Ignition DAEWOO MATIZ 2003 Service Repair Manual

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–10 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
BLOWER ELECTRICAL
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 blower.
Does the blower run at any speed?
–

System OK

Go to Step 3







3







1. Disconnect the power connector from the blower
motor under the dashboard on the passenger side
of the vehicle.
2. Use an ohmmeter check the resistance between
the 1 terminal of the blower motor connector and
each step with the blower switch place each
position.
Does the ohmmeter show the specified value of the
each position?






Refer to
“Specifica-
tions” in this
section.






Go to Step 4






Go to Step 5

4

Replace the blower motor.
Is the repair complete?
–
System OK

Go to Step 7

5

Check the fuse Ef6.
Is the fuse blown?
–
Go to Step 6

Go to Step 7






6






1. Turn the ignition ON.
2. Use a short detector to locate a possible short.

From the fuse Ef6 to the blower switch.

From the blower swtich to the blower resistor.

From the blower resistor to the blower motor.
3. Repair any short.
4. Replace any blown fuse.
Is the repair complete?





–






System OK






–











7











1. Turn the ignition ON.
2. Disconnect the power connector from the blower
motor.
3. Use a test lamp to locate a possible short.

From the terminal 2 of the motor connector to
the terminal 3 of the motor switch connector.

From the terminal 2 of the motor connector to
the terminal 4 of the motor switch connector.

From the terminal 2 of the motor connector to
the terminal 5 of the motor switch connector.

From the terminal 2 of the motor connector to
the terminal 6 of the motor switch connector.
Does the test lamp light ON?











–










Go to Step 9










Go to Step 8

8

Replace the blower resistor.
Is the repair complete?
–
System OK

Go to Step 10

9

Replace the blower motor switch.
Is the repair complete?
–
System OK

–

10


1. Check the ground of the blower motor.
2. Repair the ground of the blower motor.
Is the repair complete?
–

System OK

–

HEATING AND VENTILATION SYSTEM 7A–13
DAEWOO M-150 BL2
TOO MUCH HEAT
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


Set the mode switch to the floor position.
Is there too much heat when the mode switch is in
the floor position?
–

Go to Step 3

Go to Step 9
3

Check for defroster bleed.
Is there objectionable defroster bleed?
–

Go to Step 4

Go to Step 5



4




1. Check the door travel, the cables, the controls,
and the linkage for the heater and the defroster.
2. Adjust or repair, as required.
Is the repair complete?



–



System OK




–







5







1. In vehicles equipped with A/C, set the A/C switch
OFF.
2. In all vehicles, set the blower speed to 4.
3. Set the temperature to full hot.
4. Turn the ignition switch to ON.
5. Check for airflow from the floor outlets.
6. Check the floor outlet attachment.
Is the airflow high?







–






Go to Step 7






Go to Step 8



6




Check for a change in the airflow at different blower
speeds.
Does the airflow change as the setting for the
blower-speed switch is changed?



–



System OK




Go to ‘‘Blower
Electrical’’




7




1. Check the temperature door travel, the cables,
and the linkage.
2. Adjust to full cold.
3. Check for full hot.
Is the repair complete?



–



System OK




–

8


Adjust or repair the floor/defroster and/or the vent/
floor mode.
Is the repair complete?
–

System OK

–


9



Set the mode switch to the vent position.
In the vent position, is the problem objectionable
bleed?

–


Go to Step 10


Go to Step 15



10



1. Check the system case for leaks.
2. Check the floor outlet attachment.
Are any problems found?


–


Go to Step 11


Go to Step 12

11

Repair the system case or the floor outlet attach-
ment as required.
Is the repair complete?
–
System OK

Go to Step 12




12




1. Turn the ignition switch OFF.
2. Turn the temperature control knob to full hot, then
rapidly to full cold.
Do you hear the door slam just before you reached
the end of the control travel?



–



Go to Step 13



Go to Step 14
13

Adjust the vent door to vent more.
Is the repair complete?
–

System OK

–

7A–16 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
BLOWER NOISE
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








1. Sit inside the vehicle.
2. Close the doors and windows.
3. Turn the ignition ON.
4. Set the blower speed to 4.
5. Set the temperature to full cold.
6. Cycle through the blower speeds, the modes, and
the temperature settings in order to find the noise.
Is the blower noise constant at high blower speeds
or certain modes, but absent at lower speeds or in
other modes?







–







Go to Step 11







Go to Step 3



3



Check for vibrations from the blower motor and fan
assembly at each blower speed by feeling the
blower motor housing.
Did you find excessive vibration?


–


Go to Step 6


Go to Step 4



4




1. Remove the blower motor and fan assembly.
Refer to ‘‘Blower Motor” in this section.
2. Check for foreign material at the opening of the
blower inlet.
Did you find any foreign material at the blower inlet?



–



Go to Step 5



Go to Step 6
5

Remove all foreign material.
Is the repair complete?
–

System OK

Go to Step 6



6




1. Examine the blower fan for wear spots, cracked
blades, a cracked hub, a loose fan retaining nut,
or bad alignment.
2. Examine the blower case for wear spots.
Did you find any problem?



–



Go to Step 7



Go to Step 9
7

Lubricate the motor.
Is the repair complete?
–

System OK

Go to Step 8

8


Replace the motor and fan assembly.
Is the repair complete?
–

System OK

Go to Step 9

9


If the noise is a click/tick or whine, replace the mo-
tor.
Is the repair complete?
–

System OK

Go to Step 10
10

Reinstall the original motor.
Is the problem still present?

–

Go to Step 11

System OK



11




1. Set the blower speed on 4.
2. Check full-hot to full-cold temperature positions in
the defrost, floor, and vent modes.
Is the noise present in the defrost mode only?



–



Go to Step 12



Go to Step 13





12





1. Check the ducts for obstructions or foreign
materials.
2. Remove any obstructions or foreign materials.
3. Check floor/defroster door seals.
4. Repair or replace, as needed.
Is the repair complete?




–




System OK





–
13 Is the noise present in the floor mode only? – Go to Step 12 Go to Step 14

DAEWOO M-150 BL2

SECTION 7B
MANUAL CONTROL HEATING, VENTILATION,
AND AIR CONDITIONING 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 7B-2. . . . . . . . . . . . . . . . . .
System Components – Functional 7B-2. . . . . . . . . . .
Component Locator 7B-3. . . . . . . . . . . . . . . . . . . . . . . .
A/C System 7B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 7B-5. . . . .
General Diagnosis 7B-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing the Refrigerant System 7B-5. . . . . . . . . . . . . .
Insufficient Cooling “Quick Check”
Procedure 7B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure-Temperature Relationship
of R-134a 7B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leak Testing the Refrigerant System 7B-7. . . . . . . . .
Air Conditioning System Diagnosis 7B-8. . . . . . . . . . . . .
Insufficient Cooling Diagnosis 7B-8. . . . . . . . . . . . . . .
Symptom Diagnosis 7B-11. . . . . . . . . . . . . . . . . . . . . . . .
Pressure Test Chart (R-134a System) 7B-11. . . . . . .
Repair Instructions 7B-13. . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 7B-13. . . . . . . . . . . . . . . . . . . . . . . . .
General A/C System Service Procedures 7B-13. . . . . .
O-Ring Replacement 7B-13. . . . . . . . . . . . . . . . . . . . .
Handling Refrigerant 7B-13. . . . . . . . . . . . . . . . . . . . . .
Handling of Refrigerant Lines and Fittings 7B-13. . .
Maintaining Chemical Stability in the
Refrigeration System 7B-14. . . . . . . . . . . . . . . . . . .
Discharging, Adding Oil, Evacuating, and
Charging Procedures for A/C System 7B-14. . . . . Serviceable Components 7B-17. . . . . . . . . . . . . . . . . . . .
Control Assembly and Control Cables 7B-17. . . . . . .
Blower Motor and Cooling Hose 7B-17. . . . . . . . . . . .
Blower Resistor 7B-17. . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Switch 7B-17. . . . . . . . . . . . . . . . . . . . . .
A/C Push Knob 7B-18. . . . . . . . . . . . . . . . . . . . . . . . . .
Receiver–Dryer and Dual Cut Switch 7B-18. . . . . . . .
Receiver–Dryer Bracket 7B-20. . . . . . . . . . . . . . . . . . .
Compressor 7B-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser 7B-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C High Pressure Pipe Line 7B-22. . . . . . . . . . . . . . .
A/C Low Pressure Pipe Line 7B-25. . . . . . . . . . . . . . .
Evaporator Unit and Drain Hose 7B-26. . . . . . . . . . . .
Unit Repair 7B-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator Core and Expansion Valve 7B-28. . . . . .
Compressor Overhaul 7B-29. . . . . . . . . . . . . . . . . . . . .
Specifications 7B-30. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 7B-30. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 7B-30. . . . . . . . . .
Special Tools and Equipment 7B-31. . . . . . . . . . . . . .
Special Tools Table 7B-31. . . . . . . . . . . . . . . . . . . . . . .
Schematic and Routing Diagrams 7B-32. . . . . . . . . .
A/C Diagrams 7B-32. . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C Airflow (Typical) 7B-33. . . . . . . . . . . . . . . . . . . . . .
A/C System (Typical) 7B-33. . . . . . . . . . . . . . . . . . . . .

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

7B–10 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
Insufficient Cooling Diagnosis (Cont’d)
Step Action Value(s) Yes No
20
1. Turn the ignition switch OFF.
2. Turn the A/C switch to the OFF position.
3. Attempt to turn the clutch driver (not the pulley).
Can you turn the clutch driver freely by hand?
–
Go to Step 23Go to Step 21
21
1. Recover the A/C system refrigerant.
2. Replace the A/C compressor.
3. Evacuate and recharge the A/C system.
Is the repair complete?
–
System OK
–
221. Add the refrigerant R–134a.
Does the cooling performance improve?–System OKGo to Step 23
23
1. Recover the A/C system refrigerant.
2. Replace the compressor.
3. Evacuate and recharge the A/C system.
4. Check the A/C system for leaks.
Is the repair complete?
–
System OK
–

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. . . . . . . . . . . . . . . . . .

8A –2 SEAT BELTS
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
DRIVER SEAT BELT WARNING
The driver’s safety belt incorporates a safety belt re-
minder light in the instrument cluster to remind the driver
if the safety belt is not fastened when the ignition is
turned ON.
THREE-POINT PRETENSIONER
FRONT SEAT BELT (W/EUROPE
ONLY)
The pretensioner front seat belt is optional. It contains a
electrically-controlled pyrotechnical retractor, which re-
duces seat belt slack when it is activated in a head-on or
angled front collision. The pretensioner front seat belt
must be replaced after an accident that causes its ac-
tivation.
THREE-POINT WLR FRONT SEAT
BELT
The three-point web locking retractor (WLR) seat belt
will limit the movement of the driver and offer better
protection in an accident.
THREE-POINT ELR FRONT SEAT
BELT
The three-point emergency locking retractor (ELR) front
seat belt is always unlocked, allowing the passenger
freedom of movement, except in emergencies (rapid de-
celeration, rapid acceleration, or hard cornering maneu-
vers).
THREE-POINT ELR REAR
OUTBOARD SEAT BELT
The rear outboard seating positions use the three-point
emergency locking retractor (ELR) seat belts. The
three-point emergency locking retractor (ELR) seat beltis always unlocked, allowing the passenger freedom of
movement, except in emergencies (rapid deceleration,
rapid acceleration, or hard cornering maneuvers).
TWO-POINT LAP REAR CENTER
SEAT BELT
The two-point lap rear center seat belt is a single contin-
uous length of webbing. The webbing is routed from the
anchor through a latch plate and into a single retractor.
OPERATIONAL AND FUNCTIONAL
CHECKS
Caution:

Keep sharp objects and potentially damaging ob-
jects away from the seat belts.

Avoid bending or damaging any portion of the
buckle or the latch plate.

Do not bleach or dye the belt webbing. Use only
mild soap and water in order to clean the belts.

When installing the seat belt anchor bolts and
the screws, start the bolts and the screws by
hand in order to prevent crossthreading.

Do not attempt any repairs on the retractor mech-
anisms or the covers. Replace any defective as-
semblies with new assemblies.

Replace any belts that are cut or damaged in any
way.
1. Inspect all seat belt anchor bolts and the screws in or-
der to verify that they are secure.
2. Inspect the seat belt buckle. The buckle must lock
and unlock easily.
3. After inserting the latch into the buckle, tug sharply on
the belt. The buckle must remain locked.
4. Fully extend the shoulder belt portion to make sure
that there is no twisting or tears in the belt.
5. Let the shoulder belt retract fully. The belt should re-
tract easily.