service 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)

DAEWOO M-150 BL2
SECTION 1A
GENERAL ENGINE INFORMATION
TABLE OF CONTENTS
Description and Operation 1A-2. . . . . . . . . . . . . . . . . .
Cleanliness and Care 1A-2. . . . . . . . . . . . . . . . . . . . . .
On-Engine Service 1A-2. . . . . . . . . . . . . . . . . . . . . . . .
Component Locator 1A-3. . . . . . . . . . . . . . . . . . . . . . . .
Engine Compartment (Typical) 1A-3. . . . . . . . . . . . . .
Engine Compartment (Euro III) 1A-4. . . . . . . . . . . . . .
Diagnoctic Information and Procedure 1A-5. . . . . . .
General Diagnosis 1A-5. . . . . . . . . . . . . . . . . . . . . . . . .
Checking Engine Fluid Level 1A-11. . . . . . . . . . . . . . .
Changing Engine Oil or Oil Filter 1A-11. . . . . . . . . . . . Checking Engine Timing Belt 1A-12. . . . . . . . . . . . . . .
Checking Accessory Belt 1A-12. . . . . . . . . . . . . . . . . .
Checking Spark Plug 1A-12. . . . . . . . . . . . . . . . . . . . .
Checking Air Cleaner Element 1A-13. . . . . . . . . . . . .
Checking Fuel Filter 1A-13. . . . . . . . . . . . . . . . . . . . . .
Checking Fuel System 1A-13. . . . . . . . . . . . . . . . . . . .
Checking Hose System 1A-13. . . . . . . . . . . . . . . . . . .
Specifications 1A-14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 1A-14. . . . . . . . . . . . . . . . . . . .
Engine Performance Curve 1A-15. . . . . . . . . . . . . . . .

1A – 2 GENERAL ENGINE INFORMATION
DAEWOO M-150 BL2
DESCRIPTION AND SYSTEMOPERATION
CLEANLINESS AND CARE
An automobile engine is a combination of many ma-
chined, honed, polished and lapped surfaces with toler-
ances that are measured in the ten–thousandths of an
inch. When any internal engine parts are serviced, care
and cleanliness are important. A liberal coating of en-
gine oil should be applied to friction areas during assem-
bly, to protect and lubricate the surfaces on initial
operation. Proper cleaning and protection of machined
surfaces and friction areas is part of the repair proce-
dure. This is considered standard shop practice even if
not specifically stated.
Whenever valve train components are removed for ser-
vice, they should be kept in order. They should be
installed in the same locations, and with the same mat-
ing surfaces, as when they were removed. Battery
cables should be disconnected before any major work is
performed on the engine. Failure to disconnect cablesmay result in damage to wire harness or other electrical
parts.
ON-ENGINE SERVICE
Caution: Disconnect the negative battery cable be-
fore removing or installing any electrical unit, or
when a tool or equipment could easily come in con-
tact with exposed electrical terminals. Disconnect-
ing this cable will help prevent personal injury and
damage to the vehicle. The ignition must also be in
B unless otherwise noted.
Notice: Any time the air cleaner is removed, the intake
opening should be covered. This will protect against ac-
cidental entrance of foreign material, which could follow
the intake passage into the cylinder and cause exten-
sive damage when the engine is started.

DAEWOO M-150 BL2
SECTION 1B
SOHC ENGINE MECHANICAL
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 1B-2. . . . . . . . . . . . . . . . . .
Engine Type 1B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication 1B-2. . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Valve Train 1B-2. . . . . . . . . . . . . .
Engine Block 1B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft 1B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rod 1B-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston, Piston Ring and Piston Pin 1B-3. . . . . . . . . . .
Timing Belt and Pulley 1B-4. . . . . . . . . . . . . . . . . . . . .
Engine Mount 1B-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locator 1B-5. . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head 1B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Block 1B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold & Air Flow System 1B-7. . . . . . . . . . . . . . . . .
Timing Belt & Engine Mount 1B-8. . . . . . . . . . . . . . . .
Diagnostic Information and Procedure 1B-9. . . . . . .
Compression Pressure Check 1B-9. . . . . . . . . . . . . . .
Oil Pressure Check 1B-9. . . . . . . . . . . . . . . . . . . . . . . .
Adjustment of Valve Clearance 1B-10. . . . . . . . . . . . .
Ignition Timing Check and Adjustment
(Typical) 1B-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Timing Check and Adjustment 1B-12. . . . . . . .
Repair Instructions 1B-14. . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 1B-14. . . . . . . . . . . . . . . . . . . . . . . . . Air Filter Assembly 1B-14. . . . . . . . . . . . . . . . . . . . . . .
Air Filter Element 1B-15. . . . . . . . . . . . . . . . . . . . . . . . .
Positive Crankcase Ventilation (PCV) Hose
and Valve 1B-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold 1B-16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold (Typical) 1B-18. . . . . . . . . . . . . . . . .
Exhaust Manifold (Euro III) 1B-20. . . . . . . . . . . . . . . .
Timing Belt 1B-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan 1B-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 1B-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor Case 1B-26. . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Gasket 1B-28. . . . . . . . . . . . . . . . .
Engine Mount Damping Block 1B-32. . . . . . . . . . . . . .
Engine Mount Front Damping Bush 1B-34. . . . . . . . .
Engine Assembly 1B-35. . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 1B-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Valve Train
Components 1B-47. . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Block Components 1B-59. . . . . . . . . . . . . . . . .
Specifications 1B-71. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications 1B-71. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 1B-73. . . . . . . . . .
Special Tools 1B-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 1B-75. . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . .

ENGINE COOLING 1D–3
DAEWOO M-150 BL2
COOLANT PUMP
The belt-driven centrifugal coolant pump consists of an
impeller, a drive shaft, and a belt pulley.
The impeller is supported by a completely sealed bear-
ing.
The coolant pump is serviced as an assembly and,
therefore, cannot be disassembled.
THERMOSTAT
A wax pellet-type thermostat controls the flow of the en-
gine coolant through the engine cooling system. The
thermostat(i) is mounted in the thermostat housing.
The thermostat stops the flow of the engine coolant from
the engine to the radiator in order to provide faster
warm-up, and to regulate the coolant temperature. The
thermostat remains closed while the engine coolant is
cold, preventing circulation of the engine coolant
through the radiator. At this point, the engine coolant is
allowed to circulate only throughout the heater core to
warm it quickly and evenly.
As the engine warms, the thermostat opens. This allows
the engine coolant to flow through the radiator, where
the heat is dissipated through the radiator. This opening
and closing of the thermostat permits enough engine
coolant to enter the radiator to keep the engine within
proper engine temperature operating limits.
The wax pellet in the thermostat is hermetically sealed in
a metal case(j). The wax element of the thermostat ex-
pands when it is heated and contracts when it is cooled.
As the vehicle is driven and the engine warms, the en-
gine coolant temperature increases. When the engine
coolant reaches a specified temperature, the wax pellet
element in the thermostat expands and exerts pressure
against the metal case, forcing the valve open. This al-
lows the engine coolant to flow through the engine cool-
ing system and cool the engine.
As the wax pellet cools, the contraction allows a spring
to close the valve.
The thermostat begins to open at 82
C (180
F) and is
fully open at 95
C (203
F). The thermostat closes at
80
C (176
F).
D102D002
ELECTRIC COOLING FAN
Caution: Keep hands, tools, and clothing away from
the engine cooling fans to help prevent personal in-
jury. This fan is electric and can turn ON whether or
not the engine is running.
Caution: If a fan blade is bent or damaged in any
way, no attempt should be made to repair or reuse
the damaged part. A bent or damaged fan assembly
should always be replaced with a new one.
The cooling fans are mounted behind the radiator in the
engine compartment. The electric cooling fans increase
the flow of air across the radiator fan and across the
condenser on air conditioner (A/C)-equipped vehicles.
This helps to speed cooling when the vehicle is at idle or
moving at low speeds.
D102D003

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).

DAEWOO M-150 BL2
SECTION 1E
ENGINE ELECTRICAL
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 1E-2. . . . . . . . . . . . . . . . . .
Battery 1E-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ratings 1E-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reserve Capacity 1E-2. . . . . . . . . . . . . . . . . . . . . . . . .
Cold Cranking Amperage 1E-2. . . . . . . . . . . . . . . . . . .
Built-In Hydrometer 1E-2. . . . . . . . . . . . . . . . . . . . . . . .
Charging Procedure 1E-3. . . . . . . . . . . . . . . . . . . . . . .
Charging Time Required 1E-3. . . . . . . . . . . . . . . . . . . .
Charging a Completely Discharged Battery
(Off the Vehicle) 1E-3. . . . . . . . . . . . . . . . . . . . . . . . .
Jump Starting Procedure 1E-3. . . . . . . . . . . . . . . . . . .
Generator 1E-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging System 1E-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Starter 1E-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting System 1E-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor 1E-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Coil 1E-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug 1E-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Locator 1E-6. . . . . . . . . . . . . . . . . . . . . . . .
Starting System 1E-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging System (A-type: MANDO) 1E-7. . . . . . . . . .
Charging System (B-type: DAC) 1E-8. . . . . . . . . . . . .
Ignition System 1E-9. . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedure 1E-10. . . . . .
Ignition System 1E-10. . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Load Test 1E-12. . . . . . . . . . . . . . . . . . . . . . . . Generator Output Test 1E-12. . . . . . . . . . . . . . . . . . . .
Generator System Check 1E-13. . . . . . . . . . . . . . . . . .
Repair Instructions 1E-14. . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 1E-14. . . . . . . . . . . . . . . . . . . . . . . . .
Starter 1E-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator 1E-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery 1E-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor 1E-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Coil 1E-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 1E-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Motor 1E-19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator (A-type: MANDO) 1E-24. . . . . . . . . . . . . . .
Generator (B-type: DAC) 1E-29. . . . . . . . . . . . . . . . . .
Distributor Assembly 1E-34. . . . . . . . . . . . . . . . . . . . . .
Schematic and Routing Diagrams 1E-37. . . . . . . . . .
Starting System 1E-37. . . . . . . . . . . . . . . . . . . . . . . . . .
Charging System 1E-38. . . . . . . . . . . . . . . . . . . . . . . . .
Ignition System Circuit – Tipical 1E-39. . . . . . . . . . . .
Ignition System Circuit – Euro III 1E-40. . . . . . . . . . .
Specifications 1E-41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Specifications 1E-41. . . . . . . . . . . . . . . . . . . . .
Generator Specifications 1E-41. . . . . . . . . . . . . . . . . .
Ignition System Specifications 1E-41. . . . . . . . . . . . . .
Battery Specifications 1E-41. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 1E-42. . . . . . . . . .

1E–2 ENGINE ELECTRICAL
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
BATTERY
The battery has three major functions in the electrical
system. First, the battery provides a source of energy
for cranking the engine. Second, the battery acts as a
voltage stabilizer for the electrical system. Finally, the
battery can, for a limited time, provide energy when the
electrical demand exceeds the output of the generator.
The sealed battery is standard on all cars. There are no
vent plugs in the cover. The battery is completely
sealed, except for two small vent holes in the sides.
These vent holes allow the small amount of gas pro-
duced in the battery to escape.
The sealed battery has the following advantages over
conventional batteries:

No water need be added for the life of the battery.

It is protected against overcharge. If too much volt-
age is applied to the battery, it will not accept as much
current as a conventional battery. In a conventional
battery, the excess voltage will still try to charge the
battery, leading to gassing, which causes liquid loss.

It is not as liable to self-discharge as a conventional
battery. This is particularly important when a battery
is left standing for long periods of time.

It has more power available in a lighter and a smaller
case.
RATINGS
A battery has two ratings: (1) A reserve capacity rating
designated at 27C (81F), which is the time a fully
charged battery will provide 25 amperes current flow at
or above 10.5 volts; (2) A cold cranking amp rating de-
termined under testing at -18C (0F), which indicates
the cranking load capacity.
RESERVE CAPACITY
The reserve capacity is the maximum length of time it is
possible to travel at night with the minimum electrical
load and no generator output. Expressed in minutes,
Reserve Capacity (or RC rating) is the time required for
a fully charged battery, at a temperature of 27C (81F)
and being discharged at a current of 25 amperes, to
reach a terminal voltage of 10.5 volts.
COLD CRANKING AMPERAGE
The cold cranking amperage test is expressed at a bat-
tery temperature of -18C (0F). The current rating is
the minimum amperage, which must be maintained by
the battery for 30 seconds at the specified temperature,
while meeting a minimum voltage requirement of
7.2 volts. This rating is a measure of cold cranking ca-
pacity.The battery is not designed to last indefinitely. However,
with proper care, the battery will provide many years of
service.
If the battery tests well, but fails to perform satisfactorily
in service for no apparent reason, the following factors
may point to the cause of the trouble:

Vehicle accessories are left on overnight.

Slow average driving speeds are used for short peri-
ods.

The vehicle’s electrical load is more than the genera-
tor output, particularly with the addition of aftermarket
equipment.

Defects in the charging system, such as electrical
shorts, a slipping generator belt, a faulty generator, or
a faulty voltage regulator.

Battery abuse, including failure to keep the battery
cable terminals clean and tight, or a loose battery
hold-down.

Mechanical problems in the electrical system, such
as shorted or pinched wires.
BUILT-IN HYDROMETER
The sealed battery has a built-in, temperature-compen-
sated hydrometer in the top of the battery. This hydrom-
eter is to be used with the following diagnostic
procedure:
1. When observing the hydrometer, make sure that the
battery has a clean top.
2. Under normal operation, two indications can be ob-
served:

GREEN DOT VISIBLE – Any green appearance is
interpreted as a “green dot,” meaning the battery is
ready for testing.

DARK GREEN DOT IS NOT VISIBLE – If there is
a cranking complaint, the battery should be tested.
The charging and electrical systems should also
be checked at this time.
3. Occasionally, a third condition may appear:

CLEAR OR BRIGHT YELLOW – This means the
fluid level is below the bottom of the hydrometer.
This may have been caused by excessive or pro-
longed charging, a broken case, excessive tipping,
or normal battery wear. Finding a battery in this
condition may indicate high charging by a faulty
charging system. Therefore, the charging and the
electrical systems may need to be checked if a
cranking complaint exists. If the cranking com-
plaint is caused by the battery, replace the battery.

1E–4 ENGINE ELECTRICAL
DAEWOO M-150 BL2
3. In both vehicles, apply the parking brake firmly.
Notice: Make sure the cables are not on or near pulleys,
fans, or other parts that will move when the engine
starts, damaging the parts.
4. Shift a manual transaxle to NEUTRAL.
Caution: Do not use cables that have loose or miss-
ing insulation, or injury could result.
5. Clamp one end of the first jumper cable to the positive
terminal on the battery. Make sure it does not touch
any other metal parts. Clamp the other end of the
same cable to the positive terminal on the other bat-
tery. Never connect the other end to the negative ter-
minal of the discharged battery.
Caution: Do not attach the cable directly to the neg-
ative terminal of the discharged battery. Doing so
could cause sparks and possible battery explosion.
6. Clamp one end of the second cable to the negative
terminal of the booster battery. Make the final con-
nection to a solid engine ground, such as the engine
lift bracket, at least 450 millimeters (18 inches) from
the discharged battery.
7. Start the engine of the vehicle with the good battery.
Run the engine at a moderate speed for several min-
utes. Then start the engine of the vehicle which has
the discharged battery.
8. Remove the jumper cables by reversing the above
sequence exactly. Remove the negative cable from
the vehicle with the discharged battery first. While re-
moving each clamp, take care that it does not touch
any other metal while the other end remains at-
tached
.
GENERATOR
The Delco-Remy CS charging system has several mod-
els available, including the ∅114D (A-type) or CS114D
(B-type). The number denotes the outer diameter in
millimeters of the stator lamination.
CS generators are equipped with internal regulators.
The Y connection (A-type) or Delta (B-type) stator, a
rectifier bridge, and a rotor with slip rings and brushes
are electrically similar to earlier generators. A conven-
tional pulley and fan are used. There is no test hole.
Unlike three-wire generators, the ∅114D (A-type) or
CS114D (B-type) may be used with only two connec-
tions: battery positive and an ‘‘L’’ terminal to the charge
indicator lamp.
As with other charging systems, the charge indicator
lamp lights when the ignition switch is turned to ON, and
goes out when the engine is running. If the charge indi-
cator is on with the engine running, a charging system
defect is indicated.
The regulator voltage setting varies with temperature
and limits the system voltage by controlling the rotorfield current. The regulator switches rotor field current
on and off. By varying the on-off time, correct average
field current for proper system voltage control is ob-
tained. At high speeds, the on-time may be 10 percent
and the off-time 90 percent. At low speeds, with high
electrical loads, on-time may be 90 percent and the off-
time 10 percent.
CHARGING SYSTEM
The Delco-Remy CS charging system has several mod-
els available, including the ∅114D (A-type) or CS114D
(B-type). The number denotes the outer diameter in
millimeters of the stator laminations.
CS generators use a new type of regulator that incorpo-
rates a diode trio. The Y connection (A-type) or Delta (B-
type) stator, a rectifier bridge, and a rotor with slip rings
and brushes are electrically similar to earlier generators.
A conventional pulley and fan are used. There is no test
hole.
STARTER
Wound field starter motors have pole pieces, arranged
around the armature, which are energized by wound
field coils.
Enclosed shift lever cranking motors have the shift lever
mechanism and the solenoid plunger enclosed in the
drive housing, protecting them from exposure to dirt, icy
conditions, and splashes.
In the basic circuit, solenoid windings are energized
when the switch is closed. The resulting plunger and
shift lever movement causes the pinion to engage the
engine flywheel ring gear. The solenoid main contacts
close. Cranking then takes place.
When the engine starts, pinion overrun protects the ar-
mature from excessive speed until the switch is opened,
at which time the return spring causes the pinion to dis-
engage. To prevent excessive overrun, the switch
should be released immediately after the engine starts.
STARTING SYSTEM
The engine electrical system includes the battery, the
ignition, the starter, the generator, and all the related wir-
ing. Diagnostic tables will aid in troubleshooting system
faults. When a fault is traced to a particular component,
refer to that component section of the service manual.
The starting system circuit consists of the battery, the
starter motor, the ignition switch, and all the related elec-
trical wiring. All of these components are connected
electrically
.
DISTRIBUTOR
Distributor distributes the high tension voltage induced
from ignition coil, to each spark plug of each cylinder in