radiator DAEWOO MATIZ 2003 Service Owner's Manual

FIVE-SPEED MANUAL TRANSAXLE 5B–11
DAEWOO M-150 BL2
D13B5031
6. Disconnect the radiator lower hose.

Remove the bolts (1).

Disconnect the radiator lower hose (2).
7. Remove crankshaft position (CKP) sensor.

Remove the bolt (3).

Disconnect the CKP sensor connector

Remove the CKP sensor.
D103B507
8. Disconnect the speedometer cable.

Loosen the nut (1).

Disconnect the cable (2).
9. Remove the vehicle speed sensor (VSS) if
equipped.

Disconnect VSS connector.

Remove the VSS.
D102E502
10. Remove the starter motor.

Remove upper two bolts that securing starter mo-
tor to transaxle.
D13B5041
11. Fix the engine assembly.

Remove the cowl panel weatherstrip.

Position the engine support fixture DW110–021
on the cowl panel and the front upper panel.

Tighten the engine fixture joint with a bolt after re-
moving exhaust manifold bolt (No.4).

5B–16 FIVE-SPEED MANUAL TRANSAXLE
DAEWOO M-150 BL2
D13B5032
8. Install the radiator lower hose and crank position
(CKP) sensor.
Tighten
Tighten the radiator lower hose bolt to 8–15 Nm
(70–132 lb-in).
Tighten the CKP sensor bolt to 5–8 Nm (44–70 lb-
in).
D13B520A
9. Refill the transaxle fluid.

Tighten the drain plug to 25–30 Nm (18–22 lb-ft)
(a).

Remove the oil level plug (1).

Refill recommended fluid to the proper level.
Classification 75W – 85 (GL–4) Capacity2.1L (2.21 qt)

Tighten the oil level plug to 36–54 Nm (26–40 lb-ft)
(b).
D13B521A
10. Adjust the clutch cable. Refer to Section 5C, Clutch.

Adjust the clutch cable by the clutch cable adjust
nut.
11. Install the transaxle under cover.
Tighten
Tighten the transaxle under cover bolts to 35–55
Nm (25–41 lb-ft).
D103B501
GEAR SHIFT CONTROL CASE
ASSEMBLY
Removal Procedure
1. Remove the air hose (air cleaner to throttle body).
Refer to Section 1B, SOHC Engine Mechanical.
2. Remove the battery.
3. Disconnect the select and the shift control cable.

Remove the cable pins (1).

Remove the washers (2).

Disconnect the select and the shift control cable
(3).

Remove the cable E–rings (4).

Disconnect the cables from the cable bracket.

FIVE-SPEED MANUAL TRANSAXLE 5B–53
DAEWOO M-150 BL2
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNmLb-FtLb-In
5th/Reverse Gear Shift Shaft Bolt10 – 167 – 12–
Back Up Light Switch Nut15 – 1811 – 13–
Counter Shaft 5th Gear Nut60 – 8044 – 59–
Crankshaft Position Sensor Bolt5 – 8–44 – 70
Differential Ring Gear Bolt80 – 10059 – 74–
Engine Mounting Front Bracket Bolt
(Cylinder Block Side)35 – 4125 – 30–
Engine Mounting Front Damping Bush Bolt
(Crossmember Side)35 – 4125 – 30–
Engine Mounting Front Damping Bush Bolts
(Crossmember Side)45 – 5533 – 41–
Engine Mounting Front Damping Bush Bolt/Nut
(Bracket Side)68 – 8351 – 61–
Front Exhaust Pipe Nut
(Exhaust Manifold Side/Muffler Side)25 – 3518 – 25–
Gear Shift Control Case Bolt18 – 2813 – 21–
Gear Shift Lever Bolt4 – 7–35 – 62
High Speed Shift Shaft Bolt10 – 167 – 12–
Low Speed Shift Shaft Bolt10 – 167 – 12–
Oil Drain Plug25 – 3018 – 22–
Oil Level Plug36 – 5426 – 40–
Radiator Lower Hose Bracket Bolts8 – 15–70 – 132
Reverse Idle Gear Shaft Bolt18 – 2813 – 21–
Reverse Shift Lever Bolt18 – 2813 – 21–
Select Cable Nut(Shift Lever Side)8 – 12–71 – 106
Select Lever Bolt18 – 2813 – 21–
Side Cover Plate Screw6 – 7–53 – 62
Shift Guide Bolt18 – 2813 – 21–
Shift Interlock Bolt18 – 2813 – 21–
Side Cover Bolt8 – 12–71 – 106
Speedometer Driven Gear Bolt4 – 7–35 – 62
Starter Motor Bolt18 – 2813 – 21–
Transaxle Case Bolt15 – 2211 – 16–
Transaxle Case(left) Cap Bolt8 – 12–71 – 106
Transaxle Lower Bolt and Nut(Engine Side)55 – 6541 – 48–
Transaxle Mounting Bolt(Body Side)45 – 5533 – 41–
Transaxle Mounting Bolt and Nut(Transaxle Side)55 – 6541 – 48–
Transaxle Upper Bolt(Engine Side)55 – 6541 – 48–
Transaxle Under Cover Bolt35 – 5525 – 41–

7B–2 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
SYSTEM COMPONENTS
–FUNCTIONAL
Compressor
All compressors are belt–driven from the engine crank-
shaft through the compressor clutch pulley. The com-
pressor pulley rotates without driving the compressor
shaft until on electromagnetic clutch coils energized.
When voltage is applied to energize the clutch coil, the
clutch plate and hub assembly are drawn toward the
pulley. The magnetic force locks the clutch plate and
pulley together as one unit to drive the compressor
shaft.
Condenser Core
The condenser assembly in front of the radiator consists
of coils which carry the refrigerant and cooling fins that
provide the rapid transfer of heat. The air passing
through the condenser cools the high–pressure refriger-
ant vapor and cause it to condense into a liquid.
Expansion Valve
The expansion valve is located on the passenger
compartment side of the dash panel. The expansion
valve can fail in three different positions: open, closed,
or restricted. An expansion valve that fails in the open
position will result in a noisy A/C compressor or no cool-
ing. The cause can be a broken spring, a broken ball, or
excessive moisture in the A/C system. If the spring or
the ball is found to be detective, replace the expansion
valve. If excessive moisture is found in the A/C system,
recycle the refrigerant. An expansion valve that fails in
the closed position will result in low suction pressure and
no cooling. This may be caused by a failed power done
or excessive moisture in the A/C system. If the power
dome on the expansion valve is found to be defective,
replace the expansion valve. If excessive moisture is
found in the A/C system, recycle the refrigerant.
A restricted expansion valve will result in low suction
pressure and no cooling. This may be caused by debrisin the refrigerant system. If debris is believed to be
cause, recycle the refrigerant, replace the expansion
valve, and replace the receiver/dryer.
Evaporator Core
The evaporator is device which cools and dehumidifies
the air before it enters the vehicle. High–pressure liquid
refrigerant flows through the expansion tube (orifice)
and becomes a low–pressure gas in the evaporator. The
heat in the air passing through the evaporator core is
transferred to the cooler surface of the core, which cools
the air. As the process of heat transfer from the air to the
evaporator core surface is taking place, any moisture
(humidity) in the air condenses on the outside surface of
the evaporator core and is drained off as water.
Receiver–Dryer
The sealed receiver–dryer assembly is connected to the
evaporator outlet pipe. It acts as a refrigerant storing
container, receiving liquid and some vapor and refriger-
ant oil from the evaporator.
At the bottom the receiver–dryer is the desiccant, which
acts as a drying agent for the moisture that may have
entered the system. The receiver–dryer is serviceable
only as an assembly.
Dual Cut Switch
The dual cut switch controls compressor operation when
the cycling refrigerant pressure is dropped or surged.
Evaporator Thermistor
A semiconductor which resistance is noticeably changed
as the change of temperature. When the refrigerant tem-
perature of the evaporator drops to 0
C (32
F) and be-
low, the evaporator cores get stuck with frost or ice,
reducing the airflow, lowering the cooling capacity. The
thermistor is a sensor which is used to prevent from frost-
ing or icing.
The thermistor is installed on the evaporator.

MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B–5
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
GENERAL DIAGNOSIS
TESTING THE REFRIGERANT
SYSTEM
If you suspect a problem in the refrigerant system,
check for the following conditions:
1. Check the outer surfaces of the radiator and the con-
denser cores to be sure that the airflow is not blocked
by dirt, leaves, or other foreign material. Check be-
tween the condenser and the radiator, as well as all
outer surfaces.
2. Check for restrictions or kinks in the condenser core,
the hoses, and the tubes.
3. Check the operation of the blower fan.
4. Check all the air ducts for leaks or restrictions. A low
airflow rate may indicate a restricted evaporator core.
5. Check for slippage of the compressor clutch.
6. Check the drive belt tension.
INSUFFICIENT COOLING “QUICK
CHECK” PROCEDURE
Perform the following “hand-feel” procedure to get a
quick idea of whether the air conditioning (A/C) system
has the proper charge of Refrigerant-134a.
1. Warm up the engine. Run the engine at idle.
2. Open the hood and all the doors.
3. Turn the A/C switch ON.
4. Set the temperature control to the full cold position.
5. Set the blower speed switch on 4.
6.“Hand-feel” the temperature of the evaporator outlet
pipe. The pipe should be cold.
7. Check for other problems. Refer to “Testing the Re-
frigerant System” in this section.
8. Leak check the system. Refer to “Leak Testing the
Refrigerant System” in this section. If you find a leak,
discharge the system and repair the leak as required.
After completing the repair, evacuate and charge the
system.
9. If there is no leak, refer to “Insufficient Cooling Diag-
nosis” in this section.

MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B–11
DAEWOO M-150 BL2
SYMPTOM DIAGNOSIS
PRESSURE TEST CHART (R-134A SYSTEM)
Condition Related Symptons Probable Cause Correction



Discharge (high)
Pressure
Abnormally High


After stopping the com-
pressor, the pressure
drops quickly, then falls
gradually.


There is air in the system.


Recover, evacuate and
recharge the system with
the specified amount of
refrigerant.








The condenser is
excessively hot.




There is excessive
refrigerant in the system.




Recover, evacuate and
recharge the system with
the specified amount of
refrigerant.
Reduced or no air flow
through the condenser. The condenser or the
radiator fins are clogged. Clean the condenser or
the radiator fins.









The condenser or the
radiator fan is not working
properly.



Check the voltage and
the fan rpm.
Check the fan direction.



Line to the condenser is
excessively hot.
Restricted flow of
refrigerant in the system
Locate and repair the
restriction.



Discharge
Pressure
Abnormally Low


The condenser is not
hot.


Insufficient refrigerant in the
system.


Check the system for a
leak.
Charge the system.




High and low pressures
are balanced soon after
stopping the

Faulty compressor.

Repair or replace the
compressor.




stopping the
compressor. Low side
pressure is higher than
normal.






The outlet of the
expansion valve is not
Faulty expansion valve.
Replace the expansion
valve.




frosted, low pressure
gauge indicates
vacuum.
Moisture in the system.
Recover, evacuate, and
recharge the system.



Suction (low)
Pressure
Abnormally Low


Condenser is not hot.


Insufficient refrigerant in the
system.


Repair the leaks.
Recover, evacuate, and
recharge the system.




The expansion valve is
not frosted and the low
pressure line is not

Frozen expansion valve.

Replace the expansion
valve.




pressure line is not
cold. Low pressure
gauge indicates a
vacuum.
Faulty expansion valve.









Discharge temperature
is low and the air flow
from the vents is
restricted.




The evaporator is frozen.




Clear the restricted
evaporator case drain.




The expansion valve is
frosted.

The expansion valve is
clogged.

Clean or replace the
expansion valve.




The receiver/dryer
outlet is cool and the
inlet is warm.

The receiver/dryer is
clogged.

Replace the
receiver/dryer.

7B–12 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
Pressure Test Chart (R-134a System) (Cont’d)
Condition Related Symptons Probable Cause Correction

Suction Pressure
Abnormally High
Low pressure hose and
check joint are cooler
The expansion valve is
opened for too long.
Replace the expansion
valve.

Abnormally High

check joint are cooler
than the temperature
around the evaporator.

opened for too long.

valve.








Suction pressure is
lowered when the con-
denser is cooled by
water.



There is excessive
refrigerant in the system.



Recover, evacuate, and
recharge the system.
Suction and Dis-
charge Pressure Reduced airflow
through the condenser. The condenser or the
radiator fins are clogged. Clean the condenser and
the radiator.




Abnormally High







The radiator cooling fans
are not working properly.




Check the voltage and
the radiator cooling fan
rpm.
Check the fan direction.




Condenser is
excessively hot.

There is excessive
refrigerant in the system.

Recover, evacuate, and
recharge the system.



Suction and Dis-
charge Pressure
Abnormally Low


Low pressure hose and
metal end areas are
cooler than the
evaporator.


Clogged or kinked low
pressure hose.


Repair or replace the low
pressure hose.








Temperature around the
expansion valve is low
compared to that
around the
receiver/drier.



The high pressure line is
clogged.



Repair or replace the
high pressure line.


Refrigerant Leaks

The compressor clutch
is dirty.

The compressor shaft seal
is leaking.

Repair or replace the
compressor.
The compressor bolts
are dirty. Leaking around a
compressor housing bolt. Tighten the bolt(s) or
replace the compressor.



The compressor gasket
is wet with oil.

The compressor gasket is
leaking.

Repair or replace the
compressor.



–

Poor tightening in the
system.
Retighten the connection
(coupling, bolt etc.)
– O–ring is faulty. Replace the O–ring.

9A–10 BODY WIRING SYSTEM
DAEWOO M-150 BL2
FUSE CHART
FuseRating/ SourceCircuit
Ef1 (Engine Fuse)50ABATABS
Ef240ABATIgnition Switch, Instrument Panel Fuse Block
(F5, F11 ~ F13)
Ef310ABATFuel cut-off Switch (Inertia Switch)
Ef410AIGN 1Fuel, EBCM, Generator, VSS, Fuel Pump Relay, Main Relay,
Ignition Coil
Ef5––Not Used
Ef620ABATBlower Motor
Ef715ABATRear Window Defogger
Ef810ABATHeadlamp Hi Beam, Right Side
Ef910ABATHeadlamp Hi Beam, Left Side
Ef1010ABATHeadlamp Lo Beam, Right Side
Ef1110ABATHeadlamp Lo Beam, Left Side
Ef1210A58Tail and Illumination Lamps, Right Side
Ef1310A58Tail and Illumination Lamps, Left Side
Ef1410ABATA/C Compressor
Ef1530ABATRadiator Fan
Ef1610A–Spare
Ef1710ABATHorn
Ef1820ABATHeadlamp Relay, Hi Beam Passing, DRL Module
Ef1915ABATECM, Main Relay
Ef2015ABATFront Fog Lamp
Ef2115A–Spare
F1 (Fuse)10AIGN 1Cluster, Clock, IMMO, Anti-Theft Control Unit,
DRL Relay
F210AIGN 1SDM
F325AIGN 1Hazard Switch, DRL Module
F410AIGN 1Turn Signal Lamp
F515ABATStop Lamp
F610AACCAudio
F720AACCCigar Light
F815AIGN 2Wiper
F915AIGN 2Rear Wiper Motor, Front & Rear Washer, Backup Lamp
F1010AIGN 2Auto Miror Switch
F1110AEf2IMMO, Audio, Room Lamp
F1215AEf2Hazard, Clock
F1320AEf2Anti-Theft Control Unit, Door Lock
F1420ASTStarter Motor

9C – 2 HORN
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
HORN
The horn is located under the hood. It is attached near
the radiator at the front of the vehicle. The horn is actu-ated by pressing the steering wheel pad, which grounds
the horn’s electrical circuit.

9R – 2 BODY FRONT END
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
BODY FRONT END
This vehicle has a unitized body with a frame assembly
supporting the engine and the transaxle. The fender
panels and the radiator support are also integral parts of
the body.