DAEWOO MATIZ 2003 Service Repair Manual

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–10 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
Insufficient Cooling Diagnosis (Cont’d)
Step Action Value(s) Yes No
20
1. Turn the ignition switch OFF.
2. Turn the A/C switch to the OFF position.
3. Attempt to turn the clutch driver (not the pulley).
Can you turn the clutch driver freely by hand?
–
Go to Step 23Go to Step 21
21
1. Recover the A/C system refrigerant.
2. Replace the A/C compressor.
3. Evacuate and recharge the A/C system.
Is the repair complete?
–
System OK
–
221. Add the refrigerant R–134a.
Does the cooling performance improve?–System OKGo to Step 23
23
1. Recover the A/C system refrigerant.
2. Replace the compressor.
3. Evacuate and recharge the A/C system.
4. Check the A/C system for leaks.
Is the repair complete?
–
System OK
–

MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B–11
DAEWOO M-150 BL2
SYMPTOM DIAGNOSIS
PRESSURE TEST CHART (R-134A SYSTEM)
Condition Related Symptons Probable Cause Correction



Discharge (high)
Pressure
Abnormally High


After stopping the com-
pressor, the pressure
drops quickly, then falls
gradually.


There is air in the system.


Recover, evacuate and
recharge the system with
the specified amount of
refrigerant.








The condenser is
excessively hot.




There is excessive
refrigerant in the system.




Recover, evacuate and
recharge the system with
the specified amount of
refrigerant.
Reduced or no air flow
through the condenser. The condenser or the
radiator fins are clogged. Clean the condenser or
the radiator fins.









The condenser or the
radiator fan is not working
properly.



Check the voltage and
the fan rpm.
Check the fan direction.



Line to the condenser is
excessively hot.
Restricted flow of
refrigerant in the system
Locate and repair the
restriction.



Discharge
Pressure
Abnormally Low


The condenser is not
hot.


Insufficient refrigerant in the
system.


Check the system for a
leak.
Charge the system.




High and low pressures
are balanced soon after
stopping the

Faulty compressor.

Repair or replace the
compressor.




stopping the
compressor. Low side
pressure is higher than
normal.






The outlet of the
expansion valve is not
Faulty expansion valve.
Replace the expansion
valve.




frosted, low pressure
gauge indicates
vacuum.
Moisture in the system.
Recover, evacuate, and
recharge the system.



Suction (low)
Pressure
Abnormally Low


Condenser is not hot.


Insufficient refrigerant in the
system.


Repair the leaks.
Recover, evacuate, and
recharge the system.




The expansion valve is
not frosted and the low
pressure line is not

Frozen expansion valve.

Replace the expansion
valve.




pressure line is not
cold. Low pressure
gauge indicates a
vacuum.
Faulty expansion valve.









Discharge temperature
is low and the air flow
from the vents is
restricted.




The evaporator is frozen.




Clear the restricted
evaporator case drain.




The expansion valve is
frosted.

The expansion valve is
clogged.

Clean or replace the
expansion valve.




The receiver/dryer
outlet is cool and the
inlet is warm.

The receiver/dryer is
clogged.

Replace the
receiver/dryer.

7B–12 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
Pressure Test Chart (R-134a System) (Cont’d)
Condition Related Symptons Probable Cause Correction

Suction Pressure
Abnormally High
Low pressure hose and
check joint are cooler
The expansion valve is
opened for too long.
Replace the expansion
valve.

Abnormally High

check joint are cooler
than the temperature
around the evaporator.

opened for too long.

valve.








Suction pressure is
lowered when the con-
denser is cooled by
water.



There is excessive
refrigerant in the system.



Recover, evacuate, and
recharge the system.
Suction and Dis-
charge Pressure Reduced airflow
through the condenser. The condenser or the
radiator fins are clogged. Clean the condenser and
the radiator.




Abnormally High







The radiator cooling fans
are not working properly.




Check the voltage and
the radiator cooling fan
rpm.
Check the fan direction.




Condenser is
excessively hot.

There is excessive
refrigerant in the system.

Recover, evacuate, and
recharge the system.



Suction and Dis-
charge Pressure
Abnormally Low


Low pressure hose and
metal end areas are
cooler than the
evaporator.


Clogged or kinked low
pressure hose.


Repair or replace the low
pressure hose.








Temperature around the
expansion valve is low
compared to that
around the
receiver/drier.



The high pressure line is
clogged.



Repair or replace the
high pressure line.


Refrigerant Leaks

The compressor clutch
is dirty.

The compressor shaft seal
is leaking.

Repair or replace the
compressor.
The compressor bolts
are dirty. Leaking around a
compressor housing bolt. Tighten the bolt(s) or
replace the compressor.



The compressor gasket
is wet with oil.

The compressor gasket is
leaking.

Repair or replace the
compressor.



–

Poor tightening in the
system.
Retighten the connection
(coupling, bolt etc.)
– O–ring is faulty. Replace the O–ring.

MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B–13
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
GENERAL A/C SYSTEM
SERVICE PROCEDURES
O-RING REPLACEMENT
Important: Even though O-rings may look identical, it is
extremely important that only recommended service re-
placement air conditioning O-rings be used, or exces-
sive leakage of refrigerant may occur.
Important: Always slip the O-ring onto the flange tube
to ensure proper locating and sealing.
Install new DAEWOO-approved service replacement air
conditioning O-rings whenever a joint or a fitting is disas-
sembled, except when the O-rings are provided on new
components.
When replacing O-rings on an air conditioning compo-
nent or a joint connection, the fitting design should be
identified to ensure installation of the correct air condi-
tioning service replacement O-ring.
Before installation, verify that both O-rings and fittings
have not been nicked or deformed. Deformed or nicked
parts must be replaced. Failure to use the proper service
replacement parts and procedures may result in exces-
sive refrigerant leakage.
HANDLING REFRIGERANT
Caution: Always work in a well-ventilated area and
avoid breathing any refrigerant fumes. If you have
difficulty breathing, seek medical attention immedi-
ately. If refrigerant comes in contact with any part of
your body, flush the exposed area with water. If a
rash or pain develops, seek medical attention.
Air conditioning systems contain refrigerant. This is a
chemical mixture which requires special handling proce-
dures to avoid personal injury.
Always wear goggles and wrap a clean cloth around the
fittings, the valves and the connections when performing
work that involves opening the refrigerant system. Do
not weld or steam clean on or near any vehicle-installed
air conditioning lines or components.
All refrigerant drums are shipped with a heavy metal
screw cap. The purpose of the cap is to protect the valve
and the safety plug from damage. It is good practice to
replace the cap after each use of the drum.
If it is necessary to transport or carry any container of
refrigerant in a vehicle, do not carry it in the passenger
compartment.
HANDLING OF REFRIGERANT LINES
AND FITTINGS
Notice: Using too low or too high torque when tightening
a fitting can result in loose joints or deformed joint parts.
Both conditions can result in refrigerant leakage.
Keep all metal tubing lines free of dents or kinks. Any
line restrictions will cause the loss of system capacity.
Never bend a flexible hose line to a radius of less than
four times the diameter of the hose.
Never allow a flexible hose line to come near the ex-
haust manifold.
Inspect flexible hose lines regularly for leaks or brittle-
ness.
Replace flexible hose lines with new lines if you find
signs of deterioration or leaking.
Discharge the refrigeration system of all refrigerant
before disconnecting any fitting in the refrigeration
system.
Proceed very cautiously regardless of the gauge
readings.
Open the fittings very slowly.
Keep your face and your hands away from the fitting
so that you will not be injured if there happens to be
liquid refrigerant in the line.
If you notice pressure when you loosen a fitting, allow
the pressure to bleed off as described under “Dis-
charging, Adding Oil, Evacuating and Charging Pro-
cedures for A/C System” in this section.
Cap or tape any refrigerant line immediately after it is
opened. This will prevent the entrance of moisture
and dirt, which can cause internal compressor wear
or plugged lines in the condenser, the evaporator
core, the expansion valve or the compressor inlet
screens.
Important: Use two proper wrenches to connect the O-
ring fittings.
Back up the opposing fitting to prevent distortion of
the connecting lines or the components.
Back up both the swaged fitting on the flexible hose
connections and the coupling to which it is attached
with two wrenches to prevent turning the fitting and
damaging the ground seat.
Keep the O-rings and the seats in perfect condition. A
burr or a piece of dirt may cause a refrigerant leak.
Dip new O-rings in clean PAG refrigerant oil before
installation.

7B–14 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
MAINTAINING CHEMICAL STABILITY
IN THE REFRIGERATION SYSTEM
The efficient operation and life of the air conditioning
system is dependent upon the chemical stability of the
refrigeration system. When foreign materials, such as
dirt, air, or moisture, contaminate the refrigeration sys-
tem, they will change the stability of the refrigerant and
the PAG compressor oil. They will also affect the pres-
sure-temperature relationship, reduce efficient opera-
tion, and can possibly cause interior corrosion and
abnormal wear of moving parts.
Observe the following practices to ensure chemical sta-
bility in the system:
Wipe away dirt or oil at and near any connection be-
fore opening that connection. This will reduce the
chance of dirt entering the system.
Cap, plug, or tape both sides of a connection as soon
as possible after opening the connection. This will
prevent the entry of dirt, foreign material, and mois-
ture.
Keep all tools clean and dry, including the manifold
gauge set and all replacement parts.
Use a clean and dry transfer device and container to
add PAG refrigerant oil. This will ensure that the oil
remains as moisture-free as possible. Refer to “Dis-
charging, Adding Oil, Evacuating and Charging Pro-
cedures for A/C System” in this section.
Have everything you need ready to allow you to per-
form all operations quickly when opening an A/C sys-
tem. Do not leave the A/C system open any longer
than necessary.
Evacuate and recharge any A/C system that has
been opened. Refer to “Discharging, Adding Oil, Eva-
cuating and Charging Procedures for A/C System” in
this section for the instructions to perform this proce-
dure properly.
All service parts are dehydrated and sealed before ship-
ping. They should remain sealed until just before making
connections. All the parts should be at room tempera-
ture before uncapping. This prevents condensation of
moisture from the air from entering the system. Reseal
all parts as soon as possible if the caps have been re-
moved but the connections cannot be made promptly.
DISCHARGING, ADDING OIL,
EVACUATING, AND CHARGING
PROCEDURES FOR A/C SYSTEMS
Caution: Use only refillable refrigerant tanks that
are authorized for the charging station being used.
The use of other tanks may cause personal injury or
void the warranty. Refer to the manufacturer’s in-
structions for the charging station.Caution: To avoid personal injury, always wear
goggles and gloves when performing work that in-
volves opening the refrigeration system.
A charging station discharges, evacuates, and re-
charges an air conditioning system with one hook-up.
Filtering during the recovery cycle together with filtering
during the evacuation cycle ensures a supply of clean,
dry refrigerant for A/C system charging.
Notice:
Never use the R-134a charging station on a system
charged with R-12. The refrigerants and the oils are
not compatible and must never be mixed in even the
smallest amount. Mixing refrigerant residue will dam-
age the equipment.
Never use adapters which convert from one size fit-
ting to another. This will allow contamination which
may cause system failure.
Charging Station Setup and Maintenance
Refer to the manufacturer’s instructions for all initial set-
up procedures and all maintenance procedures. There
are many charging stations available. All perform the
various tasks required to discharge the system and re-
cover refrigerant, evacuate the system, add a measured
amount of oil, and recharge an air conditioning system
with a measured amount of refrigerant.
Control Panel Functions
A charging station will have controls and indicators to al-
low the operator to control and monitor the operation in
progress. Refer to the manufacturer’s instructions for
details. These can be expected to include:
1. Main Power Switch: The main power switch supplies
electrical power to the control panel.
2. Display: The display shows the time programmed for
vacuum and the weight of the refrigerant pro-
grammed for recharging. Refer to the manufacturer’s
instructions for detailed programming information.
3. Low Side Manifold Gauge: This gauge shows the
system’s low side pressure.
4. High Side Manifold Gauge: This gauge shows the
system’s high side pressure.
5. Controls: This will contain the controls that control
various operating functions.
6. Low Side Valve: This valve connects the low side of
the A/C system to the unit.
7. Moisture Indicator: This indicator shows if the refrig-
erant is wet or dry.
8. High Side Valve: This valve connects the high side of
the A/C system to the unit.

MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B–15
DAEWOO M-150 BL2
Refrigerant Recovery
Important: Use only a refrigerant tank that is designed
for the charging station in use. The unit’s overfill limita-
tion mechanism is calibrated specifically for use with this
tank. The tank’s valves are also specifically for this unit.
1. Attach the high side hose with the quick disconnect
coupler to the high side fitting of the vehicle’s A/C
system.
2. Open the coupler valve after attachment.
3. Attach the low side hose with the quick disconnect
coupler to the low side fitting of the vehicle’s A/C
system.
4. Open the coupler valve after attachment.
5. Check the high side and the low side gauges on the
unit’s control panel in order to ensure that the A/C
system has pressure. If there is no pressure, there
is no refrigerant in the system to recover.
Important: If there is no refrigerant in the system, do
not continue with the recovery operation. This will draw
air into the recovery tank.
6. Open both the high side and the low side valves.
7. Open the gas and the liquid valves on the tank.
8. Drain any oil that may be in the oil separator.
9. Close the oil drain valve.
10. Plug the unit into the proper voltage outlet.
11. Turn on the main power switch.
Notice: Never reuse refrigerant oil. Damage to the A/C
system may result. Dispose of the refrigerant oil proper-
ly.
12. Begin the recovery process. Refer to the manufac-
turer’s instructions for the charging station in use.
Important: Some A/C system PAG lubricating oil may
be removed with the refrigerant during recovery. The
amount of oil removed varies. A charging station sepa-
rates the oil from the refrigerant and allows a means of
determining how much oil was removed. Replace the
same amount of oil when you recharge the system. Re-
fer to the manufacturer’s instructions for the charging
station in use.
13. Wait 5 minutes. Check the control panel low side
gauge. If the A/C has maintained vacuum, the re-
covery is complete.
14. There is more refrigerant in the system if the low
side gauge pressure rises above zero. Recover the
additional refrigerant. Repeat this step until the sys-
tem maintains vacuum for two minutes.
Important: If the control indicator shows that the refrig-
erant tank is full during the recovery process and the unit
shuts off, install an empty unit tank to store the refriger-
ant needed for steps later in the procedure. Do not use
any other type of tank.
Evacuation
The unit tank must contain a sufficient amount of R-134a
refrigerant for charging. Check the amount of refrigerant
in the tank. If there is less than 3.6 kg (8 pounds) of re-
frigerant, add new refrigerant to the tank. Refer to the
manufacturer’s instructions for adding refrigerant.
1. Verify that the high side and the low side hoses are
connected to the A/C system. Open both the high
side and the low side valves on the unit’s control pan-
el.
2. Open both the gas and the liquid valves on the tank.
Important: Refer to the manufacturer’s instructions for
the charging station in use. It is necessary to evacuate
the system before recharging it with new or recycled re-
frigerant.
3. Start the vacuum pump and begin the evacuation
process. Non-condensable gases (mostly air) are au-
tomatically vented from the tank during the recycling
process. You may hear the pressure being released.
4. Check for leaks in the system. Refer to the manufac-
turer’s instructions for the charging station in use.
Important:
Change the vacuum pump oil frequently. Refer to the
manufacturer’s instructions for the charging station in
use.
A/C System Oil Charge Replenishing
Any oil removed from the A/C system during the recov-
ery process must be replenished at this time.
1. Use the correct graduated bottle of polyalkaline glycol
(PAG) oil for the R-134a system.
Important:
Keep the oil bottles tightly capped at all times to pro-
tect the oil from moisture and contamination.
Never open the oil injection valve while there is posi-
tive pressure in the A/C system. This will result in oil
blow-back through the bottle vent. You must have
A/C system vacuum for this operation.
Never let the oil level drop below the pick-up tube
while charging or replenishing the system. This will
allow air into the A/C system.
2. Refer to the manufacturer’s instructions for the charg-
ing station in use. Add the proper amount of PAG oil
to the system.
3. Close the valve when the required oil charge has
been pulled into the system.
Charging
Important: Evacuate the air conditioning system before
charging.
1. Close the low side valve on the control panel.
2. Open the high side valve on the control panel.

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.

MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B–17
DAEWOO M-150 BL2
SERVICEABLE
COMPONENTS
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
CONTROL ASSEMBLY AND
CONTROL CABLES
To remove the control assembly and control cables, re-
fer to Section 7A, Heating and Ventilation System (With-
out Air Conditioning).
BLOWER MOTOR AND COOLING
HOSE
To remove the blower motor and cooling hose, refer to
Section 7A, Heating and Ventilation System (Without Air
Conditioning).
BLOWER RESISTOR
To remove the blower resistor, refer to Section 7A, Heat-
ing and Ventilation System (Without Air Conditioning).
BLOWER MOTOR SWITCH
To remove the blower motor switch, refer to Section 7A,
Heating and Ventilation System (Without Air Condition-
ing).

7B–18 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
D108B501
A/C PUSH KNOB
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the instrument cluster housing trim panel.
Refer to Section 9E, Instrumentation/Driver Informa-
tion.
2. Remove the A/C push knob.
Disconnect the temperature control cable from the
heater module (1).
Disconnect the mode control cable from the heater
module (2).
D108B502
Remove the control assembly retaining screws (3).
Pull out the control assembly.
Remove the A/C push knob by pushing the knob
lock (4).
Disconnect the A/C push knob electrical connector
(5).
D108A506
Installation Procedure
1. Install the A/C push knob to the control assembly.
2. Connect the A/C push knob electrical connector.
3. Install the control assembly with the screws.
4. Connect the mode control cable to the heater mod-
ule.
5. Connect the temperature control cable to the heater
module.
6. Install the instrument cluster housing trim panel. Re-
fer to Section 9E, Instrumentation / Driver Informa-
tion.
D18B503A
RECEIVER DRYER AND DUAL CUT
SWITCH
Removal Procedure
1. Recover the refrigerant. Refer to “Discharging, Add-
ing Oil, Evaculating, and Charging Procedures for
A/C System” in this section.
2. Remove the front bumper fascia. Refer to Section
9O, Bumpers and Fascias.
3. Remove the receiver dryer.
Disconnect the dual cut switch connector (1).
Remove the receiver dryer flange nuts (2).
Remove the bracket bolt (3).
Discard the O–ring (4).