air condition DAEWOO MATIZ 2003 Service Repair Manual

SECTION INDEX
FRONT MATTER
0A
GENERAL INFORMATION
0B
ENGINE1
SERVICE
MATIZ
FOREWORD
This manual includes procedure for maintenance,
adjustment, service operation and removal and
installation of components.
All information, illustrations and specifications con-
tained in this manual are based on the latest prod-
uct information available at the time of manual ap-
proval.
The right is reserved to make changes at any time
without notice.
DAEWOO MOTOR CO., LTD.
INCHON, KOREA
MANUAL
SUSPENSION
2
DRIVELINE/AXLE 3
BRAKES
4
TRANSAXLE
5
STEERING
6
RESTRAINTS
8
BODY AND ACCESSORIES9 7 HVAC
(HEATING, VENTILATION,
AND AIR CONDITIONING)
(MY2003)

HVAC (HEATING, VENTILATION,
AND AIR CONDITIONING)
CONTENTS
SECTION 7A HEATING AND VENTILATION SYSTEM
SECTION 7B MANUAL CONTROL HEATING,
VENTILATION, AND AIR CONDITIONING
SYSTEM

GENERAL ENGINE INFORMATION 1A–5
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION PROCEDURE
GENERAL DIAGNOSIS
 
 Condition
 
 Probable cause
 
 Correction
Hard Starting (WithMalfunction of
Faulty fuse.
Replace the fuse.
normal cranking)Ignition System
Faulty spark plug.
Clean, adjust the plug gap or
replace.

Electric leakage at the high
tension cable.
Replace the cable.

Poor connection of the high
tension cable or lead wires.
Replace the cable or wires.

Worn distributor cap or
accumulated carbon in the
distributor cap.
Replace or clean the
distributor cap.

Damaged distributor rotor or
cap.
Replace the rotor or the cap.

Improper ignition timing.
Adjust the ignition timing.

Faulty ignition coil.
Replace the ignition coil.
Malfunction of Fuel
Lock of fuel in the fuel tank.
Feed the fuel.
System
Dirty or clogged fuel filter.
Replace the filter.

Clogged fuel pipe.
Clean the fuel pipe.

Malfunction of the fuel pump.
Replace the fuel pump.

Malfunction of the fuel
injector.
Replace the injector.

The foreign material in the
fuel tank.
Clean the fuel tank.
Decline of
Compression
Poor tightening spark plug.
Tighten to the specified
torque.
Pressure
Cracked cylinder head
gasket.
Replace the gasket.

Inadequate the valve
clearance.
Adjust the clearance.

Leakage of the valve
clearance.
Repair the valve.

Interference of the valve
stem.
Replace the valve or the
valve guide.

Low elasticity or damage of
the valve spring.
Replace the valve spring.

Abnormal interference of
pistons and cylinders.
Replace the piston ring.

Excessive wear of pistons,
rings, or cylinders.
Replace the ring or the
piston and boring or replace
the cylinder.

1A–6 GENERAL ENGINE INFORMATION
DAEWOO M-150 BL2
GENERAL DIAGNOSIS (Cont’d)
 Condition Probable cause Correction
Hard Starting (WithOthers
Broken timing belt.
Replace the belt.
normal cranking)
Malfunction of Positive
Crankcase Ventilation (PCV)
valve.
Check and replace Positive
Crankcase Ventilation (PCV)
valve if needed.

Loosening, damage or
leakage of the vacuum hose.
Connect the hose correctly
or replace it.

Leakage of intake system.
Replace intake system.
Lack of Engine PowerDecline of
Compression
Pressure
Refer to “Page 1A–5”.
Refer to “Page 1A–5”.
Malfunction of
Improper ignition timing.
Adjust the ignition timing.
Ignition System
Faulty spark plug.
Adjust or replace the spark
plug.

Malfunction of the distributor.
Repair or replace the
distributor. Check the rotor.

Electric leakage or poor
connection of the high
tension cable.
Connect the cable correctly
or replace it.
Malfunction of
Clogged fuel pipe.
Clean the pipe.
Fuel System
Clogged or contaminated
fuel filter.
Replace the filter.
Others
Clogged exhaust system.
Check and repair the
system.

Clogged or contaminated air
cleaner element.
Clean or replace the air
cleaner element.

Leak of the intake manifold
gasket.
Replace the gasket.

Dragging brakes.
Repair or replace the
brakes.

Slipping clutch.
Adjust or replace the clutch.
Rough Engine IdlingDecline of
Compression
Pressure
Refer to “Page 1A–5”.
Refer to “Page 1A–5”.
Malfunction of
Clogged fuel pipe.
Clean the pipe.
Fuel System
Clogged or contaminated
fuel filter.
Replace the filter.

Malfunction of the fuel
pressure regulator.
Replace the regulator.
Malfunction of
Ignition System
Malfunction of the spark
plug.
Adjust or replace the spark
plug.

Electric leakage or poor
connection of the high
tension cable.
Connect the cable correctly
or replace it.

Worn distributor cap terminal
or accumulated carbon in
the distributor cap.
Replace or clean the
distributor cap.

GENERAL ENGINE INFORMATION 1A–7
DAEWOO M-150 BL2
GENERAL DIAGNOSIS (Cont’d)
 Condition Probable cause Correction
Rough Engine IdlingMalfunction of
Ignition System
Loosening or damage of the
distributor rotor or cap.
Replace the rotor or cap.

Poor ignition timing.
Adjust the ignition timing.

Malfunction of the ignition
coil.
Replace the ignition coil.
Others
Clogged or contaminated air
cleaner element.
Clean or replace the air
cleaner element.

Leak of the intake manifold
gasket.
Replace the gasket.

Malfunction of Positive
Crankcase Ventilation (PCV)
valve.
Check the valve or replace it
if needed.

Poor connection or damage
or leakage of the vacuum
hose.
Connect the hose correctly
or replace it.
Engine Hesitate (Upon
pressing accelerating
pedal, the engineDecline of
Compression
Pressure
Refer to “Page 1A–5”.
Refer to “Page 1A–5”.
makes delayed
response. ThisMalfunction of
Poor ignition timing.
Adjust the ignition timing.response. This
situation is remarkable
when cruising orIgnition System
Poor spark plug or poor
adjustment of the plug gap.
Replace the plug or adjust
the gap.
starting.)
Electric leakage or poor
connection of the high
tension cable.
Connect the cable correctly
or replace it.
Others
Malfunction of the air cleaner
system.
Clean or replace the air
cleaner system.

Leak of the intake manifold
gasket.
Replace the gasket.
Engine Surging
(Engine power makes
fluctuation in a fixedDecline of
Compression
Pressure
Refer to “Page 1A–5”.
Refer to “Page 1A–5”.
speed and speed
changes withoutMalfunction of
Clogged fuel pipe.
Clean the pipe.changes without
operating the
accelerating pedal.)Fuel System
Clogged or contaminated
fuel filter.
Replace the filter.

Malfunction of the fuel
pressure regulator.
Replace the fuel pressure
regulator.
Malfunction of
Ignition System
Malfunction of the spark
plug.
Adjust or replace the spark
plug.

Electric leakage or poor
connection of the high
tension cable.
Connect the cable correctly
or replace it.

Worn distributor cap terminal
or accumulated carbon in
the distributor cap.
Clean or replace the
distributor cap.

Loosening or damage of the
distributor rotor or the cap.
Replace the distributor rotor
or the cap.

Poor ignition timing.
Adjust the ignition timing.

1A–8 GENERAL ENGINE INFORMATION
DAEWOO M-150 BL2
GENERAL DIAGNOSIS (Cont’d)
 
 Condition
 
 Probable cause
 
 Correction
Engine Surging
(Engine power makes
fluctuation in a fixedOthers
Leak of the intake manifold
gasket.
Clean or replace the gasket.
speed and speed
changes without
operating the
accelerating pedal.)
Leakage of the vacuum hose.
Connect the hose correctly
or replace it.
Excessive Detonation
(According to theOverheated
Engine
Refer to “Overheat” in this
page.
Refer to “Overheat” in this
page.
opening range of
throttle valve,Malfunction of
Abnormal spark plug.
Replace the spark plug.
knocking sound of
metallic is made withIgnition System
Poor ignition timing.
Adjust the ignition timing.metallic is made with
abnormal explosion.)

Electric leakage or poor
connection of the high tension
cable.
Connect the cable correctly
or replace it.
Malfunction of
Fuel System
Clogged or contaminated fuel
filter and fuel pipe.
Clean or replace the fuel
filter and the fuel pipe.
Others
Leak of the intake manifold
gasket.
Replace the gasket.

Excessive carbon deposit due
to abnormal combustion.
Remove the carbon.
OverheatMalfunction of
Lack of coolant.
Refill coolant.
Cooling System
Malfunction of the thermostat.
Replace the thermostat.

Malfunction of the cooling fan.
Check or replace the cooling
fan.

Poor water pump
performance.
Replace the pump.

Clogged or leaky radiator.
Clean, repair or replace the
radiator.
Malfunction of
Lubrication
Poor engine oil.
Replace engine oil with the
specified one.
System
Blocking oil filter or strainer.
Clean or replace the oil filter
or the strainer.

Lack of engine oil.
Refill oil.

Poor oil pump performance.
Replace or repair the pump.

Leakage of oil.
Repair.
Other
Damaged cylinder head
gasket.
Replace the gasket.
Poor Fuel
ConsumptionDecline of
Compression
Pressure
Refer to “Page 1A–5”.
Refer to “Page 1A–5”.
Malfunction of
Fuel System
Leakage of the fuel tank or
the fuel pipe.
Repair or replace the fuel
tank or the fuel pipe.

GENERAL ENGINE INFORMATION 1A–9
DAEWOO M-150 BL2
GENERAL DIAGNOSIS (Cont’d)
 Condition Probable cause Correction
Poor FuelMalfunction of
Improper ignition timing.
Adjust the ignition timing.
ConsumptionIgnition System
Abnormal spark plug
(Excessive carbon deposit,
inadequate gap, burnt
electrode).
Replace the plug.

Electric leakage or poor
connection of the high
tension cable.
Connect the cable normally
or replace it.
Malfunction of
Cooling System
Malfunction of the
thermostat.
Replace the thermostat.
Others
Improperly installed valve.
Repair or replace the valve.

Slipping clutch.
Repair or replace the clutch.

Low pressure of tires.
Adjust the pressure of tires.
ExcessiveLeakage of
Loosened oil drain plug.
Tighten the plug.
Consumption of
Engine OilEngine Oil
Loosened oil pan bolt.
Tighten the bolt.Engine Oil

Loosened oil filter.
Tighten the filter.

Loosened oil pressure
switch.
Tighten the switch.

Leakage of camshaft front oil
seal.
Replace the seal.

Leakage of crankshaft front
oil seal.
Replace the seal.

Leakage at the cylinder head
cover gasket.
Replace the gasket.

Damage of the cylinder head
gasket.
Replace the gasket.
Oil Mixing in
Combustion
Stuck piston ring.
Remove carbon and replace
the ring.
Chamber
Worn piston or cylinder.
Replace the piston or the
cylinder.

Worn piston ring or ring
groove.
Replace the piston or ring.

Inadequate position of the
piston ring cutting part.
Adjust the position.

Abrasion or damage of the
valve system.
Replace the valve system.
Low Oil PressureMalfunction of
Lubrication
Inadequate oil viscosity.
Replace with the specified
one.
System
Loosening of the oil pressure
switch.
Tighten the switch.

Lack of engine oil.
Refill oil.

Blocking oil strainer.
Clean the strainer.

GENERAL ENGINE INFORMATION 1A–11
DAEWOO M-150 BL2
CHECKING ENGINE FLUID LEVEL
Check the engine fluid level or condition. If needed, refill
or replace the oil.
Check the engine oil level within engine normal operat-
ing temperature as follows ;
1. After stopping the engine, wait for a few minutes to
accumulate oil into the oil pan.
2. After pulling out the oil level gauge (a), check the oil
level.
3. Clean the oil level gauge and insert the gauge into
guide.
4. After pulling out the oil level gauge again, recheck the
oil level and insert the gauge into guide again.
Important: Oil level should be between “MIN” mark and
“MAX” mark.
5. If oil level is below the “MIN” mark, refill engine oil as
much as the demanded quantify.
Important: If checking oil level under the engine cold
condition, oil is not accumulated into oil pan quickly and
correct level checking can not be performed. Therefore,
wait until temperature reaches the normal operating
condition and check the engine oil level.
D102A301
CHANGING ENGINE OIL OR OIL
FILTER
Tools Required
09915–47341 Oil Filter Wrench.
When checking engine oil level or condition, if needed,
change engine oil (including the filter) as follows ;
1. After stopping the engine, wait for a few minutes to
accumulate oil into the oil pan.
2. Remove the oil filter cap (b).3. Remove the oil drain plug (c) and draw oil off.
D102A302
4. After drawing oil completely, tighten the oil drain plug
to 30–40 Nm (22–30 lb-ft).
5. Replace the oil filter using the oil filter wrench
09915–47341 (d).

Remove the air cleaner/resonator/snorkel as-
sembly.

After removing the bolts, remove the heat
shield.

Loosen the power steering pump cap screw and
pull the power steering hose into the front.

Remove the oil filter.
Important: Whenever changing engine oil, replace the
oil filter. When replacing new oil filter, apply engine oil on
oil filter sealing.
D102A303

1A–12 GENERAL ENGINE INFORMATION
DAEWOO M-150 BL2
CHECKING ENGINE TIMING BELT
After checking the timing belt for looseness, crack, wear
or tension, replace the belt if necessary.
CHECKING ACCESSORY BELT
After checking the alternator belt (e), air conditioning/
power steering belt (f), air conditioning belt (g), power
steering belt (h), for looseness, crack, wear or tension,
replace the belt if necessary.
D102A304
CHECKING SPARK PLUG
After checking the spark plug for bad clearance, exces-
sive carbon deposit, worn electrode or damaged insula-
tor, replace the new one if necessary.
Remove and check the spark plug as follows ;
1. Pull the high tension cable cap portion (i), and discon-
nect the high tension cable from the spark plug.
If pulling the high tension cable (j), circuit could be
disconnected. Therefore, the cap portion should be
used.
D102A305
2. Remove the spark plugs from cylinder head using a
wrench.
3. Measure the spark plug clearance (k) with the filler
gauge. If measured value is not within the specified
value, adjust the grounding electrode.
When installing new spark plug, check the clearance
for equality and install it.
D102A306

1A–14 GENERAL ENGINE INFORMATION
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
 Application Description
  Maximum Speed 144 km/h (90 mph)
 Vehicle Capacity Gradeability 0.420 tan θ
 
Vehicle Capacity
 Minimum Turning Radius 4.5 m (14.8 ft)
  Bore × Stroke 68.5 × 72.0 mm (2.70 × 2.83 inch)
  Displacement 796 cm3 (48.6 in3)
  Compression Ratio 9.3 : 1
  Maximum Power 37.5 KW (6,000 rpm)
 
Engine Information
 Maximum Torque 68.6 Nm (50.59 lb-ft) (at 4,600 rpm)
Ignition Timing (Ignition Sequence)5 BTDC (1–3–2) / 10 BTDC (1–3–2)   
Air Conditioning System (ON)
 
1,000 ± 50 rpm  Idle Speed Air Conditioning System (OFF) 950 rpm  Engine Overhead Cam L–3 
 
 
 Ignition Type
 
 Direct Ignition System (DIS) /
High Energy Ignition (HEI)
  Distributor Optical Sensor Type
  Starter SD 80
   Unleaded BPR5EY–11, RN9YC4, WR8DCX
  Spark–Plug Leaded BPR5EY, RN9YC, WR8DC
  Fuel Injection Type MPI
  Fuel Pump Electric Motor Pump
Engine Part TypeFuel FilterCartridge Engine Part Type 
Lubricating Type
 
Forced Feed Type  Oil Pump Rotary Pump Type  Cooling Type Forced Water Circulation  Radiator Cross – Flow  Water Pump Centrifugal  Thermostat Pellet Type
  Air Cleaner Element Non Woven Fablic
  Muffler Catalytic Converter, Closed Circuit
  Battery MF
Engine PartEngine OilSJ Grade
SAE 5W30, SAE 10W30, SAE 15W40
CapacityRefrigerantFour Seasons   
Engine Disassembly
 
3.0 L (3.17 qt)   Oil Change (Including filter) 2.7 L (2.85 qt)  Engine Oil Oil Change (Not including filter) 2.5 L (2.64 qt)   Oil Level Gauge 1 L (1.06 qt) (MIN to MAX)  Coolant 3.8 L (4.02 qt) Engine Information Battery 12V–35 AH, 246 CCA
 Engine Information  

Generator

65 A
  Starter 0.8 kW
   Output Capacity 90 – 133 Lph
  Fuel Pump Output Pressure 380 kPa (55.1 Psi)
  Fuel Tank Capacity 35 L (9.2 gal), 38 L (10 gal)