check engine DAEWOO MATIZ 2003 Service Repair Manual

7A–14 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
Too Much Heat (Cont’d)
Step Action Value(s) Yes No




14




1. Check the temperature door travel, the cables,
and the linkage.
2. Verify that the temperature door goes to full cold.
3. Check the temperature door for full hot.
Is the temperature door travel correct?



–



System OK




–




15




1. Check for hot air leaks from the engine
compartment to the blower inlet.
2. Repair as needed.
Is the repair complete?



–



System OK




–

MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B–5
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
GENERAL DIAGNOSIS
TESTING THE REFRIGERANT
SYSTEM
If you suspect a problem in the refrigerant system,
check for the following conditions:
1. Check the outer surfaces of the radiator and the con-
denser cores to be sure that the airflow is not blocked
by dirt, leaves, or other foreign material. Check be-
tween the condenser and the radiator, as well as all
outer surfaces.
2. Check for restrictions or kinks in the condenser core,
the hoses, and the tubes.
3. Check the operation of the blower fan.
4. Check all the air ducts for leaks or restrictions. A low
airflow rate may indicate a restricted evaporator core.
5. Check for slippage of the compressor clutch.
6. Check the drive belt tension.
INSUFFICIENT COOLING “QUICK
CHECK” PROCEDURE
Perform the following “hand-feel” procedure to get a
quick idea of whether the air conditioning (A/C) system
has the proper charge of Refrigerant-134a.
1. Warm up the engine. Run the engine at idle.
2. Open the hood and all the doors.
3. Turn the A/C switch ON.
4. Set the temperature control to the full cold position.
5. Set the blower speed switch on 4.
6.“Hand-feel” the temperature of the evaporator outlet
pipe. The pipe should be cold.
7. Check for other problems. Refer to “Testing the Re-
frigerant System” in this section.
8. Leak check the system. Refer to “Leak Testing the
Refrigerant System” in this section. If you find a leak,
discharge the system and repair the leak as required.
After completing the repair, evacuate and charge the
system.
9. If there is no leak, refer to “Insufficient Cooling Diag-
nosis” in this section.

7B–8 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
AIR CONDITIONING SYSTEM DIAGNOSIS
INSUFFICIENT COOLING DIAGNOSIS
Step Action Value(s) Yes No
1Can you verify the customer complaint?–Go to Step 2System OK
2
1. Check the fuses Ef14, Ef19, and Ef12.
2. Check the blower fan operation.
3. Check the engine cooling fan operation.
4. Check the A/C compressor belt.
5. Check the A/C condenser for restricted air flow.
6. Check the slippage of the compressor clutch.
7. Repair or replace any components as needed.
8. Check the A/C system operation.
Is the A/C system operation normal?
–
System OKGo to Step 3
3
1. Turn the ignition switch OFF.
2. Connect the high and the low pressure gauges.
Are both pressures within the value specified?
Low SideGo to Step 8Go to Step 6
4Are both pressures above the specified value?Pressure:Go to Step 5–
5Are both pressures within the specified value?200 kPa
(29 Psi)Go to Step 8–
6Are both pressure below the specified value?
(29 Psi)
Go to Step 7Go to Step 4
7
1. Add the refrigerant R–134a.
2. Check the A/C system for leaks.
3. Repair any refrigerant leaks as needed.
4. Recover, evacuate, and recharge the A/C system.
Are both pressure within the specified value?High Side
Pressure:
1,500 kPa
(217.5 Psi)
Go to Step 8
–
8
1. Start the engine and allow it to run at idle.
2. Set the A/C controls to following positions.
The A/C switch to the ON position.
The fresh air control switch to fresh air.
The blower motor to 4.
The temperature to full cold.
Does the A/C compressor clutch engage?
–
Go to Step 9Go to Step 11
9
1. Check for a knocking noise from the A/C
compressor.
2. Cycle the A/C compressor ON and OFF in order
to verify the source of the noise.
Do you hear a loud knocking noise?
–
Go to Step 10Go to Step 14
10
1. Recover the A/C system refrigerant.
2. Replace the A/C compressor.
3. Evacuate and recharge the A/C system.
4. Check the A/C system for leaks.
Is the repair complete?
–
Go to Step 14
–
11
1. Turn the ignition switch OFF.
2. Disconnect the A/C compressor clutch coil
connector.
3. Connect a jumper wire from ground to one A/C
compressor clutch coil terminal.
4. Connect a fused jumper wire from the positive
battery terminal to the other A/C compressor
clutch coil terminal.
Does the A/C clutch engage?
–
Go to Step 12Go to Step 13

MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B–9
DAEWOO M-150 BL2
Insufficient Cooling Diagnosis (Cont’d)
Step Action Value(s) Yes No
12
Repair the electrical circuit to the A/C compressor
clutch coil.
Does the A/C clutch engage?
–
Go to Step 20Go to Step 13
13Replace the A/C compressor clutch coil.
Does the A/C clutch engage?–Go to Step 9Go to Step 10
14
Important: Perform this test under garage condi-
tions; 21-32
C (70-90
F) and no sun load. Follow
this test carefully for accurate results.
1. Close all of the windows and the doors of the
vehicle.
2. Set the A/C controls to the following positions:
The A/C switch to the ON position.
The fresh air control switch to fresh air.
The blower motor to 4.
The temperature to full cold.
3. Start the engine and follow it to run at idle for
5 minutes.
4. Feel the evaporator inlet and outlet pipes.
Is there a noticeable difference in the temperature of
the evaporator inlet and outlet pipes?
–
Go to Step 16Go to Step 15
15
1. Recover the A/C system refrigerant.
2. Replace the expansion valve as needed.
3. Evacuate and recharge the A/C system.
4. Check the A/C system for leaks.
5. Note the discharge air temperature with the A/C
ON.
Is the discharge temperature normal?
–
Go to Step16Go to Step 18
16
Feel the liquid pipe between the condenser and the
expansion valve.
Is the pipe cold?
–
Go to Step 19Go to Step 17
17
1. Remove the restriction of the high pressure side.
2. Check the A/C system for leaks.
Is the repair complete?
–
System OK
–
18
1. Recover the A/C system refrigerant.
2. Evacuate and recharge the A/C system.
3. Check the A/C system for leaks.
Is the repair complete?
–
System OK
–
19
1. Run the engine at 3,000 rpm.
2. Close all of the windows and doors of the vehicle.
3. Set the A/C controls to the following positions:
The A/C switch to the ON position.
The fresh air control switch to fresh air.
The blower motor to 4.
The temperature to full cold.
4. Turn the A/C switch ON and OFF every
20 seconds for 3 minutes.
Are the A/C compressor high and the low side
pressures within the specified value of each other?
Low Side
Pressure:
200 kPa
(29 psi)
High Side
Pressure:
1,500 kPa
(217.5 psi)
System OKGo to Step 22

7B–16 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
3. Refer to the manufacturer’s instructions for the charg-
ing station in use.
Enter the amount of refrigerant needed to charge
the A/C. Be sure that you are using the correct sys-
tem of measurement (kg, lb).
Begin the charging process.
Successful Transfer Complete
1. Close the high side valve on the unit’s control panel.
Both valves should be closed.
2. Start the vehicle and the A/C system.
3. Let the engine run until the readings on the high side
and low side gauges stabilize.
4. Compare the readings to the system specifications.
5. Check the evaporator outlet temperature to ensure
that the A/C system is operating within the system
specifications.
6. Keep the A/C running.
7. Close the high side coupler valve.
8. Disconnect the high side hose from the vehicle.9. Open the high side and low side valves on the con-
trol panel.
10. The system will quickly draw in refrigerant from both
hoses through the low side hose.
11. Close the low side coupler valve.
12. Disconnect the low side hose from the vehicle.
Unsuccessful Transfer
Sometimes the total charge does not transfer into the
A/C system. There are two reasons why this may occur.
1. The pressure in the unit’s tank and the pressure in the
A/C system are roughly equal. This will cause the
transfer to proceed too slowly. Refer to the manufac-
turer’s instructions for the charging station in use.
2. There was not enough refrigerant in the unit’s tank to
transfer the full charge. It is necessary to recover the
partial charge of refrigerant from the vehicle and
evacuate and charge the A/C system again. Refer to
the manufacturer’s instructions for the charging sta-
tion in use.

SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B–57
DAEWOO M-150 BL2
DTC 23 – Ignition Input Circuit, Voltage Too High
Step Action Value(s) Yes No

1


Check the vehicle’s charging system.
Refer to Section 1E, Engine Electrical.
Is the charging system OK?
–

Go to Step 3

Go to Step 2


2



Repair the charging system.
Is the repair complete?

–



Go to
Diagnostic
System Check

–

3


1. Disconnect the negative battery cable.
2. Replace the SDM.
Is the repair complete?

–


Go to
Diagnostic
System Check

–

DAEWOO M-150 BL2
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
noted.
TABLE OF CONTENTS
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 & Fuse Box Locator (Engine Room) 9A-8. . . .
Fuse Box Locator
(Passenger Compartment) 9A-9. . . . . . . . . . . . . . . . Fuse Chart 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. . . . . . . . . . . . . . . . . .

BODY WIRING SYSTEM 9A–3
DAEWOO M-150 BL2
Contents of Electrical Wiring Diagram
PositionExplanation
A
–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.
B
–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.
C
–Connector
–Connector No C202, terminal No 10
–Refer to “How to Check Terminal Number of Connect” in this section
D–Internal circuit of component (Relay)
(Component Name, Terminal Number)
E–Internal circuit of component (Switch)
(Terminal Number)
F–Wiring Harness Color
–Refer to “Wire Color Chart” in this section
G
–Ground line.
–G402: Ground Position
–In case of the ground numberless, this means the body ground.
Circuit Identification Symbol
Identification SymbolMeaning
CConnector
EfFuse in engine room fuse box
FFuse in passenger compartment fuse box
GGround

9B – 2 LIGHTING SYSTEMS
DAEWOO M-150 BL2
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 the
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.
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 ”II” position with the 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.

FRAME AND UNDERBODY 9N–3
DAEWOO M-150 BL2
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 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-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.

Install the insulators in the original position and se-
quence. Butt the pieces together in order to avoid
gapping or overlapping.

If it is 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.

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.

Route the cross-body harness for interior parts over
the floor pan insulators. Clip it in the original location.

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.