7A – 18 HEATING AND VENTILATION SYSTEM

DAEWOO M-150 BL2

REPAIR INSTRUCTIONS

ON-VEHICLE SERVICE

D108A502

D108A501

CONTROL ASSEMBLY AND
CONTROL CABLES

(Left–Hand Drive Shown, Right–Hand
Drive Similar)

Removal Procedure

1. Disconnect the negative battery cable.

2. Remove the instrument cluster housing trim panel.

Refer to Section 9E, Instrumentation/Driver informa-
tion.

3. Remove the control assembly.

D

Remove the control assembly retaining screws (1).

D

Separate the control assembly from the instrument
panel (2).

D

Disconnect the electrical connectors (3).

D

Disconnect the mode control cable from the heater
module (4).

D

Disconnect the temperature control cable from the
heater module (5).

D

Remove the glove box from the instrument panel.
Refer to Section 9E, Instrumentation/Driver Infor-
mation.

D108A503

D

Disconnect the recirculating/fresh air door cable
from the blower module (6).

HEATING AND VENTILATION SYSTEM 7A – 19

DAEWOO M-150 BL2

D108A504

D108A505

4. Disconnect the control cables from the control as-

sembly.

D

Disconnect the temperature control cable (1).

D

Disconnect the mode control cable (2).

D

Disconnect the recirculating/fresh air door cable
(3).

D108A506

Installation Procedure

1. Connect the control cables to the control assembly.

2. Connect the recirculating/fresh air door cable to the

blower module.

3. Install the glove box to the instrument panel. Refer to

Section 9E, Instrumentation/Driver Information.

4. Connect the temperature control cable and the mode

control cable to the heater module.

5. Connect the electrical connectors.

6. Install the control assembly with the screws.

7. Install the instrument cluster housing trim panel. Re-

fer to Section 9E, Instrumentation/Driver Information.

8. Connect the negative battery cable.

7A – 20 HEATING AND VENTILATION SYSTEM

DAEWOO M-150 BL2

D108A507

BLOWER MOTOR AND COOLING
HOSE

(Left–Hand Drive Shown, Right–Hand
Drive Similar)

Removal Procedure

1. Remove the blower motor cooling hose.

D108A508

2. Remove the blower motor.

D

Disconnect the motor electrical connector (1).

D

Turn the blower motor (2).

D108A509

Installation Procedure

1. Install the blower motor by turning the motor clock-

wise.

2. Connect the motor electrical connector.

3. Install the blower motor cooling hose.

D108A510

BLOWER RESISTOR

(Left–Hand Drive Shown, Right–Hand
Drive Similar)

Removal Procedure

1. Remove the blower resistor.

D

Disconnect the blower resistor connector (1).

D

Remove the screws (2).

HEATING AND VENTILATION SYSTEM 7A – 21

DAEWOO M-150 BL2

D108A511

Installation Procedure

1. Install the blower resistor with the retaining screws.

2. Connect the blower resistor connector.

D108A512

BLOWER MOTOR SWITCH

(Left–Hand Drive Shown, Right–Hand
Drive Similar)

Removal Procedure

1. Remove the control assembly. Refer to “Control As-

sembly and Control Cables” in this section.

2. Remove the blower motor switch.

D

Remove the switch knob (1).

D108A513

D

Remove the blower motor switch retaining screw
(2).

D

Turn the blower motor switch anticlockwise (3).

D108A514

Installation Procedure

1. Install the blower motor switch with the screw.

2. Install the switch knob.

3. Install the control assembly. Refer to “Control Assem-

bly and Control Cables” in this section.

7A – 22 HEATING AND VENTILATION SYSTEM

DAEWOO M-150 BL2

D18A515A

HEATER HOSES

(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Tool Required

DW100–020 Hose Remover/Installer.

Removal Procedure

1. Disconnect the negative battery cable.
2. Drain the coolant.
3. Remove the heater inlet hoses.

D

Remove the air cleaner housing.

D

Raise and suitably support the vehicle.

D

Disconnect the hose from the heater module using
a hose remover DW100–020 (1).

D108A516

D

Lower the vehicle.

D

Disconnect the hose from the thermostat (2).

D18A517A

4. Remove the heater outlet hoses.

D

Raise and suitably support the vehicle.

D

Disconnect the hose from the heater module using
a hose remover DW100–020 (1).

D

Disconnect the B

+

terminal from the starter. Refer

to Section 1E, Engine Electrical.

D108A518

D

Disconnect the heater hose from the engine (2).

HEATING AND VENTILATION SYSTEM 7A – 23

DAEWOO M-150 BL2

D108A521

Installation Procedure

1. Install the heater outlet hoses.

D

Connect the heater hose to the engine (1).

D

Connect the B

+

terminal to the starter. Refer to

Section 1E, Engine Electrical.

D18A522A

D

Connect the hose to the heater module using a
hose installer DW100–020 (2).

D

Lower the vehicle.

D108A519

2. Install the heater inlet hoses.

D

Connect the hose to the thermostat (1).

D

Raise and suitably support the vehicle.

DW100–020

D18A520A

D

Connect the hose to the heater module using a
hose installer DW100–020 (2).

D

Lower the vehicle.

D

Install the air cleaner housing.

3. Refill the coolant. Refer to Section 1D, Engine Cool-

ing.

4. Connect the negative battery cable.

7A – 24 HEATING AND VENTILATION SYSTEM

DAEWOO M-150 BL2

D108A523

HEATER MODULE

(Left–Hand Drive Shown, Right–Hand
Drive Similar)

Removal Procedure

1. Disconnect the heater hoses from the heater module.

Refer to “Heater Hoses” in this section.

2. Remove the instrument panel and the lower tie bar

center. Refer to Section 9E, Instrumentation/Driver
Information.

3. Remove the heater module–to–blower module con-

nection tube on the vehicle not equipped with A/C.

a. Heater module–to–blower module connection tube.

D108A524

4. Remove the evaporator on the vehicle equipped with

A/C. Refer to Section 7B, Manual Control Heating,
Ventilation, and Air Conditioning System.

D108A525

5. Remove the heater module.

D

Remove the upper nuts (1).

D108A526

D

Remove the lower nuts (2).

D

Remove the heater module (3).

HEATING AND VENTILATION SYSTEM 7A – 25

DAEWOO M-150 BL2

D18A527B

D18A528B

Installation Procedure

1. Install the heater module with the nuts.

Tighten

Tighten the heater module lower nuts to 3–5 N

S

m

(27–44 lb-in) (1).

Tighten the heater module upper nuts to 3–5 N

S

m

(27–44 lb-in) (2).

2. Install the evaporator on the vehicle equipped with

A/C. Refer to Section 7B, Manual Control Heating,
Ventilation, and Air Conditioning System.

3. Install the heater module–to–blower module connec-

tion tube on the vehicle not equipped with A/C with
the screw.

4. Install the instrument panel and the lower tie bar. Re-

fer to Section 9E, Instrumentation/Driver Information.

5. Connect the heater hoses to the heater module. Re-

fer to “Heater Hoses” in this section.

D108A529

D108A530

BLOWER MODULE

(Left–Hand Drive Shown, Right–Hand
Drive Similar)

Removal Procedure

1. Remove the glove box from the instrument panel. Re-

fer to Section 9E, Instrumentation/Driver Information.

2. Remove the heater module–to–blower module con-

nection tube on the vehicle not equipped with A/C.
Refer to “Heater Module” in this section.

3. Remove the evaporator on the vehicle equipped with

A/C. Refer to Section 7B, Manual Control Heating,
Ventilation, and Air Conditioning System.

4. Remove the blower resistor. Refer to “Blower Resis-

tor” in this section.

5. Disconnect the blower motor connector. Refer to

“Blower Motor and Cooling Hose” in this section.

6. Remove the blower module.

D

Remove the nuts (1).

D

Disconnect the wiring harness (2).

7A – 26 HEATING AND VENTILATION SYSTEM

DAEWOO M-150 BL2

D18A531B

Installation Procedure

1. Install the blower module with the nuts.

Tighten

Tighten the blower module retaining nuts to 3–5 N

S

m

(27–44 lb-in).

2. Connect the wiring harness.

3. Connect the blower motor connector. Refer to “Blow-

er Motor and Cooling Hose” in this section.

4. Install the blower resistor. Refer to “Blower Resistor”

in this section.

5. Install the evaporator on the vehicle equipped with

A/C. Refer to Section 7B, Manual Control Heating,
Ventilation, and Air Conditioning System.

6. Install the heater module–to–blower module connec-

tion tube on the vehicle not equipped with A/C. Refer
to “Heater Module” in this section.

7. Install the glove box to the instrument panel. Refer to

Section 9E, Instrumentation/Driver Information.

D108A532

DEFROSTER DUCT AND HOSES

(Left–Hand Drive Shown, Right–Hand
Drive Similar)

Removal Procedure

1. Remove the instrument panel. Refer to Section 9E,

Instrumentation/Driver Information.

2. Remove the defroster duct and hoses retaining

screws.

a. Retaining screw.

3. Remove the defroster duct and hoses.

b. Defroster duct and hoses.

D108A533

Installation Procedure

1. Install the defroster duct and hoses with the screws.

2. Install the instrument panel. Refer to Section 9E, In-

strumentation/Driver Information.

HEATING AND VENTILATION SYSTEM 7A – 27

DAEWOO M-150 BL2

D18A534A

VENTILATION DUCT

(Left–Hand Drive Shown, Right–Hand
Drive Similar)

Removal Procedure

1. Remove the instrument panel. Refer to Section 9E,

Instrumentation/Driver Information.

2. Remove the ventilation duct retaining screws.

a. Retaining screw.

3. Remove the ventilation duct.

b. Ventilation duct.

D108A535

Installation Procedure

1. Install the ventilation duct with the screws.

2. Install the instrument panel. Refer to Section 9E, In-

strumentation/Driver Information.

7A – 28 HEATING AND VENTILATION SYSTEM

DAEWOO M-150 BL2

UNIT REPAIR

D108A701

HEATER CORE

Disassembly Procedure

1. Remove the heater module. Refer to “Heater Module”

in this section.

2. Remove the heater core.

D

Remove the heater core cover (1).

D

Remove the heater core (2).

D108A702

Assembly Procedure

1. Install the heater core to the heater module.

2. Install the heater core cover.

3. Install the heater module. Refer to “Heater Module” in

this section.

HEATING AND VENTILATION SYSTEM 7A – 29

DAEWOO M-150 BL2

SPECIFICATIONS

GENERAL SPECIFICATIONS

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Application

ÁÁÁÁÁÁ

ÁÁÁÁÁÁ

Unit

ÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁ

Description

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Maximum Heating Capacity

ÁÁÁÁÁÁ

ÁÁÁÁÁÁ

cal/h

ÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁ

7,300

ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

1 st

ÁÁÁÁÁÁ

ÁÁÁÁÁÁ

Ω

ÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁ

2.25 – 2.75

ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

2 nd

ÁÁÁÁÁÁ

ÁÁÁÁÁÁ

Ω

ÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁ

1.08 – 1.32

ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

Blower Motor Resistance

ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

3 rd

ÁÁÁÁÁÁ

ÁÁÁÁÁÁ

Ω

ÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁ

0.36 – 0.44

ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁ

4 th

ÁÁÁÁÁÁ

ÁÁÁÁÁÁ

Ω

ÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁ

–

FASTENER TIGHTENING SPECIFICATIONS

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Application

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

N

S

m

ÁÁÁÁÁÁ

ÁÁÁÁÁÁ

Lb-Ft

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁ

Lb-In

Heater Module Nuts

3 – 5

–

27 – 44

Blower Module Nuts

3 – 5

–

27 – 44

7A – 30 HEATING AND VENTILATION SYSTEM

DAEWOO M-150 BL2

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE

D102B119

DW 100–020

Spring Clamp

Remover/Installer

HEATING AND VENTILATION SYSTEM 7A – 31

DAEWOO M-150 BL2

SCHEMATIC AND ROUTING DIAGRAMS

NON–A/C DIAGRAMS

D18A201B

7A – 32 HEATING AND VENTILATION SYSTEM

DAEWOO M-150 BL2

AIR FLOW THROUGH DUCTS (NON–A/C)

(Left–Hand Drive Shown, Right–Hand Drive Similar)

D108A202