knock DAEWOO LACETTI 2004 Service Service Manual

ELECTRICAL WIRING DIAGRAMSW5–3
4. ECM (ENGINE CONTROL MODULE) : SIRIUS D4 5–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) BATTERY POWER SUPPLY, GROUND, EI SYSTEM & CKP SENSOR CIRCUIT 5–34. . . . . . . . . . . . . . . . . . . . .
2) FUEL PUMP, INJECTOR, FUEL CONNECTOR & CMP SENSOR CIRCUIT 5–36. . . . . . . . . . . . . . . . . . . . . . . . .
3) MTIA, SENSOR(ECT, KNOCK, IAT, MAP, ACP & HO2S) & POWER STEERING PRESSURE SWITCH
CIRCUIT : EOBD5–38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4) MTIA, SENSOR(ECT, KNOCK, IAT, MAP, ACP & O2) & POWER STEERING PRESSURE SWITCH
CIRCUIT : NON EOBD5–40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5) EEGR VALVE, VR SENSOR, CLUSTER & FUEL PUMP CIRCUIT : EOBD 5–42. . . . . . . . . . . . . . . . . . . . . . . . . .
6) EGR VALVE, CLUSTER & FUEL PUMP CIRCUIT: NON EOBD 5–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7) EVAP CANISTER PURGE SOLENOID, VGIS, CLUSTER, VSS, TCM & RON SWITCH CIRCUIT 5–46. . . . . . .
8) DLC, MIL LAMP & IMMOBILIZER CONTROL CIRCUIT 5–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. TCM (TRANSMISSION CONTROL MODULE) : MR–140/HV–240 5–50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) POWER SUPPLY, GROUND, PNP SWITCH, BRAKE SWITCH & SOLENOID VALVE CIRCUIT 5–50. . . . . . . .
2) SENSOR(INPUT SPEED,OUTPUT SPEED, TRANSMISSION FLUID TEMP.), CLUSTER, DLC, ECM &
HOLD MODE SWITCH CIRCUIT5–52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3) PNP SWITCH & CLUSTER CIRCUIT 5–54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. TCM (TRANSMISSION CONTROL MODULE) : SIRIUS D4 5–56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) POWER SUPPLY, GROUND, PNP SWITCH, CLUSTER & ECM CIRCUIT : NOTCH BACK 5–56. . . . . . . . . . . .
2) POWER SUPPLY, GROUND, PNP SWITCH, CLUSTER & ECM CIRCUIT : HATCH BACK 5–58. . . . . . . . . . . .
3) BRAKE SWITCH, BTSI SOLENOID, ISS SENSOR & TRANSAXLE CIRCUIT 5–60. . . . . . . . . . . . . . . . . . . . . . . .
4) HOLD MODE SWITCH, VSS & DLC CIRCUIT 5–62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. AIR CONDITIONER5–64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) AIR CONDITIONER CONTROL SWITCH, BLOWER MOTOR RESISTER & BLOWER MOTOR
CIRCUIT5–64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2) AIR CONDITIONER CONTROL, INTAKE MOTOR SWITCH & AIR CONDITIONER COMPRESSOR
CIRCUIT5–66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL WIRING DIAGRAMSW5–11
c. POSITION OF CONNECTORS AND GROUNDS
S W/H ENGINE
S W/H FRONT
d. SPLICE PACK
S101
1
2
3
4
5
6
7
8
9
10
11
12
13
14
ECT Sensor ”2” Ter
TP Sensor ”1” Ter
Knock Sensor ”2” TerIAT Sensor ”1” TerLEGR ”2” Ter ECM ”M48” Ter
ECM ”M51” Ter ECM ”M35” Ter ECM ”M64” TerMAP Sensor ”3” Ter
ECM ”M1” Ter B
B
B
B
GW GW
GWOrB
OrB
OrB
EI System ”3” Ter
EI System ”1” TerSb Sb Sb
ECM ”M33” Ter
J3B1S001

5–14WELECTRICAL WIRING DIAGRAMS
3) IAC, SENSOR (MAP, ECT, TP, IAT, KNOCK, ACP & ROUGH ROAD) & LEGR CIRCUITa. CONNECTOR INFORMATION
CONNECTOR(NO.)
(PIN NO. COLOR)
CONNECTING, WIRING HARNESSCONNECTOR POSITION
C106 (20 Pin, White)Engine
Engine Fuse BlockEngine Fuse Block
S101 (Black)Engine (MR–140/HV–240)Upper Transmission
G107Engine (MR–140/HV–240)Under Start Motor
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
J3B1P004
LEGR

ELECTRICAL WIRING DIAGRAMSW5–15
c. POSITION OF CONNECTORS AND GROUNDS
S W/H ENGINE
d. SPLICE PACK
S101
1
2
3
4
5
6
7
8
9
10
11
12
13
14
ECT Sensor ”2” Ter
TP Sensor ”1” Ter
Knock Sensor ”2” TerIAT Sensor ”1” TerLEGR ”2” Ter ECM ”M48” Ter
ECM ”M51” Ter ECM ”M35” Ter ECM ”M64” TerMAP Sensor ”3” Ter
ECM ”M1” Ter B
B
B
B
GW GW
GWOrB
OrB
OrB
EI System ”3” Ter
EI System ”1” TerSb Sb Sb
ECM ”M33” Ter
J3B1S001

5–26WELECTRICAL WIRING DIAGRAMS
3) IAC, SENSOR (MAP, ECT, TP, IAT, KNOCK & ACP) & EGR VALVE CIRCUITa. CONNECTOR INFORMATION
CONNECTOR(NO.)
(PIN NO. COLOR)
CONNECTING, WIRING HARNESSCONNECTOR POSITION
C102 (11 Pin, White)Body
Engine Fuse BlockEngine Fuse Block
C103 (10 Pin, White)Engine
Engine Fuse BlockEngine Fuse Block
C106 (20 Pin, White)Engine
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
S101 (Black)Engine (MR–140/HV–240)Upper Transmission
G107Engine (MR–140/HV–240)Under Start Motor
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
J3B1P010

5–38WELECTRICAL WIRING DIAGRAMS
3) MTIA, SENSOR (ECT, KNOCK, IAT, MAP, ACP & HO2S) & POWER STEERING PRESSURE
SWITCH CIRCUIT : EOBDa. CONNECTOR INFORMATION
CONNECTOR(NO.)
(PIN NO. COLOR)
CONNECTING, WIRING HARNESSCONNECTOR POSITION
C103 (10 Pin, White)Engine
Engine Fuse BlockEngine Fuse Block
C104 (24 Pin, White)Front
Engine Fuse BlockEngine Fuse Block
C106 (20 Pin, White)Engine
Engine Fuse BlockEngine Fuse Block
C109 (4 Pin, White)Engine
FrontUnder Engine Fuse Block
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
J3B1P016

5–40WELECTRICAL WIRING DIAGRAMS
4) MTIA, SENSOR (ECT, KNOCK, IAT, MAP, ACP & O2) & POWER STEERING PRESSURE
SWITCH CIRCUIT : NON EOBDa. CONNECTOR INFORMATION
CONNECTOR(NO.)
(PIN NO. COLOR)
CONNECTING, WIRING HARNESSCONNECTOR POSITION
C104 (24 Pin, White)Front
Engine Fuse BlockEngine Fuse Block
C106 (20 Pin, White)Engine
Engine Fuse BlockEngine Fuse Block
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
J3B1P017

FIVE–SPEED MANUAL TRANSAXLE 5B – 5
DAEWOO V–121 BL4
DIAGNOSIS
ISOLATE NOISE
Identify the cause of any noise before attempting to repair
the clutch, the transaxle, or their related link–ages.
Symptoms of trouble with the clutch or the manual trans-
axle include:
S A great effort required to shift gears.
S The sound of gears clashing and grinding.
S Gear blockout.
Any of these conditions requires a careful analysis. Make
the following checks before disassembling the clutch or
the transaxle for repairs.
Road Travel Noise
Many noises that appear to come from the transaxle may
actually originate with other sources such as the:
S Tires.
S Road surfaces.
S Wheel bearings.
S Engine.
S Exhaust system.
These noises may vary according to the:
S Size of the vehicle.
S Type of the vehicle.
S Amount of insulation used in the body of the ve-
hicle.
Transaxle Noise
Transaxle gears, like any mechanical device, are not ab-
solutely quiet and will make some noise during normal op-
eration.
To verify suspected transaxle noises:
1. Select a smooth, level asphalt road to reduce tire
and resonant body noise.
2. Drive the vehicle far enough to warm up all the lu-
bricants thoroughly.
3. Record the speed and the gear range of the trans-
axle when the noise occurs.
4. Check for noises with the vehicle stopped, but with
the engine running.
5. Determine if the noise occurs while the vehicle op-
erates in:
S Drive – under a light acceleration or a heavy
pull.
S Float – maintaining a constant speed with a light
throttle on a level road.
S Coast – with the transaxle in gear and the
throttle partly or fully closed.
S All of the above.
Bearing Noise
Differential Side Bearing Noise
Differential side bearing noise and wheel bearing noise
can be confused easily. Since side bearings are pre–
loaded, a differential side bearing noise should not dimin-
ish much when the differential/transaxle is run with the
wheels off the ground.
Wheel Bearing Noise
Wheel bearings produce a rough growl or grating sound
that will continue when the vehicle is coasting and the
transaxle is in NEUTRAL. Since wheel bearings are not
pre–loaded, a wheel bearing noise should diminish con-
siderably when the wheels are off the ground.
Other Noise
Brinelling
A brinelled bearing causes a ”knock” or ”click” approxi-
mately every second revolution of the wheel because the
bearing rollers do not travel at the same speed as the
wheel. In operation, the effect is characterized by a low–
pitched noise.
A brinelled bearing is caused by excessive thrust which
pushes the balls up on the pathway and creates a triangu-
lar–shaped spot in the bearing race. A brinelled bearing
can also be caused from pressing one race into position
by applying pressure on the other race.
A false indication of a brinelled bearing occurs as a result
of vibration near the area where the bearing is mounted.
Brinelling is identified by slight indentations, resulting in a
washboard effect in the bearing race.
Lapping
Lapped bearing noise occurs when fine particles of abra-
sive materials such as scale, sand, or emery circulate
through the oil in the vehicle, causing the surfaces of the
roller and the race to wear away. Bearings that wear loose
but remain smooth, without spalling or pitting, are the re-
sult of dirty oil.
Locking
Large particles of foreign material wedged between the
roller and the race usually causes one of the races to turn,
creating noise from a locked bearing. Pre–loading regular
taper roller bearings to a value higher than that specified
also can result in locked bearings
Pitting
Pitting on the rolling surface comes from normal wear and
the introduction of foreign materials.
Spalling
Spalled bearings have flaked or pitted rollers or races
caused by an overload or an incorrect assembly that re-
sults in a misalignment, a cocking of bearings, or adjust-
ments that are too tight.
After completing these checks, refer to the ”Diagnosis
Chart” in this section.

5B – 6IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
SYMPTOM DIAGNOSIS
ChecksAction
Check for a knock at low speeds.S Replace any worn drive axle CV joints.
S Replace any worn side gear hub.
Check for a noise most pronounced on turns.S Correct any abnormalities in the differential gear.
Check for a clunk upon acceleration or deceleration.S Tighten any loose engine mounts.
S Replace any worn drive axle inboard joints.
S Replace any worn differential pinion shaft in the
case.
S Replace any worn side gear hub in the case.
Check for a clunking noise in turns.S Replace any worn outboard CV joint.
Check for a vibration.S Replace any rough wheel bearing.
S Replace any bent drive axle shaft.
S Replace any out–of–round tires.
S Balance any unbalanced tire.
S Replace any worn CV joint in the drive axle shaft.
S Correct an excessive drive axle angle by adjusting
the trim height.
Check for a noise in the NEUTRAL gear with the engine
running.S Replace any worn cluster bearing shaft.
S Replace any worn clutch–release bearing.
S Replace any worn input shaft cluster gears.
S Replace any worn first–gear/bearing.
S Replace any worn second–gear/bearing.
S Replace any worn third–gear/bearing.
S Replace any worn fourth–gear/bearing.
S Replace any worn fifth–gear/bearing.
S Replace any worn mainshaft bearings.
Check for a noise in the first gear (1) only.S Replace any chipped, scored, or worn first–gear
constant mesh gears.
S Replace any worn first–second gear synchronizer.
S Replace any worn first–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the second gear (2) only.S Replace any chipped, scored, or worn second–gear
constant mesh gears.
S Replace any worn first–second gear synchronizer.
S Replace any worn second–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the third gear (3) only.S Replace any chipped, scored, or worn third–gear
constant mesh gears.
S Replace any worn third–fourth gear synchronizer.
S Replace any worn third–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 13
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
81. Check for a knocking noise from the A/C com-
pressor.
2. Cycle the A/C compressor ON and OFF in or-
der to verify the source of the noise.
Do you hear a loud knocking noise?–Go to Step 9Go to Step 13
91. Recover the A/C system refrigerant.
2. Replace the A/C compressor.
3. Evacuate and recharge the A/C system.
4. Check the A/C system for leaks.
Is the compressor running normally?–Go to Step 13–
101. Turn the ignition switch to LOCK.
2. Disconnect the A/C compressor clutch coil con-
nector.
3. Connect a jumper wire from ground to one A/C
compressor clutch coil terminal.
4. Connect a fused jumper wire from the positive
battery terminal to the other A/C compressor
clutch coil terminal.
Does the A/C clutch engage?–Go to Step 11Go to Step 12
11Repair the electrical circuit to the A/C compressor
clutch coil.
Does the A/C clutch engage?–Go to Step 8–
12Replace the A/C compressor clutch coil.
Does the A/C clutch engage?–Go to Step 8–
131. Close all of the vehicle’s windows and doors.
2. Set the A/C controls to the following positions:
S The A/C switch to the ON position.
S The fresh air control switch to fresh air.
S The blower motor to 4.
S The temperature to full cold.
3. Start the engine and allow it to run at idle for 5
minutes.
4. Feel the evaporator inlet and outlet pipes.
Is there a noticeable difference in the temperature of
the evaporator inlet and outlet pipes?–Go to Step 15Go to Step 14
141. Turn the ignition switch to LOCK.
2. Recover the A/C system refrigerant.
3. Examine the high–pressure pipe for an ob-
struction.
4. Examine the expansion valve for an obstruction
or a malfunction.
5. Repair the obstruction or replace the expansion
valve as needed.
6. Evacuate and recharge the A/C system.
7. Check the A/C system for leaks.
8. Note the discharge air temperature with the
A/C ON.
Is the discharge temperature normal?At least 7°C
(12°F) below
ambient air
temperatureGo to Step 15Go to Step 13