headlamp DAEWOO MATIZ 2003 Service Repair Manual

1B –12 SOHC ENGINE MECANICAL
DAEWOO M-150 BL2
D102B310
5. If the ignition timing exceeds the specified value,
loosen the distributor bolts and adjust it to the speci-
fied ignition timing by turning the distributor body (s).
D102B311
VA LV E T I M I N G C H E C K A N D
ADJUSTMENT
Check the valve timing in the following procedures:
1. After removing the high headlamp, loosen the bolts
(a) and remove the timing belt front upper cover (b).
D102B312
2. Turning the crankshaft clockwise twice, align the
notch (d) on the crankshaft pulley (c) with the mark 0
(e) for the timing check on the timing belt front lower
cover.
D102B313
3. Check if the notch (f) on the camshaft sprocket is
aligned with the triangle pointer (g) on the timing belt
rear cover.
Important: Notch (f) should be aligned with pointer (g)
to set the valve timing normally.
D102B314

6B –4 POWER STEERING PUMP
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D105C524
PUMP DRIVE BELT
Removal Procedure
1. Remove the front passenger side headlamp. Refer to
Section 9B, Lighting Systems.
2. Remove the pump drive belt.

Loosen the rear bracket adjusting bolt (1).

Loosen the bolt (2).
D105C525

Loosen the front bracket adjusting bolts (3).

Push the pump forward (4).
18–22 Nm
20–24 Nm
20–24 Nm
D15C526A
Installation Procedure
1. Install the pump drive belt with the bolts.
Tighten

Tighten the front bracket adjusting bolt to 18–22
Nm (13–16 lb-ft) (1).

Tighten the rear bracket adjusting bolt to 20–24
Nm (15–18 lb-ft) (2).

Tighten the power steering pump bolt to 20–24
Nm (15–18 lb-ft) (3).
2. Install the front passenger side headlamp. Refer to
Section 9B, Lighting Systems.

POWER STEERING PUMP 6B–5
DAEWOO M-150 BL2
D105C527
PUMP DRIVE PULLEY
Tools Required
DW310–020 Power Steering Pulley Remove Holder
Removal Procedure
1. Remove the front passenger side headlamp.
Refer to Section 9B, Lighting Systems.
2. Remove the steering pump pulley.

Remove the pump drive belt. Refer to “Pump Drive
Belt” in this section.

Fix the pulley using the power steering pulley re-
move holder DW310–020 (1).

Remove the pump drive pulley nut (2).
55–69 Nm
D15C528A
Installation Procedure
1. Install the pump drive pulley. Install the steering pump
pulley nut.
2. Install the pump drive belt.
3. Tighten the steering pump pulley nut using the power
steering pulley remove holder DW310–020.
Tighten
Tighten the steering pump pulley nuts to 55–69 Nm
(41–51 lb-ft).
4. Install the front passenger side headlamp.
Refer to Section 9B, Lighting Systems.
D105C529
PUMP ASSEMBLY
Removal Procedure
1.Remove the front passenger side headlamp.
Refer to Section 9B, Lighting Systems.
2. Disconnect the pipe line from the pump.

Disconnect the supply line pipe hose (1).

Disconnect the pressure line pipe fitting (2).
D105C530
3. Remove the power steering pump.

Remove the pump drive belt. Refer to “Pump Drive
Belt” in this section.

Disconnect the power steering pressure switch
connector (1). Refer to Section 6A, Power Steering
Systems.

Remove the bolts (2).

6B –6 POWER STEERING PUMP
DAEWOO M-150 BL2
D105C531

Remove the bolt (3).
18–22 Nm
D15C532A
Installation Procedure
1. Install the power steering pump with the bolt.
Tighten
Tighten the bolt to 18–22 Nm (13–16 lb-ft).
2. Connect the power steering pressure switch connec-
tor. Refer to Section 6A, Power Steering System.
3. Install the pump drive belt. Refer to “Pump Drive Belt”
in this section.
20–24 Nm
20–24 Nm 21–35 Nm
D15C533A
4. Install the bolts.
Tighten

Tighten the rear bracket adjusting bolt to 20–24
Nm (15–18 lb-ft) (1).

Tighten the power steering bolt to 20–24 Nm
(15–18 lb-ft) (2).
5. Connect the pressure line pipe to the outlet connec-
tion on the steering pump.
Tighten
Tighten the pressure line pipe fitting to 21–35 Nm
(16–26 lb-ft) (3).
6. Install the front passenger side headlamp.
Refer to Section 9B, Lighting Systems.
Notice: When adding fluid or making a complete fluid
change, always use DEXRON-II or DEXRON-III pow-
er steering fluid. Failure to use the proper fluid will cause
hose and seal damage and fluid leaks.
7. Refill the pump with new fluid and bleed the air from
the system. Refer to Section 6A, Bleeding the Power
Steering System.
8. Inspect for leaks. If leaks are found, correct the cause
of the leak and bleed the system.

9A–10 BODY WIRING SYSTEM
DAEWOO M-150 BL2
FUSE CHART
FuseRating/ SourceCircuit
Ef1 (Engine Fuse)50ABATABS
Ef240ABATIgnition Switch, Instrument Panel Fuse Block
(F5, F11 ~ F13)
Ef310ABATFuel cut-off Switch (Inertia Switch)
Ef410AIGN 1Fuel, EBCM, Generator, VSS, Fuel Pump Relay, Main Relay,
Ignition Coil
Ef5––Not Used
Ef620ABATBlower Motor
Ef715ABATRear Window Defogger
Ef810ABATHeadlamp Hi Beam, Right Side
Ef910ABATHeadlamp Hi Beam, Left Side
Ef1010ABATHeadlamp Lo Beam, Right Side
Ef1110ABATHeadlamp Lo Beam, Left Side
Ef1210A58Tail and Illumination Lamps, Right Side
Ef1310A58Tail and Illumination Lamps, Left Side
Ef1410ABATA/C Compressor
Ef1530ABATRadiator Fan
Ef1610A–Spare
Ef1710ABATHorn
Ef1820ABATHeadlamp Relay, Hi Beam Passing, DRL Module
Ef1915ABATECM, Main Relay
Ef2015ABATFront Fog Lamp
Ef2115A–Spare
F1 (Fuse)10AIGN 1Cluster, Clock, IMMO, Anti-Theft Control Unit,
DRL Relay
F210AIGN 1SDM
F325AIGN 1Hazard Switch, DRL Module
F410AIGN 1Turn Signal Lamp
F515ABATStop Lamp
F610AACCAudio
F720AACCCigar Light
F815AIGN 2Wiper
F915AIGN 2Rear Wiper Motor, Front & Rear Washer, Backup Lamp
F1010AIGN 2Auto Miror Switch
F1110AEf2IMMO, Audio, Room Lamp
F1215AEf2Hazard, Clock
F1320AEf2Anti-Theft Control Unit, Door Lock
F1420ASTStarter Motor

DAEWOO M-150 BL2
SECTION 9B
LIGHTING SYSTEMS
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 9B-2. . . . . . . . . . . . . . . . . .
Headlamps and Parking Lamps 9B-2. . . . . . . . . . . . .
Front Turn Signal Lamps 9B-2. . . . . . . . . . . . . . . . . . .
Rear Fog Lamp 9B-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Taillamps 9B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
License Plate Lamp 9B-2. . . . . . . . . . . . . . . . . . . . . . . .
Interior Courtesy Lamp 9B-2. . . . . . . . . . . . . . . . . . . . .
Backup Lamp(s) 9B-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Daytime Running Lamps (DRL)
(W/Europe Only) 9B-2. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 9B-3. . . . .
Headlamps 9B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Signal Lamps and Hazard Lamps 9B-4. . . . . . .
Stoplamps and Interior Courtesy Lamp 9B-5. . . . . . .
Rear Fog Lamp 9B-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 9B-7. . . . . . . . . . . . . . . . . . . . . . . . .
Headlamps 9B-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Signal Lamps 9B-8. . . . . . . . . . . . . . . . . . . . . . . .
Side Turn Signal Lamps 9B-8. . . . . . . . . . . . . . . . . . . .
Taillamps Assembly 9B-9. . . . . . . . . . . . . . . . . . . . . . . .
Front Fog Lamp 9B-9. . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Fog/Backup Lamp(s) 9B-10. . . . . . . . . . . . . . . . .
Center High-Mounted Stoplamp 9B-11. . . . . . . . . . . . CHMSL Mounting Bracket 9B-12. . . . . . . . . . . . . . . . .
License Plate Lamps 9B-12. . . . . . . . . . . . . . . . . . . . . .
Door Jamb Switch 9B-13. . . . . . . . . . . . . . . . . . . . . . . .
Interior Courtesy Lamp 9B-13. . . . . . . . . . . . . . . . . . . .
Daytime Running Lamp Module
(W/Europe Only) 9B-14. . . . . . . . . . . . . . . . . . . . . . .
Ashtray Lamp 9B-14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Luggage Room Lamp 9B-15. . . . . . . . . . . . . . . . . . . . .
Specifications 9B-16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bulb Usage Chart 9B-16. . . . . . . . . . . . . . . . . . . . . . . .
Schematic and Routing Diagrams 9B-17. . . . . . . . . .
Backup Lamp(s) Circuit 9B-17. . . . . . . . . . . . . . . . . . .
Headlamps Circuit 9B-18. . . . . . . . . . . . . . . . . . . . . . . .
Headlamp Leveling Circuit 9B-19. . . . . . . . . . . . . . . . .
Tail and Licence Plate Lamps Circuit 9B-20. . . . . . . .
Stoplamps Circuit 9B-21. . . . . . . . . . . . . . . . . . . . . . . .
Turn and Hazard Lamps Circuit 9B-22. . . . . . . . . . . .
Interior Courtesy Lamp Circuit 9B-23. . . . . . . . . . . . . .
Front Fog Lamp Circuit 9B-24. . . . . . . . . . . . . . . . . . . .
Rear Fog Lamp Circuit 9B-25. . . . . . . . . . . . . . . . . . . .
Dimmer Control Circuit (Except W/Europe) 9B-26. .
Daytime Running Lamps Circuit
(W/Europe Only) 9B-27. . . . . . . . . . . . . . . . . . . . . . .

9B – 2 LIGHTING SYSTEMS
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
HEADLAMPS AND PARKING LAMPS
The headlamps are controlled by the multifunction lever
located on the left side of the steering column. They will
come on with the ignition switch in any position. Turning
the headlamp switch to the first position turns on the
parking lamps, the license plate lamps and the instru-
ment panel illumination. Turning the switch to the sec-
ond position turns on all of the previous lamps and the
headlamps. Turning the switch to the off position turns
off all the lamps.
The parking lamps can be turned on by turning the light-
ing switch to the first position. The parking lamps can be
turned off by turning the switch to the OFF position.
Headlamp high beam and low beam are also controlled
by this lever. When the headlamps are on, pushing the
lever away from the driver until the switch clicks
changes the lamp from low beam to high beam. An indi-
cator lamp on the instrument cluster assembly will come
on when the high beam headlamps are on. To return the
headlamps to low beam, pull the lever toward the driver.
The headlamps must be aimed for proper illumination of
the road. Headlamp aim should be checked whenever a
new headlamp assembly is installed or service repairs to
the front end area may have disturbed the headlamp as-
sembly or its mountings.
FRONT TURN SIGNAL LAMPS
When the turn signals are activated, the side turn signal
lamps flash to signal a turn. The turn signal works only
when the ignition switch is on.
The turn signals are controlled by the light switch on the
left side of the steering column. Moving the lever all the
way up or down (past the detent) will turn on the turn sig-
nals. When the turn is completed, the lever will return to
horizontal and the turn signals will stop flashing.
For changing lanes or shallow turns where the steering
wheel does not turn far enough to cancel the signal,
move the signal only to the first detent and hold it there.
When the lever is released, it will return to horizontal and
the turn signal will cancel.
REAR FOG LAMP
The rear fog lamp is incorporated in the drive side tail-
lamp assembly and are controlled by the rear fog lamp
switch on the instrument panel. The rear fog lamp can
be turned on only when headlamps are on.
TAILLAMPS
The taillamps, stoplamps, backup lamp(s), rear fog lamp
(if equipped with) and turn signal lamps are one assem-
bly.
Turning on either the headlamps or the parking lamps
will also turn on the taillamps. When the brake pedal is
pushed, the taillamps will glow brighter to serve as sto-
plamps.
The center high-mounted stoplamp is located in the rear
window and will come on when the brake pedal is
pressed.
LICENSE PLATE LAMPS
The license plate lamps will come on when the head-
lamps or the parking lamps are on. The license plate
lamps are mounted on the rear bumper, above the li-
cense plate.
INTERIOR COURTESY LAMP
The courtesy lamp is located on the headliner just be-
fore the front seats. The lamp switch has three posi-
tions. If the switch is in the center position, the lamp will
go on whenever a door is opened and go off when it is
closed. In the ON position, the lamp will stay on until it is
turned off. In the OFF position, the lamp will not come
on, even when a door is opened.
BACKUP LAMP(S)
The backup lamps are located in the rear combination
lamps. They will come on when the transaxle is shifted
into REVERSE. On a vehicle with a manual transaxle,
they are activated by a reverse switch which is part of
the transaxle.
DAYTIME RUNNING LAMPS (DRL)
(W/Europe Only)
The daytime running lamps (DRL) work in conjunction
with the exterior lamps system. When the ignition switch
is turned to the ”II” position with the light switch off, park-
ing, tail, license plate and instrument panel lights illumi-
nate. And, when the engine is started, the headlamps
(low beam) also come on.
They remain on until the ignition switch is turned off or
the light switch is turned on. They revert to normal op-
eration when the light switch is on.
The daytime running lamps (DRL) is optional.

LIGHTING SYSTEMS 9B–3
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
HEADLAMPS
ConditionProbable CauseCorrection
Low Beam Headlamps Are
Inoperative, High Beam
Faulty headlamp combination
switch.
Replace the headlamp
combination switch.
Headlamps Are OK.
The open circuit or a short circuit
between the fuse Ef10/Ef11 and
the terminal 5 of the headlamp
combination switch.
Repair or Replace the wiring
harness.

Fuse Ef10 or Ef11 is blown.
Replace the fuse Ef10 or Ef11

The open circuit or a short circuit
between the fuse Ef10 or Ef11 and
the terminal 2 of the headlamp
connector.
Repair or Replace the wiring
harness.

Headlamp bulb is blown.
Replace the headlamp bulb.

The open grounds (G101, G102)
circuit.
Repair or replace the open ground
circuit.
High Beam Headlamps Are
Inoperative, Low Beam
Faulty headlamp combination
switch.
Replace the headlamp
combination switch.
Headlamps Are OK.
The open circuit or a short circuit
between the fuse Ef8/Ef9 and the
terminal 4 of the headlamp
combination switch.
Repair or Replace the wiring
harness.

Fuse Ef8 or Ef9 is blown.
Replace the fuse Ef10 or Ef11.

The open circuit or a short circuit
between the fuse Ef8 or Ef9 and
the terminal 1 of the headlamp
connector.
Repair or Replace the wiring
harness.

Headlamp bulb is blown.
Replace the headlamp bulb.

The open grounds (G101, G102)
circuit.
Repair or Replace the open
ground circuit.
High Beam and Low Beam
Headlamps Are Inoperative On
Both Left and Right Sides.
The open circuit or a short circuit
in the power supply circuit to the
fuse Ef18.
Repair or Replace the wiring
harness.

Fuse Ef18 is blown.
Replace the fuse Ef18 (20A).

The open circuit or a short circuit
between the fuse Ef18 and the
terminal 86, 30 of the headlamp
relay.
Repair or Replace the wiring
harness.

Faulty headlamp relay.
Replace the headlamp relay.

The open circuit or a short circuit
between the terminal 87 of the
headlamp relay and the terminal 6
of the headlamp combination
switch.
Repair or Replace the wiring
harness.

Faulty headlamp combination
switch.
Replace the headlamp
combination switch.

The open ground (G201) circuit.
Repair or Replace the open
ground circuit.

9B–6 LIGHTING SYSTEMS
DAEWOO M-150 BL2
REAR FOG LAMP
Diagnostic Aids: The rear fog lamp will not operate unless the headlamps are ON. If the headlamps are not operat-
ing, repair that problem before attempting to diagnose the rear fog lamp.
ConditionProbable CauseCorrection
Rear Fog Lamp
Does Not Work.
The open circuit or a short circuit
between the terminal 87 of the
headlamp relay and terminal 15,30
of the rear fog lamp relay.
Repair or Replace the wiring
harness.

Faulty rear fog lamp relay.
Replace the rear fog lamp relay.

The open circuit or a short circuit
between the terminal 87 of the
rear fog lamp relay and terminal 6
of the rear fog lamp connector.
Repair or Replace the wiring
harness.

The open circuit or a short circuit
between the terminal E of the rear
fog lamp relay and terminal 6 of
the rear fog lamp switch.
Repair or Replace the wiring
harness.

Faulty rear fog lamp switch.
Replace the rear fog lamp switch.

The open grounds (G201, G401)
circuits.
Repair or Replace the open
ground circuit.

Rear fog lamp bulb is blown.
Replace the rear fog lamp bulb.

LIGHTING SYSTEMS 9B–7
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D209B109
HEADLAMPS
Removal Procedure
1. Support the hood suitably.
2. Disconnect the negative battery cable.
3. Remove the front bumper spacer.

Remove the bolts (1).

Remove the front bumper spacer from the bumper
fasia (2).
D19D502A
4. Remove the headlamp.

Remove the bolts and washer (1).

Disconnect the electrical connectors.

Remove the headlamp (2) .
D19D503A
Installation Procedure
1. Install the headlamp with the bolts.
2. Connect the headlamp connector and parking lamp
connector.
3. Install the front bumper spacer with the bolts.
4. Connect the negative battery cable.