SERVICE MATIZ
(MY2003)
FOREWORD
This manual includes procedure for maintenance, adjustment, service operation and removal and installation of components.
All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of manual approval.
The right is reserved to make changes at any time without notice.
HVAC (HEATING, VENTILATION, AND AIR CONDITIONING)
MOTOR CO., LTD.
AND
SECTION INDEX FRONT MATTER 0A GENERAL INFORMATION 0B ENGINE 1
DAEWOO
INCHON,
KOREA
MANUAL
SUSPENSION 2 DRIVELINE/AXLE3 BRAKES 4 TRANSAXLE 5 STEERING 6 RESTRAINTS 8 BODY
ACCESSORIES 9 7
ENGINE
CONTENTS
SECTION 1AGENERAL ENGINE INFORMATION
SECTION 1BSOHC ENGINE MECHANICAL
SECTION 1DENGINE COOLING
SECTION 1EENGINE ELECTRICAL
SECTION 1FENGINE CONTROLS
SECTION 1GENGINE EXHAUST
SUSPENSION
CONTENTS
SECTION 2ASUSPENSION DIAGNOSIS
SECTION 2BWHEEL ALIGNMENT
SECTION 2CFRONT SUSPENSION
SECTION 2DREAR SUSPENSION
SECTION 2ETIRES AND WHEELS
DRIVELINE/AXLE
CONTENTS
SECTION 3BMANUAL TRANSAXLE DRIVE AXLE
BRAKES
CONTENTS
SECTION 4AHYDRAULIC BRAKES
SECTION 4BMASTER CYLINDER
SECTION 4CPOWER BOOSTER
SECTION 4DFRONT DISC BRAKES
SECTION 4EREAR DRUM BRAKES
SECTION 4FANTILOCK BRAKE SYSTEM
SECTION 4GPARKING BRAKE
TRANSAXLE
CONTENTS
SECTION 5BFIVE–SPEED MANUAL TRANSAXLE
SECTION 5CCLUTCH
STEERING
CONTENTS
SECTION 6APOWER STEERING SYSTEM
SECTION 6BPOWER STEERING PUMP
SECTION 6CPOWER STEERING GEAR
SECTION 6DMANUAL STEERING GEAR
SECTION 6ESTEERING WHEEL AND COLUMN
HVAC (HEATING, VENTILATION, AND AIR CONDITIONING)
CONTENTS
SECTION 7AHEATING AND VENTILATION SYSTEM
SECTION 7BMANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM
RESTRAINTS
CONTENTS
SECTION 8ASEAT BELTS
SECTION 8BSUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
BODY AND ACCESSORIES
CONTENTS
SECTION
9ABODY WIRING SYSTEM SECTION 9BLIGHTING SYSTEMS SECTION 9CHORNS SECTION 9DWIPERS / WASHER SYSTEMS SECTION 9EINSTRUMENTATION / DRIVER INFORMATION SECTION 9FAUDIO SYSTEMS SECTION 9GINTERIOR TRIM SECTION 9HSEATS SECTION 9IWATERLEAKS SECTION 9JWINDNOISE SECTION 9KSQUEAKS AND RATTLES SECTION 9LGLASS AND MIRRORS SECTION 9MEXTERIOR TRIM SECTION 9NFRAME AND UNDERBODY SECTION 9OBUMPERS AND FASCIAS SECTION 9PDOORS SECTION 9QROOF SECTION 9RBODY FRONT END SECTION 9SBODY REAR END SECTION 9TIMMOBILIZER ANTI THEFT SYSTEM
1A
GENERAL ENGINE INFORMATION
TABLE OF CONTENTS
Description and Operation1A-2 . . . . . . . . . . . . . . . . . .
Cleanliness and Care1A-2
On-Engine Service1A-2 . . . . . . . . . . . . . . . . . . . . . . . .
Component Locator1A-3
Engine Compartment (Typical)1A-3 . . . . . . . . . . . . . .
Engine Compartment (Euro III)1A-4
Diagnoctic Information and Procedure1A-5 . . . . . . .
General Diagnosis1A-5
Checking Engine Fluid Level1A-11
Changing Engine Oil or Oil Filter1A-11 . . . . . . . . . . . .
Checking Engine Timing Belt1A-12
Checking Accessory Belt1A-12
Checking Spark Plug1A-12 . . . . . . . . . . . . . . . . . . . . .
Checking Air Cleaner Element1A-13
Checking Fuel Filter1A-13 . . . . . . . . . . . . . . . . . . . . . .
Checking Fuel System1A-13
Checking Hose System1A-13
Specifications1A-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications1A-14
Engine Performance Curve1A-15 . . . . . . . . . . . . . . . .
DAEWOO M-150 BL2 SECTION
DESCRIPTION AND SYSTEMOPERATION
CLEANLINESS AND CARE
An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances 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 engine oil should be applied to friction areas during assembly, to protect and lubricate the surfaces on initial operation. Proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated.
Whenever valve train components are removed for service, they should be kept in order. They should be installed in the same locations, and with the same mating surfaces, as when they were removed. Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables
may result in damage to wire harness or other electrical parts.
ON-ENGINE SERVICE
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.
Notice: Any time the air cleaner is removed, the intake opening should be covered. This will protect against accidental entrance of foreign material, which could follow the intake passage into the cylinder and cause extensive damage when the engine is started.
1A–2 GENERAL ENGINE INFORMATION DAEWOO M-150 BL2
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ENGINE COMPARTMENT (TYPICAL)
GENERAL ENGINE INFORMATION 1A 3 DAEWOO M-150 BL2 COMPONENT LOCATOR
(Left–Hand Drive Shown, Right–Hand Drive Similar) D102A401 1Power Steering Oil Reservoir 2Coolant Reservoir 3Canister 4Canister Solenoid 5Manifold Absolute Pressure (MAP) Sensor 6Intake Manifold 7Ignition Coil 8Idle Air Control (IAC) Valve 9Throttle Position (TP) Sensor 10Throttle Body 11Brake Fluid Reservoir 12Wiper Motor 13Battery 14Fuse Box 15Air Cleaner Housing 16Resonator 17PCV Hose 18Distributor 19Exhaust Manifold 20Snorkel 21Engine 22Washer Fluid Reservoir 23Oil Level Gauge 24Oil Filler Cap
ENGINE COMPARTMENT (EURO III)
Drive Shown,
Drive Similar)
Steering Oil
Absolute Pressure (MAP)
Manifold
(TP)
Control (IAC)
1A 4 GENERAL ENGINE INFORMATION DAEWOO M-150 BL2
(Left–Hand
Right–Hand
MAA1A010 1Power
Reservoir 2Coolant Reservoir 3Canister Purge Solenoid 4Manifold
Sensor 5Intake
6Throttle Position
Sensor 7Throttle Body 8Idle Air
Valve 9Brake Fluid Reservoir 10Wiper Motor 11Battery 12Fuse Box 13Air Cleaner Housing 14Resonator 15Electronic Ignition System Ignition Coil 16Exhaust Manifold 17Snorkel 18Engine 20Washer Fluid Reservoir 19Oil Level Gauge 21Oil Filler Cap
DIAGNOSTIC INFORMATION PROCEDURE
GENERAL DIAGNOSIS
Condition Probable cause Correction
Hard Starting (With Malfunction 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.
Damaged distributor rotor or cap.
Replace or clean the distributor 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.
Inadequate the valve clearance.
Leakage of the valve clearance.
Interference of the valve stem.
Low elasticity or damage of the valve spring.
Abnormal interference of pistons and cylinders.
Excessive wear of pistons, rings, or cylinders.
Replace the gasket.
Adjust the clearance.
Repair the valve.
Replace the valve or the valve guide.
Replace the valve spring.
Replace the piston ring.
Replace the ring or the piston and boring or replace the cylinder.
GENERAL ENGINE INFORMATION 1A 5 DAEWOO M-150 BL2
Condition
GENERAL DIAGNOSIS (Cont’d)
Probable cause Correction
Hard Starting (With Others
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.
Lack of Engine Power Decline of Compression Pressure
Loosening, damage or leakage of the vacuum hose.
Connect the hose correctly or replace it. Leakage of intake system. Replace intake system.
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 Idling Decline of Compression Pressure
Refer to “Page 1A 5”
Refer to “Page 1A 5”
Clean the pipe. Fuel System Clogged or contaminated fuel filter. Replace the filter.
Malfunction of Clogged fuel pipe.
Malfunction of the fuel pressure regulator.
Malfunction of Ignition System Malfunction of the spark plug.
Electric leakage or poor connection of the high tension cable.
Worn distributor cap terminal or accumulated carbon in the distributor cap.
Replace the regulator.
Adjust or replace the spark plug.
Connect the cable correctly or replace it.
Replace or clean the distributor cap.
1A 6 GENERAL ENGINE INFORMATION DAEWOO M-150 BL2
