radiator cap DAEWOO MATIZ 2003 Service Repair Manual

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)

DAEWOO M-150 BL2
SECTION 1D
ENGINE COOLING
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 1D-2. . . . . . . . . . . . . . . . . .
General Description 1D-2. . . . . . . . . . . . . . . . . . . . . . .
Radiator 1D-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Surge Tank 1D-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Pump 1D-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat 1D-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Cooling Fan 1D-3. . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature Sensor 1D-4. . . . . . . . .
Coolant Temperature Sensor 1D-4. . . . . . . . . . . . . . . .
Component Locator 1D-5. . . . . . . . . . . . . . . . . . . . . . . .
Coolant Hose and Components 1D-5. . . . . . . . . . . . .
Radiator/Fan 1D-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedure 1D-7. . . . . . .
Coolant Leaks Test 1D-7. . . . . . . . . . . . . . . . . . . . . . . .
Surge Tank Cap Test 1D-7. . . . . . . . . . . . . . . . . . . . . . .
Thermostat Test 1D-7. . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System Diagnosis 1D-8. . . . . . . . . . . . . . . . . .
Repair Instructions 1D-9. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 1D-9. . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Refilling the Cooling System 1D-9. . . .
Surge Tank 1D-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Cooling Fan 1D-11. . . . . . . . . . . . . . . . . . . . . .
Radiator 1D-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat (Typical) 1D-12. . . . . . . . . . . . . . . . . . . . . .
Thermostat (Euro III) 1D-13. . . . . . . . . . . . . . . . . . . . . .
Coolant Temperature Sensor 1D-14. . . . . . . . . . . . . . .
Engine Coolant Temperature Sensor 1D-15. . . . . . . .
Coolant Pump 1D-15. . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 1D-17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 1D-17. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 1D-18. . . . . . . . . .

1D – 2 ENGINE COOLING
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
GENERAL DESCRIPTION
The cooling system maintains the engine temperature at
an efficient level during all engine operating conditions.
When the engine is cold the cooling system cools the
engine slowly or not at all. This slow cooling of the en-
gine allows the engine to warm up quickly.
The cooling system includes a radiator(a) and cooling
fan(b), a thermostat and housing(c), a coolant pump(d),
a coolant pump drive belt and coolant hose. The timing
belt drives the coolant pump.
All components must function properly in order for the
cooling system to operate. The coolant pump draws the
coolant from the radiator. The coolant then circulates
through water jackets in the engine block and the cylin-
der head, distributor case(e), throttle body(f). When the
coolant reaches the operating temperature of the ther-
mostat, the thermostat opens. The coolant then goes
back to the radiator where it cools.
This system directs some coolant through the hoses to
the heater core(g). This provides for heating and de-
frosting. The surge tank(h) is connected to the radiator
and throttle body to recover the coolant displaced by ex-
pansion from the high temperatures. The surge tank
maintains the correct coolant level.
The cooling system for this vehicle has no radiator cap
and drain cock. The coolant is added to the cooling sys-tem through the surge tank. To drain the cooling system,
disconnect the lower radiator hose and drain the cool-
ant.
RADIATOR
This vehicle has a lightweight tube-and-fin aluminum ra-
diator.
SURGE TANK
The surge tank is a transparent plastic reservoir, similar
to the windshield washer reservoir.
The surge tank is connected to the radiator and throttle
body by a hose. As the vehicle is driven, the engine cool-
ant heats and expands. The portion of the engine cool-
ant displaced by this expansion flows from the radiator
into the surge tank. The air trapped in the radiator is de-
gassed into the surge tank.
When the engine is stops, the engine coolant cools and
contracts. The displaced engine coolant is then drawn
back into the radiator. This keeps the radiator filled with
the coolant to the desired level at all times and increases
the cooling efficiency.
Maintain the coolant level between the MIN and the
MAX marks on the surge tank when the system is cold.
D102D001

ENGINE COOLING 1D–5
DAEWOO M-150 BL2
COMPONENT LOCATOR
COOLANT HOSE AND COMPONENTS
D12D4011
1 Radiator Coolant Return Hose
2 Upper Radiator Hose
3 Not Used
4 Radiator Assembly
5 Lower Radiator Hose
6 Throttle Body Assembly
7 Surge Tank hose
8 Surge Tank
9 Coolant Temperature Sensor
10 Engine Coolant Temperature Sensor11 Surge Tank Return Hose
12 Water Inlet Cap
13 Heater Outlet Hose
14 Heater Inlet Hose
15 Distributor Case
16 Thermostat
17 Thermostat Housing
18 Throttle Body Inlet Hose
19 Throttle Body Outlet Hose
20 Hose Bracket

1D–8 ENGINE COOLING
DAEWOO M-150 BL2
COOLING SYSTEM DIAGNOSIS
Condition Probable Cause Correction
Engine OverheatsA loss of the coolant.Add the coolant.
A weak coolant solution.Confirm that the coolant solution is a
50/50 mixture of ethylene glycol and
water.
Any dirt, any leaves, or any insects
on the front of the radiator.Clean the front of the radiator.
The leakage from the hoses, the
coolant pump, the heater, the
thermostat housing, the radiator, the
heater core, or the head gasket.Replace any damaged components.
A faulty thermostat.Replace a damaged thermostat.
Retarded ignition timing.Perform an ECM code diagnosis.
Confirm the integrity of the timing
belt.
An improperly operating electric
cooling fan.Replace the electric cooling fan.
Plugged or rotted radiator hoses.Replace any damaged radiator
hoses.
A faulty water pump.Replace a faulty water pump.
A faulty surge tank cap.Replace a faulty surge tank cap.
A cracked or plugged cylinder head
or engine block.Repair the damaged cylinder head or
the damaged engine block.
A faulty radiator.Replace a faulty radiator.
Loss of CoolantA leak in the radiator.Replace a damaged radiator.
A leak in the surge tank or the hose.Replace the surge tank or the hose.
Looseness or damage of radiator
hoses, heater hoses, or connections.Reseat the hoses.
Replace the hoses or the clamps.
Leaks in the coolant pump seal.Replace the coolant pump seal.
Leaks in the coolant pump gasket.Replace the coolant pump gasket.
An improper cylinder head torque.Tighten the cylinder head bolts to
specifications.
Replace the cylinder head gasket, if
needed.
Leaks in the intake manifold, cylinder
head gasket, heater core.Repair or replace any components,
as needed to correct the leak.
Engine Fails to Reach
Normal OperatingThermostat to be stuck open or to be
wrong type.Install a new thermostat of the
correct type and heat range.
Temperature or Cool Air
from the HeaterThe coolant level below the MIN
mark on the surge tank.Add sufficient coolant to raise the
fluid to the specified mark on the
surge tank.

ENGINE COOLING 1D–9
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D12D5011
DRAINING AND REFILLING THE
COOLING SYSTEM
Caution: Do not remove the surge tank cap while
the engine and the radiator are hot. Scalding fluid
and steam may be blown out under pressure.
1. Place a pan below the vehicle to catch the draining
coolant.
2. Drain the coolant.
Remove the surge tank cap (1).
Disconnect the lower radiator hose (2).
Caution: Dispose of the used coolant to a used
coolant holding tank to be picked up with the used
oil for disposal. Never pour the used coolant down
the drain. Ethylene glycol antifreeze is an extremely
toxic chemical. Disposing of it into the sewer sys-
tem or the ground water can contaminate the local
environment.
D102D502
3. Connect the lower radiator hose.
4. Clean the cooling system.
Remove all sludge and dirt from inside the surge
tank. And install the surge tank. Refer to “Surge
Tank” in this section (1).

1D–10 ENGINE COOLING
DAEWOO M-150 BL2
D102D503
Add the clean water to the surge tank (2).
5. Run the engine until the thermostat opens. You can
tell the thermostat is open when both radiator hoses
are hot to the touch.
6. Stop the engine and disconnect the lower radiator
hose to drain the coolant.
7. Repeat steps 3 through 6 until the drained water is
clear and free of coolant and rust.
Notice: Never use an antifreeze mixture more concen-
trated than 60 percent antifreeze to 40 percent water.
The solution freezing point increases above this con-
centration.
8. Fill the cooling system through the surge tank with a
mixture of ethylene glycol antifreeze and water. The
mixture must be at least 50 percent antifreeze, but
not more than 60 percent antifreeze for cold weather
operation.
9. Fill the surge tank to the specified MAX fill mark on
the outside of the tank.
10. Install the surge tank cap.
D102D504
SURGE TANK
Removal Procedure
Caution: To prevent personal injury, do not remove
the surge tank cap while the engine and the radiator
are hot, because the heat causes the system to re-
main under pressure scalding fluid and steam may
be blown out under pressure.
1. Drain the engine coolant to below the level of the
surge tank.
2. Remove the surge tank.
Loosen the overflow hose clamps and disconnect
the overflow hoses from the surge tank (1).
Remove the surge tank (2).
3. Clean the inside and the outside of the surge tank and
the surge tank cap with soap and water.
4. Rinse the surge tank and the cap thoroughly.
5. Check the surge tank and the cap for crack or other
damage.

1D–12 ENGINE COOLING
DAEWOO M-150 BL2
D12D5091
4. Remove the electric cooling fan.
Refer to “Electric Cooling Fan” in this section.
5. Remove the radiator.
Remove the bolts (1).
Remove the radiator support brackets (2).
Remove the radiator (3).
6. Check the radiator for breaking, clog or other dam-
age.
Important: The radiator still contains a substantial
amount of coolant. Drain the remainder of the coolant
from the radiator into a drain pan.
D12D5101
Installation Procedure
1. Install the radiator with the mounting bolts (1) and the
support brackets (2).
Tighten
Tighten the support bracket bolts to 3.5–4.5 Nm
(31–40 lb-in).
2. Install the electric cooling fan.
Refer to “Electric Cooling Fan” in this section.
D12D5111
3. Connect the upper radiator hose to the radiator (1).
4. Connect the surge tank hose to the radiator (2).
5. Secure each hose with hose clamps.
6. Refill the engine cooling system. Refer to “Draining
and Refilling the Cooling System” in this section.
7. Connect the negative battery cable.
D102D512
THERMOSTAT (TYPICAL)
Removal Procedure
Caution: To prevent personal injury, do not remove
the surge tank cap while the engine and the radiator
are hot because the heat causes the system to re-
main under pressure. Scalding fluid and steam may
be blown out under pressure.
1. Remove air filter assembly. Refer to Section 1B,
SOHC Engine Mechanical.
2. Disconnect the lower radiator hose and drain the
coolant. Refer to “Drain and Refilling the Cooling Sys-
tem”
3. Disconnect the upper radiator hose.

ENGINE COOLING 1D–13
DAEWOO M-150 BL2
Loosen the hose clamp (1).
Disconnect the upper radiator hose (2).
D102D513
4. Remove the thermostat.
Remove the bolts (1).
Remove the thermostat housing (2).
Remove the thermostat with the gasket (3).
5. Check the gasket for crack or other damage.
6. Inspect the valve seat for foreign matter that could
prevent the valve from seating properly.
7. Inspect the thermostat for proper operation. Refer to
“Thermostat Test” in this section.
8–15 Nm
D12D514A
Installation Procedure
1. Install the thermostat with the bolts and the thermo-
stat housing.
Tighten
Tighten the mounting bolts to 8–15 Nm (71–130
lb-in).
2. Secure the upper radiator hose to the thermostat
housing with a hose clamp.
3. Refill the engine cooling system. Refer to “Draining
and Refilling the Cooling System” in this section.
MAA1D010
THERMOSTAT (EURO III)
Removal Procedure
Caution: To prevent personal injury, do not remove
the surge tank cap while the engine and the radiator
are hot because the heat causes the system to re-
main under pressure. Scalding fluid and steam may
be blown out under pressure.
1. Remove air filter assembly. Refer to Section 1B,
SOHC Engine Mechanical.
2. Disconnect the lower radiator hose and drain the
coolant. Refer to “Drain and Refilling the Cooling Sys-
tem”
3. Disconnect the upper radiator hose.

ENGINE COOLING 1D–17
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescriptionUnitStandardLimit
Cooling
SystemCooling Type–Forced Water
Circulation
CoolantCoolant CapacityL/qt3.8/4.00
Thermostat Type–Pellet Type
Temperature(opened initially)°C(°F)82(180)
ThermostatTemperature(perfectly opened)°C(°F)95(203.4)
Temperature(perfectly closed)°C(°F)80(176.4)
Stroke(perfectly opened)mm(in.)8 (0.32)
Cooling Fan Type–Electric
Blade NumberEA6
Cooling Fan Diametermm(inch)300(11.8)
Electric CoolingTemperature At Low Speed ON°C(°F)93(199.8)Fan
Temperature At Low Speed OFF°C(°F)90(194.4)
Temperature At High Speed ON°C(°F)100(212.4)
Temperature At High Speed OFF°C(°F)97(207)
Surge TankOpen Pressure of The Pressure ValvekPa (psi)120–150
(17.4–21.8)
Surge Tank
Open Pressure of The Vacuum ValvekPa (psi)10 (1.5)
Water Pump Type–Centrifugal
Coolant PumpImpeller Diametermm(in.)60(2.36)
Impeller Blade NumberEA7
Radiator Type–Cross–Flow
Core Widthmm(in.)458(18.03)RadiatorCore Heightmm(in.)295(11.61)
Core Depth (Standard/Heavy Duty)mm(in.)16/27(0.63/1.06)
Resistance
(Coolant Temperature 50°C(122.4°F))Ω185.2
Coolant
TemperatureResistance
(Coolant Temperature 85°C(185.4°F))Ω49.2
SensorResistance
(Coolant Temperature 105°C(221.4°F))Ω27.5
Engine CoolantResistance
(Coolant Temperature 20°C(68.4°F))Ω3,520
Temperature
SensorResistance
(Coolant Temperature 80°C(176.4°F))Ω332