Oil DAEWOO MATIZ 2003 Service Repair Manual
[x] Cancel search | Manufacturer: DAEWOO, Model Year: 2003, Model line: MATIZ, Model: DAEWOO MATIZ 2003Pages: 1184, PDF Size: 36 MB
Page 808 of 1184
7B -- 26 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
D18B530B
D18B531A
DTighten the bracket nut to 5 NSm (44 lb-in) (2).
DTighten the bolt securing the A/C low pressure pipe
line at the compressor to 23 NSm (17 lb-ft) (3).
2. Evacuate and recharge the system. Refer to “Dis-
charging, Adding Oil, Evacuating, and Charging Pro-
cedure for A/C System” in this section.
3. Connect the negative battery cable.
D108B532
D108B533
EVAPORATOR UNIT AND DRAIN
HOSE
(Left -- Hand Drive Shown, Right -- Hand
Drive Similar)
Removal Procedure
1. Disconnect the negative battery cable.
2. Discharge and recover the refrigerant. Refer to “Dis-
charging, Adding Oil, Evacuating, and Charging Pro-
cedures for A/C System” in this section.
3. Loosen the high pressure pipe line (receiver dry-
er→evaporator) nut and the low pressure pipe line
(evaporator→compressor) nut.
4. Remove the glove box. Refer toSection 9E, Instru-
mentation/Driver information.
5. Remove the evaporator unit.
DRemove the drain hose (1).
DDisconnect the thermistor connector (2).
DRemove the screws (3).
DRemove the evaporator backward slowly (4).
Page 809 of 1184
MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B -- 27
DAEWOO M-150 BL2
D18B534A
Installation Procedure
1. Install the evaporator evaporator with the screws.
2. Connect the thermistor connector.
3. Install the drain hose.
4. Install the glove box. Refer toSection 9E, Instrumen-
tation / Driver Information.
5. Tighten the high pressure pipe line (receiver dry-
er→evaporator) nut and the low pressure pipe line
(evaporator→compressor) nut to 14 NSm (10.5 lb-ft).
6. Evacuate and recharge the system. Refer to “Dis-
charging, Adding Oil, Evacuating, and Charging Pro-
cedures for A/C System” in this section.
7. Connect the negative battery cable.
Page 811 of 1184
MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B -- 29
DAEWOO M-150 BL2
D10B703A
COMPRESSOR OVERHAUL
Tools Required
DW--610--010 Clutch Hub Holding Tool
Disassembly Procedure
1.Remove the compressor. Refer to “Compressor” in
this section.
2. Remove the clutch drive plate.
DUse the clutch hub holding tool DW--610--010 to
keep the clutch drive plate (1).
DRemove the shaft bolt (2).
D18B704A
3. Remove the compressor pulley.
DRemove the snap ring using a ring pryer (1).
DRemove the pulley (2).
D18B705A
4. Disconnect the wiring harness holder and remove the
electromagnetic clutch.
a. Electromagnetic clutch
D18B706B
Assembly Procedure
1. Connect the wiring harness holder and install the
clutch coil.
2. Install the snap ring and compressor pulley.
3. Use the clutch hub holding tool DW--610--010, install
the clutch drive plate with the shaft bolt.
Tighten
Tighten the shaft bolt to 13 NSm(115lb-in).
4. Install the compressor. Refer to “Compressor” in this
section.
Page 812 of 1184
7B -- 30 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application
Unit
Description
Compressor
--
SP--10.4PK
Receiver--Dryer
--
AL R/DRIER
Refrigerant
Type
--
R--134a System
Refrigerant
Capacity
g
500 (RHD : 530)
RefrigerantOilinA/CSystem
Type
--
RL 244 PAG OIL RefrigerantOilinA/CSystem
Capacity
cc
150
A/C Cooling Capacity (Airflow rate 8.7 kg/min)
Kcal/h
5,500
Refrigerant Pressure in A/C Sys-
tem(Engine Idle, Fresh Air 30_C
(86_F)AmbientTemperature
Low Pressure Side
kPa (psi)
200 (2.9)
(86_F),AmbientTemperature
25_C--35_C(77_F--95_F), Tempera-
ture to Full Cold)
High Pressure Side
kPa (psi)
1,500 (217.5)
A/C Compressor ON/OFF Condition
(Refer toSection 1F, Engine Controls
AbouttheA/CCompressorON/OFF
Evaporator Therm-
istor Temperature
_C(_F)
2.45(36.81)
1.0 (34.2)
ON
OFF
About theA/CCompressorON/OFF
Condition According to Engine Oper-
ating Status)
Dual Cut Switch
Pressure
kPa
205--245
180--220
ON
OFF300--400
240--280
FASTENER TIGHTENING SPECIFICATIONS
Application
NSm
Lb-Ft
Lb-In
Compressor Upper Bracket Bolts
20
15
--
Compressor Front Head-to-Rear Head Through-Bolt
22
16
--
High Pressure Pipe Line (Compressor→Condenser) Bolt
23
17
--
High Pressure Pipe Line (Compressor→Condenser) Fitting
23
17
--
High Pressure Pipe Line (Compressor→Condenser) Clamp Nut
5
--
44
Receiver--Dryer Flange Nut
14
10.5
--
High Pressure Pipe Line (Condenser→Receiver--Dryer) Fitting Nut
14
10.5
--
High Pressure Pipe Line (Receiver--Dryer→Evaporator) Fitting Nut
14
10.5
--
High Pressure Pipe Line(Receiver--Dryer→Evaporator) Clamp Nut
5
--
44
Low Pressure Pipe Line (Evaporator→Compressor) Fitting Nut
14
10.5
--
Low Pressure Pipe Line (Evaporator→Compressor) Clamp Nut
5
--
44
Low Pressure Pipe Line(Evaporator→Compressor) Compressor Bolt
23
17
--
Dual Cut Switch
13
--
11 5
Receive--Dryer Bracket--to--Body Bolts
5
--
44
Receive--Dryer Bracket Bolt
5
--
44
Expansion Valve Coupling (Receiver--Dryer→Expansion Valve)
17
13
--
Expansion Valve Coupling (Expansion Valve→Evaporator)
22
16
--
Compressor Shaft Bolt
13
--
11 5
Condenser Mounting Nuts
4
--
36
Page 831 of 1184
8B–4 SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
DAEWOO M-150 BL2
If there is a failure of the sensing and diagnostic module
or the external circuits, the SIR warning lamp in the in-
strument cluster turns ON.
As a system check, the SIR warning lamp also turns ON
when the ignition is first switched to the ON position.
Correct Functioning
The system is working properly if:
The SIR warning lamp turns OFF after approximately
four seconds.
Faulty Functioning
The system is not working properly, meaning one of the
SIR components or the wiring connector is faulty, if:
The SIR warning lamp fails to turn ON when the
ignition is first switched ON.
The SIR warning lamp remains ON.
D110B009A
CLOCK SPRING
The clock spring:
Is on the steering column.
Contains a coil that is the electrical contact between
the steering column wiring harness and the driver
side airbag module.
Is part of the circuit for the horn.
Notice: Turning the steering wheel more than three and
one-quarter turns may damage the clock spring.
Turning the steering wheel:
In one direction tightens the coil.
In the opposite direction loosens the coil.
More than three and one-quarter turns may damage
the clock spring.
Caution: Disassembling the clock spring can cause
injury and vehicle damage.The clock spring should never be disassembled.
The clock spring must be replaced if the airbags have
been deployed.
D110B008A
WIRING HARNESS/CONNECTORS
The connector for the sensing and diagnostic module
(SDM) has a built-in shorting bar that will turn ON the
warning lamp if there is a poor connection at the SDM.
As an anti-deployment mechanism, additional shorting
bars are in the
Connector for the clock spring at the lower steering
column.
Passenger airbag module connector.
SDM connector.
When these connectors are separated, the shorting
bars will short circuit any current which is applied, pre-
venting the current from reaching the airbag modules.
SIR SYSTEM
The supplemental inflatable restraints (SIR) system is a
safety device used in conjunction with the seat belts.
The airbag does not replace the function of the seat belt.
The driver and the passengers must always fasten their
seat belts and adjust them for a proper fit.
The SIR is designed to protect the driver and the front
seat passenger in the event of a significant frontal im-
pact to the vehicle. The airbags deploy if the force is ap-
plied from a direction within 30 degrees of the vehicle’s
centerline and above 25 km/h (15 mph) speed.
The SIR consists of a
Driver airbag module.
Passenger airbag module.
Page 916 of 1184
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
Page 996 of 1184
9E –22 INSTRUMENT/DRIVER INFORMATION
DAEWOO M-150 BL2
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Nm
Lb-Ft
Lb-In
Passenger’s Airbag Module Blank Cover Screw
1.5–2
–
13–18
INSTRUMENT CLUSTER INDICATOR LAMPS SPECIFICATIONS
Indicator Lamp Color Bulb
ABS Warning Amber 14 v 1.4 W
Airbag Warning Red 14 v 1.4 W
Battery Charge Indicator Red 14 v 1.4 W
Fasten Seat Belt Warning Red 14 v 1.4 W
High Beam Indicator Blue 14 v 1.4 W
Low Fuel Level Warning Amber 12 v 3 W Oil Pressure Warning Red 14 v 1.4 W Parking Brake Indicator and Brake Fluid Warning Red 14 v 1.4 W Service Engine Soon Warning Amber 14 v 1.4 W
Turn Signal Indicators
Green
14 v 1.4 W
Instrument Cluster IlluminationBlue12 v 3 W
Rear Fog Lamp IndicatorAmber14 v 1.4 W
Page 1002 of 1184
9F –2 AUDIO SYSTEMS
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
STEREO CASSETTE AM/FM RADIO
WITH CD CHANGER AND
RDS/AUDIO SECURITY SYSTEM
The stereo digital logic cassette AM/FM radio with elec-
tronic tape ejection and the stereo digital logic cassette
AM/FM radio with a CD changer located under the front
seat (LH) are optional equipment.
The radio data system (RDS) uses a single button to se-
lect a specific radio station once it is set to the listener’s
preference.
The audio security system is activated whenever the au-
dio system circuit is disconnected from the battery. A
four-digit security code must be entered in order for the
audio system to be functional once again. The security
code is stamped on a card located in the vehicle (usually
in the glove box). One of the following security code en-
tering procedures can be followed.
With RDS
1. With the ignition switch in the I or II position, turn the
radio ON. At this time, “CODE” will be shown on the
radio display.
2. Press the P-UP button until the correct first digit is
shown on the display.
3. Press the P-DN button to move over to the second
digit and then press P-UP once again to enter the cor-
rect second digit.
4. Use steps two and three to enter the third and fourth
digits using the same method.
5. After entering the correct four-digit security code,
press the TP button. “CODE OK” will briefly appear
on the radio display, and the system is ready for use.
Wrong Code
If the wrong code is entered, “ERROR 1” will appear on
the display. After this, “CODE” will appear once again,
and the correct security code can be entered. The timebetween each new coding attempt is doubled; a total of
ten coding attempts can be made.
FRONT AND REAR SPEAKERS
All audio systems use four speakers: two speakers
mounted in the front doors and two speakers mounted in
the rear parcel side shelf.
ROOF ANTENNA
Roof antenna is located on the roof and is designed to
separate the antenna pole from the antenna base. The
antenna pole should be removed to prevent the painting
damage before washing the vehicle. The roof antenna
cannot be adjusted.
TAPE PLAYER AND CASSETTE CARE
The head and the capstan are the two parts of the tape
player that should be cleaned. This service should be
performed every 100 hours of cassette operation.
In order to clean the head and the capstan, use a cotton
swab dipped in rubbing alcohol.
A cassette cleaning kit may also be used to clean the
head and the capstan. Follow the cleaning kit instruc-
tions to clean the tape player.
Do not touch the tape head with magnetized tools. If the
head becomes magnetized, it will degrade cassettes
played in the player. No service is performed on the cas-
settes. The cassette manufacturer handles warranties
of the cassettes. Store cassettes away from extreme
heat and direct sunlight.
COMPACT DISC CARE
Handle discs carefully. Store the discs in protective
cases away from the sun, heat, and dust. If the surface
is soiled, dampen a clean, soft cloth in a solution of mild
neutral detergent and wipe the disc clean. Mini discs
(about 3 inches in diameter), will not eject and should
not be used.
Page 1053 of 1184
DAEWOO M-150 BL2
SECTION 9K
SQUEAKS AND RATTLES
TABLE OF CONTENTS
Diagnostic Information and Procedures 9K-1. . . . .
Squeak and Rattle Diagnosis 9K-1. . . . . . . . . . . . . . . Repair Instructions 9K-3. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 9K-3. . . . . . . . . . . . . . . . . . . . . . . . . .
Squeak and Rattle Repair 9K-3. . . . . . . . . . . . . . . . . .
DIAGNOSTIC INFORMATION AND PROCEDURES
SQUEAK AND RATTLE DIAGNOSIS
ConditionProbable CauseCorrection
Rattle Coming From the
Side RailImproperly connected brake
lines.Tap lightly on the brake lines and listen for a
rattle.
Install plastic tie straps to secure the brake
lines tightly together.
Rattle Under Vehicle at
Higher RPMThe heat shield contacts with
the underbody.Raise the vehicle and perform a visual
inspection.
Bend the heat shield slightly to gain
clearance from the underbody.
Squeak From the Front
of the Vehicle in Cold
WeatherPoor front stabilizer shaft
insulators taping.While the vehicle is cold, perform a test drive
and achieve full front suspension travel by
driving through a dip in the road.
Remove the insulators and wrap teflon tape
around the stabilizer shaft. Reinstall the
insulators over the tape.
Thump From Rear of
Vehicle on BumpsImproperly secured spare tire in
the rear compartment.Open the rear compartment and perform a
visual inspection of the spare tire and the
tools.
Tightly secure the spare tire and all tools.
Perform a road test to verify that the noise is
eliminated.
Glass Knock Coming
From the Rear of the
Vehicle When Driving
Over BumpsAn out-of-adjustment hatchback
latch.Test drive the vehicle in order to verify this
condition.
Loosen the latch nuts and adjust the latch
downward.
Rattle Coming From
DoorThe door lock solenoid is loose.Remove the door trim panel and check if the
solenoid is loose.
Tighten the solenoid bolts.
Rattling electrical connectors
inside the door trim panel.Tap on the trim panel and listen for a rattle.
Remove the trim panel and wrap foam
padding around the connectors as required.
Squeak When
Operating DoorsA lack of lubrication of the door
hinge pins.Operate the doors and listen for squeaks.
Lubricate the door hinge pins with light oil
and coat with lithium grease.
A lack of lubrication of the door
hold open link arm.Lubricate the door hold open link arm with
light oil and coat with lithium grease.
Page 1074 of 1184
DAEWOO M-150 BL2
SECTION 9M
EXTERIOR TRIM
TABLE OF CONTENTS
Description and Operation 9M-2. . . . . . . . . . . . . . . . . .
Emblems and Lettering 9M-2. . . . . . . . . . . . . . . . . . . . .
Mud Guards 9M-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 9M-3. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 9M-3. . . . . . . . . . . . . . . . . . . . . . . . . . Roof Molding 9M-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Spoiler 9M-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Bumper Spacer 9M-4. . . . . . . . . . . . . . . . . . . . . .
Tailgate Handle 9M-5. . . . . . . . . . . . . . . . . . . . . . . . . . .