headlamp DAEWOO NUBIRA 2004 Service User Guide

7B – 32IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
A/C DISCHARGE
HOSE–COMPRESSOR TO
CONDENSER
Removal Procedure
1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to ”Discharging, Add-
ing Oil, Evacuating, and Charging Procedures for
A/C System” in this section.
3. Remove the nut at the discharge hose block con-
nected to compressor.
4. Remove the headlamp housing at the left–hand
side. Refer to Section 9B, Lighting Systems.
5. Remove the nut at the condenser connecting block.
6. Remove the refrigerant discharge hose.
Installation Procedure
1. Install new sealing washers at the compressor con-
necting block end and a new O–ring at the con-
denser connecting block end.
2. Position the hose into the vehicle, and install the
nut at the condenser connecting block.
Tighten
Tighten the refrigerant discharge hose block–to–con-
denser retaining nut to 16 NSm (12 lb–ft).
3. Make the hose connecting the connecting block to
the compressor, and install the retaining nut.
Tighten
Tighten the refrigerant discharge hose block–to–
compressor retaining nut to 33 NSm (24 lb–ft).
4. Connect the negative battery cable.
5. Evacuate and recharge the A/C system. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.

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 damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
SPECIFICATIONS9B–2 . . . . . . . . . . . . . . . . . . . . . . . . . .
Bulb Usage Chart 9B–2. . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 9B–2. . . . . . . . . . .
SCHEMATIC AND ROUTING DIAGRAMS9B–3 . . . . .
Backup Lamps Circuit 9B–3. . . . . . . . . . . . . . . . . . . . . .
Instruments Circuit (W/O Dimmer Control :
General Only) 9B–4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Instruments Circuit (W/ Dimmer Control) 9B–5. . . . . .
Front And Rear Fog Lamps Circuit 9B–6. . . . . . . . . . .
Headlamps–On Reminder Chime Circuit 9B–7. . . . . .
Headlamps and Headlamp Leveling Circuit 9B–8. . . .
Daytime Running Lamps Circuit 9B–9. . . . . . . . . . . . .
Parking, Tail and License Lamps Circuit 9B–10. . . . . .
Stoplamps Circuit 9B–11. . . . . . . . . . . . . . . . . . . . . . . . .
Turn and Hazard Lamps Circuit 9B–12. . . . . . . . . . . . .
Interior Courtesy and Luggage Compartment Lamp
Circuit 9B–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS9B–14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlamps–On Reminder Chime 9B–14. . . . . . . . . . .
Headlamps 9B–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlamp Leveling 9B–20. . . . . . . . . . . . . . . . . . . . . . .
Daytime Running Lamps 9B–22. . . . . . . . . . . . . . . . . . .
Parking Lamps and Taillamps 9B–23. . . . . . . . . . . . . .
Interior Courtesy and Luggage Compartment
Lamps 9B–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fog Lamps 9B–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR9B–36 . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 9B–36. . . . . . . . . . . . . . . . . . . . Headlamps/Front Turn Signal Lamps 9B–36. . . . . . . .
Daytime Running Lamp Module 9B–37. . . . . . . . . . . . .
Parking Lamps 9B–37. . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Turn Signal Lamps 9B–38. . . . . . . . . . . . . . . . . . .
Front Fog Lamps 9B–38. . . . . . . . . . . . . . . . . . . . . . . . .
Notchback Rear Combination Lamps 9B–39. . . . . . . .
Hatchback Rear Combination Lamps 9B–40. . . . . . . .
Hatchback Extension Lamps 9B–40. . . . . . . . . . . . . . .
Notchback Center High–Mounted Stoplamp 9B–41. .
Hatchback Center High–Mounted Stoplamp 9B–41. .
License Plate Lamps 9B–42. . . . . . . . . . . . . . . . . . . . . .
Door Jamb Switch 9B–42. . . . . . . . . . . . . . . . . . . . . . . .
Center Room Lamp 9B–43. . . . . . . . . . . . . . . . . . . . . . .
Map Lamp 9B–43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Luggage Compartment Lamp 9B–44. . . . . . . . . . . . . . .
Ashtray and Cigar Lighter Lamp 9B–44. . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION9B–46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlamps–On Reminder Chime 9B–46. . . . . . . . . . .
Headlamps 9B–46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Daytime Running Lamps 9B–46. . . . . . . . . . . . . . . . . . .
Parking and Turn Signal Lamps 9B–46. . . . . . . . . . . . .
Fog Lamps 9B–46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Combination Lamps 9B–46. . . . . . . . . . . . . . . . . .
License Plate Lamp 9B–46. . . . . . . . . . . . . . . . . . . . . . .
Interior Courtesy Lamp 9B–46. . . . . . . . . . . . . . . . . . . .
Luggage Compartment Lamp 9B–46. . . . . . . . . . . . . . .
Backup Lamps 9B–47. . . . . . . . . . . . . . . . . . . . . . . . . . .

9B – 2ILIGHTING SYSTEMS
DAEWOO V–121 BL4
SPECIFICATIONS
BULB USAGE CHART
BulbReplacement Bulb Number
Backup Lamp21W
Center High–Mounted Stoplamp5W
Front Fog Lamp27W
Headlamp55W
Interior Courtesy Lamp10W
License Plate Lamp5W
Luggage Compartment Lamp10W
Park and Front Turn Signal LampDouble 21/5W
Rear Fog Lamp21W
Rear Turn Signal Lamp21W
Side Turn Signal Lamp5W
Taillamp and StoplampDouble 21/5W
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
CHMSL Mounting Nuts4–35
Door Jamb Switch Screw4–35
Front Fog Lamp Nuts4–35
Headlamp Assembly Bolts and Nuts4–35
License Plate Lamp Screws4–35
Map Lamp Screws1.5–13
Rear Combination Lamp Assembly Screws4–35
Hatchback Extension Lamp3–27

LIGHTING SYSTEMS 9B – 7
DAEWOO V–121 BL4
HEADLAMPS–ON REMINDER CHIME CIRCUIT

9B – 8ILIGHTING SYSTEMS
DAEWOO V–121 BL4
HEADLAMPS AND HEADLAMP LEVELING CIRCUIT
NOTCHBACK ONLY

9B – 14ILIGHTING SYSTEMS
DAEWOO V–121 BL4
DIAGNOSIS
HEADLAMPS–ON REMINDER CHIME
Diagnostic Aids :
The fuse for the left–side taillamps is also part of the headlamps–on reminder chime circuit. The headlamps–on reminder
chime should operate when the ignition is OFF, the headlamps or parking lamps are on, and the driver door is open.
Headlamps–On Reminder Chime Does Not Work
StepActionValue(s)YesNo
1Turn the parking lamps on, and observe the tail-
lamps.
Are the taillamps operating correctly?–Go to Step 3Go to Step 2
2Repair the left–side taillamps before completing this
diagnostic table.
After the taillamps have been repaired, does the
headlamps–on reminder chime work?–System OKGo to Step 3
31. Disconnect the chime module electrical con-
nector.
2. Turn the headlamps on.
3. Check the voltage at terminal 6 of the chime
module connector.
Is the voltage equal to the specified value?11–14 vGo to Step 5Go to Step 4
4Repair the open circuit between fuse Ef23 and termi-
nal 6 of the chime module connector.
Is the repair complete?–System OK–
5Use an ohmmeter to check the resistance between
ground and terminal 5 of the chime module.
Is the resistance equal to the specified value?
0 WGo to Step 7Go to Step 6
6Repair the open circuit between ground and terminal
5 of the chime module.
Is the repair complete?–System OK–
71. Remove the driver door contact switch.
2. Remove the electrical connector from the driv-
er door contact switch.
3. Use an ohmmeter to measure the resistance
between the driver door contact switch connec-
tor and the chime module terminal 4.
Does the ohmmeter indicate the specified value?
0 WGo to Step 9Go to Step 8
8Repair the open circuit between the driver door con-
tact switch connector and the chime module termi-
nal 4.
Is the repair complete?–System OK–
91. Connect the electrical connector to the chime
module.
2. Connect a jumper wire between ground and
the connector for the driver door contact
switch.
3. Turn the ignition OFF.
4. Turn the lights on.
Does the headlamps–on reminder chime operate?–Go to Step 11Go to Step 10

9B – 16ILIGHTING SYSTEMS
DAEWOO V–121 BL4
HEADLAMPS
Low–Beam Headlamps Are Inoperative, High–Beam Headlamps
Are OK
StepActionValue(s)YesNo
1Check fuses Ef20 (left side headlamps) and Ef27
(right side headlamps).
Is fuse Ef20 or Ef27 blown?–Go to Step 2Go to Step 3
21. Check for a short circuit and repair if neces-
sary.
2. Replace the fuse.
Is the repair complete?–System OK–
3Check the voltage at fuses Ef20 and Ef27.
Does the voltage available at fuses Ef20 and Ef27
equal the value specified?11–14 vGo to Step 4Go to Step 9
41. Disconnect both headlamp connectors.
2. Turn the headlamps ON.
3. Select the low beams.
Does the voltage at each headlamp connector termi-
nal 5 equal the value specified?11–14 vGo to Step 6Go to Step 5
5Repair the open circuit between fuses Ef20 or Ef27
and the low beam headlamps.
Is the repair complete?–System OK–
61. Disconnect the headlamp connectors.
2. Connect an ohmmeter between ground and
either headlamp connector terminal 6.
Is the resistance equal to the value specified?0 WGo to Step 8Go to Step 7
7Repair the ground circuit.
Is the repair complete?–System OK–
8Replace the faulty headlamps.
Is the repair complete?–System OK–
91. Disconnect the headlamp switch connector.
2. Select the low beams.
3. Use an ohmmeter to check the continuity be-
tween terminals 6 and 5 of the headlamp
switch.
Does the ohmmeter indicate the value specified?0 WGo to Step 10Go to Step 11
10Replace the headlamp combination switch.
Is the repair complete?–System OK–
11Repair the open circuit between fuses Ef20 and Ef27
and the headlamp switch connector terminal 5.
Is the repair complete?–System OK–

LIGHTING SYSTEMS 9B – 17
DAEWOO V–121 BL4
High–Beam Headlamps Are Inoperative, Low–Beam Headlamps
Are OK
StepActionValue(s)YesNo
1Check the high–beam headlamps in the ”flash–to–
pass” mode.
Do the high–beam headlamps work in the ”flash–to–
pass” mode?–Go to Step 11Go to Step 2
2Check the voltage at the headlamp switch connector
terminal 7.
Does the voltage equal the value specified?11–14 vGo to Step 4Go to Step 3
3Repair the open circuit between the headlamp
switch connector terminal 7 and the fuse Ef2.
Is the repair complete?–System OKGo to Step 4
4Check fuses Ef15.
Is the fuse blown?–Go to Step 5Go to Step 6
51. Check for a short circuit. Repair it if necessary.
2. Replace the fuse.
Is the repair complete?–System OK–
61. Turn the high–beam headlamps ON.
2. Check the voltage at fuses Ef15.
Does the voltage available at fuses Ef15 equal the
value specified?11–14 vGo to Step 7Go to Step 12
71. Turn the high–beam headlamps ON.
2. Check the voltage at headlamp terminal 4 with
high beams selected.
Does the voltage available at the headlamp connec-
tor terminal 4 equal the value specified?11–14 vGo to Step 9Go to Step 8
8Repair the open circuit between fuse EF16 and the
high–beam headlamps.
Is the repair complete?–System OK–
9Replace the faulty headlamps.
Is the repair complete?–System OK–
101. Disconnect the headlamp combination switch
connector.
2. Put the switch in the high–beam position.
3. Use an ohmmeter to check the continuity of the
headlamp switch between terminals 7 and 4.
Does the ohmmeter indicate the specified value?0 WGo to Step 12Go to Step 11
11Replace the headlamp combination switch.
Is the repair complete?–System OK–
12Repair the open circuit between headlamp combina-
tion switch connector (terminal 4) and Ef15.
Is the repair complete?–System OK–

9B – 18ILIGHTING SYSTEMS
DAEWOO V–121 BL4
High–Beam and Low–Beam Headlamps Are Inoperative On Both
Left and Right Sides
StepActionValue(s)YesNo
1Check fuses F6, Ef2, Ef20, Ef27 and Ef15.
Is any fuse blown?–Go to Step 2Go to Step 3
21. Check for a short circuit and repair if neces-
sary.
2. Replace the fuse.
Is the repair complete?–System OK–
31. Turn the low–beam headlamps ON.
2. Check the voltage at fuses Ef20, Ef27 and
Ef15.
Does the voltage at the headlamps equal the value
specified?11–14 vGo to Step 4Go to Step 9
41. Turn the low–beam headlamps ON.
2. Check the voltage at the headlamp connector
terminal 5.
3. Turn the high–beam headlamps ON.
4. Check the voltage at headlamp connector ter-
minal 4.
Does the battery voltage available at the headlamps
equal the value specified?11–14 vGo to Step 6Go to Step 5
5Repair the open circuit between fuses Ef20, Ef27
and Ef15 and the headlamps.
Is the repair complete?–System OK–
6Use an ohmmeter to check between ground and
each headlamp connector terminal 6.
Is the resistance equal to the specified value?0 WGo to Step 8Go to Step 7
7Repair the ground circuit.
Is the repair complete?–System OK–
81. Replace the faulty headlamps.
2. Check the charging system to make sure that
charging voltage is not excessively high. Re-
pair if necessary.
Is the repair complete?–System OK–
9Temporarily substitute the illumination relay in place
of the headlamp relay.
Do the headlamps operate with the substituted
relay?–Go to Step 10Go to Step 11
10Install the illumination relay in its original position,
and install a new headlamp relay.
Is the repair complete?–System OK–
111. With the headlamp relay removed, turn the
headlamp switch to the low–beam position.
2. Use an ohmmeter to check the continuity be-
tween the connector for relay terminal 85 and
ground.
Does the ohmmeter indicate the specified value?
0 WGo to Step 17Go to Step 12

LIGHTING SYSTEMS 9B – 19
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
121. Reinstall the headlamp relay.
2. Check the voltage at the light switch connector
terminal 2.
Does the voltage equal the specified value?11–14 vGo to Step 14Go to Step 13
13Repair the open circuit between headlamp relay ter-
minal 85 and the light switch connector terminal 2.
Is the repair complete?–System OK–
141. Disconnect the light switch connector.
2. Turn the headlamps to the low–beam position.
3. Use an ohmmeter to check the continuity be-
tween terminals 2 and 3 of light switch.
Does the ohmmeter indicate the specified value?
0 WGo to Step 16Go to Step 15
15Replace the light switch.
Is the repair complete?–System OK–
16Repair the open circuit between terminal 3 of light
switch connector and ground.
Is the repair complete?–System OK–
17Check the voltage at headlamp switch connector
terminal 6.
Does the voltage equal the specified value?11–14 vGo to Step 19Go to Step 18
18Repair the open circuit between headlamp switch
connector and terminal 87 of the headlamp relay.
Is the repair complete?–System OK–
191. Disconnect headlamp switch connector.
2. Turn the headlamps to the low–beam position.
3. Connect an ohmmeter between terminals 5
and 6 of headlamp switch connector. Observe
the reading on the ohmmeter.
4. Turn the headlamps to the high–beam position.
5. Connect an ohmmeter between terminals 4
and 6 of the headlamp switch. Observe the
reading on the ohmmeter.
Does the ohmmeter show the specified value for
both of the tests?
0 WGo to Step 20Go to Step 15
20Repair the open circuit between the headlamp
switch and fuses Ef20, Ef27 and Ef15.
Is the repair complete?–System OK–