maintenance DAEWOO LACETTI 2004 Service Manual PDF

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 – 18IHEATING AND VENTILATION SYSTEM
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
TEMPERATURE CABLE
ADJUSTMENT
Because the cable and the cable housings have fixed
lengths, it is impossible to make a temperature cable ad-
justment.
In addition, the heater/air distributor case linkage cannot
be adjusted.
If a malfunction is suspected, verify the proper operation
of the controller and the mechanical doors for the heater/
air distributor case assembly.
TEMPERATURE CONTROL CABLE
(Left–Hand Drive Shown, Right–Hand Drive
Similar)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the center molding. Refer toSection 9E,
Instrumentation/Driver Information.
3. Disconnect the mode control cable from the mode
door.
4. Disconnect the temperature control cable eyelet
from the post on the controller.
5. Pry off the clip of the temperature control cable.

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 cable will help
prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
SPECIFICATIONS7B–2 . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 7B–2. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 7B–2. . . . . . . . . . .
SPECIAL TOOLS7B–3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 7B–3. . . . . . . . . . . . . . . . . . . . . . . .
SCHEMATIC AND ROUTING DIAGRAMS7B–6 . . . . .
A/C System – Typical 7B–6. . . . . . . . . . . . . . . . . . . . . .
Manual Control A/C Diagram 7B–7. . . . . . . . . . . . . . . .
DIAGNOSIS7B–8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DIAGNOSIS 7B–8. . . . . . . . . . . . . . . . . . . . . .
Testing the Refrigerant System 7B–8. . . . . . . . . . . . . .
Insufficient Cooling ”Quick Check” Procedure 7B–8. .
A/C Performance Test 7B–9. . . . . . . . . . . . . . . . . . . . . .
Pressure–Temperature Relationship of
R–134A 7B–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leak Testing Refrigerant System 7B–11. . . . . . . . . . . .
V5 SYSTEM AIR CONDITIONING DIAGNOSIS 7B–12
Insufficient Cooling Diagnosis 7B–12. . . . . . . . . . . . . .
SYMPTOM DIAGNOSIS 7B–16. . . . . . . . . . . . . . . . . . . .
Pressure Test Chart (R–134A System) 7B–16. . . . . .
Low and High Side Pressure Relationship
Chart 7B–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR7B–19 . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 7B–19. . . . . . . . . . . . . . . . . . . .
GENERAL A/C SYSTEM SERVICE
PROCEDURES 7B–19. . . . . . . . . . . . . . . . . . . . . . . . . .
O–Ring Replacement 7B–19. . . . . . . . . . . . . . . . . . . . .
Handling Refrigerant 7B–19. . . . . . . . . . . . . . . . . . . . . .
Handling of Refrigerant Lines and Fittings 7B–19. . . .
Maintaining Chemical Stability in the Refrigeration
System 7B–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System 7B–20. . . . . . . . . . . . . .
SERVICEABLE COMPONENTS 7B–23. . . . . . . . . . . . . Components Used In Non–A/C Systems 7B–23. . . . .
A/C Pressure Transducer 7B–24. . . . . . . . . . . . . . . . . .
A/C Compressor Relay 7B–24. . . . . . . . . . . . . . . . . . . .
Air Filter 7B–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C Expansion Valve 7B–25. . . . . . . . . . . . . . . . . . . . . .
A/C High–Pressure Pipe Line 7B–26. . . . . . . . . . . . . . .
Evaporator Core 7B–29. . . . . . . . . . . . . . . . . . . . . . . . . .
A/C Suction Hose Assembly 7B–30. . . . . . . . . . . . . . .
A/C Discharge Hose Compressor to
Condenser 7B–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receiver–Dryer 7B–32. . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor 7B–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser 7B–35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 7B–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR 7B–37. . . . . . . . . . . . . . . . . . .
V5 Compressor 7B–37. . . . . . . . . . . . . . . . . . . . . . . . . . .
V5 AIR CONDITIONING COMPRESSOR
OVERHAUL 7B–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Plate and Hub Assembly 7B–38. . . . . . . . . . . .
Clutch Rotor and Bearing 7B–40. . . . . . . . . . . . . . . . . .
Clutch Coil 7B–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Seal Replacement 7B–44. . . . . . . . . . . . . . . . . . .
Control Valve Assembly 7B–46. . . . . . . . . . . . . . . . . . .
Rear Head, Gasket, Valve Plate, Reed Plate,
and O–ring 7B–47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder to Front Head O–ring 7B–48. . . . . . . . . . . . . .
Leak Testing (External) 7B–50. . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION7B–51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION 7B–51. . . . . . . . . . . . . . . . . .
The V5 A/C System 7B–51. . . . . . . . . . . . . . . . . . . . . . .
System Components – Functional 7B–51. . . . . . . . . .
System Components – Control 7B–52. . . . . . . . . . . . .
V5 Compressor – General Description 7B–52. . . . . . .
V5 Compressor – Description of Operation 7B–52. . .

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 11
DAEWOO V–121 BL4
LEAK TESTING 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
lines or the connections. Leaks are commonly found at the
refrigerant fittings or at the connections. Leaks are com-
monly caused by the following problems:
S Improper torque.
S Damaged O–ring seals.
S Dirt or lint on the O–ring seals.
Liquid Leak Detectors
Use a liquid leak detector solution on locations such as fit-
tings. Apply the solution to the area in question with the
swab that is supplied with the solution. Look for bubbles
to appear. This will indicate the existence and the location
of any leak.
For areas where this is not practical, such as sections of
the evaporator and the condenser, an electronic leak de-
tector is more useful.
Electronic Leak Detectors
Follow the manufacturer’s instructions for calibration, op-
eration, and maintenance of an electronic leak detector.
Battery condition is especially important to the accuracy
of a portable model. Set the detector to R–134a before be-
ginning the test.
Notice : Electronic leak detectors are sensitive to wind-
shield washing solutions, solvents and cleaners, and cer-
tain vehicle adhesives. Surfaces must be clean to prevent
false readings. Make sure that all surfaces are dry to pre-
vent damage to the detector.
General Testing Instructions
1. Follow the entire path of the refrigerant system.
2. Completely circle each joint at 25 to 50 mm (1 to 2
inches) per second.
3. Hold the probe tip within 6 mm (1/4 inch) of the sur-
face.4. Do not block the air intake.
5. The audible tone changes from 1 to 2 clicks per
second into a solid alarm if there is a leak. Adjust
the balance control to maintain 1 to 2 clicks per
second.
6. Test all of the following areas, even after one leak
has been confirmed:
S Evaporator inlet and outlet.
S Receiver–drier inlet and outlet.
S Condenser inlet and outlet.
S Brazed and welded areas.
S Damaged areas.
S Hose couplings.
S Compressor rear head.
S All fittings and joints.
Testing Service Ports/Access Valves
The sealing caps provide protection for the service ports.
Make sure that these caps are not missing or loose. Al-
ways use the correct cap for each port.
Testing the Evaporator Core
Leaks in the evaporator core are difficult to find. Test the
evaporator core using the following procedure:
1. Run the blower fan at the maximum speed setting
for at least 15 minutes.
2. Turn the blower OFF.
3. Wait for 10 minutes.
4. Remove the blower motor resistor. Refer to Section
7A, Heating and Ventilation System.
5. Insert the leak detector probe as close as possible
to the evaporator core. The detector will indicate a
leak with a solid alarm.
6. Use a flashlight to search for refrigerant oil on the
core surface.
Testing the Compressor Shaft Seal
1. Blow shop air behind and in front of the compressor
clutch/pulley for at least 15 seconds.
2. Wait 1 to 2 minutes.
3. Probe the area in front of the pulley. If the detector
emits a solid alarm, there is a leak.

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 19
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
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-
placement air conditioning O–rings be used or excessive
leakage of refrigerant may occur.
Important : Always slip the O–ring onto the flange tube to
ensure proper locating and sealing.
Install new Daewoo–approved service replacement air
conditioning (A/C) O–rings whenever a joint or a fitting is
disassembled, except when the O–rings are provided on
new components.
When replacing O–rings on an A/C component or a joint
connection, the fitting design should be identified to en-
sure installation of the correct air conditioning service re-
placement O–ring. Some joint connections and compo-
nents will implement a ”captured” O–ring design fitting that
uses a groove to retain the O–ring. Others do not have a
groove and use a ”non–captured” or ”standard” O–ring.
Assembly and tightening procedures are the same for
both designs, but the O–rings are different.
Notice : Before installation, verify that both O–rings and
fittings have not been nicked or deformed. Deformed or
nicked parts must be replaced. Failure to use the proper
service replacement parts and procedures may result in
excessive refrigerant leakage.
HANDLING REFRIGERANT
CAUTION : Always work in a well–ventilated area and
avoid breathing any refrigerant fumes. If you have dif-
ficulty with breathing, seek medical attention immedi-
ately. If refrigerant comes in contact with any part of
your body, flush the exposed area with water. If a rash
or pain develops, seek medical attention.
Air conditioning systems contain refrigerant. This is a
chemical mixture which requires special handling proce-
dures to avoid personal injury.
Always wear goggles and wrap a clean cloth around the
fittings, the valves and the connections when performing
work that involves opening the refrigerant system. Do not
weld or steam clean on or near any vehicle–installed air
conditioning lines or components.
All refrigerant drums are shipped with a heavy metal screw
cap. The purpose of the cap is to protect the valve and the
safety plug from damage. It is good practice to replace the
cap after each use of the drum.If it is necessary to transport or carry any container of re-
frigerant in a vehicle, do not carry it in the passenger
compartment.
HANDLING OF REFRIGERANT LINES
AND FITTINGS
Notice : Using too low or too high torque when tightening
a fitting can result in loose joints or deformed joint parts.
Both conditions can result in refrigerant leakage.
S Keep all metal tubing lines free of dents or kinks.
Any line restrictions will cause the loss of system
capacity.
S Never bend a flexible hose line to a radius of less
than four times the diameter of the hose.
S Never allow a flexible hose line to come within 65
mm (2–1/2 inches) of the exhaust manifold.
S Inspect flexible hose lines regularly for leaks or
brittleness.
S Replace flexible hose lines with new lines if you find
signs of deterioration or leaking.
S Discharge all refrigerant of the refrigeration system
before disconnecting any fitting in the refrigeration
system.
S Proceed very cautiously regardless of the gauge
readings.
CAUTION : Keep your face and your hands away from
the fitting so that you will not be injured if there hap-
pens to be liquid refrigerant in the line.
S Open the fittings very slowly.
S If you notice pressure when you loosen a fitting,
allow the pressure to bleed off as described under
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.
S Cap or tape any refrigerant line immediately after it
is opened. This will prevent the entrance of mois-
ture and dirt, which can cause internal compressor
wear or plugged lines in the condenser, the evapo-
rator core, the expansion valve, or the compressor
inlet screens.
Important : Use two proper wrenches to connect the O–
ring fittings.
S Back up the opposing fitting to prevent distortion of
the connecting lines or the components.
S Back up both the swagged fitting on the flexible
hose connections and the coupling to which it is
attached with two wrenches to prevent turning the
fitting and damaging the ground seat.
S Keep the O–rings and the seats in perfect condi-
tion. A burr or a piece of dirt may cause a refriger-
ant leak.

7B – 20IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
S Dip new O–rings in clean polyalkaline glycol refrig-
erant oil before installation.
MAINTAINING CHEMICAL STABILITY
IN THE REFRIGERATION SYSTEM
The efficient operation and the life of the air conditioning
(A/C) system is dependent upon the chemical stability of
the refrigeration system. When foreign materials, such as
dirt, air, or moisture, contaminate the refrigeration system,
they will change the stability of the refrigerant and the poly-
alkaline glycol (PAG) compressor oil. They will also affect
the pressure–temperature relationship, reduce efficient
operation, and can possibly cause interior corrosion and
abnormal wear of moving parts.
Observe the following practices to ensure chemical stabil-
ity in the system:
S Wipe away dirt or oil at and near any connection
before opening that connection. This will reduce the
chance of dirt entering the system.
S Cap, plug, or tape both sides of a connection as
soon as possible after opening the connection. This
will prevent the entry of dirt, foreign material, and
moisture.
S Keep all tools clean and dry, including the manifold
gauge set and all replacement parts.
S Use a clean and dry transfer device and container
to add polyalkaline glycol refrigerant oil. This will
ensure that the oil remains as moisture–free as
possible. Refer to ”Discharging, Adding Oil, Eva-
cuating, and Charging Procedures for A/C System”
in this section.
S Have everything you need ready to allow you to
perform all operations quickly when opening an A/C
system. Do not leave the A/C system open any lon-
ger than necessary.
S Evacuate and recharge any A/C system that has
been opened. Refer to ”Discharging, Adding Oil,
Evacuating, and Charging Procedures for A/C Sys-
tem” in this section for the instructions to perform
this procedure properly.
All service parts are dehydrated and sealed before ship-
ping. They should remain sealed until just before making
connections. All the parts should be at room temperature
before uncapping. This prevents condensation of mois-
ture from the air from entering the system. Reseal all parts
as soon as possible.
DISCHARGING, ADDING OIL,
EVACUATING, AND CHARGING
PROCEDURES FOR A/C SYSTEM
CAUTION : Use only refillable refrigerant tanks that
are authorized for the charging station being used.
The use of other tanks may cause personal injury or
void the warranty. Refer to the manufacturer’s in-
structions for the charging station.CAUTION : To avoid personal injury, always wear
goggles and gloves when performing work that in-
volves opening the refrigeration system.
A charging station discharges, evacuates, and recharges
an air–conditioning (A/C) system with one hookup. Filter-
ing the refrigerant during the recovery cycle together with
filtering during the evacuation cycle ensures a supply of
clean, dry refrigerant for A/C system charging.
S Never use the R–134a charging station on a sys-
tem charged with R–12. The refrigerants and the
oils from each system are not compatible with
those from the other system and must never be
mixed, even in the smallest amount. Mixing refriger-
ant residue will damage the equipment.
S Never use adapters which convert from one size
fitting to another. Such use allows contamination,
which may cause system failure.
Charging Station Setup and Maintenance
There are many charging stations available. All perform
the various tasks required to discharge the system and re-
cover refrigerant, evacuate the system, add a measured
amount of oil, and recharge an A/C system with a mea-
sured amount of refrigerant. Refer to the manufacturer’s
instructions for all initial setup procedures and all mainte-
nance procedures.
Control Panel Functions
A charging station will have controls and indicators to allow
the operator to control and monitor the operation in prog-
ress. Refer to the manufacturer’s instructions for details.
These can be expected to include the following:
1. Main Power Switch
S Supplies electrical power to the control panel.
2. Display
S Shows the time programmed for vacuum.
S Shows the weight of the refrigerant programmed
for recharging.
S Refer to the manufacturer’s instructions for de-
tailed programming information.
3. Low–Side Manifold Gauge
S Shows the system’s low–side pressure.
4. High–Side Manifold Gauge
S Shows the system’s high–side pressure.
5. Controls Panel
S Controls the various operating functions.
6. Low–Side Valve
S Connects the low side of the A/C system to the
unit.
7. Moisture Indicator
S Shows whether the refrigerant is wet or dry.
8. High–Side Valve
S Connects the high side of the A/C system to the
unit.

SECTION : 7D
AUTOMATIC TEMPERATURE 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 cable will help
prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
SPECIFICATIONS7D–2 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 7D–2. . . . . . . . . . .
SCHEMATIC AND ROUTING DIAGRAMS7D–3 . . . . .
A/C Sensors/Defoggers and A/C Compressor
Controls Diagram 7D–3. . . . . . . . . . . . . . . . . . . . . . . .
A/C Blower and Motor Controls Diagram 7D–4. . . . . .
DIAGNOSIS7D–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL A/C DIAGNOSTICS 7D–5. . . . . . . . . . . . . . .
V5 SYSTEM AIR CONDITIONING AND AUTOMATIC
TEMPERATURE CONTROL (ATC) 7D–5. . . . . . . . . .
Self–Diagnostic Circuit Check 7D–5. . . . . . . . . . . . . . .
Automatic Temperature Controller Does Not
Operate When Ignition Is ON 7D–6. . . . . . . . . . . . . .
Controller Does Not Illuminate When Light Switch
Is ON 7D–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No Hot Air From Blower 7D–8. . . . . . . . . . . . . . . . . . . .
No Cool Air From Blower 7D–10. . . . . . . . . . . . . . . . . .
Blower Motor Does Not Run At All 7D–12. . . . . . . . . .
Mode Control Do Not Work 7D–14. . . . . . . . . . . . . . . .
Air Source Selection Not Controlled 7D–16. . . . . . . . .
Compressor Magnetic Clutch Does Not
Engage 7D–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC TROUBLE CODES 7D–18. . . . . . . . . . . .
Code 1 – In–Car Sensor Error 7D–18. . . . . . . . . . . . .
Code 2 – Ambient Air Temperature Sensor
Error 7D–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Code 3 – Water Sensor Error 7D–22. . . . . . . . . . . . . . .
Code 4 – Air Mix Door Error 7D–24. . . . . . . . . . . . . . . . Code 5 – Sun Sensor Error 7D–27. . . . . . . . . . . . . . . .
Code 6 – Power Transistor Error 7D–29. . . . . . . . . . . .
Code 7 – Max–Hi Relay Error 7D–31. . . . . . . . . . . . . .
MAINTENANCE AND REPAIR7D–32 . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 7D–32. . . . . . . . . . . . . . . . . . . .
GENERAL A/C SYSTEM SERVICE
PROCEURES 7D–32. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Service Procedures 7D–32. . . . . . . . . . . . . . .
SERVICEABLE COMPONENTS 7D–33. . . . . . . . . . . . .
Common HVAC Components 7D–33. . . . . . . . . . . . . . .
Automatic Temperature Control Assembly 7D–33. . . .
Inlet Air Door Motor 7D–34. . . . . . . . . . . . . . . . . . . . . . .
Mode Door Motor 7D–35. . . . . . . . . . . . . . . . . . . . . . . . .
Air Mix Door Motor 7D–35. . . . . . . . . . . . . . . . . . . . . . . .
Water Sensor 7D–36. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ambient Air Temperature Sensor 7D–36. . . . . . . . . . .
In–Car Temperature Sensor 7D–37. . . . . . . . . . . . . . . .
Sun Sensor 7D–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 7D–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V5 AIR CONDITIONING COMPRESSOR
OVERHAUL 7D–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Overhaul 7D–39. . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION7D–40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION 7D–40. . . . . . . . . . . . . . . . . .
The V5 System 7D–40. . . . . . . . . . . . . . . . . . . . . . . . . . .
System Components – Control 7D–40. . . . . . . . . . . . .

7D – 32IAUTOMATIC TEMPERATURE CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
GENERAL A/C SYSTEM SERVICE PROCEDURES
GENERAL SERVICE PROCEDURES
Refer to Section 7B, Manual Control Heating, Ventilation,
and Air Conditioning System, for details of the following
procedures:
S Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System.
S Handling of Refrigerant Lines and Fittings.
S Handling Refrigerant.
S Maintaining Chemical Stability in the Refrigeration
System.
S O–Ring Replacement.

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 the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
SPECIFICATIONS8A–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 8A–1. . . . . . . . . . .
SCHEMATIC AND ROUTING DIAGRAMS8A–2 . . . . .
Driver Seat Belt Warning 8A–2. . . . . . . . . . . . . . . . . . . .
DIAGNOSIS8A–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driver Seat Belt Warning 8A–3. . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR8A–4 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 8A–4. . . . . . . . . . . . . . . . . . . . .
Pretensioner Front Seat Belt 8A–4. . . . . . . . . . . . . . . .
Front Seat Belt Height Adjuster 8A–5. . . . . . . . . . . . . . Three–Point Rear Seat Belt (LH,CENTER, RH) 8A–6
Front Seat Belt Buckle 8A–7. . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION 8A–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driver Seat Belt Warning 8A–9. . . . . . . . . . . . . . . . . . . .
Three–Point ELR Front Seat Belt With
Pretensioner 8A–9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Three–Point CLR (ELR) Rear Outboard Seat
Belt 8A–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operational and Functional Checks 8A–9. . . . . . . . . .
Child Seat Tether Anchor 8A–9. . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Child Seat Tether Anchor Bolt2518–
Front Seat Belt Height Adjuster Bolts2317–
Seat Belt Anchor Bolt3828–
Seat Belt Retractor Bracket Screws3–27
Seat Belt Retractor Bolt3828–

8A – 4ISEAT BELTS
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
PRETENSIONER FRONT SEAT BELT
Removal Procedure
1. Remove the plastic cap to reveal the lower B–pillar
seat belt anchor.
2. Remove the bolt and the lower B–pillar seat belt
anchor.
3. Remove the lower B–pillar trim panel. Refer to Sec-
tion 9G, Interior Trim.
4. Remove the plastic cap to reveal the upper B–pillar
seat belt anchor.
5. Remove the bolt and the upper B–pillar seat belt
anchor.
6. Remove the screws from the seat belt retractor
bracket.
7. Remove the bolt and the seat belt retractor.