acc DAEWOO LACETTI 2004 Service Repair Manual

7B – 34IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
COMPRESSOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Discharge and recover the refrigerant. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.
3. Remove the discharge hose mounting nut.
4. Lift the discharge hose mounting block and the suc-
tion hose from the compressor.
5. Raise and suitably support the vehicle.
6. Remove the engine under cover. Refer to Section
9N, Frame and Underbody.
7. Remove the accessory drive belt.
8. Disconnect the electrical connector at the compres-
sor.
9. Remove the compressor–to–bracket bolts. (1.4
DOHC shown, others similar)
10. Remove the compressor.
11. Drain the oil from the compressor into a container.
Measure the amount of the oil that is drained. Then
discard the used oil.
Installation Procedure
1. Add oil to the new compressor. Use the exact
amount of oil that you drained from the old com-
pressor.
2. Install the compressor.
3. Install the compressor–to–bracket mounting bolts.
Tighten
(1.4 DOHC, 1.6 DOHC only)
Tighten the upper compressor–to–bracket mounting
bolts(M8) to 25 NSm (18 lb–ft).
Tighten the lower compressor–to–bracket mounting
bolts(M10) to 45 NSm (33 lb–ft).

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 35
DAEWOO V–121 BL4
Tighten
(1.8 DOHC, 2.0 DOHC only)
Tighten the front compressor–to–bracket mounting
bolts to 35 NSm (26 lb–ft).
Tighten the rear compressor–to–bracket mounting
bolts to 20 NSm (15 lb–ft).
4. Install new sealing washers to the suction hose and
the discharge hose mounting.
5. Connect the electrical connector at the compressor.
6. Install the accessory drive belt.
7. Install the engine under cover. Refer to Section 9N,
Frame and Underbody.
8. Lower the vehicle.
9. Place the suction hose into its cavity in the com-
pressor and install the discharge hose mounting
block to clamp it into place. Hold this all together
while tightening the retaining nut.
Tighten
Tighten the refrigerant discharge hose block–to–
compressor retaining nut to 33 NSm (24 lb–ft).
10. Connect the negative battery cable.
11. Evacuate and recharge the A/C system. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.
CONDENSER
Removal Procedure
1. Disconnect the negative battery cable.
2. Discharge and recover the refrigerant. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System”in this section.
3. Remove the front bumper. Refer to Section 9O,
Bumpers and Fascias.
4. Remove the discharge hose block–to–condenser
retaining nut.
5. Remove the discharge hose from the condenser.
6. Remove the liquid pipe block–to–receiver–dryer
cretaining nut.
7. Remove the liquid pipe from the receiver–dryer.

7B – 46IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
5. Use the snap ring pliers J–5403 to install the shaft
seal retaining ring with its flat side against the seal.
6. Remove any excess oil around the shaft and the
inside of the compressor housing neck.
7. Install the clutch plate and hub assembly. Refer to
”Clutch Plate and Hub Assembly” in this section.
8. Reposition the compressor in its mounting.
9. Adjust the tension on the serpentine accessory
drive belt.
10. Connect the negative battery cable.
11. Evacuate and recharge the A/C system. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.
12. Perform a leak test of the system. Refer to ”Leak
Testing the Refrigerant System” in this section.
CONTROL VALVE ASSEMBLY
Tools Required
J–5403 Snap Ring Pliers
Removal Procedure
1. Recover the refrigerant. Refer to ”Discharging,
Adding Oil, Evacuating, and Charging Procedures
for A/C System” in this section.
2. Remove the control valve retaining ring using the
snap ring pliers J–5403.
3. Remove the control valve assembly.
Installation Procedure
1. Coat all the O–rings with clean polyalkaline glycol
(PAG) oil.
2. Push the control valve in place using thumb pres-
sure.
3. Use the snap ring pliers J–5403 to install the valve
retaining ring. The high point of the curved sides
must be against the valve housing. Be sure the re-
taining ring is properly seated in the ring groove.
4. Evacuate and recharge the A/C system. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.

7B – 52IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
SYSTEM COMPONENTS–CONTROL
Controller
The operation of the A/C system is controlled by the
switches and the lever on the control head. The compres-
sor clutch and the blower are connected electrically to the
control head by a wiring harness. The blower circuit is
open in the OFF mode. Airflow is provided by the four
blower speeds available in the remaining modes. Cooled
and dehumidified air is available in the MAX, NORMAL,
BI–LEVEL, and DEFROST modes.
The temperature is controlled by the position of the tem-
perature knob on the control head. A cable connects this
knob to the temperature door, which controls the airflow
through the heater core. As the temperature knob is
moved through its range of travel, a sliding clip on the
cable at the temperature valve connection should assume
a position ensuring that the temperature door will seat in
both extreme positions. The temperature door position is
independent of the mode control switch. The temperature
door on some models is controlled electrically, eliminating
the need for the temperature cable.
The electric engine cooling fan on some vehicles is not
part of the A/C control system; however, the fan is opera-
tional any time the A/C control is in the MAX, NORMAL,
or BI–LEVEL modes. Some models provide for engine
cooling fan operation when the controller is in the DE-
FROST mode. This added feature is part of the A/C con-
troller function and is aimed at preventing excessive com-
pressor head temperatures. It also allows the A/C system
to function more efficiently. On some models, the engine
cooling fan will be turned off during road speed conditions
above 56 km/h (35 mph), when the airflow though the con-
denser coil is adequate for efficient cooling. The operation
of the cooling fan is controlled by the powertrain control
module (PCM), or the engine control module (ECM),
through the cooling fan relay.
Pressure Transducer
The pressure transducer incorporates the functions of the
high–pressure and the low–pressure cutout switches
along with the fan cycling switch. The pressure transducer
is located in the high–side liquid refrigerant line near the
right front strut tower and the air filter assembly.
Wide–Open Throttle (WOT) Compressor
Cutoff
During full throttle acceleration on vehicles equipped with
multi–port injection (MPI), the throttle position sensor
(TPS) sends a signal to the PCM or the ECM, which then
controls the compressor clutch.
A/C Time Delay Relay
This relay on some vehicles controls the current to the en-
tire A/C system and provides a short delay of A/C opera-
tion upon start–up.
V5 COMPRESSOR–GENERAL
DESCRIPTION
Different vehicles with V5 compressors may exhibit differ-
ences in mounting and installation, but overhaul proce-
dures are similar.
Before removing the compressor or performing on–ve-
hicle repairs, clean the compressor connections and the
outside of the compressor.
Important : After removing a compressor from the vehicle
for servicing, drain the oil by removing the oil drain plug.
Also drain the oil from the suction and the discharge ports
to insure complete draining. Measure the amount of oil
drained, and record that amount. Discard the used oil and
add the same amount of new polyalkaline glycol (PAG) re-
frigerant oil to the compressor.
The compressor has been removed from the vehicle un-
less otherwise indicated.
Clean tools and a clean work area are important for proper
servicing. Keep dirt and foreign material from getting on or
into the compressor parts. Parts that are to be reassem-
bled should be cleaned with trichloroethane, naphtha,
stoddard solvent, kerosene, or equivalent solvents. Dry
the cleaned parts with clean dry air. Use only lint–free
cloths to wipe the parts.
V5 COMPRESSOR–DESCRIPTION OF
OPERATION
The V5 is a variable displacement compressor that can
match the automotive air conditioning (A/C) demand un-
der all conditions without cycling. The basic compressor
mechanism is a variable angle wobble–plate with five ax-
ially oriented cylinders. The center of control of the com-
pressor displacement is a bellows–actuated control valve
located in the rear head of the compressor. The control
valve senses compressor suction pressure.
The wobble–plate angle and the compressor displace-
ment are controlled by the crankcase suction pressure dif-
ferential. When the A/C capacity demand is high, the suc-
tion pressure will be above the control point. The valve will
maintain a bleed from crankcase to suction. With no
crankcase suction pressure differential, the compressor
will have maximum displacement.
When the A/C capacity demand is lower and the suction
pressure reaches the control point, the valve will bleed dis-
charge gas into the crankcase and close off a passage
from the crankcase to the suction plenum. The angle of the
wobble–plate is controlled by a force balance on the five
pistons. A slight elevation of the crankcase suction pres-
sure differential creates total force on the pistons resulting
in a movement about the wobbleplate pivot pin that re-
duces the plate angle.
The compressor has a unique lubrication system. The
crankcase suction bleed is routed through the rotating
wobble–plate for lubrication of the wobble–plate bearing.
The rotation acts as an oil separator which removes some

IAUTOMATIC TEMPERATURE CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7D – 33
DAEWOO V–121 BL4
SERVICEABLE COMPONENTS
COMMON HVAC COMPONENTS
Those components used in non–automatic systems are
covered in other sections of this manual.
Refer to Section 7A, Heating and Ventilation System for
the following procedures:
S Blower Motor.
S Heater Hoses.
S Blower Resistor.
S High–Blower Relay.
S Heater/Air Distributor Case Assembly (A/C Mod-
ule).
S Heater Core.
Refer to Section 7B, Manual Control Heating, Ventilation,
and Air Conditioning System, for the following proce-
dures:
S A/C Pressure Transducer.
S A/C Compressor Relay.
S Air Filter.
S A/C Expansion Valve.
S A/C High–Pressure Pipe Line.
S Evaporator Core.
S A/C Suction Hose Assembly.
S A/C Discharge Hose–Compressor to Condenser.
S Compressor.
S Condenser.
S Receiver–Dryer.
AUTOMATIC TEMPERATURE
CONTROL ASSEMBLY
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the center molding assembly. Refer to
Section 9E, Instrumentation/Driver Information.
3. Pull out the unit to gain access to the rear.
4. Disconnect the electrical connectors.
5. Remove the center molding assembly from the in-
strument panel.

7D – 40IAUTOMATIC TEMPERATURE CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
GENERAL INFORMATION
THE V5 SYSTEM
Refer to Section 7B, Manual Control Heating, Ventilation,
and Air Conditioning System,for general information de-
tails for the following:
S System Components – Functional.
S The V5 A/C System.
S V5 Compressor – Description of Operation.
S V5 Compressor – General Description.
SYSTEM COMPONENTS–CONTROL
Controller
The operation of the A/C system is controlled by the
switches on the control head. This console–mounted
heating and ventilation system contains the following
knobs and display:
Temperature Control Push Knobs
1. Raise the temperature of the air entering the ve-
hicle by pressing the top switch, with the red arrow
pointing upward.
2. Lower the temperature by pressing the bottom
switch, with the blue arrow pointing downward.
3. Actuate the air mix door by an electric motor.
4. Vary the mix of the air passing through the heater
core with the air bypassing the core.
Each press of a switch changes the set temperature by in-
crements of 0.5°C (1°F). This is shown in the temperature
window on the function display.
The Function Display
This is an LCD display indicating the status of the control
settings selected. Starting from the left end of the display,
the sections are as follows:
1. Temperature setting – Indicates the temperature set
with the temperature control knob.
2. Auto status – Indicates whether the system is oper-
ating in the full auto mode or the manual mode.
3. Defroster icon – Indicates manual selection of full
defrost mode.
4. Mode – Indicated by icon, the mode chosen by the
system in auto (or by the operator in manual) is
shown by an illumination arrow indicating the air
path.
5. A/C – A snowflake icon indicating whether the A/C
is ON or OFF.
6. Fan speed – Indicates the fan speed by illuminating
a bar based on the segment at the front, for low
speed, and adding additional segments in order up
to the fifth, for high speed.Eight Additional Push Knobs
1. Full defrost – Causes the mode motors to direct all
air to the windshield and aide window outlets for
maximum defrosting.
2. Air intake – Switches between fresh air intake, the
default, and recirculating air. Airflow arrows on the
display indicate the mode in effect.
3. Full Auto Switch – Maintains the set temperature
automatically. In this mode, the fully automatic tem-
perature control (FATC) system controls the follow-
ing:
S The air mix door motor.
S The mode door motor.
S The blower motor speed.
S The inlet air door motor.
S A/C ON/OFF.
4. OFF Switch – Turns the automatic air conditioning
and fan control off.
5. Mode Switch – Allows manual selection of the air-
flow direction.
S Selection is shown on the function display.
S Each time the mode switch is pressed, the next
function is displayed.
6. A/C Switch – Allows manual selection and control
of the air conditioning function.
7. Fan Control Switch – Allows manual selection
among five fan speeds.
8. Defogger Switch – Turns on the electric defogging
heater in the rear window and the outside rearview
mirrors, if the vehicle is equipped with heated mir-
rors.
Pressure Transducer
Pressure transducer switching incorporates the functions
of the high–pressure and the low–pressure cutout
switches along with the fan cycling switch. The pressure
transducer is located in the high–side liquid refrigerant line
behind the right strut tower, between the right strut tower
and the fire wall. The output from this pressure transducer
goes to the electronic control module (ECM), which con-
trols the compressor function based on the pressure sig-
nal.
Wide–Open Throttle (WOT) Compressor
Cutoff
During full–throttle acceleration, the throttle position sen-
sor (TPS) sends a signal to the ECM, which then controls
the compressor clutch.
High RPM Cutoff
As engine rpm approaches the maximum limit, the ECM
will disengage the compressor clutch until the engine
slows to a lower rpm.

SEAT BELTS 8A – 5
DAEWOO V–121 BL4
Installation Procedure
CAUTION : Failure to install the correct retractor
screw can cause the pretensioner seat belt to mal-
function in an accident, possibly resulting in person-
al injury.
Notice : Dissimilar metals in direct contact with each other
may corrode rapidly. Make sure to use the correct fasten-
ers to prevent premature corrosion.
1. Install the seat belt retractor with the bolt.
Tighten
Tighten the seat belt retractor bolt to 38 NSm (28 lb–
ft).
2. Install the seat belt retractor bracket with the screw.
Tighten
Tighten the seat belt bracket screw to 3 NSm (27 lb–
in).
3. Install the upper B–pillar seat belt anchor with the
bolt.
Tighten
Tighten the seat belt anchor bolt to 38 NSm (28 lb–ft).
4. Install the seat belt anchor plastic cap.
5. Install the lower B–pillar trim panel. Refer to Sec-
tion 9G, Interior Trim.
6. Install the lower B–pillar seat belt anchor with the
bolt.
Tighten
Tighten the seat belt anchor bolt to 38 NSm (28 lb–ft).
7. Install the seat belt anchor plastic cap.
FRONT SEAT BELT HEIGHT
ADJUSTER
Removal Procedure
1. Remove the upper B–pillar trim panel. Refer to
Section 9G, Interior Trim.
2. Remove the bolts and the seat belt height adjuster.

SEAT BELTS 8A – 9
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
DRIVER SEAT BELT WARNING
The driver’s safety belt incorporates a safety belt reminder
light in the instrument cluster to remind the driver if the
safety belt is not fastened when the the ignition is turned
ON.
THREE–POINT ELR FRONT SEAT
BELT WITH PRETENSIONER
The three–point emergency locking retractor (ELR) front
seat belt pretensioner is always unlocked, allowing the
passenger freedom of movement, except in emergencies
such as rapid deceleration, rapid acceleration, or hard cor-
nering maneuvers.
The front seat belt pretensioner contains an ignitor charge
and a gas generator to inflate the pretensioner. The pre-
tensioner also includes wiring and a connector. The con-
nector of the pretensioner contains a shorting bar which
short–circuits the pretensioner high circuit to the preten-
sioner low circuit when the connector is disconnected. The
shorting bar prevents current from traveling through the
pretensioner during servicing. The shorting bar disen-
gaged when the connecotr is connected.
The pretensioner is an electronically controlled pyrotech-
nical reactor which reduce seat belt slack when it is actived
with air bags.
The front seat belt pretensioner must be replaced after an
accident that cause its activation.
THREE–POINT CLR (ELR) REAR
OUTBOARD SEAT BELT
The rear outboard seating positions use the three–point
child locking retractor (CLR) or emergency locking retrac-
tor (ELR) seat belts. The three–point CLR (ELR) seat beltis always unlocked, allowing the passenger freedom of
movement, except in emergencies such as rapid decel-
eration, rapid acceleration, or hard cornering maneuvers.
OPERATIONAL AND FUNCTIONAL
CHECKS
CAUTION :
S Keep sharp objects and potentially damaging
objects away from the seat belts.
S Avoid bending or damaging any portion of the
buckle or the latch plate.
S Do not bleach or dye the belt webbing. Use
only mild soap and water in order to clean the
belts.
S When installing the seat belt anchor bolts and
the screws, start the bolts and the screws by
hand in order to prevent cross–threading.
S Do not attempt any repairs on the retractor
mechanisms or the covers. Replace any defec-
tive assemblies with new assemblies.
S Replace any belts that are cut or damaged in
any way.
1. Inspect all seat belt anchor bolts and the screws in
order to verify that they are secure.
2. Inspect the seat belt buckle. The buckle must lock
and unlock easily.
3. After inserting the latch into the buckle, tug sharply
on the belt. The buckle must remain locked.
4. Fully extend the shoulder belt portion to make sure
that there is no twisting or tears in the belt.
5. Let the shoulder belt retract fully. The belt should
retract easily.
CHILD SEAT TETHER ANCHOR
For notch back vehicle, there are three child seat tether
anchors located on the read deck lid sill plate. For hatch
back vehicle, there are three child seat fether anchors on
the lower rear tail member in the luggage compartment.
And there are 4 lower child anchors under the rear seat.
4 circular discs on the rear seat indicate the location of the
lower child anchors.

8B – 2ISUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
DAEWOO V–121 BL4
DTC 80 Driver Side Airbag Sensor Loop Is
Shorted To Power 8B–72. . . . . . . . . . . . . . . . . . . . . . .
DTC 81 Driver Side Airbag Sensor Loop Is
Shorted To Ground 8B–74. . . . . . . . . . . . . . . . . . . . . .
DTC 82 Driver Side Airbag Sensor Communication
Error 8B–76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 83 Driver Side Airbag Sensor Failure 8B–78. . .
DTC 84 Passenger Side Airbag Sensor Loop Is
Shorted To Power 8B–80. . . . . . . . . . . . . . . . . . . . . . .
DTC 85 Passenger Side Airbag Sensor Loop Is
Shorted To Ground 8B–82. . . . . . . . . . . . . . . . . . . . . .
DTC 86 Passenger Side Airbag Sensor
Communication Error 8B–84. . . . . . . . . . . . . . . . . . . .
DTC 87 Passenger Side Airbag Sensor Failure 8B–86
MAINTENANCE AND REPAIR8B–88 . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 8B–88. . . . . . . . . . . . . . . . . . . .
Disabling the Supplemental Inflatable
Restraints(SIR) 8B–88. . . . . . . . . . . . . . . . . . . . . . . . .
Enabling the Supplemental Inflatable
Restraints(SIR) 8B–88. . . . . . . . . . . . . . . . . . . . . . . . .
Handling, Installation and Diagnosis 8B–89. . . . . . . . .
Repairs and Inspections Required After an
Accident 8B–89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accident With Deployment Components
Replacements 8B–90. . . . . . . . . . . . . . . . . . . . . . . . . . Accident Without Deployment Component
Inspection 8B–90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensing and Diagnostic Module (SDM) 8B–90. . . . . .
Driver Airbag Module 8B–91. . . . . . . . . . . . . . . . . . . . . .
Clock Spring 8B–92. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clock Spring Alignment 8B–93. . . . . . . . . . . . . . . . . . . .
Passenger Airbag Module 8B–94. . . . . . . . . . . . . . . . . .
Side Airbag Sensor 8B–95. . . . . . . . . . . . . . . . . . . . . . .
Front Seat Belt Pretensioner 8B–95. . . . . . . . . . . . . . .
Airbag Module Deployment (Inside of Vehicle) 8B–95
Airbag Module Deployment (Outside of Vehicle) 8B–97
Deployed Airbag Module Disposal Procedure 8B–98.
SIR Wiring Repair 8B–99. . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION8B–100 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supplemental Inflatable Restraints(SIR) 8B–100. . . .
Airbag Modules 8B–100. . . . . . . . . . . . . . . . . . . . . . . . . .
Front Seat Belt Pretensioners 8B–101. . . . . . . . . . . . .
Sensing and Diagnostic Module (SDM) 8B–101. . . . .
Airbag Warning Lamp 8B–101. . . . . . . . . . . . . . . . . . . .
Clock Spring 8B–101. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Harness Connectors 8B–102. . . . . . . . . . . . . . .

SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B – 3
DAEWOO V–121 BL4
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescription
Airbag System Deployment Time<20ms
Detection Time<5ms
Operating Temperature–40°C~+85°C
Storage Temperature–40°C~+90°C
Voltage Range9~16 V
Current consumption5ms after ignition switch ON <1A
5ms
5sec<300Ma, after 5sec.<100Ma
Acceleration Range+/– 50g
Maximum Acceleration+/– 600g pulse
Voltage Ramp0.2~2.0 V/s
Energy Reservation150ms after battery disconnection
Inflator Ignition Energy4.3mj
Squib Resistance2.15 +/– 0.35Ω
Airbag Warning Lamp ON Time(When Ignition ON)6sec
FASTENER TIGHTENING SPECIFICATIONS
ApplicationN·mLb–FtLb–In
Clock Spring Retaining Screws3–27
Driver Airbag Module Mounting Bolts11–97
Passenger Airbag Module Mounting Bolts8–71
Sensing and Diagnostic Module(SDM) Mounting Bolts10–89
SPECIAL TOOLS
SPECIAL TOOLS TABLE
Scan Tool