2003 DAEWOO MATIZ timing belt

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–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.

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

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. . . . . . . . . . . . . . . . . . . . . . .

SOHC ENGINE MECANICAL 1B–3
DAEWOO M-150 BL2
parts are installed in the cross flow arrangement. The
rocker arm (i) operates in seesaw motion to close and
open the intake and exhaust valves (j) with camshaft by
turning the rocker arm shaft of each intake and exhaust
part.
ENGINE BLOCK
As the largest part of the engine components. the block
(l) has all the necessary parts attached to outer surface
of it.
On the inside surface of block, there are bore surfaces
by horning, which are cylinders, and on the periphery of
the cylinders, there are the passages to prevent the
over-heated and to lubricate the engine block.
CRANKSHAFT
The crankshaft (m) is to convert the rectilinear motion
into the rotation motion through the connecting rod (n)
which transmits the power generated by combustion.
On the one side of it, oil pump, crankshaft pulley and
timing belt pulley are attached, and oil seal housing and
flywheel are on the other side.
A special steel of high grade cast iron is used for the ma-
terial to stand the bending load and distortion. The mate-
rial of the main bearing (o) is aluminum alloy. The split
thrust bearings (p) are inserted in the journal bearing
part (No.3).
D102B004
CONNECTING ROD
The connecting rods (n) are made of forged steel, and
its section is typed “I” with its big end connected tocrankshaft (m) and its small end to piston pin to transmit
the power.
The big end is detachable, and its upper and lower parts
are fastened by bolting after the metal bearings (q) are
inserted.
PISTON, PISTON RING AND PISTON
PIN
Piston
The piston (r) is of the open skirt type and its crown is
exposed in the combustion chamber to generate power.
Its land and skirt parts are made of coat aluminum alloy
which is light and has excellent heat conductivity in order
to meet its continuous and high speed reciprocation
movement.
Piston Ring
It is composed of two compression rings (s) and one oil
ring (t) and installed between the grooves of the piston
to make the high speed reciprocating movement main-
taining a remarkable air tightness as well as cylinders. It
is a critical parts to affect the compression pressure, oil
consumption, compression, blow by pressure and en-
gine performance.
Piston Pin
The pin (u) is not fixed to the piston or connecting rod
and its both ends are assembled by the circlip (v) in the
full floating type. The pin is used to transmit the power
from the crown part of piston to connecting rod.
D102B005

1B –4 SOHC ENGINE MECANICAL
DAEWOO M-150 BL2
TIMING BELT AND PULLEY
The timing belt connects the camshaft timing pulley (w)
and the crankshaft timing pulley (x). The timing belt
coordinates the crankshaft and the camshaft and keeps
them synchronized. The timing belt also turns the cool-
ant pump (y). The timing belt and the pulleys are toothed
so that there is no slippage between them. There is a
tension pulley (z) that maintains the correct timing belt
tension. The timing belt is made of a tough reinforced
rubber similar to that used on the serpentine drive belt.
The timing belt requires no lubrication.
D102B006
ENGINE MOUNT
This is to absorb or reduce the engine vibration and im-
pact from the wheeled road. Engine mount is attached to
the engine–front side, the engine-right side and the en-
gine-rear side and one transaxle mount is attached to
the transaxle side.
D102B007
D102B008

1B –8 SOHC ENGINE MECANICAL
DAEWOO M-150 BL2
TIMING BELT & ENGINE MOUNT
D12B4041
1 Engine Mount Damping Block
2 Engine Mount Intermediate Bracket
3 Engine Mount Brace Bracket
4 Transaxle Mount Bracket
5 Transaxle Mount Damping Block
6 Engine Mount Front Bracket
7 Engine Mount Front Damping Bush
8 Timing Belt9 Timing Belt Tensioner
10 Crankshaft Gear
11 Timing Belt Upper Front Cover
12 Timing Belt Lower Front Cover
13 Crankshaft Pulley
14 Engine Mount Lower Bracket
15 Engine Mount Upper Bracket

1B –10 SOHC ENGINE MECANICAL
DAEWOO M-150 BL2
ADJUSTMENT OF VALVE
CLEARANCE
Adjust the valve clearance in the following procedures:
1. Remove the air filter/resonator assembly and the
relevant parts installed on the cylinder head cover.
2. Remove the cylinder head cover hexagon bolts and
remove the cover.
3. Turn over the crankshaft to make No.1 cylinder
matched with the compression top dead center.
(When the camshaft sprocket notch (d) is aligned with
the timing belt rear cover triangle pointer (e) and the
crankshaft sprocket point (f) is aligned with the oil
pump housing point (g), the compression top dead
center is on the ignition sequence for No. 1 cylinder.)
D102B303
4. Check the valve clearance for No. 1 cylinder com-
pression top dead center.

Condition

Cylinder
No.

1

2

3

Compression topIntake
dead center of
No.1 cylinder
Exhaust

marks indicates the place where the valve clear-
ance can be checked and adjusted.
5. If the checking for the valve clearance of No.1 cylin-
der compression top dead center is over, position
No.1 cylinder on the exhaust top dead center as rotat-
ing the crankshaft in a 360–degree arc. (When the
camshaft sprocket point (h) is aligned with the timing
belt rear cover triangle pointer (e), the exhaust top
dead center is on the ignition sequence for No. 1 cyl-
inder.)
D102B304
6. Check the valve clearance for the No. 1 cylinder ex-
haust top dead center.

Condition

Cylinder
No.

1

2

3

Exhaust top deadIntake
center of No.1
cylinder
Exhaust

marks indicates the place where the valve clear-
ance can be checked and adjusted.
Check and adjust the valve clearance (i) using thick-
ness gauge (j).
D102B305
D102B306