heating system DAEWOO MATIZ 2003 Service Owner's 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




–

HEATING AND VENTILATION SYSTEM 7A–15
DAEWOO M-150 BL2
CONTROLS
Step Action Value(s) Yes No

1

Verify the customer’s complaint.
Are the customer’s concerns verified?
–
Go to Step 2

System OK
2 Is excessive effort required to move a control? – Go to Step 5 Go to Step 3
3 Does a door move too easily on a high-blower
setting? –
Go to Step 4

System OK




4





1. Replace the Bowden cable with a longer cable.
2. Add a loop to the cable routing to increase the
effort required to move a control.
3. Check for instrument panel interference with the
new cable routing.
Does the control operate properly?





–




System OK




Go to Step 5

5



Check the cables for improper routing, kinks, wiring
interference, or other instrument panel interference.
Is any cable problem found?

–


Go to Step 6


Go to Step 7

6

Repair as needed.
Is the repair complete?
–
System OK

–




7




1. Remove the cable from any door that binds on
the cable.
2. Cycle the door manually.
3. Check for door binding.
Is there any door binding?



–



Go to Step 8



Go to Step 11

8


Check the door seal for proper installation.
Is the door seal OK?
–

Go to Step 9

Go to Step 10



9



1. Check a binding door for shaft alignment, a bent
shaft or a bent door, or a warped case.
2. Repair, as needed.
Is the repair complete?


–


System OK



–

10

Repair the door seal, as needed.
Is the repair complete?
–

System OK

–

11


Check for control binding.
Does the control bind?
–

Go to Step 13

Go to Step 12


12



1. Reinstall the cable to the door.
2. Check the cable-to-dash components clearances.
3. Repair any interference.
Is the repair complete?

–


System OK


–


13



1. Remove the cable from the control.
2. Check the control for binding.
Does the control bind?

–


Go to Step 14


Go to Step 15

14


Replace the control.
Is the repair complete?
–

System OK

–

15

Replace the cable.
Is the repair complete?
–
System OK

–

7A–16 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
BLOWER NOISE
Step Action Value(s) Yes No

1

Verify the customer’s complaint.
Are the customer’s concerns verified?
–
Go to Step 2

System OK








2








1. Sit inside the vehicle.
2. Close the doors and windows.
3. Turn the ignition ON.
4. Set the blower speed to 4.
5. Set the temperature to full cold.
6. Cycle through the blower speeds, the modes, and
the temperature settings in order to find the noise.
Is the blower noise constant at high blower speeds
or certain modes, but absent at lower speeds or in
other modes?







–







Go to Step 11







Go to Step 3



3



Check for vibrations from the blower motor and fan
assembly at each blower speed by feeling the
blower motor housing.
Did you find excessive vibration?


–


Go to Step 6


Go to Step 4



4




1. Remove the blower motor and fan assembly.
Refer to ‘‘Blower Motor” in this section.
2. Check for foreign material at the opening of the
blower inlet.
Did you find any foreign material at the blower inlet?



–



Go to Step 5



Go to Step 6
5

Remove all foreign material.
Is the repair complete?
–

System OK

Go to Step 6



6




1. Examine the blower fan for wear spots, cracked
blades, a cracked hub, a loose fan retaining nut,
or bad alignment.
2. Examine the blower case for wear spots.
Did you find any problem?



–



Go to Step 7



Go to Step 9
7

Lubricate the motor.
Is the repair complete?
–

System OK

Go to Step 8

8


Replace the motor and fan assembly.
Is the repair complete?
–

System OK

Go to Step 9

9


If the noise is a click/tick or whine, replace the mo-
tor.
Is the repair complete?
–

System OK

Go to Step 10
10

Reinstall the original motor.
Is the problem still present?

–

Go to Step 11

System OK



11




1. Set the blower speed on 4.
2. Check full-hot to full-cold temperature positions in
the defrost, floor, and vent modes.
Is the noise present in the defrost mode only?



–



Go to Step 12



Go to Step 13





12





1. Check the ducts for obstructions or foreign
materials.
2. Remove any obstructions or foreign materials.
3. Check floor/defroster door seals.
4. Repair or replace, as needed.
Is the repair complete?




–




System OK





–
13 Is the noise present in the floor mode only? – Go to Step 12 Go to Step 14

HEATING AND VENTILATION SYSTEM 7A–17
DAEWOO M-150 BL2
Blower Noise (Cont’d)
Step Action Value(s) Yes No
14 Is the noise present in the vent mode only? – Go to Step 15 Go to Step 16





15





1. Check the ducts for obstructions or foreign
materials.
2. Remove any obstructions or foreign materials.
3. Check the vent door seals.
4. Repair or replace as needed.
Is the repair complete?




–




System OK





–

16

Is the noise present in all modes, but not all temper-
ature positions?
–
Go to Step 17

Go to Step 18

17


1. Check the temperature door seals.
2. Repair or replace, as needed.
Is the repair complete?
–


System OK

–





18





1. Check the system for obstructions or foreign
materials between the fan and the temperature
door.
2. Repair or replace, as needed.
Is the repair complete?





–




System OK




Go to Step 2

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.

Remove the control assembly retaining screws (1).

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

Disconnect the electrical connectors (3).

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

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

Remove the glove box from the instrument panel.
Refer to Section 9E, Instrumentation/Driver Infor-
mation.
D108A503

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.

Disconnect the temperature control cable (1).

Disconnect the mode control cable (2).

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.

Disconnect the motor electrical connector (1).

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.

Disconnect the blower resistor connector (1).

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.

Remove the switch knob (1).
D108A513

Remove the blower motor switch retaining screw
(2).

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.

Remove the air cleaner housing.

Raise and suitably support the vehicle.

Disconnect the hose from the heater module using
a hose remover DW100–020 (1).
D108A516

Lower the vehicle.

Disconnect the hose from the thermostat (2).
D18A517A
4. Remove the heater outlet hoses.

Raise and suitably support the vehicle.

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

Disconnect the B
+ terminal from the starter. Refer
to Section 1E, Engine Electrical.
D108A518

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.

Connect the heater hose to the engine (1).

Connect the B
+ terminal to the starter. Refer to
Section 1E, Engine Electrical.
D18A522A

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

Lower the vehicle.
D108A519
2. Install the heater inlet hoses.

Connect the hose to the thermostat (1).

Raise and suitably support the vehicle.
DW100–020
D18A520A

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

Lower the vehicle.

Install the air cleaner housing.
3. Refill the coolant. Refer to Section 1D, Engine Cool-
ing.
4. Connect the negative battery cable.