Engine DAEWOO MATIZ 2003 Service Manual PDF

ENGINE ELECTRICAL 1E–13
DAEWOO M-150 BL2
GENERATOR SYSTEM CHECK
When operating normally, the generator indicator lamp
will come on when the ignition switch is in the ON posi-
tion and go out when the engine starts. If the lamp oper-
ates abnormally or if an undercharged or overcharged
battery condition occurs, the following procedure may
be used to diagnose the charging system. Remember
that an undercharged battery is often caused by acces-
sories being left on overnight or by a defective switch
that allows a lamp, such as a trunk or glove box lamp, to
stay on.
Diagnose the generator with the following procedure:
1. Visually check the belt and wiring.
2. With the ignition switch in the ON position and the en-
gine stopped, the charge indicator lamp should be on.
If not, detach the harness at the generator and
ground the ‘‘L’’ terminal in the harness with a fused,
5-ampere jumper lead.
If the lamp lights, replace the generator. Refer to
“Generator” in the On-Vehicle Service section.

If the lamp does not light, locate the open circuit
between the ignition switch and the harness con-
nector. The indicator lamp bulb may be burned out.
3. With the ignition switch in the ON position and the en-
gine running at moderate speed, the charge indicator
lamp should be off. If not, detach the wiring harness
at the generator.

If the lamp goes off, replace the generator. Refer to
“Generator” in the On-Vehicle Service section.

If the lamp stays on, check for a short to ground in
the harness between the connector and the indica-
tor lamp.
Important: Always check the generator for output be-
fore assuming that a grounded ‘‘L’’ terminal circuit has
damaged the regulator. Refer to “Generator” in the Unit
Repair section.

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).

ENGINE ELECTRICAL 1E–15
DAEWOO M-150 BL2
D102E504
GENERATOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the harness connector.

Remove the battery harness connector nut to dis-
connect the battery positive connector (1).

Disconnect the generator harness connector (2).
D102E505
3. Remove the generator drive belt.

Loosen the generator adjusting bolt (1).

Remove the lower bracket-to-generator bolt and
nut (2).

Separate the generator drive belt from the genera-
tor.
D102E506
4. Remove the engine mounting lower bracket.

Remove the engine mounting lower bracket, at-
taching reaction rod bolt and nut (1).

Remove the engine mounting lower bracket bolts
(2).

Remove the engine mounting lower bracket (3).
D102E507
5. Remove the generator.

Remove the generator adjusting bolt (1).

Carefully remove the genrator (2).

1E–16 ENGINE ELECTRICAL
DAEWOO M-150 BL2
D12E508A
35–41 Nm
68–83 Nm
Installation Procedure
1. Install in the reverse order of removal except genera-
tor driver velt.
2. Install the engine mounting lower bracket bolts and
nut.
Tighten

Tighten the engine mounting lower bracket bolts to
35–41 Nm (25–30 lb-ft) (a).

Tighten the engine mounting lower bracket, attach-
ing reaction rod bolt and nut to 68–83 Nm (50–61
lb-ft) (b).
D12E509A
4–7 Nm
18–28 Nm3. Install the bolts and nut.Tighten

Tighten the generator adjusting bolt to 4–7 Nm
(35–62 lb-in) (a).

Tighten the generator lower bracket bolt and nut to
18–28 Nm (13–21 lb-ft) (b).

Inspect the generator drive belt tension.
D12E511A
BATTERY
Removal Procedure
1. Disconnect the negative battery cable and then dis-
connect the positive battery cable.

Remove the battery cable nut to disconnect the
negative battery cable (1).

Remove the battery terminal cap (2).

Remove the battery cable nut to disconnect the
positive battery cable (3).
D102E512
2. Remove the battery.

Remove the battery rod nut (1).

Remove the battery rod (2).

Remove the battery (3).

ENGINE ELECTRICAL 1E–17
DAEWOO M-150 BL2
D12E513A
Installation Procedure
1. Install in the reverse order of removal.
2. Install the battery rod and cable nuts.
Tighten

Tighten the battery rod nut to 6–8 Nm (53–71 lb-
in) (a).

Tighten the battery cable nut to 9-12 Nm (80–106
lb-in) (b).
D12E514A
DISTRIBUTOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the air filter, resonator with snorkel assem-
bly. Refer to Section 1B, SOHC Engine Mechanical.
3. Disconnect the ignition wires and electrical connec-
tor.

Disconnect the optical sensor connector (1).

Disconnect the ignition wires (2).

Remove the ignition wire clip (3).
D102E515
4. Remove the distributor.
Important: Mark on the distributor housing and case
before remove distributor (a).

Remove the distributor bolts (1).

Carefully remove the distributor assembly (2).
D12E516A
10–16 Nm
Installation Procedure
1. Install in the reverse order of removal.
2. Install the distributor bolts.
Tighten
Tighten the distributor bolts to 10–16 Nm (89–142 lb-
in).

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 – 19
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
UNIT REPAIR
D102E701
STARTER MOTOR
Inspection / Measurement
(Before the Overhaul)
1. Remove the starter. Refer to “Starter” in this section.
2. Pinion clearance inspection.

Disconnect the starter motor terminal M (1).

Connect the 12-volt battery lead to the starter mo-
tor terminals M and S.
Notice: Complete the testing in a minimum amount of
time to prevent overheating and damaging the solenoid.
(in 10 seconds)
D102E702

Switch on to move the pinion gear (2).

Now check the clearance between the pinion and
the stopper with the filler gauge (3).

If the clearance does not fall within the limits,
check for improper installation and replace all worn
parts.
D102E703
3. Magnetic switch pull-in test.

Disconnect the starter motor terminal M (1).

Connect the 12-volt battery lead to the starter mo-
tor terminals M and S.
Notice: Complete the testing in a minimum amount of
time to prevent overheating and damaging the solenoid.
(in 10 seconds)

1E–20 ENGINE ELECTRICAL
DAEWOO M-150 BL2
D102E704

Inspect the pinion gear’s moving to the outside (2).

If the pinion gear does not move outside, replace
the magnetic switch.
D102E705
4. Solenoid hold-in test.

Disconnect the starter motor terminal M (1).

Connect the 12-volt battery lead to the starter mo-
tor terminal S and body.
Notice: Complete the testing in a minimum amount of
time to prevent overheating and damaging the solenoid.
D102E706

Check the pinion gear’s moving to the outside (2).

If the pinion gear move to the inside, the circuit is
open. Replace the magnetic switch.
D102E707
5. Solenoid return test.

Disconnect the starter motor terminal M (1).

Connect the 12-volt battery lead to the starter mo-
tor terminal S and body.
Notice: Complete the testing in a minimum amount of
time to prevent overheating and damaging the solenoid.

ENGINE ELECTRICAL 1E–21
DAEWOO M-150 BL2
D102E708

Check the returning speed of pinion gear (2).
If the returning speed is fast, the operation is nor-
mal.

Replace the solenoid if the operation is abnormal.
D102E709
5. No-road test.

Connect the 12-volt battery lead to the starter cir-
cuit.

Connect the current and the voltage (1).

Install the starter motor rpm gage (2).

Start the starter motor with the switch on (3).

Measure the speed of pinion gear and the current.

If the measurement satisfy the limit, the starter mo-
tor is normal.
D102E710
DesciptionLimit
The speed of pinion
gearMinimum: 2,000 rpm
Condition:
Voltage/CurrentMaximum: 9V / 150A

Replace the starter motor if necessary.
D102E711
Disassembly Procedure
1. Remove the starter contact end frame.

Remove the through-bolts (1).

Remove the contact end frame bolts (2).

Remove the frame with the spacer (3).

1E–22 ENGINE ELECTRICAL
DAEWOO M-150 BL2
D102E712
2. Remove the brush holder assembly.

Remove the starter motor terminal M nut (1).

Remove the brush holder assembly (2).
D102E713
3. Remove the field frame assembly from the armature
set (1).
D102E714
4. Remove the solenoid assembly.

Remove the solenoid screws (1).

Remove the magnetic switch (2).

Remove the spring (3).
D102E715
5. Remove the armature set and solenoid from the start-
er housing.

Remove the armature set (1).

Remove the rubber sealer (2).

Remove the shift lever plate (3).

Remove the shift lever (4).

Remove the solenoid (5).

Remove the gasket (6).