air conditioning 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

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)

POWER BOOSTER 4C–7
DAEWOO M-150 BL2
D24C003
Installation Procedure
1. Install the power booster with the new cotter pin, cle-
vis pin and nuts.
Tighten
Tighten the nuts to 16 Nm (12 lb-ft).
Important: Make sure the distance from the booster
to the center of the clevis bore should be 100mm
(3.94 in.).
2. Install the evaporator unit with the screws. Refer to
Section 7B, Manual Control Heating, Ventilation, and
Air Conditioning System.
3. Install the instrument panel assembly. Refer to Sec-
tion 9E, Instrument/Driver Information.
4. Connect the vacuum hose to the power booster.
5. Install the master cylinder assembly. Refer to Section
4B, Master Cylinder.

7A–2 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
DESCRIPTION AND SYSTEM OPERATION
HEATING AND VENTILATION
SYSTEMS
The base heater system is designed to provide heating,
ventilation, windshield defrosting, and side window de-
fogging.
The heater and fan assembly blower regulates the air-
flow from the air inlet for further processing and distribu-
tion.
The heater core transfers the heat from the engine cool-
ant to the inlet air.
The temperature door regulates the amount of the air
that passes through the heater core. The temperature
door also controls the temperature of the air by control-
ling the mix of the heated air and the ambient air.
The mode door regulates the flow and the distribution
of the processed air to the heater ducts and to the de-
froster ducts.
This console-mounted heating and ventilation panel
contains the following:
Three Rotary Control Knobs
1. The Rotary Temperature Control Knob

Actuates by cable.

Raises the temperature of the air entering the ve-
hicle by rotation toward the right, or the red portion
of the knob.
2. The Rotary Blower Control Knob

Turns on to operate the blower motor at four speeds.

Turns
to stop the blower.

Operates completely independently both from the
mode control that regulates the defroster door and
from the temperature control knob.
Changes the fan speed in any mode and at any
temperature setting.
3. The Rotary Mode Control Knob:

Actuates by cable.

Regulates the air distribution between the wind-
shield, the instrument panel, and the floor vents.
Push Knobs
1. The Rear Window Defogger Push Knob

Controls the rear window defogger.

Turns ON the rear window defogger when the push
knob is pressed and the indicator lamp is illumi-
nated.
2. The A/C Push Knob (if the vehicle is equipped with air
conditioning)

Controls the A/C.

Turns the A/C ON when the push knob is down.
However, if the blower control knob is OFF, the A/C
system is OFF, regardless of the position of the
A/C knob.
One Lever
1. The Fresh Air Control Lever

Operates by cable.

Switches between recirculating passenger compart-
ment air and bringing outside air into the passenger
compartment.

Draws in outside air when the lever is moved to the
left.

Recirculates inside air when the lever is moved to
the right.

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

7A–24 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
D108A523
HEATER MODULE
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Disconnect the heater hoses from the heater module.
Refer to “Heater Hoses” in this section.
2. Remove the instrument panel and the lower tie bar
center. Refer to Section 9E, Instrumentation/Driver
Information.
3. Remove the heater module–to–blower module con-
nection tube on the vehicle not equipped with A/C.
a. Heater module–to–blower module connection tube.
D108A524
4. Remove the evaporator on the vehicle equipped with
A/C. Refer to Section 7B, Manual Control Heating,
Ventilation, and Air Conditioning System.
D108A525
5. Remove the heater module.

Remove the upper nuts (1).
D108A526

Remove the lower nuts (2).

Remove the heater module (3).

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.