cooling DAEWOO MATIZ 2003 Service User Guide

ENGINE COOLING 1D–5
DAEWOO M-150 BL2
COMPONENT LOCATOR
COOLANT HOSE AND COMPONENTS
D12D4011
1 Radiator Coolant Return Hose
2 Upper Radiator Hose
3 Not Used
4 Radiator Assembly
5 Lower Radiator Hose
6 Throttle Body Assembly
7 Surge Tank hose
8 Surge Tank
9 Coolant Temperature Sensor
10 Engine Coolant Temperature Sensor11 Surge Tank Return Hose
12 Water Inlet Cap
13 Heater Outlet Hose
14 Heater Inlet Hose
15 Distributor Case
16 Thermostat
17 Thermostat Housing
18 Throttle Body Inlet Hose
19 Throttle Body Outlet Hose
20 Hose Bracket

1D–6 ENGINE COOLING
DAEWOO M-150 BL2
RADIATOR/FAN
D12D4021
1 Radiator Assembly2 Electric Cooling Fan Assembly

ENGINE COOLING 1D–7
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURE
COOLANT LEAKS TEST
1. Remove the surge tank cap after the engine cools.
2. Check the coolant level.
3. Install a suitable cooling system pressure tester(b) to
the surge tank filler neck using the adapter(a) and
pressurize (110–120 kPa (16.0–17.4 psi)).
4. Check the coolant leaks on the hoses and connec-
tions during 2 minutes.
5. If the leak is checked, replace the parts or repair the
connections.
D102D301
SURGE TANK CAP TEST
The surge tank cap(c) is equipped with the pressure
valve(d) and the vacuum valve(e). Therefore, the surge
tank cap maintains proper pressure. And The surge tank
cap protects the system from high-pressure by opening
a pressure valve, and protects the coolant hoses from
collapsing because of a vacuum.
1. Wash any sludge from the surge tank cap and the
valve seat of the vacuum pressure valve for the surge
tank cap.
2. Check for any damage or deformity to the vacuum
pressure valve for the surge tank cap. If any damage
or deformity is found, replace the cap.
3. Install a suitable cooling system pressure tester(b) to
the cap using the Adapter(a).
4. Pull the vacuum pressure valve to the open position.
If the surge tank cap does not seal properly, replace
the surge tank cap.
5. Pressurize the cap to 90 to 120kPa (13 to 17psi).
6. Wait 10 seconds and check the pressure held by the
tank cap tester.
7. If the pressure held by the cooling system pressure
tester falls below 80kPa (11.6psi) replace the surge
tank cap.
D102D302
THERMOSTAT TEST
1. Remove the thermostat(f) from the vehicle. Refer
to“Thermostat” in this section.
2. Make sure the valve spring is tight when the thermo-
stat is fully closed. If the spring is not tight, replace the
thermostat.
3. Suspend the thermostat and a thermometer in a pan
of 50/50mixture of ethylene glycol and water. Do not
let the thermostat or the thermometer rest on the bot-
tom of the pan because the uneven concentration of
heat on the bottom could result in inaccurate temper-
ature measurements.
4. Heat the pan on a burner.
5. Use the thermometer to measure the temperature of
the heated solution.
6. The thermostat should begin to open at 82°C (180°F)
and it should be fully open at 95°C (203.4°F) and it
should be fully close at 80°C (176.4°F). If it does not
open or close at these temperature, replace the ther-
mostat. Also, the thermostat rod’s stroke from the ini-
tially open to the fully open should be 8mm (0.31 in.).
D102D303

1D–8 ENGINE COOLING
DAEWOO M-150 BL2
COOLING SYSTEM DIAGNOSIS
Condition Probable Cause Correction
Engine OverheatsA loss of the coolant.Add the coolant.
A weak coolant solution.Confirm that the coolant solution is a
50/50 mixture of ethylene glycol and
water.
Any dirt, any leaves, or any insects
on the front of the radiator.Clean the front of the radiator.
The leakage from the hoses, the
coolant pump, the heater, the
thermostat housing, the radiator, the
heater core, or the head gasket.Replace any damaged components.
A faulty thermostat.Replace a damaged thermostat.
Retarded ignition timing.Perform an ECM code diagnosis.
Confirm the integrity of the timing
belt.
An improperly operating electric
cooling fan.Replace the electric cooling fan.
Plugged or rotted radiator hoses.Replace any damaged radiator
hoses.
A faulty water pump.Replace a faulty water pump.
A faulty surge tank cap.Replace a faulty surge tank cap.
A cracked or plugged cylinder head
or engine block.Repair the damaged cylinder head or
the damaged engine block.
A faulty radiator.Replace a faulty radiator.
Loss of CoolantA leak in the radiator.Replace a damaged radiator.
A leak in the surge tank or the hose.Replace the surge tank or the hose.
Looseness or damage of radiator
hoses, heater hoses, or connections.Reseat the hoses.
Replace the hoses or the clamps.
Leaks in the coolant pump seal.Replace the coolant pump seal.
Leaks in the coolant pump gasket.Replace the coolant pump gasket.
An improper cylinder head torque.Tighten the cylinder head bolts to
specifications.
Replace the cylinder head gasket, if
needed.
Leaks in the intake manifold, cylinder
head gasket, heater core.Repair or replace any components,
as needed to correct the leak.
Engine Fails to Reach
Normal OperatingThermostat to be stuck open or to be
wrong type.Install a new thermostat of the
correct type and heat range.
Temperature or Cool Air
from the HeaterThe coolant level below the MIN
mark on the surge tank.Add sufficient coolant to raise the
fluid to the specified mark on the
surge tank.

ENGINE COOLING 1D–9
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D12D5011
DRAINING AND REFILLING THE
COOLING SYSTEM
Caution: Do not remove the surge tank cap while
the engine and the radiator are hot. Scalding fluid
and steam may be blown out under pressure.
1. Place a pan below the vehicle to catch the draining
coolant.
2. Drain the coolant.
Remove the surge tank cap (1).
Disconnect the lower radiator hose (2).
Caution: Dispose of the used coolant to a used
coolant holding tank to be picked up with the used
oil for disposal. Never pour the used coolant down
the drain. Ethylene glycol antifreeze is an extremely
toxic chemical. Disposing of it into the sewer sys-
tem or the ground water can contaminate the local
environment.
D102D502
3. Connect the lower radiator hose.
4. Clean the cooling system.
Remove all sludge and dirt from inside the surge
tank. And install the surge tank. Refer to “Surge
Tank” in this section (1).

1D–10 ENGINE COOLING
DAEWOO M-150 BL2
D102D503
Add the clean water to the surge tank (2).
5. Run the engine until the thermostat opens. You can
tell the thermostat is open when both radiator hoses
are hot to the touch.
6. Stop the engine and disconnect the lower radiator
hose to drain the coolant.
7. Repeat steps 3 through 6 until the drained water is
clear and free of coolant and rust.
Notice: Never use an antifreeze mixture more concen-
trated than 60 percent antifreeze to 40 percent water.
The solution freezing point increases above this con-
centration.
8. Fill the cooling system through the surge tank with a
mixture of ethylene glycol antifreeze and water. The
mixture must be at least 50 percent antifreeze, but
not more than 60 percent antifreeze for cold weather
operation.
9. Fill the surge tank to the specified MAX fill mark on
the outside of the tank.
10. Install the surge tank cap.
D102D504
SURGE TANK
Removal Procedure
Caution: To prevent personal injury, do not remove
the surge tank cap while the engine and the radiator
are hot, because the heat causes the system to re-
main under pressure scalding fluid and steam may
be blown out under pressure.
1. Drain the engine coolant to below the level of the
surge tank.
2. Remove the surge tank.
Loosen the overflow hose clamps and disconnect
the overflow hoses from the surge tank (1).
Remove the surge tank (2).
3. Clean the inside and the outside of the surge tank and
the surge tank cap with soap and water.
4. Rinse the surge tank and the cap thoroughly.
5. Check the surge tank and the cap for crack or other
damage.

ENGINE COOLING 1D–11
DAEWOO M-150 BL2
D102D505
Installation Procedure
1. Install the surge tank to the vehicle.
Install the surge tank with pressing down (1).
Connect the overflow hoses to the surge tank (2).
2. Secure the overflow hoses to the surge tank with the
hose clamps.
3. Fill the surge tank with coolant to the MAX mark.
D102D506
ELECTRIC COOLING FAN
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the electric cooling fan assembly.
Disconnect the cooling fan electrical connector (1).
Remove the bolts (2).
Remove the electric cooling fan assembly (3).
3.5–4.5 Nm
D12D507A
Installation Procedure
1. Install the electric cooling fan assembly with the bolts.
Tighten
Tighten the bolts to 3.5–4.5 Nm (31–40 lb-in).
2. Connect the cooling fan electrical connector.
3. Connect the negative battery cable.
D12D5081
RADIATOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the lower radiator hose and drain the en-
gine cooling system. Refer to “Draining and Refilling
the Cooling System” in this section.
3. Disconnect the upper radiator hose and the surge
tank hose.
Loosen the upper radiator hose clamp and discon-
nect the upper radiator hose (1).
Loosen the surge tank hose clamp and disconnect
the surge tank hose (2).

1D–12 ENGINE COOLING
DAEWOO M-150 BL2
D12D5091
4. Remove the electric cooling fan.
Refer to “Electric Cooling Fan” in this section.
5. Remove the radiator.
Remove the bolts (1).
Remove the radiator support brackets (2).
Remove the radiator (3).
6. Check the radiator for breaking, clog or other dam-
age.
Important: The radiator still contains a substantial
amount of coolant. Drain the remainder of the coolant
from the radiator into a drain pan.
D12D5101
Installation Procedure
1. Install the radiator with the mounting bolts (1) and the
support brackets (2).
Tighten
Tighten the support bracket bolts to 3.5–4.5 Nm
(31–40 lb-in).
2. Install the electric cooling fan.
Refer to “Electric Cooling Fan” in this section.
D12D5111
3. Connect the upper radiator hose to the radiator (1).
4. Connect the surge tank hose to the radiator (2).
5. Secure each hose with hose clamps.
6. Refill the engine cooling system. Refer to “Draining
and Refilling the Cooling System” in this section.
7. Connect the negative battery cable.
D102D512
THERMOSTAT (TYPICAL)
Removal Procedure
Caution: To prevent personal injury, do not remove
the surge tank cap while the engine and the radiator
are hot because the heat causes the system to re-
main under pressure. Scalding fluid and steam may
be blown out under pressure.
1. Remove air filter assembly. Refer to Section 1B,
SOHC Engine Mechanical.
2. Disconnect the lower radiator hose and drain the
coolant. Refer to “Drain and Refilling the Cooling Sys-
tem”
3. Disconnect the upper radiator hose.

ENGINE COOLING 1D–13
DAEWOO M-150 BL2
Loosen the hose clamp (1).
Disconnect the upper radiator hose (2).
D102D513
4. Remove the thermostat.
Remove the bolts (1).
Remove the thermostat housing (2).
Remove the thermostat with the gasket (3).
5. Check the gasket for crack or other damage.
6. Inspect the valve seat for foreign matter that could
prevent the valve from seating properly.
7. Inspect the thermostat for proper operation. Refer to
“Thermostat Test” in this section.
8–15 Nm
D12D514A
Installation Procedure
1. Install the thermostat with the bolts and the thermo-
stat housing.
Tighten
Tighten the mounting bolts to 8–15 Nm (71–130
lb-in).
2. Secure the upper radiator hose to the thermostat
housing with a hose clamp.
3. Refill the engine cooling system. Refer to “Draining
and Refilling the Cooling System” in this section.
MAA1D010
THERMOSTAT (EURO III)
Removal Procedure
Caution: To prevent personal injury, do not remove
the surge tank cap while the engine and the radiator
are hot because the heat causes the system to re-
main under pressure. Scalding fluid and steam may
be blown out under pressure.
1. Remove air filter assembly. Refer to Section 1B,
SOHC Engine Mechanical.
2. Disconnect the lower radiator hose and drain the
coolant. Refer to “Drain and Refilling the Cooling Sys-
tem”
3. Disconnect the upper radiator hose.

1D–14 ENGINE COOLING
DAEWOO M-150 BL2
MAA1D020
4. Remove the thermostat.
Remove the bolts.
Remove the thermostat housing.
Remove the thermostat with the gasket.
5. Check the gasket for crack or other damage.
6. Inspect the valve seat for foreign matter that could
prevent the valve from seating properly.
7. Inspect the thermostat for proper operation. Refer to
“Thermostat Test” in this section.
MAA1D011
Installation Procedure
1. Install the thermostat with the bolts and the thermo-
stat housing.
Tighten
Tighten the mounting bolts to 8–15 Nm (71–130
lb-in).
2. Secure the upper radiator hose to the thermostat
housing with a hose clamp.
3. Refill the engine cooling system. Refer to “Draining
and Refilling the Cooling System” in this section.
4. Install the air filter assembly. Refer to Section 1B,
SOHC Engine Mechanical.
D102D515
COOLANT TEMPERATURE SENSOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the lower radiator hose and drain the
coolant. Refer to “Draining and Refilling the Cooling
System” in this section.
3. Remove the coolant temperature sensor.
Disconnect the electrical connector (1).
Remove the coolant temperature sensor (2).
D12D516A
10 Nm
Installation Procedure
1. Install the coolant temperature sensor into the
threaded hole in the intake manifold.
Tighten
Tighten the coolant temperature sensor to 10 Nm
(89 lb-in).
Connect the electrical connector to the coolant
temperature sensor (1).
2. Connect the lower radiator hose and refill the coolant.
Refer to “Draining and refilling the cooling system” in
this section.
3. Connect the negative battery cable.