belt DAEWOO MATIZ 2003 Service Owner's Guide

POWER STEERING PUMP 6B–5
DAEWOO M-150 BL2
D105C527
PUMP DRIVE PULLEY
Tools Required
DW310–020 Power Steering Pulley Remove Holder
Removal Procedure
1. Remove the front passenger side headlamp.
Refer to Section 9B, Lighting Systems.
2. Remove the steering pump pulley.

Remove the pump drive belt. Refer to “Pump Drive
Belt” in this section.

Fix the pulley using the power steering pulley re-
move holder DW310–020 (1).

Remove the pump drive pulley nut (2).
55–69 Nm
D15C528A
Installation Procedure
1. Install the pump drive pulley. Install the steering pump
pulley nut.
2. Install the pump drive belt.
3. Tighten the steering pump pulley nut using the power
steering pulley remove holder DW310–020.
Tighten
Tighten the steering pump pulley nuts to 55–69 Nm
(41–51 lb-ft).
4. Install the front passenger side headlamp.
Refer to Section 9B, Lighting Systems.
D105C529
PUMP ASSEMBLY
Removal Procedure
1.Remove the front passenger side headlamp.
Refer to Section 9B, Lighting Systems.
2. Disconnect the pipe line from the pump.

Disconnect the supply line pipe hose (1).

Disconnect the pressure line pipe fitting (2).
D105C530
3. Remove the power steering pump.

Remove the pump drive belt. Refer to “Pump Drive
Belt” in this section.

Disconnect the power steering pressure switch
connector (1). Refer to Section 6A, Power Steering
Systems.

Remove the bolts (2).

6B –6 POWER STEERING PUMP
DAEWOO M-150 BL2
D105C531

Remove the bolt (3).
18–22 Nm
D15C532A
Installation Procedure
1. Install the power steering pump with the bolt.
Tighten
Tighten the bolt to 18–22 Nm (13–16 lb-ft).
2. Connect the power steering pressure switch connec-
tor. Refer to Section 6A, Power Steering System.
3. Install the pump drive belt. Refer to “Pump Drive Belt”
in this section.
20–24 Nm
20–24 Nm 21–35 Nm
D15C533A
4. Install the bolts.
Tighten

Tighten the rear bracket adjusting bolt to 20–24
Nm (15–18 lb-ft) (1).

Tighten the power steering bolt to 20–24 Nm
(15–18 lb-ft) (2).
5. Connect the pressure line pipe to the outlet connec-
tion on the steering pump.
Tighten
Tighten the pressure line pipe fitting to 21–35 Nm
(16–26 lb-ft) (3).
6. Install the front passenger side headlamp.
Refer to Section 9B, Lighting Systems.
Notice: When adding fluid or making a complete fluid
change, always use DEXRON-II or DEXRON-III pow-
er steering fluid. Failure to use the proper fluid will cause
hose and seal damage and fluid leaks.
7. Refill the pump with new fluid and bleed the air from
the system. Refer to Section 6A, Bleeding the Power
Steering System.
8. Inspect for leaks. If leaks are found, correct the cause
of the leak and bleed the system.

POWER STEERING GEAR 6C–3
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
POWER RACK AND PINION STERING GEAR
ConditionProbable CauseCorrection
Hissing Noise
Loose steering coupling joints.
Tighten the steering coupling
joints.

Improperly contacted the power
steering hose with other
components.
Fit the power steerng hose into
the hose clips correctly.
Rattling Noise in Steering Gear
Improperly contacted the power
steering line with the body.
Fix the steering line correctly.

Insufficient lubricant.
Lubricate the steering gear.

Loose steering gear mounting.
Tighten the steering gear
mounting bracket bolts.

Improperly installed tie rod ends.
Tighten the tie rod joints and
replace the tie rod end as needed.
Poor Return of Steering Wheel
to Center
Improperly contacted the steering
wheel with the turn signal housing.
Adjust the turn signal housing.

Improper binding or looseness of
steering coupling.
Replace the intermediate shaft.

Stuck and improperly aligned
power steering pump flow control
valve.
Replace the power steering pump.

Improper binding or looseness of
tie rods and ball joints.
Tighten the tie rods and the ball
joints. Replace the tie rods and
the ball joints as needed.

Poor adjustments of the steering
gear.
Perform a straight-ahead check.
Momentary Increase in Effect
When Turning the Wheel
Internal leaks of the power
steering pump.
Replace the power steering pump.
Quickly
The damage or restricted flow of
the hoses.
Replace the power steering hoses
and pipes.

Insufficient power steering fluid.
Fill the power steering fluid
reservoir.

Stuck and improperly operated
power steering pump flow control
valve.
Replace the power steering pump.
Steering Surges or Jerks When
Turning with Engine Running
Insufficient pressure of the power
steering pump.
Replace the power steering pump.

Stuck and improperly operated
power steering pump flow control
valve.
Replace the power steering pump.

The slippage of the pump drive
belt.
Tighten the pump drive belt.

Contaminated air in the power
steering system.
Bleed the power steering system.

6C –4 POWER STEERING GEAR
DAEWOO M-150 BL2
POWER RACK AND PINION STERING GEAR (Cont’d)
ConditionProbable CauseCorrection
Excessive Wheel Kickback or
Loose Steering
Contaminated air in the power
steering system.
Bleed the power steering system.

Worn or damaged wheel bearings.
Replace the wheel bearings.

Loose steering gear mounting.
Tighten the steering gear
mounting bracket bolts.

Improperly installed steering
gear-to-intermediate shaft joints.
Tighten the joint bolt.

Loose tie rods and ball joints.
Tighten the tie rods and the ball
joints.

Replace the tie rods and the ball
joints as needed.
Hard Steering or Lack of Assist
(Especially During Parking)
Stuck and improperly installed
power steering pump flow control
valve.
Replace the power steering pump.

Insufficient pressure of the power
steering pump.
Replace the power steering pump.

Internal leaks of power steering
pump.
Replace the power steering pump.

Improper tension of the pump
drive belt.
Adjust the pump drive belt
tension.

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

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.

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–20 MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
DAEWOO M-150 BL2
D108B507
RECEIVER DRYER BRACKET
Removal Procedure
1. Remove the front bumper fascia. Refer to Section
9O, Bumpers and Fascias.
2. Remove the receiver dryer bracket.
Remove the receiver dryer bracket bolt (1).
Remove the receiver dryer bracket–to–body bolts
(2).
D18B508B
Installation Procedure
1. Install the receiver dry bracket with the bolts.
Tighten
Tighten the receiver dryer bracket–to–body bolts
to 5 Nm (44 lb-in) (1).
Tighten the receiver dryer bracket bolt to 5 Nm
(44 lb-in) (2).
2. Install the front bumper fascia. Refer to Section 9O,
Bumpers and Fascias.
D108B509
D18B510A
COMPRESSOR
Removal Procedure
1. Remove the receiver dryer. Refer to “Receiver Dryer
and Dual Cut Switch” in this section.
2. Remove the A/C belt. Refer to Section 6B, Power
Steering Pump.
3. Remove the compressor.
Discharge and recover the refrigerant. Refer to
“Discharging, Adding Oil, Evacuating, and Charg-
ing Provedures for A/C System” in this section.
Remove the bolt securing the low pressure pipe
line to the compressor (1).
Remove the bolt securing the high pressure pipe
line to the compressor (2).
Disconnect the electrical connector (3).
Remove the upper bolt mounting the compressor–
to–bracket (4).
Remove the lower bolts mounting the compres-
sor–to–bracket (5).

MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B -- 21
DAEWOO M-150 BL2
D18B511B
Installation Procedure
1. Install the compressor with the mounting bolts.
Tighten
DTighten the compressor--to--bracket upper bolt to
20 NSm (15 lb-ft) (1).
DTighten the compressor--to--bracket lower bolts to
22 NSm (16 lb-ft) (2).
2. Connect the electrical connector.
D18B512A
3. Install the A/C high pressure pipe line to the compres-
sor with the bolt.
Tighten
Tighten the A/C high pressure pipe line bolt to 23 NSm
(17 lb-ft) (3).
4. Install the A/C low pressure pipe line to the compres-
sor with the bolt.
Tighten
Tighten the A/C low pressure pipe line bolt to 23 NSm
(17 lb-ft) (4).
5. Evacuate and charge the system. Refer to “Discharg-
ing, Adding Oil, Evacuating, and Charging Procedure
for A/C System” in this section.
6. Install the A/C belt. Refer toSection 6B, Power Steer-
ing Pump.
7. Install the receiver dryer. Refer to “Receiver Dryer
and Dual Cut Switch” in this section.
D18B513A
CONDENSER
1. Disconnect the negative battery cable.
2. Remove the front bumper fascia. Refer toSection
9O, Bumpers and Fascias.
3. Discharge and recover the refrigerant. Refer to “Dis-
charging, Adding Oil, Evacuating, and Charging Pro-
cedures for A/C system” in this section.
4. Remove the condenser.
DLoosen the condenser pipe--to--compressor pipe
fitting (1).
DLoosen the condenser pipe--to--receiver dryer pipe
fitting (2).