width DAEWOO MATIZ 2003 Service Repair Manual

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

ENGINE CONTROLS 1F–5
DAEWOO M-150 BL2
fuel is delivered under one of several conditions, called
“modes.’’
Starting Mode
When the ignition is turned ON, the ECM turns the fuel
pump relay on for 2 seconds. The fuel pump then builds
fuel pressure. The ECM also checks the Engine Coolant
Temperature (ECT) sensor and the Throttle Position
(TP) sensor and determines the proper air/fuel ratio for
starting the engine. The ECM controls the amount of
fuel delivered in the starting mode by changing how long
the fuel injector is turned on and off. This is done by
“pulsing’’ the fuel injectors for very short times.
Run Mode
The run mode has two conditions called “open loop’’ and
“closed loop.’’
Open Loop
When the engine is first started and it is above 400 rpm,
the system goes into “open loop’’ operation. In “open
loop,’’ the ECM ignores the signal from the O2S and cal-
culates the air/fuel ratio based on inputs from the ECT
sensor and the MAP sensor. The ECM stays in ”open
loop” until the following conditions are met:

The O2S has a varying voltage output, showing that it
is hot enough to operate properly.

The ECT sensor is above a specified temperature.

A specific amount of time has elapsed after starting
the engine.
Closed Loop
The specific values for the above conditions vary with
different engines and are stored in the Electronically
Erasable Programmable Read-Only Memory (EE-
PROM). When these conditions are met, the system
goes into “closed loop” operation. In “closed loop,” the
ECM calculates the air/fuel ratio (fuel injector on-time)
based on the signals from the oxygen sensors. This al-
lows the air/fuel ratio to stay very close to 14.7 to 1.
Acceleration Mode
The ECM responds to rapid changes in throttle position
and airflow and provides extra fuel.
Deceleration Mode
The ECM responds to changes in throttle position and
airflow and reduces the amount of fuel. When decelera-
tion is very fast, the ECM can cut off fuel completely for
short periods of time.
Battery Voltage Correction Mode
When battery voltage is low, the ECM can compensate
for a weak spark delivered by the ignition module by us-
ing the following methods:

Increasing the fuel injector pulse width.

Increasing the idle speed rpm.

Increasing the ignition dwell time.
Fuel Cut-Off Mode
No fuel is delivered by the fuel injectors when the ignition
is off. This prevents dieseling or engine run-on. Also, the
fuel is not delivered if there are no reference pulses re-
ceived from the CKP sensor. This prevents flooding.
EVAPORATIVE EMISSION CONTROL
SYSTEM OPERATION
The basic Evaporative Emission (EVAP) control system
used is the charcoal canister storage method. This
method transfers fuel vapor from the fuel tank to an acti-
vated carbon (charcoal) storage canister which holds
the vapors when the vehicle is not operating. When the
engine is running, the fuel vapor is purged from the car-
bon element by intake airflow and consumed in the nor-
mal combustion process.
Gasoline vapors from the fuel tank flow into the tube la-
beled TANK. These vapors are absorbed into the car-
bon. The canister is purged by Engine Control Module
(ECM) when the engine has been running for a specified
amount of time. Air is drawn into the canister and mixed
with the vapor. This mixture is then drawn into the intake
manifold.
The ECM supplies a ground to energize the controlled
charcoal canister purge solenoid valve. This valve is
Pulse Width Modulated (PWM) or turned on and off sev-
eral times a second. The controlled charcoal canister
purge PWM duty cycle varies according to operating
conditions determined by mass airflow, fuel trim, and in-
take air temperature.
Poor idle, stalling, and poor driveability can be caused
by the following conditions:

An inoperative controlled canister purge valve.

A damaged canister.

Hoses that are split, cracked, or not connected to the
proper tubes.
CONTROLLED CHARCOAL
CANISTER
The controlled charcoal canister is an emission control
device containing activated charcoal granules. The con-
trolled charcoal canister is used to store fuel vapors from
the fuel tank. Once certain conditions are met, the En-
gine Control Module (ECM) activates the controlled
charcoal canister purge solenoid, allowing the fuel va-
pors to be drawn into the engine cylinders and burned.
POSITIVE CRANKCASE
VENTILATION CONTROL SYSTEM
OPERATION
A Positive Crankcase Ventilation (PCV) control system
is used to provide complete use of the crankcase va-

1F–282 ENGINE CONTROLS
DAEWOO M-150 BL2
Intermittent (Cont’d)
StepActionValue(s)YesNo
9
1. Turn the ignition OFF.
2. Replace the ECM.
Is the repair complete?
–
System OK
–
10Does the vehicle stall while driving?–Go to Step 11Go to Step 12
11
Monitor the oxygen sensor and the injector base
pulse width with the scan tool.
Does the scan tool display a steady low voltage
(about 0 millivolts) for the oxygen sensor with the
control module commanding an injector base pulse
width of the value specified?
8 msGo to Step 9Go to Step 12
12
1. Check for an open diode across the A/C clutch
and for other open diodes.
2. Repair or replace any components as needed.
Is the repair complete?
–
System OK
–

2E – 2 TIRES AND WHEELS
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
TIRE
Tread
A part (that contacts) road surfaces directly is fixed on
the outside of carcass and breaker. It is a strong rubber
coat made of high anti–abrasion rubber. Its running per-
formance depends on is surface profile.
Breaker
A cord belt between tread and carcass prevents dam-
ages of inner code due to outer shock and vibration.
Carcass
This major part made by pilling code papers of strong
synthetic fiber forms a structure of tire. Since it main-
tains tire pressure and endures applied load and shock
to tire, it should have a high anti–fatigue characteristic.
Bead
A steel wire winding the ending part of carcass code,
coated with rubber film and wrapped with nylon cord pa-
pers. It fixes tire to a rim.
Tube
Tires used in mostly current vehicle are mostly tubeless
tires.
Side Wall
It is provided to improve the comfortable driving by pro-
tecting carcass and cushion movement.
Structure of Tubeless Tube
D16A001A
Nomenclature
D16A002A
175 Width (mm)

60Flatness ratio 60%
(Height/Width) ×100
175/60R13RRadial
77H13Rim diameter (= Tire I.D, Inch)
77Max. load index
HMax. speed symbol

2E –4 TIRES AND WHEELS
DAEWOO M-150 BL2
WHEELS
Wheels must be replaced if they are bent, dented, have
excessive lateral or radial runout, leak air through welds,
have elongated bolt holes, or if the wheel bolts won’t
stay tight or are heavily rusted. Wheels with excessive
runout may cause vehicle vibration. Replacement
wheels must be equivalent to the original equipment
wheels in load capacity, diameter, rim width, offset, and
mounting configuration. A wheel of improper size or type
may affect wheel and bearing life, brake cooling,
speedometer/odometer calibration, vehicle ground
clearance, and tire clearance to the body and the chas-
sis.
INFLATION OF TIRES
The pressure recommended for any vehicle line is care-
fully calculated to give a satisfactory ride, handling,
tread life, and load-carrying capacity.
Tire pressure should be checked monthly or before any
extended trip. Check the tires when they are cold, after
the vehicle has sat for 3 hours or more or has been driv-
en less than 1 mile. Set the tire pressure to the specifi-
cations on the tire label located on the rear face of the
driver’s door. Tire inflation pressure is also given under
“Tire Size and Pressure Specifications” in this section.
Valve caps or extensions should be on the valves to
keep dust and water out.
Higher than recommended tire pressure can cause:

Hard ride

Tire bruising or damage

Rapid tread wear at the center of the tire
Lower than recommended pressure can cause:

Tire squeal on turns

Hard steering

Rapid and uneven wear on the edges of the tread

Tire rim bruises and rupture

Tire cord breakage

High tire temperatures
Unequal tire pressures on same axle can cause:

Uneven braking

Steering lead
Reduced handling

Swerve on acceleration

Torque steer
ROTATION TIRES
Front and rear tires perform different jobs and can wear
differently depending on the tires of road driven, driving
habit, etc.
The front tires will wear faster than the rear ones.
To avoid uneven wear of tires and to prolong tire life, in-
spect and rotate the tires every 5,000 km (3,100 miles).
After rotating the tires, adjust the tire inflation pressures
and be sure to check wheel nuts tightness.
D16A304A
WHEEL BALANCE
Balance is the easiest procedure to perform and should
be done first if the vibration occurs at high speeds, or if
the tires or the wheels are replaced.
When proceeding the wheel balancing procedure regard
the belows.
1. Do not use the wheel weight over two at the inboard
and the outboard flanges.
2. The total weight of the wheel weights should not ex-
ceed the 100 grams (3.5 ounces).
3. Blanching the assemblies with factory aluminum
wheels requires the use of special nylon–coated,
clip–on wheel weights.

FIVE-SPEED MANUAL TRANSAXLE 5B–39
DAEWOO M-150 BL2
D103B755
3. Inspecting key slot width of synchronizer ring.

Measure key slot width of synchronizer ring. Re-
place if it exceeds limit.
Unit : mm (in.)
Key Slot Width Standard Limit
1st gear8.2 (0.323)8.6 (0.339)
2nd, 3rd, 4th gear9.6 (0.378)10.0 (0.394)
5th gear9.4 (0.370)9.8 (0.386)
D103B756
4. Inspecting wear of synchronizer ring.

Check for worn or damaged synchronizer ring
teeth. Replace it if necessary.
D103B757
5. Inspecting synchronizer key and spring.

Check for worn synchronizer key (1).

Check for weak, damaged or broken spring (2).
D103B758
Assembly Procedure
1. Install the third gear bearing, the third gear / synchro-
nizer ring.
a. Third gear / synchronizer ring.
b. Third gear bearing.
Important: Coat the inner parts; gear, bearing, oil seal
etc. with gear fluid.

5B–44 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D103B773
Assembly Procedure
1. Install the related counter shaft first gear.

Install the first gear bearing (1).

Install the first gear (2).

Install the first gear synchronizer ring (3)
Important: Coat the inner parts; gear, bearing and oil
seal etc. with gear fluid.
Important: Be careful there is the difference of key
groove width between the first synchronizer ring and the
second synchronizer ring.
D103B774A
Unit : mm (in.)




First synchronizer ring (A)
: 8.2 (0.323)


Key Groove Width
Second synchronizer ring
(B) : 9.6 (0.378)
D103B775
2. Assemble the first–second synchronizer hub assem-
bly.

Install the synchronizer springs to hub.

Install the synchronizer keys to hub.
Important: Let (A)=(B) when installing the keys.

Install the hub to the sleeve.
a. Sleeve.
b. Hub.
D103B776
3. Install the first–second synchronizer hub assembly.

Insert the hub assembly into the counter shaft us-
ing the gear, bearing installer DW09940–53111,
the gear bearing remover/installer KM466–A and a
hammer (1).
Important: Position the synchronizer key to the first
gear synchronizer ring groove.

5B–52 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescriptionUnitStandardLimit
GeneralTypeForward gear–Synchronized
mesh type–
Reverse gear–Sliding mesh
type–
Gear ratio1st–3.818–
2nd–2.210–
3rd–1.423–
4th–1.029–
5th–0.837–
Reverse–3.583–
Final drive ratio–4.444–
Fluid capacityL(qt)2.1 (2.21)–
Fluid classification–75W-85 (GL-4)–
ServiceKey groove width of1st gearmm(in.)8.2 (0.323)8.6 (0.339)
synchronizer ring2nd, 3rd, 4th gearmm(in.)9.6 (0.378)10.0 (0.394)
5th gearmm(in.)9.4 (0.370)9.8 (0.386)
Shift fork end
thicknessLow speed shift fork
(1st~2nd)mm(in.)8.7 (0.343)8.1 (0.319)
High speed shift fork
(3rd~4th)mm(in.)7.8 (0.307)7.2 (0.283)
5th gear shift forkmm(in.)7.8 (0.307)7.2 (0.283)
Clearance between gear and synchronizer
ringmm(in.)1.0 (0.039)0.5 (0.020)
Clearance between sleeve and shift forkmm(in.)0.2 – 0.6
(0.008 – 0.024)1.0 (0.039)
Thrust free play of differential side gearmm(in.)0.05 – 0.33
(0.002 – 0.013)–
Speedometer gear ratio(Driven/Drive)–17/18 (0.944)–

GLASS AND MIRRORS 9L–9
DAEWOO M-150 BL2
D19E509
REAR WINDOW DEFOGGER GRID
LINE REPAIR
1. Disconnect the negative battery cable.
2. Disconnect the rear window defogger electrical con-
nector.
D19E515
3. Inspect the rear window defogger grid lines.
4. Use steel wool to buff the grid lines that are to be
repaired. Wipe the lines clean using a cloth damp-
ened with alcohol. Buff and clean about 6 mm (0.25
inch) beyond each side of the break in the grid line.
D19E516
5. Attach a grid line repair decal or two strips of tape
above and below the repair areas.

A repair decal or tape must be used in order to
control the width of the repair areas.

If a decal is used, the die–cut metered slot must
be the same width as the grid line.
6. Apply the grid repair material to the repair area using
a small wooden stick or a spatula. The grid repair
material should be at room temperature.
7. Carefully remove the decal or the tape.
D19E517
Notice: The grid line repair material must be cured with
heat. In order to avoid heat damage to the interior trim,
protect the trim near the repair area where heat will be
applied.
8. Heat the repair area for 1 to 2 minutes.
9. Hold the heat gun nozzle 25 mm (1 inch) from the
surface. A minimum temperature of 149C (300F)
is required.