2004 DAEWOO NUBIRA ESP

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

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.

8B – 8ISUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
DAEWOO V–121 BL4
SIR DIAGNOSTIC SYSTEM CHECK
Notice : If the vehicle interior has been exposed to exten-
sive water intrusion such as water leaks, driving through
high water, flooding, or other causes, the sensing and
diagnostic module(SDM) and SDM connector may need
to be replaced. With ignition OFF, inspect the area around
the SDM, including the carpet. If any significant soaking or
evidence of previous soaking is detected, the water must
be removed, water damage repaired, and the SDM and
the SDM connector must be replaced. Before attempting
any of these repairs, the supplemental inflatable re-
straints(SIR) must be disabled. Refer to ”Disabling the
SIR” and ”Sensing and Diagnostic Module(SDM)” in this
section for instructions on how to disable the SIR and re-
place the SDM.
The SIR Diagnostic System Check must always be the
starting point for any SIR diagnosis. The Diagnostic Sys-
tem Check reveals diagnostic trouble codes(DTCs)
through the use of scan tool. The diagnostic procedures
used in this section are designed to find any repair SIR
conditions. To get the best results, it is important to use the
diagnostic charts and follow the sequence listed below.
1. Perform the SIR Diagnostic System Check, which
reveal diagnostic trouble codes(DTCs) through theuse of scan tool.. It also checks for proper airbag
indicator operation.
2. Refer to the proper diagnostic chart as directed by
SIR Diagnostic System Check. Bypassing these
procedures may result in extended diagnostic time,
incorrect diagnosis, and incorrect parts replace-
ment.
3. Repeat the SIR Diagnostic System Check after any
repair or diagnostic procedures have been per-
formed to ensure that the repair has been made
correctly and that no other malfunction exists.
Circiut Description
When the ignition switch is first turned to ON, ignition volt-
age is supplied from airbag fuse to find the SDM at input
terminal A1. The SDM responds by flashing the airbag in-
dicator seven times and then turning it off while the SDM
performs tests on the SIR.
Diagnostic Aids
The order in which DTCs are diagnosed is very important.
Failure to diagnose the DTCs in the order specified may
result in extended diagnostic time, incorrect diagnosis,
and incorrect parts replacement.
SIR Diagnostic System Check
CAUTION : The sensing and the diagnosis module
(SDM) can maintain surfficient voltage to deploy the
airbags and pretensioners for 1 minute after the igni-
tion is OFF and the fuse has been removed. If the air-
bags and pretensioners are not disconnected, do not
begin service until one minute has been passed after
disconnecting power to the SDM. Otherwise, injury
could result.
CAUTION : During service procedure, be very careful
when handling the SDM. Never strike or jar the SDM.Never power the supplemental inflatable re-
straints(SIR) when the SDM is not rigidly attached to
the vehicle. All SDM mounting bolts must be carefully
tightened , and the arrow on the SDM must be point
toward the front of the vehicle to ensure proper op-
eration of the SIR. The SDM could be activated if it is
powered when it is not rigidly attached to the vehicle,
resulting in unexpected deployment and possible in-
jury.
Step
ActionValue(s)YesNo
11. Turn the ignition switch ON.
2. Observe the airbag indicator as the ignition is
being turned ON. Does the indicator flash
seven times?–System OKGo to Step 2
21. Turn the ignition to LOCK and remove the key.
2. Connect the scan tool to the data link connec-
tor(DLC). Follow the directions given in the
scan tool manual.
3. Are any DTCs displayed on the scan tool?–Go to the
DTC check
procedureGo to Step 3
3Check the fuse F1 in the interior fuse box.
Is the fuse F1 blown?–Go to Step 4Go to Step 5
4Replace the fuse F1.–––
51. Disconnect the connector C207.
2. Check the wiring shortage between the fuse F1
and the terminal 1 of the connector C207.
3. Is the wiring shorted? Then, repair the wiring.––Go to Step 6

DOORS 9P – 29
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM 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 the 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 ve-
hicle from the inside.
To activate the locks, move the levers of both rear doors
to the lock position. Then, close both doors. The rear pas-
sengers will be unable to open the doors from inside of the
vehicle.
To deactivate the locks, unlock the door from the inside of
the vehicle and open the door from the outside. Move the
lever to the unlock position. 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 cylin-
der on the driver’s side door only. When the driver’s side
door is locked or unlocked by the actuator or the lock cylin-
der, all doors are locked or unlocked accordingly.
POWER WINDOWS
The power windows are controlled by electrical switches
on the door panels and are operated by a motor at each
window regulator. Each door has a switch to control its
window, and the driver’s side door has four switches to
control all door windows on the vehicle. 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.
The driver’s side window opens automatically. By pressing
and releasing the switch, the driver ’s side window will low-
er and will stop only when the switch is activated again, or
when the window is completely open.
The driver’s side door control also contains a window lock
button that will prevent the operation of the front passen-
ger door or the rear door windows when pressed.

REMOTE KEYLESS ENTRY AND ANTI–THEFT SYSTEM 9T1 – 7
DAEWOO V–121 BL4
REMOTE KEYLESS ENTRY
TRANSMITTER PROGRAMMING
The Remote Keyless Entry System allows for the use of
as many as four(4) transmitters for each vehicle. Replace-
ment Remote Keyless Entry System Transmitters must
first be programmend to specific vehicle using the
Scan100 Secan tool.
This process is completed using serial data communica-
tion between the Scan 100 Scan tool and the Remote Key-
less Entry Control Unit and is the only method available for
programming Transmitters.
Notice : All Transmitters for a specific vehicle must be pro-
grammed at same time.
Notice : Once the programming function of the Remote
Keyless Entry System is activated, any Transmitter(exist-
ing or new) that is not programmed(or reprogrammed)
during the programming procedure will no longer operate
the Remote Keyless Entry System of that vehicle.
Notice : Ensure that the doors, hood and trunk/rear hatch
are closed prior to starting the programming procedure.
1. Connect the Scan 100 Scan Tool to the Data Link
Connector(DLC)
2. Turn the Scan 100 Scan Tool ”ON” by pressing the
”Power” Button, then wait for the MAIN MENU
screen to be displayed.
3. From the MAIN MENU screen, select ”Diagnostics”
by pressing #1 on the Key Pad.
4. From the MODEL YEAR screen, select the ap-
propriate model year of the specific vehicle by ei-
ther scrolling down to the year and pressing ”EN-
TER”, or by pressing the respective item number on
the Key Pad.
5. From the VEHICLE TYPE screen, select the specif-
ic vehicle model by either scrolling down to the
model name and pressing ”ENTER”, or by pressing
the respective item number on the Key Pad.
6. From the SYSTEM SELECTION MENU screen,
select ”Body” by pressing #2 on the Key Pad.
7. From the BODY SELECTION MENU screen, select
”Coding” by pressing #2 on the Key Pad.8. From the CODY SELECTION MENU screen, select
”Coding” by pressing #1 on the Key Pad.
9. From the SECRET NUMBER OF CODINGS
screen, enter for(4) zero’s (0–0–0–0) in the for(4)
boxes labeled ”1–2–3–4–”.
10. From the CODING SYSTEM SELECT screen, se-
lect ”Keyless Entry” by pressing #2 on the Key Pad.
Notice : A slight delay may occur and ”PLEASE WAIT”
may be displayed before the next screen appears.
11. From the KEYLESS ENTRY CODING SYSTEM
screen, select ”Coding Transmitter” by pressing #1
on the Key Pad.
12. When directed by the Scan 100 Scan Tool, press
any Button on the first Transmitter to be pro-
grammed.
CAUTION : Ensure that Transmitters from other ve-
hicles in the immediate area are not activated during
this procedure.
13. Continue programming Transmitters when directed
by the Scan 100 Scan Tool until all Transmitters
have been programmed.
Notice : A maximum of four(4) Transmitters may be pro-
grammed to a vehicle.
14. Once all Transmitters have been programmed,
press the ”ESC” Button on the Key Pad. The dis-
play will confirm the number of Transmitters pro-
grammed. If the number displayed does not match
the number of Transmitters programmed, repeat
the procedure.
15. Turn the Scan 100 Scan Tool ”OFF” by pressing the
”POWER” Button, then disconnect it from the Data
Link Connector.
16. Wait approximately 10 seconds, then test the op-
eration of each programmed Transmitter to ensure
it operates properly.
The control module/receiver leaves the programming
mode automatically and switches to the normal operating
mode when either of the following conditions occurs:
S the scan tool is disconnected from the ALDL.
S Four passwords are recorded in the control module/
receiver.

9T2 – 12IIMMOBILIZER ANTI–THEFT SYSTEM
DAEWOO V–121 BL4
The VIN code is transmitted from the Immobilizer in the re-
lease message communication only incase of using an au-
thorized key. Without an authorized key it is not possible
to getthe system VIN code.In case of ECM internal state
is in Virgin mode or neutral mode the ECM learns the sys-
tem 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.
S Communication with the DLC–test equipment. Main
functions are the key coding procedure, the VIN–
code handling and the support for system test func-
tions.
S Handling of the software watchdog
Operation
In the active mode of immobilizer (engine OFF, IG key
OFF) the status LED isblinking as mode A. When ignition
is turned ON, the system wakes up and tries to read out
the transponder.
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 similar
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 immobi-
lizer control unit to the DLC mode for diagnostics, key cod-
ing and ID coding.
S The status LED is turned off during DLC–mode
S 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 EE-
PROM.
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
tool’s ”Read immobilizer control unit VIN code” command.
SERIAL DATA LINK
Serial data can be exchanged between a scan tool and the
ECM and the Immobilizer control unit.
ELECTRONIC CONTROL MOUDLE
(ECM)
S ECM in Virgin mode
In this mode, the ECM knows 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
communication 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.
S ECM in Learnt mode
In such a state, ECM checks on every commu-
nication, the correct encoding of the ICU.
If the code received is not correct, then the vehicle is im-
mobilized.
The coded 5 bytes of data emitted by ECM are
a mixture of MIN code and random.
The coded 5 bytes of data emitted by ICU are a
mixture of VIN code and random.
S ECM in Neutral mode
This mode is a special intermediate mode, used
for ICU replacement or immobilizer option instal-
lation.
ECM request to ICU the VIN number. As soon
as the ECM receives two correct consecutive
communication 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.
S 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.

IMMOBILIZER ANTI–THEFT SYSTEM 9T2 – 13
DAEWOO V–121 BL4
1. After receiving a response message including the
information ”ICU in learnt mode” and the correct
system VIN–code

the ECM enters the release state, which al-
lows to continue the running of the engine.
2. After receiving a response message including the
information ”ICU in learnt mode” and a wrong sys-
tem VIN–code

the ECM does not send a new request and
enters the blocked state, which causes the ac-
tivation of the immobilization actions of the en-gine.
3. If the ECM doesn’t receive a response message
within a defined time from beginning of the release
time period or the ECM receives a no release an-
swer

the ECM enters the blocked state, which
causes the activation of the immobilization ac-
tions of the engine.
S The inactive state of the Immobilizer (valid key/
invalid key) ends with turning off the ignition.

1–2 GENERAL INFORMATIONNUBIRA/LACETTI
1. GENERAL INSTRUCTION
This publication is designed to help you the body repair
technician with your specialized work. Vehicle bodywork
has changed a great deal over the years. As vehicles
have developed technically, vehicle bodywork has also
had to meet new requirements with design, changes to
reconcile apparently conflicting demands to name just a
few examples:
S strength and safety ; low weight
S spaciousness ; good aerodynamices
S high quality ; low price
.
The durability and ease of repair of the bodywork also
plays an important part.
.
Nowadays, the use of highly automated production
equipment makes it possible to maintain the tightest
tolerances and thus ensure a high level of quality.
.
When bodywork is damaged, the customer rightly ex-
pects it to be expertly repaired to the same quality stan-
dards.
.
At the same time, for his safety, the customer expects
you to have comprehensive knowledge of materials,
measuring and straightening methods, possible distor-
tion, optimum corrosion prevention and much more be-
sides.
.
This publication is designed to help you update your
knowledge and give you an idea of what you require to
rectify moderate or severe accident damage, for your
own safety and for the satisfaction of your customers.
2. IMPORTANT SAFETY NOTICE
2–1. BEFORE BEGINNING WORK
S Disconnect the battery to reduce the possibility of fire
caused by electrical shorts.
S Check for fuel leaks and repair as necessary.
S Remove the fuel tank and/or fuel lines if welding equip-
ment is to be used near the fuel system.
S Before welding, sanding or cutting, protect carpets and
seats with fire–proof covers.
S Follow standard safety practices when using toxic or
flammable liquids.
S Use standard safety equipment when spraying paint,
welding, cutting, sanding or grinding. Standard safety
equipment includes.
S Respirator and filter masks: Designed to filter out toxic
fumes, mist, dust or other airborn particles. Use a respi-
rator or filter mask designed to protect you from the haz-
ards of the particular job; some respirators, for example,
are designed to filter out only dust and airborn particles,
not toxic fumes.
S Safety goggles or glasses: Designed to protect your
eyes from projectiles, dust particles or splashing liquid.
S Gloves: Rubber gloves protect against corrosive chemi-
cals. Welding gloves protect against burns and abra-
sions caused by welding, sanding or grinding.
S Safety shoes: Non–slip soles protect against slipping.
Metal toe inserts protect against falling objects.
S Ear plugs: Protect eardrums from harmful noise levels.
.
2–2. DURING WORK
S Do not smoke while working near the fuel system.
S Deposit gas or solvent–soaked shop towels in an ap-
proved container.
S Brake lining contains asbestos, which can cause cancer.
Do not use an air hose to blow off brake assemblies: use
only an approved vacuum cleaner, and wear an ap-
proved filter mask or respirator.
S Always attach a safety cable when using a hydraulic ram
or a frame straightening table: do not stand in direct line
with the chains used on such equipment.