Engine DAEWOO MATIZ 2003 Service Manual PDF

ENGINE ELECTRICAL 1E–23
DAEWOO M-150 BL2
D102E716
Inspection / Measurement
(After the Overhaul)
1. Ground test for armature coil.

Inspect the insulation between commutator and ar-
mature coil using the voltmeter.

Replace the armature assembly if necessary.
D102E717
2. Short circuit test for armature coil.

If test equipment is available, check the armature
for short circuit by placing it on a growler, and hold-
ing back a saw blade over the armature core while
the armature is rotated. If the saw blade vibrates,
replace the armature.
D102E718
3. Open circuit test for armature coil.

Check the continuity between the commutator
bars using multimeter.

Replace the armature assembly if necessary.
D102E719
4. Inspect the brushes wear.

Inspect the brushes, the pop-out springs and the
brush holder for wear and damage. Replace the
brushes, if necessary.
a. Brushes wear limit.
DesciptionStandardLimit
Brushes wear11.3–11.5 mm
(0.445–0.453 in)7.0–7.25 mm
(0.275–0.285 in)

1E–24 ENGINE ELECTRICAL
DAEWOO M-150 BL2
D12E720A
9-12 Nm
4-6 Nm
Assembly Procedure
1. Install in the reverse order of removal.
2. Install the bolts / nuts.
Tighten
Tighten the starter motor terminal M nut to 9–12 Nm
(80–106 lb-in) (a).
Tighten the through-bolts to 4–6 Nm (35–53 lb-in)
(b).
D102E721
GENERATOR (A-TYPE : MANDO)
Disassembly Procedure
1. Remove the generator. Refer to “Generator” in this
section.
2. Remove the front bracket and rear bracket.

Remove the through-bolts (1).
D102E722

Pry front bracket downwards using a screwdriver
(2).

Separate the front bracket and rear bracket (3).
D102E723
3. Remove the pulley and rotor assembly from the front
bracket.

Cover the rotor with the cloth (1).

Place the pulley upwards and vice the rotor (2).

Remove the pulley nut (3).

Remove the pulley (4).

ENGINE ELECTRICAL 1E–25
DAEWOO M-150 BL2
D102E724
4. Remove the front bracket, rotor and collar.

Remove the collar (large) (1).

Remove the rotor from the front bracket (2).

Remove the collar (small) from the rotor shaft (3).
D102E725
5. Remove the front bearing.

Remove the support plate screws (1).

Remove the plate (2).

Remove the front bearing using the press (3).
D102E726
6. Remove the battery positive terminal nut from the
rear bracket.

Remove the battery position terminal nut (1).

Remove the washer (2).
D102E727
7. Remove the stator assembly from the rear bracket.

Remove the rectifier screw (1).

Remove the brush holder and regulator assembly
screws (2).

Remove the stator assembly with the rectifier /
brush holder / regulator (3).

1E–26 ENGINE ELECTRICAL
DAEWOO M-150 BL2
D102E728
8. Remove the rectifier / brush holder / regulator from
the stator.

Remove the rectifier / brush holder / regulator con-
nections (1).

Remove the stator and rectifier connections (2).
Notice: If the stator connections are welded, melt the
lead. Avoid overheating as it can damage the diodes.
D102E729
Inspection / Measurement
1. Inspect the rotor assembly.

Test the rotor for an open circuit by using the ohm-
meter (1). Replace the rotor if necessary.
D102E730

Test the rotor for open or short circuit (2).
DesciptionLimit
The measured
resistance2.9Ω

Replace the rotor if necessary.

Test the rotor for open or ground circuit by using
the ohmmeter (3). Replace the rotor if necessary.
D102E731
2. Inspect the stator.

Test the stator for an open circuit by using the ohm-
meter (1). Replace the stator if necessary.

ENGINE ELECTRICAL 1E–27
DAEWOO M-150 BL2
D102E732

Test the stator for open or ground circuit by using
the ohmmeter (2). Replace the starter if necessary.
D102E733
3. Inspect the rectifier.

Positive rectifier test:
Inspect the open circuit for stator coil lead termi-
nals using the ohmmeter (1).
Replace the rectifier if necessary.
D102E734

Negative rectifier test:
Inspect the open circuit for stator coil lead termi-
nals using the ohmmeter (2).
Replace the rectifier if necessary.
D102E735
4. Inspect trio diodes.

Inspect the open circuit for trio diodes using the
ohmmeter (1).

Replace the heat sink if necessary (a).

1E–28 ENGINE ELECTRICAL
DAEWOO M-150 BL2
D12E736A
5. Inspect the brush wear.

If the brush wear exceeds the specified valve (a),
replace the brush.
DesciptionStandardLimit
Brushes wear18.5 (0.73)13.5 (0.53)
D102E737
Assembly Procedure
1. Install in the reverse order of removal.

Assemble the stator assembly into the rear bracket
and rotor assembly.
a. Brushes.
b. Hole.
D12E738A
2. Install the bolts / nuts / screws.
Tighten

Tighten the brush holder / regulator / rectifier
screws to 9–12 Nm (80–106 lb-in) (a).

Tighten the battery positive terminal nut to 4–7
Nm (35–62 lb-in) (b).
D102E739
6–8 Nm
Tighten the front bearing spot plate screws to 6–8
Nm (53–71 lb-in) (c).

ENGINE ELECTRICAL 1E–29
DAEWOO M-150 BL2
D12E740A
4–6 Nm
80–110 Nm
Tighten the generator pulley nut to 80–110 Nm
(59–81 lb-ft) (d).

Tighten the through-bolts to 4–6 Nm (35–53 lb-in)
(e).
D102E741
GENERATOR (B-TYPE: DAC)
Disassembly Procedure
1. Remove the generator. Refer to “Generator” in this
section.
2. Remove the cover from the generator.

Remove the battery positive terminal nut (1).

Remove the cover (2).
a. Cover.
D102E742
3. Remove the regulator / brush holder / rectifier assem-
bly.

Remove the stator coil lead and rectifier diode lead
connections (1).
D102E743

Remove the rectifier bolts (2).

Remove the rectifier / regulator screw (3).

Remove the brush holder / regulator screw (4).

Remove the regulator screw (5).

Remove the regulator / brush holder / rectifier as-
sembly (6).

1E–30 ENGINE ELECTRICAL
DAEWOO M-150 BL2
D102E744
4. Remove the regulator / brush holder / rectifier.

Remove the rectifier and regulator connection (1).

Remove the regulator and brush holder connection
(2).

Visibly inspect the rectifier / regulator / brush hold-
er for damage or broken.
a. Rectifier.
b. Regulator.
c. Brush holder.
D102E745
5. Remove the shield before the drive end bracket and
the frame.

Remove the shield (1).

Remove the through-bolts (2).

Remove the frame from the drive end bracket (3).
D102E746
6. Remove the pulley and rotor assembly from the drive
end bracket.

Cover the rotor with the cloth (1).

Place the pulley upwards and vice the rotor (2).

Remove the pulley nut (3).

Remove the pulley (4).
D102E747
7. Remove the drive end bracket, rotor and space.

Remove the collar (1).

Remove the rotor from the driver end bracket (2).

Remove the collar from the rotor shaft (3).

Inspect the front bearing for corrosion, wear, noisy
and other damage (4).

ENGINE ELECTRICAL 1E–31
DAEWOO M-150 BL2
D102E748
8. Remove the stator assembly from the frame.

Remove the remains after the welding.

Remove the stator assembly (2).
D102E749
Inspection / Measurement
1. Inspect the rotor assembly.

Test the rotor coil for an open circuit by using the
ohmmeter. The reading should be sufficiently low,
or the rotor must be replaced (1).
D102E750

Test the rotor for open or short circuits. The read-
ing should be 2.6 to 2.8 ohms, or the rotor should
be replaced (2).

Test the rotor for open or ground circuits by using
the ohmmeter. The reading should be sufficiently
high, or the rotor must be replaced (3).

Inspect the fan blade for damage.
D102E751
2. Inspect the stator.

Test the rotor for an open circuit by using the ohm-
meter. The reading should be sufficiently low, or
the stator must be replaced (1).

1E–32 ENGINE ELECTRICAL
DAEWOO M-150 BL2
D102E752

Test the stator for open or ground circuits by using
the ohmmeter. The reading should be sufficiently
high, or the stator must be replaced (2).
D102E753
3. Inspect the rectifier.

Positive rectifier test:
Inspect the open circuit for stator coil lead termi-
nals using the ohmmeter (1).
Replace the rectifier if necessary.
D102E754

Negative rectifier test:
Inspect the open circuit for stator coil lead termi-
nals using the ohmmeter (2).
Replace the rectifier if necessary.
D102E755
4. Inspect trio diodes.

Inspect the open circuit for trio diodes using the
ohmmeter (1).
Replace the heat sink if necessary (a).