Engine DAEWOO MATIZ 2003 Service Service Manual

ENGINE COOLING 1D–11
DAEWOO M-150 BL2
D102D505
Installation Procedure
1. Install the surge tank to the vehicle.
Install the surge tank with pressing down (1).
Connect the overflow hoses to the surge tank (2).
2. Secure the overflow hoses to the surge tank with the
hose clamps.
3. Fill the surge tank with coolant to the MAX mark.
D102D506
ELECTRIC COOLING FAN
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the electric cooling fan assembly.
Disconnect the cooling fan electrical connector (1).
Remove the bolts (2).
Remove the electric cooling fan assembly (3).
3.5–4.5 Nm
D12D507A
Installation Procedure
1. Install the electric cooling fan assembly with the bolts.
Tighten
Tighten the bolts to 3.5–4.5 Nm (31–40 lb-in).
2. Connect the cooling fan electrical connector.
3. Connect the negative battery cable.
D12D5081
RADIATOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the lower radiator hose and drain the en-
gine cooling system. Refer to “Draining and Refilling
the Cooling System” in this section.
3. Disconnect the upper radiator hose and the surge
tank hose.
Loosen the upper radiator hose clamp and discon-
nect the upper radiator hose (1).
Loosen the surge tank hose clamp and disconnect
the surge tank hose (2).

1D–12 ENGINE COOLING
DAEWOO M-150 BL2
D12D5091
4. Remove the electric cooling fan.
Refer to “Electric Cooling Fan” in this section.
5. Remove the radiator.
Remove the bolts (1).
Remove the radiator support brackets (2).
Remove the radiator (3).
6. Check the radiator for breaking, clog or other dam-
age.
Important: The radiator still contains a substantial
amount of coolant. Drain the remainder of the coolant
from the radiator into a drain pan.
D12D5101
Installation Procedure
1. Install the radiator with the mounting bolts (1) and the
support brackets (2).
Tighten
Tighten the support bracket bolts to 3.5–4.5 Nm
(31–40 lb-in).
2. Install the electric cooling fan.
Refer to “Electric Cooling Fan” in this section.
D12D5111
3. Connect the upper radiator hose to the radiator (1).
4. Connect the surge tank hose to the radiator (2).
5. Secure each hose with hose clamps.
6. Refill the engine cooling system. Refer to “Draining
and Refilling the Cooling System” in this section.
7. Connect the negative battery cable.
D102D512
THERMOSTAT (TYPICAL)
Removal Procedure
Caution: To prevent personal injury, do not remove
the surge tank cap while the engine and the radiator
are hot because the heat causes the system to re-
main under pressure. Scalding fluid and steam may
be blown out under pressure.
1. Remove air filter assembly. Refer to Section 1B,
SOHC Engine Mechanical.
2. Disconnect the lower radiator hose and drain the
coolant. Refer to “Drain and Refilling the Cooling Sys-
tem”
3. Disconnect the upper radiator hose.

ENGINE COOLING 1D–13
DAEWOO M-150 BL2
Loosen the hose clamp (1).
Disconnect the upper radiator hose (2).
D102D513
4. Remove the thermostat.
Remove the bolts (1).
Remove the thermostat housing (2).
Remove the thermostat with the gasket (3).
5. Check the gasket for crack or other damage.
6. Inspect the valve seat for foreign matter that could
prevent the valve from seating properly.
7. Inspect the thermostat for proper operation. Refer to
“Thermostat Test” in this section.
8–15 Nm
D12D514A
Installation Procedure
1. Install the thermostat with the bolts and the thermo-
stat housing.
Tighten
Tighten the mounting bolts to 8–15 Nm (71–130
lb-in).
2. Secure the upper radiator hose to the thermostat
housing with a hose clamp.
3. Refill the engine cooling system. Refer to “Draining
and Refilling the Cooling System” in this section.
MAA1D010
THERMOSTAT (EURO III)
Removal Procedure
Caution: To prevent personal injury, do not remove
the surge tank cap while the engine and the radiator
are hot because the heat causes the system to re-
main under pressure. Scalding fluid and steam may
be blown out under pressure.
1. Remove air filter assembly. Refer to Section 1B,
SOHC Engine Mechanical.
2. Disconnect the lower radiator hose and drain the
coolant. Refer to “Drain and Refilling the Cooling Sys-
tem”
3. Disconnect the upper radiator hose.

1D–14 ENGINE COOLING
DAEWOO M-150 BL2
MAA1D020
4. Remove the thermostat.
Remove the bolts.
Remove the thermostat housing.
Remove the thermostat with the gasket.
5. Check the gasket for crack or other damage.
6. Inspect the valve seat for foreign matter that could
prevent the valve from seating properly.
7. Inspect the thermostat for proper operation. Refer to
“Thermostat Test” in this section.
MAA1D011
Installation Procedure
1. Install the thermostat with the bolts and the thermo-
stat housing.
Tighten
Tighten the mounting bolts to 8–15 Nm (71–130
lb-in).
2. Secure the upper radiator hose to the thermostat
housing with a hose clamp.
3. Refill the engine cooling system. Refer to “Draining
and Refilling the Cooling System” in this section.
4. Install the air filter assembly. Refer to Section 1B,
SOHC Engine Mechanical.
D102D515
COOLANT TEMPERATURE SENSOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the lower radiator hose and drain the
coolant. Refer to “Draining and Refilling the Cooling
System” in this section.
3. Remove the coolant temperature sensor.
Disconnect the electrical connector (1).
Remove the coolant temperature sensor (2).
D12D516A
10 Nm
Installation Procedure
1. Install the coolant temperature sensor into the
threaded hole in the intake manifold.
Tighten
Tighten the coolant temperature sensor to 10 Nm
(89 lb-in).
Connect the electrical connector to the coolant
temperature sensor (1).
2. Connect the lower radiator hose and refill the coolant.
Refer to “Draining and refilling the cooling system” in
this section.
3. Connect the negative battery cable.

ENGINE COOLING 1D–15
DAEWOO M-150 BL2
D102D517
ENGINE COOLANT TEMPERATURE
SENSOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the lower radiator hose and drain the
coolant “Draining and Refilling the Cooling System” in
this section.
3. Remove the engine coolant temperature (ECT) sen-
sor.
Disconnect the electrical connector (1).
Remove the ECT sensor (2).
D12D518A
20 Nm
Installation Procedure
1. Install the ECT sensor.
Tighten
Tighten the ECT sensor to 20 Nm (15 lb-ft).
Connect the electrical connector to the ECT sen-
sor (1).
2. Connect the lower radiator hose and refill the coolant.
Refer to “Draining and Refilling the Cooling System”
in this section.
3. Connect the negative battery cable.
D102B533
COOLANT PUMP
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the lower radiator hose and drain the
coolant. Refer to “Draining and Refilling the Cooling
System” in this section.
3. Remove the timing belt. Refer to Section 1B, Engine
Mechanical.
4. Remove the rear timing belt cover.
Remove the bolts (1).
Remove the rear timing belt cover (2).
D102D519
5. Remove the coolant pump.
Remove the nuts (1).
Remove the bolts (2).
Remove the coolant pump (3).
Remove the gasket.
Notice: Remove the coolant pump as shown figure (a).

1D–16 ENGINE COOLING
DAEWOO M-150 BL2
9–12 Nm
9–12 Nm
D12D520A
D12D521A
Installation Procedure
1. Install the coolant pump with the new gasket.
Tighten
Tighten the bolts and the nuts to 9–12 Nm (80–106
lb-in) (a).
2. Install the rear timing belt cover.
Tighten
Tighten the bolts to 9–12 Nm (80–106 lb-in) (b).
3. Install the timing belt. Refer to Section 1B, Engine
Mechanical.
4. Connect the lower radiator hose and drain the cool-
ant. Refer to “Draining and Refilling the Cooling Sys-
tem” in this section.
5. Connect the negative battery cable.

ENGINE COOLING 1D–17
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescriptionUnitStandardLimit
Cooling
SystemCooling Type–Forced Water
Circulation
CoolantCoolant CapacityL/qt3.8/4.00
Thermostat Type–Pellet Type
Temperature(opened initially)°C(°F)82(180)
ThermostatTemperature(perfectly opened)°C(°F)95(203.4)
Temperature(perfectly closed)°C(°F)80(176.4)
Stroke(perfectly opened)mm(in.)8 (0.32)
Cooling Fan Type–Electric
Blade NumberEA6
Cooling Fan Diametermm(inch)300(11.8)
Electric CoolingTemperature At Low Speed ON°C(°F)93(199.8)Fan
Temperature At Low Speed OFF°C(°F)90(194.4)
Temperature At High Speed ON°C(°F)100(212.4)
Temperature At High Speed OFF°C(°F)97(207)
Surge TankOpen Pressure of The Pressure ValvekPa (psi)120–150
(17.4–21.8)
Surge Tank
Open Pressure of The Vacuum ValvekPa (psi)10 (1.5)
Water Pump Type–Centrifugal
Coolant PumpImpeller Diametermm(in.)60(2.36)
Impeller Blade NumberEA7
Radiator Type–Cross–Flow
Core Widthmm(in.)458(18.03)RadiatorCore Heightmm(in.)295(11.61)
Core Depth (Standard/Heavy Duty)mm(in.)16/27(0.63/1.06)
Resistance
(Coolant Temperature 50°C(122.4°F))Ω185.2
Coolant
TemperatureResistance
(Coolant Temperature 85°C(185.4°F))Ω49.2
SensorResistance
(Coolant Temperature 105°C(221.4°F))Ω27.5
Engine CoolantResistance
(Coolant Temperature 20°C(68.4°F))Ω3,520
Temperature
SensorResistance
(Coolant Temperature 80°C(176.4°F))Ω332

1D–18 ENGINE COOLING
DAEWOO M-150 BL2
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNmLb-FtLb-In
Engine Coolant Temperature Sensor10–89
Coolant Temperature Sensor2015–
Coolant Pipe Bolt8 – 15–71 – 130
Electric Cooling Fan Motor Nut3.0 – 3.2–27 – 28
Electric Cooling Fan Assembly Bolt3.5 – 4.5–31 – 40
Distributor Case Bolt/Nut8 – 12–71 – 106
Radiator Mounting Bracket Bolt3.5 – 4.5–31 – 40
Thermostat Housing Bolt8 – 15–71 – 130
Water Inlet Cap Bolt8 – 12–71 – 106
Coolant Pump Bolt/Nut9–12–80 – 106
Coolant Pump Stud Bolt9–12–80 – 106

DAEWOO M-150 BL2
SECTION 1E
ENGINE ELECTRICAL
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 1E-2. . . . . . . . . . . . . . . . . .
Battery 1E-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ratings 1E-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reserve Capacity 1E-2. . . . . . . . . . . . . . . . . . . . . . . . .
Cold Cranking Amperage 1E-2. . . . . . . . . . . . . . . . . . .
Built-In Hydrometer 1E-2. . . . . . . . . . . . . . . . . . . . . . . .
Charging Procedure 1E-3. . . . . . . . . . . . . . . . . . . . . . .
Charging Time Required 1E-3. . . . . . . . . . . . . . . . . . . .
Charging a Completely Discharged Battery
(Off the Vehicle) 1E-3. . . . . . . . . . . . . . . . . . . . . . . . .
Jump Starting Procedure 1E-3. . . . . . . . . . . . . . . . . . .
Generator 1E-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging System 1E-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Starter 1E-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting System 1E-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor 1E-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Coil 1E-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug 1E-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locator 1E-6. . . . . . . . . . . . . . . . . . . . . . . .
Starting System 1E-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging System (A-type: MANDO) 1E-7. . . . . . . . . .
Charging System (B-type: DAC) 1E-8. . . . . . . . . . . . .
Ignition System 1E-9. . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedure 1E-10. . . . . .
Ignition System 1E-10. . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Load Test 1E-12. . . . . . . . . . . . . . . . . . . . . . . . Generator Output Test 1E-12. . . . . . . . . . . . . . . . . . . .
Generator System Check 1E-13. . . . . . . . . . . . . . . . . .
Repair Instructions 1E-14. . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 1E-14. . . . . . . . . . . . . . . . . . . . . . . . .
Starter 1E-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator 1E-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery 1E-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor 1E-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Coil 1E-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 1E-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Motor 1E-19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator (A-type: MANDO) 1E-24. . . . . . . . . . . . . . .
Generator (B-type: DAC) 1E-29. . . . . . . . . . . . . . . . . .
Distributor Assembly 1E-34. . . . . . . . . . . . . . . . . . . . . .
Schematic and Routing Diagrams 1E-37. . . . . . . . . .
Starting System 1E-37. . . . . . . . . . . . . . . . . . . . . . . . . .
Charging System 1E-38. . . . . . . . . . . . . . . . . . . . . . . . .
Ignition System Circuit – Tipical 1E-39. . . . . . . . . . . .
Ignition System Circuit – Euro III 1E-40. . . . . . . . . . .
Specifications 1E-41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Specifications 1E-41. . . . . . . . . . . . . . . . . . . . .
Generator Specifications 1E-41. . . . . . . . . . . . . . . . . .
Ignition System Specifications 1E-41. . . . . . . . . . . . . .
Battery Specifications 1E-41. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 1E-42. . . . . . . . . .

1E–2 ENGINE ELECTRICAL
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
BATTERY
The battery has three major functions in the electrical
system. First, the battery provides a source of energy
for cranking the engine. Second, the battery acts as a
voltage stabilizer for the electrical system. Finally, the
battery can, for a limited time, provide energy when the
electrical demand exceeds the output of the generator.
The sealed battery is standard on all cars. There are no
vent plugs in the cover. The battery is completely
sealed, except for two small vent holes in the sides.
These vent holes allow the small amount of gas pro-
duced in the battery to escape.
The sealed battery has the following advantages over
conventional batteries:

No water need be added for the life of the battery.

It is protected against overcharge. If too much volt-
age is applied to the battery, it will not accept as much
current as a conventional battery. In a conventional
battery, the excess voltage will still try to charge the
battery, leading to gassing, which causes liquid loss.

It is not as liable to self-discharge as a conventional
battery. This is particularly important when a battery
is left standing for long periods of time.

It has more power available in a lighter and a smaller
case.
RATINGS
A battery has two ratings: (1) A reserve capacity rating
designated at 27C (81F), which is the time a fully
charged battery will provide 25 amperes current flow at
or above 10.5 volts; (2) A cold cranking amp rating de-
termined under testing at -18C (0F), which indicates
the cranking load capacity.
RESERVE CAPACITY
The reserve capacity is the maximum length of time it is
possible to travel at night with the minimum electrical
load and no generator output. Expressed in minutes,
Reserve Capacity (or RC rating) is the time required for
a fully charged battery, at a temperature of 27C (81F)
and being discharged at a current of 25 amperes, to
reach a terminal voltage of 10.5 volts.
COLD CRANKING AMPERAGE
The cold cranking amperage test is expressed at a bat-
tery temperature of -18C (0F). The current rating is
the minimum amperage, which must be maintained by
the battery for 30 seconds at the specified temperature,
while meeting a minimum voltage requirement of
7.2 volts. This rating is a measure of cold cranking ca-
pacity.The battery is not designed to last indefinitely. However,
with proper care, the battery will provide many years of
service.
If the battery tests well, but fails to perform satisfactorily
in service for no apparent reason, the following factors
may point to the cause of the trouble:

Vehicle accessories are left on overnight.

Slow average driving speeds are used for short peri-
ods.

The vehicle’s electrical load is more than the genera-
tor output, particularly with the addition of aftermarket
equipment.

Defects in the charging system, such as electrical
shorts, a slipping generator belt, a faulty generator, or
a faulty voltage regulator.

Battery abuse, including failure to keep the battery
cable terminals clean and tight, or a loose battery
hold-down.

Mechanical problems in the electrical system, such
as shorted or pinched wires.
BUILT-IN HYDROMETER
The sealed battery has a built-in, temperature-compen-
sated hydrometer in the top of the battery. This hydrom-
eter is to be used with the following diagnostic
procedure:
1. When observing the hydrometer, make sure that the
battery has a clean top.
2. Under normal operation, two indications can be ob-
served:

GREEN DOT VISIBLE – Any green appearance is
interpreted as a “green dot,” meaning the battery is
ready for testing.

DARK GREEN DOT IS NOT VISIBLE – If there is
a cranking complaint, the battery should be tested.
The charging and electrical systems should also
be checked at this time.
3. Occasionally, a third condition may appear:

CLEAR OR BRIGHT YELLOW – This means the
fluid level is below the bottom of the hydrometer.
This may have been caused by excessive or pro-
longed charging, a broken case, excessive tipping,
or normal battery wear. Finding a battery in this
condition may indicate high charging by a faulty
charging system. Therefore, the charging and the
electrical systems may need to be checked if a
cranking complaint exists. If the cranking com-
plaint is caused by the battery, replace the battery.