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  4. MATIZ
  5. Service Manual

Daewoo MATIZ Service Manual

Summary of MATIZ

  • Page 1

    Section index front matter 0a general information 0b engine 1 service matiz foreword this manual includes procedure for maintenance, adjustment, service operation and removal and installation of components. All information, illustrations and specifications con- tained in this manual are based on the...

  • Page 2: Engine

    Engine contents section 1a general engine information section 1b sohc engine mechanical section 1d engine cooling section 1e engine electrical section 1f engine controls section 1g engine exhaust.

  • Page 3: Suspension

    Suspension contents section 2a suspension diagnosis section 2b wheel alignment section 2c front suspension section 2d rear suspension section 2e tires and wheels.

  • Page 4: Driveline/axle

    Driveline/axle contents section 3b manual transaxle drive axle.

  • Page 5: Brakes

    Brakes contents section 4a hydraulic brakes section 4b master cylinder section 4c power booster section 4d front disc brakes section 4e rear drum brakes section 4f antilock brake system section 4g parking brake.

  • Page 6: Transaxle

    Transaxle contents section 5b five–speed manual transaxle section 5c clutch.

  • Page 7: Steering

    Steering contents section 6a power steering system section 6b power steering pump section 6c power steering gear section 6d manual steering gear section 6e steering wheel and column.

  • Page 8: And Air Conditioning)

    Hvac (heating, ventilation, and air conditioning) contents section 7a heating and ventilation system section 7b manual control heating, ventilation, and air conditioning system.

  • Page 9: Restraints

    Restraints contents section 8a seat belts section 8b supplemental inflatable restraints (sir).

  • Page 10: Body And Accessories

    Body and accessories contents section 9a body wiring system section 9b lighting systems section 9c horns section 9d wipers / washer systems section 9e instrumentation / driver information section 9f audio systems section 9g interior trim section 9h seats section 9i waterleaks section 9j windnoise se...

  • Page 11: Section 1A

    Daewoo m-150 bl2 section 1a general engine information table of contents description and operation 1a-2 . . . . . . . . . . . . . . . . . . Cleanliness and care 1a-2 . . . . . . . . . . . . . . . . . . . . . . On-engine service 1a-2 . . . . . . . . . . . . . . . . . . . . . . . . Component locator 1...

  • Page 12

    1a – 2 general engine information daewoo m-150 bl2 description and systemoperation cleanliness and care an automobile engine is a combination of many ma- chined, honed, polished and lapped surfaces with toler- ances that are measured in the ten–thousandths of an inch. When any internal engine parts ...

  • Page 13: Component Locator

    General engine information 1a – 3 daewoo m-150 bl2 component locator engine compartment (typical) (left–hand drive shown, right–hand drive similar) d102a401 1 power steering oil reservoir 2 coolant reservoir 3 canister 4 canister solenoid 5 manifold absolute pressure (map) sensor 6 intake manifold 7...

  • Page 14

    1a – 4 general engine information daewoo m-150 bl2 engine compartment (euro iii) (left–hand drive shown, right–hand drive similar) maa1a010 1 power steering oil reservoir 2 coolant reservoir 3 canister purge solenoid 4 manifold absolute pressure (map) sensor 5 intake manifold 6 throttle position (tp...

  • Page 15

    General engine information 1a – 5 daewoo m-150 bl2 diagnostic information procedure general diagnosis ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ condition ÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑ probable cause ÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑ correction hard starting (with malfunction of d fault...

  • Page 16

    1a – 6 general engine information daewoo m-150 bl2 general diagnosis (cont’d) ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ condition ÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑ probable cause ÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑ correction hard starting (with others d broken timing belt. D replace the belt. Normal cranking) d malfunction of pos...

  • Page 17

    General engine information 1a – 7 daewoo m-150 bl2 general diagnosis (cont’d) ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ condition ÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑ probable cause ÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑ correction rough engine idling malfunction of ignition system d loosening or damage of the distributor rotor or cap. ...

  • Page 18

    1a – 8 general engine information daewoo m-150 bl2 general diagnosis (cont’d) ÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑ condition ÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑ probable cause ÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑ correction engine surging (engine power makes fluctuation in a fixed others d...

  • Page 19

    General engine information 1a – 9 daewoo m-150 bl2 general diagnosis (cont’d) ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ condition ÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑ probable cause ÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑ correction poor fuel malfunction of d improper ignition timing. D adjust the ignition timing. Consumption ignition sy...

  • Page 20

    1a – 10 general engine information daewoo m-150 bl2 general diagnosis (cont’d) ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ condition ÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑ probable cause ÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑ correction low oil pressure malfunction of lubrication d lowered function of the oil pump. D replace the pump. Syste...

  • Page 21

    General engine information 1a – 11 daewoo m-150 bl2 checking engine fluid level check the engine fluid level or condition. If needed, refill or replace the oil. Check the engine oil level within engine normal operat- ing temperature as follows ; 1. After stopping the engine, wait for a few minutes t...

  • Page 22

    1a – 12 general engine information daewoo m-150 bl2 checking engine timing belt after checking the timing belt for looseness, crack, wear or tension, replace the belt if necessary. Checking accessory belt after checking the alternator belt (e), air conditioning/ power steering belt (f), air conditio...

  • Page 23

    General engine information 1a – 13 daewoo m-150 bl2 checking air cleaner element if the air cleaner element becomes dirty, engine efficien- cy could be deteriorated. Be sure to check the element often. Especially, if a vehicle frequently runs on a dusty road, check and replace the element often. Che...

  • Page 24: Specifications

    1a – 14 general engine information daewoo m-150 bl2 specifications general specifications ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ application ÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑ description ÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ maximum speed ÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑ 144 km/h (90 mph...

  • Page 25

    General engine information 1a – 15 daewoo m-150 bl2 engine performance curve d maximum power : 51 ps (37.5 kw) (at 6,000 rpm) d maximum torque : 7 kg s m (68.6 n s m) (at 4,600 rpm) d12a101a.

  • Page 26: Section 1B

    Daewoo m-150 bl2 section 1b sohc engine mechanical caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury a...

  • Page 27: Description And Operation

    1b – 2 sohc engine mecanical daewoo m-150 bl2 description and operation engine type the engine is 4-cycle, water-cooled, in-line 3 cylinders with displacement of 796cc (68.5 × 72.0mm) (2.70 × 2.83 in.). Engine model (specifications) f8c type sohc / 2 valve (mpi) maximum power (kw/rpm) 37.5 / 6,000 m...

  • Page 28

    Sohc engine mecanical 1b – 3 daewoo m-150 bl2 parts are installed in the cross flow arrangement. The rocker arm (i) operates in seesaw motion to close and open the intake and exhaust valves (j) with camshaft by turning the rocker arm shaft of each intake and exhaust part. Engine block as the largest...

  • Page 29

    1b – 4 sohc engine mecanical daewoo m-150 bl2 timing belt and pulley the timing belt connects the camshaft timing pulley (w) and the crankshaft timing pulley (x). The timing belt coordinates the crankshaft and the camshaft and keeps them synchronized. The timing belt also turns the cool- ant pump (y...

  • Page 30: Component Locator

    Sohc engine mecanical 1b – 5 daewoo m-150 bl2 component locator cylinder head d12b4011 1 oil filler cap 2 cylinder head cover 3 cylinder head cover (euro iii) 4 distributor case 5 camshaft 6 exhaust rocker arm 7 cylinder head gasket 8 cylinder head 9 intake rocker arm 10 exhaust valve 11 intake valv...

  • Page 31

    1b – 6 sohc engine mecanical daewoo m-150 bl2 engine block d21b0011 1 oil level gauge stick 2 piston 3 connecting rod 4 engine block 5 oil filter 6 flywheel 7 crankshaft 8 oil pan 9 oil pump strainer 10 oil pump assembly.

  • Page 32

    Sohc engine mecanical 1b – 7 daewoo m-150 bl2 manifold & air flow system d21b0021 1 intake manifold 2 exhaust gas recirculation (egr) pipe 3 exhaust gas recirculation (egr) valve and solenoid 4 throttle body assembly 5 air filter assembly 6 resonator 7 snorkel 8 oxygen sensor 9 exhaust manifold 10 e...

  • Page 33

    1b – 8 sohc engine mecanical daewoo m-150 bl2 timing belt & engine mount d12b4041 1 engine mount damping block 2 engine mount intermediate bracket 3 engine mount brace bracket 4 transaxle mount bracket 5 transaxle mount damping block 6 engine mount front bracket 7 engine mount front damping bush 8 t...

  • Page 34

    Sohc engine mecanical 1b – 9 daewoo m-150 bl2 diagnostic information and procedure compression pressure check tools required 09915–64510 compression pressure gauge check the compression pressure in the following proce- dures: 1. Warm up the engine to the normal operating tempera- ture (cooling tempe...

  • Page 35

    1b – 10 sohc engine mecanical daewoo m-150 bl2 adjustment of valve clearance adjust the valve clearance in the following procedures: 1. Remove the air filter/resonator assembly and the relevant parts installed on the cylinder head cover. 2. Remove the cylinder head cover hexagon bolts and remove the...

  • Page 36

    Sohc engine mecanical 1b – 11 daewoo m-150 bl2 the measured value of valve clearance should meet the specified value. If not, adjust the valve clearance. Important: in case of hot engine, warm up the engine until the electric cooling fan begins to work and stop the engine to adjust the clearance wit...

  • Page 37

    1b – 12 sohc engine mecanical daewoo m-150 bl2 d102b310 5. If the ignition timing exceeds the specified value, loosen the distributor bolts and adjust it to the speci- fied ignition timing by turning the distributor body (s). D102b311 valve timing check and adjustment check the valve timing in the f...

  • Page 38

    Sohc engine mecanical 1b – 13 daewoo m-150 bl2 adjust the valve timing in the following procedures: 1. Loosen the bolt and remove the timing belt pulley (c). In loosening the bolt, use the driver (h) in the picture shown. D102b315 2. Remove the oil level gauge guide tube (i) and the tim- ing belt fr...

  • Page 39: Section 1D

    Daewoo m-150 bl2 section 1d engine cooling caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damag...

  • Page 40: Description And Operation

    1d – 2 engine cooling daewoo m-150 bl2 description and operation general description the cooling system maintains the engine temperature at an efficient level during all engine operating conditions. When the engine is cold the cooling system cools the engine slowly or not at all. This slow cooling o...

  • Page 41

    Engine cooling 1d – 3 daewoo m-150 bl2 coolant pump the belt-driven centrifugal coolant pump consists of an impeller, a drive shaft, and a belt pulley. The impeller is supported by a completely sealed bear- ing. The coolant pump is serviced as an assembly and, therefore, cannot be disassembled. Ther...

  • Page 42

    1d – 4 engine cooling daewoo m-150 bl2 the main fan size is 320 mm (12.6 in.) in diameter with seven blades(k) to aid the air flow through the radiator and the condenser. An electric motor(l) attached to the radiator support drives the fan. A/c off or non-a/c model d the cooling fan is actuated by t...

  • Page 43: Component Locator

    Engine cooling 1d – 5 daewoo m-150 bl2 component locator coolant hose and components d12d4011 1 radiator coolant return hose 2 upper radiator hose 3 not used 4 radiator assembly 5 lower radiator hose 6 throttle body assembly 7 surge tank hose 8 surge tank 9 coolant temperature sensor 10 engine coola...

  • Page 44

    1d – 6 engine cooling daewoo m-150 bl2 radiator/fan d12d4021 1 radiator assembly 2 electric cooling fan assembly.

  • Page 45

    Engine cooling 1d – 7 daewoo m-150 bl2 diagnostic information and procedure coolant leaks test 1. Remove the surge tank cap after the engine cools. 2. Check the coolant level. 3. Install a suitable cooling system pressure tester(b) to the surge tank filler neck using the adapter(a) and pressurize (1...

  • Page 46

    1d – 8 engine cooling daewoo m-150 bl2 cooling system diagnosis ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ condition ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ probable cause ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ correction engine overheats d a loss of the coolant. D add the coolant. D a weak coolant solution. D confirm that the coolant solut...

  • Page 47: Repair Instructions

    Engine cooling 1d – 9 daewoo m-150 bl2 repair instructions on–vehicle service d12d5011 draining and refilling the cooling system caution: 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 veh...

  • Page 48

    1d – 10 engine cooling daewoo m-150 bl2 d102d503 d add the clean water to the surge tank (2). 5. Run the engine until the thermostat opens. You can tell the thermostat is open when both radiator hoses are hot to the touch. 6. Stop the engine and disconnect the lower radiator hose to drain the coolan...

  • Page 49

    Engine cooling 1d – 11 daewoo m-150 bl2 d102d505 installation procedure 1. Install the surge tank to the vehicle. D install the surge tank with pressing down (1). D connect the overflow hoses to the surge tank (2). 2. Secure the overflow hoses to the surge tank with the hose clamps. 3. Fill the surg...

  • Page 50

    1d – 12 engine cooling daewoo m-150 bl2 d12d5091 4. Remove the electric cooling fan. Refer to “electric cooling fan” in this section. 5. Remove the radiator. D remove the bolts (1). D remove the radiator support brackets (2). D remove the radiator (3). 6. Check the radiator for breaking, clog or oth...

  • Page 51

    Engine cooling 1d – 13 daewoo m-150 bl2 d loosen the hose clamp (1). D disconnect the upper radiator hose (2). D102d513 4. Remove the thermostat. D remove the bolts (1). D remove the thermostat housing (2). D remove the thermostat with the gasket (3). 5. Check the gasket for crack or other damage. 6...

  • Page 52

    1d – 14 engine cooling daewoo m-150 bl2 maa1d020 4. Remove the thermostat. D remove the bolts. D remove the thermostat housing. D remove the thermostat with the gasket. 5. Check the gasket for crack or other damage. 6. Inspect the valve seat for foreign matter that could prevent the valve from seati...

  • Page 53

    Engine cooling 1d – 15 daewoo m-150 bl2 d102d517 engine coolant temperature sensor removal procedure 1. Disconnect the negative battery cable. 2. Disconnect the lower radiator hose and drain the coolant “draining and refilling the cooling system” in this section. 3. Remove the engine coolant tempera...

  • Page 54

    1d – 16 engine cooling daewoo m-150 bl2 9–12 n s m 9–12 n s m d12d520a d12d521a installation procedure 1. Install the coolant pump with the new gasket. Tighten tighten the bolts and the nuts to 9–12 n s m (80–106 lb-in) (a). 2. Install the rear timing belt cover. Tighten tighten the bolts to 9–12 n ...

  • Page 55: Specifications

    Engine cooling 1d – 17 daewoo m-150 bl2 specifications general specifications application description unit standard limit cooling system cooling type – forced water circulation coolant coolant capacity l/qt 3.8/4.00 thermostat type – pellet type temperature(opened initially) ° c( ° f) 82(180) thermo...

  • Page 56

    1d – 18 engine cooling daewoo m-150 bl2 fastener tightening specifications application n s m lb-ft lb-in engine coolant temperature sensor 10 – 89 coolant temperature sensor 20 15 – coolant pipe bolt 8 – 15 – 71 – 130 electric cooling fan motor nut 3.0 – 3.2 – 27 – 28 electric cooling fan assembly b...

  • Page 57: Section 1E

    Daewoo m-150 bl2 section 1e engine electrical caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and da...

  • Page 58: Description And Operation

    1e – 2 engine electrical daewoo m-150 bl2 description and operation battery the battery has three major functions in the electrical system. First, the battery provides a source of energy for cranking the engine. Second, the battery acts as a voltage stabilizer for the electrical system. Finally, the...

  • Page 59

    Engine electrical 1e – 3 daewoo m-150 bl2 charging procedure 1. Batteries with the green dot showing do not require charging unless they have just been discharged, such as in cranking a vehicle. 2. When charging sealed-terminal batteries out of the vehicle, install the adapter kit. Make sure all the...

  • Page 60

    1e – 4 engine electrical daewoo m-150 bl2 3. In both vehicles, apply the parking brake firmly. Notice: make sure the cables are not on or near pulleys, fans, or other parts that will move when the engine starts, damaging the parts. 4. Shift a manual transaxle to neutral. Caution: do not use cables t...

  • Page 61

    Engine electrical 1e – 5 daewoo m-150 bl2 the sequence of ignition order. It also adjusts the ignition timing according to the engine condition. This vehicle uses the distributor (optical sensor type) which controls the preminary current of the ignition coil by the ecm. The ignition timing change is...

  • Page 62: Component Locator

    1e – 6 engine electrical daewoo m-150 bl2 component locator starting system d102e401 1 starter motor assembly 2 starter solenoid assembly 3 starter housing 4 shift lever 5 armature set 6 armature 7 pinion gear assembly 8 ring set 9 field frame assembly 10 brush holder assembly 11 contact end frame a...

  • Page 63

    Engine electrical 1e – 7 daewoo m-150 bl2 charging system (a-type : mando) d102e402 1 generator assembly 2 generator shackle 3 generator drive end nut 4 generator pully 5 generator collar (large) 6 generator front bracket 7 front bearing 8 bearing spot plate 9 generator collar (small) 10 generator r...

  • Page 64

    1e – 8 engine electrical daewoo m-150 bl2 charging system (b-type : dac) d102e403 1 generator assembly 2 generator shackle 3 generator drive end nut 4 generator pully 5 generator collar 6 generator drive end bracket 7 generator stator assembly 8 frame bearing 9 generator fan 10 generator rotor assem...

  • Page 65

    Engine electrical 1e – 9 daewoo m-150 bl2 ignition system d102e404 1 ignition coil 2 spark pulg 3 ignitoin wire (#0) 4 ignition wires (#1, #2, #3) 5 support clamp 6 mounting clamp 7 distributor assembly 8 coupling 9 distributor oil seal 10 distributor housing 11 distributor shaft 12 plate 13 optical...

  • Page 66

    1e – 10 engine electrical daewoo m-150 bl2 diagnostic information and procedure ignition system condition probable cause correction no crank d low battery voltage. D charging the battery or replace the battery. D battery cable is loose, corroded, or damaged. D repair or replace the battery cable. D ...

  • Page 67

    Engine electrical 1e – 11 daewoo m-150 bl2 ignition system (cont’d) condition probable cause correction hard to starting the engine d faulty ignition coil. D replace the ignition coil. D faulty distributor (include the optical sensor). D replace the distributor or the optical sensor. D faulty spark ...

  • Page 68

    1e – 12 engine electrical daewoo m-150 bl2 battery load test 1. Check the battery for obvious damage, such as a cracked or broken case or cover, which could permit the loss of electrolyte. If obvious damage is noted, re- place the battery. Caution: do not charge the battery if the hydrometer is clea...

  • Page 69

    Engine electrical 1e – 13 daewoo m-150 bl2 generator system check when operating normally, the generator indicator lamp will come on when the ignition switch is in the on posi- tion and go out when the engine starts. If the lamp oper- ates abnormally or if an undercharged or overcharged battery cond...

  • Page 70: Repair Instructions

    1e – 14 engine electrical daewoo m-150 bl2 repair instructions on–vehicle service d12e5011 starter removal procedure 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector and clip around the starter. D remove the engine oil temperature sensor to dis- connect the harness co...

  • Page 71

    Engine electrical 1e – 15 daewoo m-150 bl2 d102e504 generator removal procedure 1. Disconnect the negative battery cable. 2. Disconnect the harness connector. D remove the battery harness connector nut to dis- connect the battery positive connector (1). D disconnect the generator harness connector (...

  • Page 72

    1e – 16 engine electrical daewoo m-150 bl2 d12e508a 35–41 n s m 68–83 n s m installation procedure 1. Install in the reverse order of removal except genera- tor driver velt. 2. Install the engine mounting lower bracket bolts and nut. Tighten d tighten the engine mounting lower bracket bolts to 35–41...

  • Page 73

    Engine electrical 1e – 17 daewoo m-150 bl2 d12e513a installation procedure 1. Install in the reverse order of removal. 2. Install the battery rod and cable nuts. Tighten d tighten the battery rod nut to 6–8 n s m (53–71 lb- in) (a). D tighten the battery cable nut to 9-12 n s m (80–106 lb-in) (b). D...

  • Page 74

    1e – 18 engine electrical daewoo m-150 bl2 d102e517 ignition coil removal procedure 1. Disconnect the negative battery cable. 2. Disconnect the ignition wires and ignition coil connec- tor. D disconnect the ignition wire (1). D disconnect the ignition coil connector by pushing the connector’s lock(2...

  • Page 75: Repair Instructions

    Engine electrical 1e – 19 daewoo m-150 bl2 repair instructions unit repair d102e701 starter motor inspection / measurement (before the overhaul) 1. Remove the starter. Refer to “starter” in this section. 2. Pinion clearance inspection. D disconnect the starter motor terminal m (1). D connect the 12-...

  • Page 76

    1e – 20 engine electrical daewoo m-150 bl2 d102e704 d inspect the pinion gear’s moving to the outside (2). D if the pinion gear does not move outside, replace the magnetic switch. D102e705 4. Solenoid hold-in test. D disconnect the starter motor terminal m (1). D connect the 12-volt battery lead to ...

  • Page 77

    Engine electrical 1e – 21 daewoo m-150 bl2 d102e708 d check the returning speed of pinion gear (2). If the returning speed is fast, the operation is nor- mal. D replace the solenoid if the operation is abnormal. D102e709 5. No-road test. D connect the 12-volt battery lead to the starter cir- cuit. D...

  • Page 78

    1e – 22 engine electrical daewoo m-150 bl2 d102e712 2. Remove the brush holder assembly. D remove the starter motor terminal m nut (1). D remove the brush holder assembly (2). D102e713 3. Remove the field frame assembly from the armature set (1). D102e714 4. Remove the solenoid assembly. D remove th...

  • Page 79

    Engine electrical 1e – 23 daewoo m-150 bl2 d102e716 inspection / measurement (after the overhaul) 1. Ground test for armature coil. D inspect the insulation between commutator and ar- mature coil using the voltmeter. D replace the armature assembly if necessary. D102e717 2. Short circuit test for ar...

  • Page 80

    1e – 24 engine electrical daewoo m-150 bl2 d12e720a 9-12 n s m 4-6 n s m assembly procedure 1. Install in the reverse order of removal. 2. Install the bolts / nuts. Tighten tighten the starter motor terminal m nut to 9–12 n s m (80–106 lb-in) (a). Tighten the through-bolts to 4–6 n s m (35–53 lb-in)...

  • Page 81

    Engine electrical 1e – 25 daewoo m-150 bl2 d102e724 4. Remove the front bracket, rotor and collar. D remove the collar (large) (1). D remove the rotor from the front bracket (2). D remove the collar (small) from the rotor shaft (3). D102e725 5. Remove the front bearing. D remove the support plate sc...

  • Page 82

    1e – 26 engine electrical daewoo m-150 bl2 d102e728 8. Remove the rectifier / brush holder / regulator from the stator. D remove the rectifier / brush holder / regulator con- nections (1). D remove the stator and rectifier connections (2). Notice: if the stator connections are welded, melt the lead....

  • Page 83

    Engine electrical 1e – 27 daewoo m-150 bl2 d102e732 d test the stator for open or ground circuit by using the ohmmeter (2). Replace the starter if necessary. D102e733 3. Inspect the rectifier. D positive rectifier test: inspect the open circuit for stator coil lead termi- nals using the ohmmeter (1)...

  • Page 84

    1e – 28 engine electrical daewoo m-150 bl2 d12e736a 5. Inspect the brush wear. D if the brush wear exceeds the specified valve (a), replace the brush. Desciption standard limit brushes wear 18.5 (0.73) 13.5 (0.53) d102e737 assembly procedure 1. Install in the reverse order of removal. D assemble the...

  • Page 85

    Engine electrical 1e – 29 daewoo m-150 bl2 d12e740a 4–6 n s m 80–110 n s m d tighten the generator pulley nut to 80–110 n s m (59–81 lb-ft) (d). D tighten the through-bolts to 4–6 n s m (35–53 lb-in) (e). D102e741 generator (b-type: dac) disassembly procedure 1. Remove the generator. Refer to “gener...

  • Page 86

    1e – 30 engine electrical daewoo m-150 bl2 d102e744 4. Remove the regulator / brush holder / rectifier. D remove the rectifier and regulator connection (1). D remove the regulator and brush holder connection (2). D visibly inspect the rectifier / regulator / brush hold- er for damage or broken. A. R...

  • Page 87

    Engine electrical 1e – 31 daewoo m-150 bl2 d102e748 8. Remove the stator assembly from the frame. D remove the remains after the welding. D remove the stator assembly (2). D102e749 inspection / measurement 1. Inspect the rotor assembly. D test the rotor coil for an open circuit by using the ohmmeter...

  • Page 88

    1e – 32 engine electrical daewoo m-150 bl2 d102e752 d test the stator for open or ground circuits by using the ohmmeter. The reading should be sufficiently high, or the stator must be replaced (2). D102e753 3. Inspect the rectifier. D positive rectifier test: inspect the open circuit for stator coil...

  • Page 89

    Engine electrical 1e – 33 daewoo m-150 bl2 d12e756a 5. Inspect the brush wear d if the brush wear exceeds the specified value, re- place the brush. A. Brush wear limit. Desciption standard limit brushes wear 20 (0.79) 14 (0.55) d12e757a 9–12 n s m assembly procedure 1. Install in the reverse order o...

  • Page 90

    1e – 34 engine electrical daewoo m-150 bl2 d12e760a 4–7 n s m 4–6 n s m d tighten the through-bolts to 4–6 n s m (35–53 lb-in) (f). D tighten the battery positive terminal nut to 4–7 n s m (35–62 lb-in) (g). D102e761 distributor assembly disassembly procedure 1. Remove the distributor. Refer to “dis...

  • Page 91

    Engine electrical 1e – 35 daewoo m-150 bl2 d102e764 4. Remove the optical sensor cover and adaptor from the distributor housing. D remove the screw (1). D remove the adaptor (2). D remove the screws (3). D remove the cover (4). D remove the gasket (5). D102e765 5. Remove the optical sensor unit from...

  • Page 92

    1e – 36 engine electrical daewoo m-150 bl2 d102e768 assembly procedure 1. Install in the reverse order of removal. D lubricate the shaft with clean engine oil..

  • Page 93

    Engine electrical 1e – 37 daewoo m-150 bl2 schematic and routing diagrams starting system d12e2011.

  • Page 94

    1e – 38 engine electrical daewoo m-150 bl2 charging system d12e2021.

  • Page 95

    Engine electrical 1e – 39 daewoo m-150 bl2 ignition system circuit – typical d12e2031.

  • Page 96

    1e – 40 engine electrical daewoo m-150 bl2 ignition system circuit – euro iii maa1e010

  • Page 97: Specifications

    Engine electrical 1e – 41 daewoo m-150 bl2 specifications starter specifications application description unit standard limit starter motor type – sd 80 – output(capacity) kw 0.8 – no load test @ 9 volts drive pinion speed a rpm 150 2,000 – brushes length mm (in.) 11.3–11.5 (0.445–0.453) 7.0–7.25 (0....

  • Page 98

    1e – 42 engine electrical daewoo m-150 bl2 battery specifications application description unit standard limit battery type – mf – capacity ah 35 – cold cranking amps cca 246 – fastener tightening specifications application n s m lb-ft lb-in distributor bolts 10–16 – 89–142 battery retainer clamp–to–...

  • Page 99: Section 1F

    Daewoo m-150 bl2 section 1f engine controls caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and dama...

  • Page 100

    1f – 2 engine controls daewoo m-150 bl2 dtc p0122 throttle position sensor low voltage 1f-76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dtc p0123 throttle position sensor high voltage 1f-80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dtc p0131 oxygen sensor low v...

  • Page 101

    Engine controls 1f – 3 daewoo m-150 bl2 dtc p1628 immobilizer no successful communication 1f-270 . . . . . . . . . . . . . . . . . . . . . . . Dtc p1629 immovilizer wrong computation 1f-272 dtc p0656 fuel level gauge circuit fault 1f-274 . Dtc p1660 malfunction indicator lamp (mil) high voltage 1f-2...

  • Page 102: Description And Operation

    1f – 4 engine controls daewoo m-150 bl2 description and operation ignition system operation this ignition system does not use a conventional distrib- utor and coil. It uses a crankshaft position sensor input to the engine control module (ecm). The ecm then de- termines electronic spark timing (est) ...

  • Page 103

    Engine controls 1f – 5 daewoo m-150 bl2 fuel is delivered under one of several conditions, called “modes.’’ starting mode when the ignition is turned on, the ecm turns the fuel pump relay on for 2 seconds. The fuel pump then builds fuel pressure. The ecm also checks the engine coolant temperature (e...

  • Page 104

    1f – 6 engine controls daewoo m-150 bl2 pors. Fresh air from the air cleaner is supplied to the crankcase. The fresh air is mixed with blowby gases which then pass through a vacuum hose into the intake manifold. Periodically inspect the hoses and the clamps. Replace any crankcase ventilation compone...

  • Page 105

    Engine controls 1f – 7 daewoo m-150 bl2 manifold to decrease combustion temperature. The amount of exhaust gas recirculated is controlled by vari- ations in vacuum and exhaust back pressure. If too much exhaust gas enters, combustion will not take place. For this reason, very little exhaust gas is a...

  • Page 106

    1f – 8 engine controls daewoo m-150 bl2 tions. With the ignition on and the engine not running, the engine control module (ecm) will read the manifold pressure as barometric pressure and adjust the air/fuel ratio accordingly. This compensation for altitude allows the system to maintain driving perfo...

  • Page 107

    Engine controls 1f – 9 daewoo m-150 bl2 appropriate wiring diagram. Refer to “ecm wiring dia- grams” in this section. 95 91 terminal 49 ground open strategy-based diagnostics strategy-based diagnostics the strategy-based diagnostic is a uniform approach to repair all electrical/electronic (e/e) syst...

  • Page 108

    1f – 10 engine controls daewoo m-150 bl2 fuels use alcohol to increase the octane rating of the fuel. Although alcohol-enhanced fuels may raise the oc- tane rating, the fuel’s ability to turn into vapor in cold temperatures deteriorates. This may affect the starting ability and cold driveability of ...

  • Page 109

    Engine controls 1f – 11 daewoo m-150 bl2 d the fault identified by the diagnostic test is currently active. D the fault has been active during this ignition cycle. D the operating conditions at the time of the failure. Remember, a fuel trim diagnostic trouble code (dtc) may be triggered by a list of...

  • Page 110

    1f – 12 engine controls daewoo m-150 bl2 the enable criteria for each diagnostic is listed on the first page of the diagnostic trouble code (dtc) descrip- tion under the heading “conditions for setting the dtc.” enable criteria varies with each diagnostic and typically includes, but is not limited t...

  • Page 111

    Engine controls 1f – 13 daewoo m-150 bl2 data link connector (dlc) the provision for communicating with the control mod- ule is the data link connector (dlc). The dlc is used to connect to a scan tool. Some common uses of the scan tool are listed below: d identifying stored dtcs. D clearing dtcs. D ...

  • Page 112

    1f – 14 engine controls daewoo m-150 bl2 termittent fault will also be erased from memory. If the fault that caused the dtc to be stored into memory has been corrected, the diagnostic executive will begin to count the ‘‘warm-up” cycles with no further faults de- tected, the dtc will automatically be...

  • Page 113

    Engine controls 1f – 15 daewoo m-150 bl2 made to enter dtc numbers for tests which the diag- nostic executive does not recognize, the requested in- formation will not be displayed correctly and the scan tool may display an error message. The same applies to using the dtc trigger option in the snapsh...

  • Page 114

    1f – 16 engine controls daewoo m-150 bl2 the obstruction of the reference air and degrade the o2s performance. Misfire monitor diagnostic operation the misfire monitor diagnostic is based on crankshaft rotational velocity (reference period) variations. The en- gine control module (ecm) determines cr...

  • Page 115: System Diagnosis

    Engine controls 1f – 17 daewoo m-150 bl2 diagnostic information and procedures system diagnosis diagnostic aids if an intermittent problem is evident, follow the guide- lines below. Preliminary checks before using this section you should have already per- formed the “euro on-board diagnostic (eobd) ...

  • Page 116

    1f – 18 engine controls daewoo m-150 bl2 maa1f010 euro on-board diagnostic (eobd) system check circuit description the euro on-board diagnostic (eobd) system check is the starting point for any driveability complaint diagno- sis. Before using this procedure, perform a careful visu- al/physical check...

  • Page 117

    Engine controls 1f – 19 daewoo m-150 bl2 euro on-board diagnostic (eobd) system check step action value(s) yes no 1 1. Turn the ignition on with the engine off. 2. Observe the malfunction indicator lamp (mil). Is the mil on? – go to step 2 go to “no malfunction indicator lamp” 2 1. Turn the ignition...

  • Page 118

    1f – 20 engine controls daewoo m-150 bl2 ecm output diagnosis circuit description the engine control module (ecm) controls most com- ponents with electronic switches which complete a ground circuit when turned on. These switches are ar- ranged in groups of 4 and 7, and they are called either a surfa...

  • Page 119

    Engine controls 1f – 21 daewoo m-150 bl2 multiple ecm information sensor dtcs set circuit description the engine control module (ecm) monitors various sensors to determine engine operating conditions. The ecm controls fuel delivery, spark advance, transaxle op- eration, and emission control device o...

  • Page 120

    1f – 22 engine controls daewoo m-150 bl2 multiple ecm information sensor dtcs set step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the check complete. – go to step 2 go to “euro on-board diagnostic system check” 2 1. Turn the ignition off and disconnect the e...

  • Page 121

    Engine controls 1f – 23 daewoo m-150 bl2 multiple ecm information sensor dtcs set (cont’d) step action value(s) yes no 12 locate and repair the short to voltage in the tp sensor signal circuit. Is the repair complete? – go to step 19 – 13 locate and repair the short to voltage in the iat sensor sign...

  • Page 122

    1f – 24 engine controls daewoo m-150 bl2 maa1f020 engine cranks but wil l nut run.

  • Page 123

    Engine controls 1f – 25 daewoo m-150 bl2 engine cranks but will not run caution: use only electrically insulated pliers when handling ignition wires with the engine running to prevent an electrical shock. Caution: do not pinch or restrict nylon fuel lines. Damage to the lines could cause a fuel leak...

  • Page 124

    1f – 26 engine controls daewoo m-150 bl2 engine cranks but will not run (cont’d) step action value(s) yes no 12 check for an open or short in the wires between ckp sensor connector and ecm connector and repair as need. Is the repair complete? – go to step 2 – 13 1. Disconnect electronic ignition (ei...

  • Page 125

    Engine controls 1f – 27 daewoo m-150 bl2 engine cranks but will not run (cont’d) step action value(s) yes no 21 1. Check for any damages or poor connection in ignition wires and repair as needed. 2. Connect the ei system ignition coil connector and ecm connector. 3. Check for the presence of spark f...

  • Page 126

    1f – 28 engine controls daewoo m-150 bl2 engine cranks but will not run (cont’d) step action value(s) yes no 33 replace the fuel pump sender, the in-tank fuel filter, and/or the fuel coupling hoses as needed. Is the repair complete? – go to step 2 – 34 1. Turn the ignition off. 2. Disconnect the ele...

  • Page 127

    Engine controls 1f – 29 daewoo m-150 bl2 engine cranks but will not run (cont’d) step action value(s) yes no 42 1. Turn the ignition off. 2. Connect test light between fuel injector harness connector 2 and battery positive. 3. Crank the engine. 4. Repeat step 2 and 3 for each of the remaining fuel i...

  • Page 128

    1f – 30 engine controls daewoo m-150 bl2 maa1f030 no malfunction indicator lamp circuit description when the ignition is turned on, the malfunction indica- tor lamp (mil) will be turned on and remain on until the engine is running, if no diagnostic trouble codes (dtcs) are stored. Battery voltage is...

  • Page 129

    Engine controls 1f – 31 daewoo m-150 bl2 no malfunction indicator lamp step action value(s) yes no 1 attempt to start the engine. Does the engine start? – go to step 2 go to “engine cranks but will not run” 2 1. Turn the ignition off. 2. Disconnect the engine control module (ecm) connector. 3. Turn ...

  • Page 130

    1f – 32 engine controls daewoo m-150 bl2 maa1f030 malfunction indicator lamp on steady circuit description when the ignition is turned on, the malfunction indica- tor lamp (mil) will be turned on and remain on until the engine is running, if no diagnostic trouble codes (dtcs) are stored. Battery vol...

  • Page 131

    Engine controls 1f – 33 daewoo m-150 bl2 malfunction indicator lamp on steady step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the check complete. – go to step 2 go to “euro on-board diagnostic system check” 2 1. Turn the ignition off. 2. Install the scan too...

  • Page 132

    1f – 34 engine controls daewoo m-150 bl2 fuel system diagnosis circuit description the fuel pump is an in-tank type mounted to a fuel send- er assembly. The fuel pump will remain on as long as the engine is cranking or running and the engine control module (ecm) is receiving reference pulses from th...

  • Page 133

    Engine controls 1f – 35 daewoo m-150 bl2 fuel system pressure test (cont’d) ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 8 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ...

  • Page 134

    1f – 36 engine controls daewoo m-150 bl2 maa1f040 fuel pump relay circuit check circuit description when the ignition switch is turned on, the engine con- trol module (ecm) will supply battery voltage to activate the fuel pump relay and run the in-tank fuel pump. The fuel pump will operate as long a...

  • Page 135

    Engine controls 1f – 37 daewoo m-150 bl2 fuel pump relay circuit check (cont’d) step action value(s) yes no 3 1. Check for an open circuit between fuel pump test connector and ground g401, and repair as needed. 2. Check for the fuel cut-off switch and reset or replace the fuel cut off switch. Is the...

  • Page 136

    1f – 38 engine controls daewoo m-150 bl2 maa1f050 main relay circuit check circuit description when the ignition is turned on or to the start position, the main relay is energized. The main relay then supply voltage to the engine fuse block fuse ef25 and ef26. The electronic ignition (ei) system ign...

  • Page 137

    Engine controls 1f – 39 daewoo m-150 bl2 main relay circuit check step action value(s) yes no 1 1. Turn the ignition off. 2. Disconnect the engine fuse block fuse ef26. 3. Turn the ignition on. 4. With a test light connected to the ground, probe the fuse terminals nearest the main relay for fuse ef1...

  • Page 138

    1f – 40 engine controls daewoo m-150 bl2 maa1f060 manifold absolute pressure check circuit description the manifold absolute pressure (map) sensor measure the changes in the intake manifold pressure which result from engine load (intake manifold vacuum) and rpm changes. The map sensor converts these...

  • Page 139

    Engine controls 1f – 41 daewoo m-150 bl2 manifold absolute pressure check step action value(s) yes no 1 1. Turn the ignition off. 2. Connect a scan tool to the data link connector (dlc). 3. Turn the ignition on. 4. Compare the manifold absolute pressure (map) sensor voltage reading from scanner with...

  • Page 140

    1f – 42 engine controls daewoo m-150 bl2 maa1f070 idle air control system check circuit description the engine control module (ecm) controls the engine idle speed with the idle air control (iac) valve. To in- crease the idle speed, the ecm pulls the iac pintle away from its seat, allowing more air t...

  • Page 141

    Engine controls 1f – 43 daewoo m-150 bl2 idle air control system check step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Was the check performed? – go to step 2 go to “euro on-board diagnostic system check” 2 1. Turn the ignition off. 2. Remove idle air control (...

  • Page 142

    1f – 44 engine controls daewoo m-150 bl2 maa1f080 ig ni t io n syst em c h eck.

  • Page 143

    Engine controls 1f – 45 daewoo m-150 bl2 ignition system check circuit description the electronic ignition (ei) system uses a waste spark method of spark distribution. In this type of ei system, the crankshaft position (ckp) sensor is mounted to the oil pump near a slotted wheel that is a part of th...

  • Page 144

    1f – 46 engine controls daewoo m-150 bl2 ignition system check (cont’d) step action value(s) yes no 9 check for an open in the wire from ei system ignition coil connector terminal 2 to the engine control module (ecm) connector terminal 1. Is the problem found? – go to step 7 go to step 11 10 1. Repl...

  • Page 145

    Engine controls 1f – 47 daewoo m-150 bl2 ignition system check (cont’d) step action value(s) yes no 21 measure the voltage between the ckp sensor connector terminal 2 and ground. Is the voltage within the value specified? 0.95–1.10 v go to step 18 go to step 22 22 check the wire between the ckp sens...

  • Page 146

    1f – 48 engine controls daewoo m-150 bl2 maa1f090 engine cooling fan circuit check circuit description the engine cooling fan circuit operates the cooling fan. The cooling fan is controlled by the engine control mod- ule (ecm) based on input from the coolant temperature sensor (cts) and the a/c on/o...

  • Page 147

    Engine controls 1f – 49 daewoo m-150 bl2 engine cooling fan circuit check step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Was the check performed? – go to step 2 go to “euro on-board diagnostic system check. 2 1. Check the fuses ef3 and ef10 in engine fuse bloc...

  • Page 148

    1f – 50 engine controls daewoo m-150 bl2 engine cooling fan circuit check (cont’d) step action value(s) yes no 12 1. Turn the ignition on. 2. Connect a test light between terminals 86 and 30 of low speed cooling fan relay and ground. Does the test light on for both case? – go to step 14 go to step 1...

  • Page 149: Blank

    Engine controls 1f – 51 daewoo m-150 bl2 blank.

  • Page 150

    1f – 52 engine controls daewoo m-150 bl2 maa1f010 data link connector diagnosis circuit description the provision for communicating with the engine con- trol module (ecm) is the data link connector (dlc). It is located under the instrument panel. The dlc is used to connect the scan tool. Battery pow...

  • Page 151

    Engine controls 1f – 53 daewoo m-150 bl2 data link connector diagnosis step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Was the check performed? – go to step 2 go to “euro on-board diagnostic system check. 2 with a test light connected to the ground, probe the d...

  • Page 152

    1f – 54 engine controls daewoo m-150 bl2 fuel injector balance test a fuel injector tester is used to energize the injector for a precise amount of time, thus spraying a measured amount of fuel into the intake manifold. This causes a drop in the fuel rail pressure that can be recorded and used to co...

  • Page 153

    Engine controls 1f – 55 daewoo m-150 bl2 diagnostic trouble code diagnosis clearing trouble codes notice: to prevent engine control module (ecm) dam- age, the key must be off when disconnecting or recon- necting the power to the ecm (for example battery cable, ecm pigtail connector, ecm fuse, jumper...

  • Page 154

    1f – 56 engine controls daewoo m-150 bl2 diagnostic trouble codes (cont’d) dtc function error type illuminate mil p0336 58x crankshaft position sensor extra/missing pulse e yes p0337 58x crankshaft sensor no signal e yes p0341 camshaft position sensor rationality e yes p0342 camshaft position sensor...

  • Page 155

    Engine controls 1f – 57 daewoo m-150 bl2 diagnostic trouble codes (cont’d) dtc function error type illuminate mil p1660 malfunction indicator lamp(mil) high voltage e yes p1661 malfunction indicator lamp(mil) low voltage e yes.

  • Page 156

    1f – 58 engine controls daewoo m-150 bl2 maa1f060 diagnostic trouble code (dtc) – p0107 manifold absolute pressure sensor low voltage circuit description the engine control module (ecm) uses the manifold ab- solute pressure (map) sensor to control the fuel deliv- ery and the ignition timing. The map...

  • Page 157

    Engine controls 1f – 59 daewoo m-150 bl2 if the connections are ok monitor the manifold absolute pressure (map) sensor signal voltage while moving re- lated connectors and the wiring harness. If the failure is induced, the display on the scan tool will change. This may help to isolate the location o...

  • Page 158

    1f – 60 engine controls daewoo m-150 bl2 dtc p0107 – manifold absolute pressure sensor low voltage (cont’d) step action value(s) yes no 10 1. Repair the wire or the connector terminal as needed. 2. Clear any dtcs from the ecm. 3. Perform the diagnostic system check. Is the repair complete? – system ...

  • Page 159: Blank

    Engine controls 1f – 61 daewoo m-150 bl2 blank.

  • Page 160

    1f – 62 engine controls daewoo m-150 bl2 maa1f060 diagnostic trouble code (dtc) – p0108 manifold absolute pressure sensor high voltage circuit description the engine control module (ecm) uses the manifold ab- solute pressure (map) sensor to control the fuel deliv- ery and the ignition timing. The ma...

  • Page 161

    Engine controls 1f – 63 daewoo m-150 bl2 dtc p0108 – manifold absolute pressure sensor high voltage step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Connect the scan tool ...

  • Page 162

    1f – 64 engine controls daewoo m-150 bl2 dtc p0108 – manifold absolute pressure sensor high voltage (cont’d) step action value(s) yes no 11 1. Replace the manifold absolute pressure sensor. 2. Clear any dtcs from the ecm. 3. Perform the diagnostic system check. Is the replacement complete? – system ...

  • Page 163: Blank

    Engine controls 1f – 65 daewoo m-150 bl2 blank.

  • Page 164

    1f – 66 engine controls daewoo m-150 bl2 maa1f100 diagnostic trouble code (dtc) – p0112 intake air temperature sensor low voltage circuit description the intake air temperature (iat) sensor uses a therm- istor to control the signal voltage to the engine control module (ecm). The ecm supplies a 5 vol...

  • Page 165

    Engine controls 1f – 67 daewoo m-150 bl2 dtc p0112 – intake air temperature sensor low voltage step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Connect the scan tool to th...

  • Page 166

    1f – 68 engine controls daewoo m-150 bl2 maa1f100 diagnostic trouble code (dtc) – p0113 intake air temperature sensor high voltage circuit description the intake air temperature (iat) sensor uses a therm- istor to control the signal voltage to the engine control module (ecm). The ecm supplies a 5 vo...

  • Page 167

    Engine controls 1f – 69 daewoo m-150 bl2 dtc p0113 – intake air temperature sensor high voltage step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Connect the scan tool to t...

  • Page 168

    1f – 70 engine controls daewoo m-150 bl2 dtc p0113 – intake air temperature sensor high voltage (cont’d) step action value(s) yes no 11 1. Replace the ecm 2. Perform the diagnostic system check. Is the repair complete? – go to step 12 – 12 check if any additional dtcs are set. Are any dtcs displaced...

  • Page 169: Blank

    Engine controls 1f – 71 daewoo m-150 bl2 blank.

  • Page 170

    1f – 72 engine controls daewoo m-150 bl2 maa1f110 diagnostic trouble code (dtc) – p0117 engine coolant temperature sensor low voltage circuit description the engine coolant temperature sensor (ect) uses a thermistor to control the signal voltage to the engine control module (ecm). The ecm supplies a...

  • Page 171

    Engine controls 1f – 73 daewoo m-150 bl2 dtc p0117 – engine coolant temperature sensor low voltage step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Connect the scan tool t...

  • Page 172

    1f – 74 engine controls daewoo m-150 bl2 maa1f110 diagnostic trouble code (dtc) – p0118 engine coolant temperature sensor high voltage circuit description the coolant temperature sensor (ect) uses a thermis- tor to control the signal voltage to the engine control module (ecm). The ecm supplies a vol...

  • Page 173

    Engine controls 1f – 75 daewoo m-150 bl2 dtc p0118 – engine coolant temperature sensor high voltage step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Connect the scan tool ...

  • Page 174

    1f – 76 engine controls daewoo m-150 bl2 maa1f120 diagnostic trouble code (dtc) p0122 throttle position sensor low voltage circuit description the engine control module (ecm) supplies a 5 volt ref- erence voltage signal and a ground to the throttle posi- tion (tp) sensor. The tp sensor sends a volta...

  • Page 175

    Engine controls 1f – 77 daewoo m-150 bl2 dtc p0122 – throttle position sensor low voltage step action value(s) yes no 1 perform an on-board diagnostic (eobd) system check. Was the check performed? – go to step 2 go to “on-board diagnostic system check” 2 1. Install a scan tool to the data link conne...

  • Page 176

    1f – 78 engine controls daewoo m-150 bl2 dtc p0122 – throttle position sensor low voltage (cont’d) step action value(s) yes no 12 1. Using the scan tool, clear the diagnostic trouble codes (dtcs). 2. Start the engine and idle at normal operating temperature. 3. Operate the vehicle within the conditi...

  • Page 177: Blank

    Engine controls 1f – 79 daewoo m-150 bl2 blank.

  • Page 178

    1f – 80 engine controls daewoo m-150 bl2 maa1f120 diagnostic trouble code (dtc) p0123 throttle position sensor high voltage circuit description the engine control module (ecm) supplies a 5 volt ref- erence voltage signal and a ground to the throttle posi- tion (tp) sensor. The tp sensor sends a volt...

  • Page 179

    Engine controls 1f – 81 daewoo m-150 bl2 dtc p0123 – throttle position sensor high voltage step action value(s) yes no 1 perform an on-board diagnostic (eobd) system check. Was the check performed? – go to step 2 go to “on-board diagnostic system check” 2 1. Install a scan tool to the data link conn...

  • Page 180

    1f – 82 engine controls daewoo m-150 bl2 dtc p0123 – throttle position sensor high voltage (cont’d) step action value(s) yes no 13 check if any additional dtcs are set. Are any dtcs displayed that have not been diagnosed? – go to applicable dtc table system ok.

  • Page 181: Blank

    Engine controls 1f – 83 daewoo m-150 bl2 blank.

  • Page 182

    1f – 84 engine controls daewoo m-150 bl2 maa1f130 diagnostic trouble code (dtc) – p0131 oxygen sensor low voltage circuit description the engine control module (ecm) supplies a voltage of about 450m volts between the ecm terminals 44 and 13. The oxygen (o 2 ) sensor varies the voltage within a range...

  • Page 183

    Engine controls 1f – 85 daewoo m-150 bl2 dtc p0131 – oxygen sensor low voltage step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Connect the scan tool to the data link conn...

  • Page 184

    1f – 86 engine controls daewoo m-150 bl2 dtc p0131 – oxygen sensor low voltage (cont’d) step action value(s) yes no 12 check if any additional dtcs are set. Are any dtcs displaced that have not been diagnosed? – go to applicable dtc table system ok.

  • Page 185: Blank

    Engine controls 1f – 87 daewoo m-150 bl2 blank.

  • Page 186

    1f – 88 engine controls daewoo m-150 bl2 maa1f130 diagnostic trouble code (dtc) – p0132 oxygen sensor high voltage circuit description the engine control module (ecm) supplies a voltage of about 450mm volts between the ecm terminals 44 and 13. The oxygen (o2) sensor varies the voltage within a range...

  • Page 187

    Engine controls 1f – 89 daewoo m-150 bl2 dtc p0132 – oxygen sensor high voltage step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition switch to on, with the e...

  • Page 188

    1f – 90 engine controls daewoo m-150 bl2 maa1f130 diagnostic trouble code (dtc) – p0133 oxygen sensor no activity circuit description the engine control module (ecm) supplies a voltage of about 450mm volts between the ecm terminals 44 and 13. The oxygen (o 2 ) sensor varies the voltage within a rang...

  • Page 189

    Engine controls 1f – 91 daewoo m-150 bl2 dtc p0133 – oxygen sensor no activity step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Connect the scan tool to the data link conn...

  • Page 190

    1f – 92 engine controls daewoo m-150 bl2 dtc p0133 – oxygen sensor no activity (cont’d) step action value(s) yes no 11 replace the o 2 sensor. Is the repair complete? – go to step 12 – 12 1. Clear any dtcs from the ecm 2. Perform the diagnostic system check is the repair complete – go to step 13 – 1...

  • Page 191: Blank

    Engine controls 1f – 93 daewoo m-150 bl2 blank.

  • Page 192

    1f – 94 engine controls daewoo m-150 bl2 maa1f140 diagnostic trouble code (dtc) – p0137 heated oxygen sensor low voltage circuit description the engine control module (ecm) supplies a voltage of about 450mm volts between the ecm terminals 44 and 13. The oxygen (o 2 ) sensor varies the voltage within...

  • Page 193

    Engine controls 1f – 95 daewoo m-150 bl2 dtc p0137 – heated oxygen sensor low voltage step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition switch to on, with...

  • Page 194

    1f – 96 engine controls daewoo m-150 bl2 dtc p0137 – heated oxygen sensor low voltage (cont’d) step action value(s) yes no 10 check if any additional dtcs are set. Are any dtcs displaced that have not been diagnosed? – go to applicable dtc table system ok.

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  • Page 196

    1f – 98 engine controls daewoo m-150 bl2 maa1f140 diagnostic trouble code (dtc) – p0138 heated oxygen sensor high voltage circuit description the engine control module (ecm) supplies a voltage of about 450mm volts between the ecm terminals 64 and 13. The heated oxygen (o 2 ) sensor varies the voltag...

  • Page 197

    Engine controls 1f – 99 daewoo m-150 bl2 dtc p0138 – heated oxygen sensor high voltage step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition switch to on, wit...

  • Page 198

    1f – 100 engine controls daewoo m-150 bl2 maa1f140 diagnostic trouble code (dtc) – p0140 heated oxygen sensor no activity circuit description the engine control module (ecm) supplies a voltage of about 450mm volts between the ecm terminals 64 and 13. The oxygen (o 2 ) sensor varies the voltage withi...

  • Page 199

    Engine controls 1f – 101 daewoo m-150 bl2 dtc p0140 – heated oxygen sensor no activity step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Run the engine to above the specifi...

  • Page 200

    1f – 102 engine controls daewoo m-150 bl2 dtc p0140 – heated oxygen sensor no activity (cont’d) step action value(s) yes no 11 1. Turn the ignition switch to lock. 2. Replace the heated o2 sensor. 3. Road tests the vehicle. 4. Perform the diagnostic system check. Is the replacement complete? – go to...

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  • Page 202

    1f – 104 engine controls daewoo m-150 bl2 maa1f140 diagnostic trouble code (dtc) – p0141 heated oxygen sensor heater malfunction circuit description the engine control module (ecm) supplies a voltage of about 450mm volts between the ecm terminals 44 and 13. The oxygen (o 2 ) sensor varies the voltag...

  • Page 203

    Engine controls 1f – 105 daewoo m-150 bl2 dtc p0141 – heated oxygen sensor heater malfunction step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition switch to ...

  • Page 204

    1f – 106 engine controls daewoo m-150 bl2 diagnostic trouble code (dtc) – p0171 fuel trim system too lean system description to provide the best possible combination of driveability, fuel economy, and emission control, a closed loop air/ fuel metering system is used. While in closed loop, the engine...

  • Page 205

    Engine controls 1f – 107 daewoo m-150 bl2 dtc p0171 – fuel trim system too lean step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Install the scan tool to the data link con...

  • Page 206

    1f – 108 engine controls daewoo m-150 bl2 dtc p0171 – fuel trim system too lean (cont’d) step action value(s) yes no 9 1. Visually/physically inspect the following items for vacuum leaks: d intake manifold. D throttle body. D injector o-rings. 2. Repair any leaks found as necessary. Is the repair co...

  • Page 207

    Engine controls 1f – 109 daewoo m-150 bl2 diagnostic trouble code (dtc) – p0172 fuel trim system too rich system description to provide the best possible combination of driveability, fuel economy, and emission control, a closed loop air/ fuel metering system is used. While in closed loop, the engine...

  • Page 208

    1f – 110 engine controls daewoo m-150 bl2 dtc p0172 – fuel trim system too rich step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 install the scan tool to the data link connec...

  • Page 209

    Engine controls 1f – 111 daewoo m-150 bl2 dtc p0172 – fuel trim system too rich (cont’d) step action value(s) yes no 12 check the iac valve performance. Refer to “dtc p0506 idle speed rpm lower than desired idle speed” or “dtc p0507 idle speed rpm higher than desired idle speed” in this section and ...

  • Page 210

    1f – 112 engine controls daewoo m-150 bl2 dtc p0172 – fuel trim system too rich (cont’d) step action value(s) yes no 21 1. Using the scan tool, clear the diagnostic trouble codes (dtcs). 2. Start the engine and idle at normal operating temperature. 3. Operate the vehicle within the conditions for se...

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  • Page 212

    1f – 114 engine controls daewoo m-150 bl2 maa1f040 diagnostic trouble code (dtc) – p1230 fuel pump relay low voltage circuit description when the ignition switch is turned on, the ecm will acti- vate the fuel pump relay and run the in-tank fuel pump. The fuel pump will operate as long as the engine ...

  • Page 213

    Engine controls 1f – 115 daewoo m-150 bl2 dtc p1230 – fuel pump relay low voltage step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition switch to lock for 10 ...

  • Page 214

    1f – 116 engine controls daewoo m-150 bl2 dtc p1230 – fuel pump relay low voltage (cont’d) step action value(s) yes no 11 1. Repair the wire between the fuel pump relay connector terminal 66 and the ignition key on (ign1). 2. Install the fuel pump relay. 3. Turn the ignition off for 10 seconds. 4. C...

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  • Page 216

    1f – 118 engine controls daewoo m-150 bl2 maa1f040 diagnostic trouble code (dtc) – p1231 fuel pump relay high voltage circuit description when the ignition switch is turned on, the ecm will acti- vate the fuel pump relay and run the in-tank fuel pump. The fuel pump will operate as long as the engine...

  • Page 217

    Engine controls 1f – 119 daewoo m-150 bl2 dtc p1231 – fuel pump relay high voltage step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition switch to lock for 10...

  • Page 218

    1f – 120 engine controls daewoo m-150 bl2 dtc p1231 – fuel pump relay high voltage (cont’d) step action value(s) yes no 10 1. Replace the ecm. 2. Turn the ignition off for 10 seconds. 3. Clear any dtcs from ecm. 4. Turn the ignition switch to on. Does the fuel pump operate? 2.55 seconds system ok go...

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  • Page 220

    1f – 122 engine controls daewoo m-150 bl2 maa1f150 diagnostic trouble code (dtc) – p0261 injector 1 low voltage circuit description the engine control module (ecm) has three individual injector driver circuits, each of which controls an injector. When a driver circuit is grounded by the ecm, the inj...

  • Page 221

    Engine controls 1f – 123 daewoo m-150 bl2 dtc p0261 – injector 1 low voltage step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 with the engine start? – go to step 3 go to “eng...

  • Page 222

    1f – 124 engine controls daewoo m-150 bl2 maa1f150 diagnostic trouble code (dtc) – p0262 injector 1 high voltage circuit description the engine control module (ecm) has three individual injector driver circuits, each of which controls an injector. When a driver circuit is grounded by the ecm, the in...

  • Page 223

    Engine controls 1f – 125 daewoo m-150 bl2 dtc p0262 – injector 1 high voltage step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 with the engine start? – go to step 3 go to “en...

  • Page 224

    1f – 126 engine controls daewoo m-150 bl2 maa1f150 diagnostic trouble code (dtc) – p0264 injector 2 low voltage circuit description the engine control module (ecm) has three individual injector driver circuits, each of which controls an injector. When a driver circuit is grounded by the ecm, the inj...

  • Page 225

    Engine controls 1f – 127 daewoo m-150 bl2 dtc p0264 – injector 2 low voltage step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 with the engine start? – go to step 3 go to “eng...

  • Page 226

    1f – 128 engine controls daewoo m-150 bl2 maa1f150 diagnostic trouble code (dtc) – p0265 injector 2 high voltage circuit description the engine control module (ecm) has three individual injector driver circuits, each of which controls an injector. When a driver circuit is grounded by the ecm, the in...

  • Page 227

    Engine controls 1f – 129 daewoo m-150 bl2 dtc p0265 – injector 2 high voltage step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 with the engine start? – go to step 3 go to “en...

  • Page 228

    1f – 130 engine controls daewoo m-150 bl2 maa1f150 diagnostic trouble code (dtc) – p0267 injector 3 low voltage circuit description the engine control module (ecm) has three individual injector driver circuits, each of which controls an injector. When a driver circuit is grounded by the ecm, the inj...

  • Page 229

    Engine controls 1f – 131 daewoo m-150 bl2 dtc p0267 – injector 3 low voltage step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 with the engine start? – go to step 3 go to “eng...

  • Page 230

    1f – 132 engine controls daewoo m-150 bl2 maa1f150 diagnostic trouble code (dtc) – p0268 injector 3 high voltage circuit description the engine control module (ecm) has three individual injector driver circuits, each of which controls an injector. When a driver circuit is grounded by the ecm, the in...

  • Page 231

    Engine controls 1f – 133 daewoo m-150 bl2 the injector resistance tested at the ecm connection is slightly more than it tested directly at the injector be- cause it includes resistance of the harness wires. The normal value is about 13.5 Ω . Dtc p0268 – injector 3 high voltage step action value(s) y...

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    1f – 134 engine controls daewoo m-150 bl2 maa1f160

  • Page 233

    Engine controls 1f – 135 daewoo m-150 bl2 diagnostic trouble code (dtc) – p0300 multiple cylinder misfire system description the engine control module (ecm) monitors the crank- shaft and camshaft positions to detect if the engine is misfiring. The ecm looks for a quick drop in crankshaft speed. This...

  • Page 234

    1f – 136 engine controls daewoo m-150 bl2 dtc p0300 – multiple cylinder misfire (cont’d) step action value(s) yes no 6 1. Turn the ignition on, with the engine off. 2. Review the freeze frame data, and note the parameters. 3. Operate the vehicle within the freeze frame conditions and conditions for ...

  • Page 235

    Engine controls 1f – 137 daewoo m-150 bl2 dtc p0300 – multiple cylinder misfire (cont’d) step action value(s) yes no 18 repair the open or the shorted fuel injector driver circuit. Is the repair complete? – go to step 27 – 19 repair the open ignition feed circuit between the fuel injector harness co...

  • Page 236

    1f – 138 engine controls daewoo m-150 bl2 maa1f160

  • Page 237

    Engine controls 1f – 139 daewoo m-150 bl2 diagnostic trouble code (dtc) – p0300 multiple cylinder misfire system description the engine control module (ecm) monitors the crank- shaft and camshaft positions to detect if the engine is misfiring. The ecm looks for a quick drop in crankshaft speed. This...

  • Page 238

    1f – 140 engine controls daewoo m-150 bl2 dtc p0300 – multiple cylinder misfire (cont’d) step action value(s) yes no 3 perform a visual/physical inspection. Make any repairs that are necessary. Is the repair complete? – go to step 27 go to step 4 4 start the engine and allow it to idle. Are any misf...

  • Page 239

    Engine controls 1f – 141 daewoo m-150 bl2 dtc p0300 – multiple cylinder misfire (cont’d) step action value(s) yes no 16 replace any malfunctioning fuel injectors. Is the repair complete? – go to step 27 – 17 check the affected fuel injector driver circuit at terminals 90, 58, and 89 for an open, sho...

  • Page 240

    1f – 142 engine controls daewoo m-150 bl2 diagnostic trouble code (dtc) – p1320 crankshaft segment period segment adaptation at limit circuit description the 58x reference signal is produced by the crankshaft position (ckp) sensor. During one crankshaft revolu- tion, 58 crankshaft pulses will be pro...

  • Page 241

    Engine controls 1f – 143 daewoo m-150 bl2 dtc p1320 – crankshaft segment period segment adaptation at limit step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Was the check performed? – go to step 2 go to “on-board diagnostic system check” 2 attempt to start the e...

  • Page 242

    1f – 144 engine controls daewoo m-150 bl2 diagnostic trouble code (dtc) – p1321 crankshaft segment period tooth error circuit description the 58x reference signal is produced by the crankshaft position (ckp) sensor. During one crankshaft revolu- tion, 58 crankshaft pulses will be produced. The engin...

  • Page 243

    Engine controls 1f – 145 daewoo m-150 bl2 dtc p1321 – crankshaft segment period tooth error step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Was the check performed? – go to step 2 go to “on-board diagnostic system check” 2 attempt to start the engine. Does the ...

  • Page 244

    1f – 146 engine controls daewoo m-150 bl2 maa1f170 diagnostic trouble code (dtc) – p0327 knock sensor circuit fault circuit description the knock sensor(ks) system is used to detect engine detonation, allowing the engine control module(ecm) to retard ignition control spark timing based on the ks sig...

  • Page 245

    Engine controls 1f – 147 daewoo m-150 bl2 dtc p0327 – knock sensor circuit step action value(s) yes no 1 perform an euro on-board diagnostic (eobd ii) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Start the engine. 2. Install a scan tool. 3....

  • Page 246

    1f – 148 engine controls daewoo m-150 bl2 dtc p0327 – knock sensor circuit (cont’d) step action value(s) yes no 12 1. Using the scan tool, clear the dtcs. D start the engine and idle at normal operating temperature. D operate the vehicle within the conditions for setting this dtc as specified in the...

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  • Page 248

    1f – 150 engine controls daewoo m-150 bl2 maa1f180 diagnostic trouble code (dtc) – p0335 magnetic crankshaft position sensor electrical error circuit description the 58x reference signal is produced by the crankshaft position (ckp) sensor. During one crankshaft revolu- tion, 58 crankshaft pulses wil...

  • Page 249

    Engine controls 1f – 151 daewoo m-150 bl2 dtc p0335 – magnetic crankshaft position sensor electrical error step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 attempt to start t...

  • Page 250

    1f – 152 engine controls daewoo m-150 bl2 maa1f180 diagnostic trouble code (dtc) – p0336 58x crankshaft position sensor no plausible signal circuit description the 58x reference signal is produced by the crankshaft position (ckp) sensor. During one crankshaft revolu- tion, 58 crankshaft pulses will ...

  • Page 251

    Engine controls 1f – 153 daewoo m-150 bl2 dtc p0336 – 58x crankshaft position sensor no plausible signal step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 attempt to start the...

  • Page 252

    1f – 154 engine controls daewoo m-150 bl2 maa1f180 diagnostic trouble code (dtc) – p0337 58x crankshaft position sensor no signal circuit description the 58x reference signal is produced by the crankshaft position (ckp) sensor. During one crankshaft revolu- tion, 58 crankshaft pulses will be produce...

  • Page 253

    Engine controls 1f – 155 daewoo m-150 bl2 dtc p0337 – 58x crankshaft position sensor no signal step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 attempt to start the engine. D...

  • Page 254

    1f – 156 engine controls daewoo m-150 bl2 maa1f190 diagnostic trouble code (dtc) – p0341 camshaft position sensor rationality circuit description the camshaft position sensor is used to detect cam- shaft position and to have correlation with crankshaft position so that the ecm can determine which cy...

  • Page 255

    Engine controls 1f – 157 daewoo m-150 bl2 dtc p0341 – camshaft position sensor rationality step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition switch to loc...

  • Page 256

    1f – 158 engine controls daewoo m-150 bl2 maa1f190 diagnostic trouble code (dtc) – p0342 camshaft position sensor no signal circuit description the camshaft position sensor is used to detect cam- shaft position and to have correlation with crankshaft position so that the ecm can determine which cyli...

  • Page 257

    Engine controls 1f – 159 daewoo m-150 bl2 dtc p0342 – camshaft position sensor no signal step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition switch to lock....

  • Page 258

    1f – 160 engine controls daewoo m-150 bl2 maa1f200 diagnostic trouble code (dtc) – p0351 ignition signal coil a fault circuit description the engine control module (ecm) provides a ground for the electronic spark timing 1 circuit. When the ecm re- moves the ground path of the ignition primary coil, ...

  • Page 259

    Engine controls 1f – 161 daewoo m-150 bl2 d dtc(s) can be cleared by using the scan tool. D disconnecting the ecm battery feed for more than 10 seconds. Diagnostic aids check and correct any abnormal engine noise before using the diagnostic table. Any circuitry that is suspected as causing engine no...

  • Page 260

    1f – 162 engine controls daewoo m-150 bl2 maa1f200 diagnostic trouble code (dtc) – p0352 ignition signal coil b fault circuit description the engine control module (ecm) provides a ground for the electronic spark timing 3 circuit. When the ecm re- moves the ground path of the ignition primary coil, ...

  • Page 261

    Engine controls 1f – 163 daewoo m-150 bl2 d a history dtc will clear after 40 consecutive warm up cycles without a fault. D using the scan tool can clear dtc(s). D disconnecting the ecm battery feed for 10 seconds. Diagnostic aids check and correct any abnormal engine noise before using the diagnost...

  • Page 262

    1f – 164 engine controls daewoo m-150 bl2 maa1f200 diagnostic trouble code (dtc) – p0353 ignition signal coil c fault circuit description the engine control module (ecm) provides a ground for the electronic spark timing 3 circuit. When the ecm re- moves the ground path of the ignition primary coil, ...

  • Page 263

    Engine controls 1f – 165 daewoo m-150 bl2 d a history dtc will clear after 40 consecutive warm up cycles without a fault. D using the scan tool can clear dtc(s). D disconnecting the ecm battery feed for 10 seconds. Diagnostic aids check and correct any abnormal engine noise before using the diagnost...

  • Page 264

    1f – 166 engine controls daewoo m-150 bl2 maa1f210 diagnostic trouble code (dtc) – p1382 rough road data invalid (non abs) circuit description the vr sensor is used to detecting the road situation. By sensing difference of wheel rotation duration caused by bumps or potholes in the road, the engine c...

  • Page 265

    Engine controls 1f – 167 daewoo m-150 bl2 dtc p1382 – rough road data invalid (non abs) step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Was the check performed? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition on, with engine off. ...

  • Page 266

    1f – 168 engine controls daewoo m-150 bl2 dtc p1382 – rough road data invalid (non abs) (cont’d) step action value(s) yes no 9 check the vr sensor signal circuit for a poor connection at the ecm and repair as needed. Is the repair complete? – go to step 14 go to step 13 10 check for a poor connectio...

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    Engine controls 1f – 169 daewoo m-150 bl2 blank.

  • Page 268

    1f – 170 engine controls daewoo m-150 bl2 maa1f220 diagnostic trouble code (dtc) – p1382 rough road data invalid (abs) circuit description the wheel speed sensor is used to detecting the road situation. As the wheel is rotated, the wheel speed sensor pro- duces an ac voltage that increase with wheel...

  • Page 269

    Engine controls 1f – 171 daewoo m-150 bl2 dtc p1382 – rough road data invalid (abs) step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Was the check performed? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition on, with engine off. 2. I...

  • Page 270

    1f – 172 engine controls daewoo m-150 bl2 dtc p1382 – rough road data invalid (abs) (cont’d) step action value(s) yes no 9 check the wheel speed sensor signal circuit for a poor connection at the ecm and repair as needed. Is the repair complete? – go to step 14 go to step 13 10 check for a poor conn...

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    Engine controls 1f – 173 daewoo m-150 bl2 blank.

  • Page 272

    1f – 174 engine controls daewoo m-150 bl2 maa1f210 diagnostic trouble code (dtc) – p1385 rough road sensor circuit fault (non abs) circuit description the vr sensor is used to detecting the road situation. By sensing difference of wheel rotation duration caused by bumps or potholes in the road, the ...

  • Page 273

    Engine controls 1f – 175 daewoo m-150 bl2 dtc p1385 – rough road sensor circuit fault (non abs) step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Was the check performed? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition on, with engi...

  • Page 274

    1f – 176 engine controls daewoo m-150 bl2 dtc p1385 – rough road sensor circuit fault (non abs) (cont’d) step action value(s) yes no 9 check the vr sensor signal circuit for a poor connection at the ecm and repair as needed. Is the repair complete? – go to step 14 go to step 13 10 check for a poor c...

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    Engine controls 1f – 177 daewoo m-150 bl2 blank.

  • Page 276

    1f – 178 engine controls daewoo m-150 bl2 maa1f220 diagnostic trouble code (dtc) – p1385 rough road sensor circuit fault (abs) circuit description the wheel speed sensor is used to detecting the road situation. As the wheel is rotated, the wheel speed sensor pro- duces an ac voltage that increase wi...

  • Page 277

    Engine controls 1f – 179 daewoo m-150 bl2 dtc p1385 – rough road sensor circuit fault (abs) step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Was the check performed? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition on, with engine o...

  • Page 278

    1f – 180 engine controls daewoo m-150 bl2 dtc p1385 – rough road sensor circuit fault (abs) (cont’d) step action value(s) yes no 9 check the wheel speed sensor signal circuit for a poor connection at the ecm and repair as needed. Is the repair complete? – go to step 14 go to step 13 10 check for a p...

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    Engine controls 1f – 181 daewoo m-150 bl2 blank.

  • Page 280

    1f – 182 engine controls daewoo m-150 bl2 maa1f230 diagnostic trouble code (dtc) – p0400 electric exhaust gas recirculation out of limit circuit description an electric exhaust gas re-circulation (eegr) system is used to lower oxides of nitrogen (nox) emission lev- els caused by high combustion temp...

  • Page 281

    Engine controls 1f – 183 daewoo m-150 bl2 dtc p0400 – electric exhaust gas recirculation out of limit step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition sw...

  • Page 282

    1f – 184 engine controls daewoo m-150 bl2 dtc p0400 – electric exhaust gas recirculation out of limit (cont’d) step action value(s) yes no 14 check the 5v reference circuit for a shortage to vattery voltage and repair as necessary. Is a repair necessary? – go to step 19 go to step 12 15 check the co...

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    Engine controls 1f – 185 daewoo m-150 bl2 blank.

  • Page 284

    1f – 186 engine controls daewoo m-150 bl2 maa1f230 diagnostic trouble code (dtc) – p1402 electric exhaust gas recirculation blocked circuit description an electric exhaust gas re-circulation (eegr) system is used to lower oxides of nitrogen (nox) emission lev- els caused by high combustion temperatu...

  • Page 285

    Engine controls 1f – 187 daewoo m-150 bl2 easily verified. Check the freeze frame data to deter- mine if the dtc set when the vehicle was cold by view- ing the engine coolant temperature (ect). Dtc p1402 – electric exhaust gas recirculation blocked step action value(s) yes no 1 perform an euro on-bo...

  • Page 286

    1f – 188 engine controls daewoo m-150 bl2 maa1f230 diagnostic trouble code (dtc) – p1403 electric exhaust gas recirculation valve failure circuit description an electric exhaust gas re-circulation (eegr) system is used to lower oxides of nitrogen (nox) emission lev- els caused by high combustion tem...

  • Page 287

    Engine controls 1f – 189 daewoo m-150 bl2 repairs, the valve warms and the problem disappears. By watching the actual eegr and desired eegr posi- tions on a cold vehicle with a scan tool, the fault can be easily verified. Check the freeze frame data to deter- mine if the dtc set when the vehicle was...

  • Page 288

    1f – 190 engine controls daewoo m-150 bl2 dtc p1403 – electric exhaust gas recirculation valve failure (cont’d) step action value(s) yes no 13 check the eegr ground circuit for a poor connection or proper terminal tension at the ecm and repair as necessary. Is a repair necessary? – go to step 19 go ...

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    Engine controls 1f – 191 daewoo m-150 bl2 blank.

  • Page 290

    1f – 192 engine controls daewoo m-150 bl2 maa1f230 diagnostic trouble code (dtc) – p0404 electric exhaust gas recirculation opened circuit description an electric exhaust gas re-circulation (eegr) system is used to lower oxides of nitrogen (nox) emission lev- els caused by high combustion temperatur...

  • Page 291

    Engine controls 1f – 193 daewoo m-150 bl2 dtc p0404 – electric exhaust gas recirculation opened step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition switch t...

  • Page 292

    1f – 194 engine controls daewoo m-150 bl2 dtc p0404 – electric exhaust gas recirculation opened (cont’d) step action value(s) yes no 14 check the 5v reference circuit for a shortage to battery voltage and repair as necessary. Is a repair necessary? – go to step 19 go to step 12 15 check the control ...

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    Engine controls 1f – 195 daewoo m-150 bl2 blank.

  • Page 294

    1f – 196 engine controls daewoo m-150 bl2 maa1f230 diagnostic trouble code (dtc) – p1404 electric exhaust gas recirculation closed circuit description an electric exhaust gas re-circulation (eegr) system is used to lower oxides of nitrogen (nox) emission lev- els caused by high combustion temperatur...

  • Page 295

    Engine controls 1f – 197 daewoo m-150 bl2 dtc p1404 – electric exhaust gas recirculation opend step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition switch to...

  • Page 296

    1f – 198 engine controls daewoo m-150 bl2 dtc p1404 – electric exhaust gas recirculation opend (cont’d) step action value(s) yes no 13 check if any additional dtcs are set. Are any dtcs displayed that have not been diagnosed? – go to applicable dtc table system ok.

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    Engine controls 1f – 199 daewoo m-150 bl2 blank.

  • Page 298

    1f – 200 engine controls daewoo m-150 bl2 maa1f230 diagnostic trouble code (dtc) – p0405 eegr pintle position sensor low voltage circuit description an electric exhaust gas re-circulation (eegr) system is used to lower oxides of nitrogen (nox) emission lev- els caused by high combustion temperatures...

  • Page 299

    Engine controls 1f – 201 daewoo m-150 bl2 dtc p0405 – eegr pintle position sensor low voltage step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition switch to ...

  • Page 300

    1f – 202 engine controls daewoo m-150 bl2 dtc p0405 – eegr pintle position sensor low voltage (cont’d) step action value(s) yes no 13 check if any additional dtcs are set. Are any dtcs displayed that have not been diagnosed? – go to applicable dtc table system ok.

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    Engine controls 1f – 203 daewoo m-150 bl2 blank.

  • Page 302

    1f – 204 engine controls daewoo m-150 bl2 maa1f230 diagnostic trouble code (dtc) – p0406 eegr pintle position sensor high voltage circuit description an electric exhaust gas re-circulation (eegr) system is used to lower oxides of nitrogen (nox) emission lev- els caused by high combustion temperature...

  • Page 303

    Engine controls 1f – 205 daewoo m-150 bl2 dtc p0406 – eegr pintle position sensor high voltage step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition switch to...

  • Page 304

    1f – 206 engine controls daewoo m-150 bl2 dtc p0406 – eegr pintle position sensor high voltage (cont’d) step action value(s) yes no 13 check if any additional dtcs are set. Are any dtcs displayed that have not been diagnosed? – go to applicable dtc table system ok.

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    Engine controls 1f – 207 daewoo m-150 bl2 blank.

  • Page 306

    1f – 208 engine controls daewoo m-150 bl2 diagnostic trouble code (dtc) – p0420 catalyst low efficiency circuit description in order to control exhaust emissions of hydrocarbons (hc), carbon monoxide (co) and nitrogen oxide (nox), a three-way catalytic converter (twc) is used. The catalyst within th...

  • Page 307

    Engine controls 1f – 209 daewoo m-150 bl2 dtc p0420 – catalyst low efficiency step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Was the check performed? – go to step 2 go to “on-board diagnostic system check” 2 1. Install a scan tool to the data link connector (d...

  • Page 308

    1f – 210 engine controls daewoo m-150 bl2 maa1f240 diagnostic trouble code (dtc) – p0444 evap purge control circuit no signal circuit description the evaporative emission (evap) system includes the following components : d fuel tank. D evap vent solenoid. D fuel pipes and hoses. D fuel vapor lines. ...

  • Page 309

    Engine controls 1f – 211 daewoo m-150 bl2 d the evap system in unable to achieve or maintain vacuum during the diagnostic test. The amount of decay will vary within the fuel level. Action taken when the dtcs sets d the malfunction indicator lamp (mil) will illuminate. D the ecm will record operating...

  • Page 310

    1f – 212 engine controls daewoo m-150 bl2 dtc p0444 – evap purge control circuit no signal step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Disconnect the evaporative emis...

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    Engine controls 1f – 213 daewoo m-150 bl2 blank.

  • Page 312

    1f – 214 engine controls daewoo m-150 bl2 maa1f240 diagnostic trouble code (dtc) – p0445 evap purge control circuit fault circuit description the evaporative emission (evap) system includes the following components : d fuel tank. D evap vent solenoid. D fuel tank pressure sensor. D fuel pipes and ho...

  • Page 313

    Engine controls 1f – 215 daewoo m-150 bl2 d the evap system in unable to achieve or maintain vacuum during the diagnostic test. The amount of decay will vary within the fuel level. Action taken when the dtc sets d the malfunction indicator lamp (mil) will illuminate. D the ecm will record operating ...

  • Page 314

    1f – 216 engine controls daewoo m-150 bl2 dtc p0445 – evap purge control circuit fault (cont’d) step action value(s) yes no 5 1. Repair the high voltage or ground in the wire between the evap canister purge valve connector terminal 1 and the ecm connector terminal 66. 2. Clear any diagnostic trouble...

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  • Page 316

    1f – 218 engine controls daewoo m-150 bl2 maa1f250 diagnostic trouble code (dtc) – p0462 fuel level sensor low voltage circuit description the engine control module(ecm) uses the fuel level in- put from the fuel level sensor to calculate expected va- por pressures within the fuel system. Vapor press...

  • Page 317

    Engine controls 1f – 219 daewoo m-150 bl2 dtc p0462 – fuel level sensor low voltage step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition switch to on. 2. Ins...

  • Page 318

    1f – 220 engine controls daewoo m-150 bl2 dtc p0462 – fuel level sensor low voltage (cont’d) step action value(s) yes no 12 check if any additional dtcs are set. Are any dtcs displayed that have not been diagnosed? – go to applicable dtc table system ok.

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    Engine controls 1f – 221 daewoo m-150 bl2 blank.

  • Page 320

    1f – 222 engine controls daewoo m-150 bl2 maa1f250 diagnostic trouble code (dtc) – p0463 fuel level sensor high voltage circuit description the engine control module(ecm) uses the fuel level in- put from the fuel level sensor to calculate expected va- por pressures within the fuel system. Vapor pres...

  • Page 321

    Engine controls 1f – 223 daewoo m-150 bl2 dtc p0463 – fuel level sensor high voltage step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition switch to on. 2. In...

  • Page 322

    1f – 224 engine controls daewoo m-150 bl2 dtc p0463 – fuel level sensor high voltage (cont’d) step action value(s) yes no 12 check if any additional dtcs are set. Are any dtcs displayed that have not been diagnosed? – go to applicable dtc table system ok.

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    Engine controls 1f – 225 daewoo m-150 bl2 blank.

  • Page 324

    1f – 226 engine controls daewoo m-150 bl2 maa1f090 diagnostic trouble code (dtc) – p0480 low speed cooling fan relay circuit fault (without a/c) circuit description ignition voltage is supplied directly to the cooling fan relay coil. The engine control module(ecm) controls the relay by grounding the...

  • Page 325

    Engine controls 1f – 227 daewoo m-150 bl2 a freeze frame conditions (rpm, load, vehicle speed, temperature, etc.) that .Are noted. This will isolate when the dtc failed. Dtc p0480 – low speed cooling fan relay circuit fault (without a/c) step action value(s) yes no 1 perform an euro on-board diagnos...

  • Page 326

    1f – 228 engine controls daewoo m-150 bl2 dtc p0480 – low speed cooling fan relay circuit fault (without a/c) (cont’d) step action value(s) yes no 9 check the connection at the ecm. Is a problem found and corrected? – go to step 11 go to step 13 10 repair the faulty relay control circuit. Is the rep...

  • Page 327: Blank

    Engine controls 1f – 229 daewoo m-150 bl2 blank.

  • Page 328

    1f – 230 engine controls daewoo m-150 bl2 maa1f270 diagnostic trouble code (dtc) – p0480 low speed cooling fan relay circuit fault (with a/c) circuit description ignition voltage is supplied directly to the cooling fan relay coil. The engine control module(ecm) controls the relay by grounding the co...

  • Page 329

    Engine controls 1f – 231 daewoo m-150 bl2 a freeze frame conditions (rpm, load, vehicle speed, temperature, etc.) that .Are noted. This will isolate when the dtc failed. Dtc p0480 – low speed cooling fan relay circuit fault (with a/c) step action value(s) yes no 1 perform an euro on-board diagnostic...

  • Page 330

    1f – 232 engine controls daewoo m-150 bl2 dtc p0480 – low speed cooling fan relay circuit fault (with a/c) (cont’d) step action value(s) yes no 9 check the connection at the ecm. Is a problem found and corrected? – go to step 11 go to step 13 10 repair the faulty relay control circuit. Is the repair...

  • Page 331: Blank

    Engine controls 1f – 233 daewoo m-150 bl2 blank.

  • Page 332

    1f – 234 engine controls daewoo m-150 bl2 maa1f090 diagnostic trouble code (dtc) – p0481 high speed cooling fan relay circuit fault (without a/c) circuit description ignition voltage is supplied directly to the cooling fan relay coil. The engine control module(ecm) controls the relay by grounding th...

  • Page 333

    Engine controls 1f – 235 daewoo m-150 bl2 a freeze frame conditions (rpm, load, vehicle speed, temperature, etc.) that .Are noted. This will isolate when the dtc failed. Dtc p0481 – high speed cooling fan relay circuit fault (without a/c) step action value(s) yes no 1 perform an euro on-board diagno...

  • Page 334

    1f – 236 engine controls daewoo m-150 bl2 dtc p0481 – high speed cooling fan relay circuit fault (without a/c) (cont’d) step action value(s) yes no 9 check the connection at the ecm. Is a problem found and corrected? – go to step 11 go to step 13 10 repair the faulty relay control circuit. Is the re...

  • Page 335: Blank

    Engine controls 1f – 237 daewoo m-150 bl2 blank.

  • Page 336

    1f – 238 engine controls daewoo m-150 bl2 maa1f270 diagnostic trouble code (dtc) – p0481 high speed cooling fan relay circuit fault (with a/c) circuit description ignition voltage is supplied directly to the cooling fan relay coil. The engine control module(ecm) controls the relay by grounding the c...

  • Page 337

    Engine controls 1f – 239 daewoo m-150 bl2 a freeze frame conditions (rpm, load, vehicle speed, temperature, etc.) that .Are noted. This will isolate when the dtc failed. Dtc p0481 – high speed cooling fan relay circuit fault (with a/c) step action value(s) yes no 1 perform an euro on-board diagnosti...

  • Page 338

    1f – 240 engine controls daewoo m-150 bl2 dtc p0481 – high speed cooling fan relay circuit fault (with a/c) (cont’d) step action value(s) yes no 8 check the connections at the relay. Is a problem found and corrected? – go to step 14 go to step 12 9 check the connection at the ecm. Is a problem found...

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    Engine controls 1f – 241 daewoo m-150 bl2 blank.

  • Page 340

    1f – 242 engine controls daewoo m-150 bl2 maa1f280 diagnostic trouble code (dtc) – p0501 vehicle speed no signal (m/t only) circuit description vehicle speed information is provided to the engine con- trol module (ecm) by the voltage speed sensor (vss) is a permanent magnet generator that is mounted...

  • Page 341

    Engine controls 1f – 243 daewoo m-150 bl2 dtc p0501 – vehicle speed no signal(m/t only) step action value(s) yes no 1 perform an euro on-board diagnostic (eobd) sys- tem check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 notice: running the vehicle in gear...

  • Page 342

    1f – 244 engine controls daewoo m-150 bl2 dtc p0501 – vehicle speed no signal(m/t only) (cont’d) ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no 12 1. Using the scan tool, clear the diagnostic trouble codes (dtcs). 2. Start the engi...

  • Page 343: Blank

    Engine controls 1f – 245 daewoo m-150 bl2 blank.

  • Page 344

    1f – 246 engine controls daewoo m-150 bl2 maa1f070 diagnostic trouble code (dtc) 0505 idle air control valve (iacv) circuit fault circuit description the engine control module (ecm) controls the air en- tering into the engine with an idle air control (iac) valve. To increase the idle rpm, the ecm co...

  • Page 345

    Engine controls 1f – 247 daewoo m-150 bl2 d excessive engine overloading. Check for seized pul- leys, pumps, or motors on the accessory drive, d overweight engine oil. Dtc p0505 idle air control valve (iacv) circuit fault step action value(s) yes no 1 perform an on-board diagnostic (eobd) system che...

  • Page 346

    1f – 248 engine controls daewoo m-150 bl2 dtc p0505 idle air control valve (iacv) circuit fault (cont’d) step action value(s) yes no 11 inspect the iac valve passages and repair as needed. Is the repair complete? – go to step 15 go to step 13 12 check the test light. Does the test light remain on co...

  • Page 347: Blank

    Engine controls 1f – 249 daewoo m-150 bl2 blank.

  • Page 348

    1f – 250 engine controls daewoo m-150 bl2 maa1f300 diagnostic trouble code (dtc) – p1535 evaporator temperature sensor high voltage circuit description a semiconductor which resistance is noticeably changed as the change of temperature. When the refrig- erant temperature of the evaporator drops to 0...

  • Page 349

    Engine controls 1f – 251 daewoo m-150 bl2 dtc p1535 – evaporator temperature sensor high voltage step action value(s) yes no 1 perform an on-board diagnostic (eobd ii) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1..Turn the ignition switch to...

  • Page 350

    1f – 252 engine controls daewoo m-150 bl2 maa1f300 diagnostic trouble code (dtc) – p1536 evaporator temperature sensor low voltage circuit description a semiconductor which resistance is noticeably changed as the change of temperature. When the refrig- erant temperature of the evaporator drops to 0 ...

  • Page 351

    Engine controls 1f – 253 daewoo m-150 bl2 dtc p1536 – evaporator temperature sensor low voltage step action value(s) yes no 1 perform an on-board diagnostic (eobd ii) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 2..Turn the ignition switch to ...

  • Page 352

    1f – 254 engine controls daewoo m-150 bl2 maa1f310 diagnostic trouble code (dtc) – p1537 a/c compressor relay high voltage circuit description the a/c system uses an a/c refrigerant pressure sen- sor mounted in the high pressure side of the a/c refrig- erant system to monitor a/c refrigerant pressur...

  • Page 353

    Engine controls 1f – 255 daewoo m-150 bl2 dtc p1537 – a/c compressor relay high voltage step action value(s) yes no 1 perform an on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 3..Turn the ignition switch to lock. 2. Di...

  • Page 354

    1f – 256 engine controls daewoo m-150 bl2 maa1f310 diagnostic trouble code (dtc) – p1538 a/c compressor relay low voltage circuit description the a/c system uses an a/c refrigerant pressure sen- sor mounted in the high pressure side of the a/c refrig- erant system to monitor a/c refrigerant pressure...

  • Page 355

    Engine controls 1f – 257 daewoo m-150 bl2 dtc p1538 – a/c compressor relay low voltage step action value(s) yes no 1 perform an on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition switch to lock. 2. Dis...

  • Page 356

    1f – 258 engine controls daewoo m-150 bl2 maa1f320 diagnostic trouble code (dtc) – p0562 system voltage(engine side) too low circuit description the engine control module (ecm) monitors the ignition voltage on the ignition feed circuit to terminal 7 at the ecm. A system voltage diagnostic trouble co...

  • Page 357

    Engine controls 1f – 259 daewoo m-150 bl2 dtc p0562 – system voltage (engine side) too low step action value(s) yes no 1 perform an on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Install a scan tool and clear the di...

  • Page 358

    1f – 260 engine controls daewoo m-150 bl2 maa1f320 diagnostic trouble code (dtc) – p0563 system voltage (engine side) too high circuit description the engine control module (ecm) monitors the ignition voltage on the ignition feed circuit to terminal 7 at the ecm. A system voltage diagnostic trouble ...

  • Page 359

    Engine controls 1f – 261 daewoo m-150 bl2 dtc p0563 – system voltage (engine side) too high step action value(s) yes no 1 perform an on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Install a scan tool and clear the d...

  • Page 360

    1f – 262 engine controls daewoo m-150 bl2 diagnostic trouble code (dtc) – p0601 engine control module checksum error circuit description the engine control module (ecm) is the control center of the fuel injection system. It constantly looks at the in- formation from various sensors, and controls the...

  • Page 361

    Engine controls 1f – 263 daewoo m-150 bl2 diagnostic trouble code (dtc) – p0604 engine control module internal/external ram error circuit description the engine control module (ecm) is the control center of the fuel injection system. It constantly looks at the in- formation from various sensors, and...

  • Page 362

    1f – 264 engine controls daewoo m-150 bl2 diagnostic trouble code (dtc) – p0605 engine control module nmvy write error circuit description the engine control module (ecm) is the control center of the fuel injection system. It constantly looks at the infor- mation from various sensors, and controls t...

  • Page 363: Blank

    Engine controls 1f – 265 daewoo m-150 bl2 blank.

  • Page 364

    1f – 266 engine controls daewoo m-150 bl2 maa1f050 diagnostic trouble code (dtc) – p1610 main relay high voltage circuit description when the ignition switch to on, main relay will grounded to ecm internal ground by ecm controlling. A system voltage diagnostic trouble code (dtc) will set whenever th...

  • Page 365

    Engine controls 1f – 267 daewoo m-150 bl2 dtc p1610 – main relay high voltage step action value(s) yes no 1 perform an on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Disconnect the main relay. 2. Measure the resista...

  • Page 366

    1f – 268 engine controls daewoo m-150 bl2 maa1f050 diagnostic trouble code (dtc) – p1611 main relay low voltage circuit description when the ignition switch to on, main relay will grounded to ecm internal ground by ecm controlling. A system voltage diagnostic trouble code (dtc) will set whenever the...

  • Page 367

    Engine controls 1f – 269 daewoo m-150 bl2 dtc p1611 – main relay low voltage step action value(s) yes no 1 perform an on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Disconnect the main relay. 2. Measure the resistan...

  • Page 368

    1f – 270 engine controls daewoo m-150 bl2 maa1f330 diagnostic trouble code (dtc) – p1628 immobilizer no successful communication circuit description when the ignition switch is turned to on, the key tested by immobilizer anti-theft system. While the key code is being read by immobilizer control unit...

  • Page 369

    Engine controls 1f – 271 daewoo m-150 bl2 dtc p1628 – immobilizer no successful communication step action value(s) yes no 1 perform an on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition off. 2. Install...

  • Page 370

    1f – 272 engine controls daewoo m-150 bl2 maa1f330 diagnostic trouble code (dtc) – p1629 immobilizer wrong computation circuit description when the ignition switch is turned to on, the key tested by immobilizer anti-theft system. While the key code is being read by immobilizer control unit or integr...

  • Page 371

    Engine controls 1f – 273 daewoo m-150 bl2 dtc p1629 – immobilizer wrong computation step action value(s) yes no 1 perform an on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition off. 2. Install a scan to...

  • Page 372

    1f – 274 engine controls daewoo m-150 bl2 maa1f340 diagnostic trouble code (dtc) – p0656 fuel level gauge circuit fault circuit description the engine control module(ecm) uses the fuel level in- put from the fuel level sensor to calculate expected va- por pressures within the fuel system. Vapor pres...

  • Page 373

    Engine controls 1f – 275 daewoo m-150 bl2 dtc p0656 – fuel level gauge circuit fault step action value(s) yes no 1 perform an on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition switch to lock. 2. Conne...

  • Page 374

    1f – 276 engine controls daewoo m-150 bl2 maa1f030 diagnostic trouble code (dtc) – p1660 malfunction indicator lamp (mil) high voltage circuit description when the ignition switch to on, the malfunction indica- tor lamp (mil) is on steady. When the engine cranking, the malfunction indicator lamp (mi...

  • Page 375

    Engine controls 1f – 277 daewoo m-150 bl2 dtc p1660 – malfunction indicator lamp (mil) high voltage step action value(s) yes no 1 perform an on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition switch to...

  • Page 376

    1f – 278 engine controls daewoo m-150 bl2 maa1f030 diagnostic trouble code (dtc) – p1661 malfunction indicator lamp (mil) low voltage circuit description when the ignition switch to on, the malfunction indica- tor lamp (mil) is on steady. When the engine cranking, the malfunction indicator lamp (mil...

  • Page 377

    Engine controls 1f – 279 daewoo m-150 bl2 dtc p1661 – malfunction indicator lamp (mil) low voltage step action value(s) yes no 1 perform an on-board diagnostic (eobd) system check. Is the system check complete? – go to step 2 go to “on-board diagnostic system check” 2 1. Turn the ignition switch to ...

  • Page 378: Symptom Diagnosis

    1f – 280 engine controls daewoo m-150 bl2 symptom diagnosis important preliminary checks important: several symptom procedures call for a care- ful visual/physical inspection. Always perform the visual/ physical test first. Visual inspections may lead to correcting a problem without further checks a...

  • Page 379

    Engine controls 1f – 281 daewoo m-150 bl2 intermittent definition: the problem may or may not illuminate the malfunction indicator lamp (mil) or store a diagnostic trouble code (dtc). Important: do not use the diagnostic trouble code (dtc) tables for intermittent problems. A fault must be present in...

  • Page 380

    1f – 282 engine controls daewoo m-150 bl2 intermittent (cont’d) step action value(s) yes no 9 1. Turn the ignition off. 2. Replace the ecm. Is the repair complete? – system ok – 10 does the vehicle stall while driving? – go to step 11 go to step 12 11 monitor the oxygen sensor and the injector base ...

  • Page 381

    Engine controls 1f – 283 daewoo m-150 bl2 hard start definition: the engine cranks ok, but does not start for a long time. The engine eventually runs or may start and immediately die. Important: ensure that the driver is using the correct starting procedure. Before diagnosing, check service bulletin...

  • Page 382

    1f – 284 engine controls daewoo m-150 bl2 hard start (cont’d) step action value(s) yes no 10 1. Check the fuel injector driver circuit. 2. Disconnect all of the fuel injector harness connectors at the fuel injectors. 3. Connect an injector test light between the harness terminals of each fuel inject...

  • Page 383

    Engine controls 1f – 285 daewoo m-150 bl2 hard start (cont’d) step action value(s) yes no 23 1. Check for the proper valve timing. 2. Check the cylinder compression. 3. Inspect the pushrods, the rocker arms, the valve springs, and the camshaft lobes for excessive wear. 4. Inspect the intake manifold...

  • Page 384

    1f – 286 engine controls daewoo m-150 bl2 surges or chuggles definition: engine power variation under steady throttle or cruise. Feels like the vehicle speeds up and slows down with no change in the accelerator pedal position. Important: make sure the driver understands a/c com- pressor operation as...

  • Page 385

    Engine controls 1f – 287 daewoo m-150 bl2 surges or chuggles (cont’d) step action value(s) yes no 13 repair the electrical connections or the vacuum lines as needed. Is the repair complete? – system ok – 14 check the generator output voltage. Is the generator voltage within the value specified? 12–1...

  • Page 386

    1f – 288 engine controls daewoo m-150 bl2 lack of power, sluggishness, or sponginess definition: the engine delivers less than expected pow- er. There is little or no increase in speed when the accel- erator pedal is partially applied. Step action value(s) yes no 1 were the important preliminary che...

  • Page 387

    Engine controls 1f – 289 daewoo m-150 bl2 lack of power, sluggishness, or sponginess (cont’d) step action value(s) yes no 15 repair or replace any engine components as needed. Is the repair complete? – system ok – 16 1. Check the engine control module (ecm) grounds for being clean, tight, and in the...

  • Page 388

    1f – 290 engine controls daewoo m-150 bl2 detonation/spark knock step action value(s) yes no 1 were the important preliminary checks performed? – go to step 2 go to “important preliminary checks” 2 1. Fill the fuel tank with a known good grade of gasoline that has the octane rating of the value spec...

  • Page 389

    Engine controls 1f – 291 daewoo m-150 bl2 detonation/spark knock (cont’d) step action value(s) yes no 12 1. Inspect for carbon buildup inside the engine. 2. Remove the carbon with a top engine cleaner. Follow the instructions supplied with the product. 3. Check the basic engine parts such as the cam...

  • Page 390

    1f – 292 engine controls daewoo m-150 bl2 hesitation, sag, stumble definition: momentary lack of response as the accelera- tor is pushed down. This can occur at any vehicle speed. It is usually the most severe when first trying to make the vehicle move, as from a stop. Hesitation, sag, or stumble ma...

  • Page 391

    Engine controls 1f – 293 daewoo m-150 bl2 hesitation, sag, stumble (cont’d) step action value(s) yes no 13 repair the restriction in the fuel system or replace the faulty fuel pump. Is the repair complete? – system ok – 14 1. Check for faulty ignition wires. 2. Inspect for fouled spark plugs. 3. Che...

  • Page 392

    1f – 294 engine controls daewoo m-150 bl2 cuts out, misses definition: steady pulsation or jerking that follows en- gine speed, usually more pronounced as engine load in- creases. The exhaust has a steady spitting sound at idle or low speed. Step action value(s) yes no 1 were the important prelimina...

  • Page 393

    Engine controls 1f – 295 daewoo m-150 bl2 cuts out, misses (cont’d) step action value(s) yes no 12 1. Repair or replace the faulty injector drive circuit harness, the connector, or the connector terminal. 2. If the connections and the harnesses are good, replace the engine control module (ecm). Is t...

  • Page 394

    1f – 296 engine controls daewoo m-150 bl2 poor fuel economy definition: fuel economy, as measured by an actual road test, is noticeably lower than expected. Also, fuel economy is noticeably lower than it was on this vehicle at one time, as previously shown by an actual road test. Important: driving ...

  • Page 395

    Engine controls 1f – 297 daewoo m-150 bl2 rough, unstable, or incorrect idle, stalling definition: the engine runs unevenly at idle. If the condi- tion is bad enough, the vehicle may shake. Also, the idle varies in rpm (called “hunting”). Either condition may be severe enough to cause stalling. The ...

  • Page 396

    1f – 298 engine controls daewoo m-150 bl2 rough, unstable, or incorrect idle, stalling (cont’d) step action value(s) yes no 12 is the long term fuel trim reading below the value specified? –20% go to “diagnostic aids for dtc p0172” go to step 13 13 is the long term fuel trim reading above the value ...

  • Page 397

    Engine controls 1f – 299 daewoo m-150 bl2 rough, unstable, or incorrect idle, stalling (cont’d) step action value(s) yes no 24 1. Inspect for vacuum leaks. 2. Check for proper positive crankcase ventilation (pcv) operation. 3. Check the idle air control (iac) valve operation. 4. Inspect the ecm grou...

  • Page 398

    1f – 300 engine controls daewoo m-150 bl2 excessive exhaust emissions or odors definition: a vehicle fails an emission test. The vehicle has an excessive rotten egg smell. Excessive odors do not necessarily indicate excessive emissions. Step action value(s) yes no 1 were the important preliminary ch...

  • Page 399

    Engine controls 1f – 301 daewoo m-150 bl2 excessive exhaust emissions or odors (cont’d) step action value(s) yes no 10 1. Inspect for vacuum leaks. 2. Inspect the catalytic converter for contamination. 3. Inspect for carbon buildup on the throttle body and the throttle plate and inside the engine. R...

  • Page 400

    1f – 302 engine controls daewoo m-150 bl2 dieseling, run-on definition: an engine continues to run after the ignition switch is turned off. Step action value(s) yes no 1 were the important preliminary checks performed? – go to step 2 go to “important preliminary checks” 2 does the engine run smoothl...

  • Page 401

    Engine controls 1f – 303 daewoo m-150 bl2 backfire definition: fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise. Important: before diagnosing the symptom, check ser- vice bulletins for updates. Step action value(s) yes no 1 were the important preliminary che...

  • Page 402: Repair Instructions

    1f – 304 engine controls daewoo m-150 bl2 repair instructions on-vehicle service d102f502 d102f501 fuel pump tools required dw 140–010a fuel pump lock ring remover/installer. Removal procedure caution: the fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire,...

  • Page 403

    Engine controls 1f – 305 daewoo m-150 bl2 d12f504a 3. Remove the fuel pump assembly from the tank. D install the fuel pump lock ring remover/installer dw 140– 010a. D turn the fuel tank lock ring counterclockwise (1). D102f505 d remove the fuel pump assembly (2). D remove the fuel pump gasket (3). D...

  • Page 404

    1f – 306 engine controls daewoo m-150 bl2 d102f508 2. Remove the fuel pressure regulator from the fuel pump. D remove the retainer from the fuel pump assembly (1). D remove the fuel pressure regulator (2). D check the o–ring seals for the damage or the rip. D use a vacuum gauge to check the diaphram...

  • Page 405

    Engine controls 1f – 307 daewoo m-150 bl2 d102f512 installation procedure 1. Install in the reverse order of removal. D install the new fuel filter into the retaining clamp. Note the flow direction. D connect the inlet/outlet lines. Secure the lines with the connector lock. D perform a leak test of ...

  • Page 406

    1f – 308 engine controls daewoo m-150 bl2 d102f516 6. Remove the fuel tank. D lower slowly the jack to remove the fuel tank easi- ly (1). D disconnect the canister hose which is connected to the roll over valve from the fuel tank removed (2). D inspect the fuel tank for clacks, damages, and con- tam...

  • Page 407

    Engine controls 1f – 309 daewoo m-150 bl2 d102f520 5. Remove the fuel rail with the fuel injectors attached. D remove the bolts (1). D remove the fuel rail with the fuel injectors attached (2). Notice: before removal, the fuel rail assembly may be cleaned with a spray–type cleaner, following package...

  • Page 408

    1f – 310 engine controls daewoo m-150 bl2 maa1f410 d disconnect the canister hoses (3). D remove the evaporative emission casnister (4). Maa1f420 installation procedure 1. Install in the reverse order of removal. Maa1f430 evaporative emission canister purge solenoid 1. Disconnect the negative batter...

  • Page 409

    Engine controls 1f – 311 daewoo m-150 bl2 maa1f450 2. Remove the map sensor. D remove the bolts (1). D remove the map sensor with bracket (2). Maa1f460 installatin procedure 1. Install in the reverse order of removal. D inspect the map sensor vacuum hose for the tear and damages. 2. Install the map ...

  • Page 410

    1f – 312 engine controls daewoo m-150 bl2 d102f539 4. Disconnect the coolant hoses and vacuum hoses from the throttle body. D loosen the clamps from the coolant hoses (1). D disconnect the coolant hoses from the throttle body (2). D disconnect the vacuum hoses (3). D102f541 5. Remove the throttle bo...

  • Page 411

    Engine controls 1f – 313 daewoo m-150 bl2 d12f543b installation procedure 1. Install the engine coolant temperature sensor. Tighten tighten the engine coolant temperature sensor to 8–12 n s m (71–106 lb-ft). D102f544 intake air temperature (iat) sensor removal procedure 1. Disconnect the negative ba...

  • Page 412

    1f – 314 engine controls daewoo m-150 bl2 d102f546 oxygen sensor (o2s1) removal procedure 1. Remove the air cleaner/resonator assembly. Refer to section 1b, sohc engine mechanical. 2. Remove the oxygen sensor. D disconnect the oxygen sensor connector (1). D remove the oxygen sensor (2). Notice: the ...

  • Page 413

    Engine controls 1f – 315 daewoo m-150 bl2 important: a special anti–seize compound is used on the oxygen sensor threads. This compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sen- sor easier to remove. New or service sen...

  • Page 414

    1f – 316 engine controls daewoo m-150 bl2 d21f010 installation procedure 1. Install the knock sensor with the bolt. Tighten tighten the knock sensor retaining bolt to 15–25 n s m (11–18 lb-ft). 2. Connect the electrical connector to the knock sensor. 3. Install the starter. Refer to section 1e, engi...

  • Page 415

    Engine controls 1f – 317 daewoo m-150 bl2 maa1f550 installation procedure 1. Install the ckp sensor. 2. Tighten the ckp sensor retaining bolt to 5–8 n s m (44–71 lb-in). Uaa1f2e0 camshaft position (cmp) sensor removal procedure 1. Disconnect the negative battery cable. 2. Disconnect the camshaft pos...

  • Page 416

    1f – 318 engine controls daewoo m-150 bl2 maa1f520 2. Remove the ecm. D remove the bolts. D remove the ecm. Maa1f530 installation procedure 1. Install in the reverse order of removal. Notice: if disconnecting the battery cable to the ecm, the iac valve resetting should be proceeded. 2. Install the e...

  • Page 417: Specifications

    Engine controls 1f – 319 daewoo m-150 bl2 specifications fastener tightening specifications application n s m lb-ft lb-in camshaft position sensor bolts 10–14 – 89–124 engine coolant temperature (ect) sensor 8–12 – 71–106 crankshaft position (ckp) sensor retaining bolt 5–8 – 44–71 electronic ignitio...

  • Page 418

    1f – 320 engine controls daewoo m-150 bl2 ecm wiring diagram (sirius d3 – 1 of 5) maa1f610

  • Page 419

    Engine controls 1f – 321 daewoo m-150 bl2 ecm wiring diagram (sirius d3 – 2 of 5) maa1f620

  • Page 420

    1f – 322 engine controls daewoo m-150 bl2 ecm wiring diagram (sirius d3 – 3 of 5) maaf630

  • Page 421

    Engine controls 1f – 323 daewoo m-150 bl2 ecm wiring diagram (sirius d3 – 4 of 5) maa1f640

  • Page 422

    1f – 324 engine controls daewoo m-150 bl2 ecm wiring diagram (sirius d3 – 5 of 5) maa1f650

  • Page 423: Section 1G

    Daewoo m-150 bl2 section 1g engine exhaust table of contents description and operation 1g-2 . . . . . . . . . . . . . . . . . . Exhaust system 1g-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . Muffler 1g-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Catalytic conve...

  • Page 424: Description And Operation

    1g – 2 engine exhaust daewoo m-150 bl2 description and operation exhaust system notice: when you are inspecting or replacing exhaust system components, make sure there is adequate clear- ance from all points on the underbody to avoid possible overheating of the floor pan and possible damage to the p...

  • Page 425: Component Locator

    Engine exhaust 1g – 3 daewoo m-150 bl2 component locator exhaust system d12g4011 1 pup-up catalytic converter 2 front exhaust pipe/catalytic converter assembly 3 front muffler pipe 4 rear muffler pipe.

  • Page 426: Repair Instructions

    1g – 4 engine exhaust daewoo m-150 bl2 repair instructions on–vehicle service maa1g010 exhaust pipe/catalytic converter caution : make sure to confirm that the components is cool. And do work. Removal procedure 1. Remove the floor console. Refer to section 9g, inte- rior trim, if equipped heated oxy...

  • Page 427

    Engine exhaust 1g – 5 daewoo m-150 bl2 d102g503 6. Remove the front exhaust pipe and the catalytic con- verter assembly. A. Front exhaust pipe. B. Catalytic converter. 7. Clean the sealing surfaces on the front exhaust pipe flange and the exhaust manifold. 8. Check the exhaust pipe and the catalytic...

  • Page 428

    1g – 6 engine exhaust daewoo m-150 bl2 maa1b010 3. Remove the air cleaner assembly. Refer to section 1b, sohc engine mechanical. 4. Disconnect oxygen sensor (o2s) connector. 5. Remove the exhaust manifold heat shield. 6. Remove the exhaust manifold. Refer to section 1b, sohc engine mechanical. Maa1b...

  • Page 429

    Engine exhaust 1g – 7 daewoo m-150 bl2 d12g504b 3. Install the front exhaust pipe to pup-up catalytic con- vertor. Tighten tighten the bolts to 25–35 n s m (18–25 lb-ft). D102g502 front muffler removal procedure 1. Remove the front exhaust pipe-to-front muffler nuts. D remove the nuts (1). Maa1g030 ...

  • Page 430

    1g – 8 engine exhaust daewoo m-150 bl2 maa1g030 rear mffler removal procedure 1. Remove the front muffler-to rear muffler nuts. Tighten tighten the nuts to 25–35 n s m (18–25 lb-ft). 2. Detach the rear muffler from the rubber hangers. Maa1g040 3. Remove the rear muffler. 4. Installation should flow ...

  • Page 431: Specifications

    Engine exhaust 1g – 9 daewoo m-150 bl2 specifications fastener tightening specifications application n s m lb-ft lb-in front exhaust pipe-to-front muffler pipe nuts 25 – 35 18 – 25 – front exhaust pipe-to-exhaust manifold nuts 25 – 35 18 – 25 – front exhaust pipe-to-pup-up catalytic converter 25 – 3...

  • Page 432: Section 2A

    Daewoo m-150 bl2 section 2a suspension diagnosis table of contents diagnostic information and procedures 2a-1 . . . . . General diagnosis 2a-1 . . . . . . . . . . . . . . . . . . . . . . . . . Wheel bearing diagnosis 2a-6 . . . . . . . . . . . . . . . . . . . Diagnostic information and procedures ge...

  • Page 433

    2a – 2 suspension diagnosis daewoo m-150 bl2 ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ condition ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ probable cause ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ correction car lead/pull d mismatched or uneven tires. D replace the tires. D a broken or a sagging coil spring. D replace the coil spring. D a improp...

  • Page 434

    Suspension diagnosis 2a – 3 daewoo m-150 bl2 ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ condition ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ probable cause ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ correction hard steering (manual) d a lack of lubrication of the ball joints, the tie rods and the steering gear. D lubricate the ball joints, the tie...

  • Page 435

    2a – 4 suspension diagnosis daewoo m-150 bl2 ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ condition ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ probable cause ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ correction abnormal noise, front d a loose stabilizer shaft link. D tighten the stabilizer shaft link. Suspension d loose wheel nuts. D tighten the wh...

  • Page 436

    Suspension diagnosis 2a – 5 daewoo m-150 bl2 ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ condition ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ probable cause ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ correction steering wheel d air in the power steering system. D bleed the power steering system. Kickback (power) d a loose steering gear mounting. D ...

  • Page 437

    2a – 6 suspension diagnosis daewoo m-150 bl2 wheel bearing diagnosis this vehicle with non–serviceable bearings in the rear wheels. If any fault is found with a wheel bearing, it must be replaced. Wheel bearing noise a road test usually reveals excessive wheel bearing noise. Wheel bearings emit a ho...

  • Page 438: Section 2B

    Daewoo m-150 bl2 section 2b wheel alignment table of contents description and operation 2b-2 . . . . . . . . . . . . . . . . . . Four wheel alignment 2b-2 . . . . . . . . . . . . . . . . . . . . . Toe 2b-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caster 2b-2 . . . ...

  • Page 439: Description And Operation

    2b – 2 wheel alignment daewoo m-150 bl2 description and operation four wheel alignment the first responsibility of engineering is to design safe steering and suspension systems. Each component must be strong enough to withstand and absorb extreme punishment. Both the steering system and the front an...

  • Page 440

    Wheel alignment 2b – 3 daewoo m-150 bl2 steering axis inclination steering axis inclination (sai) is the tilt at the top of the steering knuckle from the vertical. Measure the sai angle from the true vertical to a line through the center of the strut and the lower ball joint as viewed from the front...

  • Page 441

    2b – 4 wheel alignment daewoo m-150 bl2 diagnostic information and procedures tire diagnosis ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ condition ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ probable cause ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ correction irregular and excessive tire wear d incorrect infla...

  • Page 442

    Wheel alignment 2b – 5 daewoo m-150 bl2 front toe adjustment 1. Separate the clamps from the both rack and pinion boots. 2. Loosen the right and the left tie rod end lock nuts. 3. Turn the right and the left tie rod to align the toe. In this adjustment, the right and left tie rods must be equal in l...

  • Page 443: Specifications

    2b – 6 wheel alignment daewoo m-150 bl2 specifications wheel alignment specifications ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ application ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ front ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ rear camber 0 _ 30 ′ ± 0 _ 30 ′ 0 _ " 20 ′ caster–manual steering 2 _ 48 ′ ±...

  • Page 444: Section 2C

    Daewoo m-150 bl2 section 2c front suspension table of contents description and operation 2c-2 . . . . . . . . . . . . . . . . . . Front suspension 2c-2 . . . . . . . . . . . . . . . . . . . . . . . . . Component locator 2c-3 . . . . . . . . . . . . . . . . . . . . . . . . Front suspension 2c-3 . . ....

  • Page 445: Description And Operation

    2c – 2 front suspension daewoo m-150 bl2 description and operation front suspension the front suspension for this vehicle is a combination knuckle/strut and spring design. The control arms pivot from the body. The lower control arm pivots use rubber bushing. The upper end of the strut is isolated by...

  • Page 446: Component Locator

    Front suspension 2c – 3 daewoo m-150 bl2 component locator front suspension d16b401a.

  • Page 447

    2c – 4 front suspension daewoo m-150 bl2 1. Strut bar 2. Front suspension strut assembly 3. Strut inner support 4. Strut mount assembly 5. Strut mount seat 6. Strut bearing seat 7. Strut bearing 8. Coil spring upper seat 9. Coil spring seat 10. Bumper stopper 11. Coil spring 12. Strut 13. Inner bear...

  • Page 448

    Front suspension 2c – 5 daewoo m-150 bl2 diagnostic information and procedures strut dampener a strut dampener is basically a shock absorber. However, strut dampeners are easier to extend and retract by hand than are shock absorbers. Strut dampeners are used only on the front in most vehicles, inclu...

  • Page 449

    2c – 6 front suspension daewoo m-150 bl2 front wheel bearing bearing axial end play inspection d107b303 1. Lift and suitably support the vehicle. 2. Inspect the end play of the bearing. 3. If excessive play is defeeted, free shoes from the disc or remove the calipers. 4. Check the standard torque of...

  • Page 450: Repair Instructions

    Front suspension 2c – 7 daewoo m-150 bl2 repair instructions on–vehicle service d16b501a strut assembly removal procedure 1. Open the hood. 2. Remove the top of the strut assembly at passenger seat side. D for vehicle with power steering, remove the power steering fluid reservoir (1). D remove the n...

  • Page 451

    2c – 8 front suspension daewoo m-150 bl2 d16b504a 70–90 n s m installation procedure 1. Install the strut assembly to the vehicle with the strut assembly–to–strut bracket bolts. Tighten tighten the strut assembly–to–strut bracket bolts to 70–90 n s m (52–66 lb-ft). 2. Connect the brake hose to the b...

  • Page 452

    Front suspension 2c – 9 daewoo m-150 bl2 d106b507 4. Remove the control arm from the knuckle assembly. D remove the stud bolt (1). D separate the control arm from the knuckle assem- bly (2). D106b508 5. Remove the brake caliper from the knuckle assembly. Refer to section 4d, front disc brakes. 6. Re...

  • Page 453

    2c – 10 front suspension daewoo m-150 bl2 d106b511 front longitudinal frame and stabilizer shaft removal procedure 1. Removed the front under longitudinal frame. D raise and suitably support the vehicle. D remove the front wheel. Refer to section 2e, tires and wheels. D remove the transaxle under co...

  • Page 454

    Front suspension 2c – 11 daewoo m-150 bl2 d16b515a installation procedure 1. Install in the reverse order of removal. Important: when installing the mountings, position the opened mountings forward. D16b516a 40–50 n s m 2. Install the stabilizer shaft to the vehicle. D install the castellated nut. T...

  • Page 455

    2c – 12 front suspension daewoo m-150 bl2 d106b519 control arm removal procedure 1. Remove the stabilizer shaft. Refer to “front longitu- dinal frame and stabilizer shaft” in this section. 2. Remove the control arm. D remove the stud bolt (1). D separate the control arm from the knuckle assem- bly u...

  • Page 456

    Front suspension 2c – 13 daewoo m-150 bl2 d106b523 d remove the strut bar bolts at driver side (4). Important: when removing the bolts using the tool, do not contact the battery terminal. D remove the strut bar at passenger side d16b524b installation procedure 1. Install the strut bar to the vehicle...

  • Page 457

    2c – 14 front suspension daewoo m-150 bl2 d106b527 d106b528 6. Remove the front damping bush bolts and damping bush from the crossmember. D16b529a 35–41 n s m 45–55 n s m installation procedure 1. Install in the reverse order of removal. 2. Install the front damping bush to the crossmember. Tighten ...

  • Page 458

    Front suspension 2c – 15 daewoo m-150 bl2 d16b531a 17–27 n s m 17–27 n s m c. Crossmember left rear bolt. D. Crossmember leftt side bolt. D16b532a 68–83 n s m 4. Install the front damping bush to the vehicle. Tighten tighten the front damping bush bolt and nut to 68–83 n s m (51–61 lb-ft). 5. Instal...

  • Page 459: Unit Repair

    2c – 16 front suspension daewoo m-150 bl2 unit repair d106b701 hub bearing and knuckle tools required dw 220–020a–01 differential bearing puller. Dw 220–020a–04 differential bearing plate adapter. Dw 340–010 front wheel hub remover. Dw 340–020 front wheel bearing race installer. Dw 340–030 front whe...

  • Page 460

    Front suspension 2c – 17 daewoo m-150 bl2 d16b703a d remove the wheel bearing from the wheel hub us- ing the differential bearing puller dw 220–020a–01 and differential bearing plate adapter dw 220– 020a–04 (4). D106b704 d remove the oil seal from the wheel hub (5). Important: do not use removed oil...

  • Page 461

    2c – 18 front suspension daewoo m-150 bl2 d106b707 d remove the inner bearing race (4). D106b708 assembly procedure 1. Assemble the steering knuckle assembly. D assemble the inner bearing race using the front wheel hub remover dw 340–010 and the front bearing race installer dw 340–020 (1). D106b709 ...

  • Page 462

    Front suspension 2c – 19 daewoo m-150 bl2 d106b711 2. Install the wheel hub to steering knuckle assembly. D install the brake rotor (1). D install the wheel hub to the steering knuckle as- sembly temporary (2). D press the outer wheel bearing into the wheel hub using the front wheel hub remover dw 3...

  • Page 463

    2c – 20 front suspension daewoo m-150 bl2 d106b715 d install the inner wheel bearing oil seal (7). 3. Install the steering knuckle assembly. Refer to “knuckle assembly” in this section. D106b716 front strut (including coil spring) tools required 09940–71430 front spring compressor. Disassembly proce...

  • Page 464

    Front suspension 2c – 21 daewoo m-150 bl2 d16b718a 4. Remove the coil spring. D remove the strut inner support (1). D remove the strut mount assembly (2). D remove the strut mount seat (3). D remove the strut bearing seat (4). D remove the strut bearing (5). D remove the coil spring upper seat (6). ...

  • Page 465

    2c – 22 front suspension daewoo m-150 bl2 d106b720 3. Inspect the installation of coil spring (1, 2). 4. Install the strut assembly. Refer to “strut assembly” in this section..

  • Page 466: Specifications

    Front suspension 2c – 23 daewoo m-150 bl2 specifications general specifications ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ application ÁÁÁÁÁÁ ÁÁÁÁÁÁ unit ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ description ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ suspension type ÁÁÁÁÁÁ ÁÁÁÁÁÁ – ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ mcpherson (st...

  • Page 467

    2c – 24 front suspension daewoo m-150 bl2 special tools and equipment special tools table d13b112a dw 220–020a–01 differential bearing puller d13b113a dw 220–020a–04 differential bearing plate adapter d16b101a dw 340–010 front wheel hub remover d106b102 dw 340–020 front wheel bearing race installer ...

  • Page 468: Section 2D

    Daewoo m-150 bl2 section 2d rear suspension table of contents description and operation 2d-2 . . . . . . . . . . . . . . . . . . Rear suspension 2d-2 . . . . . . . . . . . . . . . . . . . . . . . . . . Component locator 2d-3 . . . . . . . . . . . . . . . . . . . . . . . . Rear suspension 2d-3 . . . ...

  • Page 469: Description And Operation

    2d – 2 rear suspension daewoo m-150 bl2 description and operation rear suspension the rear suspension consists of an axle with trailing arms and a lateral rod, two coil springs, two shock ab- sorbers, two upper spring seats, and two bump stop- pers. The axle structure maintains the relationship of t...

  • Page 470: Component Locator

    Rear suspension 2d – 3 daewoo m-150 bl2 component locator rear suspension d106c401 1. Shock absorber 2. Bumper stopper 3. Coil spring upper seat 4. Coil spring 5. Washer 6. Bushing 7. Lateral rod 8. Rear axle 9. Oil seal 10. Wheel bearing inner 11. Abs wheel speed ring 12. Wheel bearing outer 13. Co...

  • Page 471

    2d – 4 rear suspension daewoo m-150 bl2 diagnostic information and procedures rear suspension ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ condition ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ probable cause ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ correction noise d the loosened joints. D tighten the joints....

  • Page 472

    Rear suspension 2d – 5 daewoo m-150 bl2 checking the rear wheel bearing end play 1. Release the parking brake. 2. Raise the vehicle. 3. Check the wheel bearing play by moving the top and the down of the tire in an in–and–out motion. D106c301 ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ rear wheel bearing pla...

  • Page 473: Repair Instructions

    2d – 6 rear suspension daewoo m-150 bl2 repair instructions on–vehicle service d106c501 shock absorber removal procedure 1. Support the rear axle with adjustable jack stands. D raise the vehicle and support the rear axle assem- bly (1, 2). D106c502 2. Remove the shock absorber. D remove the bolt (1)...

  • Page 474

    Rear suspension 2d – 7 daewoo m-150 bl2 d106c504 lateral rod removal procedure 1. Raise and suitably support the vehicle. 2. Remove the lateral rod. D remove the lateral rod–to– body bracket bolt (1). D106c505 d remove the lateral rod–to–rear axle nut (2). D106c506 2. Remove the lateral rod axle sid...

  • Page 475

    2d – 8 rear suspension daewoo m-150 bl2 d16c508b 3. Install the lateral rod–to–body bracket bolt. Tighten tighten the lateral rod–to–body bracket bolt to 50–70 n s m (37–52 lb-ft). D106c509 trailing arm removal procedure 1. Raise and suitably support the vehicle. 2. Support the rear axle with adjust...

  • Page 476

    Rear suspension 2d – 9 daewoo m-150 bl2 d16c515a installation procedure 1. Install the trailing arm. D install the trailing arm–to–body bracket bolt (1). Tighten tighten the trailing arm–to–body bracket bolt to 70– 90 n s m (55–66 lb-ft). D install the trailing arm–to–rear axle bolts (2). Tighten ti...

  • Page 477

    2d – 10 rear suspension daewoo m-150 bl2 d106c519 5. Remove the rear bumper stopper and rear spring up- per seat. A. Rear bumper stopper. B. Rear spring upper seat. D106c520 installation procedure 1. Install in the reverse order of removal. Important: make sure the spring diameter prior to installin...

  • Page 478

    Rear suspension 2d – 11 daewoo m-150 bl2 d16c517c 3. Install the trailing arm and the shock absorber to the rear axle. D install the trailing arm–to–rear axle bolt (1). Tighten tighten the trailing arm–to–rear axle bolt to 80–90 n s m (59–66 lb-ft). D16c516c d install the shock absorber–to–rear axle...

  • Page 479: Unit Repair

    2d – 12 rear suspension daewoo m-150 bl2 unit repair d106c701 hub and bearing assembly tools required dw 340–010 front wheel hub remover dw 350–030 rear wheel bearing race installer disassembly procedure 1. Remove the rear brake drum. Refer to section 4e, rear drum brakes. 2. Remove the rear wheel b...

  • Page 480

    Rear suspension 2d – 13 daewoo m-150 bl2 d106c704 d remove the outer bearing race (2). Important: use only new bearing race. D106c705 assembly procedure 1. Press the bearing race into the break drum using the front wheel hub remover dw 340–010 and the rear wheel bearing race installer dw 350–030. D ...

  • Page 481

    2d – 14 rear suspension daewoo m-150 bl2 d106c708 d install the outer bearing (3). 3. Install the brake drum. Refer to section 4e, rear drum brakes. 4. Adjust the end play and free load of the bearing. Re- fer to “check and adjustments” in this section..

  • Page 482: Specifications

    Rear suspension 2d – 15 daewoo m-150 bl2 specifications general specifications ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ application ÁÁÁÁÁÁ ÁÁÁÁÁÁ unit ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ description ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ suspension type – ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ isolated trailing link ÁÁÁÁÁÁÁÁÁ...

  • Page 483

    2d – 16 rear suspension daewoo m-150 bl2 special tools and equipment special tools table d16b101a dw 340–010 front wheel hub remover d106c101 dw 350–030 rear wheel bearing race installer.

  • Page 484: Section 2E

    Daewoo m-150 bl2 section 2e tires and wheels table of contents description and operation 2e-2 . . . . . . . . . . . . . . . . . . Tire 2e-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement tires 2e-3 . . . . . . . . . . . . . . . . . . . . . . . . All season ti...

  • Page 485: Description And Operation

    2e – 2 tires and wheels daewoo m-150 bl2 description and operation tire tread a part (that contacts) road surfaces directly is fixed on the outside of carcass and breaker. It is a strong rubber coat made of high anti–abrasion rubber. Its running per- formance depends on is surface profile. Breaker a...

  • Page 486

    Tires and wheels 2e – 3 daewoo m-150 bl2 hydroplaning the condition of driving a vehicle fast on the road surface covered with water can cause tires to fail to rotate with a good contact on the surface, so results in remaining them afloat. This is so–called hydroplaning. It causes brake failure, low...

  • Page 487

    2e – 4 tires and wheels daewoo m-150 bl2 wheels wheels must be replaced if they are bent, dented, have excessive lateral or radial runout, leak air through welds, have elongated bolt holes, or if the wheel bolts won’t stay tight or are heavily rusted. Wheels with excessive runout may cause vehicle v...

  • Page 488

    Tires and wheels 2e – 5 daewoo m-150 bl2 diagnostic information and procedures tire wear 1. Measure the depth of the tire tread. 2. If the depth of the tread is below the specified value, replace the tire. D106a302 ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ limit of the tread wear ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 1...

  • Page 489

    2e – 6 tires and wheels daewoo m-150 bl2 irregular or excessive tires wear condition probable cause correction d16a305a d low tire inflation pressures. D improper the tire rotation. D adjust tire inflation pressures. D rotate the tires. D16a305b d excessive tire inflation pressures. D improper the t...

  • Page 490: Repair Instructions

    Tires and wheels 2e – 7 daewoo m-150 bl2 repair instructions on-vehicle service d106a501 d106a502 wheel removal procedure 1. Remove the wheel cover on the vehicle equipped with steel wheel. 2. Loosen the wheel nuts. 3. Raise and suitably support the vehicle. 4. Remove the wheel nuts. Notice: never u...

  • Page 491

    2e – 8 tires and wheels daewoo m-150 bl2 d16a503a 90–110 n s m installation procedure notice: before installing the wheels, remove any build- up of corrosion on the wheel mounting surface and the brake drum or the rotor mounting surface by scraping and brushing them with a wire brush. Installing the...

  • Page 492

    Tires and wheels 2e – 9 daewoo m-150 bl2 another method is to dismount the tire and rotate it 180 degrees on the rim. Do this only on the tire and wheel assemblies which are known to be causing a vibration because this method is just as likely to cause good assemblies to vibrate. Tire and wheel matc...

  • Page 493: Specifications

    2e – 10 tires and wheels daewoo m-150 bl2 specifications tire size and pressure specifications inflation pressure front rear engine tires wheel kpa psi kpa psi 0.8 sohc 145/70 r13 4.5jx13 (steel) 207 (207)* 30 (30)* 207 (234)* 30 (34)* 155/65 r13 4.5jx13 (alloy) 207 (207)* 30 (30)* 207 (234)* 30 (34...

  • Page 494: Section 3B

    Daewoo m-150 bl2 section 3b manual transaxle drive axle table of contents description and operation 3b-2 . . . . . . . . . . . . . . . . . . Front drive axle 3b-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . Component locator 3b-3 . . . . . . . . . . . . . . . . . . . . . . . . Drive axle a...

  • Page 495: Description And  Operation

    3b – 2 manual transaxle drive axle daewoo m-150 bl2 description and operation front drive axle drive axles are flexible shaft assemblies that transmit a rotational force from the transaxle to the front wheel as- semblies. Each axle assembly consists of an inner constant-velocity joint and an outer c...

  • Page 496: Component Locator

    Manual transaxle drive axle 3b – 3 daewoo m-150 bl2 component locator drive axle assembly d104b401 1. Outer joint (rzeppa) 2. Outer large boot clamp 3. Outer boot 4. Outer small boot clamp 5. Drive axle shaft 6. Inner small boot clamp 7. Inner boot 8. Inner large boot clamp 9. Inner joint (tripot) 1...

  • Page 497

    3b – 4 manual transaxle drive axle daewoo m-150 bl2 diagnostic information and procedures ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ condition ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ probable cause ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ correction ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ noise ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ s bent drive axle shaft. ÁÁÁÁÁÁÁÁÁÁÁÁÁ...

  • Page 498: Repair Instructions

    Manual transaxle drive axle 3b – 5 daewoo m-150 bl2 repair instructions on–vehicle service d106b506 drive axle assembly tool required km–507–b tie rod end joint remover removal procedure 1. Remove the drive axle shaft nut. D fix the hub not to rotate by pressing the brake ped- al. D loosen the caulk...

  • Page 499

    3b – 6 manual transaxle drive axle daewoo m-150 bl2 d104b502 7. Pull the drive axle shaft (1) from the wheel hub. Important: support the unfastened end of the drive axle. Do not allow the drive axle to dangle freely from the transaxle for any length of time after it has been re- moved from the wheel...

  • Page 500

    Manual transaxle drive axle 3b – 7 daewoo m-150 bl2 d14b505b 5. Install the control arm ball joint bolt. Tighten tighten the control arm ball joint bolt to 50–70 n s m (36–52 lb-ft). A. Control arm ball joint bolt 6. Install the tie rod into the knuckle and install the tie rod end joint castellated ...

  • Page 501

    3b – 8 manual transaxle drive axle daewoo m-150 bl2 35–55 n s m d13b521a 11. Install the transaxle under cover. Tighten tighten the transaxle under cover bolts to 35–55 n s m (25–41 lb-ft).

  • Page 502: Unit Repair

    Manual transaxle drive axle 3b – 9 daewoo m-150 bl2 unit repair d104b701 inner joint (transaxle side) tool required j–35566 boot clamp pliers disassembly procedure 1. Remove the drive axle. Refer to “drive axle assem- bly” in this section. 2. Remove the clamps on the joint boot. D remove the boot cl...

  • Page 503

    3b – 10 manual transaxle drive axle daewoo m-150 bl2 d104b704 6. Remove the drive axle shaft boot. D104b705 assembly procedure 1. Install in the reverse order of removal. 2. Fill the joint housing with recommended grease when installing. ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ capacity ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ 90–100 g (3.2...

  • Page 504

    Manual transaxle drive axle 3b – 11 daewoo m-150 bl2 d104b704 5. Remove the drive axle shaft boot. D104b708 assembly procedure 1. Install in the reverse order of removal. 2. Install the joint assembly. D pre–install the joint assembly by pushing to the drive axle shaft to widen the circlip. D keep t...

  • Page 505: Specifications

    3b – 12 manual transaxle drive axle daewoo m-150 bl2 specifications general specifications ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ application ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ description ÁÁÁÁÁÁ ÁÁÁÁÁÁ unit ÁÁÁÁÁÁ ÁÁÁÁÁÁ standard ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ limit ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ inner ÁÁÁÁÁÁ ÁÁÁÁÁÁ – tripot joint ÁÁÁÁÁÁÁ ...

  • Page 506

    Manual transaxle drive axle 3b – 13 daewoo m-150 bl2 special tools and equipment special tools table d104b101 km–507–b tie rod end joint remover d105b101 j–35566 boot clamp pliers.

  • Page 507: Section 4A

    Daewoo m-150 bl2 section 4a hydraulic brakes caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and dam...

  • Page 508: Description And Operation

    4a – 2 hydraulic brakes daewoo m-150 bl2 description and operation warning lamp operation this brake system uses a brake warning lamp located in the instrument panel cluster. When the ignition switch is in the iii position, the brake warning lamp should il- luminate. It should go off when the igniti...

  • Page 509: Component Locator

    Hydraulic brakes 4a – 3 daewoo m-150 bl2 component locator brake system (non–abs) (left–hand drive shown, right–hand drive similar) mab4a001 1. Power booster 2. Power booster boot 3. Cotter pin 4. Clevis 5. Clevis pin 6. Packing 7. Spacer 8. Master cylinder assembly 9. Fluid reservoir assembly 10. R...

  • Page 510

    4a – 4 hydraulic brakes daewoo m-150 bl2 diagnositic information and procedures brake system testing (left–hand drive shown, right–hand drive similar) 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...

  • Page 511

    Hydraulic brakes 4a – 5 daewoo m-150 bl2 warning lamp operation this brake system uses a brake warning lamp located in the instrument panel cluster. When the ignition switch is in the iii position, the brake warning lamp should glow and then go off when the ignition switch returns to the ii position...

  • Page 512

    4a – 6 hydraulic brakes daewoo m-150 bl2 manual bleeding the brakes important: the bleeding sequence is as follows; right rear, left rear, right front, and left front. Important: check the fluid level and add the fluid during the bleeding operation. 1. Raise the vehicle. 2. Remove the bleeder screw ...

  • Page 513

    Hydraulic brakes 4a – 7 daewoo m-150 bl2 brake pedal free play inspection 1. Push the brake pedal several times to discharge the vacuum of the power booster. 2. Measure the pedal movement until the hardness is felt when pushing the brake pedal by hand. Unit : mm (in.) ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ s...

  • Page 514: Repair Instructions

    4a – 8 hydraulic brakes daewoo m-150 bl2 repair instructions on–vehicle service d107a528 brake hose (front) removal procedure 1. Remove the wheels. Refer to section 2e, tires and wheels. 2. Remove the brake hose. D remove the fitting (1). D remove the e–ring retainer (2). D disconnect the brake hose...

  • Page 515

    Hydraulic brakes 4a – 9 daewoo m-150 bl2 d107a530 brake hose (rear) removal procedure 1. Remove the wheels. Refer to section 2e, tires and wheels. 2. Remove the brake hose. D remove the fittings (1). D remove the e–rings (2). D plug the opening in the brake pipe to prevent fluid loss or contaminatio...

  • Page 516

    4a – 10 hydraulic brakes daewoo m-150 bl2 d107a525 brake pedal (left–hand drive) removal procedure 1. Remove the stoplamp switch. Refer to “stoplamp switch” in this section. 2. Disconnect the brake pedal from the power booster. Refer to section 4c, power booster. 3. Remove the brake pedal. D remove ...

  • Page 517

    Hydraulic brakes 4a – 11 daewoo m-150 bl2 d24d001 3. Remove the stoplamp switch. D remove the stoplamp switch (1). D remove the bolts (2). D remove the stoplamp switch bracket (3). D24d002 4. Remove the bolts mounting brake pedal bracket (1). 5. Remove the nuts mounting brake pedal bracket (2). D24d...

  • Page 518

    4a – 12 hydraulic brakes daewoo m-150 bl2 d24d005 installation procedure 1. Install the brake pedal with pad, spring, bushings, and cushion. 2. Install the bolt mounting brake pedal bracket in the engine compartment. Tighten tighten the bolt to 18–26 n s m (13–20 lb-ft). 3. Install the canister. Ref...

  • Page 519: Specifications

    Hydraulic brakes 4a – 13 daewoo m-150 bl2 specifications general specifications ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 0.8 sohc engine ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ application ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ millimeters ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ inches ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ...

  • Page 520

    4a – 14 hydraulic brakes daewoo m-150 bl2 schematic and routing diagrams brake lamp warning circuit d17a201b stoplamp switch circuit d17a202b.

  • Page 521: Section 4B

    Daewoo m-150 bl2 section 4b master cylinder table of contents description and operation 4b-2 . . . . . . . . . . . . . . . . . . Master cylinder 4b-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . Proportioning valve 4b-2 . . . . . . . . . . . . . . . . . . . . . . . . Fluid level sensor 4b-2...

  • Page 522: Description And Operation

    4b – 2 master cylinder daewoo m-150 bl2 description and operation master cylinder the master cylinder is designed for use in a direct–split system. Front right brake and rear left brake are served by the primary piston. Front left brake and rear right brake are served by the secondary piston. The ma...

  • Page 523

    Master cylinder 4b – 3 daewoo m-150 bl2 diagnostic information and procedures checking the brake fluid level 1. Check the fluid level. 2. If the fluid level is below max, refill the fluid to max. D107a302.

  • Page 524: Repair Instructions

    4b – 4 master cylinder daewoo m-150 bl2 repair instructions on–vehicle service mab4b001 d107a514 master cylinder assembly removal procedure 1. Remove the air filter assembly. Refer to section 1b, engine mechanical. 2. For vehicles with the non–abs braking system, re- move the proportioning valve. Re...

  • Page 525

    Master cylinder 4b – 5 daewoo m-150 bl2 mab4b002 2. Install the brake pipe fittings to the master cylinder. Tighten tighten the fittings to 16 n s m (12 lb-ft). 3. Connect the electrical connector. 4. For vehicles with the non–abs braking system, install the proportioning valve. Refer to “proportion...

  • Page 526

    4b – 6 master cylinder daewoo m-150 bl2 notice: brake fluid may damage paintwork, if spillage onto paintwork, wash with cold water immediately. Mab4b004 installation procedure 1. Install the proportioning valve (1). Tighten tighten the proportioning valve to 22 n s m (16 lb-ft). 2. Install the brake...

  • Page 527

    Master cylinder 4b – 7 daewoo m-150 bl2 d107a506 installation procedure 1. Install the brake fluid level switch. 2. Connect the electrical connector. 3. Install the vacuum hose to the power booster. Refer to section 4c, power booster..

  • Page 528: Unit Repair

    4b – 8 master cylinder daewoo m-150 bl2 unit repair d24b001 master cylinder (abs type master cylinder is shown, non–abs type master cylinder is similar) disassembly procedure 1. Remove the master cylinder. Refer to “master cylin- der assembly” in this section. 2. Remove the brake fluid reservoir. Re...

  • Page 529: Specifications

    Master cylinder 4b – 9 daewoo m-150 bl2 specifications general specifications ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ application ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ unit ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ description ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ type ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ – ÁÁ...

  • Page 530: Section 4C

    Daewoo m-150 bl2 section 4c power booster table of contents description and operation 4c-2 . . . . . . . . . . . . . . . . . . Power booster 4c-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic information and procedures 4c-3 . . . . . Power booster functional check 4c-3 . . . . ....

  • Page 531: Description And Operation

    4c – 2 power booster daewoo m-150 bl2 description and operation power booster this booster is a single diaphragm, vacuum-suspended unit. In a normal operating mode, with the service brakes in the release position, a vacuum-suspended booster operates with a vacuum on both sides of its diaphragm. When...

  • Page 532

    Power booster 4c – 3 daewoo m-150 bl2 diagnostic information and procedures power booster functional check 1. With the engine stopped, eliminate the vacuum in the booster by pumping the brake pedal several times. 2. Push the pedal down and hold it in this position. 3. Start the engine. 4. The booste...

  • Page 533: Repair Instructions

    4c – 4 power booster daewoo m-150 bl2 repair instructions on–vehicle service d107a501 vacuum hose and check valve removal procedure 1. Remove the vacuum hose. D disconnect the vacuum hose from the intake man- ifold (1). D17a502a d disconnect the vacuum hose from the power booster (2). D107a503 insta...

  • Page 534

    Power booster 4c – 5 daewoo m-150 bl2 d107a519 power booster assembly (left–hand drive) removal procedure 1. Remove the master cylinder assembly. Refer to sec- tion 4b, master cylinder. 2. Disconnect the vacuum hose from the power booster. 3. Remove the power booster. D straighten the cotter pin and...

  • Page 535

    4c – 6 power booster daewoo m-150 bl2 d24c001 power booster assembly (right–hand drive) removal procedure 1. Remove the master cylinder assembly. Refer to sec- tion 4b, master cylinder. 2. Disconnect the vacuum hose from the power booster. 3. Remove the instrument panel assembly. Refer to section 9e...

  • Page 536

    Power booster 4c – 7 daewoo m-150 bl2 d24c003 installation procedure 1. Install the power booster with the new cotter pin, cle- vis pin and nuts. Tighten tighten the nuts to 16 n s m (12 lb-ft). Important: make sure the distance from the booster to the center of the clevis bore should be 100mm (3.94...

  • Page 537: Specifications

    4c – 8 power booster daewoo m-150 bl2 specifications general specifications ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ application ÁÁÁÁÁÁ ÁÁÁÁÁÁ unit ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ description ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ type – ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ vacuum–suspended ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ Á...

  • Page 538: Section 4D

    Daewoo m-150 bl2 section 4d front disc brakes table of contents description and operation 4d-2 . . . . . . . . . . . . . . . . . . Disc brake caliper assembly 4d-2 . . . . . . . . . . . . . . . Clearance calibration 4d-2 . . . . . . . . . . . . . . . . . . . . . . Component locator 4d-3 . . . . . . ...

  • Page 539: Description And Operation

    4d – 2 front disc brakes daewoo m-150 bl2 description and operation disc brake caliper assembly this caliper has a single bore and is mounted to the steering knuckle with two mounting bolts. Hydraulic pressure, created by applying the brake pedal, is con- verted by the caliper to a stopping force. T...

  • Page 540: Component Locator

    Front disc brakes 4d – 3 daewoo m-150 bl2 component locator front disc brakes d17b401a 1. Front brake caliper assembly 2. Front brake boot assemblies 3. Pins 4. Pin boots 5. Front brake pads 6. Carrier 7. Pad spring 8. Piston boot 9. Piston 10. Piston seal 11. Cylinder 12. Bleeder screw cap 13. Blee...

  • Page 541

    4d – 4 front disc brakes daewoo m-150 bl2 diagnostic information and procedures front disc brake ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ condition ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ probable cause ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ correction uneven braking d inoperative carrier. D replace...

  • Page 542

    Front disc brakes 4d – 5 daewoo m-150 bl2 lining inspection 1. Raise and suitably support the vehicle. 2. Remove the front wheels. Refer to section 2e, tires and wheels. 3. Visually check the linings for minimum thickness and wear. 4. Measure the thickness. Important: the minimum thickness of the sh...

  • Page 543: Repair Instructions

    4d – 6 front disc brakes daewoo m-150 bl2 repair instructions on–vehicle service d107b501 shoe and lining removal procedure 1. Remove the front wheels. Refer to section 2e, tires and wheels. 2. Remove the brake pads. D remove the pin bolt (1). D107b502 d lift up the cylinder assembly (2). D17b503a i...

  • Page 544

    Front disc brakes 4d – 7 daewoo m-150 bl2 d107b504 caliper assembly removal procedure 1. Remove the front wheels. Refer to section 2e, tires and wheels. 2. Remove the caliper assembly. D remove the brake hose coupling bolt (1). D plug the opening in the brake hose to prevent fluid loss and contamina...

  • Page 545: Unit Repair

    4d – 8 front disc brakes daewoo m-150 bl2 unit repair d107b701 caliper overhaul disassembly procedure 1. Remove the caliper assembly. Refer to “caliper as- sembly” in this section. 2. Separate the cylinder assembly and the carrier. D remove the pin bolts (1). D separate the cylinder assembly and the...

  • Page 546

    Front disc brakes 4d – 9 daewoo m-150 bl2 d107b704 d remove the piston boot (3). Caution: do not face in the direction of removing. D107b705 d using compressed air, blow out the piston from the cylinder (4). D remove the piston (5). D107b706 d remove the piston seal (6)..

  • Page 547

    4d – 10 front disc brakes daewoo m-150 bl2 d17b708b d17b707a 26 assembly procedure important: clean all parts in denatured alcohol. Dry the parts with unlubricated compressed air. Important: lubricate the piston with brake fluid. 1. Assembly the cylinder assembly. D install the piston seal. D push t...

  • Page 548: Specifications

    Front disc brakes 4d – 11 daewoo m-150 bl2 specifications general specifications ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ application ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ unit ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ description ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ outer diameter ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ mm (in.) ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ 23...

  • Page 549: Section 4E

    Daewoo m-150 bl2 section 4e rear drum brakes table of contents description and operation 4e-2 . . . . . . . . . . . . . . . . . . Drum brakes 4e-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component locator 4e-3 . . . . . . . . . . . . . . . . . . . . . . . . Rear drum brakes 4e-3 . ...

  • Page 550: Description And Operation

    4e – 2 rear drum brakes daewoo m-150 bl2 description and operation drum brakes this drum brake assembly is a leading/trailing shoe de- sign. Both brake shoes are held against the wheel cylin- der pistons by the lower return spring and the fixed anchor plate near the lower return spring. When the bra...

  • Page 551: Component Locator

    Rear drum brakes 4e – 3 daewoo m-150 bl2 component locator rear drum brakes d107c401 1. Bleeder screw 2. Bleeder screw 3. Rear brake assembly 4. Rear brake plate 5. Wheel cylinder 6. Strut assembly 7. Brake leading shoe 8. Middle return spring 9. Upper return spring 10. Brake shoe retain spring pin ...

  • Page 552

    4e – 4 rear drum brakes daewoo m-150 bl2 diagnostic information and procedures rear drum brake ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ condition ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ probable cause ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ correction not enough braking d badly worn brake shoe lining...

  • Page 553

    Rear drum brakes 4e – 5 daewoo m-150 bl2 drums inspect the brake drum as follows ; 1. Inspect the drum for crack or damage. 2. Measure the inside diameter. Unit : mm (in.) ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ inside diameter wear limit value ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ 182 (7.165) d107c301 3. If the meas...

  • Page 554: Repair Instructions

    4e – 6 rear drum brakes daewoo m-150 bl2 repair instructions on–vehicle service d107c501 d17c502a rear brake drum removal procedure 1. Remove the rear wheels. Refer to section 6e, tires and wheels. 2. Release the parking brake. 3. Remove the brake drum. D remove the spindle cap (1). D remove the cot...

  • Page 555

    Rear drum brakes 4e – 7 daewoo m-150 bl2 d17c504a d tighten the castellated nut to 25 n s m (18 lb-ft). D loosen the castellated nut to 180 _ . D retighten the castellated nut to 2.5 n s m (22 lb-in). D install the new cotter pin and spindle cap. 2. Adjust the parking brake. 3. Install the rear whee...

  • Page 556

    4e – 8 rear drum brakes daewoo m-150 bl2 d107c508 4. Disconnect the parking brake cable from the trailing shoe and remove the trailing shoe (7). D107c509 installation procedure 1. Install in the reverse of removal. 2. Clean the adjust assembly and apply grease. 3. Connect the parking brake cable fro...

  • Page 557

    Rear drum brakes 4e – 9 daewoo m-150 bl2 d17c512a installation procedure 1. Install the wheel cylinder to the backing plate with the wheel cylinder bolt (1). Tighten tighten the wheel cylinder–to–backing plate bolt to 10 n s m (89 lb-in). 2. Connect the brake line fitting (2). Tighten tighten the br...

  • Page 558: Unit Repair

    4e – 10 rear drum brakes daewoo m-150 bl2 unit repair d107c701 wheel cylinder disassembly procedure 1. Remove the wheel cylinder assembly. Refer to “wheel cylinder assembly” in this section. 2. Disassemble wheel cylinder assembly. D remove the dust boots and do not reuse them (1). D remove the pisto...

  • Page 559: Specifications

    Rear drum brakes 4e – 11 daewoo m-150 bl2 specifications general specifications ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ application ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ unit ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ description ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ inside diameter ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ mm (in.) ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ 18...

  • Page 560: Section 4F

    Daewoo m-150 bl2 section 4f antilock brake system caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury an...

  • Page 561

    4f – 2 antilock brake system daewoo m-150 bl2 dtc 0951 right rear isolation shorted or driver open 4f-80 . . . . . . . . . . . . . . . . . . . . . . . . . . . Dtc 0952 right rear isolation open or driver shorted 4f-82 . . . . . . . . . . . . . . . . . . . . . . . . . Dtc 1102 return pump motor circu...

  • Page 562: Description And Operation

    Antilock brake system 4f – 3 daewoo m-150 bl2 description and operation abs system components the antilock braking system (abs) consists of a con- ventional hydraulic brake system plus antilock compo- nents. The conventional brake system includes a vacuum booster, master cylinder, front disc brakes,...

  • Page 563

    4f – 4 antilock brake system daewoo m-150 bl2 feed back to the master cylinder and brake pedal. D107e005 return pump motor the motor drives two pump elements through the ec- centric wheel on its shaft. Return pump description: each pump element consists of a fixed displacement piston driven by an ec...

  • Page 564

    Antilock brake system 4f – 5 daewoo m-150 bl2 d107e001 wheel speed sensors and rings front wheel speed sensors are installed to the front knuckle and rear wheel speed sensors are installed to the backing plate. Wheel speed sensors are no serviceable. And the air cap is not adjusted. Front wheel spee...

  • Page 565

    4f – 6 antilock brake system daewoo m-150 bl2 ebcm connector a connector has 31 pins which are shown below figure. And a connector includes a warning switch which grounds and lights the abs warning lamp if there is no ebcm unit plugged in, so that an indication is given that abs is not available. D1...

  • Page 566

    Antilock brake system 4f – 7 daewoo m-150 bl2 hydraulic fluid flow diagrams master cylinder high pressure attenuator high pressure attenuator return pump motor return pump return pump rr isolation valve low pressure accumulator fl isolation valve rr dump valve fl dump valve fr isolation valve low pr...

  • Page 567

    4f – 8 antilock brake system daewoo m-150 bl2 master cylinder high pressure attenuator high pressure attenuator return pump motor return pump return pump low pressure accumulator low pressure accumulator rr fl fr rl d17e206a rr isolation valve fl isolation valve rr dump valve fl dump valve fr isolat...

  • Page 568

    Antilock brake system 4f – 9 daewoo m-150 bl2 master cylinder high pressure attenuator high pressure attenuator return pump motor return pump return pump low pressure accumulator low pressure accumulator rr fl fr rl d17e207a rr isolation valve fl isolation valve rr dump valve fl dump valve fr isolat...

  • Page 569

    4f – 10 antilock brake system daewoo m-150 bl2 master cylinder high pressure attenuator return pump motor return pump return pump low pressure accumulator rr fl fr rl d17e208a rr isolation valve low pressure accumulator fl isolation valve rr dump valve fl dump valve fr isolation valve fr dump valve ...

  • Page 570

    Antilock brake system 4f – 11 daewoo m-150 bl2 master cylinder high pressure attenuator high pressure attenuator return pump motor return pump return pump low pressure accumulator rr fl fr rl d17e209a rr isolation valve low pressure accumulator fl isolation valve rr dump valve fl dump valve fr isola...

  • Page 571: Visual Identification

    4f – 12 antilock brake system daewoo m-150 bl2 visual identification ebcm connector face view terminal 9 is identified as they appear from the wire entry end of the harness connector. Ebcm connector d107e204 ÑÑÑÑÑÑ ÑÑÑÑÑÑ ÑÑÑÑÑÑ pin ÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑ signal name ÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑ c...

  • Page 572: Component Locator

    Antilock brake system 4f – 13 daewoo m-150 bl2 component locator abs d17e401a 1. Hydraulic modulator unit 2. Electronic brake control module (ebcm) 3. Bolt 4. Upper mounting bracket 5. Grommet 6. Lower mounting bracket 7. Bracket grommet 8. Rear wheel speed sensor 9. Front wheel speed sensor.

  • Page 573

    4f – 14 antilock brake system daewoo m-150 bl2 abs (cont’d) d17e402a.

  • Page 574: Blank

    Antilock brake system 4f – 15 daewoo m-150 bl2 blank.

  • Page 575

    4f – 16 antilock brake system daewoo m-150 bl2 diagnostic information and procedures d17e301a diagnostic trouble code (dtc) 0354 left front wheel speed sensor circuit open or shorted circuit description as a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause th...

  • Page 576

    Antilock brake system 4f – 17 daewoo m-150 bl2 intrusion exists, replace the wheel speed sensor har- ness. If replacing a wheel speed sensor harness, in- spect the sensor terminals. If you find evidence of corrosion or water intrusion, replace the wheel speed sensor. Refer to “front wheel speed sens...

  • Page 577

    4f – 18 antilock brake system daewoo m-150 bl2 dtc 0354 – left front wheel speed sensor circuit open or shorted (cont’d) ÑÑÑÑ ÑÑÑÑ step ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ action ÑÑÑÑÑ ÑÑÑÑÑ value(s) ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ yes ÑÑÑÑÑÑ ÑÑÑÑÑÑ no ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 10 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑ...

  • Page 578: Blank

    Antilock brake system 4f – 19 daewoo m-150 bl2 blank.

  • Page 579

    4f – 20 antilock brake system daewoo m-150 bl2 d17e301a diagnostic trouble code (dtc) 0355 left front wheel speed sensor poor air gap or missing tooth ring circuit description as a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel speed sensor to pro...

  • Page 580

    Antilock brake system 4f – 21 daewoo m-150 bl2 sensor. Refer to “front wheel speed sensor” in this section. Important: wheel speed sensor intermittent malfunc- tions may be difficult to locate. Take care not to disturb any electrical connections before performing an indi- cated step of this table. T...

  • Page 581

    4f – 22 antilock brake system daewoo m-150 bl2 d17e301a diagnostic trouble code (dtc) 0356 left front wheel speed sensor circuit intermittent shorted circuit description as a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel speed sensor to produce a...

  • Page 582

    Antilock brake system 4f – 23 daewoo m-150 bl2 intrusion exists, replace the wheel speed sensor har- ness. If replacing a wheel speed sensor harness, in- spect the sensor terminals. If you find evidence of corrosion or water intrusion, replace the wheel speed sensor. Refer to “front wheel speed sens...

  • Page 583

    4f – 24 antilock brake system daewoo m-150 bl2 d17e302a diagnostic trouble code (dtc) 0404 right front wheel speed sensor circuit open or shorted circuit description as a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel speed sensor to produce a sin...

  • Page 584

    Antilock brake system 4f – 25 daewoo m-150 bl2 intrusion exists, replace the wheel speed sensor har- ness. If replacing a wheel speed sensor harness, in- spect the sensor terminals. If you find evidence of corrosion or water intrusion, replace the wheel speed sensor. Refer to “front wheel speed sens...

  • Page 585

    4f – 26 antilock brake system daewoo m-150 bl2 dtc 0404 – right front wheel speed sensor circuit open or shorted (cont’d) ÑÑÑÑ ÑÑÑÑ step ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ action ÑÑÑÑÑ ÑÑÑÑÑ value(s) ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ yes ÑÑÑÑÑÑ ÑÑÑÑÑÑ no ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 10 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑ...

  • Page 586: Blank

    Antilock brake system 4f – 27 daewoo m-150 bl2 blank.

  • Page 587

    4f – 28 antilock brake system daewoo m-150 bl2 d17e302a diagnostic trouble code (dtc) 0405 right front wheel speed sensor poor air gap or missing tooth ring circuit description as a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel speed sensor to pr...

  • Page 588

    Antilock brake system 4f – 29 daewoo m-150 bl2 sensor. Refer to “front wheel speed sensor” in this section. Important: wheel speed sensor intermittent malfunc- tions may be difficult to locate. Take care not to disturb any electrical connections before performing an indi- cated step of this table. T...

  • Page 589

    4f – 30 antilock brake system daewoo m-150 bl2 d17e302a diagnostic trouble code (dtc) 0406 right front wheel speed sensor circuit intermittent shorted circuit description as a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel speed sensor to produce ...

  • Page 590

    Antilock brake system 4f – 31 daewoo m-150 bl2 intrusion exists, replace the wheel speed sensor har- ness. If replacing a wheel speed sensor harness, in- spect the sensor terminals. If you find evidence of corrosion or water intrusion, replace the wheel speed sensor. Refer to “front wheel speed sens...

  • Page 591

    4f – 32 antilock brake system daewoo m-150 bl2 d17e303b diagnostic trouble code (dtc) 0454 left rear wheel speed sensor circuit open or shorted circuit description as a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel speed sensor to produce a sinus...

  • Page 592

    Antilock brake system 4f – 33 daewoo m-150 bl2 intrusion exists, replace the wheel speed sensor har- ness. If replacing a wheel speed sensor harness, in- spect the sensor terminals. If you find evidence of corrosion or water intrusion, replace the wheel speed sensor. Refer to “rear wheel speed senso...

  • Page 593

    4f – 34 antilock brake system daewoo m-150 bl2 dtc 0454 – left rear wheel speed sensor circuit open or shorted (cont’d) ÑÑÑÑ ÑÑÑÑ step ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ action ÑÑÑÑÑ ÑÑÑÑÑ value(s) ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ yes ÑÑÑÑÑÑ ÑÑÑÑÑÑ no ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 10 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑ...

  • Page 594

    Antilock brake system 4f – 35 daewoo m-150 bl2 dtc 0454 – left rear wheel speed sensor circuit open or shorted (cont’d) ÑÑÑÑ ÑÑÑÑ step ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ action ÑÑÑÑÑ ÑÑÑÑÑ value(s) ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ yes ÑÑÑÑÑÑ ÑÑÑÑÑÑ no ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 23 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑ...

  • Page 595

    4f – 36 antilock brake system daewoo m-150 bl2 d17e303b diagnostic trouble code (dtc) 0455 left rear wheel speed sensor poor air gap or missing tooth ring circuit description as a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel speed sensor to prod...

  • Page 596

    Antilock brake system 4f – 37 daewoo m-150 bl2 sensor. Refer to “rear wheel speed sensor” in this sec- tion. Important: wheel speed sensor intermittent malfunc- tions may be difficult to locate. Take care not to disturb any electrical connections before performing an indi- cated step of this table. ...

  • Page 597

    4f – 38 antilock brake system daewoo m-150 bl2 d17e303b diagnostic trouble code (dtc) 0456 left rear wheel speed sensor circuit intermittent shorted circuit description as a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel speed sensor to produce a ...

  • Page 598

    Antilock brake system 4f – 39 daewoo m-150 bl2 intrusion exists, replace the wheel speed sensor har- ness. If replacing a wheel speed sensor harness, in- spect the sensor terminals. If you find evidence of corrosion or water intrusion, replace the wheel speed sensor. Refer to “rear wheel speed senso...

  • Page 599

    4f – 40 antilock brake system daewoo m-150 bl2 dtc 0456 – left rear wheel speed sensor circuit intermittent shorted (cont’d) ÑÑÑÑ ÑÑÑÑ step ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ action ÑÑÑÑÑ ÑÑÑÑÑ value(s) ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ yes ÑÑÑÑÑÑ ÑÑÑÑÑÑ no ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 11 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ...

  • Page 600: Blank

    Antilock brake system 4f – 41 daewoo m-150 bl2 blank.

  • Page 601

    4f – 42 antilock brake system daewoo m-150 bl2 d17e304b diagnostic trouble code (dtc) 0504 right rear wheel speed sensor circuit open or shorted circuit description as a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel speed sensor to produce a sinu...

  • Page 602

    Antilock brake system 4f – 43 daewoo m-150 bl2 intrusion exists, replace the wheel speed sensor har- ness. If replacing a wheel speed sensor harness, in- spect the sensor terminals. If you find evidence of corrosion or water intrusion, replace the wheel speed sensor. Refer to “rear wheel speed senso...

  • Page 603

    4f – 44 antilock brake system daewoo m-150 bl2 dtc 0504 – right rear wheel speed sensor circuit open or shorted (cont’d) ÑÑÑÑ ÑÑÑÑ step ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ action ÑÑÑÑÑ ÑÑÑÑÑ value(s) ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ yes ÑÑÑÑÑÑ ÑÑÑÑÑÑ no ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 10 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑ...

  • Page 604

    Antilock brake system 4f – 45 daewoo m-150 bl2 dtc 0504 – right rear wheel speed sensor circuit open or shorted (cont’d) ÑÑÑÑ ÑÑÑÑ step ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ action ÑÑÑÑÑ ÑÑÑÑÑ value(s) ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ yes ÑÑÑÑÑÑ ÑÑÑÑÑÑ no ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 23 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑ...

  • Page 605

    4f – 46 antilock brake system daewoo m-150 bl2 d17e304b diagnostic trouble code (dtc) 0505 right rear wheel speed sensor poor air gap or missing tooth ring circuit description as a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel speed sensor to pro...

  • Page 606

    Antilock brake system 4f – 47 daewoo m-150 bl2 sensor. Refer to “rear wheel speed sensor” in this sec- tion. Important: wheel speed sensor intermittent malfunc- tions may be difficult to locate. Take care not to disturb any electrical connections before performing an indi- cated step of this table. ...

  • Page 607

    4f – 48 antilock brake system daewoo m-150 bl2 d17e304b diagnostic trouble code (dtc) 0506 right rear wheel speed sensor circuit intermittent shorted circuit description as a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel speed sensor to produce a...

  • Page 608

    Antilock brake system 4f – 49 daewoo m-150 bl2 intrusion exists, replace the wheel speed sensor har- ness. If replacing a wheel speed sensor harness, in- spect the sensor terminals. If you find evidence of corrosion or water intrusion, replace the wheel speed sensor. Refer to “rear wheel speed senso...

  • Page 609

    4f – 50 antilock brake system daewoo m-150 bl2 dtc 0506 – right rear wheel speed sensor circuit intermittent shorted (cont’d) ÑÑÑÑ ÑÑÑÑ step ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ action ÑÑÑÑÑ ÑÑÑÑÑ value(s) ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ yes ÑÑÑÑÑÑ ÑÑÑÑÑÑ no ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 11 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ...

  • Page 610: Blank

    Antilock brake system 4f – 51 daewoo m-150 bl2 blank.

  • Page 611

    4f – 52 antilock brake system daewoo m-150 bl2 d17e305b diagnostic trouble code (dtc) 0601 left front dump shorted or driver open circuit description ebcm proceeds the self–test about the dump valve or the motor driver, if the ebcm senses the brake signal. Diagnosis if the ebcm proceeds the self–tes...

  • Page 612

    Antilock brake system 4f – 53 daewoo m-150 bl2 dtc 0601 – left front dump shorted or drive open ÑÑÑÑ ÑÑÑÑ step ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ action ÑÑÑÑÑ ÑÑÑÑÑ value(s) ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ yes ÑÑÑÑÑÑ ÑÑÑÑÑÑ no ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 1 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑ...

  • Page 613

    4f – 54 antilock brake system daewoo m-150 bl2 d17e305b diagnostic trouble code (dtc) 0602 left front dump open or driver shorted circuit description ebcm proceeds the self–test about the dump valve or the motor driver, if the ebcm senses the brake signal. Diagnosis if the ebcm proceeds the self–tes...

  • Page 614

    Antilock brake system 4f – 55 daewoo m-150 bl2 dtc 0602 – left front dump open or driver shorted ÑÑÑÑ ÑÑÑÑ step ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ action ÑÑÑÑÑ ÑÑÑÑÑ value(s) ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ yes ÑÑÑÑÑÑ ÑÑÑÑÑÑ no ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 1 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑ...

  • Page 615

    4f – 56 antilock brake system daewoo m-150 bl2 d17e305b diagnostic trouble code (dtc) 0651 left front isolation shorted or driver open circuit description ebcm proceeds the self–test about the dump valve or the motor driver, if the ebcm senses the brake signal. Diagnosis if the ebcm proceeds the sel...

  • Page 616

    Antilock brake system 4f – 57 daewoo m-150 bl2 dtc 0651 – left front isolation shorted or driver open ÑÑÑÑ ÑÑÑÑ step ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ action ÑÑÑÑÑ ÑÑÑÑÑ value(s) ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ yes ÑÑÑÑÑÑ ÑÑÑÑÑÑ no ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ ÑÑÑÑ 1 ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑ...

  • Page 617: Section 4G

    Daewoo m-150 bl2 section 4g parking brake table of contents description and operation 4g-2 . . . . . . . . . . . . . . . . . . Parking brake 4g-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component locator 4g-3 . . . . . . . . . . . . . . . . . . . . . . . . Parking brake 4g-3 . . . ...

  • Page 618: Description And Operation

    4g – 2 parking brake daewoo m-150 bl2 description and operation parking brake this braking system uses a brake warning light lo- cated in the instrument panel cluster. When the ignition switch is in the iii position, the brake warning light should glow and go off when the parking brake lever is rele...

  • Page 619: Component Locator

    Parking brake 4g – 3 daewoo m-150 bl2 component locator parking brake d107d401 1. Parking brake cable clip 2. Parking brake cable 3. Strengthener 4. Cable grommet 5. Parking brake lever assembly 6. Parking brake warning lamp switch 7. Cotter pin 8. Cable pulley 9. Pin.

  • Page 620: Repair Instructions

    4g – 4 parking brake daewoo m-150 bl2 repair instructions on-vehicle service d107d501 parking brake lever removal procedure 1. Remove the parking brake lever cover. Refer to sec- tion 9g, interior trim. 2. Remove the parking brake cable cover. Refer to sec- tion 9g, interior trim. 3. Remove the park...

  • Page 621

    Parking brake 4g – 5 daewoo m-150 bl2 d17d504a installation procedure 1. Install the parking brake lever with the cotter pin, pin, bolts, and nut. Tighten d tighten the parking brake nut to 10 n s m (89 lb-in) (1). D tighten the parking brake bolts to 10 n s m (89 lb-in) (2). 2. Connect the brake wa...

  • Page 622

    4g – 6 parking brake daewoo m-150 bl2 d107d508 parking brake cable removal procedure 1. Remove the parking brake lever. Refer to “parking brake lever” in this section. 2. Remove the parking brake cable. D remove the cable pulley (1). D loosen the adjustment nuts (2). D remove the strengthener (3). D...

  • Page 623

    Parking brake 4g – 7 daewoo m-150 bl2 d107d512 d remove the clamp bolts fastening the brake cable (lh rear brake side) (2). D17d513a d17d514a installation procedure 1. Install the fuel filter. 2. Install the parking brake cable with the clamp bolts. Tighten tighten the parking brake cable clamp bolt...

  • Page 624: Specifications

    4g – 8 parking brake daewoo m-150 bl2 specifications general specifications ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ application ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ description ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ parking brake lever notch number ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 5–7 (loaded 44....

  • Page 625

    Parking brake 4g – 9 daewoo m-150 bl2 schematic and routing diagrams parking brake system d17a201b.

  • Page 626: Section 5B

    Daewoo m-150 bl2 section 5b five-speed manual transaxle caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal inj...

  • Page 627: Description And Operation

    5b – 2 five-speed manual transaxle daewoo m-150 bl2 description and operation five-speed manual transaxle this five-speed transaxle assembly adopts the synchro- nized mesh type of 5 forward speed. The reverse speed gear is driven by sliding idle gear without synchronizer. Reverse gear misshift preve...

  • Page 628: Component Locators

    Five-speed manual transaxle 5b – 3 daewoo m-150 bl2 component locators gear shift control d13b4011 1 gear shift control lever knob 2 gear shift cable bracket 3 select cable 4 shift cable 5 select arm 6 gear shift control lever 7 gear shift control lever guide.

  • Page 629

    5b – 4 five-speed manual transaxle daewoo m-150 bl2 input shaft and counter shaft gear d13b4031.

  • Page 630

    Five-speed manual transaxle 5b – 5 daewoo m-150 bl2 1 input shaft circlip 2 5th gear synchronizer plate 3 5th gear synchronizer sleeve 4 5th gear synchronizer spring 5 5th gear synchronizer key 6 5th gear synchronizer hub 7 5th gear synchronizer ring 7-1 wave spring 8 input shaft 5th gear 9 input sh...

  • Page 631

    5b – 6 five-speed manual transaxle daewoo m-150 bl2 gear shift fork d13b4021 1 shift and select shaft 2 shift interlock bolt 3 shift lever 4 select lever 5 shift and select shaft boot 6 gearshift control case 7 shift guide bolt 8 gearshift control case guide plate 9 gearshift control case gasket 10 ...

  • Page 632

    Five-speed manual transaxle 5b – 7 daewoo m-150 bl2 differential and case d13b4041 1 speedometer driven gear 2 oil level plug 3 case cap o–ring(left) 4 case cap(left) 5 back up light switch 6 transaxle case(right) 7 oil plate 8 transaxle case(left) 9 oil drain plug 10 oil gutter 11 side cover plate ...

  • Page 633

    5b – 8 five-speed manual transaxle daewoo m-150 bl2 diagnostic information and procedure general diagnosis condition probable cause correction gear slipping out of mesh d worn shift fork. D replace shift fork. D worn synchronizer sleeve or gear. D replace sleeve or gear. D worn bearings on input sha...

  • Page 634

    Five-speed manual transaxle 5b – 9 daewoo m-150 bl2 checking fluid level check for a leak in the area of transaxle case and seal- ing and then check fluid level and condition after remov- ing oil level plug. 1. Operate the engine until it comes to normal operating temperature(coolant temperature : 8...

  • Page 635: Repair Instruction

    5b – 10 five-speed manual transaxle daewoo m-150 bl2 repair instruction on–vehicle service d103b501 manual transaxle assembly tools required dw110–021 engine support fixture dw220–031 transaxle remove/install support removal procedure 1. Remove the air cleaner assembly. Refer to section 1b, sohc eng...

  • Page 636

    Five-speed manual transaxle 5b – 11 daewoo m-150 bl2 d13b5031 6. Disconnect the radiator lower hose. D remove the bolts (1). D disconnect the radiator lower hose (2). 7. Remove crankshaft position (ckp) sensor. D remove the bolt (3). D disconnect the ckp sensor connector d remove the ckp sensor. D10...

  • Page 637

    5b – 12 five-speed manual transaxle daewoo m-150 bl2 d103b510 12. Remove the transaxle upper bolts. A. Exhaust manifold side bolt. B. Thermostat housing side bolt. D103b505 13. Remove the transaxle under cover. D remove the bolts (1). D remove the transaxle under cover (2). 14. Remove the front tire...

  • Page 638

    Five-speed manual transaxle 5b – 13 daewoo m-150 bl2 d12b5731 20. Remove the front exhaust pipe. D remove the front exhaust pipe nuts (exhaust manifold side) (1). D remove the gasket and separate exhaust man- ifold pipe (2). D make free the front exhaust pipe. D13b5111 21. Support the transaxle with...

  • Page 639

    5b – 14 five-speed manual transaxle daewoo m-150 bl2 d13b5141 24. Position the manual transaxle assembly in tilting. D to remove the manual transaxle side cover with- out the interference with the front under longitudi- nal panel (left), tilt the engine/manual transaxle by loosening the engine suppo...

  • Page 640

    Five-speed manual transaxle 5b – 15 daewoo m-150 bl2 d13b518a 3. Install the transaxle lower bolt, nut. Tighten tighten the bolt and nut to 55–65 n s m (41–48 lb-ft). A. Lower bolt. B. Lower nut. D13b5472 4. Tighten the front exhaust pipe nuts. Tighten d tighten the front exhaust pipe nuts (exhaust ...

  • Page 641

    5b – 16 five-speed manual transaxle daewoo m-150 bl2 d13b5032 8. Install the radiator lower hose and crank position (ckp) sensor. Tighten tighten the radiator lower hose bolt to 8–15 n s m (70–132 lb-in). Tighten the ckp sensor bolt to 5–8 n s m (44–70 lb- in). D13b520a 9. Refill the transaxle fluid...

  • Page 642

    Five-speed manual transaxle 5b – 17 daewoo m-150 bl2 d103b522 4. Remove the select lever. D remove the bolts (1). D remove the select lever (2). D103b523 5. Remove the shift interlock bolt. Important: certainly remove the shift interlock bolt. Otherwise, the gear shift control case can not be re- mo...

  • Page 643

    5b – 18 five-speed manual transaxle daewoo m-150 bl2 d103b526 8. Remove the select/shift shaft. D remove the shift guide bolt (1). D remove the select/shift shaft (2). D103b527 9. Remove the gear shift control case plate. D remove the bolts (1). D remove the plate from the case (2). D103b528 inspect...

  • Page 644

    Five-speed manual transaxle 5b – 19 daewoo m-150 bl2 d13b530a 3. Install the gear shift control case and the select lever. Tighten d tighten the gear shift control case bolts to 18–28 n s m (13–21 lb-ft). A. Gear shift control case bolt. D tighten the select lever bolts to 18–28 n s m (13–21 lb-ft)....

  • Page 645

    5b – 20 five-speed manual transaxle daewoo m-150 bl2 d103b534 2. Remove the battery. Refer to section 1e, engine electrical. 3. Disconnect the instrument cluster side cable. Refer to section 9e, instrumentation/driver information. 4. Remove the speedometer cable. D remove the cable grommet (1). D pu...

  • Page 646

    Five-speed manual transaxle 5b – 21 daewoo m-150 bl2 d103b501 gear shift control cable removal procedure 1. Remove the air hose (air cleaner to throttle body). Refer to section 1b, sohc engine mechanical. 2. Remove the battery. 3. Disconnect the transaxle side select and shift control cable. D remov...

  • Page 647

    5b – 22 five-speed manual transaxle daewoo m-150 bl2 d103b540 installation procedure 1. Install in the reverse order of removal. 2. Push the cables toward the engine compartment through dash panel’s hole slightly. 3. Position the cables on the select and the shift lever. D13b5411 4. Connect the tran...

  • Page 648

    Five-speed manual transaxle 5b – 23 daewoo m-150 bl2 d13b544a installation procedure 1. Install in the reverse order of removal. 2. Install the gear shift control lever assembly. Tighten tighten the bolts to 4–7 n s m (35–62 lb-in). 3. Adjust the select cables. Refer to “gear shift control cable” in...

  • Page 649: Maintenance And Repair

    5b – 24 five-speed manual transaxle daewoo m-150 bl2 maintenance and repair unit repair d13b701a gear unit tools required 09913–76010 bushing, seal installer dw09940–53111 gear, bearing installer dw09943–78210 bushing, seal installer dw220–010a transaxle fixture km519 oil seal installer disassembly ...

  • Page 650

    Five-speed manual transaxle 5b – 25 daewoo m-150 bl2 d103b704 6. Remove the select lever. D remove the bolt (1). D remove the select lever (2). D103b705 7. Remove the gear shift control case assembly. D remove the bolts (1). D remove the shift interlock bolt (2). Important: certainly remove the shif...

  • Page 651

    5b – 26 five-speed manual transaxle daewoo m-150 bl2 d103b708 10. Remove the fifth–gear shift fork pin. D shift the shift fork to the fifth–gear. D remove the fork pin using a pin punch and a hammer (1). D103b709 11. Remove the input shaft fifth–gear fork and synchro- nizer hub assembly. D pull and ...

  • Page 652

    Five-speed manual transaxle 5b – 27 daewoo m-150 bl2 d103b712 d remove the counter shaft fifth–gear (4). D103b713 14. Remove the side cover plate and the counter shaft bearing shim. D remove the screws (1). D remove the side cover plate (2). D remove the counter shaft bearing shim. D103b714 15. Remo...

  • Page 653

    5b – 28 five-speed manual transaxle daewoo m-150 bl2 d103b716 17. Remove the transaxle case (left). D remove the bolts from the left side case (1). D remove the bolts, stud bolts if equipped with auto clutch. D remove the bolts from the right side of case (2). D remove the left side case by hitting ...

  • Page 654

    Five-speed manual transaxle 5b – 29 daewoo m-150 bl2 d103b720 21. Remove the gear unit. D remove the gear unit and the shift shaft assem- bly together (1). Notice: be careful not to damage teeth of the counter shaft pinion and the differential ring gear. D remove the high and the low speed shift sha...

  • Page 655

    5b – 30 five-speed manual transaxle daewoo m-150 bl2 d103b724 24. Remove the related parts of the transaxle case (right side). D remove the input shaft oil seal using a screwdriv- er (1). D remove the differential left side oil seal using a hammer and a copper chisel (2). D103b725 synchronizer sleev...

  • Page 656

    Five-speed manual transaxle 5b – 31 daewoo m-150 bl2 d13b727a tighten tighten the bolt to 8–12 n s m (71–106 lb-in). B. Case cap retaining bolt. D install the differential left side oil seal using the oil, seal installer km519. D103b728 3. Install the differential assembly to the right side of trans...

  • Page 657

    5b – 32 five-speed manual transaxle daewoo m-150 bl2 d13b731a 8. Install the shift shaft ball and spring. D install the third–fourth gear shift shaft ball and spring. Tighten tighten the bolt to 10–16 n s m (7–12 lb-ft) (a). D install the fifth–reverse gear shift shaft ball and spring. Tighten tight...

  • Page 658

    Five-speed manual transaxle 5b – 33 daewoo m-150 bl2 d13b735a 13. Install the counter shaft bearing shim. D measure clearance between the transaxle case surface and the bearing outer race using a straight ruler and gauge. D select shim in order that clearance is within stan- dard. Unit : mm (in.) ÁÁ...

  • Page 659

    5b – 34 five-speed manual transaxle daewoo m-150 bl2 d13b737a 15. Install the counter shaft fifth gear nut. D shift the shift yoke using a screwdriver to engage the first–gear and the third–gear or the second– gear and the fourth–gear (1). Tighten tighten the fifth gear nut to 60–80 n s m (44–59 lb-...

  • Page 660

    Five-speed manual transaxle 5b – 35 daewoo m-150 bl2 d103b740 20. Install the fifth gear shift fork pin. D push the shift fork toward the fifth gear. D install the shift fork pin using a pin punch and a hammer(1). Important: use only new shift fork pin. D103b741 21. Install the input shaft fifth gea...

  • Page 661

    5b – 36 five-speed manual transaxle daewoo m-150 bl2 d13b744a 24. Install the backup light switch and the speedometer driven gear assembly. D install the backup light switch (1). Tighten tighten the nut to 15–18 n s m (11–13 lb-ft) (a). D install the speedometer driven gear assembly (2). Tighten tig...

  • Page 662

    Five-speed manual transaxle 5b – 37 daewoo m-150 bl2 d103b747 3. Remove the input shaft fifth gear spacer, the left side bearing and the fourth gear. D position the fourth gear to the gear,bearing remov- er dw09921–57810. D remove the following parts. A. Fifth gear spacer. B. Left side bearing. C. F...

  • Page 663

    5b – 38 five-speed manual transaxle daewoo m-150 bl2 d103b751 8. Disassemble the third–fourth synchronizer hub as- sembly. D remove the hub (1). D remove the synchronizer sleeve and the key (2). D remove the synchronizer springs (3). D103b752 9. Remove the input shaft third gear bearing (1). D103b75...

  • Page 664

    Five-speed manual transaxle 5b – 39 daewoo m-150 bl2 d103b755 3. Inspecting key slot width of synchronizer ring. D measure key slot width of synchronizer ring. Re- place if it exceeds limit. ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ unit : mm (in.) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ key slot width ÁÁÁÁÁÁ ÁÁÁÁÁÁ standard ÁÁÁÁÁÁ ÁÁÁÁÁÁ limit Á...

  • Page 665

    5b – 40 five-speed manual transaxle daewoo m-150 bl2 d103b759 2. Assemble the third–fourth synchronizer hub assem- bly. D install the synchronizer springs to the hub. D install the synchronizer key to the hub. Important: in case of assembling the synchronizer sleeve and the hub, let a=b. D install t...

  • Page 666

    Five-speed manual transaxle 5b – 41 daewoo m-150 bl2 d103b762 6. Install the input shaft fourth gear bearing and the fourth gear. A. Fourth gear. B. Fourth gear bearing. D103b763 7. Install the input shaft left side bearing and the fifth gear spacer. D install the following parts using the gear, bea...

  • Page 667

    5b – 42 five-speed manual transaxle daewoo m-150 bl2 disassembly procedure 1. Remove the gear unit. Refer to “gear unit” in this section. 2. Remove the counter shaft right side bearing. D103b766 3. Remove the counter shaft left side bearing and the fourth gear. D position the fourth gear to the gear...

  • Page 668

    Five-speed manual transaxle 5b – 43 daewoo m-150 bl2 d103b769 9. Remove the counter shaft first–second gear syn- chronizer hub assembly, the first gear / the first gear synchronizer ring. D position the first gear to the gear, bearing remov- er dw09921–57810. D remove the following parts by pressing...

  • Page 669

    5b – 44 five-speed manual transaxle daewoo m-150 bl2 d103b773 assembly procedure 1. Install the related counter shaft first gear. D install the first gear bearing (1). D install the first gear (2). D install the first gear synchronizer ring (3) important: coat the inner parts; gear, bearing and oil ...

  • Page 670

    Five-speed manual transaxle 5b – 45 daewoo m-150 bl2 d103b768 4. Install the second synchronizer ring. Important: position the second synchronizer ring groove to the synchronizer hub key. 5. Install the first–second gear synchronizer circlip. D103b777 6. Install the related counter shaft second gear...

  • Page 671

    5b – 46 five-speed manual transaxle daewoo m-150 bl2 d103b780 9. Install the counter shaft left side bearing. D install the left side bearing to the counter shaft us- ing the gear, bearing installer dw09925–98221 and a hammer (1). D103b765 10. Install the counter shaft right side bearing. 11. Instal...

  • Page 672

    Five-speed manual transaxle 5b – 47 daewoo m-150 bl2 d103b782 4. Disassemble the third–fourth gear shift shaft assem- bly. D fix the third–fourth gear shift shaft assembly to a vise with protector. D remove the third–fourth gear fork pin using a pin punch and a hammer (1). D remove the third–fourth ...

  • Page 673

    5b – 48 five-speed manual transaxle daewoo m-150 bl2 d103b787 inspection procedure – shift fork 1. Measure the end thickness of shift fork and replace if below limit. Unit : mm (in.) ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ shift fork end thickness (mm) ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ standard ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ limit ÁÁÁÁÁÁ...

  • Page 674

    Five-speed manual transaxle 5b – 49 daewoo m-150 bl2 d103b791 4. Remove the pinion gear shaft. D remove the shaft from the case (1). D103b792 5. Remove the pinion gears and the side gears. D remove the pinion gears and the washers (1). Important: remove the pinion gear and the washer by rotating the...

  • Page 675

    5b – 50 five-speed manual transaxle daewoo m-150 bl2 d103b795 side gear play inspection 1. Measure the axle direction play of side gear and re- place a side gear washer if it exceeds limit. Unit : mm (in.) ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ thrust free play of differential side ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ...

  • Page 676

    Five-speed manual transaxle 5b – 51 daewoo m-150 bl2 d103b799 3. Install the side gears and the pinion gears. D insert the trust adjusting shims to the side gears. D install the side gears (1). D install the pinion gears and washers (2). Important: install the pinion gears and washers simul- taneous...

  • Page 677: Specifications

    5b – 52 five-speed manual transaxle daewoo m-150 bl2 specifications general specifications application description unit standard limit general type forward gear – synchronized mesh type – reverse gear – sliding mesh type – gear ratio 1st – 3.818 – 2nd – 2.210 – 3rd – 1.423 – 4th – 1.029 – 5th – 0.83...

  • Page 678

    Five-speed manual transaxle 5b – 53 daewoo m-150 bl2 fastener tightening specifications application n s m lb-ft lb-in 5th/reverse gear shift shaft bolt 10 – 16 7 – 12 – back up light switch nut 15 – 18 11 – 13 – counter shaft 5th gear nut 60 – 80 44 – 59 – crankshaft position sensor bolt 5 – 8 – 44 ...

  • Page 679: Special Tools

    5b – 54 five-speed manual transaxle daewoo m-150 bl2 special tools special tools table d103b110 09913–76010 bushing, seal installer d103b106 dw09913–80112 gear, bearing installer d103b104 dw09921–57810 gear, bearing remover d103b107 dw09925–98221 gear, bearing installer d103b105 dw09940–53111 gear, ...

  • Page 680

    Five-speed manual transaxle 5b – 55 daewoo m-150 bl2 special tools table (cont’d) d13b112a dw220–020a–01 differential bearing puller d13b113a dw220–020a–02 differential bearing plate adapter d13b114a dw220–020a–03 differential bearing plate adapter d103b102 dw220–031 transaxle remove/ install suppor...

  • Page 681: Section 5C

    Daewoo m-150 bl2 section 5c clutch caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the...

  • Page 682: Description And Operation

    5c – 2 clutch daewoo m-150 bl2 description and operation driving members the driving members consist of two flat surfaces ma- chined to a smooth finish. One of these is the rear face of the engine flywheel, and the other is the pressure plate. The pressure plate is fitted into a steel cover, which i...

  • Page 683: Component Locator

    Clutch 5c – 3 daewoo m-150 bl2 component locator clutch components d13c4011 1 clutch disc 2 pressure plate 3 release bearing 4 release shaft 5 release shaft bushing (no.1) 6 release shaft bushing (no.2) 7 release shaft seal 8 release arm 9 clutch cable adjusting nut 10 clutch cable 11 clutch pedal.

  • Page 684

    5c – 4 clutch daewoo m-150 bl2 diagnostic information and procedures general diagnosis condition probable cause correction slipping clutch d improper clutch cable adjustment. D adjust clutch cable. D worn or oily contamination on clutch disc surface. D replace clutch disc. D worn or oily contaminati...

  • Page 685

    Clutch 5c – 5 daewoo m-150 bl2 clutch pedal operation d103c301 clutch pedal free travel it is designed that there is no clutch pedal free travel. Clutch pedal travel (a) ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ pedal travel ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ 100–110 mm (3.9–4.3 in.) clearance between pedal and floo...

  • Page 686: Instruction  Repair

    5c – 6 clutch daewoo m-150 bl2 instruction repair on–vehicle service d13b5151 d103b516 pressure plate, clutch disc and input shaft bearing tools required 09917–58010 input shaft bearing remover 09924–17810 flywheel holder 09925–98210 input shaft bearing installer dw110–021 engine fixture dw210–010 c...

  • Page 687

    Clutch 5c – 7 daewoo m-150 bl2 d13c5031 4. Remove the transaxle input shaft bearing using the input shaft bearing remover 09917–58010, the fly- wheel holder 09924–17810 and a spanner. D13c5041 inspection procedure – pressure plate and clutch disc 1. Pressure plate inspection . D check the weak and d...

  • Page 688

    5c – 8 clutch daewoo m-150 bl2 d13c5071 installation procedure 1. Install in the reverse order of removal. 2. Install the input shaft bearing using the input shaft bearing installer 09925–98210 and the flywheel hold- er 09924–17810. D13c508b 3. Install the pressure plate and the clutch disc. D insta...

  • Page 689

    Clutch 5c – 9 daewoo m-150 bl2 d103c511 d insert the tap (m14x1.5) to the busing (no.1) (2). D13c512a d insert the bushing joint pipe 09923–46040 to the tab. D connect the sliding shaft 09930–30102 to the end of the bushing joint pipe 09923–46040. D remove the bushing (no.1) by pulling. D103c513 ins...

  • Page 690

    5c – 10 clutch daewoo m-150 bl2 d103c515 installation procedure 1. Install in the reverse order of removal. 2. Install the release shaft bushing (no.1) using the bushing joint pipe 09923–46040, bushing, bearing in- staller 09943–88211 and a hammer. D103c516 3. Install the release shaft bushing (no.2...

  • Page 691

    Clutch 5c – 11 daewoo m-150 bl2 d103c519 2. Remove the clutch release arm. D remove the bolt and nut (1). D remove the release arm (2). D13c520a installation procedure 1. Install in the reverse order of removal. 2. Install the clutch release arm. D install the clutch release arm matching to punched ...

  • Page 692

    5c – 12 clutch daewoo m-150 bl2 d103c522 3. Remove the battery. Refer to section 1e, engine electrical. 4. Remove the clutch cable. D remove the nuts (1). D remove the cable grommet (2). D remove the cable from the pedal (3). D103c302 installation procedure 1. Install the clutch cable. 2 install the...

  • Page 693: Specifications

    Clutch 5c – 13 daewoo m-150 bl2 specifications general specifications ÁÁÁÁÁÁ ÁÁÁÁÁÁ application ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ description ÁÁÁÁÁ ÁÁÁÁÁ unit ÁÁÁÁÁÁ ÁÁÁÁÁÁ standard ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ limit ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ type ÁÁÁÁÁ ÁÁÁÁÁ – ÁÁÁÁÁÁ ÁÁÁÁÁÁ single dry plate ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ...

  • Page 694: Special Tools

    5c – 14 clutch daewoo m-150 bl2 special tools special tools table d103c101 09917–58010 input shaft bearing remover d103c105 09923–46040 bushing joint pipe d102b116 09924–17810 fly wheel holder d103c104 09925–48220 bushing remover/ installer d103c102 09925–98210 input shaft bearing installer d103c106...

  • Page 695: Section 6B

    Daewoo m-150 bl2 section 6b power steering pump table of contents description and operation 6b-2 . . . . . . . . . . . . . . . . . . Power steering pump 6b-2 . . . . . . . . . . . . . . . . . . . . . . Diagnostic information and procedures 6b-3 . . . . . Power steering pump 6b-3 . . . . . . . . . . ...

  • Page 696: Description And Operation

    6b – 2 power steering pump daewoo m-150 bl2 description and operation power steering pump the pump has a remote fluid reservoir. A pressure-relief valve inside the flow control valve limits pump pressure..

  • Page 697

    Power steering pump 6b – 3 daewoo m-150 bl2 diagnostic information and procedures power steering pump condition probable cause correction foaming, milky power steering fluid, d insufficient power steering fluid level. D fill the power steering fluid reservoir. Low fluid level, and possible low d con...

  • Page 698: Repair Instructions

    6b – 4 power steering pump daewoo m-150 bl2 repair instructions on–vehicle service d105c524 pump drive belt removal procedure 1. Remove the front passenger side headlamp. Refer to section 9b, lighting systems. 2. Remove the pump drive belt. D loosen the rear bracket adjusting bolt (1). D loosen the ...

  • Page 699

    Power steering pump 6b – 5 daewoo m-150 bl2 d105c527 pump drive pulley tools required dw310–020 power steering pulley remove holder removal procedure 1. Remove the front passenger side headlamp. Refer to section 9b, lighting systems. 2. Remove the steering pump pulley. D remove the pump drive belt. ...

  • Page 700

    6b – 6 power steering pump daewoo m-150 bl2 d105c531 d remove the bolt (3). 18–22 n s m d15c532a installation procedure 1. Install the power steering pump with the bolt. Tighten tighten the bolt to 18–22 n s m (13–16 lb-ft). 2. Connect the power steering pressure switch connec- tor. Refer to section...

  • Page 701: Unit Repair

    Power steering pump 6b – 7 daewoo m-150 bl2 unit repair pump the power steering pump in this vehicle is not service- able. A faulty pump must be replaced..

  • Page 702: Specifications

    6b – 8 power steering pump daewoo m-150 bl2 specifications general specifications ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ application ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ description ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ lubricant ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ power steering fluid dexron r -i...

  • Page 703

    Power steering pump 6b – 9 daewoo m-150 bl2 special tools and equipment special tools table d105c101 dw310–020 power steering pulley remove holder.

  • Page 704: Section 6C

    Daewoo m-150 bl2 section 6c power steering gear caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and ...

  • Page 705: Description And Operation

    6c – 2 power steering gear daewoo m-150 bl2 description and operation power rack and pinion the power rack and pinion steering system has a rotary control valve which directs the hydraulic fluid coming from the hydraulic pump to one side or the other side of the rack piston. The integral rack piston...

  • Page 706

    Power steering gear 6c – 3 daewoo m-150 bl2 diagnostic information and procedures power rack and pinion stering gear condition probable cause correction hissing noise d loose steering coupling joints. D tighten the steering coupling joints. D improperly contacted the power steering hose with other c...

  • Page 707

    6c – 4 power steering gear daewoo m-150 bl2 power rack and pinion stering gear (cont’d) condition probable cause correction excessive wheel kickback or loose steering d contaminated air in the power steering system. D bleed the power steering system. D worn or damaged wheel bearings. D replace the w...

  • Page 708

    Power steering gear 6c – 5 daewoo m-150 bl2 adjust the free load of the steering gear 1. Place the steering wheel in the straight-ahead posi- tion. 2. Raise and suitably support the vehicle. 3. Remove the adjust plug locknut. 4. Check the torque of the adjuster plug. 5. Check the torque is below the...

  • Page 709: Repair Instructions

    6c – 6 power steering gear daewoo m-150 bl2 repair instructions on–vehicle service rack and pinion assembly (left–hand drive shown, right–hand drive similar) removal procedure 1. Remove the intermediate shaft lower pinch bolt. Re- fer to section 6e, steering wheel and column. 2. Remove the wheel. Re...

  • Page 710

    Power steering gear 6c – 7 daewoo m-150 bl2 d105c536 6. Remove the packing (5). D15c537a installation procedure 1. Install in the reverse order of removal. 2. Install the power steering gear bracket with the bolt. Tighten tighten the bracket bolts to 50–55 n s m (36–41 lb-ft). D15c512a 21–35 n s m 2...

  • Page 711: Unit Repair

    6c – 8 power steering gear daewoo m-150 bl2 unit repair tie rod end boot refer to section 6d, manual steering gear. D105c701 hydraulic cylinder lines (left–hand drive shown, right–hand drive similar) disassembly procedure 1. Remove the rack and pinion steering assembly from the vehicle. Refer to “ra...

  • Page 712

    Power steering gear 6c – 9 daewoo m-150 bl2 d105c702 rack and pinion steering gear assembly (left–hand drive shown, right–hand drive similar) disassembly procedure 1. Remove the rack and pinion steering assembly from the vehicle. Refer to “rack and pinion assembly” in this section. 2. Remove the rac...

  • Page 713

    6c – 10 power steering gear daewoo m-150 bl2 d105c706 important: hit the drift using a hammer when the lower pinion is vertical with the drift. D remove the bearing by hitting the bearing with the flated drift and rubber hammer (6). D105c707 d remove the pinion shaft seal (7). D remove the needle be...

  • Page 714

    Power steering gear 6c – 11 daewoo m-150 bl2 d105c710 4. Inspect the bearings and the seal for damage. D inspect the pinion shaft seal for leaks and wear (1). D inspect the needle bearing for wear (2). D inspect the pinion bearing for wear (3). 5. The faulty parts must be replaced. D105c711 assembly...

  • Page 715

    6c – 12 power steering gear daewoo m-150 bl2 d105c714 6. Install the rack bearing. D install the adjuster spring (1). D tighten the adjuster plug (2). D tighten the plug locknut (3). 7. Install the rack and pinion steering assembly to the vehicle. Refer to “ rack and pinion assembly ” in this sectio...

  • Page 716: Specifications

    Power steering gear 6c – 13 daewoo m-150 bl2 specifications general specifications application description power steering fluid power steering fluid dexron r - ii or dexron r - iii capacity 1.0 l (1.056 qt) type rack and pinion overall gear ratio 15.7 : 1 power steering angle 144, 155 inside 39.5 _ ...

  • Page 717: Section 6D

    Daewoo m-150 bl2 section 6d manual steering gear caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and...

  • Page 718: Description And Operation

    6d – 2 manual steering gear daewoo m-150 bl2 description and operation manual rack and pinion the manual rack and pinion steering system consists of two main components: the rack and the pinion. The mo- tion of the pinion is transferred through the pinion teeth that mesh with the teeth on the rack, ...

  • Page 719: Component Locator

    Manual steering gear 6d – 3 daewoo m-150 bl2 component locator manual rack and pinion steering gear (left–hand drive shown, right–hand drive similar) d105b401 1. Manual steering gear 2. Steering gear bracket 3. Cotter pin 4. Castellated nut 5. Tie rod end 6. Tie rod end lock nut 7. Rack and pinion b...

  • Page 720

    6d – 4 manual steering gear daewoo m-150 bl2 diagnostic information and procedures manual rack and pinion steering gear condition probable cause correction excessive play or d poor adjustment of steering gear. D perform straight–ahead check. Looseness in the steering system d improperly installed ti...

  • Page 721

    Manual steering gear 6d – 5 daewoo m-150 bl2 straight-ahead check after all the necessary operations on the steering gear are completed, check the exact straight-ahead position of the steering in each case. With the vehicle on the floor, place the steering wheel in the straight-ahead position. Mark ...

  • Page 722

    6d – 6 manual steering gear daewoo m-150 bl2 steering wheel restoration 1. Turn the steering wheel fast to the right and left and turn it slowly as the same way. 2. Check if the steering wheel restoration for the wheel turning to right and the one to the left are same. 3. Turn the steering wheel to ...

  • Page 723: Repair Instructions

    Manual steering gear 6d – 7 daewoo m-150 bl2 repair instructions on–vehicle service d105b501 tie rod end tools required km–507–b ball joint remover removal procedure 1. Remove the wheel. Refer to section 2e, tires and wheels. 2. Disconnect the tie rod and from the steering knuckle. D remove the cott...

  • Page 724

    6d – 8 manual steering gear daewoo m-150 bl2 d15b504b installation procedure 1. Install the tie rod end. 2. Install the tie rod lock nut (1). Tighten tighten the tie rod end lock nut to 35–55 n s m (25–41 lb-ft). 3. Connect the tie rod end to the knuckle. 4. Install the tie rod end castellated nut (...

  • Page 725

    Manual steering gear 6d – 9 daewoo m-150 bl2 d105b507 d coat the greases on the tie rod to ease removal (3). D remove the boot (4). D105b508 installation procedure 1. Install the rack and pinion boot with the clamp and the wire clamp. 2. Install the tie rod end nut. 3. Install the tie rod end. Refer...

  • Page 726

    6d – 10 manual steering gear daewoo m-150 bl2 d15b511a installation procedure 1. Install the mounting to the steering gear assembly. 2. Install the steering gear assembly. 3. Install the steering gear bracket with the bolts. Tighten tighten the steering gear bracket bolts to 50–55 n s m (36–41 lb-ft...

  • Page 727: Unit Repair

    Manual steering gear 6d – 11 daewoo m-150 bl2 unit repair d105b701 tie rod end boot disassembly procedure 1. Remove the tie rod end. Refer to “tie rod end” in this section. 2. Remove the tie rod end boot. A. Tie rod end boot. D105b702 assembly procedure important : coat the grease inside of the boot...

  • Page 728

    6d – 12 manual steering gear daewoo m-150 bl2 d105b704 d coat the greases on the tie rod (5). D remove the rack and pinion boot (6). D105b705 3. Remove the tie rod d pull the rack gear perfectly from the steering gear housing by turning the pinion gear (1). D disconnect the shock damper ring from th...

  • Page 729

    Manual steering gear 6d – 13 daewoo m-150 bl2 d105b708 4. Remove the rack bearing. D remove the adjuster plug (1). D remove the adjuster spring (2). D105b709 5. Remove the pinion and bearing assembly. D remove the dust cover (1). D remove the pinion plug (2). Important: do not reuse the removed pini...

  • Page 730

    6d – 14 manual steering gear daewoo m-150 bl2 d105b712 inspection procedure 1. Inspect the rack gear deformation and damage. D set the v–block on the plate (1). D set the rack gear on the v–block (2). D check the rack gear for deformation using a dial gauge (3). D inspect the rack gear for wear and ...

  • Page 731

    Manual steering gear 6d – 15 daewoo m-150 bl2 d105b716 5. Inspect the tie rod end ball joint and tie rod ball joint for damage. D inspect the tie rod end ball joint for operation (1). D inspect the tie rod ball joint for operation and tie rod deformation (2). 6. After inspecting the parts, replace t...

  • Page 732

    6d – 16 manual steering gear daewoo m-150 bl2 d15b720a 5. Install the tie rod. D install the shock damper ring to the rack gear (1). D vise the rack gear (2). Important : clothe the rack gear with a cloth before vis- ing the rack gear. Notice: do not vise the rack gear above two teeth face. D coat t...

  • Page 733: Specifications

    Manual steering gear 6d – 17 daewoo m-150 bl2 specifications general specifications ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ application ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ description ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ type ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ rack and pinion ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ...

  • Page 734

    6d – 18 manual steering gear daewoo m-150 bl2 special tools and equipment special tools table d105b101 km–507–b ball joint remover.

  • Page 735: Section 6E

    Daewoo m-150 bl2 section 6e steering wheel and column caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injur...

  • Page 736: Description And Operation

    6e – 2 steering wheel and column daewoo m-150 bl2 description and operation steering wheel and column in addition to the steering function, the steering column provides safety and security. Caution: to ensure energy-absorbing action, it is important to use only the specified screws, bolts, and nuts,...

  • Page 737: Component Locator

    Steering wheel and column 6e – 3 daewoo m-150 bl2 component locator steering wheel and column d15a401a 1. Horn cover (airbag module) 2. Steering wheel nut 3. Locking plate 4. Steering wheel 5. Steering column upper cover 6. Steering column lower cover 7. Turn signal switch 8. Windshield wiper switch...

  • Page 738

    6e – 4 steering wheel and column daewoo m-150 bl2 diagnostic information and procedures steering column diagnosis lock system condition probable cause correction lock system will not d damaged lock cylinder. D replace the lock cylinder. Unlock d the lack of free movement for the ignition switch. D l...

  • Page 739

    Steering wheel and column 6e – 5 daewoo m-150 bl2 column (cont’d) condition probable cause correction lash in the steering column d improperly installed steering column bracket mounting nuts. D tighten the steering column bracket mounting nuts. D loose steering column housing–to–steering column jack...

  • Page 740

    6e – 6 steering wheel and column daewoo m-150 bl2 ignition switch condition probable cause correction electrical system will d damaged ignition switch. D replace the ignition switch. Not function d improperly installed ignition switch. D remove and inspect the ignition switch. D reinstall the igniti...

  • Page 741: Repair Instructions

    Steering wheel and column 6e – 7 daewoo m-150 bl2 repair instructions on–vehicle service d105a501 d15a502a dw310–010 steering wheel (left–hand drive shown, right–hand drive similar) tools required dw310–010, steering wheel puller removal procedure 1. Disconnect the negative battery cable. 2. Remove ...

  • Page 742

    6e – 8 steering wheel and column daewoo m-150 bl2 d105a504 steering column cover (left–hand drive shown, right–hand drive similar) removal procedure 1. Remove the screws. 2. Remove the steering column lower and upper cover. D105a505 installation procedure 1. Install the steering column lower and upp...

  • Page 743

    Steering wheel and column 6e – 9 daewoo m-150 bl2 d105a508 installation procedure 1. Install the wiper switch. 2. Install the turn signal switch. 3. Install the steering column cover. Refer to “steering column cover” in this section. 4. Connect the negative battery cable. D105a509 ignition switch re...

  • Page 744

    6e – 10 steering wheel and column daewoo m-150 bl2 d105a511 d remove the lock cylinder by pressing down the detent spring with a 2.5mm allen wrench, or other suitable tool, and pulling the lock cylinder out of the switch cylinder housing (2). D105a512 installation procedure important: to install the...

  • Page 745

    Steering wheel and column 6e – 11 daewoo m-150 bl2 d105a515 steering column (left–hand drive shown, right–hand drive similar) removal procedure 1. Remove the steering wheel. Refer to “steering wheel” in this section. Caution: disconnect the negative battery cable and let the vehicle sit for 1 minute...

  • Page 746

    6e – 12 steering wheel and column daewoo m-150 bl2 d105a520 intermediate shaft cover and intermediate shaft (left–hand drive shown, right–hand drive similar) removal procedure 1. Remove the intermediate shaft. D in order to install the intermediate shaft correctly, match–mark the intermediate shaft ...

  • Page 747: Unit Repair

    Steering wheel and column 6e – 13 daewoo m-150 bl2 unit repair d105a701 d15a702a d15a703a standard steering column disassembly procedure 1. Remove the steering column from the vehicle. Refer to “steering column” in this section. Caution: be careful not to impact on the steering column shaft. Plastic...

  • Page 748

    6e – 14 steering wheel and column daewoo m-150 bl2 d15a704a assembly procedure important: position the alignment spacer on the lower column shaft to install the spacer in the steering column jacket easily. 1. Install the steering column shaft to the steering col- umn. D position the locking of the a...

  • Page 749: Specifications

    Steering wheel and column 6e – 15 daewoo m-150 bl2 specifications general specifications ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ application ÁÁÁÁÁÁ ÁÁÁÁÁÁ unit ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ description ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ with airbag mm (in.) ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ 380 (14.96) ÁÁÁÁÁÁÁÁ ÁÁ...

  • Page 750

    6e – 16 steering wheel and column daewoo m-150 bl2 special tools and equipment special tools table d105a101 dw310–010 steering wheel puller.

  • Page 751: Section 7A

    Daewoo m-150 bl2 section 7a heating and ventilation system caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal ...

  • Page 752

    7a – 2 heating and ventilation system daewoo m-150 bl2 description and system operation heating and ventilation systems the base heater system is designed to provide heating, ventilation, windshield defrosting, and side window de- fogging. The heater and fan assembly blower regulates the air- flow f...

  • Page 753: Component Locator

    Heating and ventilation system 7a – 3 daewoo m-150 bl2 component locator control assembly (left–hand drive shown, right–hand drive similar) d108a401 1. Hvac control assembly 2. Temperature control cable 3. Mode select cable 4. Rack 5. Bracket 6. Cable clamp 7. Bulb socket assembly 8. Pinion assembly...

  • Page 754

    7a – 4 heating and ventilation system daewoo m-150 bl2 blower module assembly (left–hand drive shown, right–hand drive similar) d18a402a 1. Blower module assembly 2. Plastic washer 3. Blower link 4. Blower lever 5. Air intake case 6. Valve retainer 7. Heater duct assembly 8. Blower connector duct 9....

  • Page 755

    Heating and ventilation system 7a – 5 daewoo m-150 bl2 air distributor and heater module assembly (left–hand drive shown, right–hand drive similar) d108a403 1. Defroster duct hose 2. Defroster duct 3. Ventilation duct 4. Heater module assembly 5. Plastic washer 6. Temperature control lever 7. Temper...

  • Page 756: Heater System

    7a – 6 heating and ventilation system daewoo m-150 bl2 diagnostic information and procedures heater system insufficient heating or defrosting caution: the cooling system is pressurized when hot. Injury can result from removing the surge tank cap before the engine is sufficiently cool. ÁÁÁÁ ÁÁÁÁ step...

  • Page 757

    Heating and ventilation system 7a – 7 daewoo m-150 bl2 insufficient heating or defrosting (cont’d) ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 13 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ...

  • Page 758

    7a – 8 heating and ventilation system daewoo m-150 bl2 insufficient heating or defrosting (cont’d) ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 23 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ...

  • Page 759

    Heating and ventilation system 7a – 9 daewoo m-150 bl2 insufficient heating or defrosting (cont’d) ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 34 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ...

  • Page 760

    7a – 10 heating and ventilation system daewoo m-150 bl2 blower electrical ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ verify the customer’s complaint. Are th...

  • Page 761

    Heating and ventilation system 7a – 11 daewoo m-150 bl2 improper air delivery or no mode shift this procedure provides a test of all functions of the heater/defroster unit. 1. Warm up the vehicle. 2. Keep the engine running. 3. Perform the tests outlined in the table below and look for the results i...

  • Page 762

    7a – 12 heating and ventilation system daewoo m-150 bl2 improper air delivery or no mode shift (cont’d) ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 8 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ repair th...

  • Page 763

    Heating and ventilation system 7a – 13 daewoo m-150 bl2 too much heat ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ verify the customer’s complaint. Are the cu...

  • Page 764

    7a – 14 heating and ventilation system daewoo m-150 bl2 too much heat (cont’d) ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 14 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ...

  • Page 765

    Heating and ventilation system 7a – 15 daewoo m-150 bl2 controls ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ verify the customer’s complaint. Are the custome...

  • Page 766

    7a – 16 heating and ventilation system daewoo m-150 bl2 blower noise ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ verify the customer’s complaint. Are the cus...

  • Page 767

    Heating and ventilation system 7a – 17 daewoo m-150 bl2 blower noise (cont’d) ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ 14 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ is the noise present in the vent mode only? ÁÁÁÁÁ ÁÁÁÁÁ –...

  • Page 768: Repair Instructions

    7a – 18 heating and ventilation system daewoo m-150 bl2 repair instructions on-vehicle service d108a502 d108a501 control assembly and control cables (left–hand drive shown, right–hand drive similar) removal procedure 1. Disconnect the negative battery cable. 2. Remove the instrument cluster housing ...

  • Page 769

    Heating and ventilation system 7a – 19 daewoo m-150 bl2 d108a504 d108a505 4. Disconnect the control cables from the control as- sembly. D disconnect the temperature control cable (1). D disconnect the mode control cable (2). D disconnect the recirculating/fresh air door cable (3). D108a506 installat...

  • Page 770

    7a – 20 heating and ventilation system daewoo m-150 bl2 d108a507 blower motor and cooling hose (left–hand drive shown, right–hand drive similar) removal procedure 1. Remove the blower motor cooling hose. D108a508 2. Remove the blower motor. D disconnect the motor electrical connector (1). D turn the...

  • Page 771

    Heating and ventilation system 7a – 21 daewoo m-150 bl2 d108a511 installation procedure 1. Install the blower resistor with the retaining screws. 2. Connect the blower resistor connector. D108a512 blower motor switch (left–hand drive shown, right–hand drive similar) removal procedure 1. Remove the c...

  • Page 772

    7a – 22 heating and ventilation system daewoo m-150 bl2 d18a515a heater hoses (left–hand drive shown, right–hand drive similar) tool required dw100–020 hose remover/installer. Removal procedure 1. Disconnect the negative battery cable. 2. Drain the coolant. 3. Remove the heater inlet hoses. D remove...

  • Page 773

    Heating and ventilation system 7a – 23 daewoo m-150 bl2 d108a521 installation procedure 1. Install the heater outlet hoses. D connect the heater hose to the engine (1). D connect the b + terminal to the starter. Refer to section 1e, engine electrical. D18a522a d connect the hose to the heater module...

  • Page 774

    7a – 24 heating and ventilation system daewoo m-150 bl2 d108a523 heater module (left–hand drive shown, right–hand drive similar) removal procedure 1. Disconnect the heater hoses from the heater module. Refer to “heater hoses” in this section. 2. Remove the instrument panel and the lower tie bar cent...

  • Page 775

    Heating and ventilation system 7a – 25 daewoo m-150 bl2 d18a527b d18a528b installation procedure 1. Install the heater module with the nuts. Tighten tighten the heater module lower nuts to 3–5 n s m (27–44 lb-in) (1). Tighten the heater module upper nuts to 3–5 n s m (27–44 lb-in) (2). 2. Install th...

  • Page 776

    7a – 26 heating and ventilation system daewoo m-150 bl2 d18a531b installation procedure 1. Install the blower module with the nuts. Tighten tighten the blower module retaining nuts to 3–5 n s m (27–44 lb-in). 2. Connect the wiring harness. 3. Connect the blower motor connector. Refer to “blow- er mo...

  • Page 777

    Heating and ventilation system 7a – 27 daewoo m-150 bl2 d18a534a ventilation duct (left–hand drive shown, right–hand drive similar) removal procedure 1. Remove the instrument panel. Refer to section 9e, instrumentation/driver information. 2. Remove the ventilation duct retaining screws. A. Retaining...

  • Page 778: Unit Repair

    7a – 28 heating and ventilation system daewoo m-150 bl2 unit repair d108a701 heater core disassembly procedure 1. Remove the heater module. Refer to “heater module” in this section. 2. Remove the heater core. D remove the heater core cover (1). D remove the heater core (2). D108a702 assembly procedu...

  • Page 779: Specifications

    Heating and ventilation system 7a – 29 daewoo m-150 bl2 specifications general specifications ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ application ÁÁÁÁÁÁ ÁÁÁÁÁÁ unit ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ description ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ maximum heating capacity ÁÁÁÁÁÁ ÁÁÁÁÁÁ cal/h ÁÁÁÁÁÁÁÁÁÁÁÁ...

  • Page 780

    7a – 30 heating and ventilation system daewoo m-150 bl2 special tools and equipment special tools table d102b119 dw 100–020 spring clamp remover/installer.

  • Page 781

    Heating and ventilation system 7a – 31 daewoo m-150 bl2 schematic and routing diagrams non–a/c diagrams d18a201b.

  • Page 782

    7a – 32 heating and ventilation system daewoo m-150 bl2 air flow through ducts (non–a/c) (left–hand drive shown, right–hand drive similar) d108a202.

  • Page 783: Section 7B

    Daewoo m-150 bl2 section 7b manual control heating, ventilation, and air conditioning system caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this...

  • Page 784: Description And  Operation

    7b – 2 manual control heating, ventilation, and air conditioning system daewoo m-150 bl2 description and operation system components –functional compressor all compressors are belt–driven from the engine crank- shaft through the compressor clutch pulley. The com- pressor pulley rotates without drivi...

  • Page 785: Component Locator

    Manual control heating, ventilation, and air conditioning system 7b – 3 daewoo m-150 bl2 component locator a/c system (left–hand drive shown, right–hand drive similar) d18b401b.

  • Page 786

    7b – 4 manual control heating, ventilation, and air conditioning system daewoo m-150 bl2 1. High pressure pipe (receiver dryer → evaporator) 2. Low pressure hose (evaporator → compressor) 3. O–ring 4. Evaporator module 5. Evaporator upper case 6. Thermistor 7. Evaporator core 8. Expansion valve 9. E...

  • Page 787: General Diagnosis

    Manual control heating, ventilation, and air conditioning system 7b – 5 daewoo m-150 bl2 diagnostic information and procedures general diagnosis testing the refrigerant system if you suspect a problem in the refrigerant system, check for the following conditions: 1. Check the outer surfaces of the r...

  • Page 788

    7b – 6 manual control heating, ventilation, and air conditioning system daewoo m-150 bl2 pressure-temperature relationship of r-134a ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ temperature _ c ( _ f)* ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ pressure kpa (psig)* ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ temperature _ c ( _ f)* ÁÁÁÁÁ...

  • Page 789

    Manual control heating, ventilation, and air conditioning system 7b – 7 daewoo m-150 bl2 leak testing the refrigerant system test for leaks whenever you suspect a refrigerant leak in the system. You should also test for leaks whenever you perform a service operation which results in disturbing the l...

  • Page 790

    7b – 8 manual control heating, ventilation, and air conditioning system daewoo m-150 bl2 air conditioning system diagnosis insufficient cooling diagnosis ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no 1 can you verify the customer ...

  • Page 791

    Manual control heating, ventilation, and air conditioning system 7b – 9 daewoo m-150 bl2 insufficient cooling diagnosis (cont’d) ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no 12 repair the electrical circuit to the a/c compressor ...

  • Page 792

    7b – 10 manual control heating, ventilation, and air conditioning system daewoo m-150 bl2 insufficient cooling diagnosis (cont’d) ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no 20 1. Turn the ignition switch off. 2. Turn the a/c sw...

  • Page 793: Symptom Diagnosis

    Manual control heating, ventilation, and air conditioning system 7b – 11 daewoo m-150 bl2 symptom diagnosis pressure test chart (r-134a system) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ condition ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ related symptons ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ probable cause ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ correction ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁ...

  • Page 794

    7b – 12 manual control heating, ventilation, and air conditioning system daewoo m-150 bl2 pressure test chart (r-134a system) (cont’d) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ condition ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ related symptons ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ probable cause ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ correction ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ suct...

  • Page 795: Repair Instructions

    Manual control heating, ventilation, and air conditioning system 7b – 13 daewoo m-150 bl2 repair instructions on-vehicle service general a/c system service procedures o-ring replacement important: even though o-rings may look identical, it is extremely important that only recommended service re- pla...

  • Page 796

    7b – 14 manual control heating, ventilation, and air conditioning system daewoo m-150 bl2 maintaining chemical stability in the refrigeration system the efficient operation and life of the air conditioning system is dependent upon the chemical stability of the refrigeration system. When foreign mate...

  • Page 797

    Manual control heating, ventilation, and air conditioning system 7b – 15 daewoo m-150 bl2 refrigerant recovery important: use only a refrigerant tank that is designed for the charging station in use. The unit’s overfill limita- tion mechanism is calibrated specifically for use with this tank. The ta...

  • Page 798

    7b – 16 manual control heating, ventilation, and air conditioning system daewoo m-150 bl2 3. Refer to the manufacturer’s instructions for the charg- ing station in use. D enter the amount of refrigerant needed to charge the a/c. Be sure that you are using the correct sys- tem of measurement (kg, lb)...

  • Page 799: Serviceable

    Manual control heating, ventilation, and air conditioning system 7b – 17 daewoo m-150 bl2 serviceable components (left–hand drive shown, right–hand drive similar) control assembly and control cables to remove the control assembly and control cables, re- fer to section 7a, heating and ventilation sys...

  • Page 800

    7b – 18 manual control heating, ventilation, and air conditioning system daewoo m-150 bl2 d108b501 a/c push knob (left–hand drive shown, right–hand drive similar) removal procedure 1. Remove the instrument cluster housing trim panel. Refer to section 9e, instrumentation/driver informa- tion. 2. Remo...

  • Page 801

    Manual control heating, ventilation, and air conditioning system 7b – 19 daewoo m-150 bl2 d18b504a 4. Remove the dual cut switch. D with the receiver dryer clothed, vise the receiver dryer (1). D remove the dual cut switch (2). D discard the o–ring (3). D18b505b installation procedure 1. Install the...

  • Page 802

    7b – 20 manual control heating, ventilation, and air conditioning system daewoo m-150 bl2 d108b507 receiver dryer bracket removal procedure 1. Remove the front bumper fascia. Refer to section 9o, bumpers and fascias. 2. Remove the receiver dryer bracket. D remove the receiver dryer bracket bolt (1)....

  • Page 803

    Manual control heating, ventilation, and air conditioning system 7b -- 21 daewoo m-150 bl2 d18b511b installation procedure 1. Install the compressor with the mounting bolts. Tighten d tighten the compressor--to--bracket upper bolt to 20 nsm (15 lb-ft) (1). D tighten the compressor--to--bracket lower...

  • Page 804

    7b -- 22 manual control heating, ventilation, and air conditioning system daewoo m-150 bl2 d18b514a d remove the condenser mounting nuts (3). D push the top of the condenser (4). D take off the condenser from the lower bracket by lifting the condenser (5). D remove the condenser (6). D18b515b instal...

  • Page 805

    Manual control heating, ventilation, and air conditioning system 7b -- 23 daewoo m-150 bl2 d18b518a d loosen the fitting securing the high pressure pipe line to the condenser pipe line (2). D remove the clamp nut (3). D18b519a 5. Remove the a/c high pressure pipe line between the condenser and the r...

  • Page 806

    7b -- 24 manual control heating, ventilation, and air conditioning system daewoo m-150 bl2 d18b522a d18b523b d18b524a installation procedure important: discard the removed o--rings. 1. Install the high pressure pipe lines with the bolts, the nuts, and the fittings. Tighten d tighten the bolt securin...

  • Page 807

    Manual control heating, ventilation, and air conditioning system 7b -- 25 daewoo m-150 bl2 d108b526 a/c low pressure pipe line (left--hand drive shown, right--hand drive similar) removal procedure 1. Disconnect the negative battery cable. 2. Discharge and recover the refrigerant. Refer to “dis- char...

  • Page 808

    7b -- 26 manual control heating, ventilation, and air conditioning system daewoo m-150 bl2 d18b530b d18b531a d tighten the bracket nut to 5 nsm (44 lb-in) (2). D tighten the bolt securing the a/c low pressure pipe line at the compressor to 23 nsm (17 lb-ft) (3). 2. Evacuate and recharge the system. ...

  • Page 809

    Manual control heating, ventilation, and air conditioning system 7b -- 27 daewoo m-150 bl2 d18b534a installation procedure 1. Install the evaporator evaporator with the screws. 2. Connect the thermistor connector. 3. Install the drain hose. 4. Install the glove box. Refer to section 9e, instrumen- t...

  • Page 810: Unit Repair

    7b -- 28 manual control heating, ventilation, and air conditioning system daewoo m-150 bl2 unit repair d18b701a evaporator core and expansion valve disassembly procedure 1. Remove the evaporator unit. Refer to “evaporator unit and drain hose” in this section. 2. Remove the evaporator core and expans...

  • Page 811

    Manual control heating, ventilation, and air conditioning system 7b -- 29 daewoo m-150 bl2 d10b703a compressor overhaul tools required dw--610--010 clutch hub holding tool disassembly procedure 1.Remove the compressor. Refer to “compressor” in this section. 2. Remove the clutch drive plate. D use th...

  • Page 812: Specifications

    7b -- 30 manual control heating, ventilation, and air conditioning system daewoo m-150 bl2 specifications general specifications application unit description compressor -- sp--10.4pk receiver--dryer -- al r/drier refrigerant type -- r--134a system refrigerant capacity g 500 (rhd : 530) refrigerant o...

  • Page 813

    Manual control heating, ventilation, and air conditioning system 7b -- 31 daewoo m-150 bl2 special tools and equipment special tools table d108b101 dw--610--010 clutch hub holding tool.

  • Page 814

    7b -- 32 manual control heating, ventilation, and air conditioning system daewoo m-150 bl2 schematic and routing diagrams a/c diagrams d18b201b.

  • Page 815

    Manual control heating, ventilation, and air conditioning system 7b -- 33 daewoo m-150 bl2 a/c airflow (left--hand drive shown, right--hand drive similar) d108b202 a/c system (left--hand drive shown, right--hand drive similar) d18b203a.

  • Page 816: Section 8A

    Daewoo m-150 bl2 section 8a seat belts caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to...

  • Page 817: Description And Operation

    8a – 2 seat belts daewoo m-150 bl2 description and operation driver seat belt warning the driver’s safety belt incorporates a safety belt re- minder light in the instrument cluster to remind the driver if the safety belt is not fastened when the ignition is turned on. Three-point pretensioner front ...

  • Page 818: Component Locator

    Seat belts 8a – 3 daewoo m-150 bl2 component locator front and rear seat belt d1aa401b 1. Front seat belt 2. Front seat belt buckle 3. Rear seat belt (three–point) 4. Rear seat belt (two–point) / buckle (three–point) 5. Rear seat belt buckle (three–point/two–point).

  • Page 819

    8a – 4 seat belts daewoo m-150 bl2 diagnostic information and procedures seat belt warning lamp is inoperative condition probable cause correction seat belt warning d fuse f1 is blown. D replace the fuse f1. Lamp is inoperative d seat belt warning lamp wiring harness is open circuit or a short circu...

  • Page 820: Repair Instructions

    Seat belts 8a – 5 daewoo m-150 bl2 repair instructions on–vehicle service d110a501 three–point wlr/elr front seat belt removal procedure 1. Slide the front seat forward and fold the seatback. 2. Remove the bolt on the lower b–pillar. D remove the bolt (1). D remove the spacer and the fiber washer (2...

  • Page 821

    8a – 6 seat belts daewoo m-150 bl2 d1aa504d installation procedure notice: dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. 1. Install in the reverse order of removal. 2. Install the bolt on the upper b–pi...

  • Page 822

    Seat belts 8a – 7 daewoo m-150 bl2 d11a502a 3. Remove the lower b–pillar trim panel. Refer to sec- tion 9g, interior trim. 4. Remove the bolt on the upper b–pillar. D using a flathead screwdriver, open the bolt cap (1). D remove the bolt (2). D remove the spacer and the fiber washer (3). D28a001a 5....

  • Page 823

    8a – 8 seat belts daewoo m-150 bl2 d1aa505b 4. Install the bolt on the lower b–pillar. D install the bolt. Tighten tighten the lower b–pillar bolt to 30–45 n s m (22–33 lb-ft). D install the spacers and the fiber washer. D install the plastic protector on the seat belt anchor. 5. Relocate the seatba...

  • Page 824

    Seat belts 8a – 9 daewoo m-150 bl2 d110a508 3. Remove the bolt on the floor. D remove the bolt (1). D remove the spacer and the fiber washer (2). D remove the plastic protector on the seat belt an- chor. D110a509 4. Pry off the luggage compartment trim panel. Refer to section 9g, interior trim. 5. R...

  • Page 825

    8a – 10 seat belts daewoo m-150 bl2 d1aa512b 3. Install the bolt on the floor. Tighten tighten the bolt on the floor to 30–45 n s m (22–33 lb- ft). D110a513 two–point lab rear center seat belt removal procedure 1. Remove the rear seat cushion. 2. Remove the two–point rear seat belt and the buckle. D...

  • Page 826: Specifications

    Seat belts 8a – 11 daewoo m-150 bl2 specifications fastener tightening specifications ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ application ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ n s m ÁÁÁÁÁÁ ÁÁÁÁÁÁ lb-ft ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ lb-in ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ seat belt upper bolt ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁ...

  • Page 827

    8a – 12 seat belts daewoo m-150 bl2 schematic and routing diagrams driver seat belt warning d1aa201a.

  • Page 828: Section 8B

    Daewoo m-150 bl2 section 8b supplemental inflatable restraints (sir) caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent...

  • Page 829

    8b – 2 supplemental inflatable restraints (sir) daewoo m-150 bl2 diagnostic illustration 8 8b-65 . . . . . . . . . . . . . . . . . . . Diagnostic illustration 9 8b-65 . . . . . . . . . . . . . . . . . . . Diagnostic illustration 10 8b-66 . . . . . . . . . . . . . . . . . . Diagnostic illustration 11...

  • Page 830: Description And Operation

    Supplemental inflatable restraints (sir) 8b – 3 daewoo m-150 bl2 description and operation (left–hand drive shown, right–hand drive similar) airbag module driver airbag module caution: tampering with the driver side airbag module creates the risk of an injury from an unex- pected deployment. Therefo...

  • Page 831

    8b – 4 supplemental inflatable restraints (sir) daewoo m-150 bl2 if there is a failure of the sensing and diagnostic module or the external circuits, the sir warning lamp in the in- strument cluster turns on. As a system check, the sir warning lamp also turns on when the ignition is first switched t...

  • Page 832

    Supplemental inflatable restraints (sir) 8b – 5 daewoo m-150 bl2 d sensing and diagnostic module. D steering column clock spring. D wiring harness. D sir malfunction warning lamp. D110b001 general precautions the supplemental inflatable restraints (sir) warning lamp must illuminate when the ignition...

  • Page 833

    8b – 6 supplemental inflatable restraints (sir) daewoo m-150 bl2 d110b002 airbag deployment procedure 1. Non–deployment condition a. Initiator b. Piston c. Safety disc d. Compressed ar gas d110b003 2. When crashing, firing current flows from the sdm to the initiator. 3. Initiator is burning and the ...

  • Page 834: Component Locator

    Supplemental inflatable restraints (sir) 8b – 7 daewoo m-150 bl2 component locator sir component (left–hand drive shown, right–hand drive similar) d110b401 1. Driver airbag module 2. Passenger airbag module 3. Clock spring 4. Sensing and diagnostic module (sdm) 5. Wiring harness.

  • Page 835

    8b – 8 supplemental inflatable restraints (sir) daewoo m-150 bl2 diagnostic information and procedures d110b009a bulb check as soon as the operating voltage is applied to the sens- ing and diagnostic module (sdm) ignition input, the sdm activates the warning lamp for a bulb check. The sdm turns the ...

  • Page 836: Blank

    Supplemental inflatable restraints (sir) 8b – 9 daewoo m-150 bl2 blank.

  • Page 837

    8b – 10 supplemental inflatable restraints (sir) daewoo m-150 bl2 system check d1ab301b caution: use only the scan tool to check the airbag modules and the sensing and diagnostic module (sdm). Never measure the resistance of an airbag module with an ohmmeter. An ohmmeter’s battery can deploy the air...

  • Page 838

    Supplemental inflatable restraints (sir) 8b – 11 daewoo m-150 bl2 diagnostic system check (cont’d) ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 3 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ 1. Check fuse ...

  • Page 839

    8b – 12 supplemental inflatable restraints (sir) daewoo m-150 bl2 fault codes ÁÁÁÁÁÁ ÁÁÁÁÁÁ fault codes ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ fault contents ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ 01 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ dr...

  • Page 840: Blank

    Supplemental inflatable restraints (sir) 8b – 13 daewoo m-150 bl2 blank.

  • Page 841

    8b – 14 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 01 driver firing circuit, resistance too high open circuit circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will perform tests to diagnose any ma...

  • Page 842

    Supplemental inflatable restraints (sir) 8b – 15 daewoo m-150 bl2 dtc 01 – driver firing circuit, resistance too high ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ...

  • Page 843

    8b – 16 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 02 driver firing circuit, resistance too low short circuit circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will perform tests to diagnose any ma...

  • Page 844

    Supplemental inflatable restraints (sir) 8b – 17 daewoo m-150 bl2 dtc 02 – driver firing circuit, resistance too low ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ...

  • Page 845

    8b – 18 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 03 driver firing circuit, short to ground circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will perform tests to diagnose any malfunctions within...

  • Page 846

    Supplemental inflatable restraints (sir) 8b – 19 daewoo m-150 bl2 dtc 03 – driver firing circuit, short to ground ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ...

  • Page 847

    8b – 20 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 04 driver firing circuit, short to battery voltage circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will perform tests to diagnose any malfunctio...

  • Page 848

    Supplemental inflatable restraints (sir) 8b – 21 daewoo m-150 bl2 dtc 04 – driver firing circuit, short to battery voltage ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ...

  • Page 849

    8b – 22 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 05 passenger firing circuit, resistance too high open circuit circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will perform tests to diagnose any...

  • Page 850

    Supplemental inflatable restraints (sir) 8b – 23 daewoo m-150 bl2 dtc 05 – passenger firing circuit, resistance too high ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ...

  • Page 851

    8b – 24 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 06 passenger firing circuit, resistance too low short circuit circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will perform tests to diagnose any...

  • Page 852

    Supplemental inflatable restraints (sir) 8b – 25 daewoo m-150 bl2 dtc 06 – passenger firing circuit, resistance too low ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ...

  • Page 853

    8b – 26 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 07 passenger firing circuit, short to ground circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will diagnose any malfunc- tions within itself. Aft...

  • Page 854

    Supplemental inflatable restraints (sir) 8b – 27 daewoo m-150 bl2 dtc 07 passenger firing circuit, short to ground ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ...

  • Page 855

    8b – 28 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 08 passenger firing circuit, short to battery voltage circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will perform tests to diagnose any malfunc...

  • Page 856

    Supplemental inflatable restraints (sir) 8b – 29 daewoo m-150 bl2 dtc 08 – passenger firing circuit, short to battery voltage ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ...

  • Page 857

    8b – 30 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 09 driver pretensioner circuit, resistance too high open circuit circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will perform tests to diagnose ...

  • Page 858

    Supplemental inflatable restraints (sir) 8b – 31 daewoo m-150 bl2 dtc 09 – driver pretensioner circuit, resistance too high ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ...

  • Page 859

    8b – 32 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 10 driver pretensioner circuit, resistance too low short circuit circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will perform tests to diagnose ...

  • Page 860

    Supplemental inflatable restraints (sir) 8b – 33 daewoo m-150 bl2 dtc 10 – driver pretensioner circuit, resistance too low ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ...

  • Page 861

    8b – 34 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 11 driver pretensioner circuit, short to ground circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will perform tests to diagnose any malfunctions ...

  • Page 862

    Supplemental inflatable restraints (sir) 8b – 35 daewoo m-150 bl2 dtc 11 driver pretensioner circuit, short to ground ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ...

  • Page 863

    8b – 36 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 12 driver pretensioner circuit, short to battery voltage circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will perform tests to diagnose any malf...

  • Page 864

    Supplemental inflatable restraints (sir) 8b – 37 daewoo m-150 bl2 dtc 12 – driver pretensioner circuit, short to battery voltage ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁ...

  • Page 865

    8b – 38 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 13 passenger pretensioner circuit, resistance too high open circuit circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will perform tests to diagno...

  • Page 866

    Supplemental inflatable restraints (sir) 8b – 39 daewoo m-150 bl2 dtc 13 – passenger pretensioner circuit, resistance too high ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ...

  • Page 867

    8b – 40 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 14 passenger pretensioner circuit, resistance too low short circuit circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will perform tests to diagno...

  • Page 868

    Supplemental inflatable restraints (sir) 8b – 41 daewoo m-150 bl2 dtc 14 – passenger pretensioner circuit, resistance too low ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ...

  • Page 869

    8b – 42 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 15 passenger pretensioner circuit, short to ground circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will diagnose any malfunc- tions within itsel...

  • Page 870

    Supplemental inflatable restraints (sir) 8b – 43 daewoo m-150 bl2 dtc 15 passenger pretensioner circuit, short to ground ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ...

  • Page 871

    8b – 44 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 16 passenger pretensioner circuit, short to battery voltage circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will perform tests to diagnose any m...

  • Page 872

    Supplemental inflatable restraints (sir) 8b – 45 daewoo m-150 bl2 dtc 16 – passenger pretensioner circuit, short to battery voltage ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁ...

  • Page 873

    8b – 46 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 18 connection between driver firing circuit and driver pretensioner circuit open circuit circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will pe...

  • Page 874

    Supplemental inflatable restraints (sir) 8b – 47 daewoo m-150 bl2 dtc 18 – connection between driver firing circuit and driver pretensioner circuit ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁ...

  • Page 875

    8b – 48 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 19 connection between driver firing circuit and passenger pretensioner circuit open circuit circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will...

  • Page 876

    Supplemental inflatable restraints (sir) 8b – 49 daewoo m-150 bl2 dtc 19 – connection between driver firing circuit and passenger pretensioner circuit ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 Á...

  • Page 877

    8b – 50 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 20 connection between passenger firing circuit and driver pretensioner circuit open circuit circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will...

  • Page 878

    Supplemental inflatable restraints (sir) 8b – 51 daewoo m-150 bl2 dtc 20 – connection between passenger firing circuit and driver pretensioner circuit ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 Á...

  • Page 879

    8b – 52 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 21 connection between passenger firing circuit and passenger pretensioner circuit open circuit circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) w...

  • Page 880

    Supplemental inflatable restraints (sir) 8b – 53 daewoo m-150 bl2 dtc 21 – connection between passenger firing circuit and passenger pretensioner circuit ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ...

  • Page 881

    8b – 54 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 22 connection between driver pretensioner circuit and passenger pretensioner circuit open circuit circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm...

  • Page 882

    Supplemental inflatable restraints (sir) 8b – 55 daewoo m-150 bl2 dtc 22 – connection between driver pretensioner circuit and passenger pretensioner circuit ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁ...

  • Page 883

    8b – 56 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab302b diagnostic trouble code (dtc) 23 ignition input circuit, voltage too high circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will perform tests to diagnose any malfunctions with...

  • Page 884

    Supplemental inflatable restraints (sir) 8b – 57 daewoo m-150 bl2 dtc 23 – ignition input circuit, voltage too high ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ...

  • Page 885

    8b – 58 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab301b diagnostic trouble code (dtc) 24 ignition input circuit, voltage too low circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will perform tests to diagnose any malfunctions withi...

  • Page 886

    Supplemental inflatable restraints (sir) 8b – 59 daewoo m-150 bl2 dtc 24 – ignition input circuit, voltage too low ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ...

  • Page 887

    8b – 60 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab301b diagnostic trouble code (dtc) 25 warning lamp failure circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will perform tests to diagnose any malfunctions within itself. After pas...

  • Page 888

    Supplemental inflatable restraints (sir) 8b – 61 daewoo m-150 bl2 dtc 25 – warning lamp failure ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 1 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ turn the ignition...

  • Page 889

    8b – 62 supplemental inflatable restraints (sir) daewoo m-150 bl2 dtc 25 – warning lamp failure (cont’d) ÁÁÁÁ ÁÁÁÁ step ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ action ÁÁÁÁÁ ÁÁÁÁÁ value(s) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ yes ÁÁÁÁÁÁ ÁÁÁÁÁÁ no ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ 11 ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁ...

  • Page 890

    Supplemental inflatable restraints (sir) 8b – 63 daewoo m-150 bl2 diagnostic trouble code (dtc) 31 sdm internal fault circuit description when the ignition switch is turned on, the sensing and diagnostic module (sdm) will perform tests to diagnose malfunctions within itself. Dtc 31 will set when d t...

  • Page 891

    8b – 64 supplemental inflatable restraints (sir) daewoo m-150 bl2 d110b304 diagnostic illustration 2 checking the continuity on the instrument harness side between the terminal j (13) of the assembly line diag- nostic link and the terminal 4 of the connector c208. D110b305 diagnostic illustration 3 ...

  • Page 892

    Supplemental inflatable restraints (sir) 8b – 65 daewoo m-150 bl2 d110b308 diagnostic illustration 6 checking the driver airbag circuit for a short to voltage. D110b309 diagnostic illustration 7 checking the clock spring connector for a short to volt- age on the sensing and diagnostic module side. D...

  • Page 893

    8b – 66 supplemental inflatable restraints (sir) daewoo m-150 bl2 d110b311 diagnostic illustration 10 checking the passenger airbag circuit for a short to voltage. D110b312 diagnostic illustration 11 checking the sensing and diagnostic module voltage supply at the terminal 5. D110b313 diagnostic ill...

  • Page 894

    Supplemental inflatable restraints (sir) 8b – 67 daewoo m-150 bl2 d110b315 diagnostic illustration 14 checking for a short to ground in the instrument harness on the instrument harness side at the terminal 3 of the connector c208. D110b316 diagnostic illustration 15 checking the voltage of the warni...

  • Page 895

    8b – 68 supplemental inflatable restraints (sir) daewoo m-150 bl2 d110b311 diagnostic illustration 18 checking the driver seat belt pretensioner circuit for a short to voltage. D110b310 . Diagnostic illustration 19 checking the passenger seat belt pretensioner circuit continuity on the sensing and d...

  • Page 896: Repair Instructions

    Supplemental inflatable restraints (sir) 8b – 69 daewoo m-150 bl2 repair instructions on–vehicle service d110b501 driver airbag module (left–hand drive shown, right–hand drive similar) tool required ds 401 torx bolt wrench removal procedure 1. Disconnect the negative battery cable. 2. Position the s...

  • Page 897

    8b – 70 supplemental inflatable restraints (sir) daewoo m-150 bl2 d110b504 clock spring (left–hand drive shown, right–hand drive similar) removal procedure 1. Disconnect the negative battery cable. Wait 1 minute until the capacitor inside the sensing and diagnostic module has discharged. 2. Remove t...

  • Page 898

    Supplemental inflatable restraints (sir) 8b – 71 daewoo m-150 bl2 5. Properly align the pointed marks ( ) on the com- ponents of the clock spring. 6. Connect the electrical connectors on the lower spring steering column. 7. Install the lower/upper steering column cover. 8. Install the steering wheel...

  • Page 899

    8b – 72 supplemental inflatable restraints (sir) daewoo m-150 bl2 d1ab508a 3. Connect the passenger airbag module connector. 4. Install the glove box. Refer to section 9e, instrument/ driver information. 5. Connect the negative battery cable. D19e573a sensing and diagnostic module (sdm) tool require...

  • Page 900

    Supplemental inflatable restraints (sir) 8b – 73 daewoo m-150 bl2 d110b009a 3. Install the floor console. Refer to section 9g, interior trim. 4. Connect the negative battery cable. 5. Check for proper operation of the system. D turn the ignition on while watching the supple- mental inflatable restra...

  • Page 901

    8b – 74 supplemental inflatable restraints (sir) daewoo m-150 bl2 d110b010 airbag module deployment (in vehicle) (left–hand drive shown, right–hand drive similar) deploy the airbags before disposing of them. This in- cludes those in a whole vehicle being scrapped. If the vehicle is still within the ...

  • Page 902

    Supplemental inflatable restraints (sir) 8b – 75 daewoo m-150 bl2 d110b011a 8. Place the twisted ends of the two wires near the de- ployment battery. Do not connect the wires to the battery at this time. 9. Using the free ends of the 10 meters (33 feet) wires leading to the clock spring, make two sp...

  • Page 903

    8b – 76 supplemental inflatable restraints (sir) daewoo m-150 bl2 airbag module deployment (outside of vehicle) deploy all intact airbag modules that have been d removed from a scrapped vehicle. D found to be defective. D found to have been damaged during transit, storage, or service. Caution: deplo...

  • Page 904

    Supplemental inflatable restraints (sir) 8b – 77 daewoo m-150 bl2 d110b012 if the vehicle is still within the warranty period, contact the daewoo regional service manager for approval or special instructions before deploying an airbag module. Deployed airbag modules should be disposed of in the same...

  • Page 905: Specifications

    8b – 78 supplemental inflatable restraints (sir) daewoo m-150 bl2 specifications fastener tightening specifications ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ application ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ n s m ÁÁÁÁÁÁ ÁÁÁÁÁÁ lb-ft ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ lb-in ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ clock spring mounting screws ÁÁÁ...

  • Page 906

    Supplemental inflatable restraints (sir) 8b – 79 daewoo m-150 bl2 schematic and routing diagrams supplemental inflatable restraints (sir) electrical schematic d1ab201b.

  • Page 907: Section 9A

    Daewoo m-150 bl2 section 9a body wiring system caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and d...

  • Page 908: Description And Operation

    9a – 2 body wiring system daewoo m-150 bl2 description and operation how to read electrical wiring diagram d111001a.

  • Page 909

    Body wiring system 9a – 3 daewoo m-150 bl2 contents of electrical wiring diagram position explanation a – the box above the fuse box: power supply lines – power supply lines: 30, 15, 15a, ka, 58, 50 – refer to “circuit identification symbol” in this section for more details. B – ef10 or f3: fuse num...

  • Page 910

    9a – 4 body wiring system daewoo m-150 bl2 how to check terminal number of connector terminal number is given based on female terminal connector. Example: terminal number 4 of 6 pin connection. D111002a.

  • Page 911

    Body wiring system 9a – 5 daewoo m-150 bl2 special tools and equipment special tools table d1011101 dw–540–010 relay remover.

  • Page 912

    9a – 6 body wiring system daewoo m-150 bl2 schematic and routing diagrams wire color chart wire color abbreviation on schematic green dk grn blue dk blu brown brn orange orn yellow yel grey gry red red black blk white wht purple ppl wires with tracers wire color abbreviation on schematic red with wh...

  • Page 913

    Body wiring system 9a – 7 daewoo m-150 bl2 power disribution schematic d111005b.

  • Page 914

    9a – 8 body wiring system daewoo m-150 bl2 relay & fuse box locator (engine room: sirius d3) d111003b relay & fuse box locator (engine room: fenix 5mr) d111003c.

  • Page 915

    Body wiring system 9a – 9 daewoo m-150 bl2 fuse box locator (passenger compartment: lhd) d111004a fuse box locator (passenger compartment: rhd) d111004b.

  • Page 916

    9a – 10 body wiring system daewoo m-150 bl2 fuse chart fuse rating/ source circuit ef1 (engine fuse) 50a bat abs ef2 40a bat ignition switch, instrument panel fuse block (f5, f11 ~ f13) ef3 10a bat fuel cut-off switch (inertia switch) ef4 10a ign 1 fuel, ebcm, generator, vss, fuel pump relay, main r...

  • Page 917

    Body wiring system 9a – 11 daewoo m-150 bl2 front harness routing (left–hand drive shown, right–hand drive similar) d111401d.

  • Page 918

    9a – 12 body wiring system daewoo m-150 bl2 engine harness routing (sirius d3) (left–hand drive shown, right–hand drive similar) d111402d.

  • Page 919

    Body wiring system 9a – 13 daewoo m-150 bl2 engine harness routing (fenix 5nr) (left–hand drive shown, right–hand drive similar) d111411a.

  • Page 920

    9a – 14 body wiring system daewoo m-150 bl2 instrument harness routing (left–hand drive) d111403e.

  • Page 921

    Body wiring system 9a – 15 daewoo m-150 bl2 instrument harness routing (right–hand drive) d111403f.

  • Page 922

    9a – 16 body wiring system daewoo m-150 bl2 airbag harness routing (left–hand drive shown, right–hand drive similar) d111404d.

  • Page 923

    Body wiring system 9a – 17 daewoo m-150 bl2 body harness routing d111405d.

  • Page 924

    9a – 18 body wiring system daewoo m-150 bl2 body harness routing (cont’d) d111406d.

  • Page 925

    Body wiring system 9a – 19 daewoo m-150 bl2 front door harness routing d111407d.

  • Page 926

    9a – 20 body wiring system daewoo m-150 bl2 rear door harness routing d111408d.

  • Page 927

    Body wiring system 9a – 21 daewoo m-150 bl2 tailgate harness routing d111409d.

  • Page 928: Section 9B

    Daewoo m-150 bl2 section 9b lighting systems caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and dam...

  • Page 929: Description And Operation

    9b – 2 lighting systems daewoo m-150 bl2 description and operation headlamps and parking lamps the headlamps are controlled by the multifunction lever located on the left side of the steering column. They will come on with the ignition switch in any position. Turning the headlamp switch to the first...

  • Page 930

    Lighting systems 9b – 3 daewoo m-150 bl2 diagnostic information and procedures headlamps condition probable cause correction low beam headlamps are inoperative, high beam d faulty headlamp combination switch. D replace the headlamp combination switch. Headlamps are ok. D the open circuit or a short ...

  • Page 931

    9b – 4 lighting systems daewoo m-150 bl2 turn signal lamps and hazard lamps condition probable cause correction turn signal lamps and hazard lamps do not work. D the open circuit or a short circuit between the power supply circuit and the fuse ef2. D repair or replace the wiring harness. D fuse ef2 ...

  • Page 932

    Lighting systems 9b – 5 daewoo m-150 bl2 stoplamps and interior courtesy lamp condition probable cause correction stoplamps do not work. D fuse f5 is blown. D replace the fuse f5. D the open circuit or a short circuit between the fuse f11 and the terminal 2 of the stoplamps switch connector (for veh...

  • Page 933

    9b – 6 lighting systems daewoo m-150 bl2 rear fog lamp diagnostic aids: the rear fog lamp will not operate unless the headlamps are on. If the headlamps are not operat- ing, repair that problem before attempting to diagnose the rear fog lamp. Condition probable cause correction rear fog lamp does no...

  • Page 934: Repair Instructions

    Lighting systems 9b – 7 daewoo m-150 bl2 repair instructions on–vehicle service d209b109 headlamps removal procedure 1. Support the hood suitably. 2. Disconnect the negative battery cable. 3. Remove the front bumper spacer. D remove the bolts (1). D remove the front bumper spacer from the bumper fas...

  • Page 935

    9b – 8 lighting systems daewoo m-150 bl2 d19d505a turn signal lamps removal procedure 1. Disconnect the negative battery cable. 2. Remove the front bumper spacer. Refer to section 9m, exterior trim. 3. Remove the turn signal lamps from the front bumper spacer. D disconnect the electrical connector (...

  • Page 936

    Lighting systems 9b – 9 daewoo m-150 bl2 d109d507 taillamps assembly removal procedure 1. Disconnect the negative battery cable. 2. Open the tailgate. 3. Remove the luggage compartment wheelhouse trim. Refer to section 9g, interior trim. 4. Disconnect the electrical connector. D19d508b 5. Remove the...

  • Page 937

    9b – 10 lighting systems daewoo m-150 bl2 d209b100 5. Remove the front fog lamp. D remove the screws (1). D disconnect the electrical connector (2). D remove the front fog lamp (3). D209b101 installation procedure 1. Install the front fog lamp with the screws. 2. Connect the front fog lamp connector...

  • Page 938

    Lighting systems 9b – 11 daewoo m-150 bl2 d29b003b center high-mounted stoplamp (chmsl) removal procedure 1. Disconnect the negative battery cable. 2. Open the tailgate. 3. Pry off the tailgate trim panel. Refer to section 9g in- terior trim. 4. Remove the chmsl cover. D remove the screws (1). D rem...

  • Page 939

    9b – 12 lighting systems daewoo m-150 bl2 d209b102 chmsl mounting bracket removal procedure 1. Disconnect the negative battery cable. 2. Remove the center high–mounted stoplamp (chmsl). Refer to “center high–mounted stoplamp” in this section. 3. Remove the rear window wiper motor assembly. Re- fer t...

  • Page 940

    Lighting systems 9b – 13 daewoo m-150 bl2 d19d512a installation procedure 1. Install the license plate lamp socket. 2. Install the tailgate handle. Refer to section 9m, exte- rior trim. 3. Connect the electrical connector. 4. Remove the rear window wiper motor assembly. Re- fer to section 9d, wipers...

  • Page 941

    9b – 14 lighting systems daewoo m-150 bl2 d109d516 installation procedure 1. Connect the electrical connector. 2. Install the interior courtesy lamp with the screws. 3. Install the interior courtesy lamp lens. 4. Connect the negative battery cable. D29b007 daytime running lamp module (w/europe only)...

  • Page 942

    Lighting systems 9b – 15 daewoo m-150 bl2 d209b104 luggage room lamp removal procedure 1. Disconnect the negative battery cable. 2. Open the tailgate. 3. Remove the luggage room lamp. D remove the luggage room lamp (1). D disconnect the electrical connector (2). D209b105 installation procedure 1. Co...

  • Page 943: Specifications

    9b – 16 lighting systems daewoo m-150 bl2 specifications bulb usage chart bulb replacement bulb number backup lamp(s) 21w center high mounted stoplamp 21w headlamps double 60/55w interior courtesy lamp 10w license plate lamp 5w front turn signal lamps 21w rear fog lamp 21w rear turn signal lamps 21w...

  • Page 944

    Lighting systems 9b – 17 daewoo m-150 bl2 schematic and routing diagrams backup lamp(s) circuit d19d201b.

  • Page 945

    9b – 18 lighting systems daewoo m-150 bl2 headlamps circuit d19d202b.

  • Page 946

    Lighting systems 9b – 19 daewoo m-150 bl2 headlamp leveling circuit d19b723b.

  • Page 947

    9b – 20 lighting systems daewoo m-150 bl2 tail and license plate lamps circuit d19d203b.

  • Page 948

    Lighting systems 9b – 21 daewoo m-150 bl2 stoplamps circuit d19d204b.

  • Page 949

    9b – 22 lighting systems daewoo m-150 bl2 turn and hazard lamps circuit d19d205b.

  • Page 950

    Lighting systems 9b – 23 daewoo m-150 bl2 interior courtesy lamp circuit d19d206b.

  • Page 951

    9b – 24 lighting systems daewoo m-150 bl2 front fog lamp circuit d19b724a1.

  • Page 952

    Lighting systems 9b – 25 daewoo m-150 bl2 rear fog lamp circuit d19b724b.

  • Page 953

    9b – 26 lighting systems daewoo m-150 bl2 dimmer control circuit (except w/europe) d29b009a.

  • Page 954

    Lighting systems 9b – 27 daewoo m-150 bl2 daytime running lamps circuit (w/europe only) d29b010a.

  • Page 955: Section 9C

    Daewoo m-150 bl2 section 9c horns caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the ...

  • Page 956: Description And Operation

    9c – 2 horn daewoo m-150 bl2 description and operation horn the horn is located under the hood. It is attached near the radiator at the front of the vehicle. The horn is actu- ated by pressing the steering wheel pad, which grounds the horn’s electrical circuit..

  • Page 957: Repair Instructions

    Horn 9c – 3 daewoo m-150 bl2 repair instructions on–vehicle service d19c501a horn removal procedure 1. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. 3. Remove the front wheels. 4. Remove the front wheel house splash shield. D remove the clip and bolts. A. Bolts an...

  • Page 958

    9c – 4 horn daewoo m-150 bl2 schematic and routing diagrams horn wiring system d19d207b.

  • Page 959: Section 9D

    Daewoo m-150 bl2 section 9d wipers / washer systems caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury ...

  • Page 960: Description And Operation

    9d – 2 wipers/washer systems daewoo m-150 bl2 description and operation windshield wiper system the windshield wiper system consists of a wiper motor, a linkage, a wiper arm and a blade, and a wiper/washer switch. The windshield wiper circuit incorporates a self- parking device which consists of a w...

  • Page 961

    Wipers/washer systems 9d – 3 daewoo m-150 bl2 diagnostic information and procedures windshield/rear window wiper and washer system condition probable cause correction windshield wipers do not work at any speed d the open or a short in the power supply circuit to the fuse f8. D repair or replace the ...

  • Page 962

    9d – 4 wipers/washer systems daewoo m-150 bl2 windshield/rear window wiper and washer system(cont’d) condition probable cause correction wipers do not on intermittent, other speed ok d the circuit between the fuse f8 and the wiper relay is the open circuit or a short circuit. D repair or replace the...

  • Page 963

    Wipers/washer systems 9d – 5 daewoo m-150 bl2 windshield/rear window wiper and washer system(cont’d) condition probable cause correction rear wiper does not work d the open or a short in the power supply circuit to the fuse f9. D repair or replace the open or a short in the power supply circuit to t...

  • Page 964: Repair Instructions

    9d – 6 wipers/washer systems daewoo m-150 bl2 repair instructions on–vehicle service d109d519 windshield wiper arm (left–hand drive shown, right–hand drive similar) removal procedure 1. Remove the wiper arm. D remove the cap (1). D remove the nut (2). D remove the wiper arm (3). D109d520 installatio...

  • Page 965

    Wipers/washer systems 9d – 7 daewoo m-150 bl2 d109d522 installation procedure 1. Install the rear wiper arm with the nut. 2. Install the cap. 3. Install the wiper blade. Refer to “windshield wiper blade” in this section. 4. Install the washer nozzle to the wiper arm. Refer to “rear washer nozzle” in...

  • Page 966

    9d – 8 wipers/washer systems daewoo m-150 bl2 d109d526 installation procedure 1. Install the wiper motor to the engine room with the bolts. A. Wiper motor assembly bolt. 2. Connect the electrical connector. D109d527 3. Install the wiper linkage to the wiper motor linkage ball. B. Wiper linkage ball....

  • Page 967

    Wipers/washer systems 9d – 9 daewoo m-150 bl2 d19d530a caution: because the wiper motor link plate is fixed, do not separate the wiper motor from the bracket. D19d531a installation procedure 1. Install the wiper motor assembly to the tailgate with the screws. 2. Connect the electrical connector. 3. ...

  • Page 968

    9d – 10 wipers/washer systems daewoo m-150 bl2 d19d533a 1.5–2.0 n s m installation procedure 1. Install the wiper linkage with the wiper linkage nuts. Tighten tighten the wiper linkage nuts to 1.5–2.0 n s m (13–18 lb-in). A. Wiper linkage nut. 2. Install the wiper motor linkage ball. 3. Install the ...

  • Page 969

    Wipers/washer systems 9d – 11 daewoo m-150 bl2 d19d537a 3. Raise and suitably support the vehicle. 4. Remove the front rh wheelhouse splash shield. D remove the screws (1). D remove the clips (2). D remove the wheelhouse splash shield (3). D109d538 5. Remove the washer reservoir assembly. D drain th...

  • Page 970

    9d – 12 wipers/washer systems daewoo m-150 bl2 d109d539 installation procedure 1. Install the wiper motor to the washer reservoir assem- bly. 2. Install the washer reservoir assembly. Refer to “washer reservoir” in this section. 3. Connect the negative battery cable. 4. Fill the washer reservoir. D1...

  • Page 971

    Wipers/washer systems 9d – 13 daewoo m-150 bl2 d109d535 installation procedure 1. Install the washer nozzle to the wiper arm assembly. D install the washer nozzle hose in the wiper arm re- turn spring. D fix the washer nozzle into the wiper arm. D install the washer nozzle hose to the pivot cap con-...

  • Page 972

    9d – 14 wipers/washer systems daewoo m-150 bl2 d109d545 7. Remove the washer hose. A. Washer hose. D19d546a installation procedure 1. Connect the washer hose to the washer pump. 2. Install the front rh wheel house splash shield with the screws and the clips. 3. Install the front rh wheel. 4. Lower t...

  • Page 973: Specifications

    Wipers/washer systems 9d – 15 daewoo m-150 bl2 specifications fastener tightening specifications application n s m lb-ft lb-in wiper linkage conclusion nut 1.5–2.0 – 13–18.

  • Page 974

    9d – 16 wipers/washer systems daewoo m-150 bl2 schematic and routing diagrams windshield/rear window wiper and washer system d19d208b.

  • Page 975: Section 9E

    Daewoo m-150 bl2 section 9e instrumentation/driver information caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent perso...

  • Page 976: Description And Operation

    9e – 2 instrumentation/driver information daewoo m-150 bl2 description and operation cigar lighter the cigar lighter is located in the front portion of the in- strument panel. To use the lighter, push it in completely. When the lighter is hot, it will release itself from contact with the heating ele...

  • Page 977: Component Locator

    Instrumentation/driver information 9e – 3 daewoo m-150 bl2 component locator instrument panel assembly (left–hand drive shown, right–hand drive similar) d19b401a 1. Tie–bar 2. Tie–bar center 3. Instrument panel guide 4. Defroster grille 5. Instrument panel upper cap 6. Passenger’s airbag blank cover...

  • Page 978

    9e – 4 instrumentation/driver information daewoo m-150 bl2 instrument cluster d109b404 1. Instrument cluster lens 2. Instrument cluster window plate 3. Speedometer gauge 4. Fuel gauge 5. Temperature gauge 6. Instrument cluster case 7. Fronted circuit plate 8. Instrument cluster bulb.

  • Page 979

    Instrumentation/driver information 9e – 5 daewoo m-150 bl2 diagnostic information and procedures d19b301b cigar lighter ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ condition ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ probable cause ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ correction ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ cigar lighter inoperative ÁÁ...

  • Page 980

    9e – 6 instrumentation/driver information daewoo m-150 bl2 d19b302b hvac panel illumination ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ condition ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ probable cause ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ correction ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ hvac panel illumination inoperative ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ...

  • Page 981

    Instrumentation/driver information 9e – 7 daewoo m-150 bl2 d19b304b digital clock ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ condition ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ probable cause ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ correction ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ digital clock inoperative ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ...

  • Page 982: Repair Instructions

    9e – 8 instrumentation/driver information daewoo m-150 bl2 repair instructions on–vehicle service d109b501 cigar lighter (left–hand drive shown, right–hand drive similar) removal procedure 1. Disconnect the negative battery cable. 2. Remove the ashtray from the ashtray housing. 3. Remove the cigar l...

  • Page 983

    Instrumentation/driver information 9e – 9 daewoo m-150 bl2 d109b504 ashtray (left–hand drive shown, right–hand drive similar) removal procedure 1. Remove the ashtray from the ashtray bracket. D pull off the ashtray by pressing the upper button. D19b505a 2. Remove the ashtray bracket from the instrum...

  • Page 984

    9e – 10 instrumentation/driver information daewoo m-150 bl2 d109b508 installation procedure 1. Install the vents to the instrument cluster trim panel with the screws. 2. Install the instrument cluster trim panel. Refer to “in- strument cluster trim panel” in this section. D109b511 digital clock (lef...

  • Page 985

    Instrumentation/driver information 9e – 11 daewoo m-150 bl2 d109b509 glove box (left–hand drive shown, right–hand drive similar) removal procedure 1. Remove the hinge pins at the base of the glove box. D109b510 2. Remove the glove box from the instrument panel. D109b509 installation procedure 1. Ins...

  • Page 986

    9e – 12 instrumentation/driver information daewoo m-150 bl2 d19b515a installation procedure 1. Connect the electrical connector and the speedom- eter cable. 2. Install the instrument cluster assembly to instrument panel with screws. 3. Install the instrument cluster trim panel to the instru- ment pa...

  • Page 987

    Instrumentation/driver information 9e – 13 daewoo m-150 bl2 d109b518 12. Remove the instrument cluster assembly. Refer to “instrument cluster” in this section. 13. Remove the a/c controller from the instrument. Re- fer to section 7b, manual control heating, ventila- tion, and air conditioning system...

  • Page 988

    9e – 14 instrumentation/driver information daewoo m-150 bl2 7. Install the instrument cluster assembly. Refer to “in- strument cluster” in this section. 8. Install the floor console with the screws. 9. Install the passenger’s airbag module to the instru- ment panel. Refer to section 8b, supplemental...

  • Page 989

    Instrument/driver information 9e – 15 daewoo m-150 bl2 d109b523 6. Remove the defroster duct from the cowl upper pan- el. D remove the screws (1). D remove the defroster duct (2). D109b524 7. Remove the bolts and the tie–bar. A. Tie bar. D109b525 8. Remove the bolts and the tie–bar center. B. Tie ba...

  • Page 990

    9e – 16 instrument/driver information daewoo m-150 bl2 4. Connect the electrical wiring harness. 5. Connect the blow motor resistance connector. 6. Connect the blow motor connector. 7. Connect the thermostat connector. 8. Connect the brake switch connector. 9. Bind the electrical wiring harness stri...

  • Page 991

    Instrument/driver information 9e – 17 daewoo m-150 bl2 d109b702 4. Remove the passenger’s airbag module blank cover from the instrument panel. D remove the screws. D remove the passenger’s airbag module blank cov- er (1). D109b703 5. Remove the ventilation duct from the instrument pan- el. D remove ...

  • Page 992

    9e – 18 instrument/driver information daewoo m-150 bl2 d109b706 8. Remove the glove box striker and bracket from the instrument panel. D remove the screws (1). D remove the glove box striker and bracket (2). D109b707 9. Remove the instrument panel guide from the instru- ment panel. D remove the scre...

  • Page 993

    Instrument/driver information 9e – 19 daewoo m-150 bl2 d19b710a 7. Install the passenger’s airbag module blank cover to the instrument panel with the screws. Tighten tighten the screws to 1.5–2 n.M (13–18 lb-in). A. Passenger’s airbag module blank cover screw 8. Install the instrument cluster bracke...

  • Page 994

    9e – 20 instrument/driver information daewoo m-150 bl2 d109b714 4. Remove the speedometer/odometer/trip odometer. D remove the screws on the circuit plate (1). D remove the speedometer/odometer/trip odometer (2). D19b715a installation procedure 1. Install the speedometer/odometer/trip odometer with ...

  • Page 995

    Instrument/driver information 9e – 21 daewoo m-150 bl2 d19b717a installation procedure 1. Install the fuel gauge/temperature gauge to the clus- ter assembly with the screws. 2. Install the instrument cluster lens and the face plate. 3. Install the instrument cluster. Refer to “instrument cluster” in...

  • Page 996: Specifications

    9e – 22 instrument/driver information daewoo m-150 bl2 specifications fastener tightening specifications ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ application ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ n s m ÁÁÁÁÁÁ ÁÁÁÁÁÁ lb-ft ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ lb-in ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ passenger’s airbag modul...

  • Page 997

    Instrument/driver information 9e – 23 daewoo m-150 bl2 schematic and routing diagrams ins t rum e n t cl us t e r (s irius d3) d19b201b.

  • Page 998

    9e – 24 instrument/driver information daewoo m-150 bl2 inst rum ent cl ust e r (f enix 5m r) d19b201s.

  • Page 999

    Instrument/driver information 9e – 25 daewoo m-150 bl2 instrument panel illumination d19b202b.

  • Page 1000

    9e – 26 instrument/driver information daewoo m-150 bl2 digital clock d19b203b.

  • Page 1001: Section 9F

    Daewoo m-150 bl2 section 9f audio systems caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage...

  • Page 1002: Description And Operation

    9f – 2 audio systems daewoo m-150 bl2 description and operation stereo cassette am/fm radio with cd changer and rds/audio security system the stereo digital logic cassette am/fm radio with elec- tronic tape ejection and the stereo digital logic cassette am/fm radio with a cd changer located under th...

  • Page 1003: Component Locator

    Audio systems 9f – 3 daewoo m-150 bl2 component locator audio systems d19d401b 1. Roof antenna assembly 2. Roof antenna pole 3. Roof antenna base 4. Roof antenna frame 5. Roof antenna cable 6. Front speaker 7. Rear speaker 8. Audio 9. Cd changer cable 10. Cd changer bracket 11. Cd changer magazine 1...

  • Page 1004

    9f – 4 audio systems daewoo m-150 bl2 diagnostic information and procedures audio system condition probable cause correction audio system inoperative d the power supply circuit to the fuse ef2 is open circuit or short circuit. D repair or replace the power supply wiring harness. D the fuse ef2 is bl...

  • Page 1005

    Audio systems 9f – 5 daewoo m-150 bl2 audio system (cont’d) condition probable cause correction rear speakers distorted or inoperative d the connection of the rear speaker connector and the audio connector is poor. D confirm the connection. D rear speaker is out of order. D replace the rear speaker....

  • Page 1006: Repair Instructions

    9f – 6 audio systems daewoo m-150 bl2 repair instructions on–vehicle service d109d547 audio system removal procedure 1. Disconnect the negative battery cable. 2. Remove the instrument cluster trim panel from the in- strument panel. Refer to section 9e, instrument/driv- er information. 3. Remove the ...

  • Page 1007

    Audio systems 9f – 7 daewoo m-150 bl2 d19d550a 5. Disconnect the cd changer electrical connector from the cd changer (1). D19d551a 6. Remove the sponge pads and the clip. D remove the sponge pads retaining the cd chang- er cable (1). D remove the clip retaining tie-bar (2). D remove the clip retaini...

  • Page 1008

    9f – 8 audio systems daewoo m-150 bl2 d19d553a 9. Separate the cd changer and the cd changer brack- et. D remove the bolts from the cd changer bracket (1). D remove the cd changer bracket (2). D remove the cd changer (3). D19d554a installation procedure 1. Install the cd changer bracket to the cd ch...

  • Page 1009

    Audio systems 9f – 9 daewoo m-150 bl2 d109d557 front speaker covers removal procedure 1. Remove the door trim panel. Refer to section 9g, in- terior trim. 2. Remove the speaker cover from the door trim panel. D remove the screws (1). D remove the speaker cover (2). D109d558 installation procedure 1....

  • Page 1010

    9f – 10 audio systems daewoo m-150 bl2 d109d561 roof antenna removal procedure 1. Disconnect the negative battery cable. 2. Remove the interior courtesy lamp. Refer to section 9b, lighting systems. 3. Remove the roof antenna. D remove the screw from the vehicle inside (1). D remove the roof antenna ...

  • Page 1011: Specifications

    Audio systems 9f – 11 daewoo m-150 bl2 specifications fastener tightening specifications application n s m lb-ft lb-in roof antenna retaining screw 3 – 27.

  • Page 1012

    9f – 12 audio systems daewoo m-150 bl2 schematic and routing diagrams audio system circuit (left–hand drive shown, right–hand drive similar) d19d209b.

  • Page 1013: Section 9G

    Daewoo m-150 bl2 section 9g interior trim caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage...

  • Page 1014: Description And Operation

    9g – 2 interior trim daewoo m-150 bl2 description and operation interior trim panels the interior trim panels are molded plastic and fasten with screws or plastic clips. Pressure relief vent when all the windows are closed and the ventilation sys- tem is on, the addition of outside air to the interi...

  • Page 1015: Component Locator

    Interior trim 9g – 3 daewoo m-150 bl2 component locator interior trim d19e402a 1. A–pillar trim panel 2. B–pillar upper trim panel 3. C–pillar trim panel 4. Front rocker trim panel 5. B–pillar lower trim panel 6. Rear rocker trim panel 7. Rear parcel side shelf 8. Wheel house trim panel 9. Floor con...

  • Page 1016: Repair Instructions

    9g – 4 interior trim daewoo m-150 bl2 repair instructions on–vehicle service d109e532 front door trim panel (standard) tool required km 475–b trim remover. Removal procedure 1. Remove the door pull from the front door. D remove the screws (1). D remove the door pull (2). D109e533 2. Remove the insid...

  • Page 1017

    Interior trim 9g – 5 daewoo m-150 bl2 d109e535 4. Pry off the trim panel using a trim remover km 475–b. Notice: make sure to cover the remover with cloth to prevent the paint damage of the door. D109e536 installation procedure 1. Install the trim panel. 2. Install the window regulator handle with th...

  • Page 1018

    9g – 6 interior trim daewoo m-150 bl2 d109e539 4. Remove the inside channel weatherstrip. Refer to section 9p, doors. 5. Remove the map pocket from the door trim. D remove the screws (1). D remove the map pocket (2). D19e540a installation procedure 1. Install the map pocket to the door trim with the...

  • Page 1019

    Interior trim 9g – 7 daewoo m-150 bl2 d109e543 3. Remove the window regulator handle from the rear door. D using a cloth, pull out the clip (1). D remove the regulator handle (2). D109e544 4. Pry off the trim panel using a trim remover km 475–b. Notice: make sure to cover the remover with cloth to p...

  • Page 1020

    9g – 8 interior trim daewoo m-150 bl2 d109e547 4. Remove the trim panel. D remove the screws (1). D remove the clips (2). D remove the trim panel (3). 5. Remove the inside channel weatherstrip. Refer to section 9p, doors. D109e548 installation procedure 1. Install the inside channel weatherstrip. Re...

  • Page 1021

    Interior trim 9g – 9 daewoo m-150 bl2 d109e551 rear door exterior garnish molding removal procedure 1. Pry off the interior garnish molding. Refer to “rear door interior garnish molding” in this section. 2. Pry off the exterior garnish molding. D remove the screw (1). D pry off exterior garnish mold...

  • Page 1022

    9g – 10 interior trim daewoo m-150 bl2 d109e555 a–pillar trim panel removal procedure 1. Pry off the a–pillar trim panel (1). D109e556 installation procedure 1. Install the a–pillar trim panel. D109e557 upper b–pillar trim panel removal procedure 1. Remove the bolt on the upper b–pillar trim panel. ...

  • Page 1023

    Interior trim 9g – 11 daewoo m-150 bl2 d110a501 lower b–pillar trim panel removal procedure 1. Remove the bolt on the lower b–pillar trim panel. D remove the bolt (1). D remove the spacer and the spring washer (2). D remove the plastic protector from the seat belt an- chor. D109e559 2. Pry off the l...

  • Page 1024

    9g – 12 interior trim daewoo m-150 bl2 d109e562 4. Remove the rear parcel side shelf. Refer to “rear parcel side shelf” in this section. 5. Remove the rear seatback. 6. Remove the rear seat belt bolt on the c–pillar trim panel. Refer to section 8a, seat belts. 7. Pry off the c–pillar trim panel. D p...

  • Page 1025

    Interior trim 9g – 13 daewoo m-150 bl2 d109e566 rear parcel side shelf removal procedure 1. Disconnect the negative battery cable. 2. Open the tailgate. 3. Remove the seatback. 4. Remove the rear seat parcel shelf. Refer to “rear parcel shelf” in this section. 5. Remove the rear speaker from the rea...

  • Page 1026

    9g – 14 interior trim daewoo m-150 bl2 d109e570 rear rocker trim panel removal procedure 1. Remove the rear seat cushion. D110a508 2. Remove the rear seat belt bolt on the floor. D remove the bolt (1). D remove the spacer and the spring washer (2). D remove the plastic protector from the seat belt a...

  • Page 1027

    Interior trim 9g – 15 daewoo m-150 bl2 d19e573a floor console removal procedure 1. Remove the floor console screws. D19e575a 2. Remove the gear shift lever boot cover and the floor console. D remove the gear shift lever boot cover (1). D remove the screws (2). D remove the floor console (3). D19e576...

  • Page 1028

    9g – 16 interior trim daewoo m-150 bl2 d109e578 installation procedure 1. Install the parking brake cable cover with the screw. D109e581 floor carpet (left–hand drive shown, right–hand drive similar) removal procedure 1. Disconnect the negative battery cable. 2. Remove the front seats. Refer to sect...

  • Page 1029

    Interior trim 9g – 17 daewoo m-150 bl2 d109e583 installation procedure 1. Install the floor carpet. 2. Install the clips. 3. Install the parking brake cable cover. Refer to “park- ing brake cable cover” in this section. 4. Install the lower b–pillar trim panel. Refer to “lower b–pillar trim panel” i...

  • Page 1030

    9g – 18 interior trim daewoo m-150 bl2 special tools and equipment special tools table d109e101 km-475-b trim remover.

  • Page 1031: Section 9H

    Daewoo m-150 bl2 section 9h seats caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the ...

  • Page 1032: Description And Operation

    9h – 2 seats daewoo m-150 bl2 description and operation seats important: do not attempt to change the designed seat position by altering the designed seat adjuster-to-floor pan anchor provisions or the seat adjuster-to-seat frame anchor provisions. Changing the seat position could af- fect the perfo...

  • Page 1033: Component Locator

    Seats 9h – 3 daewoo m-150 bl2 component locator front seat d109b402 1. Head restraint 2. Guide sleeve 3. Seatback 4. Seatback frame 5. Seat cushion 6. Seat cushion frame 7. Recliner 8. Recliner knob 9. Seat side cover 10. Guide rail.

  • Page 1034

    9h – 4 seats daewoo m-150 bl2 rear seat d19b403a 1. Rear seatback cushion 2. Rear seatback frame 3. Rear seat hinge 4. Rear seat lock 5. Rear seat cushion 6. Seat release knob 7. Eyelet 8. Seat back hinge 9. Rear cushion pull loop.

  • Page 1035: Repair Instructions

    Seats 9h – 5 daewoo m-150 bl2 repair instructions on–vehicle service d109b528 front seats removal procedure 1. Disconnect the negative battery cable. 2. Remove the front seat. D remove the bolts (1). D disconnect the seat belt warning lamp connector (2). D remove the seat (3). 23–28 n s m d19b529a i...

  • Page 1036

    9h – 6 seats daewoo m-150 bl2 d109b531 installation procedure 1. Install the head restraint into the guide sleeves. Press down in order to engage the stop pin. D109b532 front seatback removal procedure 1. Disconnect the negative battery. 2. Remove the front seat assembly. Refer to “front seats” in t...

  • Page 1037

    Seats 9h – 7 daewoo m-150 bl2 d109b535 2 1 6. Remove the seatback bolt from the seat cushion (1). 7. Remove the seatback assembly (2). D109b536 installation procedure 1. Install the seatback assembly with the bolt. 2. Install the recliner with the bolts 3. Install the seatback cover with the hog rin...

  • Page 1038

    9h – 8 seats daewoo m-150 bl2 d109b533 5. Remove the recliner cover. D remove the screws (1). D remove the recliner cover (2). D109b538 6. Remove the seat cushion. D remove the recliner bolts on the seat cushion (1). D remove the seatback bolt (2). D remove the seat cushion (3). D109b536 installatio...

  • Page 1039

    Seats 9h – 9 daewoo m-150 bl2 d109b539 front seats guide rail removal procedure 1. Disconnect the negative battery cable. 2. Remove the front seat assembly. Refer to “front seats” in this section. 3. Remove the guide rail from the seat. D remove the bolts (1). D remove the guide rail (2). D109b540 i...

  • Page 1040

    9h – 10 seats daewoo m-150 bl2 d109b541 installation procedure 1. Install the seat cushion cover with the hog rings. D109b540 2. Install the guide rail with the bolts. 3. Install the front seat cushion. Refer to “front seat cushion” in this section. 4. Connect the negative battery cable. D109b542 re...

  • Page 1041

    Seats 9h – 11 daewoo m-150 bl2 d109b544 rear seat cushion removal procedure 1. Remove the rear seat cushion. D remove the bolts (1). D lift and remove the rear seat cushion (2). D19b546a 23 – 28 n s m installation procedure 1. Install the rear seat cushion with the bolts. Tighten tighten the rear se...

  • Page 1042

    9h – 12 seats daewoo m-150 bl2 d109b720 installation procedure 1. Install the lock to the seatback frame with the bolts. 2. Install the rear seatback cover to the seatback frame. D109b718 3. Install the lock knob to the seatback. 4. Install the rear seatback assembly. Refer to “rear seatback” in thi...

  • Page 1043: Specifications

    Seats 9h – 13 daewoo m-150 bl2 specifications fastener tightening specifications ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ application ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ n s m ÁÁÁÁÁÁ ÁÁÁÁÁÁ lb-ft ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ lb-in ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ front seat bolts (both) ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 23 – 28 ÁÁÁÁÁÁ ÁÁÁÁÁÁ 17 – ...

  • Page 1044: Section 9I

    Daewoo m-150 bl2 section 9i waterleaks table of contents diagnostic information and procedures 9i-2 . . . . . . Waterleak diagnosis 9i-2 . . . . . . . . . . . . . . . . . . . . . . . . Repair instructions 9i-5 . . . . . . . . . . . . . . . . . . . . . . . . . . On-vehicle service 9i-5 . . . . . . . ...

  • Page 1045

    9i – 2 waterleaks daewoo m-150 bl2 diagnostic information and procedures waterleak diagnosis the repair of waterleaks in the body requires proper testing and diagnosis. Repair waterleaks by adjusting the misaligned parts and using the proper repair materi- als. First, determine what conditions cause...

  • Page 1046

    Waterleaks 9i – 3 daewoo m-150 bl2 3. Perform the watertest stand leak test. Refer to “wa- tertest stand specifications” in this section. 4. If the local water pressure does not allow the required water pressure of 155 kpa (22.5 psi), move both stands closer to the vehicle so that the water spray ov...

  • Page 1047

    9i – 4 waterleaks daewoo m-150 bl2 air hose test 1. Apply soapy water to the outside of the vehicle in the suspected leak area. 2. Blow air from inside the vehicle. The air pressure should not exceed 205 kpa (29.7 psi). 3. Determine the location of the leaks from the bubbles formed in the soapy wate...

  • Page 1048: Repair Instructions

    Waterleaks 9i – 5 daewoo m-150 bl2 repair instructions on–vehicle service d109a501 d109a502 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 t...

  • Page 1049

    9i – 6 waterleaks daewoo m-150 bl2 d109a504 6. Prime the trimmed area with the primer. 7. Using a sharp knife, trim off the uneven edges of the adhesive material around the leak 75 to 100 mm (3 to 4 inches) on both sides of the leak. D109a505 8. Allow the primer to dry for 5 minutes. 9. Apply the ad...

  • Page 1050: Specifications

    Waterleaks 9i – 7 daewoo m-150 bl2 specifications recommended materials for waterleak repairs ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ leak areas ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ repair materials ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ windshield, back window ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ur...

  • Page 1051: Section 9J

    Daewoo m-150 bl2 section 9j windnoise table of contents diagnostic information and procedures 9j-1 . . . . . Windnoise diagnosis 9j-1 . . . . . . . . . . . . . . . . . . . . . . . Repair instructions 9j-2 . . . . . . . . . . . . . . . . . . . . . . . . . On-vehicle service 9j-2 . . . . . . . . . . ....

  • Page 1052: Repair Instructions

    9j – 2 windnoise daewoo m-150 bl2 repair instructions on-vehicle service 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...

  • Page 1053: Section 9K

    Daewoo m-150 bl2 section 9k squeaks and rattles table of contents diagnostic information and procedures 9k-1 . . . . . Squeak and rattle diagnosis 9k-1 . . . . . . . . . . . . . . . Repair instructions 9k-3 . . . . . . . . . . . . . . . . . . . . . . . . . On-vehicle service 9k-3 . . . . . . . . . ....

  • Page 1054

    9k – 2 squeaks and rattles daewoo m-150 bl2 squeak and rattle diagnosis (cont’d) condition probable cause correction squeak coming from console when shifting manual transaxle (condition occurs in cold weather with a cold engine) d the faulty manual transaxle control lever lower boot. D move the cont...

  • Page 1055: Repair Instructions

    Squeaks and rattles 9k – 3 daewoo m-150 bl2 repair instructions on–vehicle service squeak and rattle repair squeaks and rattles are caused by the unwanted move- ment between parts of a vehicle. There are three means to prevent squeaks or rattles. D attach the parts securely so that there is no rela-...

  • Page 1056: Section 9L

    Daewoo m-150 bl2 section 9l glass and mirrors caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and da...

  • Page 1057: Description And Operation

    9l – 2 glass and mirrors daewoo m-150 bl2 description and operation stationary glass stationary glass consists of all the glass on the vehicle which is immovable within its frame, such as the wind- shield glass, the back glass, and the inside rearview mirror. Inside rearview mirror the inside rearvi...

  • Page 1058: Components Locator

    Glass and mirrors 9l – 3 daewoo m-150 bl2 components locator glass and mirror d19e401b 1. Windshield molding 2. Windshield 3. Inside rearview mirror 4. Rear window glass 5. Rear window glass damping 6. Outside rearview mirror (manual) 7. Outside rearview mirror cover 8. Outside rearview mirror trim ...

  • Page 1059

    9l – 4 glass and mirrors daewoo m-150 bl2 diagnostic information and procedures testing rear window defogger grid line d109e301 if it has been observed during use that a grid line is inop- erative, the following procedure can be used to find the break. If none of the grid lines is operating, a full ...

  • Page 1060: Repair Instructions

    Glass and mirrors 9l – 5 daewoo m-150 bl2 repair instructions on–vehicle service d19e501 windshield tool 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 mirro...

  • Page 1061

    9l – 6 glass and mirrors daewoo m-150 bl2 d19e504 installation procedure 1. Install the new weatherstrip to the windshield. D19e505 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 ...

  • Page 1062

    Glass and mirrors 9l – 7 daewoo m-150 bl2 d19e508a 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 re...

  • Page 1063

    9l – 8 glass and mirrors daewoo m-150 bl2 d109e511 installation procedure 1. Apply tape to the new weatherstrip and the rear win- dow to hold the weatherstrip in place. 2. Apply adhesive primer to the rear window frame and the perimeter of the rear window. D109e512 3. Apply glass adhesive to the rea...

  • Page 1064

    Glass and mirrors 9l – 9 daewoo m-150 bl2 d19e509 rear window defogger grid line repair 1. Disconnect the negative battery cable. 2. Disconnect the rear window defogger electrical con- nector. D19e515 3. Inspect the rear window defogger grid lines. 4. Use steel wool to buff the grid lines that are t...

  • Page 1065

    9l – 10 glass and mirrors daewoo m-150 bl2 d109e518 10. Inspect the grid line repair area. If the repair appears discolored, apply a coating of tincture of iodine 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...

  • Page 1066

    Glass and mirrors 9l – 11 daewoo m-150 bl2 d19e522 4. Remove the glass run from the front door. D19e523 5. Remove the glass from the front door. D remove the glass retaining bolts (1). D remove the glass (2). Notice: make sure not to contact the glass with the body to prevent the paint damage. D19e5...

  • Page 1067

    9l – 12 glass and mirrors daewoo m-150 bl2 d19e521a 3. Install the division bar with the guide rail inside bolt, the guide rail outside bolt and the guide rail screw. 4. Install the outside rearview mirror. Refer to “glass and mirrors” in this section. 5. Install the front door seal trim. Refer to s...

  • Page 1068

    Glass and mirrors 9l – 13 daewoo m-150 bl2 d109e526 2. Install the division bar with the guide rail inside bolt, the guide rail outside bolt and the guide rail screw. 3. Inside the outside rearview mirror. Refer to “outside rearview mirror” in this section. 4. Install the front door seal trim. Refer...

  • Page 1069

    9l – 14 glass and mirrors daewoo m-150 bl2 d19e528 installation procedure 1. Install the inside rearview mirror with the screw. D19e529 outside rearview mirror (manual) removal procedure 1. Remove the outside rearview mirror cover from the outside rearview mirror. D19e530 2. Remove the outside rearv...

  • Page 1070

    Glass and mirrors 9l – 15 daewoo m-150 bl2 d29l001 outside rearview mirror (cable) removal procedure 1. Pry off the outside rearview mirror inside trim cover (1). 2. Remove the mirror adjusting lever mounting nuts (2). D109e529 3. Remove the outside rearview mirror cover from the outside rearview mi...

  • Page 1071

    9l – 16 glass and mirrors daewoo m-150 bl2 d109e529 outside rearview mirror (electric) removal procedure 1. Disconnect the negative battery cable. 2. Remove the outside rearview mirror cover from the outside rearview mirror. D209b108 3. Remove the outside rearview mirror. D remove the screws (1). D ...

  • Page 1072

    Glass and mirrors 9l – 17 daewoo m-150 bl2 special tools and equipment special tools table d109e102 j-24402 glass sealant remover.

  • Page 1073

    9l – 18 glass and mirrors daewoo m-150 bl2 schematic and routing diagrams rear window defogger d19e201b.

  • Page 1074: Section 9M

    Daewoo m-150 bl2 section 9m exterior trim table of contents description and operation 9m-2 . . . . . . . . . . . . . . . . . . Emblems and lettering 9m-2 . . . . . . . . . . . . . . . . . . . . . Mud guards 9m-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair instructions 9m-3 . ....

  • Page 1075: Description And Operation

    9m – 2 exterior trim daewoo m-150 bl2 description and operation emblems and lettering the emblems and lettering on the vehicle are attached by adhesive. The company emblem appears on the hood. The lettering, which appears in several places on the body of the vehicle, features the model, the grade, a...

  • Page 1076: Repair Instructions

    Exterior trim 9m – 3 daewoo m-150 bl2 repair instructions on–vehicle service d109e586 roof molding removal procedure 1. Remove the roof molding from the plastic clips (1). D109e587 installation procedure 1. Press the roof molding onto the plastic clips. D19e588a rear spoiler removal procedure 1. Ope...

  • Page 1077

    9m – 4 exterior trim daewoo m-150 bl2 d19e589a 3. Remove the rear spoiler from the tailgate. D remove the nuts (1). D remove the rear spoiler (2). D19e590a installation procedure 1. Install the rear spoiler on the tailgate with the nuts. 2. Install the spoiler seals. D209b109 front bumper spacer rem...

  • Page 1078

    Exterior trim 9m – 5 daewoo m-150 bl2 d209b111 tailgate handle removal procedure 1. Disconnect the negative battery cable. 2. Open the tailgate. 3. Remove the tailgate lock cylinder. Refer to section 9p, doors. 4. Remove the license plate lamps. Refer to section 9b, lighting systems. 5. Remove the t...

  • Page 1079: Section 9N

    Daewoo m-150 bl2 section 9n frame and underbody table of contents description and operation 9n-2 . . . . . . . . . . . . . . . . . . General body construction 9n-2 . . . . . . . . . . . . . . . . . Transaxle under covers 9n-2 . . . . . . . . . . . . . . . . . . . . Repair instructions 9n-3 . . . . ....

  • Page 1080: Description And Operation

    9n – 2 frame and underbody daewoo m-150 bl2 description and operation general body construction this vehicle is constructed with a unitized body which in- corporates integral front and rear frame side rails. The front suspension lower control arms are bolted to and retained by supports, one each on ...

  • Page 1081: Repair Instructions

    Frame and underbody 9n – 3 daewoo m-150 bl2 repair instructions on–vehicle service alignment checking an accurate method of determining the alignment of the underbody uses a measuring tram gauge. The tram gauge set used to perform the recommended measuring checks must include a vertical pointer able...

  • Page 1082: Specifications

    9n – 4 frame and underbody daewoo m-150 bl2 specifications underbody dimensions unit: mm (in.) dbdm118a.

  • Page 1083

    Frame and underbody 9n – 5 daewoo m-150 bl2 unit: mm (in.) dbdm119a unit: mm (in.) dbdm120

  • Page 1084

    9n – 6 frame and underbody daewoo m-150 bl2 unit: mm (in.) dbdm117a.

  • Page 1085: Section 9O

    Daewoo m-150 bl2 section 9o bumpers and fascias table of contents description and operation 9o-2 . . . . . . . . . . . . . . . . . . Bumpers 9o-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component locator 9o-3 . . . . . . . . . . . . . . . . . . . . . . . . Bumpers and fasci...

  • Page 1086: Description And Operation

    9o – 2 bumpers and fascias daewoo m-150 bl2 description and operation bumpers the bumper systems are installed with the body color bumper and the general bumper according to the vehicle grade. The bumper systems are designed to sustain a collision into a fixed barrier at 4 km/h (2.5 mph) without dam...

  • Page 1087: Component Locator

    Bumpers and fascias 9o – 3 daewoo m-150 bl2 component locator bumpers and fascias d19c401a 1. Front towing cover 2. Front bumper 3. Front bumper impact beam 4. Front bumper reinforcement 5. Rear bumper reinforcement 6. Rear bumper 7. Rear bumper bracket 8. Rear towing cover.

  • Page 1088: Repair Instructions

    9o – 4 bumpers and fascias daewoo m-150 bl2 repair instructions on–vehicle service d19c501a front bumper fascia removal procedure 1. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. 3. Remove the front wheels. 4. Remove the front wheel house splash shields. D remove ...

  • Page 1089

    Bumpers and fascias 9o – 5 daewoo m-150 bl2 d19c504a 7. Lower the vehicle. 8 remove the front bumper spacer from the bumper. Refer to section 9m, exterior trim. 9. Remove the front bumper fascia. D remove the bolts (1). D remove the clips (2). D remove the front bumper fascia (3). 10 remove the fron...

  • Page 1090

    9o – 6 bumpers and fascias daewoo m-150 bl2 d19c508a 3. Remove the impact bar. D remove the nuts (1). D remove the impact bar (2). D19c509a installation procedure notice: dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premat...

  • Page 1091

    Bumpers and fascias 9o – 7 daewoo m-150 bl2 d19c511a 3. Remove the fascia bolts from the rear bumper brack- et. D19c512a 4. Lower the vehicle. 5. Remove the fascia. D remove the nuts in the luggage compartment (1). D remove the screws (2). D remove the fascia (3). D19c513a installation procedure not...

  • Page 1092

    9o – 8 bumpers and fascias daewoo m-150 bl2 d19c515a rear bumper bracket removal procedure 1. Raise and suitably support the vehicle. 2. Remove the rear bumper bracket. D remove the bolts (1). D remove the bracket (2). D19c516a installation procedure 1. Install the rear bumper bracket with the bolts...

  • Page 1093: Section 9P

    Daewoo m-150 bl2 section 9p doors caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the ...

  • Page 1094: Description And Operation

    9p – 2 doors daewoo m-150 bl2 description and operation door lock striker the front and the rear door lock strikers each consist of a striker with two screws threaded into a floating cage plate in the b-pillars and c-pillars. The door is secured in the closed position when the door lock fork snaps o...

  • Page 1095: Component Locator

    Doors 9p – 3 daewoo m-150 bl2 component locator front door d19c403a.

  • Page 1096

    9p – 4 doors daewoo m-150 bl2 1. Seal trim 2. Lock button 3. Trim panel 4. Pocket handle (deluxe type) 5. Pocket handle bracket (deluxe type) 6. Inside handle 7. Manual regulator handle 8. Pocket handle (standard type) 9. Door speaker cover 10. Map pocket 11. Contact switch 12. Striker 13. Opening w...

  • Page 1097

    Doors 9p – 5 daewoo m-150 bl2 rear door d19c404a.

  • Page 1098

    9p – 6 doors daewoo m-150 bl2 1. Seal trim 2. Lock button 3. Trim panel 4. Pocket handle (deluxe type) 5. Pocket handle bracket (deluxe type) 6. Inside handle 7. Manual regulator handle 8. Pocket handle (standard type) 9. Striker 10. Opening weatherstrip 11. Door weatherstrip 12. Glass run 13. Inter...

  • Page 1099: Repair Instructions

    Doors 9p – 7 daewoo m-150 bl2 repair instructions on–vehicle service d109e521 front door glass run removal procedure 1. Remove the front door seal trim from the front door. Refer to “door seal trim” in this section. 2. Remove the outside rearview mirror from the front door. Refer to section 9l, glas...

  • Page 1100

    9p – 8 doors daewoo m-150 bl2 d109c566 rear door glass run removal procedure 1. Remove the inside channel weatherstrip from the rear door. Refer to section 9g, interior trim. 2. Remove the outside channel weatherstrip from the rear doors. Refer to section 9g, interior trim. 3. Remove the rear door t...

  • Page 1101

    Doors 9p – 9 daewoo m-150 bl2 d109c570 door lock striker removal procedure 1. Remove the door lock striker. D remove the screws (1). D remove the door lock striker (2). D109c571 installation procedure notice: dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use t...

  • Page 1102

    9p – 10 doors daewoo m-150 bl2 d109c574 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 replacement becomes necessary, the door lock striker must be repla...

  • Page 1103

    Doors 9p – 11 daewoo m-150 bl2 d109c577 5. If a fore or aft adjustment is required, use the following steps: d remove the striker screws (1). D remove the spacer in order to move the striker to- ward the rear of the vehicle (2). D add a 2 mm (0.08 inch) spacer in order to move the striker toward the...

  • Page 1104

    9p – 12 doors daewoo m-150 bl2 the tailgate 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 allows the striker to be easily adjusted in or out and up or down. The tailgate is secu...

  • Page 1105

    Doors 9p – 13 daewoo m-150 bl2 d19c580a up and down adjustment 1. The tailgate must be properly aligned. 2. Close the tailgate until the lock fork contacts the strik- er. 3. Stand next to the tailgate opening and move the tail- gate slowly up and down, just touching the striker each time. D109c581 4...

  • Page 1106

    9p – 14 doors daewoo m-150 bl2 d109c584 4. Remove the front door lock. D remove the screws (1). D remove the front door lock (2). Important: disconnect the actuator connector, if equipped with the central door lock system. D109c585 installation procedure notice: dissimilar metals in direct contact w...

  • Page 1107

    Doors 9p – 15 daewoo m-150 bl2 d109c583 5. Disconnect the outside door handle rod from the door lock. A. Outside door handle rod. D109c586 6. Disconnect the door lock from the vehicle. D remove the screws (1). D remove the door lock (2). Important: disconnect the actuator connector if equipped with ...

  • Page 1108

    9p – 16 doors daewoo m-150 bl2 d109c588 central door lock actuator removal procedure 1. Disconnect the negative battery cable. 2. Remove the door seal trim. Refer to “door seal trim” in this section. 3. Remove the door lock assembly. Refer to “door lock” in this section. 4. Remove the actuator from ...

  • Page 1109

    Doors 9p – 17 daewoo m-150 bl2 d109c592 installation procedure 1. Install the tailgate lock with the screws. 2. Install the lock rod to the tailgate lock cylinder. 3. Install the tailgate trim panel. Refer to section 9g, in- terior trim. D109c593 inside door handle removal procedure 1. Removal the i...

  • Page 1110

    9p – 18 doors daewoo m-150 bl2 d109c596 installation procedure 1. Install the outside front door lock handle with the bolts. 2. Install the front door lock rods. 3. Connect the negative battery cable. D109c597 outside rear door handle removal procedure 1. Disconnect the negative battery cable. 2. Re...

  • Page 1111

    Doors 9p – 19 daewoo m-150 bl2 d109c600 installation procedure 1. Install the door lock cylinder with the clip. 2. Install the outside door handle. Refer to “outside front door handle” in this section. 3. Connect the negative battery cable. D109c601 manual window regulator removal procedure 1. Remov...

  • Page 1112

    9p – 20 doors daewoo m-150 bl2 d109c604 4. Remove the window motor from the window regula- tor. D remove the screws (1). D remove the window regulator (2). Caution: be careful what you are doing when sepa- rating the window motor and the window regulator. You may be hurt. D109c605 installation proce...

  • Page 1113

    Doors 9p – 21 daewoo m-150 bl2 d19c608a installation procedure notice: dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fastener to prevent premature corrosion. 1. Connect the body–to–door rubber grommet. 2. With the aid of another technician, lig...

  • Page 1114

    9p – 22 doors daewoo m-150 bl2 d19c611a installation procedure notice: dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fastener to prevent premature corrosion. 1.Connect the body–to–door rubber grommet. 2. With the aid of another technician, ligh...

  • Page 1115

    Doors 9p – 23 daewoo m-150 bl2 d19c614a installation procedure notice: dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fastener to prevent premature corrosion. 1. Connect the body–to–tailgate rubber grommet. 2. With the aid of another technician,...

  • Page 1116

    9p – 24 doors daewoo m-150 bl2 d109c616 installation procedure notice: dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fastener to prevent premature corrosion. 1. With the aid of another technician, install the hinge to the door and the body with...

  • Page 1117

    Doors 9p – 25 daewoo m-150 bl2 d109c620 installation procedure 1. Install the channel weatherstrip. D109c621 inside channel weatherstrip (deluxe) removal procedure 1. Remove the door trim. Refer to section 9g, interior trim. 2. Remove the channel weatherstrip from the door trim. D straighten the ret...

  • Page 1118

    9p – 26 doors daewoo m-150 bl2 d109c624 installation procedure 1. Press the outside channel weatherstrip onto the door. 2. Install the weatherstrip screw. D109c625 door weatherstrip removal procedure 1. Remove the door hold open link bolt. D109c626 2. Remove the door weatherstrip. D remove the clip ...

  • Page 1119

    Doors 9p – 27 daewoo m-150 bl2 d109c566 door seal trim removal procedure 1. Remove the door trim panel. Refer to section 9g, in- terior trim. 2. Remove the door seal trim. A. Door seal trim. B. Door pocket handle bracket. Important: in case of the deluxe trim, remove the door pocket handle bracket i...

  • Page 1120

    9p – 28 doors daewoo m-150 bl2 d109c631 installation procedure 1. Install the door opening weatherstrip to match the marking. 2. Install the rocker panel trim and the lower b–pillar panel trim. D109e543 manual window regulator handle removal procedure 1. Remove the window regulator handle. D using a...

  • Page 1121

    Doors 9p – 29 daewoo m-150 bl2 d19c635a installation procedure 1. Install the tailgate strut with the ball studs..

  • Page 1122

    9p – 30 doors daewoo m-150 bl2 schematic and routing diagrams power door locks (left–hand drive) d19c201b.

  • Page 1123

    Doors 9p – 31 daewoo m-150 bl2 power door locks (right–hand drive) d19c201s.

  • Page 1124

    9p – 32 doors daewoo m-150 bl2 power door locks (w/ anti–theft control : lhd) d19c201s.

  • Page 1125

    Doors 9p – 33 daewoo m-150 bl2 power door locks (w/ anti–theft control : rhd) d19c202s.

  • Page 1126

    9p – 34 doors daewoo m-150 bl2 power windows (front only) d19c202b.

  • Page 1127: Section 9Q

    Daewoo m-150 bl2 section 9q roof table of contents description and operation 9q-2 . . . . . . . . . . . . . . . . . . Roof 9q-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual sunroof 9q-2 . . . . . . . . . . . . . . . . . . . . . . . . . . Sun visors 9q-2 . . . . . ...

  • Page 1128: Description And Operation

    9q – 2 roof daewoo m-150 bl2 description and operation roof the roof is a one-piece painted metal unit which incorpo- rates a single, solid headliner and two moldings, one on each side of the vehicle’s roof. The moldings, which enclose and hide the roof rail seams, are serviceable as individual unit...

  • Page 1129: Component Locator

    Roof 9q – 3 daewoo m-150 bl2 component locator roof d19c402b 1. Sunroof handle 2. Sunroof screen 3. Sunroof screen seal 4. Sunroof upper frame 5. Roof seal 6. Sunroof lower frame 7. Sunroof cover 8. Roof rail 9. Rear spoiler 10. Roof molding 11. Roof rack bracket 12. Roof rack pad 13. Cap 14. Roof r...

  • Page 1130: Repair Instructions

    9q – 4 roof daewoo m-150 bl2 repair instructions on–vehicle service d109c555 formed headliner removal procedure 1. Disconnect the negative battery cable. 2. Remove the sun visors. Refer to “sun visors” in this section. 3. Remove the interior courtesy lamp. Refer to section 9b, lighting systems. 4. P...

  • Page 1131

    Roof 9q – 5 daewoo m-150 bl2 d109c557 manual sunroof removal procedure 1. Remove the sunroof screen. D remove the clips (1). D remove the lock (2). D remove the screen (3). D109c558 2. Remove the inside sunroof molding in the passenger compartment. A. Inside sunroof molding. D109c559 3. Remove the l...

  • Page 1132

    9q – 6 roof daewoo m-150 bl2 d19c561a installation procedure 1. Install the upper sunroof frame. 2. Install the lower sunroof frame with the screws (a). 3. Install the inside sunroof molding. 4. Install the screen with the clips and the lock. Tighten tighten the screws to 3 n s m (27 lb-in). Notice:...

  • Page 1133

    Roof 9q – 7 daewoo m-150 bl2 d109c565 installation procedure 1. Install the passenger assist handle or the coat hook to the headliner with the screws..

  • Page 1134: Specifications

    9q – 8 roof daewoo m-150 bl2 specifications fastener tightening specifications ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ application ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ n s m ÁÁÁÁÁÁ ÁÁÁÁÁÁ lb-ft ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ lb-in ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ sunroof frame screws ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 3 ÁÁÁ...

  • Page 1135: Section 9R

    Daewoo m-150 bl2 section 9r body front end table of contents description and operation 9r-2 . . . . . . . . . . . . . . . . . . Body front end 9r-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair instructions 9r-3 . . . . . . . . . . . . . . . . . . . . . . . . . On-vehicle service 9r-3...

  • Page 1136: Description And Operation

    9r – 2 body front end daewoo m-150 bl2 description and operation body front end this vehicle has a unitized body with a frame assembly supporting the engine and the transaxle. The fender panels and the radiator support are also integral parts of the body..

  • Page 1137: Repair Instructions

    Body front end 9r – 3 daewoo m-150 bl2 repair instructions on–vehicle service d109c517 lubrication the hood hinges and the locking mechanisms require periodic lubrication for proper operation. Refer to sec- tion 0b, general information for the specific types and intervals of lubrication. D109c518 fa...

  • Page 1138

    9r – 4 body front end daewoo m-150 bl2 d109c520 front end sealing all locations where waterleaks may occur are sealed during production with high quality, durable sealers. If it becomes necessary to reseal specific areas, use a high quality sealer of medium-bodied consistency which will retain its f...

  • Page 1139

    Body front end 9r – 5 daewoo m-150 bl2 d109c523 2. Install the cowl vent grille with the screws and the clips. 3. Install the wiper arm assembly. Refer to section 9d, wiper/washer systems. D109c524 hood removal procedure important: install the protective coverings over the fenders and the windshield...

  • Page 1140

    9r – 6 body front end daewoo m-150 bl2 d19c527a 3. Remove the bolts on the top of the fender. A. Fender upper mounting bolt. D109c528 4. Remove the hood hinge. D remove the bolts (1). D remove the hood hinge (2). D109c529 installation procedure notice: dissimilar metals in direct contact with each o...

  • Page 1141

    Body front end 9r – 7 daewoo m-150 bl2 d109c531 3. Remove the hood prop rod from the hood prop. A. Hood prop rod. D109c532 installation procedure 1. Install the hood prop rod to the hood prop. 2. Install the hood prop to the hood with the pins. D109c533 hood latch removal procedure 1. Open the hood....

  • Page 1142

    9r – 8 body front end daewoo m-150 bl2 d109c535 hood latch release lever (left–hand drive shown, right–hand drive similar) removal procedure 1. Remove the hood latch nut into the instrument panel. A. Hood latch nut. D109c536 2. Remove the hood latch release lever. D disconnect the cable (1). D remov...

  • Page 1143

    Body front end 9r – 9 daewoo m-150 bl2 d109c538 hood latch release cable (left–hand drive shown, right–hand drive similar) removal procedure 1. Remove the hood latch release cable from the instru- ment panel. Refer to “hood latch release lever” in this section. 2. Push the cable toward the engine co...

  • Page 1144

    9r – 10 body front end daewoo m-150 bl2 d19c540a 3. Remove the bolt at the base of the fender. A. Fender mounting lower bolt. 4. Open the front door. Remove the bolt on the a–pillar. B. Fender mounting bolt. D19c541a 5. Remove the screws on the side of the front bumper fascia. A. Bumper fascia side ...

  • Page 1145

    Body front end 9r – 11 daewoo m-150 bl2 d19c544a 11. Remove the bolts along the top of the fender. A. Bolt. 12. Remove the fender. B. Fender. D19c527a installation procedure 1. Install the fender. Notice: dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the c...

  • Page 1146: Section 9S

    Daewoo m-150 bl2 section 9s body rear end table of contents description and operation 9s-2 . . . . . . . . . . . . . . . . . . Fuel filler door 9s-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair instructions 9s-3 . . . . . . . . . . . . . . . . . . . . . . . . . On-vehicle service 9s-...

  • Page 1147: Description And Operation

    9s – 2 body rear end daewoo m-150 bl2 description and operation fuel filler door the fuel filler door attaches to the fuel tank pocket on the right side of the vehicle..

  • Page 1148: Repair Instructions

    Body rear end 9s – 3 daewoo m-150 bl2 repair instructions on–vehicle service d109c546 fuel filler door removal procedure 1. Pull the fuel filler door opening lever and open the fuel filler door. 2. Remove the fuel filler door. D remove the bolts (1). D remove the fuel filler door (2). D109c547 insta...

  • Page 1149

    9s – 4 body rear end daewoo m-150 bl2 d109c549 3. Pry off the lower b–pillar trim panel. Refer to section 9g, interior trim. 4. Pry off the rear rocker trim panel. Refer to section to 9g, interior trim. 5. Pry off the luggage compartment wheelhouse trim panel. Refer to section to 9g, interior trim. ...

  • Page 1150

    Body rear end 9s – 5 daewoo m-150 bl2 d109c551 7. Connect the fuel filler door remote cable to the han- dle. 8. Install the fuel filler door remote handle with the screws. D109c548 tailgate remote cable and handle (left–hand drive shown, right–hand drive similar) removal procedure 1. Pry off the fro...

  • Page 1151: Section 9T

    Remote keyless entry and anti–theft system 9t – i daewoo m-150 bl2 section 9t remote keyless entry and anti-theft system table of contents description and operation 9t-2 . . . . . . . . . . . . . . . . . . Remote keyless entry and anti-theft system 9t-2 . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 1152: Blank

    9t – ii remote keyless entry and anti–theft system daewoo m-150 bl2 blank.

  • Page 1153: Section 9T

    Remote keyless entry and anti-theft system 9t – 1 daewoo m-150 bl2 section 9t remote keyless entry and anti-theft system caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical t...

  • Page 1154: Description And Operation

    9t – 2 remote keyless entry and anti-theft system daewoo m-150 bl2 description and operation remote keyless entry and anti-theft system the remote keyless entry and anti-theft system can per- form the following functions: d remotely lock and unlock the vehicle doors with a hand-held high-frequency t...

  • Page 1155

    Remote keyless entry and anti-theft system 9t – 3 daewoo m-150 bl2 autolocking (safety lock) the remote keyless entry system features an autolock- ing control. If the doors are unlocked with the remote transmitter when the control module/receiver is in the armed mode, the doors are automatically re-...

  • Page 1156: Repair Instructions

    9t – 4 remote keyless entry and anti-theft system daewoo m-150 bl2 repair instructions on-vehicle service d19c501a siren removal procedure 1. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. 3. Remove the front wheels. 4. Remove the front wheel house splash shield. D...

  • Page 1157

    Remote keyless entry and anti-theft system 9t – 5 daewoo m-150 bl2 password programming if a transmitter is lost or damaged, the control module/ receiver must be re-programmed to communicate with a new transmitter. The passwords recorded in the control module/receiver should not be deleted when powe...

  • Page 1158: Specifications

    9t – 6 remote keyless entry and anti-theft system daewoo m-150 bl2 specifications fastener tightening specifications application n s m lb-ft lb-in hood open switch mounting screw 8 – 71 siren bracket mounting bolt 22 16 – siren mounting screws 8 – 71.

  • Page 1159

    Remote keyless entry and anti-theft system 9t – 7 daewoo m-150 bl2 schematic and routing diagrams d209t000 rem o t e keyl ess ent r y and ant i- t hef t s yst em.

  • Page 1160: Blank

    9t – 8 remote keyless entry and anti-theft system daewoo m-150 bl2 blank.

  • Page 1161: Section 9T

    Immobilizer anti-theft system 9t – 9 daewoo m–150 bl2 section 9t immobilizer anti-theft system caution: disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting th...

  • Page 1162: Description And Operation

    9t – 10 immobilizer anti-theft system daewoo m–150 bl2 description and operation immobilizer system the purpose of the immobilizer system is to provide additional theft deterrence to the vehicle in which it is installed and to prevent it from being stolen or driven by unauthorized users. The verific...

  • Page 1163

    Immobilizer anti-theft system 9t – 11 daewoo m–150 bl2 the vin code is calculated by the immobilizer using a random generator. The vin code is transmitted from the immobilizer in the release message communication only incase of using an authorized key. Without an authorized key it is not possible to...

  • Page 1164

    9t – 12 immobilizer anti-theft system daewoo m–150 bl2 3. If the ecm doesn’t receive a response message with- in a defined time from beginning of the release time period or the ecm receives a no release answer → the ecm enters the blocked state, which causes the activation of the immobilization acti...

  • Page 1165

    Immobilizer anti-theft system 9t – 13 daewoo m–150 bl2 diagnostic information and procedures immobilizer system (fenix 5mr) the immobilizer anti-theft system requires diagnosis when it is not possible to start the engine. If the no-start condition occurs because of the immobilizer system, a diagnost...

  • Page 1166

    9t – 14 immobilizer anti-theft system daewoo m–150 bl2 d19t002b diagnostic trouble code (dtc) 1600 ecm immobilizer error (no answer) circuit description when the ignition is turned on, the key is tested by the immobilizer anti-theft system. While the key code is be- ing read by the immobilizer contr...

  • Page 1167

    Immobilizer anti-theft system 9t – 15 daewoo m–150 bl2 dtc 1600 – ecm immobilizer error (no answer) step action value yes no 1 connect the scan tool using the following procedure: 1. Insert the cartridge into the scan tool. 2. Turn the ignition switch to the off position. 3. Connect the scan tool to...

  • Page 1168

    9t – 16 immobilizer anti-theft system daewoo m–150 bl2 d19t002b diagnostic trouble code (dtc) 1601 ecm immobilizer error (incorrect answer) circuit description when the ignition is turned on, the key is tested by the immobilizer anti-theft system. While the key code is be- ing read by the immobilize...

  • Page 1169

    Immobilizer anti-theft system 9t – 17 daewoo m–150 bl2 dtc 1601 – ecm immobilizer error (incorrect answer) step action value yes no 1 connect the scan tool using the following procedure: 1. Insert the cartridge into the scan tool. 2. Turn the ignition switch to the off. 3. Connect the scan tool to t...

  • Page 1170

    9t – 18 immobilizer anti-theft system daewoo m–150 bl2 d19t002b diagnostic trouble code (dtc) 1602 ecm immobilizer error (ecm locked) circuit description when the ignition is turned on, the key is tested by the immobilizer anti-theft system. While the key code is be- ing read by the immobilizer cont...

  • Page 1171

    Immobilizer anti-theft system 9t – 19 daewoo m–150 bl2 dtc 1602 – ecm immobilizer error (ecm locked) step action value yes no 1 connect the scan tool using the following procedure: 1. Insert the cartridge into the scan tool. 2. Turn the ignition switch to the off. 3. Connect the scan tool to the dat...

  • Page 1172

    9t – 20 immobilizer anti-theft system daewoo m–150 bl2 d209t002 diagnostic trouble code (p) 1628 (sirius d3) ecm immobilizer error (no successful communication) circuit description when the ignition is turned on, the key is tested by the immobilizer anti-theft system. While the key code is be- ing r...

  • Page 1173

    Immobilizer anti-theft system 9t – 21 daewoo m–150 bl2 p 1628 – ecm immobilizer error (no successful communication) step action value yes no 1 connect the scan tool using the following procedure: 1. Insert the cartridge into the scan tool. 2. Turn the ignition switch to the off position. 3. Connect ...

  • Page 1174

    9t – 22 immobilizer anti-theft system daewoo m–150 bl2 d209t002 diagnostic trouble code (p) 1629 (sirius d3) ecm immobilizer error (incorrect answer) circuit description when the ignition is turned on, the key is tested by the immobilizer anti-theft system. While the key code is be- ing read by the ...

  • Page 1175

    Immobilizer anti-theft system 9t – 23 daewoo m–150 bl2 p 1629 – ecm immobilizer error (incorrect answer) step action value yes no 1 connect the scan tool using the following procedure: 1. Insert the cartridge into the scan tool. 2. Turn the ignition switch to the off. 3. Connect the scan tool to the...

  • Page 1176

    9t – 24 immobilizer anti-theft system daewoo m–150 bl2 key status errors (fenix 5mr) the following key status messages may be shown on the scan tool after commanding first key cod- ing and key add: d ignition off status. This message informs the technician that the ignition is off during the key cod...

  • Page 1177

    Immobilizer anti-theft system 9t – 25 daewoo m–150 bl2 communication between immobilizer control unit and test equipment (fenix 5mr) 1. Connect the test equipment as described in the scan tool equipment manual. 2. If communication between the scan tool and the test equipment was unsuccessful, wait 3...

  • Page 1178: Repair Instructions

    9t – 26 immobilizer anti-theft system daewoo m–150 bl2 repair instructions on-vehicle service key coding procedure 1. Install the immobilizer control unit cartridge in the scan tool. 2. Turn the ignition off 3. Connect the scan tool. 4. Turn the ignition on with the key to be coded. 5. Enter the fou...

  • Page 1179

    Immobilizer anti-theft system 9t – 27 daewoo m–150 bl2 6. Turn the ignition off and on again, but do not crank or start the engine. The ecm will reset the ecm id code to match the new id code that was calculated and sent by the immobilizer control unit when the ignition was first turned on after the...

  • Page 1180

    9t – 28 immobilizer anti-theft system daewoo m–150 bl2 d29t002 installation procedure 1. Install the detection coil by pressing it onto the lock cylinder until it snaps in place. 2. Connect the two-pin connector to the immobilizer. D105a505 3. Install the steering column covers with the screws. Refe...

  • Page 1181

    Immobilizer anti-theft system 9t – 29 daewoo m–150 bl2 d29t004 installation procedure after replacing the immobilizer control unit, the keys must be re-authorized using the key coding procedure. Refer to “key coding procedure” in this section. Also, the electronic control module (ecm) identification...

  • Page 1182: Specifications

    9t – 30 immobilizer anti-theft system daewoo m–150 bl2 specifications fastener tightening specifications ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ application ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ n s m ÑÑÑÑÑÑ ÑÑÑÑÑÑ lb-ft ÑÑÑÑÑÑÑ ÑÑÑÑÑÑÑ lb-in immobilizer control unit mounting bolts 4 – 35.

  • Page 1183

    Immobilizer anti-theft system 9t – 31 daewoo m–150 bl2 schematic and routing diagrams d19t001b im m o bi l iz e r ant i- t h ef t syst em.

  • Page 1184

    9t – 32 immobilizer anti-theft system daewoo m–150 bl2 schematic and routing diagrams d209t001 remote keyless entr y and immobilizer anti-theft system.