engine DAEWOO MATIZ 2003 Service Repair Manual
Page 790 of 1184
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
Page 791 of 1184
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; 21-32C (70-90F) 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
Page 798 of 1184
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.
Page 805 of 1184
MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B -- 23
DAEWOO M-150 BL2
D18B518A
DLoosen the fitting securing the high pressure pipe
line to the condenser pipe line (2).
DRemove the clamp nut (3).
D18B519A
5. Remove the A/C high pressure pipe line between the
condenser and the receiver dryer.
DLoosen the fitting securing the receiver dryer to the
condenser (1).
D108B520
DRemove the receiver dryer flange nuts (2).
D18B521A
6. Remove the A/C high pressure pipe line between the
receiver dryer and the evaporator.
DRemove the purge control valve. Refer toSection
1F, Engine Controls.
DRemove the bracket nut (1).
DLoosen the fitting (2).
Page 806 of 1184
7B -- 24 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
D18B522A
D18B523B
D18B524A
Installation Procedure
Important:Discard the removed O--rings.
1. Install the high pressure pipe lines with the bolts, the
nuts, and the fittings.
Tighten
DTighten the bolt securing the high pressure pipe
line to the compressor to 23 NSm (17 lb-ft) (1).
DTighten the fitting securing the high pressure pipe
line to the condenser pipe line to 23 NSm (17 lb-ft)
(2).
DTighten the fitting securing the high pressure pipe
line to the receiver dryer to 14 NSm (10.5 lb-ft) (3).
DTighten the bracket nut to 5 NSm (44 lb-in) (4).
DTighten the receiver dryer flange nuts to 14 NSm
(10.5 lb-ft) (5).
DTighten the nut securing the high pressure pipe line
to the evaporator to 14 NSm (10.5 lb-ft) (6).
DTighten the bracket nut to 5 NSm (44 lb-in) (7).
2. Install the purge control valve. Refer toSection 1F,
Engine controls.
3. Evacuate and recharge the system. Refer to “Dis-
charging, Adding Oil, Evaculating, and Charging Pro-
cedures for A/C System” in this section.
4. Install the front bumper fascia. Refer toSection 9O,
Bumpers and Fascias.
5. Connect the negative battery cable.
D18B525B
Page 807 of 1184
MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B -- 25
DAEWOO M-150 BL2
D108B526
A/C LOW PRESSURE PIPE LINE
(Left -- Hand Drive Shown, Right -- Hand
Drive Similar)
Removal Procedure
1. Disconnect the negative battery cable.
2. Discharge and recover the refrigerant. Refer to “Dis-
charging, Adding Oil, Evacuating, and Charging Pro-
cedures for A/C System” in this section.
3. Remove the A/C low pressure pipe line.
DRemove the bolt securing the A/C low pressure
pipe line at the compressor (1).
D18B527A
DRemove the bracket nut from shut bar (2).
D18B528A
DRemove the purge control valve. Refer toSection
1F, Engine Controls.
DLoosen the nut securing the A/C low pressure pipe
line at the evaporator (3).
D18B529B
Installation Procedure
Important:Discard the removed O--rings.
1. Install the A/C low pressure pipe line.
Tighten
DTighten the nut securing the A/C low pressure pipe
line at the evaporator to 14 NSm (10.5 lb-ft) (1).
Page 812 of 1184
7B -- 30 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application
Unit
Description
Compressor
--
SP--10.4PK
Receiver--Dryer
--
AL R/DRIER
Refrigerant
Type
--
R--134a System
Refrigerant
Capacity
g
500 (RHD : 530)
RefrigerantOilinA/CSystem
Type
--
RL 244 PAG OIL RefrigerantOilinA/CSystem
Capacity
cc
150
A/C Cooling Capacity (Airflow rate 8.7 kg/min)
Kcal/h
5,500
Refrigerant Pressure in A/C Sys-
tem(Engine Idle, Fresh Air 30_C
(86_F)AmbientTemperature
Low Pressure Side
kPa (psi)
200 (2.9)
(86_F),AmbientTemperature
25_C--35_C(77_F--95_F), Tempera-
ture to Full Cold)
High Pressure Side
kPa (psi)
1,500 (217.5)
A/C Compressor ON/OFF Condition
(Refer toSection 1F, Engine Controls
AbouttheA/CCompressorON/OFF
Evaporator Therm-
istor Temperature
_C(_F)
2.45(36.81)
1.0 (34.2)
ON
OFF
About theA/CCompressorON/OFF
Condition According to Engine Oper-
ating Status)
Dual Cut Switch
Pressure
kPa
205--245
180--220
ON
OFF300--400
240--280
FASTENER TIGHTENING SPECIFICATIONS
Application
NSm
Lb-Ft
Lb-In
Compressor Upper Bracket Bolts
20
15
--
Compressor Front Head-to-Rear Head Through-Bolt
22
16
--
High Pressure Pipe Line (Compressor→Condenser) Bolt
23
17
--
High Pressure Pipe Line (Compressor→Condenser) Fitting
23
17
--
High Pressure Pipe Line (Compressor→Condenser) Clamp Nut
5
--
44
Receiver--Dryer Flange Nut
14
10.5
--
High Pressure Pipe Line (Condenser→Receiver--Dryer) Fitting Nut
14
10.5
--
High Pressure Pipe Line (Receiver--Dryer→Evaporator) Fitting Nut
14
10.5
--
High Pressure Pipe Line(Receiver--Dryer→Evaporator) Clamp Nut
5
--
44
Low Pressure Pipe Line (Evaporator→Compressor) Fitting Nut
14
10.5
--
Low Pressure Pipe Line (Evaporator→Compressor) Clamp Nut
5
--
44
Low Pressure Pipe Line(Evaporator→Compressor) Compressor Bolt
23
17
--
Dual Cut Switch
13
--
11 5
Receive--Dryer Bracket--to--Body Bolts
5
--
44
Receive--Dryer Bracket Bolt
5
--
44
Expansion Valve Coupling (Receiver--Dryer→Expansion Valve)
17
13
--
Expansion Valve Coupling (Expansion Valve→Evaporator)
22
16
--
Compressor Shaft Bolt
13
--
11 5
Condenser Mounting Nuts
4
--
36
Page 884 of 1184
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
–
Page 907 of 1184
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. . . . . . . . . . . . . . . . . .
Page 909 of 1184
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