cooling DAEWOO MATIZ 2003 Service Workshop Manual

1F–312 ENGINE CONTROLS
DAEWOO M-150 BL2
D102F539
4. Disconnect the coolant hoses and vacuum hoses
from the throttle body.
Loosen the clamps from the coolant hoses (1).
Disconnect the coolant hoses from the throttle
body (2).
Disconnect the vacuum hoses (3).
D102F541
5. Remove the throttle body from the intake manifold.
Remove the throttle body bolts (1).
Remove the throttle body (2).
Discard the throttle body gasket (3).
Inspect the throttle body gasket for the deforma-
tion and the damages.
9–12 Nm
D12F542A
Installation Procedure
1. Install in the reverse order of removal.
Important: Make sure the throttle control cable do not
hold the throttle open. With the engine OFF, check to
see that the accelerator pedal is free.
2. Install the throttle body with the bolts.
Tighten
Tighten the throttle body bolts to 9–12 Nm (80–106
lb-in).
D12F543A
ENGINE COOLANT TEMPERATURE
(ECT) SENSOR
Removal Procedure
1. Remove the engine coolant temperature (ECT) sen-
sor. Refer to Section 1D, Engine Coolings.

2E –4 TIRES AND WHEELS
DAEWOO M-150 BL2
WHEELS
Wheels must be replaced if they are bent, dented, have
excessive lateral or radial runout, leak air through welds,
have elongated bolt holes, or if the wheel bolts won’t
stay tight or are heavily rusted. Wheels with excessive
runout may cause vehicle vibration. Replacement
wheels must be equivalent to the original equipment
wheels in load capacity, diameter, rim width, offset, and
mounting configuration. A wheel of improper size or type
may affect wheel and bearing life, brake cooling,
speedometer/odometer calibration, vehicle ground
clearance, and tire clearance to the body and the chas-
sis.
INFLATION OF TIRES
The pressure recommended for any vehicle line is care-
fully calculated to give a satisfactory ride, handling,
tread life, and load-carrying capacity.
Tire pressure should be checked monthly or before any
extended trip. Check the tires when they are cold, after
the vehicle has sat for 3 hours or more or has been driv-
en less than 1 mile. Set the tire pressure to the specifi-
cations on the tire label located on the rear face of the
driver’s door. Tire inflation pressure is also given under
“Tire Size and Pressure Specifications” in this section.
Valve caps or extensions should be on the valves to
keep dust and water out.
Higher than recommended tire pressure can cause:

Hard ride

Tire bruising or damage

Rapid tread wear at the center of the tire
Lower than recommended pressure can cause:

Tire squeal on turns

Hard steering

Rapid and uneven wear on the edges of the tread

Tire rim bruises and rupture

Tire cord breakage

High tire temperatures
Unequal tire pressures on same axle can cause:

Uneven braking

Steering lead
Reduced handling

Swerve on acceleration

Torque steer
ROTATION TIRES
Front and rear tires perform different jobs and can wear
differently depending on the tires of road driven, driving
habit, etc.
The front tires will wear faster than the rear ones.
To avoid uneven wear of tires and to prolong tire life, in-
spect and rotate the tires every 5,000 km (3,100 miles).
After rotating the tires, adjust the tire inflation pressures
and be sure to check wheel nuts tightness.
D16A304A
WHEEL BALANCE
Balance is the easiest procedure to perform and should
be done first if the vibration occurs at high speeds, or if
the tires or the wheels are replaced.
When proceeding the wheel balancing procedure regard
the belows.
1. Do not use the wheel weight over two at the inboard
and the outboard flanges.
2. The total weight of the wheel weights should not ex-
ceed the 100 grams (3.5 ounces).
3. Blanching the assemblies with factory aluminum
wheels requires the use of special nylon–coated,
clip–on wheel weights.

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–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

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

7A–20 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
D108A507
BLOWER MOTOR AND COOLING
HOSE
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the blower motor cooling hose.
D108A508
2. Remove the blower motor.

Disconnect the motor electrical connector (1).

Turn the blower motor (2).
D108A509
Installation Procedure
1. Install the blower motor by turning the motor clock-
wise.
2. Connect the motor electrical connector.
3. Install the blower motor cooling hose.
D108A510
BLOWER RESISTOR
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the blower resistor.

Disconnect the blower resistor connector (1).

Remove the screws (2).

HEATING AND VENTILATION SYSTEM 7A–25
DAEWOO M-150 BL2
D18A527B
D18A528B
Installation Procedure
1. Install the heater module with the nuts.
Tighten
Tighten the heater module lower nuts to 3–5 Nm
(27–44 lb-in) (1).
Tighten the heater module upper nuts to 3–5 Nm
(27–44 lb-in) (2).
2. Install the evaporator on the vehicle equipped with
A/C. Refer to Section 7B, Manual Control Heating,
Ventilation, and Air Conditioning System.
3. Install the heater module–to–blower module connec-
tion tube on the vehicle not equipped with A/C with
the screw.
4. Install the instrument panel and the lower tie bar. Re-
fer to Section 9E, Instrumentation/Driver Information.
5. Connect the heater hoses to the heater module. Re-
fer to “Heater Hoses” in this section.
D108A529
D108A530
BLOWER MODULE
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the glove box from the instrument panel. Re-
fer to Section 9E, Instrumentation/Driver Information.
2. Remove the heater module–to–blower module con-
nection tube on the vehicle not equipped with A/C.
Refer to “Heater Module” in this section.
3. Remove the evaporator on the vehicle equipped with
A/C. Refer to Section 7B, Manual Control Heating,
Ventilation, and Air Conditioning System.
4. Remove the blower resistor. Refer to “Blower Resis-
tor” in this section.
5. Disconnect the blower motor connector. Refer to
“Blower Motor and Cooling Hose” in this section.
6. Remove the blower module.

Remove the nuts (1).

Disconnect the wiring harness (2).

7A–26 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
D18A531B
Installation Procedure
1. Install the blower module with the nuts.
Tighten
Tighten the blower module retaining nuts to 3–5 Nm
(27–44 lb-in).
2. Connect the wiring harness.
3. Connect the blower motor connector. Refer to “Blow-
er Motor and Cooling Hose” in this section.
4. Install the blower resistor. Refer to “Blower Resistor”
in this section.
5. Install the evaporator on the vehicle equipped with
A/C. Refer to Section 7B, Manual Control Heating,
Ventilation, and Air Conditioning System.
6. Install the heater module–to–blower module connec-
tion tube on the vehicle not equipped with A/C. Refer
to “Heater Module” in this section.
7. Install the glove box to the instrument panel. Refer to
Section 9E, Instrumentation/Driver Information.
D108A532
DEFROSTER DUCT AND HOSES
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the instrument panel. Refer to Section 9E,
Instrumentation/Driver Information.
2. Remove the defroster duct and hoses retaining
screws.
a. Retaining screw.
3. Remove the defroster duct and hoses.
b. Defroster duct and hoses.
D108A533
Installation Procedure
1. Install the defroster duct and hoses with the screws.
2. Install the instrument panel. Refer to Section 9E, In-
strumentation/Driver Information.