2004 DAEWOO LACETTI gas type

5A1 – 56IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
SYMPTOM DIAGNOSIS
Oil Leakage
Notice :
– Careful localization of leakage points may make it
possible to prevent incorrect or cost–intensive re-
pairs.
Test Steps :– Thoroughly clean the transaxle, engine, and sur-
rounding area(using a steam jet, for example).
– To locate leakage, use a suitable identifying spray
or similar product.
– Depending on the amount of leakage, take the
car for a short or a longer test drive – It may prove
sufficient to place the car on a hoist and run the
engine at idle speed to trace the leak.
– If possible, determine exactly which type of oil is
escaping.
Symptom
Possible CauseAction
Transaxle Oil Leak-
ageOil Pump(Torque Converter Sealing)S Visually check torque converter sealing.
S Replace the converter sealing as described in
the transaxle repair on the vehicle service.
Crankshaft Sealing RingS Check whether engine oil or TFT is leaking out.
S If leak is engine oil, replace the sealing ring as
described in the engine repair instruction.
Torque ConverterS Visual check.
S Fit an exchange converter as described in the
repair instruction.
Oil Content Too HighS Check oil level(TFT and axle oil) as described
in this chapter.
S Correct oil level, and recheck after a test drive.
Notice : Comply with the measuring procedure (fill-
ing procedure) in the repair instruction. Check the oil
level at the overflow plug adjust to proper level if nec-
essary.
O–ring at Bolt Head Damaged or Miss-
ingS Check O–ring.
S Replace O–ring as described in the repair in-
struction.
Shaft SealS Visually check the shaft seal.
S Replace the sealing ring as described in the
repair instruction.
Hose Clamp LooseS Check to ensure that the hose clamp fits tightly.
S If necessary, retighten clamp.
Oil Pan Gasket Not Installed ProperlyS Check to see if the gasket was positioned
properly.
S Install gasket properly as described in the re-
pair instruction.
Oil Pan Gasket DamagedS Check the gasket visually.
S Replace gasket as described in the repair in-
struction.
Bolt at Bracket LooseCheck the Tightening Torque
Retighten bolt
Sealing Ring at Oil DipstickS Check O–ring.
S If necessary, replace O–ring.
Sealing Ring Near End–Cover Connec-
tion DefectiveS Check sealing rings.
S Put in new sealing ring Check O–ring as de-
scribed in the repair instruction.

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 21
DAEWOO V–121 BL4
Refrigerant Recovery
Important : Use only a refrigerant tank that is designed for
the charging station in use. The unit’s overfill limitation
mechanism is calibrated specifically for use with this tank.
The tank’s valves are also manufactured specifically for
this unit.
1. Attach the high–side hose with the quick disconnect
coupler to the high–side fitting of the vehicle’s A/C
system.
2. Open the coupler valve.
3. Attach the low–side hose with the quick disconnect
coupler to the low–side fitting of the vehicle’s A/C
system.
4. Open the coupler valve.
5. Check the high–side and the low–side gauges on
the unit’s control panel in order to ensure that the
A/C system has pressure. If there is no pressure,
there is no refrigerant in the system to recover.
Important : If there is no refrigerant in the system, do not
continue with the recovery operation which would, under
this condition, draw air into the recovery tank.
6. Open both the high–side and the low–side valves.
7. Open the gas and the liquid valves on the tank.
8. Drain any oil that may be in the oil separator.
9. Close the oil drain valve.
10. Plug the unit into the proper voltage outlet.
11. Turn on the main power switch.
Notice : Never reuse refrigerant oil. Damage to the A/C
system may result from such reuse. Dispose of the refrig-
erant oil properly.
12. Begin the recovery process. Refer to the manufac-
turer ’s instructions for the charging station in use.
Important : Some A/C system polyalkaline glycol (PAG)
lubricating oil may be removed with the refrigerant during
recovery. The amount of oil removed varies. A charging
station separates the oil from the refrigerant and provides
a means of determining how much oil was removed. Re-
place the same amount of oil when recharging the system.
Refer to the manufacturer’s instructions for the charging
station in use.
13. Wait 5 minutes, then check the control panel low–
side gauge. If the A/C has maintained vacuum, the
recovery is complete.
14. If the low–side gauge pressure rises above zero,
there is more refrigerant in the system. Recover the
additional refrigerant. Repeat this step until the sys-
tem maintains vacuum for 2 minutes.
Important : If the control indicator shows that the refriger-
ant tank is full during the recovery process and the unit
shuts off, install an empty unit tank to store the refrigerant
needed for steps later in the procedure. Do not use any
other type of tank.
Evacuation
The unit tank must contain a sufficient amount of R–134a
refrigerant for charging. Check the amount of refrigerant
in the tank. If there is less than 3.6 kg (8 pounds) of refrig-
erant, add new refrigerant to the tank. Refer to the
manufacturer ’s instructions for adding refrigerant.
1. Verify that the high–side and the low–side hoses
are connected to the A/C system. Open both the
high–side and the low–side valves on the unit’s
control panel.
2. Open both the gas and the liquid valves on the
tank.
Important : Refer to the manufacturer’s instructions for
the charging station in use. It is necessary to evacuate the
system before recharging it with new or recycled refriger-
ant.
3. Start the vacuum pump and begin the evacuation
process. Non–condensable gases (mostly air) are
vented from the tank automatically during the re-
cycling process. You may hear the pressure being
released.
4. Check for leaks in the system. Refer to the
manufacturer ’s instructions for the charging station
in use.
Important : Change the vacuum pump oil frequently. Re-
fer to the manufacturer’s instructions for the charging sta-
tion in use.
A/C System Oil Charge Replenishing
Any oil removed from the A/C system during the recovery
process must be replenished at this time.
1. Use the correct graduated bottle of PAG oil for the
R–134a system.
Important:
S Keep the oil bottles tightly capped at all times to
protect the oil from moisture and contamination.
S You must have an A/C system vacuum for this op-
eration. Never open the oil injection valve while
there is positive pressure in the A/C system. This
will result in oil blowback through the bottle vent.
S Never let the oil level drop below the pickup tube
while charging or replenishing the system, as this
will allow air into the A/C system.
2. Refer to the manufacturer’s instructions for the
charging station in use. Add the proper amount of
PAG oil to the system.
3. Close the valve when the required oil charge has
been pulled into the system.
Charging
Important : Evacuate the A/C system before charging.
1. Close the low–side valve on the control panel.
2. Open the high–side valve on the control panel.
3. Refer to the manufacturer’s instructions for the
charging station in use.
4. Enter the amount of refrigerant needed to charge
the A/C, making sure to use the correct system of
measurement, i.e. kilogram (kg) or pound (lb).
5. Begin the charging process.

7B – 50IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
LEAK TESTING (EXTERNAL)
Tools Required
J–9625–A Pressure Testing Connector
1. Install the pressure testing connector J–9625–A to
the suction/discharge ports on the compressor.
2. Attach the center hose of the manifold gauge set on
the charging station to a refrigerant drum standing
in an upright position. Open the valve on the drum.
3. Connect the charging station high– and low–pres-
sure lines to the corresponding fittings on the pres-
sure testing connector J–9625–A (or hoses
equipped with valve depressors). The suction port
(low–side) of the compressor has a large internal
opening. The discharge port (high–side) has a
smaller internal opening into the compressor.
4. Open the low–pressure control, the high–pressure
control, and the refrigerant control on the charging
station to allow the refrigerant vapor to flow into the
compressor.
5. Using a leak detector, check for leaks at the high–
pressure relief valve seal, the housing seal, the rear
head seal, the center cylinder seal, the through–bolt
gaskets, and the compressor shaft seal. After
checking for leaks, shut off the low–pressure con-
trol, the high–pressure control, and the refrigerant
control lines on the charging station.
6. If an external leak is present, perform the neces-
sary corrective measures and recheck for leaks to
verify that the leak has been corrected.
7. Loosen the manifold gauge hose connections to the
gauge adapters connected to the low and high
sides. Allow the vapor pressure to release from the
compressor. If valve depressor–type hoses are
used, loosen the hose connections at the gauge
manifold to release vapor pressure from the com-
pressor.
8. Disconnect both gauge hoses. Remove the pres-
sure testing connector J–9625–A.

SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B – 101
DAEWOO V–121 BL4
FRONT SEAT BELT
PRETENSIONERS
CAUTION : Tempering with seat belt pretensioner
creates the risk of an injury from unexpected deploy-
ment. Therefore, the driver airbag module should
never be disassembled.
The seat belt pretensioners(with load limiter for some ve-
hicles) are assembled with each front seat belt retractors
to retract the seat belt webbing when accounted frontal
collision. The seat belt pretensioners are controlled by
sensing and diagnostic module(SDM). The seat belt pre-
tensioner contains an igniter charge and a gas generator
to pull the seat belt webbing. The seat belt pretensioner
must be replaced after an accident that causes its activa-
tion.
The seat belt pretensioner also contains a shorting bar to
prevent current from travelling through the seat belt pre-
tensioner during servicing. The shorting bar is disengaged
when the connector is connected.
SENSING AND DIAGNOSTIC
MODULE (SDM)
CAUTION : During the service procedures, be careful
when handling the SDM. Never shake or jar the SDM.
Never apply power to SIR when the SDM is not rigidly
attached to the vehicle. All SDM mounting bolts and
grounding nuts must be fully tightened. Failure to fol-
low these precautions could cause deployment and
result in personal injury.
The SDM is located on the floor beneath the floor console
assembly. The SDM performs the following functions :
S Monitors the supplemental inflatable restraints(SIR)
electrical components and sets a diagnostic trouble
code(DTC) when malfunction is detected.
S Records any faults that are discovered.
S Displays SIR diagnostic trouble codes and system
status information when connected to a scan tool.
S Illuminates the airbag indicator to alert the driver to
any fault.S Provides a reserve power source to deploy the air-
bags and pretensioners if an accident has disabled
the normal power source.
S Monitors vehicle velocity changes to detect frontal
impacts, which are severe enough to warrant de-
ployment.
S Causes current to flow through the airbag modules
and pretensioner to cause deployment if a frontal
impact of sufficient force is detected.
The SDM contains no user–serviceable parts.
AIRBAG WARNING LAMP
The instrument cluster contains an airbag warning indica-
tor and sensing and diagnostic module(SDM). The SDM
performs a turn–on test when the ignition is turned ON.
The SDM flashes the airbag indicator seven times by sup-
plying an intermittent ground to the indicator lamp circuit.
After flashing seven times, the airbag indicator will turn off
if no more malfunctions have been detected.
If the SDM has detected malfunctions in the internal and
external circuits, which could potentially affect the opera-
tion of the supplemental inflatable restraints(SIR), the air-
bag indicator stays on. Some malfunctions could result in
non–deployment when necessary or deployment under
conditions which would not normally result in deployment.
When the SDM is not properly attached to its connector,
the airbag circuit is shorted to ground because there is a
shorting bar in the SDM electrical connector. The shorting
bar is disengaged when proper connection is made, but if
a poor connection exists the SDM connector supplied a
ground to the airbag indicator independently of the SDM,
and the airbag indicator turns on.
CLOCK SPRING
CAUTION : Disassembling the clock spring can cause
injury or cause the clock spring to malfunction.
CAUTION : Over–rotating the clock spring (over 3 and
one quarter turns to one direction) without the steer-
ing wheel in position could damage the clock spring
and result in an inoperative driver airbag.
There is a coil assembly in the steering which is referred
to as a clock spring because of its internal resemblance to
the type of spring used in a mechanical clock. The coil