battery DAEWOO MATIZ 2003 Service Repair Manual

STEERING WHEEL AND COLUMN 6E–7
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D105A501
D15A502A
DW310–010
STEERING WHEEL
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Tools Required
DW310–010, Steering Wheel Puller
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the SIR module. Refer to Section 8B, Sup-
plemental Inflatable Restraints. (For vehicle with SIR)
3. Remove the steering wheel.
4. Remove the steering wheel horn cover (For vehicle
without SIR) (1).

Straighten the bending locking plate (2).

Remove the nut (3).

Remove the locking plate (4).

In order to install the steering wheel correctly,
match–mark the steering column shaft to the
steering wheel (5).

Remove the steering wheel using the steering
wheel puller DW310–010 (6).
Important: Be careful not to hit the top of steering col-
umn shaft with hammer during repair work.
D15A503A
Installation Procedure
1. Install the SIR module. Refer to Section 8B, Supple-
mental Inflatable Restraints (For vehicle with SIR).
Important: Align the match marks on the steering wheel
and the steering column shaft.
2. Install the steering wheel with the nut and the locking
plate.
Tighten
Tighten the steering wheel nut to 23–33 Nm (17–24
lb-ft).
3. Bend the tabs to secure the locking plate.
4. Install the steering wheel horn cover (For vehicle
without SIR).
5. Connect the negative battery cable.

6E –8 STEERING WHEEL AND COLUMN
DAEWOO M-150 BL2
D105A504
STEERING COLUMN COVER
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the screws.
2. Remove the steering column lower and upper cover.
D105A505
Installation Procedure
1. Install the steering column lower and upper cover with
the screws.
D105A506
TURN SIGNAL SWITCH AND LEVER/
WIPER SWITCH AND LEVER
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the steering column cover. Refer to “Steer-
ing Column Cover” in this section.
3. Remove the turn signal switch.

Disconnect the turn signal switch by pushing the
locking from the switch housing (1).

Disconnect the connector (2).
D105A507
4. Remove the wiper switch.

Disconnect the wiper switch by pushing the locking
from the switch housing (1).

Disconnect the connector (2).

STEERING WHEEL AND COLUMN 6E–9
DAEWOO M-150 BL2
D105A508
Installation Procedure
1. Install the wiper switch.
2. Install the turn signal switch.
3. Install the steering column cover. Refer to “Steering
Column Cover” in this section.
4. Connect the negative battery cable.
D105A509
IGNITION SWITCH
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the steering wheel. Refer to “Steering
Wheel” in this section.
3. Remove the ignition switch.

Disconnect the electrical connector (1).

Remove the screw (2).
D105A510
Installation Procedure
1. Connect the electrical connector.
2. Install the ignition switch with the screw.
3, Install the steering wheel. Refer to “Steering Wheel”
in this section.
4. Connect the negative battery cable.
D105A511
IGNITION LOCK CYLINDER WITH
IMMOBILIZER
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the steering wheel. Refer to “Steering
Wheel” in this section.
2. Disconnect the electrical connector for the immobiliz-
er detection coil.
3. Remove the lock cylinder.

With the key in the ignition, turn to the position des-
ignated I (1).

STEERING WHEEL AND COLUMN 6E–11
DAEWOO M-150 BL2
D105A515
STEERING COLUMN
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the steering wheel. Refer to “Steering Wheel”
in this section.
Caution: Disconnect the negative battery cable and
let the vehicle sit for 1 minute to deactivate the air-
bag (For vehicle with SIR)
2. Remove the turn signal switch and wiper switch. Re-
fer to “Turn Signal Switch and Lever/Wiper Switch
and Lever in this section.
3. Remove the switch housing. Refer to “Switch Hous-
ing” in this section.
D105A516
4. Remove the ignition switch. Refer to “Ignition Switch”
in this section.
5. Remove the ignition lock cylinder. Refer to “Ignition
Lock Cylinder” in this section.
6. Remove the steering column.

Match–mark on the intermediate shaft and the
steering column shaft (1).

Remove the intermediate shaft upper pinch bolt
(2).

Remove the steering column lower nuts (3).

Remove the steering column upper nuts (4).
D15A517B
D15A518B
Installation Procedure
Important: Align the match–mark on the intermediate
shaft and the steering column shaft.
1. Install the steering column.

Install the intermediate shaft upper pinch bolt (1).
Tighten
Tighten the pinch bolt to 21–29 Nm (16–22 lb-ft).

Install the steering column lower nuts (2).
Tighten
Tighten the nuts to 15–20 Nm (11–15 lb-ft).

Install the steering column upper nuts (3).
Tighten
Tighten the nuts to 15–20 Nm (11–15 lb-ft).
2. Install the ignition lock cylinder. Refer to “Ignition Lock
Cylinder” in this section.
3. Install the ignition switch. Refer to “Ignition Switch” in
this section.
4. Install the switch housing. Refer to “Switch Housing”
in this section.
5. Install the turn signal switch and wiper switch. Refer
to “Turn Signal Switch and Lever/Wiper Switch and
Lever” in this section.
6. Install the steering wheel. Refer to “Steering Wheel”
in this section.

DAEWOO M-150 BL2
SECTION 7A
HEATING AND VENTILATION SYSTEM
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 7A-2. . . . . . . . . . . . . . . . . .
Heating and Ventilation Systems 7A-2. . . . . . . . . . . .
Component Locator 7A-3. . . . . . . . . . . . . . . . . . . . . . . .
Control Assembly 7A-3. . . . . . . . . . . . . . . . . . . . . . . . .
Blower Module Assembly 7A-4. . . . . . . . . . . . . . . . . . .
Air Distributor and Heater Module
Assembly 7A-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Informatin and Procedures 7A-6. . . . . . .
Heater System 7A-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insufficient Heating or Defrosting 7A-6. . . . . . . . . . . .
Blower Electrical 7A-10. . . . . . . . . . . . . . . . . . . . . . . . .
Improper Air Delivery or No Mode Shift 7A-11. . . . . .
Too Much Heat 7A-13. . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls 7A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Noise 7A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 7A-18. . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 7A-18. . . . . . . . . . . . . . . . . . . . . . . . .
Control Assembly and Control Cables 7A-18. . . . . . . Blower Motor and Cooling Hose 7A-20. . . . . . . . . . . .
Blower Resistor 7A-20. . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Switch 7A-21. . . . . . . . . . . . . . . . . . . . . .
Heater Hoses 7A-22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Module 7A-24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Module 7A-25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Defroster Duct and Hoses 7A-26. . . . . . . . . . . . . . . . .
Ventilation Duct 7A-27. . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 7A-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Core 7A-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 7A-29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 7A-29. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 7A-29. . . . . . . . . .
Special Tools and Equipment 7A-30. . . . . . . . . . . . . .
Special Tools Table 7A-30. . . . . . . . . . . . . . . . . . . . . . .
Schematic and Routing Diagrams 7A-31. . . . . . . . . .
Non-A/C Diagrams 7A-31. . . . . . . . . . . . . . . . . . . . . . .
Air Flow Through Ducts (Non–A/C) 7A-32. . . . . . . . .

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–22 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
D18A515A
HEATER HOSES
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Tool Required
DW100–020 Hose Remover/Installer.
Removal Procedure
1. Disconnect the negative battery cable.
2. Drain the coolant.
3. Remove the heater inlet hoses.

Remove the air cleaner housing.

Raise and suitably support the vehicle.

Disconnect the hose from the heater module using
a hose remover DW100–020 (1).
D108A516

Lower the vehicle.

Disconnect the hose from the thermostat (2).
D18A517A
4. Remove the heater outlet hoses.

Raise and suitably support the vehicle.

Disconnect the hose from the heater module using
a hose remover DW100–020 (1).

Disconnect the B
+ terminal from the starter. Refer
to Section 1E, Engine Electrical.
D108A518

Disconnect the heater hose from the engine (2).

HEATING AND VENTILATION SYSTEM 7A–23
DAEWOO M-150 BL2
D108A521
Installation Procedure
1. Install the heater outlet hoses.

Connect the heater hose to the engine (1).

Connect the B
+ terminal to the starter. Refer to
Section 1E, Engine Electrical.
D18A522A

Connect the hose to the heater module using a
hose installer DW100–020 (2).

Lower the vehicle.
D108A519
2. Install the heater inlet hoses.

Connect the hose to the thermostat (1).

Raise and suitably support the vehicle.
DW100–020
D18A520A

Connect the hose to the heater module using a
hose installer DW100–020 (2).

Lower the vehicle.

Install the air cleaner housing.
3. Refill the coolant. Refer to Section 1D, Engine Cool-
ing.
4. Connect the negative battery cable.

DAEWOO M-150 BL2

SECTION 7B
MANUAL CONTROL HEATING, VENTILATION,
AND AIR CONDITIONING SYSTEM
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 7B-2. . . . . . . . . . . . . . . . . .
System Components – Functional 7B-2. . . . . . . . . . .
Component Locator 7B-3. . . . . . . . . . . . . . . . . . . . . . . .
A/C System 7B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 7B-5. . . . .
General Diagnosis 7B-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing the Refrigerant System 7B-5. . . . . . . . . . . . . .
Insufficient Cooling “Quick Check”
Procedure 7B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure-Temperature Relationship
of R-134a 7B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leak Testing the Refrigerant System 7B-7. . . . . . . . .
Air Conditioning System Diagnosis 7B-8. . . . . . . . . . . . .
Insufficient Cooling Diagnosis 7B-8. . . . . . . . . . . . . . .
Symptom Diagnosis 7B-11. . . . . . . . . . . . . . . . . . . . . . . .
Pressure Test Chart (R-134a System) 7B-11. . . . . . .
Repair Instructions 7B-13. . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 7B-13. . . . . . . . . . . . . . . . . . . . . . . . .
General A/C System Service Procedures 7B-13. . . . . .
O-Ring Replacement 7B-13. . . . . . . . . . . . . . . . . . . . .
Handling Refrigerant 7B-13. . . . . . . . . . . . . . . . . . . . . .
Handling of Refrigerant Lines and Fittings 7B-13. . .
Maintaining Chemical Stability in the
Refrigeration System 7B-14. . . . . . . . . . . . . . . . . . .
Discharging, Adding Oil, Evacuating, and
Charging Procedures for A/C System 7B-14. . . . . Serviceable Components 7B-17. . . . . . . . . . . . . . . . . . . .
Control Assembly and Control Cables 7B-17. . . . . . .
Blower Motor and Cooling Hose 7B-17. . . . . . . . . . . .
Blower Resistor 7B-17. . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Switch 7B-17. . . . . . . . . . . . . . . . . . . . . .
A/C Push Knob 7B-18. . . . . . . . . . . . . . . . . . . . . . . . . .
Receiver–Dryer and Dual Cut Switch 7B-18. . . . . . . .
Receiver–Dryer Bracket 7B-20. . . . . . . . . . . . . . . . . . .
Compressor 7B-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser 7B-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C High Pressure Pipe Line 7B-22. . . . . . . . . . . . . . .
A/C Low Pressure Pipe Line 7B-25. . . . . . . . . . . . . . .
Evaporator Unit and Drain Hose 7B-26. . . . . . . . . . . .
Unit Repair 7B-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator Core and Expansion Valve 7B-28. . . . . .
Compressor Overhaul 7B-29. . . . . . . . . . . . . . . . . . . . .
Specifications 7B-30. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 7B-30. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 7B-30. . . . . . . . . .
Special Tools and Equipment 7B-31. . . . . . . . . . . . . .
Special Tools Table 7B-31. . . . . . . . . . . . . . . . . . . . . . .
Schematic and Routing Diagrams 7B-32. . . . . . . . . .
A/C Diagrams 7B-32. . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C Airflow (Typical) 7B-33. . . . . . . . . . . . . . . . . . . . . .
A/C System (Typical) 7B-33. . . . . . . . . . . . . . . . . . . . .