2004 DAEWOO LACETTI lighting

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TABLE OF CONTENTS
Section 0B General Information
Section 1 Engine
Section 1A General Engine Information
Section 1C1 1.4L/1.6L DOHC Engine Mechanical
Section 1C2 1.8L DOHC Engine Mechanical
Section 1D Engine Cooling
Section 1E Engine Electrical
Section 1F Engine Controls
Section 1G Engine Exhaust
Section 2 Suspension
Section 2A Suspension Diagnosis
Section 2B Wheel Alignment
Section 2C Front Suspension
Section 2D Rear Suspension
Section 2E Tires and Wheels
Section 3 Driveline/Axle
Section 3A Automatic Transaxle Drive Axle
Section 3B Manual Transaxle Drive Axle
Section 4 Brakes
Section 4A Hydraulic Brakes
Section 4B Master Cylinder
Section 4C Power Booster
Section 4D Front Disc Brakes
Section 4E1 Rear Disc Brakes
Section 4E2 Rear Drum Brakes
Section 4F Antilock Brake System
Section 4G Parking Brake
Section 5 Transmission/Transaxle
Section 5A1 ZF 4HP16 Automatic Transaxle
Section 5A2 AISIN Automatic Transaxle
Section 5B Five-Speed Manual Transaxle
Section 5C Clutch
Section 6 Steering
Section 6A Power Steering System
Section 6B Power Steering PumpSection 6C Power Steering Gear
Section 6E Steering Wheel and Column
Section 7 Heating, Ventilation, and Air
Conditioning (HVAC)
Section 7A Heating and Ventilation System
Section 7B Manual Control Heating, Ventilation,
and Air Conditioning System
Section 7D Automatic Temperature Control HVAC
Section 8 Restraints
Section 8A Seat Belts
Section 8B Supplemental Inflatable Restraints
(SIR)
Section 9 Body and Accessories
Section 9A Body Wiring System
Section 9B Lighting Systems
Section 9C Horns
Section 9D Wipers/Washer Systems
Section 9E Instrumentation/Driver Information
Section 9F Audio Systems
Section 9G Interior Trim
Section 9H Seats
Section 9I Waterleaks
Section 9J Windnoise
Section 9K Squeaks and Rattles
Section 9L Glass and Mirrors
Section 9M Exterior Trim
Section 9N Frame and Underbody
Section 9O Bumpers and Fascias
Section 9P Doors
Section 9Q Roof
Section 9R Body Front End
Section 9S Body Rear End
Section 9T1 Remote Keyless Entry and Anti–Theft
System
Section 9T2 Immobilizer Anti–Theft System

SECTION : 7A
HEATING AND VENTILATION SYSTEM
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool
or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help
prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
SPECIFICATIONS7A–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Temperature Specifications 7A–1. . . . . . . . . . .
Fastener Tightening Specifications 7A–1. . . . . . . . . . .
SCHEMATIC AND ROUTING DIAGRAMS7A–3 . . . . .
Non–A/C Diagrams 7A–3. . . . . . . . . . . . . . . . . . . . . . . .
Airflow – Typical 7A–4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Airflow with Rear Heating Duct 7A–5. . . . . . . . . . . . . .
DIAGNOSIS7A–6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATER SYSTEM 7A–6. . . . . . . . . . . . . . . . . . . . . . . . . .
Insufficient Heating or Defrosting 7A–6. . . . . . . . . . . . .
Blower Electrical 7A–9. . . . . . . . . . . . . . . . . . . . . . . . . . .
Improper Air delivery or No Mode Shift 7A–11. . . . . .
Too Much Heat 7A–13. . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls 7A–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Noise 7A–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE AND REPAIR7A–18 . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 7A–18. . . . . . . . . . . . . . . . . . . .
Temperature Cable Adjustment 7A–18. . . . . . . . . . . . .
Temperature Control Cable 7A–18. . . . . . . . . . . . . . . . .
Control Assembly 7A–20. . . . . . . . . . . . . . . . . . . . . . . . .
Control Assembly Knob Lighting 7A–21. . . . . . . . . . . .
Heater/Air Distributor Case Assembly 7A–21. . . . . . .
Blower Motor 7A–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High–Blower Relay 7A–24. . . . . . . . . . . . . . . . . . . . . . . .
Blower Resistor 7A–25. . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Hoses 7A–25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Core 7A–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION7A–28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heating and Ventilation Systems 7A–28. . . . . . . . . . . .
SPECIFICATIONS
HEATER TEMPERATURE SPECIFICATIONS
Ambient Air TemperatureHeater Outlet Air Temperature
–18°C (0°F)54°C (129°F)
– 4°C (25°F)59°C (138°F)
10°C (50°F)64°C (147°F)
24°C (75°F)68°C (154°F)
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Blower Motor–to–A/C Assembly Screws1.2–11
Blower Motor Resistor Screws1.2–11
Blower Motor Retaining Screws1.2–11
Controller Retaining Screws2–18
Heater/Air Distributor Case Assembly Screw4–35

HEATING AND VENTILATION SYSTEM 7A – 21
DAEWOO V–121 BL4
5. Gently insert the center molding into position on the
instrument panel.
6. Connect the negative battery cable.
7. Confirm the proper operation of the controller by
moving it through all of the controller’s possible
functioning positions.
CONTROL ASSEMBLY KNOB
LIGHTING
(Left–Hand Drive Shown, Right–Hand Drive Similar)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the center molding. Refer to ”Control As-
sembly” in this section.
3. Turn the bulb holder to the left and pull out the bulb.
Installation Procedure
1. Install the bulb into the holder and turn the bulb to
the right.
2. Install the control assembly. Refer to ”Control As-
sembly” in this section.
3. Connect the negative battery cable.
4. Check the knob light for proper operation.
HEATER/AIR DISTRIBUTOR CASE
ASSEMBLY
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the instrument panel and tie–bar. Refer to
Section 9E, Instrumentation/Driver Information.
3. Drain the cooling system. Refer to Section 1D, En-
gine Cooling.
4. Compress the heater hose clamps at the firewall
and slide the clamps toward the engine.
5. Remove the two heater hoses from the core pipes
at the firewall.

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 23
DAEWOO V–121 BL4
SERVICEABLE COMPONENTS
COMPONENTS USED IN NON–A/C
SYSTEMS
Refer to Section 7A, Heating and Ventilation System for
on–vehicle service procedures for the following sections:
S Blower Motor.
S Blower Resistor.
S Control Assembly Knob Lighting.
S Control Assembly.
S Heater Hoses.
S High–Blower Relay.
S A/C Control Vacuum Tank.
S Temperature Control Cable.
S Heater/Air Distributor Case Assembly (A/C Mod-
ule).
S Heater Core

7B – 26IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
Installation Procedure
1. Clean the grooves that fit the O–rings of any dirt or
contamination.
2. Install new O–rings on the evaporator tubes.
3. Install a expansion valve onto the evaporator tubes.
4. Insert the expansion valve connector block retain-
ing stud bolts.
Tighten
Tighten the expansion valve retaining stud bolts to 8
NSm (71 lb–in).
5. Install the suction hose/liquid pipe block retaining
nuts.
Tighten
Tighten the suction hose/liquid pipe block–to–expan-
sion valve retaining nuts to 14 NSm (10 lb–ft).
6. Connect the negative battery cable.
7. Evacuate and recharge the A/C system. Refer
to”Discharging, Adding Oil, Evacuating, and Charg-
ing Procedures for A/C System” in this section.
A/C HIGH–PRESSURE PIPE LINE
(Left–Hand Drive Shown, Right–Hand Drive
Similar)
Removal Procedure
1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to ”Discharging, Add-
ing Oil, Evacuating, and Charging Procedures for
A/C System” in this section.
3. Remove the nut at the discharge hose block con-
nected to compressor.
4. Remove the handlamp housing at the left–hand
side. Refer to Section 9B, Lighting Systems.
5. Remove the nut at the condenser connecting block.
6. Remove the refrigerant discharge hose.

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 27
DAEWOO V–121 BL4
7. Remove the air cleaner housing bolts and the air
filter housing assembly.
8. Disconnect the electrical connector at the pressure
transducer.
9. Remove the liquid pipe block–to–expansion valve
retaining nut at the fire wall.
10. Remove the handlamp housing at the left–hand
side. Refer to Section 9B, Lighting Systems.
11. Remove the liquid pipe block–to–receiver dryer re-
taining nut.
12. Remove the bolts which secure the support clamps
that hold the liquid pipe to the vehicle.
13. Remove the liquid pipe from the vehicle.
14. Cap the opening at the receiver–dryer to prevent
contamination.
Installation Procedure
1. Position the liquid pipe into the vehicle.
2. Install the liquid pipe support clamp bolts.
Tighten
Tighten the liquid pipe support clamp bolts to 4 NSm
(35 lb–in).

7B – 28IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
3. Install a new O–ring on the pipe at the receiver dry-
er.
4. Install the liquid pipe block–to–receiver–dryer re-
taining nut.
Tighten
Tighten the liquid pipe block–to–receiver–dryer re-
taining nut to 14 NSm (10 lb–ft).
5. Install the handlamp housing at the right–hand side.
Refer to Section 9B, Lighting Systems.
6. Install the liquid evaporator pipe block retaining nut
to the fire wall.
Tighten
Tighten the liquid pipe block–to–expansion valve re-
taining nut to 14 NSm (10 lb–ft).
7. Connect the electrical connector at the pressure
transducer.
8. Install the air cleaner housing bolts and the air filter
housing assembly.
9. Position the refrigerant discharge hose into the ve-
hicle.
10. Install the nut at the condenser connecting block.
Tighten
Tighten the refrigerant discharge hose block–to–con-
denser retaining nut to 16 NSm (12 lb–ft).
11. Install the handlamp housing at the left–hand side.
Refer to Section 9B, Lighting Systems.
12. Install the nut at the discharge hose block con-
nected to compressor.
Tighten
Tighten the refrigerant discharge hose block–to–
compressor retaining nut to 33 NSm (24 lb–ft).
13. Connect the negative battery cable.
14. Evacuate and recharge the A/C system. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.

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