battery DAEWOO MATIZ 2003 Service Repair Manual

MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B–7
DAEWOO M-150 BL2
LEAK TESTING THE REFRIGERANT
SYSTEM
Test for leaks whenever you suspect a refrigerant leak in
the system. You should also test for leaks whenever you
perform a service operation which results in disturbing
the lines or the connections. Leaks are commonly found
at the refrigerant fittings or at the connections. Leaks are
commonly caused by the following problems:
Improper torque.
Damaged O-ring seals.
Dirt or lint on the O-ring seals.
Liquid Leak Detectors
Use a liquid leak detector solution on locations such as
fittings. Apply the solution to the area in question with
the swab that is supplied with the solution. Look for
bubbles to appear. This will indicate the existence and
location of any leak.
For areas where this is not practical, such as sections of
the evaporator and the condenser, an electronic leak de-
tector is more useful.
Electronic Leak Detectors
Follow the manufacturer’s instructions for calibration,
operation, and maintenance of an electronic leak detec-
tor. Battery condition is especially important to the accu-
racy of a portable model. Set the detector to R-134a
before beginning the test.
Important: Electronic leak detectors are sensitive to
windshield washing solutions, solvents and cleaners,
and certain vehicle adhesives.
Surfaces must be clean to prevent false readings. Make
sure that all surfaces are dry to prevent damage to the
detector.
General Testing Instructions
Follow the entire path of the refrigerant system.
Completely circle each joint at 25 to 50 mm (1 to 2
inches) per second.
Hold the probe tip within 6 mm (1/4 inch) of the sur-
face.
Do not block the air intake.The audible tone changes from 1 to 2 clicks per second
into a solid alarm if there is a leak. Adjust the balance
control to maintain 1 to 2 clicks per second.
Test all of the following areas, even after one leak has
been confirmed:
Evaporator inlet and outlet.
Receiver-drier inlet and outlet.
Condenser inlet and outlet.
Brazed and welded areas.
Damaged areas.
Hose couplings.
Compressor rear head.
All fittings and joints.
Testing Service Ports/Access Valves
The sealing cap is the primary seal for the service ports.
This cap contains a special leak-free O-ring. Make sure
that this cap is not missing or loose. Always use the cor-
rect cap.
Testing the Evaporator Core
Leaks in the evaporator core are difficult to find. Test the
evaporator core using the following procedure:
1. Run the blower fan at speed setting 4 for at least
15 minutes.
2. Turn the blower to the OFF position.
3. Wait for 10 minutes.
4. Remove the blower motor resistor. Refer to “Blower
Motor Resistor” in this section.
5. Insert the leak detector probe as close as possible to
the evaporator core. The detector will indicate a leak
with a solid alarm.
6. Use a flashlight to search for refrigerant oil in the core
surface.
Testing the Compressor Shaft Seal
1. Blow shop air behind and in front of the compressor
clutch/pulley for at least 15 seconds.
2. Wait 1 to 2 minutes.
3. Probe the area in front of the pulley. If the detector
emits a solid alarm, there is a leak.

7B–8 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
AIR CONDITIONING SYSTEM DIAGNOSIS
INSUFFICIENT COOLING DIAGNOSIS
Step Action Value(s) Yes No
1Can you verify the customer complaint?–Go to Step 2System OK
2
1. Check the fuses Ef14, Ef19, and Ef12.
2. Check the blower fan operation.
3. Check the engine cooling fan operation.
4. Check the A/C compressor belt.
5. Check the A/C condenser for restricted air flow.
6. Check the slippage of the compressor clutch.
7. Repair or replace any components as needed.
8. Check the A/C system operation.
Is the A/C system operation normal?
–
System OKGo to Step 3
3
1. Turn the ignition switch OFF.
2. Connect the high and the low pressure gauges.
Are both pressures within the value specified?
Low SideGo to Step 8Go to Step 6
4Are both pressures above the specified value?Pressure:Go to Step 5–
5Are both pressures within the specified value?200 kPa
(29 Psi)Go to Step 8–
6Are both pressure below the specified value?
(29 Psi)
Go to Step 7Go to Step 4
7
1. Add the refrigerant R–134a.
2. Check the A/C system for leaks.
3. Repair any refrigerant leaks as needed.
4. Recover, evacuate, and recharge the A/C system.
Are both pressure within the specified value?High Side
Pressure:
1,500 kPa
(217.5 Psi)
Go to Step 8
–
8
1. Start the engine and allow it to run at idle.
2. Set the A/C controls to 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.
Does the A/C compressor clutch engage?
–
Go to Step 9Go to Step 11
9
1. Check for a knocking noise from the A/C
compressor.
2. Cycle the A/C compressor ON and OFF in order
to verify the source of the noise.
Do you hear a loud knocking noise?
–
Go to Step 10Go to Step 14
10
1. Recover the A/C system refrigerant.
2. Replace the A/C compressor.
3. Evacuate and recharge the A/C system.
4. Check the A/C system for leaks.
Is the repair complete?
–
Go to Step 14
–
11
1. Turn the ignition switch OFF.
2. Disconnect the A/C compressor clutch coil
connector.
3. Connect a jumper wire from ground to one A/C
compressor clutch coil terminal.
4. Connect a fused jumper wire from the positive
battery terminal to the other A/C compressor
clutch coil terminal.
Does the A/C clutch engage?
–
Go to Step 12Go to Step 13

MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B -- 21
DAEWOO M-150 BL2
D18B511B
Installation Procedure
1. Install the compressor with the mounting bolts.
Tighten
DTighten the compressor--to--bracket upper bolt to
20 NSm (15 lb-ft) (1).
DTighten the compressor--to--bracket lower bolts to
22 NSm (16 lb-ft) (2).
2. Connect the electrical connector.
D18B512A
3. Install the A/C high pressure pipe line to the compres-
sor with the bolt.
Tighten
Tighten the A/C high pressure pipe line bolt to 23 NSm
(17 lb-ft) (3).
4. Install the A/C low pressure pipe line to the compres-
sor with the bolt.
Tighten
Tighten the A/C low pressure pipe line bolt to 23 NSm
(17 lb-ft) (4).
5. Evacuate and charge the system. Refer to “Discharg-
ing, Adding Oil, Evacuating, and Charging Procedure
for A/C System” in this section.
6. Install the A/C belt. Refer toSection 6B, Power Steer-
ing Pump.
7. Install the receiver dryer. Refer to “Receiver Dryer
and Dual Cut Switch” in this section.
D18B513A
CONDENSER
1. Disconnect the negative battery cable.
2. Remove the front bumper fascia. Refer toSection
9O, Bumpers and Fascias.
3. Discharge and recover the refrigerant. Refer to “Dis-
charging, Adding Oil, Evacuating, and Charging Pro-
cedures for A/C system” in this section.
4. Remove the condenser.
DLoosen the condenser pipe--to--compressor pipe
fitting (1).
DLoosen the condenser pipe--to--receiver dryer pipe
fitting (2).

7B -- 22 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
D18B514A
DRemove the condenser mounting nuts (3).
DPush the top of the condenser (4).
DTake off the condenser from the lower bracket by
lifting the condenser (5).
DRemove the condenser (6).
D18B515B
Installation Procedure
Important:Discard the removed O--rings.
1. Install the condenser with the nuts.
Tighten
Tighten the condenser mounting nuts to 4 NSm(36lb-
in).
D18B516B
2. Tighten the fittings and the bolt.
Tighten
DTighten the condenser pipe--to--compressor pipe
fitting to 23 NSm (17 lb-ft) (1).
DTighten the condenser pipe--to--receiver dryer pipe
fitting to 14 NSm (10.5 lb-ft) (2).
3. Evacuate and recharge the system. Refer to “Dis-
charging, Adding Oil, Evacuating, and Charging Pro-
cedures for A/C System” in this section.
4. Install the front bumper fascia. Refer toSection 9O,
Bumpers and Fascias.
5. Connect the negative battery cable.
D108B517
A/C HIGH PRESSURE PIPE LINE
(Left -- Hand Drive Shown, Right -- Hand
Drive Similar)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the front bumper fascia. Refer toSection
9O, Bumpers and Fascias.
3. Discharge and recover the refrigerant. Refer to “Dis-
charging, Adding Oil, Evacuating, and Charging Pro-
cedures for A/C System” in this section.
4. Remove the A/C high pressure pipe line between the
compressor and the condenser.
DRemove the bolt securing the high pressure pipe
line to the compressor (1).

7B -- 24 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
D18B522A
D18B523B
D18B524A
Installation Procedure
Important:Discard the removed O--rings.
1. Install the high pressure pipe lines with the bolts, the
nuts, and the fittings.
Tighten
DTighten the bolt securing the high pressure pipe
line to the compressor to 23 NSm (17 lb-ft) (1).
DTighten the fitting securing the high pressure pipe
line to the condenser pipe line to 23 NSm (17 lb-ft)
(2).
DTighten the fitting securing the high pressure pipe
line to the receiver dryer to 14 NSm (10.5 lb-ft) (3).
DTighten the bracket nut to 5 NSm (44 lb-in) (4).
DTighten the receiver dryer flange nuts to 14 NSm
(10.5 lb-ft) (5).
DTighten the nut securing the high pressure pipe line
to the evaporator to 14 NSm (10.5 lb-ft) (6).
DTighten the bracket nut to 5 NSm (44 lb-in) (7).
2. Install the purge control valve. Refer toSection 1F,
Engine controls.
3. Evacuate and recharge the system. Refer to “Dis-
charging, Adding Oil, Evaculating, and Charging Pro-
cedures for A/C System” in this section.
4. Install the front bumper fascia. Refer toSection 9O,
Bumpers and Fascias.
5. Connect the negative battery cable.
D18B525B

MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B -- 25
DAEWOO M-150 BL2
D108B526
A/C LOW PRESSURE PIPE LINE
(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. Remove the A/C low pressure pipe line.
DRemove the bolt securing the A/C low pressure
pipe line at the compressor (1).
D18B527A
DRemove the bracket nut from shut bar (2).
D18B528A
DRemove the purge control valve. Refer toSection
1F, Engine Controls.
DLoosen the nut securing the A/C low pressure pipe
line at the evaporator (3).
D18B529B
Installation Procedure
Important:Discard the removed O--rings.
1. Install the A/C low pressure pipe line.
Tighten
DTighten the nut securing the A/C low pressure pipe
line at the evaporator to 14 NSm (10.5 lb-ft) (1).

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).

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.

DAEWOO M-150 BL2
SECTION 8A
SEAT BELTS
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 8A-2. . . . . . . . . . . . . . . . . .
Driver Seat Belt Warning 8A-2. . . . . . . . . . . . . . . . . . .
Three-Point Pretensioner Front Seat Belt
(W/EUROPE Only) 8A-2. . . . . . . . . . . . . . . . . . . . . .
Three-Point WLR Front Seat Belt 8A-2. . . . . . . . . . . .
Three-Point ELR Front Seat Belt 8A-2. . . . . . . . . . . .
Three-Point ELR Rear Outboard Seat Belt 8A-2. . . .
Two-Point Lap Rear Center Seat Belt 8A-2. . . . . . . .
Operational and Functional Checks 8A-2. . . . . . . . . .
Component Locator 8A-3. . . . . . . . . . . . . . . . . . . . . . . .
Front and Rear Seat Belt 8A-3. . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 8A-4. . . . .
Seat Belt Warning Lamp is Inoperative 8A-4. . . . . . . Repair Instructions 8A-5. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 8A-5. . . . . . . . . . . . . . . . . . . . . . . . . .
Three-Point WLR/ELR Front Seat Belt 8A-5. . . . . . .
Three-Point Pretensioner Front Seat Belt
(W/EUROPE Only) 8A-6. . . . . . . . . . . . . . . . . . . . . .
Front Seat Belt Buckle 8A-8. . . . . . . . . . . . . . . . . . . . .
Three–Point ELR Rear Outboard Seat Belt 8A-8. . .
Two-Point Lap Rear Center Seat Belt 8A-10. . . . . . .
Specifications 8A-11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 8A-11. . . . . . . . . .
Schematic and Routing Diagrams 8A-12. . . . . . . . . .
Driver Seat Belt Warning 8A-12. . . . . . . . . . . . . . . . . .

DAEWOO M-150 BL2
SECTION 8B
SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
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 8B-3. . . . . . . . . . . . . . . . . .
Airbag Module 8B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensing and Diagnostic Module (SDM) 8B-3. . . . . . .
SIR Warning Lamp 8B-3. . . . . . . . . . . . . . . . . . . . . . . .
Clock Spring 8B-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Harness/Connectors 8B-4. . . . . . . . . . . . . . . . .
SIR System 8B-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Precautions 8B-5. . . . . . . . . . . . . . . . . . . . . . .
Airbag Deployment Condition 8B-5. . . . . . . . . . . . . . .
Airbag Deployment Procedure 8B-6. . . . . . . . . . . . . .
Component Locator 8B-7. . . . . . . . . . . . . . . . . . . . . . . .
SIR Component 8B-7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 8B-8. . . . .
Bulb Check 8B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Indication 8B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearing Fault Codes 8B-8. . . . . . . . . . . . . . . . . . . . . .
Microprocessor – Independent Lamp
Activation 8B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Check 8B-10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Codes 8B-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 01 Driver Firing Circuit,
Resistance Too High 8B-14. . . . . . . . . . . . . . . . . . . .
DTC 02 Driver Firing Circuit,
Resistance Too Low 8B-16. . . . . . . . . . . . . . . . . . . .
DTC 03 Driver Firing Circuit,
Short To Ground 8B-18. . . . . . . . . . . . . . . . . . . . . . .
DTC 04 Driver Firing Circuit,
Short To Battery Voltage 8B-20. . . . . . . . . . . . . . . .
DTC 05 Passenger Firing Circuit,
Resistance Too High 8B-22. . . . . . . . . . . . . . . . . . . .
DTC 06 Passenger Firing Circuit,
Resistance Too Low 8B-24. . . . . . . . . . . . . . . . . . . .
DTC 07 Passenger Firing Circuit,
Short To Ground 8B-26. . . . . . . . . . . . . . . . . . . . . . .
DTC 08 Passenger Firing Circuit,
Short To Battery Voltage 8B-28. . . . . . . . . . . . . . . .
DTC 09 Driver Pretensioner Circuit,
Resistance Too High 8B-30. . . . . . . . . . . . . . . . . . . . DTC 10 Driver Pretensioner Circuit,
Resistance Too Low 8B-32. . . . . . . . . . . . . . . . . . . .
DTC 11 Driver Pretensioner Circuit,
Short to Ground 8B-34. . . . . . . . . . . . . . . . . . . . . . . .
DTC 12 Driver Pretensioner Circuit,
Short to Battery Voltage 8B-36. . . . . . . . . . . . . . . . .
DTC 13 Passenger Pretensioner Circuit,
Resistance Too High 8B-38. . . . . . . . . . . . . . . . . . . .
DTC 14 Passenger Pretensioner Circuit,
Resistance Too Low 8B-40. . . . . . . . . . . . . . . . . . . .
DTC 15 Passenger Pretensioner Circuit,
Short to Ground 8B-42. . . . . . . . . . . . . . . . . . . . . . . .
DTC 16 Passenger Pretensioner Circuit,
Short to Battery Voltage 8B-44. . . . . . . . . . . . . . . . .
DTC 18 Connection Between Driver Firing
Circuit and Driver Pretensioner Circuit 8B-46. . . . .
DTC 19 Connection Between Driver Firing
Circuit and Passenger Pretensioner Circuit 8B-48
DTC 20 Connection Between Passenger Firing
Circuit and Driver Pretensioner Circuit 8B-50. . . . .
DTC 21 Connection Between Passenger Firing
Circuit and Passenger Pretensioner Circuit 8B-52
DTC 22 Connection Between Driver Pretensioner
Circuit and Passenger Pretensioner Circuit 8B-54
DTC 23 Ignition Input Circuit, Voltage
Too High 8B-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 24 Ignition Input Circuit, Voltage
Too Low 8B-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 25 Warning Lamp Failure 8B-60. . . . . . . . . . . . .
DTC 31 SDM Internal Fault 8B-63. . . . . . . . . . . . . . . .
DTC 32 SDM Crash Recorded 8B-63. . . . . . . . . . . . .
Diagnostic Illustration 1 8B-63. . . . . . . . . . . . . . . . . . .
Diagnostic Illustration 2 8B-64. . . . . . . . . . . . . . . . . . .
Diagnostic Illustration 3 8B-64. . . . . . . . . . . . . . . . . . .
Diagnostic Illustration 4 8B-64. . . . . . . . . . . . . . . . . . .
Diagnostic Illustration 5 8B-64. . . . . . . . . . . . . . . . . . .
Diagnostic Illustration 6 8B-65. . . . . . . . . . . . . . . . . . .
Diagnostic Illustration 7 8B-65. . . . . . . . . . . . . . . . . . .