DAEWOO MATIZ 2003 Service Repair Manual

HEATING AND VENTILATION SYSTEM 7A–11
DAEWOO M-150 BL2
IMPROPER AIR DELIVERY OR NO MODE SHIFT
This procedure provides a test of all functions of the heater/defroster unit.
1. Warm up the vehicle.
2. Keep the engine running.
3. Perform the tests outlined in the table below and look for the results indicated.
CONTROL SETTINGS CORRECT RESULTS



MODE
KNOB



TEMP.
CONTROL



BLOWER
MOTOR
SWITCH


BLOWER
SPEED



POWER
VENT
OUTLET


FLOOR
OUTLET



DEFROST
OUTLET



SIDE
WINDOW
OUTLET
Vent Cold Off Off No
Airflow No
Airflow No
Airflow No
Airflow



Vent

Cold

4

High

Ambient
Airflow
No
Airflow
No
Airflow
No
Airflow



Floor

Cold to Hot

4

High

No
Airflow
Cold to Hot
Airflow

Minimum
Cold to Hot
Airflow

Minimum
Cold to Hot
Airflow




Defroster


Cold to Hot


4


High



No
Airflow



Minimum
Cold to Hot
Airflow



Cold to Hot
Airflow



Minimum
Cold to Hot
Airflow
If any of these settings does not produce the correct results, perform the following diagnostic procedure.

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





Examine the affected door in the unit for proper
cable attachment.

Check the cable connection to the door.

Check that the cable sheath is properly re-
tained.
Is the cable connected properly?




–




Go to Step 4




Go to Step 3
3

Repair as necessary.
Is the repair complete?
–

System OK

–





4





1. Disconnect the cable at the door.
2. Check the range of the door travel and the effort
required to move it.
Does the door move freely through its entire range
of travel so that it can close at both ends of the
range?




–




Go to Step 5




Go to Step 3

5


Check the travel of the Bowden cable by turning the
control knob.
Is the cable travel OK?
–

Go to Step 6

Go to Step 7



6




1. Reinstall the cable.
2. Recheck the system using the “Control
Settings/Correct Results” tests in this procedure.
Does the system perform properly?




–



System OK



Go to Step 9



7



1. Check the cable attachment at the control.
2. Check for a broken control.
Is there a problem with the cable attachment or the
control?


–


Go to Step 8


Go to Step 9

7A–12 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
Improper Air Delivery or No Mode Shift (Cont’d)
Step Action Value(s) Yes No

8


Repair the cable attachment or control as necessary.
Is the repair complete?
–

System OK

Go to Step 9

9


Recheck the system using the “Control
Settings/Correct Results” tests in this procedure.
Is the repair complete?
–

System OK

Go to Step 10



10




Check for airflow from the defroster or the vent
outlets.
Is there high airflow from the defroster or the vent
outlets?



–



Go to Step 11



Go to Step 12

11


Adjust the heater door at the floor and the vent door
to get the proper airflow.
Is the repair complete?
–

System OK

–

12

Switch the mode knob to defrost.
Is the defroster airflow OK?
–

Go to Step 13

Go to Step 14




13




1. Remove the heater outlet.
2. Check the heater outlet for obstructions.
3. Remove any obstructions in the heater outlet.
Is the repair complete?



–



System OK




–

14

Check the blower speeds for change in the airflow.
Does the blower speed increase as the control is
turned from 1 to 4?
–
Go to Step 15

Go to ‘‘Blower
Electrical’’


15



1. Check for obstructions in the system at the
blower inlet.
2. Remove any obstructions at the blower inlet.
Is the repair complete?

–


System OK



Go to Step 16




16





1. Set the blower on 4.
2. Rotate the temperature control from full hot to full
cold.
3. Listen for an airflow change.
Did the airflow change?





–




Go to Step 17




Go to Step 18



17



1. Check the temperature door adjustment, the
cables, the linkage, and the control.
2. Adjust the temperature control to full hot.
Is the repair complete?


–


System OK



–




18




1. Check the system for any obstruction between
the blower and the system outlets.
2. Remove any obstruction between the blower and
the system outlets.
Is the repair complete?



–



System OK




–

HEATING AND VENTILATION SYSTEM 7A–13
DAEWOO M-150 BL2
TOO MUCH HEAT
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


Set the mode switch to the floor position.
Is there too much heat when the mode switch is in
the floor position?
–

Go to Step 3

Go to Step 9
3

Check for defroster bleed.
Is there objectionable defroster bleed?
–

Go to Step 4

Go to Step 5



4




1. Check the door travel, the cables, the controls,
and the linkage for the heater and the defroster.
2. Adjust or repair, as required.
Is the repair complete?



–



System OK




–







5







1. In vehicles equipped with A/C, set the A/C switch
OFF.
2. In all vehicles, set the blower speed to 4.
3. Set the temperature to full hot.
4. Turn the ignition switch to ON.
5. Check for airflow from the floor outlets.
6. Check the floor outlet attachment.
Is the airflow high?







–






Go to Step 7






Go to Step 8



6




Check for a change in the airflow at different blower
speeds.
Does the airflow change as the setting for the
blower-speed switch is changed?



–



System OK




Go to ‘‘Blower
Electrical’’




7




1. Check the temperature door travel, the cables,
and the linkage.
2. Adjust to full cold.
3. Check for full hot.
Is the repair complete?



–



System OK




–

8


Adjust or repair the floor/defroster and/or the vent/
floor mode.
Is the repair complete?
–

System OK

–


9



Set the mode switch to the vent position.
In the vent position, is the problem objectionable
bleed?

–


Go to Step 10


Go to Step 15



10



1. Check the system case for leaks.
2. Check the floor outlet attachment.
Are any problems found?


–


Go to Step 11


Go to Step 12

11

Repair the system case or the floor outlet attach-
ment as required.
Is the repair complete?
–
System OK

Go to Step 12




12




1. Turn the ignition switch OFF.
2. Turn the temperature control knob to full hot, then
rapidly to full cold.
Do you hear the door slam just before you reached
the end of the control travel?



–



Go to Step 13



Go to Step 14
13

Adjust the vent door to vent more.
Is the repair complete?
–

System OK

–

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).