heating DAEWOO LACETTI 2004 Service Owner's Manual

ENGINE EXHAUST 1G – 9
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
EXHAUST SYSTEM
Notice : When you are inspecting or replacing the 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
passenger compartment insulation and trim materials.
CAUTION : Check the complete exhaust system and
the nearby body areas and the trunk lid for broken,
damaged, missing, or mispositioned parts, open
seams, holes, loose connections, or other deteriora-
tion which could permit hazardous exhaust fumes to
seep into the trunk or the passenger compartment.
Dust or water in the trunk may be an indication of a
problem in one of these areas. Any defects should be
corrected immediately.
MUFFLER
If holes, open seams or any deterioration is discovered
upon inspection of the front muffler and pipe assembly, the
complete assembly should be replaced. The same proce-
dure is applicable to the rear muffler assembly.
Heat shields in the front and the rear muffler assembly
positions, as well as for the catalytic converter and the
connecting pipe, protect the vehicle and the environment
from high temperatures the exhaust system develops.
CATALYTIC CONVERTERS
Notice : The catalytic converter requires the use of un-
leaded fuel only, or damage to the catalyst will result.
The catalytic converters are emission control devices add-
ed to the exhaust system to reduce pollutants from the ex-
haust pipes.
The three–way catalyst has coatings which contain palla-
dium, platinum and rhodium, which simultaneouly lower
the levels of HC, CO and NOx.

TIRES AND WHEELS 2E – 5
DAEWOO V–121 BL4
UNIT REPAIR
ALLOY WHEEL POROSITY
Wheel repairs that use welding, heating or peening are not
approved.
1. Raise and suitably support the vehicle.
2. Remove the wheel. Refer to ”Wheel” in this sec-
tion.
CAUTION : To avoid serious injury, do not stand over
the tire when inflating, because the bead may break
when it snaps over the safety hump. Do not exceed
275 kPa (40 psi) of air pressure in any tire if the beads
are not seated. If 275 kPa (40 psi) of air pressure will
not seat the beads, deflate the tire. Relubricate the
beads. Reinflate the tire. Overinflation may cause the
bead to break and cause serious injury.
3. Locate leaking areas by inflating the tire to 345 kPa
(50 psi) and dipping the tire and wheel assembly
into a water bath.
4. Mark the leak areas and remove the tire from the
wheel.
5. Scuff the inside wheel surface at the leak area with
80–grit sandpaper. Clean the leak area with a gen-
eral–purpose cleaner.
6. Apply a 3.3 mm (0.13 inch) thick layer of adhesive/
sealant to the leak area. Allow it to dry for 12 hours.
7. Install the tire on the wheel. Inflate the tire to 345
kPa (50 psi) and check for leaks as in step 3.
8. Adjust the tire pressure to meet specifications. Re-
fer to ”Tire Size and Pressure Specifications” in
this section.
9. Balance the wheel. Refer to ”Tire and Wheel Bal-
ancing” in this section.
10. Install the wheel. Refer to ”Wheel” in this section.
11. Lower the vehicle.
ALLOY WHEEL REFINISHING
A protective clear or color coating is applied to the surface
of the original equipment cast alloy wheels. Surface deg-
radation can develop if this clear coating is damaged or re-
moved. This can happen at some automatic car wash fa-
cilities that use silicon carbide–tipped tire brushes to clean
white walls and tires. Once the protective coating is dam-
aged, exposure to caustic cleaners or road salt causes fur-
ther surface degradation. The following procedure details
how to strip, clean and recoat alloy wheels.
CAUTION : To avoid serious personal injury, follow
the manufacturer’s recommendations and cautions
when using these materials.
Required materials:
S Amchem Alumi Prep No. 33. Stock No. DX533 or
equivalent cleaning and conditioning chemical for
alloys.

5–6WELECTRICAL WIRING DIAGRAMS
20. REAR WINDOW DEFROSTER & OSRV MIRROR HEATING SYSTEM CIRCUIT 5–144. . . . . . . . . . . . . . . . . . . . . . .
21. ELECTRIC OSRV (OUTSIDE REAR VIEW) MIRROR CIRCUIT 5–146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22. FOLDING MIRROR UNIT CIRCUIT 5–148. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23. POWER WINDOW CIRCUIT5–150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) ONLY FRONT POWER WINDOW CIRCUIT 5–150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2) FRONT & REAR POWER WINDOW CIRCUIT 5–152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24. CENTRAL DOOR LOCKING SYSTEM CIRCUIT 5–154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) NOTCH BACK5–154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2) HATCH BACK5–156 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25. CLUSTER5–158 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) TEMPERATURE GAUGE, TACHOMETER, FUEL GAUGE, ODDOMETER, SPEEDOMETER & FUEL
WARNING LAMP CIRCUIT : MR–140/HV–240 5–158. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2) TEMPERATURE GAUGE, TACHOMETER, FUEL GAUGE, ODDOMETER, SPEEDOMETER & FUEL
WARNING LAMP CIRCUIT : SIRIUS D4 5–160. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3) WARNING(MIL, ABS, TCS, PARKING BRAKE & CHARGING) LAMP CIRCUIT 5–162. . . . . . . . . . . . . . . . . . . . .
4) WARNING(SSPS, AIR BAG, OIL PRESSURE & SEAT BELT) LAMP & HOLD MODE CIRCUIT 5–164. . . . . . .
5) INDICATOR LAMP (FRONT & REAR FOG) & DOOR OPENING WARNING LAMP CIRCUIT 5–166. . . . . . . . .
6) INDICATOR LAMP (TURN SIGNAL, HIGH BEAM & HAZARD) & ILLUMINATION LAMP CIRCUIT 5–168. . . . .
26. AUDIO CIRCUIT5–170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) NOTCH BACK5–170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2) HATCH BACK5–172 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27. ABS (ANTILOCK BRAKE SYSTEM) 5–174. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) POWER SUPPLY, WHEEL SPEED SENSOR & BRAKE SWITCH CIRCUIT 5–174. . . . . . . . . . . . . . . . . . . . . . . .
2) OIL FEEDING CONNECTOR, WARNING(ABS, TCS & BRAKE) LAMP & DLC CIRCUIT 5–176. . . . . . . . . . . . .
28. AIR BAG (SDM: SENSING & DIAGNOSTIC MODULE) CIRCUIT 5–178. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5–144WELECTRICAL WIRING DIAGRAMS
20. REAR WINDOW DEFROSTER & OSRV MIRROR HEATING SYSTEM
CIRCUITa. CONNECTOR INFORMATION
CONNECTOR(NO.)
(PIN NO. COLOR)
CONNECTING, WIRING HARNESSCONNECTOR POSITION
C101 (21 Pin, White)Body
Engine Fuse BlockEngine Fuse Block
C102 (11 Pin, White)Body
Engine Fuse BlockEngine Fuse Block
C201 (76 Pin, Black)I.P
I.P Fuse BlockI.P Fuse Block
C202 (89 Pin, White)I.P
BodyLeft CO–Driver Leg Room
C208 (15 Pin, White)I.P
FAT CBehind Glove Box
C209 (20 Pin, Black)FAT C
FAT C . A u xBetween Heater Core and Evaporator Core
C351 (33 Pin, Gray)Body
Front Light DoorUnder CO–Driver A Pillar
C361 (33 Pin, Gray)Body
Front Right DoorUnder Driver A Pillar
C404 (8 Pin, White)T/Gate. EXT.
BodyInside Left C Pillar
C405 (8 Pin, White)T/Gate. EXT.
T/GateBeside Left Rear Wiper Motor
C406 (6 Pin, White)T/Gate. EXT.
T/GateBeside Left Rear Wiper Motor
S302 (Brown)BodyLeft CO–Driver Leg Room
G301BodyBelow Driver Cross Member Floor Panel
G303BodyBelow Left CO–Driver Leg Room
G402T/Gate. EXT.Inside Driver C Pillar
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 49
DAEWOO V–121 BL4
Functional Check Procedure
Inspect
1. Install a tachometer or scan tool.
2. Operate the vehicle unit proper operating tempera-
ture is reached.
3. Drive the vehicle at 80 to 88km/h (50 to 55 mph)
with light throttle(road load).
4. Maintaining throttle position, lightly touch the brake
pedal and check for release of the TCC and a slight
increase in engine speed(rpm).
5. Release the brake slowly accelerate and check for
a reapply of the Lock up clutch and a slight de-
crease in engine speed(rpm).
Torque Converter Evaluation
Torque Converter Stator
The torque converter stator roller clutch can have one of
two different type malfunctions :
A. Stator assembly freewheels in both directions.
B. Stator assembly remains Locked up at all times.
Condition A – Poor Acceleration Low
Speed
The car tends to have poor acceleration from a stand still.
At speeds above 50 to 55km/h(30 to 35mph), the car may
act normal. If poor acceleration is noted, it should first be
determined that the exhaust system is not blocked, and
the transaxle is in 1st(First) gear when starting out.
If the engine freely accelerates to high rpm in N(Neutral),
it can be assumed that the engine and exhaust system are
normal. Checking for poor performance in ”Drive” and ”Re-
verse” will help determine if the stator is freewheeling at all
times.
Condition B – Poor Acceleration High
Speed
Engine rpm and car speed limited or restricted at high
speeds. Performance when accelerating from a standstill
is normal. Engine may overheat. Visual examination of the
converter may reveal a blue color from overheating.
If the converter has been removed, the stator roller clutch
can be checked by inserting two fingers into the splined in-
ner race of the roller clutch and trying to turn freely clock-
wise, but not turn or be very difficult to turn counter clock-
wise.
Noise
Torque converter whine is usually noticed when the ve-
hicle is stopped and the transaxle is in ”Drive” or ”Re-
verse”. The noise will increase when engine rpm is in-
creased. The noise will stop when the vehicle is moving or
when the torque converter clutch is applied because both
halves of the converter are turning at the same speed.
Perform a stall test to make sure the noise is actually com-
ing from the converter :1. Place foot on brake.
2. Put gear selector in ”Drive”.
3. Depress accelerator to approximately 1200rpm for
no more than six seconds.
Notice : If the accelerator is depressed for more than six
seconds, damage to the transaxle may occur.
A torque converter noise will increase under this load.
Important : This noise should not be confused with pump
whine noise which is usually noticeable in P (Park), N
(Neutral) and all other gear ranges. Pump whine will vary
with pressure ranges.
The torque converter should be replaced under any of the
following conditions:
S External leaks in the hub weld area.
S Converter hub is scored or damaged.
S Converter pilot is broken, damaged or fits poorly
into crankshaft.
S Steel particles are found after flushing the cooler
and cooler lines.
S Pump is damaged or steel particles are found in the
converter.
S Vehicle has TCC shudder and/or no TCC apply.
Replace only after all hydraulic and electrical diag-
noses have been made.(Lock up clutch material
may be glazed.)
S Converter has an imbalance which cannot be cor–
rected. (Refer To Converter Vibration Test Proce-
dure.)
S Converter is contaminated with engine coolant con-
taining antifreeze.
S Internal failure of stator roller clutch.
S Excess end play.
S Heavy clutch debris due to overheating (blue con-
verter).
S Steel particles or clutch lining material found in fluid
filter or on magnet when no internal parts in unit are
worn or damaged(indicates that lining material
came from converter).
The torque converter should not be replace if :
S The oil has an odor, is discolored, and there is no
evidence of metal or clutch facing particles.
S The threads in one or more of the converter bolt
holes are damaged.
–correct with thread insert.
S Transaxle failure did not display evidence of dam-
age or worn internal parts, steel particles or clutch
plate lining material in unit and inside the fluid filter.
S Vehicle has been exposed to high mileage(only).
The exception may be where the Lock up clutch
damper plate lining has seen excess wear by ve-
hicles operated in heavy and/or constant traffic,
such as taxi, delivery or police use.
Lock–Up Clutch Shudder Diagnosis
The key to diagnosing lock–up clutch(TCC) shudder is to
note when it happens and under what conditions.

SECTION : 7A
HEATING AND VENTILATION SYSTEM
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool
or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help
prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
SPECIFICATIONS7A–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Temperature Specifications 7A–1. . . . . . . . . . .
Fastener Tightening Specifications 7A–1. . . . . . . . . . .
SCHEMATIC AND ROUTING DIAGRAMS7A–3 . . . . .
Non–A/C Diagrams 7A–3. . . . . . . . . . . . . . . . . . . . . . . .
Airflow – Typical 7A–4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Airflow with Rear Heating Duct 7A–5. . . . . . . . . . . . . .
DIAGNOSIS7A–6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATER SYSTEM 7A–6. . . . . . . . . . . . . . . . . . . . . . . . . .
Insufficient Heating or Defrosting 7A–6. . . . . . . . . . . . .
Blower Electrical 7A–9. . . . . . . . . . . . . . . . . . . . . . . . . . .
Improper Air delivery or No Mode Shift 7A–11. . . . . .
Too Much Heat 7A–13. . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls 7A–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Noise 7A–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE AND REPAIR7A–18 . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 7A–18. . . . . . . . . . . . . . . . . . . .
Temperature Cable Adjustment 7A–18. . . . . . . . . . . . .
Temperature Control Cable 7A–18. . . . . . . . . . . . . . . . .
Control Assembly 7A–20. . . . . . . . . . . . . . . . . . . . . . . . .
Control Assembly Knob Lighting 7A–21. . . . . . . . . . . .
Heater/Air Distributor Case Assembly 7A–21. . . . . . .
Blower Motor 7A–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High–Blower Relay 7A–24. . . . . . . . . . . . . . . . . . . . . . . .
Blower Resistor 7A–25. . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Hoses 7A–25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Core 7A–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION7A–28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heating and Ventilation Systems 7A–28. . . . . . . . . . . .
SPECIFICATIONS
HEATER TEMPERATURE SPECIFICATIONS
Ambient Air TemperatureHeater Outlet Air Temperature
–18°C (0°F)54°C (129°F)
– 4°C (25°F)59°C (138°F)
10°C (50°F)64°C (147°F)
24°C (75°F)68°C (154°F)
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Blower Motor–to–A/C Assembly Screws1.2–11
Blower Motor Resistor Screws1.2–11
Blower Motor Retaining Screws1.2–11
Controller Retaining Screws2–18
Heater/Air Distributor Case Assembly Screw4–35

7A – 2IHEATING AND VENTILATION SYSTEM
DAEWOO V–121 BL4
Application Lb–InLb–Ft NSm
Heater Core Cover Screws1.2–11
Heater Core Housing–to–Evaporator Housing Screws1.2–11

HEATING AND VENTILATION SYSTEM 7A – 3
DAEWOO V–121 BL4
SCHEMATIC AND ROUTING DIAGRAMS
NON–A/C DIAGRAMS

7A – 4IHEATING AND VENTILATION SYSTEM
DAEWOO V–121 BL4
AIRFLOW – TYPICAL

HEATING AND VENTILATION SYSTEM 7A – 5
DAEWOO V–121 BL4
AIRFLOW WITH REAR HEATING DUCT
(LEFT–HAND DRIVE SHOWN, RIGHT–HAND DRIVE
SIMILAR)