assemblies that are dynamically unbalanced may cause Adhesive wheel weights are also available. Use the follow-
wheel shimmy. ing procedure to install adhesive wheel weights.
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When tire chains are installed, follow these precautions:

S Adjust speed to road conditions.
S Avoid sharp turns.
S Avoid locked–wheel braking.
To prevent chain damage to the vehicle, install the chains
on the front tires as tightly as possible. Tighten them again
after driving 0.4 to 0.8 kilometer (0.3 to 0.5 mile). The use
of chains on the rear tires is not recommended because
they may contact the vehicle and possibly damage it. If
chains must be used on the rear tires, be sure there is suffi-
cient clearance between the chains and the body. Do not
exceed 70 km/h (45 mph) or the chain manufacturer’s
speed limit, if lower. Avoid large bumps, potholes, severe
turns and any other maneuvers which could cause the
tires to bounce. Follow any other instructions of the chain
manufacturer which do not disagree with the above in-
structions.
REPLACEMENT TIRES
A Tire Performance Criteria (TPC) specification number is
molded in the sidewall near the tire size of all original
Adhesive Wheel Weight Installation equipment tires. This specification number assures that
1. Clean the wheel by sanding it to bare alloy where the tire meets performance standards for traction, endur-
the wheel weight will be installed. ance, dimensions, noise, handling and rolling resistance.
2. Use a clean cloth or paper towel saturated with a Usually a specific TPC number is assigned each tire size.
mixture of half isopropyl alcohol and half water to CAUTION : Do not mix different types of tires on the
wipe the place where the wheel weight will be same vehicle such as radial, bias and bias–belted
installed. tires except in emergencies, because vehicle han-
3. Dry the area with hot air. The surface of the wheel dling may be seriously affected and may result in loss
should be warm to the touch. of control.
4. Warm the adhesive backing on the wheel weights
Use only replacement tires with the same size, load range,
to room temperature.
and construction as the original. The use of any other tire
5. Remove the tape from the back of the weights. Do
size or construction type may seriously affect ride, han-
not touch the adhesive surface.
dling, speedometer/odometer calibration, vehicle ground
6. Apply the the wheel weight and press it on with
clearance, and tire clearance to the body and the chassis.
hand pressure.
This does not apply to the spare tire furnished with the ve-
7. Secure the wheel weight with a 70–110 N (16–25
hicle.
lb) force applied with a roller.
It is recommended that new tires be installed in pairs on
TIRE CHAIN USAGE the same axle.the same axle.
Due to limited tire–to–body clearance on certain vehicles, If it is necessary to replace only one tire, pair it with the tire
recommendations for tire chain use are published in the having the most tread to equalize the braking action.
Owner’s Manual. When tire chains need to be used, most Although they may appear different in tread design, tires
current Daewoo vehicles require SAE Class ”S” tire built by different manufacturers with identical TPC specifi-
chains. These may also be designated as 1100 Series, cations may be used on the same vehicle.
type PL tire chains. These chains are specifically designed
to limit the ”fly off” effect which occurs when the wheel ro- ALL SEASON TIRES
tates. Most vehicles are now equipped with steel–belted all sea-
Be sure that only fine–link chains are used which do not son radial tires as standard equipment. These tires qualify
add more than 15 mm (0.590 inch), including the lock, to as snow tires, with a 37 percent higher average rating for
the tread surface and the inner sides of the tires. snow traction than the non–all season radial tires pre-
viously used. Other performance areas, such as wet trac-
Manufacturers of tire chains have a specific chain size for tion, rolling resistance, tread life, and air retention, have
each tire size to ensure a proper fit when the chain is also been improved. This was done by improvements in
installed. Be sure to purchase the correct chains for the both tread design and tread compounds. These tires are
tires on which they are to be used. Use rubber adjusters identified by an ”M + S” molded in the tire sidewall following
to take up any slack or clearance in loose chains. the size number. The suffix ”MS” is also molded in the side-
Use of chains may adversely affect vehicle handling. wall after the TPC specification number.

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The optional handling tires used on some vehicles are not to the body and the chassis. The wheel offset is 49 µ 1 mm
all season tires. These will not have the ”MS” marking after (1.93 µ 0.04 inches). Steel wheels may be identified by a
the tire size or the TPC specification number. two– or three–letter code stamped into the rim near the
valve stem. Aluminum wheels should have the code, the
PASSENGER METRIC SIZED TIRES part number, and the manufacturer ID cast into the back
All Daewoo vehicles now use Passenger (P) metric sized side.
tires. P–metric tires are available in two load ranges: stan-
dard load (35 psi maximum) and extra load (41 psi maxi-
INFLATION OF TIRES
mum). Most passenger vehicle tires are standard load. The pressure recommended for any vehicle line is careful-
ly calculated to give a satisfactory ride, handling, tread life,
Most P–metric tire sizes do not have exact corresponding
and load–carrying capacity.
alphanumeric tire sizes. For example, a P175/70R13 is
not exactly equal in size and load–carrying capacity to an Tire pressure should be checked monthly or before any
FR70–13. For this reason, replacement tires should be of extended trip. Check the tires when they are cold, after the
the same TPC specification number as the originals. If P– vehicle has sat for 3 hours or more or has been driven less
metric tires must be replaced with other sizes, consult a than 1 mile. Set the tire pressure to the specifications on
tire dealer. Tire companies can best recommend the clos- the tire label located on the rear face of the driver’s door.
est match of alphanumeric to P–metric sizes within their Tire inflation pressure is also given under ”Tire Size and
own tire lines. Pressure Specifications” in this section.
The metric term for measuring tire inflation pressure is the Valve caps or extensions should be on the valves to keep
kilopascal (kPa). Tire pressure may be printed in both kPa dust and water out.
and psi. One psi equals 6.895 kPa. For sustained driving at speeds up to 140 km/h (85 mph),
See the tire label or refer to ”Tire Size and Pressure Speci- inflate the tires to the pressure recommended on the tire.
fications” in this section for tire inflation pressures. Sustained driving at speeds faster than 140 km/h (85
mph), even if permitted by law, is not advised unless the
TIRE LABEL vehicle has special high–speed tires available from many
tire dealers. Tire pressures may increase as much as 41
The tire label is permanently located on the rear face of the kPa (6 psi) when the tires are hot.
driver’s door and should be referred to for tire information.
It lists the maximum vehicle load, the tire size (including Higher than recommended tire pressure can cause:
the spare tire), and the cold inflation pressure (including S Hard ride.
the spare tire). S Tire bruising or damage.
S Rapid tread wear at the center of the tire.
SPARE TIRE Lower than recommended pressure can cause
This vehicle comes equipped with a full–sized spare tire S Tire squeal on turns.
and wheel. S Hard steering.
S Rapid and uneven wear on the edges of the tread.
WHEELS S Tire rim bruises and rupture.
Wheels must be replaced if they are bent, dented, have S Tire cord breakage.
excessive lateral or radial runout, leak air through welds, S High tire temperatures.
have elongated bolt holes, or if the wheel bolts won’t stay Unequal tire pressures on same axle can cause
tight or are heavily rusted. Wheels with excessive runout
may cause vehicle vibration. Replacement wheels must S Uneven braking.
be equivalent to the original equipment wheels in load ca- S Steering lead.
pacity, diameter, rim width, offset, and mounting configu- S Reduced handling.
ration. A wheel of improper size or type may affect wheel S Swerve on acceleration.
and bearing life, brake cooling, speedometer/odometer S Torque steer.
calibration, vehicle ground clearance, and tire clearance
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SECTION : 3A
AUTOMATIC TRANSAXLE DRIVE AXLE
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3A–1 ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 3A–4
FASTENER TIGHTENING DRIVE AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . 3A–4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 3A–1 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A–8
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A–2 OUTER JOINT SEAL . . . . . . . . . . . . . . . . . . . . . . 3A–8
SPECIAL TOOLS TABLE . . . . . . . . . . . . . . . . . . . 3A–2 INNER TRIPOT SEAL . . . . . . . . . . . . . . . . . . . . . 3A–10
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 3A–2
FRONT DRIVE AXLE . . . . . . . . . . . . . . . . . . . . . . 3A–2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A–14
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 3A–4 FRONT DRIVE AXLE . . . . . . . . . . . . . . . . . . . . . 3A–14
SPECIFICATIONS
Axle Shaft Caulking Nut Initial Torque 180 134 –
Axle Shaft Caulking Nut Final Torque 50³ + 60³ 37³ + 60³ –
Lower Ball Joint Nut 70 52 –
Tie Rod Nut 60 44 –
Wheel Nuts 90 66 –
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3A – 2IAUTOMATIC TRANSAXLE DRIVE AXLE
SPECIAL TOOLS
SPECIAL TOOLS TABLE
J–8059 KM–460–A
Snap Ring Pliers Axle Shaft Remover
KM–507–B J–35566
Ball Joint Remover Seal Clamp Pliers
COMPONENT LOCATOR
FRONT DRIVE AXLE

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AUTOMATIC TRANSAXLE DRIVE AXLE 3A – 3
1. Caulking Nut 8. Drive Axle Inboard Seal

2. C/V Joint 9. Seal Retaining Clamp
3. Axle Shaft (right–hand shown, left–hand similar) 10. Race Retaining Ring
4. Seal Retaining Clamp 11. Tripot Joint
5. Drive Axle Outboard Seal 12. Shaft Retaining Ring
6. Seal Retaining Clamp 13. Tripot Housing
7. Seal Retaining Clamp
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DRIVE AXLE ASSEMBLY
Tools Required
KM–507–B Ball Joint Separator
KM–460–A Axle Shaft Remover
Removal Procedure

2. Remove the wheels. Refer to Section 2E, Tires and
Wheels.
3. Remove the engine under covers. Refer to Section
9N, Frame and Underbody.
4. Remove the axle shaft caulking nut. Discard the
nut.
5. Remove the lower ball joint retaining clip and the
nut.
Notice : Use only the recommended tool for separating

the lower ball joint. Failure to use the recommended tool
may cause damage to the ball joint and the seal.
6. Separate the steering knuckle from the lower ball
joint using the ball joint separator KM–507–B.

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7. Remove the tie rod nut.

the tie rod from the knuckle/strut assembly. Failure to use
the recommended tool may cause damage to the knuckle/
strut assembly.
8. Separate the tie rod end using the ball joint separa-
tor KM–507–B.
9. Push the drive axle shaft from the wheel hub.

Important : Support the unfastened end of the drive axle.
Do not allow the drive axle to dangle freely from the trans-
axle for any length of time after it has been removed from
the wheel hub.
Important : Place a drain pan below the transaxle to catch
the escaping fluid. Cap the transaxle drive opening after
the drive axle has been removed to keep the fluid in and
any contamination out.
10. Remove the drive axle from the transaxle using the
axle shaft remover KM–460–A.
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Notice : Do not damage the seals.

1. Clean the hub seal and the transaxle seal.
2. Install the drive axle into the transaxle.
3. Install the wheel hub onto the axle shaft.
4. Mount the steering knuckle onto the lower ball joint.
5. Install the tie rod into the knuckle/strut and install

the tie rod nut.
Tighten
Tighten the tie rod nut to 60 NSm (44 lb–ft).

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6. Install the lower ball joint nut.

Tighten
Tighten the lower ball joint nut to 70 NSm (52 lb–ft).
7. Loosely install a new axle shaft caulking nut. Al-

ways use a new nut.
8. Install the wheels. Loosely install the bolts. Refer to

Section 2E, Tires and Wheels.
9. Lower the vehicle to the floor.
Tighten
10. Tighten the axle shaft caulking nut to 180 NSm (134
lb–ft). Loosen the nut and re–tighten the nut to 50
NSm (37 lb–ft). Then tighten the nut further by 60
degrees.
11. Peen the caulking nut with a punch and a hammer
until the nut is locked into place on the axle shaft
hub.
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12. Install the retaining clip to the lower ball joint.

13. Install the engine under covers. Refer to Section
14. Refill the transaxle fluid to the proper level. Refer to
Section 5A, 4T40E Automatic Transaxle.
UNIT REPAIR
OUTER JOINT SEAL
Tools Required
J–8059 Snap Ring Pliers
Removal Procedure
1. Remove the inner tripot seal assembly. Refer to

”Inner Tripot Seal” in this section.
2. Remove the large seal retaining clamp. Discard the
clamp.
3. Remove the small seal retaining clamp. Discard the
clamp.
4. Degrease the joint.

CAUTION : Do not remove the axle shaft from the out-
er joint assembly or disassemble the outer joint as-
sembly. Parts are match fit and cannot be serviced
separately. Improper reassembly will adversely affect
both performance and safety.
5. Remove the seal from the joint assembly.

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Tools Required
J–35566 Seal Clamp Pliers
1. Install the seal onto the axle shaft.
2. Fill the joint seal with 75 to 95 g (2.6 to 3.4 ounces)
of the recommended grease. Repack the joint with
75 to 95 g (2.6 to 3.4 ounces) of the recommended
grease.
3. Install a new large seal retaining clamp and a new

small seal retaining clamp.
4. Crimp the new small seal retaining clamp and the

new large seal retaining clamp using the seal clamp
pliers J–35566.
5. Install the inner tripot seal assembly. Refer to ”Inner
Tripot Seal” in this section
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INNER TRIPOT SEAL

Tools Required
Removal Procedure

clamp.
clamp.
3. Remove the race retaining ring.
4. Remove the tripot housing from the seal.

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5. Degrease the tripot assembly.

6. Remove the shaft retaining ring using the snap ring
pliers J–8059.
7. Remove the tripot from the axle shaft.

8. Remove the tripot joint seal from the axle shaft.
Tools Required
1. Install a new small seal retaining clamp onto the
seal. Do not crimp the seal retaining clamp.
3. Install the tripot onto the axle shaft.
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4. Install the shaft retaining ring onto the axle shaft

using the snap ring pliers J–8059.
5. Fill the tripot housing with 140 to 160 g (4.9 to 5.6

ounces) of the recommended grease. Repack the
tripot with 140 to 160 g (4.9 to 5.6 ounces) of the
recommended grease.
6. Install the tripot housing onto the tripot assembly.
7. Install the race retaining ring.

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8. Install a new large seal retaining clamp. Crimp the

large seal retaining clamp using the seal clamp pli-
ers J–35566.
9. Crimp the new small seal retaining clamp using the
seal clamp pliers J–35566.
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outer constant–velocity joint connected to an axle shaft.

GENERAL DESCRIPTION The inner joint is completely flexible and has the ability to
move in and out. The outer joint is also flexible, but it can-
AND SYSTEM OPERATION not move in and out.
FRONT DRIVE AXLE The drive axles use one type of outboard joint and one type
of inboard joint. The inboard ends of both drive axles incor-
General Description
porate a female spline that installs over a stub shaft pro-
Drive axles are flexible shaft assemblies that transmit truding from the transaxle.
rotational force from the transaxle to the front–wheel as-
semblies. Each axle assembly consists of an inner and an

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SECTION : 3B
MANUAL TRANSAXLE DRIVE AXLE
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3B–1 ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 3B–4
FASTENER TIGHTENING DRIVE AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . 3B–4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 3B–1 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B–8
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B–2 OUTER JOINT SEAL . . . . . . . . . . . . . . . . . . . . . . 3B–8
SPECIAL TOOLS TABLE . . . . . . . . . . . . . . . . . . . 3B–2 CROSS GROOVE JOINT SEAL . . . . . . . . . . . . 3B–10
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 3B–2
FRONT DRIVE AXLE . . . . . . . . . . . . . . . . . . . . . . 3B–2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B–12
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 3B–4 FRONT DRIVE AXLE . . . . . . . . . . . . . . . . . . . . . 3B–12
SPECIFICATIONS
Axle Shaft Castle Nut Initial Torque 100 74 –
Axle Shaft Castle Nut Final Torque 20 15 –
Axle Shaft Caulking Nut Initial Torque 180 134 –
Axle Shaft Caulking Nut Final Torque 50 + 60³ 37 + 60³ –
Lower Ball Joint Nut 70 52 –
Tie Rod Nut 60 44 –
Wheel Bolts 90 66 –
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3B – 2IMANUAL TRANSAXLE DRIVE AXLE
SPECIAL TOOLS
SPECIAL TOOLS TABLE
J–8059 KM–460–A
Snap Ring Pliers Axle Shaft Remover
KM–507–B J–35566
Ball Joint Remover Seal Clamp Pliers
COMPONENT LOCATOR
FRONT DRIVE AXLE

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MANUAL TRANSAXLE DRIVE AXLE 3B – 3
1. Caulking Nut 7. Seal Retaining Clamp

2. C/V Joint 8. Drive Axle Inboard Seal
3. Axle Shaft 9. Seal Retaining Clamp
4. Seal Retaining Clamp 10. Race Retaining Ring
5. Drive Axle Outboard Seal 11. Cross Groove Joint
6. Seal Retaining Clamp 12. Retaining Ring
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DRIVE AXLE ASSEMBLY
Tools Required
KM–507–B Ball Joint Separator
KM–460–A Axle Shaft Remover
Removal Procedure

2. Remove the wheels. Refer to Section 2E, Tires and
Wheels.
3. Remove the engine under covers. Refer to Section
4. Remove the axle shaft caulking nut. Discard the
nut.
5. Remove the lower ball joint retaining clip and the
nut.

the lower ball joint. Failure to use the recommended tool
may damage the ball joint and the seal.
6. Separate the steering knuckle from the lower ball
joint using the ball joint separator KM–507–B.

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7. Remove the tie rod nut.

the tie rod from the knuckle/strut assembly. Failure to use
the recommended tool may damage the knuckle/ strut as-
sembly.
8. Separate the tie rod end using the ball joint separa-
tor KM–507–B.
9. Push the drive axle shaft from the wheel hub.

Important : Support the unfastened end of the drive axle.
Do not allow the drive axle to dangle freely from the trans-
axle for any length of time after it has been removed from
the wheel hub.
Important : Place a drain pan below the transaxle to catch
the escaping fluid. Cap the transaxle drive opening after
the drive axle has been removed to keep the fluid in and
any contamination out.
10. Remove the drive axle from the transaxle using the
axle shaft remover KM–460–A.
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Notice : Do not damage the seal.

1. Clean the hub seal and the transaxle seal.
2. Install the drive axle into the transaxle.
3. Install the wheel hub onto the drive axle shaft.
4. Mount the steering knuckle onto the lower ball joint.
5. Install the tie rod into the knuckle/strut and install

the tie rod nut.
Tighten
Tighten the tie rod nut to 60 NSm (44 lb–ft).

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6. Install the lower ball joint nut.

Tighten
Tighten the lower ball joint nut to 70 NSm (52 lb–ft).
7. Loosely install a new axle shaft caulking nut. Al-

ways use a new nut.
8. Install the wheels. Loosely install the bolts. Refer to
Section 2E, Tires and Wheels.
9. Lower the vehicle to the floor.

Tighten
Tighten
Tighten the axle shaft caulking nut to 180 NSm (134
lb–ft). Loosen the nut and re–tighten the nut to 50 NSm
(37 lb–ft). Then tighten the nut further by 60 degrees.
10. Peen the caulking nut with a punch and a hammer
until the nut is locked into place on the axle shaft
hub.
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11. Install the retaining clip to the lower ball joint.

12. Install the engine under covers. Refer to Section
13. Refill the transaxle fluid to the proper level. Refer to
Section 5B, Five–Speed Manual Transaxle.
UNIT REPAIR
OUTER JOINT SEAL

Tools Required
Removal Procedure
1. Remove the cross groove joint seal assembly. See

”Cross Groove Joint Seal” in this section.
clamp.
clamp.
CAUTION : Do not remove the axle shaft from the out-
er joint assembly or disassemble the outer joint as-
sembly. Parts are match fit and cannot be serviced
separately. Improper reassembly will adversely affect
both performance and safety.

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2. Fill the joint seal with 175 to 195 g (6.2 to 6.8
joint with 175 to 195 g (6.2 to 6.8 ounces) of the
recommended grease.
3. Install a new large seal retaining clamp and a new

small seal retaining clamp.
4. Crimp the new small seal retaining clamp and the

new large seal retaining clamp using the seal clamp
pliers J–35566.
5. Install the cross groove joint seal assembly. Refer
to the ”Cross Groove Joint Seal” in this section.
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CROSS GROOVE JOINT SEAL

Tools Required
Removal Procedure

clamp.
clamp.

4. Remove the shaft retaining ring using the snap ring
pliers J–8059.
5. Remove the axle shaft from the joint assembly.

CAUTION : The ball retainer is staked in position and
must not be disassembled. Cross groove joint inter-
nal parts are match fit and cannot be serviced sepa-
rately. Improper reassembly will adversely affect both
performance and safety.

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1. Install a new small retaining clamp onto the seal.

Do not crimp.
3. Install the joint assembly onto the axle shaft.
4. Install the shaft retaining ring using the snap ring

pliers J–8059.
5. Fill the joint assembly with 120 to 140 g (4.2 to 4.9

joint seal with 120 to 140 g (4.2 to 4.9 ounces) of
the recommended grease.
6. Install a new large seal retaining clamp.
7. Crimp the new large seal retaining clamp using the
seal clamp pliers J–35566.
8. Crimp the new small retaining clamp using the seal
clamp pliers J–35566.
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constant–velocity joint and an outer constant–velocity

GENERAL DESCRIPTION joint connected to an axle shaft. The inner joint is com-
pletely flexible and has the ability to move in and out. The
AND SYSTEM OPERATION outer joint is also flexible, but it cannot move in and out.
FRONT DRIVE AXLE The drive axles use one type of outboard joint and one type
of inboard joint. The inboard ends of both drive axles incor-
General Description
porate a male spline that interlocks with the transaxle
Drive axles are flexible shaft assemblies that transmit a gears using snap rings.
rotational force from the transaxle to the front–wheel as-
semblies. Each axle assembly consists of an inner

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SECTION : 4A
HYDRAULIC BRAKES
prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.o-
therwise noted.
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 4A–1 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 4A–14
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 4A–1 ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 4A–14
FASTENER TIGHTENING SPECIFICATIONS . 4A–2 MANUAL BLEEDING THE BRAKES . . . . . . . . 4A–14
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 4A–3 PRESSURE BLEEDING THE BRAKES . . . . . 4A–17
BRAKE SYSTEM (ABS) . . . . . . . . . . . . . . . . . . . . 4A–3 BRAKE HOSE (REAR) . . . . . . . . . . . . . . . . . . . . 4A–18
BRAKE SYSTEM (NON–ABS) . . . . . . . . . . . . . . 4A–5
BRAKE HOSE (FRONT) . . . . . . . . . . . . . . . . . . . 4A–19
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A–6 STOPLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 4A–21
BRAKE SYSTEM TESTING . . . . . . . . . . . . . . . . 4A–6
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . 4A–22
BRAKE HOSE INSPECTION . . . . . . . . . . . . . . . . 4A–7
WARNING LAMP OPERATION . . . . . . . . . . . . . . 4A–7 GENERAL DESCRIPTION AND SYSTEM
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A–25
BRAKE LAMP WARNING CIRCUIT DIAGNOSIS 4A–
8 HYDRAULIC FLUID . . . . . . . . . . . . . . . . . . . . . . . 4A–25
SPECIFICATIONS
Application 1.5 SOHC Engine 1.6 DOHC Engine
Millimeters Inches Millimeters Inches
Brake Drums: 200.00 7.87 200.00 7.87
Inside Diameter 201.00 7.91 201.00 7.91
Maximum Rebore 0.08 0.003 0.08 0.003
Diameter
Out–of–Round
Brake Rotors: 19.00 0.75 23.00 0.90
Discard Thickness 0.030 0.001 0.030 0.001
Lateral Runout 236.00 9.29 256.00 10.08
(Installed) 20.00 0.79 24.00 0.95
Rotor Diameter 0.005 0.0002 0.005 0.0002
Rotor Thickness
(New)
Thickness Variation
Master Cylinder: 20.71 0.82 22.29 0.88
Bore Diameter 20.64 0.81 22.22 0.88
Minimum Bore Di-
ameter
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4A – 2IHYDRAULIC BRAKES
Application
Millimeters Inches Millimeters Inches
Caliper: 47.99 1.89 51.99 2.05
Piston Minimum Di-
ameter
Wheel Cylinder Di- 19.05 0.750 20.64 0.813
ameter: 19.116 0.753 – –
Maximum
Nominal

Application N L L
S b b
m– –
F I
t n
Bleeder Screw 9 – 8
0
Brake Lines 1 1 –
6 2
Brake Pedal–to–Pedal Bracket Hex Nut 2 1 –
2 6
Front Brake Hose–to–Caliper Bolt 4 3 –
0 0
Trim Panel Screws 7 – 6
2

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HYDRAULIC BRAKES 4A – 3
COMPONENT LOCATOR
BRAKE SYSTEM (ABS)
1. Rear Brake Hose 2. E–ring
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3. Rear Brake Pipe 9. LH 2nd Front Brake Pipe

4. LH 2nd Rear Brake Pipe 10. Brake Hose
5. RH 2nd Rear Brake Pipe 11. RH 1st Front Brake Pipe
6. 3rd Rear Brake Pipe 12. RH 1st Rear Brake Pipe
7. Secondary Brake Pipe 13. LH 1st Rear Brake Pipe
8. Primary Brake Pipe 14. RH 2nd Front Brake Pipe
15. LH 1st Front Brake Pipe

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BRAKE SYSTEM (NON–ABS)
1. LH or RH Rear Brake Hose
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2. E–ring 7. RH Front Brake Pipe

3. LH or RH Rear Brake Pipe 8. RH 1st Rear Brake Pipe
4. LH 2nd Rear Brake Pipe 9. LH 1st Rear Brake Pipe
5. RH 2nd Rear Brake Pipe 10. LH Front Brake Pipe
6. 3rd Rear Brake Pipe 11. Brake Hose
DIAGNOSIS
BRAKE SYSTEM TESTING
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake perfor-
mance cannot be made if the roadway is wet, greasy, or
covered with loose dirt whereby all tires do not grip the
road equally. Testing will also be adversely affected if the
roadway is crowned so as to throw the weight so roughly
that the wheels tend to bounce.
Test the brakes at different vehicle speeds with both light
and heavy pedal pressure; however, avoid locking the
brakes and sliding the tires. Locked brakes and sliding
tires do not indicate brake efficiency since heavily braked,
but turning, wheels will stop the vehicle in less distance
than locked brakes. More tire–to–road friction is present
with a heavily braked, turning tire than with a sliding tire.
Because of the high deceleration capability, a firmer pedal
may be felt at higher deceleration levels.
There are three major external conditions that affect brake
performance:
S Tires having unequal contact and grip of the road
will cause unequal braking. Tires must be equally
inflated, and the tread pattern of the right and the
left tires must be approximately equal.
S Unequal loading of the vehicle can affect the brake
performance since the most heavily loaded wheels
require more braking power, and thus more braking
effort, than the others.
S Misalignment of the wheels, particularly conditions
of excessive camber and caster, will cause the
brakes to pull to one side.
To check for brake fluid leaks, hold constant foot pressure
on the pedal with the engine running at idle and the shift
lever in N (Neutral). If the pedal gradually falls away with
the constant pressure, the hydraulic system may be leak-
ing. Perform a visual check to confirm any suspected
leaks.
Check the master cylinder fluid level. While a slight drop
in the reservoir level results from normal lining wear, an ab-
normally low level indicates a leak in the system. The hy-
draulic system may be leaking either internally or external-
ly. Refer to the procedure below to check the master
cylinder. Also, the system may appear to pass this test
while still having a slight leak. If the fluid level is ormal,
check the vacuum booster pushrod length. If an incorrect
pushrod length is found, adjust or replace the rod.
Check the master cylinder using the following procedure:

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S Check for a cracked master cylinder casting or cylinder with brake fluid, refill the master cylinder, and
brake fluid leaking around the master cylinder. bleed the system. Refer to ”Manual Bleeding the Brakes”
Leaks are indicated only if there is at least one drop or”Pressure Bleeding the Brakes” in this section.
of fluid. A damp condition is not abnormal.
S Check for a binding pedal linkage and for an incor- BRAKE HOSE INSPECTION
rect pushrod length. If both of these parts are in
The hydraulic brake hoses should be inspected at least
satisfactory condition, disassemble the master cyl-
twice a year. The brake hose assembly should be checked
inder and check for an elongated or swollen primary
for road hazard damage, cracks, chafing of the outer cov-
cylinder or piston seals. If swollen seals are found,
er, and for leaks or blisters. Inspect the hoses for proper
substandard or contaminated brake fluid should be
routing and mounting. A brake hose that rubs on a suspen-
suspected. If contaminated brake fluid is found, all
sion component will wear and eventually fail. A light and
the components should be disassembled and
a mirror may be needed for an adequate inspection. If any
cleaned, and all the rubber components should be
of the above conditions are observed on the brake hose,
replaced. All of the pipes must also be flushed.
adjust or replace the hose as necessary.
Improper brake fluid, or mineral oil or water in the fluid,
may cause the brake fluid to boil or cause deterioration of WARNING LAMP OPERATION
the rubber components. If the primary piston cups in the
master cylinder are swollen, then the rubber parts have This brake system uses a BRAKE warning lamp located
deteriorated. This deterioration may also be evidenced by in the instrument cluster. When the ignition switch is in the
swollen wheel cylinder piston seals on the drum brake START position, the BRAKE warning lamp should glow
wheels. and then go off when the ignition switch returns to the RUN
position.
If rubber deterioration is evident, disassemble all the hy-
draulic parts and wash the parts with alcohol. Dry these The following conditions will activate the BRAKE lamp:
parts with compressed air before reassembly to keep alco- S Parking brake applied. The light should be on
hol out of the system. Replace all the rubber parts in the whenever the parking brake is applied and the igni-
system, including the hoses. Also, when working on the tion switch is ON.
brake mechanisms, check for fluid on the linings. If exces- S Low fluid level. A low fluid level in the master cylin-
sive fluid is found, replace the linings. der will turn the BRAKE lamp on.
If the master cylinder piston seals are in satisfactory condi- S As a test of the lamp circuit. Vehicles with antilock
tion, check for leaks or excessive heat conditions. If these brakes will illuminate the BRAKE lamp for 3 sec-
conditions are not found, drain the fluid, flush the master onds when the ignition starter is turned ON.
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BRAKE LAMP WARNING CIRCUIT DIAGNOSIS

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trol module (EBCM) in a vehicle with ABS.

Test Description 14. This removes the parking brake switch circuit.
The number(s) below refer to step(s) on the diagnostic 16. This removes the brake fluid level switch circuit.
table. 18. This checks the only remaining circuitry that can
activate the brake warning lamp.
1. There are three possible symptoms of a problem: 20. This tests for the presence of battery voltage used
the brake warning lamp is always on; the brake by both the oil pressure lamp and the brake warn-
warning lamp is never on; the brake warning lamp ing lamp.
will not operate for a particular function. This test 21. This step begins a sequence that will restore volt-
takes you to the appropriate starting point in the age to the lamps.
procedure. 29. This checks for a burned out indicator lamp.
2. This test checks whether the Antilock Brake Sys- 31. This begins a sequence that will find the open that
tem (ABS) system has turned on the brake warning prevents contact to ground needed to operate the
lamp. If the vehicle is not equipped with ABS, the lamp.
answer will be NO. 33. This checks whether the ABS system has tried to
4. 5. These steps test for simple conditions that can turn on the brake warning lamp and could not. If the
turn on the brake warning lamp. vehicle is not equipped with ABS, the answer is
7. This checks whether the brake fluid level switch is NO.
faulty. 34. This step begins a search for a problem in the park-
9. This checks whether the parking brake switch is ing brake switch circuit.
faulty. 38. This step begins a search for a problem in the
12. This removes the circuit to the electronic brake con- brake fluid level switch circuit.
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Brake Lamp Warning Circuit Diagnosis

1 Turn the ignition ON. Go to Step 2 Go to Step 19
Is the brake warning lamp always on?
2 Check the ABS warning lamp. Go to Step 3 Go to Step 3
Is the ABS warning lamp also on?
3 Use a scan tool to check for diagnostic trouble codes Go to Step 4 System OK
(DTCs) and follow the procedures for any DTCs
found.
Is the lamp still on?
4 Release the parking brake fully. System OK Go to Step 5
Is the lamp off?
5 Check the brake fluid level. Go to Step 7 Go to Step 6
Is the fluid level acceptable?
6 1. Fill the brake fluid reservior with clean DOT 3 Go to Step 7 System OK
equivalent hydraulic fluid.
2. Replace the cap on the brake fluid reservoir.
Is the lamp stil on?
7 Unplug the harness connector from the brake fluid Go to Step 9 Go to Step 8
sensor switch.
8 Replace the parking brake lever switch. System OK
9 1. Reconnect the brake fluid level switch. Go to Step 10 Go to Step 11
2. Remove the rear console cover to expose the
parking brake mechanism.
3. Release the brake completely.
4. Slide off the terminal with the BRN/BLK wire
from the wiring harness.
Does the lamp go out?
10 Replace the switch. System OK
11 Replace the terminal back onto the switch. Go to Step 12 Go to Step 14
Is the vehicle equipped with ABS?
12 Unplug connector C302. This is a flat, 6–pin connec- Go to Step 13 Go to Step 14
tor found under the passenger seat near the engine
control module (ECM).
13 Repair the short to ground in circuit BRN/BLK be- System OK
tween terminal 2 of connector C302 and terminal B5
of connector J1 on the EBCM.
14 Disconnect connector C205. This is the large con- Go to Step 16 Go to Step 15
nector in the center of the connection block behind
the left–side kick panel.
tween connector C205 and connector C302 or be-
tween connector C205 and the parking brake switch.

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16 Disconnect connector C202. This is the 18–pin con- Go to Step 17 Go to Step 18
nector to the front harness just above the left side
kick panel, near the grommet that allows that har-
ness through the fire wall.
tween connector C202 and the brake fluid level
switch.
tween terminal 25 of the instrument cluster and
splice S201, or between S201 and connector C202
or connector C205.
19 Check the brake lamp after doing each of the follow- Go to Step 32 Go to Step 20
ing functions:
S Apply the parking brake.
S Remove the cap from the brake fluid reservoir.
S Command the lamp on using a scan tool.
Does the brake warning lamp operate for any of
these conditions?
20 Turn the ignition ON. Go to Step 24 Go to Step 21
Does the oil pressure indicator light?
21 Check fuse 11 in the I/P fuse block behind the left– Go to Step 23 Go to Step 22
side kick panel.
Is the fuse in good condition?
22 Replace fuse 11 with another 10–amp fuse. System OK
Does the brake warning lamp function now?
23 Check EF2 in the engine fuse block. Go to step 25 Go to Step 24
Is EF2 in good condition?
24 Replace EF2 with another 30–amp device. System OK
25 1. Unplug C206 from the connection box behind 11–14 v Go to Step 27 Go to Step 26
the left–side kick panel. This is the large con-
nector at the bottom of the box.
2. Use a digital volt meter (DVM) to measure volt-
age from terminal 8 of the connector in the box
to ground. This is the fourth pin from the left on
the top row as you face the connection box.
Does the DVM indicate the specified voltage?
26 Repair the open in circuit GRY from connector C206 System OK
in the connection box fuse 11 in the I/P fuse block.
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27 1. Reconnect harness connector C206 to the con- 11–14 v Go to Step 28 Go to Step 29
nection box.
2. Gain access to the rear of the instrument clus-
ter.
3. Unplug the instrument 10–pin cluster connec-
tor.
4. Use a DVM to measure the voltage from termi-
nal 26 of the 10–pin cluster connector to
ground.
Does the DVM show the specified value?
28 Repair the open in circuit PNK between the 10–pin System OK
instrument cluster connector terminal 26 and splice
S201 or from there in circuit GRY to terminal 8 of
connector C206.
29 Remove the brake indicator lamp from its socket and Go to Step 30 Go to Step 31
examine it.
Is the lamp burned out?
30 Replace the brake indicator lamp. System OK
31 1. Return the brake indicator lamp to its socket System OK
the instrument cluster.
2. Look for the open in circuit BRN/BLK between
terminal 25 of the 10–pin I/P harness cluster
connector and splice S201.
3. Repair any open found in circuit BRN/BLK.
32 Check the ABS lamp. Go to Step 33 Go to Step 34
Is the ABS lamp flashing?
33 Use a scan tool to determine what DTCs are present System OK
and repair them according to the tables for the DTCs
involved.
34 Try applying the parking brake fully. Go to Step 35 Go to Step 38
Does the brake warning lamp fail to light when the
parking brake is applied?
35 1. Expose the parking brake mechanism by re- Go to Step 36 Go to Step 37
moving the rear console. Use a jumper to short
the terminal from the
2. BRN/BLK wire to ground.
Does the lamp come on?
36 Replace the parking brake switch or repair the System OK
grounding between the parking brake switch and the
brake handle mounting or between the brake handle
mounting and the vehicle body.

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37 Repair the open in circuit BRN/BLK. This will be in System OK
one of two places:
S The I/P harness between splice S201 and ter-
minal 10 of connector C205.
S The floor harness between terminal 10 of con-
nector C205 and the parking brake switch.
38 If the brake warning lamp is not indicating low brake System OK Go to Step 39
fluid, remove the cap from the brake fluid reservoir
to lift the sensor from the brake fluid.
39 1. Unplug the harness connector from the sensor Go to Step 40 Go to Step 41
on the brake fluid reservoir cap.
2. Use a jumper to short the terminals in the har-
ness connector together.
40 Install a new fluid level sensor switch into the brake System OK
fluid reservoir.
41 Use the jumper to short terminal B (BRN/BLK wire) Go to Step 42 Go to Step 43
to ground.
42 Repair the open to ground in circuit BLK between the System OK
terminal A (BLK wire) of the harness connector for
the level sensor switch and ground G102 at the left
front corner of the vehicle.
43 Repair the open in circuit BRN/BLK. There are two System OK
possible locations for this open:
S The I/P harness between splice S201 and ter-
minal 12 of connector C202.
S The front harness between terminal 12 of con-
nector C202 and terminal B of the harness
connector for the level sensor switch.
A low brake fluid level in the master cylinder will turn the BRAKE lamp ON. Refer to ”Brake System Testing” in this section
to test for fluid leaks.
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MANUAL BLEEDING THE BRAKES
1. Remove the booster reserve by applying the brakes
several times with the engine OFF until all the re-
serve is depleted.
Important : If the master cylinder is known or suspected

to have air in the bore, then it must be bled before any
wheel cylinder or caliper is bled.
2. Fill the master cylinder reservoir with brake fluid.
Keep the master cylinder at least one–half full of
fluid during the bleeding operation.
3. Disconnect the front brake line(s) at the master cyl-

inder.
4. Allow the brake fluid to fill the master cylinder until it
begins to flow from the front pipe connector port.
5. Connect the front brake line(s) to the master cylin-
der.
Tighten
Tighten the brake lines to 16 NSm (12 lb–ft).

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6. Slowly push and hold the brake pedal one time.
7. Loosen the front brake line at the master cylinder to

purge all air from the cylinder.
8. Tighten the brake line as in Step 5, and then re-
lease the brake pedal slowly. Wait 15 seconds be-
fore proceeding to the next step.
9. Repeat the sequence, including the 15–second
wait, until all the air is removed from the master
cylinder bore.
Notice : Care must be taken to prevent brake fluid from

contacting any painted surface to prevent damage to the
paint finish.
10. After all the air has been removed at the forward
connection(s), bleed the master cylinder at the rear
(cowl) connection(s) in the same manner as with
the front connections.
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Important : For vehicles equipped with a non–antilock

braking system, non–ABS, the bleeding sequence is as
follows: right rear, left front, left rear, and right front. For
ABS–equipped vehicles, refer to Section 4F, Antilock
Brake System for the correct sequence and bleeding pro-
cedure.
11. Attach a transparent tube over the valve. Allow the
tube to hang submerged in brake fluid in a transpar-
ent container.
12. Slowly push and hold the brake pedal one time.
13. Remove the bleeder cap and loosen the bleeder
screw to purge the air from the cylinder.
14. Tighten the bleeder screw.
Tighten
Tighten the bleeder screw to 9 NSm (80 lb–in).
15. Slowly release the brake pedal. Wait 15 seconds
before proceeding with the next step.
Important : Rapid pumping of the brake pedal pushes the
master cylinder secondary piston down the bore in a man-
ner that makes it difficult to bleed the system.
16. Repeat the sequence, including the 15–second
wait, until all the air is removed. It may be neces-
sary to repeat the sequence 10 or more times to
remove all the air.
17. Locate the front bleeder caps.
18. Proceed to bleed the front brakes following the ap-

propriate sequence, beginning with Step 12.
19. Check the brake pedal for sponginess. Repeat the
entire bleeding procedure to correct this condition.

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PRESSURE BLEEDING THE BRAKES

Notice : Pressure bleeding equipment must be of the dia-
phragm type. It must have a rubber diaphragm between
the air supply and the brake fluid to prevent air, moisture,
oil, and other contaminants from entering the hydraulic
system. Contamination could lead to deterioration of the
braking components and loss of braking action.
1. Disconnect the master cylinder electrical connector.
2. Remove the master cylinder reservoir cap.
3. Connect the bleeder with the adapter to the master

cylinder reservoir.
4. For vehicles with the antilock brake system (ABS),
locate and remove the hydraulic modulator bleeder
valves. Refer to Section 4F, Antilock Brake System
5. Charge the bleeder ball to 140 to 172 kPa (20 to 25
psi).
6. Connect the line to the adapter. Open the line
valve.
Important : The bleeding sequence is as follows: right
rear, left front, left rear, and right front.
8. Attach the bleeder hose to the bleeder valve. Sub-
merge the opposite end of the hose in a clean con-
tainer partially filled with brake fluid.
9. Open the bleeder valve one–half to three–fourths of
a turn and allow the fluid to flow until no air is seen
in the fluid.
Notice : After the bleeding operation, the brake reservoir

may be pressurized. While disconnecting the bleeder
hose or the unthreaded adapter cap, cover the cap and the
connection with a shop towel to protect painted surfaces
from contact with the brake fluid.
10. Inspect the brake pedal for sponginess. Repeat the
entire bleeding procedure to correct this condition.
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BRAKE HOSE (REAR)

Removal Procedure

2. Disconnect the brake lines from the brake hoses at
the body and the rear axle brackets.
3. Remove both brake hose E–ring retainers.

4. Remove the brake hoses from the brackets.
1. Install the brake hoses to the body and the rear

axle brackets.
2. Connect the brake lines to the brake hose.
Tighten

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3. Install the brake hose retainers.

5. Bleed the brake system. Refer to ”Manual Bleeding
the Brakes” in this section.
6. Check the brake system for leaks.
BRAKE HOSE (FRONT)

Removal Procedure

2. Disconnect the brake line from the brake hose sup-
port bracket on the wheel housing.
3. Remove the E–ring retainer.
4. Remove the brake hose from the wheel housing

bracket.
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5. Remove the bolt from the brake caliper.

6. Remove the seal rings and the brake hose.
1. Install the new brake hose to the caliper with new

seal rings and the bolt.
Tighten
Tighten the front brake hose–to–caliper bolt to 40
NSm (30 lb–ft).
2. Install the brake hose and the E–ring retainer to the

wheel housing bracket.
3. Connect the brake line to the brake hose.
Tighten
Tighten the brake line to 16 NSm (12 lb–ft).
5. Bleed the brake system. Refer to ”Manual Bleeding
the Brakes” in this section.
6. Check the brake system for leaks.

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STOPLAMP SWITCH
Removal Procedure

2. Remove the trim panel screws.
3. Remove the trim panel.
4. Turn the stoplamp switch and the connector assem-

bly, and pull it from the brake pedal bracket.
5. Separate the stoplamp switch from the connector to
replace the stoplamp switch.
1. Install the connector to the stoplamp switch.

2. Turn the stoplamp switch and the connector assem-
bly, and twist it into the brake pedal bracket.
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3. Press the brake pedal and pull the switch plunger to

its maximum setting to adjust the switch.
4. Release the plunger and pull up on the pedal.
5. Install the trim panel screws.
Tighten
Tighten the trim panel screws to 7 NSm (62 lb–in).
6. Press the brake pedal and pull the switch plunger to
its maximum setting to adjust the switch.
BRAKE PEDAL
Removal Procedure
1. Remove the screws that hold the trim panel to the

instrument panel.
2. Remove the trim panel.
3. Remove the stoplamp switch. Refer to ”Stoplamp
Switch” in this section.
4. Disconnect the retaining ring, the pin, and the
spring from the pushrod/brake pedal connection.
5. Remove the pedal mounting shaft and nut.

6. Remove the brake pedal, exposing the brake boost-
er pushrod and the pedal–to–dash panel bracket.

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7. Remove the brake pedal cover.
1. Install a new brake pedal cover, if needed.

2. Coat the pedal shaft with grease.
3. Position the brake pedal on the pedal–to–dash pan-
el bracket and the pedal shaft.
4. Place the nut on the pedal mounting shaft.
Tighten
Tighten the brake pedal–to–pedal bracket nut to 22
NSm (16 lb–ft.)
5. Install the pushrod to the pedal with the pin and the
retaining ring.
6. Install the spring on the shaft in its original position.

7. Connect the stoplamp switch and the connector
assembly by twisting it into the pedal bracket.
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8. Install the trim panel with the screws.

Tighten
Tighten the trim panel screws to 7 NSm (62 lb–in).

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Thoroughly clean the master cylinder reservoir cap before

GENERAL DESCRIPTION removing it. Do not let any dirt or foreign material fall into
the fluid reservoir.
There is a fluid level switch in the master cylinder reservoir.
HYDRAULIC FLUID When the fluid level is low, the BRAKE lamp in the instru-
ment cluster will turn on. The correct master cylinder fluid
Master cylinder fluid should meet the DOT 3 specification.
level is marked on the left side of the master cylinder reser-
Use DOT 4 for heavy duty applications, such as trailer tow-
voir. If the fluid level is below the MIN indicator mark, check
ing or mountain driving.
the hydraulic brake system for leaks, and then refill the
Use only clear fluid from a sealed container. Fluid that is reservoir to the MAX indicator mark.
exposed to the air will absorb moisture. Water in the mas-
ter cylinder fluid will cause the fluid to boil and the rubber
components to deteriorate.
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SECTION : 4B
MASTER CYLINDER
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 4B–1 PROPORTIONING VALVE . . . . . . . . . . . . . . . . . . 4B–6
FASTENER TIGHTENING SPECIFICATIONS . 4B–1 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B–7
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B–1 MASTER CYLINDER OVERHAUL . . . . . . . . . . . 4B–7
CHECKING BRAKE PROPORTIONING VALVE 4B–1 GENERAL DESCRIPTION AND SYSTEM
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 4B–2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B–10
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 4B–2 MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . 4B–10
MASTER CYLINDER ASSEMBLY . . . . . . . . . . . 4B–2 PROPORTIONING VALVES . . . . . . . . . . . . . . . 4B–10
BRAKE FLUID RESERVOIR . . . . . . . . . . . . . . . . 4B–4 FLUID LEVEL SENSOR . . . . . . . . . . . . . . . . . . . 4B–10
SPECIFICATIONS
Brake Lines 16 12 –
Master Cylinder Attaching Nuts 18 13 –
Proportioning Valves 35–44 26–33 –
Bleeder Valves 6 – 53
When checking the brake proportioning valves, be sure
DIAGNOSIS that the hydraulic line pressure is measured simulta-
neously and diagonally on the front and the rear axles.
To measure the pressure, use the following steps:
CHECKING BRAKE 1. Remove the bleeder valve and install a pressure
gauge to one of the rear wheel cylinders.
PROPORTIONING VALVE 2. At the diagonally opposite front brake caliper, re-
Use two brake pressure gauges to check the brake pro- move the bleeder valve and install another pressure
portioning valves that are attached to the master cylinder gauge.
on non–ABS braking systems. These valves limit the out- 3. Build pressure by pressing firmly on the brake ped-
let pressure to the rear brakes after a predetermined mas- al several times. (The pressure indicated on the
ter cylinder pressure has been reached. (On vehicles gauge is not regulated and represents the actual
equipped with ABS, the hydraulic modulator assembly brake system hydraulic pressure.)
controls the hydraulic pressure to both the rear wheel cyl- 4. Build pressure until the test values in the following
inders and the front calipers.) proportioning valve test chart are achieved.
Engine Reference Number for Input Pressure Read on Output Pressure Read
Gradient and Switching the Manometer at the on the Manometer at the
Pressure on the Valve Front Axle in kPa (psi) Rear Axle in kPa (psi)
Housing
1.5L 0.3/40 500 (73) 500 (73)
5 500 (798) 4 450 µ 200(645 µ 29)
10 000 (1,450) 5 800 µ 300(841 µ 44)
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4B – 2IMASTER CYLINDER
1.6L 0.3/30 500 (73) 500 (73

4 500 (653) 3 450 µ 200(500 µ 29)
10 000 (1,450) 5 100 µ 300(740 µ 44)
Important : If the pressure exceeds 10 000 kPa 1,450 Tighten the bleeder valves to 6 NSm (53 lb–in).
psi), the pressure reading on the rear gauge will not be ac- 7. Repeat the test on the remaining front/rear brake
curate. circuit.
5. Remove the gauges from the tested brake circuit. 8. Reinstall the bleeder valves.
6. Reinstall the bleeder valves. Tighten
Tighten Tighten the bleeder valves to 6 NSm (53 lb–in).

MASTER CYLINDER ASSEMBLY
Removal Procedure
1. Disconnect the electrical connector from the reser-

voir cap.
2. For vehicles with the ABS braking system, discon-

nect the brake lines from the master cylinder body.
3. For vehicles with the non–ABS braking system, dis-
connect the brake lines from the proportioning
valves.
4. For vehicles with the manual transaxle, disconnect
the clip to the clutch hose connection at the master
cylinder.
5. Plug the opening to the brake lines to prevent fluid
loss and contamination.

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MASTER CYLINDER 4B – 3
6. Remove the attaching nuts from the power booster.

7. Remove the master cylinder assembly.
8. Remove the seal from the booster housing. Discard
the seal.
9. Drain the brake fluid.
1. Install the master cylinder assembly with the new

attaching nuts.
2. Install the new seal to the booster housing.
Tighten
Tighten the master cylinder attaching nuts to 18 NSm
(13 lb–ft)..
3. For vehicles with the ABS braking system (as

shown), connect the brake lines to the cylinder
body.
4. For vehicles with the non–ABS braking system,
connect the brake lines to the proportioning valves.
Tighten
5. For vehicles with the manual transaxle, connect the
clip to the clutch hose connection at the master cyl-
inder.
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6. Connect the electrical connector on the reservoir

cap.
7. Add brake fluid.
8. Check for leaks and recheck the fluid level.
9. Bleed the brake system. Refer to Section 4A, Hy-
draulic Brakes.
BRAKE FLUID RESERVOIR

Removal Procedure
Important : Remove the reservoir only when replacing a

damaged or a leaking reservoir.
voir cap.
2. For vehicles with the manual transaxle, disconnect

the clip to the clutch hose connection at the master
cylinder.
3. Gently pry upward with a screwdriver to release the
reservoir.
4. Tilt the reservoir and pull it upward in order to re-
move it.

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5. Remove the reservoir seals from the master cylin-

der body.
1. Lubricate the new seals with clean brake fluid.

Install the seals into the cylinder body.
2. Install the reservoir on the master cylinder body.
(The ABS system is shown.)
3. For vehicles with the manual transaxle, connect the

clip to the clutch hose connection at the master cyl-
inder.
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4. Add brake fluid.

6. Bleed the braking system. Refer to Section 4A, Hy-
draulic Brakes orSection 4F, Antilock Brake Sys-
tem. Bleed the clutch master cylinder. Refer to Sec-
tion 5C, Clutch.
8. Connect the reservoir electrical connector.
PROPORTIONING VALVE
Removal Procedure
1. Disconnect the brake lines from the proportioning
valves.
2. Remove the valves from the master cylinder body.
Important : Since these valves are adjusted in pairs to the
correct control range, they must be replaced in pairs.
1. Install the proportioning valves to the cylinder body.
Tighten
Tighten the proportioning valves to 35–44 NSm (26–
33 lb–ft).
2. Connect the brake lines to the valves.
Tighten
tem.

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UNIT REPAIR
MASTER CYLINDER OVERHAUL
1. Remove the master cylinder. Refer to ”Master Cyl-

inder Assembly” in this section.
2. Remove the brake fluid reservoir. Refer to ”Brake
Fluid Reservoir” in this section.
3. Remove the seal ring from the cylinder bore.
Notice : When removing the retaining ring, avoid damag-
ing the piston or the cylinder wall.
Important : A welding rod or its equivalent can be used in

a compensating port to keep the piston pressed down.
4. Remove and discard the retaining ring from the cyl-
inder body using a suitable screwdriver. (The non–
ABS master cylinder body is shown.)
5. Remove the primary piston. (The ABS master cylin-

der body is shown.)
6. Carefully remove the secondary piston assembly
and the spring from the master cylinder bore.
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Assembly Procedure
Notice : Do not use abrasives in the master cylinder bore.

Abrasives can damage the bore.
Important : Rubber parts and retaining rings must be dis-
carded and replaced with new parts
1. Clean all parts with denatured alcohol or clean
brake fluid. Dry the parts with compressed air.
2. Inspect the master cylinder bore for scoring or cor-
rosion. If scoring or corrosion is evident, replace the
master cylinder body.
3. Lubricate the master cylinder bore with clean brake
fluid. (The non–ABS master cylinder is shown.)
4. Carefully insert the secondary piston assembly bore

until the secondary piston contacts the base of the
cylinder body. Use a wood or a plastic drift, if nec-
essary.
5. Insert the primary piston.
6. Press the pistons into the cylinder bore using a

wooden or a plastic drift.
Notice : When installing the new retaining ring, take care
not to damage the cylinder bore.
7. Insert the new retaining ring into the groove in the
cylinder bore. (The non–ABS cylinder body is
shown.) Remove the welding rod.
8. Move the pistons backward and forward after instal-
lation to check for free movement.

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9. Lubricate the seal ring and insert the seal on the

shaft into the cylinder bore. The open side must
face outward until the seal rests on the piston.
10. Install the brake fluid reservoir to the master cylin-
der. Refer to ”Brake Fluid Reservoir” in this section.
11. Install the master cylinder assembly. Refer to Mas-
ter Cylinder Assembly in this section
tem.
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S if any hydraulic component is removed or discon-

GENERAL DESCRIPTION nected, it may be necessary to bleed all or part of
the brake system.
AND SYSTEM OPERATION S The torque values specified are for dry, unlubri-
cated fasteners.
S Perform all service operations on a clean bench,
MASTER CYLINDER free from all traces of mineral oil.
The master cylinder is designed for use in a diagonalsplit
system. One front and one diagonally opposite rear brake PROPORTIONING VALVES
are served by the primary piston. The opposite front and The proportioning valves limit the outlet pressure to the
rear brakes are served by the secondary piston. The mas- rear brakes on the non–antilock braking system after a
ter cylinder incorporates the functions of the standard dual predetermined master cylinder pressure has been
master cylinder, plus a low fluid level indicator and the pro- reached. This is used when less rear apply force is needed
portioning valves in the non–antilock braking system. The to obtain optimum braking and is usually found on disc/
proportioning valves limit the outlet pressure to the rear drum brake configurations. On ABS–equipped vehicles,
brakes after a predetermined master cylinder pressure refer to Section 4F, Antilock Brake System.
has been reached.
Notice : Do not use lubricated shop air on brake parts, as FLUID LEVEL SENSOR
this may damage rubber components. The master cylinder is equipped with a fluid level sensor.
S Replace all the components included in the repair This sensor will activate the BRAKE light if a low fluid level
kits used to service this master cylinder. condition is detected. Once the fluid level is corrected, the
S Lubricate rubber parts with clean brake fluid to ease BRAKE light will go out.
assembly.

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SECTION : 4C
POWER BOOSTER
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–1 ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 4C–2
FASTENER TIGHTENING SPECIFICATIONS . 4C–1 VACUUM HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–2
POWER BOOSTER ASSEMBLY . . . . . . . . . . . . 4C–3
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–1
POWER BOOSTER FUNCTIONAL CHECK . . . 4C–1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–9
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 4C–2 POWER BOOSTER . . . . . . . . . . . . . . . . . . . . . . . 4C–9
SPECIFICATIONS
Booster and Support Bracket–to–Dash Panel 24 18 –
Nuts
Booster Pushrod Hex Nut 18 13 –
Booster–to–Support Bracket Nuts 18 13 –
Master Cylinder Attaching Nuts 18 13 –
2. Push the pedal down and hold it in this position.
DIAGNOSIS 3. Start the engine.
4. The booster is OK if the pedal drops further be-
POWER BOOSTER FUNCTIONAL cause of extra force produced.
5. If the brake pedal does not drop, the vacuum sys-
CHECK tem (vacuum hoses, check valve, etc.) is probably
1. With the engine stopped, eliminate the vacuum in defective and should be checked.
the booster by pumping the brake pedal several 6. If no defect is revealed by checking the vacuum
times. system, the defect is in the booster itself.
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4C – 2IPOWER BOOSTER
VACUUM HOSE
Removal Procedure
1. For vehicles with a DOHC engine, remove the clip

on the vacuum hose connection at the intake man-
ifold.
2. Pull the hose from the union nut connection. If the
hose does not remove easily or is deteriorated, pry
off and discard the hose.
3. For vehicles with a SOHC engine, similarly remove
the clip on the vacuum hose nut connection to the
intake manifold.
4. Pull the hose from the union nut connection. If the
hose does not remove easily or is deteriorated, pry
off and discard the hose.
5. Remove the clip on the vacuum hose connection to

the brake booster.
6. Remove the vacuum hose.

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POWER BOOSTER 4C – 3
1. Mount the vacuum hose (DOHC engine connection
shown), and make sure the connections are tight
on each end.
2. Install the vacuum hose clips.
3. Check the function of the booster. Refer to the
”Power Booster Functional Check” in this section.
POWER BOOSTER ASSEMBLY

Removal Procedure

voir cap.
2. For vehicles with a manual transaxle, disconnect

the clip on the clutch hose connection to the master
cylinder.
3. Plug the clutch hose and the master cylinder so
that the fluid does not escape.
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4. Remove the master cylinder attaching nuts.

5. Push the master cylinder forward slightly and move
it out of the way. Do not disconnect the brake lines.
6. Remove and discard the booster housing seal.
7. Remove the clip on the vacuum hose connection to

the booster (DOHC engine connection shown).
8. Disconnect the brake lamp switch.
9. Remove the brake pedal spring.
10. Disconnect the clip and the pushrod pin from the
pedal bracket assembly. Refer to Section 4A, Hy-
draulic Brakes.
11. Remove the booster and the support bracket–to-

dash panel nuts.

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12. Remove the booster and the bracket assembly

from the dash panel.
13. Remove the bracket nuts from the booster and re-
move the booster.
14. Remove the rubber boot and the retainer.
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15. Remove the pushrod.

16. Remove the adjustment sleeve from the pushrod.
17. Remove the hex nut.
1. Check the pushrod and the adjustment sleeve for

damage and proper fit.
2. Install the hex nut and the adjustment sleeve on the

booster.
Tighten
Tighten the booster pushrod hex nut and the adjust-
ment sleeve to 18 NSm (13 lb–ft).

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3. Insert the pushrod in the adjustment sleeve and

mount the retainer.
4. Measure the distance from the booster to the cen-
ter of the fork bin bore.
Important : This measurement should be 278.5 mm (10
inches).
5. Install the rubber boot on the booster.
6. Install the brackets to the booster.

Tighten
Tighten the booster–to–support bracket nuts to 18
NSm (13 lb–ft).
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7. Install the booster and the bracket assembly to the

dash panel.
Tighten
Tighten the booster and support bracket–to–dash
panel nuts to 24 NSm (18 lb–ft).
8. Connect the master cylinder to the booster and

install a new booster housing seal.
Tighten
Tighten the master cylinder attaching nuts to 18 NSm
(13 lb–ft).
9. Install the new vacuum hose to the booster (DOHC

engine connection shown). Refer to Vacuum
Hose" in this section.
10. Install new hose clamps on the vacuum hose.
11. Install the pushrod pin to the brake pedal bracket
assembly and connect the clip and the spring. Re-
fer to Section 4A, Hydraulic Brakes.
12. Install the brake lamp switch.

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When the brakes are applied, air at atmospheric pressure

GENERAL DESCRIPTION is admitted to one side of the diaphragm to provide the
power assist. When the brakes are released, atmospheric
AND SYSTEM OPERATION air is shut off from that side of the diaphragm. The air is
then drawn from the booster through the vacuumcheck
POWER BOOSTER valve by the vacuumsource.
This booster is a single diaphragm, vacuum–suspended Important : If any hydraulic component is removed or dis-
unit. In a normal operating mode, with the service brakes connected, it may be necessary to bleed all or part of the
in the release position, a vacuum–suspended booster op- brake system.
erates with a vacuum on both sides of its diaphragm.
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SECTION : 4D
FRONT DISC BRAKES
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 4D–1 CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 4D–4
FASTENER TIGHTENING SPECIFICATIONS . 4D–1 ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D–6
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D–1 SPLASH SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . 4D–7
LINING INSPECTION . . . . . . . . . . . . . . . . . . . . . . 4D–1 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D–8
ROTOR INSPECTION . . . . . . . . . . . . . . . . . . . . . 4D–1 CALIPER OVERHAUL . . . . . . . . . . . . . . . . . . . . . 4D–8
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 4D–3 GENERAL DESCRIPTION AND SYSTEM
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 4D–3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D–11
SHOE AND LINING . . . . . . . . . . . . . . . . . . . . . . . . 4D–3 DISC BRAKE CALIPER ASSEMBLY . . . . . . . . 4D–11
SPECIFICATIONS
Brake Hose Inlet Fitting–to–Caliper Bolt 40 30 –
Caliper Bleeder Valve 6 – 53
Caliper–to–Steering Knuckle Mounting Bolts 95 70 –
Retaining Frame–to–Caliper Housing Bolts 27 20 –
Rotor–to–Front Wheel Hub Detent Screw 4 – 35
Splash Shield–to–Steering Knuckle Screws 4 – 35
Thickness variation can be checked by measuring the
DIAGNOSIS thickness of the rotor at four or more points around the cir-
cumference of the rotor. All measurements must be made
at the same distance in from the edge of the rotor.
LINING INSPECTION Thickness variation can be checked by measuring the
1. Raise and suitably support the vehicle. thickness of the rotor at four or more points around the cir-
2. Remove the front wheels. Refer to Section 2E, cumference of the rotor. All measurements must be made
Tires and Wheels. at the same distance from the edge of the rotor. A rotor that
3. Visually check the linings for minimum thickness varies by more than .10 mm (0.004 inch) can cause pedal
and wear. pulsation and/or front end vibration during braking. Thick-
4. Measure the thickness. ness can be measured with a commercial–ly available mi-
Important : The minimum thickness of the inner or the crometer.
outer pad is 7 mm (0.28 inch). A rotor that varies by more than 0.10 mm (0.004 inch) can
5. Install the brake pads in axle sets only. cause pedal pulsations and/or front end vibration during
6. Install the front wheels. Refer to Section 2E, Tires brake applications. A rotor that does not meet these speci-
and Wheels. fications should be refinished to specifications or re-
7. Lower the vehicle. placed.
Lateral runout cannot exceed 0.10 mm (0.004 inch). If lat-
ROTOR INSPECTION eral runout exceeds the specification, make sure that
there is no dirt between the rotor and the hub and that hub–
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4D – 2IFRONT DISC BRAKES
to–rotor contact surfaces are smooth and free from burrs. 6. Remove the dial indicator and connecting wheel
Use a commercially available dial indicator to check the bolts to the hub.
lateral runout according to the following procedure: Important : Since accurate control of the rotor tolerances
During manufacturing, the brake rotor and the tolerances is necessary for proper performance of the disc brakes, re-
of the braking surface regarding flatness, thickness varia- finishing of the rotor should be done only with precision
tion, and lateral runout are held very close. equipment.
The maintenance of close tolerances on the shape of the 7. Refinish the rotor, if required, with precision equip-
braking surfaces is necessary to prevent brake rough- ment.
ness. 8. Install the rotor. Refer to ”Rotor” in this section.
In addition to these tolerances, the surface finish must be
held to a specified range. The control of the braking sur-
face finish is necessary to avoid pulls and erratic perfor-
mance and to extend lining life.
Light scoring of the rotor surfaces not exceeding 0.40 mm
(0.016 inch) in depth, which may result from normal use,
is not detrimental to brake operation. Using a commercial-
ly available dial indicator, check lateral runout as follows:
Notice : Permissible lateral runout is a maximum 0.10 mm
0.004 inch). If lateral runout exceeds the specification,
make sure there is no dirt between the rotor and the hub
and that contact surfaces are smooth and free from burrs.
1. Position the transaxle in NEUTRAL.
2. Remove the rotor. Refer to ”Rotor” in this section.
3. Fasten the brake rotor to the wheel hub with two
wheel bolts.
4. Fasten a dial indicator to the brake caliper.
5. Set the gauge probe tip to approximately 10 mm
(0.39 inch) from the outer edge of the brake rotor,
perpendicular to the disc and under slight preload.

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FRONT DISC BRAKES 4D – 3
SHOE AND LINING
Removal Procedure

2. To pressure wheel balance, mark the relative posi-
tions of the wheel and the hub, and remove the
front wheel. Refer to Section 2E, Tires and Wheels.
3. Remove the lower bolt of the caliper assembly re-
taining frame.
Important : It is not necessary to remove the caliper to
service the brake shoes.
4. Pull the caliper piston housing up.
5. Remove the brake pads.
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1. Measure the minimum lining thickness. Refer to

”Lining Inspection” in this section.
2. Install the brake pads into the caliper.
3. Push the piston inward, if necessary.
Notice : Take care not to damage the piston seal when the
piston housing is pulled down.
4. Pull down the caliper piston housing and secure it
to the retaining frame with the lower bolt.
Tighten
Tighten the retaining frame–to–caliper housing bolts
to 27 NSm (20 lb–ft).
5. Align the marks that were made before the wheel
removal and install the front wheels. Refer to Sec-
tion 2E, Tires and Wheels.
CALIPER ASSEMBLY
Removal Procedure

2. Mark the position of the front wheels relative to the
wheel hubs and remove the wheels. Refer to Sec-
tion 2E, Tires and Wheels.
3. Remove the bolt and the washers that attach the
brake hose to the caliper.

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4. Disconnect the brake hose, and plug the openings

in the caliper and the brake hose to prevent fluid
loss and contamination.
5. Remove the caliper mounting bolts from the steer-
ing knuckle, and remove the caliper assembly.
1. Install the caliper assembly with the mounting bolts.

Tighten
Tighten the caliper–to–steering knuckle mounting
bolts to 95 NSm(70 lb–ft).
2. Connect the brake hose.

Tighten
Tighten the brake hose inlet fitting–to–caliper bolt and
washers to 40 NSm (30 lb–ft).
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3. Install the front wheels. Refer to Section 2E, Tires

and Wheels.
5. Fill the master cylinder to the proper level with
clean brake fluid.
6. Bleed the caliper. Refer to Section 4A, Hydraulic
Brakes or Section 4F, Antilock Brakes, if applicable.
7. Recheck the fluid level.
Notice : Do not move the vehicle until a firm pedal is ob-
tained, or improper braking action will result.
8. Repeatedly press the brake pedal to bring the pads
in contact with the rotor.,
ROTOR
Removal Procedure
Notice : Do not hang the caliper assembly from the brake
hose. Any resulting internal hose restriction will impede
uniform braking action.
Important : To guarantee uniform braking on both sides,

both rotors must have identical surfaces regarding
smoothness and scoring depth. For this reason, always
replace both rotors.
1. Remove the caliper assembly without disconnecting
the brake hoses. Refer to ”Caliper Assembly” in this
section.
2. Remove the caliper bracket.
3. Remove the rotor–to–front wheel hub detent screw
from the rotor and the front wheel hub.
4. Pull off the rotor.
1. Inspect the rotor. Refer to ”Rotor Inspection” in this
section.
2. Install the rotor to the front wheel hub by tightening
the detent screw.
Tighten
Tighten the rotor–to–front wheel hub detent screw to
4 NSm (35 lb–in).
3. Install the caliper bracket.
Tighten
Tighten the caliper bracket mounting bolts to 95 NSm
(70 lb–ft).
4. Install the caliper assembly. Refer to ”Caliper As-
sembly” in this section.

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SPLASH SHIELD
Removal Procedure
1. Remove the rotor. Refer to ”Rotor” in this section.
2. Remove the screws for the splash shield from the
steering knuckle.
3. Remove the splash shield.
1. Install the splash shield.
2. Secure the splash shield to the steering knuckle
with the screws.
Tighten
Tighten the splash shield–to–steering knuckle screws
to 4 NSm (35 lb–in).
3. Install the rotor. Refer to ”Rotor” in this section.
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UNIT REPAIR
CALIPER OVERHAUL
1. Remove the caliper assembly. Refer to ”Caliper As-

2. Remove the caliper guide pin that connects the cali-
per piston housing to the retaining frame.
3. Remove the front pad brake set, including the pad

springs, from the caliper. Refer to ”Shoe and Lining”
in this section.
CAUTION : Do not attempt to catch the piston when
removing the piston with compressed air. The piston
will pop out of its bore with enough force to damage
a hand or finger.
Important : Insert a piece of hardwood into the caliper
housing interior when removing the piston.
4. Using compressed air, blow out the piston from the
housing.
5. Remove the outer seal.
6. Remove the inner seal from the caliper piston bore.

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7. Remove the bleeder valve protector and the bleed-

er valve.
8. Pull out the pins and the rubber boots.
Assembly Procedure
1. Clean all parts in denatured alcohol or brake fluid.

Dry the parts with unlubricated compressed air and
blow out all passages in the housing and the bleed-
er valve.
2. Inspect the piston and the caliper for scoring, nicks,
and corrosion. Replace components if these ele-
ments are found.
3. Inspect the caliper bleeder valve.
Important : Do not use a hone or any other procedure to
remove material from the piston or the caliper bore.
4. Lubricate a new piston inner seal.

5. Install the piston inner seal into the caliper housing
groove. Make sure the seal is not twisted.
6. Install the outer piston dust seal in the groove.
7. Lubricate the piston with brake fluid.
8. Push the piston into its bore and make sure the
dust seal is seated in the piston groove.
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9. Coat the pins with rubber grease and install the

boots.
10. Install the caliper bleeder valve and the dust cap.
Tighten
Tighten the caliper bleeder valve to 6 NSm (53 lb–in).
11. Connect the brake pads and the pad springs.
Important : Make sure the pad springs are properly
installed.
12. Connect the retaining frame to the caliper housing

with the guide pin bolts.
Tighten
Tighten the retaining frame–to–caliper housing bolts
to 27 NSm (20 lb–ft).
13. Install the caliper assembly. Refer to ”Caliper As-
14. Bleed the brake system. Refer to Section 4A, Hy-
draulic Brakes (or Section 4F, Antilock Brakes, if
applicable.)
15. Repeatedly apply the brakes until a firm pedal ob-
tained.

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S Replace all components included in the repair kits

GENERAL DESCRIPTION used to service this caliper.
AND SYSTEM OPERATION S Lubricate the rubber parts with clean brake fluid to
ease assembly.
S Do not use lubricated shop air on brake parts, as
DISC BRAKE CALIPER ASSEMBLY damage to the rubber components may result.
This caliper has a single bore and is mounted to the steer- S If any hydraulic component is removed or discon-
ing knuckle with two mounting bolts. Hydraulic pressure, nected, it may be necessary to bleed all or part of
created by applying the brake pedal, is converted by the the brake system.
caliper to a stopping force. This force acts equally against S Replace the pads in axle sets only.
the piston and the bottom of the caliper bore to move the S The torque values specified are for dry, unlubri-
piston outward and to slide the caliper inward, resulting in cated fasteners.
a clamping action on the rotor. This clamping action forces S Perform the service operations on a clean bench,
the linings against the rotor, creating friction to stop the ve- free from all mineral oil materials.
hicle.
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SECTION : 4E
REAR DRUM BRAKES
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 4E–1 TWO–PIECE DRUM . . . . . . . . . . . . . . . . . . . . . . . 4E–5
FASTENER TIGHTENING SPECIFICATIONS . 4E–1 SHOE AND LINING . . . . . . . . . . . . . . . . . . . . . . . . 4E–6
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E–1 WHEEL CYLINDER ASSEMBLY . . . . . . . . . . . 4E–11
LINING INSPECTION . . . . . . . . . . . . . . . . . . . . . . 4E–1 BACKING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . 4E–13
DRUMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E–1 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E–14
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 4E–3 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 4E–14
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 4E–3 GENERAL DESCRIPTION AND SYSTEM
BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 4E–3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E–16
ONE–PIECE DRUM . . . . . . . . . . . . . . . . . . . . . . . 4E–4 DRUM BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 4E–16
SPECIFICATIONS
Brake Drum Detent Screw 4 – 35
Brake Line 16 12 –
Brake Wheel Hub/Backing Plate–to–Rear 28 21 –
Axle Nuts
One–Piece Drum Castle Nut 25 – 180? + 2 18 – 180? + 1.5 –
Wheel Cylinder–to–Backing Plate Bolt 8 – 71
1. Install the drum, if removed. Refer to ”One–Piece
DIAGNOSIS Drum” or ”Two–Piece Drum” in this section.
2. Install the wheel, if removed. Refer to Section 2E,
Tires and Wheels.
LINING INSPECTION 3. Lower the vehicle.
2. Remove the wheel. Refer to Section 2E, Tires and DRUMS
Wheels. Whenever brake drums are removed, they should be thor-
3. Release the parking brake. oughly cleaned and inspected to see if the drums are
4. Remove the drum. Refer to ”One–Piece Drum” or cracked, scored, deeply grooved, or beyond the specified
”Two–Piece Drum” in this section. out–of–round limit.
5. Measure the lining thickness. The minimum lining S A cracked drum is unsafe for further service and-
thickness is 0.5 mm (0.02 inch). must be replaced. Do not attempt to weld a cracked
CAUTION : To avoid injury when servicing brake drum. Smooth out any slight scores.
parts, do not create dust by grinding or sanding the S Heavy or extensive scoring will cause excessive
brake linings or by cleaning the wheel brake parts brake lining wear and may require refinishing the
with a dry brush or with compressed air. drum braking surface.
S If the brake linings are slightly worn but are still re-
Important : Replace the shoe and lining assembly in axle
usable and the drum is grooved, polish the drum
sets only.
with a fine emery cloth but do not refinish it. Elimi-
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4E – 2IREAR DISC BRAKES
nating all grooves in the drum and smoothing the An out–of–round drum can also cause severe and
ridges on the lining would remove too much metal irregular tire tread wear, as well as a pulsating
and lining. If left alone, the grooves and ridges brake pedal.
match, and satisfactory service can be obtained. If S The extent to which a drum is worn or out of round
the brake linings need to be replaced, refinish a can be measured accurately with an inside microm-
grooved drum. A grooved drum, used with a new eter fitted with the proper extension rods. When
lining, will not only wear the lining, but also will measuring a drum for wear or the extent to which it
make it difficult, if not impossible, to obtain proper is out of round, take measurements from the inside
brake performance. edge to the outside edge of the machined surface
S An out–of–round drum makes accurate brake shoe at 90–degree intervals around the circumference of
adjustment impossible and is likely to cause exces- the drum. When the drum exceeds the specified
sive wear of other parts of the brake mechanism. out–of–round limit, refinish the drum.

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REAR DISC BRAKES 4E – 3
BRAKE ADJUSTMENT
Removal Procedure
1. Release the parking brake.

2. Operate the brake at least 10 times until the jump-
ing of the adjustment spring on the adjustment nut
can no longer be heard on either brake drum.
and Wheels. Mark the position of the wheels rela-
tive to the wheel hubs.
5. For vehicles with an ABS braking system, remove
the detent screw from the brake drum.
6. For vehicles without ABS system, remove the split
pin and the nut that secures the drum to the
spindle.
7. Remove the brake drum.
8. Using the rear brake adjuster nut, turn the adjuster

assembly in until there is a sufficient amount of
drag on the brake drum.
9. Make sure that the parking brake lever stops are
against the edge of the shoe web. If they are not,
loosen the parking brake cable at the equalizer. Re-
fer to Section 4G, Parking Brake.
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1. For vehicles with an ABS braking system, position

rear brake drum and fasten the detent screw.
Tighten
Tighten the brake drum detent screw to 4 NSm (35
lbin).
2. For vehicles without ABS braking system, position

the rear brake drum. Fasten the one–piece drum
castle nut and secure it with the new split pin.
Tighten
Tighten the one–piece drum castle nut to 25 NSm (18
lb–ft) minus 180 degrees plus 2 NSm (18 lb–in).
3. Install the rear wheels. Refer to Section 2E, Tires
Important : The brake pedal must be operated more than
10 times. When the clicking can no longer be heard, the
clearance between the brake shoe and drum is adjusted.
4. Apply the foot brake several times until the clicking
of the adjustment actuator can no longer be heard.
Parking Brake.
ONE–PIECE DRUM
Removal Procedure
Wheels. Mark the position of the wheels relative to
the wheel hubs.
3. Remove the split pin and the castle nut that se-
cures the drum to the spindle. Discard the split pin.
4. Remove the rear brake drum.

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1. Inspect the hub bearing, and coat it with grease, if
needed.
2. Install the rear brake drum.
3. Secure the drum with the castle nut and the new
split pin.
Tighten
Wheels.
TWO–PIECE DRUM
Removal Procedure
Wheels. Mark the position of the wheels relative to
the wheel hubs.
3. Remove the detent screw from the brake drum.
1. Inspect the brake drum. Refer to ”Drums” in this
section.
2. Install the brake drum.
3. Tighten the detent screw to secure the brake drum.
Tighten
lbin).
Wheels.
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SHOE AND LINING

Removal Procedure

3. Mark the position of the wheels relative to the
wheel hub.
4. Loosen the parking brake cable. Refer to Section
4G, Parking Brake. Mark the position of the wheels
relative to the wheel hubs.
5. For vehicles with the ABS braking system, remove
the detent screw from the brake drum. Remove the
brake drum.
6. For vehicles without ABS braking system, remove

the rear brake drum by unfastening the split pin and
the one–piece drum castle nut. Discard the split
pin.
7. Loosen the leading shoe hold–down return spring.

(The ABS braking system configuration is illus-
trated.)

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8. Disconnect the upper link of the connecting lin-

kspring of the leading shoe to relieve tension on the
upper return spring.
9. Remove the upper return spring and the adjuster.
10. Remove the leading shoe by unlatching it from the

lower return spring.
11. Unfasten the trailing shoe and lining assembly hold-

down return spring.
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12. Disconnect the trailing shoe and lining assembly on

the right side.
13. Detach the lower return spring.
1. Measure the minimum brake lining thickness. Refer

to ”Lining Inspection” in this section.
2. Clean the adjuster assembly and apply grease.
Notice : If any parts are of questionable strength or quality
because of heat discoloration, excessive stress, or wear,
the shoes, the springs, or the adjuster assembly should be
replaced.
3. Inspect the threads of the adjuster assembly for
smooth rotation.
4. Coat the backing plate with grease at the brake

shoe contact points.

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5. Install the trailing shoe and lining assembly with the

hold–down spring, the washer, and the pin.
6. Make sure the parking brake cable is properly
routed and attached to the shoe lever.
Notice : Do not overstretch the lower return spring.
7. Fasten the lower return spring on the shoe.
8. Position the leading shoe and the adjuster assem-

bly against the backing plate.
9. Fasten the lower return spring to the leading shoe.
10. Install the adjuster assembly.

11. Turn the adjuster in as far as possible.
12. Position the spring clip toward the backing plate.
13. Install the leading shoe with the hold–down spring.
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14. Attach the leading shoe upper link–spring connec-

tion, which applies tension to the upper return
spring.
Notice : Do not overstretch the upper return spring.
15. Install the upper return spring from the spring con-
necting link to the brake shoe.
Notice : The nut must not lock firmly at the end of the ad-
justment assembly.
16. Before installing the brake drum, make sure the
adjuster assembly nut is drawn all the way to the
stop.
17. For vehicles with the ABS braking system, install

the brake drum and fasten it with the detent screw.
Tighten
lbin).

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18. For vehicles without ABS braking system, install the

brake drum and fasten it with the castle nut and the
new split pin.
Tighten
and Wheels.
20. Adjust the rear wheel brakes. Refer to ”Brake Ad-
justment” in this section.
Parking Brake.
WHEEL CYLINDER ASSEMBLY

Removal Procedure

and Wheels.
3. Mark the position of the wheels relative to the
wheel hubs.
5. Remove the shoe and lining. Refer to ”Shoe and
Lining” in this section.
6. Clean dirt and foreign material from around the

wheel cylinder brake line inlet, the pilot, and the
bolt.
7. Disconnect the brake line from the wheel cylinder.
8. Plug the opening in the brake line to prevent fluid
loss or contamination.
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9. Remove the wheel cylinder–to–backing plate bolt.

10. Gently tap out the wheel cylinder from the backing
plate, using care not to damage the bleeder valve
or its cap.
1. Install the wheel cylinder to the backing plate with

the wheel cylinder bolt.
Tighten
Tighten the wheel cylinder–to–backing plate bolt to 8
NSm (71 lb–in).
2. Connect the brake line to the wheel cylinder.

Tighten
Tighten the brake line to 16 NSm (12 lb–ft)
3. Install the shoe and lining, and the brake drum. Re-
fer to ”Shoe and Lining” in this section.
4. Bleed the brakes. Refer to Section 4A, Hydraulic
Brakes.

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BACKING PLATE
Removal Procedure

2. Remove the brake shoe components, including
complete removal of the parking brake with the re-
tainer. Refer to ”Shoe and Lining” in this section
and Section 4A, Hydraulic Brakes.
3. Remove the nuts that secure the wheel hub assem-
bly to the backing plate.
4. Remove the brake line and plug the opening in the
line to prevent fluid loss or contamination.
5. Remove the wheel cylinder assembly. Refer to

”Wheel Cylinder Assembly” in this section.
6. Remove the wheel hub assembly. (The ABS hub is
shown.) Disconnect the cable that goes to the
wheel speed sensor on ABS brakes.
7. Separate the backing plate and the gasket.
1. Place the backing plate with a new gasket on the

wheel hub. (The ABS hub is shown.).
2. Insert the complete wheel hub/backing plate as-
sembly into the rear axle plate. Install the nuts and
connect the wheel speed sensor on ABS brakes.
Tighten
Tighten the brake wheel hub/backing plate–to–rear
axle nuts to 28 NSm (21 lb–ft).
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3. Install the brake wheel cylinder assembly to the

backing plate. Refer to ”Wheel Cylinder Assembly”
in this section.
4. Connect the brake line.
Tighten
Tighten the brake line to 16 NSm (12 lb–ft).
5. Install the brake components. Refer to ”Shoe and
Lining” in this section.
6. Install the parking brake cable with the retainer by
attaching the cable to the brake shoe lever. Refer to
Section 4G, Parking Brake.
7. Bleed the brakes. Refer to Section 4A, Hydraulic
Brakes.
UNIT REPAIR
WHEEL CYLINDER
1. Remove the wheel cylinder assembly from the

backing plate. Refer to ”Wheel Cylinder Assembly”
in this section.
2. Twist off the boots, the pistons, and the seals from
each end of the wheel cylinder.
3. Remove the spring assembly.
4. Remove the bleeder cap and the bleeder valve.

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Assembly Procedure
1. Inspect the wheel cylinder bore and the pistons for

scoring, nicks, corrosion, and wear.
2. Use a crocus cloth to polish out light corrosion in
the wheel cylinder bore.
Important : If the bore will not clean up with a crocus cloth,
replace the assembly.
3. Clean all the parts in clean denatured alcohol or

brake fluid. Dry all the parts with unlubricated com-
pressed air and lubricate the new seals, the pis-
tons, and the wheel cylinder bore with clean brake
fluid before assembly.
4. Thinly coat all the parts except the dust caps with
brake cylinder fluid.
5. Fasten the bleeder valve and the cap to the wheel
cylinder.
6. Attach to the wheel cylinder the spring assembly,

followed by the pistons, the seals, and the boots.
7. Inspect the pistons for free movement.
8. Install the wheel cylinder assembly. Refer to ”Wheel
Cylinder Assembly” in this section.
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of shoes that have been in service, as this may render the

GENERAL DESCRIPTION self–adjustment feature inoperative and result in in-
creased pedal travel.
AND SYSTEM OPERATION Notice : To avoid damaging the vehicle, observe the fol-
lowing directions:
DRUM BRAKES S Replace all the components included in the repair
This drum brake assembly is a leading/trailing shoe de- kits used to service this drum brake.
sign. Both brake shoes are held against the wheel cylinder S Do not use lubricated shop air on the brake parts,
pistons by the lower return spring and the fixed anchor as damage to the rubber components may result.
plate near the lower return spring. When the brakes are S If any hydraulic component is removed or discon-
applied, the wheel cylinder pistons move both shoes out nected, it may be necessary to bleed all or part of
to contact the drum. With forward wheel rotation, the for- the braking system.
ward brake shoe will wrap into the drum and become self– S Replace the shoe and linings in axle sets only.
energized. With reverse wheel rotation, the rear brake S The torque values specified are for dry, unlubri-
shoe is self–energized. Force from the brake shoes is cated fasteners.
transferred to the anchor plate through the backing plate S Perform service operations on a clean bench that is
to the axle flange. Adjustment is automatic and occurs on free from all mineral oil materials.
any service brake application. Do not switch the position

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SECTION : 4F
ANTILOCK BRAKE SYSTEM

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 4F–2 DTC C0080/C0085 LEFT REAR INLET AND
FASTENER TIGHTENING OUTLET VALVE SOLENOID FAULT . . . . . . 4F–36
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 4F–2 DTC C0090/C0095 RIGHT REAR INLET AND
OUTLET VALVE SOLENOID FAULT . . . . . . 4F–38
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F–2
DTC C0110 PUMP MOTOR CIRCUIT
SPECIAL TOOLS TABLE . . . . . . . . . . . . . . . . . . . 4F–2 MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . 4F–40
SCHEMATIC AND ROUTING DIAGRAMS . . . . . 4F–3 DTC C0121 VALVE RELAY CIRCUIT
ABS CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F–3 MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . 4F–42
EBCM CONNECTOR FACE VIEW . . . . . . . . . . . 4F–4 DTC C0161 ABS BRAKE SWITCH CIRCUIT
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . 4F–44
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 4F–5 DTC C0245 WHEEL SPEED SENSOR
ABS/EBD SYSTEM DRIVE . . . . . . . . . . . . . . . . . 4F–5 FREQUENCY ERROR . . . . . . . . . . . . . . . . . . 4F–47
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F–6 DTC C0550 ABS CONTROL MODULE
INTERNAL FAULT4F . . . . . . . . . . . . . . . . . . . . 4F–51
DIAGNOSTIC CIRCUIT CHECK . . . . . . . . . . . . . 4F–6
DTC C0800 LOW VOLTAGE FAULT . . . . . . . . 4F–53
ABS INDICATOR LAMP INOPERATIVE . . . . . . 4F–8
POWER SUPPLY TO CONTROL MODULE, MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 4F–56
NO DTCs STORED . . . . . . . . . . . . . . . . . . . . . . 4F–11 ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 4F–56
ABS INDICATOR LAMP ILLUMINATED SERVICE PRECAUTIONS . . . . . . . . . . . . . . . . . 4F–56
CONTINUOUSLY, NO DTCs STORED . . . . 4F–15 BLEEDING SYSTEM . . . . . . . . . . . . . . . . . . . . . 4F–57
ELECTRONIC BRAKE–FORCE DISTRIBUTION ABS 5.3 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 4F–57
(EBD) SYSTEM INDICATOR LAMP FRONT WHEEL SPEED SENSOR . . . . . . . . . 4F–58
INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . 4F–17
REAR WHEEL SPEED SENSOR . . . . . . . . . . . 4F–59
SELF–DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . 4F–20
REAR WHEEL SPEED SENSOR JUMPER
DISPLAYING DTCs . . . . . . . . . . . . . . . . . . . . . . . 4F–20 HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F–59
CLEARING DTCs . . . . . . . . . . . . . . . . . . . . . . . . 4F–20 SYSTEM FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . 4F–60
INTERMITTENTS AND POOR INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F–61
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . 4F–20
DIAGNOSTIC TROUBLE CODE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F–62
(DTC) C0035 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F–21
BASIC KNOWLEDGE REQUIRED . . . . . . . . . . 4F–62
DIAGNOSTIC TROUBLE CODE
ABS SYSTEM COMPONENTS . . . . . . . . . . . . . 4F–62
(DTC) C0040 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F–24
BASE BRAKING MODE . . . . . . . . . . . . . . . . . . . 4F–62
DIAGNOSTIC TROUBLE CODE
(DTC) C0045 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F–27 ANTILOCK BRAKING MODE – APPLY . . . . . . 4F–63
DIAGNOSTIC TROUBLE CODE ANTILOCK BRAKING MODE – HOLD . . . . . . 4F–64
(DTC) C0050 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F–30 ANTILOCK BRAKING MODE – RELEASE . . . 4F–65
DTC C0060/C0065 LEFT FRONT INLET AND EBD SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F–66
OUTLET VALVE SOLENOID FAULT . . . . . . 4F–32 ELECTRONIC BRAKE – FORCE DISTRIBUTION
DTC C0070/C0075 RIGHT FRONT INLET AND (EBD) FAILURE MATRIX . . . . . . . . . . . . . . . . 4F–67
OUTLET VALVE SOLENOID FAULT . . . . . . 4F–34 TIRES AND ABS/EBD . . . . . . . . . . . . . . . . . . . . 4F–68
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4F – 2IANTILOCK BRAKE SYSTEM
ELECTRONIC BRAKE CONTROL AND RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F–68

MODULE (EBCM) . . . . . . . . . . . . . . . . . . . . . . 4F–68 VALVE RELAY AND PUMP
FRONT WHEEL SPEED SENSORS . . . . . . . . 4F–68 MOTOR RELAY . . . . . . . . . . . . . . . . . . . . . . . . 4F–68
FRONT WHEEL SPEED SENSOR RINGS . . . 4F–68 WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . 4F–68
REAR WHEEL SPEED SENSORS INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F–68
SPECIFICATIONS
ABS 5.3 Mounting Nuts 8 – 71
Brake Pipe Nuts 16 12 –
Front Wheel Speed Sensor Bolt 10 – 89
SPECIAL TOOLS
SPECIAL TOOLS TABLE
Scan Tool

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ANTILOCK BRAKE SYSTEM 4F – 3

ABS CIRCUIT
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EBCM CONNECTOR FACE VIEW

EBCM Connector
Pin Color Circuit 17 RED Battery

1 BRN Right Rear Ground 18 RED Battery
2 WHT Right Rear Sensor 19 BLK Instrument Ground
3 BRN Right Front Ground 20 LT GRN ABS Warning Lamp
4 – Not Used 21 BRN/BLK EBD Warning
Lamp(Parking Brake
5 DK GRN Right Front Sensor Lamp)
6 YEL Left Front Ground 22 – Not Used
7 LT BLU Left Front Sensor 23 – Not Used
8 BLK Left Rear Ground 24 – Not Used
9 RED Left Rear Sensor 25 – Not Used
10 – Not Used 26 – Not Used
11 BLK/WHT Data Link Connec- 27 – Not Used
tor(DLC)
28 – Not Used
12 – Not Used
29 – Not Used
13 – Not Used
30 – Not Used
14 BRN/BLK Stop Lamp Switch
31 – Not Used
15 RED/WHT Switched Ignition
SB – Shorting Bar
16 BLK Motor Ground

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COMPONENT LOCATOR
ABS/EBD SYSTEM DRIVE
(Left–Hand Drive Shown, Right–Hand Drive Similar)
1. Right Front Wheel Speed Sensor 9. Connector C902

2. Hydraulic Modulator with Attached EBCM 10. Right Rear Wheel Speed Sensor
3. Grommet 11. Left Front Wheel Speed Sensor
4. EBCM Connector 12. Grommet
5. Connector C210 13. Brake Master Cylinder
6. Connector C206 14. Brake Fluid Level Switch Connector
7. Instrument Cluster 15. Left Rear Wheel Speed Sensor
8. Body Wiring Harness
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DIAGNOSIS
DIAGNOSTIC CIRCUIT CHECK

The Diagnostic Circuit Check is an organized approach to 1. Perform the tests of the table below.
identifying a problem created by an antilock brake system 2. Perform a road test if directed by the table.
(ABS) malfunction. It must be the starting point for any S Test drive the vehicle while using the snapshot
ABS complaint diagnosis because it directs the service feature of the scan tool.
technician to the next logical step in diagnosing the com- S Perform normal acceleration, stopping, and turn-
plaint. ing maneuvers.
S If this does not reproduce the malfunction, per-
Diagnostic Process
form an ABS stop or TCS maneuver on a low
Perform the following steps in order when servicing the friction surface such as gravel.
ABS/EBD system. Failure to do so may result in the loss
of important diagnostic data and may lead to difficulties 3. Clear the diagnostic trouble codes (DTCs) after all
and time–consuming diagnosis procedures. system malfunctions have been corrected.
Diagnostic Circuit Check

1 1. Install the scan tool. Go to Step 2 Go to Step 6
2. Turn ignition switch to ON.
3. Select the Data List mode.
Is the scan tool receiving data from the electronic
brake control module (EBCM)?
2 Check the display. Refer to the ap- Go to Step 3
Are there any current DTCs displayed? plicable DTC
table

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3 1. Turn the ignition switch to LOCK for 10 sec- Go to Step 5 Go to Step 4
onds.
2. Turn the ignition switch to ON and observe the
ABS indicator.
Does the indicator light for 4 seconds and then go
off?
4 Check the ABS indicator. Go to ”ABS In- Go to ”ABS In-
Did the ABS indicator turn on and stay on? dicator Lamp Il- dicator Lamp
luminated Inoperative”
Constantly”
5 1. Turn the ignition switch to LOCK for 10 sec- Go to Step 12 Go to ”EBD
onds. System Indica-
2. Turn the ignition switch to ON and observe the tor Lamp Inop-
parking brake / EBD indicator. erative”
Does the indicator light for 4 seconds and then go
off?
6 1. Turn the ignition switch to LOCK. 11–14 v Go to Step 7 Go to ”Power
2. Disconnect the EBCM harness connector Supply to Con-
3. Turn the ignition switch to ON. trol Module, No
4. Use a digital voltmeter (DVM) to measure the DTCs Stored”
voltage from ground to terminal 15, 17, and 18
of EBCM harness connector.
Is the voltage within the specified value on each ter-
minal?
7 1. Turn the ignition switch to LOCK. [0Ω Go to Step 9 Go to Step 8
2. Use a DVM to measure the resistance from the
EBCM harness connector, terminals 16 and 19
to ground.
Is the resistance equal to the specified value?
8 Repair the open in the circuit BLK and BLK that System OK
failed.
9 Use a DVM to measure the resistance between ter- 2W Go to Step 10 Go to Step 11
minal 11 of the EBCM harness connector and termi-
nal 12 of the Data Link Connector (DLC)
Is the resistance below the specified value?
10 Replace the ABS unit assembly. System OK
11 Repair the open or high resistance in circuit DK BLK/ Go to Step 1
WHT between terminal 11 of the EBCM harness
connector and terminal 12 of the DLC jack.
12 Perform the road test described above. Go to the table System OK
Are any DTCs set? for the DTC
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ABS INDICATOR LAMP INOPERATIVE

S There is a corroded or broken connector terminal.
Circuit Description
S There is a faulty ground connection.
Battery voltage is supplied to the ABS warning lamp with S There is a broken wire in a wiring harness.
the ignition switch in the ON or START positions. The S The EBCM is faulty.
warning lamp can be activated only by the ABS control
module internally supplying ground to terminal 20 or by the Test Description
shorting bar in the ABS module connector when it is dis- The number(s) below refer to step(s) on the diagnostic
connected from the module. table.
Diagnosis 1. This test checks for any DTCs that may cause ABS
indicator lamp to be inoperative.
This procedure checks for a problem in the wiring, a faulty
2. This test verifies an inoperative lamp condition.
ground, a voltage supply problem, a burned out indicator
3. This test checks for voltage on the lamp circuit.
lamp, or a contact problem in a connector.
4. This begins a series of tests of the circuit from indi-
Cause(s) cator the lamp to the EBCM and ground.
S A fuse has blown. 19. This begins a series of tests of the voltage supply
S The indicator lamp has burned out. circuits that power the indicator lamp.
ABS Indicator Lamp Inoperative

1 Install the scan tool and check for any DTCs. Go to the chart Go to Step 2
Is any DTC set? for the DTC
2 1. Turn the ignition switch to LOCK. Go toIntermit- Go to Step 3
2. Disconnect the scan tool. tents and Poor
3. Turn the ignition switch to ON. Connections”
4. Observe the ABS indicator lamp.
Does the lamp illuminate for about 4 seconds, then
turn off?

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3 With the ignition still ON, observe the oil pressure Go to Step 4 Go to Step 19
lamp.
Is the oil pressure lamp illuminated?
4 1. Turn the ignition to LOCK. Go to Step 5 Go to Step 8
2. Disconnect the connector from the electronic
brake control module (EBCM).
3. Turn the ignition switch to ON.
Does the ABS indicator illuminate?
5 1. Turn the ignition switch to LOCK. Go to Step 6 Go to Step 7
2. Examine terminals 19 and 21 at the EBCM
connector on both the ABS wiring harness and
on the EBCM.
Is there a poor connection at any of these terminals?
6 Repair the faulty terminals or replace the ABS unit, System OK
as required.
7 Replace the ABS unit. System OK
8 1. Turn the ignition to LOCK. 0W Go to Step 10 Go to Step 9
2. Disconnect the wire from the negative battery
terminal.
3. Measure the resistance between the negative
battery wire, which is attached to ground, and
the shorting bar in the EBCM connector.
9 Repair the open or high resistance in the circuit from System OK
EBCM connector, terminal 19 to ground G108.
10 1. Remove the I/P cluster. Go to Step 11 Go to Step 12
2. Remove and check the ABS indeicator bulb.
Is the bulb burned out?
11 1. Replace the ABS indicator bulb. System OK
2. Install the I/P cluster.
12 Check the continuity at the I/P cluster connector ter- 0W Go to Step 14 Go to Step 13
minal 30.
Is the continuity equal to the specified value?
Does th ohmmeter show the specified value?
13 Repair the contact at the I/P cluster connector termi- System OK
nal 30.
14 Check the wiring harnesses and the connectors in R Go to Step 15 Go to Step 16
circuit DK GRN/BLK from the I/P cluster terminal 30
to terminal 20 of the EBCM connector.
Does the ohmmeter show the specified value?
15 Repair the open or high resistance found. System OK
16 Check for continuity between terminal 19 of the ABS 0W Go to Step 17 Go to Step 18
connector and ground G108.
Does the ground connection match the specified val-
ue?
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18 Repair the continuity problem between terminal 19 System OK
of the EBCM connector and ground G108.
2. Check fuse F11 in the I/P fuse block.
Is this fuse blown?
20 Replace fuse F11. System OK
21 Check fuse EF3 in the engine fuse block. Go to Step 22 Go to Step 23
Is this fuse blown?
22 Replace fuse EF3. System OK
23 Measure the voltage at terminal 2 of the ignition 11–14 v Go to Step 25 Go to Step 24
switch connector by backprobing.
Does the voltage match the specified value?
24 1. Check circuit RED/BLK between terminal 1 of System OK
C201 at the engine fuse block and terminal 2 of
the ignition switch for continuity.
2. Repair any open or high resistance found.
25 1. Turn the ignition switch to ON. 11–14 v Go to Step 27 Go to Step 26
2. Backprobe terminal 4 (RED) of the ignition
switch connector.
Does the voltage match the specified value?
27 1. Turn the ignition switch to LOCK ? Go to Step 28 Go to Step 29
2. Check circuit RED from terminal 4 of ignition
switch to fuse F11 in the I/P fuse block.
28 Repair the open or the high resistance System OK
29 Remove the instrument cluster. System OK
Check circuit RED from fuse F11 to terminal 9 of the
I/P cluster.
Repair any open or high resistance found in a wiring
harness, splice pack, or connector.

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POWER SUPPLY TO CONTROL MODULE, NO DTCs

STORED
Fail Action
Circuit Description
ABS action is disabled during the period of low voltage,
Battery voltage is supplied to the electronic brake control
module (EBCM) through fuse F19 in the I/P fuse block, to Test Description
terminal 15 of the EBCM connector. The voltage is present The number(s) below refer to step(s) on the diagnostic
when the ignition switch is in the ON or START position. table.
1. This step determines whether there is voltage at
Diagnosis the battery and the high current source.
This test checks for battery output, proper grounding, 7. This step checks for voltage at the ignition 1
blown fuses, a faulty ignition switch, and problems in the source.
circuitry. 11. This step begins the check for voltage at the EBCM
end of the ABS harness.
15. This step checks for a defective ground connection.
Cause(s)
16. This is a check for a defective EBCM connector.
S The battery is defective.
S There is a defective ground connection. Diagnostic Aids
S A connector is damaged. It is very important to perform a thorough inspection of the
S A wire is broken or shorted. wiring and the connectors. Failure to do so may result in
S A fuse is blown. misdiagnosis, causing part replacement with a reappear-
S The ignition switch is malfunctioning. ance of the malfunction.
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Power Supply to Control Module, No DTCs Stored

1 Check the voltage at the battery. 11–14 v Go to Step 3 Go to Step 2
Is the voltage equal to the specified value?
2 Charge or replace the battery, as required. System OK
Is the fuse blown?
4 1. Replace fuse EF6. Go to Step 6 Go to Step 5
2. Turn the ignition to ON.
Does the fuse blow again?
5 Check the ABS function. System OK
6 1. Turn the ignition to OFF. 0W Go to Step 7 Go to Step 25
2. Remove fuse EF6.
3. Disconnect the ABS connector from the
EBCM.
4. Measure the resistance to ground at terminals
17 and 18.
7 Repair the short to ground in circuit RED/BLK be- System OK
tween terminal 1 of connector C102 and the ABS
harness EBCM connector.
Is the fuse blown?
9 1. Replace fuse EF2. Go to Step 11 Go to Step 20
10 Check the ABS function System OK
11 1.Turn the ignition to OFF. 0Ω Go to Step 12 Go to Step 25
2.Remove fuse EF2.
3.Disconnect ABS connector from the EBCM.
4.Measure the resistance to ground at terminal
15.
12 1. Examine circuit RED between terminal 3 of System OK
connector C201 and terminal 2 of the ignition
switch.
2. Examine circuit ORN from terminal 4 of the
ignition switch to terminal 15 of connector
C201.
3. Examine circuit ORN from terminal 15 of con-
nector C206 of the ignition switch to fuse F19
in the I/P fuse block.
4. Examine circuit RED/WHT from fuse F19 in the
I/P fuse block to terminal 15 of the ABS EBCM
connector.
5. Repair any short to ground found in the wiring
or the ignition switch.

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13 Check fuse F19 in the I/P fuse block. R Go to Step 14 Go to Step 18
Is the fuse blown?
14 1. Replace fuse F19. Go to Step 16 Go to Step 15
15 Check the ABS function System OK
16 1.Turn the ignition to OFF. 0Ω Go to Step 17 Go to Step 25
2.Remove fuse F19.
3.Disconnect ABS connector from the EBCM.
4.Measure the resistance to ground at terminal
15.
17 Repair the short to ground in circuit RED/WHT fuse System OK
F19 of the I/P fuse block and terminal 15 of the ABS
harness EBCM connector.
18 1. Disconnect the EBCM connector from the 11–14 v Go to Step 20 Go to Step 19
EBCM.
3. Check for the presence of battery voltage be-
tween ground and terminal 17, and between
ground and terminal 18.
Is the voltage within the specified value?
19 1. Turn the ignition switch to OFF. System OK
2. Trace the RED wires between terminals 17 and
18 of the EBCM connector to terminal 1 of con-
nector C102.
3. Repair the open in this circuit.
20 Check the voltage between ground and terminal 15 11–14 v Go to Step 22 Go to Step 21
of the EBCM connector.
21 1. Turn the ignition switch to OFF. System OK
2. Trace circuit RED/WHT between terminal 15 of
the ABS harness EBCM connector and termi-
nal 1 of connector C302.
3. Trace circuit RED/WHT from terminal 1 of con-
nector C302 to fuse F19 in the I/P fuse bolck.
4. Trace circuit ORN from fuse F19 of the I/P fuse
block to terminal 1 (IG1) of the ignition switch.
5. Trace circuit RED/WHT from terminal 5 (B1) of
the ignition switch to terminal 3 of connector
C201 and to fuse EF2.
6. Repair the open in the wiring or possibly bad
connector terminal, defective ignition switch, or
blown fuse EF2.
22 1. Turn the ignition to OFF. 0Ω Go to Step 23 Go to Step 26
2. Check the resistance between ground and ter-
minals 19 and 16 of the EBCM connector.
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23 Examine terminals 15, 19, 17, 18, and 16 of the Go to Step 24 Go to Step 25
EBCM connector.
Is there a defective terminal?
24 Repair the defective terminal or replace the connec- System OK
tor or wiring harness as required.
25 Repair the ABS unit System OK
26 Repair the defective ground connection. System OK

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ABS INDICATOR LAMP ILLUMINATED CONTINUOUSLY,

NO DTCs STORED
S There is a short to ground in the circuit between the
Circuit Description
cluster terminal 30 and the EBCM terminal 20.
Battery voltage is supplied to the ABS warning lamp with S The EBCM is faulty.
the ignition switch in the ON or START position. The warn-
ing lamp should be activated only by the ABS control mod- Test Description
ule internally supplying ground to terminal 20. The number(s) below refer to step(s) on the diagnostic
Diagnosis table.
This procedure checks for a short to ground in the wiring 3. This step determines whether the EBCM is faulty.
or a defective electronic brake control module (EBCM). 5. This begins a search for a short to ground in the
circuit between the ABS indicator lamp and the
Cause(s) EBCM.
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ABS Indicator Lamp Illuminated Continuously, No DTCs Stored

1 Check the EBCM connector. Go to Step 3 Go to Step 2
Is it connected properly?
2 Connect the EBCM connector. System OK
3 1. Disconnect the EBCM connector. Go to Step 4 Go to Step 5
3. Use an insulated tool to push the shorting bar
in the connector away from terminal 20.
Does the ABS indicator lamp go out?
5 1. Turn the ignition to OFF. Go to Step 7 Go to Step 6
2. Connect the EBCM connector.
Does the ABS indicator lamp illuminate?
6 Repair the short to ground in circuit LT GRN between System OK
connector C210 and the EBCM connector.
7 1. Turn the ignition to OFF. System OK
2. Connect connector C107.
Repair the short to ground in circuit LT GRN between
I/P cluster connector 30 and connector C210.

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ELECTRONIC BRAKE–FORCE DISTRIBUTION (EBD)

SYSTEM INDICATOR LAMP INOPERATIVE
S There is a faulty ground connection.
Circuit Description
S There is a broken wire in a wiring harness.
Battery voltage is supplied to the EBD warning lamp with S The EBCM is faulty.
the ignition switch in the ON or START position. The warn-
ing lamp can be activated only by the ABS control module Test Description
internally supplying ground to terminal 21. The number(s) below refer to step(s) on the diagnostic
Diagnosis table.
This procedure checks for a problem in the wiring, a faulty 1. This test checks for any DTCs that may cause the
ground, a voltage supply problem, a burned out indicator EBD indicator lamp to be inoperative.
lamp, or a contact problem in a connector. 2. This test verifies an inoperative lamp condition.
3. This test checks for voltage on the lamp circuit.
Cause(s) 4. This begins a series of tests of the circuit from the
S A fuse has blown. indicator lamp to the EBCM and ground.
S The indicator lamp has burned out. 19. This begins a series of tests of the voltage supply
S There is a corroded or broken connector terminal. circuits that power the indicator lamp.
DAEWOO V–121 BL4
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EBD System Indicator Lamp Inoperative

1 Install the scan tool and check for any DTCs. Go to the chart Go to Step 2
Is any DTC set? for the DTC
2 1. Turn the ignition switch to LOCK. Go to ”Intermit- Go to Step 3
2. Disconnect the scan tool. tents and Poor
3. Release the parking brake fully. Connections”
4. Push the brake pedal.
5. Turn the ignition switch to ON.
6. Observe the EBD indicator lamp.
Does the lamp illuminate for about 4 seconds, then
turn off?
3 With the ignition still ON, observe the oil pressure Go to Step 4 Go to Step 19
lamp.
Is the oil pressure lamp illuminated?
2. Disconnect the connector from the EBCM.
3. Connect a jumper from terminal 21 ot the
grounding bar in the connector.
Does the EBD indicator illuminate?
2. Examine terminals 19 and 21 at the EBCM
connector on both the ABS wiring harness and
on the EBCM.
Is there a poor connection at any of these terminals?
6 Repair the faulty terminals or replace the ABS unit, System OK
as required.
8 1. Turn the ignition to LOCK. 0W Go to Step 10 Go to Step 9
2. Disconnect the wire from the negative battery
terminal.
3. Measure the resistance between the negative
battery wire, which is attached to ground, and
the shorting bar in the EBCM connector.
Does the resistance match the specified value?
9 Repair the open or high resistance in the circuit from System OK
EBCM connector, terminal 19 to ground G108.
10 1. Remove the I/P cluster. Go to Step 11 Go to Step 12
2. Remove and check the EBD indicator bulb.
Is the bulb burned out?
11 1. Replace the EBD indicator bulb. System OK
2. Replace the I/P cluster.
12 Check continuity at the I/P cluster connector termi- 0W Go to Step 14 Go to Step 13
nal 26.

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13 Repair the contact at the I/P cluster connector termi- System OK
nal 26.
14 Check the wiring harnesses and connectors in cir- R Go to Step 15 Go to Step 16
cuit BRN/WHT from the I/P cluster terminal 26 to ter-
minal 21 of the EBCM connector.
15 Repair the open or high resistance found. System OK
16 Check for continuity between terminal 19 of the ABS 0W Go to Step 17 Go to Step 18
connector and ground G108.
Does the ground connection match the specified val-
ue?
18 Repair the continuity problem between terminal 19 System OK
of the EBCM connector and ground G108.
2. Check fuse F11 in the I/P fuse block.
Is this fuse blown?
20 Replace fuse F11. System OK
Is this fuse blown?
22 Replace fuse EF3. System OK
23 Measure the voltage at terminal 2 of the ignition 11–14 v Go to Step 25 Go to Step 24
switch connector by backprobing.
24 1. Check circuit RED/BLK between terminal 1 of System OK
C201 and terminal 2 of the ignition switch conti-
nuity.
2. Repair any open or high resistance found.
25 1. Turn the ignition switch to ON. 11–14 v Go to Step 27 Go to Step 26
2. Backprobe terminal 4 (RED) of the ignition
switch connector.
27 1. Turn the ignition switch to LOCK. R Go to Step 28 Go to Step 29
2. Check circuit RED from terminal 4 of the igni-
tion switch to fuse F11 in the I/P fuse block.
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28 Repair the open or the high resistance. System OK
29 1. Remove the I/P cluster. System OK
2. Check circuit RED from fuse F11 to terminal 25
of the I/P cluster connector.
3. Repair any open or high resistance found in a
wiring harness, a splice pack, or a connector.
S Use the scan tool ”Clear DTCs”selection.
SELF–DIAGNOSTICS
The method is detailed below. Be sure to verify proper sys-
Important : The electronic brake control module (EBCM) tem operation and absence of DTCs when the clearing
turns the valve relay off when a diagnostic trouble code procedure is completed.
(DTC) is set. The scan tool will indicate that the valve relay
is off when it is used to monitor the data list. This is normal The EBCM will not permit DTC clearing until all DTCs have
and should not be considered a malfunction.. been displayed. Also, DTCs cannot be cleared by discon-
necting the EBCM, disconnecting the battery cables, or
Important : Important: For safety reasons it is recom- turning the ignition switch to LOCK.
mended that the vehicle not be driven with test equipment
connected. Exception : for testing of wheel speeds pro- Scan Tool Method
vided the test regulations are met. The scan tool can clear ABS system DTCs using the mass
The EBCM performs system self–diagnostics and can de- storage cartridge.
tect and often isolate system malfunctions. When it de- 1. Install the scan tool and the mass storage cartridge.
tects a malfunction, the EBCM sets a DTC that represents 2. Select ”Fault Memory.”
the malfunction, turns ON the ABS and/or the EBD indica- 3. Select ”Clear Fault Memory.”
tors in most instances, and may disable the ABS and/or
the EBD functions as necessary for the duration of the igni- Clearing the fault memory cannot reset a valve relay which
tion cycle. was shut down when the fault was recognized. Changes
are possible only after the fault has been eliminated and
Once each ignition cycle, the EBCM performs an automat- the next ignition cycle has begun.
ic test when the vehicle speed > 6 km/h and the brake ped-
al is not actuated or when the vehicle speed > 15 km/h and INTERMITTENTS AND POOR
the brake pedal is actuated. In the course of this test, the
system cycles each valve solenoid and the pump motor, CONNECTIONS
along with the necessary relays, to check component op- As with most electronic systems, intermittent malfunctions
eration. If the EBCM detects any malfunctions, it will set may be difficult to diagnose accurately. The following is a
a DTC as described above. method to try to isolate an intermittent malfunction, espe-
cially in wheel speed circuitry.
DISPLAYING DTCs If an ABS malfunction occurs, the ABS indicator will illumi-
Tools Required nate during the ignition cycle in which the malfunction was
Scan Tool detected. If it is an intermittent problem which seems to
DTCs can be read through the use of the scan tool. have corrected itself (ABS indicator off), a history DTC will
be stored. Also stored will be the history data of the DTC
CLEARING DTCs at the time the malfunction occurred. Use the scan tool
Tools Required modular diagnostic system to read ABS history data.
Scan Tool Most intermittents are caused by faulty electrical connec-
The diagnostic trouble codes (DTCs) in the electronic tions or wiring, although a sticking relay or solenoid can oc-
brake control module (EBCM) memory are erased: casionally be at fault.

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DIAGNOSTIC TROUBLE CODE (DTC) C0035

LEFT FRONT WHEEL SPEED SENSOR CIRCUIT
MALFUNCTION
1. This step begins an examination for a defective
Circuit Description
wheel speed sensor.
The toothed wheel generates a voltage pulse as it moves 6. This step tests the wiring for a short to voltage.
past the sensor. Each tooth–gap–tooth series on the 8. This step tests the wiring for a short to ground.
wheel generates the pulses. The electronic brake control 10. This step tests for an open or high resistance in the
module (EBCM) uses the frequency of these pulses to de- wiring.
termine the wheel speed. The voltage generated depends
on the air gap between the sensor and the toothed wheel,
and on the wheel speed. Diagnostic Aids
Be sure that the speed sensor wiring is properly routed and
Diagnosis
retained. This will help to prevent false signals due to the
This procedure checks for amalfunctioning wheel speed pickup of electrical noise.
sensor, a short to ground or to voltage in the wiring, or a
contact problem in a connector. It is very important to perform a thorough inspection of the
wiring and the connectors. Failure to inspect the wiring
Cause(s)
and the connectors carefully and completely may result in
S The wheel speed sensor is defective or discon- misdiagnosis, causing part replacement with the reap-
nected. pearance of the malfunction.
S There is a problem in the wiring.
S There is a problem with a connector. You can use the scan tool to monitor wheel speeds during
S There is a problem in the toothed ring a road test. Watch the wheel speeds being displayed on
S Wrong installed WSS. the scan tool to see if any of the readings is unusual, such
S Wrong sensor signal. as one sensor varying in speed from the other three, a sig-
S Signal noise via WSS. nal going intermittently high or low, etc. If this does not
identify the intermittent, wet the speed sensor harness on
Fail Action the underside of the vehicle and perform a road test, moni-
ABS action is disabled, and the ABS warning lamp is ON. toring the wheel speeds with the scan tool.
EBD is enabled. (refer to the EBD failure matrix in this sec-
tion). Important : If the WSS signal fault input to the EBCM, the
ABS warning lamp turns on. As if a sensor signal fault can
Test Description be removed by the scan tool, the ABS warning lamp
The number(s) below refer to step(s) on the diagnostic doesn’t turn off. In order to turn ABS warning lamp off, you
table. should driver a car up to 12 km/h.
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DTC C0035 –– Left Front Wheel Speed Sensor Circuit Malfunction

1 Examine the wheel speed sensor. Go to Step 3 Go to Step 2
Are there any signs of physical damage?
2 1. Turn the ignition to LOCK. 988–1208 W Go to Step 4 Go to Step 3
2. Disconnect the right front wheel speed sensor
connector.
3. Use a digital voltmeter (DVM) to measure the
resistance between the sensor terminals.
Is the resistance within the specified value at
approximately 25?C (77?F)?
3 Replace the wheel speed sensor. System OK
4 1. Switch the DVM to the AC millivolt range. [ 120 mv Go to Step 6 Go to Step 5
2. Measure the voltage output of between the
wheel speed sensor terminals while rotating
the wheel about 1 revolution every 2 seconds.
Is the output within the specified value?
5 Replace the speed sensor or the toothed wheel as System OK
required.
6 1. Disconnect the harness from the EBCM. >1v Go to Step 7 Go to Step 8
2. Connect a DVM between ground and one ter-
minal of the wheel speed connector.
4. Repeat the above test for the other terminal of
the wheel speed connector.
Is the voltage for either of these terminals within the
specified value?
7 Repair the short to voltage in the affected circuit. System OK
8 1. Turn the ignition to LOCK. R Go to Step 9 Go to Step 10
2. Measure the resistance to ground from termi-
nal 6 at the harness EBCM connector.
Is the resistance at either circuit less than the speci-
fied value?
9 Repair the short to ground in the affected circuit. System OK
10 1. Measure the resistance between terminal 6 at >5W Go to Step 11 Go to Step 12
the harness EBCM connector and the harness
wheel speed sensor connector terminal con-
nected to the YEL wire.
2. Measure the resistance between terminal 7 at
nected to the LT BLU wire.
Is the resistance on either circuit within the specified
value?

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11 Repair the open or high resistance in the affected cir- System OK
cuit as required.
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RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT
MALFUNCTION
Circuit Description
wheel speed sensor.
wheel generates the pulses. The electronic brake control 10. This step tests for an open or a high resistance in
module (EBCM) uses the frequency of these pulses to de- the wiring.
Diagnostic Aids
and on the wheel speed.
Diagnosis retained. This will help to prevent false signals due to the
It is very important to perform a thorough inspection of the
contact problem in a connector.
Cause(s) and the connectors carefully and completely may result in
misdiagnosis, causing part replacement with the reap-
S The wheel speed sensor is defective or discon-
pearance of the malfunction.
nected.
S There is a problem in the wiring. You can use the scan tool to monitor wheel speeds during
S There is a problem with a connector. a road test. Watch the wheel speeds being displayed on
Fail Action
the underside of the vehicle and perform a road test, moni-
ABS action is disabled, and the ABS warning lamp is ON. toring the wheel speeds with the scan tool.
EBD is enabled. (Refer to the EBD failure matrix in this
section) Important : If the WSS signal fault input to the EBCM, the
table. should drive a car up to 12 km/h.

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DTC C0040 – Right Front Wheel Speed Sensor Circuit Malfunction

2 1. Turn the ignition to LOCK. 988–1208 Ω Go to Step 4 Go to Step 3
2. Disconnect the right front wheel speed sensor
connector.
specified value?
fied value?
10 1. Measure the resistance between terminal 3 at >5Ω Go to Step 11 Go to Step 12
nected to the BRN wire.
nected to the DK GRN wire.
value?
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cuit as required.

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LEFT REAR WHEEL SPEED SENSOR CIRCUIT
MALFUNCTION
Circuit Description
wheel speed sensor.
Diagnostic Aids
S The wheel speed sensor is defective or discon-
nected.
S There is a problem in the wiring.. You can use the scan tool to monitor wheel speeds during
S There is a problem with a connector. a road test. Watch the wheel speeds being displayed on
Fail Action
ABS action is disabled, and the ABS warning lamp is ON. toring wheel speeds with the scan tool.
DAEWOO V–121 BL4
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DTC C0045 – Left Rear Wheel Speed Sensor Circuit Malfunction

2 1. Turn the ignition to LOCK. 900~1760 W Go to Step 4 Go to Step 3
2. Disconnect the left front wheel speed sensor
connector.
4 S Switch the DVM to the AC millivolt range. [ 120 mv Go to Step 6 Go to Step 5
S Measure the voltage output of between the
required.
6 1. Disconnect the from the EBCM. >1v Go to Step 7 Go to Step 8
specified value?
8 1. Turn the ignition to LOCK. R Go to Step 9 Go to Step 10
fied value?
10 1. Measure the resistance between terminal 8 at >5W Go to Step 11 Go to Step 12
nected to the BLK wire.
nected to the RED wire.
value?

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11 Repair the open or the high resistance in the affected System OK
circuit as required. Be sure to check terminals 3 and
4 of connector C302 and terminal 1 and 3 of connec-
tor C902.
DAEWOO V–121 BL4
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RIGHT REAR WHEEL SPEED SENSOR CIRCUIT
MALFUNCTION
Circuit Description
wheel speed sensor.
Diagnostic Aids
S The wheel speed sensor is defective.
S There is a problem in the wiring.
S There is a problem with a connector. You can use the scan tool to monitor wheel speeds during
S There is a promblem in the toothed ring a road test. Watch the wheel speeds being displayed on
S Wrong installed WSS the scan tool to see if any of the readings is unusual, such
Fail Action
ABS action is disabled, and the ABS warning lamp is ON. toring wheel speeds with the scan tool.

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DTC C0050 – Right Rear Wheel Speed Sensor Circuit Malfunction

2 1. Turn the ignition to LOCK. 900~1760 W Go to Step 4 Go to Step 3
2. Disconnect the left front wheel speed sensor
connector.
required.
specified value?
fied value?
10 1. Measure the resistance between terminal 1 at >5Ω Go to Step 11 Go to Step 11
nected to the BRN wire.
nected to the WHT wire.
value?
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cuit as required. Be sure to check terminals 5 and 6
of connector C302 and terminals 2 and 4 of connec-
tor C902.

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SECTION : 4G
PARKING BRAKE
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 4G–1 PARKING BRAKE LEVER . . . . . . . . . . . . . . . . . . 4G–3
FASTENER TIGHTENING SPECIFICATIONS . 4G–1 PARKING BRAKE CABLE . . . . . . . . . . . . . . . . . . 4G–6
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 4G–2 GENERAL DESCRIPTION AND SYSTEM
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 4G–2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G–12
PARKING BRAKE ADJUSTMENT . . . . . . . . . . . 4G–2 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 4G–12
SPECIFICATIONS
Front Muffler Heat Shield Nuts 2.5 – 22
Parking Brake Cable–to–Fuel Tank Bracket 12 – 106
Nut
Parking Brake Cable–to–Rear Axle Bracket 12 – 106
Nut
Parking Brake Cable–to–Underbody Side and 12 – 106
Near Side Bracket Nuts
Parking Brake Console Hood–to–Tunnel 2.5 – 22
Bracket Screws
Parking Brake Lever–to–Vehicle Underbody 20 15 –
Bolts
Parking Brake Switch–to–Parking Brake Le- 4 – 35
ver Screw
Rear Brake Drum Castle Nut (Non–ABS) 25 –180? + 2 18 –180? + 1.5 –
Rear Brake Drum Detent Screw (ABS) 4 – 35
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4G – 2IPARKING BRAKE

PARKING BRAKE ADJUSTMENT
Adjustment Procedure
1. Adjust the rear brakes. Refer to Section 4E, Rear

Drum Brakes.
4. Check the parking brake cables for free movement.
5. Lower the vehicle

6. Move the front seats forward.
7. Pry off the plastic caps that cover the access holes
to the parking brake console hood–to–tunnel brack-
et screws.
8. Unfasten the screws that secure the parking brake
console hood to the tunnel brackets.
9. Raise the console hood to expose the parking

brake lever assembly and the adjustment nut.

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PARKING BRAKE 4G – 3
10. Partially raise and suitably support the vehicle.

11. Turn the adjustment nut on the lever assembly until
the wheels are difficult to turn.
12. Loosen the nut until the rear wheels are just free to
turn.

14. Position the parking brake console hood and fasten
it to the tunnel brackets with the screws.
Tighten
Tighten the parking brake console hood–to–tunnel
bracket screws to 2.5 NSm (22 lb–in).
15. Snap in the plastic caps that cover the access
holes to the parking brake console hood–to–tunnel
bracket screws.
16. Adjust the front seats to their previous position.
PARKING BRAKE LEVER

Removal Procedure

2. Move the front seats forward.
3. Pry off the plastic caps that cover the access holes
et screws.
4. Remove the screws that secure the parking brake
console hood–to–the–tunnel brackets. Raise the
console hood.
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5. Measure the thread length from the end of the

pushrod to the adjustment nut. Loosen the adjust-
ment nut.
6. LRaise and suitably support the vehicle.

7. Disconnect the front muffler assembly from the
flange of the rear muffler assembly and from the
flange of the catalytic converter. Refer to Section
1G, Engine Exhaust.
8. Remove the heat shield nuts. Remove the heat
shield.
9. Twist the brake cables from the equalizer. Remove

the equalizer.
10. Dislodge the rubber grommet from the underbody.

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12. Remove the complete parking brake lever assem-
bly and the cable from the assembly by unfastening
the parking brake lever–to–vehicle underbody bolts
and removing the adjustment nut which was pre-
viously loosened on the pushrod.
Notice : The parking brake switch should be replaced if
the BRAKE warning light in the instrument panel cluster
does not glow when the parking brake is applied with the
ignition switch ON.
13. If necessary, remove the parking brake switch,
which is attached to the parking brake lever assem-
bly by a small screw.
14. Inspect the parking brake lever cable and the lever
grip for damage, and replace if necessary.
Notice : If the parking brake lever is bent or damaged or

if a new grip is required, replace the complete parking
brake lever assembly, which includes a new parking brake
switch and lever cable.
1. Fasten the parking brake switch to the parking
brake lever with the screw.
Tighten
Tighten the parking brake switch–to–parking brake
lever screw to 4 NSm (35 lb–in).
2. Fasten the parking brake lever assembly to the ve-
hicle underbody. Insert the cable, and the pushrod.
3. Tighten the hex adjusting nut on the pushrod
approximating the measurement noted in the re-
moval procedure.
Tighten
Tighten the parking brake lever–to–vehicle under-
body bolts to 20 NSm (15 lb–ft).
4. Install the screws that secure the parking brake
console hood to the tunnel brackets.
Tighten
Tighten the parking brake console hood–to–tunnel
bracket screws to 2.5 NSm (22 lb–in).
5. Install the plastic caps that cover the access holes
et screws.
7. Insert the rubber grommet into the vehicle under-
body and fasten the equalizer.
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8. Insert the parking brake cables into the equalizer.
9. Install the front muffler heat shield to the underbody

with the heat shield nuts.
Tighten
Tighten the front muffler heat shield nuts to 2.5 NSm
(22 lb–in).
10. Install the front muffler assembly. Refer to Section
1G, Engine Exhaust.
11. Check the parking brake adjustment. Refer to
”Parking Brake Adjustment” in this section.
PARKING BRAKE CABLE

Removal Procedure
1. To remove the parking brake console hood, the

front muffler, and the heat shield, refer to ”Parking
Brake Lever” in this section.
and Wheels.
3. For the ABS braking system (shown), unfasten the
detent screw to remove the rear brake drums. For
the non–ABS system, remove the split pin and the
castle nut to remove the brake drum.

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4. Remove the retaining ring for the parking brake

cable on each side of the vehicle.
5. Remove the plastic sleeve.
6. Remove the brake cable from the parking brake
shoe lever and from the brake backing plate.
7. Remove the nut that fastens the brake cable to

holding bracket on the rear axle. Remove the cable
from the bracket on each side of the vehicle.
8. Remove the nut that fastens the brake cable to the

underbody side bracket on each side of the vehicle.
Remove the cable.
9. Remove the nut that fastens the brake cable to a
holding bracket near the underbody side bracket
(driver side only).
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10. Remove the brake cable from the wire hanger (pas-
senger side only). Remove the cable.
11. Grasp and pull the brake cable from the open–en-
ded holding bracket near the wire hanger.
12. Remove the nut that fastens the brake cable to the
fuel tank bracket near the edge of the fuel tank.
Remove the cable.
13. Twist the brake cables from the equalizer.

14. Remove the equalizer.

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15. Remove the parking brake cables from the welded

body bracket.
1. Install the new parking brake cable through the

brake backing plate. Use a new cable if the original
is frayed or damaged. Attach the cable to the park-
ing brake shoe lever.
2. Insert the plastic sleeve into the brake backing

plate and press in the retaining ring. Make sure the
parking brake cable is routed correctly.
3. For the ABS braking system (shown), install the
brake drums and the detent screw. For the non–
ABS braking system, remove the brake drums by
unfastening the split pin and the castle nut.
Tighten
Tighten the rear brake drum detent screw (ABS) to 4
NSm (35 lb–in).
Tighten the rear brake drum castle nut (non–ABS) to
25 NSm (18 lb–ft) minus 180 degrees plus 2 NSm (18
lb–in).
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and Wheels.
5. Install the parking brake cable to the fuel tank
bracket.
Tighten
Tighten the parking brake cable–to–fuel tank bracket
nut to 12 NSm (106 lb–in).
6. Install the parking brake cable on the wire hanger

(passenger side only).
7. Insert the brake cable into the open–ended holding
bracket near the wire hanger.
8. Install the parking brake cable to the underbody

side brackets on each side of the vehicle, and a
bracket near the underbody side bracket (passen-
ger side only).
Tighten
Tighten the parking brake cable–to–underbody side
and near side bracket nuts to 12 NSm (106 lb–in).

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9. Install the parking brake cable on the rear axle

brackets on each side of the vehicle.
Tighten
Tighten the parking brake cable–to–rear axle bracket
nut to 12 NSm (106 lb–in).
10. Insert the parking brake cables through the welded
body bracket.
11. To install the equalizer, the front muffler, and the
heat shield, refer to ”Parking Brake Lever” in this
section.
12. If the parking brake shoe lever was pressed back-
ward before removing the brake drum, press it for-
ward and adjust the parking brake. Refer to ”Park-
ing Brake Lever” in this section.
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position. Whenever the parking brake is applied and the

GENERAL DESCRIPTION ignition switch is ON, the BRAKE warning light should
glow.
When the brake is firmly applied, the parking brake should
PARKING BRAKE securely hold the vehicle with ample pedal travel remain-
ing. Check for frayed cables, rust, etc., or any condition
This braking system uses a BRAKE warning light located that may inhibit present (or future) free movement of the
in the instrument panel cluster. When the ignition switch parking brake lever assembly.
is in the START position, the BRAKE warning light should
glow and go off when the ignition switch returns to the RUN

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SECTION : 5A
4T40–E AUTOMATIC TRANSAXLE

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–6 FORWARD CLUTCH SUPPORT
END PLAY SPECIFICATIONS . . . . . . . . . . . . . . 5A–6 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–28
TRANSAXLE GENERAL FINAL DRIVE AND DIFFERENTIAL
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 5A–6 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–29
MANUAL SHAFT, PARKING PANEL AND
FLUID CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . 5A–6
ACTUATOR ASSEMBLY . . . . . . . . . . . . . . . . . 5A–30
RANGE REFERENCE . . . . . . . . . . . . . . . . . . . . . 5A–6
CASE AND ASSOCIATED PARTS (1 OF 3) . . 5A–31
4T40–E GEAR RATIOS . . . . . . . . . . . . . . . . . . . . 5A–8
CASE AND ASSOCIATED PARTS (2 OF 3) . . 5A–32
SHIFT SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–8 CASE AND ASSOCIATED PARTS (3 OF 3) . . 5A–34
LINE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 5A–8 VALVE BODY–TO–SPACER
FASTENER TIGHTENING PLATE GASKET . . . . . . . . . . . . . . . . . . . . . . . . 5A–36
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 5A–9 CHANNEL PLATE PASSAGES ––
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–10 CASE SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–37
SPECIAL TOOLS TABLE . . . . . . . . . . . . . . . . . . 5A–10 CASE PASSAGES –
CHANNEL PLATE SIDE . . . . . . . . . . . . . . . . . 5A–38
SCHEMATIC AND ROUTING DIAGRAMS . . . . 5A–15 CASE PASSAGES – BOTTOM . . . . . . . . . . . . . 5A–39
POWERTRAIN CONTROL SPACER PLATE–TO –
MODULE (1 OF 3) . . . . . . . . . . . . . . . . . . . . . . 5A–15 CHANNEL PLATE GASKET . . . . . . . . . . . . . . 5A–40
POWERTRAIN CONTROL CHANNEL PLATE–TO–
MODULE (2 OF 3) . . . . . . . . . . . . . . . . . . . . . . 5A–16 CASE GASKET . . . . . . . . . . . . . . . . . . . . . . . . 5A–41
POWERTRAIN CONTROL SPACER PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–42
MODULE (3 OF 3) . . . . . . . . . . . . . . . . . . . . . . 5A–17 PUMP BODY OIL CHANNELS . . . . . . . . . . . . . 5A–43
VISUAL IDENTIFICATION . . . . . . . . . . . . . . . . . . 5A–18 4T40–E LEAK INSPECTION POINTS . . . . . . . 5A–44
TRANSAXLE IDENTIFICATION ELECTRONIC COMPONENT
INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . 5A–18 LOCATION VIEWS . . . . . . . . . . . . . . . . . . . . . 5A–45
CONTROL VALVE BODY CHANNELS ––
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . 5A–19
CHANNEL PLATE SIDE . . . . . . . . . . . . . . . . . 5A–46
OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . 5A–19
CONTROL VALVE BODY CHANNELS ––
CONTROL VALVE BODY ASSEMBLY . . . . . . 5A–20 OIL PUMP SIDE . . . . . . . . . . . . . . . . . . . . . . . . 5A–47
DRIVEN SPROCKET SUPPORT CHANNEL PLATE PASSAGES ––
ASSEMBLY/2ND CLUTCH . . . . . . . . . . . . . . . 5A–21 CONTROL VALVE BODY SIDE . . . . . . . . . . . 5A–48
REVERSE INPUT CLUTCH ASSEMBLY . . . . 5A–22 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–49
DIRECT AND COAST CLUTCH BASIC KNOWLEDGE REQUIRED . . . . . . . . . . 5A–49
ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–23
FUNCTIONAL CHECK PROCEDURE . . . . . . . 5A–49
REACTION CARRIER ASSEMBLY . . . . . . . . . 5A–24 4T40–E TRANSAXLE FUNCTIONAL
INPUT CARRIER ASSEMBLY . . . . . . . . . . . . . . 5A–25 CHECK PROCEDURE . . . . . . . . . . . . . . . . . . 5A–49
INPUT INTERNAL GEAR AND LINE PRESSURE CHECK PROCEDURE . . . . 5A–50
FORWARD CLUTCH HUB . . . . . . . . . . . . . . . 5A–26 COMPONENT RESISTANCE CHECK
FORWARD CLUTCH ASSEMBLY . . . . . . . . . . 5A–27 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–51
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5A – 2I4T40–E AUTOMATIC TRANSAXLE
PRESSURE SWITCH ASSEMBLY NO ENGINE BRAKING;

RESISTANCE CHECK . . . . . . . . . . . . . . . . . . 5A–52 ALL MANUAL RANGES . . . . . . . . . . . . . . . . . 5A–75
CLUTCH PLATE DIAGNOSIS . . . . . . . . . . . . . . 5A–53 NO ENGINE BRAKING; MANUAL
ENGINE COOLANT IN TRANSAXLE . . . . . . . 5A–53 SECOND – SECOND GEAR . . . . . . . . . . . . . 5A–76
NO ENGINE BRAKING; MANUAL
COOLER FLUSHING AND FLOW TEST . . . . 5A–54
FIRST FIRST GEAR . . . . . . . . . . . . . . . . . . . . 5A–76
FLUID LEAK DIAGNOSIS AND REPAIR . . . . . 5A–54
DRIVES IN NEUTRAL . . . . . . . . . . . . . . . . . . . . 5A–77
CASE POROSITY REPAIR . . . . . . . . . . . . . . . . 5A–54 NO GEAR SELECTION . . . . . . . . . . . . . . . . . . . 5A–77
4T40–E FLUID LEVEL SERVICE SHIFT INDICATOR INDICATES
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–55 WRONG GEAR SELECTION . . . . . . . . . . . . . 5A–77
ELECTRICAL/GARAGE SHIFT TESTS . . . . . 5A–55 SHIFT OCCURS WITHOUT
ROAD TEST PROCEDURE . . . . . . . . . . . . . . . . 5A–56 ENGAGING BRAKE PEDAL . . . . . . . . . . . . . 5A–77
TORQUE CONVERTER CLUTCH KEY CAN BE TURNED TO
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–57 LOCK"IN ANY GEAR . . . . . . . . . . . . . . . . . . 5A–78
TORQUE CONVERTER EVALUATION . . . . . . 5A–57 KEY CANNOT BE TURNED TO
LOCK"WHILE IN PARK . . . . . . . . . . . . . . . . . 5A–79
TCC SHUDDER DIAGNOSIS . . . . . . . . . . . . . . 5A–58
FLUID LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–79
FLEXPLATE/TORQUE CONVERTER
FLUID FOAMING . . . . . . . . . . . . . . . . . . . . . . . . . 5A–79
VIBRATION TEST PROCEDURE . . . . . . . . . 5A–59
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–79
HYDRA–MATIC 4T40–E SHIFT
NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–80
SPEED CHART . . . . . . . . . . . . . . . . . . . . . . . . 5A–59
NO TCC/SLIPPING/SOFT APPLY . . . . . . . . . . 5A–81
INTERNAL WIRING HARNESS CHECK . . . . . 5A–60
NO TCC RELEASE . . . . . . . . . . . . . . . . . . . . . . . 5A–81
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . 5A–62
TCC APPLY WITH COLD ENGINE . . . . . . . . . 5A–81
4T40–E COMPONENT RESISTANCE TCC SHUDDER . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–81
CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–63
DIAGNOSTIC TROUBLE CODE DIAGNOSIS . 5A–82
AUTOMATIC TRANSMISSION FLUID
PRESSURE MANUAL VALVE POSITION DIAGNOSTIC TROUBLE CODE (DTC)
SWITCH RESISTANCE CHECK . . . . . . . . . 5A–63 IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . 5A–82
DTC TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–84
SYMPTOM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 5A–66
DTC P0218 TRANSMISSION FLUID
HIGH OR LOW LINE PRESSURE . . . . . . . . . . 5A–66 OVERTEMPERATURE . . . . . . . . . . . . . . . . . . 5A–85
INACCURATE/INCONSISTENT DTC P0560 SYSTEM VOLTAGE
SHIFT POINTS . . . . . . . . . . . . . . . . . . . . . . . . . 5A–66 MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . 5A–560
HARSH SHIFTS . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–67 DTC P0711 TRANSMISSION FLUID
NO REVERSE, SLIPS IN REVERSE . . . . . . . . 5A–67 TEMPERATURE SENSOR CIRCUIT
RANGE/PERFORMANCE . . . . . . . . . . . . . . . 5A–89
NO FIRST GEAR, SLIPS IN FIRST GEAR . . . 5A–68
DTC P0712 TRANSMISSION FLUID
NO SECOND GEAR, TEMPERATURE SENSOR CIRCUIT
SLIPS IN SECOND GEAR . . . . . . . . . . . . . . . 5A–69 LOW INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–92
NO THIRD GEAR, DTC P0713 TRANSMISSION FLUID
SLIPS IN THIRD GEAR . . . . . . . . . . . . . . . . . 5A–70 TEMPERATURE SENSOR CIRCUIT
SECOND GEAR ONLY . . . . . . . . . . . . . . . . . . . . 5A–71 HIGH INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–95
NO FOURTH GEAR, DTC P0716 AUTOMATIC INPUT SPEED
SLIPS IN FOURTH GEAR . . . . . . . . . . . . . . . 5A–71 SENSOR CIRCUIT
RANGE/PERFORMANCE . . . . . . . . . . . . . . . 5A–97
LOSS OF DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . 5A–72
DTC P0717 AUTOMATIC INPUT SPEED
LOSS OF POWER . . . . . . . . . . . . . . . . . . . . . . . 5A–73
SENSOR CIRCUIT NO SIGNAL . . . . . . . . . 5A–100
ENGINE STALL . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–73 DTC P0719 BRAKE SWITCH
FIRST AND SECOND GEARS ONLY . . . . . . . 5A–74 CIRCUIT LOW . . . . . . . . . . . . . . . . . . . . . . . . 5A–103
THIRD AND FOURTH GEARS ONLY . . . . . . . 5A–74 DTC P0722 AUTOMATIC TRANSMISSION
FIRST AND FOURTH GEARS ONLY . . . . . . . 5A–74 VEHICLE SPEED SENSOR
(A/T VSS) LOW INPUT . . . . . . . . . . . . . . . . . 5A–105
SECOND AND THIRD GEARS ONLY . . . . . . . 5A–74
DTC P0723 AUTOMATIC TRANSMISSION
NO PARK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–74 VEHICLE SPEED SENSOR
RATCHETING NOISE . . . . . . . . . . . . . . . . . . . . . 5A–75 (A/T VSS) INTERMITTENT . . . . . . . . . . . . . 5A–107

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4T40–E AUTOMATIC TRANSAXLE 5A – 3
DTC P0724 BRAKE SWITCH 2–3 SHIFT SOLENOID . . . . . . . . . . . . . . . . . . . 5A–175

CIRCUIT HIGH . . . . . . . . . . . . . . . . . . . . . . . . 5A–109 PRESSURE CONTROL SOLENOID . . . . . . . 5A–176
DTC P0730 INCORRECT GEAR RATIO . . . . 5A–111 TCC SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . 5A–177
DTC P0741 TCC CIRCUIT STUCK OFF . . . . 5A–114 DRIVE AXLE OIL SEAL . . . . . . . . . . . . . . . . . . 5A–177
DTC P0742 TCC CIRCUIT STUCK ON . . . . . 5A–117 OIL COOLER PIPES . . . . . . . . . . . . . . . . . . . . . 5A–178
DTC P0748 PC SOLENOID OIL COOLER HOSES . . . . . . . . . . . . . . . . . . . . 5A–179
CIRCUIT ELECTRICAL . . . . . . . . . . . . . . . . . 5A–121 TRANSAXLE MOUNT . . . . . . . . . . . . . . . . . . . . 5A–179
DTC P0751 1–2 SHIFT SOLENOID TRANSAXLE BRACKET . . . . . . . . . . . . . . . . . 5A–181
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . 5A–124 TRANSAXLE ASSEMBLY . . . . . . . . . . . . . . . . 5A–184
DTC P0753 1–2 SHIFT TRANSAXLE BRACE . . . . . . . . . . . . . . . . . . . . 5A–191
SOLENOID ELECTRICAL . . . . . . . . . . . . . . 5A–128
UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–194
DTC P0756 2–3 SHIFT
TORQUE CONVERTER REMOVAL . . . . . . . . 5A–194
SOLENOID PERFORMANCE . . . . . . . . . . . 5A–131
TRANSAXLE HOLDING
DTC P0758 2–3 SHIFT
FIXTURE ASSEMBLY . . . . . . . . . . . . . . . . . . 5A–194
SOLENOID ELECTRICAL . . . . . . . . . . . . . . 5A–135
STUB SHAFT REMOVAL . . . . . . . . . . . . . . . . . 5A–195
DTC P1790 MEMORY
CHECKSUM ERROR . . . . . . . . . . . . . . . . . . 5A–138 AUTOMATIC TRANSMISSION VEHICLE
SPEED SENSOR (A/T VSS) REMOVAL . . 5A–195
DTC 1792 EEPROM
OIL PAN AND GASKET REMOVAL . . . . . . . . 5A–196
CHECKSUM ERROR . . . . . . . . . . . . . . . . . . 5A–139
OIL FILTER/SEAL, OIL LEVEL
DTC P1810 AUTOMATIC TRANSMISSION
CONTROL VALVE REMOVAL . . . . . . . . . . . 5A–196
FLUID PRESSURE MANUAL VALVE
POSITION SWITCH OIL FEED PIPES REMOVAL . . . . . . . . . . . . . . 5A–196
(TFP VAL. POSITION SW.) INTER 4TH SERVO REMOVAL . . . . . . . . . . . 5A–197
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . 5A–140 LOW/REVERSE SERVO REMOVAL . . . . . . . 5A–197
DTC P1811 MAXIMUM ADAPT CASE SIDE COVER REMOVAL . . . . . . . . . . . 5A–197
AND LONG SHIFT . . . . . . . . . . . . . . . . . . . . 5A–145 OIL PUMP AND OIL PUMP SHAFT
DTC P1887 TCC RELEASE SWITCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–198
CIRCUIT MALFUNCTION . . . . . . . . . . . . . . . 5A–149 WIRE HARNESS DISCONNECT . . . . . . . . . . 5A–198
MAINTENANCE AND REPAIR . . . . . . . . . . . . . 5A–152 PRESSURE SWITCH ASSEMBLY
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 5A–152 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–198
TRANSAXLE FLUID LEVEL CHECKING CONTROL VALVE BODY ASSEMBLY
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 5A–152 AND GASKET REMOVAL . . . . . . . . . . . . . . . 5A–199
SPACER PLATE AND
CHANGING THE FLUID . . . . . . . . . . . . . . . . . . 5A–153
GASKET REMOVAL . . . . . . . . . . . . . . . . . . . 5A–199
REPAIRING FLUID LEAKS . . . . . . . . . . . . . . . 5A–153
CHECKBALL REMOVAL . . . . . . . . . . . . . . . . . 5A–199
CASE POROSITY REPAIR . . . . . . . . . . . . . . . 5A–154
MANUAL VALVE CLIP REMOVAL . . . . . . . . . 5A–200
FLUID LEVEL SET AFTER SERVICE . . . . . . 5A–155 CHANNEL PLATE AND
OIL COOLER FLUSHING . . . . . . . . . . . . . . . . 5A–155 GASKET REMOVAL . . . . . . . . . . . . . . . . . . . 5A–200
SHIFT CONTROL LEVER . . . . . . . . . . . . . . . . 5A–156 ACCUMULATOR SPRING REMOVAL . . . . . . 5A–200
SHIFT CONTROL CABLE . . . . . . . . . . . . . . . . 5A–162 OUTPUT SHAFT SLEEVE REMOVAL . . . . . 5A–201
CONTROL CABLE ADJUSTMENT . . . . . . . . 5A–165 DRIVE, DRIVEN SPROCKETS,
PARK/NEUTRAL POSITION SWITCH . . . . . . 5A–165 DRIVE LINK REMOVAL . . . . . . . . . . . . . . . . 5A–201
BRAKE TRANSAXLE SHIFT INTERLOCK . . 5A–167 INPUT SPEED SENSOR REMOVAL . . . . . . . 5A–201
WIRING HARNESS REMOVAL . . . . . . . . . . . 5A–202
KEY INTERLOCK . . . . . . . . . . . . . . . . . . . . . . . 5A–168
DRIVEN SPROCKET SUPPORT
AUTOMATIC TRANSMISSION VEHICLE
ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . 5A–202
SPEED SENSOR (A/T VSS) . . . . . . . . . . . . 5A–170
2ND CLUTCH PLATES REMOVAL . . . . . . . . 5A–202
PAN, GASKET, AND FILTER . . . . . . . . . . . . . . 5A–171
REVERSE INPUT CLUTCH HOUSING
REVERSE/LOW SERVO ASSEMBLY . . . . . . 5A–172 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–203
2ND/4TH SERVO ASSEMBLY . . . . . . . . . . . . 5A–173 INTERMEDIATE 4TH BAND REMOVAL . . . . 5A–203
CASE SIDE COVER PAN AND GASKETS . . 5A–173 DIRECT/COAST CLUTCH AND
1–2 SHIFT SOLENOID . . . . . . . . . . . . . . . . . . . 5A–175 REACTION GEAR SET REMOVAL . . . . . . 5A–203
DAEWOO V–121 BL4
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INPUT CARRIER AND REACTION INPUT INTERNAL GEAR,

GEAR ASSEMBLY REMOVAL . . . . . . . . . . . 5A–204 FORWARD CLUTCH HUB ASSEMBLE . . . 5A–224
INPUT INTERNAL GEAR, FORWARD INPUT INTERNAL GEAR,
CLUTCH HUB REMOVAL . . . . . . . . . . . . . . . 5A–204 FORWARD CLUTCH HUB INSTALL . . . . . . 5A–225
FORWARD CLUTCH AND LOW/REVERSE REACTION INTERNAL GEAR,
BAND REMOVAL . . . . . . . . . . . . . . . . . . . . . . 5A–204 INPUT CARRIER DISASSEMBLE . . . . . . . 5A–225
FORWARD CLUTCH SUPPORT, INPUT CARRIER PINION GEAR
LOW ROLLER CLUTCH REMOVAL . . . . . . 5A–205 CLEARANCE CHECK . . . . . . . . . . . . . . . . . . 5A–225
OUTPUT SHAFT AND FINAL DRIVE REACTION INTERNAL GEAR,
ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . 5A–206 INPUT CARRIER ASSEMBLE . . . . . . . . . . . 5A–226
FINAL DRIVE INTERNAL REACTION INTERNAL GEAR,
GEAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . 5A–206 INPUT CARRIER INSTALL . . . . . . . . . . . . . . 5A–226
DIRECT/COAST CLUTCH,
MANUAL SHAFT, DETENT LEVER,
REACTION CARRIER DISASSEMBLE . . . 5A–226
PARK LOCK REMOVAL . . . . . . . . . . . . . . . . 5A–206
REACTION CARRIER PINION
TRANSAXLE COOLER LINE
CLEARANCE CHECK . . . . . . . . . . . . . . . . . . 5A–231
SEAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . 5A–207
DIRECT/COAST CLUTCH,
TORQUE CONVERTER SEAL REMOVAL . . 5A–207 REACTION CARRIER ASSEMBLE . . . . . . 5A–232
DRIVE SPROCKET SUPPORT REMOVAL . 5A–207 DIRECT AND COAST CLUTCH
RIGHT HAND AXLE SEAL REMOVAL . . . . . 5A–208 FUNCTIONAL AIR CHECKS . . . . . . . . . . . . 5A–236
CASE INSPECTION . . . . . . . . . . . . . . . . . . . . . 5A–208 DIRECT/COAST CLUTCH,
ACTUATOR GUIDE REPLACEMENT . . . . . . 5A–209 REACTION CARRIER INSTALL . . . . . . . . . 5A–237
SELECTIVE WASHER MEASUREMENT
DRIVE SPROCKET SUPPORT
AND INSTALLATION . . . . . . . . . . . . . . . . . . . 5A–238
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 5A–209
REVERSE INPUT AND 2ND ROLLER
TORQUE CONVERTER SEAL
CLUTCH DISASSEMBLE . . . . . . . . . . . . . . . 5A–238
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 5A–210
TRANSAXLE COOLER LINE SEALS CLUTCH ASSEMBLE . . . . . . . . . . . . . . . . . . 5A–241
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 5A–210
REVERSE CLUTCH FUNCTIONAL
MANUAL SHAFT, DETENT LEVER, AIR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–242
PARK LOCK INSTALLATION . . . . . . . . . . . . 5A–210
FINAL DRIVE ASSEMBLY DISASSEMBLE . 5A–211 CLUTCH INSTALL . . . . . . . . . . . . . . . . . . . . . 5A–244
FINAL DRIVE ASSEMBLY ASSEMBLE . . . . 5A–214 INTERMEDIATE 4TH BAND
FINAL DRIVE PINION END PLAY CHECK . . 5A–215 ASSEMBLY INSTALL . . . . . . . . . . . . . . . . . . 5A–244
FRETTING RING, FINAL DRIVE 2ND CLUTCH PLATE INSTALLATION . . . . . 5A–245
INTERNAL GEAR INSTALL . . . . . . . . . . . . . 5A–216 DRIVEN SPROCKET ASSEMBLY
FINAL DRIVE AND DIFFERENTIAL DISASSEMBLE . . . . . . . . . . . . . . . . . . . . . . . . 5A–245
ASSEMBLY INSTALL . . . . . . . . . . . . . . . . . . 5A–216 DRIVE SPROCKET SUPPORT
FORWARD CLUTCH SUPPORT, ASSEMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–248
ROLLER CLUTCH DISASSEMBLE . . . . . . 5A–216 2ND CLUTCH FUNCTIONAL
AIR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–249
FORWARD CLUTCH SUPPORT,
LOW ROLLER CLUTCH ASSEMBLE . . . . . 5A–218 DRIVEN SPROCKET SUPPORT
ASSEMBLY INSTALLATION . . . . . . . . . . . . 5A–249
FORWARD CLUTCH SUPPORT,
LOW ROLLER CLUTCH INSTALL . . . . . . . 5A–219 WIRING HARNESS INSTALLATION . . . . . . . 5A–250
FORWARD CLUTCH DISASSEMBLE . . . . . . 5A–219 INPUT SPEED SENSOR INSTALL . . . . . . . . 5A–250
DRIVE, DRIVEN SPROCKETS
FORWARD CLUTCH ASSEMBLE . . . . . . . . . 5A–221
AND DRIVE LINK DISASSEMBLE . . . . . . . 5A–250
FORWARD CLUTCH FUNCTIONAL
DRIVE, DRIVEN SPROCKETS
AIR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–222
AND DRIVE LINK ASSEMBLE . . . . . . . . . . 5A–251
LOW/REVERSE BAND INSTALL . . . . . . . . . . 5A–223 DRIVE, DRIVEN SPROCKETS
FORWARD CLUTCH INSTALLATION . . . . . . 5A–223 AND DRIVE LINK INSTALL . . . . . . . . . . . . . 5A–252
INPUT INTERNAL GEAR, FORWARD CHANNEL PLATE ASSEMBLY
CLUTCH HUB DISASSEMBLE . . . . . . . . . . 5A–224 DISASSEMBLE . . . . . . . . . . . . . . . . . . . . . . . . 5A–253

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CHANNEL PLATE ASSEMBLY ASSEMBLE . 5A–253 GENERAL DESCRIPTION AND SYSTEM

ACCUMULATOR SPRINGS INSTALL . . . . . . 5A–254 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–278
TRANSAXLE DEFINITIONS AND
CHANNEL PLATE ASSEMBLY
ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . 5A–278
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 5A–254
TRANSAXLE GENERAL DESCRIPTION . . . 5A–279
MANUAL VALVE INSTALL . . . . . . . . . . . . . . . . 5A–255
TRANSAXLE COMPONENT AND SYSTEM
CHECKBALLS INSTALLATION . . . . . . . . . . . . 5A–255 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 5A–279
SPACER PLATE AND RANGE REFERENCE CHART . . . . . . . . . . . . 5A–282
GASKETS INSTALL . . . . . . . . . . . . . . . . . . . . 5A–255
BTSI AND KEY INTERLOCK SYSTEM . . . . . 5A–283
CONTROL VALVE BODY
AUTOMATIC TRANSMISSION
DISASSEMBLE . . . . . . . . . . . . . . . . . . . . . . . . 5A–257
VEHICLE SPEED SENSOR (A/T VSS) . . . 5A–283
CONTROL VALVE BODY ASSEMBLE . . . . . 5A–261 AUTOMATIC TRANSMISSION INPUT
CONTROL VALVE ASSEMBLY AND (SHAFT) SPEED SENSOR (A/T ISS) . . . . . 5A–283
TFP SWITCH INSTALL . . . . . . . . . . . . . . . . . 5A–265 SHIFT SOLENOIDS: 1–2 AND 2–3 . . . . . . . . 5A–284
WIRING HARNESS ASSEMBLY PRESSURE CONTROL SOLENOID
CONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–266 VALVE (PC SOL. VALVE) . . . . . . . . . . . . . . . 5A–284
OIL PUMP CLEAN AND INSPECT . . . . . . . . . 5A–267 TORQUE CONVERTER CLUTCH
OIL PUMP ASSEMBLY INSTALLATION . . . . 5A–267 SOLENOID VALVE (TCC SOL. VALVE) . . . 5A–285
SIDE COVER/GASKETS, DISASSEMBLE, AUTOMATIC TRANSMISSION FLUID
ASSEMBLE, INSTALL . . . . . . . . . . . . . . . . . . 5A–267 PRESSURE MANUAL VALVE POSITION
SWITCH (TFP VAL. POSITION SW.) . . . . . 5A–286
OUTPUT SHAFT SLEEVE ASSEMBLE . . . . 5A–269
TRANSMISSION FLUID
OUTPUT SHAFT AND SLEEVE TEMPERATURE (TFT) SENSOR . . . . . . . . 5A–287
ASSEMBLY INSTALL . . . . . . . . . . . . . . . . . . 5A–269
TRANSMISSION ELECTRICAL
SIDE COVER AXLE SEAL INSTALL . . . . . . . 5A–270 CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . 5A–288
STUB SHAFT SLEEVE ASSEMBLE POWERTRAIN CONTROL
AND INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . 5A–271 MODULE (PCM) . . . . . . . . . . . . . . . . . . . . . . . 5A–289
RIGHT HAND AXLE SEAL ASSEMBLE . . . . 5A–271 DATA LINK CONNECTOR (DLC) . . . . . . . . . . 5A–289
VEHICLE SPEED SENSOR PCM INPUTS THAT AFFECT THE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 5A–272 4T40– TRANSMISSION . . . . . . . . . . . . . . . . 5A–289
INTER 4TH SERVO DISASSEMBLE, PARK (ENGINE RUNNING) . . . . . . . . . . . . . . . 5A–291
ASSEMBLE, AND INSTALL . . . . . . . . . . . . . 5A–272 REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–293
LOW/REVERSE SERVO ASSEMBLY NEUTRAL (ENGINE RUNNING) . . . . . . . . . . . 5A–295
DISASSEMBLE . . . . . . . . . . . . . . . . . . . . . . . . 5A–274 OVERDRIVE RANGE – FIRST GEAR . . . . . . 5A–297
LOW/REVERSE SERVO ASSEMBLY OVERDRIVE RANGE – SECOND GEAR . . . 5A–299
ASSEMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–274
OVERDRIVE RANGE – THIRD GEAR . . . . . 5A–301
OIL FEED PIPES ASSEMBLE . . . . . . . . . . . . 5A–274 OVERDRIVE RANGE – FOURTH GEAR . . . 5A–303
FILTER ASSEMBLY AND SEAL INSTALL . . 5A–275 OVERDRIVE RANGE – 4–3 DOWNSHIFT . . 5A–305
OIL LEVEL CONTROL VALVE INSTALL . . . . 5A–276 MANUAL THIRD – THIRD GEAR . . . . . . . . . . 5A–307
OIL PAN AND GASKET INSTALL . . . . . . . . . . 5A–276 MANUAL SECOND – SECOND GEAR . . . . . 5A–309
TORQUE CONVERTER INSTALLATION . . . 5A–277 MANUAL FIRST – FIRST GEAR . . . . . . . . . . 5A–311
DAEWOO V–121 BL4
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SPECIFICATIONS
END PLAY SPECIFICATIONS
Dimension A (mm) Washer Selection Washer Dimension
100.40–100.70 Brown 1.50–1.60
100.70–100.99 Grey 1.80–1.90
100.99–101.29 Natural 2.09–2.19
101.29–101.59 Black 2.39–2.49
101.59–101.88 Orange 2.68–2.78
101.88–102.18 Violet 2.98–3.08
102.18–102.48 Yellow 3.28–3.38
102.48–102.77 Red 3.57–3.67
102.77–103.07 Green 3.87–3.97
TRANSAXLE GENERAL SPECIFICATIONS

Dimension A (mm) Backing Plate Identification
8.970–9.433 A
9.434–10.007 B
10.008–10.470 C
FLUID CAPACITY
Litres Quarts
Bottom Pan Removal 6.5 6.9
Complete Overhaul 9.0 9.5
Dry 12.2 12.9
(Measurements are approximate)
RANGE REFERENCE
Park/
Rever
Range Neutr D 3 2 1
se
al
Gear N R 1st 2nd 3rd 4th 1st 2nd 3rd 1st 2nd 3rd** 1st 2nd***
1–2 Shift
ON ON ON OFF OFF ON ON OFF OFF ON OFF OFF ON OFF
Solenoid
1–2 Shift
OFF OFF OFF OFF ON ON OFF OFF ON OFF OFF ON OFF OFF
Solenoid
2nd
– – – A A* A* – A A* – A A* – A
Clutch
2nd Roll-
– – – H O – – H O – H O – H
er Clutch
Int./4th
– – – – – A – – – – A – – A
Band
Reverse
– A – – – – – – – – – – – –
Clutch

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Gear N R 1st 2nd 3rd 4th 1st 2nd 3rd 1st 2nd 3rd** 1st 2nd***
Coast
– – – – – – A A A A A A A A
Clutch
Input
– – H H H O H H H H H H H H
Sprag
Direct
– – – – A A – – A – – A – –
Clutch
Forward
– – A A A A* A A A A A A A A
Clutch
LO/Rev
A A – – – – – – – – – – A –
Band
LO Roll-
– – H O O O H O O H O O H O
er Clutch
A = Applied
H = Holding
O = Overrunnig
ON = The solenoid is energized.
OFF = The solenoid is de–energized.
* = Applied with no load.
** = Manual Second–Third gear is only available above approximately 100 km/h (62 mph).
*** = Manual First–Second gear is only available above approximately 60 km/h (37 mph).
NOTE: Manual First–Third gear is also possible at high vehicle speed as a safety feature.
DAEWOO V–121 BL4
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4T40–E GEAR RATIOS

Gear Ratio
First 2.96
Second 1.62
Third 1.00
Fourth 0.68
Reverse 2.14
SHIFT SPEED
% of TPS 1–2 Shift @ +/– 3 2–3 Shift @ +/– 4 3–4 Shift @ +/– 5 Downshift @ +/– TCC
mph mph mph 4 mph Applyy
Model Series 10 25 50 10 25 50 10 25 50 4–3 3–2 2–1 4th
Coa Coa Coa Gear
st st st
WKR J 9 14.5 20 17 25 39.5 30 36 57 26 11.5 6 42
WBR J 9 15 27 17 28 51 38 40 78 30 13 7 36
LINE PRESSURE
Pressure Control Solenoid Current Approximate Line Pressure
(Amp) (psi)
0.00 152–160
0.10 149–151
0.30 141–143
0.50 124–127
0.60 111–115
0.70 97–101
0.80 81–84
0.90 64–67
0.95 56–58
1.00 50–51
1.05 50
1.10 50

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A/T VSS Stud 12 – 106
Bell Housing Bolts 75 55 –
Channel Plate–to–Case Bolt 12 9 –
Channel Plate–to–Case Valve Body Bolts 12 – 106
Channel Plate–to–Case Valve Body Pressure Switch Manual 12 – 106
Bolts
Channel Plate–to–Case Valve Body Pump Bolts 12 – 106
Channel Plate–to–Support–Driven Sprocket Bolt 14 10.5 –
Channel Plate–to–Support–Driven Sprocket Spacer Bolts 14 10.5 –
Channel Plate Valve Body Pressure Switch Manual Bolts 12 – 106
Detent–to–Channel Plate Spring & Roller Assembly 12 – 106
Drive Sprocket–to–Case Support Assembly Bolts 12 9 –
Engine Mounting Bolts 75 55 –
Floor Bracket Bolt 8 – 71
Fluid Level Plug 12 – 106
Flywheel Bolts 65 48 –
Frame Bolts 75 55 –
Input Speed Sensor Bolt 12 – 106
Key Interlock Solenoid Screws 2 – 18
Oil Pipe Bolts 12 9 –
Pivot Bolt 65 48 –
Servo Cover Bolts 12 – 106
Side Cover Bolts 20 15 –
Shift Control Cable Adjuster Pinch Bolt 6 – 53
Shift Interlock Solenoid Bolts –
Side–to–Case (Stud) Cover 20 15 –
Speed Sensor Stud 12 9 –
Transaxle Mount Bolts 75 55 –
Transaxle Mounting Bracket Bolt 75 55 –
Transaxle Pan Bolts 12 – 106
Trans Oil–to–Cover LO/Reverse Servo Tube Assembly 12 – 106
Trans Oil–to–Support Forward Clutch Tube Assembly 12 – 106
Valve Body–to–Channel Plate Bolts 12 – 106
Valve Body–to–Channel Plate Pump Bolts 12 – 106
Wiring Harness Retainer Bolt 12 9 –
DAEWOO V–121 BL4
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SPECIAL TOOLS
SPECIAL TOOLS TABLE
J 34142–B
Scan Tool
Universal Test Lamp
J 21867 J 35616
Universal Pressure Connector Test
Gauge Set Adapter Kit
J 28742–A J 35689–A
Weather Pack Metri–pack Terminal
Terminal Remover Remover
J 33095
Control Module J 36169–A
Connector Terminal Fused Jumper Wire
Remover

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J 38125–4 J 6125–1B
Terminal Repair Kit Slide Hammer
J 39200 J 38868
Digital Volt–Ohmmeter Stub Shaft
(DVOM) Sleeve Remover
J 41227
J 39775
Output Shaft
Jumper Harness
Sleeve Remover
J 3289–20 J 41101
Transmission Holding Pass Through
Fixture Base Connector Remover
J 41230
J 36850
Transmission Holding
Assembly Lubricant
Fixture
DAEWOO V–121 BL4
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J 41229
J 41102
Manual Shaft to
Axle Seal Installer
Case Pin
J 41239–2 J 23327
Cooler Line Seal Clutch Spring
Remover Compressor
J 41236
J 28540–A
Coast Clutch Return
Torque Converter
Spring Compressor
Seal Installer
Adapter
J 41232
J 28585 Direct Reverse,
Snap Ring Second Clutch
Screwdriver Return Spring
Compressor Adapter
J 41239–1 J 41228
Cooler Line Stub Shaft
Seal Installer Sleeve Installer

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J 25031–A
J 41234–3
Forward and Reverse
Input Shaft Seal
Clutch Inner Seal
Installer Sizer
Assembly Remover
J 41097–2 J 34673
Inner Seal Assembly Input Shaft End
Remover – Disc Play Gauge Block
J 41231
J 41233
Forward Clutch
Reverse Clutch
Inner Seal Assembly
Inner Seal Installer
Installer
J 41234–1 J 41235
Input Shaft Seal Second Roller
Installer Pusher Clutch Installer
J 41234–2 J 29569–1/J 29829–1

Input Shaft Seal Turbine Shaft Seal
Installer Protector Installer
DAEWOO V–121 BL4
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J 29569–2/J 29829–2 J 41103

Turbine Shaft Torque Converter
Seal Sizer Seal Remover Set
J 21366 J 28467–B
Torque Converter Engine Support
Holding Strap Fixture

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POWERTRAIN CONTROL MODULE (1 OF 3)
DAEWOO V–121 BL4
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DAEWOO V–121 BL4
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VISUAL IDENTIFICATION
TRANSAXLE IDENTIFICATION INFORMATION
1. Assembly Plant (Windsor, Canada) 6. Sequential Number

2. Model Year (1996) 7. Manufacturer
3. Broadcast Code 8. Part Number
4. Model Name (4T40E)
5. Update Level

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SECTION : 5B
FIVE–SPEED MANUAL TRANSAXLE

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–2 GEARSHIFT, TUBE, BOOT, BUSHING
FASTENER TIGHTENING AND/OR BEARING RING . . . . . . . . . . . . . . . . 5B–17
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 5B–2 CONTROL SHIFT ROD . . . . . . . . . . . . . . . . . . . 5B–25
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–3 LINKAGE LEVER AND/OR BUSHINGS . . . . . 5B–26
SPECIAL TOOLS TABLE . . . . . . . . . . . . . . . . . . . 5B–3 SPEEDOMETER–DRIVEN GEAR . . . . . . . . . . 5B–32
GEARSHIFT LEVER COVER . . . . . . . . . . . . . . 5B–34
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–5
DRIVE AXLE SEAL . . . . . . . . . . . . . . . . . . . . . . . 5B–36
ISOLATE NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–5
TRANSAXLE ASSEMBLY . . . . . . . . . . . . . . . . . 5B–36
SYMPTOM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 5B–6
UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–44
COMPONENT LOCATORS . . . . . . . . . . . . . . . . . . 5B–9 MAJOR COMPONENT DISASSEMBLYL . . . . 5B–44
GEARS AND CASE . . . . . . . . . . . . . . . . . . . . . . . . 5B–9 INPUT SHAFT AND CLUSTER GEAR . . . . . . 5B–55
DIFFERENTIAL AND CASE . . . . . . . . . . . . . . . 5B–11 MAINSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–58
SHIFT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . 5B–12 HOUSING CASE . . . . . . . . . . . . . . . . . . . . . . . . . 5B–73
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 5B–14 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–76
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 5B–14 MAJOR COMPONENT ASSEMBLY . . . . . . . . . 5B–84
CHECKING FLUID LEVEL . . . . . . . . . . . . . . . . . 5B–14 GENERAL DESCRIPTION AND SYSTEM
SHIFT LINKAGE ADJUSTMENT . . . . . . . . . . . 5B–14 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–93
GEARSHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . 5B–16 FIVE–SPEED MANUAL TRANSAXLE . . . . . . . 5B–93
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5B – 2IFIVE–SPEED MANUAL TRANSAXLE
SPECIFICATIONS
Backup Lamp Switch 20 15 –
Bearing Plate Bolts 22 16 –
Bearing Retainer Bolts, Right Side 25 18 –
Bearing–Adjusting Ring–Retainer Plate Bolt 5 – 44
Center Console Screws, Front 4 – 35
Center Console Screws, Rear 4 – 35
Clutch–Release Cylinder Bracket Bolts 75 55 –
Differential Cover Bolts 40 30 –
Fifth–Gear Fork Bolts 22 16 –
Fifth–Gearshift Connector Bolts 7 – 62
Gearshift Housing Bolts 6 – 53
Gearshift Lever Cover Bolts 22 16 –
Input Driveshaft Detent Screw 15 11 –
Left Front Transaxle Support Bracket Bolts 60 44 –
Left Rear Transaxle Support Bracket Bolts 90 66 –
Lower Transaxle–to–Engine Bolts 75 55 –
Ring–Gear Bolts 70 52 –
Rod Clamp Bolt 14 – 124
Speedometer Housing Retaining Bolt 4 – 35
Speedometer–Driven Gear Bolt 5 – 44
Support Bracket Bolt 7 – 62
Transaxle Cover Bolts 18 13 –
Upper Transaxle–to–Engine Bolts 75 55 –

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FIVE–SPEED MANUAL TRANSAXLE 5B – 3
SPECIAL TOOLS
SPECIAL TOOLS TABLE
J–6125–B KM–553–A
Slide Hammer Fifth–Gear Puller
J–22888–20–A
Bearing Puller with J–36633
J–22888–35 Snap Ring Retainer
Puller Legs
J–22912–01
KM–113–2
Universal Bearing
Base
Puller
J–28467–B KM–334
Engine Support Fixture Installer Sleeve
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J–42469 KM–525
Shift Rod Remover Installer
KM–519 KM–552
Ring Installer Fixture
KM–520 KM–554
Remover/Installer Installer
KM–522
Installer

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DIAGNOSIS
Bearing Noise
ISOLATE NOISE
Differential Side Bearing Noise
Identify the cause of any noise before attempting to repair Differential side bearing noise and wheel bearing noise
the clutch, the transaxle, or their related linkages. can be confused easily. Since side bearings are pre-
Symptoms of trouble with the clutch or the manual trans- loaded, a differential side bearing noise should not dimin-
axle include: ish much when the differential/transaxle is run with the
wheels off the ground.
S A great effort required to shift gears.
Wheel Bearing Noise
S The sound of gears clashing and grinding.
Wheel bearings produce a rough growl or grating sound
S Gear blockout.
that will continue when the vehicle is coasting and the
Any of these conditions requires a careful analysis. Make transaxle is in NEUTRAL. Since wheel bearings are not
the following checks before disassembling the clutch or pre–loaded, a wheel bearing noise should diminish con-
the transaxle for repairs. siderably when the wheels are off the ground.
Other Noise
Road Travel Noise Brinelling
Many noises that appear to come from the transaxle may A brinelled bearing causes a ”knock” or ”click” approxi-
actually originate with other sources such as the: mately every second revolution of the wheel because the
bearing rollers do not travel at the same speed as the
S Tires.
wheel. In operation, the effect is characterized by a low–
S Road surfaces.
pitched noise.
S Wheel bearings.
S Engine. A brinelled bearing is caused by excessive thrust which
S Exhaust system. pushes the balls up on the pathway and creates a triangu-
lar– shaped spot in the bearing race. A brinelled bearing
These noises may vary according to the: can also be caused from pressing one race into position
by applying pressure on the other race.
S Size of the vehicle.
S Type of the vehicle. A false indication of a brinelled bearing occurs as a result
S Amount of insulation used in the body of the ve- of vibration near the area where the bearing is mounted.
hicle. Brinelling is identified by slight indentations, resulting in a
washboard effect in the bearing race.
Transaxle Noise Lapping
Lapped bearing noise occurs when fine particles of abra-
Transaxle gears, like any mechanical device, are not ab-
sive materials such as scale, sand, or emery circulate
solutely quiet and will make some noise during normal op-
through the oil in the vehicle, causing the surfaces of the
eration.
roller and the race to wear away. Bearings that wear loose
To verify suspected transaxle noises: but remain smooth, without spalling or pitting, are the re-
sult of dirty oil.
1. Select a smooth, level asphalt road to reduce tire
and resonant body noise. Locking
2. Drive the vehicle far enough to warm up all the lu- Large particles of foreign material wedged between the
bricants thoroughly. roller and the race usually causes one of the races to turn,
3. Record the speed and the gear range of the trans- creating noise from a locked bearing. Pre–loading regular
axle when the noise occurs. taper roller bearings to a value higher than that specified
4. Check for noises with the vehicle stopped, but with also can result in locked bearings
the engine running. Pitting
5. Determine if the noise occurs while the vehicle op- Pitting on the rolling surface comes from normal wear and
erates in: the introduction of foreign materials.
S Drive – under a light acceleration or a heavy Spalling

pull. Spalled bearings have flaked or pitted rollers or races
S Float – maintaining a constant speed with a light caused by an overload or an incorrect assembly that re-
throttle on a level road. sults in a misalignment, a cocking of bearings, or adjust-
S Coast – with the transaxle in gear and the ments that are too tight.
throttle partly or fully closed. After completing these checks, refer to the ”Diagnosis
S All of the above. Chart” in this section.
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SYMPTOM DIAGNOSIS
Checks Action
Check for a knock at low speeds. S Replace any worn drive axle CV joints.
S Replace any worn side gear hub.
Check for a noise most pronounced on turns. S Correct any abnormalities in the differential gear.
Check for a clunk upon acceleration or deceleration. S Tighten any loose engine mounts.
S Replace any worn drive axle inboard joints.
S Replace any worn differential pinion shaft in the
case.
S Replace any worn side gear hub in the case.
Check for a clunking noise in turns. S Replace any worn outboard CV joint.
Check for a vibration. S Replace any rough wheel bearing.
S Replace any bent drive axle shaft.
S Replace any out–of–round tires.
S Balance any unbalanced tire.
S Replace any worn CV joint in the drive axle shaft.
S Correct an excessive drive axle angle by adjusting
the trim height.
Check for a noise in the NEUTRAL gear with the engine S Replace any worn cluster bearing shaft.
running. S Replace any worn clutch–release bearing.
S Replace any worn input shaft cluster gears.
S Replace any worn first–gear/bearing.
S Replace any worn second–gear/bearing.
S Replace any worn third–gear/bearing.
S Replace any worn fourth–gear/bearing.
S Replace any worn fifth–gear/bearing.
S Replace any worn mainshaft bearings.
Check for a noise in the first gear (1) only. S Replace any chipped, scored, or worn first–gear
constant mesh gears.
S Replace any worn first–second gear synchronizer.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the second gear (2) only. S Replace any chipped, scored, or worn second–gear
Check for a noise in the third gear (3) only. S Replace any chipped, scored, or worn third–gear
S Replace any worn third–fourth gear synchronizer.

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Checks Action
Check for a noise in the fourth gear (4) only. S Replace any chipped, scored, or worn fourth gear or
output gear.
Check for a noise in the fifth gear (5) only. S Replace any chipped, scored, or worn fifth gear or
output gear.
S Repair any worn fifth–gear synchronizer.
Check for a noise in the reverse (R) gear only. S Replace any chipped, scored, or worn reverse idler
gear, idler–gear bushing, input gear, or output gear.
S Replace any worn output gear.
Check for a noise in all gears. S Add sufficient lubricant.
S Replace any worn bearings.
S Replace any chipped, scored, or worn input–gear
shaft or output–gear shaft.
Check for the transaxle slipping out of gear. S Adjust or replace the linkage, as needed.
S Adjust, repair, or replace any binding shift linkage.
S Tighten or replace the input–gear bearing retainer, as
needed.
S Repair or replace any worn or bent shift fork.
Check for a leak in the area of the clutch. S Repair the transaxle casing.
S Replace any damaged release bearing guide.
Check for a leak at the center of the transaxle. S Repair the transaxle casing.
S Repair the shift mechanism.
S Replace the damaged backup lamp switch.
Check for a leak at the differential. S Adjust or replace the bearing retainers.
S Tighten or replace the differential cover.
S Adjust or replace the drive axle shaft seals.
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Checks Action
Check for a hard shift. S Replace any damaged release–bearing guide.
S Adjust, repair, or replace the shift mechanism.
S Adjust, repair, or replace the clutch–release system.
S Replace any chipped, scored, or worn fifth–gear syn-
chronizer.
S Replace any chipped, scored, or worn first–second
gear synchronizer.
Check for a clashing of gears. S Replace any damaged release–bearing guide.
S Adjust, repair, or replace the clutch–release system.
S Replace the chipped, scored, or worn input shaft/
gear–cluster gears.
S Replace any worn fifth–gear synchronizer.
S Replace any worn third–fourth synchronizer.
S Replace any worn reverse–idler gear.

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COMPONENT LOCATORS
GEARS AND CASE
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1. Case 44. Gasket

2. Mainshaft Bearing 45. Cover
3. Fourth Gear 46. Bolt
4. Synchronizer Blocking Ring 47. Plug
5. Synchronizer Sleeve 48. Bolt
6. Pin 49. Screw
7. Third–Fourth Gearshift Fork 50. Synchronizer Gear
8. Third–Fourth Gearshift Shaft 51. Spring
9. Spring 52. Synchronizer Sleeve
10. Key 53. Synchronizer Blocking Ring
11. Third–Fourth Synchronizer Gear 54. Mainshaft Driven Fifth Gear
12. Synchronizer Blocking Ring 55. Ring
13. Third Gear 56. Thrust Washer
14. Second Gear 57. Ring
15. First–Second Gear Blocking Ring 58. Input Drive Fifth Gear
16. First–Second Gearshift Fork 59. Bolt
17. First–Second Gearshift Shaft 60. Cluster Gear Snap Ring
18. Synchronizer Hub Sleeve 61. Screw
19. Synchronizer Spring 62. Cluster Shaft Bearing
20. Key 63. Ring
21. First–Second Synchronizer Gear 64. Input Shaft Cluster Gear
22. Snap Ring 65. Ball
23. Outer Blocking Ring 66. Reverse Idler Gear Shaft
24. First Gear 67. Reverse Idler Gear
25. First Gear Needle Bearing 68. Washer
26. Mainshaft Wear Plate 69. Reverse Gear Fork Shaft
27. Snap Ring 70. Reverse Gearshift Fork
28. Mainshaft Bearing 71. Input Drive Shaft
29. Shift Rod Plug (21.5 mm) 72. Bolt
30. Spring 73. Fifth–Gear Pawl
31. Shift Rod Lock Pin 74. Fifth–Gear Needle Bearing
32. Bearing Plate 75. First–Gear Needle Bearing
33. Shift Rod Plug (50.4 mm) 76. Main Driven Shaft
34. Detent Rod Bolt 77. Fifth Gearshift Lever
35. Bolt 78. Hex Plug
36. Bolt 79. Gasket
37. Support 80. Reverse Lamp Switch
38. Fifth Gearshift Fork 81. Input Shaft Bearing
39. Pin 82. Second–Gear Needle Bearing
40. Fifth Gear Connector 83. Third–Gear Needle Bearing
41. Shoe 84. Fourth–Gear Needle Bearing
42. Key 85. Washer
43. Snap Ring

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DIFFERENTIAL AND CASE
1. Speedometer–Driven Gear 15. Pinion Gear Shaft

2. Seal 16. Differential Housing
3. Hex Bolt 17. Thrust Washer
4. Bearing Plate 18. Side Gear
5. Washer 19. Washer
6. Bolt 20. Pinion Gear
7. Seal 21. Ring Gear
8. Seal 22. Speedometer Drive Gear
9. Bearing Adjusting Ring 23. Bolt
10. Side Bearing Race 24. Pinion Shaft Lock Pin
11. Housing Cover Gasket 25. Right Side Bearing Retainer
12. Differential Cover 26. Seal
13. Bolt 27. Retainer Bolt
14. Differential Bearing
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SHIFT LINKAGE

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1. Gearshift Lever Knob 22. Clip

2. Gearshift Lever Boot 23. Gearshift Rod
3. Gearshift Lever 24. Shift Finger Lever
4. Gearshift Lever Stop Clamp 25. Cover Bolt
5. Gearshift Lever Shaft 26. Intermediate Lever
6. Gearshift Lever Stop Bushing 27. Shift Lever Thrust Spring
7. Gearshift Lever Stop Bushing 28. Bushing
8. Bolt 29. Snap Ring
9. Gearshift Housing 30. Oil Filler Plug
10. Shift Rod Clamp Bolt 31. Oil Plug Cap
11. Washer 32. Gearshift Lever Cover
12. Clamp 33. Pin
13. Linkage Adjuster Bolt 34. Bolt
14. Gearshift Control Rod 35. Gearshift Adjuster Linkage
15. Linkage Ball Socket 36. Shift Reverse Pivot Bolt
16. Circlip Ring 37. Boot
17. Linkage Reverse Lever 38. Gearshift Tube
18. Gearshift Boot 39. Bushing
19. Bushing 40. Gearshift Tube Bearing
20. Bushing
21. Rod U–Joint Bushing
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SECTION : 6A
POWER STEERING SYSTEM
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–1 ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6A–3
FASTENER TIGHTENING BLEEDING THE POWER STEERING
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 6A–1 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–1 CHECKING AND ADDING FLUID . . . . . . . . . . . 6A–3
SPECIAL TOOLS TABLE . . . . . . . . . . . . . . . . . . . 6A–1
FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . 6A–4
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–2
HOSES AND PIPES . . . . . . . . . . . . . . . . . . . . . . . 6A–5
PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . 6A–2 GENERAL DESCRIPTION AND SYSTEM
POWER STEERING SYSTEM LEAK TEST . . . 6A–2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–10
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 6A–3 POWER STEERING SYSTEM . . . . . . . . . . . . . 6A–10
SPECIFICATIONS
Air Cleaner Housing Bolts 12 – 106
Power Steering Fluid Reservoir Attaching Bolts 7 – 62
Power Steering Line Fittings–Cylinder End 28 21 –
Power Steering Line Fittings–Valve End 18 13 –
Power Steering Pump Pressure Line Union Nut 27 20 –
Steering Gear Inlet and Outlet Pipe Fittings 28 21 –
SPECIAL TOOLS
SPECIAL TOOLS TABLE
KM–354–B
Pressure Test
Gauge Kit
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6A – 2IPOWER STEERING SYSTEM
DIAGNOSIS POWER STEERING SYSTEM LEAK

TEST
PRESSURE TEST General Procedure
Tools Required Inspect the following:
KM–354–B Pressure Test Gauge Kit
Check the fluid pressure as follows to determine whether S The fluid reservoir for overfill.
the trouble is in the pump or the gear unit. S Fluid for aeration and overflow.
S The hoses for loose connections.
Test Procedure S The torsion bar, stub shaft and adjuster seals for
1. Check the power steering fluid level and the power leaks.
steering pump belt tension. Refer to”Checking and S The component sealing surfaces for damage.
Adding Fluid” in this section andSection 6B, Power
Steering Pump. Important : Verify the exact point of the leak. The point
2. Disconnect the high pressure line at the pump. Use from which the fluid is dripping is not necessarily the point
a small container to catch any fluid. at which the system is leaking. When service is required,
3. Connect the hose of the pressure test gauge kit clean the leak area upon disassembly, replace the leaking
KM–354–B to the power steering pressure hose seal, check the component sealing surfaces for damage
from the power steering pump. and reset the torque bolt to specifications, where required.
4. Place the gear selector lever in PARK (automatic
transaxle–equipped vehicles) or NEUTRAL (manual External Leak Check
transaxle–equipped vehicles). Set the parking
The purpose of this procedure is to pinpoint the location of
brake.
the leak. In some cases, the leak can be easily located, but
5. Open the gauge valve fully.
seepage–type leaks may be harder to find. To locate seep-
6. Start the engine and let it idle.
age leaks, use the following method:
7. Turn the steering wheel from lock–to–lock several
times to warm the fluid to operating temperature. 1. With the engine off, wipe dry the complete power
8. Increase the engine speed to 1,500 rpm. steering system.
Notice : The power steering pump could be damaged if 2. Check the power steering fluid level in the pump’s
the valve is fully closed for more than five seconds. reservoir. Adjust the fluid level as necessary. Refer
1. Close the gauge valve fully, and read the pressure. to”Checking and Adding Fluid”in this section.
The pump pressure with the valve closed should be Notice : Notice: Do not hold the steering wheel at a stop
between 7 088 kPa to 8 619 kPa (1,028 psi to for any length of time as this can damage the power steer-
1,250 psi). ing pump.
2. Immediately open the gauge valve fully.
3. Turn the steering wheel all the way to the left and 1. Start the engine. Turn the steering wheel counter-
the right. If the pressure is within the specified lim- clockwise and clockwise from stop to stop several
its, the problem is not in the pump. Check the pow- times.
er steering gear for leaks. 2. Find the exact area of the leak and repair it.

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POWER STEERING SYSTEM 6A – 3

BLEEDING THE POWER STEERING
SYSTEM
If the power steering hydraulic system has been serviced,
an accurate fluid level reading cannot be obtained until the
air is bled from the system. Follow these steps to bleed the
air from the system.
1. Turn the wheels all the way to the left and add the
power steering fluid to the MIN mark on the fluid
level indicator.
Notice : When adding fluid or making a complete fluid
change, always use DEXRON± III power steering fluid.
Failure to use the proper fluid will cause hose and seal
damage and fluid leaks.
2. Start the engine. With the engine running at fast
idle, recheck the fluid level. If necessary, add fluid
to bring the level up to the MIN mark.
3. Bleed the system by turning the wheels from side to
side without reaching the stop at either end. Keep
the fluid level at the MIN mark. The airmust be
eliminated from the fluid before normal steering ac-
tion can be obtained.
4. Return the wheels to the center position. Continue
running the engine for two to three minutes.
5. Road test the car to be sure the steering functions
normally and is free from noise.
6. Recheck the fluid level as described in steps 1 and
2. Make sure the fluid level is at the MAX mark af-
ter the system has stabilized at its normal operating
temperature. Add fluid as needed.
CHECKING AND ADDING FLUID
1. The power steering fluid level is indicated either by
marks on a see–through fluid reservoir or by marks
on a fluid level indicator on the fluid reservoir cap.
2. If the fluid is warmed up to 66³C (150³F), the fluid
level should be between the MAX and MIN marks.
Add fluid as needed.
3. If the fluid is cool, 21³C (70³F), the fluid level
should be at the MIN mark. Add fluid as needed.
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FLUID RESERVOIR
Removal Procedure
1. Siphon the power steering fluid from the fluid reser-

voir.
2. Loosen the hose clamps and remove both hoses.
3. Remove the fluid reservoir attaching bolts and re-

move the fluid reservoir from the power steering
fluid reservoir bracket.
1. Attach the fluid reservoir to the power steering fluid

reservoir bracket with the power steering fluid res-
ervoir attaching bolts.
Tighten
Tighten the power steering fluid reservoir attaching
bolts to 7 NSm (62 lb–in).

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2. Connect both hoses and secure the hose clamps.

3. Fill the fluid reservoir with power steering fluid.
4. Inspect for leaks. If there are leaks, correct the
cause of the leaks and bleed the system. Refer
to”Bleeding the Power Steering System”in this sec-
tion.
HOSES AND PIPES

Steering Gear Cylinder Pipes
Removal Procedure
1. Siphon the power steering fluid from the fluid reser-
voir.
2. Disconnect and remove the steering gear cylinder
pipes at the rack and pinion housing. Remove the
O–ring seals from the housing.
1. Install new O–rings onto the cylinder pipes. Install
the steering gear cylinder pipes into the rack and
pinion housing.
Tighten
Tighten the power steering line fittings at the cylinder
end to 28 NSm (21 lb–ft).
Tighten
Tighten the power steering line fittings at the valve
end to 18 NSm (13 lb–ft).
tion.
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Power Steering Pump Hoses and Pipes

Removal Procedure
1. Remove the battery and battery tray. Refer to Sec-

tion 1E, Engine Electrical.
2. Siphon the power steering fluid fromthe fluid reser-
voir.
3. On SOHC engines, disconnect the pressure line
pipe and the supply line hose from the inlet and out-
let connections on the power steering pump.
4. On DOHC engines, remove the air cleaner housing

and disconnect the pressure line pipe and the sup-
ply line hose from the inlet and outlet connections
on the power steering pump.
5. Disconnect the pressure line and return line hoses

from the retaining clips at the bottom and the side
of the radiator.
6. Disconnect the pressure line inlet pipe from the
steering gear.

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7. Disconnect the supply line hose from the power

steering fluid reservoir.
8. Remove the power steering pump pressure line and
return line.
1. Install the power steering pump pressure line and

return line.
2. Connect the supply line hose to the power steering
fluid reservoir.
3. Connect the pressure line inlet pipe to the steering

gear.
Tighten
Tighten the steering gear inlet pipe fitting to 28 NSm
(21 lb–ft).
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4. Connect the pressure line and return line hoses to

the retaining clips at the bottom and the side of the
radiator.
5. On SOHC engines, connect the pressure line pipe
and the supply line hose to the inlet and outlet con-
nections on the power steering pump.
6. On DOHC engines, install the air cleaner housing.

Tighten
Tighten the air cleaner housing bolts to 12 NSm (106
lb–in).
7. On DOHC engines, connect the pressure line pipe
and the supply line hose to the inlet and outlet con-
nections on the power steering pump.
Tighten
Tighten the power steering pump pressure line union
nut to 28 NSm (21 lb–ft).
8. Install the battery and battery tray. Refer to Section
1E, Engine Electrical.
tion.
Power Steering Fluid Reservoir Hose
Removal Procedure
1. Siphon the power steering fluid fromthe fluid reser-

voir.
2. Disconnect the return line pipe from the outlet con-
nection at the steering gear.

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3. Disconnect the fluid reservoir hose from the fluid

reservoir.
4. Remove the fluid reservoir hose.
1. Connect the fluid reservoir hose at the fluid reser-
voir.
2. Connect the fluid reservoir pipe to the outlet con-
nection at the steering gear.
Tighten
Tighten the steering gear outlet pipe fittings to 28 NSm
(21 lb–ft).
to”Bleeding the Power Steering System in this
Section
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gine. It draws on the power steering fluid reservoir, which

GENERAL DESCRIPTION in turn is connected to the power steering gear. A pres-
sure–relief valve inside the flow control valve limits the
AND SYSTEM OPERATION pump pressure. The power steering rack and pinion gear
has a rotary control valve which directs hydraulic fluid
POWER STEERING SYSTEM coming from the power steering pump to one side or the
other side of the rack piston. The integral rack piston is at-
General Description tached to the rack. The rack piston converts hydraulic
The power steering system consists of three components: pressure to a linear force which moves the rack to the left
the power steering pump, the power steering fluid reser- or the right. The force is then transmitted through the inner
voir and the the power steering rack and pinion gear. The and the outer tie rods to the steering knuckles, which turn
power steering pump is a vane–type pump providing hy- the wheels.
draulic pressure for the system and is powered by the en-

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SECTION : 6B
POWER STEERING PUMP
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–1 PUMP DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . 6B–4
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 6B–1 SOHC PUMP DRIVE PULLEY . . . . . . . . . . . . . . 6B–4
FASTENER TIGHTENING DOHC PUMP DRIVE PULLEY . . . . . . . . . . . . . . 6B–6
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 6B–1 SOHC PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . 6B–9
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–2 DOHC PUMP ASSEMBLY . . . . . . . . . . . . . . . . . 6B–14
SPECIAL TOOLS TABLE . . . . . . . . . . . . . . . . . . . 6B–2 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–22
PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–22
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–2
POWER STEERING PUMP DIAGNOSIS . . . . . 6B–2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–23
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 6B–4 POWER STEERING PUMP . . . . . . . . . . . . . . . . 6B–23
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6B–4 SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–23
SPECIFICATIONS
Lubricant Power Steering Fluid DEXRON±–III
Capacity 1.0 Liter (1.05 qt)

Air Cleaner Housing Bolts 12 – 106
Crankshaft Pulley Bolt 95 + 30³ + 15³ 70 + 30³ + 15³ –
Engine Bracket–to–Mount Bolts 60 44 –
Power Steering Pump Retaining Bolts 25 18 –
Tension Pulley Securing Bolt 25 18 –
Timing Belt Cover Bolts 10 – 89
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6B – 2IPOWER STEERING PUMP
SPECIAL TOOLS
SPECIAL TOOLS TABLE
J–28467–B
J–23600–B
Engine Support
Belt Tension Gauge
Fixture
DIAGNOSIS
POWER STEERING PUMP DIAGNOSIS
Foaming, Milky Power Steering Fluid, Low Fluid Level, and
Possible Low Pressure
Checks Action
Check the power steering fluid level. Fill the power steering fluid reservoir.
Check for air contamination in the power steering fluid. Bleed the power steering system.
Check the power steering pump for internal leaks and Replace the power steering pump.
overflow.
Check the power steering pump housing and the soft plug Replace the power steering pump.
for leaks.
Low Pressure Due to Steering Pump

Checks Action
Check the power steering pump flow control valve for Replace the power steering pump.
sticking and improper operation.
Check the power steering pump seals for wear. Replace the power steering pump.
Check the pressure plate, the pump ring, the thrust plate, Replace the power steering pump.
and the rotor for scores, cracks, or breaks.
Check the vanes for sticking in the rotor slots. Replace the power steering pump.
Check the power steering pump for internal leaks and Replace the power steering pump.
overflow.
Growling Noise in Steering Pump

Checks Action
Check the pump hoses and the steering gear pipes for re- Clean out the pipes and the hoses. Replace the pipes and
stricted flow. the hoses as needed.
Check the pressure plate, the pump ring, the thrust plate, Replace the power steering pump.
and the rotor for scores, cracks, or breaks.

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POWER STEERING PUMP 6B – 3
Checks Action
Check the power steering hose for contact with the body. Secure the pump hose in a clamp away from the body.
Check the power steering fluid level. Fill the power steering pump reservoir.
Rattling Noise in the Steering Pump

Checks Action
Check for air contamination in the power steering fluid. Bleed the power steering system.
Check the power steering hose for contact with the body. Secure the pump hose in a clamp away from the body.
Check the power steering fluid level. Fill the power steering pump reservoir.
Check the pump mounting for improper installation. Tighten the power steering pump attachment bolts.
Swishing Noise in the Steering Pump

Checks Action
Check the power steering pump flow control valve for dam- Replace the power steering pump.
age.
Whining Noise in the Steering Pump

Checks Action
Check the pressure plate and the vanes for scores. Replace the power steering pump.
Check the pump shaft bearing for scores. Replace the power steering pump.
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PUMP DRIVE BELT
Tools Required
J–23600–B Belt Tension Gauge
Checking Belt Tension
1. Using belt tension gauge J–23600–B, check the
tension on the pump drive belt.
2. If belt tension gauge J–23600–B does not indicate
the proper tension, adjust the belt.
Adjusting Belt Tension
1. With belt tension gauge J–23600–B on the pump
drive belt, loosen the alternator adjusting bolt and
move the alternator until the gauge indicates the
proper tension.
2. Tighten the alternator adjusting bolt.
Tighten
Tighten the alternator adjusting bolt to 20 NSm(15 lb–
ft).
SOHC PUMP DRIVE PULLEY

Removal Procedure
1. Remove the air cleaner housing by removing the

housing bolts and loosening the clamp.

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2. Loosen the steering pump pulley bolts.

3. Remove the pump drive belt from the pulley by
loosening the alternator adjusting bolt and pulling it
forward.
4. Remove the steering pump pulley bolts that con-
nect the pulley to the pump.
5. Remove the pulley from the pump.
1. Replace the pump on the engine if the pump was

previously removed. Refer to ”Pump Assembly” in
this section.
2. Install the pulley on the pump. Install the steering
pump pulley bolts.
3. Install the pump drive belt.
4. Tighten the steering pump pulley bolts to fasten the
pulley to the pump.
Tighten
Tighten the steering pump pulley bolts to 25 NSm (18
lb–ft).
5. Adjust the belt tension. Refer to ”Pump Drive Belt”
in this section.
6. Install the air cleaner housing with the housing bolts

and the clamp.
Tighten
lb–in).
7. If the pump was removed from the engine, bleed
the power steering system. Refer to Section 6A,
Power Steering System.
change, always use DEXRON±–III power steering fluid.
8. Inspect for leaks. If leaks are found, correct the
cause of the leak and bleed the system.
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DOHC PUMP DRIVE PULLEY

Tools Required
J–28467–B Engine Support Fixture
Removal Procedure

2. Loosen the steering pump pulley bolts.

loosening the alternator adjusting bolt and pulling it
forward.
4. Install the engine support fixture J–28467–B. Sup-

port the engine.

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5. Remove the engine bracket–to–mount bolts.
6. Raise the engine using the engine support fixture

J–28467–B.
7. Remove the steering pump pulley bolts that con-
nect the pulley to the pump.
8. Remove the pulley from the pump.
1. Replace the pump on the engine if the pump was

previously removed. Refer to ”Pump Assembly” in
this section.
2. Install the pulley onto the pump. Install the steering
pump pulley bolts.
3. Install the pump drive belt.
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4. Tighten the steering pump pulley bolts to fasten the

pulley to the pump.
Tighten
lb–ft).
5. Adjust the belt tension. Refer to ”Pump Drive
Belt”in this section.
6. Lower the engine using the engine support fixture

J–28467–B.
7. Install the engine bracket–to–mount bolts.
Tighten
Tighten the engine bracket–to–mount bolts to 60 NSm
(44 lb–ft).
8. Remove the engine support fixture J–28467–B.

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and the clamp.
Tighten
lb–in).
10. If the pump was removed from the engine, bleed
the power steering system. Refer to Section 6A,
Power Steering System.
SOHC PUMP ASSEMBLY

Tools Required
Removal Procedure

2. Remove the the upper timing belt cover bolts and

the upper timing belt cover.
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loosening the alternator adjusting bolt and pulling
the alternator forward.
4. Remove the power steering pump pulley bolts and

the power steering pump pulley.
5. Drain the power steering fluid by disconnecting the

pressure and supply lines from the pump.

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6. Install the engine support fixture J–28467–B.

9. Remove the right wheel. Refer to Section 2E, Tires
and Wheels.
10. Remove the right engine undercover. Refer to Sec-
tion 9N, Frame and Underbody.

J–28467–B.
12. Remove the pump assembly by removing the steer-
ing pump retaining bolts.
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1. Install the pump and the steering pump retaining

bolts.
Tighten
Tighten the steering pump retaining bolts to 25 NSm
(18 lb–ft).

J–28467–B.
Tighten
(44 lb–ft).
4. Install the right engine under cover. Refer to Sec-
5. Install the right wheel. Refer to Section 2E, Tires
and Wheels.


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8. Connect the pressure and supply lines to the power

steering pump.
9. Install the power steering pump pulley and the

pulley bolts.
Tighten
Tighten the power steering pump pulley bolts to 25
NSm (18 lbft).
10. Install the upper timing belt cover and the cover
bolts.
Tighten
Tighten the timing belt cover bolts to 10 NSm (89 lbin).
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11. Install the pump drive belt onto the pulley. Push the
alternator rearward and tighten the alternator ad-
justing bolt.
Tighten
Tighten the alternator adjusting bolt to 20 NSm (15
lbft).
and the clamp.
Tighten
lb–in).
13. Refill the pump with new fluid and bleed the air from
the system. Refer toSection 6A, Bleeding the Pow-
er Steering System.
DOHC PUMP ASSEMBLY

Tools Required
Removal Procedure


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2. Disconnect the throttle body inlet coolant hose from

the throttle body and the timing belt cover and
move it aside.
3. Loosen the power steering pump pulley bolts.

loosening the alternator adjusting bolt and pulling
the alternator forward.
6. Remove the right wheel. Refer toS ection 2E, Tires
and Wheels.
7. Remove the right engine under cover. Refer to
Section 9N, Frame and Underbody.
8. Loosen the securing bolt on the tension pulley and

release the tension on the A/C compressor belt by
turning the tightening bolt.
9. Remove the A/C compressor belt.
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10. Remove the crankshaft pulley and the bolt.
11. Remove the timing belt cover lower bolts and the
clip.
13. Install the engine support fixture J–28467–B. Sup-

port the engine.

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J–28467–B.
16. Remove the power steering pump pulley bolts. Re-
move the power steering pump pulley.
17. Remove the the timing belt cover upper bolts and
the timing belt cover.
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18. Drain the power steering fluid by disconnecting the

pressure and supply lines from the pump.
19. Remove the pump assembly by removing the steer-

ing pump retaining bolts.
1. Install the power steering pump and the power

steering pump retaining bolts.
Tighten
Tighten the power steering pump retaining bolts to 25
NSm (18 lb–ft).

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2. Connect the pressure and the supply lines to the

power steering pump.
3. Install the timing belt cover and timing belt cover

upper bolts.
Tighten

5. Install the timing belt cover lower bolts and the clip.
Tighten
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6. Install the crankshaft pulley and the bolt.

Tighten
Tighten the crankshaft pulley bolt to 95 NSm (70 lb–ft),
then tighten the bolt another 30 degrees plus 15 de-
grees.
7. Install the A/C compressor belt.
8. Turn the tightening bolt on the tension pulley to

tighten the A/C compressor belt. Tighten the secur-
ing bolt on the tension pulley.
Tighten
Tighten the tension pulley securing bolt to 25 NSm (18
lb–ft).

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9. Install the right engine under cover. Refer to Sec-

10. Install the right wheel. Refer to Section 2E, Tires
and Wheels.
12. Install the power steering pump pulley and the
pulley bolts.
Tighten
lb–ft).

J–28467–B.
Tighten
(44 lb–ft).
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16. Install the pump drive belt onto the pulley. Push the
alternator rearward and tighten the alternator ad-
justing bolt.
Tighten
Tighten the alternator adjusting bolt to 20 NSm (15
lbft).
17. Connect the throttle body inlet coolant hose to the
throttle body and the timing belt cover.
and the clamp.
Tighten
lb–in).
19. Refill the pump with new fluid and bleed the air from
the system. Refer to Section 6A, Bleeding the Pow-
er Steering System.
UNIT REPAIR
PUMP
The power steering pump in this vehicle is not serviceable.
A faulty pump must be replaced.

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SEALS
GENERAL DESCRIPTION Seal Replacement
AND SYSTEM OPERATION Lip seals, which seal the rotating shafts, are used on the
driveshaft of the pump. This type of seal requires special
treatment. When leakage occurs in this area, always re-
place the seal after inspecting and thoroughly cleaning the
POWER STEERING PUMP sealing surfaces. If the corrosion in the lip seal contact
zone is slight, clean the surface of the shaft with a crocus
cloth. Replace the shaft only if the leakage cannot be
General Description stopped by first smoothing the shaft with the crocus cloth.
The pump has a remote fluid reservoir. A pressure–relief
valve inside the flow control valve limits pump pressure.
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SECTION : 7B
MANUAL CONTROL HEATING, VENTILATION,

AND AIR CONDITIONING SYSTEM
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–3 O–RING REPLACEMENT . . . . . . . . . . . . . . . . . 7B–24
A/C SYSTEM CHARGING CAPACITY . . . . . . . 7B–3 HANDLING REFRIGERANT . . . . . . . . . . . . . . . 7B–24
FASTENER TIGHTENING HANDLING OF REFRIGERANT
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 7B–3 LINES AND FITTINGS . . . . . . . . . . . . . . . . . . 7B–24
MAINTAINING CHEMICAL STABILITY
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–4
IN THE REFRIGERATION SYSTEM . . . . . . 7B–24
SPECIAL TOOLS TABLE . . . . . . . . . . . . . . . . . . . 7B–4
DISCHARGING, ADDING OIL, EVACUATING,
SCHEMATIC AND ROUTING DIAGRAMS . . . . . 7B–7 AND CHARGING PROCEDURES FOR A/C
A/C REFRIGERANT SYSTEM (TYPICAL) . . . . 7B–7 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–24
SERVICEABLE COMPONENTS . . . . . . . . . . . . . 7B–28
A/C AIRFLOW (TYPICAL) . . . . . . . . . . . . . . . . . . 7B–8
HVAC CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–28
A/C SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–9
TEMPERATURE CABLE ADJUSTMENT . . . . 7B–29
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–10 CONTROL ASSEMBLY . . . . . . . . . . . . . . . . . . . 7B–30
GENERAL DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . 7B–10 CONTROL ASSEMBLY KNOB LIGHTING . . . 7B–31
TESTING THE REFRIGERANT SYSTEM . . . 7B–10 BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 7B–31
INSUFFICIENT COOLING ”QUICK CHECK” HIGH–BLOWER RELAY . . . . . . . . . . . . . . . . . . . 7B–32
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–10
BLOWER MOTOR RESISTOR . . . . . . . . . . . . . 7B–32
A/C PERFORMANCE TEST . . . . . . . . . . . . . . . 7B–11 BLOWER SWITCH . . . . . . . . . . . . . . . . . . . . . . . 7B–32
PRESSURE–TEMPERATURE A/C/DEFOGGER SWITCH ASSEMBLY . . . . . 7B–33
RELATIONSHIP OF R–134a . . . . . . . . . . . . . 7B–12
A/C PRESSURE TRANSDUCER . . . . . . . . . . . 7B–34
LEAK TESTING THEREFRIGERANT
A/C COMPRESSOR RELAY . . . . . . . . . . . . . . . 7B–34
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–13
A/C EXPANSION VALVE . . . . . . . . . . . . . . . . . . 7B–35
V5 SYSTEM AIR CONDITIONING
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–14 HEATER/AIR DISTRIBUTION
CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 7B–37
INSUFFICIENT COOLING DIAGNOSIS . . . . . 7B–14
A/C HIGH–PRESSURE LINE . . . . . . . . . . . . . . 7B–39
SYMPTOM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 7B–18
HEATER HOSES . . . . . . . . . . . . . . . . . . . . . . . . . 7B–42
PRESSURE TEST CHART
HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–43
(R–134a SYSTEM) . . . . . . . . . . . . . . . . . . . . . . 7B–18
EVAPORATOR CORE . . . . . . . . . . . . . . . . . . . . 7B–44
LOW AND HIGH SIDE PRESSURE
RELATIONSHIP CHART . . . . . . . . . . . . . . . . . 7B–20 A/C HOSE ASSEMBLY . . . . . . . . . . . . . . . . . . . . 7B–45
RECEIVER–DRYER . . . . . . . . . . . . . . . . . . . . . . 7B–47
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . 7B–21
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–48
V5 COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . 7B–22
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–50
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 7B–24 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–52
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 7B–24 V5 AIR CONDITIONING COMPRESSOR
GENERAL A/C SYSTEM SERVICE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–52
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–24 CLUTCH PLATE AND HUB ASSEMBLY . . . . . 7B–52
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7B – 2IMANUAL CONTROL HEATING, VENTILATION,AND AIR CONDITIONING SYSTEM
CLUTCH ROTOR AND BEARING . . . . . . . . . . 7B–54 GENERAL DESCRIPTION AND SYSTEM

CLUTCH COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–57 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–68
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 7B–68
SHAFT SEAL REPLACEMENT . . . . . . . . . . . . . 7B–59
THE V5 A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . 7B–68
PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . 7B–61
SYSTEM COMPONENTS – FUNCTIONAL . . 7B–68
CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . 7B–62
SYSTEM COMPONENTS – CONTROL . . . . . 7B–69
REAR HEAD, GASKET, VALVE PLATE,
V5 COMPRESSOR –
REED PLATE, AND O–RING. . . . . . . . . . . . . 7B–63
GENERAL DESCRIPTION . . . . . . . . . . . . . . . 7B–69
CYLINDER–TO–FRONT HEAD O–RING . . . . 7B–65 V5 COMPRESSOR – DESCRIPTION OF
LEAK TESTING (EXTERNAL) . . . . . . . . . . . . . . 7B–67 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–69

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MANUAL CONTROL HEATING, VENTILATION,AND AIR CONDITIONING SYSTEM 7B – 3
SPECIFICATIONS
A/C SYSTEM CHARGING CAPACITY
R–134a System 750 µ 20 g
Refrigerant Oil in A/C System Synthetic Polyalkaline Glycol (PAG) 220 ml

A/C System Hose Connector Retaining Nut 33 24 –
Air Cleaner Housing Assembly Retaining Bolts 12 – 106
Clutch Plate and Hub Assembly Nut 17 13 –
Compressor Bracket Bolt 50 37 –
Compressor Front Head–to–Rear Head Through–Bolt 10 – 89
Condenser Upper Mount Nuts 3 – 27
Control Assembly Retaining Screws 2 – 18
Discharge Hose–to–Condenser Pipe Connector Block Retain- 16 12 –
ing Nut
Expansion Valve Retaining Bolts 12 – 106
Heater/Air Distribution Case Assembly Retaining Bolts (Fire 8 – 71
Wall Side)
Idler Pulley Lock Nut 50 36 –
Liquid Condenser Pipe Connector Block–to–Receiver–Dryer 14 10 124
Nut
Liquid Evaporator Pipe Connector Block–to–Receiver–Dryer 12 – 106
Bolt
Liquid Evaporator Pipe Connector Block–to–Liquid Condenser 15 11 –
Pipe Connector Block Retaining Bolt
Pressure Relief Valve 17 13
Pressure Transducer 8 – 71
Suction Hose Connecting Block Retaining Nut 12 – 106
Suction Hose Support Clamp Bolt 4 – 35
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SPECIAL TOOLS
SPECIAL TOOLS TABLE
J–5403 J–8433–3
Snap Ring Pliers Forcing Screw
J–6083 J–9398–A
Snap Ring Pliers Bearing Remover
J–8092 J–9481
Driver Handle Bearing Installer
J–8433–1 J–9553–1
Puller Crossbar O–Ring Remover

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J–9625–A
J–34993
Pressure Test Set Con-
Cylinder Alignment Rods
nector
J–23128–A J–33017
Seal Seat Remover and Pulley Rotor and Bearing
Installer Assembly Installer
J–33019
Bearing Staking Tool Set
Includes:
J–35372
J–33019–1
Support Block
Bearing Staking Guide
J–33019–2
Bearing Staking Pin
J–33011 J–33020
O–Ring Installer Pulley Puller
J–33013–B
J–34614
Hub and Drive Plate Re-
Shaft Seal Protector
mover and Installer
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J–34992
J–33022
Compressor Holding Fix-
Shaft Nut Socket
ture
J–33023–A J–33027
Puller Pilot Clutch Hub Holding Tool
J–33024 J–42428
Clutch Coil Installer Compressor
Adapter Holding Fixture
J–33025
Clutch Coil Puller Legs

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A/C REFRIGERANT SYSTEM (TYPICAL)
1. Compressor 4. Receiver–Dryer
2. Pressure Relief Valve 5. Evaporator
3. Condenser 6. Expansion Valve
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A/C AIRFLOW (TYPICAL)

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A/C SCHEMATIC
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DIAGNOSIS
GENERAL DIAGNOSIS
quick idea of whether the air conditioning (A/C) system
TESTING THE REFRIGERANT has the proper charge of Refrigerant–134a. The air tem-
SYSTEM perature must be above 21³C (70³F) for most models.
If you suspect a problem in the refrigerant system, check 1. Warm up engine. Run the engine at idle.
for the following conditions: 2. Open the hood and all the doors.
1. Check the outer surfaces of the radiator and the 3. Turn the A/C switch ON.
condenser cores to be sure that the airflow is not 4. Set the temperature control to the full cold position.
blocked by dirt, leaves, or other foreign material. 5. Set the blower speed switch on 4.
Check between the condenser and the radiator, as 6. ”Hand–feel” the temperature of the evaporator out-
well as all outer surfaces. let pipe. The pipe should be cold.
2. Check for restrictions or kinks in the condenser 7. Check for other problems. Refer to ”Testing the Re-
core, the hoses, and the tubes. frigerant System” in this section.
3. Check the operation of the blower fan. 8. Leak check the system. Refer to ”Leak Testing the
4. Check all the air ducts for leaks or restrictions. A Refrigerant System”in this section. If you find a
low airflow rate may indicate a restricted evaporator leak, discharge the system and repair the leak as
core. required. After completing the repair, evacuate and
5. Check for slippage of the compressor clutch. charge the system.
6. Check the tension on the serpentine accessory 9. If there is no leak, refer to ”Insufficient Cooling
drive belt. Diagnosis” in this section.
INSUFFICIENT COOLING ”QUICK
CHECK” PROCEDURE
Perform the following hand–feel" procedure to get a

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A/C PERFORMANCE TEST

RELATIVE AMBIENT AIR LOW SIDE ENGINE CENTER DUCT AIR HIGH SIDE
HUMIDITY TEMPERATURE PRESSURE SPEED (RPM) TEMPERATURE PRESSURE
(%) ³C ³F kPa psig ³C ³F kPa psig
20 21 70 200 29 2000 4 39 1034 150
27 81 200 29 7 45 1310 190
32 90 207 30 9 48 1689 245
38 100 214 31 14 57 2103 305
30 21 70 200 29 2000 6 43 1034 150
27 81 207 30 8 46 1413 205
32 90 214 31 11 52 1827 265
38 100 221 32 16 61 2241 325
40 21 70 200 29 2000 7 45 1138 165
27 81 207 30 9 48 1482 215
32 90 221 32 13 55 1931 280
38 100 269 39 18 64 2379 345
50 21 70 207 30 2000 8 46 1241 180
27 81 221 32 12 54 1620 235
32 90 234 34 15 59 2034 295
38 100 276 40 21 70 2413 350
60 21 70 207 30 2000 9 48 1241 180
27 81 228 33 13 56 1655 240
32 90 248 36 17 63 2068 300
38 100 296 43 23 73 2482 360
70 21 70 207 30 2000 10 50 1276 185
27 81 234 34 14 57 1689 245
32 90 262 38 18 64 2103 305
38 100 303 44 24 75 2517 365
80 21 70 207 30 2000 10 50 1310 190
27 81 234 34 15 59 1724 250
32 90 269 39 19 66 2137 310
90 21 70 207 30 2000 10 50 1379 200
27 81 248 36 17 63 1827 265
32 90 290 42 22 72 2275 330
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PRESSURE–TEMPERATURE RELATIONSHIP OF R–134a

TEMPERATURE PRESSURE TEMPERATURE PRESSURE
³C (³F)* kPa (psig)* ³C (³F)* kPa (psig)*
–8.89 (16) 105.70 (15.33) 37.78 (100) 856.84 (124.27)
–7.78 (18) 114.87 (16.66) 38.89 (102) 886.56 (128.58)
–6.67 (20) 124.32 (18.03) 40.00 (104) 916.35 (132.98)
–5.56 (22) 134.11 (19.45) 41.11 (106) 947.92 (137.48)
–4.44 (24) 144.24 (20.92) 42.22 (108) 979.64 (142.08)
–3.33 (26) 154.65 (22.43) 43.33 (110) 1012.11 (146.79)
–2.22 (28) 165.48 (24.00) 44.44 (112) 1045.21 (151.59)
–1.11 (30) 176.65 (25.62) 45.56 (114) 1079.14 (156.51)
0.00 (32) 188.16 (27.29) 46.67 (116) 1113.75 (161.53)
1.11 (34) 200.02 (29.01) 47.78 (118) 1149.12 (166.66)
2.22 (36) 212.30 (30.79) 48.89 (120) 1185.18 (171.89)
3.33 (38) 224.98 (32.63) 50.00 (122) 1222.07 (177.24)
4.44 (40) 238.08 (34.53) 51.11 (124) 1259.72 (182.70)
7.22 (45) 272.49 (39.52) 52.22 (126) 1298.12 (188.27)
10.00 (50) 309.58 (44.90) 53.33 (128) 1337.35 (193.96)
12.77 (55) 349.51 (50.69) 54.44 (130) 1377.35 (199.76)
15.56 (60) 392.33 (56.90) 57.22 (135) 1480.91 (214.78)
18.33 (65) 438.18 (63.55) 60.00 (140) 1589.57 (230.54)
21.11 (70) 487.27 (70.67) 62.78 (145) 1703.62 (247.08)
23.89 (75) 539.67 (78.27) 65.56 (150) 1823.04 (264.40)
26.67 (80) 609.38 (88.38) 68.33 (155) 1948.04 (282.53)
29.44 (85) 655.09 (95.01) 71.11 (160) 2078.77 (301.49)
32.22 (90) 718.39 (104.19) 73.89 (165) 2215.29 (321.29)
35.00 (95) 785.61 (113.94) 76.67 (170) 2357.81 (341.96)
* All values rounded to two decimal places.

EVAPORATOR RANGE: From –6.67 to 7.22³C (20 to 45³F), the temperatures represent the gas temperatures inside the
coil and not on the coil surfaces. Add 1.67 to 5.56³C (3to10³F) to the temperature for coil and air–off temperatures.
CONDENSER RANGE: From 110 to 160³F, temperatures are not ambient. Add 19.4 to 22.2³C (35 to 40³F) for proper
heat transfer, then refer to the pressure chart.
Example:
32³C (90³F) ambient temperature
+ 22³C + (40³F)
54³C (130³F)
Condenser temperature = 1379 kPa (200 psig)
Based on 48.3 km/h (30 mph) air flow.

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S Do not block the air intake.

LEAK TESTING THEREFRIGERANT
The audible tone changes from 1 to 2 clicks per second
SYSTEM into a solid alarm if there is a leak. Adjust the balance con-
Test for leaks whenever you suspect a refrigerant leak in trol to maintain 1 to 2 clicks per second.
the system. You should also test for leaks whenever you Test all of the following areas, even after one leak has been
perform a service operation which results in disturbing the confirmed:
lines or the connections. Leaks are commonly found at the
refrigerant fittings or at the connections. Leaks are com- S Evaporator inlet and outlet.
monly caused by the following problems: S Receiver–drier inlet and outlet.
S Condenser inlet and outlet.
S Improper torque. S Brazed and welded areas.
S Damaged O–ring seals. S Damaged areas.
S Dirt or lint on the O–ring seals. S Hose couplings.
S Compressor rear head.
Liquid Leak Detectors
S All fittings and joints.
Use a liquid leak detector solution on locations such as fit-
tings. Apply the solution to the area in question with the Testing Service Ports/Access Valves
swab that is supplied with the solution. Look for bubbles
The sealing cap is the primary seal for the service ports.
to appear. This will indicate the existence and location of
This cap contains a special leak–free O–ring. Make sure
any leak.
that this cap is not missing or loose. Always use the correct
For areas where this is not practical, such as sections of cap.
the evaporator and the condenser, an electronic leak de-
tector is more useful. Testing the Evaporator Core
Leaks in the evaporator core are difficult to find. Test the
Electronic Leak Detectors evaporator core using the following procedure:
Follow the manufacturer’s instructions for calibration, op-
1. Run the blower fan at speed setting 4 for at least 15
eration, and maintenance of an electronic leak detector.
minutes.
Battery condition is especially important to the accuracy
2. Turn the blower to the OFF position.
of a portable model. Set the detector to R–134a before be-
3. Wait for 10 minutes.
ginning the test.
4. Remove the blower motor resistor. Refer to”Blower
Important : Electronic leak detectors are sensitive to Resistor” in this section.
windshield washing solutions, solvents and cleaners, and 5. Insert the leak detector probe as close as possible
certain vehicle adhesives. to the evaporator core. The detector will indicate a
Surfaces must be clean to prevent false readings. Make leak with a solid alarm.
sure that all surfaces are dry to prevent damage to the de- 6. Use a flashlight to search for refrigerant oil in the
tector. core surface.
General Testing Instructions Testing the Compressor Shaft Seal

S Follow the entire path of the refrigerant system. 1. Blow shop air behind and in front of the compressor
S Completely circle each joint at 25 to 50 mm (1 to 2 clutch/pulley for at least 15 seconds.
inches) per second. 2. Wait 1 to 2 minutes.
S Hold the probe tip within 6 mm (1/4 inch) of the sur- 3. Probe the area in front of the pulley. If the detector
face. emits a solid alarm, there is a leak.
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V5 SYSTEM AIR CONDITIONING DIAGNOSIS
INSUFFICIENT COOLING DIAGNOSIS

1 Can you verify the customer’s complaint? Go to Step 2 System OK
2 1. Check the A/C fuse. At least 7³C System OK Go to Step 3
2. Check the blower fan operation. (13³F) below
3. Check the engine cooling fan operation. ambient air
4. Check the A/C compressor belt. temperature
5. Check the A/C condenser for restricted airflow.
6. Check the clutch coil connection.
7. Repair or replace any components as needed.
8. Check the discharge air temperature with the
A/C turned on.
Is the discharge air temperature normal?
3 1. Turn the ignition switch to LOCK. 69–345 kPa Go to Step 4 Go to Step 5
2. Connect the high and the low pressure gauges. (10–50 psi)
Are both pressures within the value specified?
4 1. Check the A/C system for leaks. 345 kPa (50 Go to Step 7
2. Repair any refrigerant leaks, as needed. psi)
3. Recover, evacuate, and recharge the A/C sys-
tem.
Are both pressures above the value specified?
5 Observe the two pressure gauges. 69 kPa (10 psi) Go to Step 6 Go to Step 7
Are both pressures below the value specified?
6 1. Add 0.45 kg (1 pound) of refrigerant R–134a. 345 kPa (50 Go to Step 7
2. Check the A/C system for leaks. psi)
3. Repair any refrigerant leaks, as needed.
4. Recover, evacuate, and recharge the A/C sys-
tem.
Are both pressures above the value specified?
7 1. Start the engine and allow it to run at idle. Go to Step 8 Go to Step 10
2. Set the A/C controls to the following positions:
SThe A/C switch to the ON position.
SThe fresh air control switch to fresh air (in-
dicator lamp OFF).
S The blower motor to 4.
S The temperature to full cold.
Does the A/C compressor clutch engage?
8 1. Check for a knocking noise from the A/C com- Go to Step 9 Go to Step 13
pressor.
2. Cycle the A/C compressor ON and OFF in or-
der to verify the source of the noise.
Do you hear a loud knocking noise?
9 1. Recover the A/C system refrigerant. Go to Step 13
2. Replace the A/C compressor.
3. Evacuate and recharge the A/C system.
4. Check the A/C system for leaks.
Is the compressor running normally?

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2. Disconnect the A/C compressor clutch coil con-
nector.
3. Connect a jumper wire from ground to one A/C
compressor clutch coil terminal.
4. Connect a fused jumper wire from the positive
battery terminal to the other A/C compressor
clutch coil terminal.
Does the A/C clutch engage?
11 Repair the electrical circuit to the A/C compressor Go to Step 8
clutch coil.
12 Replace the A/C compressor clutch coil. Go to Step 8
13 Important : Perform this test under garage condi- Go to Step 15 Go to Step 14
tions; 1–32_C [70–90_F) and no sun load. Follow
this test carefully for accurate results.
1. Close all of the vehicle’s windows and doors.
S The A/C to ON.
S The fresh air control switch to fresh air.
S The temperature control knob to full cold.
3. Start the engine and allow it to run at idle for 5
minutes.
4. Feel the evaporator inlet and outlet pipes.
Is there a noticeable difference in the temperature of
the evaporator inlet and outlet pipes?
14 1. Turn the ignition switch to LOCK. At least 7³C Go to Step 15 Go to Step 13
2. Recover the A/C system refrigerant. (13³F) below
3. Examine the high–pressure pipe for an ob- ambient air
struction. temperature
4. Examine the expansion valve for a malfunction
if there is no obstruction.
5. Repair the obstruction or replace the expansion
valve as needed.
8. Note the discharge air temperature with the
A/C ON.
Is the discharge temperature normal?
15 1. Record the low and the high side pressures System OK Go to Step 16
after the A/C system has been operating for 5
minutes or more and the engine cooling fan is
ON. .
2. Locate the intersection of the low and the high
side pressures. Refer to”Low– and High–Side
Pressure Relationship Chart” in this section.
Do the low– and high–side pressures intersect in the
white area of the chart?
16 Check the high– and low–side pressures. Go to Step 17 Go to Step 20
Do the low– and the high–side pressures intersect
in the gray area of the chart?
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17 Feel the liquid pipe between the condenser and the Go to Step 18 Go toStep 19
expansion valve.
Is the pipe cold?
18 1. Examine the condenser for any restriction of Go to Step 13
the airflow.
2. Check the cooling fans for proper operation.
3. Remove the restriction or repair the fan(s) as
required.
Is the pipe temperature normal now?
19 1. Recover, evacuate, and recharge the A/C sys- Go to Step 13
tem.
Is the system leak tight?
20 Observe the readings on the pressure gauges. 207 kPa (30 Go to Step 21 Go to Step 26
Are the A/C compressor high– and the low–side psi)
pressures within the specified value of each other?
21 1. Run the engine at 3,000 rpm. 207 kPa (30 Go to Step 22 Go to Step 13
2. Set the A/C controls to the following positions: psi)
S The A/C switch to the ON position.
S The fresh air control switch to fresh air.
S The temperature to full cold.
3. Close all of the windows and the doors of the
vehicle.
4. Turn the A/C switch ON and OFF every 20
seconds for 3 minutes.
Are the A/C compressor high– and the low–side
pressures within the specified value of each other?
22 Observe the pressure rise on both gauges and the Go to Step 25 Go to Step 23
temperatures of both the compressor suction pipe
and the discharge pipe.
Is the pressure rise on both gauges slow and the
suction pipe warm with the discharge pipe very hot?
2. Confirm that the compressor clutch is disen-
gaged.
3. Attempt to turn the clutch driver (not the
pulley).
Can you turn the clutch driver freely by hand?
24 1. Start the engine. Go to Step 32 Go to Step 25
2. Observe the low–side pressure gauge while
running the engine between 3,000 and 3,800
rpm.
Does the low–side pressure rise rapidly?
2. Replace the A/C compressor.
Is the compressor functioning normally?
26 Check the low–side pressure. 172–241 kPa Go to Step 27 Go to Step 32
Is the low–side pressure within the specified value? (27–38 psi)

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27 Feel the high–side pipe leading up to the expansion Go to Step 28 Go to Step 29
valve connecting block.
Is the pipe cold before the connecting block?
28 1. Check for a restriction in the high–side pipe Go toStep 13
before the expansion valve.
2. Repair or replace the high–side pipe.
Is the pipe performing normally?
29 Add the specified amount of refrigerant to the A/C 0.40 kg (14 Go to Step 30 Go to Step 31
system. ounces)
Does the cooling performance improve?
30 1. Check the A/C system for leaks. Go to Step 13
2. Repair any refrigerant leaks, as needed.
Is the system leak free?
31 1. Recover the refrigerant. Go to Step 13
2. Check the expansion valve for obstructions.
3. Repair or replace the expansion valve, as re-
quired.
4. Evacuate and recharge the system.
5. Leak check the system.
Is the system leak free?
32 Important : Perform this test exactly as described 172–241 kPa Go to Step 13 Go to Step 33
to obtain accurate results. (25–35 psi)
1. Run the engine for 5 minutes at 2,000 rpm.
The A/C switch to the ON position.
The fresh air control switch to recirculate
(indicator lamp ON).
The blower motor to 1.
The temperature to full cold.
3. Close all of the windows and the doors of the
vehicle.
4. Open the vehicle hood.
Is the low–side pressure within the specified value?
2. Replace the A/C compressor control valve.
Is the system free from leaks?
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SYMPTOM DIAGNOSIS
PRESSURE TEST CHART (R–134a SYSTEM)
TEST RESULTS RELATED SYMPTOMS PROBABLE CAUSE REMEDY
Discharge (high) After stopping the compres- Air in the system. Recover, evacuate and re-
pressure abnormally sor, the pressure drops charge the system with the
high about 299 kPa (28 psi) specified amount of refrig-
quickly, then falls gradually. erant.
The condenser is exces- Excessive refrigerant in the sys- Recover, evacuate and re-
sively hot. tem. charge the system with the
specified amount of refrig-
erant.
Reduced or no airflow Condenser or the radiator fins are Clean the condenser or the
through the condenser. clogged. radiator fins.
Condenser or the radiator Check the voltage and the fan
fan is not working properly. rpm. Check the fan direction.
Line to the condenser is ex- Restricted flow of refrigerant in Locate and repair the re-
cessively hot. the system. striction.
Discharge pressure The condenser is not hot. Insufficient refrigerant in the sys- Check the system for a
abnormallyy low tem. leak. Charge the system.
High and low pressures are Faulty compressor pressure relief Repair or replace the com-
balanced soon after stop- valve. pressor.
ping the compressor. Low–
side pressure is higher than
normal.
Faulty compressor seal.
The outlet of the expansion Faulty expansion valve. Replace the expansion
valve is not frosted. Low valve.
pressure gauge indicates
vacuum.
Moisture in the system. Recover, evacuate, and recharge
the system.
Suction (low) pres- Condenser is not hot. Insufficient refrigerant in the sys- Repair the leaks. Recover,
sure abnormally low tem. evacuate, and recharge the
system.
The expansion valve is not Frozen expansion valve. Replace the expansion
frosted and the lowpressure valve.
line is not cold. pressure
Low–pressure gauge indi-
cates a vacuum.
Faulty expansion valve.
Discharge temperature is Evaporator is frozen. Clear the restricted evapo-
low and the airflow from the rator case drain.
vents is restricted.
The expansion valve is Expansion valve is clogged. Clean or replace the expan-
frosted. sion valve.
The receiver–dryer outlet is Receiver–dryer is clogged. Replace the receiver–dryer.
cool and the inlet is warm.

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TEST RESULTS RELATED SYMPTOMS PROBABLE CAUSE REMEDY

Suction pressure ab- Low–pressure hose and Expansion valve is opened for too Replace the expansion
normally high check joint are cooler than long. valve.
the temperature around the
evaporator.
A capillary tube is loose.
Suction pressure abnor- Suction pressure is lowered when Excessive refrigerant in the
mally high the condenser is cooled by water. system.
High and low pressure are Faulty gasket. Repair or replace the com-
equalized as soon as the pressor.
compressor is stopped and
both gauges fluctuate while
the compressor is running.
Faulty high–pressure valve.
Foreign particles stuck in
the high–pressure valve.
Suction and dis- Reduced airflow through Clogged condenser or radiator Clean the condenser and
charge
g pressure ab- the condenser. fins. the radiator.
normally
ll high
hi h charge
h Radiator cooling fans work- Check the voltage and the radia-
ing improperly. tor cooling fan rpm. Check the fan
direction.
Condenser is excessively Excessive refrigerant in the sys- Recover, evacuate, and re-
hot. tem. charge the system.
Suction and dis- Low–pressure hose and Clogged or kinked low–pressure Repair or replace the low–
charge pressure ab- metal end areas are cooler hose. pressure hose.
normally low than the evaporator.
Temperature around the ex- Clogged high–pressure line. Repair or replace the high–
pansion valve is low pressure line.
compared to that around
the receiver–dryer.
Refrigerant leaks The compressor clutch is Leaking compressor shaft seal. Repair or replace the com-
dirty. pressor.
The compressor bolts are Leaking around a compressor Tighten the bolt(s) or re-
dirty. housing bolt. place the compressor.
The compressor gasket is Leaking compressor gasket. Repair or replace the com-
wet with oil. pressor.
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LOW AND HIGH SIDE PRESSURE RELATIONSHIP CHART

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COMPONENT LOCATOR
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V5 COMPRESSOR
1. Rear Head Compressor 18. Pulley Bearing to Head Retaining Ring
2. Control Valve O–Ring 19. Rotor Pulley
3. Rear Head Gasket 20. Through–Bolt
4. Valve Plate 21. Through–Gasket
5. Suction Reed 22. Compressor Housing–to–Cylinder O–Ring
6. Clutch Coil 23. Shaft and Guide Pin Assembly Cylinder
7. Retaining Ring 24. Rear Head O–Ring
8. Drive Plate Clutch 25. Thrust Washer
9. Pulley Bearing 26. Race
10. Clutch Hub Key 27. Bearing
11. Shaft Nut 28. Oil Drain Plug
12. Seal Retaining Ring 29. Clutch and Hub Keyway
13. Shaft Lip Seal 30. Compressor Shaft
14. Shaft Seal O–Ring 31. Pressure Relief Valve O–ring
15. Compressor Housing 32. Adaptor Compressor
16. Compressor Control Valve 33. Adaptor Bolt
17. Pressure Relief Valve

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SECTION : 8A
SEAT BELTS
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–1 THREE–POINT REAR OUTBOARD SEAT BELT 8A–
FASTENER TIGHTENING SPECIFICATIONS . 8A–1 11
TWO–POINT LAP REAR CENTER SEAT BELT 8A–
SCHEMATIC AND WIRING DIAGRAMS . . . . . . . 8A–2
13
DRIVER SEAT BELT WARNING . . . . . . . . . . . . . 8A–2
CHILD SEAT TETHER ANCHOR . . . . . . . . . . . 8A–13
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–3 GENERAL DESCRIPTION AND SYSTEM
SEAT BELT WARNING LAMP IS INOPERATIVE 8A– OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–15
3 DRIVER SEAT BELT WARNING . . . . . . . . . . . . 8A–15
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 8A–5 THREE–POINT ELR FRONT SEAT BELT . . . 8A–15
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 8A–5 THREE–POINT CLR SEAT BELT . . . . . . . . . . . 8A–15
THREE–POINT FRONT SEAT BELT . . . . . . . . . 8A–5 TWO–POINT LAP REAR CENTER SEAT BELT 8A–
THREE–POINT FRONT SEAT BELT (HATCHBACK) 8 15
A–7 OPERATIONAL AND FUNCTIONAL CHECKS 8A–15
FRONT SEAT BELT HEIGHT ADJUSTER . . . 8A–10 CHILD SEAT TETHER ANCHOR . . . . . . . . . . . 8A–15
SPECIFICATIONS
Application N·m Lb–Ft Lb–In
Child Seat Tether Anchor Bolt 25 18 –
Seat Belt Anchor Bolt 38 28 –
Seat Belt Bracket Screws 10 – 89
Seat Belt Height Adjuster Bolts 23 17 –
Seat Belt Retractor Screw 38 28 –
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8A – 2ISEAT BELTS
SCHEMATIC AND WIRING DIAGRAMS

DRIVER SEAT BELT WARNING

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SEAT BELTS 8A – 3
DIAGNOSIS
SEAT BELT WARNING LAMP IS INOPERATIVE

Diagnostic Aids
The chime module is located above the I/P fuse block.
Seat Belt Warning Lamp Is Inoperative

1 Check fuse F11. Go toStep 2 Go toStep 3
Is fuse F11 blown?
2 1. Check for a short circuit and repair it, if neces- System OK
sary.
2. Replace the fuse.
3 1. Turn the ignition ON. 11–14 v Go toStep 5 Go toStep 4
2. Use a multimeter to check the voltage at fuse
F11.
Does the voltmeter show the specified value?
4 Repair the open power supply circuit for fuse F11. System OK
5 1. Disconnect the chime module connector. 11–14 v Go to Step 7 Go toStep 6
2. Turn the ignition ON.
3. Check the voltage at terminal 8 of the chime
module connector.
6 Repair the open circuit between fuse F11 and the System OK
chime module.
7 1. Make sure the seat belt is unfastened. [0Ω Go toStep 13 Go toStep 8
2. With the chime module connector discon-
nected, use an ohmmeter to measure continu-
ity between terminal 1 of the chime module and
ground.
8 1. Make sure the seat belt is unfastened. [0Ω Go toStep 9 Go toStep 12
2. Disconnect the seat belt connector under the
driver’s seat.
3. Use an ohmmeter to measure between the two
terminals at the switch side of the connector.
9 While the seat belt connector is disconnected, mea- [0Ω Go toStep 10 Go toStep 11
sure the continuity between the terminal for the BLK
wire and ground.
10 1. The chime module connector is disconnected. System OK
2. Turn the ignition OFF.
3. Use an ohmmeter to measure resistance be-
tween ground and terminal 5 of the chime mod-
ule.
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8A – 4ISEAT BELTS

11 Repair the open circuit between terminal 1 of the System OK
chime module and the seat belt switch.
12 Replace the seat belt switch. System OK
13 With the chime module disconnected, use an ohm- [0Ω Go toStep 15 Go toStep 14
meter to measure continuity between terminal 5 of
the chime module and ground.
chime module and ground.
15 With the chime module disconnected, use an ohm- R Go toStep 17 Go toStep 16
meter to measure continuity between terminal 7 of
the chime module and ground.
16 Replace the chime module. 11–14 v System OK
17 Check the seat belt warning lamp. Go to Step 19 Go to Step 18
Is the warning lamp OK?
18 Replace the seat belt warning lamp. System OK
19 1. Disconnect the instrument cluster connector for [0Ω Go toStep 21 Go toStep 20
terminal 5.
2. Check the continuity between terminal 7 of the
chime module and terminal 5 of the instrument
cluster connector.
chime module and terminal 5 of the instrument clus-
ter connector.
21 Repair the open circuit between the instrument clus- System OK
ter and splice S203.

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SEAT BELTS 8A – 5

THREE–POINT FRONT SEAT BELT
Removal Procedure
1. Remove the bolt and the seat belt anchor on the

lower B–pillar.
2. Remove the lower B–pillar trim panel. Refer to Sec-

tion 9G, InteriorTrim.
upper B–pillar.
4. Remove the screws and the seat belt bracket.
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8A – 6ISEAT BELTS
5. Remove the screw and the seat belt retractor.
Notice : Remove the screw and the seat belt retractor.

1. Install the seat belt retractor with the screw.
Tighten
Tighten the seat belt retractor screw to 38 NSm (28
lbft).
2. Install the seat belt bracket with the screws.

Tighten
Tighten the seat belt bracket screws to 10 NSm (89 lb–
in).

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SEAT BELTS 8A – 7
3. Install the seat belt anchor to the upper B–pillar

with the bolt.
Tighten
Tighten the seat belt anchor bolt to 38 NSm (28 lb–ft).
4. Install the lower B–pillar trim panel. Refer to Sec-

5. Install the seat belt anchor to the lower B–pillar with
the bolt.
Tighten
THREE–POINT FRONT SEAT BELT

(HATCHBACK)
Removal Procedure
1. Remove the bolt and the seat belt anchor rail.
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8A – 8ISEAT BELTS

upper B–pillar.
5. Remove the screw and the seat belt retractor.

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SEAT BELTS 8A – 9
Notice : Dissimilar metals in direct contact with each other

may corrode rapidly. Make sure to use the correct fasten-
ers to prevent premature corrosion.
1. Install the seat belt retractor with the screw.
Tighten
Tighten the seat belt retractor screw to 38 NSm (28
lbft).

Tighten
Tighten the seat belt bracket screws to 10 NSm (89
lbin).
3. Install the seat belt anchor to the upper B–pillar

with the bolt.
Tighten
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8A – 10ISEAT BELTS

5. Install the seat belt anchor rail with the bolt.
Tighten
FRONT SEAT BELT HEIGHT

ADJUSTER
Removal Procedure
1. Remove the upper B–pillar trim panel. Refer to
Section 9G, InteriorTrim.
2. Remove the bolts and the seat belt height adjuster.
Note : Dissimilar metals in direct contact with each other
1. Install the seat belt height adjuster with the bolts.
Tighten
Tighten the seat belt height adjuster bolts to 23 NSm
(17 lb–ft).
2. Install the upper B–pillar trim panel. Refer to Sec-

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SEAT BELTS 8A – 11
THREE–POINT REAR OUTBOARD

SEAT BELT
(Notchback Shown, Hatchback
Similar)
Removal Procedure
1. Open the luggage compartment.

2. Remove the lower B–pillar trim panel. Refer toSec-
tion 9G, Interior Trim.
3. Remove the bolt and the seat belt anchor in the
luggage compartment.
4. Remove the rear seat cushion and the rear seat-

back. Refer to Section 9G, Interior Trim.
5. Remove the C–pillar trim panel. Refer to Section
9G, Interior Trim.
Cpillar.

floor.
8. Remove the seat belt.
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1. Install the seat belt anchor in the luggage compart-

ment with the bolt.
Tighten
2. Feed the free end of the seat belt from the luggage
compartment through the deck lid sill plate.
3. Feed the free end of the seat belt through the C–
pillar trim panel.
4. Install the seat belt anchor to the floor with the bolt.
Tighten
5. Install the seat belt anchor to the C–pillar with the

bolt.
Tighten
6. Install the C–pillar trim panel. Refer to Section 9G,
Interior Trim.
7. Install the rear seat cushion and rear seatback. Re-
fer to Section 9H, Seats.
8. Install the luggage compartment wheelhouse trim
panel. Refer to Section 9G, Interior Trim.

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TWO–POINT LAP REAR CENTER

SEAT BELT
Removal Procedure
1. Remove the rear seat cushion. Refer to Section 9H,
Seats.
2. Remove the bolts and the seat belt anchors.
1. Install the seat belt anchors with the bolts.
Tighten
Tighten the seat belt anchor bolts to 38 NSm (28 lb–ft).
2. Install the rear seat cushion. Refer to Section 9H,
Seats.
CHILD SEAT TETHER ANCHOR

Removal Procedure
1. Open the tether anchor access cap.
2. Remove the bolt and the tether anchor.
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1. Install the tether anchor with the bolt.
Tighten
Tighten the child seat tether anchor bolt to 25 NSm (18
lb–ft).
2. Close the tether anchor access cap.

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GENERAL DESCRIPTION OPERATIONAL AND FUNCTIONAL

AND SYSTEM OPERATION CHECKS
S Keep sharp objects and potentially damaging ob-
DRIVER SEAT BELT WARNING jects away from the seat belts.
S Avoid bending or damaging any portion of the
The driver’s seat belt incorporates a seat belt reminder buckle or the latch plate.
light in the instrument cluster to remind the driver if the seat S Do not bleach or dye the belt webbing. Use only
belt is not fastened when the ignition is turned ON. mild soap and water in order to clean the belts.
S When installing the seat belt anchor bolts and the
THREE–POINT ELR FRONT SEAT screws, start the bolts and the screws by hand in
BELT order to prevent cross–threading.
The three–point emergency locking retractor (ELR) driver S Do not attempt any repairs on the retractor mecha-
seat belt is always unlocked, allowing the passenger free- nisms or the covers. Replace any defective assem-
dom of movement, except in emergencies (rapid decel- blies with new assemblies.
eration, rapid acceleration, or hard cornering maneuvers). S Replace any belts that are cut or damaged in any
way.
THREE–POINT CLR SEAT BELT 1. Inspect all seat belt anchor bolts and the screws in
Three–point CLR seat belts are standard for the front seat order to verify that they are secure.
passenger and the rear seat outboard passenger posi- 2. Inspect the seat belt buckle. The buckle must lock
tions. The CLR seat belt has two operation modes. Nor- and unlock easily.
mally, the seat belt operates in the ELR mode, which al- 3. After inserting the latch into the buckle, tug sharply
lows the passenger freedom of movement, except in on the belt. The buckle must remain locked.
emergency situations. However, when the belt is fully ex- 4. Fully extend the shoulder belt portion to make sure
tended and released, the seat belt operates in the ALR that there is no twisting or tears in the belt.
(auto–locking) mode. The ALR mode does not allow 5. Let the shoulder belt retract fully. The belt should
movement and is designed to hold a child seat firmly to the retract easily.
seat.
TWO–POINT LAP REAR CENTER CHILD SEAT TETHER ANCHOR

SEAT BELT There are three child seat tether anchors located on the
rear deck lid sill plate. There is one anchor for each rear
The two–point lap rear center seat belt is a single continu-
seat position.
ous length of webbing. The webbing is routed from the an-
chor through a latch plate and into a single retractor.
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SECTION : 8B
SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–2 DIAGNOSTIC ILLUSTRATION 5 . . . . . . . . . . . 8B–36
FASTENER TIGHTENING DIAGNOSTIC ILLUSTRATION 6 . . . . . . . . . . . 8B–36
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 8B–2 DIAGNOSTIC ILLUSTRATION 7 . . . . . . . . . . . 8B–36
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–2 DIAGNOSTIC ILLUSTRATION 8 . . . . . . . . . . . 8B–37
SPECIAL TOOLS TABLE . . . . . . . . . . . . . . . . . . . 8B–2 DIAGNOSTIC ILLUSTRATION 9 . . . . . . . . . . . 8B–37
SCHEMATIC AND ROUTING DIAGRAMS . . . . . 8B–3 DIAGNOSTIC ILLUSTRATION 10 . . . . . . . . . . 8B–37
SUPPLEMENTAL INFLATABLE RESTRAINT DIAGNOSTIC ILLUSTRATION 11 . . . . . . . . . . 8B–38
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–3 DIAGNOSTIC ILLUSTRATION 12 . . . . . . . . . . 8B–38
SIR COMPONENT LOCATOR . . . . . . . . . . . . . . 8B–4 DIAGNOSTIC ILLUSTRATION 13 . . . . . . . . . . 8B–38
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–5 DIAGNOSTIC ILLUSTRATION 14 . . . . . . . . . . 8B–39
BULB CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–5 DIAGNOSTIC ILLUSTRATION 15 . . . . . . . . . . 8B–39
FAULT INDICATION . . . . . . . . . . . . . . . . . . . . . . . 8B–5 DIAGNOSTIC ILLUSTRATION 16 . . . . . . . . . . 8B–40
CLEARING FAULT CODES . . . . . . . . . . . . . . . . . 8B–5
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 8B–41
MICROPROCESSOR–INDEPENDENT LAMP
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 8B–41
ACTIVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–5
DRIVER AIRBAG MODULE . . . . . . . . . . . . . . . . 8B–41
DIAGNOSTIC SYSTEM CHECK . . . . . . . . . . . . . 8B–6
CLOCK SPRING . . . . . . . . . . . . . . . . . . . . . . . . . 8B–42
DIAGNOSTIC SYSTEM CHECK . . . . . . . . . . . . . 8B–6
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–8 PASSENGER AIRBAG MODULE . . . . . . . . . . . 8B–44
DIAGNOSTIC TROUBLE CODE (DTC) 01 . . . . 8B–9 SENSING AND DIAGNOSTIC
MODULE (SDM) . . . . . . . . . . . . . . . . . . . . . . . . 8B–45
DIAGNOSTIC TROUBLE CODE (DTC) 02 . . . 8B–12
AIRBAG MODULE DEPLOYMENT
(IN VEHICLE) . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–46
AIRBAG MODULE DEPLOYMENT
DIAGNOSTIC TROUBLE CODE (DTC) 05 . . . 8B–18 (OUTSIDE OF VEHICLE) . . . . . . . . . . . . . . . 8B–50
DIAGNOSTIC TROUBLE CODE (DTC) 06 . . . 8B–20 DEPLOYED AIRBAG MODULE DISPOSAL
DIAGNOSTIC TROUBLE CODE (DTC) 07 . . . 8B–22 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 8B–50
DIAGNOSTIC TROUBLE CODE (DTC) 08 . . . 8B–24 GENERAL DESCRIPTION AND SYSTEM
DIAGNOSTIC TROUBLE CODE (DTC) 23 . . . 8B–26 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–52
DIAGNOSTIC TROUBLE CODE (DTC) 24 . . . 8B–28 AIRBAG MODULE . . . . . . . . . . . . . . . . . . . . . . . . 8B–52
DIAGNOSTIC TROUBLE CODE (DTC) 25 . . . 8B–31 SENSING AND DIAGNOSTIC
DIAGNOSTIC TROUBLE CODE (DTC) 31 . . 8B–34 MODULE (SDM) . . . . . . . . . . . . . . . . . . . . . . . . 8B–52
DIAGNOSTIC TROUBLE CODE (DTC) 32 . . . 8B–34 SIR WARNING LAMP . . . . . . . . . . . . . . . . . . . . 8B–53
DIAGNOSTIC ILLUSTRATION 1 . . . . . . . . . . . 8B–34 CLOCK SPRING . . . . . . . . . . . . . . . . . . . . . . . . . 8B–53
DIAGNOSTIC ILLUSTRATION 2 . . . . . . . . . . . 8B–35 WIRING HARNESS/CONNECTORS . . . . . . . 8B–54
DIAGNOSTIC ILLUSTRATION 3 . . . . . . . . . . . 8B–35 SIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–54
DIAGNOSTIC ILLUSTRATION 4 . . . . . . . . . . . 8B–35 GENERAL PRECAUTIONS . . . . . . . . . . . . . . . . 8B–54
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8B – 2ISUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
SPECIFICATIONS
Application N·m Lb–Ft Lb–In
Clock Spring Mounting Screws 3 – 27
Driver Airbag Module Mounting Bolts 14.7 – 130
Passenger Airbag Module Mounting Nuts 22 16 –
Passenger Airbag Module Mounting Bolts 12 – 106
Sensing and Diagnostic Module Mounting Bolts 14 10 –
SPECIAL TOOLS
SPECIAL TOOLS TABLE
Wiring Harness
Deployment Tool
Checker
Connector Test
Scan Tool Adapter Kit
J–35616–Az

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SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B – 3

SUPPLEMENTAL INFLATABLE RESTRAINT SYSTEM
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SIR COMPONENT LOCATOR
1. Steering Wheel 4. Wiring Harness

2. Driver Airbag Module 5. Sensing and Diagnostic Module
3. Passenger Airbag Module 6. Clock Spring

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DIAGNOSIS
A scan tool connected to the data link connector (DLC):
S Reveals the fault codes.
S Receives serial data transmission through the ter-
minal 13 of the DLC.
S Receives ground through the terminal 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:
S Clears the entire fault memory.
S Turns OFF the warning lamp.
S Resets for fault detection.
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.
BULB CHECK In the case of an internal fault of the SDM or a CRASH RE-
As soon as the operating voltage is applied to the sensing CORDED fault code, the SDM must be replaced.
and diagnostic module (SDM) ignition input, the SDM acti- Voltage–Low Fault
vates the warning lamp for a bulb check.
An internal fault of the SDM or a CRASH RECORDED
The SDM turns the lamp ON for 7 seconds, and then the fault code cannot be reset.
SDM turns the lamp OFF.
In the case of an internal fault of the SDM or a CRASH RE-
During the bulb check, the SDM is not ready to detect a CORDED fault code, the SDM must be replaced.
crash or deploy the supplemental inflatable restraints. The SDM will turn OFF the VOLTAGE LOW fault as soon
as the voltage recovers.
FAULT INDICATION
The sensing and diagnostic module records the system’s MICROPROCESSOR–INDEPENDENT
faults in two categories:
LAMP ACTIVATION
S Current faults. If the sensing and diagnostic module (SDM) electrical con-
S Historic faults, which are those that were detected nector is not properly attached, the SDM cannot function
in the past, but are no longer active. and cannot control the warning lamp.
The warning lamp: If this fault is present, the warning lamp will operate inde-
S Indicates a fault as soon as it occurs. pendently from the SDM through the use of shorting bars
S Stays ON, even if a fault is no longer active. that are built into the SDM connector.
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DIAGNOSTIC SYSTEM CHECK
DIAGNOSTIC SYSTEM CHECK

can create a high–resistance connection which can
Circuit Description set a DTC code and keep the airbags from deploying
When the ignition switch is turned ON, the Sensing and when needed.
Diagnostic Module (SDM) is able to send serial data from CAUTION : Before replacing components, discon-
terminal 9 of the SDM to terminal 13 of the Data Link Con- nect the negative battery cable. Wait one minute for
nector (DLC). the SDM capacitor to discharge. The capacitor sup-
CAUTION : If a defect is located in the Supplemental plies reserve power to deploy the airbags, even if the
Inflatable estraints (SIR) wiring harness, replace, battery is disconnected. Unintentional deployment of
rather than repair, the wiring harness. A wiring repair the airbags can cause injury.
Diagnostic System Check

1 1. Turn the ignition OFF. Go toStep 17 Go toStep 2
2. Connect the scan tool according to the instruc-
tions in the scan tool manual.
4. Wait at least four seconds for the Sensing and
Diagnostic Module (SDM) to finish the bulb
check before continuing.
5. Select the airbag main menu on the scan tool.
6. Select VIEW DTC from the scan tool menu.
Is the diagnostic system working?
Is fuse F13 blown?
3 1. Disconnect the SDM connector and wait 1 min- Go toStep 1
ute before proceeding.
2. Replace fuse F13.
3. Connect the scan tool to the data link connec-
tor (DLC). Follow the directions given in the
scan tool manual.

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4 Use an ohmmeter to check resistance between ter- [0Ω Go toStep 6 Go to Step 5
minal 4 of the DLC and ground.
5 Repair the open circuit between terminal 4 of the Go to Step 1
DLC and ground.
6 Check the power supply for the scan tool. Go to Step 8 Go to Step 7
Is the scan tool receiving the correct voltage?
7 Repair the power supply for the scan tool. Go toStep 1
8 1. Disconnect the SDM electrical connector and [0Ω Go toStep 12 Go toStep 9
wait 1 minute before proceeding.
2. Use an ohmmeter to check resistance between
terminal 13 of the DLC and terminal 9 of the
SDM connector. Use Connector Test Adapter
Kit J–35616–A to make the connection at the
SDM connector.
S Refer to ”Diagnostic Illustration 1” in this sec-
tion.
9 Use an ohmmeter to check the resistance between [0Ω Go toStep 11 Go toStep 10
terminal 13 of the DLC and terminal 6 of connector
C209.
1. D Refer to ”Diagnostic Illustration 2” in this sec-
tion.
10 Repair the serial data wire which is open between Go toStep 1
terminal 13 of the DLC and terminal 6 of connector
C209.
11 Repair the serial data wire which is open between Go toStep 1
terminal 6 of connector C209 and terminal 9 of the
SDM connector.
12 Use an ohmmeter to check resistance between [ 100K Ω Go toStep 14 Go toStep 13
ground and terminal 13 of the DLC.
13 Repair the short circuit between terminal 13 of the System OK
DLC and ground.
14 Turn the ignition ON. 0–1 v Go toStep 16 Go toStep 15
Use a voltmeter to check terminal 13 of the DLC.
15 Repair the short to voltage in the wire leading to ter- Go toStep 1
minal 13 of the DLC.
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16 Replace the SDM. Go toStep 1
17 Check the scan tool display. Refer to the System OK
Is a fault indicated by the scan tool? DTC procedure
in this section
indicated by the
DTC displayed
on the scan
tool
FAULT CODES
Fault Codes Fault Contents
01 Driver Firing Circuit, Resistance Too High
02 Driver Firing Circuit, Resistance Too Low
03 Driver Firing Circuit, Short to Ground
04 Driver Firing Circuit, Short to Battery Ground
05 Passenger Firing Circuit, Resistance Too High
06 Passenger Firing Circuit, Resistance Too Low
07 Passenger Firing Circuit, Short to Ground
08 Passenger Firing Circuit, Short to Ground
23 Passenger Firing Circuit, Short to Battery Voltage
24 Ignition Input Circuit, Voltage Too High
25 Ignition Input Circuit, Voltage Too Low
31 SDM Internal Fault
32 SDM Crash Recorded

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DIAGNOSTIC TROUBLE CODE (DTC) 01

DRIVER FIRING CIRCUIT, RESISTANCE TOO HIGH
S The combined resistance of the driver airbag mod-
Circuit Description ule, the harness wiring, and the connector contacts
When the ignition switch is turned ON, the Sensing and is above a specified value, as with an open circuit.
Diagnostic Module (SDM) will perform tests to diagnose CAUTION : Nevermeasure the resistance of an inflator
any malfunctions within itself. After passing these tests, module with an ohmmeter. An ohmmeter’s battery
the SDM will test the driver airbag module firing circuit. The can deploy the airbag and cause injury.
SDM allows a very small amount of current to flow through
CAUTION : Do not attempt to repair the Supplemental
the driver airbag module firing circuit, and the SDM moni-
Inflatable Restraints (SIR) wiring harness. A repair
tors the circuit resistance during this test.
can create a high–resistance connection which can
keep the airbags from deploying when needed, re-
DTC 01 Will Set When
sulting in injury.
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DTC 01 – Driver Firing Circuit, Resistance Too High

1 Examine the connector at the clock spring and at the Go to Step 2 Go to ”Diag-
driver airbag module. nostic System
Is a connector disconnected? Check”
2 1. Reconnect the disconnected connector. Go to ”Diag-
2. Reinstall the driver airbag module in the steer- nostic System
ing wheel. Check”
3. Erase the current DTCs with the scan tool.
3 1. Remove the driver airbag module. [0Ω Go to Step 4 Go toStep 6
2. Place the driver airbag module in a secure
position with the decorative surface facing up-
ward.
3. Disconnect the electrical connector at the
sensing and diagnostic module (SDM). The
shorting bar at the disconnected SDM connec-
tor will create a complete circuit between the
wires from the driver airbag module.
4. Connect an ohmmeter to the terminals of the
wiring harness connector for the driver airbag
module. Use Connector Test Adapter Kit
J–35616–A to make the connection.
S Refer to the ”Diagnostic Illustration 3” in this
section.
4 1.Replace the SDM. Go to Step 5 System OK
2.Reconnect the negative battery cable.
3.Erase the current DTCs with the scan tool.
4.Perform the ”Diagnostic System Check”in this
section.
Does the Code 01 show as a current fault?
5 1. Replace the driver airbag module. Go to”Diagnos-
2. Erase the current DTCs with the scan tool. tic System
Is the repair complete? Check”
6 1. Disconnect the clock spring wiring harness at [0Ω Go to Step 7 Go toStep 8

the lower steering column. The shorting bar at
the disconnected SDM connector will create a
complete circuit between the wires from the
clock spring. ”Diagnostic Illustration 4” in this
section..
2. Connect an ohmmeter to the terminals at the
SDM side of the clock spring connector. Refer
to
tion..
Does the AIRBAG indicator stay on?

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7 1. Replace the clock spring. Go to”Diagnos-
8 1. Replace the SIR wiring harness. Go to”Diagnos-

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DRIVER FIRING CIRCUIT, RESISTANCE TOO LOW
S The combined resistance of the driver airbag mod-
ule, the harness wiring, and the connector contacts
Circuit Description
is below a specified value, as with a short circuit
When the ignition switch is turned ON, the Sensing and between the wires to the driver airbag module.
Diagnostic Module (SDM) will perform tests to diagnose CAUTION : Before replacing components, discon-
any malfunctions within itself. After passing these tests, nect the negative battery cable. Wait one minute for
the SDM will check the airbag module firing circuit. The the SDM capacitor to discharge. The capacitor sup-
SDM allows a very small amount of current to flow through plies reserve power to deploy the airbags, even if the
the airbag module firing circuit, and the SDM monitors the battery is disconnected. Unintentional deployment of
circuit resistance during this check. the airbags can cause injury.
CAUTION : Nevermeasure the resistance of an inflator
DTC 02 Will Set When module with an ohmmeter. An ohmmeter’s battery
can deploy the airbag and cause injury.

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DTC 02 – Driver Firing Circuit, Resistance Too Low

1 1. Remove the driver airbag module. R Go to Step 2 Go toStep 4
2. Store the driver airbag module with the decora-
tive side facing upward.
3. Connect an ohmmeter to the terminals of the
J–356161–A to make the connections at the
driver airbag connector.
S Refer to the ”Diagnostic Illustration 3” in this
section.
2 1. Replace the sensing and diagnostic module Go to Step 3 System OK
(SDM).
3. Perform the”Diagnostic System Check” in this
section.
Does the Code 02 show as a current fault?
3 1. Remove the driver airbag module. Go to”Diagnos-
4 1. Connect an ohmmeter to the terminals at the R Go to Step 5 Go toStep 6

SDM side of the clock spring connector.
2. Reconnect the negative battery cable.
tion..
6 1. Erase the current DTCs with the scan tool. Go to”Diagnos-

2. Replace the Supplemental Inflatable Restraints tic System
(SIR) wiring harness. Check”
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DRIVER FIRING CIRCUIT, SHORT TO GROUND
Circuit Description DTC 03 Will Set When
When the ignition switch is turned ON, the Sensing and S The firing circuit is shorted to ground.
any malfunctions within itself. If a failure is not detected by nect the negative battery cable. Wait one minute for
the internal tests, the SDM will test the drive airbag module the SDM capacitor to discharge. The capacitor sup-
firing circuit. The SDM allows a very small amount of cur- plies reserve power to deploy the airbags, even if the
rent to flow through the driver airbag module firing circuit. battery is disconnected. Unintentional deployment of
The SDM monitors the voltage during this test. the airbags can cause injury.

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DTC 03 – Driver Firing Circuit, Short To Ground

1 Visually inspect the Supplemental Inflatable Re- Go to Step 2 Go toStep 3
straints (SIR) wiring harness for damage.
Is there any visible damage to the SIR harness?
3 1. Remove the driver airbag module. R Go toStep 6 Go toStep 4

position with the decorative surface facing up-
ward.
SDM. The shorting bar at the disconnected
SDM connector will create a complete circuit
between the wires from the driver airbag mod-
ule.
4. Use an ohmmeter to check the continuity be-
tween ground and one of the terminals on the
J–35616–A to make the connection at the driv-
er airbag connector.
tion..
Is the resistance less than the specified value?
4 1. Replace the sensing and diagnostic module Go to Step 5 System OK
(SDM).
3. Perform the ”Diagnostic System Check”in this
section.
Does the scan tool indicate DTC 03 as a current
fault?
6 1. Disconnect the clock spring wiring harness at R Go to Step 2 Go toStep 7

the lower steering column. The shorting bar at
the disconnected SDM connector will create a
complete circuit between the wires from the
clock spring.
2. Using an ohmmeter, check the resistance be-
tween ground and one of the terminals on the
SDM side of the clock spring connector. the
resistance less than the specified value?
Is the resistance less than the specified value?
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DRIVER FIRING CIRCUIT, SHORT TO BATTERY VOLTAGE
When the ignition switch is turned ON, the Sensing and S The firing circuit is shorted to voltage.
the internal tests, the SDM will test the driver airbag mod- the SDM capacitor to discharge. The capacitor sup-
ule firing circuit. The SDM allows a very small amount of plies reserve power to deploy the airbags, even if the
current to flow through the circuit. The SDM monitors volt- battery is disconnected. Unintentional deployment of
age during this test. the airbags can cause injury.

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DTC 04 – Driver Firing Circuit, Short To Battery Voltage

1 Visually inspect the Supplemental Inflatable Re- Go to Step 2 Go toStep 3
straints (SIR) wiring harness for damage.
Is there any visible damage to the SIR harness?
3 1. Remove the driver airbag module. 0v Go toStep 6 Go toStep 4

position with the decorative surface facing
upward.
sensing and diagnostic module (SDM).
S The shorting bar at the disconnected SDM
connector will create a complete circuit be-
tween the wires from the driver airbag mod-
ule.
5. Use a multimeter to check the voltage at one
of the terminals on the wiring harness con-
nector for the driver airbag module. Use Con-
nector Test Adapter Kit J–35616–A to make
the connection at the driver airbag connector.
tion..
Is the voltage greater than the specified value?
4 1. Replace the SDM. Go to Step 5 System OK
section.
fault?
6 1. Disconnect the clock spring wiring harness at 0v Go toStep 7 Go toStep 2

the lower steering column.
2. Using a multimeter, check the voltage at one of
the terminals on the SDM side of the clock
spring connector.
S The shorting bar at the disconnected SDM con-
nector will create a complete circuit between
the wires at the clock spring connector.
S Refer to ”Diagnostic Illustration 7”
Did the voltmeter indicate the specified value?
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PASSENGER FIRING CIRCUIT, RESISTANCE TOO HIGH
S The combined resistance of the passenger airbag
module, the harness wiring, and the connector con-
Circuit Description
tacts is above a specified value, as in an open cir-
When the ignition switch is turned ON, the Sensing and cuit.
the internal tests, the SDM will test the passenger airbag the SDM capacitor to discharge. The capacitor sup-
module firing circuit. The SDM allows a very small amount plies reserve power to deploy the airbags, even if the
of current to flow through the circuit. The SDM monitors battery is disconnected. Unintentional deployment of
the circuit resistance during this test. the airbags can cause injury.
CAUTION : Never measure the resistance of an airbag
DTC 05 Will Set When module. The meter’s battery could deploy the airbag
and cause injury.

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DTC 05 – Passenger Firing Circuit, Resistance Too High

1 1. Disconnect the negative battery cable. Go to Step 2 Go toStep 2
2. Wait one minute for the SDM capacitor to dis-
charge.
3. Examine the wiring and the connector at the
passenger airbag module.
Is the connector disconnected?
2 1. Reconnect the passenger airbag module con- Go to”Diagnos-
nector. tic System
2. Erase the current DTCs with the scan tool. Check”
3 1. Disconnect the electrical connector for the pas- [0Ω Go toStep 4 Go toStep 6
senger airbag module.
sensing and diagnostic module (SDM).
3. Connect an ohmmeter to the terminals on the
SDM side of the wiring harness connector for
the passenger airbag module.
tion..
4 1. Replace the SDM. Go to Step 5 System OK
section.
fault?
5 1. Replace the passenger airbag module. Go to”Diagnos-
6 1. Replace the Supplemental Inflatable Restraints Go to”Diagnos-

SIR) wiring harness. tic System
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PASSENGER FIRING CIRCUIT, RESISTANCE TOO LOW
module, the harness wiring, and the connector con-
tacts is below a specified value, as in a short circuit
Circuit Description
between the wires to the passenger airbag module.
When the ignition switch is turned ON, the Sensing and CAUTION : Before replacing components, discon-
Diagnostic Module (SDM) will perform tests to diagnose nect the negative battery cable. Wait one minute for
any malfunctions within itself. If a failure is not detected by the SDM capacitor to discharge. The capacitor sup-
the internal tests, the SDM will test the passenger airbag plies reserve power to deploy the airbags, even if the
module firing circuit. The SDM allows a very small amount battery is disconnected. Unintentional deployment of
of current to flow through the circuit. The SDM monitors the airbags can cause injury.
the circuit resistance during this test.
CAUTION : Nevermeasure the resistance of an inflator
module. If the anti–deployment shorting bar on the
module–side of the connector is not working proper-
ly, themeter’s battery could deploy the airbag and
S The combined resistance of the passenger airbag cause injury.

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DTC 06 –Passenger Firing Circuit, Resistance Too Low

1 1. Disconnect the negative battery cable. R Go to Step 2 Go toStep 4
2. Disconnect the negative battery cable. Connect
an ohmmeter to the terminals of the wiring har-
ness connector for the passenger airbag mod-
ule on the sensing and diagnostic module
(SDM) side of the connector.
tion..
2 1. Replace the SDM. Go toStep 3 System OK
section.
fault?
3 1. Replace the passenger airbag module. Go to ”Diag-
2. Erase the current DTCs with the scan tool. nostic System
4 1. Replace the Supplemental Inflatable Restraints Go to ”Diag-

(SIR) wiring harness. nostic System
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PASSENGER FIRING CIRCUIT, SHORT TO GROUND
When the ignition switch is turned ON, the Sensing and S The firing circuit is shorted to ground.
Diagnostic Module (SDM) will diagnose any malfunctions CAUTION : Before replacing components, discon-
within itself. If a failure is not detected by the internal tests, nect the negative battery cable. Wait one minute for
the SDM will test the passenger airbagmodule firing cir- the SDM capacitor to discharge. The capacitor sup-
cuit. The SDM allows a very small amount of current to plies reserve power to deploy the airbags, even if the
flow through the circuit. The SDM monitors the voltage battery is disconnected. Unintentional deployment of
during this test. the airbags can cause injury.

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DTC 07 – Passenger Firing Circuit, Short To Ground

1 1. Disconnect the negative battery cable. Go to Go toStep
2. Wait one minute for the sensing and diagnos- Step 2 3
tic module (SDM) capacitor to discharge.
3. Visually inspect the Supplemental Inflatable
Restraints (SIR) wiring harness.
Is there any visible damage to the SIR har-
ness?
2 1. Replace the SIR wiring harness. Go to
2. Reconnect the negative battery cable. ”Diagnos-
Is the repair complete? tic System
Check”
3 1. Disconnect the electrical connector for the R Go to Go toStep
passenger airbag module. Step 2 4
SDM.
tween the wires from the passenger airbag
module.
tween ground and one of the terminals at the
S Refer to”Diagnostic Illustration 9” in this sec-
tion.
Is the resistance less than the specified val-
ue?
4 1. Replace the SDM. Go toStep System
2. Reconnect the negative battery cable. 5 OK
4. Perform the ”Diagnostic System Check”in
this section.
Does the scan tool indicate DTC 07 as a cur-
rent fault?
5 1. Replace the passenger airbag module. Go
2. Erase the current DTCs with the scan tool. to”Diag-
Is the repair complete? nostic
System
Check”
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PASSENGER FIRING CIRCUIT, SHORT TO BATTERY
VOLTAGE
When the ignition switch is turned ON, the Sensing and S The firing circuit is shorted to the voltage.
the internal tests, the SDM will test the passenger airbag the SDM capacitor to discharge. The capacitor sup-
module firing circuit. The SDM allows a very small amount plies the reserve power to deploy the airbags, even if
of current to flow through the circuit. The SDM monitors the battery is disconnected. Unintentional deploy-
the voltage during this test. ment of the airbags can cause injury.

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DTC 08 – Passenger Firing Circuit, Short To Battery Voltage

1 1. Disconnect the negative battery cable. Go to Go toStep
2. Wait one minute for the sensing and diagnos- Step 2 3
tic module (SDM) capacitor to discharge.
3. Visually inspect the Supplemental Inflatable
Restraints (SIR) wiring harness.
Is there any visible damage to the SIR har-
ness?
2. Reconnect the negative battery cable. ”Diagnos-
3 1. Disconnect the electrical connector for the 0v Go to Go toStep
passenger airbag module. Step 2 4
SDM.
tween the wires from the passenger airbag
module.
tween ground and one of the terminals at the
S Refer to”Diagnostic Illustration 10” in this
section.
Is the resistance less than the specified val-
ue?
4 1. Replace the SDM. Go toStep System
2. Reconnect the negative battery cable. 5 OK
4. Perform the ”Diagnostic System Check”in
this section.
Does the scan tool indicate DTC 08 as a cur-
rent fault?
5 1. Replace the passenger airbag module. Go
2. Erase the current DTCs with the scan tool . to”Diag-
3. Erase the current DTCs with the scan tool . nostic
Is the repair complete? System
Check”
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IGNITION INPUT CIRCUIT, VOLTAGE TOO HIGH
Circuit Description S The SDM receives the voltage higher than a speci-
When the ignition switch is turned ON, the Sensing and fied value.
the internal tests, the SDM will test its voltage supply. If the the SDM capacitor to discharge. The capacitor sup-
voltage supply is too high or too low, the SDM may not re- plies reserve power to deploy the airbags, even if the
ceive the proper information when it attempts to use a battery is disconnected. Unintentional deployment of
known current to test the airbag module circuits. the airbags can cause injury.

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DTC 23 – Ignition Input Circuit, Voltage Too High

1 Check the vehicle’s charging system. Go toStep 3 Go toStep 2
S Refer to Section 1E, Engine Electrical.
Is the charging system OK?
2 Repair the charging system. Go to ”Diag-
Is the repair complete? nostic System
Check”
3 1. Disconnect the negative battery cable. Go to”Diagnos-
2. Replace the sensing and diagnostic module tic System
(SDM). Check”
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IGNITION INPUT CIRCUIT, VOLTAGE TOO LOW
Circuit Description S The SDM receives the voltage lower than a speci-
When the ignition switch is turned ON, the Sensing and fied value.
the internal tests, the SDM will test its voltage supply. If the the SDM capacitor to discharge. The capacitor sup-
voltage supply is too high or too low, the SDM may not re- plies reserve power to deploy the airbags, even if the
ceive the proper information when it attempts to use a battery is disconnected. Unintentional deployment of
known current to test the airbag module circuits. the airbags can cause injury.

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DTC 24 – Ignition Input Circuit, Voltage Too Low

1 Check fuse F13. Go toStep Go toStep
Is the fuse blown? 2 3
2 1. Check for a short circuit and repair it, if nec- Go to
essary. ”Diagnos-
2. Replace fuse F13. tic System
3 1. Turn the ignition ON. 11–14 v Go toStep Go toStep
2. Using a multimeter, check the voltage at the 5 4
fuse F13.
Is the specified voltage available at fuse F13?
4 1. Repair the power supply to fuse F13. Go to
2. Erase the current DTCs with the scan tool. ”Diagnos-
Check”
5 1. Disconnect the negative battery cable. 11–14 v Go toStep Go toStep
2. Disconnect the clock spring connector at the 6 7
lower steering column.
3. Disconnect the connector for the passenger
airbag module.
4. Disconnect the connector at the sensing and
diagnostic module (SDM).
5. Reconnect the battery.
6. Turn the ignition key ON.
7. Measure the voltage at terminal 5 of the
SDM Connector.
S Refer to ”Diagnostic Illustration 11” in this
section.
6 1. Replace the SDM. Go to
2. Reconnect the electrical connectors. ”Diagnos-
Check”
7 1. Disconnect the Connector C209. 11–14 v Go toStep Go toStep
8 9
S Connector C209 is the connector between
the instrument harness and the Supplemen-
tal Inflatable Restraints (SIR) harness.
2. Using a multimeter, check the voltage on the
instrument harness side at terminal 1 of the
Connector C209.
S Refer to ”Diagnostic Illustration 12” in this
section.
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2. Reconnect the battery. ”Diagnos-
9 1. Repair the open circuit between fuse F13 Go to
and connector C209. ”Diagnos-

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WARNING LAMP FAILURE
Circuit Description Test Description
When the ignition switch is turned ON, the Sensing and Steps 1–8 below diagnose a lamp that is ON when it is sup-
Diagnostic Module (SDM) will perform tests to diagnose posed to be OFF.
any malfunctions within itself. If a failure is not detected by
the internal tests, the SDM will test the warning lamp cir- Steps 9–15 below diagnose a lamp that is OFF when it is
cuit. The SDM constantly measures the voltage at the supposed to be ON.
warning lamp output in order to determine if the lamp is ON CAUTION : Before replacing any components, dis-
or OFF at the correct time. connect the negative battery cable. Wait one minute
for the SDM capacitor to discharge. The capacitor
DTC 25Will Set When
supplies reserve power to deploy the airbags, even
S The lamp is ON when it should be OFF. the battery is disconnected. Unintentional deploy-
S The lamp is OFF and it should be ON. ment of the airbags can cause injury.
Diagnostic Aids CAUTION : If the Supplemental Inflatable Restraints
When the warning lamp operates correctly, the lamp turns (SIR) wiring harness is damaged, do not attempt to re-
ON for approximately four seconds after the ignition is first pair it. The repair might create a high–resistance con-
switched ON, and then the lamp turns OFF. When the nection which can keep the airbags from deploying
warning lamp continues to blink four times per second, the when needed, resulting in injury. Replace the SIR wir-
SDM is faulty and must be replaced. ing harness if it is damaged.
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DTC 25 – Warning Lamp Failure

1 Turn the ignition ON. Go toStep 2 Go toStep 9
Does the warning lamp stay ON?
2 Make sure the sensing and diagnostic module Go to ”Diag- Go toStep 3
(SDM) connector is attached correctly. nostic System
Does the warning lamp turn OFF when the SDM Check”
connector is attached correctly?
3 1. Check the scan tool for DTCs other than DTC Go toStep 4 System OK
25.
2. Go to the appropriate DTC charts and repair
each additional problem.
section.
fault?
4 Check for a short to ground between the SDM and R Go to Step 6 Go to Step 5
the warning lamp using the following method:
2. Disconnect the Connector C209.
3. Connect one ohmmeter lead to ground.
4. Touch the other ohmmeter lead to terminal 4 of
the Connector C209 on the instrument harness
side.
tion.
Does the ohmmeter indicate continuity?
5 Repair the short to ground in the instrument harness. Go to”Diagnos-
Check”
6 1. The Connector C209 remains disconnected. R Go to Step 7 Go to Step 8
2. One lead of the ohmmeter remains connected
to ground.
3. Move the ohmmeter lead at the Connector
C209 to the SDM side of the Connector.
tion.
Does the ohmmeter indicate continuity?
7 Replace the SDM. Go to”Diagnos-
Check”
8 1. Disconnect the negative battery cable. Go to Step 5 System OK
2. Replace the SIR wiring harness.
section.
fault?
9 Check fuse F11. Go to Step 10 Go to Step 11
Is fuse F11 blown?

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10 1. With the connector C209 temporarily discon- Go to ”Diag-
nected, check for a short to ground between nostic System
fuse F11 and the warning lamp. Check”
2. Repair it, if needed.
11 1. Turn the ignition ON. 11–14 v Go to Step 13 Go to Step 12
2. Using a multimeter, check the voltage at fuse
F11.
Does the multimeter show the specified value?
12 Repair the open power supply circuit for fuse F11. Go to ”Diag-
Is the repair complete? nostic System
Check”
13 1. Disconnect connector C209. 11–14 v Go to Step 15 Go to Step 14
3. Using a multimeter, check the voltage on the
instrument harness side of terminal 5 of con-
nector C209.
tion.
Does the multimeter show the specified value?
14 1. Check the warning lamp bulb. Go to ”Diag-
2. Replace the warning lamp bulb, if needed. nostic System
3. If the bulb is OK, repair the open circuit be- Check”
tween fuse F11 and terminal 5 of connector
C209.
15 1. Disconnect the negative battery terminal. Go to ”Diag-
2. Wait at least one minute before proceeding. nostic System
3. Disconnect the SDM. Check”
4. Replace the SIR wiring harness
5. Reconnect the electrical connectors.
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SDM INTERNAL FAULT
S The SDM does not pass the internal tests.
Circuit Description
When the ignition switch is turned ON, the sensing and Before replacing the SDM, disconnect the negative bat-
diagnostic module (SDM) will perform tests to diagnose tery cable. Wait 1 minute for the SDM capacitor to dis-
malfunctions within itself. charge. The capacitor supplies reserve power to deploy
the airbags, even if the battery is disconnected. Uninten-
DTC 31Will Set When tional deployment of the airbags can cause injury.
DTC 31– SDM Internal Fault

(SDM). Check”

SDM CRASH RECORDED
S The SDM has previously detected a crash.
Circuit Description
CAUTION : Before replacing the SDM, disconnect the
When the ignition switch is turned ON, the sensing and negative battery cable. Wait 1 minute for the SDM ca-
diagnostic module (SDM) will perform tests to diagnose pacitor to discharge. The capacitor supplies reserve
any malfunctions within itself. power to deploy the airbags, even if the battery is dis-
connected. Unintentional deployment of the airbags
DTC 32Will Set When can cause injury.
DTC 32 – SDM Crash Recorded

(SDM). Check”
CAUTION : Do not use these illustrations to trou-

bleshoot without consulting the diagnostic
trouble code (DTC) charts. The DTC charts give
additional safety precautions and detailed in-
structions for each test. Failure to follow the
proper precautions can result in injury from unin-
tended airbag deployment.
DIAGNOSTIC ILLUSTRATION 1
Checking the continuity between terminal 9 of the
sensing and diagnostic module (SDM) connector and
terminal 13 of the data link connector.
Use the proper terminal adapter from connector test
adapter kit J–35616–A to make the connection at the
SDM connector.

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Checking the continuity on the instrument harness
side between terminal 13 of the data link connector
and terminal 6 of the connector C209.
Measuring the wiring harness for the continuity of the
driver’s side airbag module circuit.
airbag connector.
Checking the continuity between terminal 9 of the
sensing and diagnostic module (SDM) connector and
terminal 13 of the data link connector.
SDM connector.
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Checking the driver airbag circuit for a short to ground
with the sensing and diagnostic module discon-
nected.
airbag connector.
Checking the driver airbag circuit for a short to volt-
age.
airbag connector.
Checking the clock spring connector for a short to
voltage on the sensing and diagnostic module side.

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Checking the passenger airbag circuit continuity on
the sensing and diagnostic module side of the con-
nector.
Checking the passenger airbag circuit for a short to
ground.
Checking the passenger airbag circuit for a short to
voltage.
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Checking the sensing and diagnostic module (SDM)
voltage supply at terminal 5.
airbag connecto
Checking the voltage supply on the instrument har-
ness side at terminal 2 of the connector C209.
Checking for a short to ground on the sensing and iag-
nostic module side of the supplemental inflatable re-
straints harness at terminal 5 of the connector C209.

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Checking for a short to ground in the instrument har-
ness on the instrument harness side at terminal 5 of
the connector C209.
Checking the voltage of the warning lamp circuit on
the instrument harness side at terminal 5 of the con-
nector C209.
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Supplemental Inflatable Restraints (SIR) Harness And Connectors
1. Instrument Harness Connector C209 8. Sensing and Diagnostic Module Connector

2. Supplemental Inflatable Restraints Harness 9. Horn Connector
3. Connector C209 10. Clock Spring Connector
4. Instrument Harness 11. Driver Airbag Module Connector
5. Data Link Connector (DLC)
6. Passenger Airbag Module Connector
7. Supplemental Inflatable Restraints Harness

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SECTION : 9A
BODY WIRING SYSTEM

TABLE OF CONTENTS
SCHEMATIC AND ROUTING DIAGRAMS . . . . . 9A–1 FUSE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–10
WIRE COLOR CHART . . . . . . . . . . . . . . . . . . . . . 9A–1 FRONT HARNESS ROUTING . . . . . . . . . . . . . 9A–12
POWER DISTRIBUTION SCHEMATIC . . . . . . . 9A–3 REAR HARNESS ROUTING . . . . . . . . . . . . . . . 9A–13
CONNECTION BOX HARNESS ROUTING . . . 9A–8
FLOOR HARNESS ROUTING . . . . . . . . . . . . . 9A–14
FUSE BLOCK LOCATOR (ENGINE) . . . . . . . . . 9A–9
INSTRUMENT HARNESS ROUTING . . . . . . . 9A–15
FUSE BLOCK LOCATOR (PASSENGER
COMPARTMENT) . . . . . . . . . . . . . . . . . . . . . . . 9A–9 DOOR HARNESS ROUTING . . . . . . . . . . . . . . 9A–16

WIRE COLOR CHART
Wire Color Abbreviation On Schematic
Green DK GRN
Light Green LT GRN
Blue DK BLU
Brown BRN
Orange ORN
Yellow YEL
Grey GRY
Sky Blue LT BLU
Red RED
Black BLK
Pink PNK
White WHT
Purple PPL
Wires With Tracers

Red with White Tracer RED/WHT
Red with Black Tracer RED/BLK
Brown with White Tracer BRN/WHT
Black with White Tracer BLK/WHT
Black with Yellow Tracer BLK/YEL
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9A – 2IBODY WIRING SYSTEM

Green with Black Tracer DK GRN/BLK
Green with White Tracer DK GRN/WHT
Light Green with Black Tracer LT GRN/BLK
Red with Yellow Tracer RED/YEL
Red with Blue Tracer RED/DK BLU
Black with Brown Tracer BLK/BRN

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BODY WIRING SYSTEM 9A – 3
POWER DISTRIBUTION SCHEMATIC
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CONNECTION BOX HARNESS ROUTING
1. Fuse Block 4. Floor Harness to Roof Harness

2. Front Harness to Instrument Harness 5. Floor Harness to Instrument Harness
3. Floor Harness to Front Harness

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FUSE BLOCK LOCATOR (ENGINE)
FUSE BLOCK LOCATOR (PASSENGER COMPARTMENT)
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FUSE CHART
Fuse Rating/Source Circuit
EF1 (En- 80A B+ Engine Fuses EF15 to EF20 and Fuses F1 to F7
gine Fuse)
EF2 30A B+ Ignition Switch, A (F9 and F10), and IGN 1 ( F11
to F17)
EF3 30A B+ Ignition Switch, START and IGN 2 (F18, F19,
F20)
EF4 30A B+ Radiator Fans
EF5 30A B+ Power Windows, Sunroof Module
EF6 40A B+ Antilock Brakes
EF7 30A B+ Rear Window Defogger
EF8 30A B+ Hi Blower
EF10 20A EF19 Headlamp Hi Beam
EF11 10A EF19 Headlamp Lo Beam (Left Side)
EF12 10A EF19 Headlamp Lo Beam (Right Side)
EF13 10A EF20 Tail and Illumination Lamps (Left Side)
EF14 10A EF20 Tail and Illumination Lamps (Right Side)
EF15 15A EF1 Front Fog Lamps
EF16 15A EF1 Fuel Pump Relay
EF17 10A EF1 Horn, Anti–Theft Siren
EF18 10A EF1 A/C Compressor
EF19 25A EF1 Hi Beam Passing, Daytime Running Lamps
EF20 20A EF1 EF13, EF14
F1 (Fuse) 10A EF1 Interior Courtesy Lamp, Luggage Compartment
Lamp, ESDS
F2 10A EF1 Clock, Door Open Warning Lamps, DLC, Head-
lamp Combination Switch, Key Reminder Switch
F3 15A EF1 Hazard Lamp
F4 15A EF1 Door Lock, Keyless Entry Module
F5 10A EF1 ABS, PCM/ECM
F6 10A EF1 Audio
F7 15A EF1 Stoplamp, Center High–Mounted Stoplamp
D8 (Diode)
F9 10A ACC Audio, Key Interlock System
F10 15A ACC Cigar Lighter
F11 10A IGN 1 Instrument Cluster, Clock, Daytime Running
Lamps, Chime Module
F12 10A IGN 1 Backup Lamp, Keyless Entry Module
F13 15A IGN 1 Supplemental Inflatable Restraints
F14 15A IGN 1 Injectors, Generator, EGR Valve, Vehicle Speed
Sensor, EVAP Canister Purge Valve, Post–Con-
verter Oxygen Sensor, Camshaft Position Sen-
sor, PCM/ECM
F15 15A IGN 1 Ignition Control Module

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Fuse Rating/Source Circuit

F16 15A IGN 1 Turn Signal Lamp, Electric Outside Rearview
Mirrors
F17 15A IGN 1 PCM/ECM, ABS Warning Lamp, Variable Geom-
etry Induction Solenoid
F18 20A IGN 2 Wipers/Washer System
F19 10A IGN 2 Power Window Relay, A/C Compressor Relay,
Radiator Fan Relays, Defogger Relay, ABS
Relay, Sunroof Switch
F20 20A IGN 2 Blower Position 1, 2, 3
DAEWOO V–121 BL4
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FRONT HARNESS ROUTING

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REAR HARNESS ROUTING
DAEWOO V–121 BL4
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FLOOR HARNESS ROUTING

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INSTRUMENT HARNESS ROUTING
DAEWOO V–121 BL4
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DOOR HARNESS ROUTING

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SECTION : 9B
LIGHTING SYSTEMS
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9B–2 DAYTIME RUNNING LAMP MODULE . . . . . . . 9B–36
BULB USAGE CHART . . . . . . . . . . . . . . . . . . . . . 9B–2 SIDEMARKER LAMPS . . . . . . . . . . . . . . . . . . . . 9B–37
FASTENER TIGHTENING SPECIFICATIONS . 9B–2 TAILLAMPS (NOTCHBACK) . . . . . . . . . . . . . . . 9B–38
SCHEMATIC AND ROUTING DIAGRAMS . . . . . 9B–3 TAILLAMPS (HATCHBACK) . . . . . . . . . . . . . . . 9B–38
BACKUP LAMPS CIRCUIT . . . . . . . . . . . . . . . . . 9B–3 STOP/BACKUP LAMPS (NOTCHBACK) . . . . 9B–39
INSTRUMENTS CIRCUIT . . . . . . . . . . . . . . . . . . 9B–4 STOP/BACKUP LAMPS (HATCHBACK) . . . . . 9B–40
FRONT FOG LAMPS CIRCUIT . . . . . . . . . . . . . 9B–5 CENTER HIGH–MOUNTED STOPLAMP
HEADLAMPS–ON REMINDER CHIME CIRCUIT 9B– (NOTCHBACK) . . . . . . . . . . . . . . . . . . . . . . . . 9B–41
6 CENTER HIGH–MOUNTED STOPLAMP
HEADLAMPS CIRCUIT . . . . . . . . . . . . . . . . . . . . 9B–7 (HATCHBACK) . . . . . . . . . . . . . . . . . . . . . . . . . 9B–42
DAYTIME RUNNING LAMPS CIRCUIT . . . . . . . 9B–8 FOG LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B–42
PARKING, TAIL, AND LICENSE LAMPS CIRCUIT LICENSE PLATE LAMP . . . . . . . . . . . . . . . . . . . 9B–45
(NOTCHBACK) . . . . . . . . . . . . . . . . . . . . . . . . . . 9B–9 DOOR JAMB SWITCH . . . . . . . . . . . . . . . . . . . . 9B–46
PARKING, TAIL, AND LICENSE LAMPS CIRCUIT INTERIOR COURTESY LAMP . . . . . . . . . . . . . 9B–46
(HATCHBACK) . . . . . . . . . . . . . . . . . . . . . . . . . 9B–10
ASHTRAY LAMP . . . . . . . . . . . . . . . . . . . . . . . . . 9B–48
STOPLAMPS CIRCUIT . . . . . . . . . . . . . . . . . . . 9B–11
LUGGAGE COMPARTMENT LAMP . . . . . . . . 9B–49
TURN AND HAZARD LAMPS CIRCUIT . . . . . 9B–12
INTERIOR COURTESY AND LUGGAGE GENERAL DESCRIPTION AND SYSTEM
COMPARTMENT LAMP CIRCUIT . . . . . . . . 9B–13 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B–50
HEADLAMPS–ON REMINDER CHIME . . . . . . 9B–50
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B–14
HEADLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B–50
HEADLAMPS–ON REMINDER CHIME . . . . . . 9B–14
HEADLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B–15 DAYTIME RUNNING LAMPS . . . . . . . . . . . . . . 9B–50
DAYTIME RUNNING LAMPS . . . . . . . . . . . . . . 9B–19 PARKING AND TURN SIGNAL LAMPS . . . . . 9B–50
PARKING LAMPS AND TAILLAMPS . . . . . . . . 9B–21 SIDEMARKER LAMPS . . . . . . . . . . . . . . . . . . . . 9B–50
INTERIOR COURTESY AND LUGGAGE FOG LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B–50
COMPARTMENT LAMPS . . . . . . . . . . . . . . . . 9B–29 TAILLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B–50
FOG LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B–32 LICENSE PLATE LAMP . . . . . . . . . . . . . . . . . . . 9B–50
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 9B–34 INTERIOR COURTESY LAMP . . . . . . . . . . . . . 9B–50
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 9B–34 ASHTRAY LAMP . . . . . . . . . . . . . . . . . . . . . . . . . 9B–51
HEADLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B–34 LUGGAGE COMPARTMENT LAMP . . . . . . . . 9B–51
HEADLAMP AIMING . . . . . . . . . . . . . . . . . . . . . . 9B–35 BACKUP LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . 9B–51
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9B – 2ILIGHTING SYSTEMS
SPECIFICATIONS
BULB USAGE CHART
Bulb Replacement Bulb Number
Backup Lamp 27W
Center High–Mounted Stoplamp 27W
Front Fog Lamp 55W
Headlamp Double 65/55W
Interior Courtesy Lamp 10W
License Plate Lamp 5W
Luggage Compartment Lamp 10W
Park and Front Turn Signal Lamp Double 27W/8W
Rear Turn Signal Lamp Single 27W
Sidemarker Lamps 5W
Tail and Stoplamp Double 27/8W

CHMSL Mounting Nuts 3 – 27
CHMSL Mounting Screws 3 – 27
Cupholder Screws 2 – 18
Daytime Running Lamp Module Screws 2.5 – 22
Door Jamb Switch Screw 4.5 – 40
Front Fog Lamp Assembly Screw 3 – 27
Headlamp Assembly Bolts and Nut 6 – 53
Interior Courtesy Lamp Housing Screws 2 – 18
License Plate Lamp Screws 1.5 – 13
Stop/Backup Lamp Assembly Nuts 2.5 – 22
Taillamp Assembly Nuts 2.5 – 22
Taillamp Assembly Screws 3 – 27

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LIGHTING SYSTEMS 9B – 3

BACKUP LAMPS CIRCUIT
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INSTRUMENTS CIRCUIT

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FRONT FOG LAMPS CIRCUIT
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HEADLAMPS–ON REMINDER CHIME CIRCUIT

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HEADLAMPS CIRCUIT
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DAYTIME RUNNING LAMPS CIRCUIT

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PARKING, TAIL, AND LICENSE LAMPS CIRCUIT

(NOTCHBACK)
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PARKING, TAIL, AND LICENSE LAMPS CIRCUIT

(HATCHBACK)

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STOPLAMPS CIRCUIT
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TURN AND HAZARD LAMPS CIRCUIT

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INTERIOR COURTESY AND LUGGAGE COMPARTMENT

LAMP CIRCUIT
DAEWOO V–121 BL4
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DIAGNOSIS
HEADLAMPS–ON REMINDER CHIME

Diagnostic Aids :
The fuse for the left–side taillamps is also part of the headlamps–on reminder chime circuit. The headlamps–on reminder
chime should operate when the ignition is OFF, the headlamps or parking lamps are on, and the driver door is open.
Headlamps–On Reminder Chime Does Not Work

1 Turn the parking lamps on, and observe the tail- Go toStep 3 Go toStep 2
lamps.
Are the taillamps operating correctly?
2 Repair the left–side taillamps before completing this System OK Go toStep 3
diagnostic table.
After the taillamps have been repaired, does the
headlamps–on reminder chime work?
3 1. Disconnect the chime module electrical con- 11–14 v Go toStep 5 Go toStep 4
nector.
2. Turn the headlamps on.
module connector.
4 Repair the open circuit between fuse EF13 and ter- System OK
minal 6 of the chime module connector.
5 Use an ohmmeter to check the resistance between [0W Go toStep 7 Go toStep 6
ground and terminal 5 of the chime module.
6 Repair the open circuit between ground and terminal System OK
5 of the chime module.
7 1. Remove the driver door contact switch. [0W Go toStep 9 Go toStep 8
2. Remove the electrical connector from the driv-
er door contact switch.
3. Use an ohmmeter to measure the resistance
between the driver door contact switch connec-
tor and the chime module terminal 4.
8 Repair the open circuit between the driver door con- System OK
tact switch connector and the chime module termi-
nal 4.
9 1. Connect the electrical connector to the chime Go toStep 11 Go toStep 10
module.
2. Connect a jumper wire between ground and
the connector for the driver door contact
switch.
4. Turn the lights on.
Does the headlamps–on reminder chime operate?

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10 Replace the chime module. System OK
11 Replace the driver door contact switch. System OK
HEADLAMPS
Low Beam Headlamps Are Inoperative, High Beam Headlamps Are
OK
1 Check fuses EF11 (left–side headlamps) and EF12 Go toStep 2 Go toStep 3
(right–side headlamps).
Is fuse EF11 or EF12 blown?
sary.
3 Check the voltage at fuses EF11 and EF12. 11–14 v Go toStep 7 Go toStep 4
Does the voltage available at fuses EF11 and EF12
equal the value specified?
4 1. Disconnect the headlamp combination switch 0W Go toStep 6 Go toStep 5
connector C1.
2. Select the low beams.
tween terminals 6 and 5 of the headlamp com-
bination switch.
Does the ohmmeter indicate the value specified?
5 Replace the headlamp combination switch. System OK
6 Repair the open circuit between fuses EF11 and System OK
EF12 and the headlamp combination switch con-
nector C1 terminal 5.
7 1. Disconnect both headlamp connectors. 11–14 v Go toStep 9 Go toStep 8
2. Turn the headlamps on.
Does the voltage at each headlamp connector termi-
nal 5 equal the value specified?
8 Repair the open circuit between fuses EF11 or EF12 System OK
and the low beam headlamps.
9 Replace the faulty headlamps. System OK
DAEWOO V–121 BL4
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High Beam Headlamps Are Inoperative, Low Beam Headlamps Are

OK
1 Check the high beam headlamps in the ”flash–to- Go toStep 2 Go toStep 3
pass” mode.
Do the high beam headlamps work in the ”flash–to-
pass” mode?
3 Check fuse EF10. Go toStep 4 Go toStep 5
Is fuse EF10 blown?
4 1. Check for a short circuit. Repair it, if necessary. System OK
5 1. Turn the high beam headlamps on. 11–14 v Go toStep 7 Go toStep 6
2. Check the voltage at fuse EF10.
Does the voltage available at fuse EF10 equal the
value specified?
6 Repair the open circuit between headlamp combina- System OK
tion switch connector C1 terminal 4 and fuse EF10.
7 1. Turn the high beam headlamps on. 11–14 v Go toStep 9 Go toStep 8
2. Check the voltage at headlamp terminal 4 with
the high beams selected.
Does the voltage available at the headlamp connec-
tor terminal 4 equal the value specified?
8 Repair the open circuit between fuse EF10 and the System OK
high beam headlamps.
9 Replace the faulty headlamps. System OK

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High Beam and Low Beam Headlamps Are Inoperative on Both

Left and Right Sides
Diagnostic Aids:
If there are several other symptoms, including an inoperative radiator fan, the windshield washer pump, or the left–side
turn signal lamps, check ground G102.

1 Check fuses EF10, EF11, EF12, EF19, and F2. Go toStep 2 Go toStep 3
Are any fuses blown?
sary.
3 1. Turn the low beam headlamps on. 11–14 v Go toStep 4 Go toStep 9
2. Check the voltage at fuses EF11 and EF12.
3. Check the voltage at fuse EF10 with the high
beams selected.
Does the voltage at the headlamps equal the value
specified?
4 1. Turn the low beam headlamps on. 11–14 v Go toStep 6 Go toStep 5
2. Check the voltage at the headlamp connector
terminal 5.
3. Turn the high beam headlamps on.
4. Check the voltage at headlamp connector ter-
minal 4.
Does the battery voltage available at the headlamps
qual the value specified?
5 Repair the open circuit between fuses EF10, EF11, System OK
and EF12 and the headlamps.
6 Use an ohmmeter to check between ground and the 0W Go toStep 8 Go toStep 7
headlamp connector terminal 6.
7 Repair the ground circuit. System OK
8 1. Replace the faulty headlamps. System OK
2. Check the charging system to make sure that
the charging voltage is not excessively high.
Repair if necessary.
9 Use a voltmeter to check for power to the fuses F2 11–14 Go toStep 11 Go toStep 10
and EF19.
Does the voltage at fuses F2 and EF19 equal the val-
ue specified?
10 Repair the power supply circuit to the fuses F2 and System OK
EF19.
11 1. Remove the headlamp relay. 11–14 v Go toStep 13 Go toStep 12
2. Use a voltmeter to check the headlamp relay
connector for terminal 30.
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connector for terminal 30 of the headlamp relay.
13 Temporarily substitute the illumination lamp relay in Go toStep 14 Go toStep 15
place of the headlamp relay.
Do the headlamps operate with the substituted
relay?
14 Reinstall the illumination lamp relay in its original System OK
position, and install a new headlamp relay.
15 1. Reinstall the illumination lamp relay in its origi- Go toStep 21 Go toStep 16
nal position before proceeding.
2. Before reinstalling the headlamp relay, turn the
low beam switch on.
3. Use a test lamp to check the relay socket at
the terminal that connects to terminal 85 of the
relay.
Does the test lamp illuminate?
16 Check the headlamp combination switch connector 11–14 Go toStep 18 Go toStep 17
C2 with a voltmeter.
Does the voltage at the headlamp switch connector
C2, terminal 2 equal the specified value?
17 Repair the open circuit between fuse F2 and head- System OK
lamp combination switch connector C2.
18 1. Disconnect the C2 connector for the headlamp 0W Go toStep 20 Go toStep 19
combination switch.
2. Select the low beam headlamp position.
3. At connector C2 (on the switch side of the con-
nector), measure with an ohmmeter between
terminals 1 and 2.
20 Repair the open circuit between headlamp switch System OK
connector C2 and terminal 85 of the headlamp relay.
21 1. Disconnect the headlamp combination switch 0W Go toStep 22 Go toStep 19
connector C1.
3. Check the resistance between switch terminals
6 and 5 with the low beams selected.
4. Select the high beams.
5. Check the resistance between switch terminals
6 and 4.
Are both resistance measurements equal to the spe-
cified value?
22 Repair the open circuit between the headlamp com- System OK
bination switch connector C1 and the fuses EF10,
EF11, and EF12.

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DAYTIME RUNNING LAMPS

Diagnostic Aids eleased. If the parking brake circuit is shorted to ground
The daytime running lamp (DRL) system will not work if the or the switch stays closed when the engine is running, the
parking brake is applied. The system is designed to work DRL system will not work.
only when the engine is running and the parking brake is
Daytime Running Lamps (DRL) Do Not Turn ON

1 Turn the headlamps ON with the headlamp switch. Go toStep 3 Go toStep 2
Do the headlamps work?
2 Repair the regular headlamp system before com- System OK Go toStep 3
pleting this diagnostic table.
Does the DRL system work after the headlamps
have been repaired?
Is fuse EF19 blown?
4 1. Check for a short circuit and repair if neces- System OK
sary.
2. Replace fuse EF19.
2. Check the voltage at fuse EF19.
Does the voltage equal the specified value?
6 Repair the power supply circuit for fuse EF19. System OK
7 1. Disconnect the electrical connector from the 11–14 v Go toStep 9 Go toStep 8
DRL module.
3. Check the voltage at terminal A of the DRL
module.
8 Repair the open circuit between fuse EF19 and ter- System OK
minal A of the DRL module connector.
9 With the DRL module still disconnected, use an [0W Go toStep 11 Go toStep 10
ohmmeter to check the resistance between ground
and terminal E of the DRL module connector.
10 Repair the circuit between ground and terminal E of System OK
the DRL module connector.
11 1. Release the parking brake. Go toStep 12 Go toStep 15
2. Turn the ignition switch ON.
3. Observe the parking brake indicator lamp.
Is the parking brake indicator lamp ON?
12 Disconnect the electrical connector to the parking Go toStep 13 Go toStep 14
brake lever switch.
Is the parking brake indicator lamp still ON?
13 Repair the short to ground in the parking brake cir- System OK
cuit.
DAEWOO V–121 BL4
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14 Replace the parking brake lever switch. System OK
15 1. Make sure the headlamps are turned OFF. 0v Go toStep 17 Go toStep 16
2. With the DRL module disconnected, turn the
ignition ON.
3. Check the voltage at terminal F of the DRL
module.
16 Repair the open between fuse F11 and terminal F of System OK
the DRL module.
17 Replace the DRL module. System OK

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PARKING LAMPS AND TAILLAMPS

Parking Lamps and Taillamps Do Not Work
1 Check the headlamps. Go toStep 3 Go toStep 2
Do the headlamps work?
2 Repair the headlamps before continuing with this Go toStep 3 System OK
chart.
After the headlamps have been repaired, are the
parking lamps and taillamps still inoperative?
3 1. Turn the parking lamps on. 11–14 v Go toStep 4 Go toStep 7
2. Use a voltmeter to check voltage at the bulb
socket positive terminal.
Does voltage at the bulb socket equal the specified
value?
4 Connect an ohmmeter between ground and the [0W Go toStep 6 Go toStep 5
lamp socket negative terminal.
5 Repair the ground circuit for the lamps. System OK
6 Replace the faulty bulbs. System OK
7 Check fuses EF20, EF13, and EF14. Go toStep 8 Go toStep 9
Are any of the fuses blown?
sary.
9 1. Turn the headlamps on. 11–14 v Go toStep 23 Go toStep 10
2. Check the voltage at fuses EF13 (left–side illu-
mination lamp) and EF14 (right–side illumina-
tion lamp).
Does the voltage at the fuses equal the specified val-
ue?
10 Check the voltage at fuse EF20. 11–14 v Go toStep 12 Go toStep 11
Does the voltage at fuse EF20 equal the specified
value?
11 Repair the battery supply circuit to fuse EF20. System OK
12 1. Temporarily substitute the headlamp relay for Go toStep 13 Go toStep 14
the illumination lamp relay.
2. Turn the illumination lamp switch on.
Do the lamps illuminate?
13 1. Return the headlamp relay to its original posi- System OK
tion.
2. Replace the illumination lamp relay.
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14 1. Remove the illumination relay. 11–14 v Go toStep 16 Go toStep 15
2. Use a voltmeter to check the illumination lamp
relay socket at the connector for terminal 30.
Is the voltage at the connector for terminal 30 of the
illumination lamp relay equal to the specified value?
connector for the illumination lamp relay terminal 30.
16 Connect an ohmmeter between ground and the illu- [0W Go toStep 18 Go toStep 17
mination lamp relay terminal 85.
17 Repair the ground circuit for the illumination lamp System OK
relay.
18 1. Turn the illumination lamps on. 11–14 v Go toStep 22 Go toStep 19
2. Check the voltage at the connector for terminal
86 of the illumination lamp relay.
19 1. Disconnect the headlamp combination switch [0W Go toStep 21 Go toStep 20
connector C2.
2. On the disconnected switch, select the illumi-
nation lamps on position.
3. At the switch side of the connector C2, use an
ohmmeter to check for continuity between ter-
minal 2 and terminal 4.
20 Repair the open circuit between the headlamp System OK
switch connector C2 terminal 4 and terminal 86 of
the illumination lamp relay.
21 Replace the headlamp switch. System OK
22 Repair the open circuit between terminal 87 of the il- System OK
lumination lamp relay and fuses EF13 and EF14.
23 Repair the open circuit between the fuses EF13 and System OK
EF14 and the illumination lamps.

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Stoplamps Do Not Work

Notice : When probing a bulb socket with a voltmeter or a test lamp, do not contact the side of the socket (ground) when
you are testing the positive contact at the bottom of the socket. If the voltage and the ground are both available at the bulb
socket, contacting both at the same time with a test probe will cause a blown fuse.

Is fuse F7 blown?
sary.
3 Use a voltmeter to check the voltage at fuse F7. 11–14 v Go toStep 5 Go toStep 4
Is the voltage at F7 equal to the specified value?
4 Repair the power supply circuit for fuse F7. System OK
5 1. Press the brake pedal. Go toStep 6 Go toStep 8
2. Check the positive terminals of the bulb sock-
ets with a test lamp.
Does the test lamp illuminate?
6 Connect an ohmmeter between ground and the sto- 0W Go toStep 8 Go toStep 7
plamp ground terminal.
7 Repair the ground circuit. System OK
8 1. Disconnect the wiring connector from the sto- 0W Go toStep 10 Go toStep 9
plamp switch.
2. Press the brake pedal.
3. Use an ohmmeter to check continuity between
terminals 1 and 2.
9 Replace the stoplamp switch. System OK
10 1. Disconnect the stoplamp switch electrical con- 11–14 v Go toStep 12 Go toStep 11
nector.
2. Check the voltage at terminal 1.
Does the voltmeter show the specified value?
11 Repair the open circuit between the fuse F7 and the System OK
stoplamp switch.
12 Repair the open circuit between the stoplamp switch System OK
and the stoplamps.
DAEWOO V–121 BL4
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Center High–Mounted Stoplamp (CHMSL) Does Not Work

1 1. Turn the lights on. Go toStep 3 Go toStep 2
2. Observe the taillamps.
Are the taillamps on?
2 Repair the taillamps before completing this diagnos- System OK Go toStep 3
tic table.
Does the CHMSL work after the taillamps are re-
paired?
3 1. Remove the CHMSL bulb. Go toStep 4 Go toStep 5
2. Check the CHMSL bulb.
Is the lamp bulb defective?
4 Replace the CHMSL bulb. System OK
5 1. Disconnect the CHMSL connector. [0W Go toStep 7 Go toStep 6
between ground and the BLK wire in the
CHMSL connector.
6 Repair the open circuit between ground and the BLK System OK
wire in the CHMSL connector.
7 Repair the open circuit between the stoplamp switch System OK
and the CHMSL.
Backup Lamps Inoperative

1 1. Block the wheels. 11–14 v Go toStep 3 Go toStep 2
2. Apply the parking brake to prevent the vehicle
from moving.
3. Turn the ignition on.
4. Put the transaxle in reverse (R).
5. Remove one of the backup lamps from its
socket.
6. Test the lamp socket positive terminal with a
voltmeter.
Does the battery voltage available at the backup
lamp socket positive terminal equal the specified
value?
backup lamps.
3 Connect an ohmmeter between ground and the neg- 0W Go toStep 4 Go toStep 5
ative terminal at the bulb socket.
4 Replace the faulty backup lamps. System OK

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5 1. Reinstall the backup lamps. 11–14 v Go toStep 7 Go toStep 6
2. Disconnect the electrical connector at the re-
verse switch. (On automatic transaxle (A/T)
vehicles, disconnect the neutral safety/backup
switch.)
4. Put the transaxle in R.
5. Use a voltmeter to check for the reverse switch
terminal A. (On A/T vehicles, test terminal 6 of
the neutral safety/backup switch).
Does the battery voltage available at terminal A (or
terminal 6, if equipped with A/T) equal the specified
value?
6 Repair the open circuit between the backup lamps System OK
and the, reverse switch (or the neutral safety/backup
switch if equipped with A/T).
7 1. Put the transaxle in R. 0W Go toStep 9 Go toStep 8
tween reverse switch terminal A and terminal B
(terminals 6 and 2 on the neutral safety/backup
switch, if equipped with A/T).
Does the continuity between terminals A and B (ter-
minals 6 and 2, if equipped with A/T) equal the speci-
fied value?
8 Replace the reverse switch (neutral safety/backup System OK
switch, if equipped with A/T).
9 Repair the ground circuit between the reverse switch System OK
(neutral safety/backup switch, if equipped with A/T)
and ground G105.
Turn Signal Lamps and Hazard Lamps Do Not Work

1 Check fuses F3 and F16. Go toStep 2 Go toStep 3
Is either fuse blown?
sary.
2. Check the voltage at fuses F16 and F3.
Does the battery voltage available at both fuses F3
and F16 equal the specified value?
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4 1. Turn the hazard switch on. 11–14 v Go toStep 5 Go toStep 9
2. Remove each of the inoperative lamps from its
socket.
3. Test each lamp socket positive terminal with a
voltmeter.
Does the battery voltage pulsing at the turn signal
hazard lamp socket positive terminal equal the spe-
cified value?
5 At each bulb socket, use an ohmmeter to check the [0W Go toStep 6 Go toStep 8
ground circuit.
6 Replace any faulty turn signal/hazard bulbs. System OK
7 Repair the power supply circuit to fuses. System OK
8 Repair the open ground wires. System OK
9 1. Turn on the hazard lamp switch. 11–14 Go toStep 15 Go toStep 10
2. Test the blinker unit connector terminal 49a
with a voltmeter.
Does the battery voltage pulsing at the blinker unit
terminal 49a equal the specified value?
10 1. Turn on the hazard lamp switch. 11–14 Go toStep 11 Go toStep 14
2. Test the blinker unit connector terminal 49 with
a voltmeter.
Does the battery voltage available at the blinker unit
terminal 49 equal the specified value?
11 1. Disconnect the blinker unit from the connector. [0W Go toStep 13 Go toStep 12
2. Use an ohmmeter to check between ground
and the connector for terminal 31 of the blinker
unit.
12 Repair the blinker unit ground connection. System OK
13 Replace the faulty blinker unit. System OK
14 1. Disconnect the hazard lamp switch connector. 11–14 v Go toStep 15 Go toStep 20
2. Check for voltage at terminal 8.
4. Check for voltage at terminal 10.
Does the battery voltage available at both terminals
equal the specified value?
15 1. Remove the hazard lamp switch. 0W Go toStep 18 Go toStep 17
2. Turn the hazard lamp switch off.
3. Check for continuity between terminals 7 and
10.
4. Turn the hazard lamp switch on.
5. Check for continuity between terminals 7 and
8.
Do both tests show the specified value?

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16 1. Remove the hazard lamp switch. 0W Go toStep 19 Go toStep 17
2. Turn the hazard lamp switch on.
3. Use an ohmmeter to check for continuity be-
tween terminals 5, 6, and 9.
Does the continuity between terminals 5, 6, and 9
17 Replace the faulty hazard lamp switch. System OK
18 Repair the open circuit between the hazard lamp System OK
switch terminal 7 and the blinker unit terminal 49.
19 Repair the open circuit between the splice S202 and System OK
splice S301.
20 Repair the open circuit between the hazard lamp System OK
switch and the fuses F3 or F16.
Hazard Lamps Do Not Operate, Turn Signals Are OK

Is fuse F3 blown?
sary.
3 Use a voltmeter to check for power to fuse F3. 11–14 v Go toStep 5 Go toStep 4
Does the battery voltage available at fuse F3 equal
the value specified?
4 Repair the power supply circuit to fuse F3. System OK
5 1. Disconnect the hazard switch connector. 11–14 v Go toStep 6 Go toStep 9
2. Use a voltmeter to check power to the hazard
switch terminal 8.
Does the battery voltage available at connector ter-
minal 8 equal the value specified?
6 1. Remove the hazard switch and disconnect it 0W Go toStep 7 Go toStep 10
for testing.
2. Turn the hazard switch on.
3. Test with an ohmmeter between terminals 7
and 8.
7 1. With the hazard switch still removed and dis- 0W Go toStep 8 Go toStep 10
connected for testing, turn the hazard switch
on.
2. Use an ohmmeter to check between terminals
5, 6, and 9.
DAEWOO V–121 BL4
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8 Repair the open circuit between the hazard switch System OK
connector and splice S202.
9 Repair the open circuit between the hazard switch System OK
connector terminal 8 and fuse F3.
10 Replace the faulty hazard switch. System OK

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INTERIOR COURTESY AND LUGGAGE COMPARTMENT

LAMPS
Interior Courtesy Lamp Inoperative
CAUTION : Always make sure there is an electrical table.
load (lamp bulb, etc.) in any circuit between battery
terminals. Do not make a short circuit between bat- 1. Bulb test. Clip one end of a jumper wire to the neg-
tery terminals with a jumper wire. Hazardous spark- ative battery terminal. Clip the other end of the
ing would result and could cause injury. jumper wire onto one end of the bulb. Take the free
end of the bulb (the end without the jumper at-
Test Description
tached) and touch it to the positive battery terminal.
The number(s) below refer to step(s) on the diagnostic

1 1. Remove the interior courtesy lamp bulb and Go toStep 3 Go toStep 2
inspect the filament.
2. If the filament is not broken, test the bulb using
the vehicle’s battery and a jumper wire.
Does the bulb pass the visual and physical checks?
2 Replace the bulb. System OK
3 1. Reinstall the interior courtesy lamp bulb. Go toStep 4 Go toStep 5
2. Check fuse F1.
Is fuse F1 blown?
sary.
5 Check fuse F1. 11–14 v Go toStep 7 Go toStep 6
Does the voltage at fuse F1 equal the specified val-
ue?
7 1. Disconnect the interior courtesy lamp electrical 11–14 v Go toStep 8 Go toStep 9
connector.
2. Check the voltage at connector terminal 1.
Does the voltage at connector terminal 1 equal the
value specified?
8 Repair the open circuit between fuse F1 and the inte- System OK
rior courtesy lamp terminal 1.
9 1. With the interior courtesy lamp disconnected, 0W Go toStep 10 Go toStep 11
turn it to the on position.
2. Use an ohmmeter to check the resistance be-
tween ground and terminal 3 of the interior
courtesy lamp connector (harness side).
10 Replace the interior courtesy lamp switch assembly. System OK
11 Repair the ground circuit for the interior courtesy System OK
lamp.
DAEWOO V–121 BL4
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Luggage Compartment Lamp Inoperative

CAUTION : Always make sure there is an electrical table.
load (lamp bulb, etc.) in any circuit between battery
terminals. Do not make a short circuit between bat- 1. Bulb test. Clip one end of a jumper wire to the neg-
tery terminals with a jumper wire. Hazardous spark- ative battery terminal. Clip the other end of the
ing would result and could cause injury. jumper wire onto one end of the bulb. Take the free
end of the bulb (the end without the jumper at-
Test Description
tached) and touch it to the positive battery terminal.
The number(s) below refer to step(s) on the diagnostic
1 1. Remove the luggage compartment lamp bulb Go toStep 3 Go toStep 2
and inspect the filament.
2. If the filament is not broken, test the bulb using
the vehicle’s battery and a jumper wire.
Does the bulb pass the visual and physical check?
2 Replace the bulb. System OK
3 1. Reinstall the luggage compartment lamp bulb. Go toStep 4 Go toStep 5
2. Check fuse F1.
Is fuse F1 blown?
sary.
5 Check fuse F1. 11–14 v Go toStep 7 Go toStep 6
Does the voltage at fuse F1 equal the specified val-
ue?
7 1. Disconnect the luggage compartment lamp 11–14 v Go toStep 8 Go toStep 9
electrical connector.
2. Check the voltage at the orange wire.
Does the voltage at the ORN wire equal the specified
value?
8 Repair the open circuit between fuse F1 and the lug- System OK
gage compartment lamp.
9 1. Reconnect the luggage compartment lamp. 11–14 v Go toStep 11 Go toStep 10
2. Remove the luggage compartment lamp
switch.
3. With a voltmeter (or test lamp), test the BLK/
WHT wire at the luggage compartment lamp
switch.
Does the voltage at the luggage compartment lamp
switch equal the specified value?
10 Repair the open circuit between the luggage System OK
compartment lamp and the luggage compartment
lamp switch.

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11 Use an ohmmeter to check the resistance between 0W Go toStep 12 Go toStep 13
ground and the BLK wire at the luggage compart-
ment lamp switch connector (harness side).
12 Replace the luggage compartment lamp switch. System OK
13 Repair the ground circuit for the interior courtesy System OK
lamp.
DAEWOO V–121 BL4
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FOG LAMPS
Diagnostic Aids
The front fog lamps will not operate unless the illumination lamps or daytime running lamps are on. If the illumination lamps
or daytime running lamps are not operating, repair that problem before attempting to diagnose the fog lamps.
Front Fog Lamps Inoperative

Is fuse EF15 blown?
sary.
3 Use a voltmeter to check fuse EF15. 11–14 v Go toStep 5 Go toStep 4
Does the battery voltage available at fuse EF15
4 Repair the open circuit from the battery to fuse System OK
EF15.
5 Remove the fog lamp relay and temporarily substi- Go toStep 6 Go toStep 7
tute a known good relay, such as the headlamp relay.
(Do not substitute the illumination lamp relay.)
Do the fog lamps work with the substituted relay?
6 1. Return the substituted relay to its original posi- System OK
tion.
2. Replace the inoperative fog lamp relay.
7 1. Return the substituted relay to its original posi- 11–14 v Go toStep 9 Go toStep 8
tion, but do not reinstall the fog lamp relay.
2. Turn on the exterior lamps and the front fog
lamps.
3. Using a voltmeter, check the fog lamp relay
socket at the connector for fog lamp relay ter-
minal 30.
Does the voltage available at the fog lamp relay
socket equal the specified value?
fog lamp relay.
9 At the fog lamp relay socket, use an ohmmeter to 0W Go toStep 11 Go toStep 10
verify that the connector for relay terminal 86 is con-
nected to ground.
Does the resistance equal the specified value?
10 Repair the ground circuit for the fog lamp relay. System OK
11 1. Reinstall the fog lamp relay. 11–14 v Go toStep 13 Go toStep 12
2. Turn ON the exterior lamps and the front fog
lamps.
3. Test for voltage at terminal 1 of the fog lamp
connector.
Does the battery voltage available at terminal 1 of
the fog lamp connector equal the specified value?

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12 Repair the open circuit between the fog lamp relay System OK
terminal 87 and the fog lamps.
13 Use an ohmmeter (or test lamp) to check the ground 0W Go toStep 15 Go toStep 14
at terminal 2 of the fog lamp connector.
Does the resistance equal the specified value?
14 Repair the fog lamp ground circuit. System OK
15 Replace the faulty fog lamp bulbs. System OK
DAEWOO V–121 BL4
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SECTION : 9C
HORNS
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9C–1 ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9C–3
FASTENER TIGHTENING SPECIFICATIONS . 9C–1 DUAL HORNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9C–3
SCHEMATIC AND ROUTING DIAGRAMS . . . . . 9C–2 GENERAL DESCRIPTION AND SYSTEM
HORN WIRING SYSTEM . . . . . . . . . . . . . . . . . . . 9C–2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9C–4
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 9C–3 HORNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9C–4
SPECIFICATIONS
Horn Bolt 15 11 –
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9C – 2IHORNS

HORN WIRING SYSTEM

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HORNS 9C – 3

DUAL HORNS
Removal Procedure
2. Remove the bolt from the horn.
3. Disconnect the electrical connector.
4. Remove the horn.
1. Connect the electrical connector.
2. Install the horn with the bolt.
Tighten
Tighten the horn bolt to 15 NSm (11 lb–ft).
DAEWOO V–121 BL4
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9C – 4IHORNS
GENERAL DESCRIPTION
HORNS
The horns are located under the hood. They are attached
near the radiator at the front of the vehicle. The horns are
actuated by pressing the steering wheel pad, which
grounds the horns’electrical circuit.

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SECTION : 9D
WIPERS/WASHER SYSTEMS
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9D–1 WINDSHIELD WIPER MOTOR . . . . . . . . . . . . . 9D–12
FASTENER TIGHTENING SPECIFICATIONS . 9D–1 WINDSHIELD WIPER BLADE . . . . . . . . . . . . . . 9D–14
SCHEMATIC AND ROUTING DIAGRAMS . . . . . 9D–2 WINDSHIELD WIPER BLADE INSERT . . . . . . 9D–15
WINDSHIELD WIPERS AND WASHER SYSTEM 9D– WINDSHIELD WASHER RESERVOIR . . . . . . 9D–16
2 WINDSHIELD WASHER PUMP(S) . . . . . . . . . . 9D–18
REAR WINDOW WIPER AND WASHER SYSTEM 9D
WINDSHIELD WASHER NOZZLES . . . . . . . . . 9D–18
–3
WINDSHIELD WASHER HOSES . . . . . . . . . . . 9D–19
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9D–4
REAR WINDOW WIPER ARM . . . . . . . . . . . . . 9D–20
INTERMITTENT WINDSHIELD WIPERS . . . . . 9D–4
REAR WINDOW WIPER MOTOR . . . . . . . . . . 9D–20
WINDSHIELD WASHER SYSTEM . . . . . . . . . . . 9D–8
REAR WINDOW WASHER NOZZLE . . . . . . . . 9D–21
REAR WINDOW WIPER (HATCHBACK) . . . . . 9D–9
REAR WINDOW WASHER SYSTEM (HATCHBACK) GENERAL DESCRIPTION AND SYSTEM
9D–11 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9D–22
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 9D–12 WINDSHIELD WIPER SYSTEM . . . . . . . . . . . . 9D–22
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 9D–12 WINDSHIELD WASHER SYSTEM . . . . . . . . . . 9D–22
WINDSHIELD WIPER ARM . . . . . . . . . . . . . . . . 9D–12 REAR WINDOW WIPER/WASHER SYSTEM 9D–22
SPECIFICATIONS
Engine Coolant Reservoir Nuts 4 – 35
Front Wheel Well Splash Shield Screws 1.5 – 13
Washer Fluid Reservoir Bolts and Nuts 9 – 80
Wiper Arm Linkage Nut 8.5 – 75
Wiper Arm Nut 11 – 97
Wiper Motor Bolts 9 – 80
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9D – 2IWIPERS/WASHER SYSTEMS

WINDSHIELD WIPERS AND WASHER SYSTEM

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WIPERS/WASHER SYSTEMS 9D – 3
REAR WINDOW WIPER AND WASHER SYSTEM
DAEWOO V–121 BL4
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DIAGNOSIS
INTERMITTENT WINDSHIELD WIPERS
Windshield Wipers Do Not Work At Any Speed
Is fuse F18 blown?
sary.
3 Check the battery voltage at fuse F18. 11–14 v Go toStep 5 Go toStep 4
Is battery voltage available at fuse F18?
4 Repair the open in the power supply circuit to fuse System OK
F18.
2. Turn the wiper switch to HI.
Is battery voltage available at wiper motor connector
terminal 1?
6 Replace the faulty wiper motor. System OK
7 1. Disconnect the wiper switch connector. 11–14 v Go toStep 9 Go toStep 8
3. With a voltmeter, check for battery voltage at
connector terminal 8.
Is battery voltage available at the wiper switch con-
nector terminal 8?
8 Repair the open circuit between wiper switch con- System OK
nector terminal 8 and fuse F18.
9 1. Use an ohmmeter to test the continuity of the 0W Go toStep 11 Go toStep 10
wiper switch.
2. Turn the wiper switch to HI. Check for continu-
ity between wiper switch terminal 8 and 9.
Is there continuity between terminals 8 and 9?
10 Replace the faulty wiper switch. System OK
11 Repair the open circuit between the wiper switch and System OK
the wiper motor.

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Wipers Do Not Work On HI Speed, LO Speed OK

terminal 1?
3 1. Use an ohmmeter to test the continuity of the 0W Go to Step 5 Go to Step 4
wiper switch.
2. Turn the wiper switch to HI. Check for continu-
ity between the wiper switch terminal 8 and 9.
5 Repair the open circuit between wiper switch con- System OK
nector terminal 9 and wiper motor connector termi-
nal 1.
Wipers Do Not Work On LO Speed, HI Speed OK

2. Turn the wiper switch to LO.
terminal 2?
3 1. Use an ohmmeter to test the continuity of the 0W Go toStep 5 Go toStep 4
wiper switch.
2. Turn the wiper switch to LO. Check for continu-
ity between the wiper switch terminal 8 and 5.
5 Repair the open circuit between the wiper switch System OK
connector terminal 5 and the wiper motor connector
terminal 2.
DAEWOO V–121 BL4
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Wipers Do Not Work On Intermittent, Other Speeds OK

Diagnostic Aids
The wiper relay is located behind the instrument panel, below the cluster dimmer switch. Remove the cluster dimmer
switch and the instrument panel side cover to access the wiper relay.

2. Use a voltmeter to test for battery voltage at
the wiper relay connector terminal 15.
Is battery voltage available at connector terminal
15?
2 Repair the open circuit between the wiper relay con- System OK
nector terminal 15 and fuse F18.
2. Turn the wiper switch to INT.
Using a voltmeter, is battery voltage available at the
wiper relay connector terminal I?
Using a voltmeter, is battery voltage available at wip-
er switch connector terminal 7?
5 Replace the wiper switch. System OK
6 Repair the open circuit between the wiper switch System OK
connector terminal 7 and the wiper relay connector
terminal I.
Using a voltmeter, is battery voltage pulsing at wiper
relay connector terminal 53e?
8 Using an ohmmeter, check the wiper relay ground 0W Go toStep 10 Go toStep 9
circuit (connector terminal 31).
Is the ground circuit OK?
9 Repair the open ground circuit. System OK
10 Replace the wiper relay. System OK
11 1. Disconnect the wiper switch connector. 0W Go toStep 13 Go toStep 12
3. Using an ohmmeter, check the wiper switch.
13 Repair the open circuit between the wiper switch and System OK
the wiper relay.

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Windshield Wipers Do Not Return To Park Position

2. Use a voltmeter to test the battery voltage at
the wiper motor.
terminal 4?
2 Repair the open circuit between the wiper motor and System OK
fuse F18.
3 1. Turn the ignition ON 11–14 v Go toStep 5 Go toStep 4
3. Use a voltmeter to test for a pulse of battery
power at the wiper motor when turning the wip-
er switch OFF.
Is a pulse of battery voltage available at the wiper
motor connector terminal 3 when the wiper switch is
turned OFF?
3. Use a voltmeter to test for a pulse of battery
power at the wiper relay when turning the wiper
switch OFF.
Is a pulse of battery voltage available at the wiper
relay connector terminal 31b when the wiper switch
is turned OFF?
6 Repair the open circuit between the wiper motor and System OK
the wiper relay.
7 1. Disconnect the wiper relay from the connector. 0W Go toStep 9 Go toStep 8
2. Use an ohmmeter to test the continuity of the
relay.
Is there continuity between wiper relay connector
terminals 31b and 53e?
8 Replace the faulty wiper relay. System OK
9 Replace the faulty wiper relay. System OK
DAEWOO V–121 BL4
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WINDSHIELD WASHER SYSTEM

Windshield Washer Does Not Work, Wipers Are OK
1 Do the windshield wipers operate when the washer Go toStep 4 Go toStep 2
switch is activated?
2. While activating the washer switch, use a volt-
meter to test for battery voltage at the wind-
shield wiper switch.
Is battery voltage available at the windshield wiper
switch connector terminal 4?
3 Replace the windshield wiper switch. System OK
4 Is there washer fluid in the windshield washer fluid Go toStep 6 Go toStep 5
reservoir?
5 Fill the windshield washer fluid reservoir. System OK
6 Are the windshield washer hoses or the nozzles Go toStep 7 Go toStep 8
clogged or damaged?
7 Repair the washer hoses and the nozzles. System OK
2. With the windshield washer activated, use a
voltmeter to test for battery voltage at the wind-
shield washer pump.
Is battery voltage available at the windshield washer
pump ?
9 Repair the open circuit between the windshield System OK
washer pump and the windshield wiper switch.
10 Use an ohmmeter to check the ground circuit at the 0W Go toStep 12 Go toStep 11
windshield washer pump.
Is the ground circuit OK?
11 Repair the windshield washer pump ground circuit. System OK
12 Replace the windshield washer pump. System OK

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REAR WINDOW WIPER (HATCHBACK)

Diagnostic Aids
If the front wiper is operating correctly, begin the diagnostic table at Step 5. It would not be necessary to check the fuse
or power supply circuit.
Rear Window Wiper (Hatchback)

Is fuse F18 blown?
2 1. Check for a short circuit and repair, if neces- System OK
sary.
2. Check the voltage at fuse F18.
5 1. Disconnect the rear wiper motor electrical con- 11–14 v Go toStep 7 Go toStep 6
nector.
3. Check the voltage at the PNK wire of the rear
wiper motor electrical connector.
6 Repair the open circuit for the PNK wire between System OK
fuse F18 and connector at the rear wiper motor.
7 With the rear wiper motor still disconnected, use an [0W Go toStep 9 Go toStep 8
ohmmeter to check continuity between ground and
the BLK wire of the rear wiper motor connector.
8 Repair the open ground circuit for the rear wipermo- System OK
tor.
2. Turn the rear wiper ON.
3. Check the voltage at the WHT wire at the rear
wiper motor connector.
10 Replace the rear wiper motor. System OK
11 1. Disconnect the wiper switch electrical connec- 11–14 v Go toStep 13 Go toStep 12
tor.
3. Check the voltage at terminal 3 (PNK).
wiper switch connector terminal 3.
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13 1. Connect an ohmmeter between terminals 1 [0W Go toStep 14 Go toStep 15
and 3 of the wiper switch.
2. Observe the ohmmeter when the rear wiper
switch is moved to the WIPE position.
wiper connector (WHT wire) and the rear wiper mo-
tor.

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REAR WINDOW WASHER SYSTEM (HATCHBACK)

1 Check the washer fluid level. Go toStep 3 Go toStep 2
Is there fluid in the washer reservoir?
2 Fill the washer reservoir. System OK
3 Verify that the hoses are not obstructed or leaking by Go toStep 4 Go toStep 5
disconnecting the washer hose and blowing through
it toward the reservoir and also toward the nozzle.
Are the hoses obstructed or leaking?
4 Repair or replace the hoses. System OK
5 Check the function of the rear wiper. Go toStep 7 Go toStep 6
Does the rear wiper function correctly?
6 Repair the rear wiper. Go toStep 7
Is the rear wiper repair complete?
7 1. Disconnect the electrical connector at the rear [0W Go toStep 9 Go toStep 8
washer pump.
2. Use an ohmmeter to check continuity between
the BLK wire of the rear washer pump connec-
tor and ground.
8 Repair the open or the high–resistance ground con- System OK
nection.
9 Check the voltage at the rear washer pump connec- 11–14 v Go toStep 10 Go toStep 11
tor (DK GRN wire) when the rear washer is turned
ON.
10 Replace the rear washer pump. System OK
11 1. Disconnect the wiper switch. [0W Go toStep 12 Go toStep 13
2. Connect an ohmmeter between terminal 2 and
terminal 3 of the wiper switch.
3. Observe the ohmmeter when the switch is
moved to the rear WASH position.
wiper switch connector and the rear washer pump.
DAEWOO V–121 BL4
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WINDSHIELD WIPER ARM
(Typical)
Removal Procedure
1. Open the hood.
2. Remove the nut from the wiper arm.
3. Pull the wiper arm off.
1. Install the wiper arm.
2. Secure the wiper arm with the nut.
Tighten
Tighten the wiper arm nut to 11 NSm (97 lb–ft).
3. Close the hood.
WINDSHIELD WIPER MOTOR

(Typical)
Removal Procedure

2. Put the wiper arms in the upright position.
3. Remove the left side portion of the cowl vent grille.
Refer to Section 9R, Body Front End.
4. Remove the nut securing the wiper arm linkage to
the motor drive shaft.

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5. Pry the wiper arm linkage off the motor drive shaft.
6. Remove the nuts and reposition the engine coolant
reservoir.
7. Disconnect the electrical connectors.

8. Remove the bolts and the wiper motor.

1. Install the wiper motor with the bolts.
Tighten
Tighten the wiper motor bolts to 9 NSm (80 lb–in).
DAEWOO V–121 BL4
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3. Install the engine coolant reservoir with the nuts.

Tighten
Tighten the engine coolant reservoir nuts to 4 NSm (35
lb–in).
4. Press the wiper arm linkage onto the motor drive

shaft.
5. Install the wiper arm linkage to the motor drive shaft
with the nut.
Tighten
Tighten the wiper arm linkage nut to 8.5 NSm (75 lbin).
6. Install the left side portion of the cowl vent grille.
Refer to Section 9R, Body Front End.
WINDSHIELD WIPER BLADE

(Typical)
Removal Procedure
1. Rotate the wiper blade on the arm.
2. Pull the wiper blade off the arm.

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1. Push the wiper blade onto the arm.
WINDSHIELD WIPER BLADE INSERT

(Typical)
Removal Procedure
1. Slide the insert out of the wiper blade.
1. Slide the insert into the wiper blade.
DAEWOO V–121 BL4
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WINDSHIELD WASHER RESERVOIR

(Typical)
Removal Procedure

2. Remove the front left wheel. Refer to Section 2E,
Tires and Wheels.
3. Remove the screws and the front wheel well splash
shield.
4. Disconnect the washer hose(s) from the reservoir.
5. Disconnect the reservoir pump electrical connec-

tor(s).
6. Remove the bolts, the nuts and the reservoir.

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1. Install the reservoir with the nuts and the bolts.
Tighten
Tighten the washer fluid reservoir nuts to 9 NSm (80
lb–in).
Tighten the washer fluid reservoir bolts to 9 NSm (80
lb–in).
2. Connect the reservoir pump electrical connector(s).
3. Connect the washer hose(s) to the reservoir.
4. Install the front wheel well splash shield with the

screws.
Tighten
Tighten the front wheel well splash shield screws to
1.5 NSm (13 lb–in).
5. Install the front left wheel. Refer to Section 2E,
Tires and Wheels.
DAEWOO V–121 BL4
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WINDSHIELD WASHER PUMP(S)

(Typical)
Removal Procedure
2. Remove the left front left wheel. Refer to Section
2E, Tires and Wheels.
shield.
5. Disconnect the washer hose.
6. Remove the washer pump.
1. Install the washer pump.
2. Connect the washer hose.
screws.
Tighten
1.5 NSm (13 lb–in).
Tires and Wheels.
WINDSHIELD WASHER NOZZLES

Removal Procedure
1. Open the hood.
2. Disconnect the washer hose from the nozzle.
3. Remove the nozzle from the hood.

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1. Install the nozzle onto the hood.
2. Connect the washer hose to the nozzle.
3. Close the hood.
WINDSHIELD WASHER HOSES

Removal Procedure
1. Open the hood.
2. Disconnect the windshield washer hose from the
washer nozzles on the hood.
3. Remove the front left wheel. Refer to Section 2E,
Tires and Wheels.
shield.
5. Disconnect the washer hose from the washer reser-
voir.
1. Connect the washer hose to the washer reservoir.
screws.
Tighten
1.5 NSm (13 lb–in).
Tires and Wheels.
4. Connect the windshield washer hose to the washer
nozzles on the hood.
5. Close the hood.
DAEWOO V–121 BL4
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REAR WINDOW WIPER ARM

Removal Procedure
1. Remove the hatchback door upper garnish molding.
Refer to Section 9G, Interior Trim.
2. Remove the washer hose from the nozzle.
3. Remove the nut and the washer nozzle.
1. Install the washer nozzle with the nut.
2. Install the washer hose to the nozzle.
3. Install the hatchback door upper garnish molding.
REAR WINDOW WIPER MOTOR

Removal Procedure
2. Remove the rear window wiper arm. Refer to ”Rear
Window Wiper Arm” in this section.
3. Remove the hatchback door lower garnish molding.
4. Remove the bolts and the rear wiper motor.

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2. Install the rear wiper motor with the bolts.
Tighten
Tighten the wiper motor bolts to 9 NSm (80 lb–in).
3. Install the hatchback door lower garnish molding.
4. Install the rear window wiper arm. Refer to ”Rear
Window Wiper Arm” in this section.
REAR WINDOW WASHER NOZZLE

Removal Procedure
1. Open the wiper arm access cap.
2. Remove the nut and the rear wiper arm.
1. Install the rear wiper arm with the nut.
Tighten
Tighten the wiper arm nut to 11 NSm (97 lb–in).
2. Close the wiper arm access cap.
DAEWOO V–121 BL4
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fluid reservoir, a washer fluid pump, hoses, nozzles, and

GENERAL DESCRIPTION a wiper/washer switch. The windshield washer reservoir
is mounted behind the front left wheel well splash shield.
AND SYSTEM OPERATION Attached to the reservoir is a washer pump, which pumps
fluid through the hoses to the two nozzles mounted on the
WINDSHIELD WIPER SYSTEM hood. The washer switch is an integral part of the wiper/
washer switch. Windshield washer operation is actuated
The windshield wiper system consists of a wiper motor, a through the lever on the right side of the steering column.
linkage, a wiper arm and a blade, and a wiper/washer
switch. The windshield wiper circuit incorporates a elfpark-
ing device which consists of a worm gear and a cam plate REAR WINDOW WIPER/WASHER
in order to keep the circuit complete temporarily when the
switch is turned off. The wiper system is driven by a per-
SYSTEM
manent magnet–type motor. The windshield wiper motor The hatchback rear window wiper system consists of a
is mounted on the dash panel and is directly connected to wiper motor, a wiper arm, and a blade. The rear window
the windshield wiper linkage. wiper motor is located inside the hatchback door and is di-
The windshield wiper motor has two speeds, LO and HI, rectly connected to the rear window wiper. The hatchback
and intermittent wiper capability. The wiper switch is an in- rear window washer systemis equipped with a separate
tegral part of the wiper/washer switch. Windshield wiper washer fluid pump, hose, and nozzle. The rear window
operation is actuated through the lever on the right side of washer reservoir is mounted behind the front left wheel
the steering column. well splash shield. Attached to the reservoir is a washer
pump, which pumps fluid through a hose to the nozzle
WINDSHIELD WASHER SYSTEM mounted on the hatch.
The windshield washer system is equipped with a washer

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SECTION : 9E
INSTRUMENTATION/DRIVER INFORMATION
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9E–2 INSTRUMENT CLUSTER TRIM PANEL VENTS 9E–2
FASTENER TIGHTENING SPECIFICATIONS . 9E–2 7
INSTRUMENT CLUSTER INDICATOR LAMPS GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E–27
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 9E–2 DIGITAL CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . 9E–28
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . 9E–29
SCHEMATIC AND ROUTING DIAGRAMS . . . . . 9E–3
INSTRUMENT CLUSTER DIMMER SWITCH 9E–29
INSTRUMENT CLUSTER CIRCUIT (1 OF 2) . . 9E–3
SPEEDOMETER/ODOMETER/TRIP ODOMETER 9E
INSTRUMENT CLUSTER CIRCUIT (2 OF 2) . . 9E–4
–30
INSTRUMENT PANEL ILLUMINATION CIRCUIT 9E– FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E–31
5
TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . 9E–31
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E–6 INSTRUMENT CLUSTER INDICATOR LAMPS 9E–32
CIGAR LIGHTER . . . . . . . . . . . . . . . . . . . . . . . . . . 9E–6 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . 9E–33
ASHTRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E–8 INSTRUMENT CLUSTER TRIM PANEL . . . . . 9E–39
DIGITAL CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . 9E–9 CHIME MODULE . . . . . . . . . . . . . . . . . . . . . . . . . 9E–43
INSTRUMENT PANEL ILLUMINATION . . . . . . 9E–11 GENERAL DESCRIPTION AND SYSTEM
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . . 9E–13 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E–44
FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E–14 CIGAR LIGHTER . . . . . . . . . . . . . . . . . . . . . . . . . 9E–44
TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . 9E–15 ASHTRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E–44
INSTRUMENT CLUSTER INDICATOR LAMPS 9E–17 INSTRUMENT PANEL VENTS . . . . . . . . . . . . . 9E–44
INSTRUMENT CLUSTER INDICATOR LAMPS 9E–18 GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E–44
CHIME MODULE . . . . . . . . . . . . . . . . . . . . . . . . . 9E–19 DIGITAL CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . 9E–44
CHIME MODULE . . . . . . . . . . . . . . . . . . . . . . . . . 9E–20 INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . 9E–44
SPEEDOMETER/ODOMETER/TRIP ODOMETER 9E
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 9E–25 –44
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 9E–25 FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E–44
CIGAR LIGHTER . . . . . . . . . . . . . . . . . . . . . . . . . 9E–25 TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . 9E–44
ASHTRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E–25 INSTRUMENT CLUSTER INDICATOR LAMPS 9E–44
CUPHOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E–26 CHIME MODULE . . . . . . . . . . . . . . . . . . . . . . . . . 9E–44
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9E – 2IINSTRUMENTATION/DRIVER INFORMATION
SPECIFICATIONS
Air Deflector Screws 2 – 18
Chime Module Screws 3.5 – 31
Clock Screws 2 – 18
Cupholder Screws 2.5 – 22
Deposit Box Screws 2.5 – 22
Driver Knee Bolster Bolts 10 – 89
Floor Console Brace Bolts 4 – 35
Floor Console Brace Nuts 4 – 35
Glove Box Screws 3 – 27
HVAC Controls Screws 4 – 35
Instrument Cluster Screws 4 – 35
Instrument Cluster Trim Panel Screws 4 – 35
Instrument Panel End Bolts 20 15 –
Instrument Panel End Screws 4 – 35
Instrument Panel Nuts Above the Steering Column 20 15 –
Instrument Panel Bolts Behind the HVAC Controls 4 – 35
Steering Column Bracket Nut 22 16 –
Steering Column Lower Trim Cover Screws 2.5 – 22
Steering Column U–Clamp Nuts 22 16 –
Steering Column Upper Trim Cover Screws 3 – 27
INSTRUMENT CLUSTER INDICATOR LAMPS

SPECIFICATIONS
Indicator Lamp Color Bulb
ABS Warning Amber 14 v 1.4 W
Airbag Warning Red 14 v 1.4 W
Battery Charge Indicator Red 14 v 1.4 W
Check Engine Amber 14 v 1.4 W
Door Open Warning Red 14 v 1.4 W
Engine Overheat Red 14 v 1.4 W
Fasten Seat Belt Warning Red 14 v 1.4 W
High Beam Indicator Blue 14 v 1.4 W
Low Fuel Level Warning Amber 14 v 1.4 W
Oil Pressure Warning Red 14 v 1.4 W
Parking Brake Indicator and Brake Fluid Warning Red 14 v 1.4 W
Service Engine Soon Warning Amber 14 v 1.4 W
Transaxle Power Mode Indicator Amber 14 v 1.4 W
Turn Signal Indicators Green 14 v 1.4 W

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INSTRUMENTATION/DRIVER INFORMATION 9E – 3

INSTRUMENT CLUSTER CIRCUIT (1 OF 2)
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INSTRUMENT CLUSTER CIRCUIT (2 OF 2)

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INSTRUMENT PANEL ILLUMINATION CIRCUIT
DAEWOO V–121 BL4
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DIAGNOSIS
CIGAR LIGHTER
Cigar Lighter Inoperative
Is the fuse blown?
sary.
3 1. Turn the ignition key to ACC. 11–14 v Go toStep 5 Go toStep 4
2. Use a voltmeter to check for voltage at fuse
F10.
Does the battery voltage available at the fuse F10
match the value specified?
5 1. Remove the electrical connector from the back 11–14 v Go toStep 7 Go toStep 6
of the cigar lighter.
2. Turn the ignition key to ACC.
3. Use a voltmeter to check the voltage at the
BRN wire.
Does the battery voltage available at the BRN wire
match the value specified?
6 Repair the open circuit between fuse F10 and the ci- System OK
gar lighter.
7 With the ignition key still in the ACC position, con- 11–14 v Go toStep 9 Go toStep 8
nect the voltmeter between the BRN and the BLK
wires at the cigar lighter connector.
Does the battery voltage match the value specified?

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8 Repair the open ground circuit. System OK
9 Replace the cigar lighter. System OK
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ASHTRAY
Diagnostic Aids
If power to splice S204 is lost, all of the following functions will also be lost: A/C control switch illumination, audio system
illumination, headlamp reminder chime, instrument cluster illumination, and hazard switch illumination.
Ashtray Lamp Inoperative, All Other Instrument Lamps OK

1 1. Turn the light switch on. 11–14 v Go toStep 3 Go toStep 2
2. Remove the ashtray lamp from the socket.
3. Use a voltmeter to check battery voltage avail-
able at the ashtray lamp socket.
2 Repair the open circuit between the ashtray lamp System OK
socket and splice S204.
3 1. Turn the light switch on. [0W Go toStep 5 Go toStep 4
2. Using an ohmmeter, check the ground circuit to
the lamp socket.
Does the resistance equal the value specified?
4 Repair the open ground circuit between the ashtray System OK
lamp socket and ground G201.
5 Replace the ashtray lamp. System OK

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DIGITAL CLOCK
Digital Clock Inoperative
1 Check fuses F2 and F11. Go toStep 2 Go toStep 3
Is either fuse F2 or F11 blown?
sary.
2. Replace the blown fuses.
able at fuses F2 and F11.
4 Repair the open power supply circuit for the fuse. System OK
5 Use a voltmeter to check the battery voltage avail- 11–14 v Go toStep 7 Go toStep 6
able at the clock connector terminal 2.
6 Repair the open circuit between the clock connector System OK
terminal 2 and the fuse F2.
7 Turn the ignition ON. Go toStep 9 Go toStep 8
Is battery voltage available at the clock connector
terminal 5?
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clock connector and fuse F11.
9 Check continuity between terminal 3 of the clock 0W Go toStep 10 Go toStep 11
connector and ground.
Does the multimeter indicate the value specified?
10 Replace the clock. System OK
11 Repair the open ground circuit between terminal 3 System OK
the clock connector and ground G201.

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INSTRUMENT PANEL ILLUMINATION

Instrument Panel Illumination Lamps Inoperative
Is fuse EF13 blown?
2 1. Check for a short circuit and repair it, if neces- System OK Go toStep 3
sary.
2. Replace the blown fuse.
3 1. Turn the lamp switch on. 11–14 v Go toStep 5 Go toStep 4
2. Use a voltmeter to check battery voltage at
fuse EF13.
4 Repair the open power supply circuit to fuse EF13. System OK
5 Use an ohmmeter to check the resistance between 0 Go toStep 7 Go toStep 6
ground and the BLK wire of the dimmer control
switch connector.
6 Repair the open ground circuit. System OK ––
2. Use a voltmeter to check for battery voltage at
the BRN/WHT wire of the dimmer control
switch connector.
8 Repair the open circuit between the BRN/WHT wire System OK
of the dimmer control switch connector and fuse
EF13.
9 1. Disconnect the dimmer control switch. 11–14 v Go toStep 11 Go toStep 10
2. Turn the lamp switch on.
3. Use a voltmeter to check for battery voltage at
the DK GRN wire of the dimmer control switch
connector.
10 Repair the open circuit between the DK GRN wire of System OK
the dimmer control switch connector and splice
S204.
11 Replace the dimmer control switch. System OK ––
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Automatic Transaxle Gear Position Illumination Lamp Inoperative,

All Other Instrument Lamps OK
Notice : When probing a bulb socket with a voltmeter or a test lamp, do not allow the probe to touch both the positive and
the negative contacts at the same time. This will cause a blown fuse.

Is fuse EF14 blown?
sary.
able at fuse EF14.
4 Repair the open circuit power supply circuit to fuse System OK
EF14.
2. Remove the automatic transaxle position lamp.
able at the lamp socket.
6 Repair the open circuit between the automatic trans- System OK
axle position lamp socket and fuse EF14.
7 1. Turn the lamp switch on. [0W Go toStep 9 Go toStep 8
2. Remove the automatic transaxle position lamp.
3. Use an ohmmeter to check the resistance be-
tween the ground circuit and the lamp socket.
Is the resistance equal to the value specified?
8 Repair the open ground circuit between the auto- System OK
matic transaxle position lamp socket and ground.
9 Replace the automatic transaxle position lamp. System OK

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SPEEDOMETER
Speedometer Inoperative, Other Gauges and Warning Lamps Are
OK
1 1. Connect a scan tool. Go toSection Go toStep 2
2. Check for engine control diagnostic trouble 1F, Engine
codes (DTCs). Controls
Is the vehicle speed sensor DTC set?
2 1. Turn the ignition OFF. 0W Go toStep 4 Go toStep 3
2. Disconnect the powertrain control module
(PCM)/engine control module (ECM) connector
2.
3. Remove the instrument cluster.
4. Check continuity between PCM/ECM terminal
C11 and the instrument cluster connector ter-
minal 16.
ter connector terminal 16 and the PCM/ECM.
4 Replace the speedometer. System OK
DAEWOO V–121 BL4
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FUEL GAUGE
Fuel Gauge Inoperative, Other Gauges and Warning Lamps are OK
1 1. Connect a scan tool. Go toSection Go toStep 2
2. Check for engine control diagnostic trouble 1F, Engine
codes (DTCs). Controls
Is the vehicle speed sensor DTC set?
2 1. Turn the ignition OFF. 0W Go toStep 4 Go toStep 3
2. Disconnect the powertrain control module
(PCM)/engine control module (ECM) connector
2.
3. Remove the instrument cluster.
4. Check continuity between PCM/ECM terminal
C3 and the instrument cluster terminal 11.
ter connector terminal 11 and the PCM/ECM termi-
nal C3.
4 Replace the fuel gauge. System OK

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TEMPERATURE GAUGE
Temperature Gauge Inoperative, Other Gauges and Warning
Lamps are OK
1 Allow the engine to cool to room temperature. Go toStep 7 Go toStep 2
With the ignition ON, does the temperature gauge al-
ways read at the high end of the scale?
2 Disconnect the coolant temperature sensor (CTS) Go toStep 3 Go toStep 4
Does the temperature gauge indicator drop to the
low end of the scale?
3 Replace the CTS. System OK
4 Check for a short to ground between the CTS and Go toStep 5 Go toStep 6
the temperature gauge.
Is there a short to ground?
5 Repair the short to ground. System OK
6 Replace the temperature gauge. System OK
7 1. Disconnect the CTS. 11–14 v Go toStep 10 Go toStep 8
3. Check the voltage at the CTS.
Does the the voltage equal the value specified?
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8 Check for an open circuit between the CTS and the Go toStep 9 Go toStep 6
temperature gauge.
Is there an open circuit?
9 Repair the open circuit between the CTS and the System OK
temperature gauge.
10 1. Disconnect the CTS. Go toStep 3 Go toStep 6
2. Connect a jumper wire between the CTS con-
nector and ground.
Does the temperature gauge move to the high end
of the scale?

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DAEWOO V–121 BL4
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Instrument Panel Indicator Lamps Do Not Operate
Is fuse F11 blown?
sary.
4 Repair the open power supply circuit to fuse F11. System OK Go toStep 3
5 1. Remove the instrument cluster. 11–14 v Go toStep 7 Go toStep 6
2. Disconnect the instrument cluster connectors B
(terminals 9–20) and C (terminals 21–30).
4. Check the voltage at terminals 9 and 25.
6 Repair the open circuit between fuse F11 and the in- System OK
strument cluster connectors 9 and 25.
7 Check the instrument cluster indicator lamp bulbs. Go toStep 9 Go toStep 8
Are the bulbs OK?
8 1. Replace any bulbs that are defective. System OK
2. Check the charging system to make sure the
alternator is not overcharging.
3. Repair the charging system, if necessary.
10 Replace the instrument cluster. System OK

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CHIME MODULE
DAEWOO V–121 BL4
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CHIME MODULE
Seat Belt Warning Chime Inoperative
1 Check the chime module connector to make sure it Go toStep 2 Go toStep 3
is connected properly.
Is the connector disconnected or partially discon-
nected?
2 Connect the electrical connector for the chime mod- System OK
ule.
Is fuse F11 blown?
sary.
7 1. Disconnect the chime module. 11–14 v Go toStep 9 Go toStep 8
module connector.
chime module connector.
9 With the chime module disconnected, use an ohm- [0W Go toStep 11 Go toStep 10
meter to check continuity between terminal 5 of the
chime module connector and ground.
11 1. Disconnect the chime module connector. [0W Go toStep 12 Go toStep 13
2. Make sure the driver’s side seat belt is unfas-
tened.
tween terminal 1 of the chime module and
ground.

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13 1. Disconnect the seat belt switch. [0Ω Go toStep 15 Go toStep 14
2. Make sure the driver’s side seat belt is unfas-
tened.
3. Use an ohmmeter to check the continuity of the
switch.
14 Replace the seat belt switch. System OK
15 Use an ohmmeter to check the continuity of the wire [0W Go toStep 17 Go toStep 16
between terminal 1 of the chime module and the seat
belt switch.
chime module and the seat belt switch.
17 Repair the open circuit between the seat belt switch System OK
connector and ground.
Door–Open Warning Chime Inoperative

nected?
2 Connect the electrical connector for the chime mod- System OK
ule.
Is fuse F11 blown?
sary.
module connector.
chime module connector.
DAEWOO V–121 BL4
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meter to check the continuity between terminal 5 of
the chime module connector and ground.
11 1. Disconnect the chime module connector. [0W Go toStep 12 Go toStep 13
2. Make sure the driver’s side door is open.
tween terminal 4 of the chime module and
ground.
13 1. Disconnect the front door contact switch. [0W Go toStep 15 Go toStep 14
tween the door contact switch and terminal 4 of
the chime module.
14 Repair the open circuit between the door contact System OK
switch and terminal 4 of the chime module.
15 Replace the door contact switch. System OK
Key Reminder Chime Inoperative

nected?
2 Connect the electrical connector for the chime mod- System OK Go toStep 3
ule.
Is fuse F2 blown?
4 1. Check for a short circuit and repair it, if neces- System OK Go toStep 3
sary.
module connector.

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8 1. Disconnect the key reminder switch. [0W Go toStep 10 Go toStep 9
tween the key reminder switch and fuse F2.
9 Repair the open circuit between the key reminder System OK
switch and fuse F2.
10 With the key reminder switch and the chime module [0W Go toStep 12 Go toStep 11
disconnected, check the continuity between the key
reminder switch and terminal 2 of the chime module
connector .
11 Repair the open circuit between the key reminder System OK
switch and terminal 2 of the chime module connec-
tor.
12 Replace the key reminder switch. System OK
meter to check continuity between terminal 5 of the
DAEWOO V–121 BL4
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SECTION : 9F
AUDIO SYSTEMS
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9F–1 REAR SPEAKERS (NOTCHBACK) . . . . . . . . . . 9F–9
FASTENER TIGHTENING SPECIFICATIONS . 9F–1 REAR SPEAKERS (HATCHBACK) . . . . . . . . . . 9F–11
SCHEMATIC AND ROUTING DIAGRAMS . . . . . 9F–2 MAST ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . 9F–11
AUDIO SYSTEM CIRCUIT . . . . . . . . . . . . . . . . . . 9F–2 GENERAL DESCRIPTION AND SYSTEM
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F–3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F–13
STEREO CASSETTE AM/FM RADIO . . . . . . . . 9F–3 STEREO CASSETTE AM/FM RADIO . . . . . . . 9F–13
SPEAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F–5 AUDIO SECURITY SYSTEM . . . . . . . . . . . . . . . 9F–13
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 9F–7 FRONT AND REAR SPEAKERS . . . . . . . . . . . 9F–13
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9F–7 MANUAL ANTENNA . . . . . . . . . . . . . . . . . . . . . . 9F–13
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 9F–7 TAPE PLAYER AND CASSETTE CARE . . . . . 9F–13
FRONT SPEAKERS . . . . . . . . . . . . . . . . . . . . . . . 9F–8 COMPACT DISC CARE . . . . . . . . . . . . . . . . . . . 9F–13
SPECIFICATIONS
Antenna Cap Nut 5 – 44
Audio System Screws 6 – 53
Front Speaker Screws 3.5 – 31
Mast Antenna Nuts 4 – 35
Rear Speaker Screws 3 – 27
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9F – 2IAUDIO SYSTEMS

AUDIO SYSTEM CIRCUIT

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AUDIO SYSTEMS 9F – 3
DIAGNOSIS
STEREO CASSETTE AM/FM RADIO
CD Player Inoperative, AM/FM Functions OK
1 Using a good–quality CD, determine if the CD player Go to Step 2 Go to Step 3
performs poorly or is inoperative.
Does the CD player function correctly?
2 Inform the customer that the problem is with the CD, System OK
not the CD player.
Has the customer been informed?
3 Check the CD player for obstructions behind the Go to Step 4 Go to Step 6
tape door.
Is an obstruction found?
4 Check to see if the obstruction can be removed. Go to Step 5 Go to Step 6
Can the obstruction be removed?
5 Remove the obstruction. System OK
6 Replace the CD player. System OK
AM/FM Cassette Radio Inoperative

1 Check fuses F6 and F9. Go to Step 2 Go to Step 3
Are fuses F6 and F9 blown?
sary.
2. Replace the blown fuses.
3 1. Use a voltmeter to test for battery voltage at 11–14 v Go to Step 5 Go to Step 4
fuse F6.
2. Turn the ignition ON and test for battery volt-
age at fuse F9.
Does the battery voltagematch the specified value at
fuses F6 and F9?
4 Repair the power supply circuit to the fuses. System OK
5 1. Remove the cassette radio. 11–14 v Go to Step 7 Go to Step 6
3. Use a voltmeter to test for battery voltage at
the audio system connector terminals 4 and 5.
Does the battery voltagematch the specified value at
both terminals?
6 Repair the open circuit between the audio system System OK
connector and the fuse.
7 Use an ohmmeter to test the ground circuit at the au- [0W Go to Step 9 Go to Step 8
dio system connector terminal 14.
Does the resistancematch the specified value?
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8 Repair the open ground circuit between the audio System OK
system connector and ground G201.
9 Replace the cassette radio. System OK
Cassette Player Inoperative, AM/FM Functions OK

1 Verify the customer complaint. Go to Step 5 Go to Step 2
Does the cassette player destroy tapes?
2 Using a good–quality tape, determine whether the Go to Step 5 Go to Step 3
cassette player performs poorly or is inoperative.
Does the cassette player perform poorly?
3 Check the cassette player for obstructions behind Go to Step 4 Go to Step 8
the tape door.
Is an obstruction found?
4 Check to see if the obstruction can be removed us- Go to Step 5 Go to Step 6
ing gentle force.
Is the obstruction removed?
5 Clean the cassette player head, the capstan, and the Go to Step 7 Go to Step 6
drive system.
Does the tape play properly?
7 Check the cassette player for normal operation. System OK
8 Advise the owner of a defective or worn tape. System OK
AM Does Not Work, FM and Cassette OK

1 Check the audio system for normal operation. Go to Step 2 System OK
Is AM inoperative and the rest of the system operat-
ing properly?
2 Replace the radio. System OK
FM Radio Does Not Work, AM and Cassette OK

1 1. Unplug the antenna cable from the antenna. Go to Step 2 Go to Step 3
2. Connect the test antenna to the antenna cable.
3. Check the FM radio reception.
Is the FM radio operating properly?
2 Replace the antenna. System OK

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3 1. Remove the cassette radio from the instrument Go to Step 4 Go to Step 5
panel.
2. Unplug the antenna cable from the audio sys-
tem.
3. Plug the test cable into the audio system.
4. Check the FM radio reception.
Is the FM radio operating properly?
4 Replace the antenna cable between the audio sys- System OK
tem and the antenna.
SPEAKERS
Front Speakers Distorted or Inoperative, Rest of Audio System OK
1 1. Turn the ignition and the radio ON. Go to Step 2 Go to Step 4
2. Check for distorted or inoperative front speak-
ers using the fader and the balance controls
with all of the sources (AM, FM, tape, CD).
Are the front speakers distorted?
2 Check the speaker and the door area for damage, Go to Step 3 Go to Step 4
rattles, or vibration.
Is there anything loose or in the way of the speaker
causing the distortion?
3 Make the necessary repairs to secure the compo- System OK
nent causing the distortion.
4 1. Remove the front speakers and disconnect the [0W Go to Step 6 Go to Step 5
speaker connector.
2. Using an ohmmeter, test the speaker wires for
a short to ground.
5 Repair the short circuit between the front speaker System OK
connector and the radio connector.
6 Substitute a known good speaker for the speaker Go to Step 7 Go to Step 8
causing the distortion.
Is the distortion eliminated?
7 Replace the speaker. System OK
Rear Speakers Distorted or Inoperative, Rest of Audio System OK
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1 1. Turn the ignition and the radio on. Go to Step 2 Go to Step 4
2. Check for distorted or inoperative rear speak-
ers using the fader and the balance controls
with all the of the sources (AM, FM, tape, CD).
Are the rear speakers distorted?
2 Check the speakers, the rear deck, and the trunk Go to Step 3 Go to Step 4
area for damage, rattles, or vibration.
Is there anything loose or in the way of the speaker
causing the distortion?
3 Make the necessary repairs to secure the compo- System OK
nent causing the distortion.
4 1. Disconnect the rear speakers. R Go to Step 6 Go to Step 5
2. Using an ohmmeter, test the speaker wires for
a short to ground.
5 Repair the short circuit between the rear speaker System OK
connector and the radio connector.
6 Substitute a known good speaker for the speaker Go to Step 7 Go to Step 8
causing the distortion.
Is the distortion eliminated?
7 Replace the speaker. System OK
8 Replace the audio system. System OK

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AUDIO SYSTEM
Removal Procedure

2. Remove the audio system trim plate.
3. Remove the screws and the audio system.
4. Disconnect the audio system electrical connector

and the antenna cable.
1. Connect the audio system electrical connector and

the antenna cable.
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2. Install the audio system with the screws.

Tighten
Tighten the audio system screws to 6 NSm (53 lb–in).
3. Install the audio system trim plate.
5. Enter the audio security system four–digit code.
Refer to ”Audio Security System” in this section.
FRONT SPEAKERS
Removal Procedure

2. Remove the front door trim panel. Refer to Section
9G, Interior Trim.
3. Remove the screws and the front speaker.

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2. Install the front speaker with the screws.

Tighten
Tighten the front speaker screws to 3.5 NSm (31 lbin).
3. Install the front door trim panel. Refer to Section
9G, Interior Trim.
REAR SPEAKERS (NOTCHBACK)

Removal Procedure

2. Remove the deck lid sill plate trim cover. Refer to
Section 9G, Interior Trim.
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4. Remove the screws and the rear speakers.
1. Install the rear speakers with the screws.

Tighten
Tighten the rear speaker screws to 3 NSm (27 lb–in).

3. Install the rear seatback and the rear seat cushion.
Refer to Section 9H, Seats.

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REAR SPEAKERS (HATCHBACK)

Removal Procedure
2. Remove the luggage compartment wheelhouse trim
panel (hatchback). Refer to Section 9G, Interior
Trim.
4. Remove the screws and the rear speaker.
1. Install the rear speaker with the screws.
Tighten
Tighten the rear speaker screws to 3 NSm (27 lb–in).
3. Install the luggage compartment wheelhouse trim
panel (hatchback). Refer to Section 9G, Interior
Trim.
MAST ANTENNA
Removal Procedure

2. Remove the luggage compartment rear quarter trim
3. Unscrew and remove the top half of the mast an-
tenna.
4. Remove the antenna cap nut and the rubber grom-
met.
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5. Disconnect the antenna cable.

6. Remove the nut and the mast antenna.

1. Install the mast antenna with the nut.
Tighten
Tighten the mast antenna nut to 4 NSm (35 lb–in).
2. Connect the antenna cable.

3. Install the rubber grommet and the antenna cap
nut.
Tighten
Tighten the antenna cap nut to 5 NSm (44 lb–in).
4. Install the top half of the mast antenna.
5. Install the luggage compartment rear quarter trim

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3) Press the preset button No. 3, and ”123–” will

GENERAL DESCRIPTION appear.
4) Press the preset button No. 4, and ”1234” will
AND SYSTEM OPERATION appear and flash three times.
3. The audio system will function and will transfer to
STEREO CASSETTE AM/FM RADIO the radio.
The stereo cassette AM/FM radio is standard and the If you fail to enter the correct security number into the unit,
compact disc player is offered as optional equipment. All ”Err” will appear followed by ”COdE”. In addition, several
audio systems use four speakers: two speakers mounted audible beeps will be heard. If this happens, repeat the
in the front doors and two speakers mounted behind the procedure beginning with Step 2.
rear seats.
FRONT AND REAR SPEAKERS
AUDIO SECURITY SYSTEM All audio systems use four speakers: two speakers
The audio security system is activated whenever the audio mounted in the front doors and two speakers mounted in
system circuit is disconnected from the battery. A four– the rear deck lid sill plate, on the notchback. On the hatch-
digit security code must be entered for the audio system back, the rear speakers are mounted in the luggage
to resume functioning. The security code is stamped on a compartment wheelhouse trim panel. A coaxial two–way
card located in the vehicle (usually in the glove box). The rear speaker is offered as an option.
following security code entering procedure must be used
to deactivate the audio security system: MANUAL ANTENNA
The two–piece mast antenna is standard equipment. The
Model AKF–4306 mast antenna is designed to withstand car washes without
1. After connecting the audio system to the battery, damage. The upper portion of the antenna can be un-
the warning LED will flash. screwed and removed if height clearance problems occur.
2. Turn the audio system on and ”COdE” will flash on If the mast becomes slightly bent, it can be straightened
the display along with an audible beep. by hand. The mast antenna can be replaced if it is severely
3. Enter the proper security number into the unit, us- bent. Mast antennas must be kept clean for good perfor-
ing the preset buttons No. 1 through 6. For exam- mance.
ple, if the security number is ”1234”:
1) Press the preset button No. 1. ”COdE” will dis- TAPE PLAYER AND CASSETTE
appear and ”1–––” will appear on the display.
2) Press the preset button No. 2, and ”12––” will
CARE
appear. The head and the capstan are the two parts of the tape
3) Press the preset button No. 3, and ”123–” will player that should be cleaned. This service should be per-
appear. formed every 100 hours of cassette operation.
4) Press the preset button No. 4, and ”1234” will In order to clean the head and the capstan, use a cotton
appear and flash three times. swab dipped in rubbing alcohol.
4. The audio system will function and will transfer to A cassette cleaning kit may also be used to clean the head
the radio. and the capstan. Follow the cleaning kit instructions to
If you fail to enter the correct security number into the unit, clean the tape player.
”Err” will appear followed by ”COdE”. In addition, several
Do not touch the tape head with magnetized tools. If the
audible beeps will be heard. If this happens, repeat the
head becomes magnetized, it will degrade cassettes
procedure beginning with Step 3.
played in the player. No service is performed on the cas-
Models AKF–0816W and AKD–4342W settes. The cassette manufacturer handles warranties of
the cassettes. Store cassettes away from extreme heat
1. After connecting the audio security system to the
and direct sunlight.
battery, ”COdE” will flash on the display.
2. Enter the proper security number into the unit, us-
ing the preset buttons No. 1 through 8. For exam-
COMPACT DISC CARE
ple, if the security number is ”1234”: Handle discs carefully. Store the discs in protective cases
1) Press the preset button No. 1. ”COdE” will dis- away from the sun, heat, and dust. If the surface is soiled,
appear and ”1–––” will appear on the display. dampen a clean, soft cloth in a solution of mild neutral de-
2) Press the preset button No. 2, and ”12––” will tergent and wipe the disc clean.
appear.
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SECTION : 9G
INTERIOR TRIM
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9G–2 REAR ROCKER TRIM PANEL . . . . . . . . . . . . . 9G–17
FASTENER TIGHTENING FLOOR CARPET . . . . . . . . . . . . . . . . . . . . . . . . . 9G–17
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 9G–2 FLOOR CONSOLE . . . . . . . . . . . . . . . . . . . . . . . 9G–20
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G–2 A–PILLAR TRIM PANEL . . . . . . . . . . . . . . . . . . . 9G–23
SPECIAL TOOLS TABLE . . . . . . . . . . . . . . . . . . . 9G–2 C–PILLAR TRIM PANEL . . . . . . . . . . . . . . . . . . . 9G–24
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 9G–3 C–PILLAR TRIM PANEL . . . . . . . . . . . . . . . . . . . 9G–26
FRONT DOOR ESCUTCHEON . . . . . . . . . . . . 9G–26
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9G–3
LUGGAGE COMPARTMENT
FRONT DOOR TRIM PANEL . . . . . . . . . . . . . . . 9G–3
WHEELHOUSE TRIM PANEL . . . . . . . . . . . . 9G–27
REAR DOOR TRIM PANEL . . . . . . . . . . . . . . . . . 9G–5
LUGGAGE COMPARTMENT
UPPER B–PILLAR TRIM PANEL . . . . . . . . . . . . 9G–7 WHEELHOUSE TRIM PANEL . . . . . . . . . . . . 9G–28
UPPER B–PILLAR TRIM PANEL . . . . . . . . . . . . 9G–9 LUGGAGE COMPARTMENT
LOWER B–PILLAR TRIM PANEL . . . . . . . . . . . 9G–11 REAR QUARTER TRIM PANEL . . . . . . . . . . 9G–28
LOWER B–PILLAR TRIM PANEL . . . . . . . . . . . 9G–11 LUGGAGE COMPARTMENT
DECK LID SILL PLATE COVER . . . . . . . . . . . . 9G–13 REAR TRIM PANEL . . . . . . . . . . . . . . . . . . . . . 9G–29
REAR DOOR INTERIOR GENERAL DESCRIPTION AND SYSTEM
GARNISH MOLDING . . . . . . . . . . . . . . . . . . . . 9G–13 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G–30
HATCHBACK DOOR UPPER INTERIOR TRIM PANELS . . . . . . . . . . . . . . . . . 9G–30
GARNISH MOLDING . . . . . . . . . . . . . . . . . . . . 9G–14 PRESSURE RELIEF VENT . . . . . . . . . . . . . . . . 9G–30
HATCHBACK DOOR LOWER FLOOR CONSOLE . . . . . . . . . . . . . . . . . . . . . . . 9G–30
GARNISH MOLDING . . . . . . . . . . . . . . . . . . . . 9G–15 FLOOR CARPET . . . . . . . . . . . . . . . . . . . . . . . . . 9G–30
KICK PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9G–15 REAR COMPARTMENT SECURITY
FRONT ROCKER TRIM PANEL . . . . . . . . . . . . 9G–16 COVER (HATCHBACK) . . . . . . . . . . . . . . . . . 9G–30
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9G – 2IINTERIOR TRIM
SPECIFICATIONS
Door Pull Screw 3.5 – 31
Floor Console Brace Bolts 5 – 44
Front Floor Console Screws 4 – 35
Gearshift Housing Bolts 5 – 44
Rear Floor Console Screws 4 – 35
Rear Seat Belt Anchor Bolts 38 28 –
Rear Seatback Bolt 25 18 –
Seat Belt Anchor Bolts 38 28 –
Seat Belt Bracket Screws 10 – 89
Trim Panel Screws 3.5 – 31
SPECIAL TOOLS
SPECIAL TOOLS TABLE
KM–475–B
Trim Remover

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INTERIOR TRIM 9G – 3

FRONT DOOR TRIM PANEL
Tools Required
KM–475–B Trim Remover
Removal Procedure
1. Lower the front window.

2. Remove the door pull screw.
3. Pry off the inside door handle trim bezel.
4. Remove the screws at the base of the trim panel.

5. Pry off the trim panel using the trim remover
KM–475–B.
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1. Install the trim panel.

2. Install the screws at the base of the trim panel.
Tighten
Tighten the trim panel screws to 3.5 NSm (31 lb–in).
3. Install the inside door handle trim bezel.
4. Install the door pull screw.

Tighten
Tighten the door pull screw to 3.5 NSm (31 lb–in).
5. Raise the window.

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REAR DOOR TRIM PANEL

Tools Required
Removal Procedure
1. Lower the rear window.

2. Remove the rear window regulator handle. Refer to
Section 9P, Doors.
3. Remove the door pull screw.
4. Pry off the inside door handle trim bezel.
5. Remove the rear door interior garnish molding.

6. Remove the screws at the base of the trim panel.
7. Pry off the trim panel using the trim remover
KM–475–B.
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1. Install the trim panel.

2. Install the screws at the base of the trim panel.
Tighten
3. Install the rear door interior garnish molding.

4. Install the inside door handle trim bezel.
5. Install the door pull screw.

Tighten
Tighten the door pull screw to 3.5 NSm (31 lb–in).
6. Install the rear window regulator handle. Refer to
Section 9P, Doors.

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UPPER B–PILLAR TRIM PANEL

(NOTCHBACK)
Removal Procedure
1. Remove the bolt and the upper front seat belt an-
chor.
2. Remove the lower B–pillar trim panel. Refer to

”Lower B–Pillar Trim Panel (Notchback)” in this
section.
4. Pry off the upper B–pillar trim panel.
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1. Install the upper B–pillar trim panel.

Tighten
lbin).
3. Install the lower B–pillar trim panel. Refer to ”Lower

B–Pillar Trim Panel (Notchback)” in this section.
4. Install the upper front seat belt anchor with the bolt.
Tighten

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UPPER B–PILLAR TRIM PANEL

(HATCHBACK)
Removal Procedure
1. Remove the bolt and the upper front seat belt an-
chor.

”Lower B–Pillar Trim Panel (Hatchback)” in this sec-
tion.
3. Remove the C–pillar trim panel. Refer to ”C–Pillar
Trim Panel (Hatchback)” in this section.
5. Remove the screw and the upper B–pillar trim pan-

el.
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1. Install the upper B–pillar trim panel with the screw.
Tighten
Tighten the trim panel screw to 3.5 NSm (31 lb–in).

Tighten
lbin).
3. Install the C–pillar trim panel. Refer to ”C–Pillar

Trim Panel (Hatchback)” in this section.
tion.
5. Install the upper front seat belt anchor with the bolt.
Tighten

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LOWER B–PILLAR TRIM PANEL

(NOTCHBACK)
Removal Procedure
1. Reposition the rear portion of the front rocker trim
panel and the front portion of the rear rocker trim
panel.
2. Pry off the lower B–pillar trim panel.
1. Install the lower B–pillar trim panel.
2. Install the front rocker trim panel.
3. Install the rear rocker trim panel to its original posi-
tion.
LOWER B–PILLAR TRIM PANEL

(HATCHBACK)
Removal Procedure
1. Reposition the rear portion of the front rocker trim

panel.
2. Remove the rear seatback and the cushion. Refer
to Section 9H, Seats.
3. Remove the bolt and the lower rear seat belt an-
chor.
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4. Remove the lower B–pillar trim panel.
1. Install the lower B–pillar trim panel.

2. Install the lower rear seat belt anchor with the bolt.
Tighten
Tighten the rear seat belt anchor bolt to 38 NSm (28
lb–ft).
3. Install the rear seatback and the cushion. Refer to
Section 9H, Seats.
4. Install the rear portion of the front rocker trim panel
to the original position.

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DECK LID SILL PLATE COVER

(NOTCHBACK)
Removal Procedure
1. Lower the folding rear seatback.
2. Remove the center high–mounted stoplamp. Refer
to Section 9B, Lighting Systems.
3. Remove the child seat tether anchor. Refer to Sec-
tion 8A, Seat Belts.
4. Remove the plastic retaining clips and the deck lid
sill plate cover.
1. Install the rear deck lid sill plate cover with the plas-
tic retaining clips.
2. Install the center high–mounted stoplamp. Refer to
Section 9B, Lighting Systems.
3. Install the child seat tether anchor. Refer to Section
8A, Seat Belts.
4. Raise and secure the rear seatback.
REAR DOOR INTERIOR GARNISH

MOLDING
Removal Procedure
1. Pry off the rear door interior garnish molding.
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1. Install the rear door interior garnish molding.
HATCHBACK DOOR UPPER

GARNISH MOLDING
Removal Procedure
1. Open the hatchback door.
2. Pry off the hatchback door upper garnish molding.
1. Install the hatchback door upper garnish molding.
2. Close the hatchback door.

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HATCHBACK DOOR LOWER

GARNISH MOLDING
Tools Required
Removal Procedure
2. Remove the lower garnish molding clips using the
trim remover KM–475–B.
3. Remove the lower garnish molding.
1. Install the lower garnish molding with the clips.
KICK PANEL
Removal Procedure
1. Remove the kick panel fastener.
2. Pry off the kick panel.
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1. Install the kick panel.
2. Install the kick panel fastener.
FRONT ROCKER TRIM PANEL

Similar)
Removal Procedure
1. Pry off the front rocker trim panel.
1. Install the front rocker trim panel.

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REAR ROCKER TRIM PANEL

Removal Procedure
1. Remove the rear seat cushion and rear seatback.
Refer to Section 9H, Seats.
2. Remove the screw securing the rear rocker trim
panel.
3. Pry off the rear rocker trim panel.
1. Install the rear rocker trim panel.
2. Install the rear rocker trim panel with the screw.
3. Install the rear seatback with the bolt.
Tighten
Tighten the rear seatback bolt to 25 NSm (18 lb–ft).
Seats.
FLOOR CARPET

Similar)
Removal Procedure

2. Remove the left and the right rear rocker trim pan-
els. Refer to ”Rear Rocker Trim Panel” in this sec-
tion.
3. Remove the bolts and the left and the right lower
front seat belt anchors from the B–pillar.
4. Remove the left and the right lower B–pillar trim
panels. Refer to ”Lower B–Pillar Trim Panel” in this
section.
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5. Remove the front seats. Refer to Section 9H,

Seats.
6. Remove the left and the right kick panels. Refer to
”Kick Panel” in this section.
7. Pry off the left and the right front rocker trim panels.
8. Remove the floor console. Refer to ”Floor Console”
in this section.
9. Remove the gearshift housing bolts, (if equipped).
10. Reposition the gearshift housing, (if equipped).

11. Remove the bolts and the nuts and the floor con-
sole braces.
12. Disconnect the airbag control module electrical con-
nector.
13. Remove the floor carpet.
1. Install the floor carpet.

2. Connect the airbag control module electrical con-
nector.
3. Install the floor console braces with the bolts and
the nuts.
Tighten
Tighten the floor console brace bolts to 5 NSm (44 lb–
in).

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4. Install the gearshift housing to its original position,

(if equipped).
5. Install the gearshift housing bolts, (if equipped).
Tighten
Tighten the gearshift housing bolts to 5 NSm (44 lb–
in).
6. Install the floor console. Refer to ”Floor Console” in

this section.
7. Install the left and the right front rocker trim panels.
8. Install the left and the right kick panels. Refer to
”Kick Panel” in this section.
9. Install the front seats. Refer to Section 9H, Seats.
10. Install the left and the right lower B–pillar trim pan-
els. Refer to ”Lower B–Pillar Trim Panel” in this
section.
11. Install the left and the right lower front seat belt an-
chors to the B–pillar with the bolts.
Tighten
Tighten the seat belt anchor bolts to 35 NSm (26 lb–ft).
12. Install the rear seatback. Refer to Section 9H,
Seats.
13. Install the left and the right rear rocker trim panels.
Refer to ” Rear Rocker Trim Panel” in this section.
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FLOOR CONSOLE
Removal Procedure

2. Slide the front seats forward.
3. Remove the screws and the rear portion of the floor
console.
4. Disconnect the power window controls’electrical

connector.
5. Remove the gearshift lever boot, (if equipped).

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6. Remove the screws from the front portion of the

floor console.
7. Disconnect the cigar lighter electrical connector.

8. Remove the front portion of the floor console.
1. Connect the cigar lighter electrical connector.
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2. Install the front portion of the floor console with the

screws.
Tighten
Tighten the front floor console screws to 4 NSm (35 lb–
in).
3. Connect the power window controls’ electrical con-

nector.
4. Install the gearshift lever boot, (if equipped).

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5. Install the rear portion of the floor console with the

screw.
Tighten
Tighten the rear floor console screws to 4 NSm (35
lbin).
A–PILLAR TRIM PANEL

Removal Procedure
1. Pry off the A–pillar trim panel.
1. Install the A–pillar trim panel.
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C–PILLAR TRIM PANEL

(NOTCHBACK)
Removal Procedure
1. Remove the rear seat cushion. Refer to Section 9H,

Seats.
2. Remove the bolt and the rear seat belt floor anchor.
3. Pry off the C–pillar trim panel from the body.
4. Remove the seat belt trim piece.

5. Remove the C–pillar trim panel from the seat belt.

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1. Feed the seat belt through the C–pillar trim panel.

2. Install the seat belt trim piece.
3. Install the C–pillar trim panel.
4. Install the rear seat belt floor anchor with the bolt.
Tighten
Tighten the rear seat belt anchor bolt to 38 NSm (28
lb–ft).
Seats.
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C–PILLAR TRIM PANEL

(HATCHBACK)
Removal Procedure
tion.
2. Remove the screws, the clip, and the C–pillar trim
panel.
3. Remove the seat belt from the C–pillar trim panel.
1. Feed the seat belt through the C–pillar trim panel.
2. Install the C–pillar trim panel with the clip and the
screws.
Tighten
Install the lower B–pillar trim panel. Refer to ”Lower B–Pil-
lar Trim Panel (Hatchback)” in this section.
FRONT DOOR ESCUTCHEON

Removal Procedure
1. Pry off the escutcheon.

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1. Install the escutcheon.
LUGGAGE COMPARTMENT
WHEELHOUSE TRIM PANEL
(NOTCHBACK)
Removal Procedure
1. Remove the rear seatback. Refer to Section 9H,
Seats.
2. Remove the plastic retaining clips and the rear
seatback panel.
3. Remove the plastic retaining clips and the wheel-
house trim panel.
1. Install the wheelhouse trim panel with the plastic
retaining clips.
2. Install the rear seatback panel with the plastic re-
taining clips.
3. Install the rear seatback. Refer to Section 9H,
Seats.
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LUGGAGE COMPARTMENT
WHEELHOUSE TRIM PANEL
(HATCHBACK)
Removal Procedure
1. Remove the luggage compartment rear trim panel.
Refer to ”Luggage Compartment Rear Trim Panel”
in this section.
2. Remove the screw, the clips, and the wheelhouse
trim panel.
1. Install the wheelhouse trim panel with the clips and
the screw.
Tighten
Tighten the trim panel screw to 3.5 NSm (31 lb–in).
2. Install the luggage compartment rear trim panel.
Refer to ”Luggage Compartment Rear Trim Panel”
in this section.
LUGGAGE COMPARTMENT REAR

QUARTER TRIM PANEL
(NOTCHBACK)
Removal Procedure
1. Remove the plastic retaining clips and the rear
quarter trim panel.

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1. Install the rear quarter trim panel with the plastic
retaining clips.
LUGGAGE COMPARTMENT REAR

TRIM PANEL
Similar)
Removal Procedure
1. Remove the plastic retaining clips and the rear trim
panel.
1. Install the rear trim panel with the plastic retaining
clips.
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hicle and extends from under the center of the instrument

GENERAL DESCRIPTION panel to the rear seat area. The front portion of the console
contains the cigar lighter and the transaxle shift lever. The
AND SYSTEM OPERATION rear portion of the console contains the parking brake le-
ver, the power window switches, (if equipped), and a cu-
pholder.
INTERIOR TRIM PANELS
The sensing and diagnostic module (SDM) for the airbag
The interior trim panels are molded plastic and fasten with
system is located under the front part of the console.
screws or plastic clips.
FLOOR CARPET
PRESSURE RELIEF VENT
The molded one–piece floor carpet goes over both the
When all the windows are closed and the ventilation sys- front and the rear floor pans.
tem is on, the addition of outside air to the interior of the
vehicle causes a positive pressure within the vehicle. In or- REAR COMPARTMENT SECURITY
der to relieve the pressure, air is released through two
pressure relief vents. The pressure relief vents are located COVER (HATCHBACK)
at the rear quarter of the vehicle, behind the bumper fas- A rear compartment security cover is provided on the
cia. hatchback model. The security cover is attached to the
hatch and can be easily removed if more cargo space is
FLOOR CONSOLE needed.
The floor console fits over the tunnel in the floor of the ve-

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SECTION : 9H
SEATS
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9H–1 FRONT SEAT COVER . . . . . . . . . . . . . . . . . . . . . 9H–8
FASTENER TIGHTENING SPECIFICATIONS . 9H–1 REAR SEAT CUSHION . . . . . . . . . . . . . . . . . . . . 9H–9
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 9H–2 SPLIT REAR SEATBACK . . . . . . . . . . . . . . . . . . 9H–10
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9H–2 REAR SEATBACK LOCK STRIKER . . . . . . . . 9H–11
FRONT BUCKET SEATS . . . . . . . . . . . . . . . . . . . 9H–2 REAR SEATBACK LOCK ASSEMBLY . . . . . . . 9H–13
HEAD RESTRAINT . . . . . . . . . . . . . . . . . . . . . . . . 9H–3 SEAT COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . 9H–13
FRONT SEATBACK . . . . . . . . . . . . . . . . . . . . . . . 9H–4 CHILD SEAT ANCHORAGE . . . . . . . . . . . . . . . 9H–14
FRONT SEAT CUSHION . . . . . . . . . . . . . . . . . . . 9H–5 GENERAL DESCRIPTION AND SYSTEM
FRONT SEAT ADJUSTERS . . . . . . . . . . . . . . . . 9H–6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9H–15
HEIGHT ADJUSTMENT KNOBS . . . . . . . . . . . . 9H–7 SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9H–15
SPECIFICATIONS
Height Adjustment Knob Screw 12 – 106
Front Bucket Seat Bolts 25 18 –
Front Seat Belt Buckle Bolt 24 28 –
Front Seat Cover Screw 12 – 106
Front Seat Cushion Bolts 17 13 –
Front Seatback Bolts 45 33 –
Lock Assembly Screws 20 15 –
Lock Striker Bolts 24 18 –
Lower Rear Seat Belt Anchor Bolt 38 28 –
Rear Seat Cushion Bolt 25 18 –
Rear Seatback Bolts 25 18 –
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9H – 2ISEATS

FRONT BUCKET SEATS
Removal Procedure
1. Remove the plastic caps to reveal the bolts that

secure the rear portion of the front seat to the floor.
2. Remove the bolts that secure the rear portion of the
seat to the floor.
3. Remove the bolts that secure the front portion of

the front seat to the floor.
4. Disconnect the electrical connector from the driv-
er’s seat.
5. Remove the seat.
1. Install the seat.

2. Connect the electrical connector to the driver’s
seat.
3. Install the bolts into the front portion of the front
seat.
Tighten
Tighten the front bucket seat bolts to 25 NSm (18 lbft).

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SEATS 9H – 3
4. Install the bolts into the rear portion of the front

seat.
Tighten
Tighten the front bucket seat bolts to 25 NSm (18 lbft).
5. Install the plastic caps.
HEAD RESTRAINT
Removal Procedure
1. Press the head restraint adjust button and remove

the head restraint from the seatback.
2. Insert two flathead screwdrivers down the front and

the back side of the guide sleeves.
3. With the screwdrivers, press in the retaining latches
and remove the guide sleeves.
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9H – 4ISEATS
1. Install the guide sleeves into the seatback, making
sure the angle of the guide sleeves is parallel to the
seatback. Press down in order to engage the guide
sleeve retaining latches.
2. Install the head restraint into the guide sleeves.
Press down in order to engage the stop pin.
FRONT SEATBACK
Removal Procedure
1. Remove the front bucket seat from the vehicle. Re-

fer to ”Front Bucket Seats” in this section.
2. Remove the recliner adjustment knob cap and the
recliner adjustment knob.
3. Remove the bolt and seat belt buckle.

4. Remove the front seat cover. Refer to ”Front Seat
Cover” in this section.
5. Remove the clips and the seatback bolts.
6. Remove the seatback.

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SEATS 9H – 5
1. Install the seatback onto the seat cushion.

2. Install the clips and the seatback bolts.
Tighten
Tighten the front seatback bolts to 45 NSm (33 lb–ft).
3. Install the front seat cover. Refer to ”Front Seat

Cover” in this section.
4. Install the seat belt buckle with the bolt.
Tighten
Tighten the front seat belt buckle bolt to 38 NSm (28
lb–ft).
5. Install the recliner adjustment knob and the recliner
adjustment knob cap.
6. Install the front bucket seat in the vehicle. Refer to
”Front Bucket Seats” in this section.
FRONT SEAT CUSHION

Removal Procedure
1. Remove the seatback. Refer to ”Front Seatback” in

this section.
2. Remove any remaining front seat cover.
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9H – 6ISEATS
3. Remove the seat cushion bolts.

4. Remove the cushion from the seat adjuster.
1. Install the seat cushion to the seat adjuster with the
bolts.
Tighten
Tighten the front seat cushion bolts to 17 NSm (13
lbft).
2. Install the seatback. Refer to ”Front Seatback” in
this section.
3. Install all remaining front seat cover.
Tighten
Tighten the front seat cover screw to 12 NSm (106
lbin).
FRONT SEAT ADJUSTERS
Removal Procedure
1. Remove the seatback. Refer to ”Front Seatback” in
this section.
2. Remove any remaining seat cushion trim.
3. Remove the seat cushion bolts and the front seat
adjusters from the seat cushion.

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SEATS 9H – 7
1. Install the front seat adjusters to the seat cushion
with the bolts.
Tighten
Tighten the front seat cushion bolts to 17 NSm (13
lbft).
2. Install the seatback. Refer to ”Front Seatback” in
this section.
3. Install all remaining front seat cover.
Tighten
lbin).
HEIGHT ADJUSTMENT KNOBS
Removal Procedure
1. Remove the screw and the height adjustment knob.
1. Install the height adjustment knob with the screw.
Tighten
Tighten the front seat height adjustment knob screw
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9H – 8ISEATS
FRONT SEAT COVER

Removal Procedure
1. Remove the front bucket seat from the vehicle. Re-

fer to ”Front Bucket Seats” in this section.
2. Remove the recliner adjustment knob cap and the
recliner adjustment knob.
3. Remove the upper seat cover.
4. Remove the screw and the lower seat cover.

may corrode repidly. Make sure to use the correct fasten-
1. Install the lower seat cover with the screw.
Tighten
lbin).

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SEATS 9H – 9
2. Install the upper seat cover with new pin.

3. Install the recliner adjustment knob and the recliner
adjustment cap.
4. Install the front bucket seat in the vehicle. Refer to
”Front Bucket Seats” in this section.
REAR SEAT CUSHION

Removal Procedure
1. Remove the bolt at the base of the rear seatback.
2. Lift and remove the rear seat cushion.
1. Insert the wire loops along the front edge of the

rear seat cushion into the recesses in the floor pan.
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9H – 10ISEATS
2. Install the rear seat cushion with the bolt.

Tighten
Tighten the rear seat cushion bolt to 25 NSm (18 lb–ft).
SPLIT REAR SEATBACK

Removal Procedure
1. Lower the rear seatbacks.
2. Remove the bolts that secure the rear seatbacks to
the hinges.
3. Remove the rear seatbacks by pulling the seat
hinge posts out of the lower C–pillars.
1. Install the rear seatback by inserting the seat hinge
posts into the lower C–pillars.
2. Install the seatbacks to the hinges with the bolts.
Tighten
Tighten the rear seatback bolts to 25 NSm (18 lb–ft).
3. Raise the rear seatbacks in the upright position.

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SEATS 9H – 11
REAR SEATBACK LOCK STRIKER

Removal Procedure
1. Remove the rear seat cushion. Refer to ”Rear Seat

Cushion” in this section.
2. Remove the rear seatback. Refer to ”Split Rear
Seatback” in this section.
3. Remove the C–pillar trim panel. Refer to Section
9G, Interior Trim.
4. Remove the bolt and the lower rear seat belt an-
chor.
5. Reposition the door opening weatherstrip. Refer

toSection 9P, Doors.
6. Remove the retaining clips and the lower C–pillar
trim panel.
7. Remove the bolts and the rear seatback lock strik-

er.
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9H – 12ISEATS

1. Install the rear seatback lock striker with the bolts.
Tighten
Tighten the lock striker bolts to 24 NSm (18 lb–ft).
2. Install the lower C–pillar trim panel with the retain-

ing clips.
3. Install the door opening weatherstrip to its original

position. Refer toSection 9P, Doors.
4. Install the lower rear seat belt anchor with the bolt.
Tighten
Tighten the lower rear seat belt anchor bolt to 38 NSm
(28 lb–ft).
5. Install the C–pillar trim panel. Refer to Section 9G,
Interior Trim.
6. Install the rear seatback. Refer to ”Split Rear Seat-
back” in this section.
7. 7. Install the rear seat cushion. Refer to ”Rear Seat
Cushion” in this section.

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SEATS 9H – 13
REAR SEATBACK LOCK ASSEMBLY

Removal Procedure
1. Remove the rear seatback lock release knob.
2. Reposition the rear seatback cover.
3. Remove the screws and the lock assembly.
1. Install the rear seatback lock assembly with the
screws.
Tighten
Tighten the lock assembly screws to 20 NSm (15 lbft).
2. Install the rear seatback cover to its original posi-
tion.
3. Install the rear seatback lock release knob.
SEAT COVERS
(Rear Seatback Cover Shown, Other
Seat Covers Similar)
Removal Procedure
1. Remove the seatback and/or the seat cushion. Re-
fer to ”Front Seatback,” ”Front Seat Cushion,” ”Split
Rear Seatback,” and/or ”Rear Seat Cushion” in
this section.
2. Remove the hog rings or the retaining clips from
the seatback and/or the seat cushion.
3. Remove the seat cover from the seatback and/or
the seat cushion.
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9H – 14ISEATS
1. Install the seat cover onto the seatback and/or the
seat cushion with the retaining clips or the new hog
rings.
2. Install the seatback and/or the seat cushion. Refer
to ”Front Seatback,” ”Front Seat Cushion,” ”Split
Rear Seatback,” and/or ”Rear Seat Cushion” in
this section.
CHILD SEAT ANCHORAGE

Removal Procedure
1. Remove child seat anchorage cover.
2. Remove bolt and the child seat anchorage.
1. Install the child seat anchorage with the bolt.
Tighten
Tighten the child seat anchorage bolt to 10 NSm (89
lb–in).
2. Install the child seat anchorage cover.

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SEATS 9H – 15
This vehicle is equipped with low–backed front bucket

GENERAL DESCRIPTION seats with separate head restraints and a three–passen-
ger split folding rear seat. Seat cushions and seatbacks
AND SYSTEM OPERATION have formed foam pads, which fit the contours of the full–
panel seatback frame assembly and the designed contour
SEATS of the seat cushion frame. There are no front seat forward
Important : Do not attempt to change the designed seat or rearward relocation provisions provided at either the
position by altering the designed seat adjuster–to–floor seat adjuster–to–seat frame or the seat adjuster– to–floor
pan anchor provisions or the seat adjuster–to–seat frame pan anchor attachments.
anchor provisions. Changing the seat position could affect
the performance of the seat system.
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SECTION : 9I
WATERLEAKS
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 9I–1 WATERLEAK DIAGNOSIS . . . . . . . . . . . . . . . . . . . 9I–2
RECOMMENDED MATERIALS FOR WATERLEAK
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9I–1 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . . 9I–5
WATERTEST STAND SPECIFICATIONS . . . . . . 9I–1 ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . 9I–5
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9I–2 WATERLEAK REPAIR . . . . . . . . . . . . . . . . . . . . . . 9I–5
SPECIFICATIONS
RECOMMENDED MATERIALS FOR WATERLEAK
REPAIRS
Leak Areas Repair Materials
Windshield, back window Urethane adhesive, caulking kit, or the equivalent
Metal joints Brushable seam sealer which can be painted
Ventilation ducts 3MT Auto Bedding and Glazing Compound or the equiva-
lent
Small cracks and pin holes 3MT Drip–Check Sealer or the equivalent
Large holes 3MT Automotive Joint and Seam Sealert
Weatherstrips 3MT 08011 Weatherstrip Adhesive or the equivalent
Bolts, studs, and screws Strip caulk
WATERTEST STAND SPECIFICATIONS

Nozzle Type Full jet spray nozzle #1/2 GG–25 or equivalent with a
60?³included angle
Nozzle Height Approximately 1,600 mm (63.0 in.) from the floor
Volume of Flow 14L (3.7 gal) per minute
Pressure 155 kPa (22.5 psi) measured at the nozzle
Windshield and A–Pillar Test Stand Position Approximately 30³ down, 45³ toward the rear, and aimed
at the corner of the windshield
B–Pillar Test Stand Position Approximately 30³ down, 45³ toward the rear, and aimed
at the center of the rear door
Back Window and Rear Deck Lid Test Stand Position Approximately 30³ down, 30³ toward the front and aimed
approximately 610 mm (24.0 in.) from the corner of the
back window
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9I – 2IWATERLEAKS
DIAGNOSIS
4. 1/2–inch Coupling
WATERLEAK DIAGNOSIS 5. 1/2–inch by 1/2–inch by 1/4–inch Reducing T (Right
The repair of waterleaks in the body requires proper test- Only)
ing and diagnosis. Repair waterleaks by adjusting the mis- 6. 1/2–inch Coupling (Left Only)
aligned parts and using the proper repair materials. First, 7. 1/2–inch Cross (Right Only)
determine what conditions cause the leak. For example, 8. 1/2–inch Tee (Left Only)
the leak may occur only when the vehicle is parked on an 9. 1/2–inch Pipe–to–Hose Nipple (Right Only)
incline, or water may appear only in the spare tire compart- 10. 5/8–inch Female Hose Coupling
ment. Second, test the area for the source of the leak us- 11. 5/8–inch Input Hose (2 Feet Long, Right Only)
ing the following testing methods. If the general leak area 12. 1/2–inch Close Nipple
is found, determine the exact entry point of the leak by us- 13. 1/2–inch Cross with Weld–on 1/2–inch Cap
ing a water hose or an air hose. If the general leak area is 14. 1/2–inch by 12–inch Nipple
not obvious, use the watertest stands to determine the 15. 1/2–inch Cap
area of the leak. It may be necessary to remove some inte- 16. 5/8–inch Female Hose Coupling
rior trim panels or some parts in order to locate the leaks. 17. 5/8–inch Cross Hose (12 Feet Long)
Important : It is necessary to find the origin of all the leaks 18. 5/8–inch Hose Quick Connect
before making any repairs. Random repairs may stop the 19. 1/2–inch Pipe–to–Hose Nipple
leak only temporarily and may make future repairs more 20. 1/2–inch by 30–inch Pipe (Straight)
difficult. Continue localized testing in the general area in 21. 1/4–inch Water Pressure Gauge (Right Only)
order to ensure that all leaks are found. 22. Set up the watertest stand leak test.
Generalized Testing
1. Set up the watertest stands.
23. Perform the watertest stand leak test. Refer to ”Wa-

tertest Stand Specifications” in this section.
24. If the local water pressure does not allow the re-
2. 1/2–inch by 36–inch Pipe quired water pressure of 155 kPa (22.5 psi), move
3. Full–jet Spray Nozzle #1/2 GG–25 or Equivalent both stands closer to the vehicle so that the water
Nozzle Height at 1,600 mm to the Floor spray overlaps.

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WATERLEAKS 9I – 3
Localized Testing (Spot Test)

1. Do localized testing with a water hose or an air
hose.
2. Begin testing by spraying the air or the water at the
base of the suspected leak area. Continue spraying
the air or the water upward until the leak is found.
Water Hose Test
1. Place another person inside the vehicle in order to

detect the location of the leak.
2. Use a water hose without a nozzle.
3. Begin spraying the water at the base of the sus-

pected leak area. Continue spraying the water up-
ward until the leak is found.
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9I – 4IWATERLEAKS
2. Blow air from inside the vehicle. The air pressure

should not exceed 205 kPa (29.7 psi).
3. Determine the location of the leaks from the
bubbles formed in the soapy water.
Air Hose Test

1. Apply soapy water to the outside of the vehicle in
the suspected leak area.

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WATERLEAKS 9I – 5

WATERLEAK REPAIR
Some waterleaks around the glass can be repaired with-
out removing the glass.
Important : This type of repair may be used only for ure-
thane– 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.
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9I – 6IWATERLEAKS
7. Prime the trimmed area with the primer.
8. Allow the primer to dry for 5 minutes.

9. Apply the adhesive over the leak and for a distance
of 75 to 100 mm (3 to 4 inches) on both sides of the
leak.
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 ma-
terial and the vehicle body in order to ensure a wa-
tertight 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,
re–test the area using the watertest stands. Do not use
localized testing procedures on the newly–repaired areas,
as the repair material may dislodge under abnormal pres-
sure.

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SECTION : 9J
WINDNOISE
TABLE OF CONTENTS
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–1 ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . 9J–2
WINDNOISE DIAGNOSIS . . . . . . . . . . . . . . . . . . . 9J–1 WINDNOISE REPAIR . . . . . . . . . . . . . . . . . . . . . . . 9J–2
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . . 9J–2
DIAGNOSIS
5. Internal windnoise is air leaving the vehicle and
WINDNOISE DIAGNOSIS should be repaired in the following manner.
CAUTION : An assistant should drive the vehicle
S In order to locate the leak, tape off the body lock
while the technician checks for the location of the
pillar pressure relief valves. This will cause air
windnoise, in order to prevent personal injury or ve-
pressure to build up inside the vehicle and en-
hicle damage.
hance the windnoise.
A test drive in the vehicle is necessary to accurately deter- S Use a stethoscope or a vacuum hose to locate
mine the location of the windnoise. Often there is a primary the leak.
leak and secondary leaks. Failure to repair all leaks will S Temporarily repair the leak with masking tape.
only reduce the windnoise, not eliminate it.
During the test drive the technician should bring the follow-
ing items to aid in determining the location of the wind-
noise.
S A mechanics stethoscope or vacuum hose
S Masking tape
S Strip caulk
S A china marking pencil
S A screwdriver
Perform the following steps in order to conduct the road
test:
1. Choose a route that includes smooth straight
streets that run in all four directions (north, south,
east, and west).
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: S Continue testing in order to determine if the
S The windnoise is caused by the wind. noise has been eliminated or if other leaks exist.
S The windnoise can be heard with the door glass S When all leaks have been found, return to the
lowered and while the vehicle is being driven. shop and make permanent repairs with the
S The windnoise is eliminated when tape is placed proper alignment techniques and sealing materi-
over various moldings and gaps. als.
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9J – 2IWINDNOISE
WINDNOISE REPAIR
Windnoise leak repairs are very similar to waterleak re-
pairs. Refer to Section 9I, Waterleaks.The actual proce-
dure depends on the type of seal being repaired.
Leaks around the door opening weatherstrips do not al-

ways indicate a faulty weatherstrip. A door or window ad-
justment may resolve the condition. Refer to Section 9P,
Doors or Section 9L, Glass and Mirrors.

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SECTION : 9K
SQUEAKS AND RATTLES
TABLE OF CONTENTS
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9K–1 ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9K–3
SQUEAK AND RATTLE DIAGNOSIS . . . . . . . . 9K–1 SQUEAK AND RATTLE REPAIR . . . . . . . . . . . . 9K–3
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 9K–3
DIAGNOSIS
SQUEAK AND RATTLE DIAGNOSIS
Rattle Coming From the Side Rail
Checks Action
Check the brake lines. S Tap lightly on the brake lines and listen for a rattle.
S Install plastic tie straps to secure the brake lines
tightly together.
Rattle Under Vehicle at Higher RPM

Checks Action
Check for heat shield contact with the underbody. S Raise the vehicle and perform a visual inspection.
S Bend the heat shield slightly to gain clearance from
the underbody.
Squeak From the Front of the Vehicle in Cold Weather

Checks Action
Check the front stabilizer shaft insulators. S While the vehicle is cold, perform a test drive and
achieve full front suspension travel by driving through
a dip in the road.
S Remove the insulators and wrap teflon tape around
the stabilizer shaft. Reinstall the insulators over the
tape.
Thump From Rear of Vehicle on Bumps

Checks Action
Check for a properly secured spare tire in the rear S Open the rear compartment and perform a visual
compartment. inspection of the spare tire and the tools.
S Tightly secure the spare tire and all tools.
S Perform a road test to verify that the noise is elimi-
nated.
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9K – 2ISQUEAKS AND RATTLES
Glass Knock Coming From the Rear of the Vehicle When Driving
Over Bumps
Checks Action
Check for an out–of–adjustment hatchback latch. S Test drive the vehicle in order to verify this condition.
S Loosen the latch nuts and adjust the latch downward.
Rattle Coming From Door

Checks Action
Check the door lock solenoid. S Remove the door trim panel and check if the sole-
noid is loose.
S Tighten the solenoid bolts.
Check for rattling electrical connectors inside the door trim S Tap on the trim panel and listen for a rattle.
panel. S Remove the trim panel and wrap foam padding
around the connectors as required.
Squeak When Operating Doors

Checks Action
Check for a lack of lubrication of the door hinge pins. S Operate the doors and listen for squeaks.
S Lubricate the door hinge pins with light oil and coat
with lithium grease.
Squeak Coming From Console When Shifting Manual Transaxle

(Condition Occurs In Cold Weather with a Cold Engine)
Checks Action
Check the manual transaxle control lever lower boot. S Move the control lever between gears and listen for
squeaks.
S Remove the floor console and replace the lower shift
boot or apply talcum powder to the lower shift boot.
Buzz From the Left Side of Instrument Panel

Checks Action
Check for vibration of the fuse box cover against the instru- S Tap on the cover with a finger and listen for a buzz.
ment panel side trim. S Apply 6.35 mm (0.250 inch) by 25.4 mm (1.00 inch)
felt pads to the side trim where the cover makes con-
tact.
Squeak Coming From Instrument Cluster Trim Plate

Checks Action
Check for rubbing of the cluster trim plate on the instru- S Test drive the vehicle in order to verify this condition.
ment panel. S Remove the instrument cluster trim plate and install
felt tape to the edges.

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SQUEAKS AND RATTLES 9K – 3

SQUEAK AND RATTLE REPAIR
Squeaks and rattles are caused by the unwanted move-
ment between parts of a vehicle. There are threemeans to
prevent squeaks or rattles.
S Attach the parts securely so that there is no relative
motion during the operation of the vehicle.
S Separate the parts so that there is no contact dur-
ing operation.
S Insulate the parts so that no squeaks or rattles oc-
cur with the movement of the parts. Low uniform
friction surfaces can be used to eliminate ”stick–
slip” motion.
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SECTION : 9L
GLASS AND MIRRORS

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L–2 WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L–8
FASTENER TIGHTENING REAR WINDOW GLASS . . . . . . . . . . . . . . . . . . . 9L–10
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 9L–2 REAR WINDOW DEFOGGER
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L–2 GRID LINE REPAIR . . . . . . . . . . . . . . . . . . . . . . 9L–12
SPECIAL TOOLS TABLE . . . . . . . . . . . . . . . . . . . . 9L–2 REAR WINDOW DEFOGGER BRAIDED
LEAD WIRE REPAIR . . . . . . . . . . . . . . . . . . . . . 9L–14
SCHEMATIC AND ROUTING DIAGRAMS . . . . . . 9L–3
FRONT DOOR GLASS . . . . . . . . . . . . . . . . . . . . . 9L–14
REAR WINDOW DEFOGGER . . . . . . . . . . . . . . . 9L–3
REAR DOOR GLASS . . . . . . . . . . . . . . . . . . . . . . 9L–15
ELECTRIC CONTROL OUTSIDE REARVIEW
MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L–4 MOVABLE QUARTER WINDOW . . . . . . . . . . . . 9L–17
INSIDE REARVIEW MIRROR . . . . . . . . . . . . . . . 9L–19
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L–4
OUTSIDE REARVIEW MIRRORS . . . . . . . . . . . 9L–20
TESTING REAR WINDOW DEFOGGER
GRID LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L–4 GENERAL DESCRIPTION AND SYSTEM
ELECTRIC CONTROL OUTSIDE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9L–22
REARVIEW MIRRORS . . . . . . . . . . . . . . . . . . . . 9L–5 STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . . . 9L–22
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . . 9L–8 INSIDE REARVIEW MIRROR . . . . . . . . . . . . . . . 9L–22
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . 9L–8 OUTSIDE REARVIEW MIRRORS . . . . . . . . . . . 9L–22
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9L – 2IGLASS AND MIRRORS
SPECIFICATIONS
Glass Screws 1.5 – 13
Door Glass Screws 7 – 62
Guide Rail Bolts 7 – 62
Movable Quarter Window Hinge Screws 3 – 27
Movable Quarter Window Latch Screws 3 – 27
Outside Rearview Mirror Assembly Screws 4.5 – 40
Rearview Mirror Mounting Screw 1.2 – 11
SPECIAL TOOLS
SPECIAL TOOLS TABLE
J–24402
Glass Sealant Remover

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GLASS AND MIRRORS 9L – 3

REAR WINDOW DEFOGGER
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ELECTRIC CONTROL OUTSIDE REARVIEW MIRROR
DIAGNOSIS
4. If a grid line is found to be open, move a voltmeter
TESTING REAR WINDOW terminal from one side of the grid line and retest at
DEFOGGER GRID LINE a point nearer to the other side of the window. Con-
tinue to retest, each time bringing one of the volt-
If it has been observed during use that a grid line is inop-
meter terminals closer to the opposite side of the
erative, the following procedure can be used to find the
window from where it was originally connected. The
break. If none of the grid lines is operating, a full system
break in the grid line is at the point where the volt-
diagnosis should be completed before attempting to repair
meter begins reading 0 volts instead of battery volt-
the grid lines.
age.
1. Turn the ignition ON. 5. Use a marking crayon to lightly mark the break
2. Turn on the rear window defogger. point on the rear window. Mark the glass instead of
Notice : Use care when touching the voltmeter terminals marking directly on the grid line, and make the
to a grid line. If the terminals are roughly applied, the grid mark far enough from the grid line so that the mark
line may be scratched, resulting in an open circuit. can easily be removed without disturbing the repair.
3. From the inside of the vehicle, connect a voltmeter 6. Use a grid line repair kit to fix the break in the grid
to each end of a grid line. The voltmeter will indi- line. Refer to ”Rear Window Defogger Grid Line
cate battery voltage if the grid line is open. Repair” in this section.

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ELECTRIC CONTROL OUTSIDE REARVIEW MIRRORS
Outside Rearview Mirror Does Not Adjust

1 Check the electric control mirror’s left–and–right and Go to Step 12 Go to Step 2
up–and–down adjustments.
Is the mirror operating for either the left–and–right or
up–and–down adjustments?
2 Check fuse F16. Go to Step 3 Go to Step 4
Is fuse F16 blown?
sary.
4 1. Turn the ignitionON. 11–14 v Go to Step 6 Go to Step 5
Is the voltage at fuse F16 equal to the specified val-
ue?
6 1. From below the instrument panel, reach up and Go to Step 8 Go to Step 7
press one of the retaining tabs for the electric
control mirror switch trim panel.
2. While pressing one of the retaining tabs, pull
the switch assembly away from the instrument
panel so that the connector is visible.
Is the connector properly connected to the electric
control mirror switch?
7 Connect the connector to the electric control mirror System OK
switch.
8 1. Disconnect the electric control mirror switch 11–14 v Go to Step 13 Go to Step 9
connector.
3. Connect a voltmeter between terminal 6 (ORN)
and terminal 8 (BLK).
9 1. Turn the ignition ON. 11–14 v Go to Step 10 Go to Step 11
2. Check the voltage at terminal 6 (ORN).
10 Repair the open circuit between ground and terminal System OK
8 (BLK).
electric control mirror switch.
12 Check the left–and–right adjustment for the electric Go to Step 18 Go to Step 13
control mirror.
Is the left–and–right adjustment working for the elec-
tric control mirror?
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13 1. Make sure the electric control mirror switch has 11–14 v Go to Step 17 Go to Step 14
been reconnected.
2. On the passenger door, remove the black plas-
tic escutcheon to expose the electric control
mirror connector.
3. Disconnect the connector at the passenger
door electric control mirror.
4. Connect a voltmeter between terminal 1 (GRY/
WHT) and terminal 3 (YEL).
5. Observe the voltmeter while operating the elec-
tric control mirror switch to select the left–and–
right adjustment.
Does the voltmeter indicate the specified voltage in
one direction, and the same voltage with reverse po-
larity when operated in the opposite direction?
14 1. Disconnect the electric control mirror switch [0W Go to Step 16 Go to Step 15
connector.
2. Use an ohmmeter to measure the continuity
between terminal 5 (RED/WHT) at the electric
control mirror switch and terminal 3 (YEL) at
the power mirror connector.
between terminal 4 (GRY/WHT) at the electric
control mirror switch and terminal 1 (GRY/
WHT) at the power mirror connector.
Does the ohmmeter indicate the specified value for
both measurements?
15 Repair the open circuit between the electric control System OK
mirror switch and the electric control mirror connec-
tor.
16 Replace the electric control mirror switch. System OK
17 Replace the electric control mirror. System OK

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18 1. If the electric control mirror switch was pre- Go to Step 17 Go to Step 19
viously disconnected for testing, make sure it is
reconnected.
2. Disconnect the electric control mirror connector
at the passenger door power mirror.
3. Connect a voltmeter between terminal 1 (GRY/
WHT) and terminal 2 (LT GRN).
4. Observe the voltmeter while operating the pow-
er mirror switch to select the up–and–down
adjustment.
Does the voltmeter indicate the specified voltage in
one direction, and the same voltage with reverse po-
larity when operated in the opposite direction?
19 1. Disconnect the electric control mirror switch [0W Go to Step 16 Go to Step 15
connector.
between terminal 1 (PPL/WHT) at the electric
control mirror switch and terminal 2 (LT GRN)
at the electric control mirror connector.
between terminal 4 (GRY/WHT) at the electric
control mirror switch and terminal 1 (GRY/
WHT) at the electric control mirror connector.
Does the ohmmeter indicate the specified value for
both measurements?
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WINDSHIELD
Tools Required
J–24402 Glass Sealant Remover
Removal Procedure
1. Remove the cowl vent grille. Refer to Section 9R,

Body Front End.
2. Remove the inside rearview mirror. Refer to”‘Inside
Rearview Mirror” in this section.
3. Remove the weatherstrip around the windshield.
4. Using the glass sealant remover J–24402, cut the
adhesive around the windshield.
5. Remove the windshield from the vehicle.

6. Using a knife, remove the adhesive from the wind-
shield.
7. Using a knife, remove the adhesive from the wind-
shield frame.

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1. Install the new weatherstrip to the windshield.
2. Apply tape to the new weatherstrip and the wind-

shield to hold the weatherstrip in place.
3. Apply adhesive primer to the windshield frame and
the perimeter of the windshield.e.
4. Apply glass adhesive to the windshield frame.

5. Install the windshield into the windshield frame.
6. Reposition the tape over the weatherstrip, the wind-
shield, and the windshield frame to hold the wind-
shield in place.
7. Let the adhesive dry for 24 hours.
8. Remove the tape.
9. Check for waterleaks by pouring water on the wind-
shield. If a leak is found, dry the windshield and fill
the area that leaks with adhesive. If the leak per-
sists, remove the windshield and repeat the entire
procedure.
10. Install the inside rearview mirror. Refer to ”‘Inside
Rearview Mirror” in this section.
11. Install the cowl vent grille. Refer to Section 9R,
Body Front End.
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REAR WINDOW GLASS

Similar)
Tools Required
J–24402 Glass Sealant Remover
Removal Procedure

2. Disconnect the rear window defogger electrical con-
nectors (left side electrical connector shown, right
side electrical connector similar).
3. Remove the weatherstrip around the rear window.
4. Using the glass sealant remover J–24402, cut the

adhesive around the rear window.

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5. Remove the rear window from the vehicle.

6. Using a knife, remove the adhesive from the rear
window.
7. Using a knife, remove the adhesive from the rear
window frame.
1. Install the new weatherstrip to the rear window.
2. Apply tape to the new weatherstrip and the rear

window to hold the weatherstrip in place.
3. Apply adhesive primer to the rear window frame
and the perimeter of the rear window.
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4. Apply glass adhesive to the rear window frame.
5. Install the rear window into the rear window frame.

6. Reposition the tape over the weatherstrip, the rear
window, and the rear window frame to hold the rear
window in place.
7. Let the adhesive dry for 24 hours.
8. Remove the tape.
9. Check for waterleaks by pouring water on the rear
window. If a leak is found, dry the window and fill
the area that leaks with adhesive. If the leak per-
sists, remove the rear window and repeat the entire
procedure.
10. Connect the rear window defogger electrical con-
REAR WINDOW DEFOGGER GRID

LINE REPAIR
2. Disconnect the rear window defogger electrical con-
3. Inspect the rear window defogger grid lines.
4. Mark the grid line break on the outside of the glass
with a wax pencil or a crayon.
5. Use steel wool to buff the grid lines that are to be
repaired. Wipe the lines clean using a cloth damp-
ened with alcohol. Buff and clean about 6 mm (0.25
inch) beyond each side of the break in the grid line.

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6. Attach a grid line repair decal or two strips of tape

above and below the repair areas.
S A repair decal or tapemust be used in order to
control the width of the repair areas.
S If a decal is used, the die–cut metered slot must
be the same width as the grid line.
7. Apply the grid repair material to the repair area us-
ing a small wooden stick or a spatula. The grid re-
pair material should be at room temperature.
8. Carefully remove the decal or the tape.
Notice : The grid line repair material must be cured with

heat. In order to avoid heat damage to the interior trim, pro-
tect the trim near the repair area where heat will be ap-
plied.
9. Heat the repair area for 1 to 2 minutes.
10. Hold the heat gun nozzle 25 mm (1 inch) from the
surface. A minimum temperature of 149³C (300³F)
is required.
11. Inspect the grid line repair area. If the repair ap-
pears discolored, apply a coating of tincture of io-
dine to the area using a pipe cleaner or a line
brush. Allow the iodine to dry for about 30 seconds.
Carefully wipe off the excess iodine with a lint–free
cloth.
12. Connect the rear window defogger electrical con-
nectors.
13. Test the operation of the rear window defogger in
order to verify that the repair was successful.
Important : At least 24 hours is required for complete cur-
ing of the repair materials. The repair area should not be
physically disturbed until after that time.
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REAR WINDOW DEFOGGER

BRAIDED LEAD WIRE REPAIR
The rear window defogger bus lead wire or the terminal
can be reattached by resoldering. Use a solder containing
3 percent silver and a rosin flux paste.
1. The repair area should be buffed with fine steel
wool before soldering the bus lead wire.
2. Apply the paste–type rosin flux in small quantities
to the wire lead and the bus lead wire repair area
using a brush.
3. Coat the soldering iron tip with solder. Use only
enough solder to ensure a complete repair.
4. Use only enough heat to melt the solder. Do not
overheat the wire when resoldering to the bus lead
wire.
FRONT DOOR GLASS

Similar)
Removal Procedure
1. Remove the front door trim panel. Refer to Section

9G, Interior Trim.
2. Remove the door seal trim. Refer to Section 9P,
Doors.
3. Remove the outside channel molding. Refer to Sec-
tion 9P, Doors.
4. Remove the screws that secure the glass to the
window regulator.
5. Remove the bolts and the guide rail.

6. Remove the glass from the door.

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1. Install the glass in the door.

2. Install the guide rail and the bolts.
Tighten
Tighten the guide rail bolts to 7 NSm (62 lb–in).
3. Install the glass to the window regulator with the

screws.
Tighten
Tighten the door glass screws to 7 NSm (62 lb–in).
4. Install the outside channel molding. Refer to Sec-
tion 9P, Doors.
5. Install the door seal trim. Refer to Section 9P,
Doors.
6. Install the front door trim panel. Refer to Section
9G, Interior Trim.
REAR DOOR GLASS

Removal Procedure
1. Remove the rear door trim panel. Refer to Section

9G, Interior Trim.
2. Remove the outside channel molding. Refer to Sec-
tion 9P, Doors.
3. Remove the interior rear door garnish molding.
4. Remove the screws and the exterior rear door gar-
nish molding.
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5. Remove the door seal trim. Refer to Section 9P,

Doors.
6. Remove the screws that secure the glass to the
window regulator.

8. Remove the glass from the door.
1. Install the glass in the door.

2. Install the guide rail and the bolts.
Tighten

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3. Position the glass within the window regulator.

4. Install the glass screws.
Tighten
Tighten the door glass screws to 7 NSm (62 lb–in).
5. Install the door seal trim. Refer to Section 9P,

Doors.
6. Install the exterior rear door garnish molding with
the screws.
Tighten
Tighten the exterior rear door garnish molding screws
to 1.5 NSm (13 lb–in).
7. Install the interior rear door garnish molding.
8. Install the outside channel molding. Refer to Sec-
tion 9P, Doors.
9. Install the rear door trim panel. Refer to Section
9G, Interior Trim.
MOVABLE QUARTER WINDOW

(THREE–DOOR HATCHBACK)
Removal Procedure
1. Remove the front seat belt height adjuster. Refer to

Section 8A, Seat Belts.
2. Remove the B–pillar molding. Refer to Section 9M,
Exterior Trim.
3. Remove the screws and the movable quarter win-
dow latch.
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4. Remove the screws and themovable quarter win-

dow.
1. Install the movable quarter window with the screws.

Tighten
Tighten the movable quarter window hinge screws to
3 NSm (27 lb–in).
2. Install the movable quarter window latch with the

screws.
Tighten
Tighten the movable quarter window latch screws to
3 NSm (27 lb–in).
3. Install the B–pillar molding. Refer to Section 9M,
Exterior Trim.
4. Install the front seat belt height adjuster. Refer to
Section 8A, Seat Belts.

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INSIDE REARVIEW MIRROR

The inside rearviewmirror is attached to a support which
is secured to the windshield glass. The support is installed
by the glass supplier using a plastic–polyvinyl butyl adhe-
sive.
Service replacement windshield glass has the mirror sup-

port bonded to the glass assembly. In order to install a de-
tached mirror support or install a new part, the following
items will be needed:
S Loctite± Minute–Bond Adhesive.
S Original or replacement mirror support.
S Wax marking pencil or crayon.
S Rubbing alcohol.
S Clean paper towel.
S Fine grit sandpaper (grit #320 or #360).
S 2 mm allen wrench.
1. Measure the distance from the headliner to the bot-

tom of where the mirror support will be mounted on
the windshield.
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2. Mark this position on the outside of the glass with a

wax pencil or crayon. Draw a large diameter circle
on the outside of the glass around the mirror sup-
port location.
3. Clean the inside surface of the glass with paper
towels and a domestic scouring cleanser, a glass
cleaning solution, or a polishing compound. Rub the
glass until the area is completely dry. When the
area is dry, clean the area with an alcohol–satu-
rated paper towel in order to remove any traces of
scouring powder or glass cleaning solution.
4. If the mirror support is new, clean the bonding sur-
face with fine grit sandpaper #320 or #360. If the
original mirror support is being used, all traces of
factoryinstalled adhesive must be removed prior to
reinstallation.
5. Wipe the sanded mirror support with a clean paper
towel saturated with rubbing alcohol. Allow the sup-
port to dry.
6. Follow the adhesive kit manufacturer’s directions
for adhesive application and mirror support prepa-
ration before installing the mirror support to the
glass.
7. Position the mirror support to its premarked posi-
tion. Use steady pressure and press the support
against the glass for 30 to 60 seconds.
8. After 5 minutes, remove the excess adhesive with
an alcohol–moistened towel or a glass cleaning
solution. Install the inside rearview mirror to the mir-
ror support with the mounting screw.
9. After 5 minutes, remove the excess adhesive with
an alcohol–moistened towel or a glass cleaning
solution.
10. Install the inside rearview mirror to the mirror sup-
port with the mounting screw.
Tighten
Tighten the rearview mirror mounting screw to 1.2
NSm(11 lb–in).
OUTSIDE REARVIEW MIRRORS
Removal Procedure
1. Remove the front door escutcheon. (Manual remote

control mirror shown.)

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2. Disconnect the electric control rearview mirror elec-

trical connector, if equipped.
3. Remove the screws and the outside rearview mirror
assembly from the door. (Manual remote control
mirror shown.)
1. Install the outside rearview mirror assembly to the

door with the screws..
Tighten
Tighten the outside rearview mirror assembly screws
to 4.5 NSm (40 lb–in). (Manual remote control mirror
shown.)
2. Connect the electric control rearview mirror electri-
cal connector, if equipped.
3. Install the escutcheon. (Manual remote control mir-

ror shown.
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down, fore/aft, and left/right. The rearview mirror pivots in

GENERAL DESCRIPTION two places: the ball–and–socket mirror pivot and the up/
down hinge lever at the mirror support.
STATIONARY GLASS OUTSIDE REARVIEW MIRRORS
Stationary glass consists of all the glass on the vehicle Two types of outside rearview mirrors are available. The
which is immovable within its frame, such as the wind- driver side is equipped with a remote control mirror. On the
shield glass, the back glass, and the inside rearview mir- passenger side, a remote control mirror is standard, and
ror. an electric remote control mirror is optional. The electric
control outside rearview mirror can be adjusted by an elec-
INSIDE REARVIEW MIRROR tric control switch on the instrument panel.
The inside rearview mirror can be manually adjusted up/

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SECTION : 9M
EXTERIOR TRIM
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9M–1 MUD GUARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9M–3
FASTENER TIGHTENING SPECIFICATIONS . 9M–1
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 9M–2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9M–4
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9M–2
B–PILLAR MOLDING . . . . . . . . . . . . . . . . . . . . . . 9M–2 EMBLEMS AND LETTERING . . . . . . . . . . . . . . . 9M–4
ROOF MOLDING . . . . . . . . . . . . . . . . . . . . . . . . . . 9M–2 MUD GUARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9M–4
SPECIFICATIONS
B–Pillar Molding Screws 10 – 89
Mud Guard Screw 1.5 – 13
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9M – 2IEXTERIOR TRIM

B–PILLAR MOLDING
Removal Procedure
1. Move the weatherstrip aside in order to access the
screws.
2. Remove the screws and the B–pillar molding.
1. Install the screws and the B–pillar molding.
Tighten
Tighten the B–pillar molding screws to 10 NSm (89
lbin).
ROOF MOLDING
Removal Procedure
1. Remove the roof molding from the plastic clips.

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EXTERIOR TRIM 9M – 3
1. Press the roof molding onto the plastic clips.
MUD GUARDS
Removal Procedure
1. Remove the screws and the mud guard.
1. Install the screws and the mud guard.
Tighten
Tighten the mud guard screws to 1.5 NSm (13 lb–in).
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9M – 4IEXTERIOR TRIM
GENERAL DESCRIPTION MUD GUARDS

AND SYSTEM OPERATION Front and rear mud guards are optional equipment on all
models. Mud guards will help prevent an excessive build-
up of mud on the body.
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 com-
pany name.

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SECTION : 9N
FRAME AND UNDERBODY
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9N–1 FLOOR PAN INSULATORS . . . . . . . . . . . . . . . . . 9N–5
FASTENER TIGHTENING SPECIFICATIONS . 9N–1 ENGINE UNDER COVER . . . . . . . . . . . . . . . . . . 9N–6
UNDERBODY DIMENSIONS (NOTCHBACK) . 9N–1 GENERAL DESCRIPTION AND SYSTEM
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 9N–5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9N–7
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9N–5 GENERAL BODY CONSTRUCTION . . . . . . . . . 9N–7
ALIGNMENT CHECKING . . . . . . . . . . . . . . . . . . . 9N–5 ENGINE UNDER COVERS . . . . . . . . . . . . . . . . . 9N–7
SPECIFICATIONS
Engine Under Cover Bolts 3.5 – 31
Engine Under Cover Nuts 3.5 – 31
UNDERBODY DIMENSIONS (NOTCHBACK)
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9N – 2IFRAME AND UNDERBODY

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FRAME AND UNDERBODY 9N – 3
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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 recommendedmeasuring 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 easure-
ments calculated on a horizontal plane (datum line) paral-
lel 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 bemeasured.
Dimensions–to–gauge holes are measured to the center
of the holes and flush to the adjacent surface metal unless
otherwise specified. It is recommended that the diagonal
dimensions to the cross–body be checked on both sides
in order to verify the dimensional accuracy of the vehicle
underbody.
FLOOR PAN INSULATORS
The floor pan insulators have been designed for the higher
floor pan temperatures that result from the use of the cata-
lytic converter in the exhaust system. Therefore, when
servicing a vehicle, it is essential that any insulators that
may have been disturbed or removed be reinstalled in the
original sequence and location. Also, an insulator needs
to be replaced, use only the insulation specified for that
location on the floor pan.
When servicing or replacing interior insulators, observe
the following instructions.
S Install the insulators in the original position and se-
quence. Butt the pieces together in order to avoid
gapping or overlapping.
S If it is necessary to replace an insulator, use only
the specified insulation.
S Use the original part to determine the amount of
replacement material required and as a template for
cutting and fitting the new piece to the floor pan.
S When installing the insulator, do not enlarge any
cutouts or holes that are used for the attachment of
interior parts such as the instrument panel or the
floor console.
S Route the cross–body harness for interior parts
over the floor pan insulators. Clip it in the original
location.
S Do not apply spray–on deadeners or trim adhesives
to the top of the floor pan at the area directly over
the catalytic converter or the muffler.
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Any insulator service repair or replacement should be the

same thickness, size, and location as the original installa-
tion in the vehicle.
ENGINE UNDER COVER
Removal Procedure
and Wheels.
3. Remove the nuts and the bolts and the engine un-
der cover.
1. Install the engine under cover with the bolts and
nuts.
Tighten
Tighten the engine under cover bolts to 3.5 NSm (31
lb–in).
Tighten the engine under cover nuts to 3.5 NSm (31
lb–in).
2. Install the front wheel. Refer to Section 2E, Tires
and Wheels.

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Since the individual underbody parts contribute directly to

GENERAL DESCRIPTION the overall strength of the body, it is essential to observe
proper welding techniques during service repair opera-
AND SYSTEM OPERATION tions. The underbody parts should be properly sealed and
rustproofed whenever body repair operations destroy or
damage the original sealing and rustproofing. When rust-
proofing critical underbody parts, use a good–quality type
GENERAL BODY CONSTRUCTION of air–dry primer, such as a corrosionresistant chromate
This vehicle is constructed with a unitized body which in- or an equivalent material. Combination– type primer/sur-
corporates integral front and rear frame side rails. facers are not recommended.
The front suspension lower control arms are bolted to and ENGINE UNDER COVERS
retained by supports, one each on the right and left sides.
The front suspension lower control arm supports are at- The engine under covers are molded pieces of plastic that
tached to the underbody with three bolts at two locations. serve as shields for the underside of the engine. The cov-
The engine is bolted to the integral front side rails. The ers help protect the engine from small rocks, gravel and
suspension strut towers must be dimensionally correct in other objects that would otherwise come into contact with
relation to the remainder of the underbody in order to main- the engine during normal driving conditions.
tain specified suspension strut and caster/ camber angles.
DAEWOO V–121 BL4
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SECTION : 9O
BUMPERS AND FASCIAS
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9O–1 FRONT BUMPER IMPACT BAR . . . . . . . . . . . . . 9O–4
FASTENER TIGHTENING SPECIFICATIONS . 9O–1 REAR BUMPER FASCIA . . . . . . . . . . . . . . . . . . . 9O–5
REAR BUMPER ENERGY ABSORBER . . . . . . 9O–9
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 9O–2
REAR BUMPER IMPACT BAR . . . . . . . . . . . . . 9O–10
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9O–2
FRONT BUMPER FASCIA . . . . . . . . . . . . . . . . . . 9O–2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9O–11
FRONT BUMPER ENERGY ABSORBER . . . . . 9O–4 BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9O–11
SPECIFICATIONS
Behind Fascia Screws 5.5 – 49
Front Bumper Impact Bar Nuts 27 20 –
Front Wheel Well Screws 1.5 – 13
Lower Rear Impact Bar Nuts 27 20 –
Luggage Compartment Fascia Bolts 5.5 – 49
Mud Guard Screws 1.5 – 13
Rear Impact Bar Nuts 27 20 –
Rear Upper Fascia Screws 1.5 – 13
Splash Shield Bolts 1.5 – 13
Splash Shield Nuts 1.5 – 13
Splash Shield Screws 1.5 – 13
Trim Panel Bolts 10 – 89
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9O – 2IBUMPERS AND FASCIAS

FRONT BUMPER FASCIA
Removal Procedure

2. Remove the front wheels. Refer toSection 2E, Tires
and Wheels.
3. Remove the screws, the bolts, the nuts, and the
front wheel well splash shields.
4. Remove the headlamps, the front side marker

lamps, and the front fog lamps. Refer toSection 9B,
Lighting Systems.
5. Remove the screws from the wheel wells.
6. Remove the screws from behind the fascia.
7. Remove the screws from underneath the fascia.
8. Remove the screws on the top of the fascia.

9. Remove the front bumper fascia.

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BUMPERS AND FASCIAS 9O – 3

1. Install the bumper fascia.
2. Install the screws on the top of the fascia.
3. Install the screws underneath the fascia.

4. Install the screws behind the fascia.
Tighten
Tighten the behind fascia screws to 5.5NSm(49 lb–in).
5. Install the screws in the wheel wells.
Tighten
Tighten the frontwheelwell screws to 1.5NSm(13 lb–
in).
6. Install the headlamps, the front side marker lamps,
and the front fog lamps. Refer to Section 9B, Light-
ing Systems.
7. Install the front wheel well splash shields with the

screws, the bolts, and the nuts.
8. Install the front wheels. Refer to Section 2E, Tires
and Wheels.
Tighten
Tighten the splash shield screws to 1.5NSm(13 lb–in).
Tighten the splash shield bolts to 1.5 NSm (13 lb–in).
Tighten the splash shield nuts to 1.5 NSm (13 lb–in).
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FRONT BUMPER ENERGY

ABSORBER
Removal Procedure
1. Remove the front bumper fascia. Refer to ”Front
Bumper Fascia” in this section.
2. Remove the energy absorber.
1. Install the energy absorber.
2. Install the front bumper fascia. Refer to”Front
FRONT BUMPER IMPACT BAR

Removal Procedure
1. Remove the front bumper energy absorber. Refer
to ”Front Bumper Energy Absorber” in this section.
2. Remove the nuts and the front bumper impact bar.

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1. Install the front bumper impact bar with the nuts.
Tighten
Tighten the front bumper impact bar nuts to 27 NSm
(20 lb–ft).
2. Install the front bumper energy absorber. Refer to
”Front Bumper Energy Absorber” in this section.
REAR BUMPER FASCIA

Removal Procedure

and Wheels.
2. Remove the screws and the mud guards.
3. Remove the screws and the splash shields.
4. Remove the rear side marker lamps. Refer to Sec-
tion 9B, Lighting Systems.
5. Remove the screws behind the fascia.
6. Remove the screws underneath the fascia.
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7. Remove the luggage compartment rear quarter trim

panels. Refer to Section 9G, Interior Trim.
8. Remove the bolts in the luggage compartment.
9. Remove the bolts and the exterior trim panels be-

neath the taillamps.
10. Remove the fascia screws beneath the taillamps.

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11. Remove the rear upper fascia screws beneath the

luggage compartment opening.
12. Remove the fascia.

ers to prevent premature corrosion..
1. Install the fascia with the rear upper fascia screws
beneath the luggage compartment opening.
Tighten
Tighten the rear upper fascia screws to 1.5 NSm (13
lb–in).
2. Install the fascia screws beneath the taillamps.
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3. Install the exterior trim panels beneath the taillamps

with the bolts.
Tighten
Tighten the trim panel bolts to 10 NSm (89 lb–in).
4. Install the bolts in the luggage compartment.

Tighten
Tighten the luggage compartment fascia bolts to 5.5
NSm (49 lb–in).
5. Install the luggage compartment rear quarter trim

panels.Refer toSection 9G, Interior Trim.
6. Install the screws underneath the fascia.

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7. Install the screws behind the fascia.

Tighten
Tighten the behind fascia screws to 5.5 NSm (49 lbin).
8. Install the rear side marker lamps. Refer to Section
9B, Lighting Systems.
9. Install the splash shields with the screws.
Tighten
Tighten the splash shield screws to 1.5 NSm(13 lb–in).
10. Install the mud guards with the screws.
Tighten
Tighten themud guard screws to 1.5 NSm(13 lb–in).
and Wheels.
REAR BUMPER ENERGY

ABSORBER
Removal Procedure
1. Remove the rear bumper fascia. Refer to ”Rear
2. Remove the energy absorber.
1. Install the energy absorber.
2. Install the rear bumper fascia. Refer to ”Rear
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REAR BUMPER IMPACT BAR

Removal Procedure
1. Remove the rear bumper energy absorber. Refer to
”Rear Bumper Energy Absorber” in this section.
2. Remove the two nuts beneath the vehicle.
3. Remove the four nuts inside the luggage compart-
ment.
4. Disconnect the harness connector.
5. Remove the impact bar.
1. Connect the harness connector.
2. Secure the rear bumper impact bar with the four
nuts inside the luggage compartment.
Tighten
Tighten the rear impact bar nuts to 27 NSm (20 lb–ft).
3. Install the two lower rear impact bar nuts beneath
the vehicle.
Tighten
Tighten the two lower rear impact bar nuts to 27 NSm
(20 lb–ft).
4. Install the energy absorber. Refer to ”Rear Bumper
Energy Absorber” in this section.

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restore themselves to their original position. Both the front

GENERAL DESCRIPTION and the rear bumpers feature an internal foam energy ab-
sorber and a polymer fascia cover. The rear bumper fascia
AND SYSTEM OPERATION must be removed before access can be gained to the en-
ergy absorber and the bumper. The front bumper assem-
BUMPERS bly can be removed as a whole unit or the fascia cover can
The bumper systems are designed to sustain a collision be removed separately.
into a fixed barrier at 8 km/h (5 mph) without damage. After
bsorbing the energy of a collision, these bumper systems
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SECTION : 9P
DOORS
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9P–1 INSIDE DOOR HANDLE . . . . . . . . . . . . . . . . . . 9P–23
FASTENER TIGHTENING SPECIFICATIONS . 9P–1 INSIDE LOCK ROD . . . . . . . . . . . . . . . . . . . . . . . 9P–24
SCHEMATIC AND ROUTING DIAGRAMS . . . . . 9P–3 OUTSIDE DOOR HANDLE . . . . . . . . . . . . . . . . 9P–25
POWER DOOR LOCKS CIRCUIT (NOTCHBACK) 9P DOOR LOCK CYLINDER . . . . . . . . . . . . . . . . . . 9P–25
–3 POWER WINDOW REGULATOR . . . . . . . . . . . 9P–26
POWER DOOR LOCKS CIRCUIT (HATCHBACK) 9P– MANUAL FRONT WINDOW REGULATOR . . 9P–27
4 MANUAL REAR WINDOW REGULATOR . . . . 9P–27
POWER WINDOWS CIRCUIT (FRONT ONLY) 9P–5 FRONT DOOR ASSEMBLY . . . . . . . . . . . . . . . . 9P–28
POWER WINDOWS CIRCUIT (FRONT AND REAR)9 REAR DOOR ASSEMBLY . . . . . . . . . . . . . . . . . 9P–29
P–6
DOOR HINGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P–31
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P–7 DOOR HOLD OPEN LINK . . . . . . . . . . . . . . . . . 9P–31
POWER WINDOWS . . . . . . . . . . . . . . . . . . . . . . . 9P–7 INSIDE CHANNEL MOLDING . . . . . . . . . . . . . . 9P–32
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 9P–14 OUTSIDE CHANNEL MOLDING . . . . . . . . . . . 9P–33
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 9P–14 DOOR WEATHERSTRIP . . . . . . . . . . . . . . . . . . 9P–33
FRONT DOOR GLASS RUN . . . . . . . . . . . . . . . 9P–14 DOOR SEAL TRIM . . . . . . . . . . . . . . . . . . . . . . . 9P–34
REAR DOOR GLASS RUN . . . . . . . . . . . . . . . . 9P–14 DOOR OPENING WEATHERSTRIP . . . . . . . . 9P–35
FRONT DOOR SECONDARY WEATHERSTRIP 9P– MANUAL WINDOW REGULATOR HANDLE . 9P–35
15 GENERAL DESCRIPTION AND SYSTEM
REAR DOOR SECONDARY WEATHERSTRIP 9P–16 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9P–37
DOOR LOCK STRIKER . . . . . . . . . . . . . . . . . . . 9P–16 DOOR LOCK STRIKER . . . . . . . . . . . . . . . . . . . 9P–37
DOOR LOCK STRIKER ADJUSTMENT . . . . . 9P–17 CHILDPROOF REAR DOOR LOCK . . . . . . . . . 9P–37
FRONT DOOR LOCK . . . . . . . . . . . . . . . . . . . . . 9P–19 POWER DOOR LOCKS . . . . . . . . . . . . . . . . . . . 9P–37
CHILDPROOF REAR DOOR LOCK . . . . . . . . . 9P–20 POWER WINDOWS . . . . . . . . . . . . . . . . . . . . . . 9P–37
SPECIFICATIONS
Door Hinge–to–Body Bolts 35 26 –
Door Hinge–to–Door Bolts 15 11 –
Door Hold Open Link–to–Body Bolts 35 26 –
Door Hold Open Link–to–Door Bolts 5 – 44
Door Lock Screws 8 – 71
Door Lock Striker Screws 24 18 –
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9P – 2IDOORS

Door Pull Bracket Screws 3.5 – 31
Guide Rail Bolts 7 – 62
Inside Door Handle Screw 3 – 27
Outside Door Handle Bolts 4.5 – 40
Window Regulator Nuts 7 – 62

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DOORS 9P – 3

POWER DOOR LOCKS CIRCUIT (NOTCHBACK)
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9P – 4IDOORS
POWER DOOR LOCKS CIRCUIT (HATCHBACK)

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DOORS 9P – 5
POWER WINDOWS CIRCUIT (FRONT ONLY)
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9P – 6IDOORS
POWER WINDOWS CIRCUIT (FRONT AND REAR)

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DOORS 9P – 7
DIAGNOSIS
POWER WINDOWS
System With Only Front Power Windows, One or Both Windows
are Inoperative
CAUTION : When powering the window motors directly from a battery with jumper wires, make sure one of the
jumper wires contains a fuse. If the jumpers are accidentally touched together, the fuse will prevent sparking
and burns from sudden terminal heating.

1 1. Turn the ignition ON. Go toStep Go toStep
2. Attempt to operate both power windows. 18 2
Is either window working?
2 Visually inspect the connection at the dual Go toStep Go toStep
power window switch. 4 3
Is the electrical connector correctly attached
to the switch?
3 Correctly attach the electrical connector to System
the dual power window switch. OK
4 1. Disconnect the electrical connector from the 11–14 v Go toStep Go toStep
dual power window switch. 16 5
3. Check the voltage at terminal 13 of the power
window main switch connector.
5 Check fuses F19 and EF5. Go toStep Go toStep
Is either fuse blown? 6 7
6 1. Check for a short circuit and repair if neces- System
sary. OK
2. Replace the blown fuse(s).
2. Check the voltages at fuses F19 and EF5. 9 8
Are both voltages equal to the specified val-
ue?
8 Repair the power supply to the fuse which did System
not indicate battery voltage with the ignition OK
on.
9 1. Remove the power window relay. 11–14 v Go toStep Go toStep
2. Turn the ignition ON. 11 10
3. Check the voltage at terminal 30 and terminal
86 of the power window relay socket. (Termi-
nals of the relay socket can be identified by
the markings on the bottom of the relay.)
Does the voltmeter indicate the specified val-
ue?
10 Repair the open circuit between the fuses and System
the power window relay. OK
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9P – 8IDOORS

11 With the power window relay still removed, [0W Go toStep Go toStep
use an ohmmeter to check the resistance be- 13 12
tween ground and terminal 85 of the power
window relay socket.
Does the ohmmeter indicate the specified val-
ue?
12 Repair the open circuit between ground and System
terminal 85 of the power window relay socket. OK
13 1. Temporarily substitute a known good relay in Go toStep Go toStep
place of the power window relay. 14 15
2. Attempt to operate the power windows.
Do the power windows operate with the sub-
stituted relay?
14 1. Return the substituted relay to its original System
position. OK
2. Replace the original power window relay.
15 Repair the open circuit between the power System
window relay ket terminal 87 and the power OK
window switch terminal 13.
16 With the power window main switch discon- [0W Go toStep Go toStep
nected,use an ohmmeter to check the resist- 18 17
ance between ground and inal 2 of the power
window switch connector.
terminal 2 of the power window main switch OK
connector.

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DOORS 9P – 9

18 1. Remove the trim panel from a door which Go toStep Go toStep
has an inoperative power window. 20 19
2. Move a vehicle battery close enough to the
door so that the window motor can be pow-
ered directly from the battery with jumper
wires.
3. Disconnect the the two–pin window motor
connector in the door.
Important : To prevent the fuse in the jumper wire
from blowing, do not touch the jumper wires togeth-
er.
1. Attach a jumper wire between the battery
negative terminal and one of the terminals in
the two–pin window motor connector.
2. Attach a fused jumper wire between the bat-
tery positive terminal and the remaining ter-
minal in the two–pin window motor connec-
tor. Unless the motor is at the end of its trav-
el, the window should move with the jumpers
attached.
3. To move the window in the opposite direc-
tion, reverse the jumper wire connections at
the window motor connector.
Does the power window operate in both direc-
tions when the motor is operated directly from
a battery?
19 Replace the window motor. System
Is the repair complete? OK
20 1. Before reconnecting the two–pin window mo- Go toStep Go toStep
tor connector, connect an ohmmeter between 22 21
the terminals to check the resistance of the
motor.
2. Record the ohmmeter reading for motor re-
sistance.
3. Reconnect the motor connector and reinstall
the door trim panel.
4. Disconnect the electrical connector from the
dual power window switch.
5. At the power window main switch connector,
use an ohmmeter to check the resistance
between the terminals which lead to the mo-
tor that was tested inStep 15
21 Repair the open circuit between the window System
motor and the window switch. OK
22 Replace the power window switch. System
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9P – 10IDOORS
System With Front and Rear Power Windows, One or Both Rear
Windows are Inoperative
CAUTION : When powering the window motors directly from a battery with jumper wires, make sure one of the
jumper wires contains a fuse. If the jumpers are accidentally touched together, the fuse will prevent sparking
and burns from sudden terminal heating.

1 1. Turn the ignition ON. Go toStep Go toStep
2. Attempt to operate each rear power window. 18 2
Is either rear power window working?
2 Visually inspect the connection at the power Go toStep Go toStep
window main switch. 4 3
Is the electrical connector correctly attached
to the main switch?
3 Correctly attach the electrical connector to System
the power window main switch. OK
4 1. Disconnect the electrical connector from the 11–14 v Go toStep Go toStep
power window main switch. 16 5
window main switch connector.
5 Check fuses F19 and EF5. Go toStep Go toStep
Is either fuse blown? 6 7
6 1. Check for a short circuit and repair, if neces- System
sary. OK
2. Check the voltages at fuses F19 and EF5. 9 8
Are both voltages equal to the specified val-
ue?
8 Repair the power supply to the fuse which did System
not indicate battery voltage with the ignition OK
on.
9 1. Remove the power window relay. 11–14 v Go toStep Go toStep
2. Turn the ignition ON. 11 10
3. Check the voltage at terminal 30 and terminal
86 of the power window relay socket. (Termi-
nals of the relay socket can be identified by
the markings on the bottom of the relay.)
Does the voltmeter indicate the specified val-
ue?
10 Repair the open circuit between the fuses and System
the power window relay. OK

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DOORS 9P – 11

11 With the power window relay still removed, [0W Go toStep Go toStep
use an ohmmeter to check the resistance be- 13 12
tween ground and terminal 85 of the power
window relay socket.
Does the ohmmeter indicate the specified val-
ue?
terminal 85 of the power window relay socket. OK
13 1. Temporarily substitute a known good relay in Go toStep Go toStep
place of the power window relay. 14 15
2. Attempt to operate the power windows.
Do the power windows operate with the sub-
stituted relay?
14 1. Return the substituted relay to its original System
position. OK
2. Replace the original power window relay.
window relay socket terminal 87 and the pow- OK
er window main switch terminal 13.
16 With the power window main switch discon- [0W Go toStep Go toStep
nected, use an ohmmeter to check the resist- 18 17
ance between ground and terminal 2 of the
power window main switch connector.
terminal 2 of the power window switch con- OK
nector.
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9P – 12IDOORS

18 1. Remove the trim panel from the rear door Go toStep Go toStep
which has an inoperative power window. 20 19
2. Move a vehicle battery close enough to the
door so that the window motor can be pow-
ered directly from the battery with jumper
wires.
3. Disconnect the the two–pin window motor
connector in the door.
Important : To prevent the fuse in the jumper wire
from blowing, do not touch the jumper wires togeth-
er.
1. Attach a jumper wire between the negative
battery terminal and one of the terminals in
the two–pin window motor connector.
2. Attach a fused jumper wire between the posi-
tive battery terminal and the remaining termi-
nal in the two–pin power window motor con-
nector. Unless the motor is at the end of its
travel, the power window should move with
the jumpers attached.
3. To move the power window in the opposite
direction, reverse the jumper wire connec-
tions at the power window motor connector.
Does the power window operate in both direc-
tions when the motor is operated directly from
a battery?
19 Replace the window motor. System
20 1. Make sure the window lock on the main 11–14v Go toStep Go toStep
switch is off. 21 29
3. At the rear power window switch connector,
check the voltage at terminal 1.
21 1. At the power window motor two–pin connec- Go toStep Go toStep
tor, use an ohmmeter to measure the resist- 23 22
ance of the power window motor. Record the
resistance.
2. Re–connect the two–pin power window motor
connector.
3. Disconnect the rear power window switch
connector.
4. Use an ohmmeter to measure between termi-
nals 3 and 6 of the rear power window switch
connector.
Is the resistance measured at the rear power
window switch connector equal to the resist-
ance previously measured at the rear power
window motor connector?
22 Repair the open circuit between the rear pow- System
er window switch and the rear power window OK
motor connector.

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DOORS 9P – 13

23 1. Remove the rear power window switch for [0W Go toStep Go toStep
testing. 25 24
2. Connect an ohmmeter between terminals 4
and 3 of the rear power window switch, and
observe the ohmmeter.
3. Connect the ohmmeter between terminals 2
and 6 of the rear power window switch, and
observe the ohmmeter.
For both tests, did the ohmmeter indicate the
specified value?
24 Replace the rear power window switch. System
25 1. With the rear power window switch removed [0W Go toStep Go toStep
for testing, connect an ohmmeter between 26 24
terminals 1 and 3, and put the switch in the
DOWN position. Observe the ohmmeter.
2. Connect the ohmmeter between terminals 1
and 6, and put the switch in the UP position
and observe the ohmmeter.
For both tests, did the ohmmeter indicate the
specified value?
26 1. Reconnect the rear power window switch Go toStep Go toStep
connector. 28 27
2. Disconnect the electrical connector from the
power window main switch.
at the power window main switch between
between terminals 7 and 10 if you are testing
the left rear window, or terminals 11 and 14 if
you are testing the right rear window.
Is the resistance equal to the resistance pre-
viously measured at the motor connector?
window main switch and the rear power win- OK
dow switch.
28 Replace the power window main switch. System
29 1. Remove the power window main switch, but 11–14 v Go toStep Go toStep
do not disconnect the electrical connector. 27 28
2. Make sure the window lock is off.
window main switch.
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9P – 14IDOORS

FRONT DOOR GLASS RUN
Removal Procedure
1. Remove the outside rearview mirror. Refer to Sec-
tion 9L, Glass and Mirrors.
2. Remove the front door glass. Refer to Section 9L,
Glass and Mirrors.
3. Remove the glass run.
1. Install the glass run.
2. Install the front door glass. Refer to Section 9L,
Glass and Mirrors.
3. Install the outside rearview mirror. Refer to Section
9L, Glass and Mirrors.
REAR DOOR GLASS RUN

Removal Procedure
1. Remove the rear door glass. Refer to Section 9L,
Glass and Mirrors.
2. Remove the rear door interior and exterior garnish
trim.
3. Remove the glass run.

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DOORS 9P – 15
1. Install the glass run.
2. Install the rear door interior and exterior garnish
trim.
3. Install the rear door glass. Refer to Section 9L,
Glass and Mirrors.
FRONT DOOR SECONDARY

WEATHERSTRIP
Removal Procedure
1. Remove the outside rearview mirror. Refer to Sec-
tion 9L, Glass and Mirrors.
2. Remove the front door secondary weatherstrip.
1. Install the front door secondary weatherstrip.
2. Install the outside rearview mirror. Refer to Section
9L, Glass and Mirrors.
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9P – 16IDOORS
REAR DOOR SECONDARY

WEATHERSTRIP
Removal Procedure
1. Remove the rear door interior and exterior garnish
trim.
2. Remove the rear door secondary weatherstrip.
1. Install the rear door secondary weatherstrip.
2. Install the rear door interior and exterior garnish
trim.
DOOR LOCK STRIKER

Removal Procedure
1. Remove the screws and the door lock striker.

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DOORS 9P – 17
1. Install the screws and the door lock striker.
Tighten
Tighten the door lock striker screws to 24 NSm (18
lbft).
DOOR LOCK STRIKER ADJUSTMENT

Notice : The door lock striker is an important attaching
part that can affect the performance of vital components
and systems and can cause major repair expenses. If re-
placement becomes necessary, the door lock striker must
be replaced by one with the same part number or with an
equivalent part. Do not use a replacement part of lesser
quality or of a substitute design. The specified torque val-
ues must be used during reassembly in order to ensure the
proper retention of the part.
The door lock striker consists of a striker with two screws
that are threaded into a tapped, floating cage plate located
in the appropriate body pillar. This floating cage plate al-
lows the striker to be easily adjusted in or out and up or
down. The door is secured in the closed position when the
door lock fork snaps over and engages the striker.
Fore/Aft Adjustment
1. The door must be properly aligned.

2. Close the door until the lock fork contacts the strik-
er.
3. Stand next to the door opening and move the door
slowly in and out, just touching the striker each
time.
4. The alignment of the lock fork and the striker can
be easily seen. The lock fork should be perpendicu-
lar to and fall near the middle of the striker between
the Bpillar and the end of the striker.
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9P – 18IDOORS
5. If a fore or aft adjustment is required, use the fol-

lowing steps:
1) Remove the striker screws.
2) Remove the spacer in order to move the striker
toward the rear of the vehicle.
3) Add a 2 mm (0.08 inch) spacer in order to move
the striker toward the front of the vehicle.
4) Install the striker screws.
6. Perform the up/down or the in/out adjustment. Re-
fer to ”Up/Down or In/Out Adjustment” in this sec-
tion.
Up/Down or In/Out Adjustment

An adjustment of the striker in the up/down or in/out direc-
tionsmay be necessary for a number of reasons:
S Vehicle frame damage as the result of a collision.
S Installation of new door weatherstripping.
S Customer complaints of excessive windnoise.
S Difficulty in opening or closing the door.
In order to adjust the door striker in an up/down or in/out
direction, perform the following procedure:
5. The door must be properly aligned.
6. Loosen the striker screws.
7. The floating cage plate can be moved slightly using
the ends of the striker screws. Move the floating
cage plate to the desired position.
Notice : It is important to use a flat–end rotary file in order
not to damage the tapped floating cage plate. The striker
screws and the tapped floating cage plate are important
attaching parts that could affect the performance of vital
components and systems.
8. If proper adjustment requires that the floating cage
plate be moved more than is possible, use an elec-
tric hand drill and a 3/8–inch rotary file with a flat
head in order to enlarge the body opening in the
direction required.
9. Tighten the striker screws to the correct position.
Tighten
Tighten the door lock striker screws to 20 NSm (15
lbft).

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DOORS 9P – 19
FRONT DOOR LOCK

Removal Procedure

2. Remove the seal trim. Refer to”Door Seal Trim” in
this section.
3. Disconnect the inside door handle and the lock
rods.
4. Disconnect the outside door handle and the lock

rods.

6. Remove the screws and the front door lock.
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9P – 20IDOORS
2. Connect the inside door handle and the lock rods.
3. Connect the outside door handle and the lock rods.
4. Install the front door lock with the screws.
Tighten
Tighten the front door lock screws to 8 NSm (71 lb–in).
5. Install the guide rail with the bolts.
Tighten
6. Install the seal trim. Refer to ”Door Seal Trim” in
this section.
CHILDPROOF REAR DOOR LOCK
Removal Procedure

2. Remove the door seal trim. Refer to”Door Seal
Trim” in this section.
rods.

rods.

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DOORS 9P – 21
6. Remove the screws and the lock.

8. Disconnect the lock rods at the lock.

1. Install the rear door lock with the screws.
Tighten
Tighten the rear door lock screws to 8 NSm (71 lb–in).
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9P – 22IDOORS

3. Install the guide rail with the bolts.
Tighten

6. Install the door seal trim. Refer to ”Door Seal Trim”
in this section.

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DOORS 9P – 23
INSIDE DOOR HANDLE

Removal Procedure
1. Remove the door seal trim. Refer to ”Door Seal

2. Remove the screw securing the door handle to the
door.
3. Slide the door handle forward and remove it from
the door.

rods.
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9P – 24IDOORS
2. Insert the inside door handle into the slots in the

door.
3. Slide the door handle rearward.
4. Install the inside door handle screw.
Tighten
Tighten the inside door handle screw to 3 NSm (27
lbin).
in this section.
INSIDE LOCK ROD

Removal Procedure
1. Remove the inside door handle. Refer to ”Inside
Door Handle” in this section.
2. Disconnect the inside lock rods from the door han-
dle and the lock.
1. Connect the inside lock rods to the door handle and
the lock.
2. Install the inside door handle. Refer to ”Inside Door
Handle” in this section.

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DOORS 9P – 25
OUTSIDE DOOR HANDLE

Removal Procedure
rods.
3. Remove the bolts and the door handle.
2. Install the door handle with the bolts.
Tighten
Tighten the outside door handle bolts to 4.5 NSm (40
lb–in).
in this section.
DOOR LOCK CYLINDER

Removal Procedure
rods.
3. Remove the retaining clip and the lock cylinder.
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9P – 26IDOORS
1. Install the lock cylinder with the retaining clip.
in this section.
POWER WINDOW REGULATOR

(Front Door Power Window Regulator
Shown, Rear Door Power Window
Regulator Similar)
Removal Procedure
2. Remove the door glass. Refer to Section 9L, Glass
and Mirrors.
3. Remove the nuts and the regulator.
2. Install the window regulator with the nuts.
Tighten
Tighten the window regulator nuts to 7 NSm (62 lb–in).
Glass and Mirrors.

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DOORS 9P – 27
MANUAL FRONT WINDOW

REGULATOR
Removal Procedure
1. Remove the front door glass. Refer to Section 9L,
Glass and Mirrors.
2. Remove the nuts and the window regulator.
1. Install the window regulator and the nuts.
Tighten
Glass and Mirrors.
MANUAL REAR WINDOW

REGULATOR
Removal Procedure
1. Remove the rear door glass. Refer to Section 9L,
Glass and Mirrors.
2. Remove the nuts and the window regulator.
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9P – 28IDOORS
1. Install the window regulator with the nuts.
Tighten
2. Install the rear door glass. Refer to Section 9L,
Glass and Mirrors.
FRONT DOOR ASSEMBLY

Removal Procedure

2. Remove the door hold open link. Refer to ”Door
Hold Open Link” in this section.
3. Remove the body–to–door rubber grommet and the
electrical wires.
4. With the aid of another technician, remove the bolts
and the front door.
5. Disconnect the body–to–door rubber grommet and

the electrical connector.

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DOORS 9P – 29
1. Connect the electrical connector and the body–to-

door rubber grommet.

2. With the aid of another technician, lightly secure the
front door with the bolts.
3. Adjust the door for proper fit.
Tighten
Tighten the door hinge–to–body bolts to 35 NSm (26
lb–ft).
Tighten the door hinge–to–door bolts to 15 NSm (11
lbft).
4. Install the door hold open link. Refer to ”Door Hold
Open Link” in this section.
6. Perform the waterleak test. Refer to Section 9I,
Waterleaks.
7. Check for windnoise. Refer to Section 9J, Wind-
noise.
REAR DOOR ASSEMBLY
Removal Procedure

2. Remove the door hold open link. Refer to ”Door
and the rear door.
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9P – 30IDOORS
4. Disconnect the body–to–door rubber grommet and

the electrical connector.
1. Connect the body–to–door rubber grommet and the


2. With the aid of another technician, lightly secure the
rear door with the bolts.
3. Adjust the door for proper fit.
Tighten
lb–ft).
lbft).
4. Install the rear door hold open link. Refer to ”Door
6. Perform the waterleak test. Refer to Section 9I,
Waterleaks.
7. Check for windnoise. Refer to Section 9J, Wind-
noise.

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DOORS 9P – 31
DOOR HINGE
Removal Procedure
and the hinge from the door and the body.
1. With the aid of another technician, install the hinge
to the door and the body with the bolts.
Tighten
lb–ft).
lbft).
DOOR HOLD OPEN LINK

Removal Procedure
1. Remove the door trim panel. Refer to Section 9G,
Interior Trim.
2. Reposition the door seal trim.
3. Remove the bolts on the door and on the body.
4. Remove the door hold open link.
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9P – 32IDOORS
1. Install the door hold open link to the door and the
body with the bolts.
Tighten
Tighten the door hold open link–to–body bolts to 35
NSm (26 lb–ft).
Tighten the door hold open link–to–door bolts to 5
NSm (44 lb–in).
2. Reposition the door seal trim.
3. Install the door trim panel. Refer to Section 9G, In-
terior Trim.
INSIDE CHANNEL MOLDING

Removal Procedure
Interior Trim.
2. Straighten the retaining tabs in order to release the
channel molding from the door trim panel.
3. Remove the channel molding.
1. Install the channel molding onto the door trim panel.
2. Bend the retaining tabs to secure the channel mold-
ing to the door trim panel.
terior Trim.

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DOORS 9P – 33
OUTSIDE CHANNEL MOLDING

Removal Procedure
1. Lower the window completely.
2. Lift the outside channel molding off the door.
1. Press the outside channel molding onto the door.
DOOR WEATHERSTRIP
Removal Procedure
1. Remove the door hold open link–to–body bolt.
2. Remove the door weatherstrip.
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9P – 34IDOORS
1. Install the door weatherstrip.
2. Install the door hold open link to the body with the
bolt.
Tighten
Tighten the door hold open link–to–body bolt to 35
NSm (26 lb–ft).
DOOR SEAL TRIM

Removal Procedure
Interior Trim.
2. Remove the screws and the door pull bracket.
3. Remove the door seal trim.
1. Install the door seal trim.
2. Install the door pull bracket with the screws.
Tighten
Tighten the door pull bracket screws to 3.5 NSm (31
lb–in).
terior Trim.

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DOORS 9P – 35
DOOR OPENING WEATHERSTRIP

Removal Procedure
1. Remove the door opening weatherstrip.
1. Install the door opening weatherstrip.
MANUAL WINDOW REGULATOR

HANDLE
Removal Procedure
1. Push the plastic ring behind the window regulator
handle toward the door to reveal the metal clip.
2. Pry off the metal clip.
3. Remove the window regulator handle and the plas-
tic ring.
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9P – 36IDOORS
1. Install the plastic ring.
2. Install the window regulator handle.
3. Insert the metal clip.

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DOORS 9P – 37
To deactivate the door locks, unlock the doors from the in-
GENERAL DESCRIPTION side of the vehicle and open the doors from the outside.
Move the lever to the unlock position. The rear doors will
AND SYSTEM OPERATION now work normally.
POWER DOOR LOCKS

DOOR LOCK STRIKER The power door locks use a solenoid that is contained in
The front and the rear door lock strikers each consist of a each door lock assembly. The door locks are activated by
striker with two screws threaded into a floating cage plate the actuator on the inside door handle or by the lock cylin-
in the B–pillars and the C–pillars. The door is secured in der on the driver’s side door only. When the driver’s side
the closed position when the door lock fork snaps over and door is locked or unlocked by the actuator or lock cylinder,
engages the striker. all doors are locked or unlocked accordingly.
CHILDPROOF REAR DOOR LOCK POWER WINDOWS

The childproof rear door locks help prevent passengers, The power windows are controlled by electrical switches
especially children, from opening the rear doors of the ve- on the console and are operated by a motor at each win-
hicle from the inside. dow regulator. The windows are lowered by pressing the
To activate the door locks, move the levers of both rear switch and are raised by pulling up on the switch. The win-
doors to the lock position and close both doors. Now the dow will stop movement when the switch is released or
rear passengers will be unable to open the doors from in- when the window is completely open or closed.
side of the vehicle.
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SECTION : 9Q
ROOF
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q–1 FORMED HEADLINER . . . . . . . . . . . . . . . . . . . . . 9Q–9
FASTENER TIGHTENING SPECIFICATIONS . 9Q–1 SUN VISORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q–12
PASSENGER ASSIST HANDLES . . . . . . . . . . 9Q–13
SCHEMATIC AND ROUTING DIAGRAMS . . . . . 9Q–2
COAT HOOK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q–14
POWER SUNROOF SYSTEM . . . . . . . . . . . . . . 9Q–2
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q–3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q–15
POWER SUNROOF . . . . . . . . . . . . . . . . . . . . . . . 9Q–3 ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q–15
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 9Q–5 POWER SUNROOF . . . . . . . . . . . . . . . . . . . . . . 9Q–15
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9Q–5 POWER SUNROOF CONTROL SWITCH . . . 9Q–15
POWER SUNROOF . . . . . . . . . . . . . . . . . . . . . . . 9Q–5 SUN VISORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q–15
INTERIOR COURTESY LAMP/POWER SUNROOF PASSENGER ASSIST HANDLES . . . . . . . . . . 9Q–15
CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . 9Q–8 COAT HOOK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Q–15
SPECIFICATIONS
B–Pillar Seat Belt Bolts 38 28 –
Coat Hook Screw 3.5 – 31
Interior Courtesy Lamp/Power Sunroof Control Switch Screws 4 – 35
Passenger Assist Handle Screws 3.5 – 31
Sunroof Glass Screws 7 – 62
Sunroof Housing Bolts 7 – 62
Sunroof Motor Screws 5 – 44
Sun Visor Screws 1.5 – 13
Sun Visor Support Screw 1.5 – 13
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9Q – 2IROOF

POWER SUNROOF SYSTEM

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ROOF 9Q – 3
DIAGNOSIS
POWER SUNROOF
Power Sunroof Does Not Work
1 Check fuses F19 and EF5. Go to Step 2 Go to Step 3
Is either fuse blown?
sary.
3 1. Turn the ignition on. 11 – 14 v Go to Step 5 Go to Step 4
2. Check the voltages at fuses F19 and EF5.
Are both voltages equal to the specified value?
4 Repair the power supply to the fuse which did not in- System OK
dicate battery voltage with the ignition on.
5 1. Disconnect the interior courtesy lamp/power 11–14 v Go to Step 7 Go to Step 6
sunroof control switch connector.
3. Check the voltage at terminal 1 of the interior
courtesy lamp/power sunroof control switch
connector.
6 Repair the open circuit between fuse F19 and the in- System OK
terior courtesy lamp/power sunroof control switch
connector.
7 1. Reconnect the interior courtesy lamp/power 11 – 14 v Go to Step 9 Go to Step 8
sunroof control switch connector.
2. With the sunroof switch in the OPEN position,
check the voltage at terminal 3 of the interior
connector.
3. With the sunroof switch in the CLOSE position,
check the voltage at terminal 4 of the interior
connector.
Do both voltages equal the specified value?
8 Replace the interior courtesy lamp/power sunroof System OK
control switch.
9 1. Disconnect the 6–pin sunroof module connec- 11–14 v Go to Step 11 Go to Step 10
tor.
2. With the sunroof switch in the OPEN position,
check the voltage at terminal 4 of the sunroof
module connector.
3. With the sunroof switch in the CLOSE position,
check the voltage at terminal 6 of the sunroof
module connector.
Are the voltages equal to the specified value?
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9Q – 4IROOF

10 Repair the open circuit between the interior courtesy System OK
lamp/power sunroof control switch and the sunroof
module connector.
11 1. Reconnect the sunroof module. Go to Step 12 Go to Step 13
2. Remove the sunroof motor, but leave the con-
nectors attached.
4. Use the sunroof switch to attempt to operate
the motor in both directions.
Does the motor operate?
12 Repair the jammed sunroof mechanism. System OK
13 1. Disconnect both of the one–wire connectors at Go to Step 15 Go to Step 14
the sunroof motor.
2. Connect a voltmeter between the one–wire
connectors, on the module side of the connec-
tors.
4. Turn the sunroof switch to the OPEN position
and observe the voltmeter reading.
5. Turn the sunroof switch to the CLOSE position
and observe the voltmeter reading.
Does the voltmeter indicate the specified voltage
when the switch is in either the OPEN or the CLOSE
position (one of the switch positions should show re-
verse polarity)?
14 Replace the sunroof module. System OK
15 Replace the sunroof motor. System OK Go to Step 14
Does the sunroof operate with the new motor?

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ROOF 9Q – 5

POWER SUNROOF
Removal Procedure

2. Remove the headliner. Refer to”Formed Headliner”
in this section.
3. Remove the drain hoses.
4. Remove the electrical connectors.

5. Remove the screws and the motor.
6. Remove the motor control module.

7. Remove the bolts and the housing from the vehicle.
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9Q – 6IROOF
8. Remove the rubber end caps.

9. Remove the drain nozzles.
10. Remove the shade stops.
11. Remove the glass stops.
12. Remove the shade.

13. Remove the glass and the frame from the housing.
14. Remove the plastic trim.
15. Remove the screws and the glass from the frame.

1. Install the glass to the frame with the screws.
Tighten
Tighten the sunroof glass screws to 7 NSm (62 lb–in).

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ROOF 9Q – 7
2. Install the plastic trim.

3. Install the glass and the frame to the housing.
4. Install the shade.
5. Install the glass stops.
6. Install the shade stops.
7. Install the drain nozzles.
8. Install the rubber end caps.
9. Install the housing to the roof of the vehicle with the

bolts.
Tighten
Tighten the sunroof housing bolts to 7 NSm (62 lb–in).
10. Install the motor control module.

11. Install the motor with the screws.
Tighten
Tighten the sunroof motor screws to 5 NSm (44 lb–in).
12. Connect the electrical connectors.
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9Q – 8IROOF
13. Install the drain hoses.

14. Install the headliner. Refer to ”Formed Headliner”
in this section.
INTERIOR COURTESY LAMP/POWER

SUNROOF CONTROL SWITCH
Removal Procedure
2. Pry off the interior courtesy lamp lens.
3. Remove the screws and the lamp/power sunroof
control switch.
2. Install the lamp/power sunroof control switch with
the screws.
Tighten
Tighten the interior courtesy lamp/power sunroof con-
trol switch screws to 4 NSm (35 lb–in).
3. Install the interior courtesy lamp lens.

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ROOF 9Q – 9
FORMED HEADLINER
Removal Procedure
1. Remove the passenger assist handles. Refer to

”Passenger Assist Handles” in this section.
2. Remove the coat hook. Refer to ”Coat Hook” in
this section.
3. Remove the plastic retainers in the headliner on the
driver’s side.
4. Remove the sun visors. Refer to ”Sun Visors” in

this section.
5. Remove the interior courtesy lamp. Refer to Sec-
tion 9B, Lighting Systems.
6. Remove the left and the right A–pillar trim panels.
7. Remove the bolts and the seat belt anchors from

the left and the right B–pillars.
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9Q – 10IROOF
8. Reposition the top of the left and the right B–pillar

trim panels.
9. Remove the left and the right C–pillar trim panels.

10. Remove the sunroof molding, if equipped.
11. Remove the plastic retainers in the headliner along
the rear window.
12. Slide and tilt both front seats forward.
13. Pull the headliner down and turn it 45 degrees.
14. Remove the headliner through a rear door.
1. Recline both front seats.

2. Tilt the headliner on its side and slide it through a
rear door.
3. Tilt and rotate the headliner until it is in position.
Push it in place until the seals around the doors
cover the edges of the headliner.
4. Install the plastic retainers along the rear window.

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ROOF 9Q – 11
5. Install the plastic retainers in the headliner on the

driver’s side.
6. Install the sunroof molding, if equipped.

7. Install the left and the right C–pillar trim panels.
8. Install the top of the left and the right B–pillar trim
panels to the original position.

9. Install the seat belt anchors with the bolts in the left
and the right B–pillar panels.
Tighten
Tighten the B–pillar seat belt bolts to 38 NSm (28 lb–
ft).
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9Q – 12IROOF
10. Install the left and the right A–pillar trim panels.
11. Install the interior courtesy lamp. Refer to Section
9B, Lighting Systems.
12. Install the sun visors. Refer to ”Sun Visors” in this
section.
13. Install the coat hook. Refer to ”Coat Hook” in this
section.
14. Install the passenger assist handles. Refer to ”Pas-
senger Assist Handles” in this section.
SUN VISORS
Removal Procedure
1. Remove the screws and the sun visor from the

headliner.
2. Remove the screw and the sun visor support from

the headliner.

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ROOF 9Q – 13

1. Install the sun visor support to the headliner with
the screw.
Tighten
Tighten the sun visor support screw to 1.5 NSm (13 lb–
in).
2. Install the sun visor to the headliner with the

screws.
Tighten
Tighten the sun visor screws to 1.5 NSm (13 lb–in).
PASSENGER ASSIST HANDLES

Removal Procedure
1. Remove the screws and the assist handle from the
headliner.
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9Q – 14IROOF
1. Install the assist handle to the headliner with the
screws.
Tighten
Tighten the passenger assist handle screws to 3.5
NSm (31 lb–in).
COAT HOOK
Removal Procedure
1. Pry open the screw cover on the coat hook.
2. Remove the screw and the coat hook from the
headliner.
1. Install the coat hook with the screw.
Tighten
Tighten the coat hook screw to 3.5 NSm (31 lb–in).
2. Close the screw cover.

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ROOF 9Q – 15
GENERAL DESCRIPTION Tilting the Power Sunroof Open and Closed

To tilt open the rear end of the power sunroof, press and
AND SYSTEM OPERATION hold the forward portion of the toggle button until the power
sunroof tilts open.
ROOF To close the power sunroof from a tilted–open position,
The roof is a one–piece paintedmetal unit which incorpo- press and hold the rear portion of the toggle button until the
rates a single, solid headliner and twomoldings with one sunroof tilts closed.
on each side of the vehicle’s roof.
Sliding the Power Sunroof Open and Closed
The moldings, which enclose and hide the roof rail seams,
To slide open the power sunroof, press the rear portion of
are serviceable as individual units.
the toggle button until the sunroof slides. If the sunshade
The one–piece formed headliner, common to both the is closed, the power sunroof will pull the sunshade open
notchback and the hatchback, consists of a molded sub- as the sunroof slides open.
strate covered with a foam–backed cloth facing. The one–
piece construction requires servicing the headliner as a To close the power sunroof from a slid–open position,
complete assembly. press the forward portion of the toggle button until the sun-
roof slides closed.
POWER SUNROOF
The sunroof is built into the roof and is made of glass. It SUN VISORS
is intended to provide light and air through the roof of the The sun visors swing down in order to block out glare.
vehicle. The sunroof is powered by an electric motor and They also swing to the side when they are released from
controlled by a toggle switch built into the interior courtesy the support. Each sun visor has a vanity mirror.
lamp assembly. The sunroof is also equipped with a sun-
shade that opens and closes manually. PASSENGER ASSIST HANDLES
POWER SUNROOF CONTROL There is a passenger assist handle for the right, rear out-
board seat and for the front passenger seat. Passengers
SWITCH can use these handles to assist in keeping their balance
The power sunroof control switch is a toggle button lo- over rough roads or during sharp turns.
cated on the right side of the interior courtesy lamp/power
sunroof control switch assembly. COAT HOOK
Operating the Power Sunroof The coat hook is fastened to the headliner above the left–
The ignition must be ON in order to operate the power sun- hand rear passenger’s seat.
roof.
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SECTION : 9R
BODY FRONT END
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9R–1 HOOD HINGES . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R–5
FASTENER TIGHTENING SPECIFICATIONS . 9R–1 HOOD PROP ROD . . . . . . . . . . . . . . . . . . . . . . . . 9R–5
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 9R–2 HOOD SECONDARY LATCH . . . . . . . . . . . . . . . 9R–6
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9R–2 HOOD LATCH RELEASE CABLE . . . . . . . . . . . . 9R–7
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R–2
RADIATOR GRILLE . . . . . . . . . . . . . . . . . . . . . . . . 9R–9
FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R–2
FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R–10
ANTICORROSION MATERIALS . . . . . . . . . . . . . 9R–2
FRONT END SEALING . . . . . . . . . . . . . . . . . . . . 9R–2 GENERAL DESCRIPTION AND SYSTEM
COWL VENT GRILLE . . . . . . . . . . . . . . . . . . . . . . 9R–3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R–14
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9R–4 BODY FRONT END . . . . . . . . . . . . . . . . . . . . . . 9R–14
SPECIFICATIONS
Cowl Vent Grille Screws 2 – 18
Fender Screws (Rear of Fascia) 4 – 35
Fender–to–A–Pillar Bolt 8 – 71
Front Bumper Fascia–to–Fender Screw 1.5 – 13
Hinge Bolts 20 15 –
Hood Latch Screws 8 – 71
Hood Release Handle Screws 1.5 – 13
Hood–to–Hinge Bolts 20 15 –
Lower Fender Bolts 8 – 71
Radiator Grille Nuts 2 – 18
Splash Shield Screws 1.5 – 13
Upper Fender Bolts 8 – 71
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9R – 2IBODY FRONT END

LUBRICATION
The hood hinges and the locking mechanisms require pe-
riodic lubrication for proper operation. Refer toSection 0B,
General Informationfor the specific types and intervals of
lubrication.
FASTENERS
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 fasten-
ers 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.
ANTICORROSION MATERIALS
In order to provide rust resistance, anticorrosion materials
have been applied to the interior surfaces of most of the
metal panels. When servicing these panels, properly re–
coat them with a service–type anticorrosion material if any
of the original material has been disturbed.
FRONT END SEALING
All locations where waterleaks may occur are sealed dur-
ing production with high quality, durable sealers. If it be-
comes necessary to reseal specific areas, use a high qual-
ity sealer of medium–bodied consistency which will retain
its flexible characteristics after drying and can be painted,
if necessary.

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BODY FRONT END 9R – 3
COWL VENT GRILLE

Removal Procedure
1. Raise the hood and support it with the hood prop.

2. Remove the nuts and the wiper arms.
3. Remove the cowl vent grille screws and the two–

piece grille.

1. Install the two–piece grille and the cowl vent grille
screws.
Tighten
Tighten the cowl vent grille screws to 2 NSm (18 lb–in).
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2. Install the nuts and the wiper arms.
HOOD
Removal Procedure
Important : Install protective coverings over the fenders
and the windshield in order to prevent damage to the paint,
the glass, and the moldings when removing and installing
the hood.
1. Raise and support the hood.
2. Mark the position of the hinge to the hood in order
to aid in alignment during installation.
3. Remove the bolts retaining the hood to both hinges.
4. With the aid of another technician, remove the hood
from the hinges.
1. With the aid of another technician, position the
hood in the location marked during removal.
2. Install the two bolts securing the hood to each
hinge.
Tighten
Tighten the hood–to–hinge bolts to 20 NSm (15 lb–ft).
3. Inspect the hood for proper alignment.

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HOOD HINGES
Removal Procedure
1. Remove the hood. Refer to”Hood” in this section.
2. Remove the bolts and the hinge.
1. Install the hinge with the bolts.
Tighten
Tighten the hinge bolts to 20 NSm (15 lb–ft).
2. Install the hood. Refer to”Hood” in this section.
HOOD PROP ROD

Removal Procedure
1. Support the hood in the open position.
2. Remove the hood prop rod by gently prying the
base from the radiator support.
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1. Install the hood prop rod by snapping the base back
into the radiator support.
HOOD SECONDARY LATCH

Removal Procedure
1. Open the hood.
2. Remove the screws and the hood latch.
3. Disconnect the hood release cable.
1. Connect the hood release cable to the latch.
2. Install the hood latch with the screws.
Tighten
Tighten the hood latch screws to 8 NSm (71 lb–in).

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HOOD LATCH RELEASE CABLE

Removal Procedure
1. Pull out the hood release handle in order to access

the screws.
2. Remove the screws and the hood release handle
from the instrument panel.

and Wheels.
5. Remove the screws and the splash shield.
6. Open the hood.

7. Remove the screws and the hood secondary latch.
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8. Remove the cable from the hood release handle.

9. Remove the cable from inside the vehicle.
1. Install the cable from inside the vehicle.

2. Install the cable to the hood release handle.

3. Install the screws and the hood secondary latch.
Tighten
Tighten the hood latch screws to 8 NSm (71 lb–in).

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4. Install the splash shield with the screws.

Tighten
Tighten the splash shield screws to 1.5NSm(13 lb–in).

and Wheels.
7. Install the hood release handle on the instrument
panel with the screws.
Tighten
Tighten the hood release handle screws to 1.5 NSm
(13 lb–in).
RADIATOR GRILLE
Removal Procedure
1. Open the hood.
2. Remove the nuts and the radiator grille.
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1. Install the radiator grille with the nuts.
Tighten
Tighten the radiator grille nuts to 2 NSm (18 lb–in).
FENDER
Removal Procedure
1. Remove the front wheel. Refer to

2. Remove the front wheel. Refer toSection 2E, Tires
and Wheels.
3. Remove the bolts and the splash shield.
4. Remove the screws underneath the front bumper

fascia.

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5. Remove the screw securing the front bumper fascia

to the fender.
6. Remove the bolts at the base of the fender.
7. Open the front door. Remove the bolt at the base of

the A–pillar.
8. Open the hood.

9. Remove the headlamp. Refer to Section 9B, Light-
ing Systems.
10. Remove the bolts along the top of the fender.
11. Remove the fender.
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1. Install the headlamp. Refer to Section 9B, Lighting

Systems.
2. Install the fender.
3. Install the bolts along the top of the fender.
Tighten
Tighten the upper fender bolts to 8 NSm (71 lb–in).
4. Install the bolt at the base of the A–pillar.

Tighten
Tighten the fender–to–A–pillar bolt to 8 NSm (71 lb–
in).
5. Install the bolts at the base of the fender.

Tighten
Tighten the lower fender bolts to 8 NSm (71 lb–in).

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6. Secure the fender to the front bumper fascia with

the screw.
Tighten
Tighten the front bumper fascia screw to 1.5 NSm (13
lb–in).
7. Secure the fender behind the front bumper fascia
with the screws.
Tighten
Tighten the fender screws to 4 NSm (35 lb–in).
8. Install the splash shield with the screws.

Tighten
Tighten the splash shield screws to 1.5 NSm(13 lb–in).
and Wheels.
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GENERAL DESCRIPTION
BODY FRONT END
This vehicle has a unitized body with a frame assembly
supporting the engine and the transaxle. The fender pan-
els and the radiator support are also integral parts of the
body.

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SECTION : 9S
BODY REAR END

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9S–1 LUGGAGE COMPARTMENT LOCK STRIKER
FASTENER TIGHTENING SPECIFICATIONS . 9S–1 (NOTCHBACK) . . . . . . . . . . . . . . . . . . . . . . . . . . 9S–9
LUGGAGE COMPARTMENT LOCK (NOTCHBACK) 9
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 9S–2 S–10
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9S–2 WEATHERSTRIP (NOTCHBACK) . . . . . . . . . . 9S–11
FUEL FILLER DOOR . . . . . . . . . . . . . . . . . . . . . . 9S–2 HATCHBACK DOOR . . . . . . . . . . . . . . . . . . . . . . 9S–12
FUEL FILLER DOOR REMOTE CABLE AND GAS SUPPORT ASSEMBLIES . . . . . . . . . . . . . 9S–12
HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9S–2 HATCHBACK DOOR LOCK STRIKER . . . . . . 9S–13
REAR DECK LID (NOTCHBACK) . . . . . . . . . . . . 9S–4 HATCHBACK DOOR LOCK . . . . . . . . . . . . . . . . 9S–14
REAR DECK LID REMOTE CABLE AND HANDLE 9S GENERAL DESCRIPTION AND SYSTEM
–6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9S–15
TORQUE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9S–8 FUEL FILLER DOOR . . . . . . . . . . . . . . . . . . . . . 9S–15
LUGGAGE COMPARTMENT LOCK CYLINDER 9S– REAR DECK LID (NOTCHBACK) . . . . . . . . . . . 9S–15
8 HATCHBACK DOOR . . . . . . . . . . . . . . . . . . . . . . 9S–15
SPECIFICATIONS
Fuel Filler Door Screws 2 – 18
Gas Support Assembly Studs 8 – 71
Hatchback Door Hinge Bolts 20 15 –
Hatchback Door Lock Screws 6 – 53
Hatchback Door Lock Striker Screws 20 15 –
Luggage Compartment Lock Cylinder Nuts 3 – 27
Luggage Compartment Lock Screws 6 – 53
Luggage Compartment Lock Striker Bolts 8 – 71
Rear Deck Lid Bolts 10 – 89
Remote Cable Handle Bolt 8 – 71
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9S – 2IBODY REAR END

FUEL FILLER DOOR
Removal Procedure
1. Remove the screws and the fuel filler door.
1. Install the fuel filler door with the screws.
Tighten
Tighten the fuel filler door screws to 2 NSm (18 lb–in).
FUEL FILLER DOOR REMOTE CABLE

AND HANDLE
Removal Procedure

2. Remove the left luggage compartment wheelhouse
trim panel, both luggage compartment rear quarter
trim panels, and the luggage compartment rear trim
3. Disconnect the cable from the fuel filler door.
4. Remove the driver front and the rear seats. Refer
5. Reposition the floor carpet on the left side of the
vehicle.
6. Remove the bolt and the handle.

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BODY REAR END 9S – 3
7. Disconnect the cable from the handle.

8. Remove the cable
1. Feed the cable from the luggage compartment to

the passenger compartment.
2. Connect the cable to the handle.
3. Install the handle with the bolt.

Tighten
Tighten the remote cable handle bolt to 8 NSm (71
lbin).
4. Install the floor carpet to its original position.
5. Install the front and the rear seats. Refer to Section
9H, Seats.
6. Connect the cable to the fuel filler door.
7. Install the left luggage compartment wheelhouse
trim panel, both luggage compartment rear quarter
trim panels, and the luggage compartment rear trim
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REAR DECK LID (NOTCHBACK)

Removal Procedure

3. Disconnect the electrical harness from the rear

deck lid hinge arm.
4. Remove the bolts and the rear deck lid.

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1. Install the rear deck lid with the bolts.

Tighten
Tighten the rear deck lid bolts to 10 NSm (89 lb–in).
2. Connect the electrical harness to the rear deck lid

hinge arm.

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REAR DECK LID REMOTE CABLE

AND HANDLE
Removal Procedure

2. Remove the luggage compartment left side wheel
house, the rear quarter, and the rear trim panels.
3. Remove the lock striker. Refer to ”Luggage
Compartment Lock Striker (Notchback)” in this
section.
4. Disconnect the cable from the lock striker.
5. Remove the driver front and the rear seats. Refer

6. Reposition the floor carpet on the left side of the
vehicle.
7. Remove the bolt and the handle.
8. Disconnect the cable from the handle.

9. Remove the cable.

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1. Feed the cable from the luggage compartment to

the passenger compartment.
2. Connect the cable to the handle.
3. Install the handle with the bolt.

Tighten
Tighten the remote cable handle bolt to 8 NSm (71
lbin).
4. Install the floor carpet to its original position.

5. Install the front and the rear seats. Refer to Section
9H, Seats.
6. Connect the cable to the lock striker.
7. Install the lock striker. Refer to ”Luggage Compart-
ment Lock Striker (Notchback)” in this section.
8. Install the luggage compartment left side wheel
house, the rear quarter, and the rear trim panels.
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TORQUE ROD
Removal Procedure
1. Remove the torque rod from the rear deck lid hinge
arm.
2. Remove the torque rod from the hinges.
1. Install the torque rod onto the hinges.
2. Install the torque rod onto the rear deck lid hinge
arm.
LUGGAGE COMPARTMENT LOCK

CYLINDER
Removal Procedure
1. Remove the hatchback door lower garnish molding
(if equipped). Refer toSection 9G, Interior Trim.
2. Disconnect the lock rod.
3. Remove the nuts and the lock cylinder.

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1. Install the lock cylinder with the nuts.
Tighten
Tighten the luggage compartment lock cylinder nuts
2. Connect the lock rod.
3. Install the hatchback door lower garnish molding (if
equipped). Refer toSection 9G, Interior Trim.

STRIKER (NOTCHBACK)
Removal Procedure

3. Remove the bolts that secure the lock striker.
4. Pull the lock striker out.

5. Disconnect the cable from the lock striker.
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1. Connect the lock release cable.
2. Install the lock striker with the bolts.

Tighten
Tighten the luggage compartment lock striker bolts to
8 NSm (71 lb–in).

(NOTCHBACK)
Removal Procedure
2. Remove the screws and the luggage compartment
lock.
4. Disconnect the lock rod.

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1. Connect the lock rod.
3. Install the luggage compartment lock with the
screws.
Tighten
Tighten the luggage compartment lock screws to 6
NSm (53 lb–in).
WEATHERSTRIP (NOTCHBACK)
Similar)
Removal Procedure
1. Open the luggage compartment lid.
2. Remove the luggage compartment rear quarter and
rear trim panels. Refer to Section 9G, Interior Trim.
3. Remove the weatherstrip from around the gutter.
1. Install the weatherstrip onto the gutter flange.
2. Inspect the weatherstrip. Make sure that the clinch
is completely seated onto the flange.
3. Using a water hose without a nozzle, test the rear
deck lid to make sure that no leaks are present.
4. Install the luggage compartment rear quarter and
rear trim panels. Refer to Section 9G, Interior Trim.
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HATCHBACK DOOR
Removal Procedure
1. Open and suitably support the hatchback door.
2. Disconnect the hatchback door grommet, the elec-
trical connector, and the washer hose.
3. Remove the gas support assemblies from the
hatchback door and the body. Refer to ”Gas Sup-
port Assemblies” in this section.
and the hatchback door from the hinges.
1. With the aid of another technician, install the hatch-
back door to the hinges with the bolts.
Tighten
Tighten the hatchback door hinge bolts to 20 NSm (15
lb–ft).
2. Install the gas support assemblies to the hatchback
door and the body. Refer to ”Gas Support Assem-
blies” in this section.
3. Connect the hatchback door electrical connector,
the washer hose, and the grommet.
GAS SUPPORT ASSEMBLIES

Removal Procedure
1. Open and suitably support the hatchback door.
2. Unscrew and remove the gas support assembly
from the hatchback door and the body.

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1. Install the gas support assembly onto the hatch-
back door and the body.
Tighten
Tighten the gas support assembly studs to 8 NSm (71
lb–in).
HATCHBACK DOOR LOCK STRIKER

Removal Procedure
3. Remove the screws that secure the lock striker.
1. Install the lock striker with the screws.
Tighten
Tighten the hatchback door lock striker screws to 20
NSm (15 lb–ft).
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HATCHBACK DOOR LOCK

Removal Procedure
2. Remove the hatchback door lower garnish molding.
3. Remove the screws and the hatchback lock.
4. Disconnect the lock rods.
1. Connect the lock rods.
2. Install the hatchback lock with the screws.
Tighten
Tighten the hatchback door lock screws to 6 NSm (53
lb–in).
3. Install the hatchback door lower garnish molding.

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hemmed around the perimeter and bonded together with

GENERAL DESCRIPTION structural adhesive. The torque rods assist in the opening
of the rear deck lid and hold it in the open position.
HATCHBACK DOOR
The hatchback door consists of the rear hatch glass within
FUEL FILLER DOOR a steel frame. The steel frame is made of an inner and an
The fuel filler door attaches to the fuel tank pocket on the outer panel hemmed around the perimeter, and bonded
right side of the vehicle. together with structural adhesive. The gas support assem-
blies assist in the opening of the hatchback door, and can
REAR DECK LID (NOTCHBACK) hold the door open.
The rear deck lid consists of an inner and an outer panel
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SECTION : 9T
REMOTE KEYLESS ENTRY AND ANTI–THEFT

SYSTEM
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 9T–1 PASSWORD PROGRAMMING . . . . . . . . . . . . . . 9T–9
FASTENER TIGHTENING SPECIFICATIONS . 9T–1 GENERAL DESCRIPTION AND SYSTEM
SCHEMATIC AND ROUTING DIAGRAMS . . . . . 9T–2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9T–11
REMOTE KEYLESS ENTRY AND ANTI–THEFT REMOTE KEYLESS ENTRY AND ANTI–THEFT
SYSTEM (1 OF 3) . . . . . . . . . . . . . . . . . . . . . . . 9T–2 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9T–11
REMOTE KEYLESS ENTRY AND ANTI–THEFT REMOTE LOCKING AND UNLOCKING . . . . . . 9T–11
SYSTEM (2 OF 3) . . . . . . . . . . . . . . . . . . . . . . . 9T–3 SECURITY INDICATOR . . . . . . . . . . . . . . . . . . . . 9T–11
WIRING HARNESS CONNECTORS . . . . . . . . . 9T–5 INTRUSION SENSING . . . . . . . . . . . . . . . . . . . . . 9T–11
CONTROL MODULE/RECEIVER CONNECTOR 9T– SIREN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9T–12
6 VEHICLE LOCATOR . . . . . . . . . . . . . . . . . . . . . . 9T–12
MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 9T–7 AUTOLOCKING (SAFETY LOCK) . . . . . . . . . . 9T–12
ON–VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9T–7 CONTROL MODULE/RECEIVER . . . . . . . . . . . 9T–12
CONTROL MODULE/RECEIVER . . . . . . . . . . . . 9T–8 FAULT OR ALARM INDICATION . . . . . . . . . . . 9T–12
SIREN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9T–8 PANIC BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . 9T–12
SPECIFICATIONS
Siren Mounting Screws 4 – 35
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9T – 2IREMOTE KEYLESS ENTRY AND ANTI–THEFT SYSTEM

REMOTE KEYLESS ENTRY AND ANTI–THEFT SYSTEM (1
OF 3)

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REMOTE KEYLESS ENTRY AND ANTI–THEFT SYSTEM 9T – 3
REMOTE KEYLESS ENTRY AND ANTI–THEFT SYSTEM (2

OF 3)
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WIRING HARNESS CONNECTORS
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CONTROL MODULE/RECEIVER CONNECTOR
9 – –
Termina Color Description
l 10 DK GRN Lock
1 – – 11 BLK Ground
2 DK BLU Unlock 12 YEL Siren
3 – – 13 DK GRN Door and Trunk Tamper
Switches
4 WHT Security Indicator
14 BLK/WHT Trunk Open Switch
5 LT BLU Left Turn Signal Bulb
15 WHT Door Contact Switch
6 GRY Diagnostic Communica-
tion 16 DK GRN Hood Open Switch
7 – – 17 PNK Ignition +
8 DK BLU Right Turn Signal Bulb 18 WHT Battery +

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DAEWOO V–121 BL4
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2. Remove the rear portion of the floor console. Refer

to Section 9G, Interior Trim.
CONTROL MODULE/RECEIVER 3. Disconnect the control module/receiver electrical
connector.
Removal Procedure 4. Slide the control module/receiver away from its
1. Disconnect the negative battery cable. mounting bracket.
1. Install the control module/receiver on its mounting
bracket.
2. Connect the control module/receiver electrical con-
nector.
3. Install the floor console. Refer to Section 9G, Interi-
or Trim.
SIREN
Removal Procedure
1. Remove the siren electrical connector.
2. Remove the siren bracket mounting screws and
siren.

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1. Install the siren with the mounting screws.
Tighten
Tighten the siren mounting screws to 4 NSm (35 lbin).
2. Connect the siren electrical connector.
PASSWORD PROGRAMMING
If a transmitter is lost or damaged, the control module/ re-
ceiver must be re–programmed to communicate with a
new transmitter. The passwords recorded in the control
module/receiver should not be deleted when power is not
connected to the control module/receiver.
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Each control module/receiver should be able to record five 1. Connect the scan tool to the data link connector
passwords. The following method is used to record new (DLC).
passwords in the control module/receiver: 2. Turn the ignition ON.
3. Use the scan tool to delete the current passwords.
4. Send the programming mode message to the con-
trol module/receiver.
5. Press any button of the transmitter to generate a
data code, including a password which will be re-
corded by the control module/receiver. The control
module/receiver will send a response message to
the scan tool to indicate that the first password has
been recorded.
6. Press any button of the transmitter to generate a
data code, including a password which will be re-
corded by the control module/receiver. The control
module/receiver will then send a response mes-
sage to the scan tool to indicate that the second
password has been recorded.
7. Press any button of the transmitter three more
times until the control module/receiver has indi-
cated to the scan tool that the third, fourth, and fifth
passwords have been recorded.
9. Disconnect the scan tool.
The control module/receiver leaves the programming
mode automatically and switches to the normal operating
mode when either of the following conditions occur:
S The scan tool is disconnected from the DLC.
S Five passwords are recorded in the control module/
receiver.

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S Keyless entry and anti–theft control module/receiv-

GENERAL DESCRIPTION er.
S Security indicator.
AND SYSTEM OPERATION S Trunk open switch.
S Trunk tamper switch.
REMOTE KEYLESS ENTRY AND S Front door tamper switches.
S Door contact switches.
ANTI–THEFT SYSTEM S Door contact switches.
The remote keyless entry and anti–theft system can per- S Central door lock relay.
form the following functions: S Turn signal bulbs.
S Remotely lock and unlock the vehicle doors by S Siren.
means of a hand–held, high–frequency transmitter. S Hood open switch.
S Sense intrusion into the vehicle. REMOTE LOCKING AND UNLOCKING
S Activate a warning in the event of an intrusion.
The hand–held transmitter locks and unlocks the vehicle
S Help the driver find the vehicle in a parking area.
doors by sending radio waves to the control module/re-
S Automatically re–lock the doors if the door or the
ceiver in the vehicle. The effective range of the transmitter
trunk is not opened within 30 seconds after the ve- varies between 5 and 10 meters, (approximately 16 to 32
hicle has been unlocked by the remote keyless
feet), depending on whether or not objects, such as other
entry.
vehicles are blocking the path of the radio waves.
S Communicate serial data to a scan tool to help
The transmitter has a LOCK button and an UNLOCK but-
diagnose system faults.
ton which only function when the ignition is OFF. Pressing
The remote keyless entry and anti–theft system consists the UNLOCK button has the following effects:
of the following components:
S The doors are unlocked.
S The turn signal bulbs flash twice.
S The control module is disarmed.
Pressing the LOCK button has the following effects:
S The doors are locked.
S The turn signal bulbs flash once.
S The control module is armed.
The transmitter has a replaceable battery. The battery is
designed to last at least three years before replacement
is necessary.
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 0.1 second
and OFF for 0.7 second. It then flashes that frequency until
the control module/receiver is disarmed.
INTRUSION SENSING
The anti–theft function is armed if the transmitter sends
the LOCK message to the control module/receiver when
the ignition is OFF. When the hood, door, or trunk is
opened, the hood open, door contact, or trunk open switch
sends a ”ground” signal to the control module/receiver.
Unless the control module/receiver is disarmed, the siren
will be activated when the ”ground” signal is received from
the trunk open, hood open, or door contact switches.
The following actions disarm the anti–theft system:
S An UNLOCK message is received from the trans-
mitter.
S Key operation is detected by the tamper switches.
(The tamper switches are operated by the lock cyl-
inders in the front doors and trunk.)
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The alarm will also be activated if the control module/re- switches. It activates the alarm if an intrusion is detected.
ceiver detects voltage from the ignition before either of the The controlmodule/receiver also has a self–diagnostic
following conditions occur: function which will display trouble codes. In order to dis-
S An UNLOCK message is received from the trans- play trouble codes, a scan tool must be connected to the
mitter. data link connector (DLC).
S Key operation is indicated by the tamper switches.
The control module/receiver will not communicate with
transmitters from other vehicles because there are over
SIREN four billion possible electronic password combinations. It
The remote keyless entry system is armed when the is highly unlikely that any transmitters will use the same
LOCK message is received from the transmitter when the password. The control module/receiver has an attached
ignition is OFF. When the system is armed, it will activate antenna to detect signals from the transmitter.
the siren and flash the turn signals for 28 seconds if any
of the following conditions occur:
S Close all the windows. FAULT OR ALARM INDICATION
S Turn the ignition key to LOCK and remove the key. When the UNLOCK button on the remote transmitter is
S Have all passengers get out of the vehicle. pressed, the control module/receiver will flash the parking
S Close all doors, the hood and the turnk lid. lights to indicate information about the remote keyless
S The control module/receiver detects ignition voltage entry and anti–theft system.
while the system is armed.
The siren will not operate if any of the following conditions Normal Condition: If there has not been an intrusion, and
occur after the system has been armed: no fault has been detected, the control module/receiver
will signal a normal condition when the UNLOCK button is
S The door is opened with the key.
pressed. The parking lights will flash twice for 0.5 second,
S The trunk is opened with the key.
with a 0.5 second pause between flashes.
S The UNLOCK or LOCK button on the remote trans-
mitter is pressed within 2 seconds after the siren is Fault Indication: If there is a fault in the remote keyless
activated. entry and anti–theft system, the control module/receiver
will signal the fault when the UNLOCK button is pressed.
VEHICLE LOCATOR The parking lights will flash twice for 1 second, with a 0.5
The remote keyless entry system assists the driver in lo- second pause between flashes.
cating the vehicle. When the vehicle is unlocked with the
remote control, the turn signals flash twice to indicate the Alarm Indication: If there has been an intrusion since the
location of the vehicle. The duration of the flashes and the last time the LOCK button was pressed, the control mod-
length of time between flashes is used to indicate certain ule/receiver will signal that there has been an intrusion
vehicle conditions. Refer to ”Fault or Alarm Indication” in when the UNLOCK button is pressed. The parking lights
this section. will flash twice for 0.5 second, with a 1.5 second pause be-
tween flashes.
AUTOLOCKING (SAFETY LOCK)
Alarm and fault information will be erased the next time the
The remote keyless entry system features an autolocking
transmitter arms the control module/receiver by transmit-
feature. If the doors are unlocked with the remote transmit-
ting a LOCK message.
ter when the control module/receiver is in the armed
mode, the doors are automatically re–locked after 30 sec-
onds unless any of the following events occur:
PANIC BUTTON
S A door is opened.
S The ignition is ON. In addition to the LOCK and UNLOCK buttons on the
S The trunk is opened. transmitter, there is another button which is used to acti-
S The hood is opened. vate the siren if a threatening situation occurs while the
driver is approaching the vehicle. If the panic button is held
CONTROL MODULE/RECEIVER down for 2 seconds, the siren will be activated for 30 sec-
onds, and the turn signal lamps will flash during that time.
The remote keyless entry control module/receiver is con-
tained in the floor console. The module/receiver pro-
cesses signals from the remote transmitter and various

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Performance – Automatic Transaxle

Clutch – Manual Transaxle

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Application 1.5L SOHC 1.6L DOHC

Tire and Wheel

DAEWOO V–121 BL4

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DAEWOO V–121 BL4

VEHICLE DIMENSIONS AND WEIGHTS

Vehicle Weights Ĉ 3 Door

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Vehicle Weights Ĉ 4 Door

DAEWOO V–121 BL4

STANDARD BOLT SPECIFICATIONS

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tions require higher viscosity engine oils for satisfactory lu-

DAEWOO V–121 BL4

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SCHEDULED MAINTENANCE CHARTS

Drive belt 1.5L I R I R I

Engine oil & engine oil filter (1)(3) R R R R R R R R R R R R R R R R R

Engine coolant (3) I I I I R I I I I R I I I I R I I

DAEWOO V–121 BL4

Chassis and Body

Maintenance Item Maintenance Interval

Exhaust pipes & mountings I* I* I* I* I* I* I* I*

Rear hub bearing & clearance I I I I I I I I

Tire condition & inflation pres- I I I I I I I I I I I I I I I I I

Wheel alignment (8) Inspect when abnormal condition is noted.

Tire rotation Rotate every 6,000 miles (9,600 km)

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Engine Coolant Level and Condition

Steering System Operation Fluid Leak Check

DAEWOO V–121 BL4

EACH TIME THE OIL IS CHANGED AT LEAST ANNUALLY

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sion protection and engine operating temperature. Inspect

RECOMMENDED FLUIDS AND LUBRICANTS

DAEWOO V–121 BL4

S Use genuine DAEWOO parts.

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DAEWOO V–121 BL4

Schemetic Of On Board Refueling Vapor Recovery System

1. Manifold (Intake) 9. Discriminator

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1. Fuel Tank 6. Purge Valve

DAEWOO V–121 BL4

VEHICLE AND COMPONENT IDENTIFICATION

Certification plate 1. Production Date

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VIN Plate Location

Certification Label Engraved VIN Location

The vehicle identification number (VIN) is engraved in the

DAEWOO V–121 BL4

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DAEWOO V–121 BL4

Engine Number Location – DOHC Body Identification Number Plate Location

The body identification number plate is attached to the top

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1. Assembly Plant (Windsor, Canada)

Automatic Transaxle Identification Number

The manual transaxle identification number is attached to