Front door DAEWOO MATIZ 2003 Service Repair Manual

BODY AND ACCESSORIES
CONTENTS
SECTION 9A BODY WIRING SYSTEM
SECTION 9B LIGHTING SYSTEMS
SECTION 9C HORNS
SECTION 9D WIPERS / WASHER SYSTEMS
SECTION 9E INSTRUMENTATION / DRIVER INFORMATION
SECTION 9F AUDIO SYSTEMS
SECTION 9G INTERIOR TRIM
SECTION 9H SEATS
SECTION 9I WATERLEAKS
SECTION 9J WINDNOISE
SECTION 9K SQUEAKS AND RATTLES
SECTION 9L GLASS AND MIRRORS
SECTION 9M EXTERIOR TRIM
SECTION 9N FRAME AND UNDERBODY
SECTION 9O BUMPERS AND FASCIAS
SECTION 9P DOORS
SECTION 9Q ROOF
SECTION 9R BODY FRONT END
SECTION 9S BODY REAR END
SECTION 9T IMMOBILIZER ANTI–THEFT SYSTEM

1F–8 ENGINE CONTROLS
DAEWOO M-150 BL2
tions. With the ignition ON and the engine not running,
the Engine Control Module (ECM) will read the manifold
pressure as barometric pressure and adjust the air/fuel
ratio accordingly. This compensation for altitude allows
the system to maintain driving performance while hold-
ing emissions low. The barometric function will update
periodically during steady driving or under a wide open
throttle condition. In the case of a fault in the barometric
portion of the MAP sensor, the ECM will set to the de-
fault value.
A failure in the MAP sensor circuit sets a diagnostic
trouble codes P0107, P0108 or P0106.
ENGINE CONTROL MODULE
The Engine Control Module (ECM), is the control center
of the fuel injection system. It constantly looks at the in-
formation from various sensors and controls the sys-
tems that affect the vehicle’s performance. The ECM
also performs the diagnostic functions of the system. It
can recognize operational problems, alert the driver
through the Malfunction Indicator Lamp (MIL), and store
diagnostic trouble code(s) which identify the problem
areas to aid the technician in making repairs.
There are no serviceable parts in the ECM. The calibra-
tions are stored in the ECM in the Programmable Read
Only Memory (PROM).
The ECM supplies either 5 or 12 volts to power the sen-
sors or switches. This is done through resistance in the
ECM which are so high in value that a test light will not
come on when connected to the circuit. In some cases,
even an ordinary shop voltmeter will not give an accu-
rate reading because its resistance is too low. You must
use a digital voltmeter with a 10 megohm input imped-
ance to get accurate voltage readings. The ECM con-
trols output circuits such as the fuel injectors, the Idle Air
Control (IAC) valve, the A/C clutch relay, etc., by control-
ling the ground circuit through transistors or a device
called a “quad-driver.”
FUEL INJECTOR
The Multi-port Fuel Injection (MFI) assembly is a sole-
noid-operated device controlled by the Engine Control
Module (ECM) that meters pressurized fuel to a single
engine cylinder. The ECM energizes the fuel injector or
solenoid to a normally closed ball or pintle valve. This al-
lows fuel to flow into the top of the injector, past the ball
or pintle valve, and through a recessed flow director
plate at the injector outlet.
The director plate has six machined holes that control
the fuel flow, generating a conical spray pattern of finely
atomized fuel at the injector tip. Fuel from the tip is di-
rected at the intake valve, causing it to become further
atomized and vaporized before entering the combustion
chamber. A fuel injector which is stuck partially open
would cause a loss of fuel pressure after the engine is
shut down. Also, an extended crank time would be no-
ticed on some engines. Dieseling could also occur be-cause some fuel could be delivered to the engine after
the ignition is turned off.
FUEL CUT-OFF SWITCH
The fuel cutoff switch is a safety device. In the event of a
collision or a sudden impact, it automatically cuts off the
fuel supply and activates the door lock relay. After the
switch has been activated, it must be reset in order to
restart the engine. Reset the fuel cutoff switch by press-
ing the rubber top of the switch. The switch is located
near the right side of the passenger’s seat.
KNOCK SENSOR
The knock sensor detects abnormal knocking in the en-
gine. The sensor is mounted in the engine block near the
cylinders. The sensor produces an AC output voltage
which increases with the severity of the knock. This sig-
nal is sent to the Engine Control Module (ECM). The
ECM then adjusts the ignition timing to reduce the spark
knock.
VARIABLE RELUCTANCE (VR)
SENSOR
The variable reluctance sensor is commonly refered to
as an “inductive” sensor.
The VR wheel speed sensor consists of a sensing unit
fixed to the left side front macpherson strut, for non-ABS
vehicle.
The ECM uses the rough road information to enable or
disable the misfire diagnostic. The misfire diagnostic
can be greatly affected by crankshaft speed variations
caused by driving on rough road surfaces. The VR sen-
sor generates rough road information by producing a
signal which is proportional to the movement of a small
metal bar inside the sensor.
If a fault occurs which causes the ECM to not receive
rough road information between 30 and 70 km/h (1.8
and 43.5 mph), Diagnostic Trouble Code (DTC) P1391
will set.
OCTANE NUMBER CONNECTOR
The octane number connector is a jumper harness that
signal to the engine control module (ECM) the octane
rating of the fuel.
The connector is located on the next to the ECM. There
are two different octane number connector settings
available. The vehicle is shipped from the factory with a
label attached to the jumper harness to indicate the oc-
tane rating setting of the ECM. The ECM will alter fuel
delivery and spark timing based on the octane number
setting. The following table shows which terminal to
jump on the octane number connector in order to
achieve the correct fuel octane rating. Terminal 2 is
ground on the octane number connector. The find the

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.

8B–74 SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
DAEWOO M-150 BL2
D110B010
AIRBAG MODULE DEPLOYMENT
(IN VEHICLE)
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Deploy the airbags before disposing of them. This in-
cludes those in a whole vehicle being scrapped.
If the vehicle is still within the warranty period, contact
the Daewoo regional service manager for approval or
special instructions before deploying the airbag mod-
ules.
Caution: Before deploying the airbags, remove all
loose objects from the airbags expansion area.
Caution: Deploy the airbags with the vehicle doors
closed and the side windows open.
Caution: Deploy the airbags only in an evacuated
area. Service personnel who must be present dur-
ing the deployment should be at least 10 meters
(33 feet) in front of the vehicle.
Caution: Do not connect the voltage source until af-
ter having completed all other preparations for the
deployment of the airbags.
Caution: Allow a deployed airbag module to cool
for at least 30 minutes before handling.
Caution: Wear the gloves and the eye protectors
during the disposal process.
Caution: If the deployment fails, disconnect the volt-
age source and wait 5 minutes before approaching
the vehicle.
Deployment Procedure
1. Disconnect both battery cables and place the battery
at least 10 meters (32.8 feet) from the vehicle.
Caution: Wait 1 minute after disconnecting both
battery cables to allow the capacitor inside the
sensing and diagnostic module (SDM) to discharge
before taking any other action. The capacitor sup-
plies the reserve power to deploy the airbags, even
if the battery is disconnected. Unintentional deploy-
ment of the airbags can cause injury.
2. Remove the lower cover from the steering column.
3. At the lower steering column, cut the two wires lead-
ing from the supplemental inflatable restraint (SIR)
harness to the clock spring.
4. Strip 13 mm (0.5 inch) of insulation from the ends of
the wires leading to the clock spring.
5. Use two additional wires, each at least 10 meters
(33 feet) long, to reach from the deployment battery
to the airbag module.
6. Strip 13 mm (0.5 inch) of insulation from the ends of
these two additional wires.
7. Twist the two wires together at one end.

8B–76 SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
DAEWOO M-150 BL2
AIRBAG MODULE DEPLOYMENT
(OUTSIDE OF VEHICLE)
Deploy all intact airbag modules that have been

Removed from a scrapped vehicle.

Found to be defective.

Found to have been damaged during transit, storage,
or service.
Caution: Deploy the airbags only in an evacuated
area. Service personnel who must be present dur-
ing the deployment should be at least 10 meters
(33 feet) in front of the vehicle.
Caution: Do not connect the voltage source until
completing all other preparations for the deploy-
ment of the airbags.
Caution: Allow a deployed airbag module to cool
for at least 30 minutes before removing it from the
vehicle.
Caution: Wear gloves and eye protection during the
disposal process.
Caution: If the deployment fails, disconnect the volt-
age source and wait 5 minutes before approaching
the vehicle.
1. Position the airbag module face up, on flat ground
outdoors, at least 10 meters (33 feet) from any ob-
stacles or people.
2. Place a vehicle battery at least 10 meters (33 feet)
away from the airbag module.
3. Deploy the airbag module using the deployment tool.
4. Using the proper precautions, dispose of the
deployed airbag. Refer to “Deployed Airbag Module
Disposal Procedure” in this section.
DEPLOYED AIRBAG MODULE
DISPOSAL PROCEDURE
Caution: After an airbag module has been
deployed, the surface of the airbag may contain a
powdery residue. The powder lubricates the airbag
as it inflates. The dust that is produced as a by-
product of the deployment is unlikely to be harmful,
but use the gloves and the safety glasses in order to
prevent any possible irritation of the skin and the
eyes.
Caution: After deployment, the metal surfaces of
the airbag module will be hot. In order to avoid the
risk of an injury or a fire, do not place the deployed
airbag modules near any flammable objects, and al-
low the airbag modules to cool for 30 minutes be-
fore handling them.
Deploy an airbag before disposing of it. This includes
those in a whole vehicle being scrapped.

DAEWOO M-150 BL2
SECTION 9A
BODY WIRING 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 9A-2. . . . . . . . . . . . . . . . . .
How to Read Electrical Wiring Diagram 9A-2. . . . . . .
How to Check Terminal Number of Connector 9A-4.
Special Tools and Equipment 9A-5. . . . . . . . . . . . . . .
Special Tools Table 9A-5. . . . . . . . . . . . . . . . . . . . . . . .
Schematic and Routing Diagrams 9A-6. . . . . . . . . . .
Wire Color Chart 9A-6. . . . . . . . . . . . . . . . . . . . . . . . . .
Power Distribution Schematic 9A-7. . . . . . . . . . . . . . .
Relay & Fuse Box Locator (Engine Room) 9A-8. . . .
Fuse Box Locator
(Passenger Compartment) 9A-9. . . . . . . . . . . . . . . . Fuse Chart 9A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Harness Routing 9A-11. . . . . . . . . . . . . . . . . . . .
Engine Harness Routing 9A-12. . . . . . . . . . . . . . . . . . .
Instrument Harness Routing 9A-14. . . . . . . . . . . . . . .
Airbag Harness Routing 9A-16. . . . . . . . . . . . . . . . . . .
Body Harness Routing 9A-17. . . . . . . . . . . . . . . . . . . .
Front Door Harness Routing 9A-19. . . . . . . . . . . . . . .
Rear Door Harness Routing 9A-20. . . . . . . . . . . . . . . .
Tailgate Harness Routing 9A-21. . . . . . . . . . . . . . . . . .

9A–10 BODY WIRING SYSTEM
DAEWOO M-150 BL2
FUSE CHART
FuseRating/ SourceCircuit
Ef1 (Engine Fuse)50ABATABS
Ef240ABATIgnition Switch, Instrument Panel Fuse Block
(F5, F11 ~ F13)
Ef310ABATFuel cut-off Switch (Inertia Switch)
Ef410AIGN 1Fuel, EBCM, Generator, VSS, Fuel Pump Relay, Main Relay,
Ignition Coil
Ef5––Not Used
Ef620ABATBlower Motor
Ef715ABATRear Window Defogger
Ef810ABATHeadlamp Hi Beam, Right Side
Ef910ABATHeadlamp Hi Beam, Left Side
Ef1010ABATHeadlamp Lo Beam, Right Side
Ef1110ABATHeadlamp Lo Beam, Left Side
Ef1210A58Tail and Illumination Lamps, Right Side
Ef1310A58Tail and Illumination Lamps, Left Side
Ef1410ABATA/C Compressor
Ef1530ABATRadiator Fan
Ef1610A–Spare
Ef1710ABATHorn
Ef1820ABATHeadlamp Relay, Hi Beam Passing, DRL Module
Ef1915ABATECM, Main Relay
Ef2015ABATFront Fog Lamp
Ef2115A–Spare
F1 (Fuse)10AIGN 1Cluster, Clock, IMMO, Anti-Theft Control Unit,
DRL Relay
F210AIGN 1SDM
F325AIGN 1Hazard Switch, DRL Module
F410AIGN 1Turn Signal Lamp
F515ABATStop Lamp
F610AACCAudio
F720AACCCigar Light
F815AIGN 2Wiper
F915AIGN 2Rear Wiper Motor, Front & Rear Washer, Backup Lamp
F1010AIGN 2Auto Miror Switch
F1110AEf2IMMO, Audio, Room Lamp
F1215AEf2Hazard, Clock
F1320AEf2Anti-Theft Control Unit, Door Lock
F1420ASTStarter Motor

BODY WIRING SYSTEM 9A–19
DAEWOO M-150 BL2
FRONT DOOR HARNESS ROUTING
D111407D

DAEWOO M-150 BL2
SECTION 9B
LIGHTING SYSTEMS
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 9B-2. . . . . . . . . . . . . . . . . .
Headlamps and Parking Lamps 9B-2. . . . . . . . . . . . .
Front Turn Signal Lamps 9B-2. . . . . . . . . . . . . . . . . . .
Rear Fog Lamp 9B-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Taillamps 9B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
License Plate Lamp 9B-2. . . . . . . . . . . . . . . . . . . . . . . .
Interior Courtesy Lamp 9B-2. . . . . . . . . . . . . . . . . . . . .
Backup Lamp(s) 9B-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Daytime Running Lamps (DRL)
(W/Europe Only) 9B-2. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 9B-3. . . . .
Headlamps 9B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Signal Lamps and Hazard Lamps 9B-4. . . . . . .
Stoplamps and Interior Courtesy Lamp 9B-5. . . . . . .
Rear Fog Lamp 9B-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 9B-7. . . . . . . . . . . . . . . . . . . . . . . . .
Headlamps 9B-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Signal Lamps 9B-8. . . . . . . . . . . . . . . . . . . . . . . .
Side Turn Signal Lamps 9B-8. . . . . . . . . . . . . . . . . . . .
Taillamps Assembly 9B-9. . . . . . . . . . . . . . . . . . . . . . . .
Front Fog Lamp 9B-9. . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Fog/Backup Lamp(s) 9B-10. . . . . . . . . . . . . . . . .
Center High-Mounted Stoplamp 9B-11. . . . . . . . . . . . CHMSL Mounting Bracket 9B-12. . . . . . . . . . . . . . . . .
License Plate Lamps 9B-12. . . . . . . . . . . . . . . . . . . . . .
Door Jamb Switch 9B-13. . . . . . . . . . . . . . . . . . . . . . . .
Interior Courtesy Lamp 9B-13. . . . . . . . . . . . . . . . . . . .
Daytime Running Lamp Module
(W/Europe Only) 9B-14. . . . . . . . . . . . . . . . . . . . . . .
Ashtray Lamp 9B-14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Luggage Room Lamp 9B-15. . . . . . . . . . . . . . . . . . . . .
Specifications 9B-16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bulb Usage Chart 9B-16. . . . . . . . . . . . . . . . . . . . . . . .
Schematic and Routing Diagrams 9B-17. . . . . . . . . .
Backup Lamp(s) Circuit 9B-17. . . . . . . . . . . . . . . . . . .
Headlamps Circuit 9B-18. . . . . . . . . . . . . . . . . . . . . . . .
Headlamp Leveling Circuit 9B-19. . . . . . . . . . . . . . . . .
Tail and Licence Plate Lamps Circuit 9B-20. . . . . . . .
Stoplamps Circuit 9B-21. . . . . . . . . . . . . . . . . . . . . . . .
Turn and Hazard Lamps Circuit 9B-22. . . . . . . . . . . .
Interior Courtesy Lamp Circuit 9B-23. . . . . . . . . . . . . .
Front Fog Lamp Circuit 9B-24. . . . . . . . . . . . . . . . . . . .
Rear Fog Lamp Circuit 9B-25. . . . . . . . . . . . . . . . . . . .
Dimmer Control Circuit (Except W/Europe) 9B-26. .
Daytime Running Lamps Circuit
(W/Europe Only) 9B-27. . . . . . . . . . . . . . . . . . . . . . .

9B – 2 LIGHTING SYSTEMS
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
HEADLAMPS AND PARKING LAMPS
The headlamps are controlled by the multifunction lever
located on the left side of the steering column. They will
come on with the ignition switch in any position. Turning
the headlamp switch to the first position turns on the
parking lamps, the license plate lamps and the instru-
ment panel illumination. Turning the switch to the sec-
ond position turns on all of the previous lamps and the
headlamps. Turning the switch to the off position turns
off all the lamps.
The parking lamps can be turned on by turning the light-
ing switch to the first position. The parking lamps can be
turned off by turning the switch to the OFF position.
Headlamp high beam and low beam are also controlled
by this lever. When the headlamps are on, pushing the
lever away from the driver until the switch clicks
changes the lamp from low beam to high beam. An indi-
cator lamp on the instrument cluster assembly will come
on when the high beam headlamps are on. To return the
headlamps to low beam, pull the lever toward the driver.
The headlamps must be aimed for proper illumination of
the road. Headlamp aim should be checked whenever a
new headlamp assembly is installed or service repairs to
the front end area may have disturbed the headlamp as-
sembly or its mountings.
FRONT TURN SIGNAL LAMPS
When the turn signals are activated, the side turn signal
lamps flash to signal a turn. The turn signal works only
when the ignition switch is on.
The turn signals are controlled by the light switch on the
left side of the steering column. Moving the lever all the
way up or down (past the detent) will turn on the turn sig-
nals. When the turn is completed, the lever will return to
horizontal and the turn signals will stop flashing.
For changing lanes or shallow turns where the steering
wheel does not turn far enough to cancel the signal,
move the signal only to the first detent and hold it there.
When the lever is released, it will return to horizontal and
the turn signal will cancel.
REAR FOG LAMP
The rear fog lamp is incorporated in the drive side tail-
lamp assembly and are controlled by the rear fog lamp
switch on the instrument panel. The rear fog lamp can
be turned on only when headlamps are on.
TAILLAMPS
The taillamps, stoplamps, backup lamp(s), rear fog lamp
(if equipped with) and turn signal lamps are one assem-
bly.
Turning on either the headlamps or the parking lamps
will also turn on the taillamps. When the brake pedal is
pushed, the taillamps will glow brighter to serve as sto-
plamps.
The center high-mounted stoplamp is located in the rear
window and will come on when the brake pedal is
pressed.
LICENSE PLATE LAMPS
The license plate lamps will come on when the head-
lamps or the parking lamps are on. The license plate
lamps are mounted on the rear bumper, above the li-
cense plate.
INTERIOR COURTESY LAMP
The courtesy lamp is located on the headliner just be-
fore the front seats. The lamp switch has three posi-
tions. If the switch is in the center position, the lamp will
go on whenever a door is opened and go off when it is
closed. In the ON position, the lamp will stay on until it is
turned off. In the OFF position, the lamp will not come
on, even when a door is opened.
BACKUP LAMP(S)
The backup lamps are located in the rear combination
lamps. They will come on when the transaxle is shifted
into REVERSE. On a vehicle with a manual transaxle,
they are activated by a reverse switch which is part of
the transaxle.
DAYTIME RUNNING LAMPS (DRL)
(W/Europe Only)
The daytime running lamps (DRL) work in conjunction
with the exterior lamps system. When the ignition switch
is turned to the ”II” position with the light switch off, park-
ing, tail, license plate and instrument panel lights illumi-
nate. And, when the engine is started, the headlamps
(low beam) also come on.
They remain on until the ignition switch is turned off or
the light switch is turned on. They revert to normal op-
eration when the light switch is on.
The daytime running lamps (DRL) is optional.