2003 DAEWOO MATIZ Service Repair Manual

ENGINE ELECTRICAL 1E–17
DAEWOO M-150 BL2
D12E513A
Installation Procedure
1. Install in the reverse order of removal.
2. Install the battery rod and cable nuts.
Tighten

Tighten the battery rod nut to 6–8 Nm (53–71 lb-
in) (a).

Tighten the battery cable nut to 9-12 Nm (80–106
lb-in) (b).
D12E514A
DISTRIBUTOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the air filter, resonator with snorkel assem-
bly. Refer to Section 1B, SOHC Engine Mechanical.
3. Disconnect the ignition wires and electrical connec-
tor.

Disconnect the optical sensor connector (1).

Disconnect the ignition wires (2).

Remove the ignition wire clip (3).
D102E515
4. Remove the distributor.
Important: Mark on the distributor housing and case
before remove distributor (a).

Remove the distributor bolts (1).

Carefully remove the distributor assembly (2).
D12E516A
10–16 Nm
Installation Procedure
1. Install in the reverse order of removal.
2. Install the distributor bolts.
Tighten
Tighten the distributor bolts to 10–16 Nm (89–142 lb-
in).

1E–18 ENGINE ELECTRICAL
DAEWOO M-150 BL2
D102E517
IGNITION COIL
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the ignition wires and ignition coil connec-
tor.

Disconnect the ignition wire (1).

Disconnect the ignition coil connector by pushing
the connector’s lock(2).
D102E518
3. Remove the ignition coil.

Remove the screws (1).

Remove the ignition coil (2).
D12E519A
4–7 Nm
Installation Procedure
1. Install in the reverse order of removal.
2. Install the ignition coil screws.
Tighten
Tighten the ignition coil screws to 4–7 Nm (35–62 lb-
in).

ENGINE ELECTRICAL 1E – 19
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
UNIT REPAIR
D102E701
STARTER MOTOR
Inspection / Measurement
(Before the Overhaul)
1. Remove the starter. Refer to “Starter” in this section.
2. Pinion clearance inspection.

Disconnect the starter motor terminal M (1).

Connect the 12-volt battery lead to the starter mo-
tor terminals M and S.
Notice: Complete the testing in a minimum amount of
time to prevent overheating and damaging the solenoid.
(in 10 seconds)
D102E702

Switch on to move the pinion gear (2).

Now check the clearance between the pinion and
the stopper with the filler gauge (3).

If the clearance does not fall within the limits,
check for improper installation and replace all worn
parts.
D102E703
3. Magnetic switch pull-in test.

Disconnect the starter motor terminal M (1).

Connect the 12-volt battery lead to the starter mo-
tor terminals M and S.
Notice: Complete the testing in a minimum amount of
time to prevent overheating and damaging the solenoid.
(in 10 seconds)

1E–20 ENGINE ELECTRICAL
DAEWOO M-150 BL2
D102E704

Inspect the pinion gear’s moving to the outside (2).

If the pinion gear does not move outside, replace
the magnetic switch.
D102E705
4. Solenoid hold-in test.

Disconnect the starter motor terminal M (1).

Connect the 12-volt battery lead to the starter mo-
tor terminal S and body.
Notice: Complete the testing in a minimum amount of
time to prevent overheating and damaging the solenoid.
D102E706

Check the pinion gear’s moving to the outside (2).

If the pinion gear move to the inside, the circuit is
open. Replace the magnetic switch.
D102E707
5. Solenoid return test.

Disconnect the starter motor terminal M (1).

Connect the 12-volt battery lead to the starter mo-
tor terminal S and body.
Notice: Complete the testing in a minimum amount of
time to prevent overheating and damaging the solenoid.

ENGINE ELECTRICAL 1E–21
DAEWOO M-150 BL2
D102E708

Check the returning speed of pinion gear (2).
If the returning speed is fast, the operation is nor-
mal.

Replace the solenoid if the operation is abnormal.
D102E709
5. No-road test.

Connect the 12-volt battery lead to the starter cir-
cuit.

Connect the current and the voltage (1).

Install the starter motor rpm gage (2).

Start the starter motor with the switch on (3).

Measure the speed of pinion gear and the current.

If the measurement satisfy the limit, the starter mo-
tor is normal.
D102E710
DesciptionLimit
The speed of pinion
gearMinimum: 2,000 rpm
Condition:
Voltage/CurrentMaximum: 9V / 150A

Replace the starter motor if necessary.
D102E711
Disassembly Procedure
1. Remove the starter contact end frame.

Remove the through-bolts (1).

Remove the contact end frame bolts (2).

Remove the frame with the spacer (3).

1E–22 ENGINE ELECTRICAL
DAEWOO M-150 BL2
D102E712
2. Remove the brush holder assembly.

Remove the starter motor terminal M nut (1).

Remove the brush holder assembly (2).
D102E713
3. Remove the field frame assembly from the armature
set (1).
D102E714
4. Remove the solenoid assembly.

Remove the solenoid screws (1).

Remove the magnetic switch (2).

Remove the spring (3).
D102E715
5. Remove the armature set and solenoid from the start-
er housing.

Remove the armature set (1).

Remove the rubber sealer (2).

Remove the shift lever plate (3).

Remove the shift lever (4).

Remove the solenoid (5).

Remove the gasket (6).

ENGINE ELECTRICAL 1E–23
DAEWOO M-150 BL2
D102E716
Inspection / Measurement
(After the Overhaul)
1. Ground test for armature coil.

Inspect the insulation between commutator and ar-
mature coil using the voltmeter.

Replace the armature assembly if necessary.
D102E717
2. Short circuit test for armature coil.

If test equipment is available, check the armature
for short circuit by placing it on a growler, and hold-
ing back a saw blade over the armature core while
the armature is rotated. If the saw blade vibrates,
replace the armature.
D102E718
3. Open circuit test for armature coil.

Check the continuity between the commutator
bars using multimeter.

Replace the armature assembly if necessary.
D102E719
4. Inspect the brushes wear.

Inspect the brushes, the pop-out springs and the
brush holder for wear and damage. Replace the
brushes, if necessary.
a. Brushes wear limit.
DesciptionStandardLimit
Brushes wear11.3–11.5 mm
(0.445–0.453 in)7.0–7.25 mm
(0.275–0.285 in)

1E–24 ENGINE ELECTRICAL
DAEWOO M-150 BL2
D12E720A
9-12 Nm
4-6 Nm
Assembly Procedure
1. Install in the reverse order of removal.
2. Install the bolts / nuts.
Tighten
Tighten the starter motor terminal M nut to 9–12 Nm
(80–106 lb-in) (a).
Tighten the through-bolts to 4–6 Nm (35–53 lb-in)
(b).
D102E721
GENERATOR (A-TYPE : MANDO)
Disassembly Procedure
1. Remove the generator. Refer to “Generator” in this
section.
2. Remove the front bracket and rear bracket.

Remove the through-bolts (1).
D102E722

Pry front bracket downwards using a screwdriver
(2).

Separate the front bracket and rear bracket (3).
D102E723
3. Remove the pulley and rotor assembly from the front
bracket.

Cover the rotor with the cloth (1).

Place the pulley upwards and vice the rotor (2).

Remove the pulley nut (3).

Remove the pulley (4).