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9 Body and Accessories – Daewoo Matiz Service Manual

Contents

1. 9B 2 Rear Fog Lamp 9B 2 5 eripiet y Exe X en eee es 9B 2 License Plate 9B 2 Interior Courtesy Lamp 9B 2 Backup 9B 2 Daytime Running Lamps DRL W Europe Only 9B 2 Diagnostic Information and Procedures 9B 3 Headlamps 98 3 Signal Lamps and Hazard Lamps 9B 4 Stoplamps and Interior Courtesy Lamp 9B 5 Rear Fog sisareen ne Es 9B 6 Repair Instructions 9B 7 Headlamps 9B 7 Turn Signal Lamps 9B 8 Side Turn Signal Lamps 9B 8 Taillamps 9B 9 Front Fog Lamp 9B 9 Rear Fog Backup 9B 10 Center High Mounted Stoplamp 9B 11 DAEWOO M 150 BL2 CHMSL Mounting Bracket 9B 12 License Plate 9B 12 Door Jamb Switch 9B 13 Interior Courtesy Lamp 9B 13 Daytime Running Lamp Module W Europe Only 9B 14 Ashtray Lamp 98 14 Luggage Room Lamp 9B 15 Specifications 9B 16 Bulb Usage Chart
2. 9D 6 Rear Window Wiper Arm 9D 6 Windshield Wiper Motor 9D 7 Rear Window Wiper Motor 9D 8 DAEWOO M 150 BL2 Windshield Wiper Linkage 9D 9 Windshield Wiper Blade 9D 10 Washer Reservoir 9D 10 Washer Pump 9D 11 Windshield Washer Nozzle 9D 12 Rear Window Washer Nozzle 9D 12 Washer Hose 9D 13 Specifications 9D 15 Fastener Tightening Specifications 9D 15 Schematic and Routing Diagrams 9D 16 Windshield Rear Window Wiper Washer NECI 9D 16 90 2 WIPERS WASHER SYSTEMS DESCRIPTION AND OPERATION WINDSHIELD WIPER SYSTEM The windshield wiper system consists of a wiper motor a linkage a wiper arm and a blade and a wiper washer switch The windshield wiper circuit incorporates a self parking device which consists of a worm gear and a cam plate in order to keep the circuit engage temporarily when the switch is turned off The wiper system is driven by a permanent magnet type motor The windshield wip er motor is mounted on the dash panel and is directly connected to the windshield wiper linkage The windshield wiper motor has two speeds LOW and HIGH and also has intermittent wiper capability The wiper switch is an integral part of the wiper washer switch Windshield w
3. D109B535 Installation Procedure 1 Install the seatback assembly with the bolt 2 Install the recliner with the bolts 3 Install the seatback cover with the hog rings D109B536 4 Install the recliner knob and the cover with the screws 5 Install the front seat assembly Refer to Front Seat in this section 6 Connect the negative battery cable D109B537 FRONT SEAT CUSHION Removal Procedure 1 Disconnect the negative battery cable 2 Remove the front seat assembly Refer to Front Seat in this section 3 Remove the seat belt buckle Refer to Section 8A Seat Belts 4 Remove the recliner knob e Remove the screw 1 e Remove the recliner knob 2 D109B532 DAEWOO M 150 BL2 9H 8 SEATS 5 Remove the recliner cover e Remove the screws 1 e Remove the recliner cover 2 01098533 6 Remove the seat cushion e Remove the recliner bolts on the seat cushion 1 e Remove the seatback bolt 2 e Remove the seat cushion 3 D109B538 Installation Procedure 1 Install the seat cushion with the seatback bolt and the recliner bolts D109B536 2 Install the recliner cover and the recliner knob with the Screws 3 Install the seat belt buckle Refer to Section 8A Seat Belts 4 Install the front seat assembly Refer to Front Seats in this section 5 Connect the negative battery cable D109B537 DAEWOO M 150 BL2 DAE
4. Installation Procedure 1 Install the trim to the tailgate Notice In case of the loose clips replace the clips with the new ones 9G 10 INTERIOR TRIM A PILLAR TRIM PANEL Removal Procedure 1 Pry off the trim panel 1 D109E555 Installation Procedure 1 Install the A pillar trim panel UPPER B PILLAR TRIM PANEL Removal Procedure 1 Remove the bolt on the upper B pillar trim panel Re fer to Section 8A Seat Belts 2 Pry off the upper B pillar trim panel e Pry off the upper B pillar trim panel by hands 1 D109E557 Installation Procedure 1 Install the upper B pillar trim panel 2 Install the bolt on the upper B pillar trim panel Refer to Section 8A Seat Belts D109E558 DAEWOO M 150 BL2 DAEWOO M 150 BL2 D110A501 D109E559 D109E560 D109E561 INTERIOR TRIM 9G 11 LOWER B PILLAR TRIM PANEL Removal Procedure 1 Remove the bolt on the lower B pillar trim panel e Remove the bolt 1 e Remove the spacer and the spring washer 2 e Remove the plastic protector from the seat belt an chor 2 Pry off the lower B pillar trim panel Installation Procedure 1 Install the lower B pillar trim panel 2 Install the bolt on the lower B piller trim panel Refer to Section 8A Seat Belts C PILLAR TRIM PANEL Removal Procedure 1 Disconnect the negative battery cable 2 Open the tailgate 3 Dis
5. 9T 30 DTC 1602 ECM Immobilizer Error Schematic and Routing Diagrams 9T 31 ECM Locked 9T 18 Immobilizer Anti Theft System 9T 31 P1628 ECM Immobilizer Error 9T 20 Remote Keyless Entry and Immobilizer P1629 ECM Immobilizer Error 9T 22 Anti theft System 9T 32 DAEWOO M 150 BL2 9T 10 IMMOBILIZER ANTI THEFT SYSTEM DESCRIPTION AND OPERATION IMMOBILIZER SYSTEM The purpose of the Immobilizer system is to provide additional theft deterrence to the vehicle in which it is installed and to prevent it from being stolen or driven by unauthorized users The verification of the user authorization is done by an ignition key with integrated transponder The external LED displays the Immobilizer status and has an additional theft deterrence function To secure the communication the status is exchanged between the Immobilizer and the ECM in a 5 byte of en coded data These 5 bytes are composed by a mixture of random data and two types of fixed code e avehicle model identification number MIN e a vehicle specific identification VIN The MIN is known from the first supply of the system The VIN is realized by ICU on the special order from the key coding reading of transponder code and storing it as valid key code in Immobilizer EEPROM A different random data is computed at each key transi tion All the immobilization communica
6. Turn the ignition switch to the OFF Connect the scan tool to the data link connector DLC Connect the scan tool s power cord to the cigar lighter socket Turn the ignition ON but do not start the engine Is communication established between the scan tool and the immobilizer control unit 1 Select CURRENT KEY STATUS from the scan tool menu 2 Read the STATUS OF CURRENT KEY message Does the KEY STATUS message indicate KEY IS WRONG 1 Select DIAGNOSIS from the scan tool menu 2 Read the IMMO amp ECM ID CODE immobilization and electronic control module identification code message Did the message differ from normal message Normal Message ECM MODE LEARNT IMMO MODE LEARNT VIN CODE SAME Check for an open serial data wire between the immobilizer control unit and the electronic control module ECM Was the circuit open Repair the open serial data wire between the ECM and the immobilizer control unit Is the repair complete 1 Replace the ECM 2 Reprogram the ID code Is the repair complete Go to Communi cation Between Immobilizer and Test Go to Step 2 Equipment Go to Key Status Errors Go to Step 3 Go to Identification ID Code Repro gramming Go to Step 4 Go to Step 5 Go to Step 6 9T 18 IMMOBILIZER ANTI THEFT SYSTEM Without Keyless Entry DK BLU YEL 1 Immobilizer Seral Data Control Unit With Keyless Entry DK BLU YEL Keyless
7. e Route the cross body harness for interior parts over the floor pan insulators Clip it in the original location e Do not apply spray on deadeners or trim adhesives to the top of the floor pan at the area directly over the catalytic converter or the muffler Any insulator service repair or replacement should be the same thickness size and location as the original installation in the vehicle 4 FRAME AND UNDERBODY SPECIFICATIONS UNDERBODY DIMENSIONS Unit mm in DBDM118A FRAME AND UNDERBODY 9N 5 Unit mm in 28 22 904 V 0p 4842 80 OT D Oo cv9 lt Oc S 768 QE ger DBDM119A Unit mm in 99 8 286 98 VLLL 69 61 009 N 4 ce 19 lt 96 19 92 026 L9 9 026 DAEWOO 150 812 9N 6 FRAME AND UNDERBODY Unit mm in 02 92 vos 058 g a LSS o nd 9 L6 C05 8z 6 968 L9 9 06 brs DBDM117A DAEWOO M 150 BL2 SECTION 90 BUMPERS AND FASCIAS TABLE OF CONTENTS Description and Operation 90 2 oc
8. 0109 101 SECTION 9H SEATS 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 B unless otherwise noted TABLE OF CONTENTS Description and Operation 9H 2 Front Seat Cushion 9H 7 ebur 9H 2 Front Seats Guide Rail 9H 9 Component Locator 9H 3 Front Seat Cushion Frame 9H 9 From Seabed oie eR e Re d 9H 3 Rear Sealback 9H 10 Rear geak Ls eiie bid un ASTA 9H 4 Rear Seat Cushion 9H 11 Repair Instructions 9H 5 Rear Seatback Latch 9H 11 On Vehicle Service 9H 5 Rear Seatback Hinge 9H 12 Front Seats 9H 5 Specifications 9H 13 Head 9H 5 Fastener Tightening Specifications 9H 13 Front Seatback 9H 6 DAEWOO M 150 BL2 9H 2 SEATS DESCRIPTION AND OPERATION SEATS Important Do not attempt to change the designed seat position by altering the designed seat adjuster
9. 1 Remove the tailgate trim panel Refer to Section 9G Interior Trim 2 Remove the lock rod from the tailgate lock cylinder a Lock rod D109C590 m 3 Remove the tailgate lock e Remove the screws 1 E pes e Remove the tailgate lock 2 p Dom Bm 1 0109 591 DAEWOO 150 BL2 D109C592 D109C593 D109C594 D109C595 DAEWOO M 150 BL2 DOORS 9P 17 Installation Procedure 1 Install the tailgate lock with the screws 2 Install the lock rod to the tailgate lock cylinder 3 Install the tailgate trim panel Refer to Section 9G In terior Trim INSIDE DOOR HANDLE Removal Procedure 1 Removal the inside door handle e Remove the screw 1 e Remove the inside door handle 2 Installation Procedure 1 Install the inside door handle with the screw OUTSIDE FRONT DOOR HANDLE Removal Procedure 1 Disconnect the negative battery cable 2 Remove the front door lock rods 3 Remove the outside front door handle e Remove the bolts 1 e Remove the outside front door handle 2 9P 18 DOORS D109C596 D109C597 D109C598 D109C599 Installation Procedure 1 Install the outside front door lock handle with the bolts 2 Install the front door lock rods 3 Connect the negative battery cable OUTSIDE REAR DOOR HANDLE Removal Procedure 1 Disconnect the negative battery
10. 4 Remove the cigar lighter socket from the cigar lighter housing Caution Ashtray housing edge could cause seri ous injury e Push out the socket e Disconnect the electrical connector 1 e Remove the socket 2 Installation Procedure 1 Connect the electrical connector 2 Install the cigar lighter socket 3 Install the cigar lighter in the cigar lighter socket 4 Install the ashtray 5 Connect the negative battery cable DAEWOO M 150 BL2 INSTRUMENTATION DRIVER INFORMATION 9E 9 D109B504 D19B505A D109B506 D109B507 DAEWOO M 150 BL2 ASHTRAY Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Remove the ashtray from the ashtray bracket Pull off the ashtray by pressing the upper button 2 Remove the ashtray bracket from the instrument pan el e Remove the screws 1 e Remove the ashtray bracket 3 Installation Procedure 1 Install the ashtray bracket with the screws 2 Install the ashtray INSTRUMENT CLUSTER TRIM PANEL VENTS Left Hand Drive Shown Right Hand Drive Similar Removal Procedure Remove the instrument cluster trim panel from the in strument panel Refer to Instrument Cluster Trim Panel in this section Remove the vent from the instrument cluster trim panel e Remove the screws 1 e Remove the vents 2 9E 10 INSTRUMENTATION DRIVER INFORMATION In
11. 5 D109D539 D109D541 D109D542 D109D543 Installation Procedure 1 Install the wiper motor to the washer reservoir assem bly 2 Install the washer reservoir assembly Refer to Washer Reservoir in this section 3 Connect the negative battery cable 4 Fill the washer reservoir WINDSHIELD WASHER NOZZLE Removal Procedure 1 Remove the cowl vent grille Refer to Section 9H Body Front End 2 Remove the washer nozzle from the cowl vent grille e Disconnect the washer nozzle hose 1 e Remove the washer nozzle 2 Installation Procedure 1 Install the washer nozzle to the cowl vent grille 2 Install the washer nozzle hose to the washer nozzle 3 Install the cowl vent grille Refer to Sec tion 9R Body Front REAR WINDOW WASHER NOZZLE Removal Procedure 1 Remove the washer nozzle from the wiper arm e Disconnect the washer nozzle hose 1 e Remove the washer nozzle 2 DAEWOO M 150 BL2 D109D535 D109C522 D19D537A DAEWOO M 150 BL2 WIPERS WASHER SYSTEMS 9D 13 Installation Procedure 1 Install the washer nozzle to the wiper arm assembly e Install the washer nozzle hose in the wiper arm re turn spring e Fix the washer nozzle into the wiper arm e Install the washer nozzle hose to the pivot cap con nector WASHER HOSE Removal Procedure 1 Remove the cowl vent grille Refer to Section 9R Body
12. Entry Control Module Immobilizer Receiver Electronic Control DKBLU YEL 1 Immobilizer Resistor Data Link G Connector DLC Electronic Control Module 1 ECM 11 DK BLU YEL Data Link Connector DLC D19T002B DIAGNOSTIC TROUBLE CODE DTC 1602 ECM IMMOBILIZER ERROR ECM LOCKED Circuit Description When the ignition is turned ON the key is tested by the immobilizer anti theft system While the key code is be ing read by the immobilizer control unit the engine can start and run with any key that will turn the lock cylinder The key code is read and compared with key codes that have been stored in the memory of the immobilizer con trol unit If a valid key is detected the immobilizer control unit sends a serial data release message to the elec tronic control module ECM Included in the release message is an identification ID code which assures that neither the immobilizer control unit nor the ECM has been substituted to defeat the system If the ECM re ceives an invalid release message the ECM performs the following actions e Disables the fuel injector circuit e Disables the fuel pump circuit e Disables the ignition coil DTC 1602 Will Set When e The immobilizer control unit does not learn and store the codes of valid keys DTC 1602 Will Clear When e The ignition switch is turned OFF or the scan tool TROUBLE CODE CLEAR command is issued
13. REAR DOOR TRIM PANEL STANDARD Tool Required KM 475 B Trim Remover Removal Procedure 1 Remove the inside door handle e Remove the screw 1 e Disconnect the inside door handle rod Pry off the inside door handle 2 D109E541 2 Remove the door pull e Remove the screws 1 e Remove the door pull 2 D109E542 DAEWOO M 150 BL2 INTERIOR TRIM 9G 7 3 Remove the window regulator handle from the rear door Using a cloth pull out the clip 1 e Remove the regulator handle 2 D109E543 4 Pry off the trim panel using a trim remover KM 475 B Notice Make sure to cover the remover with cloth to prevent the paint damage of the door D109E544 Installation Procedure 1 Install the trim panel 2 Install the window regulator handle with the clip 3 Install the inside door handle and the door pull with the screws D109E545 REAR DOOR TRIM PANEL DELUXE Removal Procedure 1 Remove the inside door handle Refer to Section 9P Doors 2 Remove the window regulator handle from the rear door Refer to Section 9P Doors 3 Remove the door pull e Remove the screw 1 e Remove the door pull 2 D109E546 DAEWOO M 150 BL2 9G 8 INTERIOR TRIM D109E547 D109E548 D109E549 D109E550 4 Remove the trim panel e Remove
14. REAR SPOILER Removal Procedure 1 Open the tailgate 2 Remove the spoiler seals D19E588A 9M 4 EXTERIOR TRIM 3 Remove the rear spoiler from the tailgate e Remove the nuts 1 e Remove the rear spoiler 2 D19E589A Installation Procedure 1 Install the rear spoiler on the tailgate with the nuts 2 Install the spoiler seals D19E590A FRONT BUMPER SPACER Removal Procedure 1 Support the hood suitably 2 Disconnect the negative battery cable 3 Remove the front bumper spacer e Remove the bolts 1 e Remove the front bumper spacer from the bumper fascia 2 4 Remove the turn signal lamps Refer to Section 9B Lighting Systems Installation Procedure 1 Install the turn signal lamps Refer to Section 9B Lighting Systems 2 Install the front bumper spacer with the bolts 3 Connect the negative battery cable D209B110 DAEWOO M 150 BL2 EXTERIOR TRIM 9M 5 TAILGATE HANDLE Removal Procedure 1 Disconnect the negative battery cable 2 Open the tailgate 3 Remove the tailgate lock cylinder Refer to Section 9P Doors 4 Remove the license plate lamps Refer to Section 9B Lighting Systems 5 Remove the tailgate handle e Remove the screws 1 e Remove the tailgate handle 2 D209B111 Installation Procedure 1 Install the tailgate handle with the screws 2 Install the license plate lamps Refer to Section 9B Lighting Systems 3 R
15. TAILLAMPS The taillamps stoplamps backup lamp s rear fog lamp if equipped with and turn signal lamps are one assem bly Turning on either the headlamps or the parking lamps will also turn on the taillamps When the brake pedal is pushed the taillamps will glow brighter to serve as sto plamps The center high mounted stoplamp is located in the rear window and will come on when the brake pedal is pressed LICENSE PLATE LAMPS The license plate lamps will come on when the head lamps or the parking lamps are on The license plate lamps are mounted on the rear bumper above the li cense plate INTERIOR COURTESY LAMP The courtesy lamp is located on the headliner just be fore the front seats The lamp switch has three posi tions If the switch is in the center position the lamp will go on whenever a door is opened and go off when it is closed In the ON position the lamp will stay on until it is turned off In the OFF position the lamp will not come on even when a door is opened BACKUP LAMP S The backup lamps are located in the rear combination lamps They will come on when the transaxle is shifted into REVERSE On a vehicle with a manual transaxle they are activated by a reverse switch which is part of the transaxle DAYTIME RUNNING LAMPS DRL W Europe Only The daytime running lamps DRL work in conjunction with the exterior lamps system When the ignition switch is turned to the Il position with the
16. e Disconnect the electrical connector 2 e Remove the front fog lamp 3 Installation Procedure 1 Install the front fog lamp with the screws 2 Connect the front fog lamp connector 3 Install the front wheelhouse splash shields with the clips and the bolts 4 Install the front wheels 5 Lower the vehicle 6 Connect the negative battery cable REAR FOG BACKUP LAMP S Removal Procedure 1 Disconnect the negative battery cable 2 Remove the taillamp assembly Refer to Taillamps Assembly in this section 3 Remove the bulb s Installation Procedure 1 Install the bulb s 2 Install the taillamp assembly Refer to Taillamps As sembly in this section 3 Connect the negative battery cable DAEWOO M 150 BL2 LIGHTING SYSTEMS 9B 11 CENTER HIGH MOUNTED STOPLAMP CHMSL Removal Procedure 1 Disconnect the negative battery cable 2 Open the tailgate 3 Pry off the tailgate trim panel Refer to Section 9G In terior Trim 4 Remove the CHMSL cover e Remove the screws 1 e Remove the CHMSL cover 2 5 Remove the CHMSL and bulb e Remove the screws 1 D29B004A e Remove the screw from bulb socket 2 e Remove the CHMSL 3 e Remove the bulb 4 D29B005B Installation Procedure 1 Install the CHMSL bulb 2 Install the CHMSL with the screws 3 Install the CHMSL cover with the screws 4 Install the tailgate trim panel Refer to Section 9G In terior Trim
17. BODY WIRING SYSTEM 9A 5 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE DW 540 010 Relay Remover D1011101 9A 6 BODY WIRING SYSTEM SCHEMATIC AND ROUTING DIAGRAMS WIRE COLOR CHART ED B Red Black BLK WHT Wires With Tracers Wire Color Abbreviation On Schematic Red with White Tracer RED WHT DAEWOO M 150 BL2 BODY WIRING SYSTEM 9A 7 POWER DISRIBUTION SCHEMATIC FS 3 15A Battery q 9 50 10A 4 F12 F13 lt X91 50A RED F6 9 10A Ef2 BYE ya Ka ACC2 SPA S Bi YEL 20A 15A IGN2 E F8 30 ORN Ef12 Ignition BAN lt D lt 10 Switch F9 EH3 15 IGN1 15A illumination lt P 4 F10 Relay 10A RED YEL P VP 85 s RED YEL Ignition pets ORN lt X 20A Headlamp Relay lt D EH9 87 DK BLU 99 is Ef20 9 C205 4 V9 15A D111005B DAEWOO M 150 BL2 9A 8 BODY WIRING SYSTEM RELAY amp FUSE BOX LOCATOR ENGINE ROOM SIRIUS D3 COOLING FAN HIGH SPEED RELAY m COOLING ILLUMINATIOI FAN LOW FOG RELAY ISPEED RELA RELAY COMP RELAY HEAD FUEL LAMP PUMP RELAY RELAY D111003B COOLING FAN IGNITION HIGH SPEED RELAY RELAY ILLUMINATION pope AC RELAY SPEED RELA RELAY RELAY HEAD RELAY D111003C DAEWOO M 150 BL2 BODY WIRING SYSTEM 9A 9 FUSE BOX
18. JOjeolpu 9020 snieis Herd yeu 12 neziiqouiu Jeinpoy 5 ss j y xoojuf 201 6 81 01 1029 134 AH9 SL OL di v 1 3207 100 1 1 uoniub esnd 1 9514 Joy pue Sow Iv uny ul 0 10 easnivis TEM PER XIN33 I WALSAS L33H L LLNV H3ZI TlIHOWINI ANV AH LN3 SS31A3 1l 30IN3H D209T001 DAEWOO M 150 BL2
19. Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fastener to prevent premature corrosion 1 Connect the body to door rubber grommet 2 With the aid of another technician lightly secure the front door with the bolts 3 Adjust the door for proper fit 4 Tighten the hinge to body bolts 5 Install the door hold open link with the bolt 6 Install the fender Refer to Section 9R Body Front End 7 Connect the electrical connector 8 Connect the negative battery cable 9 Perform the waterleak test Refer to Section 91 Wa terleak 10 Check for windnoise Refer to Section 9J Wind noise D19C608A REAR DOOR ASSEMBLY Removal Procedure 1 Disconnect the negative battery cable 2 Pry off the lower B pillar trim panel Refer to Section 9G Interior Trim 3 Disconnect the rear door electrical connector a Rear door electrical connector 4 Remove the rear door assembly e Remove the door hinge bolts 1 e Remove the door hold open link bolt 2 e Disconnect the body to door rubber grommet 3 e Remove the rear door assembly 4 NE 3 DAEWOO M 150 BL2 9P 22 DOORS D19C611A D109C612 D109C636 D19C613A Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fastener to prevent premature corr
20. Removal Procedure 1 Disconnect the negative battery cable 2 Remove the glass Refer to Section 9L Glass and Mirrors 3 Remove the window regulator assembly e Disconnect the window motor electrical connector 1 e Remove the screws 2 e Remove the window regulator assembly 3 9P 20 DOORS 4 Remove the window motor from the window regula tor e Remove the screws 1 e Remove the window regulator 2 Caution Be careful what you are doing when sepa rating the window motor and the window regulator You may be hurt Installation Procedure 1 Install the window motor to the window regulator with the screws 2 Install the window regulator assembly with the screws 3 Connect the window motor electrical connector 4 Install the glass Refer to Section 9L Glass and Mir rors 5 Connect the negative battery cable D109C605 FRONT DOOR ASSEMBLY Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the electrical connector under the instru ment panel Important In case of the front passenger door remove the glove box in advance 3 Remove the fender Refer to Section 9H Body Front End 4 Remove the front door assembly e Remove the door hinge bolts 1 e Remove the door hold open bolt 2 e Disconnect the body to door rubber grommet 3 e Remove the front door assembly 4 D109C607 DAEWOO M 150 BL2 DOORS 9P 21 Installation Procedure
21. e Disconnect the front washer hose connector e Remove the vent grille a Cowl vent grille b Front washer hose connector Installation Procedure 1 Connect the front washer hose connector DAEWOO M 150 BL2 0109 526 DAEWOO 150 BL2 BODY FRONT END 9R 5 2 Install the cowl vent grille with the screws and the clips 3 Install the wiper arm assembly Refer to Section 9D Wiper Washer Systems HOOD Removal Procedure Important Install the protective coverings over the fenders and the windshield in order to prevent damage to the paint the glass and the moldings when you are removing and installing the hood 1 Raise and support the hood 2 Remove the hood e Remove the bolts 1 e Remove the hood 2 Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasteners to prevent premature corrosion 1 Install the hood with the bolts 2 Inspect the hood for proper alignment HOOD HINGE Removal Procedure 1 Remove the hood Refer to Hood in this section 2 Take off the cowl vent grille e Remove the screws after removing the upper caps 1 e Remove the retaining screw on the cowl vent grille 2 e Take off the cowl vent grill
22. e The circuit between the e Repair or Replace the wiring wiper washer switch and the rear harness window wiper motor is the open circuit or a short circuit e The circuit between the fuse F9 e Repair or Replace the wiring and the rear window wiper motor harness is the open circuit or a short circuit e Faulty rear window wiper motor e Replace the rear window wiper motor Poor ground G403 e Repair or Replace the wiring harness Rear Window Washer Does Not The open or a short the power e Repair or Replace the open or a Work Rear Window Wiper OK supply circuit to the fuse F9 short in the power supply circuit to the fuse F9 e Fuse F9 is blown e Replace the fuse F9 e The circuit between the fuse F9 e Repair or Replace the wiring and wiper washer switch is the harness open circuit or a short circuit e Faulty wiper washer switch e Replace the wiper washer switch e The circuit between the e Repair or replace the wiring wiper washer switch and the harness windshield washer pump is the open circuit or a short circuit e Faulty windshield washer pump e Replace the windshield washer pump Poor ground G102 e Repair or Replace the wiring harness DAEWOO M 150 BL2 9D 6 WIPERS WASHER SYSTEMS REPAIR INSTRUCTIONS ON VEHICLE SERVICE D109D519 D109D520 D109D521 WINDSHIELD WIPER ARM Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Remove the wiper arm e
23. rnc arta nanan eee nous 9T 2 Remote Keyless Entry and Autolocking Safety Lock 9T 3 Anti Theft System 9T 7 Control Module Receiver 9T 3 DAEWOO M 150 BL2 9T 2 REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM DESCRIPTION AND OPERATION REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM The remote keyless entry and anti theft system can per form the following functions e Remotely lock and unlock the vehicle doors with a hand held high frequency transmitter e Sense intrusion into the vehicle through the doors the tailgate or the hood Activate a warning to signal an intrusion e Help the driver find the vehicle in a parking area e Automatically re lock the doors if a door or the trunk is not opened within 30 seconds after the vehicle has been unlocked by the remote keyless entry e Communicate serial data to a scan tool to help diag nose system faults The remote keyless entry and anti theft system consists of the following components Keyless entry and anti theft control module receiver Security indicator Tailgate open switch Door open switches Central locking unit Flashing turn signal lamps Siren Hood open switch REMOTE LOCKING AND UNLOCKING The hand held transmitter locks and unlocks the vehicle doors by sending radio waves to the control module re ceiver in the vehicle The effective range of the transmit ter varies between 5 and 10
24. 019 509 3 Inspect the rear window defogger grid lines 4 Use steel wool to buff the grid lines that are to be repaired Wipe the lines clean using a cloth damp ened with alcohol Buff and clean about 6 mm 0 25 inch beyond each side of the break in the grid line D19E515 5 Attach a grid line repair decal or two strips of tape above and below the repair areas A repair decal or tape must be used in order to control the width of the repair areas e f a decal is used the die cut metered slot must be the same width as the grid line 6 Apply the grid repair material to the repair area using a small wooden stick or a spatula The grid repair material should be at room temperature 7 Carefully remove the decal or the tape D19E516 Notice The grid line repair material must be cured with heat In order to avoid heat damage to the interior trim protect the trim near the repair area where heat will be applied 8 Heat the repair area for 1 to 2 minutes 9 Hold the heat gun nozzle 25 mm 1 inch from the surface A minimum temperature of 149 C 300 F is required D19E517 DAEWOO M 150 BL2 9L 10 GLASS AND MIRRORS D109E518 D109E519 D109E520 N D109E521 10 Inspect the grid line repair area If the repair appears discolored apply a coating of tincture of iodine to the area using a pipe cleaner or a line brush Allow the iodine to d
25. 9B 16 Schematic and Routing Diagrams 9B 17 Backup Lamp s Circuit 9B 17 Headlamps Circuit 9B 18 Headlamp Leveling Circuit 9B 19 Tail and Licence Plate Lamps Circuit 9B 20 Stoplamps Circuit 9B 21 Turn and Hazard Lamps Circuit 9B 22 Interior Courtesy Lamp Circuit 9B 23 Front Fog Lamp 9B 24 Rear Fog Lamp Circuit 9B 25 Dimmer Control Circuit Except W Europe 9B 26 Daytime Running Lamps Circuit W Europe Only 9B 27 9B 2 LIGHTING SYSTEMS DESCRIPTION AND OPERATION HEADLAMPS AND PARKING LAMPS The headlamps are controlled by the multifunction lever located on the left side of the steering column They will come on with the ignition switch in any position Turning the headlamp switch to the first position turns on the parking lamps the license plate lamps and the instru ment panel illumination Turning the switch to the sec ond position turns on all of the previous lamps and the headlamps Turning the switch to the off position turns off all the lamps The parking lamps can be turned on by turning the light ing switch to the first position The parking lamps can be turned off by turning the switch to the OFF position Headlamp high beam and low beam are also controlled by this lever When the headlamps are on pushing t
26. 9G 14 On Vehicle Service 9G 4 Floor Console 9G 15 Front Door Trim Panel Standard 9G 4 Parking Brake Cable Cover 9G 15 Front Door Trim Panel Deluxe 9G 5 Floor Carpet 9G 16 Rear Door Trim Panel Standard 9G 6 Luggage Compartment Wheelhouse Rear Door Trim Panel Deluxe 9G 7 Tam Panel uk 9G 17 Rear Door Interior Garnish Molding 9G 8 Special Tools and Equipment 9G 18 Rear Door Exterior Garnish Molding 96 9 Special Tools Table 9G 18 DAEWOO M 150 BL2 9 2 INTERIOR TRIM DESCRIPTION AND OPERATION INTERIOR TRIM PANELS The interior trim panels are molded plastic and fasten with screws or plastic clips PRESSURE RELIEF VENT When all the windows are closed and the ventilation sys tem is on the addition of outside air to the interior of the vehicle causes a positive pressure within the vehicle In order to relieve the pressure air is released through one pressure relief vents The pressure relief vent is located in the luggage compartment behind the spare wheel FLOOR CONSOLE The floor console fits over the tunnel in the floor of the vehicle and extends from under the center of the instru ment panel to the front seat area The floor console con tains the transaxle shift lever and a cupholder The sensing and d
27. INSTRUMENT DRIVER INFORMATION 9E 21 Installation Procedure 1 Install the fuel gauge temperature gauge to the clus ter assembly with the screws 2 Install the instrument cluster lens and the face plate 3 Install the instrument cluster Refer to Instrument Cluster in this section 4 Connect the negative battery cable D19B717A DAEWOO M 150 BL2 9E 22 INSTRUMENT DRIVER INFORMATION SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Passenger s Airbag Module Blank Cover Screw _ 152 O O 13 18 INSTRUMENT CLUSTER INDICATOR LAMPS SPECIFICATIONS ABS Warning Amber 14v 1 4W Airbag Warning Red eae Battery Charge Indicator 14v 1 4W Fasten Seat Belt Warning 14v 1 4W High Beam Indicator 14v 1 4W Low Fuel Level Warning 3 W Oil Pressure Warning Red 14v 1 4W Parking Brake Indicator and Brake Fluid Warning _____ 14v 1 4W Service Engine Soon Warning Amber 14v 1 4W Turn Signal Indicators 14v 1 4W Instrument Cluster Illumination Blue 12 Rear Fog Lamp Indicator 14v 1 4W DAEWOO M 150 BL2 INSTRUMENT DRIVER INFORMATION 9E 23 SCHEMATIC AND ROUTING DIAGRAMS YOUMS eJnsseJd YOUMS pini exyelg YOUMS YOM joe1u02 aye 7069 8 NUS 1HM AWS 1HM wig 13 NHO Hg AN us LN VA Jejsn o j1ueuinugsu 029 LHMWNYa 0cO 2 9 Seul pv ye 10H UO 14617 10H
28. Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Remove the steering column covers Refer to Section 6E Steering Wheel and Column 2 Remove the detection coil e Disconnect the two pin connector from the detec tion coil 1 e Pry the detection coil away from the lock cylinder 2 Important If the detection coil will be replaced with a new one it does not matter if the key position trim ring is damaged during removal A new trim ring is part of the new detection coil 9T 28 IMMOBILIZER ANTI THEFT SYSTEM D29T002 D105A505 D105A504 NES A RV NN RENE D29T003 Installation Procedure 1 Install the detection coil by pressing it onto the lock cylinder until it snaps in place 2 Connect the two pin connector to the immobilizer 3 Install the steering column covers with the screws Refer to Section 6E Steering Wheel and Column IMMOBILIZER CONTROL UNIT Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Disconnect the negative battery cable 2 Remove the steering column covers Refer to Section 6E Steering Wheel and Column 3 Slide the immobilizer control unit toward steering wheel until it slides off its mounting bracket 4 Disconnect the electrical connectors from the immo bilizer control unit 1 DAEWOO M 150 BL2 IMMOBILIZER ANTI THEFT SYSTEM 9T 29 Installation Procedure After replacing the immobilizer co
29. a Fender front bolt D19C543A DAEWOO M 150 BL2 BODY FRONT END 9R 11 11 Remove the bolts along the top of the fender a Bolt 12 Remove the fender b Fender Installation Procedure 1 Install the fender Notice Dissimilar metals in direct contact with each CER other may corrode rapidly Make sure to use the correct fasteners to prevent premature corrosion 2 Install the bolts along the top of the fender D19C527A Install the front bumper spacer Install the cowl vent grille Raise and suitably support the vehicle Install the bolts under the fender Install the screws on the side of the front bumper fascia 8 Open the front door Install the bolt on the A pillar 9 Install the bolt at the base of the fender 10 Install the wheelhouse splash shield with the Screws 11 Lower the vehicle gt D19C545A DAEWOO M 150 BL2 SECTION 9S BODY REAR END Description and Operation 95 2 Fuel Filler Door 95 3 Fuel Filler Door 95 2 Fuel Filler Door Remote Cable and Handle 95 3 Repair Instructions 95 3 Tailgate Remote Cable and Handle 9S 5 On Vehicle Service 9S 3 DAEWOO M 150 BL2 95 2 BODY REAR END DESCRIPTION AND OPERATION FUEL FILLER DOOR The fuel filler door attaches
30. code Refer to Identification ID Code Reprogramming in this section Is the repair complete System OK Go to Step 6 1 Replace the ECM 2 Turn the ignition ON OFF for more than 4 seconds 3 Turn the ignition ON Is the repair complete DAEWOO M 150 BL2 9T 22 IMMOBILIZER ANTI THEFT SYSTEM Without Keyless Entry ata Link connector DLC With Keyless Entry Keyless Entry Control Module Immobilizer 17 Receiver DK BLU YEL ata onnector DLC DK BLU YEL DK BLU YEL 56 Engine Control Module ECM C204 DK BLU YEL Link Engine Control Module ECM D209T002 DIAGNOSTIC TROUBLE CODE P 1629 SIRIUS D3 ECM IMMOBILIZER ERROR Circuit Description When the ignition is turned ON the key is tested by the immobilizer anti theft system While the key code is be ing read by the immobilizer control unit the engine can start and run with any key that will turn the lock cylinder The key code is read and compared with key codes that have been stored in the memory of the immobilizer con trol unit If a valid key is detected the immobilizer control unit sends a serial data release message to the elec tronic control module ECM Included in the release message is an identification ID code which assures that neither the immobilizer control unit nor the ECM has INCORRECT ANSWER been substituted to defeat the system If the ECM re ceives an inval
31. e Disconnect the seat belt warning lamp connector 2 e Remove the seat 3 Installation Procedure 1 Connect the seat belt warning lamp connector 2 Install the front seat with the bolts Tighten Tighten the seat bolt to 23 28 Nem 17 21 Ib ft a Seat bolt 3 Connect the negative battery cable HEAD RESTRAINT Removal Procedure 1 Pull the head restraint up to the stop position 2 Insert a small flathead screwdriver in the notch in the left guide sleeve and pull up the head restraint by pushing the head restraint left 9H 6 SEATS D109B531 D109B532 D109B533 D109B534 Installation Procedure 1 Install the head restraint into the guide sleeves Press down in order to engage the stop pin FRONT SEATBACK Removal Procedure 1 Disconnect the negative battery 2 Remove the front seat assembly Refer to Front Seats in this section 3 Remove the recliner knob from the front seat e Remove the screw 1 e Remove the recliner knob 2 4 Remove the recliner cover from the front seat e Remove the screws 1 e Remove the recliner cover 2 5 Remove the recliner from the front seat e Remove the bolts on the seat cushion 1 e Remove the seatback cover hog rings e Remove the seatback cover 2 e Remove the bolts on the seatback 3 DAEWOO M 150 BL2 SEATS 9H 7 6 Remove the seatback bolt from the seat cushion 1 7 Remove the seatback assembly 2
32. position when the tailgate lock fork snaps over and en gages the striker Fore Aft or In Out Adjustment An adjustment of the striker in the fore and aft or in and out directions may be necessary for a number of reasons vehicle frame damage as the result of a collision installa tion of new tailgate weatherstripping customer com plaints of excessive windnoise or difficulty in opening or closing the tailgate In order to adjust the tailgate striker in an fore and aft or in and out direction perform the follow ing procedure 1 The tailgate must be properly aligned 2 Loosen the striker screws 3 The floating cage plate can be moved slightly using the ends of the striker screws Move the floating cage plate to the desired position Notice It is important to use a flat end rotary file in or der not to damage the tapped floating cage plate The striker screws and the tapped floating cage plate are im portant attaching parts that could affect the performance of vital components and systems 4 f proper adjustment requires that the floating cage plate be moved more than is possible use an electric hand drill and a 3 8 inch rotary file with a flat head in order to enlarge the body opening in the direction required 5 Tighten the striker screws to the correct position 6 Perform the up down adjustment Refer to Up and Down Adjustment in this section DAEWOO M 150 BL2 D19C580A D109C582 D19
33. 1 e Remove the hinge to door bolts 2 e Remove the door hold open link 3 D109C617 Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fastener to prevent premature corrosion 1 Install the door hold open link to the door and the body with the bolts 2 Remove the door seal trim Refer to Door Seal Trim in this section INSIDE CHANNEL WEATHERSTRIP STANDARD Removal Procedure 1 Remove the channel weatherstrip a Weatherstrip D109C619 DAEWOO M 150 BL2 D109C620 D109C621 D109C622 D109C623 DAEWOO M 150 BL2 DOORS 9P 25 Installation Procedure 1 Install the channel weatherstrip INSIDE CHANNEL WEATHERSTRIP DELUXE Removal Procedure 1 Remove the door trim Refer to Section 9G Interior Trim 2 Remove the channel weatherstrip from the door trim e Straighten the retaining tabs 1 e Remove the channel weatherstrip 2 Installation Procedure 1 Install the channel weatherstrip onto the door trim panel 2 Bend the retaining tabs to secure the channel weath erstrip to the door trim panel 3 Install the door trim panel Refer to Section 9G Interi or Trim DOOR OUTSIDE CHANNEL WEATHERSTRIP Removal Procedure 1 Remove the channel weatherstrip e Remove the screw 1 e Lift off the outside channel weatherstrip 2 9P 26 DOORS Installation Procedure 1 Pre
34. 3 Remove the instrument cluster assembly from the in strument panel e Remove the screws 1 e Disconnect the electrical connector and the speedometer cable 2 e Remove the instrument cluster 3 12 INSTRUMENTATION DRIVER INFORMATION D19B515A D109B516 D109B517 Installation Procedure 1 Connect the electrical connector and the speedom eter cable 2 Install the instrument cluster assembly to instrument panel with screws 3 Install the instrument cluster trim panel to the instru ment panel Refer to Instrument Cluster Trim Pan el in this section 4 Connect the negative battery cable INSTRUMENT PANEL Left Hand Drive Shown Right Hand Drive Similar Removal Procedure Disconnect the negative battery cable Remove the driver s airbag module from the steer ing wheel Refer to Section 8B Supplemental Inflat able Restraints SIR For the vehicle equipped with the airbag Remove the steering wheel from the steering col umn Refer to Section 6E Steering Wheel and Col umn Remove the steering column trim cover Refer to Section 6E Steering Wheel and Column Remove the signal lamp switch and the wiper switch Refer to Section 6E Steering Wheel and Column Pry off the A pillar trim panels Refer to Section 9G Interior Trim Remove the instrument cluster trim panel from the instrument panel e Remove the screws
35. 5 Connect the negative battery cable D19E554A DAEWOO M 150 BL2 9B 12 LIGHTING SYSTEMS D19D510A D19D511A CHMSL MOUNTING BRACKET Removal Procedure 1 Disconnect the negative battery cable 2 Remove the center high mounted stoplamp CHMSL Refer to Center High Mounted Stoplamp in this section 3 Remove the rear window wiper motor assembly Re fer to Section 9D Wipers Washer Systems 4 Remove the CHMSL mounting bracket e Remove the bolts 1 e Remove the CHMSL mounting bracket 2 Installation Procedure 1 Install the CHMSL mounting bracket with the bolts 2 Install the rear window wiper motor assembly Refer to Section 9D Wipers Washer Systems 3 Install the CHMSL Refer to Center High Mounted Stoplamp in this section 4 Connect the negative battery cable LICENSE PLATE LAMPS Removal Procedure 1 Disconnect the negative battery cable 2 Remove the license plate lamp from the tailgate han dle e Remove the screws 1 e Draw out the license plate lamp 2 e Remove the license plate lamp bulb 3 3 Remove the rear window wiper motor assembly Re fer to Section 9D Wipers Washer Systems 4 Disconnect the electrical connector in the tailgate 5 Remove the tailgate handle Refer to Section 9M Ex terior Trim 6 Remove the license plate lamp socket e Remove the socket 1 DAEWOO M 150 BL2 b D19D51
36. All Times Hot in Run and Start Engine Fuse Center High Mount Stop Lamp D111001A DAEWOO M 150 BL2 BODY WIRING SYSTEM 9A 3 Contents of Electrical Wiring Diagram The box above the fuse box Power supply lines Power supply lines 30 15 15A Ka 58 50 Refer to Circuit Identification Symbol in this section for more details Ef10 or F3 Fuse Number Ef10 Fuse No 10 in the engine room fuse box F3 Fuse No 3 in the passenger room fuse box 40A Fuse Capacity Refer to Relay Box Locator and Fuse Box Locator in this section Connector Connector No C202 terminal No 10 Refer to How to Check Terminal Number of Connect in this section Internal circuit of component Relay Component Name Terminal Number nternal circuit of component Switch Terminal Number Wiring Harness Color Refer to Wire Color Chart in this section Ground line G402 Ground Position In case of the ground numberless this means the body ground Circuit Identification Symbol Fuse in engine room fuse box Fuse in passenger compartment fuse box DAEWOO M 150 BL2 9A 4 BODY WIRING SYSTEM HOW TO CHECK TERMINAL NUMBER OF CONNECTOR Terminal number is given based on female terminal connector Example Terminal number 4 of 6 pin connection Locking Male connector Female connector CXXX W H Body D111002A DAEWOO M 150 BL2
37. DAEWOO M 150 BL2 DAEWOO M 150 BL2 IMMOBILIZER ANTI THEFT SYSTEM 9T 19 DTC 1602 ECM Immobilizer Error ECM Locked Connect the scan tool using the following procedure Insert the cartridge into the scan tool Turn the ignition switch to the OFF Connect the scan tool to the data link connector DLC Connect the scan tool s power cord to the cigar lighter socket Turn the ignition ON but do not start the engine Is communication established between the scan tool and the immobilizer control unit 1 Select CURRENT KEY STATUS from the scan tool menu 2 Read the STATUS OF CURRENT KEY message Does the KEY STATUS message indicate KEY IS WRONG 1 Select DIAGNOSIS from the scan tool menu 2 Read the IMMO amp ECM ID CODE immobilization and electronic control module identification code message Did the message differ from normal message Normal Message ECM MODE LEARNT IMMO MODE LEARNT VIN CODE SAME Check for an open serial data wire between the immobilizer control unit and the electronic control module ECM Was the circuit open Repair the open serial data wire between the ECM and the immobilizer control unit Is the repair complete 1 Replace the ECM 2 Reprogram the ID code Is the repair complete Go to Communi cation Between Immobilizer and Test Go to Step 2 Equipment Go to Key Status Errors Go to Step 3 Go to Identification ID Code Repro grammi
38. Front End a Cowl vent grille Disconnect the washer hose connector b Washer hose connector Raise and suitably support the vehicle 4 Remove the front RH wheel Remove the front RH wheel house splash shield e Remove the screws 1 e Remove the clips 2 e Remove the wheel house splash shield 3 Disconnect the washer hose from the washer pump a Washer hose 9D 14 WIPERS WASHER SYSTEMS D109D545 D19D546A 7 Remove the washer hose a Washer hose Installation Procedure 1 Connect the washer hose to the washer pump 2 Install the front RH wheel house splash shield with the screws and the clips 3 Install the front RH wheel 4 Lower the vehicle 5 Connect the washer hose connector 6 Install the cowl vent grille Refer to Section 9R Body Front End DAEWOO M 150 BL2 WIPERS WASHER SYSTEMS 9D 15 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Also Nm um Wiper Linkage Conclusion Nut 15 20 138 9D 16 WIPERS WASHER SYSTEMS SCHEMATIC AND ROUTING DIAGRAMS WINDSHIELD REAR WINDOW WIPER AND WASHER SYSTEM Hot in Run and Start Hot in Run and Start RED YEL Rear Rear Front Wiper Washe Washer e Switch Switch e Switch BLR RED YEL RED YEL GRN DK BLU ront Wiper Motor Activated Park Position Switch D19D208B DAEWOO M 150 BL2 SECTION 9E INSTRUMENTATION DRIVER INFORMATION CAUTION Disconnect the negat
39. Install the wiper motor assembly to the tailgate with the screws Connect the electrical connector Install the tailgate inside trim Refer to Section 9G In terior Trim Install the wiper arm Refer to Windshield Wiper Arm in this section Connect the negative battery cable WINDSHIELD WIPER LINKAGE Left Hand Drive Shown Right Hand Drive Similar Removal Procedure Remove the windshield wiper arms Refer to Wind shield Wiper Arm in this section Remove the cowl vent grille Refer to Section 9H Body Front End Separate the wiper linkage from the wiper motor e Separate the wiper linkage from the wiper motor linkage ball 1 Remove the wiper linkage e Remove the wiper linkage nuts 1 e Remove the wiper linkage 2 9D 10 WIPERS WASHER SYSTEMS D19D533A D109D534 D109D535 D109D536 Installation Procedure 1 Install the wiper linkage with the wiper linkage nuts Tighten Tighten the wiper linkage nuts to 1 5 2 0 Nem 13 18 Ib in a Wiper linkage nut Install the wiper motor linkage ball Install the cowl vent grille Refer to Section 9R Body Front End Install the windshield wiper arms Refer to Wind shield Wiper Arm in this section WINDSHIELD WIPER BLADE Removal Procedure 1 Pull the wiper blade off the arm by pushing the wiper blade retaining clip 1 Installation Procedure 1 Install the w
40. Motor Switch Rear Defroster Switch Wiper Switch Light Switch Headlamp Leveling Switch C205 Audio ra Connector Cigar Lighter DLC Blower Motor Blower Ragistor Direction A Evaporator Thermistor C201 C203 C204 Ignition Switch Immobilizer Stop Lamp Switch Anti theft Control Unit D111403E DAEWOO M 150 BL2 Cluster Connector Wiper Light Switch Switch cL CRY rr BODY WIRING SYSTEM 9A 15 INSTRUMENT HARNESS ROUTING Right Hand Drive Direction B Front or Hazard Switch Rear Fog Lamp Switch Immobilizer Display Fuse Block and Relays Blower Motor Switch Rear Defroster Swtich C202 Stop lamp Switch Headlamp Mee Leveling Dimmer Switch Control Switch DAEWOO M 150 BL2 3 Audio Cigar Lighter Direction A M DLC Connector Blower Motor Blower Resistor Evaporator Thermistor D111403F 9A 16 BODY WIRING SYSTEM AIRBAG HARNESS ROUTING Left Hand Drive Shown Right Hand Drive Similar Air bag Module EON 3 Passenger DLC Connector Sensing and Diagnostic Module SDM G302 Contact Coil BODY WIRING SYSTEM 9A 17 BODY HARNESS ROUTING D111405D Left Rear Wheel Speed Sensor C371 Fuel
41. Pry off the outside rearview mirror inside trim cover 1 2 Remove the mirror adjusting lever mounting nuts 2 3 Remove the outside rearview mirror cover from the outside rearview mirror D109E529 4 Remove the outside rearview mirror e Remove the screws 1 e Remove the outside rearview mirror 2 D109E530 Installation Procedure 1 Install the outside rearview mirror with the screws 2 Install the outside rearview mirror cover 3 Install the mirror adjusting lever with the nuts 4 Install the outside rearview inside trim cover D109E531 DAEWOO M 150 BL2 9L 16 GLASS AND MIRRORS D109E529 D209B108 D109E531 OUTSIDE REARVIEW MIRROR ELECTRIC Removal Procedure 1 Disconnect the negative battery cable 2 Remove the outside rearview mirror cover from the outside rearview mirror 3 Remove the outside rearview mirror e Remove the screws 1 e Disconnect the electrical connector 2 e Remove the outside rearview mirror 3 Installation Procedure 1 Connect the outside rearview mirror 2 Install the outside rearview mirror with the screws 3 Install the outside rearview mirror cover 4 Connect the negative battery cable DAEWOO M 150 BL2 GLASS AND MIRRORS 9L 17 SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE J 24402 Glass Sealant Remover D109E102 9L 18 GLASS AND MIRRORS SCHEMATIC AND ROUTING DIAGRAMS REAR WINDOW DEFOGGER Hot
42. REPAIR INSTRUCTIONS ON VEHICLE SERVICE FRONT BUMPER FASCIA Removal Procedure 1 Disconnect the negative battery cable 2 Raise and suitably support the vehicle 3 Remove the front wheels 4 Remove the front wheel house splash shields e Remove the clip and bolts a Bolt and clip e Remove the wheel house splash shield b Splash shield D19C501A 5 Remove the bolts on the both side of the fascia a Bolt D109C502 6 Remove the clips under the fascia a Clip P D109C503 DAEWOO M 150 BL2 GaN TES UE A D109C506 D19C507A DAEWOO M 150 BL2 BUMPERS AND FASCIAS 90 5 Lower the vehicle 8 Remove the front bumper spacer from the bumper Refer to Section 9M Exterior Trim 9 Remove the front bumper fascia e Remove the bolts 1 e Remove the clips 2 e Remove the front bumper fascia 3 10 Remove the front fog lamps Refer to Section 9B Lighting Systems Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasteners to prevent premature corrosion 1 Install the front fog lamps Refer to Section 9B Lighting Systems 2 Install the bumper fascia 3 Install the clips on the top of the fascia a Fascia upper clip 4 Install the bolts on the top of the fascia b Fascia upper bolt 5 Install the front bu
43. Right Side Turn m DK BLU Side Signal Signal GRY Signal Right Rear Turn Signal BLK D19D205B DAEWOO M 150 BL2 LIGHTING SYSTEMS 9B 23 INTERIOR COURTESY LAMP CIRCUIT Hot at All Times Roomlamp T GATE Switch D19D206B DAEWOO M 150 BL2 9B 24 LIGHTING SYSTEMS FRONT FOG LAMP CIRCUIT Hot at All Times Hot with Light On Hot at All Times BRN WHT C205 5 202 7 203 ORN BLK BRN WHT Cluster D19B724A1 DAEWOO M 150 BL2 LIGHTING SYSTEMS 9B 25 REAR FOG LAMP CIRCUIT 1 Fog Lamp Switch Hot at All Times Hot with Lights On Engine illumination 2 be BRN WHT Relay pees 85 50202 7 C203 BRNWHT BRN WHT Headlamp Relay i Fog Lamp Switch 77 Headlamp Switch Light Switch Instrument Cluster G401 LHD G402 RHD D19B724B DAEWOO M 150 BL2 98 26 LIGHTING SYSTEMS DIMMER CONTROL CIRCUIT EXCEPT W EUROPE W FRT Fog Lamp Switch Hot at All Times Illumination Relay em C203 BRN WHT BRN WHT Headlamp Relay Dimmer Control Relay D29B009A DAEWOO M 150 BL2 Instrument Ciuster DAEWOO M 150 BL2 LIGHTING SYSTEMS 9B 27 DAYTIME RUNNING LAMPS CIRCUIT W EUROPE ONLY Hot in Run and Start Hot with Lights On Hot at Times Oil Pressure Warming Lamp Oil Pressure Switch Engine Fuse Block DK BLU RED 94C205 34 C206 YEL Flash to Pass Switch DK GRN H
44. a Defroster grille b Demister grille D109B708 Installation Procedure 1 Install the defroster grilles and the demister grilles to the instrument 2 Install the instrument panel guide to the instrument panel with the screws 3 Install the glove box striker and the bracket to the in strument panel with the screws 4 Install the cigar lighter housing to the instrument pan el with the screws 5 Install the ventilation grilles to the instrument panel with the screws 6 Install the ventilation duct to the instrument panel with 01098521 the screws DAEWOO M 150 BL2 INSTRUMENT DRIVER INFORMATION 9E 19 7 Install the passenger s airbag module blank cover to the instrument panel with the screws Tighten Tighten the screws to 1 5 2 N m 13 18 Ib in a Passenger s airbag module blank cover screw 8 Install the instrument cluster brackets to the instru 1 5 2 0 ment panel with the screws 9 Install the instrument panel assembly Refer to In strument Panel in this section 10 Connect the negative battery cable D19B710A INSTRUMENT CLUSTER INDICATOR LAMPS Removal Procedure 1 Disconnect the negative battery cable 2 Remove the instrument cluster from the instrument panel Refer to Instrument Cluster in this section 3 Remove the indicator bulbs from the rear of the clus ter D109B711 Installation Procedure 1 Install the indicator bulb 2 Install the inst
45. e Remove the rear parcel side shelf 2 Installation Procedure Install the rear parcel side shelf with the screw Install the rear speaker to the rear parcel shelf Refer to Section 9F Audio Systems Install the rear parcel shelf Refer to Rear Parcel Shelf in this section 4 Install the seatback Connect the negative battery cable FRONT ROCKER TRIM PANEL Removal Procedure 1 Pry off the rocker trim panel e Remove the clip 1 e Remove the screw 2 Pry off the rocker trim panel 3 Installation Procedure 1 Install the rocker trim panel with the clip and the Screw 9G 14 INTERIOR TRIM REAR ROCKER TRIM PANEL Removal Procedure 1 Remove the rear seat cushion D109E570 2 Remove the rear seat belt bolt on the floor e Remove the bolt 1 e Remove the spacer and the spring washer 2 e Remove the plastic protector from the seat belt an chor D110A508 3 Pry off the rear rocker trim panel e Remove the screws securing the rear rocker trim panel 1 e Remove the clip 2 e Pry off the rear rocker trim panel 3 Installation Procedure 1 Install the rear rocker trim panel with the screws and the clip 2 Install the rear seat belt bolt on the floor 3 Install the rear seat cushion D109E572 DAEWOO M 150 BL2 DAEWOO M 150 BL2 PSS D19E575A D19E576
46. immo bilizer Refer to Immobilizer Control Unit in this section NO TRANSPONDER DETECTED The fault may be in ignition key transponder the detection coil or the immobilizer Follow the steps below to diagnose the problem 1 Tryadifferent key If a different key works the problem is in the original key 2 If trying a different key results in the same er ror message check the connection of the detection coil 3 connection of the detection coil is okay disconnect the detection coil and use an ohm meter to check for an open detection coil 4 If the detection coil is not open replace the immobilizer control unit Refer to Immobilizer Control Unit in this section KEY STATUS ERRORS SIRIUS D3 The following KEY STATUS messages may be shown on the scan tool after commanding FIRST KEY COD ING and KEY ADD IGNITION OFF STATUS This message informs the technician that the ignition is off during the key coding process Turn the ignition ON during key coding but do not start the engine e KEY IS OCCUPIED Only five keys may be coded If a new key is desired the previous key codes must be deleted Up to five keys may then be authorized ALREADY AUTHORIZED Key coding is being at tempted with a key that is already authorized e ERROR NO A3 A4 A5 There is no communication between the transponder in the ignition key and the detection coil Follow the steps below to diagnose the problem 1 Tr
47. key that will turn the lock cylinder The key code is read and compared with key codes that have been stored in the memory of the immobilizer con trol unit If a valid key is detected the immobilizer control unit sends a serial data release message to the elec tronic control module ECM Included in the release message is an identification ID code which assures that neither the immobilizer control unit nor the ECM has been substituted to defeat the system If the ECM re ceives an invalid release message the ECM performs the following actions e Disables the fuel injector circuit e Disables the fuel pump circuit e Disables the ignition coil DTC Will Set When e The ECM does not receive the signal from the immo bilizer control module when the ignition is turned on e The above conditions are maintained until the ignition is switched OFF DTC 1600 Will Clear When e The ignition switch is turned OFF or the scan tool TROUBLE CODE CLEAR command is issued DAEWOO M 150 BL2 DAEWOO M 150 BL2 IMMOBILIZER ANTI THEFT SYSTEM 9T 15 DTC 1600 ECM Immobilizer Error No Answer Connect the scan tool using the following procedure Insert the cartridge into the scan tool Turn the ignition switch to the OFF position Connect the scan tool to the data link connector DLC Connect the scan tool s power cord to the cigar lighter socket Turn the ignition ON but do not start the engine Is communication establ
48. light switch off park ing tail license plate and instrument panel lights illumi nate And when the engine is started the headlamps low beam also come on They remain on until the ignition switch is turned off or the light switch is turned on They revert to normal op eration when the light switch is on The daytime running lamps DRL is optional DAEWOO M 150 BL2 LIGHTING SYSTEMS 9B 3 DIAGNOSTIC INFORMATION AND PROCEDURES HEADLAMPS Condition Probable Cause Correction Low Beam Headlamps Are e Faulty headlamp combination e Replace the headlamp Inoperative High Beam switch combination switch Headlamps Are OK e The open circuit or a short circuit e Repair or Replace the wiring between the fuse Ef10 Ef11 and harness the terminal 5 of the headlamp combination switch e Fuse Ef10 or Ef11 is blown e Replace the fuse Ef10 between the fuse Ef10 or Ef11 and harness the terminal 2 of the headlamp connector e Headlamp bulb is blown e Replace the headlamp bulb e The open grounds G101 G102 e Repair or replace the open ground e The open circuit or a short circuit e Repair or Replace the wiring circuit circuit High Beam Headlamps Are e Faulty headlamp combination Replace the headlamp Inoperative Low Beam switch combination switch Headlamps Are OK e The open circuit or a short circuit e Repair or Replace the wiring between the fuse Ef8 Ef9 and the harness terminal 4 of the hea
49. meters approximately 16 to 32 feet depending on whether or not objects such as other vehicles are blocking the path of the radio waves The transmitter has a LOCK button and an UNLOCK button which only function when the ignition is OFF Pressing the UNLOCK button has the following effects e The doors are unlocked e The turn signal lamps flash twice e The control module is disarmed Pressing the LOCK button has the following effects e The doors are locked e The turn signal lamps flash once e The control module is armed The transmitter has a replaceable battery The battery is designed to last at least two years before replacement is necessary SECURITY INDICATOR There is a security indicator on the instrument panel Af ter the LOCK button of the transmitter is pressed the module is placed in the armed mode and the security indicator flashes The security indicator turns ON for 1 8 second and OFF for 7 8 second It then flashes at that frequency until the control module receiver is disarmed INTRUSION SENSING The anti theft function is armed if the transmitter sends the LOCK message to the control module receiver when the ignition is OFF When the hood the door or the tailgate is opened the hood open switch the door open switch or the tailgate open switch will change its input to ground The alarm will be activated if the hood open sensor the door open sensor or the tailgate open sensor changes its input t
50. occurs e The scan tool is disconnected from the DLC Five passwords are recorded in the control module receiver 9T 6 REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS 8 71 Hood Open Switch Mounting Screw E EE NN DAEWOO M 150 BL2 REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM 9T 7 SCHEMATIC AND ROUTING DIAGRAMS YOUMS uedo uedo Jooq 4ooq YMS uedo 1 JOAUp 05 ssajAey TAA 501415 YS XIN33 X18 LHM 6029 8 8 H Jo12euuo yur uos uedo jooq JeAug 1 yams P YOUMS uedo 1 POOH 2079 A v 9 90204 vl 069 8 8 vl yooig esnj 218 pue ung JOjE2IDU Snes yeu HUY TAA y ojun 001 49071 400q soul Iv ye 10H IN31SAS LASHLILNV ANV AHLN3 SS31A3 I SLOWSY D209T000 DAEWOO M 150 BL2 9T 8 REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM BLANK IMMOBILIZER ANTI THEFT SYSTEM 9T 9 SECTION 9T IMMOBILIZER ANTI THEFT 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 Dis
51. running of the engine 2 After receiving a response message including the in formation ICU in learnt mode and a wrong system VIN code ECM does not send a new request and enters the blocked state which causes the activation of the immobilization actions of the engine 9T 12 IMMOBILIZER ANTI THEFT SYSTEM 3 If the ECM doesn t receive a response message with in a defined time from beginning of the release time period or the ECM receives a no release answer the ECM enters the blocked state which causes the activation of the immobilization actions of the engine e The inactive state of the Immobilizer valid key invalid key ends with turning off the ignition SECURITY INDICATOR There is a security indicator on the instrument panel Status LED An external LED displays the immobilizer system status The immobilizer contains the LED driver hardware for di rect connection of one LED Status LED Modes Status Immobilizer LED System Status Blinking Ignition OFF Blinking Active Invalid key detected Ignition ON OFF Inactive Valid key detected Ignition ON VIN code is different between ICU and ECM in learnt state Ignition ON Transponder reading error Ignition ON Reader exciter ASIC error Ignition OFF Blinking Active Active Active Blinking DAEWOO M 150 BL2 IMMOBILIZER ANTI THEFT SYSTEM 9T 13 DIAGNOSTIC INFORMATION AND PROCEDURE
52. seatback with the hinge bolts Tighten Tighten the hinge bolts to 23 28 N m 17 21 lb ft a Rear seatback hinge bolt 2 Press the lock knob DAEWOO M 150 BL2 D109B544 DAEWOO M 150 BL2 D19B546A D109B718 D109B719 SEATS 9H 11 REAR SEAT CUSHION Removal Procedure 1 Remove the rear seat cushion e Remove the bolts 1 e Lift and remove the rear seat cushion 2 Installation Procedure 1 Install the rear seat cushion with the bolts Tighten Tighten the rear seat cushion bolt to 23 28 N m 17 21 lb ft a Rear seat cushion bolt REAR SEATBACK LATCH Removal Procedure 1 Remove the rear seatback assembly Refer to Rear Seatback in this section 2 Remove the lock knob from the seatback e Remove the lock knob by twisting it 1 3 Remove the rear seatback cover from the seatback frame 4 Remove the lock from the seatback frame e Remove the bolts 1 e Remove the lock 2 9H 12 SEATS D109B720 D109B718 D109B721 D109B722 Installation Procedure 1 Install the lock to the seatback frame with the bolts 2 Install the rear seatback cover to the seatback frame 3 Install the lock knob to the seatback 4 Install the rear seatback assembly Refer to Rear Seatback in this section REAR SEATBACK HINGE Removal Procedure 1 Remove the rear seatback assembly Refer to Rear Seatback in this section 2 Remove the hinge from the seatback e Remove
53. the general leak area is found determine the exact entry point of the leak by using a water hose or an air hose If the general leak area is not obvious use the watertest stands to determine the area of the leak It may be nec essary to remove some interior trim panels or some parts in order to locate the leaks Important It is necessary to find the origin of all the leaks before making any repairs Random repairs may stop the leak only temporarily and may make future re pairs more difficult Continue localized testing in the gen eral area in order to ensure that all leaks are found Generalized Testing 1 Set up the watertest stands 19 D109A301 1 2 inch by 36 inch Pipe 2 Full jet Spray Nozzle 1 2 GG 25 or Equivalent Nozzle Height at 1 600 mm to the Floor 1 2 inch Coupling 1 2 inch by 1 2 inch by 1 4 inch Reducing T Right Only 1 2 inch Coupling Left Only 1 2 inch Cross Right Only 1 2 inch Tee Left Only 1 2 inch Pipe to Hose Nipple Right Only 5 8 inch Female Hose Coupling 5 8 inch Input Hose 2 Feet Long Right Only 1 2 inch Close Nipple 1 2 inch Cross with Weld on 1 2 inch Cap 1 2 inch by 12 inch Nipple 1 2 inch Cap 5 8 inch Female Hose Coupling 5 8 inch Cross Hose 12 Feet Long 5 8 inch Hose Quick Connect 1 2 inch Pipe to Hose Nipple 1 2 inch by 30 inch Pipe Straight 1 4 inch Water Pressure Gauge Right Only 2 Set up the watertest stand leak test D19A302A DAEWOO M 150 BL
54. the nut e Remove the hinge Installation Procedure 1 Install the hinge to the seatback with the nut 2 Install the rear seatback assembly Refer to Rear Seatback in this section DAEWOO M 150 BL2 SEATS 9H 13 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Amin Nm iR im Front Seat Bolts Both 23 28 17 21 Rear Seat Cushion Bos 98 ra Rear Seatback Bolts 23 28 17 21 c cx T SECTION 9 WATERLEAKS TABLE OF CONTENTS Diagnostic Information and Procedures 91 2 Waterleak Diagnosis 91 2 Repair Instructions 91 5 On Vehicle Service 91 5 Waterleak Repair 91 5 DAEWOO 150 812 Specifications 91 7 Recommended Materials for Waterleak Repairs 91 7 Watertest Stand Specifications 91 7 9 2 WATERLEAKS DIAGNOSTIC INFORMATION AND PROCEDURES WATERLEAK DIAGNOSIS The repair of waterleaks in the body requires proper testing and diagnosis Repair waterleaks by adjusting the misaligned parts and using the proper repair materi als First determine what conditions cause the leak For example the leak may occur only when the vehicle is parked on an incline or water may appear only in the spare tire compartment Second test the area for the source of the leak using the following testing methods If
55. to floor pan anchor provisions or the seat adjuster to seat frame anchor provisions Changing the seat position could af fect the performance of the seat system This vehicle is equipped with low backed front seats with separate head restraints and a three passenger folding rear seat Split folding rear seat is optional Seats cushions and seatbacks have formed foam pads which fit the contours of the full panel seatback frame assem bly and the designed contour of the seat cushion frame There are no front seat forward or rearward relocation provisions provided at either the seat adjuster to seat frame or the seat adjuster to floor pan anchor attach ments DAEWOO M 150 BL2 o Roma Head Restraint Guide Sleeve Seatback Seatback Frame Seat Cushion COMPONENT LOCATOR FRONT SEAT ON Seat Cushion Frame Recliner Redliner Knob Seat Side Cover Guide Rail SEATS 9H 3 D109B402 9H 4 SEATS REAR SEAT D19B403A Rear Seatback Cushion Rear Seatback Frame Rear Seat Hinge Rear Seat Lock Rear Seat Cushion Seat Release Knob Eyelet Seat Back Hinge Rear Cushion Pull Loop OND DAEWOO M 150 BL2 SEATS 9H 5 REPAIR INSTRUCTIONS ON VEHICLE SERVICE D109B528 D19B529A D109B530 FRONT SEATS Removal Procedure 1 Disconnect the negative battery cable 2 Remove the front seat e Remove the bolts 1
56. when the control module receiver is in the armed mode the doors are automatically re locked after 30 seconds unless any of the following events occur e The door is opened e The ignition switch is turned ON e The tailgate is opened e The hood is opened DAEWOO M 150 BL2 CONTROL MODULE RECEIVER The remote keyless entry control module receiver is contained in the tie bar center The module receiver pro cesses signals from the remote transmitter and the in trusion sensors and it activates the alarm if an intrusion is detected The control module receiver will not communicate with transmitters from other vehicles because there are over four billion possible electronic password combinations and passwords are not duplicated The control module receiver has an attached antenna to detect signals from the transmitter 9T 4 REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM REPAIR INSTRUCTIONS ON VEHICLE SERVICE D19C501A 02098106 02098107 Removal Procedure 1 Disconnect the negative battery cable 2 Raise and suitably support the vehicle 3 Remove the front wheels 4 Remove the front wheel house splash shield e Remove the clip and bolts a Bolts and clips e Remove the wheel house splash shield b Splash shield 5 Remove the siren e Remove the screws 1 e Disconnect the electrical connector 2 Installation Procedure 1 Install the siren with the screws 2 Connect the electrical connec
57. 01 e Repair or Replace the open circuits ground circuit e Rear fog lamp bulb is blown e Replace the rear fog lamp bulb DAEWOO M 150 BL2 DAEWOO M 150 BL2 LIGHTING SYSTEMS 9B 7 REPAIR INSTRUCTIONS ON VEHICLE SERVICE D19D502A D19D503A HEADLAMPS Removal Procedure 1 Support the hood suitably 2 Disconnect the negative battery cable 3 Remove the front bumper spacer e Remove the bolts 1 e Remove the front bumper spacer from the bumper fasia 2 A Remove the headlamp e Remove the bolts and washer 1 e Disconnect the electrical connectors e Remove the headlamp 2 Installation Procedure 1 Install the headlamp with the bolts 2 Connect the headlamp connector and parking lamp connector 3 Install the front bumper spacer with the bolts 4 Connect the negative battery cable 9B 8 LIGHTING SYSTEMS D19D505A D19D506A D29B001 D29B002 TURN SIGNAL LAMPS Removal Procedure 1 Disconnect the negative battery cable 2 Remove the front bumper spacer Refer to Section 9M Exterior Trim 3 Remove the turn signal lamps from the front bumper spacer e Disconnect the electrical connector 1 e Remove the screw 2 e Remove the turn signal lamp assembly 3 Installation Procedure 1 Connect the electrical connector 2 Install the turn signal lamp assembly with the screw 3 Install the front bumper spacer Refer to Section 9M Exterior Trim 4 Connect the
58. 1 Using a flathead screwdriver remove the instru ment cluster trim panel 2 Notice To prevent the instrument panel damage cover the flathead screwdriver with a soft cloth 8 10 11 Remove the hood latch release lever from the in strument panel Refer to Section 9H Body Front End Remove the glove box assembly from the instru ment panel Refer to Glove Box in this section Remove the passenger s airbag module from the in strument panel Refer to Section 8B Supplemental Inflatable Restraints SIR For vehicle equipped with the airbag Put aside the floor console after removing the Screws 1 DAEWOO M 150 BL2 INSTRUMENTATION DRIVER INFORMATION 9E 13 D109B518 D109B520 D109B521 DAEWOO M 150 BL2 12 13 14 15 16 17 18 Remove the instrument cluster assembly Refer to Instrument Cluster in this section Remove the A C controller from the instrument Re fer to Section 7B Manual Control Heating Ventila tion and Air Conditioning System Remove the audio system from the instrument pan el Refer to Section 9F Audio Systems Disconnect the cigar lighter connector Disconnect the ashtray lamp if equipped Disconnect the ALDL connector e Remove the screws 1 e Disconnect the ALDL connector 2 Remove the instrument trim panel assembly e Remove t
59. 1A D109C562 D109C563 D109C564 Installation Procedure 1 Install the upper sunroof frame 2 Install the lower sunroof frame with the screws a 3 Install the inside sunroof molding 4 Install the screen with the clips and the lock Tighten Tighten the screws to Nem 27 lb in Notice When installing the lower sunroof frame make sure to tighten the screws previously as shown the fig ure and tighten all the screws SUN VISORS Removal Procedure 1 Remove the sun visors e Remove the screws 1 e Remove the sun visors 2 Installation Procedure 1 Install the sun visors with the screws PASSENGER ASSIST HANDLE OR THE COAT HOOK Removal Procedure 1 Remove the passenger assist handle or the coat hook from the headliner e Remove the screws 1 e Remove the coat hook or the assist handle 2 DAEWOO M 150 BL2 ROOF 9Q 7 Installation Procedure 1 Install the passenger assist handle or the coat hook to the headliner with the screws D109C565 DAEWOO M 150 BL2 9Q 8 ROOF SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS SECTION 9R BODY FRONT END TABLE OF CONTENTS Description and Operation 9R 2 Cowl Vent Grille 9R 4 Body Front End 9R 2 Hood cto enor ie ete 9R 5 Repair Instructions 9R 3 Hood HINGE s ies atecihteitiefsteusri d s 9R 5 On Vehicle S
60. 2 WATERLEAKS 91 3 3 Perform the watertest stand leak test Refer to Wa 4 If the local water pressure does not allow the required tertest Stand Specifications in this section water pressure of 155 kPa 22 5 psi move both stands closer to the vehicle so that the water spray overlaps 3 000mm D109A303 Localized Testing Spot Test 3 Begin spraying the water at the base of the suspected 1 Do localized testing with a water hose or an air hose leak area Continue spraying the water upward until the leak is found 2 Begin testing by spraying the air or the water at the base of the suspected leak area Continue spraying the air or the water upward until the leak is found Water Hose Test 1 Place another person inside the vehicle in order to detect the location of the leak 2 Use a water hose without a nozzle D109A305 D109A304 DAEWOO M 150 BL2 91 4 WATERLEAKS Air Hose Test 1 Apply soapy water to the outside of the vehicle in the suspected leak area Blow air from inside the vehicle The air pressure should not exceed 205 kPa 29 7 psi Determine the location of the leaks from the bubbles formed in the soapy water D109A306 DAEWOO M 150 BL2 DAEWOO M 150 BL2 WATERLEAKS 91 5 REPAIR INSTRUCTIONS ON VEHICLE SERVICE D109A501 D109A502 D109A503 WATERLEAK REPAIR Some waterleaks around the glass can be repaired with out removing the gla
61. 2A D109D514 D19D515A DAEWOO M 150 BL2 LIGHTING SYSTEMS 9B 13 Installation Procedure 1 Install the license plate lamp socket 2 Install the tailgate handle Refer to Section 9M Exte rior Trim 3 Connect the electrical connector 4 Remove the rear window wiper motor assembly Re fer to Section 9D Wipers Washer Systems 5 Install the license plate lamp bulb 6 Install the license plate lamp with the screws 7 Connect the negative battery cable DOOR JAMB SWITCH Removal Procedure 1 Disconnect the negative battery cable 2 Remove the door jamb switch e Remove the screw 1 e Disconnect the electrical connector 2 e Remove the door jamb switch 3 Installation Procedure 1 Install the door jamb switch with the screw 2 Connect the electrical connector 3 Connect the negative battery cable INTERIOR COURTESY LAMP Removal Procedure 1 Disconnect the negative battery cable 2 Remove the interior courtesy lamp Pry off the interior courtesy lamp lens 1 Remove the screws 2 Disconnect the electrical connector 3 Remove the interior courtesy lamp 4 9B 14 LIGHTING SYSTEMS D109D516 D29B007 D29B008 Installation Procedure 1 Connect the electrical connector 2 Install the interior courtesy lamp with the screws 3 Install the interior courtesy lamp lens 4 Connect the negative battery cable DAYTIME RUNNING
62. 3 9R 6 BODY FRONT END D109C528 D109C529 D109C530 3 Remove the bolts on the top of the fender a Fender upper mounting bolt 4 Remove the hood hinge e Remove the bolts 1 e Remove the hood hinge 2 Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasteners to prevent premature corrosion 1 Install the hood hinge with the bolts 2 Install the bolts along the top of the fender 3 Install the cowl vent grille with the screws and the caps 4 Install the hood Refer to Hood in this section HOOD PROP ROD Removal Procedure 1 Support the hood in the open position 2 Remove the hood prop from the hood e Using a sharp gimlet press the pins 1 e Remove the hood prop 2 DAEWOO M 150 BL2 BODY FRONT END 9R 7 3 Remove the hood prop rod from the hood prop a Hood prop rod NAI 7 D109C531 Installation Procedure 1 Install the hood prop rod to the hood prop 2 Install the hood prop to the hood with the pins D109C532 HOOD LATCH Removal Procedure 1 Open the hood 2 Remove the hood latch e Remove the screws 1 e Disconnect the hood latch release cable 2 e Remove the hood latch 3 D109C533 Installation Procedure 1 Connect the hood latch release cable to the latch Notice Dissimilar metals in direct contact with each other may corrode ra
63. 351 3 1 C351 10 WHT DKBLU 4 DKBLU Left Fornt YEL YEL Door Lock Actuator C381 3 1 C381 2 WHT BLU 4 DK BLU Right Rear YEL YEL Door Lock Actuator C371 1 3 C371 gt WHT DKBLU 2 DKBLU Left Rear YEL YEL Door Lock Actuator D19C201S DAEWOO M 150 BL2 9P 32 DOORS POWER DOOR LOCKS W ANTI THEFT CONTROL LHD W FRT Fog Lamp Switch Hot at All Times Central Door Lock Relay DK BLU DK BLU TEL 4 TEL es WHT 19 WHT C361 Ti 13 C361 DK BLU TEL 1 Anti theft RR LH Door Actuator Control Unit DK BLU DK BLU EL 2 T O S WHT d C381 3 C381 DK BLU BRN DK GRN Switcht Door Actuator D19C201S DAEWOO M 150 BL2 DOORS 9P 33 POWER DOOR LOCKS W ANTI THEFT CONTROL RHD W FRT Fog Lamp Switch Hot at All Times Engine Ef2 Fuse Block RED Central Door Lock Relay DK BLU DK BLU TEL 4 TEL TOR WHT 10 WHT 1 13 C351 FR LH Door Actuator DK BLU DK BLU TEL O 2 1 13 C381 Anti theft RR RH Door Actuator Control Unit DK BLU DK BLU E 1 TEL 2 TEL ie wy o WHT 4 C371 3 C371 DK BLU TEL 4 DKBLU C362 3 GRN Switcht Door Actuator D19C202S DAEWOO M 150 BL2 34 DOORS POWER WINDOWS FRONT ONLY Hot in Run and Start C203 BRN 4 C351 LHD C361 RHD Power Window Switch LT BLU C351 LHD gf C361 RHD LT BLU 5 C3
64. 51 LHD C361 LHD 10 R 6364 RHD C351 RHD DK BLU BRN BLK DK BLU LT BLU GRY Co Driver Power Window Driver Power Co Driver Power Window Motor Window Motor D19C202B DAEWOO M 150 BL2 SECTION 9Q ROOF TABLE OF CONTENTS Description and Operation 9Q 2 On Vehicle Service adus atts actos anette Mer eran LE 9Q 2 Formed Headliner Manual SunRoof 9Q 2 Manual SunRoof VISOS lent suk e ae 9Q 2 Sun Visors Passenger Assist Handles 9Q 2 Passenger Assist Handle and the Coat Hook tak tet Rue ed esee ere lont 9Q 2 Coat Component Locator 9Q 3 Specifications ROOT deos Sect Se ceti cens mod Olas 9Q 3 Fastener Tightening Specifications Repair 90 4 DAEWOO 150 BL2 9Q 2 ROOF DESCRIPTION AND OPERATION ROOF The roof is a one piece painted metal unit which incorpo rates a single solid headliner and two moldings one on each side of the vehicle s roof The moldings which enclose and hide the roof rail seams are serviceable as individual units The one piece formed headliner common to both the notchback and the hatchback consists of a molded sub strate covered with a foam ba
65. A D109E577 INTERIOR TRIM 9G 15 FLOOR CONSOLE Removal Procedure 1 Remove the floor console screws 2 Remove the gear shift lever boot cover and the floor console e Remove the gear shift lever boot cover 1 e Remove the screws 2 e Remove the floor console 3 Installation Procedure 1 Install the floor console 2 Install the gear shift lever boot cover to the floor con sole 3 Tighten the floor console screws PARKING BRAKE CABLE COVER Removal Procedure 1 Remove the parking brake cable cover e Remove the screw 1 e Remove the cable cover 2 9G 16 INTERIOR TRIM D109E578 D109E581 D109E582 Installation Procedure 1 Install the parking brake cable cover with the screw FLOOR CARPET Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 11 Disconnect the negative battery cable Remove the front seats Refer to Section 9H Seats Remove the rear seat cushion Refer to Section 9H Seats Remove the floor console Refer to Floor Console in this section Pry off the front rocker trim panel Refer to Front Rocker Trim Panel in this section Pry off the rear rocker trim panel Refer to Rear Rocker Trim Panel in this section Pry off the lower B pilla
66. BLE OF CONTENTS Description and Operation 9T 10 Key Status Errors FENIX 5MR 9T 24 Immobilizer System 9T 10 Key Status Errors SIRIUS D3 9T 24 Electronically Coded Keys 9T 10 Communication Between Immobilizer and Detection Coil 9T 10 Test Equipment FENIX SMR 91 25 Immobilizer Control Unit 9T 10 Communication Between Immobilizer and Serial Data LINK 9T 11 Tes aa a Rit DA em Electronic Control Module ECM 9T 11 Repair Instructions 9T 26 Security eee Diagnostic Information and Procedures 9T 13 Key Coding procedure ee wor re den Immobilizer System FENIX 5MR 9T 13 DCode REPO que bad oou Piep Immobilizer System SIRIUS D3 9T 13 Transponder 9T 27 DTC 1600 ECM Immobilizer Error Detection 9 27 NG Answer 9T 14 Immobilizer Control Unit 9T 28 DTC 1601 ECM Immobilizer Error Specifications 9T 30 Incorrect Answer 9T 16 Fastener Tightening Specifications 9T 30 DTC 1602 ECM Immobilizer Error Schematic and Routing Diagrams 9T 31 ECM Locke
67. C583A DAEWOO M 150 BL2 DOORS 9P 13 Up and Down Adjustment 1 2 3 The tailgate must be properly aligned Close the tailgate until the lock fork contacts the strik er Stand next to the tailgate opening and move the tail gate slowly up and down just touching the striker each time The alignment of the lock fork and the striker can be easily seen The lock fork should be perpendicular to and fall near the middle of the striker The lock fork should fall near the middle of the striker between the rear body pillar and the end of the striker up and down adjustment is required use the fol lowing steps e Remove the striker screws 1 e Remove the spacer in order to move the striker to ward the down of the vehicle 2 Add a 2 mm 0 08 inch spacer in order to move the striker toward the up of the vehicle e Install the striker screws FRONT DOOR LOCK Removal Procedure Disconnect the negative battery cable if equipped with the central door lock system Remove the seal trim Refer to Door Seal Trim in this section Disconnect the outside door handle rod from the door lock a Outside door handle rod b Key rod 14 DOORS D109C584 Cz D109C585 D109C566 D109C567 4 Remove the front door lock e Remove the screws 1 e Remove the front door lock 2 Important Disconnec
68. D changer bracket 1 e Remove the CD changer bracket 2 e Remove the CD changer 3 Installation Procedure 1 Install the CD changer bracket to the CD changer with the bolts 2 Mount the CD changer assembly under the Driver s seat with the bolts and the screws 3 Arrange the CD changer cable with the sponge pads and the clip 4 Connect the CD changer electrical connectors 5 Install the floor console Refer to Section 9G Interior Trim 6 Install the Audio System to the instrument panel Re fer to Audio System in this section 7 Connect the negative battery cable FRONT SPEAKERS Removal Procedure 1 Disconnect the negative battery cable 2 Remove the door seal trim Refer to Section 9P Doors 3 Remove the speaker e Remove the screws 1 e Disconnect the electrical connector e Remove the speaker 2 Installation Procedure 1 Connect the electrical connector 2 Install the speaker with the screws 3 Install the door seal trim Refer to Section 9P Doors 4 Connect the negative battery cable DAEWOO M 150 BL2 DAEWOO M 150 BL2 D109D557 D109D560 AUDIO SYSTEMS 9F 9 FRONT SPEAKER COVERS Removal Procedure 1 Remove the door trim panel Refer to Section 9G In terior Trim 2 Remove the speaker cover from the door trim panel e Remove the screws 1 e Remove the speaker cover 2 Installation Procedure 1 Install the speaker cover to the door trim panel with the sc
69. F 9 Rear Speakers 9F 9 Roof Antenna 9F 10 Specifications 9F 11 Fastener Tightening Specifications 9F 11 Schematic and Routing Diagrams 9F 12 Audio System 9F 12 9F 2 AUDIO SYSTEMS DESCRIPTION AND OPERATION STEREO CASSETTE AM FM RADIO WITH CD CHANGER AND RDS AUDIO SECURITY SYSTEM The stereo digital logic cassette AM FM radio with elec tronic tape ejection and the stereo digital logic cassette AM FM radio with a CD changer located under the front seat LH are optional equipment The radio data system RDS uses a single button to se lect a specific radio station once it is set to the listener s preference The audio security system is activated whenever the au dio system circuit is disconnected from the battery A four digit security code must be entered in order for the audio system to be functional once again The security code is stamped on a card located in the vehicle usually in the glove box One of the following security code en tering procedures can be followed With RDS 1 With the ignition switch in the or Il position turn the radio ON At this time CODE will be shown on the radio display 2 Press the P UP button until the correct first digit is shown on the display 3 Press the P DN button to move over to the second digit and then press P UP once again to en
70. GHTING SYSTEMS Hot at All Times Illumination Headlamp Relay Light 6 Headlamp Switch 4 Switch 64 HEADLAMPS CIRCUIT BRN BLK DK GRN GRY EMO 10A DK GRN GRY HI Beam Indicator Instrument Cluster D19D202B DAEWOO M 150 BL2 DAEWOO M 150 BL2 LIGHTING SYSTEMS 9B 19 HEADLAMP LEVELING CIRCUIT W FRT Fog Lamp Switch Hot at Times Hot at Times Engine 1 Fuse Block Illumination Relay Headlamp WHT BLU 6 2 Al Head Lamp Leveling Switch DK GRN BLK 3 C205 DK GRN BLK Left Right Head Lamp Head Lamp Leveling Leveling Motor Motor D19B723B 98 20 LIGHTING SYSTEMS TAIL AND LICENSE PLATE LAMPS CIRCUIT 1 WFRT Fog Lamp Switch Hot at All Times Illumination Relay BRN WHT Left Right To s n 5 goni osition osition Headlamp Relay Lamp Lamp BRN WHT Right Left Tailamp Tailamp License Lamps D19D203B DAEWOO M 150 BL2 DAEWOO M 150 BL2 LIGHTING SYSTEMS 9B 21 STOPLAMPS CIRCUIT Hot at All Times Center High Mount Stoplamp Stoplamp S witch Left Stoplamp Electronic Brake Control Module Right Stoplamp EBCM D19D204B 9 22 LIGHTING SYSTEMS TURN AND HAZARD LAMPS CIRCUIT Hot in Run and Start Hot with Lights On Engine Fuse 10 EH2 Fuse Block i Block BRN WHT C202 Combination Switch DK BLU GRY DK BLU GRY DK BLU GRY 4 C202 Right Left
71. IM 9G 5 4 Pry off the trim panel using a trim remover KM 475 B Notice Make sure to cover the remover with cloth to prevent the paint damage of the door Installation Procedure 1 Install the trim panel 2 Install the window regulator handle with the clip 3 Install the inside door handle and the door pull with the screws FRONT DOOR TRIM PANEL DELUXE Removal Procedure 1 Remove the inside door handle Refer to Section 9P Doors 2 Remove the power window mirror control switch as sembly from the front door e Remove the screws 1 e Remove the power window mirror control switch assembly 2 e Disconnect the electrical connectors 3 3 Remove the trim panel e Remove the screws 1 e Remove the clips 2 e Remove the trim panel 3 9G 6 INTERIOR TRIM 4 Remove the inside channel weatherstrip Refer to Section 9P Doors 5 Remove the map pocket from the door trim e Remove the screws 1 e Remove the map pocket 2 S NS y SI NS 5 RYAN SS NS S NS SS SS SS SRM _ D109E539 Installation Procedure 1 Install the map pocket to the door trim with the Screws 2 Install the inside channel weatherstrip Refer to Sec tion 9P Doors 3 Install the door trim panel with the screws and the clips 4 Install the power window mirror control switch assem bly with the screw 5 Install the inside door handle Refer to Section 9P Doors
72. LAMP MODULE W Europe Only Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the electrical connector 1 3 Remove the screws 2 and the daytime running lamp module Installation Procedure 1 Install the daytime running lamp module with the bolts 2 Connect the electrical connector 3 Connect the negative battery cable DAEWOO M 150 BL2 DAEWOO M 150 BL2 D209B104 D209B105 LIGHTING SYSTEMS 9B 15 LUGGAGE ROOM LAMP Removal Procedure 1 Disconnect the negative battery cable 2 Open the tailgate 3 Remove the luggage room lamp e Remove the luggage room lamp 1 e Disconnect the electrical connector 2 Installation Procedure 1 Connect the electrical connector 2 Install the luggage room lamp 3 Connect the negative battery cable 9B 16 LIGHTING SYSTEMS SPECIFICATIONS BULB USAGE CHART Replacement Bulb Number Backup Lampis Headlamps Double 60 55W Interior Courtesy Lamp 10W License Plate Lamp Front Turn Signal Lamps Rear Fog Lamp 5W Side Marker Turn Signal Lamps Tail and Stoplamp Double 5 21W 5W Parking Lamp W DAEWOO M 150 BL2 DAEWOO M 150 BL2 LIGHTING SYSTEMS 9B 17 SCHEMATIC AND ROUTING DIAGRAMS BACKUP LAMP S CIRCUIT Hot in Run and Start RED YEL 2 AS Reverse Switch DK GRN GRY 1Y GRN GRY 6 C102 13 C202 DK GRN GRY Right Backup Left Backup Lamp Lamp W O Rear Fog Lamp D19D201B 9B 18 LI
73. LOCATOR PASSENGER COMPARTMENT LHD BLINKER UNIT TURN SIGNAL LAMP RELAY D111004A FUSE BOX LOCATOR PASSENGER COMPARTMENT RHD BLINKER UNIT TURN SIGNAL LAMP RELAY DIMMER CONTROL RELAY REAR FOG LAMP RELAY D111004B DAEWOO M 150 BL2 9A 10 BODY WIRING SYSTEM FUSE CHART Ef1 Engine Fuse 50A BAT ABS Ignition Switch Instrument Panel Fuse Block F5 F11 F13 Fuel cut off Switch Inertia Switch Fuel EBCM Generator VSS Fuel Pump Relay Main Relay ET 10A en Ignition Coil Ef6 20A BAT Blower Motor Ef7 BAT Rear Window Defogger Ef8 BAT Headlamp Hi Beam Right Side Ef9 BAT Headlamp Hi Beam Left Side Headlamp Lo Beam Right Side Headlamp Lo Beam Left Side 2 Tail and Illumination Lamps Right Side Tail and Illumination Lamps Left Side Ef15 30A BAT Radiator Fan Ef2 40A BAT Ef18 20A BAT Headlamp Relay Hi Beam Passing DRL Module Ef19 BAT ECM Main Relay Ef20 BAT Front Fog Lamp F1 Fuse 10A IGN 1 Se IMMO Anti Theft Control Unit 25A IGN 1 Hazard Switch DRL Module Stop Lamp IGN 2 Rear Wiper Motor Front amp Rear Washer Backup Lamp Auto Miror Switch 20A Ef2 Anti Theft Control Unit Door Lock DAEWOO M 150 BL2 BODY WIRING SYSTEM 9A 11 FRONT HARNESS ROUTING Left Hand Drive Shown Right Hand Drive Similar CCP Solenoid Right Front Wheel Speed ABS Sensor Control C101 Unit Left Front Wheel Se
74. ND MIRRORS 9L 13 2 Install the division bar with the guide rail inside bolt the guide rail outside bolt and the guide rail screw 3 Inside the outside rearview mirror Refer to Outside Rearview Mirror in this section 4 Install the front door seal trim Refer to Section 9P Doors REAR DOOR GLASS Removal Procedure 1 Remove the glass run Refer to Section 9P Doors 2 Remove the glass e Remove the bolts 1 e Remove the glass 2 Notice Make sure not to contact the glass with the body to prevent the paint damage Installation Procedure 1 Install the glass with the bolts 2 Install the glass run Refer to Section 9P Doors INSIDE REARVIEW MIRROR Removal Procedure 1 Remove the inside rearview mirror e Remove the screw 1 e Remove the inside rearview mirror 2 9L 14 GLASS AND MIRRORS D19E528 D19E529 D19E530 D19E531 Installation Procedure 1 Install the inside rearview mirror with the screw OUTSIDE REARVIEW MIRROR MANUAL Removal Procedure 1 Remove the outside rearview mirror cover from the outside rearview mirror 2 Remove the outside rearview mirror e Remove the screws 1 e Remove the outside rearview mirror 2 Installation Procedure 1 Install the outside rearview mirror with the screws 2 Install the outside rearview mirror cover DAEWOO M 150 BL2 GLASS AND MIRRORS 9L 15 OUTSIDE REARVIEW MIRROR CABLE Removal Procedure 1
75. NSTRUCTIONS ON VEHICLE SERVICE D109E526 FRONT DOOR GLASS RUN Removal Procedure A Remove the front door seal trim from the front door Refer to Door Seal Trim in this section Remove the outside rearview mirror from the front door Refer to Section 9L Glass and Mirrors Remove the guide rail from the door e Remove the screws 1 e Remove the inside bolts 2 e Remove the outside bolts 3 e Remove the division bar 4 Remove the glass run a Glass run Installation Procedure Install the glass run Install the division bar with the bolts and the screws Install the outside rearview mirror Refer to Section 9L Glass and Mirrors Install the front door seal trim Refer to Door Seal Trim in this section 8 DOORS REAR DOOR GLASS RUN Removal Procedure 1 Remove the inside channel weatherstrip from the rear door Refer to Section 9G Interior Trim 2 Remove the outside channel weatherstrip from the rear doors Refer to Section 9G Interior Trim 3 Remove the rear door trim panel Refer to Section 9G Interior Trim 4 Remove the rear door seal trim a Door seal trim b Door pocket handle bracket Important In case of the deluxe type remove the seal trim after removing the door pocket handle bracket 5 Remove the guide piece e Remove the screw 1 e Remove the guide piece 2 D109C567 6 Remove the upper guid
76. ON VEHICLE SERVICE KEY CODING PROCEDURE 1 oR I 10 11 12 13 Install the immobilizer control unit cartridge in the scan tool Turn the ignition OFF Connect the scan tool Turn the ignition ON with the key to be coded Enter the four digit password that enables service personnel to use the scan tool for coding keys A lost key can be deleted only by deleting all keys and reauthorizing the remaining keys as new keys If a key is lost go to the next step If no keys have been lost but an additional key is desired go to Step 8 Use the scan tool command DELETE ALL KEY CODES Use the scan tool command AUTHORIZE ONE ADDITIONAL KEY Repeat Steps 4 5 and 6 until the immobilizer con trol unit has recorded all of the new keys or after a deletion has reauthorized all of the remaining keys The immobilizer control unit can record a maximum of five keys Return the system to the normal mode Turn OFF the ignition Turn ON the ignition Crank to start the engine ID CODE REPROGRAMMING Reprogram the identification ID code in the following situations An immobilizer control unit has been replaced An electronic control module ECM has been re placed If a valid key has been lost refer to Key Coding Proce du re in this section Reprogramming Procedure 1 Turn the ignition OFF Reprogramming is not allowed while the engine is running Insert the immobili
77. Pump Driver Door Contact Switch Right Tail Lamp Right Rear Speaker Seat Belt Switch Right Rear Wheel Speed V Passenger Door Contact Switch 9A 18 BODY WIRING SYSTEM BODY HARNESS ROUTING Cont d Detail of B D111406D BODY WIRING SYSTEM 9A 19 FRONT DOOR HARNESS ROUTING OSRV Switch dum A Front Speaker C351 LHD C352 LHD C361 RHD C362 RHD Direction A D111407D 9A 20 BODY WIRING SYSTEM REAR DOOR HARNESS ROUTING Rear Power Window Switch Rear Door Lock Actuator C371 LH C381 RH A Direction D111408D BODY WIRING SYSTEM 9A 21 TAILGATE HARNESS ROUTING Rear Defroster Connector Rear Wiper Motor License Lamp Detail of A Detail of B D111409D 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 B unless otherwise TABLE OF CONTENTS noted Description and Operation 9B 2 Headlamps and Parking Lamps 9B 2 Front Turn Signal Lamps
78. RIM PANEL ASSEMBLY Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Disconnect the negative battery cable 2 Remove the instrument panel assembly Refer to In strument Panel in this section 3 Remove the instrument cluster brackets from the in strument panel e Remove the screws e Remove the instrument cluster brackets 1 DAEWOO M 150 BL2 DAEWOO M 150 BL2 D109B702 D109B703 D109B704 D109B705 INSTRUMENT DRIVER INFORMATION 9E 17 4 Remove the passenger s airbag module blank cover from the instrument panel e Remove the screws e Remove the passenger s airbag module blank cov er 1 5 Remove the ventilation duct from the instrument pan el e Remove the screws e Remove the ventilation duct 1 Remove the ventilation grilles from the instrument panel e Remove the screws e Remove the ventilation grilles 1 7 Remove the cigar lighter housing from the instrument panel e Remove the screws e Remove the cigar lighter housing 1 9E 18 INSTRUMENT DRIVER INFORMATION 8 Remove the glove box striker and bracket from the instrument panel e Remove the screws 1 e Remove the glove box striker and bracket 2 9 Remove the instrument panel guide from the instru ment panel e Remove the screws 1 e Remove the instrument panel guide 2 D109B707 10 Remove the defroster grilles and the demister grilles from the instrument panel
79. Rearview 9L 2 Front Door Quarter Glass 9L 12 Components Locator 9L 3 Rear Door Glass 9L 13 Glass and Mirror 9L 3 Inside Rearview Mirror 9L 13 Diagnostic Information and Procedures 9L 4 Outside Rearview Mirror Manual 9L 14 Testing Rear Window Defogger Grid Line 9L 4 Outside Rearview Mirror Cable 9L 15 Repair Instructions 9L 5 Outside Rearview Mirror Electric 9L 16 On Vehicle Service 9L 5 Special Tools and Equipment 9L 17 Windshield 91 5 Special Tools Table 9L 17 Rear Window Glass 9L 7 Schematic and Routing Diagrams 9L 18 Rear Window Defogger Grid Line Repair 9L 9 Rear Window Defogger 9L 18 DAEWOO M 150 BL2 9L 2 GLASS AND MIRRORS DESCRIPTION AND OPERATION STATIONARY GLASS Stationary glass consists of all the glass on the vehicle which is immovable within its frame such as the wind shield glass the back glass and the inside rearview mirror INSIDE REARVIEW MIRROR The inside rearview mirror can be manually adjusted up down fore aft and left right The rearview mirror pivots in two places the ball and socket mirror pivot and the up down hinge lever at
80. Remove the cap 1 e Remove the nut 2 e Remove the wiper arm 3 Installation Procedure 1 Install the wiper arm with the nut 2 Install the cap REAR WINDOW WIPER ARM Removal Procedure Remove the washer nozzle from the wiper arm Refer to Rear Washer Nozzle in this section Remove the wiper blade Refer to Windshield Wiper Blade in this section Remove the wiper arm e Remove the cap 1 e Remove the nut 2 e Remove the wiper arm 3 DAEWOO 150 812 D109D522 DAEWOO M 150 BL2 D109D524 D109D525 WIPERS WASHER SYSTEMS 9D 7 Installation Procedure 1 Install the rear wiper arm with the nut 2 Install the cap 3 Install the wiper blade Refer to Windshield Wiper Blade in this section 4 Install the washer nozzle to the wiper arm Refer to Rear Washer Nozzle in this section WINDSHIELD WIPER MOTOR Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Disconnect the negative battery cable 2 Remove the windshield wiper arm Refer to Wind shield Wiper Arm in this section 3 Remove the cowl vent grille Refer to Section 9H Body Front End 4 Separate the wiper motor from the wiper linkage e Remove the wiper linkage ball from the wiper linka ge 1 5 Remove the wiper motor from the engine room e Disconnect the electrical connector 1 e Remove the bolts 2 e Remove the wiper moto
81. S IMMOBILIZER SYSTEM FENIX 5MR The immobilizer anti theft system requires diagnosis when it is not possible to start the engine If the no start condition occurs because of the immobilizer system a diagnostic trouble code DTC 1600 1601 or 1602 should be set The immobilizer control unit monitors the detection and the reading of the ignition key The self test capacity is limited to those functions Faults are communicated to a scan tool during diagnosis but they are not stored in the immobilizer control units memory Unauthorized use of a scan tool could be a method of defeating the immobilizer anti theft system so certain scan tool procedures require the use of a password The following functions are password protected e Coding of an additional key e Deleting all key codes e Deletion of the immobilizer identification ID code e Deletion of the electronic control module ECM ID code The following functions do not require a password e Reading an ignition key to determine if the transpond er is working or if a key is authorized DAEWOO M 150 BL2 e Reading the immobilizer ID code to verify that it matches the ECM ID code IMMOBILIZER SYSTEM SIRIUS D3 The immobilizer anti theft system requires diagnosis when it is not possible to start the engine If the no start condition occurs because of the immobilizer system a diagnostic trouble code P 1628 1629 should be set The immobilizer control unit m
82. SECTION 9A BODY WIRING 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 B unless otherwise TABLE OF CONTENTS noted Description and Operation 9A 2 How to Read Electrical Wiring Diagram 9A 2 How to Check Terminal Number of Connector 9A 4 Special Tools and Equipment 9A 5 Special Tools Table 9A 5 Schematic and Routing Diagrams 9A 6 Wire Color Chart 9A 6 Power Distribution Schematic 9A 7 Relay amp Fuse Box Locator Engine Room 8 Fuse Box Locator Passenger Compartment 9A 9 DAEWOO M 150 BL2 Fuse Chart te eed gunni 9A 10 Front Harness Routing 9A 11 Engine Harness Routing 9A 12 Instrument Harness Routing 9A 14 Airbag Harness Routing 9A 16 Body Harness Routing 9A 17 Front Door Harness Routing 9A 19 Rear Door Harness Routing 9A 20 Tailgate Harness Routing 9A 21 9A 2 BODY WIRING SYSTEM DESCRIPTION AND OPERATION HOW TO READ ELECTRICAL WIRING DIAGRAM Hot at
83. WOO M 150 BL2 D109B539 D109B541 SEATS 9H 9 FRONT SEATS GUIDE RAIL Removal Procedure 1 Disconnect the negative battery cable 2 Remove the front seat assembly Refer to Front Seats in this section 3 Remove the guide rail from the seat e Remove the bolts 1 e Remove the guide rail 2 Installation Procedure 1 Install the guide rail to the seat with the bolts 2 Install the front seat assembly Refer to Front Seat in this section 3 Connect the negative battery cable FRONT SEAT CUSHION FRAME Removal Procedure 1 Disconnect the negative battery cable 2 Remove the front seat cushion Refer to Front Seat Cushion in this section 3 Remove the guide rail e Remove the bolts 1 e Remove the guide rail 2 4 Remove the seat cushion cover e Remove the hog rings 5 Remove the seat cushion frame 9H 10 SEATS D109B541 D109B540 D109B542 D19B543A Installation Procedure 1 Install the seat cushion cover with the hog rings 2 Install the guide rail with the bolts 3 Install the front seat cushion Refer to Front Seat Cushion in this section 4 Connect the negative battery cable REAR SEATBACK Removal Procedure 1 Remove the rear seatback e Remove the rear seatback lock by pulling the lock knob upward 1 e Remove the seatback hinge bolts 2 e Remove the rear seatback 3 Installation Procedure 1 Install the rear
84. Y Hazard Switch D19B202B 9E 26 INSTRUMENT DRIVER INFORMATION DIGITAL CLOCK Hot with Lights On Hot at All Times Hot in Run and Start BRN WHT BRN WHT RED YEL BRN WHT Digital Clock D19B203B DAEWOO M 150 BL2 SECTION 9F AUDIO 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 B unless otherwise TABLE OF CONTENTS noted Description and Operation 9F 2 Stereo Cassette AM FM Radio with CD Changer and RDS Audio Security System 9F 2 Front and Rear Speakers 9F 2 Roof Antenna 9F 2 Tape Player and Cassette Care 9F 2 Compact Disc Care 9F 2 Component Locator 9F 3 Audio Systems 9F 3 Diagnostic Information and Procedures 9F 4 Audio System 9F 4 DAEWOO M 150 BL2 Repair Instructions 9F 6 On Vehicle Service 9F 6 Audio System 9F 6 CD Changer 9F 6 Front Speakers 9F 8 Front Speaker 5 9
85. al 2 of the cigar lighter connector is harness the open circuit or a short circuit e Faulty the cigar lighter connector e Repair or Replace the cigar lighter connector e Cigar lighter element is blown e Replace the cigar lighter Open ground G201 circuit e Repair the open ground circuit DAEWOO M 150 BL2 6 INSTRUMENTATION DRIVER INFORMATION Hot with Lights On Engine Ef2 Fuse Block BRN WHT BRN WHT D19B302B HVAC PANEL ILLUMINATION e HVAC panel illumination bulb is blown e Replace the bulb Open ground G201 circuit e Repair the open ground circuit Condition Probable Cause Correction HVAC Panel Illumination e The open or a short in the power supply e Repair or Replace the wiring Inoperative circuit to the fuse Ef12 harness e Fuse Ef12 is blown e Replace the fuse Ef12 e The circuit between the fuse Ef12 and the e Repair or Replace the wiring terminal 2 of the HVAC panel illumination harness connector is the open circuit or a short circuit e Faulty the HVAC panel illumination e Repair or Replace the connector instrument panel illumination connector DAEWOO M 150 BL2 INSTRUMENTATION DRIVER INFORMATION 9E 7 Hot with Lights On Hot in Run and Start 5A C202 BRN WHT 7 C208 BRN WHT D19B304B DIGITAL CLOCK Condition Probable Cause Correction Digital Clock Inoperative e The open or a short in the power supply circuit
86. ar Left Right Left Right Speaker Speaker Speaker Speaker GRN GRY BRN DK GRN GRN GRN GRY BLK Cassette Radio Illumination Lamp D19D209B DAEWOO M 150 BL2 SECTION 9G INTERIOR TRIM 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 B unless otherwise noted TABLE OF CONTENTS Description and Operation 9G 2 Tailgate Trim Panel 9G 9 Interior Trim Panels 9G 2 A Pillar Trim Panel 9G 10 Pressure Relief Vent 9G 2 Upper B Piller Trim Panel 9G 10 Floor Console 9G 2 Lower B Pillar Trim Panel 9G 11 Parking Brake Cable Cover 9G 2 C Pillar Trim Panel 9G 11 Floor Carpet 9G 2 Rear Parcel Shelf 9G 12 Component Locator 9G 3 Rear Parcel Side 9G 13 Interior Trim 9G 3 Front Rocker Trim Panel 9G 13 Repair Instructions 9G 4 Rear Rocker Trim Panel
87. as specified for each point to be measured Dimensions to gauge holes are measured to the center of the holes and flush to the adjacent surface metal un less otherwise specified It is recommended that the di agonal dimensions to the cross body be checked on both sides in order to verify the dimensional accuracy of the vehicle underbody FLOOR PAN INSULATORS The floor pan insulators have been designed for the higher floor pan temperatures that result from the use of the catalytic converter in the exhaust system There fore when servicing a vehicle it is essential that any in DAEWOO M 150 BL2 sulators that may have been disturbed or removed be reinstalled in the original sequence and location Also if an insulator needs to be replaced use only the insula tion specified for that location on the floor pan When servicing or replacing interior insulators observe the following instructions e Install the insulators in the original position and se quence Butt the pieces together in order to avoid gapping or overlapping e f itis necessary to replace an insulator use only the specified insulation Use the original part to determine the amount of re placement material required and as a template for cutting and fitting the new piece to the floor pan e When installing the insulator do not enlarge any cut outs or holes that are used for the attachment of interi or parts such as the instrument panel or the floor console
88. cable 2 Remove the rear door lock Refer to Childproof Rear Door Lock in this section 3 Remove the outside rear door handle e Remove the bolts 1 e Remove the outside rear door handle 2 Installation Procedure 1 Install the outside rear door handle with the bolts 2 Install the rear door lock Refer to Childproof Rear door Lock in this section 3 Connect the negative battery cable DOOR LOCK CYLINDER Removal Procedure 1 Disconnect the negative battery cable 2 Remove the outside door handle Refer to Outside Front Door Handle in this section 3 Remove the door lock cylinder from the outside door handle e Remove the clip 1 e Remove the door lock cylinder 2 DAEWOO M 150 BL2 DAEWOO M 150 BL2 D109C600 DOORS 9P 19 Installation Procedure 1 Install the door lock cylinder with the clip 2 Install the outside door handle Refer to Outside Front Door Handle in this section 3 Connect the negative battery cable MANUAL WINDOW REGULATOR Removal Procedure 1 Remove the glass Refer to Section 9L Glass and Mirrors 2 Remove the window regulator e Remove the screws 1 e Remove the regulator 2 Installation Procedure 1 Install the regulator with the screws 2 Install the glass Refer to Section 9L Glass and Mir rors POWER FRONT WINDOW REGULATOR
89. caulk A china marking pencil A screwdriver Perform the following steps in order to conduct the road test 1 Choose a route that includes smooth straight streets that run in all four directions north south east and west 2 Choose streets with little traffic or noise that would in terfere with the test 3 Drive the vehicle at the speeds at which the noise was noticed by the customer or until the noise is pro D109A307 duced Do not exceed legal speed limits 4 The windnoise is external if any of the following condi e Temporarily repair the leak with masking tape e Continue testing in order to determine if the noise has been eliminated or if other leaks exist 1008 iiic Ac When all leaks have been found return to the shop e The windnoise is caused by the wind and make permanent repairs with the proper align e The windnoise can be heard with the door glass ment techniques and sealing materials lowered and while the vehicle is being driven e The windnoise is eliminated when tape is placed over various moldings and gaps DAEWOO M 150 BL2 9J 2 WINDNOISE REPAIR INSTRUCTIONS ON VEHICLE SERVICE WINDNOISE REPAIR Windnoise leak repairs are very similar to waterleak re pairs Refer to Section 91 Waterleaks The actual proce dure depends on the type of seal being repaired Leaks around the door opening weatherstrips do not always in dicate a faulty weatherstrip A door or window adjust ment may res
90. ch release cable from the hood latch Refer to Hood Latch in this section Remove the hood latch release cable after removing the plastic strip a Hood latch release cable Installation Procedure Connect the hood latch release cable to the hood latch Refer to Hood Latch in this section Arrange the hood latch release cable with the plastic strip Push the cable toward the passenger compartment through the body hole Connect the hood latch release cable to the hood latch release lever Refer to Hood Latch Release Le ver in this section FENDER Removal Procedure 1 Raise and suitably support the vehicle 2 Remove the wheelhouse splash shield e Remove the clip and the bolt a Clip and bolt e Remove the wheel house splash shield a Wheel house splash shield 9R 10 BODY FRONT END 3 Remove the bolt at the base of the fender a Fender mounting lower bolt 4 Open the front door Remove the bolt on the A pillar b Fender mounting bolt D19C540A Remove the screws on the side of the front bumper fascia a Bumper fascia side bolts Remove the bolt under the fender e b Fender mounting bolt Lower the vehicle Take off the cowl vent grille Remove the bolt on the top of the fender a Fender mounting bolt Remove the front bumper spacer Refer to Section 9M Exterior Trim 10 Remove the fender front bolt
91. chniques during service repair operations The underbody parts should be properly sealed and rustproofed whenever body repair operations destroy or damage the original sealing and rustproof ing When rustproofing critical underbody parts use a good quality type of air dry primer such as a corrosion resistant chromate or an equivalent material Combina tion type primer surfacers are not recommended TRANSAXLE UNDER COVER The transaxle under cover is one piece of steel that Serve as shields for the underside of the transaxle The covers help protect the engine from small rocks gravel and other objects that would otherwise come into con tact with the transaxle during normal driving conditions DAEWOO M 150 BL2 FRAME AND UNDERBODY 9N 3 REPAIR INSTRUCTIONS ON VEHICLE SERVICE ALIGNMENT CHECKING An accurate method of determining the alignment of the underbody uses a measuring tram gauge The tram gauge set used to perform the recommended measuring checks must include a vertical pointer able to reach 457 mm 18 inches Two types of measurements can be made with a tram gauge direct point to point measurements and mea surements calculated on a horizontal plane datum line parallel to the underbody Point to point measurements are generally taken on steering and suspension engine compartment parts and simply require the vertical point ers to be set equally For horizontal plane measurements the vertical pointers must be set
92. cked cloth facing The one piece construction requires servicing the headliner as a complete assembly MANUAL SUNROOF The sunroof is e Intended to provide light and air through the roof of the vehicle during the driving e Built into the roof e Made of glass SUN VISORS The sun visors swing down or side in order to block out glare They also swing to the side when they are re leased from the support PASSENGER ASSIST HANDLE There is a passenger assist handle for the front passen ger seat Passengers can use these handles to assist in keeping their balance over rough roads or during sharp turns COAT HOOK The coat hook is fastened to the headliner above the left hand rear passenger seat for Left Hand Drive or right hand rear passenger seat for Right Hand Drive This position has a coat hook in the place of a passenger assist handle DAEWOO M 150 BL2 ROOF 90 3 COMPONENT LOCATOR ROOF D19C402B 1 Sunroof Handle 8 Roof Rail 2 Sunroof Screen 9 Rear Spoiler 3 Sunroof Screen Seal 10 Roof Molding 4 Sunroof Upper Frame 11 Roof Rack Bracket 5 Roof Seal 12 Roof Rack Pad 6 Sunroof Lower Frame 13 Cap 7 Sunroof Cover 14 Roof Rack DAEWOO M 150 BL2 90 4 ROOF REPAIR INSTRUCTIONS ON VEHICLE SERVICE FORMED HEADLINER Removal Procedure 1 Disconnect the negative battery cable 2 Remove the sun visors Refer to Sun Visors in this section 3 Remove the interior courtesy
93. connect the rear speaker electrical connector 9G 12 INTERIOR TRIM D109E562 D109E563 D109E564 D109E565 4 Remove the rear parcel side shelf Refer to Rear Parcel Side Shelf in this section 5 Remove the rear seatback 6 Remove the rear seat belt bolt on the C pillar trim panel Refer to Section 8A Seat Belts 7 Pry off the C pillar trim panel e Pry off the trim panel hands 1 Installation Procedure 1 Install the C pillar trim panel 2 Install the rear seat belt bolt on the C pillar trim panel Refer to Section 8A Seat Belts 3 Install the rear seatback 4 Install the rear parcel side shelf Refer to Rear Parcel Side Shelf in this section 5 Connect the rear speaker connector 6 Connect the negative battery cable REAR PARCEL SHELF Removal Procedure 1 Open the tailgate 2 Remove the rear parcel shelf 1 Installation Procedure 1 Install the rear parcel shelf DAEWOO M 150 BL2 D109E566 D109E567 DAEWOO M 150 BL2 D109E569 INTERIOR TRIM 9G 13 REAR PARCEL SIDE SHELF Removal Procedure Disconnect the negative battery cable Open the tailgate Remove the seatback Remove the rear seat parcel shelf Refer to Rear Parcel Shelf in this section Remove the rear speaker from the rear parcel shelf Refer to Section 9F Audio Systems Remove the rear parcel side shelf e Remove the screws 1
94. connecting 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 Description and Operation 9T 10 Key Status Errors FENIX 5MR 9T 24 Immobilizer System 9T 10 Key Status Errors SIRIUS D3 9T 24 Electronically Coded Keys 9T 10 Communication Between Immobilizer and Detection Coil 9T 10 Test Equipment FENIX SMR 91 25 Immobilizer Control Unit 9T 10 Communication Between Immobilizer and Serial Data Link 9T 11 Devs core succus a gt Electronic Control Module ECM 9T 11 Repair structions LUPA DR ota Ud Uem Ir 9T 26 Security grip CUENTE SO OP conecte atitem alee Diagnostic Information and Procedures 9T 13 Key Coding Fropoauig AO ee gee Immobilizer System FENIX 5MR 9T 13 15 Immobilizer System SIRIUS D3 9T 13 Iransponger E LEASES 9T 27 DTC 1600 ECM Immobilizer Error Detection 9T 27 No 9T 14 Immobilizer Control Unit 9T 28 DTC 1601 ECM Immobilizer Error Specifications 9T 30 Incorrect Answer 9T 16 Fastener Tightening Specifications
95. d 9T 18 Immobilizer Anti Theft System 9T 31 P1628 ECM Immobilizer Error 9T 20 P1629 ECM Immobilizer Error 9T 22 DAEWOO M 150 BL2 Remote Keyless Entry and Immobilizer Anti theft System 9T 32 9T ii REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM BLANK REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM 9T 1 SECTION 9T REMOTE KEYLESS ENTRY AND ANTI THEFT 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 Description and Operation 9T 2 Repair Instructions 9T 4 Remote Keyless Entry and On Vehicle Service 9T 4 Anti Theft System 9T 2 E AE ETE ed SAAT 9T 4 Remote Locking and Unlocking 9r2 Password Programming 9T 5 Security 9T 2 Specifications 9T 6 Intrusion 91 2 Fastener Tightening Specifications 9T 6 IPED dm ERES 9T 2 Schematic and Routing Diagrams 9T 7 Vehicle Locator
96. der In case of the detection of a valid key The release mes sage communication with the ECM takes place The sta tus LED displays the Immobilizer state valid key After turning off the ignition ignition OFF detection simi lar to the ECM ignition OFF detection the Immobilizer changes to the active mode The status LED is blinking as Mode A Data Link Connector DLC Mode When the ignition is on a scan tool can switch the immo bilizer control unit to the DLC mode for diagnostics key coding and ID coding e The status LED is turned off during DLC mode e The Immobilizer will answer all correct messages which are defined as Immobilizer messages ID Code Handling One of 65 535 VIN codes is stored in the immobilizer EEPROM The VIN code can be erased by using Reset VIN code command of the scan tool When the immobilizer control unit calculates a new VIN code ECM VIN code should be reset to get identical with the immobilizer control unit s During diagnostic procedures the VIN code can be read for comparison with the ECM VIN code by using the scan tools Read immobilizer control unit VIN code command DAEWOO M 150 BL2 IMMOBILIZER ANTI THEFT SYSTEM 9T 11 SERIAL DATA LINK Serial data can be exchanged between a scan tool and the ECM and the Immobilizer control unit The scan tool connection is the data link connector DLC ELECTRONIC CONTROL MOUDLE ECM e in Virgin mode In this mode the ECM know
97. dlamp combination switch Fuse Ef8 or Ef9 is blown e Replace the fuse Ef10 or Ef11 e The open circuit or a short circuit e Repair or Replace the wiring between the fuse Ef8 or Ef9 and harness the terminal 1 of the headlamp connector e Headlamp bulb is blown e Replace the headlamp bulb e The open grounds G101 G102 e Repair or Replace the open circuit ground circuit High Beam and Low Beam e The open circuit or a short circuit e Repair or Replace the wiring Headlamps Are Inoperative On in the power supply circuit to the harness Both Left and Right Sides fuse Ef18 e Fuse Ef18 is blown e Replace the fuse Ef18 20A e The open circuit or a short circuit e Repair or Replace the wiring between the fuse Ef18 and the harness terminal 86 30 of the headlamp relay e Faulty headlamp relay e Replace the headlamp relay e The open circuit or a short circuit e Repair or Replace the wiring between the terminal 87 of the harness headlamp relay and the terminal 6 of the headlamp combination switch e Faulty headlamp combination e Replace the headlamp switch combination switch e The open ground G201 circuit e Repair or Replace the open ground circuit DAEWOO M 150 BL2 9B 4 LIGHTING SYSTEMS TURN SIGNAL LAMPS AND HAZARD LAMPS Probable Cause Turn Signal Lamps and Hazard The open circuit or a short circuit e Repair or Replace the wiring Lamps Do Not Work between the power supply circuit ha
98. door Back Window and tailgate Test Stand Position Approximately 30 down 45 toward the front and aimed approximately 610 mm 24 0 in from the corner of the back window DAEWOO M 150 BL2 SECTION 9J WINDNOISE TABLE OF CONTENTS Diagnostic Information and Procedures 9J 1 Repair Instructions 9J 2 Windnoise Diagnosis 9J 1 On Vehicle Service 9J 2 Windnoise Repair 9J 2 DIAGNOSTIC INFORMATION AND PROCEDURES WINDNOISE DIAGNOSIS 5 Internal windnoise is air leaving the vehicle and should be repaired in the following manner e In order to locate the leak tape off the body lock pillar pressure relief valves This will cause air pressure to build up inside the vehicle and en Caution An assistant should drive the vehicle while the technician checks for the location of the wind noise in order to prevent personal injury or vehicle Damage hance the windnoise A test drive in the vehicle is necessary to accurately de Use a stethoscope or a vacuum hose to locate the termine the location of the windnoise Often there is a leak primary leak and secondary leaks Failure to repair all leaks will only reduce the windnoise not eliminate it During the test drive the technician should bring the fol lowing items to aid in determining the location of the windnoise A mechanics stethoscope or vacuum hose Masking tape Strip
99. e Controlling the states LED e Controlling the transponder read write process mod ulation demodulation decoding comparison of the read code with the code of the valid keys e Communication with the ECM after ignition ON re ceiving of the ECM request and transmission of re lease message e Special functions for calculation and handling of the VIN code DAEWOO M 150 BL2 The VIN code is calculated by the Immobilizer using a random generator The VIN code is transmitted from the Immobilizer in the release message communication only incase of using an authorized key Without an authorized key it is not possible to getthe system VIN code In case of ECM in ternal state is in Virgin mode or neutral mode the ECM learns the system VIN code automatically after receiving the first release response message To get a synchronized Immobilizer system same VIN code in Immobilizer and ECM authorized key the DLC test equipment has to be used for authorization of the keys first key coding The usage of this test equipment is restricted to authorized persons e Communication with the DLC test equipment Main functions are the key coding procedure the VIN code handling and the support for system test functions e Handling of the software watchdog Operation In the active mode of immobilizer engine OFF IG key OFF the status LED is blinking as mode A When igni tion is turned ON the system wakes up and tries to read out the transpon
100. e cable to the fuel filler door 2 Retain the cable with the strip D19C550C 3 Install the lock striker of the fuel filler 4 Install the luggage compartment wheelhouse trim panel Refer to Section 9G Interior Trim 5 Install the rear rocker trim panel Refer to Section 9G Interior Trim 6 Install the lower B pillar trim panel Refer to Section 9G Interior Trim SW D19C549A DAEWOO M 150 BL2 DAEWOO M 150 BL2 D19C633A D109C551 BODY REAR END 95 5 7 Connect the fuel filler door remote cable to the han 8 dle Install the fuel filler door remote handle with the Screws TAILGATE REMOTE CABLE AND HANDLE Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Pry off the front rocker trim panel Refer to Section 9G Interior Trim Remove the tailgate remote handle e Remove the screws 1 e Disconnect the cable 2 e Remove the tailgate remote handle 3 Pry off the lower B pillar trim panel Refer to Section 9G Interior Trim Pry off the rear rocker trim panel Refer to Section 9G Interior Trim Pry off the luggage compartment wheelhouse trim panel Refer to Section 9G Interior Trim Disconnect the cable from the tailgate lock striker Refer to Section 9P Doors Remove the tailgate remote cable e Remove the cable retaining strip e Disconnect the tailgate remote cable 1 Installation Procedure Connect t
101. e perpendicular to and fall near the middle of the striker The lock fork should fall near the middle of the striker between the B pillar and the end of the striker DAEWOO M 150 BL2 j AL D109C577 D109C574 D109C578 DAEWOO M 150 BL2 DOORS 9P 11 5 If a fore or aft adjustment is required use the following steps e Remove the striker screws 1 e Remove the spacer in order to move the striker to ward the rear of the vehicle 2 e Add a 2 mm 0 08 inch spacer in order to move the striker toward the front of the vehicle e Install the striker screws 6 Perform the up down or the in out adjustment Refer to Up Down or In Out Adjustment in this section Up Down or In Out Adjustment An adjustment of the striker in the up and down or in and out directions may be necessary for a number of reasons vehicle frame damage as the result of a collision installa tion of new door weatherstripping customer complaints of excessive windnoise or difficulty in opening or closing the door In order to adjust the door striker in an up and down or in and out direction perform the following proce dure 1 The door must be properly aligned 2 Loosen the striker screws 3 The floating cage plate can be moved slightly using the ends of the striker screws Move the floating cage plate to the desired position Notice It is important to u
102. e rail and the glass run e Remove the bolts 1 e Lift up and remove the upper guide rail and the glass run simultaneously 2 D109C568 Installation Procedure 1 Install the upper guide rail and the rear door glass run 2 Install the guide piece with the screw Install the rear door seal trim Install the rear door trim panel Refer to Section 9G Interior Trim 5 Install the outside channel weatherstrip to the rear door Refer to Section 9G Interior Trim 6 Install the inside channel weatherstrip to the rear door Refer to Section 9G Interior Trim 22 S N A D109C569 DAEWOO M 150 BL2 DOORS 9P 9 DOOR LOCK STRIKER Removal Procedure 1 Remove the door lock striker e Remove the screws 1 e Remove the door lock striker 2 Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasteners to prevent premature corrosion 1 Install the door lock striker with the screws D109C571 TAILGATE LOCK STRIKER lt 0 OQ EH Removal Procedure V 1 Open the tailgate and suitably support it 1 2 2 Y 2 Remove the tailgate lock striker 24 e Remove the screws 1 e Disconnect the cable 2 e Remove the striker 3 gt D109C572 Installation Procedure Notice Dissimilar metal in direct contact with each oth er may corrode rapidly Make sure to use the c
103. e tailgate electrical connector 6 Install the luggage compartment wheelhouse trim pan el Refer to Section 9G Interior Trim 7 Connect the negative battery cable TAILGATE LOCK CYLINDER Removal Procedure 1 Disconnect the negative battery cable 2 Open the tailgate 3 Remove the rear window wiper motor assembly Re fer to Section 9D Wipers Washer Systems 4 Remove the tailgate lock cylinder e Disconnect the tailgate lock rod 1 e Remove the nuts from the tailgate lock cylinder 2 e Remove the tailgate lock cylinder 3 Installation Procedure 1 Install the tailgate lock cylinder 2 Install the rear window wiper motor assembly Refer to Section 9D Wipers Washer Systems 3 Connect the negative battery cable DOOR HINGE Removal Procedure 1 With the aid of another technician remove the door hinge e Remove the hinge to body bolts 1 e Remove the hinge to door bolts 2 e Remove the door hinge 3 9P 24 DOORS Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fastener to prevent premature corrosion 1 With the aid of another technician install the hinge to the door and the body with the bolts D109C616 DOOR HOLD OPEN LINK Removal Procedure 1 Remove the door seal trim Refer to Door Seal Trim in this section 2 Remove the door hold open link e Remove the hinge to body bolt
104. e to open the doors from the inside of the vehicle In order to deactivate the childproof rear door lock un lock the door from the inside of the vehicle and open the door from the outside Move the lever to the unlock posi tion The rear door will now work normally POWER DOOR LOCKS The power door locks use a solenoid that is contained in each door lock assembly The door locks are activated by the actuator on the inside door handle or by the lock cylinder on the driver door only When the driver door is locked or unlocked by the actuator or lock cylinder all doors are locked or unlocked accordingly POWER WINDOWS The power windows are controlled by electrical switches on the front door tirm and operated by a motor at each window regulator The windows are lowered by pressing the switch and raised by pulling up on the switch The window will stop movement when the switch is released or when the window is completely open or closed TAILGATE STRUT This vehicle is equipped with the gas struts The struts support the tailgate suitably when opening the tailgate The strut contained the high pressure compressed gas Therefore be careful not to take apart puncture apply heat or fire bacause the strut may explode DAEWOO M 150 BL2 DOORS 9P 3 COMPONENT LOCATOR FRONT DOOR lt e o 9P 4 DOORS Seal Trim Lock Button Trim Panel Pocket Handle Deluxe Type Pock
105. eadlamp Switch C1 BRN DK GRN Headlamp To Headlamp D29B010A SECTION 9C HORNS 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 B unless otherwise TABLE OF CONTENTS noted Description and Operation 9C 2 Floris od eis wie tet hee Sek 9C 2 Repair Instructions 9C 3 On Vehicle Service 9C 3 DAEWOO M 150 BL2 9C 3 Schematic and Routing Diagrams 9C 4 Horn Wiring System 9C 4 9C 2 HORN DESCRIPTION AND OPERATION ated by pressing the steering wheel pad which grounds HORN is NICE Dus The horn is located under the hood It is attached near tne Horse optio suelen the radiator at the front of the vehicle The horn is actu DAEWOO M 150 BL2 HORN 9C 3 REPAIR INSTRUCTIONS ON VEHICLE SERVICE D19C501A D19D518A DAEWOO M 150 BL2 HORN Removal Procedure 1 Disconnect the negative battery cable 2 Raise and suitably support the vehicle 3 Remove the front wheels 4 Remove the front wheel house splash shield e Remove the clip and bolts a Bolts and clips e Remove the wheel house splash sh
106. ean sisters M ELE ERES 90 2 Component Locator 90 3 Bumpers Fascias 90 3 Repair Instructions 90 4 DAEWOO M 150 BL2 On Vehicle Service Front Bumper Fascia Front Bumper Impact Rear Bumper Fascia Rear Bumper Bracket BAM said cic 90 2 BUMPERS AND FASCIAS DESCRIPTION AND OPERATION BUMPERS The bumper systems are installed with the body color bumper and the general bumper according to the vehicle grade The bumper systems are designed to sustain a collision into a fixed barrier at 4 km h 2 5 mph without damage After absorbing the energy of a collision these bumper Systems restore themselves to their original position Both the front and the rear bumpers feature an internal foam energy absorber and a polymer fascia cover The front bumper consists of the bumper fascia and the im pact bar Remove the fascia before removing the impact bar The rear bumper consists of the bumper fascia and the bracket Removal of rear bumper brackets can be possible without removing the bumper fascia DAEWOO M 150 BL2 BUMPERS AND FASCIAS 90 3 COMPONENT LOCATOR BUMPERS AND FASCIAS D19C401A Front Towing Cover Front Bumper Front Bumper Impact Beam Front Bumper Reinforcement Rear Bumper Reinforcement Rear Bumper Rear Bumper Bracket Rear Towing Cover ROD 90 4 BUMPERS AND FASCIAS
107. ehicle connect a voltmeter to each end of a grid line The voltmeter will indicate bat tery voltage if the grid line is open 4 grid line is found to be open move a voltmeter ter minal from one side of the grid line and retest at a D109E301 point nearer to the other side of the window Continue to retest each time bringing one of the voltmeter ter minals closer to the opposite side of the window from where it was originally connected The break in the grid line is at the point where the voltmeter begins reading 0 volts instead of battery voltage Use a marking crayon to lightly mark the break point on the rear window Mark the glass instead of mark ing directly on the grid line and make the mark far enough from the grid line so that the mark can easily be removed without disturbing the repair Use a grid line repair kit to fix the break in the grid line Refer to Rear Window Defogger Grid Line Repair in this section DAEWOO M 150 BL2 DAEWOO M 150 BL2 GLASS AND MIRRORS 9L 5 REPAIR INSTRUCTIONS ON VEHICLE SERVICE WINDSHIELD Tool Required J 24402 Glass Sealant Remover Removal Procedure 1 Remove the cowl vent grille Refer to Section 9H Body Front End 2 Remove the inside rearview mirror Refer to Inside Rearview Mirror in this section 3 Remove the weatherstrip around the windshield D19E501 4 Using the glass sealant remover J 24402 cut the adhesive around the windshie
108. emove the tailgate lock cylinder Refer to Section 9P Doors 4 Connect the negative battery cable D209B112 DAEWOO M 150 BL2 SECTION 9N FRAME AND UNDERBODY TABLE OF CONTENTS Description and Operation 9N 2 Alignment Checking General Body Construction 9N 2 Floor Pan Insulators Transaxle Under 5 9N 2 Specifications Repair Instructions 9N 3 Underbody Dimensions On Vehicle Service 9N 3 DAEWOO M 150 BL2 9N 2 FRAME AND UNDERBODY DESCRIPTION AND OPERATION GENERAL BODY CONSTRUCTION This vehicle is constructed with a unitized body which in corporates integral front and rear frame side rails The front suspension lower control arms are bolted to and retained by supports one each on the right and left sides The front suspension lower control arm supports are attached to the underbody with three bolts at two locations The engine is bolted to the integral front side rails The suspension strut towers must be dimensional ly correct in relation to the remainder of the underbody in order to maintain specified suspension strut and caster camber angles Since the individual underbody parts contribute directly to the overall strength of the body it is essential to ob serve proper welding te
109. eplace the open G401 G402 circuits ground circuit Hazard Lamps Do Not Operate The open circuit or a short circuit e Repair or Replace the open Turn Signals Are OK between the terminal 49a of the circuit turn signal lamp relay and the terminal 9 of the hazard lamp switch connector e The open circuit or a short circuit e Repair or Replace the wiring between the terminals 5 6 of the harness hazard lamp switch connector and the terminals 2 5 of the turn signal lamp connectors DAEWOO M 150 BL2 LIGHTING SYSTEMS 9B 5 STOPLAMPS AND INTERIOR COURTESY LAMP Probable Cause Stoplamps Do Not Work e Fuse F5 is blown e Replace the fuse F5 e The open circuit or a short circuit e Repair or Replace the wiring between the fuse F11 and the harness terminal 2 of the stoplamps switch connector For vehicle equipped with M T e Faulty stoplamp switch e Replace the stoplamp switch e The open circuit or a short circuit e Repair or Replace the wiring between the terminal 1 of the harness stoplamp switch connector and the terminal 3 of the stoplamps connector For vehicle equipped with M T e Stoplamp bulb is blown e Replace the stoplamp bulb e The open ground G401 G402 e Repair or Replace the open circuits ground circuit Interior Courtesy Lamp Does e The open circuit or a short circuit e Repair or Replace the wring Not Work in the power supply circuit to the harness fuse Ef2 e Fuse Ef2 is blown e Replace
110. er J 24402 cut the adhesive around the rear window glass D19E510 4 Remove the rear window glass from the vehicle 5 Using a knife remove the adhesive from the rear win dow glass 6 Using a knife remove the adhesive from the rear win dow frame D19E503 DAEWOO M 150 BL2 9L 8 GLASS AND MIRRORS Installation Procedure 1 Apply tape to the new weatherstrip and the rear win dow to hold the weatherstrip in place 2 Apply adhesive primer to the rear window frame and the perimeter of the rear window D109E511 3 Apply glass adhesive to the rear window frame D109E512 4 Install the rear window into the rear window frame 5 Reposition the tape over the weatherstrip the rear window and the rear window frame to hold the rear window in place 6 Letthe adhesive dry for 24 hours 7 Remove the tape D19E513A 8 Check for waterleaks by pouring water on the rear window If a leak is found dry the window and fill the area that leaks with adhesive If the leak persists remove the rear window and repeat the entire pro cedure 9 Connect the rear window defogger electrical con nector 10 Connect the negative battery cable D19E514A DAEWOO M 150 BL2 GLASS AND MIRRORS 9L 9 REAR WINDOW DEFOGGER GRID LINE REPAIR 1 Disconnect the negative battery cable 2 Disconnect the rear window defogger electrical con nector
111. ervice 9R 3 Hood Prop Rod 9R 6 Lubrication 9R 3 Hood Eatch 9R 7 Fasteners 9R 3 Hood Latch Release 9R 8 Anticorrosion Materials 9R 3 Hood Latch Release Cable 9R 9 Front End Sealing 9R 4 Ferideru 9R 9 DAEWOO M 150 BL2 9R 2 BODY FRONT END DESCRIPTION AND OPERATION BODY FRONT END This vehicle has a unitized body with a frame assembly supporting the engine and the transaxle The fender panels and the radiator support are also integral parts of the body DAEWOO M 150 BL2 DAEWOO M 150 BL2 BODY FRONT END 9R 3 REPAIR INSTRUCTIONS ON VEHICLE SERVICE D109C517 D109C518 D109C519 LUBRICATION The hood hinges and the locking mechanisms require periodic lubrication for proper operation Refer to Sec tion OB General Information for the specific types and intervals of lubrication FASTENERS Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasteners to prevent premature corrosion Many aluminum components are used on current models Aluminum in contact with steel may corrode rapidly if it is not protected by special finishes or isolators The fasteners used have a special finish which provid
112. es adequate protection from corrosion These special fas teners differ in color in order to easily identify them from the standard metric fasteners which are medium blue in color When replacing fasteners avoid substituting otherwise similar fasteners in the same location ANTICORROSION MATERIALS In order to provide rust resistance anticorrosion materi als have been applied to the interior surfaces of most of the metal panels When you service these panels properly re coat them with a service type anticorrosion material if any of the original material has been dis turbed 9R 4 BODY FRONT END FRONT END SEALING All locations where waterleaks may occur are sealed during production with high quality durable sealers If it becomes necessary to reseal specific areas use a high quality sealer of medium bodied consistency which will retain its flexible characteristics after curing and can be painted if necessary COWL VENT GRILLE Removal Procedure 1 Remove the wiper arm assembly Refer to Section 9D Wiper Washer Systems 2 Remove the cowl vent grille screws and the clips e Remove the screws after removing the upper cap 1 e Remove the lower retaining plastic clips 2 e Close the hood e Lift up the cowl vent grille 3 3 Remove the cowl vent grille
113. et Handle Bracket Deluxe Type Inside handle Manual Regulator Handle Pocket Handle Standard Type Door Speaker Cover Map Pocket Contact Switch Striker Opening Weatherstrip Door Weatherstrip Glass Run Front Door Inside Channel Weatherstrip Inside Handle Rod Door Lock Door Lock Cylinder Rod Lock Rod Actuator Rod Actuator Window Regulator Outside Channel Weatherstrip Outside Handle Rod Outside Handle Division Bar Quarter Glass Quarter Glass Run Door Hinge Door Hold Open Link Power Window Switch Cover Mirror Switch Power Window Switch Assembly Mirror switch Blank Door Side Molding DAEWOO M 150 BL2 DOORS 9P 5 REAR DOOR D19C404A 9P 6 DOORS Seal Trim Lock Button Trim Panel Pocket Handle Deluxe Type Pocket Handle Bracket Deluxe Type Inside handle Manual Regulator Handle Pocket Handle Standard Type Striker Opening Weatherstrip Door Weatherstrip Glass Run Interior Garnish Molding Rear Door Inside Channel Weatherstrip Upper Guide Rail Exterior Garnish Molding Lower Guide Rail Lock Rod Door Lock Inside Handle Rod Actuator Rod Actuator Outside Handle Rod Outside Handle Window Regulator Outside Channel Weatherstrip Door Hinge Door Hold Open Link Door Side Molding DAEWOO M 150 BL2 DAEWOO M 150 BL2 DOORS 9P 7 REPAIR I
114. he lever away from the driver until the switch clicks changes the lamp from low beam to high beam An indi cator lamp on the instrument cluster assembly will come on when the high beam headlamps are on To return the headlamps to low beam pull the lever toward the driver The headlamps must be aimed for proper illumination of the road Headlamp aim should be checked whenever a new headlamp assembly is installed or service repairs to the front end area may have disturbed the headlamp as sembly or its mountings FRONT TURN SIGNAL LAMPS When the turn signals are activated the side turn signal lamps flash to signal a turn The turn signal works only when the ignition switch is on The turn signals are controlled by the light switch on the left side of the steering column Moving the lever all the way up or down past the detent will turn on the turn sig nals When the turn is completed the lever will return to horizontal and the turn signals will stop flashing For changing lanes or shallow turns where the steering wheel does not turn far enough to cancel the signal move the signal only to the first detent and hold it there When the lever is released it will return to horizontal and the turn signal will cancel REAR FOG LAMP The rear fog lamp is incorporated in the drive side tail lamp assembly and are controlled by the rear fog lamp switch on the instrument panel The rear fog lamp can be turned on only when headlamps are on
115. he bolts after removing the caps 1 e Remove the screws on the side plate 2 e Remove the tie bar retaining bolts on the lower panel 3 Remove the instrument trim panel assembly 4 Installation Procedure Install the instrument trim panel assembly with the bolts and screws Connect the ALDL connector with the screws Connect the ashtray lamp if equipped with Connect the cigar lighter connector Install the audio system to the instrument panel Re fer to Section 9F Audio Systems Install the A C controller to the instrument panel Refer to Section 7B Manual Control Heating Ven and Air Conditioning System 14 INSTRUMENTATION DRIVER INFORMATION 9 01098522 D19B547A 7 10 11 12 13 14 15 16 17 18 Install the instrument cluster assembly Refer to In strument Cluster in this section Install the floor console with the screws Install the passenger s airbag module to the instru ment panel Refer to Section 8B Supplemental In flatable Restraints SIR For vehicle equipped with the airbag Install the glove box assembly to the instrument panel Refer to Glove Box in this section Install the hood latch release lever to the instrument panel Refer to Section 9H Body Front End Install the instrument cluster trim panel to the instru ment cluster trim panel with the screws Install the A pillar trim panels Refer
116. he rocker panel trim and the lower B pillar panel trim D109C631 MANUAL WINDOW REGULATOR HANDLE Removal Procedure 1 Remove the window regulator handle Using a cloth pull out the clip 1 e Remove the window regulator handle 2 Installation Procedure 1 Install the window regulator handle with the clip D109C632 TAILGATE STRUT Removal Procedure 1 Open the tailgate and suitably support it 2 Remove the tailgate strut assembly e Remove the end fitting nut from the ball studs rear body 1 e Removethe end fitting nut from the ball studs tail gate 2 D19C634A DAEWOO M 150 BL2 DOORS 9P 29 Installation Procedure 1 Install the tailgate strut with the ball studs DAEWOO M 150 BL2 30 DOORS SCHEMATIC AND ROUTING DIAGRAMS POWER DOOR LOCKS LEFT HAND DRIVE Hot at All Times Engine Fuse Block Fuse Block Left Front Door Lock Switch DK BLU YEL DKBLU 4 DK BLU Right Rear YEL YEL Door Lock Actuator C371 3 1 C371 2 WHT DKBLU Y X DKBLU Left Rear YEL YEL Door Lock Actuator C381 1 3 C381 gt k j DKBLU DKBLU Right Rear YEL YEL Door Lock Actuator D19C201B DAEWOO M 150 BL2 DOORS 9P 31 POWER DOOR LOCKS RIGHT HAND DRIVE Hot at All Times Engine Fuse Left Front Door Lock Switch C
117. he tailgate remote cable to the tailgate lock striker Retain the cable with the strip Install the luggage compartment wheelhouse trim panel Refer to Section 9G Interior Trim Install the rear rocker trim panel Refer to Section 9G Interior Trim Install the lower trim panel Refer to Section 9G Interior Trim Connect the tailgate remote cable to the handle Install the tailgate remote handle with the screws REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM 9T i SECTION 9T REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM TABLE OF CONTENTS Description and Operation 9T 2 Repair Instructions 9T 4 Remote Keyless Entry and On Vehicle Service 9T 4 Anti Theft System 9T 2 Sirem a Aveta e a O A AR 9T 4 Remote Locking and Unlocking 9r2 Password Programming 9T 5 Security 91 2 Specifications 9T 6 Intrusion 91 2 Fastener Tightening Specifications 9T 6 SIEM PL ES 9T 2 Schematic and Routing Diagrams 9T 7 Vehicle Locator 9T 2 Remote Keyless Entry and Autolocking Safety Lock 9T 3 Anti Theft System 9T 7 Control Module Receiver 9T 3 IMMOBILIZER ANTI THEFT SYSTEM TA
118. iagnosis module SDM for the airbag System is located under the floor console PARKING BRAKE CABLE COVER The parking brake cable cover should be removed to ad just the free play of the parking brake cable FLOOR CARPET The molded one piece floor carpet goes over both the front and the rear floor pans DAEWOO M 150 BL2 INTERIOR TRIM 9 3 COMPONENT LOCATOR INTERIOR TRIM D19E402A 1 A Pillar Trim Panel 8 Wheel House Trim Panel 2 B Pillar Upper Trim Panel 9 Floor Console 3 C Pillar Trim Panel 10 Parking Brake Cable Cover 4 Front Rocker Trim Panel 11 Console Cover Assembly 5 B Pillar Lower Trim Panel 12 Deposit Box 6 Rear Rocker Trim Panel 13 Console Boot Assembly 7 Rear Parcel Side Shelf DAEWOO M 150 BL2 9G 4 INTERIOR TRIM REPAIR INSTRUCTIONS ON VEHICLE SERVICE FRONT DOOR TRIM PANEL STANDARD Tool Required KM 475 B Trim Remover Removal Procedure 1 Remove the door pull from the front door e Remove the screws 1 e Remove the door pull 2 D109E532 2 Remove the inside door handle e Remove the screw 1 e Disconnect the inside door handle rod 2 e Pry off the inside door handle 3 3 Remove the window regulator handle from the front door Using a cloth pull out the clip 1 e Remove the regulator handle 2 D109E534 DAEWOO M 150 BL2 DAEWOO M 150 BL2 D109E535 D109E536 D19E538A INTERIOR TR
119. id release message the ECM performs the following actions e Disables the fuel injector circuit P 1629 Will Set When e The ECM receives an incorrect release message from the immobilizer control unit more than five times P 1629 Will Clear When e The ignition switch is turned OFF or the scan tool TROUBLE CODE CLEAR command is issued DAEWOO M 150 BL2 DAEWOO M 150 BL2 IMMOBILIZER ANTI THEFT SYSTEM 9T 23 P 1629 ECM Immobilizer Error Incorrect Answer ww Vale Connect the scan tool using the following procedure Insert the cartridge into the scan tool Turn the ignition switch to the OFF Connect the scan tool to the data link connector Go to DLO Communi Connect the scan tool s power cord to the cigar cation lighter socket Between Turn the ignition ON but do not start the engine Immobilizer Is communication established between the scan tool and Test and the immobilizer control unit Go to Step 2 Equipment 1 Select DIAGNOSIIS from the scan tool menu 2 Read the IMMO amp ECM ID CODE immobilization and electronic control module identification code message Go to Did the message differ from normal message Identification Normal Message ECM MODE LEARNT ID Code IMMO MODE LEARNT Repro VIN CODE SAME gramming Go to Step 3 1 Replace the ECM 2 Reprogram the ID code Is the repair complete System OK Go to Step 4 1 Replace the ECM 2 Turn the igniti
120. ield b Splash shield 5 Remove the horn e Remove the bolt 1 e Disconnect the electrical connector 2 Installation Procedure 1 Install the horn with the bolt 2 Connect the electrical connector 3 Install the front wheel house splash shield with the clips and the bolts 4 Install the front wheels 5 Lower the vehicle 6 Connect the negative battery cable 9C 4 HORN SCHEMATIC AND ROUTING DIAGRAMS HORN WIRING SYSTEM Hot in Run and Start Engine Fuse Block DK GRN BLK DK GRN BLK Horn Switch Without Airbags With Airbags D19D207B DAEWOO M 150 BL2 SECTION 9D WIPERS WASHER 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 B unless otherwise TABLE OF CONTENTS noted Description and Operation 9D 2 Windshield Wiper System 9D 2 Windshield Washer System 9D 2 Rear Window Wiper Washer System 9D 2 Diagnostic Information and Procedures 9D 3 Windshield Rear Window Wiper and Washer SV SUSY sium cos aon deter ied rro bebe m 9D 3 Repair Instructions 9D 6 On Vehicle Service 9D 6 Windshield Wiper Arm
121. ify that the noise is eliminated Glass Knock Coming An out of adjustment hatchback Test drive the vehicle in order to verify this From the Rear of the latch condition Vehicle When Driving e Loosen the latch nuts and adjust the latch Over Bumps downward Rattle Coming From The door lock solenoid is loose Remove the door trim panel and check if the Door solenoid is loose e Tighten the solenoid bolts Rattling electrical connectors e Tap on the trim panel and listen for a rattle inside the door trim panel e Remove the trim panel and wrap foam padding around the connectors as required Squeak When A lack of lubrication of the door Operate the doors and listen for squeaks Operating Doors hinge pins e Lubricate the door hinge pins with light oil and coat with lithium grease e A lack of lubrication of the door e Lubricate the door hold open link arm with hold open link arm light oil and coat with lithium grease DAEWOO M 150 BL2 9K 2 SQUEAKS AND RATTLES SQUEAK AND RATTLE DIAGNOSIS Cont d Squeak Coming From e The faulty manual transaxle e Move the control lever between gears and Console When Shifting control lever lower boot listen for squeaks Manual Transaxle e Remove the floor console and replace the Condition Occurs In lower shift boot or apply talcum powder to Cold Weather with a the lower shift boot Cold Engine Squeak Coming From e Rubbing of the cluster trim plate Test drive the vehicle in o
122. iper blade to the arm WASHER RESERVOIR Removal Procedure 1 Disconnect the negative battery cable 2 Remove the washer reservoir inlet e Remove the bolt 1 e Remove the washer reservoir inlet 2 DAEWOO M 150 BL2 DAEWOO M 150 BL2 D19D537A D109D538 D109D540 3 4 WIPERS WASHER SYSTEMS 9D 11 Raise and suitably support the vehicle Remove the front RH wheelhouse splash shield e Remove the screws 1 e Remove the clips 2 e Remove the wheelhouse splash shield 3 Remove the washer reservoir assembly e Drain the washer fluid e Disconnect the washer hose connector 1 e Disconnect the washer pump electrical connector 2 e Remove the bolts 3 e Remove the washer reservoir assembly 4 Installation Procedure Install the washer reservoir assembly with the bolts Connect the washer pump electrical connector Connect the washer hose connector Install the front RH wheelhouse splash shield with the screws and the clips Lower the vehicle Install the washer reservoir with the bolt Connect the negative battery cable WASHER PUMP Removal Procedure Disconnect the negative battery cable Remove the washer reservoir assembly Refer to Washer Reservoir in this section Drain the washer fluid Remove the wiper motor from the washer reservoir assembly a Washer pump 9D 12 WIPERS WASHER SYSTEMS amp
123. iper operation is actuated through the lever on the right side of the steering column WINDSHIELD WASHER SYSTEM The windshield washer system is equipped with a wash er fluid reservoir a washer fluid pump hoses nozzles and a wiper washer switch The windshield washer res ervoir is mounted inner the front right wheel well splash shield Attached to the reservoir is a washer pump which pumps fluid through the hoses to the two nozzles mounted on the cowl panel The washer switch is an in tegral part of the wiper washer switch Windshield wash er operation is actuated through the lever on the right side of the steering column REAR WIPER WASHER SYSTEM The rear wiper washer system is equipped with the high grade vehicle The rear wiper and the washer are one assembly The rear washer is installed to the rear wiper The rear wiper washer switch is same with the wind shield wiper Push the switch to one position forward and the rear wiper operate slowly And push more the switch forward and the rear wiper washer system oper ate DAEWOO M 150 BL2 WIPERS WASHER SYSTEMS 90 3 DIAGNOSTIC INFORMATION AND PROCEDURES WINDSHIELD REAR WINDOW WIPER AND WASHER SYSTEM Windshield Wipers Do Not e The open or a short in the power e Repair or replace the open a short Work At Any Speed supply circuit to the fuse F8 in the power supply circuit to the fuse F8 e Fuse F8 is blown e Replace the fuse F8 e Faulty wiper washer switch e Replace
124. ished between the scan tool and the immobilizer control unit Select CURRENT KEY STATUS from the scan tool menu Did the STATUS OF CURRENT KEY message indicate KEY IS WRONG Read the IMMO amp ECM ID CODE message that was displayed after requesting DIAGNOSIS Did the message differ from normal message Normal Message ECM MODE LEARNT IMMO MODE LEARNT VIN CODE SAME Check for an open serial data wire between the immobilizer control unit and the ECM Was the circuit open Repair the open serial data wire between the ECM and the immobilizer control unit Is the repair complete 1 Replace the ECM 2 Reprogram the identification ID code Refer to Identification ID Code Reprogramming in this section Is the repair complete Go to Step 2 Go to Key Status Errors Go to Identification ID Code Repro gramming Go to Step 5 System OK System OK Go to Communi cation Between Immobilizer and Test Equipment Go to Step 3 Go to Step 4 Go to Step 6 9T 16 IMMOBILIZER ANTI THEFT SYSTEM Without Keyless Entry DK BLU YEL 1 Immobilizer Seral Data Control Unit With Keyless Entry DK BLU YEL Keyless Entry Control Module Immobilizer Receiver Electronic Control DKBLU YEL 1 Immobilizer Resistor Data Link G Connector DLC Electronic Control Module 1 ECM 11 DK BLU YEL Data Link Con
125. ive 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 B unless otherwise TABLE OF CONTENTS noted Description and Operation 9E 2 Cigar 9E 2 IDEE 9E 2 Instrument Panel Vents 9E 2 Glove ata eb erga 9E 2 Digital Clock 9E 2 Instrument Cluster 9E 2 Speedometer Odometer Trip Odometer 9E 2 Fuel Gauge s eto Se oett 9E 2 Temperature Gauge 9E 2 Instrument Cluster Indicator Lamps 9E 2 Component Locator 9E 3 Instrument Panel Assembly 9E 3 Instrument 9E 4 Diagnostic Information and Procedures 9E 5 Cigar 9E 5 HVAC Panel Illumination 9E 6 Digital Glock Ree et 9E 7 Repair Instructions 9E 8 On Vehicle Service 9E 8 Cigar 9E 8 DAEWOO M 150 BL2 5 nee Dni 9E 9 Instrument Cluster Trim Panel Vents 9E 9 Digital Clock 9E 10 Gl
126. l door lock system D109C586 Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasteners to prevent premature corrosion 1 Install the rear door lock with the screws Important Connect the actuator connector if equipped with the central door lock system 2 Connect the outside door handle rod to the door lock 3 Install the guide rail with the screw 4 Install the seal trim Refer to Door Seal Trim in this D109C587 section 5 Install the door trim panel Refer to Section 9G Interi or Trim 6 Connect the negative battery cable if equipped with the central door lock system DAEWOO M 150 BL2 9P 16 DOORS CENTRAL DOOR LOCK ACTUATOR Removal Procedure 1 Disconnect the negative battery cable 2 Remove the door seal trim Refer to Door Seal Trim in this section 3 Remove the door lock assembly Refer to Door Lock in this section 4 Remove the actuator from the door lock assembly e Remove the screws 1 e Remove the actuator 2 D109C588 Installation Procedure 1 Install the door lock actuator to the door lock assem bly with the screws 2 Install the door lock assembly to the vehicle Refer to Door Lock in this section 3 Install the door seal trim Refer to Door Seal Trim in this section 4 Connect the negative battery cable TAILGATE LOCK Removal Procedure
127. lamp Refer to Section 9B Lighting Systems 4 Pry off the A pillar trim panel Refer to Section 9G Interior Trim 5 Pry off the upper trim panel Refer to Sec tion 9G Interior Trim Pry off the C pillar trim panel Refer to Section 9G Interior Trim D109C555 6 7 Remove the passenger assist handle and the coat hook Refer to Passenger Assist Handle and The Coat Hook in this section 8 Remove the sunroof molding if equipped with Re fer to Manual Sunroof in this section 9 Take off the tailgate opening weatherstrip Refer to Section 9P Doors 10 Remove the headliner e Remove the clips 1 e Remove the headliner 2 Installation Procedure 1 Install in the reverse order of removal anan ANAL D109C556 DAEWOO M 150 BL2 oc D109C557 D109C558 D109C559 D109C560 DAEWOO M 150 BL2 ROOF 9Q 5 MANUAL SUNROOF Removal Procedure 1 Remove the sunroof screen e Remove the clips 1 e Remove the lock 2 e Remove the screen 3 2 Remove the inside sunroof molding in the passenger compartment a Inside sunroof molding 3 Remove the lower sunroof frame e Remove the screws 1 e Remove the lower sunroof frame 2 4 Remove the upper sunroof frame a Upper sunroof frame 9Q 6 ROOF D19C56
128. ld D19E502 5 Remove the windshield from the vehicle 6 Using a knife remove the adhesive from the wind shield D19E503 9L 6 GLASS AND MIRRORS Installation Procedure 1 Install the new weatherstrip to the windshield D19E504 2 Apply tape to the new weatherstrip and the wind shield to hold the weatherstrip in place 3 Apply adhesive primer to the windshield frame and the perimeter of the windshield D19E505 4 Apply glass adhesive to the windshield frame D19E506 5 Install the windshield into the windshield frame 6 Reposition the tape over the weatherstrip the wind shield and the windshield frame to hold the wind shield in place 7 Letthe adhesive dry for 24 hours 8 Remove the tape D19E507A DAEWOO M 150 BL2 GLASS AND MIRRORS 9L 7 9 Check for waterleaks by pouring water on the wind shield If a leak is found dry the windshield and fill the area that leaks with adhesive If the leak per sists remove the windshield and repeat the entire procedure 10 Install the inside rearview mirror Refer to Inside Rearview Mirror in this section 11 Install the cowl vent grille Refer to Section 9R Body Front End D19E508A REAR WINDOW GLASS Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the rear window defogger electrical con nectors D19E509 3 Using the glass sealant remov
129. lizer and ECM ELECTRONICALLY CODED KEYS Each valid ignition key has an internal transponder which is a read write transponder The transponder contains an implementation of a cryp to algorithm with 96 bits of user configurable s cret key contained in EEPROM and transmits data to the ICU by modulating the amplitude of the ele tromagnetic field and receives data and commands in a similar way DETECTION COIL The toroidal coil is mounted at the ignition lock in front of the key barrel It is connected to the ICU with a four terminal connector fixed at the body of the coil The length of the connection between coil and Immobi lizer is restricted to 50cm The correct placement on the ignition lock and the exact electrical data is very impor tant for the reading distance of transponder The toroidal coil and receiving coil inside the transpond er built a transformer During the readingprocess the coil induces energy into the transponder The transponder charges the field and generates an amplitude modulated signal with the manchester coded data This charge of the field is demodulated inside the Immobilizer The Immobilizer contains the coil driver hardware for di rect connection of the toroidal coil IMMOBILIZER CONTROL UNIT The function of the Immobilizer System is shared be tween the ICU and the ECM The task of the Immobilizer Electronic Control unit ICU are e Reading of the input information ignition ON OFF
130. m the front door 5 Remove the glass from the front door e Remove the glass retaining bolts 1 e Remove the glass 2 Notice Make sure not to contact the glass with the body to prevent the paint damage Installation Procedure 1 Install the front door glass with the bolts D19E524 2 Install the front door glass run D19E522 9L 12 GLASS AND MIRRORS 3 Install the division bar with the guide rail inside bolt the guide rail outside bolt and the guide rail screw 4 Install the outside rearview mirror Refer to Glass and Mirrors in this section 5 Install the front door seal trim Refer to Section 9 Doors FRONT DOOR QUARTER GLASS Removal Procedure 1 Remove the front door seal trim Refer to Section 9P Doors 2 Remove the outside rearview mirror Refer to Out side Rearview Mirror in this section 3 Remove the guide rail Remove the screw 1 Remove the inside bolt 2 Remove the outside bolt 3 Remove the division bar 4 D109E521 4 Remove the quarter glass from the front door e Remove the quarter glass assembly 1 e Remove the quarter glass run 2 D109E525 Installation Procedure 1 Install the quarter glass with the quarter glass run D19E525A DAEWOO M 150 BL2 SETS D19E524 D19E527 DAEWOO M 150 BL2 GLASS A
131. mbly 9P 20 Rear Door Assembly 9P 21 Tailgate s 9P 22 Tailgate Lock 9P 23 Door Hinge 9P 23 Door Hold Open Link 9P 24 Inside Channel Weatherstrip Standard 9P 24 Inside Channel Weatherstrip Deluxe 9P 25 Door Outside Channel Weatherstrip 9P 25 Door Weatherstrip 9P 26 Door Seal Trim 9P 27 Door Opening Weatherstrip 9P 27 Manual Window Regulator Handle 9P 28 Tailgate Strut 9P 28 Schematic and Routing Diagrams 9P 30 Power Door Locks 9P 30 Power Windows Front 9P 34 9P 2 DOORS DESCRIPTION AND OPERATION DOOR LOCK STRIKER The front and the rear door lock strikers each consist of a striker with two screws threaded into a floating cage plate in the B pillars and C pillars The door is secured in the closed position when the door lock fork snaps over and engages the striker CHILDPROOF REAR DOOR LOCK The childproof rear door locks help prevent passengers especially children from opening the rear doors of the vehicle from the inside In order to activate these locks move the levers of both rear doors to the lock position Then close both doors Rear passengers will be unabl
132. mes magnetized it will degrade cassettes played in the player No service is performed on the cas settes The cassette manufacturer handles warranties of the cassettes Store cassettes away from extreme heat and direct sunlight COMPACT DISC CARE Handle discs carefully Store the discs in protective cases away from the sun heat and dust If the surface is soiled dampen a clean soft cloth in a solution of mild neutral detergent and wipe the disc clean Mini discs about 3 inches in diameter will not eject and should not be used DAEWOO M 150 BL2 AUDIO SYSTEMS 9F 3 COMPONENT LOCATOR AUDIO SYSTEMS D19D401B Roof Antenna Assembly Roof Antenna Pole Roof Antenna Base Roof Antenna Frame Roof Antenna Cable Front Speaker Rear Speaker Audio CD Changer Cable CD Changer Bracket CD Changer Magazine CD Changer oo m DAEWOO M 150 BL2 9F 4 AUDIO SYSTEMS DIAGNOSTIC INFORMATION AND PROCEDURES AUDIO SYSTEM Condition Probable Cause Correction Audio System Inoperative e The power supply circuit to the e Repair or Replace the power fuse Ef2 is open circuit or short supply wiring harness circuit e The fuse Ef2 is blown e Replace the fuse e The circuit between the fuse Ef2 e Repair or Replace the wiring and the fuse F11 is open or short harness e The fuse F6 or the fuse F11 is e Replace the fuse blown e The audio system circuit t
133. mper spacer Refer to Section 9M Exterior Trim 6 Raise and suitably support the vehicle 7 Install the clips under the fascia c Fascia lower clip 8 Install the bolts on the both side of the fascia 9 Install the front wheelhouse splash shields with the clips and the bolts 10 Install the front wheels 11 Lower the vehicle 12 Connect the negative battery cable FRONT BUMPER IMPACT BAR Removal Procedure 1 Disconnect the negative battery cable 2 Remove the front bumper fascia Refer to Front Bumper Fascia in this section 3 Remove the front wiring harness retaining clip from the impact bar 90 6 BUMPERS AND FASCIAS 3 Remove the impact bar e Remove the nuts 1 e Remove the impact bar 2 Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasteners to prevent premature corrosion 1 Install the impact bar with the nuts 2 Install the front wiring harness retaining clip to the im pact bar 3 Install the front bumper fascia Refer to Front Bump er Fascia in this section 4 Connect the negative battery cable C19C507A REAR BUMPER FASCIA Removal Procedure 1 Raise and suitably support the vehicle 2 Remove the bolts underneath the fascia e Remove
134. nector DLC D19T002B DIAGNOSTIC TROUBLE CODE DTC 1601 ECM IMMOBILIZER ERROR INCORRECT ANSWER Circuit Description When the ignition is turned ON the key is tested by the immobilizer anti theft system While the key code is be ing read by the immobilizer control unit the engine can start and run with any key that will turn the lock cylinder The key code is read and compared with key codes that have been stored in the memory of the immobilizer con trol unit If a valid key is detected the immobilizer control unit sends a serial data release message to the elec tronic control module ECM Included in the release message is an identification ID code which assures that neither the immobilizer control unit nor the ECM has been substituted to defeat the system If the ECM re ceives an invalid release message the ECM performs the following actions e Disables the fuel injector circuit e Disables the fuel pump circuit e Disables the ignition coil DTC 1601 Will Set When e The ECM receives an incorrect release message from the immobilizer control unit more than five times DTC 1601 Will Clear When e The ignition switch is turned OFF or the scan tool TROUBLE CODE CLEAR command is issued DAEWOO M 150 BL2 DAEWOO M 150 BL2 IMMOBILIZER ANTI THEFT SYSTEM 9T 17 DTC 1601 ECM Immobilizer Error Incorrect Answer Connect the scan tool using the following procedure Insert the cartridge into the scan tool
135. negative battery cable SIDE TURN SIGNAL LAMPS Removal Procedure 1 Disconnect the negative battery cable 2 Slide the side turn signal lamp rearward 3 Remove the lamp 4 Disconnect the electrical connector Installation Procedure 1 Connect the electrical connector 2 Install the side turn signal lamp 3 Connect the negative battery cable DAEWOO M 150 BL2 DAEWOO M 150 BL2 yee D109D507 D19D508B D19D509A D19C501A LIGHTING SYSTEMS 9B 9 TAILLAMPS ASSEMBLY Removal Procedure 1 Disconnect the negative battery cable 2 Open the tailgate 3 Remove the luggage compartment wheelhouse trim Refer to Section 9G Interior Trim 4 Disconnect the electrical connector 5 Remove the taillamp assembly e Remove the screws 1 e Remove the taillamp 2 Installation Procedure 1 Install the taillamp assembly with the screws 2 Connect the electrical connector 3 Install the luggage compartment wheelhouse trim Refer to Section 9G Interior Trim 4 Connect the negative battery cable FRONT FOG LAMP Removal Procedure 1 Disconnect the negative battery cable 2 Raise and suitably support the vehicle 3 Remove the front wheels 4 Remove the front wheel house splash shield e Remove the clip and bolts a Bolt and clips e Remove the wheel house splash shield b Splash shield 9B 10 LIGHTING SYSTEMS D19D508C D19D509A 5 Remove the front fog lamp e Remove the screws 1
136. ng Go to Step 4 Go to Step 5 Go to Step 6 9T 20 IMMOBILIZER ANTI THEFT SYSTEM Without Keyless Entry ata Link connector DLC With Keyless Entry Keyless Entry Control Module Immobilizer 17 Receiver DK BLU YEL ata onnector DLC DK BLU YEL DK BLU YEL 56 Engine Control Module ECM C204 DK BLU YEL Link Engine Control Module ECM D209T002 DIAGNOSTIC TROUBLE CODE P 1628 SIRIUS D3 ECM IMMOBILIZER ERROR NO SUCCESSFUL COMMUNICATION Circuit Description When the ignition is turned ON the key is tested by the immobilizer anti theft system While the key code is be ing read by the immobilizer control unit the engine can start and run with any key that will turn the lock cylinder The key code is read and compared with key codes that have been stored in the memory of the immobilizer con trol unit If a valid key is detected the immobilizer control unit sends a serial data release message to the elec tronic control module ECM Included in the release message is an identification ID code which assures that neither the immobilizer control unit nor the ECM has been substituted to defeat the system If the ECM re ceives an invalid release message the ECM performs the following actions e Disables the fuel injector circuit P 1628 Will Set When e The ECM does not receive the signal from the immo bilizer control module within 1 260 seconds after
137. nsor Head Lamp LH Horn 5 G101 Head Lamp i 122 RH FRT Fog Lamp LH G102 Engine Cooling Fan Hood Switch Power Steering Dual Pressure Switch Cil Pressure Switch FRT Fog Lamp RH Direction A Direction B D111401D DAEWOO M 150 BL2 9A 12 BODY WIRING SYSTEM ENGINE HARNESS ROUTING SIRIUS D3 Left Hand Drive Shown Right Hand Drive Similar El System Battery B TP sensor CMP sensor Reverse Lamp Switch CKP Sensor O2 Sensor ECT Sensor EEGR Injector 1 2 3 Generator Generator B Start Motor G103 KS BODY WIRING SYSTEM 9A 13 ENGINE HARNESS ROUTING FENIX 5NR Left Hand Drive Shown Right Hand Drive Similar Idle Air Control Valve IAC Coolant Temperature Sensor ECT O2 Sensor Only Unleaded Optical Sensor Engine Speed Sensor Manifold Air Temperature Sensor IAT DAEWOO M 150 BL2 Yi ENN EGR Only Unleaded TP Sensor Manifold Air Temperature Sensor IAT Optical Sensor Engine Speed Sensor Reverse Lamp Switch Idle Air Control Valve IAC Throttle Position Sensor TP Sensor Exhaust Gas Recirculation Solenoid EGR 9 XY 2 D111411A 9A 14 BODY WIRING SYSTEM INSTRUMENT HARNESS ROUTING Left Hand Drive Fuse Block and Relays Direction B Hazard Switch Front or Rear Fog Cluster Connector Immobilizer Display Lamp Switch Blower
138. ntrol unit the keys must be re authorized using the key coding procedure Refer to Key Coding Procedure in this section Also the electronic control module ECM identification ID code must be reset Refer to Identification ID Code Reprogramming in this section 1 Connect the electrical connectors to the immobilizer control unit 2 Slide the immobilizer control unit onto its mounting bracket D29T004 3 Install the steering column covers Refer to Section 6E Steering Wheel and Column 4 Connect the negative battery cable D105A505 DAEWOO M 150 BL2 9T 30 IMMOBILIZER ANTI THEFT SYSTEM SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS IMMOBILIZER ANTI THEFT SYSTEM 97 31 SCHEMATIC AND ROUTING DIAGRAMS 5MR SIRIUS 03 Hot at All Times Engine Electronic Control Module ECM 11 56 DK BLU Hot in Run and Start Fuse Block DK BLU YEL Immobilizer Resistor Only FENIX ORN 5MR ORN Data Link RED YEL Connector Status Indicator IMMOBILIZER ANTI THEFT SYSTEM Detection Coil D19T001B DAEWOO M 150 BL2 9T 32 IMMOBILIZER ANTI THEFT SYSTEM SCHEMATIC AND ROUTING DIAGRAMS YOUMS YOUMS uedo uedo YOUMS 400q uedo JeoH Jooq d ut 1 YOUMS i uedo 1 5 O M v 9
139. o ground before either of the following conditions occurs e An UNLOCK message is received from the transmit ter SIREN The remote keyless entry system is armed when the LOCK message is received from the transmitter when the ignition is OFF When the system is armed it will ac tivate the siren and flash the turn signals for 28 seconds if any of the following conditions occurs A door is opened front door open switch input is changed to ground e The tailgate is opened tailgate open switch input is changed to ground e The hood is opened while the anti theft system is armed hood open switch input is changed to ground The siren is disarmed when any of the following condi tions occurs e The ignition switch is turned ON with the key e The UNLOCK button or the LOCK button on the re mote transmitter is pressed VEHICLE LOCATOR The remote keyless entry system assists the driver in lo cating the vehicle When the vehicle is unlocked with the remote control the turn signals flash twice to indicate the location of the vehicle The duration of the flashes and the length of time between flashes is used to indi cate certain vehicle conditions Refer to Fault or Alarm Indication in this section DAEWOO M 150 BL2 REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM 9T 3 AUTOLOCKING SAFETY LOCK The remote keyless entry system features an autolock ing control If the doors are unlocked with the remote transmitter
140. o the e Repair or Replace the wiring fuse F6 or the fuse F11 is open harness circuit or short circuit Poor ground G201 e Replace or Replace the wiring harness e Audio system is out of order e Replace the audio system Cassette Player Inoperative e Bad quality tape e Do not use a bad quality tape AM FM Functions OK e The cassette player destroy a e Clean the cassette player head good quality tape the capstan and the drive system e Obstructions behind the tape door Remove the obstruction using gentle force e Cassette player is out of order e Replace the audio system FM Does Not Work AM and e Audio system is out of order e Replace the audio system Cassette OK AM Radio Does Not Work FM e AM radio reception is poor Using e Replace the audio system and Cassette OK a test antenna test the AM radio reception AM radio reception is good Using Replace the antenna cable a test antenna test the AM radio between the audio system and the reception antenna Front Speakers Distorted or Damage rattles or vibration of Make the necessary repairs to Inoperative the speaker and the door area secure the component causing the distortion The circuit between the front Repair or Replace the wiring speaker connector and the radio harness connector is open circuit or short circuit The connection of the front Confirm the connection speaker connector and the audio connector is poor e Front speaker is out of orde
141. olve the condition Refer to Section 9L Glass and Mirrors DAEWOO M 150 BL2 SECTION 9K SQUEAKS AND RATTLES TABLE OF CONTENTS Diagnostic Information and Procedures 9K 1 Repair Instructions 9K 3 Squeak and Rattle Diagnosis 9K 1 On Vehicle Service 9K 3 Squeak and Rattle Repair 9K 3 DIAGNOSTIC INFORMATION AND PROCEDURES SQUEAK AND RATTLE DIAGNOSIS Rattle Coming From the Improperly connected brake e Tap lightly on the brake lines and listen for a Side Rail lines rattle e Install plastic tie straps to secure the brake lines tightly together Rattle Under Vehicle at The heat shield contacts with e Raise the vehicle and perform a visual Higher RPM the underbody inspection e Bend the heat shield slightly to gain clearance from the underbody Squeak From the Front Poor front stabilizer shaft e While the vehicle is cold perform a test drive of the Vehicle in Cold insulators taping and achieve full front suspension travel by Weather driving through a dip in the road e Remove the insulators and wrap teflon tape around the stabilizer shaft Reinstall the insulators over the tape Thump From Rear of Improperly secured spare tire in Open the rear compartment and perform a Vehicle on Bumps the rear compartment visual inspection of the spare tire and the tools e Tightly secure the spare tire and all tools e Perform a road test to ver
142. ommunication between the scan tool and the test equipment was unsuccessful wait 30 seconds and try again If communication was not successful on the second try turn the ignition OFF and check the wire and con nectors between the immobilizer control unit termi nal 10 17 and the data link connector DLC terminal M If the wire and connectors between the DLC and the immobilizer control unit are okay replace the immobi lizer control unit Refer to Immobilizer Control Unit in this section Notice Install the resistor cover in the DLC connec tor after remove the scan tool Because ECM Immo bilizer Error Problem may exist DAEWOO M 150 BL2 IMMOBILIZER ANTI THEFT SYSTEM 9T 25 COMMUNICATION BETWEEN IMMOBILIZER CONTROL UNIT AND TEST EQUIPMENT SIRIUS D3 1 Connect the test equipment as described in the Scan Tool Equipment Manual If communication between the scan tool and the test equipment was unsuccessful wait 30 seconds and try again If communication was not successful on the second try turn the ignition OFF and check the wire and con nectors between the immobilizer control unit termi nal 10 and the data link connector DLC terminal 7 8 If the wire and connectors between the DLC and the immobilizer control unit are okay replace the immobi lizer control unit Refer to Immobilizer Control Unit in this section 9T 26 IMMOBILIZER ANTI THEFT SYSTEM REPAIR INSTRUCTIONS
143. on ON OFF for more than 4 seconds 3 Turn the ignition ON Is the repair complete System OK 9T 24 IMMOBILIZER ANTI THEFT SYSTEM KEY STATUS ERRORS FENIX 5MR The following KEY STATUS messages may be shown on the scan tool after commanding FIRST KEY COD ING and KEY ADD IGNITION OFF STATUS This message informs the technician that the ignition is OFF during the key cod ing process Turn the ignition ON during key coding but do not start the engine e KEY IS OCCUPIED Only five keys may be coded If a new key is desired the previous key codes must be deleted Up to five keys may then be authorized ALREADY AUTHORIZED Key coding is being at tempted with a key that is already authorized e ERROR NO A3 A4 A5 There is no communication between the transponder in the ignition key and the detection coil Follow the steps below to diagnose the problem 1 Try a different key If a different key works the problem is in the original key 2 If trying a different key results in the same er ror message replace the detection coil e INVALID KEY The communication between the im mobilizer control unit and the key transponder has not validated the key Follow the steps below to diagnose the problem 1 Code the key Refer to Key Coding Proce dure in this section 2 f the same message is received after key coding check the connection of the detection coil 3 If the detection coil is okay replace the
144. on and clean it up The ashtray lamp is optional INSTRUMENT PANEL VENTS The center and the side vents in the instrument panel can be adjusted up and down and from side to side The side vents can also be aimed toward the side windows in order to defog them GLOVE BOX The glove box can be opened by pulling up on the latch handle The glove box must be removed in order to gain access to the passenger side airbag module DIGITAL CLOCK The digital clock is located in the instrument panel be low the defroster grille The clock is capable of a 12 hour display INSTRUMENT CLUSTER The instrument cluster is located above the steering col umn and in the instrument cluster trim panel The instru ment cluster contains the instruments that provide the driver with vehicle performance information The instru ment cluster contains a speedometer an odometer a trip odometer a temperature gauge a fuel gauge and several indicator lamps For replacement of the indicator lamp bulbs contained in the instrument cluster refer to Instrument Cluster Indicator Lamps Specifications in this section SPEEDOMETER ODOMETER TRIP ODOMETER The speedometer measures the speed of the vehicle It consists of an instrument cluster gauge connected to the vehicle speed sensor on the transaxle output shaft The odometer measures the total distance the vehicle has traveled since it was manufactured It consists of an instrument cluster gauge connec
145. onitors the detection and the reading of the ignition key The self test capacity is limited to those functions Faults are communicated to a scan tool during diagnosis but they are not stored in the immobilizer control units memory Unauthorized use of a scan tool could be a method of defeating the immobilizer anti theft system so certain scan tool procedures require the use of a password The following functions are password protected e Coding of an additional key e Deleting all key codes The following functions do not require a password e Reading an ignition key to determine if the transpond er is working or if a key is authorized e Reading the immobilizer ID code to verify that it matches the ECM ID code 9T 14 IMMOBILIZER ANTI THEFT SYSTEM Without Keyless Entry DK BLU YEL 1 Immobilizer Control Unit With Keyless Entry DK BLU YEL Keyless Entry Control Module Immobilizer Receiver Electronic Control DKBLU YEL 1 Immobilizer Resistor Data Link G Connector DLC Electronic Control Module 1 ECM 11 DK BLU YEL Data Link Connector DLC D19T002B DIAGNOSTIC TROUBLE CODE DTC 1600 ECM IMMOBILIZER ERROR NO ANSWER Circuit Description When the ignition is turned ON the key is tested by the immobilizer anti theft system While the key code is be ing read by the immobilizer control unit the engine can start and run with any
146. orrect fas teners to prevent premature corrosion 1 Connect the cable 2 Install the tailgate lock striker with the screws D109C573 DAEWOO M 150 BL2 9P 10 DOORS D109C574 D19C575A D109C576 DOOR LOCK STRIKER ADJUSTMENT Notice The door lock striker is an important attaching part that can affect the performance of vital components and systems and can cause major repair expenses If replacement becomes necessary the door lock striker must be replaced by one with the same part number or with an equivalent part if replacement becomes neces sary Do not use a replacement part of lesser quality or of a substitute design The specified torque values must be used during reassembly in order to ensure the proper retention of the part The door lock striker consists of a striker with two screws that are threaded into a tapped floating cage plate located in the appropriate body pillar This floating cage plate allows the striker to be easily adjusted in or out and up or down The door is secured in the closed position when the door lock fork snaps over and en gages the striker Fore Aft Adjustment 1 The door must be properly aligned 2 Close the door until the lock fork contacts the striker 3 Stand next to the door opening and move the door slowly in and out just touching the striker each time 4 The alignment of the lock fork and the striker can be easily seen The lock fork should b
147. osion 1 Connect the body to door rubber grommet With the aid of another technician lightly secure the rear door with the bolts Adjust the door for proper fit Install the door hold open link with the bolt Connect the rear door electrical connector Connect the negative battery cable Perform the waterleak test Refer to Section 91 Wa lerleaks Check for windnoise Refer to Section 9J Windnoise TAILGATE Removal Procedure Disconnect the negative battery cable Remove the luggage compartment wheelhouse trim panel Refer to Section 9G Interior Trim Disconnect the tailgate electrical connector a Tailgate electrical connector Remove the tailgate strut Refer to Tailgate Strut in this section Remove the tailgate e Remove the hinge bolts e Disconnect the body to tailgate rubber grommet e Remove the tailgate DAEWOO M 150 BL2 D19C614A D209B113 D209B114 D109C615 DAEWOO M 150 BL2 DOORS 9P 23 Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fastener to prevent premature corrosion 1 Connect the body to tailgate rubber grommet 2 With the aid of another technician lightly secure the tailgate with the bolts 3 Adjust the tailgate for proper fit 4 Install the tailgate strut Refer to Tailgate Strut in this section 5 Connect th
148. ove Box 21 sioe e A Rl 9E 11 Instrument Cluster 9E 11 Instrument Panel 9E 12 ail wae eee EL UR ERE E 14 Instrument Cluster Trim 9E 16 Instrument Trim Panel Assembly 9E 16 Instrument Cluster Indicator Lamps 9E 19 Speedometer Odometer Trip Odometer 9E 19 Fuel Gauge Temperature Gauge 9E 20 Specifications 9E 22 Fastener Tightening Specifications 9E 22 Instrument Cluster Indicator Lamps Specifications 9E 22 Schematic and Routing Diagrams 9E 23 Instrument Cluster 9E 23 Instrument Panel Illumination 9E 25 Digital Clock 9E 26 2 INSTRUMENTATION DRIVER INFORMATION DESCRIPTION AND OPERATION CIGAR LIGHTER The cigar lighter is located in the front portion of the in strument panel To use the lighter push it in completely When the lighter is hot it will release itself from contact with the heating element The lighter and the heating element can be damaged if the lighter is not allowed to release itself fully from the heating element Cigar lighter is not equipped with the lamp ASHTRAY The ashtray is located in the lower portion of the instru ment panel In case of cleaning the ashtray up remove the ashtray by pushing the upper butt
149. pidly Make sure to use the correct fasteners to prevent premature corrosion 2 Install the hood latch with the screws D109C534 DAEWOO M 150 BL2 9R 8 BODY FRONT END D109C535 NS D109C536 ser D19C536A D109C537 HOOD LATCH RELEASE LEVER Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Remove the hood latch nut into the instrument panel a Hood latch nut 2 Remove the hood latch release lever e Disconnect the cable 1 e Remove the hood latch release lever 2 Installation Procedure 1 Connect the hood latch release cable to the hood latch lever Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasteners to prevent premature corrosion 2 Install the hood latch lever release to the instrument panel with the hood latch nut DAEWOO M 150 BL2 DAEWOO M 150 BL2 D109C538 D19C539B D19C539C D19C501A BODY FRONT END 9R 9 HOOD LATCH RELEASE CABLE Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Remove the hood latch release cable from the instru ment panel Refer to Hood Latch Release Lever in this section Push the cable toward the engine compartment through the body hole a Hood latch lever cable Open and suitably support the hood Disconnect the hood lat
150. r e Replace the front speaker e Audio system is out of order e Replace the audio system Rear Speakers Distorted or e Damage rattles or vibration of e Make the necessary repairs to Inoperative the rear speaker and the rear secure the component causing the parael side shelf distortion e The circuit between the rear e Repair or Replace the wiring speaker connector and the radio harness connector is open circuit or short circuit DAEWOO M 150 BL2 AUDIO SYSTEMS 9F 5 AUDIO SYSTEM Cont d Rear Speakers Distorted or e The connection of the rear e Confirm the connection Inoperative speaker connector and the audio connector is poor e Rear speaker is out of order e Replace the rear speaker e Audio system is out of order e Replace the audio system DAEWOO M 150 BL2 9F 6 AUDIO SYSTEMS REPAIR INSTRUCTIONS ON VEHICLE SERVICE 6 1 LP SEE SNL Yop omms a DNE amp 4 01090547 01090548 0190549 AUDIO SYSTEM Removal Procedure 1 Disconnect the negative battery cable 2 Remove the instrument cluster trim panel from the in strument panel Refer to Section 9E Instrument Driv er Information 3 Remove the audio system from the instrument panel e Remove the screws 1 e Disconnect the electrical connector and the anten na cable 2 e Remove the audio system 3 Ins
151. r assembly 3 Caution Because the wiper motor link plate is fixed do not separate the wiper motor from the bracket 9D 8 WIPERS WASHER SYSTEMS Bp 01090526 01090527 01090528 0190529 Installation Procedure 1 Install the wiper motor to the engine room with the bolts a Wiper motor assembly bolt 2 Connect the electrical connector 3 Install the wiper linkage to the wiper motor linkage ball b Wiper linkage ball 4 Install the cowl vent grille Refer to Section 9H Body Front End 5 Install the windshield wiper arm Refer to Windshield Wiper Arm in this section 6 Connect the negative battery cable REAR WINDOW WIPER MOTOR Removal Procedure 1 Disconnect the negative battery cable 2 Remove the wiper arm from the tailgate Refer to Windshield Wiper Arm in this section 3 Remove the tailgate inside trim Refer to Section 9G Interior Trim 4 Remove the rear wiper motor assembly e Disconnect the electrical connector 1 e Remove the screws 2 e Remove the rear wiper motor assembly 3 DAEWOO M 150 BL2 D19D530A D19D531A a D109D523 D109D532 DAEWOO M 150 BL2 WIPERS WASHER SYSTEMS 9D 9 Caution Because the wiper motor link plate is fixed do not separate the wiper motor from the bracket Installation Procedure
152. r trim panel Refer to Lower B pillar Trim Panel in this section Remove the parking brake cable cover Refer to Parking Brake Cable Cover in this section Remove the clips under the front seats Remove the floor carpet a Floor carpet DAEWOO M 150 BL2 INTERIOR TRIM 9G 17 Installation Procedure 1 Install the floor carpet 2 Install the clips 3 Install the parking brake cable cover Refer to Park ing Brake Cable Cover in this section 4 Install the lower B pillar trim panel Refer to Lower B pillar Trim Panel in this section 5 Install the rear rocker trim panel Refer to Rear Rocker Trim Panel in this section 6 Install the front rocker trim panel Refer to Front Rocker Trim Panel in this section D109E583 7 Install the floor console Refer to Floor Console in this section 8 Install the rear seat cushion Refer to Section 9H Seats 9 Install the front seats Refer to Section 9H Seats 10 Connect the negative battery cable LUGGAGE COMPARTMENT WHEELHOUSE TRIM PANEL Removal Procedure 1 Pry off the luggage compartment wheel house trim panel e Remove the screws 1 e Pry off the trim panel 2 D109E584 Installation Procedure 1 Install the luggage compartment wheelhouse trim panel with the plastic screws D109E585 DAEWOO M 150 BL2 9G 18 INTERIOR TRIM SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE KM 475 B A Trim Remover SF 0
153. rder to verify this Instrument Cluster Trim on the instrument panel condition Plate e Remove the instrument cluster trim plate and install felt tape to the edges DAEWOO M 150 BL2 SQUEAKS AND RATTLES 9K 3 REPAIR INSTRUCTIONS ON VEHICLE SERVICE SQUEAK AND RATTLE REPAIR Squeaks and rattles are caused by the unwanted move ment between parts of a vehicle There are three means to prevent squeaks or rattles e Attach the parts securely so that there is no rela tive motion during the operation of the vehicle Separate the parts so that there is no contact dur ing operation e Insulate the parts so that no squeaks or rattles oc cur with the movement of the parts Low uniform friction surfaces can be used to eliminate stick slip motion DAEWOO M 150 BL2 SECTION 9L GLASS AND MIRRORS 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 B unless otherwise noted TABLE OF CONTENTS Description and System Operation 9L 2 Rear Window Defogger Braided Lead Stationary Glass 9L 2 Wire 9L 10 Inside Rearview Mirror 9L 2 Front Door 9L 10 Outside
154. ream of water directly on the freshly applied adhesive Install the trim strip lace if it was removed Install the garnish molding if it was removed Install the reveal molding Important After the completion of any waterleak repair re test the area using the watertest stands Do not use localized testing procedures on the newly repaired areas as the repair material may dislodge under abnor mal pressure DAEWOO M 150 BL2 WATERLEAKS 91 7 SPECIFICATIONS RECOMMENDED MATERIALS FOR WATERLEAK REPAIRS Windshield back window Urethane adhesive caulking kit or the equivalent Metal joints Brushable seam sealer which can be painted Ventilation ducts Auto Bedding and Glazing Compound or the equivalent Small cracks and pin holes Sealer or the equivalent Large holes Automotive Joint and Seam Sealer Weatherstrips 08011 Weatherstrip Adhesive or the equivalent WATERTEST STAND SPECIFICATIONS DEDE Nozzle Type Full jet spray nozzle 1 2 GG 25 or equivalent with a 60 included angle Nozzle Height Approximately 1 600 mm 63 0 in from the floor Volume of Flow 14L 3 7 gal per minute Pressure 155 kPa 22 5 psi measured at the nozzle Windshield and A Pillar Test Stand Position Approximately 30 down 45 toward the rear and aimed at the corner of the windshield B Pillar Test Stand Position Approximately 30 down 45 toward the rear and aimed at the center of the rear
155. rews 2 Install the door trim panel Refer to Section 9G Interi or Trim REAR SPEAKERS Removal Procedure 1 Disconnect the negative battery cable 2 Open the tailgate 3 Remove the rear speaker from the rear parcel side shelf e Disconnect the electrical connector 1 e Remove the screws 2 e Remove the rear speaker 3 Installation Procedure 1 Install the rear speaker to the rear parcel side shelf with the screws 2 Connect the electrical connector 3 Connect the negative battery cable 9F 10 AUDIO SYSTEMS ROOF ANTENNA Removal Procedure 1 Disconnect the negative battery cable 2 Remove the interior courtesy lamp Refer to Section 9B Lighting Systems 3 Remove the roof antenna e Remove the screw from the vehicle inside 1 e Remove the roof antenna 2 D109D561 Installation Procedure 1 Install the roof antenna with the screw Tighten Tighten the roof antenna retaining screw to 3 Nem 27 Ib in a Roof antenna retaining screw 2 Install the interior courtesy lamp Refer to Section 9B Lighting Systems 3 Connect the negative battery cable D19D562A DAEWOO M 150 BL2 AUDIO SYSTEMS 9F 11 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS 12 AUDIO SYSTEMS SCHEMATIC AND ROUTING DIAGRAMS AUDIO SYSTEM CIRCUIT Left Hand Drive Shown Right Hand Drive Similar Hot with Lights On Hot at All Times Hot in ACC and Run F6 Fuse Block Front Front Rear Re
156. rness and the fuse Ef2 e Fuse Ef2 is blown e Replace the fuse Ef2 e The open circuit or a short circuit e Repair of Replace the wiring between the fuse Ef2 and the fuse harness F12 e Fuse F12 is blown e Replace the fuse F12 e The open circuit or a short circuit e Repair or Replace the wiring between the fuse F12 and the harness terminal 8 of the hazard lamp switch connector e Faulty hazard lamp switch e Replace the hazard lamp switch e The open circuit or a short circuit e Repair or Replace the wiring between the terminal 7 of the harness hazard lamp switch connector and the terminal 49 of the turn signal lamp relay e The open circuit or a short circuit e Repair or Replace the wiring between the terminal 49a of the harness turn signal lamp relay and the terminal 9 of the hazard lamp switch connector e Faulty turn signal lamp relay e Replace the turn signal lamp relay e The open circuit or a short circuit between the terminal 49a of the turn signal lamp relay and the terminal 2 of the turn signal lamp switch connector e Faulty turn signal lamp switch e Replace the turn signal lamp switch e The open circuit or a short circuit e Repair or Replace the wiring between the terminal 1 3 of the harness turn signal switch connector and the terminal 2 5 of each turn signal lamp connectors e Turn signal lamp bulb is blown e Replace the turn signal lamp bulb e The open grounds G101 G102 e Repair or R
157. rument cluster to the instrument panel Refer to Instrument Cluster in this section 3 Connect the negative battery cable D109B712 SPEEDOMETER ODOMETER TRIP ODOMETER Removal Procedure 1 Disconnect the negative battery cable 2 Remove the instrument cluster from the instrument panel Refer to Instrument Cluster in this section 3 Remove the instrument cluster lens and the face plate a Window plate D109B713 DAEWOO M 150 BL2 9E 20 INSTRUMENT DRIVER INFORMATION 4 Remove the speedometer odometer trip odometer e Remove the screws on the circuit plate 1 e Remove the speedometer odometer trip odometer 2 D109B714 Installation Procedure 1 Install the speedometer odometer trip odometer with the screws 2 Install the instrument cluster lens and the face plate 3 Install the instrument cluster Refer to Instrument Cluster in this section 4 Connect the negative battery cable D19B715A FUEL GAUGE TEMPERATURE GAUGE Removal Procedure 1 Disconnect the negative battery cable 2 Remove the instrument cluster Refer to Instrument Cluster in this section 3 Remove the instrument cluster lens and the face plate a Window plate D109B713 4 Remove the fuel gauge temperature gauge from the cluster assembly e Remove the screws on the circuit plate 1 e Remove the fuel gauge 2 e Remove the temperature gauge 3 D109B716 DAEWOO M 150 BL2
158. ry for about 30 seconds Carefully wipe off the excess iodine with a lint free cloth 11 Test the operation of the rear window defogger in or der to verify that the repair was successful Important At least 24 hours is required for complete curing of the repair materials The repair area should not be physically disturbed until after that time REAR WINDOW DEFOGGER BRAIDED LEAD WIRE REPAIR The rear window defogger bus lead wire or the terminal can be reattached by resoldering Use a solder contain ing 3 percent silver and a rosin flux paste 1 Disconnect the negative battery cable 2 The repair area should be buffed with fine steel wool before soldering the bus lead wire 3 Apply the paste type rosin flux in small quantities to the wire lead and the bus lead wire repair area using a brush 4 Coat the soldering iron tip with solder use only enough solder to ensure a complete repair 5 Use only enough heat to melt the solder Do not over heat the wire when resoldering to the bus lead wire FRONT DOOR GLASS Removal Procedure 1 Remove the front door seal trim Refer to Section 9P Doors 2 Remove the outside rearview mirror from the front door Refer to Glass and Mirrors in this section 3 Remove the division bar e Remove the screw 1 e Remove the inside bolt 2 e Remove the outside bolt 3 e Remove the division bar 4 DAEWOO M 150 BL2 GLASS AND MIRRORS 9L 11 4 Remove the glass run fro
159. s only the model vehicle identifier code The engine can be locked unlocked ECM requests to ICU the VIN number As soon as the ECM receives two correct consecutive communica tion frames with the same VIN code the ECM learns it The VIN code will be stored in non volatile memory at the end of power latch phase ECM enters in Learnt mode e EOM in Learnt mode In such a state ECM checks on every communica tion the correct encoding of the ICU If the code received is not correct then the vehicle is immobilized The coded 5 bytes of data emitted by ECM are a mix ture of MIN code and random The coded 5 bytes of data emitted by ICU are a mix ture of VIN code and random e in Neutral mode This mode is a special intermediate mode used for ICU replacement or immobilizer option installation ECM request to ICU the VIN number As soon as the ECM receives two correct consecutive communica tion frames with the same VIN code the ECM learns it The VIN code will be stored in non volatile memory at the end of power latch phase ECM enters in Learnt mode e After turning on the ignition the ECM will control the engine in a normal way for starting and running while waiting for a valid release response message from the Immobilizer 1 After receiving a response message including the in formation ICU in learnt mode and the correct sys tem VIN code the ECM enters the release state which allows to continue the
160. s section DAEWOO M 150 BL2 INSTRUMENTATION DRIVER INFORMATION 9E 3 COMPONENT LOCATOR INSTRUMENT PANEL ASSEMBLY Left Hand Drive Shown Right Hand Drive Similar D19B401A 1 Tie Bar 11 Instrument Cluster Housing Molding 2 Tie Bar Center 12 Center Ventilation Grille 3 Instrument Panel Guide 13 Switch Blank Cover Fog Lamp Switch 4 Defroster Grille 14 Hazard Warning Switch 5 Instrument Panel Upper Cap 15 Immobilizer LED Indicator Switch 6 Passenger s Airbag Blank Cover 16 Ashtray Bracket 7 Demister Grille 17 Ashtray 8 Side Ventilation Grille 18 Ashtray Lamp 9 Glove Box Bracket 19 Cigar Lighter Housing 10 Glove Box 20 Instrument Cluster Bracket 21 Instrument Panel DAEWOO M 150 BL2 9E 4 INSTRUMENTATION DRIVER INFORMATION INSTRUMENT CLUSTER D109B404 Instrument Cluster Lens Instrument Cluster Window Plate Speedometer Gauge Fuel Gauge Temperature Gauge Instrument Cluster Case Fronted Circuit Plate Instrument Cluster Bulb DAEWOO M 150 BL2 INSTRUMENTATION DRIVER INFORMATION 9E 5 DIAGNOSTIC INFORMATION AND PROCEDURES Hot in Run and Start Hot in ACC and Run D19B301B CIGAR LIGHTER Cigar Lighter Inoperative e The open or a short in the power supply e Repair or Replace the wiring circuit to the fuse F7 harness e Fuse F7 is blown e Replace the fuse F7 e The circuit between the fuse F7 and the e Repair or Replace the wiring termin
161. se a flat end rotary file in or der not to damage the tapped floating cage plate The striker screws and the tapped floating cage plate are im portant attaching parts that could affect the performance of vital components and systems 4 f proper adjustment requires that the floating cage plate be moved more than is possible use an electric hand drill and a 3 8 inch rotary file with a flat head in order to enlarge the body opening in the direction required 5 Tighten the striker screws to the correct position TAILGATE LOCK STRIKER ADJUSTMENT Notice The tailgate lock striker is an important attaching part that can affect the performance of vital components and systems and can cause major repair expenses If re placement becomes necessary the tailgate lock striker must be replaced by one with the same part number or with an equivalent part if replacement becomes neces sary Do not use a replacement part of lesser quality or of a substitute design The specified torque values must be used during reassembly in order to ensure the proper retention of the part 9P 12 DOORS D109C578 D109C579 The tailgate lock striker consists of a striker with two screws that are threaded into a tapped floating cage plate located in the appropriate body pillar This floating cage plate allows the striker to be easily adjusted in or out and up or down The tailgate is secured in the closed
162. ss Important This type of repair may be used only for ure thane installed glass 1 Remove the reveal molding in the area of the leak It may be necessary to remove the garnish molding or the trim strip lace in order to locate the leak While spraying water over leak area carefully push the glass outward in order to determine the size of the leak Mark the location of the leak Use water to clean any dirt frame the area Dry the area with an air hose Using a sharp knife trim off the uneven edges of the adhesive caulking material around the leak for a dis tance of 75 to 100 mm 3 to 4 inches on both side of the leak 9 6 WATERLEAKS D109A504 D109A505 gt 01094506 0109 304 10 11 12 13 14 6 the trimmed area with the primer 7 Using a sharp knife trim off the uneven edges of the adhesive material around the leak 75 to 100 mm 3 to 4 inches on both sides of the leak Allow the primer to dry for 5 minutes Apply the adhesive over the leak and for a distance of 75 to 100 mm 3 to 4 inches on both sides of the leak Immediately after applying the adhesive use a flat stick or a similar tool to work the adhesive into the leak area and into the joint between the original ma terial and the vehicle body in order to ensure a wa tertight seal Spray warm or hot water over the repaired area in order to determine if the leak was repaired Do not run a heavy st
163. ss the outside channel weatherstrip onto the door 2 Install the weatherstrip screw D109C624 DOOR WEATHERSTRIP Removal Procedure 1 Remove the door hold open link bolt 2 Remove the door weatherstrip e Remove the clip 1 e Remove the weatherstrip pins 2 D109C626 Installation Procedure 1 Install the door weatherstrip with the clip and the pins 2 Install the door hold open link bolt D109C627 DAEWOO M 150 BL2 D109C566 D109C628 D109C629 D109C630 DAEWOO M 150 BL2 DOORS 9P 27 DOOR SEAL TRIM Removal Procedure 1 Remove the door trim panel Refer to Section 9G In terior Trim 2 Remove the door seal trim a Door seal trim b Door pocket handle bracket Important In case of the deluxe trim remove the door pocket handle bracket in advance Installation Procedure 1 Install the door seal trim 2 Install the door pocket handle bracket for the deluxe trim 3 Install the door trim panel Refer to Section 9G Interi or Trim DOOR OPENING WEATHERSTRIP Removal Procedure 1 Mark the door opening weatherstrip edge by a soluble pen 2 Remove the door opening weatherstrip e Take off the rocker trim panel partially 1 e Take off the lower B pillar trim panel partially 2 e Remove the door opening weatherstrip 3 9P 28 DOORS Installation Procedure 1 Install the door opening weatherstrip to match the marking 2 Install t
164. stallation Procedure 1 Install the vents to the instrument cluster trim panel with the screws 2 Install the instrument cluster trim panel Refer to In strument Cluster Trim Panel in this section D109B508 DIGITAL CLOCK Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Disconnect the negative battery cable 2 Pry off the defroster grille 3 Unlock the locking of the digital clock a Digital clock 4 Remove the digital clock from the instrument panel e Disconnect the electrical connector 1 e Remove the digital clock 2 D109B512 Installation Procedure 1 Connect the electrical connector 2 Install the digital clock to the instrument panel 3 Connect the negative battery cable 4 Set the clock D109B513 DAEWOO M 150 BL2 DAEWOO M 150 BL2 INSTRUMENTATION DRIVER INFORMATION 9E 11 D109B509 D109B510 D109B509 D19B514A GLOVE BOX Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Remove the hinge pins at the base of the glove box 2 Remove the glove box from the instrument panel Installation Procedure 1 Install the glove box to the instrument panel with the hinge pins INSTRUMENT CLUSTER Removal Procedure 1 Disconnect the negative battery cable 2 Remove the instrument cluster trim panel from the in strument panel Refer to Instrument Cluster Trim Panel in this section
165. t in the power supply circuit to the fuse F9 e Fuse F9 is blown e Replace the fuse e The circuit between the fuse F9 e Repair or Replace the wiring and the wiper washer switch is the harness open circuit or a short circuit e Faulty wiper washer switch e Replace the wiper washer switch e The circuit between the wiper e Repair or Replace the wiring washer switch and the wiper relay harness is the open circuit or a short circuit e Faulty wiper relay e Replace the wiper relay e The circuit between the wiper e Repair or Replace the wiring relay and ground G201 is the harness open circuit or a short circuit e The circuit between the e Repair or Replace the wiring wiper washer switch and the harness windshield washer pump is the open circuit or a short circuit e Faulty windshield washer pump e Replace the windshield wash pump Poor ground G201 e Repair or Replace the wiring harness DAEWOO M 150 BL2 WIPERS WASHER SYSTEMS 9D 5 WINDSHIELD REAR WINDOW WIPER AND WASHER SYSTEM Cont d Rear Wiper Does Not Work e The open or a short in the power e Repair or Replace the open or a supply circuit to the fuse F9 short in the power supply circuit to the fuse F8 e Fuse F9 is blown e Replace the fuse F9 e The circuit between the fuse F9 e Repair or Replace the wiring and the wiper washer switch is the harness open circuit or a short circuit e Faulty wiper washer switch e Replace the wiper washer switch
166. t the actuator connector if equipped with the central door lock system Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasteners to prevent premature corrosion 1 Install the front door lock with screws Important Connect the actuator connector if equipped with the central door lock system 2 Connect the outside door handle rod and the key rod to the door lock 3 Install the seal trim Refer to Door Seal Trim in this section 4 Connect the negative battery cable if equipped with the central door lock system CHILDPROOF REAR DOOR LOCK Removal Procedure 1 Disconnect the negative battery cable if equipped with the central door lock system 2 Remove the door trim panel Refer to Section 9G In terior Trim 3 Remove the door seal trim Refer to Door Seal Trim in this section a Door seal trim b Door pocket handle bracket Important In case of the deluxe type remove the seal trim after removing the door pocket handle bracket 4 Remove the guide piece e Remove the screw 1 e Remove the guide piece 2 DAEWOO M 150 BL2 DOORS 9P 15 5 Disconnect the outside door handle rod from the door lock a Outside door handle rod D109C583 6 Disconnect the door lock from the vehicle e Remove the screws 1 e Remove the door lock 2 Important Disconnect the actuator connector if equipped with the centra
167. tallation Procedure 1 Connect the electrical connector and the antenna cable 2 Install the audio system with the screws 3 Install the instrument cluster trim panel Refer to Sec tion 9E Instrument Driver Information 4 Connect the negative battery cable CD CHANGER Removal Procedure 1 Disconnect the negative battery cable 2 Remove the audio system from the instrument panel Refer to Audio System in this section 3 Remove the floor console Refer to Section 9G Inte rior Trim 4 Disconnect the CD changer electrical connector from the audio system a CD changer electrical connector DAEWOO M 150 BL2 DAEWOO M 150 BL2 D19D550A D19D551A D19D550A D19D552A AUDIO SYSTEMS 9F 7 5 Disconnect the CD changer electrical connector from the CD changer 1 6 Remove the sponge pads and the clip e Remove the sponge pads retaining the CD chang er cable 1 e Remove the clip retaining tie bar 2 e Remove the clip retaining instrument panel wiring harness 3 7 Remove the CD changer cable e Remove the CD changer cable 1 8 Remove the CD changer assembly e Remove the CD changer bracket mounting bolts 1 e Remove the CD changer bracket mounting screws 2 e Remove the CD changer assembly 3 9F 8 AUDIO SYSTEMS D19D553A D19D554A D109D556 9 Separate the CD changer and the CD changer brack et e Remove the bolts from the C
168. ted to the vehicle speed sensor on the transaxle output shaft The trip odometer measures the distance the vehicle has traveled since the odometer was last reset It con sists of an instrument cluster gauge connected to the vehicle speed sensor on the transaxle output shaft The trip odometer can be reset to zero at any time so that the driver can record the distance traveled from any starting point FUEL GAUGE The fuel gauge consists of an instrument cluster gauge connected to a sending unit in the fuel tank The fuel gauge indicates the quantity of fuel in the tank without the ignition switch position TEMPERATURE GAUGE The temperature gauge consists of an instrument clus ter gauge connected to a temperature sensor that is in contact with the circulating engine coolant The temperature gauge indicates the temperature of the coolant Prolonged driving or idling in very hot weather may cause the pointer to move beyond the center of the gauge The engine is overheating if the pointer moves into the red zone at the upper limit of the gauge INSTRUMENT CLUSTER INDICATOR LAMPS The instrument cluster contains indicator lamps that in dicate the functioning of certain systems or the exis tence of potential problems with the operation of the vehicle The indicator lamps are replaceable For re placement of the indicator lamps contained in the instru ment cluster refer to Instrument Cluster Indicator Lamps Specifications in thi
169. ter the cor rect second digit 4 Use steps two and three to enter the third and fourth digits using the same method 5 After entering the correct four digit security code press the TP button CODE will briefly appear on the radio display and the system is ready for use Wrong Code If the wrong code is entered ERROR 1 will appear on the display After this CODE will appear once again and the correct security code can be entered The time between each new coding attempt is doubled a total of ten coding attempts can be made FRONT AND REAR SPEAKERS All audio systems use four speakers two speakers mounted in the front doors and two speakers mounted in the rear parcel side shelf ROOF ANTENNA Roof antenna is located on the roof and is designed to separate the antenna pole from the antenna base The antenna pole should be removed to prevent the painting damage before washing the vehicle The roof antenna cannot be adjusted TAPE PLAYER AND CASSETTE CARE The head and the capstan are the two parts of the tape player that should be cleaned This service should be performed every 100 hours of cassette operation In order to clean the head and the capstan use a cotton swab dipped in rubbing alcohol A cassette cleaning kit may also be used to clean the head and the capstan Follow the cleaning kit instruc tions to clean the tape player Do not touch the tape head with magnetized tools If the head beco
170. the ignition is turned on e The above conditions are maintained until the ignition is switched OFF P 1628 Will Clear When e The ignition switch is turned OFF or the scan tool TROUBLE CODE CLEAR command is issued DAEWOO M 150 BL2 IMMOBILIZER ANTI THEFT SYSTEM 9T 21 P 1628 ECM Immobilizer Error No Successful Communication Connect the scan tool using the following procedure Insert the cartridge into the scan tool Turn the ignition switch to the OFF position Connect the scan tool to the data link connector DLC Connect the scan tool s power cord to the cigar D lighter socket cation Select immobilizer mode on the scan tool Between Turn the ignition ON but do not start the engine Immobilizer Is communication established between the scan tool and Test and the immobilizer control unit Go to Step 2 Equipment Read the IMMO amp ECM ID CODE message that was displayed after requesting DIAGNOSIS Go to Did the message differ from normal message Identification Normal Message ECM MODE LEARNT ID Code IMMO MODE LEARNT Repro Go to VIN CODE SAME gramming Go to Step 3 Check for an open serial data wire between the immobilizer control unit and the ECM Was the circuit open Go to Step 4 Goto Step 5 Repair the open serial data wire between the ECM and the immobilizer control unit Is the repair complete System OK 1 Replace the immobilizer 2 Reprogram the identification ID
171. the bolts 1 D19C510A DAEWOO M 150 BL2 BUMPERS AND FASCIAS 90 7 3 Remove the fascia bolts from the rear bumper brack et D19C511A 4 Lower the vehicle 5 Remove the fascia e Remove the nuts in the luggage compartment 1 e Remove the screws 2 e Remove the fascia 3 D19C512A Installation Procedure Notice Dissimilar metals in direct contact with each other may corrode rapidly Make sure to use the correct fasteners to prevent premature corrosion 1 Install the fascia 2 Install the fascia upper nut a The fascia upper nut 3 Install the fascia upper screws b The fascia upper screws D19C513A 4 Raise and suitably support the vehicle 5 Install the fascia lower bolts The fascia lower bolts 6 Lower the vehicle D19C514A DAEWOO M 150 BL2 90 8 BUMPERS AND FASCIAS REAR BUMPER BRACKET Removal Procedure 1 Raise and suitably support the vehicle 2 Remove the rear bumper bracket e Remove the bolts 1 e Remove the bracket 2 Installation Procedure 1 Install the rear bumper bracket with the bolts 2 Lower the vehicle D19C516A DAEWOO M 150 BL2 SECTION 9P DOORS 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
172. the fuse Ef2 e The open circuit or a short circuit e Repair or Replace the wiring between the fuse Ef2 and the fuse harness F11 e Fuse F11 is blown e Replace the fuse F11 e The open circuit or a short circuit e Repair or Replace the wiring between the fuse F11 and the connector terminal 1 of the interior courtesy lamp connector e Interior courtesy lamp bulb is e Replace the bulb blown e Faulty interior courtesy lamp e Replace the interior courtesy lamp DAEWOO M 150 BL2 9B 6 LIGHTING SYSTEMS REAR FOG LAMP Diagnostic Aids The rear fog lamp will not operate unless the headlamps are ON If the headlamps are not operat ing repair that problem before attempting to diagnose the rear fog lamp Probable Cause Rear Fog Lamp e The open circuit or a short circuit e Repair or Replace the wiring Does Not Work between the terminal 87 of the harness headlamp relay and terminal 15 30 of the rear fog lamp relay e Faulty rear fog lamp relay e Replace the rear fog lamp relay e The open circuit or a short circuit e Repair or Replace the wiring between the terminal 87 of the harness rear fog lamp relay and terminal 6 of the rear fog lamp connector e The open circuit or a short circuit e Repair or Replace the wiring between the terminal E of the rear harness fog lamp relay and terminal 6 of the rear fog lamp switch e Faulty rear fog lamp switch e Replace the rear fog lamp switch e The open grounds G201 G4
173. the mirror support OUTSIDE REARVIEW MIRRORS Three types of outside rearview mirrors are available The outside rearview mirrors are adjusted by hand which is standard The remote control and the electric outside rearview mirrors are optional The outside rear view mirrors are installed on the front doors DAEWOO M 150 BL2 GLASS AND MIRRORS 9L 3 COMPONENTS LOCATOR GLASS AND MIRROR D19E401B 1 Windshield Molding 7 Outside Rearview Mirror Cover 2 Windshield 8 Outside Rearview Mirror Trim Cover 3 Inside Rearview Mirror 9 Outside Rearview Mirror Cable 4 Rear Window Glass 10 Nuts 5 Rear Window Glass Damping 11 Front Door Glass 6 Outside Rearview Mirror Manual 12 Rear Door Glass 13 Outside Rearview Mirror Electric DAEWOO M 150 BL2 9L 4 GLASS AND MIRRORS DIAGNOSTIC INFORMATION AND PROCEDURES TESTING REAR WINDOW DEFOGGER GRID LINE If it has been observed during use that a grid line is inop erative the following procedure can be used to find the break If none of the grid lines is operating a full system diagnosis should be completed before attempting to re pair the grid lines 1 Turn the ignition ON 2 Turn on the rear window defogger Notice Use care when touching the voltmeter terminals to a grid line If the terminals are roughly applied the grid line may be scratched resulting in an open circuit 3 From the inside of the v
174. the screws 1 e Remove the clips 2 e Remove the trim panel 3 5 Remove the inside channel weatherstrip Refer to Section 9P Doors Installation Procedure 1 Install the inside channel weatherstrip Refer to Sec tion 9P Doors Install the trim panel with the screws and the clips Install the door pull with the screw Install the window regulator handle Refer to Section 9P Doors Install the inside door handle Refer to Section 9P Doors REAR DOOR INTERIOR GARNISH MOLDING Removal Procedure 1 Pry off interior garnish molding e Pry off the garnish molding caps 1 Installation Procedure 1 Install the interior garnish molding DAEWOO M 150 BL2 DAEWOO M 150 BL2 D109E551 D109E552 D19E553A D19E554A INTERIOR TRIM 9G 9 REAR DOOR EXTERIOR GARNISH MOLDING Removal Procedure 1 Pry off the interior garnish molding Refer to Rear Door Interior Garnish Molding in this section 2 Pry off the exterior garnish molding e Remove the screw 1 e Pry off exterior garnish molding 2 Installation Procedure 1 Install the exterior garnish molding with the screw 2 Install the interior garnish molding Refer to Rear Door Interior Garnish Molding in this section TAILGATE TRIM PANEL Removal Procedure 1 Open the tailgate 2 Remove the trim from the tailgate e Remove the clips by pushing the center of the clip 1 e Remove the trim 2
175. the wiper washer switch e The circuit between the e Repair or Replace the wiring wiper washer switch connector harness and the wiper relay is open or short e The circuit between the fuse F8 e Repair or Replace the wiring and the wiper relay is open or harness short e Faulty wiper relay e Replace the wiper relay e The circuit between the wiper e Repair or Replace the open circuit relay and the ground G201 is the or a short circuit between the open circuit or a short circuit wiper relay and the ground G201 e The circuit between the e Repair or Replace the wiring wiper washer switch and the wiper harness motor is the open circuit or a short circuit e The circuit between the fuse F8 e Repair or Replace the wiring and the wiper motor is the open harness circuit or a short circuit e The circuit between the wiper e Repair or Replace the wiring relay and the wiper motor is the harness open circuit or a short circuit e Faulty wiper motor e Replace the wiper motor e The connection of the wiper e Tighten completely the nut linkage and the wiper motor is e Tighten completely the ball poor e Wiper linkage is out of order e Replace the wiper linkage Wipers Do Not Work On High e Faulty wiper washer switch e Replace the wiper washer switch Speed Low Speed OK e The circuit between the e Repair or Replace the wiring wiper washer switch and the wiper harness motor is the open circuit or a short circuit e Faul
176. tion between the ECM and ICU is made on K line K line Serial data line 7 Due to the learning of the Vehicle specific identification Number both ICU and ECM can stay in 3 stable modes e Virgin mode VIN not learnt Learnt mode VIN learnt Neutral mode for a new VIN learning In case of using valid key the release message commu nication with the ECM take place and the LED displays the Immobilizer status valid key In case of using invalid key the ECM disables the fuel injector circuit with coded intervention and sets DTC Diagnostic Trouble Code The above conditions are maintained until the ignition is switched off An ECM without an immobilizer control unit cannot be interchanged for an ECM that is used with an immobiliz er control unit system The Immobilizer control unit and ECM must have a matching ID code ID coding and key coding are accomplished by using Scanner 100 The Immobilizer system consists of e a maximum or 5 ignition keys with integrated trans ponder e the toroidal coil Detection coil for energizing and reading the transponder mounted at the ignition lock e the Immobilizer control unit ICU with power supply ignition input circuit transponder modulation and demodulation unit EEPROM driver electronic for the external status LED serial data link hardware e the external status LED for displaying the Immobilizer status e the serial data link between Immobi
177. to Section 9G Interior Trim Install the signal lamp switch and the wiper switch Refer to Section 6E Steering Wheel and Column Install the steering column trim cover Refer to Sec tion 6E Steering Wheel and Column Install the steering wheel to the steering column Install the driver s airbag module to the steering wheel Refer to Section 8B Supplemental Inflatable Restraints SIR For vehicle equipped with the air bag Connect the negative battery cable TIE BAR Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 2 Disconnect the negative battery cable Remove the instrument panel assembly Refer to In strument Panel in this section Remove the defroster duct hose from the tie bar e Remove the screws 1 e Remove the defroster duct hose 2 Remove the nuts and the steering column Refer to Section 6E Steering Wheel and Column Disconnect the electrical connectors and electrical wiring harness after removing the electrical wiring harness strips e Remove the electrical wiring harness strip Disconnect the brake switch connector 1 Disconnect the thermostat connector 2 Disconnect the blow motor connector 3 Disconnect the blow motor resistance connector 4 e Disconnect the electrical wiring harness 5 DAEWOO M 150 BL2 INSTRUMENT DRIVER INFORMATION 9E 15 6 Remove the defroster duct from the cowl upper pan el e Remove the screws 1 e Remo
178. to the fuel tank pocket on the right side of the vehicle BODY REAR END 95 3 REPAIR INSTRUCTIONS ON VEHICLE SERVICE D109C546 D109C547 D109C548 DAEWOO M 150 BL2 FUEL FILLER DOOR Removal Procedure Pull the fuel filler door opening lever and open the fuel filler door Remove the fuel filler door e Remove the bolts 1 e Remove the fuel filler door 2 Installation Procedure 1 Install the fuel filler door with the bolts FUEL FILLER DOOR REMOTE CABLE AND HANDLE Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Pry off the front rocker trim panel Refer to Section 9G Interior Trim 2 Remove the fuel filler door remote handle e Remove the screws 1 e Disconnect the cable 2 e Remove the fuel filler door remote handle 3 95 4 BODY REAR END 3 Pry off the lower B pillar trim panel Refer to Section 9G Interior Trim 4 Pry off the rear rocker trim panel Refer to Section to 9G Interior Trim 5 Pry off the luggage compartment wheelhouse trim panel Refer to Section to 9G Interior Trim 6 Remove the lock striker of the fuel filler e Remove the lock striker by turning it rectangularly a Lock striker D109C549 7 Remove the fuel filler door remote cable e Remove the cable retaining strip e Disconnect the fuel filler door remote cable 1 D19C550B Installation Procedure 1 Connect the fuel filler door remot
179. to the fuse Ef2 regardless of the ignition position e Repair or Replace the power supply circuit wiring harness e The open or a short in the power supply circuit to the fuse F1 with the ignition position e Repair or Replace the power supply circuit wiring harness e The open or a short in the power supply circuit to the fuse Ef12 with the interior courtesy lamp ON e Repair or Replace the power supply circuit wiring harness e The circuit between the fuse Ef2 and the e Repair or Replace the wiring fuse F12 is open or short harness Fuse Ef2 Ef12 F1 or F12 is blown e Replace and fuse e The circuit between the fuse F12 and the e Repair or Replace the wiring digital clock connector harness e The circuit between the fuse F1 and the e Repair or Replace the wiring digital clock connector harness e The circuit between the Ef12 and the e Repair or Replace the wiring digital clock connector harness e Faulty digital clock e Replace the digital clock Open ground G201 circuit the open ground DAEWOO M 150 BL2 8 INSTRUMENTATION DRIVER INFORMATION REPAIR INSTRUCTIONS ON VEHICLE SERVICE D109B501 D19B502A D109B503 CIGAR LIGHTER Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Disconnect the negative battery cable 2 Remove the ashtray from the ashtray housing 3 Remove the cigar lighter from the cigar lighter socket
180. to the vehicle The ignition must also be in B unless otherwise TABLE OF CONTENTS noted Description and Operation 9P 2 Door Lock 5 9P 2 Childproof Rear Door Lock 9P 2 Power Door Locks 9P 2 Power Windows 9P 2 Tailgate Strut 9P 2 Component Locator 9P 3 Front DOOF sx 9P 3 Rear DOO 9P 5 Repair Instructions 9P 7 On Vehicle Service 9P 7 Front Door Glass Run 9P 7 Rear Door Glass Run 9P 8 Door Lock Striker 9P 9 Tailgate Lock Striker 9P 9 Door Lock Striker Adjustment 9P 10 Tailgate Lock Striker Adjustment 9P 11 Front Door Lock 9P 13 Childproof Rear Door Lock 9P 14 Central Door Lock Actuator 9P 16 Tailgate Lock 9P 16 Inside Door Handle 9P 17 DAEWOO M 150 BL2 Outside Front Door Handle 9P 17 Outside Rear Door Handle 9P 18 Door Lock Cylinder 9P 18 Manual Window Regulator 9P 19 Power Front Window Regulator 9P 19 Front Door Asse
181. tor 3 Install the front wheel house splash shield with the clips and the bolts 4 Install the front wheels 5 Lower the vehicle 6 Connect the negative battery cable DAEWOO M 150 BL2 DAEWOO M 150 BL2 REMOTE KEYLESS ENTRY AND ANTI THEFT SYSTEM 9T 5 PASSWORD PROGRAMMING If a transmitter is lost or damaged the control module receiver must be re programmed to communicate with a new transmitter The passwords recorded in the control module receiver should not be deleted when power is off in the control module receiver Each control module receiver should be able to record five passwords The following method is used to record new passwords in the control module receiver 1 Connect the scan tool to the data link connector DLC connector 2 Send the programming mode message to the control module receiver 3 Press any button of the transmitter to generate a data code including a password which will be recorded by the control module receiver The control module re ceiver sends a response message to the scan tool to indicate that the first password has been recorded 4 Press any button of the transmitter three more times until the control module receiver has responded that the third fourth and fifth passwords have been re corded 5 Disconnect the scan tool The control module receiver leaves the programming mode automatically and switches to the normal operat ing mode when either of the following conditions
182. ty wiper motor e Replace the wiper motor Wipers Do Not Work On Low e Faulty wiper washer switch e Replace the wiper washer switch Speed High Speed OK e The circuit between the e Repair or Replace the wiring wiper washer switch and the wiper harness motor is the open circuit or a short circuit e Faulty wiper motor e Replace the wiper motor DAEWOO M 150 BL2 90 4 WIPERS WASHER SYSTEMS WINDSHIELD REAR WINDOW WIPER AND WASHER SYSTEM Cont d Wipers Do Not On Intermittent The circuit between the fuse F8 e Repair or Replace the wiring Other Speed OK and the wiper relay is the open harness circuit or a short circuit e The circuit between the fuse F8 e Repair or Replace the wiring and the wiper motor is the open harness circuit or a short circuit e Faulty wiper washer switch e Replace the wiper washer switch e The circuit between e Repair or Replace the wiring wiper washer switch and the wiper harness relay is the open circuit or a short circuit e Faulty wiper relay e Replace the wiper relay e The circuit between the wiper e Repair or Replace the wiring relay and the wiper motor is the harness open circuit or a short circuit Poor ground G201 e Repair or Replace the wiring harness e Faulty wiper motor e Replace the wiper motor Windshield Washer Does Not e The open or a short in the power e Repair or Replace the open or a Work Windshield Wipers OK supply circuit to the fuse F9 shor
183. vOZOY 2 Idd za Jed jsa jea YDDDDD 9 V Y Y Y ueuegY jens VOcO AV NHH AH9 NHD9 YOUMS 1a NHO VOCO AS NHO BIG Josueg 1121009 134 13A 1838 Weis 101891 qing ung SNIYIS H31Sn19 LNSWNYLSNI e AN HOA Yev Yew Yev 90694 AeH due dure JeeH 10 4 D19B201B DAEWOO M 150 BL2 9E 24 INSTRUMENT DRIVER INFORMATION YMS aNSS ld YoUMS 12210009 pe 1HM AWD tHM 68 AN PAN DOD k E Jejsnjo IHAVNH8 COCO AS SOUL 446 10H AN PAS Y JojeJeuet xa NH9 029 Idd old 449 Je NHH Xa y n4 AYD NYD YOUMS DISD Maneg dY Tera Josues aunyesodwe S o L Y TBA TAA Q34j wegs 10 159 uny YING XIN33 H31S6119 LNSWNYLSNI Aejay KejeH dwe due JeoH 10014 01982015 DAEWOO M 150 BL2 BRN WHT Headlamp Leveling Switch DAEWOO M 150 BL2 INSTRUMENT DRIVER INFORMATION 9E 25 INSTRUMENT PANEL ILLUMINATION Hot at All Times Ignition Relay 5 C202 Switch BRN WHT 7 C203 To Clock Display o
184. ve the defroster duct 2 7 Remove the bolts and the tie bar a Tie bar DAEWOO M 150 BL2 D109B524 8 Remove the bolts and the tie bar center b Tie bar center D109B525 Installation Procedure 1 Install the tie bar with the bolts 2 Install the tie bar center with the bolts 3 Install the defroster duct to the cowl upper panel with the screws D109B526 9E 16 INSTRUMENT DRIVER INFORMATION D109B701 Connect the electrical wiring harness Connect the blow motor resistance connector Connect the blow motor connector Connect the thermostat connector Connect the brake switch connector 9 Bind the electrical wiring harness strip 10 Install the steering column with the nuts 11 Install the defroster duct hose with the screws 12 Install the instrument panel assembly Refer to In strument Panel in this section 13 Connect the negative battery cable ON DOO fF INSTRUMENT CLUSTER TRIM PANEL Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Remove the instrument cluster trim panel from the in strument panel e Remove the screws 1 e Using a flathead screwdriver remove the central console cover 2 Notice To prevent the instrument panel damage cover the flathead screwdriver with a soft cloth Installation Procedure 1 Install the instrument cluster trim panel with the Screws INSTRUMENT T
185. with Lights On Hot at All Times Hot in Run and Start Engine T Fuse Ignition Block Relay BRN WHT 7 C203 Ar wr Illumination Lamp Defogger Grid Lines BLK G404 D19E201B DAEWOO M 150 BL2 SECTION 9M EXTERIOR TRIM TABLE OF CONTENTS Description and Operation 9M 2 Roof Molding 9M 3 Emblems and Lettering 9M 2 Rear Spoiler 9M 3 M d GUards e csaten te 9M 2 Front Bumper Spacer 9M 4 Repair Instructions 9M 3 Tailgate Handle 9M 5 On Vehicle Service 9M 3 DAEWOO M 150 BL2 2 EXTERIOR TRIM DESCRIPTION AND OPERATION EMBLEMS AND LETTERING MUD GUARDS The emblems and lettering on the vehicle are attached Front and rear mud guards are optional equipment on all by adhesive The company emblem appears on the models Mud guards will help prevent an excessive hood The lettering which appears in several places on buildup of mud on the body the body of the vehicle features the model the grade and the company name DAEWOO M 150 BL2 EXTERIOR TRIM 9M 3 REPAIR INSTRUCTIONS ON VEHICLE SERVICE ROOF MOLDING Removal Procedure 1 Remove the roof molding from the plastic clips 1 Installation Procedure 1 Press the roof molding onto the plastic clips
186. y a different key If a different key works the problem was in the original key 2 If trying a different key resulted in the same error message replace the detection coil e INVALID KEY The communication between the im mobilizer control unit and the key transponder has not validated the key Follow the steps below to diagnose the problem 1 Code the key Refer to Key Coding Procedure in this section 2 If the same message is received after key coding check the connection of the detection coil 3 If the detection coil is okay replace the immobiliz er Refer to Immobilizer Control Unit in this sec tion NO TRANSPONDER DETECTED The fault may be in ignition key transponder the detection coil or the Immobilizer Follow the steps below to diagnose the problem 1 Try a different key If a different key works the problem was in the original key 2 f trying a different key resulted in the same error message check the connection of the detection coil 3 If the connection of the detection coil is okay dis connect the detection coil and use an ohmmeter to check for an open detection coil 4 If the detection coil was not open replace the im mobilizer control unit Refer to Immobilizer Control Unit in this section DAEWOO M 150 BL2 COMMUNICATION BETWEEN IMMOBILIZER CONTROL UNIT AND TEST EQUIPMENT FENIX 5MR 1 Connect the test equipment as described in the Scan Tool Equipment Manual If c
187. zer control unit cartridge into the scan tool Do not start the vehicle but turn the ignition ON Enter the four digit password that enables service personnel to use the scan tool for ID code reprogram ming Use the scan tool to command RESET ID CODE DAEWOO M 150 BL2 DAEWOO M 150 BL2 D29T001 IMMOBILIZER ANTI THEFT SYSTEM 9T 27 6 Turn the ignition OFF and ON again but do not crank or start the engine The ECM will reset the ECM ID code to match the new ID code that was calculated and sent by the immobilizer control unit when the ignition was first turned ON after the reset command 7 Return the system to the normal mode 8 Turn OFF the ignition 9 Turn ON the ignition 10 Start the engine After reprogramming the ID code the scan tool SYS TEM DIAGNOSIS command can verify that the ECM ID code matches the immobilizer control unit ID code If the reprogramming procedure does not result in matching ID codes check the electrical connectors for the serial data wire between the immobilizer control unit and the ECM TRANSPONDER Each valid ignition key has an internal transponder which is a read write transponder The transponder contains an implementation of a cryp to algorithm with 96 bits of user configurable secret key contained in EEPROM and transmits data to the ICU by modulating the amplitude of the electromagnetic field and receives data and commands in a similar way DETECTION COIL

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