Oil DAEWOO MATIZ 2003 Service Owner's Manual

DAEWOO M-150 BL2
SECTION 1E
ENGINE ELECTRICAL
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 1E-2. . . . . . . . . . . . . . . . . .
Battery 1E-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ratings 1E-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reserve Capacity 1E-2. . . . . . . . . . . . . . . . . . . . . . . . .
Cold Cranking Amperage 1E-2. . . . . . . . . . . . . . . . . . .
Built-In Hydrometer 1E-2. . . . . . . . . . . . . . . . . . . . . . . .
Charging Procedure 1E-3. . . . . . . . . . . . . . . . . . . . . . .
Charging Time Required 1E-3. . . . . . . . . . . . . . . . . . . .
Charging a Completely Discharged Battery
(Off the Vehicle) 1E-3. . . . . . . . . . . . . . . . . . . . . . . . .
Jump Starting Procedure 1E-3. . . . . . . . . . . . . . . . . . .
Generator 1E-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging System 1E-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Starter 1E-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting System 1E-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor 1E-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Coil 1E-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug 1E-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locator 1E-6. . . . . . . . . . . . . . . . . . . . . . . .
Starting System 1E-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging System (A-type: MANDO) 1E-7. . . . . . . . . .
Charging System (B-type: DAC) 1E-8. . . . . . . . . . . . .
Ignition System 1E-9. . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedure 1E-10. . . . . .
Ignition System 1E-10. . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Load Test 1E-12. . . . . . . . . . . . . . . . . . . . . . . . Generator Output Test 1E-12. . . . . . . . . . . . . . . . . . . .
Generator System Check 1E-13. . . . . . . . . . . . . . . . . .
Repair Instructions 1E-14. . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 1E-14. . . . . . . . . . . . . . . . . . . . . . . . .
Starter 1E-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator 1E-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery 1E-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor 1E-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Coil 1E-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 1E-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Motor 1E-19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator (A-type: MANDO) 1E-24. . . . . . . . . . . . . . .
Generator (B-type: DAC) 1E-29. . . . . . . . . . . . . . . . . .
Distributor Assembly 1E-34. . . . . . . . . . . . . . . . . . . . . .
Schematic and Routing Diagrams 1E-37. . . . . . . . . .
Starting System 1E-37. . . . . . . . . . . . . . . . . . . . . . . . . .
Charging System 1E-38. . . . . . . . . . . . . . . . . . . . . . . . .
Ignition System Circuit – Tipical 1E-39. . . . . . . . . . . .
Ignition System Circuit – Euro III 1E-40. . . . . . . . . . .
Specifications 1E-41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Specifications 1E-41. . . . . . . . . . . . . . . . . . . . .
Generator Specifications 1E-41. . . . . . . . . . . . . . . . . .
Ignition System Specifications 1E-41. . . . . . . . . . . . . .
Battery Specifications 1E-41. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 1E-42. . . . . . . . . .

1E–4 ENGINE ELECTRICAL
DAEWOO M-150 BL2
3. In both vehicles, apply the parking brake firmly.
Notice: Make sure the cables are not on or near pulleys,
fans, or other parts that will move when the engine
starts, damaging the parts.
4. Shift a manual transaxle to NEUTRAL.
Caution: Do not use cables that have loose or miss-
ing insulation, or injury could result.
5. Clamp one end of the first jumper cable to the positive
terminal on the battery. Make sure it does not touch
any other metal parts. Clamp the other end of the
same cable to the positive terminal on the other bat-
tery. Never connect the other end to the negative ter-
minal of the discharged battery.
Caution: Do not attach the cable directly to the neg-
ative terminal of the discharged battery. Doing so
could cause sparks and possible battery explosion.
6. Clamp one end of the second cable to the negative
terminal of the booster battery. Make the final con-
nection to a solid engine ground, such as the engine
lift bracket, at least 450 millimeters (18 inches) from
the discharged battery.
7. Start the engine of the vehicle with the good battery.
Run the engine at a moderate speed for several min-
utes. Then start the engine of the vehicle which has
the discharged battery.
8. Remove the jumper cables by reversing the above
sequence exactly. Remove the negative cable from
the vehicle with the discharged battery first. While re-
moving each clamp, take care that it does not touch
any other metal while the other end remains at-
tached
.
GENERATOR
The Delco-Remy CS charging system has several mod-
els available, including the ∅114D (A-type) or CS114D
(B-type). The number denotes the outer diameter in
millimeters of the stator lamination.
CS generators are equipped with internal regulators.
The Y connection (A-type) or Delta (B-type) stator, a
rectifier bridge, and a rotor with slip rings and brushes
are electrically similar to earlier generators. A conven-
tional pulley and fan are used. There is no test hole.
Unlike three-wire generators, the ∅114D (A-type) or
CS114D (B-type) may be used with only two connec-
tions: battery positive and an ‘‘L’’ terminal to the charge
indicator lamp.
As with other charging systems, the charge indicator
lamp lights when the ignition switch is turned to ON, and
goes out when the engine is running. If the charge indi-
cator is on with the engine running, a charging system
defect is indicated.
The regulator voltage setting varies with temperature
and limits the system voltage by controlling the rotorfield current. The regulator switches rotor field current
on and off. By varying the on-off time, correct average
field current for proper system voltage control is ob-
tained. At high speeds, the on-time may be 10 percent
and the off-time 90 percent. At low speeds, with high
electrical loads, on-time may be 90 percent and the off-
time 10 percent.
CHARGING SYSTEM
The Delco-Remy CS charging system has several mod-
els available, including the ∅114D (A-type) or CS114D
(B-type). The number denotes the outer diameter in
millimeters of the stator laminations.
CS generators use a new type of regulator that incorpo-
rates a diode trio. The Y connection (A-type) or Delta (B-
type) stator, a rectifier bridge, and a rotor with slip rings
and brushes are electrically similar to earlier generators.
A conventional pulley and fan are used. There is no test
hole.
STARTER
Wound field starter motors have pole pieces, arranged
around the armature, which are energized by wound
field coils.
Enclosed shift lever cranking motors have the shift lever
mechanism and the solenoid plunger enclosed in the
drive housing, protecting them from exposure to dirt, icy
conditions, and splashes.
In the basic circuit, solenoid windings are energized
when the switch is closed. The resulting plunger and
shift lever movement causes the pinion to engage the
engine flywheel ring gear. The solenoid main contacts
close. Cranking then takes place.
When the engine starts, pinion overrun protects the ar-
mature from excessive speed until the switch is opened,
at which time the return spring causes the pinion to dis-
engage. To prevent excessive overrun, the switch
should be released immediately after the engine starts.
STARTING SYSTEM
The engine electrical system includes the battery, the
ignition, the starter, the generator, and all the related wir-
ing. Diagnostic tables will aid in troubleshooting system
faults. When a fault is traced to a particular component,
refer to that component section of the service manual.
The starting system circuit consists of the battery, the
starter motor, the ignition switch, and all the related elec-
trical wiring. All of these components are connected
electrically
.
DISTRIBUTOR
Distributor distributes the high tension voltage induced
from ignition coil, to each spark plug of each cylinder in

ENGINE ELECTRICAL 1E–5
DAEWOO M-150 BL2
the sequence of ignition order. It also adjusts the ignition
timing according to the engine condition.
This vehicle uses the distributor (optical sensor type)
which controls the preminary current of the ignition coil
by the ECM.
The ignition timing change is controlled electronically by
the ECM.
When diagnosing the ignition system, refer to Section
1F, Engine Controls.
IGNITION COIL
Ignition coil is a sort of transformer to generate high volt-
age (15,000–25,000V) which can bring spark at the
spark plugs and has an iron cored closed magnetic type.The closed magnetic typed ignition coil is used for the
High Energy Ignition (H.E.I) system. Comparing with the
iron cored open magnetic type, the closed type almost
has no loss of magnetic flux, and smaller in size, so it
produces the high voltage of secondary voltage.
SPARK PLUG
It is a part of ignition secondary current, and it burns the
compressed mixture by sparking the high voltage in-
duced from the ignition coil.

ENGINE ELECTRICAL 1E–9
DAEWOO M-150 BL2
IGNITION SYSTEM
D102E404
1 Ignition Coil
2 Spark Pulg
3 Ignitoin Wire (#0)
4 Ignition Wires (#1, #2, #3)
5 Support Clamp
6 Mounting Clamp
7 Distributor Assembly
8 Coupling
9 Distributor Oil Seal
10 Distributor Housing
11 Distributor Shaft12 Plate
13 Optical Sensor Unit
14 Plate
15 Bushing
16 Disc Wheel
17 Inner Cover
18 Outer Cover
19 Distributor Rotor
20 Distributor Cap Seal
21 Distributor Cap

ENGINE ELECTRICAL 1E–11
DAEWOO M-150 BL2
IGNITION SYSTEM (Cont’d)
ConditionProbable CauseCorrection
Hard to Starting the Engine
Faulty ignition coil.
Replace the ignition coil.

Faulty distributor (include the
optical sensor).
Replace the distributor or the
optical sensor.

Faulty spark plug.
Replace the spark plug or Adjust
the gap.

Poor ignition timing.
Reset the valve timing.
Engine Idling State is Unstable
Faulty spark plug.
Replace the spark plug or Adjust
the gap.

Faulty ignition coil.
Replace the ignition coil.

Poor ignition timing.
Reset the valve timing.
Poor Engine Accelerating
Poor ignition timing.
Reset the valve timing.

1E–14 ENGINE ELECTRICAL
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D12E5011
STARTER
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector and clip around
the starter.

Remove the engine oil temperature sensor to dis-
connect the harness connector (1).

Remove the starter solenoid nut to disconnect the
electrical cable (2).

Remove the harness clip bolt to disconnect the
harness clip (3).

Remove the ground bolt (4).
D102E502
3. Remove the starter assembly.

Remove the starter mounting bolts (1).

Remove the starter assembly (2).
D12E5031
Installation procedure
1. Install in the reverse order of removal.
2. Install the starter mounting bolts and starter solenoid
nut.
Tighten

Tighten the starter mounting bolts to 55–65 Nm
(41–48 lb-ft) (a).

Tighten the starter solenoid nut to 9–12 Nm
(80–106 lb-in) (b).

Tighten the harness clip bolt to 9–12 Nm (80–106
lb-in) (c).

Tighten the ground bolt to 35–41 Nm (26–30 lb-ft)
(d).

1E–18 ENGINE ELECTRICAL
DAEWOO M-150 BL2
D102E517
IGNITION COIL
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the ignition wires and ignition coil connec-
tor.

Disconnect the ignition wire (1).

Disconnect the ignition coil connector by pushing
the connector’s lock(2).
D102E518
3. Remove the ignition coil.

Remove the screws (1).

Remove the ignition coil (2).
D12E519A
4–7 Nm
Installation Procedure
1. Install in the reverse order of removal.
2. Install the ignition coil screws.
Tighten
Tighten the ignition coil screws to 4–7 Nm (35–62 lb-
in).

ENGINE ELECTRICAL 1E–23
DAEWOO M-150 BL2
D102E716
Inspection / Measurement
(After the Overhaul)
1. Ground test for armature coil.

Inspect the insulation between commutator and ar-
mature coil using the voltmeter.

Replace the armature assembly if necessary.
D102E717
2. Short circuit test for armature coil.

If test equipment is available, check the armature
for short circuit by placing it on a growler, and hold-
ing back a saw blade over the armature core while
the armature is rotated. If the saw blade vibrates,
replace the armature.
D102E718
3. Open circuit test for armature coil.

Check the continuity between the commutator
bars using multimeter.

Replace the armature assembly if necessary.
D102E719
4. Inspect the brushes wear.

Inspect the brushes, the pop-out springs and the
brush holder for wear and damage. Replace the
brushes, if necessary.
a. Brushes wear limit.
DesciptionStandardLimit
Brushes wear11.3–11.5 mm
(0.445–0.453 in)7.0–7.25 mm
(0.275–0.285 in)

ENGINE ELECTRICAL 1E–27
DAEWOO M-150 BL2
D102E732

Test the stator for open or ground circuit by using
the ohmmeter (2). Replace the starter if necessary.
D102E733
3. Inspect the rectifier.

Positive rectifier test:
Inspect the open circuit for stator coil lead termi-
nals using the ohmmeter (1).
Replace the rectifier if necessary.
D102E734

Negative rectifier test:
Inspect the open circuit for stator coil lead termi-
nals using the ohmmeter (2).
Replace the rectifier if necessary.
D102E735
4. Inspect trio diodes.

Inspect the open circuit for trio diodes using the
ohmmeter (1).

Replace the heat sink if necessary (a).

ENGINE ELECTRICAL 1E–29
DAEWOO M-150 BL2
D12E740A
4–6 Nm
80–110 Nm
Tighten the generator pulley nut to 80–110 Nm
(59–81 lb-ft) (d).

Tighten the through-bolts to 4–6 Nm (35–53 lb-in)
(e).
D102E741
GENERATOR (B-TYPE: DAC)
Disassembly Procedure
1. Remove the generator. Refer to “Generator” in this
section.
2. Remove the cover from the generator.

Remove the battery positive terminal nut (1).

Remove the cover (2).
a. Cover.
D102E742
3. Remove the regulator / brush holder / rectifier assem-
bly.

Remove the stator coil lead and rectifier diode lead
connections (1).
D102E743

Remove the rectifier bolts (2).

Remove the rectifier / regulator screw (3).

Remove the brush holder / regulator screw (4).

Remove the regulator screw (5).

Remove the regulator / brush holder / rectifier as-
sembly (6).