heater DAEWOO MATIZ 2003 Service User Guide

ENGINE CONTROLS 1F–105
DAEWOO M-150 BL2
DTC P0141 – Heated Oxygen Sensor Heater Malfunction
StepActionValue(s)YesNo
1
Perform an Euro On-Board Diagnostic (EOBD)
System Check.
Is the system check complete?
–
Go to Step 2
Go to
“On-Board
Diagnostic
System Check”
2
1. Turn the ignition switch to LOCK.
2. Disconnect the Heated O2 sensor connector and
engine control module (ECM) connector.
3. Check the Heated O2 sensor heater wire
between the Heated O2 sensor connector
terminal 4 and ECM connector terminal 35 for an
open or short to ground.
Is the problem found?
–
Go to Step 3Go to Step 4
3
1. Repair the wire of the connector terminal as
needed.
2. Clear the DTCs from the ECM.
3. Road tests the vehicle.
4. Perform the diagnostic system check.
Is the repair complete?
–
System OK
–
4
1. Turn the ignition switch to LOCK.
2. Replace the Heated O2 sensor.
3. Road tests the vehicle.
4. Perform the diagnostic system check.
Is the replacement complete?
–
Go to Step 6
–
5
Check if any additional DTCs are set.
Are any DTCs displaced that have not been
diagnosed?
–
Go to
applicable DTC
table
System OK

1F–208 ENGINE CONTROLS
DAEWOO M-150 BL2
DIAGNOSTIC TROUBLE CODE (DTC) – P0420 CATALYST LOW EFFICIENCY
Circuit Description
In order to control exhaust emissions of Hydrocarbons
(HC), Carbon Monoxide (CO) and Nitrogen Oxide
(NOx), a Three-Way Catalytic Converter (TWC) is used.
The catalyst within the converter promotes a chemical
reaction which oxidizes the HC and CO present in the
exhaust gas, converting them into harmless water vapor
and carbon dioxide, it also reduces NOx, converting it
into nitrogen. The catalytic converter also has the ability
to store oxygen. The Engine Control Module (ECM) has
the capability to monitor this process using a Heated
Oxygen Sensor (HO2S) located in the exhaust stream
past the TWC. The HO2S produces an output signal
which indicates the oxygen storage capacity of the cata-
lyst; this in turn indicates the catalyst’s ability to convert
exhaust emissions effectively. The ECM monitors the
catalyst efficiency by first allowing the catalyst to heat
up, waiting for a stabilization period while the engine is
idling, and then adding and removing fuel while monitor-
ing the reaction of the HO2S. When the catalyst is func-
tioning properly, the HO2S response to the extra fuel is
slow compared to the Oxygen Sensor (O2S). When the
HO2S response is close to that of the O2S, the Oxygen
storage capability or efficiency of the catalyst is consid-
ered to be bad, and the Malfunction Indicator Lamp
(MIL) will illuminate.
Conditions for Setting the DTC

Oxygen Sensor Capacity test condition:

Closed loop stoichiometry.

Engine is running more than 300 seconds.

Airflow is between 25~50kg/h.

Engine Coolant Temperature (ECT) is more than
70°C(176°F) .

Engine speed between 2,400rpm and 3,000rpm.

Vehicle speed is between 64km/h(28.6mph) and
80km/h(49.7mph).
Note: Test is aborted for this idle if:

Change in engine speed is greater than 80 rpm.

A/C status changed.

Cooling fan status changed.
Insufficient air/fuel shift.

DTC(s) P0106, P0107, P0108, P0117, P0118,
P0122, P0123, P0125, P0131, P0132, P0133,
P1133, P0134, P1134, P0137, P0138, P0140,
P0141, P1167, P1171, P0171, P0172, P0201,
P0202, P0203, P0204, P0300, P0336, P0337,
P0341, P0342, P0351, P0352, P0402, P0404,
P0405, P0406, P0506, P0507, and P0562 are NOT
SET.
Action Taken When the DTC Sets

The Malfunction Indicator Lamp (MIL) will illuminate.

The ECM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Freeze Frame and Failure Records buffers.

A history DTC is stored.
Conditions for Clearing the MIL/DTC

The MIL will turn off after four consecutive ignition
cycles in which the diagnostic runs without a fault.

A history DTC will clear after 40 consecutive warm-up
cycles without a fault.

DTC(s) can be cleared by using the scan tool.
Diagnostic Aids
The catalyst test may abort due to a change in the en-
gine load. Do not change the engine load (i.e. A/C, cool-
ant fan, heater motor) while a catalyst test is in progress.
An intermittent problem may be caused by a poor con-
nection, rubbed-through wire insulation, or a wire that is
broken inside the insulation.
Any circuitry, that is suspected as causing the intermit-
tent complaint, should be thoroughly checked for the fol-
lowing conditions:

Backed-out terminals

Improper mating

Broken locks

Improperly formed

Damaged terminals

Poor terminal-to-wire connection.

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–2 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
DESCRIPTION AND SYSTEM OPERATION
HEATING AND VENTILATION
SYSTEMS
The base heater system is designed to provide heating,
ventilation, windshield defrosting, and side window de-
fogging.
The heater and fan assembly blower regulates the air-
flow from the air inlet for further processing and distribu-
tion.
The heater core transfers the heat from the engine cool-
ant to the inlet air.
The temperature door regulates the amount of the air
that passes through the heater core. The temperature
door also controls the temperature of the air by control-
ling the mix of the heated air and the ambient air.
The mode door regulates the flow and the distribution
of the processed air to the heater ducts and to the de-
froster ducts.
This console-mounted heating and ventilation panel
contains the following:
Three Rotary Control Knobs
1. The Rotary Temperature Control Knob

Actuates by cable.

Raises the temperature of the air entering the ve-
hicle by rotation toward the right, or the red portion
of the knob.
2. The Rotary Blower Control Knob

Turns on to operate the blower motor at four speeds.

Turns
to stop the blower.

Operates completely independently both from the
mode control that regulates the defroster door and
from the temperature control knob.
Changes the fan speed in any mode and at any
temperature setting.
3. The Rotary Mode Control Knob:

Actuates by cable.

Regulates the air distribution between the wind-
shield, the instrument panel, and the floor vents.
Push Knobs
1. The Rear Window Defogger Push Knob

Controls the rear window defogger.

Turns ON the rear window defogger when the push
knob is pressed and the indicator lamp is illumi-
nated.
2. The A/C Push Knob (if the vehicle is equipped with air
conditioning)

Controls the A/C.

Turns the A/C ON when the push knob is down.
However, if the blower control knob is OFF, the A/C
system is OFF, regardless of the position of the
A/C knob.
One Lever
1. The Fresh Air Control Lever

Operates by cable.

Switches between recirculating passenger compart-
ment air and bringing outside air into the passenger
compartment.

Draws in outside air when the lever is moved to the
left.

Recirculates inside air when the lever is moved to
the right.

7A–4 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
BLOWER MODULE ASSEMBLY
(Left–Hand Drive Shown, Right–Hand Drive Similar)
D18A402A
1. Blower Module Assembly
2. Plastic Washer
3. Blower Link
4. Blower Lever
5. Air Intake Case
6. Valve Retainer
7. Heater Duct Assembly
8. Blower Connector Duct9. Orifice Case
10. Cable Clamp
11. Blower Valve
12. Blower Resistor
13. Lower Case
14. Cooling Hose
15. Blower Motor

HEATING AND VENTILATION SYSTEM 7A–5
DAEWOO M-150 BL2
AIR DISTRIBUTOR AND HEATER MODULE ASSEMBLY
(Left–Hand Drive Shown, Right–Hand Drive Similar)
D108A403
1. Defroster Duct Hose
2. Defroster Duct
3. Ventilation Duct
4. Heater Module Assembly
5. Plastic Washer
6. Temperature Control Lever
7. Temperature Control Lever Bearing
8. Defroster Link
9. Defroster Lever
10. Spring
11. Ventilation Link
12. Ventilation Lever13. Temperature Control Link
14. Heater Link
15. Heater Lever
16. Cable Link
17. Left Heater Case
18. Defroster Valve
19. Ventilation Valve
20. Temperature Control Valve
21. Right Heater Case
22. Case Seal
23. Heater Core Cover
24. Heater Core

7A–6 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
HEATER SYSTEM
INSUFFICIENT HEATING OR DEFROSTING
Caution: The cooling system is pressurized when hot. Injury can result from removing the surge tank cap
before the engine is sufficiently cool.
Step Action Value(s) Yes No

1

Verify the customer’s complaint.
Are the customer’s concerns verified?
–
Go to Step 2

System OK
2 Check the coolant level.
Is the coolant level correct? – Go to Step 4 Go to Step 3
3

Add coolant as needed.
Is the repair complete?
–

System OK

Go to Step 4
4

Check the timing belt for tension or damage.
Is the timing belt OK?
–

Go to Step 6

Go to Step 5

5

Correct any problem with the drive belts.
Is the repair complete?
–
System OK

Go to Step 6

6

Check the coolant hoses for leaks or kinks.
Are the coolant hoses OK?
–
Go to Step 8

Go to Step 7
7 Repair any problem with the coolant hoses.
Is the repair complete? –
System OK

Go to Step 8

8



Check the surge tank cap. Refer to Section 1D,
Engine Cooling.
Is the surge tank cap OK?


–


Go to Step 10


Go to Step 9

9


Repair or replace the surge tank cap as needed.
Is the repair complete?
–

System OK

Go to Step 10






10






1. Set the A/C switch OFF on vehicles equipped
with air conditioning.
2. Set the blower motor switch on 4.
3. Set the heater control to full hot.
4. Turn the ignition ON.
5. Check for airflow from the heater outlet.
Is there heavy airflow from the heater outlet?





–





Go to Step 11





Go to Step 25



11



Check for a change in the airflow at various blower
speeds.
Does the blower speed increase as the switch is
turned from 1 to 4?


–


Go to Step 12


Go to ‘‘Blower
Electrical’’








12








1. Set the A/C switch to OFF, on vehicles equipped
with air conditioning.
2. Set the temperature lever to full hot.
3. Set the blower motor switch on 4.
4. With the engine sufficiently cool, remove the
surge tank cap.
5. Start the vehicle and idle the engine.
6. Watch for the flow of the coolant.
Is the coolant flow visible?







–







Go to Step 14







Go to Step 13

HEATING AND VENTILATION SYSTEM 7A–7
DAEWOO M-150 BL2
Insufficient Heating or Defrosting (Cont’d)
Step Action Value(s) Yes No





13





1. Check for a

Restriction in the cooling system.

Failed water pump impeller.

Faulty thermostat.
2. Make repairs to the cooling system, as needed.
Are the repairs complete?




–




System OK





–






14






1. Check the vehicle for cold air leaks at the

Dash.

Heater cases.

Vents.
2. Check under the seat for obstructions.
3. Repair any leaks or obstructions.
Are the repairs complete?





–





System OK






–






15






1. Turn the ignition OFF.
2. Turn the temperature control knob to full cold,
then rapidly to full hot.
3. Listen for the sound of the temperature door slam
just before reaching the end of the travel range of
the control knob.
Did the door slam?





–





Go to Step 17





Go to Step 16







16







1. Check the temperature door

Travel.

Cables.

Linkage.
2. Verify the accuracy of the temperature controls at
full hot.
3. Verify the accuracy of the temperature controls at
full cold.
Is the repair complete?






–






System OK







–





17





1. Set the temperature door to full hot.
2. Start the vehicle.
3. Check the temperature of the heater inlet hose
and the heater outlet hose by feel.
Is the heater inlet hose hot and the heater outlet
hose warm?




–




Go to Step 18




Go to Step 21


18



Check the thermostat. Refer to Section 1D, Engine
Cooling.
Is the thermostat installed and seated properly?


–


Go to Step 19


Go to Step 20

19


Replace the thermostat. Refer to Section 1D, Engine
Cooling.
Is the repair complete?
–

System OK

–

20

Reinstall the thermostat.
Is the repair complete?
–

System OK

–

21


Inspect the heater hoses for proper installation.
Are heater hoses reversed?
–

Go to Step 22

Go to Step 23

22

Reinstall the heater hoses properly.
Is the repair complete?
–
System OK

–

7A–8 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
Insufficient Heating or Defrosting (Cont’d)
Step Action Value(s) Yes No







23







1. Back flush the heater core.
2. Drain the cooling system.
3. Replace the coolant.
4. Warm the engine to an average operating
temperature.
5. Feel the heater inlet hose and the heater outlet
hose.
Is the heater inlet hose hot and the heater outlet
hose warm?






–






System OK






Go to Step 24
24

Replace the heater core.
Is the repair complete?

–

System OK

–




25




Recheck the system using the “Control
Settings/Correct Results” tests. Refer to ‘‘Improper
Air Delivery or No Mode Shift” in this section.
Is the repair complete?




–



System OK



Go to Step 26



26



Check for airflow from the defroster or the vent
outlets.
Is there high airflow from the defroster or the vent
outlets?


–


Go to Step 27


Go to Step 28

27



Adjust the heater door at the floor and the vent door
to get the proper airflow.
Is the repair complete?

–


System OK


–

28

Switch the mode knob to defrost.
Is the defroster airflow OK?
–

Go to Step 29

Go to Step 30




29




1. Remove the heater outlet and check for
obstructions.
2. Remove any obstructions in the heater outlet.
Is the repair complete?



–



System OK




–

30


Check for airflow change at various blower speeds.
Does the blower speed increase as the control is
turned from 1 to 4?
–

Go to Step 31

Go to ‘‘Blower
Electrical’’


31



Check for obstructions in the system at the blower
inlet.
Are there any obstructions?


–


Go to Step 32


Go to Step 33



32



Remove the obstructions in the system at the blower
inlet.
Is the repair complete?


–


System OK



–




33




1. Set the blower on 4.
2. Rotate the temperature control from full hot to full
cold.
3. Listen for an airflow change.
Does the airflow change?



–



Go to Step 34



Go to Step 35

HEATING AND VENTILATION SYSTEM 7A–11
DAEWOO M-150 BL2
IMPROPER AIR DELIVERY OR NO MODE SHIFT
This procedure provides a test of all functions of the heater/defroster unit.
1. Warm up the vehicle.
2. Keep the engine running.
3. Perform the tests outlined in the table below and look for the results indicated.
CONTROL SETTINGS CORRECT RESULTS



MODE
KNOB



TEMP.
CONTROL



BLOWER
MOTOR
SWITCH


BLOWER
SPEED



POWER
VENT
OUTLET


FLOOR
OUTLET



DEFROST
OUTLET



SIDE
WINDOW
OUTLET
Vent Cold Off Off No
Airflow No
Airflow No
Airflow No
Airflow



Vent

Cold

4

High

Ambient
Airflow
No
Airflow
No
Airflow
No
Airflow



Floor

Cold to Hot

4

High

No
Airflow
Cold to Hot
Airflow

Minimum
Cold to Hot
Airflow

Minimum
Cold to Hot
Airflow




Defroster


Cold to Hot


4


High



No
Airflow



Minimum
Cold to Hot
Airflow



Cold to Hot
Airflow



Minimum
Cold to Hot
Airflow
If any of these settings does not produce the correct results, perform the following diagnostic procedure.

Step

Action

Value(s)

Yes

No
1

Verify the customer’s complaint.
Are the customer’s concerns verified?

–

Go to Step 2

System OK




2





Examine the affected door in the unit for proper
cable attachment.

Check the cable connection to the door.

Check that the cable sheath is properly re-
tained.
Is the cable connected properly?




–




Go to Step 4




Go to Step 3
3

Repair as necessary.
Is the repair complete?
–

System OK

–





4





1. Disconnect the cable at the door.
2. Check the range of the door travel and the effort
required to move it.
Does the door move freely through its entire range
of travel so that it can close at both ends of the
range?




–




Go to Step 5




Go to Step 3

5


Check the travel of the Bowden cable by turning the
control knob.
Is the cable travel OK?
–

Go to Step 6

Go to Step 7



6




1. Reinstall the cable.
2. Recheck the system using the “Control
Settings/Correct Results” tests in this procedure.
Does the system perform properly?




–



System OK



Go to Step 9



7



1. Check the cable attachment at the control.
2. Check for a broken control.
Is there a problem with the cable attachment or the
control?


–


Go to Step 8


Go to Step 9